670D, 672D, 770D, 772D,

870D, and 872D

Motor Grader
Repair

TECHNICAL MANUAL
D Series Motor Grader Repair
09JAN07 (ENGLISH)

For complete service information also see:

D Series Motor Grader Operation and
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM2246
D Series Motor Grader Operator’s
Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OMT202890
TEAMMATE II 1200, 1400, and 1600 Series
Inboard Planetary Axles . . . . . . . . . . . . . . . . CTM43
Alternators and Starting Motors . . . . . . . . . . CTM77
PowerTech 8.1 L Diesel Engines Base
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CTM86
PowerTech 4.5 L & 6.8 L Diesel Engines
Base Engine. . . . . . . . . . . . . . . . . . . . . . . . . . CTM104
PowerTech 4.5 L & 6.8 L Diesel Engines
Level 11 Electronic Fuel System With
Denso HPCR . . . . . . . . . . . . . . . . . . . . . . . . . CTM220
PowerTech 8.1 L Diesel Engines Level 9
Electronic Fuel System With Denso
HPCR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CTM255
DF180 Series Powershift Transmission
Repair Manual . . . . . . . . . . . . . . . . . . . . . . . . CTM308
Super Caddy Oil Cleanup Procedure . . . . . . CTM310
DF230 Series Transmission Repair
Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CTM362
120 Series Hydraulic Cylinders . . . . . . . . . . TM-H120A
SERVICE ADVISOR System Computer
Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . T133991
Worldwide Construction
And Forestry Division
LITHO IN U.S.A.
 Introduction

Foreword

This manual is written for an experienced technician.

Essential tools required in performing certain service work
are identified in this manual and are recommended for
use.

Live with safety: Read the safety messages in the

introduction of this manual and the cautions presented
throughout the text of the manual.

This is the safety-alert symbol. When you see this

symbol on the machine or in this manual, be alert to the
potential for personal injury.

Technical manuals are divided in two parts: repair and

operation and tests. Repair sections tell how to repair the
components. Operation and tests sections help you
identify the majority of routine failures quickly.

Information is organized in groups for the various

components requiring service instruction. At the beginning
of each group are summary listings of all applicable
essential tools, service equipment and tools, other
materials needed to do the job, service parts kits,
specifications, wear tolerances, and torque values.

Technical Manuals are concise guides for specific

machines. They are on-the-job guides containing only the
vital information needed for diagnosis, analysis, testing,
and repair.

Fundamental service information is available from other

sources covering basic theory of operation, fundamentals
of troubleshooting, general maintenance, and basic type
of failures and their causes.

TX,INTR,MB52 –19–12SEP97–1/1

TM2256 (09JAN07) D Series Motor Grader Repair

020207
PN=3
 Introduction

Technical Information Feedback Form

We need your help to continually improve our technical

publications. Please copy this page and FAX or mail your
comments, ideas and improvements.

SEND TO: John Deere Dubuque Works

P.O. Box 538
Attn: Publications Supervisor, Dept. 303
Dubuque, IA 52004-0538

FAX NUMBER: 563-589-5800

Ideas, Comments (Please State Page Number):

OVERALL, how would you rate the quality of this publication? (Check one)

Poor Fair Good Very Good Excellent

1 2 3 4 5 6 7 8 9 10

Company Name:

Technician Name:

Address:

Phone:

Fax No.:

Dealer Acct. No.:

THANK YOU!

TX,TM,FAX –19–03JUL01–1/1

TM2256 (09JAN07) D Series Motor Grader Repair

020207
PN=4
 Contents
00
SECTION 00—General Information SECTION 18—Operator’s Station
Group 001—Safety Group 1800—Removal and Installation
Group 0003—Torque Values Group 1810—Operator Enclosure
Group 1821—Seat and Seat Belt
SECTION 01—Wheels Group 1830—Heating and Air Conditioning
01
Group 0110—Powered Wheels and Fasteners
SECTION 19—Sheet Metal and Styling
Group 1921—Grille and Grille Housing
SECTION 02—Axles and Suspension Systems
Group 0225—Input Drive Shafts and U-Joints
SECTION 21—Main Hydraulic System
Group 0230—Non-Powered Wheel Axles
Group 2160—Hydraulic System 02
Group 0240—Powered Wheel Axles
Group 0250—Axle Shafts, Bearings, and Reduction
SECTION 34—Grading Device
Gears
Group 3415—Controls Linkage
Group 0260—Hydraulic System
Group 3440—Frames
Group 3450—Circle Gearbox
SECTION 03—Transmission 03
Group 3460—Hydraulic System
Group 0300—Removal and Installation
Group 0360—Hydraulic System SECTION 42—Ground Conditioning Tool
Group 4240—Frames
SECTION 04—Engine
Group 0400—Removal and Installation SECTION 99—Dealer Fabricated Tools 04
Group 9900—Dealer Fabricated Tools
SECTION 05—Engine Auxiliary System
Group 0510—Cooling System
Group 0560—External Fuel Supply Systems
05
SECTION 07—Torsional Isolator
Group 0752—Elements

SECTION 09—Steering System

Group 0920—Power Steering 07
Group 0960—Hydraulic System

SECTION 10—Service Brakes

Group 1011—Active Elements
Group 1060—Hydraulic System 09

SECTION 11—Park Brake

Group 1111—Active Elements

SECTION 17—Frame, Chassis or Supporting 10

Structure
Group 1740—Frame Installation

All information, illustrations and specifications in this 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. 11

COPYRIGHT  2007
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION Manual
Previous Editions
Copyright  2005, 2006

TM2256 (09JAN07) i D Series Motor Grader Repair

020207
PN=1
 Contents

00

01

02

03

04

05

07

09

10

11

TM2256 (09JAN07) ii D Series Motor Grader Repair

020207
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 Contents

17

18

19

21

34

42

99

INDX

TM2256 (09JAN07) iii D Series Motor Grader Repair

020207
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 Contents

17

18

19

21

34

42

99

INDX

TM2256 (09JAN07) iv D Series Motor Grader Repair

020207
PN=4
 00

Section 00
General Information
Contents

Page

Group 001—Safety . . . . . . . . . . . . . . . . . . . .00-001-1

Group 0003—Torque Values

Torque Value
Metric Bolt and Cap Screw . . . . . . . . . . . .00-0003-1
Additional Metric Cap Screw Torque
Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-2
Torque Value
Unified Inch Bolt and Cap Screw . . . . . . . .00-0003-4
Service Recommendations for 37° Flare
and 30° Cone Seat Connectors . . . . . . . . .00-0003-5
Service Recommendations for O-Ring
Boss Fittings . . . . . . . . . . . . . . . . . . . . . . .00-0003-6
Service Recommendations For Flared
Connections—Straight or Tapered
Threads . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-8
Service Recommendations For Flat Face
O-Ring Seal Fittings. . . . . . . . . . . . . . . . . .00-0003-9
Service Recommendation
O-Ring Face Seal Fittings with SAE
Inch Hex Nut and Stud End for High
Pressure. . . . . . . . . . . . . . . . . . . . . . . .00-0003-10
O-Ring Face Seal Fittings with Metric
Hex Nut and Stud End for Standard
Pressure. . . . . . . . . . . . . . . . . . . . . . . .00-0003-12
O-Ring Face Seal Fittings with Metric
Hex Nut and Stud End for High
Pressure. . . . . . . . . . . . . . . . . . . . . . . .00-0003-14
Service Recommendations for Metric
Series Four Bolt Flange Fitting . . . . . . . .00-0003-16
Service Recommendations For Inch
Series Four Bolt Flange Fittings. . . . . . . .00-0003-17
Service Recommendation
Inch Series Four Bolt Flange For High
Pressure. . . . . . . . . . . . . . . . . . . . . . . .00-0003-18
Service Recommendations For
Non-Restricted Banjo (Adjustable)
Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-19
Service Recommendations For O-Ring
Boss Fittings With Shoulder . . . . . . . . . . .00-0003-21
Service Recommendation
Metric 24° O-Ring Seal DIN 20078 . . . . .00-0003-24

TM2256 (09JAN07) 00-1 D Series Motor Grader Repair

020207
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 Contents

00

TM2256 (09JAN07) 00-2 D Series Motor Grader Repair

020207
PN=2
 Group 001
Safety
00
Recognize Safety Information 001
1

This is the safety alert symbol. When you see this

–UN–28AUG00
symbol on your machine or in this manual, be alert
for the potential of personal injury.

Follow the precautions and safe operating practices

T133555
highlighted by this symbol.

A signal word — DANGER, WARNING, or CAUTION — is

used with the safety alert symbol. DANGER identifies the
most serious hazards.

–19–28AUG00
On your machine, DANGER signs are red in color,
WARNING signs are orange, and CAUTION signs are
yellow. DANGER and WARNING signs are located near
specific hazards. General precautions are on CAUTION

T133588
labels.

TX03679,00016CC –19–03JAN07–1/1

Follow Safety Instructions

Read the safety messages in this manual and on the

–UN–24AUG00
machine. Follow these warnings and instructions carefully.
Review them frequently. Keep safety signs in good
condition. Replace missing or damaged safety signs. Be
sure new equipment components and repair parts include

T133556
the current safety signs. Replacement safety signs are
available from your John Deere dealer.

Be sure all operators of this machine understand every

safety message. Replace operator’s manual and safety
labels immediately if missing or damaged.

TX03679,00016F9 –19–11AUG03–1/1

TM2256 (09JAN07) 00-001-1 D Series Motor Grader Repair

020207
PN=9
 Safety

00
001 Operate Only If Qualified
2

Do not operate this machine unless you have read the machine functions with the machine in an open area
operator’s manual carefully and you have been before starting to work.
qualified by supervised training and instruction.
Know and observe all safety rules that may apply to
Familiarize yourself with the job site and your your work situation and your work site.
surroundings before operating. Try all controls and

TX03679,00016FA –19–03JAN07–1/1

Wear Protective Equipment

Guard against injury from flying pieces of metal or debris;

wear goggles or safety glasses.

Wear close fitting clothing and safety equipment

appropriate to the job.

–UN–23AUG88
Prolonged exposure to loud noise can cause impairment
or loss of hearing. Wear suitable hearing protection such
as earmuffs or earplugs to protect against objectionable or

TS206
uncomfortable loud noises.

TX03679,00016D0 –19–03JAN07–1/1

Avoid Unauthorized Machine Modifications

Modifications of this machine, or addition of Always contact an authorized dealer before making
unapproved products or attachments, may affect machine modifications that change the intended use,
machine stability or reliability, and may create a hazard weight or balance of the machine, or that alter
for the operator or others near the machine. The machine controls, performance or reliability.
installer of any modification which may affect the
electronic controls of this machine is responsible for
establishing that the modification does not adversely
affect the machine or its performance.

TX03679,00016B7 –19–11AUG03–1/1

TM2256 (09JAN07) 00-001-2 D Series Motor Grader Repair

020207
PN=10
 Safety

00
Inspect Machine 001
3

Inspect machine carefully each day by walking around it

before starting.

Keep all guards and shields in good condition and

–UN–18OCT88
properly installed. Fix damage and replace worn or broken
parts immediately. Pay special attention to hydraulic
hoses and electrical wiring.

T6607AQ
TX03679,0001734 –19–03JAN07–1/1

Stay Clear of Moving Parts

–UN–12SEP01
Entanglements in moving parts can cause serious injury.

Stop engine before examining, adjusting or maintaining

any part of machine with moving parts.

T133592
Keep guards and shields in place. Replace any guard or
shield that has been removed for access as soon as
service or repair is complete.

TX03679,00016D2 –19–03JAN07–1/1

Avoid High-Pressure Oils

This machine uses a high-pressure hydraulic system.

Escaping oil under pressure can penetrate the skin
causing serious injury.

–UN–17MAR06
Never search for leaks with your hands. Protect hands.
Use a piece of cardboard to find location of escaping oil.
Stop engine and relieve pressure before disconnecting
lines or working on hydraulic system.

T133509
If hydraulic oil penetrates your skin, see a doctor
immediately. Injected oil must be removed surgically
within hours or gangrene may result. Contact a
knowledgeable medical source or the Deere & Company
Medical Department in Moline, Illinois, U.S.A.
–UN–20SEP00
T133840

TX03679,00016D3 –19–10JAN07–1/1

TM2256 (09JAN07) 00-001-3 D Series Motor Grader Repair

020207
PN=11
 Safety

00
001 Beware of Exhaust Fumes
4

Prevent asphyxiation. Engine exhaust fumes can cause

sickness or death.

–UN–24AUG00
If you must operate in a building, provide adequate
ventilation. Use an exhaust pipe extension to remove the
exhaust fumes or open doors and windows to bring

T133546
outside air into the area.

TX03679,00016D4 –19–03JAN07–1/1

Prevent Fires

–UN–14SEP00
Handle Fuel Safely: Store flammable fluids away from
fire hazards. Never refuel machine while smoking or when
near sparks or flame.

T133552
Clean Machine Regularly: Keep trash, debris, grease
and oil from accumulating in engine compartment, around
fuel lines, hydraulic lines and electrical wiring. Never store
oily rags or flammable materials inside a machine
compartment.

–UN–07SEP00
Maintain Hoses and Wiring: Replace hydraulic hoses
immediately if they begin to leak, and clean up any oil

T133553
spills. Examine electrical wiring and connectors frequently
for damage.

Keep A Fire Extinguisher Available: Always keep a

multi-purpose fire extinguisher on or near the machine.

–UN–07SEP00
Know how to use extinguisher properly.

T133554

TX03679,00016F5 –19–03JAN07–1/1

Prevent Battery Explosions

Battery gas can explode. Keep sparks, lighted matches,

and open flame away from the top of battery.

Never check battery charge by placing a metal object

across the posts. Use a voltmeter or hydrometer.
–UN–23AUG88

Do not charge a frozen battery; it may explode. Warm

battery to 16°C (60°F).
TS204

TX03679,000174A –19–03JAN07–1/1

TM2256 (09JAN07) 00-001-4 D Series Motor Grader Repair

020207
PN=12
 Safety

00
Handle Chemical Products Safely 001
5

Exposure to hazardous chemicals can cause serious

–UN–25AUG00
injury. Under certain conditions, lubricants, coolants,
paints and adhesives used with this machine may be
hazardous.

T133580
If uncertain about safe handling or use of these chemical
products, contact your authorized dealer for a Material
Safety Data Sheet (MSDS) or go to
[Link] The MSDS describes physical
and health hazards, safe use procedures, and emergency
response techniques for chemical substances. Follow
MSDS recommendations to handle chemical products
safely.

TX03679,00016D7 –19–11AUG03–1/1

Dispose of Waste Properly

Improper disposal of waste can threaten the environment.

–UN–25AUG00
Fuel, oils, coolants, filters and batteries used with this
machine may be harmful if not disposed of properly.

Never pour waste onto the ground, down a drain, or into

T133567
any water source.

Air conditioning refrigerants can damage the atmosphere.

Government regulations may require using a certified
service center to recover and recycle used refrigerants.

If uncertain about the safe disposal of waste, contact your

local environmental or recycling center or your authorized
dealer for more information.

TX03679,0001733 –19–31JAN07–1/1

Prepare for Emergencies

Be prepared if an emergency occurs or a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service,

–UN–23AUG88

hospital, and fire department near your telephone.

TS291

TX03679,000174B –19–31JAN07–1/1

TM2256 (09JAN07) 00-001-5 D Series Motor Grader Repair

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PN=13
 Safety

00
001 Use Steps and Handholds Correctly
6

Prevent falls by facing the machine when you get on and

–UN–30AUG00
off. Maintain 3-point contact with steps and handrails.
Never use machine controls as handholds.

Use extra care when mud, snow, or moisture present

T133468
slippery conditions. Keep steps clean and free of grease
or oil. Never jump when exiting machine. Never mount or
dismount a moving machine.

TX03679,00016F2 –19–25JAN07–1/1

Start Only From Operator’s Seat

–UN–07SEP00
Avoid unexpected machine movement. Start engine only
while sitting in operator’s seat. Ensure all controls and
working tools are in proper position for a parked machine.

T133715
Never attempt to start engine from the ground. Do not
attempt to start engine by shorting across the starter
solenoid terminals.

TX03679,0001799 –19–03JAN07–1/1

Use and Maintain Seat Belt

Use seat belt when operating machine. Remember to

–19–14SEP00
fasten seat belt when loading and unloading from trucks
and during other uses.

T133716
Examine seat belt frequently. Be sure webbing is not cut
or torn. Replace seat belt immediately if any part is
damaged or does not function properly.

The complete seat belt assembly should be replaced

every three years, regardless of appearance.

TX03679,00016DD –19–03JAN07–1/1

TM2256 (09JAN07) 00-001-6 D Series Motor Grader Repair

020207
PN=14
 Safety

00
Prevent Unintended Machine Movement 001
7

Be careful not to accidentally actuate controls when

co-workers are present.

Lower all equipment to the ground during work

–UN–31OCT01
interruptions. Place transmission control and park brake
lever in park position “P” before allowing anyone to
approach the machine.

T147606
Follow these same precautions before standing up,
leaving the operator’s seat, or exiting the machine.

TX03679,00017C5 –19–02MAY01–1/1

Avoid Work Site Hazards

Avoid contact with gas lines, buried cables and water

lines. Call utility line location services to identify all

–UN–15JUN01
underground utilities before starting work.

Prepare work site properly. Avoid operating near

structures or objects that could fall onto the machine.

T141905
Clear away debris that could move unexpectedly if run
over.

Avoid contact with overhead obstacles or overhead

electrical lines. Never move machine closer than 3 m (10
ft) plus twice the line insulator length to overhead wires.

Keep bystanders clear at all times. Use barricades or a

signal person to keep vehicles and pedestrians away. Use

–UN–15MAY01
a signal person if moving machine in congested areas or
where visibility is restricted. Always keep signal person in
view. Coordinate hand signals before starting machine.
T141904

Operate only on solid footing with strength sufficient to

support machine. Be especially alert working near
embankments or excavations.

TX03679,00017A4 –19–14MAY01–1/1

TM2256 (09JAN07) 00-001-7 D Series Motor Grader Repair

020207
PN=15
 Safety

00
001 Keep Riders Off Machine
8

Only allow operator on machine.

–UN–07MAY01
Riders are subject to injury. They may fall from machine,
be caught between machine parts, or be struck by foreign
objects.

T141744
Riders may obstruct operator’s view or impair his ability to
operate machine safely.

TX03679,00017A2 –19–20APR01–1/1

Avoid Backover Accidents

Before moving machine, be sure all persons or

vehicles are clear of machine path. Turn around and

–UN–04MAY01
look directly for best visibility. Use mirrors to assist in
checking all around machine. Keep windows and mirrors
clean, adjusted, and in good repair.

T141745
Be certain reverse warning alarm is working properly.

Use a signal person when backing if view is

obstructed or when in close quarters. Keep signal
person in view at all times. Use prearranged hand signals
to communicate.

TX03679,00017A3 –19–20APR01–1/1

TM2256 (09JAN07) 00-001-8 D Series Motor Grader Repair

020207
PN=16
 Safety

00
Avoid Machine Tip Over 001
9

Use seat belt at all times.

–19–14SEP00
Do not jump if the machine tips. You will be unlikely to
jump clear and the machine may crush you.

T133716
Load and unload from trucks or trailers carefully. Be
sure truck is wide enough and on a firm level surface. Use
loading ramps and attach them properly to truck bed.

Be careful on slopes. Drive directly up or down steep

slopes whenever possible. Minimize articulation for best

–UN–22MAY01
machine stability when driving and turning across slopes.
Use extra care on wet, soft or frozen surfaces because
machine may slide more easily with these conditions.

T142271
Ensure solid footing. Do not operate close to banks or
open excavations that may cave in and cause machine to
top or fall. fall.

TX03679,00017A5 –19–02MAY01–1/1

Operating Or Traveling On Public Roads

Machines that work near vehicle traffic or travel slower

than normal highway speeds must have proper lighting

–UN–22MAY01
and markings to assure they are visible to other drivers.

Install additional lights, beacons, slow moving vehicle

(SMV) emblems, or other devices and use as required to

T141891
make the machine visible and identify it as a work
machine. Check state and local regulations to assure
compliance. Keep these devices clean and in working
condition.

TX03679,00017C8 –19–14JUN01–1/1

TM2256 (09JAN07) 00-001-9 D Series Motor Grader Repair

020207
PN=17
 Safety

00
001 Inspect and Maintain ROPS
10

A damaged roll-over protective structure (ROPS) To maintain the ROPS:

should be replaced, not reused.
• Replace missing hardware using correct grade
The protection offered by ROPS will be impaired if hardware.
ROPS is subjected to structural damage, is involved in • Check hardware torque.
an overturn incident, or is in any way altered by • Check isolation mounts for damage, looseness or
welding, bending, drilling, or cutting. wear; replace them if necessary.
• Check ROPS for cracks or physical damage.
If ROPS was loosened or removed for any reason,
inspect it carefully before operating the machine again.

TX03679,000179F –19–20APR01–1/1

Add and Operate Attachments Safely

Always verify compatibility of attachments by that all connections are secure and attachment
contacting your authorized dealer. Adding unapproved responds properly to controls.
attachments may affect machine stability or reliability,
and may create a hazard for others near the machine. Carefully read attachment manual and follow all
instructions and warnings. In an area free of
Ensure that a qualified person is involved in bystanders and obstructions, carefully operate
attachment installation. Add guards to machine if attachment to learn its characteristics and range of
operator protection is required or recommended. Verify motion.

TX03679,00016F0 –19–24JAN07–1/1

TM2256 (09JAN07) 00-001-10 D Series Motor Grader Repair

020207
PN=18
 Safety

00
Park And Prepare For Service Safely 001
11

Warn others of service work. Always park and prepare

your machine for service or repair properly.

• Park machine on a level surface and lower equipment

–19–14DEC01
to the ground.
• Place transmission control and park brake lever in “P”
park position. Stop engine and remove key.
• Attach a “Do Not Operate” tag in an obvious place in

T133332
the operator’s station.

Securely support machine or attachment before working

under it.

• Do not support machine with any hydraulically actuated

equipment.
• Do not support machine with cinder blocks or wooden
pieces that may crumble or crush.
• Do not support machine with a single jack or other

–UN–23AUG88
devices that may slip out of place.

Understand service procedures before beginning repairs.

Keep service area clean and dry. Use two people

TS229
whenever the engine must be running for service work.

TX03679,00016E9 –19–02MAY01–1/1

Service Cooling System Safely

Explosive release of fluids from pressurized cooling

system can cause serious burns.

Shut off engine. Only remove filler cap when cool enough
to touch with bare hands. Slowly loosen cap to first stop
–UN–23AUG88

to relieve pressure before removing completely.

TS281

DX,RCAP –19–04JUN90–1/1

TM2256 (09JAN07) 00-001-11 D Series Motor Grader Repair

020207
PN=19
 Safety

00
001 Remove Paint Before Welding or Heating
12

Hazardous fumes can be generated when paint is heated

by welding or using a torch. Dust from sanding or grinding

–UN–24AUG00
paint can also be hazardous.

Remove paint to at least 76 mm (3 in.) from area to be

heated. Wear an approved respirator when sanding or

T133546
grinding paint. If a solvent or paint stripper is used, wash
area with soap and water. Remove solvent or paint
stripper containers from work area and allow fumes to
disperse at least 15 minutes before welding or heating.

Work outside or in a well-ventilated area. Dispose of

waste, paint and solvents properly.

TX03679,0001732 –19–04DEC06–1/1

Make Welding Repairs Safely

NOTE: Disable electrical power before welding. Turn off

–UN–31AUG00
main battery switch or disconnect positive battery
cable. Separate harness connectors to engine and
vehicle microprocessors.

T133547
Avoid welding or heating near pressurized fluid lines.
Flammable spray may result and cause severe burns if
pressurized lines fail as a result of heating. Do not let heat
go beyond work area to nearby pressurized lines.

Remove paint properly. Do not inhale paint dust or fumes.

Use a qualified welding technician for structural repairs.
Make sure there is good ventilation. Wear eye protection
and protective equipment when welding.

TX03679,00016D5 –19–03JAN07–1/1

Drive Metal Pins Safely

–UN–14SEP00

Always wear protective goggles or safety glasses and

other protective equipment before striking hardened parts.
Hammering hardened metal parts such as pins and
bucket teeth may dislodge chips at high velocity.
T133738

Use a soft hammer or a brass bar between hammer and

object to prevent chipping.

TX03679,0001745 –19–03JAN07–1/1

TM2256 (09JAN07) 00-001-12 D Series Motor Grader Repair

020207
PN=20
 Group 0003
Torque Values
00
Metric Bolt and Cap Screw Torque Values 0003
1

–UN–07SEP99
TORQ2
Top—Property Class and Head Markings; Bottom—Property Class and Nut Markings

METRIC BOLT AND CAP SCREW TORQUE VALUES—Tolerance is ±10% unless otherwise specified
Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9
a b a b a b
Thread Lubricated Dry Lubricated Dry Lubricated Dry Lubricateda Dryb
Size N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft)
M6 4.7 (3.5) 6 (4.4) 9 (6.6) 11.5 (8.5) 13 (9.5) 16.5 (12.2) 15.5 (11.5) 19.5 (14.5)
M8 11.5 (8.5) 14.5 (10.7) 22 (16) 28 (20.5) 32 (23.5) 40 (29.5) 37 (27.5) 47 (35)
M10 23 (17) 29 (21) 43 (32) 55 (40) 63 (46) 80 (59) 75 (55) 95 (70)
M12 40 (29.5) 50 (37) 75 (55) 95 (70) 110 (80) 140 (105) 130 (95) 165 (120)
M14 63 (46) 80 (59) 120 (88) 150 (110) 175 (130) 220 (165) 205 (150) 260 (190)
M16 100 (74) 125 (92) 190 (140) 240 (175) 275 (200) 350 (255) 320 (235) 400 (300)
M18 135 (100) 170 (125) 265 (195) 330 (245) 375 (275) 475 (350) 440 (325) 560 (410)
M20 190 (140) 245 (180) 375 (275) 475 (350) 530 (390) 675 (500) 625 (460) 790 (580)
M22 265 (195) 330 (245) 510 (375) 650 (480) 725 (535) 920 (680) 850 (625) 1080 (800)
M24 330 (245) 425 (315) 650 (480) 820 (600) 920 (680) 1150 (850) 1080 (800) 1350 (1000)
M27 490 (360) 625 (460) 950 (700) 1200 (885) 1350 (1000) 1700 (1250) 1580 (1160) 2000 (1475)
M30 660 (490) 850 (625) 1290 (950) 1630 (1200) 1850 (1350) 2300 (1700) 2140 (1580) 2700 (2000)
M33 900 (665) 1150 (850) 1750 (1300) 2200 (1625) 2500 (1850) 3150 (2325) 2900 (2150) 3700 (2730)
M36 1150 (850) 1450 (1075) 2250 (1650) 2850 (2100) 3200 (2350) 4050 (3000) 3750 (2770) 4750 (3500)
a
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
b
"Dry" means plain or zinc plated without any lubrication.

Fasteners should be replaced with the same or higher property class.

CAUTION: Use only metric tools on metric hardware. If higher property class fasteners are used, these should only be
Other tools may not fit properly. Tool may slip and tightened to the strength of the original.
cause injury.
Make sure fastener threads are clean and that you properly start
thread engagement. This will prevent them from failing when
DO NOT use these values if a different torque value or tightening tightening.
procedure is given for a specific application. Torque values listed are
for general use only. Check tightness of fasteners periodically. Tighten plastic insert or crimped steel-type lock nuts to approximately
50 percent of the dry torque shown in the chart, applied to the nut,
Shear bolts are designed to fail under predetermined loads. Always not to the bolt head. Tighten toothed or serrated-type lock nuts to the
replace shear bolts with identical property class. full torque value.

OUT3035,TORQUE2 –19–22MAR06–1/1

TM2256 (09JAN07) 00-0003-1 D Series Motor Grader Repair

020207
PN=21
 Torque Values

00
0003 Additional Metric Cap Screw Torque Values
2

–UN–18OCT88
CAUTION: Use only metric tools on metric
hardware. Other tools may not fit properly. They
may slip and cause injury.

T6873AA
Check tightness of cap screws periodically. Torque values
listed are for general use only. Do not use these values if
a different torque value or tightening procedure is listed
for a specific application.

–UN–18OCT88
Shear bolts are designed to fail under predetermined
loads. Always replace shear bolts with identical grade.

Fasteners should be replaced with the same or higher

T6873AB
grade. If higher grade fasteners are used, these should
only be tightened to the strength of the original.

Make sure fastener threads are clean and you properly

start thread engagement. This will prevent them from
failing when tightening.

–UN–18OCT88
Tighten cap screws having lock nuts to approximately 50
percent of amount shown in chart.

T6873AC
Continued on next page 04T,90,M170 –19–29SEP99–1/2

TM2256 (09JAN07) 00-0003-2 D Series Motor Grader Repair

020207
PN=22
 Torque Values

00
METRIC CAP SCREW TORQUE VALUESa 0003
3
T-Bolt H-Bolt M-Bolt
Nominal
Dia N•m lb-ft N•m lb-ft N•m lb-ft
8 29 21 20 15 10 7
10 63 46 45 33 20 15
12 108 80 88 65 34 25
14 176 130 137 101 54 40
16 265 195 206 152 78 58
18 392 289 294 217 118 87
20 539 398 392 289 167 125
22 735 542 539 398 216 159
24 931 687 686 506 274 202
27 1372 1012 1029 759 392 289
30 1911 1410 1421 1049 539 398
33 2548 1890 1911 1410 735 542
36 3136 2314 2401 1772 931 687
a
Torque tolerance is ±10%.

04T,90,M170 –19–29SEP99–2/2

TM2256 (09JAN07) 00-0003-3 D Series Motor Grader Repair

020207
PN=23
 Torque Values

00
0003 Unified Inch Bolt and Cap Screw Torque Values
4

–UN–27SEP99
TORQ1A
Top—SAE Grade and Head Markings; Bottom—SAE Grade and Nut Markings

UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUES—Tolerance is ±10% unless otherwise specified
Grade 1 (No Mark) Grade 2a (No Mark) Grade 5, 5.1 or 5.2 Grade 8 or 8.2
b c b c b c
Thread Lubricated Dry Lubricated Dry Lubricated Dry Lubricatedb Dryc
Size N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft)
1/4 3.8 (2.8) 4.7 (3.5) 6 (4.4) 7.5 (5.5) 9.5 (7) 12 (9) 13.5 (10) 17 (12.5)
5/16 7.7 (5.7) 9.8 (7.2) 12 (9) 15.5 (11.5) 19.5 (14.5) 25 (18.5) 28 (20.5) 35 (26)
3/8 13.5 (10) 17.5 (13) 22 (16) 27.5 (20) 35 (26) 44 (32.5) 49 (36) 63 (46)
7/16 22 (16) 28 (20.5) 35 (26) 44 (32.5) 56 (41) 70 (52) 80 (59) 100 (74)
1/2 34 (25) 42 (31) 53 (39) 67 (49) 85 (63) 110 (80) 120 (88) 155 (115)
9/16 48 (35.5) 60 (45) 76 (56) 95 (70) 125 (92) 155 (115) 175 (130) 220 (165)
5/8 67 (49) 85 (63) 105 (77) 135 (100) 170 (125) 215 (160) 240 (175) 305 (225)
3/4 120 (88) 150 (110) 190 (140) 240 (175) 300 (220) 380 (280) 425 (315) 540 (400)
7/8 190 (140) 240 (175) 190 (140) 240 (175) 490 (360) 615 (455) 690 (510) 870 (640)
1 285 (210) 360 (265) 285 (210) 360 (265) 730 (540) 920 (680) 1030 (760) 1300 (960)
1-1/8 400 (300) 510 (375) 400 (300) 510 (375) 910 (670) 1150 (850) 1450 (1075) 1850 (1350)
1-1/4 570 (420) 725 (535) 570 (420) 725 (535) 1280 (945) 1630 (1200) 2050 (1500) 2600 (1920)
1-3/8 750 (550) 950 (700) 750 (550) 950 (700) 1700 (1250) 2140 (1580) 2700 (2000) 3400 (2500)
1-1/2 990 (730) 1250 (930) 990 (730) 1250 (930) 2250 (1650) 2850 (2100) 3600 (2650) 4550 (3350)
a
Grade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long,
and for all other types of bolts and screws of any length.
b
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
c
"Dry" means plain or zinc plated without any lubrication.

DO NOT use these values if a different torque value or tightening Make sure fastener threads are clean and that you properly start
procedure is given for a specific application. Torque values listed are thread engagement. This will prevent them from failing when
for general use only. Check tightness of fasteners periodically. tightening.

Shear bolts are designed to fail under predetermined loads. Always Tighten plastic insert or crimped steel-type lock nuts to approximately
replace shear bolts with identical grade. 50 percent of the dry torque shown in the chart, applied to the nut,
not to the bolt head. Tighten toothed or serrated-type lock nuts to the
Fasteners should be replaced with the same or higher grade. If full torque value.
higher grade fasteners are used, these should only be tightened to
the strength of the original.

OUT3035,TORQUE1 –19–14JAN04–1/1

TM2256 (09JAN07) 00-0003-4 D Series Motor Grader Repair

020207
PN=24
 Torque Values

00
Service Recommendations for 37° Flare and 0003
5
30° Cone Seat Connectors

1. Inspect flare and flare seat. They must be free of dirt

or obvious defects.

–UN–18OCT88
2. Defects in tube flare cannot be repaired.
Overtightening a defective flared fitting will not stop
leaks.

T6234AC
3. Align tube with fitting before attempting to start nut.

4. Lubricate male threads with hydraulic fluid or petroleum

jelly.

5. Index angle fittings and tighten by hand.

6. Tighten fitting or nut to torque value shown on torque

chart. Do not allow hoses to twist when tightening
fittings.

STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART

Thread Size N•m lb-ft
3/8 - 24 UNF 8 6
7/16 - 20 UNF 12 9
1/2 - 20 UNF 16 12
9/16 - 18 UNF 24 18
3/4 - 16 UNF 46 34
7/8 - 14 UNF 62 46
1-1/16 - 12 UN 102 75
1-3/16 - 12 UN 122 90
1-5/16 - 12 UN 142 105
1-5/8 - 12 190 140
1-7/8 - 12 UN 217 160
NOTE: Torque tolerance is ± 10%.

T82,BHMA,EL –19–29SEP99–1/1

TM2256 (09JAN07) 00-0003-5 D Series Motor Grader Repair

020207
PN=25
 Torque Values

00
0003 Service Recommendations for O-Ring Boss
6
Fittings

Straight Fitting

1. Inspect O-ring boss seat for dirt or defects.

–UN–18OCT88
2. Lubricate O-ring with petroleum jelly. Place electrical
tape over threads to protect O-ring. Slide O-ring over
tape and into O-ring groove of fitting. Remove tape.

T6243AE
3. Tighten fitting to torque value shown on chart.

Continued on next page 04T,90,K66 –19–29SEP99–1/2

TM2256 (09JAN07) 00-0003-6 D Series Motor Grader Repair

020207
PN=26
 Torque Values

00
Angle Fitting 0003
7

1. Back-off lock nut (A) and back-up washer (B)

completely to head-end (C) of fitting.

2. Turn fitting into threaded boss until back-up washer

–UN–18OCT88
contacts face of boss.

3. Turn fitting head-end counterclockwise to proper index

(maximum of one turn).

T6520AB
NOTE: Do not allow hoses to twist when tightening
fittings.

4. Hold fitting head-end with a wrench and tighten locknut

and back-up washer to proper torque value.

STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART

Thread Size N•m lb-ft
3/8-24 UNF 8 6
7/16-20 UNF 12 9
1/2-20 UNF 16 12
9/16-18 UNF 24 18
3/4-16 UNF 46 34
7/8-14 UNF 62 46
1-1/16-12 UN 102 75
1-3/16-12 UN 122 90
1-5/16-12 UN 142 105
1-5/8-12 UN 190 140
1-7/8-12 UN 217 160
NOTE: Torque tolerance is ± 10%.

04T,90,K66 –19–29SEP99–2/2

TM2256 (09JAN07) 00-0003-7 D Series Motor Grader Repair

020207
PN=27
 Torque Values

00
0003 Service Recommendations For Flared
8
Connections—Straight or Tapered Threads

1. Inspect flare and flare seat. They must be free of dirt

or obvious defects.

–UN–18OCT88
2. Defects in the tube flare cannot be repaired.
Overtightening a defective flared fitting will not stop
leaks.

T6873AE
3. Align the tube with the fitting before attempting to start
the nut.
Straight Thread
4. Lubricate the male threads with hydraulic fluid or
petroleum jelly.

5. Index angle fittings and tighten by hand.

6. Tighten fitting or nut to torque value shown on the

chart. Do not allow hoses to twist when tightening

–UN–18OCT88
fittings.
a
TORQUE CHART

T6873AD
b
Straight Thread Tapered Thread
Thread
Size N•m lb-ft N•m lb-ft Tapered Thread
1/8 15 11
1/4 20 15 45 33
3/8 29 21 69 51
1/2 49 36 93 69
3/4 69 51 176 130
1 157 116 343 253
1-1/2 196 145 539 398
2 255 188 588 434
Torque tolerance is ±10%.
a

b
With seat face.

NOTE: If female thread is cast iron (control valves, brake

valves motors, etc.), torque must be reduced
approximately 10%.

04T,90,M171 –19–28JAN92–1/1

TM2256 (09JAN07) 00-0003-8 D Series Motor Grader Repair

020207
PN=28
 Torque Values

00
Service Recommendations For Flat Face O-Ring Seal Fittings 0003
9

1. Inspect the fitting sealing surfaces and O-ring. They fittings, use backup wrench on straight hose
must be free of dirt or defects. couplings.

2. Lubricate O-rings and install into grove using IMPORTANT: Tighten fittings to 150% of listed
petroleum jelly to hold in place. torque value if indexing is necessary
or if fitting is attached to an
3. Index angle fittings and tighten by hand pressing actuating devise.
joint together to insure O-ring remains in place.
Tighten fittings to 50% of listed
4. Tighten fitting or nut to torque value shown on the torque value if used in aluminum
chart. Do not allow hoses to twist when tightening housing.

FLAT FACE O-RING SEAL FITTING TORQUE*

Nomial Tube O.D. Thread Size Swivel Nut Bulkhead Nut
mm in. in. N•m lb-ft N•m lb-ft
6.35 0.250 9/16-18 16 12 12 9
9.52 0.375 11/16-16 24 18 24 18
12.70 0.500 13/16-16 50 37 46 34
15.88 0.625 1-14 69 51 62 46
19.05 0.750 1 3/16-12 102 75 102 75
22.22 0.875 1 3/16-12 102 75 102 75
25.40 1.000 1 7/16-12 142 105 142 105
31.75 1.250 1 11/16-12 190 140 190 140
38.10 1.500 2-12 217 160 217 160
*Torque tolerance is +15 -20% unless otherwise specified.
Stud End O-ring Seal Torque for Straight and Adjustable Fittings*
Thread Size Straight Hex Size Locknut Hex Size Straight Fitting or Locknut Toque
Inch Inch Inch N•m lb-ft
3/8-24 5/8 9/16 12 9
7/16-20 5/8 5/8 21 15
1/2-20 3/4 11/16 26 19
9/16-18 3/4 3/4 34 25
3/4-16 7/8 15/16 73 55
7/8-14 1 1/16 1 1/16 104 76
1 1/16-12 1 1/4 1 3/8 176 130
1 3/16-12 1 3/8 1 1/2 230 170
1 5/16-12 1 1/2 1 5/8 285 210
*Torque tolerance is +15 -20% unless otherwise specified.

04T,90,K67 –19–02MAR00–1/1

TM2256 (09JAN07) 00-0003-9 D Series Motor Grader Repair

020207
PN=29
 Torque Values

00
0003 O-Ring Face Seal Fittings With SAE Inch Hex Nut And Stud End For High Pressure
10
Service Recommendations

A B
C D

–UN–12DEC01
E
H F
F

H70406
E

A—90° Swivel Elbow and Tube C—Stud Straight and Tube Nut E—Stud End G—Swivel Nut
Nut D—Bulkhead Union and Nut F—Tube Nut H—Hex Nut
B—90° Adjustable Stud Elbow

O-RING FACE SEAL FITTINGS WITH SAE INCH HEX NUT AND STUD END FOR HIGH PRESSURE, ABOVE 27 600 kPa (276 bar) (4000
psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified
Nominal Tube OD or Hose ID O-Ring Face Seal Hose or Tube Swivel Nut Bulkhead Nut
Metric Tube Inch Tube OD or Hose ID Thread Size Hex Size Torque Hex Size Torque
OD
mm Dash Size mm (in.) in. in. N•m (lb-ft) in. N•m (lb-ft)
5 -3 4.78 (0.188) — — — — —
6 -4 6.35 (0.250) 9/16-18 11/16 24 (18) 13/16 32 (24)
8 -5 7.92 (0.312) — — — — —
10 -6 9.53 (0.375) 11/16-16 13/16 37 (27) 1 42 (31)
12 -8 12.70 (0.500) 13/16-16 15/16 75 (55) 1-1/8 93 (69)
16 -10 15.88 (0.625) 1-14 1-1/8 103 (76) 1-5/16 118 (87)
20 -12 19.05 (0.750) 1-3/16-12 1-3/8 152 (112) 1-1/2 175 (129)
22 -14 22.23 (0.875) 1-3/16-12 — 152 (112) — 175 (129)
25 -16 25.40 (1.000) 1-7/16-12 1-5/8 214 (158) 1-3/4 247 (182)
32 -20 31.75 (1.250) 1-11/16-12 1-7/8 286 (211) 2 328 (242)
38 -24 38.10 (1.500) 2-12 2-1/4 326 (240) 2-3/8 374 (276)

Continued on next page OUT3035,0000420 –19–14JAN04–1/2

TM2256 (09JAN07) 00-0003-10 D Series Motor Grader Repair

020207
PN=30
 Torque Values

00
O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH SAE INCH STUD END FOR HIGH PRESSURE, ABOVE 27 600 0003
kPa (276 bar) (4000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified 11
Thread Size Straight Hex Sizea Adjustable Nut Hex Size Steel or Gray Iron Torque
in. in. in. N•m (lb-ft)
3/8-24 5/8 9/16 18 (13)
7/16-20 5/8 5/8 24 (18)
1/2-20 3/4 11/16 30 (22)
9/16-18 3/4 3/4 37 (27)
3/4-16 7/8 15/16 75 (55)
7/8-14 1-1/16 1-1/16 103 (76)
1-1/16-12 1-1/4 1-3/8 177 (131)
1-3/16-12 1-3/8 1-1/2 231 (170)
1-5/16-12 1-1/2 1-5/8 270 (199)
1-5/8-12 1-3/4 1-7/8 286 (211)
1-7/8-12 2-1/8 2-1/8 326 (240)
a
Straight hex size applies to fittings only and may not be the same as the corresponding plug of the same thread size.

1. Inspect fitting and connector sealing surfaces and To protect an O-ring from threads, wrap electrical
the O-rings. They must be free of dirt, scratches, tape over the threads. Slide O-ring over the tape
nicks, and burrs. O-ring must be free of dirt, cuts, into the turned down section. Remove the tape.
cracks, swelling or flatten condition.
4. Turn fitting into the boss by hand until face of nut or
2. Back the stud end hex nut off as far as possible. washer squeezes the O-ring into the seat and
Push backup washer towards the nut to fully contacts face of boss. Loosen adjustable fittings no
expose the turn down section. Washer must fit more than one turn for alignment.
turned down section and not be too loose
Hold connections together while tightening nut to
3. Lubricate O-rings using a thin film of clean hydraulic ensure O-ring remains in place.
oil or as needed, petroleum jelly to hold O-ring in
place. 5. Tighten fitting or nut to torque value shown. Use a
second wrench to hold the fitting in position or to
Install O-ring into groove making sure it is seated at keep hose from twisting while tightening nut.
the bottom. Excess petroleum jelly will prevent
seating of O-ring and cause it to pop out.

OUT3035,0000420 –19–14JAN04–2/2

TM2256 (09JAN07) 00-0003-11 D Series Motor Grader Repair

020207
PN=31
 Torque Values

00
0003 O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For Standard Pressure
12
Service Recommendations

1 2 3 4
10

–UN–18NOV03
7 9
11 8 11
6 6 5
10 11

T196337
10
8 8
T196337

1—90° Swivel Elbow 4—Bulkhead Union and Nut 7—Swivel Nut 10—O-Ring
2—90° Adjustable Stud Elbow 5—External Hex Stud End Plug 8—Stud End 11—Identification Groove
3—Stud Straight 6—Tube Nut 9—Hex Nut

O-RING FACE SEAL AND FITTINGS WITH METRIC HEX NUT AND STUD END FOR STANDARD PRESSURE, BELOW 27 600 kPa
(275.8 bar) (4,000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified
Nominal Tube OD or Hose ID O-Ring Face Seal Hose or Tube Swivel Nut Bulkhead Nut
Metric Tube Inch Tube OD or Hose ID Thread Size Hex Size Torque Hex Size Torque
OD
mm Dash Size mm (in.) in. mm N•m (lb-ft) mm N•m (lb-ft)
4 -2 3.18 (0.125) — — — — —
5 -3 4.78 (0.188) — — — — —
6 -4 6.35 (0.250) 9/16-18 17 16 (12) 22 32 (24)
8 -5 7.92 (0.312) — — — — —
10 -6 9.53 (0.375) 11/16-16 22 24 (18) 27 42 (31)
12 -8 12.70 (0.500) 13/16-16 24 50 (37) 30 93 (69)
16 -10 15.88 (0.625 1-14 30 69 (51) 36 118 (87)
20 -12 19.05 (0.750) 1-3/16-12 36 102 (75) 41 175 (129)
22 -14 22.23 (0.875) 1-3/16-12 36 102 (75) 41 175 (129)
25 -16 25.40 (1.000) 1-7/16-12 41 142 (105) 46 247 (182)
28 — — — — — — —
32 -20 31.75 (1.250) 1-11/16-12 50 190 (140) 50 328 (242)
38 -24 38.10 (1.500) 2-12 60 217 (160) 60 374 (276)
50 -32 50.80 (2.000) — — — — —

Continued on next page OUT3035,0000366 –19–14JAN04–1/2

TM2256 (09JAN07) 00-0003-12 D Series Motor Grader Repair

020207
PN=32
 Torque Values

00
O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH METRIC STUD END FOR STANDARD PRESSURE, BELOW 27 0003
600 kPa (275.8 bar) (4,000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified 13
Thread Sizea Straight Hex Sizeb Adjustable Nut Hex Steel or Gray Iron Torque Aluminum or Brass
Size Torque
mm. mm mm N•m (lb-ft) N•m (lb-ft)
M8 x 1 12 12 8 (6) 5 (4)
M10 x 1 14 14 15 (11) 10 (7)
M12 x 1.5 17 17 25 (18) 17 (12)
M14 x 1.5 19 19 40 (30) 27 (20)
M16 x 1.5 22 22 45 (33) 30 (22)
M18 x 1.5 24 24 50 (37) 33 (25)
M22 x 1.5 27 27 69 (51) 46 (34)
M27 x 2 32 32 100 (74) 67 (49)
M30 x 2 36 36 130 (96) 87 (64)
M33 x 2 41 41 160 (118) 107 (79)
M38 x 2 46 46 176 (130) 117 (87)
M42 x 2 50 50 210 (155) 140 (103)
M48 x 2 55 55 260 (192) 173 (128)
M60 x 2 65 65 315 (232) 210 (155)
a
Stud end threads are identified as metric by an identification groove in the hex nut next to the O-ring.
b
Straight hex size applies to fittings only and may not be the same as the corresponding plug of the same thread size.

1. Inspect fitting and connector sealing surfaces and To protect an O-ring from threads, wrap electrical
the O-rings. They must be free of dirt, scratches, tape over the threads. Slide O-ring over the tape
nicks, and burrs. O-ring must be free of dirt, cuts, into the turned down section. Remove the tape.
cracks, swelling or flatten condition.
4. Turn fitting into the boss by hand until face of nut or
2. Back the stud end hex nut off as far as possible. washer squeezes the O-ring into the seat and
Push backup washer towards the nut to fully contacts face of boss. Loosen adjustable fittings no
expose the turn down section. Washer must fit more than one turn for alignment.
turned down section and not be too loose
Hold connections together while tightening nut to
3. Lubricate O-rings using a thin film of clean hydraulic ensure O-ring remains in place.
oil or as needed, petroleum jelly to hold O-ring in
place. 5. Tighten fitting or nut to torque value shown. Use a
second wrench to hold the fitting in position or to
Install O-ring into groove making sure it is seated at keep hose from twisting while tightening nut.
the bottom. Excess petroleum jelly will prevent
seating of O-ring and cause it to pop out.

OUT3035,0000366 –19–14JAN04–2/2

TM2256 (09JAN07) 00-0003-13 D Series Motor Grader Repair

020207
PN=33
 Torque Values

00
0003 O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For High Pressure Service
14
Recommendations

1 2 3 4
10

–UN–18NOV03
7 9
11 8 11
6 6 5
10 11

T196337
10
8 8
T196337

1—90° Swivel Elbow 4—Bulkhead Union and Nut 7—Swivel Nut 10—O-Ring
2—90° Adjustable Stud Elbow 5—External Hex Stud End Plug 8—Stud End 11—Identification Groove
3—Stud Straight 6—Tube Nut 9—Hex Nut

O-RING FACE SEAL FITTINGS WITH METRIC HEX NUT AND STUD END FOR HIGH PRESSURE, ABOVE 27 600 kPa (275.8 bar) (4,000
psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified
Nominal Tube OD or Hose ID O-Ring Face Seal Hose or Tube Swivel Nut Bulkhead Nut
Metric Tube Inch Tube OD or Hose ID Thread Size Hex Size Torque Hex Size Torque
OD
mm Dash Size mm (in.) in. mm N•m (lb-ft) mm N•m (lb-ft)
4 -2 3.18 (0.125) — — — — —
5 -3 4.78 (0.188) — — — — —
6 -4 6.35 (0.250) 9/16-18 17 24 (18) 22 32 (24)
8 -5 7.92 (0.312) — — — — —
10 -6 9.53 (0.375) 11/16-16 22 37 (27) 27 42 (31)
12 -8 12.70 (0.500) 13/16-16 24 75 (55) 30 93 (69)
16 -10 15.88 (0.625) 1-14 30 103 (76) 36 118 (87)
20 -12 19.05 (0.750) 1-3/16-12 36 152 (112) 41 175 (129)
22 -14 22.23 (0.875) 1-3/16-12 36 152 (112) 41 175 (129)
25 -16 25.40 (1.000) 1-7/16-12 41 214 (158) 46 247 (182)
28 — — — — — — —
32 -20 31.75 (1.250) 1-11/16-12 — 286 (211) 50 328 (242)
38 -24 38.10 (1.500) 2-12 — 326 (240) 60 374 (276)

Continued on next page OUT3035,0000421 –19–14JAN04–1/2

TM2256 (09JAN07) 00-0003-14 D Series Motor Grader Repair

020207
PN=34
 Torque Values

00
O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH METRIC STUD END FOR HIGH PRESSURE, ABOVE 27 600 0003
KPA (275.8 BAR) (4,000 PSI), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified 15
Thread Sizea Straight Hex Sizeb Adjustable Nut Hex Size Steel or Gray Iron Torque
mm. mm mm N•m (lb-ft)
M8 x 1 12 12 8 (6)
M10 x 1 14 14 15 (11)
M12 x 1.5 17 17 35 (26)
M14 x 1.5 19 19 45 (33)
M16 x 1.5 22 22 55 (41)
M18 x 1.5 24 24 70 (52)
M22 x 1.5 27 27 100 (74)
M27 x 2 32 32 170 (125)
M30 x 2 36 36 215 159)
M33 x 2 41 41 260 (192)
M38 x 2 46 46 320 (236)
M42 x 2 50 50 360 (266)
M48 x 2 55 55 420 (310)
a
Stud end threads are identified as metric by an identification groove in the hex nut next to the O-ring.
b
Straight hex size applies to fittings only and may not be the same as the corresponding plug of the same thread size.

1. Inspect fitting and connector sealing surfaces and To protect an O-ring from threads, wrap electrical
the O-rings. They must be free of dirt, scratches, tape over the threads. Slide O-ring over the tape
nicks, and burrs. O-ring must be free of dirt, cuts, into the turned down section. Remove the tape.
cracks, swelling or flatten condition.
4. Turn fitting into the boss by hand until face of nut or
2. Back the stud end hex nut off as far as possible. washer squeezes the O-ring into the seat and
Push backup washer towards the nut to fully contacts face of boss. Loosen adjustable fittings no
expose the turn down section. Washer must fit more than one turn for alignment.
turned down section and not be too loose
Hold connections together while tightening nut to
3. Lubricate O-rings using a thin film of clean hydraulic ensure O-ring remains in place.
oil or as needed, petroleum jelly to hold O-ring in
place. 5. Tighten fitting or nut to torque value shown. Use a
second wrench to hold the fitting in position or to
Install O-ring into groove making sure it is seated at keep hose from twisting while tightening nut.
the bottom. Excess petroleum jelly will prevent
seating of O-ring and cause it to pop out.

OUT3035,0000421 –19–14JAN04–2/2

TM2256 (09JAN07) 00-0003-15 D Series Motor Grader Repair

020207
PN=35
 Torque Values

00
0003 Service Recommendations for Metric Series Four Bolt Flange Fitting
16

–UN–01MAR90
T6890BB
A—Sealing Surface B—Split Flange C—Pinched O-Ring D—Single Piece Flange

1. Clean sealing surfaces (A). Inspect. Scratches then tighten the diagonally opposite cap screw.
cause leaks. Roughness causes seal wear. Tighten two remaining cap screws. Tighten all cap
Out-of-flat causes seal extrusion. If defects cannot screws as specified in the chart below.
be polished out, replace component.
DO NOT use air wrenches. DO NOT tighten one
2. Install the correct O-ring (and backup washer if cap screw fully before tightening the others. DO
required) into groove using petroleum jelly to hold it NOT over tighten.
in place.
TORQUE CHARTa
3. Split flange: Loosely assemble split flange (B) Thread b
N•m lb-ft
halves. Make sure split is centrally located and M6 12 9
perpendicular to the port. Hand tighten cap screws M8 30 22
to hold parts in place. Do not pinch O-ring (C).
M10 57 42

4. Single piece flange (D): Place hydraulic line in M12 95 70

center of flange and install four cap screws. Flange M14 157 116
must be centrally located on port. Hand tighten cap M16 217 160
screws to hold flange in place. Do not pinch O-ring. M18 334 246
M20 421 318
5. After components are properly positioned and cap a
Tolerance ± 10%. The torques given are enough for the given
screws are hand tightened, tighten one cap screw, size connection with the recommended working pressure.
Increasing cap screw torque beyond these amounts will result in
flange and cap screw bending and connection failures.
b
Metric standard thread.

04T,90,K175 –19–29SEP99–1/1

TM2256 (09JAN07) 00-0003-16 D Series Motor Grader Repair

020207
PN=36
 Torque Values

00
Service Recommendations For Inch Series Four Bolt Flange Fittings 0003
17

–UN–01MAR90
T6890BB
A—Sealing Surface B—Split Flange C—Pinched O-Ring D—Single Piece Flange

1. Clean sealing surfaces (A). Inspect. Scratches TORQUE CHART

cause leaks. Roughness causes seal wear. N•m lb-ft
Out-of-flat causes seal extrusion. If defects cannot Nominal Cap Screw
be polished out, replace component. Flange Size
Size Min Max Min Max
2. Install O-ring (and backup washer if required) into 1/2 5/16-18 20 31 15 23
groove using petroleum jelly to hold it in place. UNC
3/4 3/8-16 UNC 28 54 21 40
3. Split flange: Loosely assemble split flange (B) 1 3/8-16 UNC 37 54 27 40
halves. Make sure split is centrally located and 1-1/4 7/16-14 47 85 35 63
perpendicular to port. Hand tighten cap screws to UNC
hold parts in place. Do not pinch O-ring (C). 1-1/2 1/2-13 UNC 62 131 46 97
2 1/2-13 UNC 73 131 54 97
4. Single piece flange (D): Place hydraulic line in
center of flange and install cap screws. Flange 2-1/2 1/2-13 UNC 107 131 79 97
must be centrally located on port. Hand tighten cap 3 5/8-11 UNC 158 264 117 195
screws to hold flange in place. Do not pinch O-ring. 3-1/2 5/8-11 UNC 158 264 117 195
4 5/8-11 UNC 158 264 117 195
5. Tighten one cap screw, then tighten the diagonally 5 5/8-11 UNC 158 264 117 195
opposite cap screw. Tighten two remaining cap
screws. Tighten all cap screws as specified in the
chart below.

DO NOT use air wrenches. DO NOT tighten one

cap screw fully before tightening the others. DO
NOT over tighten.

04T,90,K174 –19–01AUG94–1/1

TM2256 (09JAN07) 00-0003-17 D Series Motor Grader Repair

020207
PN=37
 Torque Values

00
0003 Inch Series Four Bolt Flange Fitting For High Pressure Service Recommendations
18

–UN–01MAR90
T6890BB
A—Sealing Surface B—Split Flange C—Pinched O-Ring D—Single Piece Flange

INCH SERIES FOUR BOLT FLANGE FITTING FOR 41 400 kPa 2. Install the O-ring (and backup ring, if used) into
(414 bar) (6000 psi) PRESSURE SERIES TORQUE VALUES—
groove. Use petroleum jelly to hold it in place.
Tolerance is ± 10% unless otherwise specified
Nominal Cap Screw Sizea Min—Max Torque
IMPORTANT: DO NOT use air wrenches. DO NOT
Flange Size
tighten one cap screw fully before
in. in. N•m (lb-ft)b
tightening the others. DO NOT over
1/2 5/16-18 UNC 20—31 (15—23) tighten.
3/4 3/8-16 UNC 34—54 (25—40)
1 7/16-14 UNC 57—85 (42—63) 3. Split flange: Loosely assemble split flange (B)
1-1/4 1/2-13 UNC 85—131 (63—97) halves. Make sure split is centrally located and
perpendicular to port. Hand tighten cap screws to
1-1/2 5/8-11 UNC 159—264 (117—195)
hold flange halves and line in place. Do not pinch
2 3/4-10 UNC 271—468 (200—345)
O-ring (C).
a
JDM A17D, SAE Grade 5 or better cap screws with plated
hardware. Single piece flange (D): Make sure flange is
Lock washers are permissible but not recommended.
centrally located on port and line is centered in
b
Minimum torques given are enough for the given size connection flange. Install the cap screws. Hand tighten cap
with the recommended working pressure. Torques can be
increased to the maximum shown for each cap screw size if screws to hold flange and line in place. Do not
desired. Increasing cap screw torque beyond the maximum will pinch O-ring.
result in flange and cap screw bending and connection failures.
4. Tighten one cap screw and then the diagonally
1. Clean sealing surfaces (A). Inspect. Scratches, opposite cap screw. Tighten the two remaining cap
nicks, and burrs cause leaks. Roughness causes screws. Tighten cap screws within the specified
O-ring wear. Out-of-flat causes O-ring extrusion. If torque values.
imperfection cannot be polished out, replace
component.

OUT3035,0000422 –19–14JAN04–1/1

TM2256 (09JAN07) 00-0003-18 D Series Motor Grader Repair

020207
PN=38
 Torque Values

00
Service Recommendations For 0003
19
Non-Restricted Banjo (Adjustable) Fittings

1. Inspect all fitting sealing surfaces. They must be free of

dirt and defects.

2. Inspect O-ring (A). It must be free of damage or

defects.

3. Inspect sealing ring (B) for damage or defects.

4. Hold body in desired position while tightening stud by

hand.

–UN–06MAR98
5. Tighten stud (C) to torque value shown on the chart.
Do not allow body to twist when tightening stud.

NOTE: The L in the Tube Fitting OD Size column

T113948
indicates “light” designed fitting and the S
indicates “heavy” designed fitting.

Torque Value
Tube Fitting Metric Thread N•m lb-ft
O.D. Size
6L M 10 x 1 30 22
8L M 12 x 1.5 40 30
10 L M 14 x 1.5 60 44
12 L M 16 x 1.5 100 74
15 L M 18 x 1.5 130 96
18 L M 22 x 1.5 160 118
22 L M 26 x 1.5 250 184
28 L M 33 x 2 400 295
35 L M 42 x 2 600 443
42 L M48 x 2 800 590
6S M 12 x 1.5 40 30
8S M 14 x 1.5 60 44
10 S M 16 x 1.5 100 74
12 S M 18 x 1.5 130 96
14 S M 20 x 1.5 160 118
16 S M 22 x 1.5 160 118
20 S M 27 x 2 250 184
25 S M 33 x 2 400 295
30 S M 42 x 2 600 443
38 S M 48 x 2 800 590

Continued on next page CED,OUO1002,562 –19–09MAR98–1/2

TM2256 (09JAN07) 00-0003-19 D Series Motor Grader Repair

020207
PN=39
 Torque Values

00
0003 Torque Value
20
Tube Fitting Inch Size N•m lb-ft
O.D. Size
6L 1/8 25 18
8L 1/4 50 37
10 L 1/4 50 37
12 L 3/8 90 66
15 L 1/2 130 96
18 L 1/2 150 111
22 L 3/4 250 184
28 L 1 400 295
35 L 1-1/4 600 443
42 L 1-1/2 800 590
6S 1/4 50 37
8S 1/4 50 37
10 S 3/8 90 66
12 S 3/8 100 74
14 S 1/2 130 96
16 S 1/2 150 111
20 S 3/4 250 184
25 S 1 400 295
30 S 1-1/4 600 443
38 S 1-1/2 800 590

CED,OUO1002,562 –19–09MAR98–2/2

TM2256 (09JAN07) 00-0003-20 D Series Motor Grader Repair

020207
PN=40
 Torque Values

00
Service Recommendations For O-Ring Boss 0003
21
Fittings With Shoulder

1. Inspect component seal boss seat for dirt or defects.

2. Inspect EOlastic seal (A) for damage. Replace seal or

–UN–06MAR98
fitting as necessary.

To replace seal, put electrical tape over threads to

protect seal. Slide seal over tape and into seal groove

T113957
of fitting. Remove tape.

3. Tighten fitting to torque value shown on chart.

IMPORTANT: Do not allow hoses to twist when

tightening fittings.

NOTE: The L in the Tube Fitting OD Size column

indicates “light” designed fitting and the S
indicates “heavy” designed fitting.

Torque Value
Tube Fitting Metric Thread N•m lb-ft
O.D. Size
6L M 10 x 1 20 15
8L M 12 x 1.5 30 22
10 L M 14 x 1.5 45 33
12 L M 16 x 1.5 60 44
15 L M 18 x 1.5 80 59
18 L M 22 x 1.5 130 96
22 L M 26 x 1.5 190 140
28 L M 33 x 2 300 221
35 L M 42 x 2 600 443
42 L M48 x 2 800 590
6S M 12 x 1.5 40 30
8S M 14 x 1.5 60 44
10 S M 16 x 1.5 80 59
12 S M 18 x 1.5 110 81
14 S M 20 x 1.5 140 103
16 S M 22 x 1.5 170 125
20 S M 27 x 2 250 184
25 S M 33 x 2 450 332
30 S M 42 x 2 600 443
38 S M 48 x 2 800 590

Continued on next page CED,OUO1002,563 –19–09MAR98–1/3

TM2256 (09JAN07) 00-0003-21 D Series Motor Grader Repair

020207
PN=41
 Torque Values

00
0003 Torque Value
22
Tube Fitting Inch Size N•m lb-ft
O.D. Size
6L 1/8 20 15
8L 1/4 40 30
10 L 1/4 40 30
12 L 3/8 80 59
15 L 1/2 140 103
18 L 1/2 100 74
22 L 3/4 180 133
28 L 1 300 221
35 L 1-1/4 600 443
42 L 1-1/2 800 590
6S 1/4 50 37
8S 1/4 50 37
10 S 3/8 90 66
12 S 3/8 90 66
14 S 1/2 160 118
16 S 1/2 140 103
20 S 3/4 250 184
25 S 1 400 295
30 S 1-1/4 650 479
38 S 1-1/2 800 590

Continued on next page CED,OUO1002,563 –19–09MAR98–2/3

TM2256 (09JAN07) 00-0003-22 D Series Motor Grader Repair

020207
PN=42
 Torque Values

00
Hex Socket Head Plugs Only 0003
23
Torque Value
Thread Size N•m lb-ft
M 10 x 1 13 10
M 12 x 1.5 30 22
M 14 x 1.5 40 30
M 16 x 1.5 60 44
M 18 x 1.5 70 52
M 20 x 1.5 90 66
M 22 x 1.5 100 74
M 26 x 1.5 120 89
M 27 x 2 150 111
M 33 x 2 250 184
M 42 x 2 400 295
M 48 x 2 500 369
1/8 15 11
1/4 33 24
3/8 70 52
1/2 90 66
3/4 150 111
1 220 162
1-1/4 600 443
1-1/2 800 590

CED,OUO1002,563 –19–09MAR98–3/3

TM2256 (09JAN07) 00-0003-23 D Series Motor Grader Repair

020207
PN=43
 Torque Values

00
0003 Metric 24° O-Ring Seal DIN 20078 Service
24
Recommendations

METRIC 24° O-RING SEAL DIN 20078 TORQUE VALUES

Fitting Heavy Fitting Light Fitting Torque
Tube OD Size Size
Size
mm mm mm Turns
6 — M12 x 1.5 Hand tighten so
O-ring contacts
seat plus an
additional 1/4—1/3
turn using a
wrench
8 M16 x 1.5 M14 x 1.5
10 M18 x 1.5 M16 x 1.5
12 M20 x 1.5 M18 x 1.5
14 M22 x 1.5 —
15 — M22 x 1.5
16 M24 x 1.5 —
18 — M26 x 1.5
20 M30 x 2 —
22 — M30 x 2
25 M36 x 2 —
28 — M36 x 2
30 M42 x 2 —

–UN–06MAR98
35 — M45 x 2
38 M52 x 2 —

NOTE: These fittings are also referred to as EO and

T113889
EO-2 Bite Type or Ermeto style fittings.

IMPORTANT: In this style of fittings, there are

“heavy” and “light” designs. Usually
“heavy” is used for pressure lines and
“light” for return lines.

Some “heavy” and “light” sizes can be

threaded together but do not seal
properly. Be sure not to mix “heavy”
and “light” fittings.

1. Inspect the fitting sealing surfaces. They must be free

of dirt scratches, nicks, and burrs.

Continued on next page CED,OUO1002,517 –19–14JAN04–1/2

TM2256 (09JAN07) 00-0003-24 D Series Motor Grader Repair

020207
PN=44
 Torque Values

00
2. Inspect the O-ring. It must be free dirt, cuts, cracks, 0003
25
swelling or flatten condition.

3. Lubricate O-rings using a thin film of clean hydraulic

oil.

4. Align an adjustable fitting with the tube.

Hold connections together while tightening nut to

ensure proper seal.

5. Tighten nut (A) hand tight so O-ring contacts seat and

then an additional 1/4—1/3 turn using a wrench.

CED,OUO1002,517 –19–14JAN04–2/2

TM2256 (09JAN07) 00-0003-25 D Series Motor Grader Repair

020207
PN=45
 Torque Values

00
0003
26

TM2256 (09JAN07) 00-0003-26 D Series Motor Grader Repair

020207
PN=46
 Section 01
Wheels
Contents 01

Page

Group 0110—Powered Wheels and Fasteners

Tire Remove and Install . . . . . . . . . . . . . . . .01-0110-1

TM2256 (09JAN07) 01-1 D Series Motor Grader Repair

020207
PN=1
 Contents

01

TM2256 (09JAN07) 01-2 D Series Motor Grader Repair

020207
PN=2
 Group 0110
Powered Wheels and Fasteners

Tire Remove and Install

01
0110
1

–UN–21JUL97
T110424
1—Valve Stem 3—Washer 5—Wheel Ring 7—Split Ring
2—Wheel Rim 4—Cap Screw 6—O-Ring

NOTE: Tire can be removed without removing wheel. 5. Install valve stem in rim base and tighten valve core
housing finger tight.
CAUTION: Failure to follow proper
6. Put John Deere Non-Soap Lubricating Grease, or
procedures when demounting a tire from a
an equivalent, on threads of pipe cap (if equipped).
wheel or rim can produce an explosion
Install pipe cap on valve stem shield.
which may result in serious bodily injury. DO
NOT attempt to demount a tire unless you
have the proper equipment and experience CAUTION: Serious bodily injury can occur
to perform the job safely. Have it done by a from explosion when mounting and inflating
qualified repair service. tires if safe procedures are not followed.

1. Before attempting any demounting operation, 7. Before mounting tire on rim, add soap lubricant to
always completely deflate tire by removing valve beads of the tire and O-ring.
core from valve. Check the valve stem by running a
probe through it, making sure the valve stem is not 8. Before adding air to tire, make sure the back ring
plugged. Remove valve nut. fits tight against the base all around the
circumference.
2. Inspect all parts for damage; replace parts as
necessary. 9. Clear the area of all persons.

3. Make sure all parts are clean and free from rust or 10. Use a pressure-regulating valve with clip-on chuck
grease before assembly. and extension hose long enough to allow you to
stand well to one side and NOT in front of the
4. To prevent slipping of the wheel under load, the assembly while inflating.
inside and outside of wheel (1) must be free of
paint, rust, oil, grease, dirt or other foreign material 11. Use only recommended air pressure. Pressure
before installation. over this limit can cause explosion.

Continued on next page TX19495,000014F –19–19NOV04–1/2

TM2256 (09JAN07) 01-0110-1 D Series Motor Grader Repair

020207
PN=49
 Powered Wheels and Fasteners

12. Seat tire to rim by adding air to specification. 14. Cross tighten cap screws to specification.

Tire Remove and Install—Specification Specification

Air Pressure to Seat Tire on Wheel Cap Screw—Torque ...................................................495 N•m
Rim—Pressure (Bias Ply) ......................................................379 KPa 365 lb-ft
01 55 psi
0110 Pressure (Radial) ................................................................... 386 KPa
2 65 psi

13. Check tire pressure. For correct pressures, see

Checking Tire Pressure. (Operator’s Manual.)

TX19495,000014F –19–19NOV04–2/2

TM2256 (09JAN07) 01-0110-2 D Series Motor Grader Repair

020207
PN=50
 Section 02
Axles and Suspension Systems
Contents

Page Page

Group 0225—Input Drive Shafts and U-Joints Tandem Front Wheel Axle Assembly Remove
Transmission-to-Rear Axle Drive Shaft and Install . . . . . . . . . . . . . . . . . . . . . . . .02-0250-17 02
Remove and Install . . . . . . . . . . . . . . . . . .02-0225-1 Tandem Wheel Axle Assembly Disassemble
Transmission-to-Rear Axle Drive Shaft and Assemble . . . . . . . . . . . . . . . . . . . . .02-0250-20
Disassemble and Assemble. . . . . . . . . . . .02-0225-2 Tandem Pivot Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .02-0250-26
Group 0230—Non-Powered Wheel Axles Final Drive Axle Remove and Install . . . . . .02-0250-30
Front Wheel Hub and Spindle Remove Final Drive Axle Disassemble and
and Install—Non HFWD. . . . . . . . . . . . . . .02-0230-1 Assemble. . . . . . . . . . . . . . . . . . . . . . . . .02-0250-36
Front Wheel Hub and Spindle Brake Component Remove and Install . . . .02-0250-39
Disassemble and Assemble—Non Planet Pinion Carrier Remove and
HFWD . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0230-2 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0250-40
Front Axle Remove and Install—Non Tandem Drive Shaft Remove and Install . . .02-0250-42
HFWD . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0230-4 Drive Chain Remove and Install . . . . . . . . .02-0250-53
Metal Face Seals Inspection . . . . . . . . . . . .02-0250-54
Group 0240—Powered Wheel Axles
Front Wheel Hub and Spindle Remove and Group 0260—Hydraulic System
Install—HFWD . . . . . . . . . . . . . . . . . . . . . .02-0240-1 HFWD Pump Remove and Install . . . . . . . . .02-0260-1
Front Wheel Hub and Spindle HFWD Pump Disassemble and Assemble. . .02-0260-4
Disassemble and Assemble—HFWD . . . . .02-0240-6 HFWD Charge Pump Remove and
Front Wheel Hub and Spindle Disassemble Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-32
and Assemble with Steering Angle Sensor— HFWD Charge Pump Disassemble and
HFWD . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0240-11 Assemble. . . . . . . . . . . . . . . . . . . . . . . . .02-0260-33
HFWD Drive Hub Disassemble and HFWD Engagement Manifold Remove
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .02-0240-15 and Install . . . . . . . . . . . . . . . . . . . . . . . .02-0260-33
Planetary Drive Disassemble and HFWD Engagement Manifold Disassemble
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .02-0240-18 and Assemble . . . . . . . . . . . . . . . . . . . . .02-0260-36
Planetary Brake Disassemble and Differential Lock Pump Remove and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .02-0240-22 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-37
HFWD Bearings Remove and Install . . . . . .02-0240-28 Park Brake Valve Remove and Install . . . . .02-0260-39
HFWD O-Ring Metal Face Seal Remove Park Brake Valve Disassemble and
and Install . . . . . . . . . . . . . . . . . . . . . . . .02-0240-33 Assemble. . . . . . . . . . . . . . . . . . . . . . . . .02-0260-40
Front Axle Remove and Install—HFWD . . .02-0240-41 HFWD Motor Remove and Install . . . . . . . .02-0260-42
Steering Angle Sensor Remove and Install HFWD Motor Disassemble and
(S.N. 611296— ) . . . . . . . . . . . . . . . . . . .02-0240-48 Assemble. . . . . . . . . . . . . . . . . . . . . . . . .02-0260-44

Group 0250—Axle Shafts, Bearings, and Reduction

Gears
TEAMMATE II 1400 Series Inboard
Planetary Axle—Use CTM43 . . . . . . . . . . .02-0250-1
Rear Axle Remove and Install . . . . . . . . . . . .02-0250-2
Rear Axle Disassemble and Assemble . . . .02-0250-10
Tandem and Wheel Axle Assembly Remove
and Install . . . . . . . . . . . . . . . . . . . . . . . .02-0250-11
Tandem Rear Wheel Axle Assembly Remove
and Install . . . . . . . . . . . . . . . . . . . . . . . .02-0250-16

TM2256 (09JAN07) 02-1 D Series Motor Grader Repair

020207
PN=1
 Contents

02

TM2256 (09JAN07) 02-2 D Series Motor Grader Repair

020207
PN=2
 Group 0225
Input Drive Shafts and U-Joints

Transmission-to-Rear Axle Drive Shaft Remove and Install

02
0225
1

–UN–08JUL98
T114574
Transmission-to-Rear Axle Drive Shaft

A—Cap Screw (4 used) C—Drive Shaft Assembly D—Transmission Yoke E—Cap Screw (4 used)
B—Axle Yoke

4. Clean and inspect parts. Repair or replace parts as

CAUTION: When drive shaft assembly is
necessary. See Transmission-to-Rear Axle Drive
removed, park brake is inoperative. Chock
Shaft Disassemble and Assemble. (Group 0225.)
wheels to prevent rolling.
NOTE: Universal joints are “Lube for Life” and are not
1. Loosen cap screws (A and E). Do not remove.
serviceable or repairable. Replace if worn.
2. Remove cap screws (A) and push transmission
5. Install drive shaft (C) and cap screws (A and E).
yoke into transmission as far as possible.
Tighten cap screws to specification.
3. Remove cap screws (E) and remove drive shaft Specification
(C). Transmission-to-Rear Axle
Drive Shaft Cap Screw—
Specification Torque.................................................................................... 111 N•m
Transmission-to-Rear Axle 82 lb-ft
Drive Shaft Cap Screw—
Torque.................................................................................... 111 N•m
82 lb-ft

TX19495,0000150 –19–19NOV04–1/1

TM2256 (09JAN07) 02-0225-1 D Series Motor Grader Repair

020207
PN=53
 Input Drive Shafts and U-Joints

Transmission-to-Rear Axle Drive Shaft

Disassemble and Assemble

1. Remove cap screws (A) and separate cross and

bearing assemblies (B) from coupling (C).

2. Clean and inspect parts. Repair or replace parts as

necessary.

NOTE: Cross and bearing assemblies are “Lube for Life.”

02 They are not repairable and do not require

–UN–21JUL97
0225
periodic service. Replace if worn or rough in
2
operation.

3. Position cross and bearing assemblies (B) on coupling

T110573
(C) and install cap screws (A). Tighten cap screws to
specification. Rear Axle Drive Shaft

Specification A—Cap Screw (8 used)

Transmission-to-Rear Axle Drive B—Cross and Bearing Assemblies
Shaft Cap Screw—Torque ...........................................................111 N•m C—Coupling
82 lb-ft D—Drive Shaft Assembly

TX19495,0000151 –19–19NOV04–1/1

TM2256 (09JAN07) 02-0225-2 D Series Motor Grader Repair

020207
PN=54
 Group 0230
Non-Powered Wheel Axles

Front Wheel Hub and Spindle Remove and Install—Non HFWD

02
0230
1

–UN–24JUN97
T110200
Front Wheel Hub and Spindle

A—Hub C—Thrust Washer E—Cap Screw (4 used) G—Yoke

B—Spindle D—Spindle Pin F—Washer (4 used)

NOTE: Removal of hub and spindle as an assembly is 770D—Weight.........................................................................3860 kg

8510 lb
only required to service spindle pin (D), yoke
870D—Weight.........................................................................4173 kg
(G), or thrust washer (C). 9200 lb

CAUTION: Prevent possible injury from 4. Remove front wheel. See Tire Remove and Install.
unexpected machine movement. Install (Group 0110.)
articulation lock pin when machine is raised
or when working in articulation joint area. 5. Repair or replace parts as necessary. See Front
Wheel Hub and Spindle Disassemble and
1. Install articulation lock pin. See Locking Machine Assemble—Non HFWD. (Group 0230.)
Frame. (Operator’s Manual.)
6. Install front wheel. See Tire Remove and Install for
2. Raise front of machine using moldboard. lug nut torque specification. (Group 0110.)

3. Support front of machine with jack stands. 7. Lower front of machine.

Front Operating Weight—Standard Equipment—Specification 8. Remove articulation lock pin.

670D—Weight.........................................................................3855 kg
8500 lb

TX19495,0000153 –19–19NOV04–1/1

TM2256 (09JAN07) 02-0230-1 D Series Motor Grader Repair

020207
PN=55
 Non-Powered Wheel Axles

Front Wheel Hub and Spindle Disassemble and Assemble—Non HFWD

02
0230
2

–UN–16MAR98
TP57330
Front Wheel Hub

1—Cap Screw (3 used) 6—Gasket 11—Bearing Cone 16—Spindle

2—Lock Washer (3 used) 7—Washer 12—Bearing Cup 17—Washer
3—Cap 8—Bearing Cone 13—Grease Seal 18—Lubrication Fitting
4—Cotter Pin 9—Hub 14—Oil Cup (2 used)
5—Nut 10—Bearing Cup 15—Bushing 19—Orifice (2 used)

1. Remove front wheel. See Tire Remove and Install. 10. Position hub on spindle and install parts (5, 7 and
(Group 0110.) 8).

2. Remove parts (1—9 and 11, 13 and 14). 11. Lubricate threads on spindle.

3. Press bearing cups (10 and 12) from hub (9). 12. Rotate hub while tightening nut (5). Back off nut to
install cotter pin (4).
4. Replace parts as necessary.
Specification
5. Position and press bearing cups (10 and 12) into Hub Nut—Torque.....................................................................95 N•m
70 lb-ft
hub (9).
NOTE: No measurable play is allowed in hub
6. Fill lip of grease seal (13) with PT507 Multi-Purpose
assembly.
Grease.
13. Install parts (1—3 and 6).
7. Grease bearing cones (8 and 11).
14. Install front wheel. See Tire Remove and Install for
8. Install bearing cone (11) and oil cup (14) in hub.
lug nut torque specification. (Group 0110.)
9. Position grease seal (13) with metal face toward
spindle (15) and install in hub.

TX19495,0000154 –19–19NOV04–1/1

TM2256 (09JAN07) 02-0230-2 D Series Motor Grader Repair

020207
PN=56
 Non-Powered Wheel Axles

02
0230
3

TM2256 (09JAN07) 02-0230-3 D Series Motor Grader Repair

020207
PN=57
 Non-Powered Wheel Axles

Front Axle Remove and Install—Non HFWD

02
0230
4

–UN–07AUG03
T193519

Front Axle—Non HFWD

Continued on next page TX19495,0000152 –19–19NOV04–1/2

TM2256 (09JAN07) 02-0230-4 D Series Motor Grader Repair

020207
PN=58
 Non-Powered Wheel Axles

1—Snap Ring (4 used) 9—Cap Screw 15—Link 22—Washer

2—Bushing (2 used) 10—Adapter (5 used) 16—Bushing (2 used) 23—Pin
3—Bushing (2 used) 11—Nut (5 used) 17—Pin (2 used) 24—Cap Screw
4—Front Axle 12—Lubrication Fitting (4 18—Lubrication Fitting (2 25—Cap Screw
5—Washer (2 used) used) used) 26—Lock Nut
6—Pin 13—Washer 19—Pin 27—Lubrication Fitting
7—Spacer 14—Lubrication Fitting (5 20—Pin 28—Lubrication Fitting
8—Washer used) 21—Spacer 29—Elbow Fitting

1. If equipped, remove pushblock, scarifier or front 6. Connect front axle (4) to a hoist using lifting straps.
attachments. See Scarifier Remove and Install.
(Group 4240.) 7. Remove cap screw (9), washer (8) and spacer (7) 02
to remove pin and washers (5 and 13). Take notice 0230
of location and quantity of washers. 5
CAUTION: Prevent possible injury from
unexpected machine movement. Install
8. Repair or replace parts as needed.
articulation lock pin when machine is raised
or when working in articulation joint area.
9. Tighten nuts (11) to specifications.
2. Install articulation lock pin. See Locking Machine Specification
Frame. (Operator’s Manual.) Lubrication Fitting and
Adapter-to-Front Axle Nut—
3. Support front of machine main frame using shop Torque...................................................................................... 16 N•m
stands. 144 lb-in.

Front Operating Weight—With Standard Equipment— 10. Install washers (5) as needed to obtain the
Specification minimum amount of clearance between front axle
670D—Weight.........................................................................3855 kg and main frame. Axle must be free to pivot in the
8500 lb
main frame without binding.
770D—Weight.........................................................................3860 kg
8510 lb
870D—Weight.........................................................................4173 kg 11. Lower machine to the ground.
9200 lb
12. Remove articulation lock pin.
4. Remove the front wheels.
13. If equipped, install push block, scarifier or front
5. Disconnect lines from steering and wheel lean attachments. See Scarifier Remove and Install.
cylinders. Close openings using cap and plugs. (Group 4240.)

CAUTION: Prevent possible injury from

crushing. Use appropriate lifting device.

Specification
Front Axle—Weight..............................................114 kg approximate
250 lb approximate

TX19495,0000152 –19–19NOV04–2/2

TM2256 (09JAN07) 02-0230-5 D Series Motor Grader Repair

020207
PN=59
 Non-Powered Wheel Axles

02
0230
6

TM2256 (09JAN07) 02-0230-6 D Series Motor Grader Repair

020207
PN=60
 Group 0240
Powered Wheel Axles

Front Wheel Hub and Spindle Remove and

Install—HFWD

CAUTION: Prevent possible injury from

unexpected machine movement. Install
articulation lock pin when machine is raised or
when working in articulation joint area.

1. Install articulation lock pin. See Locking Machine

Frame. (Operator’s Manual.) 02
0240
2. Raise front of machine using moldboard. 1

3. Support front of machine with jack stands.

Specification
672D Front Axle Operating—
Weight............................................................................................ 4358 kg
9610 lb
772D Front Axle Operating—
Weight............................................................................................ 4364 kg
9620 lb
872D Front Axle Operating—
Weight............................................................................................ 4613 kg
10,170 lb

4. Remove front wheel. See Tire Remove and Install.

(Group 0110.)

CAUTION: Prevent possible injury from

crushing. Use appropriate lifting device.

Specification
HFWD Front Wheel Hub, Spindle,
and Yoke (motor full of oil)—
Weight Approximate ........................................................................ 390 kg
860 lb

5. Support lean yoke, front wheel hub, and spindle using

hoist.

Continued on next page AC12469,0000036 –19–18JAN07–1/4

TM2256 (09JAN07) 02-0240-1 D Series Motor Grader Repair

020207
PN=61
 Powered Wheel Axles

6. Disconnect tie rod ball joint (34) on side being

serviced.

NOTE: If servicing left front wheel hub and spindle, lean

cylinder must also be disconnected from lean
yoke.

–UN–11DEC01
7. Disconnect steering cylinder ball joint (35).

8. Remove front hose guard (24).

T149051B
02
0240 9. Pull a vacuum on hydraulic oil tank.
2 Lean Yoke Front View
10. Disconnect motor hoses. Close all openings using
caps and plugs.

11. Disconnect motor shift solenoid and wheel speed

sensor harness.

–UN–11DEC01
NOTE: (S.N. 611296— ) If servicing right front wheel hub
and spindle, disconnect steering angle sensor
plug and remove wire harness on top of lean
yoke.

T149052B
12. Tie hose bundle aside to allow access.
Lean Yoke Rear View
13. Disconnect yoke pivot pin grease hoses (36).
14—Lean Yoke Pin
14. Remove lean bar pin and brackets (33). 24—Hose Guard
33—Lean Bar Bracket (2 used)
34—Tie Rod
15. Remove cap screw, washer, and spacer retaining 35—Steering Cylinder
yoke pivot pin. 36—Lean Yoke Pin Grease Hose (2 used)

16. Remove yoke pivot pin (14).

17. Remove front wheel hub and spindle.

18. Clean and inspect parts. Repair or replace parts as

necessary. See Front Wheel Hub and Spindle
Disassemble and Assemble—HFWD. See Front
Wheel Hub and Spindle Disassemble and Assemble
with Steering Angle Sensor—HFWD. (Group 0240.)

19. Position front wheel hub and spindle in axle (10).

20. Install yoke pivot pin (14).

Continued on next page AC12469,0000036 –19–18JAN07–2/4

TM2256 (09JAN07) 02-0240-2 D Series Motor Grader Repair

020207
PN=62
 Powered Wheel Axles

21. Install yoke pivot pin cap screw, washer, and spacer.
Tighten cap screw to specification.

Specification
Yoke Pivot Pin Cap Screw—
Torque .......................................................................................... 140 N•m
103 lb-ft

22. Install lean bar, lean bar brackets, and lean bar pin.
Tighten cap screws (33) to specification.

Specification 02
HFWD Lean Bar Pin Cap 0240
Screw—Torque .............................................................................133 N•m 3
98 lb-ft

23. Connect yoke pivot pin grease hoses (36).

NOTE: (S.N. 611296— ) If servicing right front wheel hub

and spindle, connect steering angle sensor plug
and install wire harness on top of lean yoke.

24. Connect motor shift solenoid and wheel speed sensor

harness.

25. Connect motor hoses. See HFWD System

Component Location. (Group 9016-15.)

26. Relieve vacuum on hydraulic oil tank.

27. Install front hose guard.

28. Connect steering cylinder ball joint and tie rod ball
joint.

29. Tighten ball joint nuts to specification. Install cotter

pin. If cotter pin holes do not line up, tighten nut until
the first available hole lines up.

Specification
Steering Cylinder Ball Joint Nut—
Torque .......................................................................................... 170 N•m
125 lb-ft
Tie Rod Ball Joint Nut—Torque ...................................................170 N•m
125 lb-ft

30. Install front wheel. See Tire Remove and Install for
lug nut torque specification. (Group 0110.)

31. Lower machine to the ground.

Continued on next page AC12469,0000036 –19–18JAN07–3/4

TM2256 (09JAN07) 02-0240-3 D Series Motor Grader Repair

020207
PN=63
 Powered Wheel Axles

32. Remove articulation lock pin.

33. Run machine and check for leaks.

34. Check hydraulic tank oil level. See Checking

Hydraulic Tank Oil Level. (Operator’s Manual.)

02
0240
4 AC12469,0000036 –19–18JAN07–4/4

TM2256 (09JAN07) 02-0240-4 D Series Motor Grader Repair

020207
PN=64
 Powered Wheel Axles

02
0240
5

TM2256 (09JAN07) 02-0240-5 D Series Motor Grader Repair

020207
PN=65
 Powered Wheel Axles

Front Wheel Hub and Spindle Disassemble and Assemble—HFWD

02
0240
6

–UN–22DEC06
TX1016901

Front Wheel Hub, Spindle, and Yoke Exploded View (Without Steering Angle Sensor)
Continued on next page AC12469,0000037 –19–18JAN07–1/6

TM2256 (09JAN07) 02-0240-6 D Series Motor Grader Repair

020207
PN=66
 Powered Wheel Axles

1—Cap Screw 10—Cap Screw 19—Shim (as required) 27—Brake Pressure Tube
2—Lubrication Fitting 11—Cap Screw 20—Bottom King Pin 28—Cap Screw (3 used)
3—Spacer 12—Washer 21—Cap Screw (8 used) 29—Rear Hose Guard
4—Upper King Pin 13—Rubber Guard 22—Lubrication Fitting 30—Spindle
5—Key 14—Lean Yoke Pin 23—Cap Screw 31—Cap Screw (2 used)
6—Bearing (2 used) 15—Lean Yoke 24—Front Hose Guard 32—Cap Screw (4 used)
7—Lubrication Fitting (2 used) 16—Bushing (2 used) 25—Nut (4 used) 33—Lean Bar Bracket (2 used)
8—Spacer 17—Shim (as required) 26—O-Ring (2 used) 34—Snap Ring
9—Washer 18—Shim (as required)

NOTE: Starting with serial number 611296, a steering Specification

HFWD Front Wheel Hub,
angle sensor is fitted on right-hand side. See
Spindle, and Yoke (motor full of 02
Front Wheel Hub and Spindle Disassemble oil)—Weight Approximate .........................................................390 kg 0240
and Assemble with Steering Angle Sensor— 860 lb 7
HFWD for right-hand hub and spindle HFWD Lean Yoke—Weight
disassembly and assembly. Approximate ................................................................................ 52 kg
115 lb
NOTE: The following procedure must be performed
with front wheel hub, spindle, and yoke 1. Position lean yoke (15) vertically using hoist.
removed from machine and wheel hub face set
flat on work surface.

CAUTION: Prevent possible injury from

crushing. Use appropriate lifting device.

Continued on next page AC12469,0000037 –19–18JAN07–2/6

TM2256 (09JAN07) 02-0240-7 D Series Motor Grader Repair

020207
PN=67
 Powered Wheel Axles

2. Remove lower king pin cap screws (21). Use two cap
screws (21) to push lower king pin (20) from lean yoke
as shown.

3. Remove cap screw (1) from upper king pin (4).

–UN–11DEC01
4. Remove spacer (3).

5. Remove snap ring (34).

T149042B
02 6. Remove upper king pin (4).
0240
8 Lower King Pin Removal
7. Lift lean yoke straight up to separate it from spindle
and hub.
21—Cap Screw

NOTE: Bearing, seal, and bearing cup are serviced as an

assembly.

8. Inspect upper and lower king pin grease seals,

bearings and bearing cups (6). Replace parts as
necessary.

9. Inspect bushings (16). Replace if necessary.

10. Position yoke on spindle and hub.

11. Install upper king pin (4).

12. Install snap ring (34).

13. Install spacer (3) and cap screw (1). Tighten to

specification.

Specification
Upper King Pin Cap Screw—
Torque .......................................................................................... 138 N•m
102 lb-ft

NOTE: If bearings are not replaced, original shim pack

can be used.

14. Install lower king pin (20) without shims using four
cap screws (21) evenly spaced. Tighten cap screws
to specification.

Specification
Lower King Pin Cap Screw
Bearing Adjustment—Torque .........................................................20 N•m
177 lb-in.

Continued on next page AC12469,0000037 –19–18JAN07–3/6

TM2256 (09JAN07) 02-0240-8 D Series Motor Grader Repair

020207
PN=68
 Powered Wheel Axles

NOTE: Make sure that upper king pin is against snap

ring.

15. Rotate lean yoke back and fourth a minimum of five

times. Tighten cap screws again to specification.
Repeat this sequence until torque is maintained.

02
0240
AC12469,0000037 –19–18JAN07–4/6 9

16. Measure gap between lower king pin and lean yoke in
three places.

17. Use shims as required to obtain the average

measured clearance.

–UN–13DEC01
NOTE: If the exact shim thickness can not be obtained,
set clearance to the next thinnest size using
available shims.

T149129B
18. Remove lower king pin and install shims.

19. Install lower king pin using four evenly spaced cap Shim Measurement
screws. Tighten to specification.
15—Lean Yoke
20—Lower King Pin
Specification
Lower King Pin Cap Screw
Final—Torque ...............................................................................138 N•m
102 lb-ft

20. Rotate lean yoke back and fourth a minimum of five

times.

Continued on next page AC12469,0000037 –19–18JAN07–5/6

TM2256 (09JAN07) 02-0240-9 D Series Motor Grader Repair

020207
PN=69
 Powered Wheel Axles

21. Attach DFT1282 King Pin Torque Adapter (58) to king

pin as shown. See DFT1282 King Pin Torque
Adapter. (Group 9900.)

22. Position angle finder (59) as shown.

23. Measure rolling drag torque in both directions from

5-15° clockwise from vertical using torque wrench as
shown. Measurement must be within specification.

02 Specification
0240 Front Axle Lean Yoke—Rolling
10 Drag Torque ................................................ 15—25 N•m in each direction
with no more than 5 N•m

–UN–13DEC06
difference
133—221 [Link] each direction
with no more than 44 lb-in.
difference

TX1016268A
24. If rolling drag torque is not within specification, adjust
shim thickness. Rotate yoke and repeat rolling torque
measurement. Lean Yoke Rolling Torque Measurement

25. If rolling drag torque is within specification, install 15—Lean Yoke

20—Lower King Pin
remaining four cap screws and tighten to final torque
58—King Pin Torque Adapter
specification. 59—Angle Finder
60—M12x20 Flanged Cap Screw
Specification
Lower King Pin Cap Screw
Final—Torque ...............................................................................138 N•m
102 lb-ft

AC12469,0000037 –19–18JAN07–6/6

TM2256 (09JAN07) 02-0240-10 D Series Motor Grader Repair

020207
PN=70
 Powered Wheel Axles

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

02
0240
11

–UN–04DEC06
TX1015886

Continued on next page AC12469,0000039 –19–18JAN07–1/7

Front Wheel Hub, Spindle, and Yoke Exploded View (With Steering Angle Sensor)
TM2256 (09JAN07) 02-0240-11 D Series Motor Grader Repair
020207
PN=71
 Powered Wheel Axles

2—Lubrication Fitting 14—Lean Yoke Pin 24—Front Hose Guard 33—Lean Bar Bracket (2 used)
5—Key 15—Lean Yoke 25—Nut (4 used) 34—Snap Ring
6—Bearing (2 used) 16—Bushing (2 used) 26—O-Ring (2 used) 48—Steering Angle Sensor
7—Lubrication Fitting (2 used) 17—Shim (as required) 27—Brake Pressure Tube 49—Upper King Pin
8—Spacer 18—Shim (as required) 28—Cap Screw 50—Shaft
9—Washer 19—Shim (as required) 29—Rear Hose Guard 51—Spacer
10—Cap Screw 20—Bottom King Pin 30—Spindle 52—Cap Screw
11—Cap Screw 21—Cap Screw (8 used) 31—Cap Screw (2 used) 53—Dowel Pin
12—Washer 22—Lubrication Fitting 32—Cap Screw (4 used) 54—Seal
13—Rubber Guard 23—Cap Screw

NOTE: Starting with serial number 611296, a steering Specification

02 HFWD Front Wheel Hub,
angle sensor is fitted on right-hand side
0240 Spindle, and Yoke (motor full of
12 spindle. See Front Wheel Hub and Spindle oil)—Weight Approximate .........................................................390 kg
Disassemble and Assemble—HFWD for 860 lb
left-hand hub and spindle disassembly and HFWD Lean Yoke—Weight
assembly. Approximate ................................................................................ 52 kg
115 lb
NOTE: The following procedure must be performed
with front wheel hub, spindle, and yoke 1. Position lean yoke (15) vertically using hoist.
removed from machine and wheel hub face set
flat on work surface.

CAUTION: Prevent possible injury from

crushing. Use appropriate lifting device.

AC12469,0000039 –19–18JAN07–2/7

2. Remove lower king pin cap screws (21). Use two cap
screws to push lower king pin (20) from lean yoke as
shown.

3. Remove steering angle sensor (48).

–UN–11DEC01

4. Remove spacer (51).

5. Remove lubrication fitting (2).

T149042B

6. Remove snap ring (34).

Lower King Pin Removal

21—Cap Screw

Continued on next page AC12469,0000039 –19–18JAN07–3/7

TM2256 (09JAN07) 02-0240-12 D Series Motor Grader Repair

020207
PN=72
 Powered Wheel Axles

IMPORTANT: Attach gear puller with longer cap

screws to allow for full thread
engagement.

7. Secure gear puller (57) to upper king pin using cap

screws (55).

8. Thread adapter (56) into gear puller.

9. Using a slide hammer, remove upper king pin.

02
10. Drive dowel pin (53) from bore. 0240
13

–UN–13DEC06
11. Remove shaft (50) from bore.

12. Lift lean yoke straight up to separate it from spindle

and hub.

TX1016267A
NOTE: Bearing, seal, and bearing cup are serviced as an
assembly.
Puller Attached to Upper King Pin
13. Inspect upper and lower king pin grease seals,
15—Lean Yoke
bearings and bearing cups (6). Replace parts as 49—Upper King Pin
necessary. 55—M6x25 Cap Screw
56—Male-to-Female Thread Adapter
14. Inspect bushings (16). Replace if necessary. 57—Gear Puller

15. Position yoke on spindle and hub.

16. Apply LOCTITE 271 Thread Lock and Sealer (High

Strength) to dowel pin (53) and install in bore.

17. Install shaft (50).

18. Install upper king pin (49).

19. Install snap ring (34).

NOTE: Steering angle sensor connector must face front

of machine.

20. Install steering angle sensor (48) and tighten cap

screws (52).

21. Install spacer (51) and tighten cap screws (23).

LOCTITE is a trademark of Henkel Corp. Continued on next page AC12469,0000039 –19–18JAN07–4/7

TM2256 (09JAN07) 02-0240-13 D Series Motor Grader Repair

020207
PN=73
 Powered Wheel Axles

NOTE: If bearings are not replaced, original shim pack

can be used.

22. Install lower king pin (20) without shims using four
cap screws (21) evenly spaced. Tighten cap screws
to specification.

Specification
Lower King Pin Cap Screw
Bearing Adjustment—Torque .........................................................20 N•m
177 lb-in.
02
0240
14 NOTE: Make sure that upper king pin is against snap
ring.

23. Rotate lean yoke back and fourth a minimum of five

times. Tighten cap screws again to specification.
Repeat this sequence until torque is maintained.

AC12469,0000039 –19–18JAN07–5/7

24. Measure gap between lower king pin and lean yoke in
three places.

25. Use shims as required to obtain the average

measured clearance.

–UN–13DEC01
NOTE: If the exact shim thickness can not be obtained,
set clearance to the next thinnest size using
available shims.

T149129B
26. Remove lower king pin and install shims.

27. Install lower king pin using four evenly spaced cap Shim Measurement
screws. Tighten to specification.
15—Lean Yoke
20—Lower King Pin
Specification
Lower King Pin Cap Screw
Final—Torque ...............................................................................138 N•m
102 lb-ft

28. Rotate lean yoke back and fourth a minimum of five

times.

Continued on next page AC12469,0000039 –19–18JAN07–6/7

TM2256 (09JAN07) 02-0240-14 D Series Motor Grader Repair

020207
PN=74
 Powered Wheel Axles

29. Attach DFT1282 King Pin Torque Adapter (58) to king

pin as shown. See DFT1282 King Pin Torque
Adapter. (Group 9900.)

30. Position angle finder (59) as shown.

31. Measure rolling drag torque in both directions from

5-15° clockwise from vertical using torque wrench as
shown. Measurement must be within specification.

Specification 02
Front Axle Lean Yoke—Rolling 0240
Drag Torque ................................................ 15—25 N•m in each direction 15
with no more than 5 N•m

–UN–13DEC06
difference
133—221 [Link] each direction
with no more than 44 lb-in.
difference

TX1016268A
32. If rolling drag torque is not within specification, adjust
shim thickness. Rotate yoke and repeat rolling torque
measurement. Lean Yoke Rolling Torque Measurement

33. If rolling drag torque is within specification, install 15—Lean Yoke

20—Lower King Pin
remaining four cap screws and tighten to final torque
58—King Pin Torque Adapter
specification. 59—Angle Finder
60—M12x20 Flanged Cap Screw
Specification
Lower King Pin Cap Screw
Final—Torque ...............................................................................138 N•m
102 lb-ft

AC12469,0000039 –19–18JAN07–7/7

HFWD Drive Hub Disassemble and Assemble

1. Remove front wheel. See Tire Remove and Install.

(Group 0110.)

2. Drain HFWD drive hub. See Replacing 6WD Hub Oil-If

Equipped. (Operator’s Manual.)

3. Remove HFWD drive hub. See Front Wheel Hub and

Spindle Remove and Install—HFWD. (Group 0240.)

Continued on next page TX19495,000015D –19–01DEC04–1/2

TM2256 (09JAN07) 02-0240-15 D Series Motor Grader Repair

020207
PN=75
 Powered Wheel Axles

4. Remove cap screws (45) and plug (46). Use cap screw
(45) in threaded hole for plug (46) to separate wheel
drive hub.

5. Perform Planetary Drive Disassemble and Assemble,

or perform Planetary Brake Disassemble and

–UN–08NOV01
Assemble. (Group 0240.)

6. Install planetary assembly to spindle assembly.

T147937B
02 Tighten cap screws to specification.
0240
16 Specification HFWD Drive Hub
Drive Hub Cap Screws—Torque ....................................................80 N•m
59 lb-ft 45—Hub Mounting Cap Screws
46—Plug
7. Install HFWD drive hub. See Front Wheel Hub and
Spindle Remove and Install—HFWD. (Group 0240.)

8. Fill HFWD drive hub with oil. See Replacing 6WD Hub
Oil-If Equipped. (Operator’s Manual.)

9. Install front wheel. See Tire Remove and Install for lug
nut torque specification. (Group 0110.)

10. Calibrate HFWD control unit. See Hydrostatic Front

Wheel Drive (6WD) Controller Calibration. (Group
9015-20.)

TX19495,000015D –19–01DEC04–2/2

TM2256 (09JAN07) 02-0240-16 D Series Motor Grader Repair

020207
PN=76
 Powered Wheel Axles

02
0240
17

TM2256 (09JAN07) 02-0240-17 D Series Motor Grader Repair

020207
PN=77
 Powered Wheel Axles

Planetary Drive Disassemble and Assemble

02
0240
18

–UN–08NOV01
T147942

T147942
Planetary Assembly Exploded View
Continued on next page TX19495,000015E –19–01DEC04–1/3

TM2256 (09JAN07) 02-0240-18 D Series Motor Grader Repair

020207
PN=78
 Powered Wheel Axles

1—Snap Ring 8 —Cap Screw (3 used) 13—First Stage Planet Gear 18—Hub
2—Collar 9—Second Stage Planet Gear Pin Retainers 19—Thrust Bearing
3—Second Stage Sun Gear Pin 14—First Stage Planet Gear 20—First Stage Planet Gear
4—Snap Ring 10—Second Stage Planet Gear 15—First Stage Carrier Roller Bearings
5—First Stage Drive Shaft 11—Second Stage Carrier 16—First Stage Planet Gear 21—Second Stage Planet Gear
6—Washer 12—Second Stage Planet Gear Pin Roller Bearings
7—Second Stage Cap Screw Pin Retainers 17—Cap Screw (3 used)
(12 used)

1. Remove cap screws (7). Remove second planet Repair or replace as necessary.
pinion carrier assembly (11) from hub (18).
5. Repeat above steps for first stage planet gears. 02
2. Remove retaining cap screws (8) and pin retainers 0240
(12). Repair or replace parts as necessary. 19

3. Remove pins (9) using a press.

4. Remove planet gears (10), planet bearings (21) and

spacers.

Continued on next page TX19495,000015E –19–01DEC04–2/3

TM2256 (09JAN07) 02-0240-19 D Series Motor Grader Repair

020207
PN=79
 Powered Wheel Axles

6. Remove snap ring (1).

7. Remove washer (2) and drive shaft.

8. Remove snap ring (4).

–UN–17DEC01
9. Remove second stage sun gear from carrier.

10. Inspect thrust bearing (19) in center of hub (18).

T148071B
02 11. Apply oil to all parts before assembly.
0240
20 First Stage Carrier, Second Stage Sun Gear, and Drive Shaft
12. Install second stage sun gear (3) and snap ring (4) in
first stage carrier (15). Assembly

13. Install one washer (2) on drive shaft (5).

14. Install drive shaft into first stage carrier assembly.

Install second washer (2) and snap ring (1).

–UN–17DEC01
15. Assemble first and second carrier assemblies. Use
press to install pins (9 and 16).

16. Install pin retainers (9 and 16) using cap screws (8

T148072B
and 17) and backing plates (12 and 13).

Tighten cap screws to specification. Second Stage Sun Gear Snap Ring

Specification 1—Snap Ring

Planet Pin Retainer Cap 2—Washer
Screws—Torque .............................................................................50 N•m 3—Second Stage Sun Gear
204 lb-in. 4—Snap Ring
5—Drive Shaft
17. Install trust bearing (19) with washers (6).

18. Install first stage carrier assembly into hub.

19. Install second stage carrier assembly.

Tighten cap screws (7) to specification.

Specification
Second Stage Carrier Mounting
Cap Screws—Torque ...................................................................340 N•m
251 lb-ft

TX19495,000015E –19–01DEC04–3/3

TM2256 (09JAN07) 02-0240-20 D Series Motor Grader Repair

020207
PN=80
 Powered Wheel Axles

02
0240
21

TM2256 (09JAN07) 02-0240-21 D Series Motor Grader Repair

020207
PN=81
 Powered Wheel Axles

Planetary Brake Disassemble and Assemble

02
0240
22

–UN–13NOV01
T147943

T147943
Planetary Brake Assembly Exploded View
Continued on next page TX19495,000015F –19–01DEC04–1/8

TM2256 (09JAN07) 02-0240-22 D Series Motor Grader Repair

020207
PN=82
 Powered Wheel Axles

25—Cap Screw (12 used) 31—Roller Bearing 37—Friction Disk (3 used) 42—Cap Screw (24 used)
26—Plate 32—Backup Ring 38—Wear Plate (3 used) 43—Seal
27—Shim 33—Brake Seal 39—Spring (12 used) 44—Cover
28—Shim 34—Backup Ring 40—Snap Ring 45—Cap Screws
29—Shim 35—Brake Seal 41—Brake Pressure Plate 46—Cap Screw
30—Brake Piston Carrier 36—Ring Gear

NOTE: Planetary Brake Disassemble and Assemble is 1. Place spindle assembly on blocks to level ring gear.
recommended to be done with spindle and
lean yoke assembly removed from machine. 2. Remove caps crews (25).
See Front Wheel Hub and Spindle Remove
and Install—HFWD. (Group 0240.) 02
0240
23

Continued on next page TX19495,000015F –19–01DEC04–2/8

TM2256 (09JAN07) 02-0240-23 D Series Motor Grader Repair

020207
PN=83
 Powered Wheel Axles

02
0240
24

–UN–23AUG01
T144992B
1—Ring Gear 2—Mark Position 3—Hoist Lift Chain (3 used) 4—Lift Eyelet (3 used)

3. Install three lifting eyelets (4). 4. Mark position (2) as shown to aid assembly.

IMPORTANT: Damage to brake pressure tube will 5. Lift planetary brake using hoist chains (3).
occur if planetary brake is not lined
up appropriately.

Continued on next page TX19495,000015F –19–01DEC04–3/8

TM2256 (09JAN07) 02-0240-24 D Series Motor Grader Repair

020207
PN=84
 Powered Wheel Axles

6. Remove brake pressure tube (27). Replace O-rings if

necessary.

27—Brake Pressure Tube

–UN–17DEC01
T147981B
02
0240
Brake Pressure Tube 25

TX19495,000015F –19–01DEC04–4/8

7. Replace lifting eyelets with cap screws (2) removed

when splitting planetary housing from brake housing.
Install cap screws until flush with ring gear as shown.

8. Turn planetary brake housing over.

–UN–23AUG01
IMPORTANT: Pressure plate retaining cap screws (42)
must be replaced with new cap screws
after disassembly.

T145014B
9. Remove caps crews (42) and pressure plate (41).
Discard cap screws.
Screws In Brake Housing

1—Strait Edge
2—Cap Screw (3 used)

Continued on next page TX19495,000015F –19–01DEC04–5/8

TM2256 (09JAN07) 02-0240-25 D Series Motor Grader Repair

020207
PN=85
 Powered Wheel Axles

NOTE: Springs (39) alternate every other three holes.

10. Remove springs (39).

11. Remove snap ring (40).

–UN–08NOV01
12. Remove friction disks (37) and wear plates (38).

13. Remove ring gear (36).

T145018B
02 14. Turn brake piston assembly over.
0240
26 Snap Ring
15. Remove piston (35) with rubber hammer.
38—Friction Disk
16. Remove backup rings (32 and 34) and brake piston 39—Spring (12 used)
seals (33). 40—Snap Ring

17. Inspect O-rings, friction disks, and wear plates.

18. Apply oil to O-ring and piston before assembly.

19. Install seals and backup rings on brake piston carrier

(30).

20. Flip brake housing so three cap screws are on level

surface.

21. Install brake piston on brake piston carrier using

rubber hammer.

22. Install ring gear with snap ring grove up.

NOTE: Holes for springs must line up when assembling

friction disks and brake plates.

23. Install one wear plate.

24. Install friction disk.

Install remaining wear plates and friction disks in this

order.

25. Install springs (39) in sets of three alternating every

other three holes.

26. Install pressure plate (41) with new cap screws.

Tighten cap screws (42) to specification.

Continued on next page TX19495,000015F –19–01DEC04–6/8

TM2256 (09JAN07) 02-0240-26 D Series Motor Grader Repair

020207
PN=86
 Powered Wheel Axles

Specification
Planetary Brake Pressure Plate
Cap Screws—Torque .....................................................................20 N•m
168 lb-in.
Torque Turn .................................................................................... 1/6 turn

27. See HFWD Bearings Remove and Install to service

bearings. (Group 0240.)

28. See Metal Face Seals Inspection to service seals.

(Group 0240.)
02
0240
29. Install brake pressure tube (27).
27

30. Install brake assemble to spindle.

31. Install shims (27—29).

32. Install plate (26). Tighten cap screws (25) to

specification.

Specification
Carrier Brake Retaining Plate
Cap Screws—Torque ...................................................................138 N•m
102 lb-ft

Continued on next page TX19495,000015F –19–01DEC04–7/8

TM2256 (09JAN07) 02-0240-27 D Series Motor Grader Repair

020207
PN=87
 Powered Wheel Axles

33. Install JT07192 Hydraulic Pump to brake port (65).

34. Pressurize brake to specification (1). Pressure must

hold for 60 seconds.

Specification

–UN–17DEC01
Brake Pressure Test (1)—
Pressure ..................................................................................... 2000 KPa
20 bar
290 psi

T149262B
02 35. Pressurize brake to specification (2). Pressure must
0240
hold for 60 seconds.
28 Brake Pressure Port
Specification
65—Brake Pressure Port
Brake Pressure Test (2)—
Pressure .................................................................................. 10 000 KPa
100 bar
1450 psi

36. Pressurize brake to specification (3). Pressure must

hold for 60 seconds.

Specification
Brake Pressure Test (3)—
Pressure .................................................................................. 40 000 KPa
400 bar
5800 psi

If pressure drop occurs, check brake seals and brake

pressure tube.

TX19495,000015F –19–01DEC04–8/8

HFWD Bearings Remove and Install

1. Remove wheel. See Tire Remove and Install. (Group

0110.)

2. Remove wheel end.

Continued on next page BT40170,0000093 –19–26SEP03–1/5

TM2256 (09JAN07) 02-0240-28 D Series Motor Grader Repair

020207
PN=88
 Powered Wheel Axles

02
0240
29

–UN–13NOV01
T147944
T147944
Hub Cover and Face Seals

44—Hub Cover 48—Metal Face Seals (2 used) 50—Alignment Pin 52—Backup Ring
47—Roller Bearing 49—Wheel Spindle Assembly 51—O-ring 53—Brake Pressure Tube

3. Remove cover (44) from spindle. a. Remove metal face seal from cover (44). Face
seal in spindle assembly (49) can remain
4. Inspect roller bearing (47) and bearing cups. installed during preload adjustment.
Replace if necessary.
b. Install cover (44).
NOTE: Go to next step if roller bearings were not
replaced.

5. Adjust bearing preload using the following

procedure:

Continued on next page BT40170,0000093 –19–26SEP03–2/5

TM2256 (09JAN07) 02-0240-29 D Series Motor Grader Repair

020207
PN=89
 Powered Wheel Axles

c. Remove brake pressure tube (27).

d. Apply oil to spindle and install carrier brake

assembly.

–UN–17DEC01
27—Brake Pressure Tube

T147981B
02
0240
30 Brake Pressure Tube

Continued on next page BT40170,0000093 –19–26SEP03–3/5

TM2256 (09JAN07) 02-0240-30 D Series Motor Grader Repair

020207
PN=90
 Powered Wheel Axles

e. Install retaining plate (26).

f. Install four cap screws (25). Cross tighten to

specification.

Specification

–UN–17DEC01
Carrier Brake Retaining Plate
Cap Screws to Adjust Bearing
Preload.—Torque ...........................................................................20 N•m
177 lb-in.

T149252B
02
0240
Shim Measurement 31
g. Rotate cover (44) two revolutions in both directions.
25—Retaining Plate Cap Screws
h. Torque cap screws to above specification. 26—Retaining Plate
49—Spindle
i. Repeat above two steps until torque stays at
specification.

j. Measure distance between retaining plate (26) and

spindle (49) in four places using feeler gauge.

k. Build a shim pack with a thickness that is 0.12 mm

(0.005 in) less than average of four measurements.

Specification
Wheel Drive Shim Pack
Thickness—Thickness ...........................0.12 mm less than measurement
between brake carrier face and
spindle face
0.005 in. less than measurement
between brake carrier face and
spindle face

l. Remove retaining plate.

m. Install shims and retaining plate with all cap

screws. Tighten cap screws to specification.

Specification
Carrier Brake Retaining Plate
Cap Screws—Torque ...................................................................138 N•m
102 lb-ft

n. Rotate cover two revolutions in each direction.

Continued on next page BT40170,0000093 –19–26SEP03–4/5

TM2256 (09JAN07) 02-0240-31 D Series Motor Grader Repair

020207
PN=91
 Powered Wheel Axles

NOTE: Make sure DFT1225 tool is installed with center

nut (56) directly over motor shaft (57).

o. Install rolling torque measurement tool (55). See

DFT1225—Rolling Torque Measurement Tool.
(Group 9900.) Measure rolling torque using torque

–UN–17DEC01
wrench on center nut (56). Rolling torque must be
within specification.

Specification

T149254B
02 HFWD Bearing—Rolling Drag
0240 Torque ....................................................................................... 3—10 N•m
32 27—89 lb-in.
Measure Rolling Torque

55—DFT1225 Rolling Torque Measurement Tool

56—Center Nut
If rolling torque is not within specification, adjust shim 57—Motor Shaft
pack thickness.

p. Remove retaining plate and brake carrier assembly.

q. Install face seal in cover. See HFWD O-Ring Metal

Face Seal Remove and Install. (Group 0240.)

6. Install cover, brake assembly and retaining plate.

Tighten cap screws to specification.

Specification
Carrier Brake Retaining Plate
Cap Screws—Torque ...................................................................138 N•m
102 lb-ft

7. Install wheel. See Tire Remove and Install for lug nut
torque specification. (Group 0110.)

BT40170,0000093 –19–26SEP03–5/5

TM2256 (09JAN07) 02-0240-32 D Series Motor Grader Repair

020207
PN=92
 Powered Wheel Axles

HFWD O-Ring Metal Face Seal Remove and

Install

1. Lean top of wheel hub approximately five degrees

inward towards machine frame.

2. Remove front wheel. See Tire Remove and Install.

(Group 0110.)

3. Drain HFWD drive hub. See Replacing 6WD Hub Oil-If

Equipped. (Operator’s Manual.) 02
0240
33

BT40170,000008C –19–26SEP03–1/14

4. Disconnect brake pressure supply line (1). Cap and

plug line.

CAUTION: Prevent possible injury from

crushing. Use appropriate lifting device.

–UN–19AUG03
Specification
Wheel End—Weight .....................................................48 kg approximate
105 lb approximate

T194252A
5. Support wheel end using hoist and strap.

Brake Pressure Supply Line

1—Brake Pressure Supply Line

Continued on next page BT40170,000008C –19–26SEP03–2/14

TM2256 (09JAN07) 02-0240-33 D Series Motor Grader Repair

020207
PN=93
 Powered Wheel Axles

NOTE: HFWD hub assembly shown removed from

machine for clarity.

6. Remove cap screws (45) and plug (46). Use cap screw
(45) in threaded hole for plug (46) to separate wheel
drive hub.

–UN–08NOV01
45—Hub Mounting Cap Screws
46—Plug

T147937B
02
0240
34 Wheel End Cap Screws

BT40170,000008C –19–26SEP03–3/14

CAUTION: Prevent possible injury from

crushing. Support cover with floor jack.

7. Support cover (6) using floor jack (5).

CAUTION: Prevent possible injury from

crushing. Use appropriate lifting device.

8. Support brake clutch assembly (8) using hoist and

strap (7).

5—Floor Jack
6—Cover

–UN–18AUG03
7—Hoist Strap
8—Brake Clutch Assembly

T194174A

Brake Clutch Assembly

Continued on next page BT40170,000008C –19–26SEP03–4/14

TM2256 (09JAN07) 02-0240-34 D Series Motor Grader Repair

020207
PN=94
 Powered Wheel Axles

IMPORTANT: Avoid damage to timing pin by marking

an index position on brake clutch
assembly.

9. Mark index position (9) on brake clutch assembly (8)

and hub (10) to aid in assembly.

–UN–19AUG03
NOTE: Keep brake clutch in hoist strap for ease of
assembly.

T194172B
10. Remove brake clutch assembly (8). 02
0240
Index Position 35
8—Brake Clutch Assembly
9—Index Position
10—Hub

BT40170,000008C –19–26SEP03–5/14

CAUTION: Prevent possible injury from

crushing. Use appropriate lifting device.

11. Remove cover (6).

12. Inspect metal face seals for wear. See Metal Face
Seals Inspection. (Group 0250.)

13. Remove seals by prying on edges.

IMPORTANT: Use extreme care not to scratch metal

face seal surface throughout this
procedure.

–UN–14AUG03
14. Thoroughly clean O-ring pockets of both seals and
exposed surfaces using TY16041 Brake and Clutch
Cleaner.

5—Floor Jack T194016A

6—Cover Cover

Continued on next page BT40170,000008C –19–26SEP03–6/14

TM2256 (09JAN07) 02-0240-35 D Series Motor Grader Repair

020207
PN=95
 Powered Wheel Axles

NOTE: Seal installing tool is shown expanded to show

proper installation.

15. Install JDG1824 Seal Installing Tool (7) to seal (9).

Check that lip (8) is fully inserted around entire seal.

–UN–18AUG03
IMPORTANT: Use only rubbing alcohol on seals.
Damage could occur to seals if other
lubricants are used.

T194164A
02 16. Spray rubbing alcohol on O-ring seal and pockets for
0240 lubrication.
36 Seal Installing Tool

7—JDG1824 Seal Installing Tool

8—JDG1824 Tool Lip
9—Seal

BT40170,000008C –19–26SEP03–7/14

17. Before alcohol evaporates, install seal (8) by pushing

evenly and firmly on tool (7) until tool bottoms out all
way around housing.

IMPORTANT: Damage will occur to O-ring seal if

unseated during tool removal. Use care
when removing tool from seal.

18. Remove tool (7).

19. Inspect O-ring to see that it is seated at same height

all the way around.

–UN–19AUG03
7—Seal
8—JDG1824 Seal Installing Tool

T194018B

Seal Installing Tool

Continued on next page BT40170,000008C –19–26SEP03–8/14

TM2256 (09JAN07) 02-0240-36 D Series Motor Grader Repair

020207
PN=96
 Powered Wheel Axles

IMPORTANT: Failure to properly lubricate outer zone

of seals may result in seal failure.

20. Lubricate outer zone (13) of metal face on seal using

TY6354 HY-GARD oil.

–UN–20AUG03
21. Repeat procedure for remaining seal.

13—Outer Zone of Seal

T194304A
02
0240
Metal Face of Seal 37

HY-GARD is a trademark of Deere & Company BT40170,000008C –19–26SEP03–9/14

CAUTION: Prevent possible injury from

crushing. Use appropriate lifting device.

22. Raise cover (6) into position.

5—Floor Jack
6—Cover

–UN–14AUG03
T194023A

Cover and Floor Jack

Continued on next page BT40170,000008C –19–26SEP03–10/14

TM2256 (09JAN07) 02-0240-37 D Series Motor Grader Repair

020207
PN=97
 Powered Wheel Axles

IMPORTANT: Damage will occur to seals if not

properly aligned. Seals must be aligned
top-to-bottom and left-to-right to avoid
damage.

23. Adjust floor jack height until seal halves (11) are at

–UN–18SEP03
same height and aligned left-to-right.

11—Seal Half (2 used)

T194175B
02
0240
38 Seal Alignment

Continued on next page BT40170,000008C –19–26SEP03–11/14

TM2256 (09JAN07) 02-0240-38 D Series Motor Grader Repair

020207
PN=98
 Powered Wheel Axles

IMPORTANT: Timing pin must be in center of through

hole when installing brake clutch
assembly. Damage could occur to brake
supply line if timing pin is not in center
of through hole.

24. Install brake clutch assembly (8) using hoist strap (7).

25. Use indexing position to line up brake clutch

assembly and hub.
02
26. With correct indexing and role pin in center of through 0240
39
hole slide brake clutch assembly onto splines on
spindle. Install retainer plate and shims.

–UN–18AUG03
NOTE: Since seals are not fully compressed brake clutch
assembly may protrude as far as 19 mm (0.75 in)
from retainer plate bolt pattern on spindle.

T194174A
27. Using three evenly spaced cap screws carefully turn
each cap screw, one turn at a time until retainer plate Clutch Assembly
is 3 mm (0.125 in) from being fully seated.
5—Floor Jack
6—Cover
28. Remove floor jack and hoist strap on brake clutch 7—Hoist Strap
when brake clutch is within 3 mm (0.125 in.) of 8—Brake Clutch Assembly
retainer plate pattern on spindle.

29. Install remaining cap screws. Cross tighten cap

screws to specification.

Specification
Cap Retainer Plate Cap Screw—
Torque .......................................................................................... 138 N•m
102 lb-ft

30. Rotate cover three revolutions in each direction to

check for binding.

Continued on next page BT40170,000008C –19–26SEP03–12/14

TM2256 (09JAN07) 02-0240-39 D Series Motor Grader Repair

020207
PN=99
 Powered Wheel Axles

31. Push in on sun gear shaft (11) to make sure it is

seated and rotates freely.

32. Install wheel end and cap screws. Tighten cap screws
to specification.

Specification
Wheel End Cap Screw—Torque ....................................................80 N•m
59 lb-ft

02 11—Sun Gear Shaft

0240
40

–UN–09SEP03
T194649A
Wheel End

BT40170,000008C –19–26SEP03–13/14

33. Connect brake pressure supply line (1).

34. Fill front wheel drive hub. See Replacing 6WD Hub
Oil-If Equipped. (Group 3-8.)

35. Install front wheel. See Tire Remove and Install for

–UN–19AUG03
lug nut torque specification. (Group 0110.)

1—Brake Pressure Supply Line

T194252A

Brake Pressure Supply Line

BT40170,000008C –19–26SEP03–14/14

TM2256 (09JAN07) 02-0240-40 D Series Motor Grader Repair

020207
PN=100
 Powered Wheel Axles

Front Axle Remove and Install—HFWD

1. If equipped, remove pushblock, scarifier or front

attachments.

CAUTION: Prevent possible injury from

unexpected machine movement. Install
articulation lock pin when machine is raised or
when working in articulation joint area.
02
2. Install articulation lock pin. See Locking Machine 0240
Frame. (Operator’s Manual.) 41

3. Raise front of machine using moldboard.

NOTE: Do not support machine by front axle.

4. Support front of machine.

Specification
672D Front Axle Operating—
Weight............................................................................................ 4358 kg
9610 lb
772D Front Axle Operating—
Weight............................................................................................ 4364 kg
9620 lb
872D Front Axle Operating—
Weight............................................................................................ 4613 kg
10,170 lb

5. Remove front wheels. See Tire Remove and Install.

(Group 0110.)

6. Pull a vacuum on hydraulic oil tank.

Continued on next page AC12469,000003D –19–04JAN07–1/7

TM2256 (09JAN07) 02-0240-41 D Series Motor Grader Repair

020207
PN=101
 Powered Wheel Axles

NOTE: Left motor hoses are on right side of HFWD

engagement manifold. Right motor hoses are on
left side of HFWD engagement manifold.

7. Disconnect hoses (1—8) from HFWD engagement

manifold. Close all openings using caps or plugs.

1—Return Hose—Right Side

2—Forward Pressure Hose—Right Side
3—Forward Pressure Hose—Left Side
02 4—Reverse Pressure Hose—Right Side
0240 5—Reverse Pressure Hose—Left Side
42 6—Right Brake Pressure Hose
7—Left Brake Pressure Hose
8—Return Hose—Left Side

–UN–06DEC01
T148927B
HFWD Engagement Manifold—Left Side

–UN–06DEC01
T148928B

HFWD Engagement Manifold—Right Side

Continued on next page AC12469,000003D –19–04JAN07–2/7

TM2256 (09JAN07) 02-0240-42 D Series Motor Grader Repair

020207
PN=102
 Powered Wheel Axles

8. Disconnect right and left motor flushing hoses from tee

(2). Close all openings using caps or plugs.

9. Disconnect hoses from steering cylinders. Close all

openings using caps or plugs.

1—Motor Flushing Hose

2—Motor Flushing Hose Tee

02
0240
43

–UN–01OCT04
T203719A
Motor Flushing Hose

Continued on next page AC12469,000003D –19–04JAN07–3/7

TM2256 (09JAN07) 02-0240-43 D Series Motor Grader Repair

020207
PN=103
 Powered Wheel Axles

02
0240
44

–UN–26FEB02
T150964B
Hose Routing—Left Side

–UN–07DEC01
T148938B

Hose Routing—Right Side

Continued on next page AC12469,000003D –19–04JAN07–4/7

TM2256 (09JAN07) 02-0240-44 D Series Motor Grader Repair

020207
PN=104
 Powered Wheel Axles

1—Return Hose—Right Side 4—Reverse Pressure Hose— 7—Left Brake Pressure Hose 11—Tie Rod
2—Forward Pressure Hose— Right Side 8—Return Hose—Left Side 12—Wire Harness
Right Side 5—Reverse Pressure Hose— 9—Lean Bar 13—Left Motor Flushing Hose
3—Forward Pressure Hose— Left Side 10—Right Motor Flushing
Left Side 6—Right Brake Pressure Hose Hose

IMPORTANT: Hose routing is critical around lean 11. Disconnect wire harness (12).
bar.

10. Remove lean bar (9). Mark hoses to aid

installation in original location.
02
0240
Continued on next page AC12469,000003D –19–04JAN07–5/7 45

TM2256 (09JAN07) 02-0240-45 D Series Motor Grader Repair

020207
PN=105
 Powered Wheel Axles

02
0240
46

–UN–23OCT01
T145719

HFWD Front Axle

Continued on next page AC12469,000003D –19–04JAN07–6/7

TM2256 (09JAN07) 02-0240-46 D Series Motor Grader Repair

020207
PN=106
 Powered Wheel Axles

1—Cap Screw 4—Pin 7—Shim 9—Cap Screw

2—Washer 5—Washer 8—Wear Plate 10—Front Axle
3—Spacer 6—Bushing

12. Remove cap screw (1), washer (2) and spacer (3). 22. Install lean bar, lean bar pins, and lean bar
brackets. Tighten cap screws to specification.
CAUTION: Prevent possible injury from Specification
crushing. Use appropriate lifting device. Lean Bar Pin Cap Screw
(HFWD Axle)—Torque...........................................................133 N•m
Specification 98 lb-ft
HFWD Front Axle With Hubs, 02
Lean Yokes, Tie Rod, Steering
IMPORTANT: Hydraulic hoses must be installed in 0240
Cylinders—Weight Approximate .............................................1075 kg 47
2370 lb original locations. Failure to do so
will result in premature hose failure.
13. Support front axle with hoist.
23. Connect all hoses. See HFWD System
14. Remove pin (4). Component Location. (Group 9016-15.)

15. Remove washers (5) and shims (7). 24. Connect wire harnesses.

16. Remove front axle (10). 25. Relieve vacuum on hydraulic oil tank.

17. Inspect pin (4), washers (5), bushings (6) , shims 26. Install front wheels. See Tire Remove and Install.
(7), and wear plate (8). Replace if necessary. (Group 0110.)

18. Position front axle (10) in frame. 27. Lower front of machine to the ground.

19. Install pin (4) with washers (5) and shims (7). 28. Remove articulation lock pin.

20. Add or remove shims to have minimum fore-aft 29. Run machine and check for leaks.
movement of axle with no binding through range
of side-to-side motion. 30. Check hydraulic oil level. See Checking Hydraulic
Tank Oil Level. (Operator’s Manual.)
21. Install spacer (3), washer (2), and cap screw (1).
Torque cap screw to specifications.

Specification
Pivot Pin Retaining Cap
Screw—Torque ......................................................................140 N•m
103 lb-ft

AC12469,000003D –19–04JAN07–7/7

TM2256 (09JAN07) 02-0240-47 D Series Motor Grader Repair

020207
PN=107
 Powered Wheel Axles

Steering Angle Sensor Remove and Install

(S.N. 611296— )

CAUTION: Prevent possible injury from

unexpected machine movement. Install
articulation lock pin when machine is raised or
when working in articulation joint area.

1. Install articulation lock pin. See Locking Machine

02 Frame. (Operator’s Manual.)
0240
48 2. Raise front of machine using moldboard.

3. Support front of machine with jack stands.

Specification
672D Front Axle Operating—
Weight............................................................................................ 4358 kg
9610 lb
772D Front Axle Operating—
Weight............................................................................................ 4364 kg
9620 lb
872D Front Axle Operating—
Weight............................................................................................ 4613 kg
10,170 lb

4. Remove right side front wheel. See Tire Remove and

Install. (Group 0110.)

Continued on next page AC12469,0000038 –19–01FEB07–1/4

TM2256 (09JAN07) 02-0240-48 D Series Motor Grader Repair

020207
PN=108
 Powered Wheel Axles

CAUTION: Prevent possible injury from

crushing. Use appropriate lifting device.

Specification
HFWD Front Wheel Hub, Spindle,
and Yoke (motor full of oil)—
Weight Approximate ........................................................................ 390 kg
860 lb

5. Support front wheel hub, spindle, and yoke (3) using

strap (1) attached to hoist. 02
0240
6. Remove right side lean bar brackets (2). 49

–UN–04DEC06
7. Lift right side front wheel hub, spindle, and yoke
slightly with strap attached to hoist.

NOTE: Left side front wheel hub, spindle, and yoke will

TX1015199A
be supported by lean cylinder.

8. Lift lean bar above right side lean yoke bracket and
support with a block of wood placed on top of front 1—Supporting Strap
axle. 2—Lean Bar Pin, Brackets, and Cap Screws
3—HFWD Front Wheel Hub, Spindle, and Yoke

Continued on next page AC12469,0000038 –19–01FEB07–2/4

TM2256 (09JAN07) 02-0240-49 D Series Motor Grader Repair

020207
PN=109
 Powered Wheel Axles

9. Disconnect steering angle sensor (5) from wire

harness.

10. Remove cap screws (4) retaining steering angle

sensor.

11. Remove steering angle sensor by pulling straight up.

12. Remove spacer cap screws (6) and lubrication fitting

(8).
02
0240 13. Remove spacer (7).
50

–UN–01DEC06
14. Inspect steering angle sensor. Replace as necessary.

NOTE: Steering angle sensor connector must face front

of machine.

TX1015200A
15. Install steering angle sensor (5) and tighten cap
screws (4).

16. Install spacer (7) and tighten cap screws (6) 4—Steering Angle Sensor Cap Screw
5—Steering Angle Sensor
6—Spacer Cap Screw
NOTE: Rotation of spacer may be necessary to allow to 7—Spacer
allow spacer plate to sit flush beneath steering 8—Lubrication Fitting
angle sensor.

17. Install lubrication fitting (8).

18. Connect wire harness to steering angle sensor.

19. Remove block holding lean bar above lean yoke

assembly (3).

20. Lower lean bar into place. Start cap screws (2) in
holes but do not tighten them.

21. Lower right side lean yoke until lean yoke brackets
contact lean yoke.

22. Tighten lean bar cap screws to specification.

Specification
Lean Bar Pin Cap Screw (HFWD
Axle)—Torque...............................................................................133 N•m
98 lb-ft

23. Remove strap (1) supporting right side lean yoke.

Continued on next page AC12469,0000038 –19–01FEB07–3/4

TM2256 (09JAN07) 02-0240-50 D Series Motor Grader Repair

020207
PN=110
 Powered Wheel Axles

24. Install front wheel. See Tire Remove and Install for
lug nut torque specification. (Group 0110.)

25. Lower machine to the ground.

26. Remove articulation lock pin.

27. Calibrate HFWD Controller. See Hydrostatic Front

Wheel Drive (6WD) Controller Calibration (S.N.
611296— ). (Group 9015-20.)
02
0240
AC12469,0000038 –19–01FEB07–4/4 51

TM2256 (09JAN07) 02-0240-51 D Series Motor Grader Repair

020207
PN=111
 Powered Wheel Axles

02
0240
52

TM2256 (09JAN07) 02-0240-52 D Series Motor Grader Repair

020207
PN=112
 Group 0250
Axle Shafts, Bearings, and Reduction Gears

TEAMMATE II 1400 Series Inboard

Planetary Axle—Use CTM43

For complete repair information, the component technical

manual (CTM) is also required.

Use the CTM in conjunction with this machine manual.

–UN–17JAN89
TS225
02
0250
Component Technical Manual (CTM) 1

TEAMMATE is a trademark of Deere & Company BT40170,0000070 –19–19MAY03–1/1

TM2256 (09JAN07) 02-0250-1 D Series Motor Grader Repair

020207
PN=113
 Axle Shafts, Bearings, and Reduction Gears

Rear Axle Remove and Install

02
0250
2

–UN–12DEC03
T196630

Cross Section of Rear Axle

Continued on next page TX19495,0000169 –19–15DEC04–1/7

TM2256 (09JAN07) 02-0250-2 D Series Motor Grader Repair

020207
PN=114
 Axle Shafts, Bearings, and Reduction Gears

A—Rear Axle C—Right Final Drive Axle D—Differential F—Right Final Drive Axle
B—Left Final Drive Axle Housing E—Left Final Drive Axle G—Tandem Pivot Housings
Housing

Continued on next page TX19495,0000169 –19–15DEC04–2/7

02
0250
3

TM2256 (09JAN07) 02-0250-3 D Series Motor Grader Repair

020207
PN=115
 Axle Shafts, Bearings, and Reduction Gears

02
0250
4

–19–12DEC03
T196629

Rear Axle and Tandem Assembly

Continued on next page TX19495,0000169 –19–15DEC04–3/7

TM2256 (09JAN07) 02-0250-4 D Series Motor Grader Repair

020207
PN=116
 Axle Shafts, Bearings, and Reduction Gears

A—Tandem Housing G—Planet Pinions M—Tandem Drive Sprocket S—Differential with Differential
B—Tandem Pivot Housing H—O-Rings—Tandem Pivot N—Tandem Drive Shaft Lock
C—Oil Seal—Tandem Drive Housing O—Final Drive Gear T—Axle Input Yoke
Shaft I—Wheel Axle Sprocket P—Final Drive Planetary U—Oil Seal—Wheel Axle
D—Final Drive Axle Housing J—Outboard Hub Carrier V—Tandem Pivot Bushings
E—Final Drive Shaft and Sun K—Wheel Axle Q—Brake Backing Plate W—Tandem Pivot Thrust
Pinion L—Chain R—Brake Piston Washers
F—Brake Disks and Plates

1. If equipped, remove bottom guard or snow wing. articulation lock pin when machine is raised
or when working in articulation joint area.
2. If equipped with rear mounted ripper, remove lower 02
linkage between ripper frame and final drive axle 3. Install articulation lock pin. See Locking Machine 0250
housing. See Ripper Remove and Install. (Group Frame. (Operator’s Manual.) 5
4240.)
4. Pump brake pedal to completely discharge brake
accumulator.
CAUTION: Prevent possible injury from
unexpected machine movement. Install

Continued on next page TX19495,0000169 –19–15DEC04–4/7

TM2256 (09JAN07) 02-0250-5 D Series Motor Grader Repair

020207
PN=117
 Axle Shafts, Bearings, and Reduction Gears

CAUTION: Prevent possible injury from

crushing. Use appropriate lifting device.

5. Raise rear of machine and install shop stands under

rear of engine frame.

Rear Operating Weight—With Standard Equipment—Specification

670D—Weight ............................................................................10 663 kg
23 510 lb
672D—Weight ............................................................................10 895 kg
02 24 020 lb
0250 770D—Weight ............................................................................10 959 kg
6 24 160 lb
772D—Weight ............................................................................11 186 kg
24 660 lb
870D—Weight ............................................................................11 589 kg
25 550 lb
872D—Weight ............................................................................11 812 kg
26 040 lb

6. Drain differential case and final drive housings. See

Drain and Refill Capacities. (Operator’s Manual.)

–UN–21JUL97
7. Remove transmission-to-rear axle drive shaft. See
Transmission-to-Rear Axle Drive Shaft Remove and
Install. (Group 0225.)

T110625
8. Remove tandem and wheel axle assemblies. See
Floor Stand Placement
Tandem and Wheel Axle Assembly Remove and
Install. (Group 0250.)

9. Disconnect wiring harness from differential.

10. Disconnect hydraulic lines from differential. Cap and

plug openings. See Power Train Component Location.
(Group 9020-15.)

11. Install hydraulic lift scissors jack and wooden blocks

under rear axle (A).

Continued on next page TX19495,0000169 –19–15DEC04–5/7

TM2256 (09JAN07) 02-0250-6 D Series Motor Grader Repair

020207
PN=118
 Axle Shafts, Bearings, and Reduction Gears

CAUTION: Prevent possible crushing injury

from heavy component. Use appropriate lifting
device.

Rear Axle Remove and Install—Specification

Rear Axle—Approximate Weight...................................................1361 kg
3000 lb
Rear Axle and Tandem—
Approximate Weight ...................................................................... 2722 kg
6000 lb

02
12. Remove cap screws and washers from front mounts 0250
of final drive axle housings (B and C) to engine 7
frame.

13. Remove cap screws and washers from top mounts of

final drive axle housings (B and C) to engine frame.

14. Lower rear axle and remove from under machine.

15. Clean and inspect parts. Repair or replace parts as

necessary. See Rear Axle Disassemble and
Assemble. (Group 0250.)

16. Support rear axle (A) with a hydraulic lift scissors jack
and wooden blocks.

17. Position rear axle (A) under machine and align final
drive axle housing (B and C) front and top mount cap
screw holes with holes in engine frame.

18. Install cap screws and washers through engine frame

to final drive axle housing front mounts. Do not
tighten.

19. Install cap screws and washers through engine frame

to final drive axle housing top mounts. Do not tighten.

20. Position rear axle tightly against engine frame to

eliminate gap between engine frame and final drive
axle housing mounts.

21. Tighten top mount cap screws to specification.

Specification
Final Drive-to-Engine Frame Cap
Screw—Torque ...........................................................................1070 N•m
790 lb-ft

Continued on next page TX19495,0000169 –19–15DEC04–6/7

TM2256 (09JAN07) 02-0250-7 D Series Motor Grader Repair

020207
PN=119
 Axle Shafts, Bearings, and Reduction Gears

22. Tighten front mount cap screws to specification.

Specification
Final Drive-to-Front Support Cap
Screw—Torque .............................................................................620 N•m
460 lb-ft

23. Connect hydraulic lines to differential.

24. Disconnect wiring harness from differential.

02
25. Install tandem and wheel axle assemblies. See
0250
8 Tandem and Wheel Axle Assembly Remove and
Install. (Group 0250.)

26. Install transmission-to-rear axle drive shaft. See

Transmission-to-Rear Axle Drive Shaft Remove and
Install. (Group 0225.)

27. Fill differential case and final drive housings. See

Drain and Refill Capacities. (Operator’s Manual.)

28. Lower machine to the ground.

29. Remove articulation lock pin.

30. If equipped with rear mounted ripper, install lower

linkage between ripper frame and final drive axle
housings. See Ripper Remove and Install. (Group
4240.)

31. If equipped, install bottom guard or snow wing.

TX19495,0000169 –19–15DEC04–7/7

TM2256 (09JAN07) 02-0250-8 D Series Motor Grader Repair

020207
PN=120
 Axle Shafts, Bearings, and Reduction Gears

02
0250
9

TM2256 (09JAN07) 02-0250-9 D Series Motor Grader Repair

020207
PN=121
 Axle Shafts, Bearings, and Reduction Gears

Rear Axle Disassemble and Assemble

02
0250
10

–19–
T196630

Assemble Rear Axle

Continued on next page TX,02,DU2612 –19–12DEC03–1/2

TM2256 (09JAN07) 02-0250-10 D Series Motor Grader Repair

020207
PN=122
 Axle Shafts, Bearings, and Reduction Gears

A—Rear Axle C—Right Final Drive Axle D—Differential F—Right Final Drive Axle
B—Left Final Drive Axle Housing E—Left Final Drive Axle G—Tandem Pivot Housings
Housing

To disassemble and assemble rear axle, see the • Tandem Pivot—See Tandem Pivot Disassemble and
following procedures: Assemble. (Group 0250.) (Optional—Not required to
remove final drive axle.)
• Final Drive Axle—See Final Drive Axle Remove and • Differential—See 1400 John Deere Grader
Install. (Group 0250.) Differential Housing. (CTM43)

02
0250
TX,02,DU2612 –19–12DEC03–2/2 11

Tandem and Wheel Axle Assembly Remove

and Install

1. If equipped, remove ripper or rear attachments. See

Ripper Remove and Install. (Group 4240.)

CAUTION: Prevent possible injury from

unexpected machine movement. Install
articulation lock pin when machine is raised or
when working in articulation joint area.

2. Install articulation lock pin. See Locking Machine

Frame. (Operator’s Manual.)

3. Drain tandem housing. See Changing Tandem Oil.

(Operator’s Manual.)

Continued on next page TX19495,0000155 –19–19NOV04–1/5

TM2256 (09JAN07) 02-0250-11 D Series Motor Grader Repair

020207
PN=123
 Axle Shafts, Bearings, and Reduction Gears

CAUTION: Prevent possible injury from

crushing. Use appropriate lifting device.

4. Raise rear of machine and install shop stands under

rear of engine frame.

Rear Operating Weight—With Standard Equipment—Specification

670D—Weight ............................................................................10 663 kg
23 510 lb
672D—Weight ............................................................................10 895 kg
02 24 020 lb
0250 770D—Weight ............................................................................10 959 kg
12 24 160 lb
772D—Weight ............................................................................11 186 kg
24 660 lb
870D—Weight ............................................................................11 589 kg
25 550 lb
872D—Weight ............................................................................11 812 kg
26 040 lb

5. Remove wheels from tandem being removed.

–UN–21JUL97
6. Remove step and round cover from side of tandem
housing.

T110625
Shop Stand Installation

Continued on next page TX19495,0000155 –19–19NOV04–2/5

TM2256 (09JAN07) 02-0250-12 D Series Motor Grader Repair

020207
PN=124
 Axle Shafts, Bearings, and Reduction Gears

7. Remove drive sprocket retaining ring (A).

CAUTION: Prevent possible crushing injury

from heavy component. Use appropriate lifting
device.

8. Install hoist with chains on tandem housing.

Specification
Tandem and Wheel Axle
Assembly—Approximate Weight .....................................................726 kg 02
1600 lb 0250
13

A—Retaining Ring

–UN–18JUN97
T109890
Drive Sprocket Retaining Ring

Continued on next page TX19495,0000155 –19–19NOV04–3/5

TM2256 (09JAN07) 02-0250-13 D Series Motor Grader Repair

020207
PN=125
 Axle Shafts, Bearings, and Reduction Gears

9. Remove tandem pivot to tandem housing cap screws

and washers (B).

10. Pull tandem housing tandem drive sprocket and

chains straight off tandem drive shaft.

11. Replace parts as necessary.

IMPORTANT: Carefully align tandem drive sprocket

with tandem drive shaft for ease of
02 installation.
0250
14
12. Lubricate O-ring on tandem pivot housing pilot
diameter and mating surface in tandem housing with

–UN–18JUN97
petroleum jelly.

13. Install tandem housing onto tandem pivot housing.

Apply T43512 Thread Lock and Sealer (Medium

T109891
Strength) to threads of cap screws with washers (B)
and tighten.
Tandem Pivot
Specification
B—Cap Screw and Washer
Pivot Housing Retaining Ring
Cap Screw—Torque .....................................................................258 N•m
190 lb-ft

14. Install drive sprocket retaining ring (A).

15. Install tandem round side cover and step. Apply

T43512 Thread Lock and Sealer (Medium Strength)
to threads of cap screws and tighten.

Specification
Tandem Housing Cover Cap
Screw—Torque ...............................................................................47 N•m
35 lb-ft

16. Install wheels and tighten to specification. See Tire

Remove and Install for lug nut torque specification.
(Group 0110.)

17. Lower machine to the ground.

18. Fill tandem housing flush to bottom of oil level check

plug. See Drain and Refill Capacities. (Operator’s
Manual.)

Fill oil collection cups in wheel axle assemblies.

Continued on next page TX19495,0000155 –19–19NOV04–4/5

TM2256 (09JAN07) 02-0250-14 D Series Motor Grader Repair

020207
PN=126
 Axle Shafts, Bearings, and Reduction Gears

19. Remove articulation lock pin.

20. If equipped, install ripper or rear attachments. See

Ripper Remove and Install. (Group 4240.)

TX19495,0000155 –19–19NOV04–5/5

02
0250
15

TM2256 (09JAN07) 02-0250-15 D Series Motor Grader Repair

020207
PN=127
 Axle Shafts, Bearings, and Reduction Gears

Tandem Rear Wheel Axle Assembly Remove

and Install

CAUTION: Prevent possible injury from

unexpected machine movement. Install
articulation lock pin when machine is raised or
when working in articulation joint area.

1. Install articulation lock pin. See Locking Machine

02 Frame. (Operator’s Manual.)
0250
16 2. Drain tandem housing. See Changing Tandem Oil.
(Operator’s Manual.)

–UN–12AUG97
3. Install 10-ton shop stands under each end of tandem
housing (A).

T109897
4. Remove wheel.
Tandem Rear Wheel Axle Assembly
CAUTION: Excessive lifting force can split
flange on wheel axle assembly. A—Tandem Housing
B—O-Ring
C—DF1017 Axle Lift Eye
5. Install DF1017 Axle Lift Eye (C) and hoist to wheel D—Oil Collection Cup
axle flange. See DF1017—Axle Lift Eye. (Group 9900.)

6. Remove cap screws and washers from wheel axle

assembly flange.

CAUTION: Prevent possible injury from

crushing. Use appropriate lifting device.

Specification
Wheel Axle Assembly—Weight—
Approximate ................................................................................... 145 kg
320 lb

7. Pull wheel axle assembly out of tandem housing until

pilot on outboard hub disengages the tandem housing.
Move wheel axle assembly forward and remove chain
from wheel axle sprocket. Remove wheel axle
assembly.

8. Repair or replace parts as necessary.

9. Lubricate O-ring (B) and mating bore of tandem

housing (A) with petroleum jelly.

Continued on next page TX19495,0000156 –19–19NOV04–1/2

TM2256 (09JAN07) 02-0250-16 D Series Motor Grader Repair

020207
PN=128
 Axle Shafts, Bearings, and Reduction Gears

10. Position wheel axle assembly in tandem housing,

install chain on wheel axle sprocket, and then insert
pilot diameter of wheel axle assembly into tandem
housing (A).

11. Apply T43512 Thread Lock and Sealer (Medium

Strength) to threads of cap screws. Install cap screws
and washers and tighten to specification.

Specification
Wheel Axle Housing-to-Tandem 02
Cap Screw—Torque .....................................................................258 N•m 0250
190 lb-ft 17

12. Install wheels and tighten to specification. See Tire

Remove and Install for lug nut torque specification.
(Group 0110.)

13. Fill tandem housing flush to bottom of oil level check

plug. See Drain and Refill Capacities. (Operator’s
Manual.)

Fill oil collection cup (D) in wheel axle assembly.

14. Lower articulation lock pin.

TX19495,0000156 –19–19NOV04–2/2

Tandem Front Wheel Axle Assembly Remove

and Install

CAUTION: Prevent possible injury from

unexpected machine movement. Install
articulation lock pin when machine is raised or
when working in articulation joint area.

1. Install articulation lock pin. See Locking Machine

Frame. (Operator’s Manual.)

2. Drain tandem housing. See Changing Tandem Oil.

(Operator’s Manual.)

Continued on next page TX19495,0000157 –19–19NOV04–1/3

TM2256 (09JAN07) 02-0250-17 D Series Motor Grader Repair

020207
PN=129
 Axle Shafts, Bearings, and Reduction Gears

3. Install 10-ton shop stands under each end of tandem

housing (A).

4. Remove wheel.

CAUTION: Excessive lifting force can split

flange on wheel axle assembly.

5. Install DF1017 Axle Lift Eye (D) and hoist to wheel

axle flange. See DF1017—Axle Lift Eye. (Group 9900.)
02
0250
18 6. Remove drive chain from wheel axle sprocket. See
Drive Chain Remove and Install. (Group 0250.)

–UN–12AUG97
CAUTION: Prevent possible injury from
crushing. Use appropriate lifting device.

T109843
Specification
Wheel Axle Assembly—Weight—
Approximate ................................................................................... 145 kg Tandem Front Wheel Axle Assembly
320 lb
A—Tandem Housing
7. Remove cap screws and washers from wheel axle B—Oil Collection Cup
C—O-Ring
assembly flange and remove wheel axle assembly.
D—DF1017 Lift Eye

8. Repair or replace parts as necessary.

9. Lubricate O-ring (C) and mating bore of tandem

housing (A) with petroleum jelly.

10. Position wheel axle assembly in tandem housing.

11. Apply T43512 Thread Lock and Sealer (Medium

Strength) to threads of cap screws. Install cap screws
and washer and tighten.

Specification
Wheel Axle Housing-to-Tandem
Cap Screw—Torque .....................................................................258 N•m
190 lb-ft

12. Install drive chain. See Drive Chain Remove and

Install. (Group 0250.)

13. Install wheel and tighten to specification. See Tire

Remove and Install for lug nut torque specification.
(Group 0110.)

Continued on next page TX19495,0000157 –19–19NOV04–2/3

TM2256 (09JAN07) 02-0250-18 D Series Motor Grader Repair

020207
PN=130
 Axle Shafts, Bearings, and Reduction Gears

14. Fill tandem housing flush to bottom of oil level check

plug. See Drain and Refill Capacities. (Operator’s
Manual.)

Fill oil collection cup (B) in wheel axle assembly.

15. Remove articulation lock pin.

02
0250
TX19495,0000157 –19–19NOV04–3/3 19

TM2256 (09JAN07) 02-0250-19 D Series Motor Grader Repair

020207
PN=131
 Axle Shafts, Bearings, and Reduction Gears

Tandem Wheel Axle Assembly Disassemble and Assemble

02
0250
20

–UN–21JUL97
T109859

Tandem Wheel Axle Assemblies

Continued on next page TX,02,DU2625 –19–29JUL99–1/5

TM2256 (09JAN07) 02-0250-20 D Series Motor Grader Repair

020207
PN=132
 Axle Shafts, Bearings, and Reduction Gears

A—Cotter Pin E—Wheel Axle Sprocket H—Thrust Washer M—Outer Bearing Cone
B—Slotted Nut F—Oil Collection Cup (rear I—Inner Bearing Cone N—Oil Seal
C—Sprocket Retainer axle) J—Inner Bearing Cup O—Wheel Axle
D—Cap Screw (2 used per G—Oil Collection Plate (front K—Wheel Axle Housing P—Clearance—Wheel Axle
axle) axle) L—Outer Bearing Cup Flange-to-Housing

Continued on next page TX,02,DU2625 –19–29JUL99–2/5

02
0250
21

TM2256 (09JAN07) 02-0250-21 D Series Motor Grader Repair

020207
PN=133
 Axle Shafts, Bearings, and Reduction Gears

CAUTION: Prevent possible injury from

crushing. Use appropriate lifting device.

Specification
Tandem Wheel Axle Assembly—
Weight—Approximate ......................................................................145 kg
320 lb

1. Remove parts (A—E, F or G, and H).

02 2. Press wheel axle (O) through inner bearing cone (I)

0250 and out of housing (K).
22
NOTE: Seal (N) will be destroyed when installing the
puller.

3. Pull outer bearing cone (M) off wheel axle using puller.

IMPORTANT: Metal faced seals can be reused if

rubber lips show no signs of damage
and metal face seals are not worn or

–UN–18JUN97
damaged. See Metal Face Seals
Inspection. (Group 0250.)

T109864
4. Remove seal (N) from wheel axle.

5. Drive bearing cups (J and L) out of housing. Bearing Cups Position

6. Repair or replace parts as necessary.

7. Position bearing cups (J and L) in housing (K) and

press firmly against shoulders in housing.

NOTE: Rubber lips on seal (N), seal mounting surface on

wheel axle (O) and wheel axle housing (K) must
be dry and free of oil.

8. Install new seal (N) onto wheel axle (O).

–UN–18JUN97
T109865

Wheel Axle Press

Continued on next page TX,02,DU2625 –19–29JUL99–3/5

TM2256 (09JAN07) 02-0250-22 D Series Motor Grader Repair

020207
PN=134
 Axle Shafts, Bearings, and Reduction Gears

CAUTION: DO NOT heat oil over 182°C (360°F).

Oil fumes or oil can ignite above 193°C (380°F).
Use a thermometer. DO NOT allow a flame or
heating element to come in direct contact with
the oil. Heat the oil in a well-ventilated area.
Plan a safe handling procedure to avoid burns.

–UN–23AUG88
9. Heat bearing cones (I and M) to specification.

Specification
Bearing Cone—Temperature ...........................................................118 °C 02

TS227
250°F 0250
Handle Fluids Safely—Avoid Fires 23

10. Position and install outer bearing cone (M) firmly

against shoulder on wheel axle.

11. Position wheel axle vertical, check oil seal to be sure

it is properly seated, and slowly lower housing (K)
onto wheel axle. Carefully guide housing (K) over
rubber lip on oil seal (N).

12. Position and install inner bearing cone (I) on wheel

axle and into housing.

13. Install thrust washer (H).

NOTE: When assembling the front tandem wheel axle

assembly, position sprocket (E) with teeth toward
wheel axle housing (K) as shown.

When assembling the rear tandem wheel axle

assembly, position sprocket (E) with teeth away
from wheel axle housing (K) as shown.

14. Install sprocket (E).

15. Install sprocket retainer (C) and slotted nut (B).

16. Position wheel axle assembly on a heavy table or

plate with wheel axle flange (O) down. Secure wheel
axle flange (O) to allow torque to be applied to slotted
nut (B) without moving.

17. Rotate wheel axle housing (K) in both directions to

seat bearings.

Continued on next page TX,02,DU2625 –19–29JUL99–4/5

TM2256 (09JAN07) 02-0250-23 D Series Motor Grader Repair

020207
PN=135
 Axle Shafts, Bearings, and Reduction Gears

18. Partially tighten slotted nut (B) and measure rolling

torque on wheel axle housing (K) with end play on
bearings.

NOTE: There is end play on bearings as long as

clearance (P) between the wheel axle housing (K)
and the wheel axle flange (O) changes when the
wheel axle housing (K) is pushed downward
compressing the rubber lips on oil seal (N).

02 19. Preload bearings by tightening slotted nut (B) until

0250 rolling torque increases more than rolling torque with
24
end play.

Specification
Slotted Nut—Torque .............................5—13 N•m more than rolling drag
torque with end play
44—115 lb-in. more than rolling
drag torque with end play

20. Apply TY6304 Flexible Form-In-Place Gasket to oil

collector cup (F) and/or oil collector plate (G).

21. Install oil collector cup (rear wheel axle) or oil

collector plate (front wheel axle) with cap screws (D).

22. Lubricate bearings and flood oil seal cavity with John
Deere HY-GARD oil.

HY-GARD is a trademark of Deere & Company. TX,02,DU2625 –19–29JUL99–5/5

TM2256 (09JAN07) 02-0250-24 D Series Motor Grader Repair

020207
PN=136
 Axle Shafts, Bearings, and Reduction Gears

02
0250
25

TM2256 (09JAN07) 02-0250-25 D Series Motor Grader Repair

020207
PN=137
 Axle Shafts, Bearings, and Reduction Gears

Tandem Pivot Disassemble and Assemble

1. Remove tandem and wheel axle assembly. See

Tandem and Wheel Axle Assembly Remove and
Install. (Group 0250.)

2. Remove cap screws (D) from pivot retainer (A).

3. Remove pivot retainer (A), shims (B) and outboard

thrust washer segments (C). Retain shims for
02 installation.
0250
26
CAUTION: Prevent possible injury from
crushing. Use appropriate lifting device.

–UN–18JUN97
Specification
Tandem Pivot Housing—
Weight—Approximate ........................................................................91 kg

T109889
200 lb

4. Install hoist and chains to tandem pivot housing (E). Outboard Thrust Washer Segment

5. Remove tandem pivot housing (E) by pulling straight

off final drive axle housing (J).

6. Remove inboard thrust washer segments (G) and

tandem pivot bushings (H).

7. Repair or replace parts as necessary.

8. Lubricate O-rings (F) on final drive axle housing (J)

and mating surface on tandem pivot housing (E) with
grease.

9. Coat final drive axle housing (J) with heavy grease and
install inboard thrust washer segments (G) with

–UN–21JUL97
chamfer facing toward radius on final drive axle
housing. Press into position to secure.

10. Lubricate tandem pivot bushings (H) with oil and T109892
install on final drive axle housing. Stagger bushing
openings 180° apart. Inboard Thrust Washer Segment

A—Pivot Retainer
B—Shim
C—Outboard Thrust Washer Segment (3 used)
D—Cap Screw (16 used)
E—Tandem Pivot Housing
F—O-Ring (2 used)
G—Inboard Thrust Washer Segment (3 used)
H—Tandem Pivot Bushing (2 used)
J—Final Drive Axle Housing

Continued on next page TX19495,0000158 –19–19NOV04–1/5

TM2256 (09JAN07) 02-0250-26 D Series Motor Grader Repair

020207
PN=138
 Axle Shafts, Bearings, and Reduction Gears

11. Position tandem pivot housing (E) with sloping flange

to the top and install halfway. Push in slowly, making
sure thrust washer segments (G) remain in position.
Continue installing until contact with O-rings (F) is
made and tandem pivot housing becomes difficult to
move by hand.

12. Lubricate outboard thrust washer segments (C) with

oil and install with corner chamfer facing outward so it
is visible when installed.
02
13. Install pivot retainer (A) without shims (B) using four 0250
27
evenly spaced cap screws and washers (D). Using
hand wrench, gradually tighten cap screws to pull
tandem pivot housing (E) over O-rings (F).

Continued on next page TX19495,0000158 –19–19NOV04–2/5

TM2256 (09JAN07) 02-0250-27 D Series Motor Grader Repair

020207
PN=139
 Axle Shafts, Bearings, and Reduction Gears

14. Using feeler gauge, check clearance (L) between

tandem pivot housing (E) and final drive axle housing
(J). It should measure approximately 2.5 mm (0.098
in.) when tandem pivot housing stops moving and the
torque on the cap screws (D) begins to rise.

Specification
Tandem Pivot Housing-to-Final
Drive Axle Housing—Approximate
Clearance ....................................................................................... 2.5 mm
0.098 in.
02
0250
If clearance (L) measures approximately 8.5 mm (0.335
28
in.), inboard thrust washer segments (G) have moved and
must be repositioned.

Specification
Inboard Thrust Washer
Segments—Approximate
Clearance ....................................................................................... 8.5 mm
0.335 in.

–UN–21JUL97
A—Pivot Retainer
B—Shim
C—Outboard Thrust Washer Segment (3 used)
D—Cap Screw (16 used)

T110373
E—Tandem Pivot Housing
F—O-Ring (2 used)
G—Inboard Thrust Washer Segment (3 used) Tandem Pivot Component Identification
H—Tandem Pivot Bushing (2 used)
J—Final Drive Axle Housing
K—Hardened Washers (16 used)
L—Clearance

Continued on next page TX19495,0000158 –19–19NOV04–3/5

TM2256 (09JAN07) 02-0250-28 D Series Motor Grader Repair

020207
PN=140
 Axle Shafts, Bearings, and Reduction Gears

15. When the clearance between the tandem pivot

housing and the main drive axle housing measures
approximately 2.5 mm (0.098 in.), install four more
cap screws (D) (evenly spaced). Tighten all eight cap
screws to specification to extrude excess grease from
the surfaces of the inboard thrust washer segments
(G).

Specification
Tandem Pivot Housing-to-Main
Drive Axle Housing—Clearance—
02
Approximate.................................................................................... 2.5 mm
0250
0.098 in.
29
Inboard Thrust Washer
Segments—Torque.......................................................................140 N•m
103 ft-lb

16. Remove pivot retainer (A) and install with the

previously removed shims (B) and eight evenly
spaced cap screws (D) and washers (K). Tighten to
278 N•m (205 ft-lb).

–UN–21JUL97
Specification
Pivot Housing Retaining Ring
Cap Screw—Torque .....................................................................278 N•m
205 ft-lb

T110373
17. Using a feeler gauge, check end play clearance (I)
between the pivot retainer and the outboard tandem Tandem Pivot Component Identification
pivot segments (C). Move feeler gauge completely
A—Pivot Retainer
around the joint. End play should be 0.026—0.040
B—Shim
mm (0.010—0.015 in.). Add or subtract shims to C—Outboard Thrust Washer Segment (3 used)
establish correct end play. D—Cap Screw (16 used)
E—Tandem Pivot Housing
Specification F—O-Ring (2 used)
Pivot Retainer-to-Outboard G—Inboard Thrust Washer Segment (3 used)
Tandem Pivot Segments—End H—Tandem Pivot Bushing (2 used)
Play ................................................................................ 0.026—0.040 mm J—Final Drive Axle Housing
0.010—0.015 in. K—Hardened Washers (16 used)
L—Clearance
18. Remove the eight cap screws and discard. Dip
threads of 16 new cap screws (D) in oil and install
with hardened washers (K) after allowing excess oil to
drip off. Tighten to specification. Go around bolt circle
twice with torque wrench.

Specification
Wheel Axle Housing-to-Tandem
Cap Screw—Torque .....................................................................258 N•m
190 lb-ft

Continued on next page TX19495,0000158 –19–19NOV04–4/5

TM2256 (09JAN07) 02-0250-29 D Series Motor Grader Repair

020207
PN=141
 Axle Shafts, Bearings, and Reduction Gears

19. Install tandem and wheel axle assembly. See Tandem

and Wheel Axle Assembly Remove and Install.
(Group 0250.)

20. Using grease fitting on front of tandem pivot housing

(E), pump grease into cavity between O-rings (F) until
grease that is free of air is purged out of hole in rear
of tandem pivot housing (E). Clean up excess grease.

02
0250
30 TX19495,0000158 –19–19NOV04–5/5

Final Drive Axle Remove and Install

1. If equipped, remove bottom guard or snow wing.

2. If equipped with rear mounted ripper, remove lower

linkage between ripper frame and final drive axle
housing. See Ripper Remove and Install. (Group
4240.)

CAUTION: Prevent possible injury from

unexpected machine movement. Install
articulation lock pin when machine is raised or
when working in articulation joint area.

3. Install articulation lock pin. See Locking Machine

Frame. (Operator’s Manual.)

4. Pump brake pedal to completely discharge brake

accumulator.

Continued on next page TX19495,0000168 –19–14DEC04–1/7

TM2256 (09JAN07) 02-0250-30 D Series Motor Grader Repair

020207
PN=142
 Axle Shafts, Bearings, and Reduction Gears

CAUTION: Prevent possible injury from

crushing. Use appropriate lifting device.

5. Raise rear of machine and install shop stands under

rear of engine frame.

Rear Operating Weight—With Standard Equipment—Specification

670D—Weight ............................................................................10 663 kg
23 510 lb
672D—Weight ............................................................................10 895 kg
24 020 lb 02
770D—Weight ............................................................................10 959 kg 0250
24 160 lb 31
772D—Weight ............................................................................11 186 kg
24 660 lb
870D—Weight ............................................................................11 589 kg
25 550 lb
872D—Weight ............................................................................11 812 kg
26 040 lb

6. Drain differential case and final drive housing. See

Drain and Refill Capacities. (Operator’s Manual.)

–UN–21JUL97
7. Disassemble tandem pivot housing for side of machine
being serviced. See Tandem Pivot Disassemble and
Assemble. (Group 0250.)

T110625
8. Place shop stands under both ends of tandem housing
Floor Stand Placement
opposite side of machine being serviced.

Continued on next page TX19495,0000168 –19–14DEC04–2/7

TM2256 (09JAN07) 02-0250-31 D Series Motor Grader Repair

020207
PN=143
 Axle Shafts, Bearings, and Reduction Gears

02
0250
32

–19–12DEC03
T196631

Final Drive Axle Component Identification

Continued on next page TX19495,0000168 –19–14DEC04–3/7

TM2256 (09JAN07) 02-0250-32 D Series Motor Grader Repair

020207
PN=144
 Axle Shafts, Bearings, and Reduction Gears

A—Differential Case H—Brake Separator Plate (6 M—O-Ring S—Inboard Bearing Cone

B—Final Drive Axle Housing used) N—Special Cap Screw T—Snap Ring
C—Final Drive Ring Gear I—Brake Disk (5 used) O—Lock Plate U—Oil Seal
D—Brake Backing Plate J—Brake Pack Retaining Pin P—Planet Pinion Carrier V—Outboard Bearing Cup
E—Dowel Pin (2 used) (2 used) Assembly W—Inboard Bearing Cup
F—Sun Pinion Shaft K—Dowel Pins (2 used) Q—Snap Ring X—Outboard Bearing Cup
G—Brake Pack Retaining Snap L—Dowel Pins (2 used) R—Tandem Drive Shaft
Ring (2 used)

9. Support final drive axle with a hydraulic lift scissors 17. Use two pry bars at notches between differential
jack and wooden blocks. case (A) and brake backing plate (D) to break
sealed joint at this location. 02
10. Support final drive axle housing (B) at bottom of 0250
front and rear mounting pads. IMPORTANT: During removal of the final drive 33
axle, sealant holding brake backing
11. Support pivot bushing journal near the outboard plate (D), final drive ring gear (C) and
end. final drive axle housing (B) may
break. However, do not allow these
12. Remove three cap screws and washers that attach parts to separate from each other.
lower front mount of final drive axle housing to the
front engine frame support. 18. Pull final drive axle away from differential case (A)
as shown. Differential case to brake backing plate
13. Remove four cap screws and washers that attach dowel pins (E) will stay with the differential case
top mounts of final drive axle housing to engine (A).
frame.
IMPORTANT: The sun pinion shaft (F) is not
14. Position hydraulic jack under center of tandem retained in the differential or the final
housing on opposite side and raise slightly. drive. Do not allow this shaft to fall
when final drive axle is moved away
15. Check for clearance between top mounts of final from differential case (A).
drive axle and engine frame on side of machine
being serviced. If clearance exists, securely block 19. Remove sun pinion shaft (F).
ends of tandem housing on either side of jack to
prevent tandems from rotating. If clearance 20. Clean and inspect parts. Repair or replace parts
doesn’t exist, apply just enough pressure on as necessary. See Final Drive Axle Disassemble
tandem with the jack to create 0.5—1.0 mm and Assemble. (Group 0250.)
(0.020—0.040 in.) clearance. Do not apply so
much load that the engine frame comes off other 21. Apply TY6304 flexible form-in-place gasket onto
supports. Block ends of tandem housing on either the mounting surface of the differential case (A).
side of jack to prevent tandem from rotating. Check to be sure the mounting surface of the
differential case contains two locating dowel pins
Specification (E).
Tandem Housing—Clearance ........................................0.5—1.0 mm
0.020—0.040 in.
22. Install final drive axle onto differential case (A).
16. Remove and discard final drive axle housing to
differential case cap screws and washers.

Continued on next page TX19495,0000168 –19–14DEC04–4/7

TM2256 (09JAN07) 02-0250-33 D Series Motor Grader Repair

020207
PN=145
 Axle Shafts, Bearings, and Reduction Gears

23. Rotate differential input yoke to align splines on

sun pinion shaft (F) with splines in differential side
gears.

TX19495,0000168 –19–14DEC04–5/7

IMPORTANT: Cap screws removed from the final

drive axle housing-to-differential case
joint during disassembly have been
02 torqued to yield and must be replaced
0250
with new cap screws for assembly.
34

24. Loosely install final drive axle housing-to-differential

case cap screws and washers.

25. Tighten cap screws to specification in sequential

pattern shown.

Specification
Final Drive Axle
Housing-to-Differential Case Cap

–19–21JUL97
Screws—Torque ...........................................................................230 N•m
170 lb-ft

T109839
Final Drive Axle Housing to Differential Case

Continued on next page TX19495,0000168 –19–14DEC04–6/7

TM2256 (09JAN07) 02-0250-34 D Series Motor Grader Repair

020207
PN=146
 Axle Shafts, Bearings, and Reduction Gears

02
0250
35

–19–13AUG97
T110705
Cap Screw Heads and Final Drive Axle Housing

26. Mark cap screws as shown. Tighten each cap 31. Perform vacuum leak down test on brake piston
screw and additional 90° in same sequential packing rings. See Brake Piston Packings—
pattern. Vacuum Leakdown Test. (1400 Multiple Disk
Brakes.) (CTM43.)
27. Lower jack under opposite tandem housing.
32. Assemble tandem pivot housing. See Tandem
28. Loosely install three cap screws and washers that Pivot Disassemble and Assemble. (Group 0250.)
attach the lower front mount of final drive axle
housing (B). 33. Fill differential and final drive axle assembly with
oil. Fill flush with bottoms of oil level check hole in
29. Loosely install four cap screws and washers that front of differential case. Recheck oil level after a
attach the top mounts of the final drive axle few minutes and add oil as necessary. See Drain
housing to the engine frame. and Refill Capacities for amount of oil needed.
(Operator’s Manual.)
30. With axle held against the engine frame at the two
top mounts and the front mount (no gaps), tighten 34. Remove articulation lock pin.
cap screws to specification.
35. If equipped with rear mounted ripper, install lower
Specification linkage between ripper frame and final drive axle
Final Drive-to-Engine Frame housing. See Ripper Remove and Install. (Group
Cap Screw—Torque ............................................................1070 N•m
790 lb-ft
4240.)
Final Drive-to-Front Support
Cap Screw—Torque ..............................................................620 N•m 36. If equipped, install snow wing or bottom guard.
460 lb-ft

TX19495,0000168 –19–14DEC04–7/7

TM2256 (09JAN07) 02-0250-35 D Series Motor Grader Repair

020207
PN=147
 Axle Shafts, Bearings, and Reduction Gears

Final Drive Axle Disassemble and Assemble

02
0250
36

–19–12DEC03
T196631

Final Drive Axle Component Identification

Continued on next page TX,02,DU2617 –19–12DEC03–1/4

TM2256 (09JAN07) 02-0250-36 D Series Motor Grader Repair

020207
PN=148
 Axle Shafts, Bearings, and Reduction Gears

A—Differential Case H—Brake Separator Plate (6 M—O-Ring S—Inboard Bearing Cone

B—Final Drive Axle Housing used) N—Special Cap Screw T—Snap Ring
C—Final Drive Ring Gear I—Brake Disk (5 used) O—Lock Plate U—Oil Seal
D—Brake Backing Plate J—Brake Pack Retaining Pin P—Planet Pinion Carrier V—Outboard Bearing Cup
E—Dowel Pin (2 used) (2 used) Assembly W—Inboard Bearing Cup
F—Sun Pinion Shaft K—Dowel Pins (2 used) Q—Snap Ring X—Outboard Bearing Cup
G—Brake Pack Retaining Snap L—Dowel Pins (2 used) R—Tandem Drive Shaft
Ring (2 used)

1. Remove brake components. See Brake Component 4. Remove inboard bearing cup (W) and outboard
Remove and Install. (Group 0250.) bearing cup (X) from final drive axle housing (B).
02
2. Remove planet pinion carrier. See Planet Pinion 5. Remove tandem drive shaft oil seal (U). 0250
Carrier Remove and Install. (Group 0250.) 37
6. Clean and inspect final drive axle housing (B).
3. Remove tandem drive shaft. See Tandem Drive Dowel pins (L) must be tight in the axle housing.
Shaft Remove and Install. (Group 0250.) Replace final drive axle housing (B) if necessary.

Continued on next page TX,02,DU2617 –19–12DEC03–2/4

TM2256 (09JAN07) 02-0250-37 D Series Motor Grader Repair

020207
PN=149
 Axle Shafts, Bearings, and Reduction Gears

7. If a new final drive axle housing (B) is being

assembled, install two new dowel pins (L) in the
mounting surface that mates with the final drive ring
gear (C).

NOTE: Dowel pins (L) are tight in the final drive housing
and cannot be reused.

8. Thoroughly clean all parts to be assembled.

–UN–21JUL97
02 9. Coat seal bore in axle housing (B) with TY16285 Cure
0250 Primer and cover outside diameter of oil seal with
38
plastic gasket.

T110624
10. Install tandem drive shaft oil seal (U) into bore in final
drive axle housing (B) with spring side of oil seal (U)
Clearance Between Seal/Bottom Seal Bore
facing oil seal driver. Drive oil seal (U) into bore until
driver seats against bearing shoulder (Y). Clearance B—Final Drive Axle Housing
between the seal and the bottom of the seal bore will U—Oil Seal
be approximately 3 mm (0.12 in.). See DFT1153—Oil Y—Bearing Installer
Seal Driver. (Group 9900.)

Specification
Tandem Drive Shaft Oil Seal to
Final Drive Axle Housing Bore
Bottom—Approximate Gap.............................................................3.0 mm
0.12 in.

NOTE: Oil seal (U) must be positioned as shown and

either side of the seal must not be more than 0.51
mm (0.020 in.) deeper than its opposite side when
installed.

Specification
Oil Seal—Depth ............................................................................0.51 mm
0.020 in.

11. Chill bearing cups (W and X) in dry ice or in a freezer

and drive firmly against shoulders in each end of final
drive axle housing (B) using oil seal driver and a lead
hammer. See DFT1153—Oil Seal Driver. (Group
9900.)

12. Install drive shaft. See Tandem Drive Shaft Remove

and Install. (Group 0250.)

13. Install planet pinion carrier. See Planet Pinion Carrier

Remove and Install. (Group 0250.)

Continued on next page TX,02,DU2617 –19–12DEC03–3/4

TM2256 (09JAN07) 02-0250-38 D Series Motor Grader Repair

020207
PN=150
 Axle Shafts, Bearings, and Reduction Gears

14. Install brake components. See Brake Component

Remove and Install. (Group 0250.)

TX,02,DU2617 –19–12DEC03–4/4

Brake Component Remove and Install

1. Remove final drive axle. See Final Drive Axle Remove

and Install. (Group 0250.) 02
0250
39
2. Remove brake components. See Remove and Install
Brake Components from Differential Case. (1400
Multiple Disk Brakes.) (CTM43.)

3. Install final drive axle. See Final Drive Axle Remove

and Install. (Group 0250.)

TX19495,0000167 –19–13DEC04–1/1

TM2256 (09JAN07) 02-0250-39 D Series Motor Grader Repair

020207
PN=151
 Axle Shafts, Bearings, and Reduction Gears

Planet Pinion Carrier Remove and Install

1. Remove final drive axle. See Final Drive Axle Remove

and Install. (Group 0250.)

2. Remove brake components. See Brake Component

Remove and Install. (Group 0250.)

3. Remove O-ring (M) from head of cap screw (N) and

lock plate (O).
02
0250 4. Remove cap screw (N).
40

5. Remove planet pinion carrier from axle shaft. See

Disassemble Planet Pinion Carrier. (1400 John Deere
Grader Planetary Carrier.) (CTM43.)

6. Inspect planet pinion carrier components. See Inspect

Planet Pinion Components. (1400 John Deere Grader
Planetary Carrier.) (CTM43.)

7. Install planet pinion carrier to axle shaft. See Assemble

Planet Pinion Carrier. (1400 John Deere Grader
Planetary Carrier.) (CTM43.)

8. Install cap screw (N). Tighten to specification.

Specification
Planet Pinion-to-Axle Shaft Cap
Screw—Torque .............................................................................908 N•m
670 lb-ft

9. Install O-ring (M) from head of cap screw (N) and lock
plate (O).

10. Install brake components. See Brake Component

Remove and Install. (Group 0250.)

11. Install final drive axle. See Final Drive Axle Remove
and Install. (Group 0250.)

TX19495,000016A –19–15DEC04–1/1

TM2256 (09JAN07) 02-0250-40 D Series Motor Grader Repair

020207
PN=152
 Axle Shafts, Bearings, and Reduction Gears

02
0250
41

TM2256 (09JAN07) 02-0250-41 D Series Motor Grader Repair

020207
PN=153
 Axle Shafts, Bearings, and Reduction Gears

Tandem Drive Shaft Remove and Install

02
0250
42

–19–12DEC03
T196631

Final Drive Axle Component Identification

Continued on next page TX19495,000016B –19–17DEC04–1/12

TM2256 (09JAN07) 02-0250-42 D Series Motor Grader Repair

020207
PN=154
 Axle Shafts, Bearings, and Reduction Gears

A—Differential Case H—Brake Separator Plate (6 M—O-Ring S—Inboard Bearing Cone

B—Final Drive Axle Housing used) N—Special Cap Screw T—Snap Ring
C—Final Drive Ring Gear I—Brake Disk (5 used) O—Lock Plate U—Oil Seal
D—Brake Backing Plate J—Brake Pack Retaining Pin P—Planet Pinion Carrier V—Outboard Bearing Cup
E—Dowel Pin (2 used) (2 used) Assembly W—Inboard Bearing Cup
F—Sun Pinion Shaft K—Dowel Pins (2 used) Q—Snap Ring X—Outboard Bearing Cup
G—Brake Pack Retaining Snap L—Dowel Pins (2 used) R—Tandem Drive Shaft
Ring (2 used)

1. Remove final drive axle. See Final Drive Axle

CAUTION: Prevent possible injury from
Remove and Install. (Group 0250.)
crushing. Use appropriate lifting device.
02
2. Remove brake components. See Brake Component Specification 0250
Remove and Install. (Group 0250.) Final Drive Axle Housing with 43
Tandem Drive Shaft—
3. Remove planet pinion carrier. See Planet Pinion Approximate Weight ................................................................. 203 kg
450 lb
Carrier Remove and Install. (Group 0250.)
Tandem Drive Shaft—
Approximate Weight ................................................................... 27 kg
IMPORTANT: Protect all exposed machined 60 lb
surfaces on the final drive axle
housing (B) from damage. 5. Hoist axle housing (B) to an upright position (bolting
flange up).
4. Remove the inboard (carrier end) bearing retaining
snap ring (Q).

TX19495,000016B –19–17DEC04–2/12

6. Attach axle adjusting tool (A) to axle housing (B). See

DF1057—Axle Adjusting Tool. (Group 9900.)

7. Attach chain hoist to axle adjusting tool (A).

A—Axle Adjusting Tool

B—Axle Housing

–UN–12AUG97
T110737

Attach Axle Adjusting Tool and Chain Hoist

Continued on next page TX19495,000016B –19–17DEC04–3/12

TM2256 (09JAN07) 02-0250-43 D Series Motor Grader Repair

020207
PN=155
 Axle Shafts, Bearings, and Reduction Gears

02
0250
44

–19–12DEC03
T196631

Final Drive Axle Component Identification

Continued on next page TX19495,000016B –19–17DEC04–4/12

TM2256 (09JAN07) 02-0250-44 D Series Motor Grader Repair

020207
PN=156
 Axle Shafts, Bearings, and Reduction Gears

A—Differential Case H—Brake Separator Plate (6 M—O-Ring S—Inboard Bearing Cone

B—Final Drive Axle Housing used) N—Special Cap Screw T—Snap Ring
C—Final Drive Ring Gear I—Brake Disk (5 used) O—Lock Plate U—Oil Seal
D—Brake Backing Plate J—Brake Pack Retaining Pin P—Planet Pinion Carrier V—Outboard Bearing Cup
E—Dowel Pin (2 used) (2 used) Assembly W—Inboard Bearing Cup
F—Sun Pinion Shaft K—Dowel Pins (2 used) Q—Snap Ring X—Outboard Bearing Cup
G—Brake Pack Retaining Snap L—Dowel Pins (2 used) R—Tandem Drive Shaft
Ring (2 used)

8. Put disks between hydraulic jack and tandem drive 11. Cleans and inspect parts. Repair or replace as
shaft (R). necessary. Tandem axle shaft bearings must be
replaced with reassembly. 02
9. Push the tandem drive shaft (R) through the 0250
inboard bearing cone (S). 45

10. Remove outboard bearing cone retaining snap ring

(T) and pull bearing cone (V) off of shaft.

Continued on next page TX19495,000016B –19–17DEC04–5/12

TM2256 (09JAN07) 02-0250-45 D Series Motor Grader Repair

020207
PN=157
 Axle Shafts, Bearings, and Reduction Gears

02
0250
46

–19–12DEC03
T196631

Final Drive Axle Component Identification

Continued on next page TX19495,000016B –19–17DEC04–6/12

TM2256 (09JAN07) 02-0250-46 D Series Motor Grader Repair

020207
PN=158
 Axle Shafts, Bearings, and Reduction Gears

A—Differential Case H—Brake Separator Plate (6 M—O-Ring S—Inboard Bearing Cone

B—Final Drive Axle Housing used) N—Special Cap Screw T—Snap Ring
C—Final Drive Ring Gear I—Brake Disk (5 used) O—Lock Plate U—Oil Seal
D—Brake Backing Plate J—Brake Pack Retaining Pin P—Planet Pinion Carrier V—Outboard Bearing Cup
E—Dowel Pin (2 used) (2 used) Assembly W—Inboard Bearing Cup
F—Sun Pinion Shaft K—Dowel Pins (2 used) Q—Snap Ring X—Outboard Bearing Cup
G—Brake Pack Retaining Snap L—Dowel Pins (2 used) R—Tandem Drive Shaft
Ring (2 used)

12.

02
0250
TX19495,000016B –19–17DEC04–7/12 47

NOTE: While working with tandem drive shaft (R), protect

sealing surface with a single wrap of electrical
tape.

CAUTION: DO NOT heat oil over 182°C (360°F).

Oil fumes or oil can ignite above 193°C (380°F).

–UN–23AUG88
Use a thermometer. DO NOT allow a flame or
heating element to come in direct contact with
the oil. Heat the oil in a well-ventilated area.
Plan a safe handling procedure to avoid burns.

TS227
Heat bearing cone (V) and install on the outboard Handle Fluids Safely—Avoid Fires
(sprocket) end of the tandem drive shaft (R) just far
enough past the groove in shaft (R) to allow
installation of bearing retaining snap ring (T).

Specification
Bearing Cone—Temperature ..................................................116—127 °C
240—260°F

13. Install bearing retaining snap ring (T) in groove next

to the outboard bearing cone (V). Be sure snap ring
(T) is firmly seated in groove.

14. Seat outboard bearing cone (V) firmly against bearing

retaining snap ring (T) using outboard bearing driver
and inboard bearing driver.

Install the beveled end of outboard bearing driver

against bearing cone (V) and inboard bearing driver
against outboard bearing driver and rap inboard
bearing driver with a lead hammer. See DFT1151—
Outboard Bearing Driver. (Group 9900.) See
DFT1152—Inboard Bearing Driver. (Group 9900.)

Continued on next page TX19495,000016B –19–17DEC04–8/12

TM2256 (09JAN07) 02-0250-47 D Series Motor Grader Repair

020207
PN=159
 Axle Shafts, Bearings, and Reduction Gears

NOTE: If bearing cone (V) did not properly seat against

snap ring (T), install a 1.0 in. UNC cap screw with
a washer through the hole in inboard bearing
driver and into the tapped hole in tandem drive
shaft (R).

Use the tandem drive sprocket as a holding tool

and tighten the cap screw to push bearing cone
(V) firmly against snap ring (T). Be careful not to
damage threads in shaft (R).
02
0250 15. Remove electrical tape from the oil seal surface on
48
tandem drive shaft (R) and wipe clean.

16. Protect seal (U) from damage by wrapping inboard

(carrier) end shaft splines and groove edges with
electrical tape. Install tandem drive shaft (R) with
outboard bearing cup (V) into the outboard (sprocket)
end of the final drive axle housing (B).

Continued on next page TX19495,000016B –19–17DEC04–9/12

TM2256 (09JAN07) 02-0250-48 D Series Motor Grader Repair

020207
PN=160
 Axle Shafts, Bearings, and Reduction Gears

02
0250
49

TM2256 (09JAN07) 02-0250-49 D Series Motor Grader Repair

020207
PN=161
 Axle Shafts, Bearings, and Reduction Gears

02
0250
50

–19–12DEC03
T196631

Final Drive Axle Component Identification

Continued on next page TX19495,000016B –19–17DEC04–10/12

TM2256 (09JAN07) 02-0250-50 D Series Motor Grader Repair

020207
PN=162
 Axle Shafts, Bearings, and Reduction Gears

A—Differential Case H—Brake Separator Plate (6 M—O-Ring S—Inboard Bearing Cone

B—Final Drive Axle Housing used) N—Special Cap Screw T—Snap Ring
C—Final Drive Ring Gear I—Brake Disk (5 used) O—Lock Plate U—Oil Seal
D—Brake Backing Plate J—Brake Pack Retaining Pin P—Planet Pinion Carrier V—Outboard Bearing Cup
E—Dowel Pin (2 used) (2 used) Assembly W—Inboard Bearing Cup
F—Sun Pinion Shaft K—Dowel Pins (2 used) Q—Snap Ring X—Outboard Bearing Cup
G—Brake Pack Retaining Snap L—Dowel Pins (2 used) R—Tandem Drive Shaft
Ring (2 used)

17. Position the final drive axle housing (B) with the 18. Remove electrical tape from shaft (R).
mounting flange up. Support the tandem drive
shaft (R) using a steel ball in the center to allow 02
bearing cone (V) to be seated in bearing cup (X) 0250
while rotating shaft (R). 51

Continued on next page TX19495,000016B –19–17DEC04–11/12

TM2256 (09JAN07) 02-0250-51 D Series Motor Grader Repair

020207
PN=163
 Axle Shafts, Bearings, and Reduction Gears

CAUTION: DO NOT heat oil over 182°C (360°F).

Oil fumes or oil can ignite above 193°C (380°F).
Use a thermometer. DO NOT allow a flame or
heating element to come in direct contact with
the oil. Heat the oil in a well-ventilated area.
Plan a safe handling procedure to avoid burns.

–UN–23AUG88
19. Heat inboard (carrier) end bearing cone (S) and install
over the inboard (carrier) end of tandem drive shaft
(R). Quickly seat bearing cone (S) firmly into the
02

TS227
0250 inboard bearing cup (W) using inboard bearing driver
52 and a lead hammer while rotating shaft (R). Handle Fluids Safely—Avoid Fires

Specification
Bearing Cone—Temperature ..................................................116—127 °C
240—260°F

NOTE: If bearing cone (S) did not install onto shaft (R) far
enough to permit installation of snap ring (Q),
place a 1.0 in. UNC cap screw with washer
through the hole in inboard bearing driver and into
the tapped hole in tandem drive shaft (R). Use the
tandem drive sprocket as a holding tool and
alternately tighten the cap screw and turn the
shaft (R) to push bearing cone (S) past the
groove in shaft (R) just enough to allow snap ring
(Q) to be installed in the groove. Be careful not to
damage threads in shaft (R).

20. Install bearing retaining snap ring (Q) in groove next

to inboard bearing cone (S). Be sure snap ring (Q) is
firmly seated in groove.

21. Install planet pinion carrier. See Planet Pinion Carrier

Remove and Install. (Group 0250.)

22. Install brake components. See Brake Component

Remove and Install. (Group 0250.)

23. Install final drive axle. See Final Drive Axle Remove
and Install. (Group 0250.)

TX19495,000016B –19–17DEC04–12/12

TM2256 (09JAN07) 02-0250-52 D Series Motor Grader Repair

020207
PN=164
 Axle Shafts, Bearings, and Reduction Gears

Drive Chain Remove and Install

02
0250
53

–UN–30JUL97
T109861
Drive Chain

A—End Plate B—Cotter Pin (2 used) C—Connecting Link

IMPORTANT: Chains must be removed one chain 5. Remove cotter pins (B) and end plate (A) from
at a time. connecting link through side cover.

6. Using two-jaw puller, drive out connecting link.

CAUTION: Prevent possible injury from
unexpected machine movement. Install
7. Remove chain from tandem housing.
articulation lock pin when machine is raised
or when working in articulation joint area.
8. Clean and inspect parts. Repair or replace parts as
necessary.
1. Install articulation lock pin. See Locking Machine
Frame. (Operator’s Manual.)
9. Position chain on drive sprocket and turn opposing
wheel to feed chain to wheel axle sprocket. Position
2. Raise tandem housing and install shop stands.
ends of chain in top cover opening.
3. Remove rectangular top and side covers.
10. Using JT07271 Chain Puller, pull chain ends
together.
4. Rotate wheels to position chain connecting link (C)
in a top cover opening.

Continued on next page TX19495,000014E –19–17NOV04–1/2

TM2256 (09JAN07) 02-0250-53 D Series Motor Grader Repair

020207
PN=165
 Axle Shafts, Bearings, and Reduction Gears

11. Install connecting link (C) so pins are directed specification.

away from center of tandem housing. Cotter pins
will be close to sides of tandem housing. Specification
Planetary Housing-to-Wheel
Hub Cap Screw—Torque ........................................................47 N•m
12. Install end plate (A) and cotter pins (B). 35 lb-ft

13. Install top and side rectangular covers. Apply 14. Remove articulation lock pin.
T43512 Thread Lock and Sealer (Medium
Strength) to threads of cap screws and tighten to

02
0250
54 TX19495,000014E –19–17NOV04–2/2

Metal Face Seals Inspection

1. Inspect for the following conditions to determine if

seals can be reused:

a. The narrow, highly polished sealing area (E) must

be in the outer half of seal ring face (D).

b. Sealing area must be uniform and concentric with

the ID and OD of seal ring (A).

c. Sealing area must not be chipped, nicked, or

scratched.

A—Seal Ring
B—Worn Area (Shaded Area)
C—Seal Ring Face

–UN–24AUG93
D—Outer Half of Seal Ring Face
E—Sealing Area (Dark Line)

T85079
Metal Face Seals

Continued on next page TX19495,0000165 –19–13DEC04–1/3

TM2256 (09JAN07) 02-0250-54 D Series Motor Grader Repair

020207
PN=166
 Axle Shafts, Bearings, and Reduction Gears

2. Illustration shows examples of worn seal rings (A).

I—Sealing area (D) is in inner half of seal ring face (C).

II—Sealing area (D) not concentric with ID and OD of

seal ring.

–UN–05DEC96
A—Seal Ring
B—Worn Area (Shaded Area)
C—Inner Half of Seal Ring Face

T85080
D—Sealing Area (Dark Line) 02
0250
Worn Seal Rings 55

TX19495,0000165 –19–13DEC04–2/3

3. Clean reusable seals by removing all foreign material

from seal rings, except seal face (A), using a scraper
or a stiff bristled fiber brush.

4. Wash seal rings and O-rings using a volatile,

non-petroleum base solvent to remove all oil.

–UN–23FEB89
Thoroughly dry parts using a lint-free tissue.

Apply a thin film of oil to seal ring face. Put face of seal
rings together and hold using a narrow strip of masking

T82840
tape.
Seal Face
A—Seal Face

TX19495,0000165 –19–13DEC04–3/3

TM2256 (09JAN07) 02-0250-55 D Series Motor Grader Repair

020207
PN=167
 Axle Shafts, Bearings, and Reduction Gears

02
0250
56

TM2256 (09JAN07) 02-0250-56 D Series Motor Grader Repair

020207
PN=168
 Group 0260
Hydraulic System

HFWD Pump Remove and Install

02
0260
1

–UN–24NOV04
T204922
2 1
T204922
HFWD Pumps—Left Side

4
–UN–24NOV04

3
T204923

T204923
HFWD Pumps—Right Side

1—Cap Screw 2—Cap Screw (2 used) 3—Cap Screw (2 used) 4—Cap Screw (4 used)

Continued on next page TX,02,DU2596 –19–03OCT01–1/2

TM2256 (09JAN07) 02-0260-1 D Series Motor Grader Repair

020207
PN=169
 Hydraulic System

7. Repair or replace parts as necessary. See HFWD

CAUTION: Prevent possible injury from
Pump Disassemble and Assemble. (Group 0260.)
unexpected machine movement. Install
articulation lock pin when machine is raised
8. Install HFWD pumps. Tighten cap screws to
or when working in articulation joint area.
specification.
1. Install articulation lock pin. See Locking Machine Specification
Frame. (Operator’s Manual.) Pump Cap
Screw-to-Transmission Charge
NOTE: The HFWD pumps and HFWD motor flushing Pump—Torque.......................................................................129 N•m
pump are removed and installed as an 95 lb-ft
02
0260 assembly.
9. Connect all lines and electrical connectors. See
2
2. Remove fuel tank. See Fuel Tank Remove and HFWD System Component Location. (Group
Install. (Group 0560.) 9016-15.)

3. Remove hydraulic oil tank. See Hydraulic Oil Tank 10. Install hydraulic oil tank. See Hydraulic Oil Tank
Remove and Install. (Group 2160.) Remove and Install. (Group 2160.)

4. Disconnect all lines and electrical connectors. 11. Install fuel tank. See Fuel Tank Remove and
Install. (Group 0560.)

CAUTION: Prevent possible injury from 12. Remove articulation lock pin.
crushing. Use appropriate lifting device
13. Perform HFWD start-up procedure. See HFWD
5. Support HFWD pumps with lifting strap. Start-Up Procedure. (Group 1916-20.)
Specification
14. Calibrate HFWD control unit. See Hydrostatic
HFWD Pumps (both pumps)—
Weight—Approximate ...............................................................115 kg Front Wheel Drive (6WD) Controller Calibration.
330 lb (Group 9015-20.)

6. Remove cap screws (1—4) and remove HFWD

pumps.

TX,02,DU2596 –19–03OCT01–2/2

TM2256 (09JAN07) 02-0260-2 D Series Motor Grader Repair

020207
PN=170
 Hydraulic System

02
0260
3

TM2256 (09JAN07) 02-0260-3 D Series Motor Grader Repair

020207
PN=171
 Hydraulic System

HFWD Pump Disassemble and Assemble

02
0260
4

–UN–05JAN05
T205107

HFWD Pump Housing Assembly

Continued on next page TX19495,0000142 –19–12NOV04–1/47

TM2256 (09JAN07) 02-0260-4 D Series Motor Grader Repair

020207
PN=172
 Hydraulic System

1—Pump Housing 9—O-Ring 29—Control Piston Cover 62—Plug

2—Drive Shaft 10—Nut 30—Control Piston Cover 66—Plug (3 used)
3—Tube 11—Control Link 31—Cap Screw (8 used) 67—Plug
4—Cap Screw 12—Orifice 32—O-Ring (as required) 87—Seal
6—Control Valve 13—Kit 40—Bearing Cup 88—Retaining Ring
7—Gasket 27—O-Ring (2 used) 48—Pressure Relief Valve 96—Kit
8—Solenoid Valve Coil 28—Ring (2 used) 61—Plug

02
0260
Continued on next page TX19495,0000142 –19–12NOV04–2/47 5

TM2256 (09JAN07) 02-0260-5 D Series Motor Grader Repair

020207
PN=173
 Hydraulic System

02
0260
6

–UN–15DEC04
T205108

HFWD Pump End Cap Assembly

Continued on next page TX19495,0000142 –19–12NOV04–3/47

TM2256 (09JAN07) 02-0260-6 D Series Motor Grader Repair

020207
PN=174
 Hydraulic System

3—End Cap 24—O-Ring 42—Bearing 66—Plug (2 used)

4—Cap Screw (8 used) 25—Seal Kit 55—Pin (2 used) 67—Plug (2 used)
5—Gasket 26—Pin 56—Dowel Pin (3 used) 76—Pressure Override Valve
6—Kit 27—Rotator 57—Seal (4 used) (2 used)
13—Valve Plate 28—Ring 59—Ring (2 used) 79—Pressure Override Fitting
21—Kit 29—Shaft 60—Ring (2 used)
22—Valve Plate 30—Cover 63—Fitting (2 used) 95—Kit
23—Snap Ring 41—Shim (as required) 64—Plug

02
0260
Continued on next page TX19495,0000142 –19–12NOV04–4/47 7

TM2256 (09JAN07) 02-0260-7 D Series Motor Grader Repair

020207
PN=175
 Hydraulic System

02
0260
8

–UN–29NOV01
T148543

HFWD Pump Rotate Group

Continued on next page TX19495,0000142 –19–12NOV04–5/47

TM2256 (09JAN07) 02-0260-8 D Series Motor Grader Repair

020207
PN=176
 Hydraulic System

12—Kit 44—Bearing (2 used) 47—Link 54—Washer (2 used)

14—Valve Plate 45—Pin (2 used) 53—Spring (2 used) 56—Dowel Pin (3 used)
26—Piston 46—Link (2 used)

TX19495,0000142 –19–12NOV04–6/47

NOTE: Solenoid coils are serviced as a set.

1. Remove control valve assembly (1).

02
0260
Service parts (1, 43, 44) as necessary.
9

–UN–16OCT01
HFWD Pump—Specification
Solenoid Tube—Torque .................................................................27 N•m
240 lb in.
Solenoid Coil Nut—Torque...............................................................3 N•m
36 lb in.

T146464B
1—Control Valve Control Valve Assembly
43—Solenoid Tube
44—Solenoid Cap

TX19495,0000142 –19–12NOV04–7/47

2. Remove feed back link (4).

3. Remove clocking pin plug (5).

4—Feedback Link
5—Clocking Pin Plug

–UN–16OCT01
T146466B
Control Feedback Link and Clocking Pin Plug

Continued on next page TX19495,0000142 –19–12NOV04–8/47

TM2256 (09JAN07) 02-0260-9 D Series Motor Grader Repair

020207
PN=177
 Hydraulic System

NOTE: Perform the following step if disassembling the

right pump.

4. Remove retaining ring (A).

5. Remove pressure override valves (76).

–UN–18JUL97
6. Inspect and install valves. Tighten cap (40) to
specification.

T110495
02 Specification
0260 Pressure Override Valve—Torque ...............................................136 N•m
10 100 lb ft Retaining Ring

A—Retaining Ring

TX19495,0000142 –19–12NOV04–9/47

7. Remove and inspect HFWD circuit relief and make-up

valves (25).

Replace as necessary.

Specification

–UN–16OCT01
HFWD Circuit Relief and
Make-Up Valve—Torque ..............................................................176 N•m
130 lb ft

T146467B
IMPORTANT: Mark orientation of HFWD motor
flushing pump cover before
disassembly.
HFWD Circuit Relief and Make-Up Valves

8. Remove HFWD motor flushing pump cover. 25—HFWD Circuit Relief and Make-Up Valve (2
used)

Continued on next page TX19495,0000142 –19–12NOV04–10/47

TM2256 (09JAN07) 02-0260-10 D Series Motor Grader Repair

020207
PN=178
 Hydraulic System

9. Remove HFWD motor flushing pump coupling and

gerotor star (A).

A—HFWD Motor Flushing Pump Coupling and

Gerotor Star
B—Coupling

–UN–18JUL97
C—Gerotor Star
D—Pin
E—Retaining Ring

T110504
02
0260
Pump Coupling and Gerotor Star 11

–UN–18JUL97
T110505
HFWD Motor Flushing Pump Coupling and Gerotor Star

TX19495,0000142 –19–12NOV04–11/47

10. Remove gerotor outer ring (A).

A—Gerotor Outer Ring

–UN–18JUL97
T110506
Coupling, Gerotor Star, Pin, Retaining Ring

Continued on next page TX19495,0000142 –19–12NOV04–12/47

TM2256 (09JAN07) 02-0260-11 D Series Motor Grader Repair

020207
PN=179
 Hydraulic System

IMPORTANT: Mark orientation of eccentric ring before

disassembly.

11. Remove eccentric ring (41).

–UN–16OCT01
41—Eccentric Ring

T146470B
02
0260
12 Eccentric Ring

TX19495,0000142 –19–12NOV04–13/47

IMPORTANT: Mark orientation of valve plate before

disassembly.

12. Remove valve plate (C).

–UN–18JUL97
C—Valve Plate

T110508
Position of Valve Plate

Continued on next page TX19495,0000142 –19–12NOV04–14/47

TM2256 (09JAN07) 02-0260-12 D Series Motor Grader Repair

020207
PN=180
 Hydraulic System

13.

CAUTION: Use caution when removing cap

screws (A) as end cover (B) has internal
preload.

–UN–18JUL97
Slowly remove cap screws (A) in cross-cross pattern.

NOTE: Carefully remove end cover (B) as internal parts

T110509
may fall out.
02
0260
14. Remove end cover (B). Cap Screws and End Cover 13

A—Cap Screw
B—End Cover

TX19495,0000142 –19–12NOV04–15/47

15. Remove valve plate (C).

C—Valve Plate
D—Dowel Pin

–UN–18JUL97
T110510
Valve Plate

Continued on next page TX19495,0000142 –19–12NOV04–16/47

TM2256 (09JAN07) 02-0260-13 D Series Motor Grader Repair

020207
PN=181
 Hydraulic System

16. Remove bearing race (E).

E—Bearing Race

–UN–18JUL97
T110512
02
0260
14 Bearing Race

TX19495,0000142 –19–12NOV04–17/47

17. Remove shims (A).

A—Shim

–UN–22JUL97
T110513
Shims

Continued on next page TX19495,0000142 –19–12NOV04–18/47

TM2256 (09JAN07) 02-0260-14 D Series Motor Grader Repair

020207
PN=182
 Hydraulic System

18. Remove bearing plate (41).

19. Remove springs and washers (45).

41—Springs and Washers

45—Bearing Plate

–UN–18OCT01
T146471B
02
0260
Bearing Plate 15

TX19495,0000142 –19–12NOV04–19/47

20. Install low clearance split type bearing puller (A)

under bearing (B). Do not remove bearing (B) at this
time.

21. Install puller (C) on split type bearing puller (A).

–UN–18JUL97
22. Remove rotating group (D) from main housing (E).

A—Split Type Bearing Puller

T110517
B—Bearing
C—Puller
D—Rotating Group
E—Main Housing Split Type Bearing Puller Under Bearing

–UN–18JUL97
T110518

Bearing Puller & Rotating Group/Main Housing

Continued on next page TX19495,0000142 –19–12NOV04–20/47

TM2256 (09JAN07) 02-0260-15 D Series Motor Grader Repair

020207
PN=183
 Hydraulic System

23. Remove slide block (A) from swash plate (B).

A—Slide Block
B—Swash Plate

–UN–18JUL97
T110519
02
0260
16 Slide Block from Swashplate

TX19495,0000142 –19–12NOV04–21/47

24. Remove bearing (A).

NOTE: Rotate group and swash plate block are serviced

as one assembly.

25. Carefully remove swash plate and rotating group from

–UN–18JUL97
pump shaft assembly.

A—Bearing

T110520
Bearing

Continued on next page TX19495,0000142 –19–12NOV04–22/47

TM2256 (09JAN07) 02-0260-16 D Series Motor Grader Repair

020207
PN=184
 Hydraulic System

26. Remove clocking link retaining plug (A).

A—Clocking Link Retaining Plug

–UN–18JUL97
T110527
02
0260
Clocking Link Retaining Plug 17

TX19495,0000142 –19–12NOV04–23/47

27. Remove two bearings (B), clocking links (C) and

bearing races (D).

B—Bearing (2 used)
C—Clocking Link (2 used)
D—Bearing Race (2 used)

–UN–18JUL97
T110528
Bearings, Clocking Links and Bearing Races

Continued on next page TX19495,0000142 –19–12NOV04–24/47

TM2256 (09JAN07) 02-0260-17 D Series Motor Grader Repair

020207
PN=185
 Hydraulic System

28. Remove seal (A) from main housing (B).

29. Press or pull bearing race (C) from main housing (B).

A—Seal
B—Main Housing

–UN–18JUL97
C—Bearing Race

T110530
02
0260
18 Main Housing Seal

Continued on next page TX19495,0000142 –19–12NOV04–25/47

TM2256 (09JAN07) 02-0260-18 D Series Motor Grader Repair

020207
PN=186
 Hydraulic System

30. Remove cap screws (A).

31. Remove control piston cover (B).

32. Remove control piston adjustment screw lock nut,

beveled washer and threaded seal (C) from the

–UN–18JUL97
adjustable side control piston cover (D).

33. Remove cap screws (E).

T110532
34. Remove adjustable side control piston cover (D). 02
0260
Cap Screws and Control Piston Cover 19
35. Remove and inspect O-rings (E). Replace if
necessary.

A—Cap Screw (4 used)

B—Control Piston Cover
C—Control Piston Adjustment Screw Lock Nut,
Beveled Washer and Threaded Seal

–UN–18JUL97
D—Adjustable Side Control Piston Cover
E—Cap Screw (4 used)
F—O-Ring (2 used)

T110533
Lock Nut, Piston Cover, and Cap Screws

–UN–18JUL97
T110534
Covers and O-Rings

Continued on next page TX19495,0000142 –19–12NOV04–26/47

TM2256 (09JAN07) 02-0260-19 D Series Motor Grader Repair

020207
PN=187
 Hydraulic System

CAUTION: Do not scratch or damage control

piston bore (B) when removing O-rings and
back-up rings (A).

36. Remove O-rings and back-up rings (A) from control

–UN–18JUL97
piston bore (B).

Replace if necessary.

T110535
37. Clean all parts and assemblies before assembly.
02
0260 Inspect and replace damaged parts and assemblies.
20 Lubricate all seals with petroleum jelly. Apply clean Rings and Control Piston Bore
hydraulic oil to all bearings and finished surfaces.

38. Install bearing race into main housing.

39. Lubricate and install two new O-rings and back-up

rings into control piston bore.

–UN–18JUL97
40. Lubricate and install two new O-ring on control piston
end covers.

T110537
A—O-Ring and Back-Up Ring (2 used)
B—Control Piston Bore
C—O-Ring (2 used) O-Rings and Back-Up Rings
D—Back-Up Ring (2 used)

Continued on next page TX19495,0000142 –19–12NOV04–27/47

TM2256 (09JAN07) 02-0260-20 D Series Motor Grader Repair

020207
PN=188
 Hydraulic System

41. Install adjustable side control piston cover (C) on

control adjustment screw (A) about half way down.

IMPORTANT: The beveled side of washer (D) must

face the threaded seal washer.

–UN–18JUL97
42. Install new threaded seal washer (E), beveled washer
(D) and lock nut (B) on adjustment screw (A). Do not
tighten lock nut (B) at this time.

T110598
43. Lubricate and install control piston assembly (F) into 02
main housing (G). 0260
Adjustment Screw 21

Tighten end cover cap screws to specification.

Specification
Control Piston End Cover Cap
Screws—Torque .............................................................................23 N•m
204 lb-in.

–UN–18JUL97
A—Adjustment Screw
B—Lock Nut
C—Adjustable Side Control Piston Cover
D—Beveled Washer

T110601
E—Threaded Seal Washer
F—Control Piston Assembly
G—Main Housing Control Piston Cover Cap Screw to Main Housing
H—Cap Screw (4 used)

TX19495,0000142 –19–12NOV04–28/47

44. Use a square to make sure that the flat side of the
control piston (B) is perpendicular to the main housing
face (A).

A—Main Housing Face

B—Control Piston
–UN–18JUL97
T110602

Continued on next page TX19495,0000142 –19–12NOV04–29/47

TM2256 (09JAN07) 02-0260-21 D Series Motor Grader Repair

020207
PN=189
 Hydraulic System

45. Lubricate and install two bearing races (D) on their

locating pins with the groove side of the races toward
the center of the main housing.

46. Apply petroleum jelly on pin pivots and install two

clocking links (C) into main housing.

–UN–18JUL97
47. Lubricate and install two bearings (B) into main
housing.

T110528
02
B—Bearing (2 used)
0260
C—Clocking Link (2 used) Bearings, Clocking Links and Bearing Races
22
D—Bearing Race (2 used)

TX19495,0000142 –19–12NOV04–30/47

48. Lubricate and install shaft assembly (A) into rotating

group (C) and swash plate assembly (B).

A—Shaft Assembly
B—Swash Plate Assembly
C—Rotating Group

–UN–18JUL97
T110521
Shaft Assembly

Continued on next page TX19495,0000142 –19–12NOV04–31/47

TM2256 (09JAN07) 02-0260-22 D Series Motor Grader Repair

020207
PN=190
 Hydraulic System

49. Lubricate and install bearing (A).

A—Bearing

–UN–18JUL97
T110664
02
0260
Lubricate Bearing 23

TX19495,0000142 –19–12NOV04–32/47

50. Install two heavy duty rubber bands (A) across both
arms.

A—Rubber Band

–UN–18JUL97
T110665
Heavy Duty Rubber Bands

Continued on next page TX19495,0000142 –19–12NOV04–33/47

TM2256 (09JAN07) 02-0260-23 D Series Motor Grader Repair

020207
PN=191
 Hydraulic System

51. Apply petroleum jelly to the backside of slide block

(B).

52. Lubricate and install slide block (B) on swash plate

(A).

–UN–18JUL97
A—Swash Plate
B—Slide Block

T110666
02
0260
24 Lubricate Slide Block on Swash Plate

TX19495,0000142 –19–12NOV04–34/47

53. Install split type bearing puller (A) and puller (C) on
bearing.

54. Very carefully install rotating group (D) and shaft

assembly into main housing (E).

–UN–18JUL97
A—Split-Type Bearing Puller
B—Bearing
C—Puller
D—Rotating Group

T110518
E—Main Housing

Bearing Puller and Rotating Group

Continued on next page TX19495,0000142 –19–12NOV04–35/47

TM2256 (09JAN07) 02-0260-24 D Series Motor Grader Repair

020207
PN=192
 Hydraulic System

55. Install two lower clocking link retaining plugs (A).

Tighten to specification.

Specification
Lower Clocking Link Retaining
Plugs—Torque ..............................................................................169 N•m

–UN–18JUL97
125 lb-ft

A—Clocking Link Retaining Plug (2 used)

T110527
02
0260
Lower Clocking Link Retaining Plugs 25

TX19495,0000142 –19–12NOV04–36/47

56. Place parallel bar (A) across the face of main housing
(C).

57. Use a depth micrometer (B) to measure distance from

parallel bar (A) to face of swash plate (D).

–UN–18JUL97
A—Parallel Bar
B—Depth Micrometer
C—Main Housing
D—Swashplate

T110667
Measure Distance Parallel Bar Using Depth Micrometer

Continued on next page TX19495,0000142 –19–12NOV04–37/47

TM2256 (09JAN07) 02-0260-25 D Series Motor Grader Repair

020207
PN=193
 Hydraulic System

58. Move parallel bar (A) and depth micrometer (B) to the
opposite side of the swash plate.

59. Measure distance from parallel bar (A) to the face of

swash plate (D).

–UN–18JUL97
60. Turn the face of depth micrometer (B) so that the
zero position is right between the two measured
dimensions.

T110668
02 61. Turn control piston adjustment screw (E) clockwise or
0260 counterclockwise to bring the swash plate to the zero
26
position.

62. Hold control piston adjustment screw (E) to zero

position and tighten control piston adjustment lock nut
(F) to specification.

Specification

–UN–18JUL97
Control Piston Adjustment Lock
Nut—Torque ...................................................................................61 N•m
45 lb-ft

T110669
Control Piston Adjustment Screw and Lock Nut

A—Parallel Bar
B—Depth Micrometer
C—Main Housing
D—Swash Plate
E—Control Piston Adjustment Screw
F—Control Piston Adjustment Lock Nut

TX19495,0000142 –19–12NOV04–38/47

63. Install dowels (C), washers (D), springs (B) and

gasket (A).

A—Gasket
B—Spring (2 used)
C—Dowel (2 used)
–UN–18JUL97

D—Washer
T110670

Dowels, Washers, Springs and Gasket

Continued on next page TX19495,0000142 –19–12NOV04–39/47

TM2256 (09JAN07) 02-0260-26 D Series Motor Grader Repair

020207
PN=194
 Hydraulic System

64. Lubricate and install shims (A) and bearing (C) into
end cover (B).

A—Shim
B—End Cover
C—Bearing

–UN–18JUL97
T110671
02
0260
Shim Installation 27

Continued on next page TX19495,0000142 –19–12NOV04–40/47

TM2256 (09JAN07) 02-0260-27 D Series Motor Grader Repair

020207
PN=195
 Hydraulic System

65. Install end cover (A) on main housing (B).

66. Use machinist ruler (C) to align swash plate hold

down ears and springs with recesses.

67. Install four cap screws (D) and tighten

–UN–18JUL97
68. Use hammer (E) to gently tap shaft (F).

T110672
A—End Cover
02 B—Main Housing
0260 C—Machinist Ruler
28 Swash Plate Alignment
D—Cap Screw (4 used)
E—Hammer
F—Shaft

–UN–18JUL97
T110673
Cap Screws

–UN–18JUL97
T110674
Use Hammer to Gently Tap Shaft

Continued on next page TX19495,0000142 –19–12NOV04–41/47

TM2256 (09JAN07) 02-0260-28 D Series Motor Grader Repair

020207
PN=196
 Hydraulic System

69. Measure shaft end play with dial indicator (A) while
prying shaft (B) upward with pliers (C).

Specification
HFWD Pump Shaft—End Play .................................0.0508—0.1778 mm
0.002—0.007 in.

–UN–18JUL97
A—Dial Indicator
B—Shaft
C—Pliers

T110675
02
0260
Shaft End Play Measurement 29

TX19495,0000142 –19–12NOV04–42/47

70. Remove cap screws (D) and remove end cover.

D—Cap Screw (4 used)

–UN–18JUL97
T110673
Cap Screws

Continued on next page TX19495,0000142 –19–12NOV04–43/47

TM2256 (09JAN07) 02-0260-29 D Series Motor Grader Repair

020207
PN=197
 Hydraulic System

71. Install bearing plate (C).

C—Dowel Pins and Bearing Plate

–UN–18JUL97
T110515
02
0260
30 Dowel Pins and Bearing Plate

TX19495,0000142 –19–12NOV04–44/47

72. Apply petroleum jelly on the end cover side of the

valve plate (A).

73. Install valve plate (A) into end cover (B).

74. Install end cover (A). Tighten cap screws to

–UN–18JUL97
specification.

Specification
End Cover Cap Screw-to-Main

T110676
Housing—Torque............................................................................88 N•m
65 lb-ft
Dowel Pins and Valve Plate Installation
A—Valve Plate
B—End Cover

Continued on next page TX19495,0000142 –19–12NOV04–45/47

TM2256 (09JAN07) 02-0260-30 D Series Motor Grader Repair

020207
PN=198
 Hydraulic System

75. Lubricate and install valve plate (A) in its original

orientation. Narrow side of the kidney slot (C) aligned
with mark (B) on end cover (D).

76. Lubricate and install eccentric ring (E) in its original

orientation.

–UN–18JUL97
77. Install flushing pump gerotor and shaft.

T110609
A—Valve Plate
B—Alignment Mark 02
C—Narrow Side of Kidney Slot 0260
Valve Plate Installation 31
D—End Cover
E—Eccentric Ring
F—Alignment Mark
G—Alignment Mark

TX19495,0000142 –19–12NOV04–46/47

78. Install HFWD seal and cover (B) so that large recess
with notch (F) faces charge pump inlet (E).

Tighten cap screws to specification.

Specification

–UN–14JUN00
Motor Flushing Pump Cover Cap
Screws—Torque .............................................................................30 N•m
22 lb-ft

T131796B
79. Install clocking link plug (5). Tighten to specifications.

Specification HFWD Motor Flushing Cover Notch

Upper Clocking Link Plug—
Torque .......................................................................................... 170 N•m
125 lb-ft

80. Lubricate and install control valve feedback link (4).

81. Install control valve assembly with gasket. Tighten

–UN–14JUN00
cap screws to specification.

Specification
Control Valve Cap Screws—
T131797B

Torque ........................................................................................... 30 N•m

22 lb-ft

HFWD Motor Flushing Pump Cover

A—Cap Screws (4 used)

B—HFWD Motor Flushing Pump Cover
C—End Cover
D—Alignment Mark
E—Charge Pump Inlet
F—Notch

TX19495,0000142 –19–12NOV04–47/47

TM2256 (09JAN07) 02-0260-31 D Series Motor Grader Repair

020207
PN=199
 Hydraulic System

HFWD Charge Pump Remove and Install

CAUTION: Prevent possible injury from

unexpected machine movement. Install
articulation lock pin when machine is raised or
when working in articulation joint area.

1. Install articulation lock pin. See Locking Machine

Frame. (Operator’s Manual.)
02
0260 2. Remove left rear finger guard.
32
3. Disconnect lines from HFWD charge pump. Mark lines
for ease of assembly. Cap and plug all openings. See
HFWD System Component Location. (Group 9016-15.)

4. Remove cap screws and HFWD charge pump.

5. Clean and inspect parts. Repair or replace as

necessary.

IMPORTANT: Fill pump case with oil before startup.

6. Install charge pump. Tighten cap screws to

specification.

Specification
HFWD Charge Pump Mounting
Cap Screw—Torque .....................................................................237 N•m
175 lb-ft

7. Connect lines.

8. Install left rear finger guard.

9. Remove articulation lock pin.

TX19495,0000164 –19–10DEC04–1/1

TM2256 (09JAN07) 02-0260-32 D Series Motor Grader Repair

020207
PN=200
 Hydraulic System

HFWD Charge Pump Disassemble and Assemble

02
0260
33

–UN–11JAN05
T206310
HFWD Charge Pump

1—Flange 4—Gear Assembly 6—Seal (2 used) 8—O-Ring (2 used)

2—Housing 5—Cap Screw (4 used) 7—Back-Up Ring (2 used) 9—Shaft Seal
3—Rear Cover

1. Disassemble parts as shown. Specification

HFWD Charge Pump Cap
Screw—Torque .................................................................61—68 N•m
2. Replace seals, back-up rings and o-rings (6—9). 45—50 lb-ft

3. Assemble parts. Tighten cap screws to

specification.

TX19495,0000163 –19–10DEC04–1/1

HFWD Engagement Manifold Remove and

Install

1. Pull a vacuum on hydraulic oil tank.

Continued on next page TX19495,0000149 –19–13OCT06–1/3

TM2256 (09JAN07) 02-0260-33 D Series Motor Grader Repair

020207
PN=201
 Hydraulic System

NOTE: Left motor lines are on right side of HFWD

engagement manifold. Right motor lines are on
left side of HFWD engagement manifold.

2. Disconnect hoses (1—8) from HFWD engagement

manifold.

1—Return Line—Right Side

2—Forward Pressure Line—Right Side
3—Forward Pressure Line—Left Side
02 4—Reverse Pressure Line—Right Side
0260 5—Reverse Pressure Line—Left Side
34 6—Right Brake Pressure Line
7—Left Brake Pressure Line
8—Return Line—Left Side

–UN–06DEC01
T148927B
HFWD Engagement Manifold—Left Side

–UN–06DEC01
T148928B

HFWD Engagement Manifold—Right Side

Continued on next page TX19495,0000149 –19–13OCT06–2/3

TM2256 (09JAN07) 02-0260-34 D Series Motor Grader Repair

020207
PN=202
 Hydraulic System

3. Disconnect right and left motor flushing lines from tee

(2).

CAUTION: Avoid crushing injury. Later

machines have gray iron HFWD engagement
manifold, use care when removing manifold
because of increased weight.

4. Remove mounting cap screws to remove HFWD

engagement manifold.
02
0260
Specification 35
HFWD Engagement Manifold
Approximate—Weight ........................................................................22 kg

–UN–01OCT04
50 lb

5. Clean and inspect parts. Repair or replace parts as

necessary. See HFWD Engagement Manifold

T203719A
Disassemble and Assemble. (Group 0260.)

6. Install HFWD engagement manifold. Motor Flushing Lines

7. Connect hoses. 2—Motor Flushing Line Tee

TX19495,0000149 –19–13OCT06–3/3

TM2256 (09JAN07) 02-0260-35 D Series Motor Grader Repair

020207
PN=203
 Hydraulic System

HFWD Engagement Manifold Disassemble and Assemble

02
0260
36

–UN–11JAN05
T206133

HFWD Engagement Manifold

Continued on next page TX19495,000014A –19–12NOV04–1/2

TM2256 (09JAN07) 02-0260-36 D Series Motor Grader Repair

020207
PN=204
 Hydraulic System

1—HFWD Engagement 4—Flushing Valve (2 used) 10—O-Ring (8 used) 14—HFWD Engagement

Manifold 5—Plug (8 used) 11—O-Ring (5 used) Manifold Assembly
2—Operating Charge Pressure 6—Plug (5 used) 12—O-Ring (2 used) 15—Plug
Regulating Valve (2 used) 7—Plug (2 used) 13—O-Ring
3—HFWD Engagement 9—HFWD Engagement
Solenoid Valve (2 used) Solenoid (4 used)

1. Disassemble parts as shown. Plug (6)—Torque ........................................................15.6—18.3 N•m

138—162 lb-in.
Plug (7)—Torque ..............................................................81—95 N•m
2. Clean and inspect parts. Repair or replace parts as 60—70 lb-ft
necessary. Plug (15)—Torque ............................................................36—40 N•m
26.5—29.5 lb-ft 02
3. Assemble parts as shown. Tighten to specification. HFWD Engagement Solenoid 0260
Valve Cap Screw (not 37
shown)—Torque .............................................................4.5—6.0 N•m
HFWD Engagement Manifold—Specification
40—53 lb-in.
Flushing Valve (4)—Torque...................................................122 N•m
HFWD Engagement Solenoid
90 lb-ft
Nut (not shown)—Torque ...............................................5.0—6.8 N•m
Plug (5)—Torque ............................................................6.1—7.5 N•m
44—60 lb-in.
54—66 lb-in.

TX19495,000014A –19–12NOV04–2/2

Differential Lock Pump Remove and Install

CAUTION: Prevent possible injury from

unexpected machine movement. Install
articulation lock pin when machine is raised or
when working in articulation joint area.

1. Install articulation lock pin. See Locking Machine

Frame. (Operator’s Manual.)

Continued on next page TX19495,0000141 –19–10NOV04–1/2

TM2256 (09JAN07) 02-0260-37 D Series Motor Grader Repair

020207
PN=205
 Hydraulic System

2. Remove differential oil filter assembly and axle

breather and set aside.

3. Disconnect lines.

4. Remove differential lock pump (1).

–UN–25OCT01
5. Remove O-ring.

6. Replace parts as necessary.

T147723B
02
0260 IMPORTANT: Fill pump case with oil before startup.
38 Differential Lock Pump
IMPORTANT: Position pump with large fitting facing
1—Differential Lock Pump
up. 2—Differential Lock Pump Inlet Line (large fitting)
3—Transmission (left front side)
7. Install O-ring.

8. Position pump input shaft in coupling and push into

place.

9. Install cap screws and tighten to specification.

Specification
Differential Lock Pump Cap
Screw-to-Transmission—Torque ....................................................61 N•m
45 lb-ft

10. Connect lines.

11. Install differential oil filter assembly and axle breather.

12. Remove articulation lock pin.

TX19495,0000141 –19–10NOV04–2/2

TM2256 (09JAN07) 02-0260-38 D Series Motor Grader Repair

020207
PN=206
 Hydraulic System

Park Brake Valve Remove and Install

CAUTION: Prevent possible injury from

unexpected machine movement. Install
articulation lock pin when machine is raised or
when working in articulation joint area.

1. Install articulation lock pin. See Locking Machine

Frame. (Operator’s Manual.)
02
NOTE: For component location, see Power Train 0260
Component Location. (Group 9020-15.) 39

2. Disconnect electrical connectors.

3. Disconnect lines.

4. Remove cap screws and remove park brake valve.

5. Replace parts as necessary. See Park Brake Valve

Disassemble and Assemble. (Group 0260.)

6. Install park brake valve. Tighten cap screws.

7. Connect lines.

8. Connect electrical connectors.

9. Remove articulation lock pin.

TX19495,0000144 –19–12NOV04–1/1

TM2256 (09JAN07) 02-0260-39 D Series Motor Grader Repair

020207
PN=207
 Hydraulic System

Park Brake Valve Disassemble and Assemble

02
0260
40

–UN–22JUN04
T201054

Park Brake Valve

Continued on next page TX19495,0000145 –19–12NOV04–1/2

TM2256 (09JAN07) 02-0260-40 D Series Motor Grader Repair

020207
PN=208
 Hydraulic System

1—Cap Screw (2 used) 4—Park Brake Solenoid 7—Seal (4 used) 10—Park Brake Pressure
2—Check Valve 5—Park Brake Valve 8—O-Ring Switch
3—Seal (3 used) 6—Cap Screw (2 used) 9—Washer (2 used)

1. Remove parts as shown. 5. Install park brake pressure switch. Tighten to

specification.
2. Inspect and replace parts and necessary.
Specification
3. Install park brake solenoid (4). Tighten cap screws Park Brake Pressure Switch—
Torque..................................................................................... 8.1 N•m
(1) to specification. 72 lb-in.
02
Specification
0260
Park Brake Solenoid Cap
41
Screw—Torque ...............................................................3.0—4.1 N•m
26.4—36.0 lb-in.

4. Install check valve (2). Tighten to specification.

Specification
Check Valve—Torque.......................................................33—35 N•m
24—26 lb-ft

TX19495,0000145 –19–12NOV04–2/2

TM2256 (09JAN07) 02-0260-41 D Series Motor Grader Repair

020207
PN=209
 Hydraulic System

HFWD Motor Remove and Install

1. Straighten front wheels.

2. Place vacuum on hydraulic oil tank. See Vacuum

Pump Installation. (Group 9025-25.)

3. Remove hose guards from motor.

4. Disconnect and cap all motor lines.

02
0260 See HFWD System Component Location. (Group
42
9016-15.)

5. Remove steel pressure lines from motor.

6. Disconnect front wheel harness connector.

IMPORTANT: Vacuum on hydraulic oil tank may

cause pump cavitation. Remove
vacuum before starting machine.

7. Remove vacuum from hydraulic oil tank.

8. Turn wheel so motor faces front of machine. Lean

wheel back.

NOTE: Approximately two quarts of oil will drain from

HFWD hub when motor is removed.

9. Remove motor.

10. Repair or replace parts as necessary. See HFWD

Motor Disassemble and Assemble. (Group 0260.)

11. Install motor. Tighten cap screws to specification.

Specification
Motor-to-Drive Housing Cap
Screw—Torque .............................................................................495 N•m
365 lb-ft

12. Install steel pressure tubes. Tighten flange cap

screws to specification.

Specification
HFWD Motor Steel Tube Flange
Cap Screw—Torque ................................................................34—54 N•m
22—42 lb-ft

Continued on next page TX19495,0000147 –19–12NOV04–1/2

TM2256 (09JAN07) 02-0260-42 D Series Motor Grader Repair

020207
PN=210
 Hydraulic System

13. Install hose guards on motor.

14. Check oil level in HFWD hub. See Check HFWD Hub
Oil Level—If Equipped. (Operator’s Manual.)

15. Calibrate HFWD control unit. See Hydrostatic Front

Wheel Drive (6WD) Controller Calibration. (Group
9015-20.)

02
0260
TX19495,0000147 –19–12NOV04–2/2 43

TM2256 (09JAN07) 02-0260-43 D Series Motor Grader Repair

020207
PN=211
 Hydraulic System

HFWD Motor Disassemble and Assemble

02
0260
44

–UN–30NOV04
T204743

HFWD Motor
Continued on next page TX19495,0000148 –19–12NOV04–1/4

TM2256 (09JAN07) 02-0260-44 D Series Motor Grader Repair

020207
PN=212
 Hydraulic System

1—Ring 7—Cap Screw (2 used) 13—Spring Seat (2 used) 20—End Cap

2—O-Ring 8—O-Ring 14—Spool 21—Solenoid Valve
3—Piston 9—O-Ring (5 used) 15—Plug (4 used) 22—Solenoid Valve Spool
4—Plug (4 used) 10—Gasket 16—O-Ring (4 used) 23—Solenoid Valve Coil
5—O-Ring (6 used) 11—Plug (2 used) 18—Cap Screw (4 used) 24—Nut
6—HFWD Motor Shuttle Valve 12—O-Ring (2 used) 19—Kit
Plug (2 used)

02
0260
Continued on next page TX19495,0000148 –19–12NOV04–2/4 45

TM2256 (09JAN07) 02-0260-45 D Series Motor Grader Repair

020207
PN=213
 Hydraulic System

02
0260
46

–UN–22NOV04
T204742

HFWD Motor

Continued on next page TX19495,0000148 –19–12NOV04–3/4

TM2256 (09JAN07) 02-0260-46 D Series Motor Grader Repair

020207
PN=214
 Hydraulic System

1—Valve 7—Valve Plate 12—Gasket 16—Speed Sensor

2—Dowel Pin (2 used) 8—Seal 13—Seal 17—O-Ring
3—Plug (2 used) 9—O-Ring 14—Shaft 18—Screw
4—O-Ring (2 used) 10—Retaining Ring (2 used) 15—Ring (9 used) 19—Kit
5—O-Ring 11—Retaining Ring

1. Disassemble parts as shown. End Cap Cap Screw (18)—

Torque.................................................................................... 110 N•m
81 lb-ft
2. Clean and inspect parts. Repair or replace parts as Plug (4)—Torque .....................................................................20 N•m
necessary. 177 lb-in.
End Cap Plug (15)—Torque ......................................................9 N•m
3. Assemble parts. Tighten to specifications. 80 lb-in. 02
Housing Cap Screw (7)— 0260
Torque...................................................................................... 66 N•m 47
HFWD Motor—Specification
49 lb-ft
HFWD Motor Shuttle Valve
Plug (11)—Torque ............................................................32—44 N•m
Plug (6)—Torque .....................................................................37 N•m
24—33 lb-ft
27 lb-ft
HFWD High/Low Speed
Solenoid Valve Nut (24)—
Torque................................................................................... 5—7 N•m
44—62 lb-in.

TX19495,0000148 –19–12NOV04–4/4

TM2256 (09JAN07) 02-0260-47 D Series Motor Grader Repair

020207
PN=215
 Hydraulic System

02
0260
48

TM2256 (09JAN07) 02-0260-48 D Series Motor Grader Repair

020207
PN=216
 Section 03
Transmission
Contents

Page

Group 0300—Removal and Installation

Funk Transmission . . . . . . . . . . . . . . . . . . . .03-0300-1
Transmission Remove and Install . . . . . . . . .03-0300-3

Group 0360—Hydraulic System

Transmission Charge Pump Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-1
03
Transmission Oil Filter Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-2
Transmission Accumulator Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-3

TM2256 (09JAN07) 03-1 D Series Motor Grader Repair

020207
PN=1
 Contents

03

TM2256 (09JAN07) 03-2 D Series Motor Grader Repair

020207
PN=2
 Group 0300
Removal and Installation

Funk Transmission

For additional information on Funk transmissions and

components, see the following Component Technical
Manuals.

• DF180 Series Powershift Transmission Repair Manual.

(CTM308.)
(Models 670D, 672D, 770D, 772D)
• DF230 Series Transmission Repair Manual. (CTM362.)
(Models 870D, 872D)

03
0300
1

Continued on next page TX19495,000016C –19–17DEC04–1/2

TM2256 (09JAN07) 03-0300-1 D Series Motor Grader Repair

020207
PN=219
 Removal and Installation

–UN–25JAN05
03
0300
2

YZ5394
Control Valve Components (DF180, DF230)

A—Direction Clutch 2 D—Speed Clutch C (3rd or 4th F—Pressure Regulating Valve H—Speed Clutch B (5th or 6th
(High-Forward) Gear) (System Pressure) Gear)
B—Direction Clutch 4 E—Speed Clutch D (7th or 8th G—Speed Clutch A (1st or 2nd I—Direction Clutch 1
(High-Reverse) Gear) Gear) (Low-Forward)
C—Direction Clutch 3
(Low-Reverse)

FORWARD
Gear Range Directional Clutch Speed Clutch
1st 1 (Low) A (1st)
2nd 2 (High) A (1st)
3rd 1 (Low) C (2nd)
4th 2 (High) C (2nd)
5th 1 (Low) B (3rd)
6th 2 (High) B (3rd)
7th 1 (Low) D (4th)
8th 2 (High) D (4th)
REVERSE
Gear Range Directional Clutch Speed Clutch
1st 3 (Low) A (1st)
2nd 4 (High) A (1st)
3rd 3 (Low) C (2nd)
4th 4 (High) C (2nd)
5th 3 (Low) B (3rd)
6th 4 (High) B (3rd)
7th 3 (Low) D (4th)
8th 4 (High) D (4th)

TX19495,000016C –19–17DEC04–2/2

TM2256 (09JAN07) 03-0300-2 D Series Motor Grader Repair

020207
PN=220
 Removal and Installation

Transmission Remove and Install

CAUTION: Park brake will not operate when

transmission is removed. Chock at least two
wheels before starting this procedure.

CAUTION: Prevent possible injury from

unexpected machine movement. Install
articulation lock pin when machine is raised or
when working in articulation joint area.

1. Install articulation lock pin. See Locking Machine

Frame. (Operator’s Manual.)

2. Drain transmission oil. See Drain and Refill Capacities.

03
(Operator’s Manual.) 0300
3
3. Remove fuel tank. See Fuel Tank Remove and Install.
(Group 0560.)

4. Remove hydraulic oil tank. See Hydraulic Oil Tank

Remove and Install. (Group 2160.)

5. Remove HFWD pumps, if equipped. See HFWD Pump

Remove and Install. (Group 0260.)

6. Remove hydraulic pump. See Hydraulic Pump Remove

and Install. (Group 2160.)

7. Remove differential lock pump. See Differential Lock

Pump Remove and Install. (Group 0260.)

NOTE: Remove transmission harness with transmission.

8. Disconnect transmission harness connector from

machine harness.

9. Disconnect lines from transmission proportional

solenoid control valve.

10. Disconnect all lines from front and rear of

transmission housing.

11. Remove transmission oil filler tube. Replace O-rings

as necessary.

Continued on next page TX19495,000014B –19–16NOV04–1/5

TM2256 (09JAN07) 03-0300-3 D Series Motor Grader Repair

020207
PN=221
 Removal and Installation

12. Remove drive shaft assembly. See

Transmission-to-Rear Axle Drive Shaft Remove and
Install. (Group 0225.)

Continued on next page TX19495,000014B –19–16NOV04–2/5

03
0300
4

TM2256 (09JAN07) 03-0300-4 D Series Motor Grader Repair

020207
PN=222
 Removal and Installation

NOTE: When removing a bare transmission or one with

only the hydraulic pump attached, install lifting
eyebolt in front hole (as shown). When removing
transmission with both hydraulic pump and HFWD
pumps attached, install lifting eyebolt in rear hole
(1).

–UN–19OCT01
13. Install lifting eyebolt (2).

T137632B
CAUTION: Prevent possible injury from
crushing. Use appropriate lifting device.

Transmission Remove and Install—Specification

Transmission—DF180 (670D,
672D, 770D, and 772D)—Weight ..............................567 kg approximate
1250 lb approximate
Transmission—DF230 ( 870D 03
and 872D)—Weight ....................................................675 kg approximate 0300
1489 lb approximate 5

14. Install hoist.

15. Remove cap screws (3). Move transmission rearward

until drive hub spline is disengaged from torsional
isolator on engine flywheel.

16. Remove transmission. Repair or replace parts as

necessary. See Funk Transmission for component
technical manual information. (Group 0300.)

17. Clean mating surfaces on flywheel housing and

transmission housing.

18. Apply TY6304 Flexible Form-In-Place Gasket to

flywheel housing and transmission housing.

NOTE: Use JDG820 Flywheel Turning Tool to engage

spline on transmission drive hub with the mating
spline in the torsional isolator.

19. Install transmission.

For 670D and 672D machines, apply T43512 Thread

Lock and Sealer (Medium Strength) to first five
threads of cap screws installed in top two and bottom
two locations, as these tapped holes in the flywheel
housing are exposed to oil on the inside of the
flywheel housing.

Continued on next page TX19495,000014B –19–16NOV04–3/5

TM2256 (09JAN07) 03-0300-5 D Series Motor Grader Repair

020207
PN=223
 Removal and Installation

Tighten cap screws to specification.

Transmission Remove and Install—Specification

Transmission-to-Engine Flywheel
Cap Screw—Torque .......................................................................73 N•m
54 lb-ft

20. Install drive shaft assembly. See

Transmission-to-Rear Axle Drive Shaft Remove and
Install. (Group 0225.)

21. Install transmission oil filler tube. Replace O-rings as

necessary.

22. Connect all lines to front and rear of transmission

housing.
03
0300 23. Connect lines to transmission proportional solenoid
6 control valve.

24. Connect transmission harness connector to machine

harness.

25. Install differential lock pump. See Differential Lock

Pump Remove and Install. (Group 0260.)

26. Install hydraulic pump. See Hydraulic Pump Remove

and Install. (Group 2160.)

27. Install HFWD pumps, if equipped. See HFWD Pump

Remove and Install. (Group 0260.)

28. Install hydraulic oil tank. See Hydraulic Oil Tank

Remove and Install. (Group 2160.)

29. Install fuel tank. See Fuel Tank Remove and Install.
(Group 0560.)

30. Fill transmission with oil. See Changing Transmission

Oil and Cleaning Transmission Pump Inlet Screen
and Clean Transmission Pump Inlet Screen.
(Operator’s Manual.)

31. Remove articulation lock pin.

32. If equipped with HFWD, perform HFWD Start-Up

Procedure. (Group 9016-20.)

Continued on next page TX19495,000014B –19–16NOV04–4/5

TM2256 (09JAN07) 03-0300-6 D Series Motor Grader Repair

020207
PN=224
 Removal and Installation

33. Calibrate transmission control unit. See Transmission

Control Unit Calibration. (Group 9015-20.)

TX19495,000014B –19–16NOV04–5/5

03
0300
7

TM2256 (09JAN07) 03-0300-7 D Series Motor Grader Repair

020207
PN=225
 Removal and Installation

03
0300
8

TM2256 (09JAN07) 03-0300-8 D Series Motor Grader Repair

020207
PN=226
 Group 0360
Hydraulic System

Transmission Charge Pump Remove and

Install

1. Remove hydraulic pump. See Hydraulic Pump Remove

and Install. (Group 2160.)

2. Disconnect lines (B and E).

3. Remove transmission charge pump.

• For DF180 transmission, See Remove and Install

Charge Pump - Engine Mount. (CTM308.)
• For DF230 transmission, See Remove Oil Pump.
(CTM362.)

–UN–18JUN97
4. Connect lines (B and E). Tighten to specification. 03
0360
Specification 1

T109903
Transmission Pump Inlet Line—
Torque .......................................................................................... 324 N•m
238 lb-ft Transmission Charge Pump Lines

5. Install hydraulic pump. See Hydraulic Pump Remove A—O-Ring

B—To Transmission Oil Filter
and Install. (Group 2160.)
C—Cap Screw (3 used)
D—Transmission Charge Pump
E—To Transmission

TX19495,000014C –19–17NOV04–1/1

TM2256 (09JAN07) 03-0360-1 D Series Motor Grader Repair

020207
PN=227
 Hydraulic System

Transmission Oil Filter Remove and Install

03
0360
2

–UN–29NOV04
T202000

Transmission Oil Filter Assembly

Continued on next page TX19495,000014D –19–17NOV04–1/2

TM2256 (09JAN07) 03-0360-2 D Series Motor Grader Repair

020207
PN=228
 Hydraulic System

1—Cap Screw (5 used) 7—Elbow Fitting 13—Hose 16—O-Ring

2—Washer (5 used) 8—O-Ring (2 used) 14—Transmission Oil Filter 17—Transmission Oil Filter
3—Mounting Bracket 9—Adapter Manifold 18—Quick Coupler (2 used)
4—Elbow Fitting (2 used) 10—Tee Fitting 15—Transmission Oil Filter 19—Cover (2 used)
5—O-Ring (6 used) 11—Hose Restriction Switch 20—O-Ring (2 used)
6—O-Ring (3 used) 12—Hose

7. Install O-rings, quick couplers and covers (18—20).

CAUTION: Prevent possible injury from
Tighten to specification.
unexpected machine movement. Install
articulation lock pin when machine is raised Specification
or when working in articulation joint area. Quick Coupler—Torque ...........................................................12 N•m
106 lb-in.
1. Install articulation lock pin. See Locking Machine
Frame. (Operator’s Manual.) 8. Lubricate transmission oil filter threads and O-ring
with oil.
2. Remove transmission oil filter and O-ring (17 and
16). 9. Install transmission oil filter. 03
0360
3
3. Remove parts as shown. 10. Remove articulation lock pin.

4. Repair or replace parts as necessary.

5. Install parts as shown

6. Install hoses (11—13). Tighten to specification.

Specification
Transmission Oil Filter Hose
Connection—Torque ..............................................................102 N•m
75 lb-ft

TX19495,000014D –19–17NOV04–2/2

Transmission Accumulator Remove and

Install

CAUTION: Prevent possible injury from

unexpected machine movement. Install
articulation lock pin when machine is raised or
when working in articulation joint area.

1. Install articulation lock pin. See Locking Machine

Frame. (Operator’s Manual.)

Continued on next page AM40430,0000002 –19–22DEC04–1/4

TM2256 (09JAN07) 03-0360-3 D Series Motor Grader Repair

020207
PN=229
 Hydraulic System

2. Remove finger guard and panel (1 and 2).

1—Finger Guard
2—Panel

–UN–22DEC04
T206432A
Left Side Of Machine

03
0360
4

Continued on next page AM40430,0000002 –19–22DEC04–2/4

TM2256 (09JAN07) 03-0360-4 D Series Motor Grader Repair

020207
PN=230
 Hydraulic System

03
0360
5

TM2256 (09JAN07) 03-0360-5 D Series Motor Grader Repair

020207
PN=231
 Hydraulic System

03
0360
6

–UN–08DEC04
T202093

Transmission Accumulator

Continued on next page AM40430,0000002 –19–22DEC04–3/4

TM2256 (09JAN07) 03-0360-6 D Series Motor Grader Repair

020207
PN=232
 Hydraulic System

1—Elbow Fitting 4—O-Ring (4 used) 7—Tee Fitting 10—Washer (2 used)

2—O-Ring (7 used) 5—Hose 8—Hose 11—Accumulator
3—Adapter (4 used) 6—Hose 9—Cap Screw (2 used) 12—P-Clamp (2 used)

3. Disconnect hoses (6 and 8) from accumulator (11). 7. Connect hoses.

4. Remove cap screws (9). Remove accumulator. 8. Install finger guard and panel.

5. Clean and inspect parts. Repair or replace parts as 9. Remove articulation lock pin.
necessary.

6. Install accumulator.

03
0360
7

AM40430,0000002 –19–22DEC04–4/4

TM2256 (09JAN07) 03-0360-7 D Series Motor Grader Repair

020207
PN=233
 Hydraulic System

03
0360
8

TM2256 (09JAN07) 03-0360-8 D Series Motor Grader Repair

020207
PN=234
 Section 04
Engine
Contents

Page

Group 0400—Removal and Installation

POWERTECH 4.5 L & 6.8 L (4045 &
6068) John Deere Engines . . . . . . . . . . . .04-0400-1
POWERTECH 8.1 L (6081) John Deere
Engines . . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-1
Engine Remove and Install—6.8 L . . . . . . . .04-0400-2
Engine Remove and Install—8.1 L . . . . . . . .04-0400-8

04

TM2256 (09JAN07) 04-1 D Series Motor Grader Repair

020207
PN=1
 Contents

04

TM2256 (09JAN07) 04-2 D Series Motor Grader Repair

020207
PN=2
 Group 0400
Removal and Installation

POWERTECH 4.5 L & 6.8 L (4045 & 6068)

John Deere Engines

For more information on John Deere engines and

components, see the following Component Technical
Manuals.

• PowerTech 4.5 L & 6.8 L Diesel Engines Base Engine

(CTM104.)
• PowerTech 4.5 L & 6.8 L Diesel Engines Level 11
Electronic Fuel System With Denso HPCR (CTM220.)
• Alternators and Starting Motors (CTM77.)

POWERTECH is a trademark of Deere & Company TX19495,00000D5 –19–18JUN04–1/1

POWERTECH 8.1 L (6081) John Deere 04

0400
Engines 1

For more information on John Deere engines and

components, see the following Component Technical
Manuals.

• PowerTech 8.1 L Diesel Engines Base Engine

(CTM86.)
• PowerTech 8.1 L Diesel Engines Level 9 Electronic
Fuel System With Denso HPCR (CTM255.)
• Alternators and Starting Motors (CTM77.)

POWERTECH is a trademark of Deere & Company LD30992,00000D4 –19–27AUG04–1/1

TM2256 (09JAN07) 04-0400-1 D Series Motor Grader Repair

020207
PN=237
 Removal and Installation

Engine Remove and Install—6.8 L

1. Park machine on flat level surface. Lower all

implements to ground.

2. Disconnect all cables from batteries from both sides of

machine.

3. Drain engine coolant. See Draining The Cooling

System. (Operator’s Manual.)

4. Remove muffler.

CAUTION: Prevent crushing injury from heavy

component. Use appropriate lifting device when
lifting component.

5. Disconnect air filter restriction switch and remove

engine cover with air cleaner attached.

Specification
04 Engine Cover With Air Cleaner—
0400 Weight................................................................................................ 89 kg
2 195 lb

CAUTION: Prevent crushing injury from heavy

component. Use appropriate lifting device when
lifting component.

CAUTION: Sulfuric acid in battery electrolyte is

poisonous. It is strong enough to burn skin, eat
holes in clothing, and cause blindness if
splashed into eyes. Batteries must be securely
fastened to engine access doors and remain
upright while removing engine access doors.

6. Remove engine access doors with batteries.

Specification
Engine Access Doors With
Batteries—Weight ............................................................................120 kg
265 lb

7. Disconnect and remove main battery disconnect switch

from front engine shield.

Continued on next page LD30992,0000111 –19–20DEC04–1/6

TM2256 (09JAN07) 04-0400-2 D Series Motor Grader Repair

020207
PN=238
 Removal and Installation

CAUTION: Prevent crushing injury from heavy

component. Use appropriate lifting device when
lifting component.

8. Remove front engine shield.

Specification
Front Engine Shield—Weight ............................................................36 kg
80 lb

9. Disconnect lower charge air cooler line from

turbocharger.

10. Remove upper coolant line.

11. Clamp fuel return line and remove fuel return line
from injection pump. Cap and plug lines.

12. Remove harness from engine oil pressure sensor, air

conditioner compressor, fuel injection pump, engine
coolant temperature sensor, fuel pressure sensor and
crankshaft position sensor. 04
0400
3
13. Remove engine accessory belt.

NOTE: Note location of spacers when removing air

conditioner compressor.

14. Remove air conditioner compressor and

receiver/dryer from engine and set aside.

Continued on next page LD30992,0000111 –19–20DEC04–2/6

TM2256 (09JAN07) 04-0400-3 D Series Motor Grader Repair

020207
PN=239
 Removal and Installation

15. Remove inlet line (2) from differential pump and move
aside. Cap and plug line.

16. Remove differential filter housing (1) from fuel tank

and set aside.

17. Remove transmission fill tube clamp (3) from engine

mount.

18. Remove engine coolant surge tank from fuel tank and
hoses from engine.

19. Remove upper charge air cooler line.

20. Close fuel feed line valve and remove fuel feed line
from filter housing.

21. Remove engine coolant heater and move aside.

22. Remove heater hot water lines from engine. Cap and

–UN–20DEC04
plug lines.
04
0400 23. Remove lower coolant line.
4

T206384A
24. Disconnect harness from manifold air temperature
sensor, injector harness, alternator, starter and water
in fuel sensor. Differential Filter Housing and Transmission Fill Tube

25. Remove harness clamps and remove harness from 1—Differential Filter Housing
engine. 2—Differential Pump Inlet Line
3—Clamp

CAUTION: Prevent crushing injury from heavy

component. Use appropriate lifting device when
lifting component.

26. Remove bottom guard.

Specification
Bottom Guard—Weight ...................................................................159 kg
350 lb

Continued on next page LD30992,0000111 –19–20DEC04–3/6

TM2256 (09JAN07) 04-0400-4 D Series Motor Grader Repair

020207
PN=240
 Removal and Installation

27. Install DF1253 Transmission Support Bracket (6) to

transmission. See DFT1253 Transmission Support
Bracket. (Group 9900.)

28. Remove drain line from flywheel housing.

29. Remove engine flywheel housing-to-transmission cap

screws.

6—DF1253 Transmission Support Bracket (2 used)

–UN–20DEC04
7—Transmission

T206385A
DF1253 Transmission Support Bracket

Continued on next page LD30992,0000111 –19–20DEC04–4/6

04
0400
5

TM2256 (09JAN07) 04-0400-5 D Series Motor Grader Repair

020207
PN=241
 Removal and Installation

30. Install lifting brackets (11 and 13) to engine.

CAUTION: Prevent crushing injury from heavy

component. Use appropriate lifting device when
lifting component.

31. Attach an appropriate lifting device to engine lifting

brackets.

Specification

–UN–12JAN05
Engine—Weight ...............................................................................587 kg
1294 lb

32. Remove engine mounting cap screws.

T206970A
33. Remove engine.
Front Lifting Bracket
34. Repair or replace parts as necessary.

35. Clean mating surfaces on flywheel housing and

transmission housing.
04
0400 36. Align engine with transmission but do not install.
6

37. Apply TY6304 Flexible Form-in-Place Gasket to

flywheel housing and transmission housing.

38. Install engine to transmission and tighten cap screws.

–UN–12JAN05
39. Install engine mounting cap screws.

Specification
Front Engine Isolator-To-Frame

T206972A
Cap Screw—Torque ............................................................310—381 N•m
230—281 lb-ft

Specification Rear Lifting Bracket

Rear Engine Isolator-To-Frame
Cap Screw—Torque ............................................................610—746 N•m 10—Valve Cover
450—550 lb-ft 11—Front Lifting Bracket
13—Rear Lifting Bracket
40. Remove engine lifting brackets.

41. Install drain line to flywheel housing.

42. Remove DF1253 Transmission Support Bracket from

transmission.

43. Position harness on engine so harness will reach all

sensors and components when installed.

Continued on next page LD30992,0000111 –19–20DEC04–5/6

TM2256 (09JAN07) 04-0400-6 D Series Motor Grader Repair

020207
PN=242
 Removal and Installation

44. Connect harness to manifold air temperature sensor,

injector harness, alternator, starter and water in fuel
sensor.

45. Install lower coolant line and heater hot water lines.

46. Install engine coolant heater to frame.

47. Connect fuel return and fuel feed line to engine.

48. Install upper charge air cooler line.

49. Install coolant surge tank to fuel tank and hoses to

engine.

50. Install air conditioner compressor and receiver/dryer

to engine.

51. Install engine accessory belt.

52. Install lower charge air cooler line to turbocharger.

04
53. Install differential oil filter and inlet line to differential 0400
7
pump.

54. Install transmission fill tube clamp to engine mount.

55. Install front engine cover.

56. Install main battery disconnect switch.

57. Install engine access doors with batteries.

58. Install engine cover with air cleaner.

59. Install muffler.

60. Fill cooling system with coolant. See Filling The

Cooling System. (Operator’s Manual.)

61. Check engine oil level. See Check Engine Oil Level.
(Operator’s Manual.)

LD30992,0000111 –19–20DEC04–6/6

TM2256 (09JAN07) 04-0400-7 D Series Motor Grader Repair

020207
PN=243
 Removal and Installation

Engine Remove and Install—8.1 L

1. Park machine on flat level surface. Lower all

implements to ground.

2. Disconnect all cables from batteries from both sides of

machine.

3. Drain engine coolant. See Draining The Cooling

System. (Operator’s Manual.)

4. Remove muffler.

CAUTION: Prevent crushing injury from heavy

component. Use appropriate lifting device when
lifting component.

5. Remove engine cover with air cleaner attached.

Specification
Engine Cover With Air Cleaner—
04 Weight................................................................................................ 89 kg
0400 195 lb
8

CAUTION: Prevent crushing injury from heavy

component. Use appropriate lifting device when
lifting component.

CAUTION: Sulfuric acid in battery electrolyte is

poisonous. It is strong enough to burn skin, eat
holes in clothing, and cause blindness if
splashed into eyes. Batteries must be securely
fastened to engine access doors and remain
upright while removing engine access doors.

6. Remove engine access doors with batteries.

Specification
Engine Access Doors With
Batteries—Weight ............................................................................120 kg
265 lb

7. Disconnect and remove main battery disconnect switch

from front engine shield.

8. Disconnect and remove ether start aid and bracket

from front engine shield.

Continued on next page LD30992,000010F –19–15DEC04–1/7

TM2256 (09JAN07) 04-0400-8 D Series Motor Grader Repair

020207
PN=244
 Removal and Installation

CAUTION: Prevent crushing injury from heavy

component. Use appropriate lifting device when
lifting component.

9. Remove front engine shield.

Specification
Front Engine Shield—Weight ............................................................36 kg
80 lb

10. Disconnect lower charge air cooler line from engine.

11. Disconnect heater hot water lines from engine.

12. Remove engine accessory belt.

NOTE: Note location of spacers when removing air

conditioner compressor.

13. Remove air conditioner compressor and

receiver/dryer from engine and set aside.
04
0400
9

Continued on next page LD30992,000010F –19–15DEC04–2/7

TM2256 (09JAN07) 04-0400-9 D Series Motor Grader Repair

020207
PN=245
 Removal and Installation

14. Remove inlet line (2) from differential pump and move
aside. Cap and plug line.

15. Remove differential filter housing (1) from fuel tank

and set aside.

16. Remove transmission fill tube clamp (3) from engine

mount.

17. Remove harness from air conditioner compressor,

manifold air temperature sensor and starter.

18. Remove engine coolant surge tank from fuel tank and
hoses engine.

19. Remove upper charge air cooler line.

20. Remove upper coolant line.

21. Disconnect harness from alternator, fuel injection

–UN–20DEC04
pump, oil pressure sensor, fuel pressure sensor and
04 water in fuel sensor.
0400
10
22. Close fuel feed line valve and remove fuel feed line

T206384A
from filter housing.

23. Clamp fuel return line and remove fuel return line Differential Filter Housing and Transmission Fill Tube
from injection pump. Cap and plug openings.
1—Differential Filter Housing
24. Remove engine coolant heater and move aside. 2—Differential Pump Inlet Line
3—Clamp

25. Remove harness clamps and remove harness from

engine.

CAUTION: Prevent crushing injury from heavy

component. Use appropriate lifting device when
lifting component.

26. Remove bottom guard.

Specification
Bottom Guard—Weight ...................................................................159 kg
350 lb

Continued on next page LD30992,000010F –19–15DEC04–3/7

TM2256 (09JAN07) 04-0400-10 D Series Motor Grader Repair

020207
PN=246
 Removal and Installation

27. Install DF1253 Transmission Support Bracket (6) to

transmission. See DFT1253 Transmission Support
Bracket. (Group 9900.)

28. Remove drain line from flywheel housing.

29. Remove engine flywheel housing-to-transmission cap

screws.

6—DF1253 Transmission Support Bracket (2 used)

–UN–20DEC04
7—Transmission

T206385A
DF1253 Transmission Support Bracket

Continued on next page LD30992,000010F –19–15DEC04–4/7

04
0400
11

TM2256 (09JAN07) 04-0400-11 D Series Motor Grader Repair

020207
PN=247
 Removal and Installation

30. Install lifting brackets (11 and 13) to engine.

CAUTION: Prevent crushing injury from heavy

component. Use appropriate lifting device when
lifting component.

31. Attach an appropriate lifting device to engine lifting

brackets.

Specification

–UN–20DEC04
Engine—Weight ...............................................................................805 kg
1775 lb

32. Remove engine mounting cap screws.

T206386A
33. Remove engine.
Rear Engine Lift Bracket
34. Repair or replace parts as necessary.

35. Clean mating surfaces on flywheel housing and

transmission housing.
04
0400 36. Align engine with transmission but do not install.
12

37. Apply TY6304 Flexible Form-in-Place Gasket to

flywheel housing and transmission housing.

38. Install engine to transmission and tighten cap screws.

–UN–20DEC04
39. Install engine mounting cap screws.

Specification
Front Engine Isolator-To-Frame

T206387A
Cap Screw—Torque ............................................................310—381 N•m
230—281 lb-ft

Specification Front Engine Lift Bracket

Rear Engine Isolator-To-Frame
Cap Screw—Torque ............................................................610—746 N•m 10—Turbocharger
450—550 lb-ft 11—Rear Engine Lift Bracket
12—Engine Valve Cover
13—Front Engine Lift Bracket
40. Remove engine lifting brackets. 14—Alternator

Continued on next page LD30992,000010F –19–15DEC04–5/7

TM2256 (09JAN07) 04-0400-12 D Series Motor Grader Repair

020207
PN=248
 Removal and Installation

IMPORTANT: Cap screw installs to engine coolant

gallery. Apply sealant to cap screw to
ensure opening is sealed correctly.

41. Apply thread sealant to cap screw (18) and install.

42. Install drain line to flywheel housing.

43. Remove DF1253 Transmission Support Bracket from

transmission.

–UN–13JAN05
44. Position harness on engine so harness will reach all
sensors and components when installed.

45. Install engine coolant heater to frame.

T206388A
46. Connect fuel return and fuel feed line to engine.
Front Engine Lift Bracket Plug

47. Install harness to alternator, fuel injection pump, oil 18—5/8 X 1.5 Cap Screw
pressure sensor, fuel pressure sensor and water in
fuel sensor.
04
48. Install heater hot water lines to thermostat housing. 0400
13

49. Install coolant surge tank to fuel tank and hoses to

engine.

50. Install upper coolant line and upper charge air cooler
line.

51. Install air conditioner compressor and receiver/dryer

to engine.

52. Install engine accessory belt.

53. Install lower charge air cooler hose.

54. Install differential oil filter and inlet line to differential

pump.

55. Connect harness to air conditioner compressor,

manifold air temperature sensor and starter.

56. Install transmission fill tube clamp to engine mount.

57. Install front engine cover.

58. Install ether start aid and bracket to front engine

cover.

Continued on next page LD30992,000010F –19–15DEC04–6/7

TM2256 (09JAN07) 04-0400-13 D Series Motor Grader Repair

020207
PN=249
 Removal and Installation

59. Install main battery disconnect switch.

60. Install engine access doors with batteries.

61. Install engine cover with air cleaner.

62. Install muffler.

63. Fill cooling system with coolant. See Filling The

Cooling System. (Operator’s Manual.)

64. Check engine oil level. See Check Engine Oil Level.
(Operator’s Manual.)

LD30992,000010F –19–15DEC04–7/7

04
0400
14

TM2256 (09JAN07) 04-0400-14 D Series Motor Grader Repair

020207
PN=250
 Section 05
Engine Auxiliary System
Contents

Page

Group 0510—Cooling System

Fan Remove and Install . . . . . . . . . . . . . . . .05-0510-1
Fan Pulley Remove and Install . . . . . . . . . . .05-0510-2
Fan Pulley Disassemble and Assemble. . . . .05-0510-3
Fan Belt Tensioner Remove and Install. . . . .05-0510-5
Fan Drive Assembly Remove and Install . . . .05-0510-6
Fan Drive Hub Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . . .05-0510-7
Radiator Remove and Install . . . . . . . . . . . . .05-0510-8
Oil Cooler Remove and Install. . . . . . . . . . .05-0510-10
Charge Air Cooler Remove and Install . . . .05-0510-13

Group 0560—External Fuel Supply Systems

Fuel Tank Remove and Install. . . . . . . . . . . .05-0560-1

05

TM2256 (09JAN07) 05-1 D Series Motor Grader Repair

020207
PN=1
 Contents

05

TM2256 (09JAN07) 05-2 D Series Motor Grader Repair

020207
PN=2
 Group 0510
Cooling System

Fan Remove and Install

1. Park machine on flat level surface. Lower all

implements to ground

2. Remove left rear access door.

LD30992,0000109 –19–07DEC04–1/3

3. Remove fan finger guards (1 and 3) from left side of

machine.

NOTE: It is not necessary to evacuate the air conditioning

system or remove any air conditioning lines from
air conditioner condenser.

4. Remove air conditioner condenser and set aside.

1—Lower Fan Finger Guard

2—Cap Screw (3 used)
3—Upper Fan Finger Guard
4—Cap Screw (6 used) 05
0510
1

–UN–08DEC04
T205947A
Fan Finger Guards

Continued on next page LD30992,0000109 –19–07DEC04–2/3

TM2256 (09JAN07) 05-0510-1 D Series Motor Grader Repair

020207
PN=253
 Cooling System

NOTE: Radiator removed for clarity.

5. Remove cap screws (6) and fan (7).

6. Repair or replace parts as necessary.

7. Install fan and cap screws.

8. Install air conditioner condenser.

9. Install finger guards and access door.

–UN–08DEC04
6—Cap Screw (6 used)
7—Fan

T205946A
Fan and Cap Screws

LD30992,0000109 –19–07DEC04–3/3

Fan Pulley Remove and Install

1. Remove fan. See Fan Remove and Install. (Group

0500.)

05 2. Remove belt.

–UN–06JUL01
0510
2
3. Remove cap screws (J). Remove pulley (I).

4. Repair or replace parts as necessary.

T143765B
NOTE: Fan pushes air from inside the engine
compartment, through the coolers, radiator and Pulley and Cap Screws
out through the grille screen.
I—Pulley
J—Cap Screw and Washer (6 used)
5. Install pulley, cap screws, and belt.

6. Install fan. See Fan Remove and Install. (Group 0500.)

LD30992,0000104 –19–06DEC04–1/1

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020207
PN=254
 Cooling System

Fan Pulley Disassemble and Assemble

NOTE: Thread lock and sealer (high strength) may have

been used for assembly of bearing adjuster (A).
Using heat may aid in its removal.

1. Using special spanner wrench, remove bearing

adjuster (A) from shaft (E).

2. Remove snap ring (G) from shaft (E) in pulley (F).

–UN–02JUN98
A—Bearing Adjuster
B—Hub
C—Hub Bearing
D—Snap Ring

T114847
E—Shaft
F—Pulley
G—Snap Ring Disassemble Fan Pulley

LD30992,0000103 –19–06DEC04–1/3
05
0510
3
3. Press shaft (E) from Pulley (F) and hub bearing (C).

4. Remove snap ring (D) from hub (B).

C—Hub Bearing
E—Shaft
F—Pulley

–UN–02JUN98
T114848

Pressing Shaft From Pulley

Continued on next page LD30992,0000103 –19–06DEC04–2/3

TM2256 (09JAN07) 05-0510-3 D Series Motor Grader Repair

020207
PN=255
 Cooling System

5. Press hub bearing (C) from hub (B).

6. Replace parts as necessary.

IMPORTANT: When installing hub bearing, press

against outer edge only.

7. Press hub bearing (C) into hub (B) until it bottoms in

hub bore.

8. Install snap ring (D) in hub to retain hub bearing.

–UN–02JUN98
9. Install snap ring (G) on shaft (E).

10. Press shaft (E) into pulley (F) from small end of pulley

T114849
until snap ring bottoms in pulley counterbore.
Pressing Bearing From Hub
11. While supporting hub bearing (C) inner race, press
shaft (E) and pulley (F) as an assembly into hub B—Hub
bearing until it bottoms on hub bearing inner race. C—Hub Bearing

12. Apply thread lock and sealer (high strength) to

threads of bearing adjuster (A) and screw onto shaft
(E), holes out.

13. Torque bearing adjuster to specification using special

spanner wrench while holding pulley to prevent
05
0510 rotating.
4
Specification
Fan Pulley Bearing Adjuster—
Torque .......................................................................................... 312 N•m
230 lb-ft

14. Rotate pulley to insure smooth rotation.

LD30992,0000103 –19–06DEC04–3/3

TM2256 (09JAN07) 05-0510-4 D Series Motor Grader Repair

020207
PN=256
 Cooling System

Fan Belt Tensioner Remove and Install

1. Remove finger guards.

2. Remove fan belt.

3. Remove cap screw (1 and 2). Remove fan belt

tensioner and spacer (3).

4. Repair or replace parts as necessary.

5. Install fan belt tensioner, spacer, and cap screws.

6. Install fan belt. See Fan Belt Tensioner Spring Check

–UN–06JUL01
to check tensioner. (Group 9010-20.)

1—Cap Screw
2—Cap Screw

T143774B
3—Spacer

Fan Belt Tensioner

LD30992,0000105 –19–06DEC04–1/1
05
0510
5

TM2256 (09JAN07) 05-0510-5 D Series Motor Grader Repair

020207
PN=257
 Cooling System

Fan Drive Assembly Remove and Install

1. Remove fan guards.

2. Remove cap screws (3) on couplings (4).

–UN–14NOV03
NOTE: To aid in removal and installation of fan drive
assembly (2), slide fan drive assembly against
transmission shaft (1).

T196267A
3. Remove fan drive assembly from fan shaft (5).
Remove fan drive assembly from transmission shaft
(1). Fan Drive Assembly Remove and Install

4. Repair or Replace as necessary.

5. Install fan drive assembly.

6. Tighten cap screws (3) on couplings (4) to

–UN–14NOV03
specification.

Specification
Coupler Cap Screw—Torque .........................................................75 N•m
55 lb-ft

T196264A
7. Install fan guards.
Fan Drive Assembly Remove and Install
05
0510 1—Transmission Shaft
6 2—Fan Drive Assembly
3—Cap Screw (2 used)
4—Coupling
5—Fan Shaft

LD30992,000010A –19–07DEC04–1/1

TM2256 (09JAN07) 05-0510-6 D Series Motor Grader Repair

020207
PN=258
 Cooling System

Fan Drive Hub Disassemble and Assemble

1. Remove fan drive hub. See Fan Drive Assembly

Remove and Install. (Group 0500.)

2. Remove cap screws and washers (G) and pulley (F).

NOTE: Thread lock and sealer (high strength) may have

been used for the assembly of bearing adjuster
(A). Heat may aid in its removal.

–UN–02JUN98
3. Using special spanner wrench, remove bearing
adjuster (A) from shaft (E).

4. Press shaft (E) from hub bearing (C).

T114916
5. Remove snap ring (D) from drive hub (B).
Disassemble Drive Hub

6. Press hub bearing (C) from drive hub (B).

7. Replace parts as necessary.

IMPORTANT: When installing hub bearing, press

against outer edge only.

8. Press hub bearing (C) into drive hub (B) until it

bottoms in hub bore.
05
0510
9. Install snap-ring (D) in drive hub (B) to retain hub 7

–UN–02JUN98
bearing.

10. While supporting hub bearing (C) inner race, press

shaft (E) into bearing until it bottoms on bearing inner

T114917
race.

11. Apply thread lock and sealer (high strength) to Shaft Removal
threads of bearing adjuster (A) and screw onto shaft
(E), holes out.
A—Bearing Adjuster
B—Drive Hub
C—Hub Bearing
D—Snap Ring
E—Shaft
F—Pulley
G—Cap Screw and Washer (6 used)
–UN–02JUN98
T114918

Bearing Removal

Continued on next page LD30992,000010B –19–07DEC04–1/2

TM2256 (09JAN07) 05-0510-7 D Series Motor Grader Repair

020207
PN=259
 Cooling System

12. Torque bearing adjuster (A) to specification using

special spanner wrench, while holding shaft to
prevent rotating.

Specification
Fan Drive Hub Bearing
Adjuster—Torque..........................................................................312 N•m
230 lb-ft

13. Rotate shaft to insure smooth rotation.

14. Position pulley (F) on shaft (E) and install cap screws
and washers (G).

15. Install fan drive hub. See Fan Drive Assembly

Remove and Install. (Group 0500.)

LD30992,000010B –19–07DEC04–2/2

Radiator Remove and Install

1. Park machine on flat level surface. Lower all

implements to ground.

05 2. Drain coolant. See Draining The Cooling System.

0510 (Operator’s Manual.)
8

3. Remove rear access doors.

CAUTION: Avoid crushing injury. Use

appropriate lifting device when removing cover.

4. Using an appropriate lifting device, remove cover over

hydraulic oil and fuel tank.

Specification
Hydraulic Oil and Fuel Tank
Cover—Weight ..................................................................................35 kg
76 lb

NOTE: It is not necessary to remove cover over hydraulic

oil and fuel tank, but will aid in removal of
radiator.

5. Remove grille housing assembly. See Grille Housing

Remove and Install. (Group 1900.)

Continued on next page LD30992,0000106 –19–06DEC04–1/4

TM2256 (09JAN07) 05-0510-8 D Series Motor Grader Repair

020207
PN=260
 Cooling System

6. Remove lower fan finger guard (5) from both sides of

machine.

7. Remove fan shroud cap screws from radiator.

4—Cap Screw (3 used)

5—Fan Finger Guard

–UN–06DEC04
T205905A
Fan Finger Guard—Left Side Shown

LD30992,0000106 –19–06DEC04–2/4

NOTE: Fan shown removed for clarity.

8. Remove cap screws (7) holding radiator (8) to oil

cooler (9).

9. Remove reverse alarm and grille bracket. 05

0510
9
10. Remove foam from top of radiator.

11. Remove upper radiator hose.

CAUTION: Avoid crushing injury. Use

appropriate lifting device when removing
radiator.

12. Attach an appropriate lifting device to radiator.

Specification
Radiator—Weight ..............................................................................50 kg
110 lb
–UN–06DEC04

7—Cap Screw (4 used)

8—Radiator
9—Oil Cooler
T205907A

Radiator and Oil Cooler

Continued on next page LD30992,0000106 –19–06DEC04–3/4

TM2256 (09JAN07) 05-0510-9 D Series Motor Grader Repair

020207
PN=261
 Cooling System

13. Remove cap screws (13) from bottom of radiator.

14. Remove lower radiator hose.

15. Remove radiator.

–UN–06DEC04
16. Repair or replace parts as necessary.

17. Install radiator and bottom cap screws.

T205908A
18. Connect upper and lower radiator hoses.

19. Install cap screws to hold radiator to oil cooler. Radiator Bottom Cap Screws

13—Cap Screw (4 used)

IMPORTANT: Foam must be installed to ensure
proper cooling.

20. Use AT317949 Spray Adhesive or equivalent to install

foam to top of radiator.

21. Install fan shroud and cap screws to radiator.

22. Install reverse alarm and grille bracket.

23. Install lower fan finger guards.

24. Install grill housing assembly. See Grille Housing

05
0510 Remove and Install. (Group 1900.)
10
25. Install cover over hydraulic oil and fuel tank.

26. Install rear access doors.

27. Refill radiator and bleed system. See Filling The

Cooling System. (Operator’s Manual.)

LD30992,0000106 –19–06DEC04–4/4

Oil Cooler Remove and Install

1. Park machine on flat level surface. Lower all

implements to ground.

2. Remove charge air cooler. See Charge Air Cooler

Remove and Install. (Group 0500.)

3. Place vacuum on hydraulic oil tank. See Vacuum

Pump Installation. (Group 9025-25.)

Continued on next page LD30992,0000107 –19–06DEC04–1/4

TM2256 (09JAN07) 05-0510-10 D Series Motor Grader Repair

020207
PN=262
 Cooling System

4. Remove hydraulic lines (3) from oil cooler (2). Cap and
plug lines.

5. Remove transmission oil lines (4) from oil cooler. Cap

and plug lines.

6. Remove differential oil lines (5) from oil cooler. Cap

and plug lines.

7. Remove foam from top of oil cooler.

–UN–07DEC04
1—Radiator
2—Oil Cooler
3—Hydraulic Oil Line
4—Transmission Oil Line

T205933A
5—Differential Oil Line

Oil Cooler Lines

LD30992,0000107 –19–06DEC04–2/4

8. Remove cap screws (7).

CAUTION: Avoid crushing injury. Use

appropriate lifting device when removing oil
cooler.
05

–UN–07DEC04
0510
9. Attach an appropriate lifting device to oil cooler. 11

Specification
Oil Cooler—Weight ............................................................................29 kg

T205934A
64 lb

Oil Cooler Lower Cap Screws

1—Radiator
2—Oil Cooler
7—Cap Screw (2 used)

Continued on next page LD30992,0000107 –19–06DEC04–3/4

TM2256 (09JAN07) 05-0510-11 D Series Motor Grader Repair

020207
PN=263
 Cooling System

NOTE: Fan shown removed for clarity.

10. Remove cap screws (9) and oil cooler (2).

11. Repair or replace as necessary.

12. Install oil cooler and cap screws.

IMPORTANT: Foam must be installed to ensure

proper cooling.

13. Use AT317949 Spray Adhesive or equivalent to install

foam to top of oil cooler.

14. Install differential, transmission and hydraulic oil lines.

15. Install charge air cooler. See Charge Air Cooler

Remove and Install. (Group 0500.)

16. Check oil levels. See Checking Transmission Oil

–UN–07DEC04
Level, See Checking Hydraulic Tank Oil Level, and
See Checking Differential Housing Oil Level.
(Operator’s Manual.)

T205935A
1—Radiator
2—Oil Cooler
9—Cap Screw (4 used) Oil Cooler Inner Cap Screws
05
0510
12

LD30992,0000107 –19–06DEC04–4/4

TM2256 (09JAN07) 05-0510-12 D Series Motor Grader Repair

020207
PN=264
 Cooling System

Charge Air Cooler Remove and Install

1. Park machine on flat level surface. Lower all

implements to ground.

2. Remove rear access doors.

CAUTION: Avoid crushing injury. Use

appropriate lifting device when removing cover.

3. Using an appropriate lifting device, remove cover over

hydraulic oil and fuel tank.

Specification
Hydraulic Oil and Fuel Tank
Cover—Weight ..................................................................................35 kg
76 lb

NOTE: It is not necessary to remove cover over hydraulic

oil and fuel tank, but will aid in removal of charge
air cooler.

4. Remove grille housing assembly. See Grille Housing

Remove and Install. (Group 1900.)

05
0510
13

LD30992,0000108 –19–06DEC04–1/4

5. Remove lower fan finger guard (5) from left side of

machine.

6. Remove fan shroud cap screws from charge air cooler.

7. Remove grille bracket.

4—Cap Screw (3 used)

5—Fan Finger Guard
–UN–06DEC04
T205905A

Fan Finger Guard

Continued on next page LD30992,0000108 –19–06DEC04–2/4

TM2256 (09JAN07) 05-0510-13 D Series Motor Grader Repair

020207
PN=265
 Cooling System

8. Remove cap screws (8) from charge air cooler (10).

9. Disconnect upper and lower charge air cooler lines.

10. Remove foam from top of charge air cooler.

–UN–06DEC04
CAUTION: Avoid crushing injury. Use
appropriate lifting device when removing
charge air cooler.

T205912A
11. Attach an appropriate lifting device to charge air
cooler. Charge Air Cooler Upper Cap Screws

12. Remove cap screws (11) from charge air cooler (10).

NOTE: Hose clamps on lower charge air cooler line may

need to be loosened and rotated to remove
charge air cooler.

13. Remove charge air cooler.

Specification
Charge Air Cooler—Weight ...............................................................43 kg
95 lb

–UN–06DEC04
14. Repair or replace parts as necessary.
05
0510 15. Install charge air cooler and upper cap screws.

T205913A
14
16. Connect upper and lower charge air cooler lines.
Charge Air Cooler Lower Cap Screws
IMPORTANT: Foam must be installed to ensure
proper cooling. 8—Cap Screw (4 used)
9—Oil Cooler
10—Charge Air Cooler
17. Use AT317949 Spray Adhesive or equivalent to install
11—Cap Screw (2 used)
foam to top of charge air cooler.

18. Install lower charge air cooler mounting cap screws.

19. Install grille bracket.

20. Install fan shroud cap screws to charge air cooler.

21. Install fan finger guard.

22. Install grille housing assembly. See Grille Housing

Remove and Install. (Group 1900.)

23. Install cover over hydraulic oil and fuel tank cover.

Continued on next page LD30992,0000108 –19–06DEC04–3/4

TM2256 (09JAN07) 05-0510-14 D Series Motor Grader Repair

020207
PN=266
 Cooling System

24. Install rear access doors.

LD30992,0000108 –19–06DEC04–4/4

05
0510
15

TM2256 (09JAN07) 05-0510-15 D Series Motor Grader Repair

020207
PN=267
 Cooling System

05
0510
16

TM2256 (09JAN07) 05-0510-16 D Series Motor Grader Repair

020207
PN=268
 Group 0560
External Fuel Supply Systems

Fuel Tank Remove and Install

1. Park machine on flat level surface. Lower all

implements to ground.

2. Disconnect machine power at main battery disconnect

switch.

3. Disconnect fuel feed line from filter housing and drain

fuel from fuel tank.

4. Drain engine coolant. See Draining The Cooling

System. (Operator’s Manual.)

CAUTION: Avoid crushing injury. Use

appropriate lifting device when removing cover.

5. Using an appropriate lifting device, remove cover over

hydraulic oil and fuel tank.

Specification
Hydraulic Oil and Fuel Tank
Cover—Weight ..................................................................................35 kg
76 lb

6. Remove muffler.
05
CAUTION: Prevent crushing injury from heavy 0560
component. Use appropriate lifting device when 1
lifting component.

7. Remove engine cover with air cleaner attached.

Specification
Engine Cover With Air Cleaner—
Weight................................................................................................ 89 kg
195 lb

8. Disconnect charge air cooler lines at both ends of fuel

tank and remove.

9. Disconnect engine coolant line at both ends of fuel

tank and remove.

10. Remove engine coolant surge tank from fuel tank and
set aside.

11. Remove engine control unit, starter relay, air heater

or glow plug relay and fuse.

Continued on next page TX19495,00000FC –19–18JUN04–1/3

TM2256 (09JAN07) 05-0560-1 D Series Motor Grader Repair

020207
PN=269
 External Fuel Supply Systems

12. Disconnect differential filter housing from fuel tank.

13. Remove soft start solenoid valve from under fuel tank.

14. Remove fuel return line from under fuel tank.

15. Disconnect hydraulic oil tank from fuel tank.

CAUTION: Avoid crushing injury. Use

appropriate lifting device when removing fuel
tank.

16. Attach an appropriate lifting device to fuel tank.

Specification
Fuel Tank (Empty)—Weight ............................................................206 kg
454 lb

17. Remove cap screws from under rear of fuel tank.

18. Remove cap screws from front fuel tank support.

19. Remove fuel tank.

20. Repair or replace parts as necessary.

21. Install fuel tank to frame and hydraulic oil tank.

05
0560
2 22. Install soft start solenoid, fuel return line, and
differential filter housing.

23. Install engine control unit, starter relay, and air heater
or glow plug relay and fuse.

24. Install surge tank, engine coolant lines and charge air
cooler lines.

25. Install engine cover with air cleaner and muffler.

26. Install cover over fuel and hydraulic oil tank.

27. Fill engine cooling system. See Filling The Cooling

System. (Operator’s Manual.)

28. Connect fuel feed line to fuel filter housing.

29. Connect battery power.

Continued on next page TX19495,00000FC –19–18JUN04–2/3

TM2256 (09JAN07) 05-0560-2 D Series Motor Grader Repair

020207
PN=270
 External Fuel Supply Systems

30. Fill fuel tank and bleed fuel system. See Bleeding The
Fuel System. (Operator’s Manual.)

TX19495,00000FC –19–18JUN04–3/3

05
0560
3

TM2256 (09JAN07) 05-0560-3 D Series Motor Grader Repair

020207
PN=271
 External Fuel Supply Systems

05
0560
4

TM2256 (09JAN07) 05-0560-4 D Series Motor Grader Repair

020207
PN=272
 Section 07
Torsional Isolator
Contents

Page

Group 0752—Elements
Torsional Isolator Remove and Install . . . . . .07-0752-1

07

TM2256 (09JAN07) 07-1 D Series Motor Grader Repair

020207
PN=1
 Contents

07

TM2256 (09JAN07) 07-2 D Series Motor Grader Repair

020207
PN=2
 Group 0752
Elements

Torsional Isolator Remove and Install

1. Remove transmission. See Transmission Remove and

Install. (Group 0300.)

2. Remove cap screws and washers (A) and discard.

3. Remove torsional isolator (C) from flywheel housing

(B).

4. Replace parts as necessary.

5. Position torsional isolator (C) on flywheel (D).

–UN–18JUN97
6. Lubricate threads of cap screws with engine oil, install
new cap screws and washers (A) and tighten to
specification.

T109961
Specification
Torsional Isolator-to-Flywheel
Cap Screw—Torque ................................................................45—55 N•m
33—41 lb-ft A—Cap Screw and Washer (12 used)
B—Flywheel Housing
7. Install transmission. See Transmission Remove and C—Torsional Isolator
Install. (Group 0300.) D—Flywheel

07
0752
TX19495,00000FD –19–18JUN04–1/1
1

TM2256 (09JAN07) 07-0752-1 D Series Motor Grader Repair

020207
PN=275
 Elements

07
0752
2

TM2256 (09JAN07) 07-0752-2 D Series Motor Grader Repair

020207
PN=276
 Section 09
Steering System
Contents

Page

Group 0920—Power Steering

Toe-In Check and Adjustment—(HFWD or
Non-HFWD) . . . . . . . . . . . . . . . . . . . . . . . .09-0920-1

Group 0960—Hydraulic System

Steering Wheel, Column, and Valve Remove
and Install . . . . . . . . . . . . . . . . . . . . . . . . .09-0960-1
Steering Valve Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . . .09-0960-2
Steering Cylinder Remove and Install . . . . . .09-0960-7
Hydraulic Cylinder Repair . . . . . . . . . . . . . . .09-0960-8
Wheel Lean Cylinder Remove and Install . . .09-0960-9

09

TM2256 (09JAN07) 09-1 D Series Motor Grader Repair

020207
PN=1
 Contents

09

TM2256 (09JAN07) 09-2 D Series Motor Grader Repair

020207
PN=2
 Group 0920
Power Steering

Toe-In Check and Adjustment—(HFWD or Non-HFWD)

–UN–06NOV01
T147843
1—Left Cylinder Length 4—Left Wheel Axle Center 6—Axle Center Line 9—Tie Rod Cap Screws
2—Right Cylinder Length Measurement 7—Tire Center Line 10—Cylinder Ends
3—Right Wheel Axle Center 5—Floor 8—Toe-in Measurement
Measurement

1. Position grader on a level surface. Check and Adjust Toe-In (HFWD or Non-HFWD)—
Specification
Cylinder Overall Length
2. Raise front wheels off floor and support with a 5-ton (Compare Left to Right)—
stand. Distance ................................................................................. 0—3 mm
0.0—0.12 in. 09
NOTE: Cylinder overall length is measured to align 0920
1
front wheels in center position for starting point 4. Measure distance (3 and 4) from the floor (5) to the
for adjustment. Steering cylinders are not center of axle.
adjustable, tie rod ends (10) are locked in
place with flexible sealant and torqued to a 5. Draw a horizontal (axle center) line (6) on the back
specification. See Steering Cylinder Remove side of each tire. Draw a vertical centerline (7) on
and Install. (Group 0960.) the back side of each tire.

3. Straighten wheels. Steering cylinder rod length (1 6. Measure distance (8) between centerlines.
and 2) must be within specification of each other.

Continued on next page AM40430,0000001 –19–13OCT06–1/2

TM2256 (09JAN07) 09-0920-1 D Series Motor Grader Repair

020207
PN=279
 Power Steering

7. Rotate both tires 180° so marks are at the front. as required. Place container under cylinder to
catch oil..
8. Measure distance (8) between centerlines.
b. Loosen tie rod ends (9). Rotate tie rod to adjust
Front measurement must be less than specification length.
from rear measurement.
c. Check measurements. Adjust until within toe-in
Check and Adjust Toe-In (HFWD or Non-HFWD)—Specification specification.
Toe-In (front less than rear )—
Distance .............................................................................. 3—13 mm
0.12—0.50 in.
d. Tighten steering cylinder hoses. Properly
dispose of waste oil.
If measurement is not to specification:

a. Loosen cylinder hose to both ends of one

cylinder so cylinder rod is free to move in or out

AM40430,0000001 –19–13OCT06–2/2

09
0920
2

TM2256 (09JAN07) 09-0920-2 D Series Motor Grader Repair

020207
PN=280
 Group 0960
Hydraulic System

Steering Wheel, Column, and Valve Remove and Install

1
2
4

5
6
3

–UN–08DEC04
T205605
T205605
Steering Wheel and Valve

1—Cover 3—Steering Wheel (4 used) 5—Steering Column 6—Steering Valve

2—Nut 4—Cap Screws

5. Remove console. See Steering Support Console

CAUTION: Prevent possible injury from
Remove and Install. (Group 3415.)
unexpected machine movement. Install
articulation lock pin when machine is raised
6. Remove hydraulic lines at steering valve. Mark for
or when working in articulation joint area.
ease of assembly. Cap and seal all openings.
09
1. Install articulation lock pin. See Locking Machine
7. Remove steering valve mounting cap screws (4). 0960
Frame. (Operator’s Manual.) 1
8. Remove steering valve (6) from machine.
2. Remove cover (1) with a quick pull from one of the
spokes.
9. Repair or replace valve as [Link] Steering
Valve Disassemble and Assemble. (Group 0960.)
3. Remove steering wheel retaining nut (2).
10. Mount steering valve to column with cap screws.
4. Use bearing pulling attachment D01243AA from 17
1/2-ton capacity puller set D01048AA to remove
11. Install hydraulic lines to steering valve.
steering wheel (3).
12. Install console.
NOTE: Use shop rag around puller to prevent
damaging steering wheel.

Continued on next page CED,OUOE027,172 –19–19JAN05–1/2

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020207
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 Hydraulic System

13. Install steering wheel and tighten to specification. 14. Install cover.
See Steering Support Console Remove and
Install. (Group 3415.) 15. Remove articulation lock pin.

Specification
Steering Wheel Nut—Torque .................................39 N•m— 48 N•m
29 lb-ft— 35 lb-ft

CED,OUOE027,172 –19–19JAN05–2/2

Steering Valve Disassemble and Assemble

2
IMPORTANT: Perform all service on the steering
valve in a clean, isolated work area. Use
the proper tools, cleaning material and 1
lubricants.

–UN–08DEC04
IMPORTANT: Clamp steering valve in vise, gerotor 2
meter end up. Clamp lightly on edges of
port face sides. Use Protective material

T205906
on vise jaws. Housing distortion could 2
result if jaws are overtightened.
Manual Steer Check Valve Location

IMPORTANT: To ensure spool, sleeve, and drive pin 1—Cap Screw (0.3125 in x 1.875 in)
link does not slip or lock up, secure 2—Cap Screw (0.3125 in x 1.750 in)
valve with gerotor end facing up.

1. Remove cap screw (1).

09
0960
2

Continued on next page CED,OUOE027,170 –19–19JAN05–1/6

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020207
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 Hydraulic System

–UN–08DEC04
T205909A
Steering Valve Assembly

1—Cap Screw 4—Gerotor Cap 7—Spacer Plate 10—Thrust Washer (2 used)

2—Cap Screws (6 used) 5—Gerotor Star 8—Spool and Drive 11—Housing
3—Manual Steering Steel Ball 6—Gerotor Meter 9—Bearing
and Pin

2. Remove manual steering steel ball and pin (3) from 4. Remove gerotor cap (4), gerotor star (5), gerotor
cap screw (1) hole. meter (6) and spacer plate (7).

3. Remove remaining cap screws from gerotor meter

end.

09
0960
3

Continued on next page CED,OUOE027,170 –19–19JAN05–2/6

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020207
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 Hydraulic System

IMPORTANT: Spring must be compressed before

spool (8) is removed or it may break
steering valve housing.

5. Insert a M10 x 120 mm cap screw (22) into the spool

so that the head engages into the input spline.

Install two nuts (23) on the other end of the cap screw.

6. Hold drive spline head (20) using 20 mm socket (21).

7. Rotate cap screw using a wrench to compress spring.

IMPORTANT: Spool is not serviceable. Do not

disassemble spool and sleeve.

8. Push spool (8) down out of housing (11) while spring is

compressed.

IMPORTANT: If components are contaminated or

–UN–11JAN05
damaged replace valve.

9. Inspect all parts for contamination, nicks and burrs.

8—Spool and Sleeve

T206825A
11—Housing
20—Spline Head
21—20 mm Socket
22—M10 x 120 mm Cap Screw
23—Nuts

09
0960
4 –UN–11JAN05
T206827A

Continued on next page CED,OUOE027,170 –19–19JAN05–3/6

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020207
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 Hydraulic System

IMPORTANT: Lubricate O-rings and seals with 18

Multi-Purpose HD Lithium Complex
grease (TY24416). If petroleum jelly is 12
used for o-ring lubrication use small
enough amount to avoid spreading on
surfaces of other parts. 13

–UN–11JAN05
NOTE: Lubricate spool, sleeve and gerotor star with
hydraulic oil before assembling.

T206829
10. Place new O-rings (18) in gerotor end of housing
(11).

11. Install seals in steering input shaft end of housing 18—O-Ring (3 used)
(11) with dust seal (13) lip facing out and oil seal (12) 12—Oil Seal
13—Dust Seal
lip facing inward toward spool.

12. Install thrust washers (10) and bearings (9).

Continued on next page CED,OUOE027,170 –19–19JAN05–4/6

09
0960
5

TM2256 (09JAN07) 09-0960-5 D Series Motor Grader Repair

020207
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 Hydraulic System

13. Mark line (16) on top of drive spline (19) parallel to

5
pin (14) in bottom of spool.

IMPORTANT: Spool must rotate freely inside of drive

with torque less than specification. 6

17
14. Install spool (8) into housing (11). 18

Specification
Spool—Torque..............................................................................0.11 Nm
1 lb-in 7

15. Install spacer plate (7) on top of valve housing (11). 18

IMPORTANT: Timing of drive with respect to gerotor

19
star is critical. Line on top of drive
spline must be aligned with valley
(inner radius) of gerotor star.

16. Install gerotor star (5) on to shaft spline. 16

–UN–08DEC04
17. Install gerotor meter (6) housing over gerotor star (5). 14

18. Install gerotor cap (4) on to assembly.

T205910
19. Insert manual steering check ball and pin (3) in cap 15
screw hole (1). Housing and Component Alignment

20. Apply TY9375 John Deere pipe sealant with teflon on 5—Gerotor Star
bottom side of cap screw heads. 6—Gerotor Meter
7—Spacer Plate
14—Pin
NOTE: Cap screw (1) is longer than other six cap screws. 15—Alignment Mark
16—Alignment Mark
21. Install cap screw (1). 17—Alignment Mark
18—O-ring (3 used)
22. Install remaining cap screws. 19—Drive Spline

09
0960
6

CED,OUOE027,170 –19–19JAN05–5/6

23. Torque all cap screws evenly to initial specification.

Then torque in sequence to final specification.

Specification 7
Cap screws—Initial Torque ......................................................11—17 Nm
100—150 lb-in.
2 5
–UN–11JAN05

Specification
Cap screws—Final Torque .......................................................25—28 Nm
4 3
225—250 lb-in.
6 1
T206828

CED,OUOE027,170 –19–19JAN05–6/6

TM2256 (09JAN07) 09-0960-6 D Series Motor Grader Repair

020207
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 Hydraulic System

Steering Cylinder Remove and Install

NOTE: Steering cylinders are not adjustable, tie rod ends

are locked in place with tread lock/sealer and
torqued to a specification.

1. Stop engine and relieve hydraulic pressure in steering

cylinders by moving steering wheel back and forth.

2. Place container under cylinder to catch oil. Remove

cylinder hoses and cap ends.

3. Remove tie rod cotter pin and remove nut. Use tie rod
separator fork to remove tie rod from wheel lean
assembly yoke.

4. Remove head end pin retaining cap screw and pin.

IMPORTANT: If new cylinder is installed and tie rod

end replaced, tie rod must be secured
with thread lock/sealer on cylinder rod
and torqued to a specification.

5. Make cylinder repairs as required.

If new cylinder is installed, put high strength thread

lock/sealer to rod threads and tighten tie rod end to
specifications.

Specification
Tie Rod End to Cylinder Rod—
Torque .......................................................................................... 270 N.m
200 lb-ft

6. Install cylinder.

7. Tighten cylinder nut and tie rod to specification. Install

cotter pin.
09
Specification 0960
Steering Cylinder Nut—Torque ...........................................153—186 N•m 7
112.5—137.5 lb-ft
Tie Rod Nut—Torque ..........................................................153—186 N•m
112.5—137.5 lb-ft

8. Install hoses on cylinder and properly dispose of waste

oil.

MR50960,000014F –19–13OCT06–1/1

TM2256 (09JAN07) 09-0960-7 D Series Motor Grader Repair

020207
PN=287
 Hydraulic System

Hydraulic Cylinder Repair

For repair information on hydraulic cylinders, see 120

Series Hydraulic Cylinders. (TM-H120A.)

IMPORTANT: The following procedure must be

performed when assembling front
steering cylinder.

1. Apply T43513 Thread Lock and Sealer (High Strength)

to thread of steering cylinder rod.

2. Install tie rod end onto cylinder rod. Tighten to

specification.

Specification
Front Steering Cylinder—Torque .................................................271 N•m
200 lb-ft

TX19495,0000174 –19–10JAN05–1/1

09
0960
8

TM2256 (09JAN07) 09-0960-8 D Series Motor Grader Repair

020207
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 Hydraulic System

Wheel Lean Cylinder Remove and Install

1. If equipped, remove push block, scarifier or front

attachments. See Scarifier Remove and Install. (Group
4240.)

CAUTION: Prevent possible injury from

unexpected machine movement. Install
articulation lock pin when machine is raised or
when working in articulation joint area.

2. Install articulation lock pin. See Locking Machine

Frame. (Operator’s Manual.)

3. Support front of machine main frame using shop

stands.

Front Operating Weight—With Standard Equipment—Specification

670D—Weight ...............................................................................3855 kg
8500 lb
672D—Weight ...............................................................................4358 kg
9610 lb
770D—Weight ...............................................................................3860 kg
8510 lb
772D—Weight ...............................................................................4364 kg
9620 lb
870D—Weight ...............................................................................4173 kg
9200 lb
872D—Weight ...............................................................................4613 kg
10,170 lb

4. Remove left front wheel. See Tire Remove and Install.

(Group 0110.)

5. Place wheel chocks at front and rear of right front tire.

6. Support left lean yoke assembly using hoist and lifting

strap.

09
0960
9

Continued on next page TX19495,0000170 –19–10JAN05–1/6

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020207
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 Hydraulic System

7. Remove lean bar pin cap screw (1 or 2).

8. Remove lean bar pin (3) and disconnect lean bar from
lean yoke assembly.

–UN–13JAN05
1—Lean Bar Pin Cap Screw
2—Lean Bar Pin Cap Screw (6 used)
3—Lean Bar Pin

T207025A
Non-HWFD Axle

–UN–13JAN05
T207026A
HFWD Axle
TX19495,0000170 –19–10JAN05–2/6

9. Remove cotter pin and nut (4 and 5) from steering

cylinder and tie rod. Disconnect steering cylinder and
tie rod from lean yoke assembly.

4—Steering Cylinder Cotter Pin and Nut

5—Tie Rod Cotter Pin and Nut

–UN–13JAN05
09

T207060A
0960
10
HFWD Axle Shown

Continued on next page TX19495,0000170 –19–10JAN05–3/6

TM2256 (09JAN07) 09-0960-10 D Series Motor Grader Repair

020207
PN=290
 Hydraulic System

10. Disconnect lubrication lines (6).

11. Remove pin (7) at rod end of wheel lean cylinder to

disconnect from lean yoke assembly.

12. Lower lean yoke assembly and support with blocks.

–UN–13JAN05
6—Lubrication Line (3 used)
7—Wheel Lean Cylinder Pin

T207061A
HFWD Axle Shown

Continued on next page TX19495,0000170 –19–10JAN05–4/6

09
0960
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 Hydraulic System

13. If equipped with HFWD, disconnect hydraulic line (8)

from steering cylinder.

14. Disconnect hydraulic lines from wheel lean cylinder.

–UN–13JAN05
CAUTION: Prevent possible injury from
crushing. Use appropriate lifting device.

15. Support wheel lean cylinder using hoist and lifting

T207067A
strap.

Specification
HFWD Axle Shown
Wheel Lean Cylinder—Weight—
Approximate.................................................................................... 29.5 kg
8—Hydraulic Line
65 lb

16. Remove wheel lean cylinder pin and cylinder.

17. Clean and inspect parts. Repair or replace parts as

necessary. See Hydraulic Cylinder Repair. (Group
0960)

18. Install wheel lean cylinder and pin.

19. Connect hydraulic lines to wheel lean cylinder.

20. If equipped with HFWD, connect hydraulic line (8) to

steering cylinder.

21. Raise lean yoke assembly into position.

22. Install pin at rod end of wheel lean cylinder to connect

lean yoke assembly.

23. Connect lubrication lines.

24. Install steering cylinder and tie rod. Install nut and
cotter pin. Tighten nut to specification.
09
0960
Wheel Lean Yoke—Specification
12
Steering Cylinder Nut—Torque ...........................................153—186 N•m
112.5—137.5 lb-ft
Tie Rod Nut—Torque ..........................................................153—186 N•m
112.5—137.5 lb-ft

25. Install lean bar and pin. Tighten lean bar pin cap
screw to specification.

Continued on next page TX19495,0000170 –19–10JAN05–5/6

TM2256 (09JAN07) 09-0960-12 D Series Motor Grader Repair

020207
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 Hydraulic System

Specification
Lean Bar Pin Cap Screw (HFWD
Axle)—Torque......................................................................119—146 N•m
88—108 lb-ft

26. Install left front wheel. See Tire Remove and Install
for lug nut torque specification. (Group 0110.)

27. Lower machine to the ground

28. Remove articulation lock pin.

29. If equipped, install push block, scarifier or front

attachments. See Scarifier Remove and Install.
(Group 4240.)

TX19495,0000170 –19–10JAN05–6/6

09
0960
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020207
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 Hydraulic System

09
0960
14

TM2256 (09JAN07) 09-0960-14 D Series Motor Grader Repair

020207
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 Section 10
Service Brakes
Contents

Page

Group 1011—Active Elements

Service Brake Repair . . . . . . . . . . . . . . . . . .10-1011-1

Group 1060—Hydraulic System

Service Brake Valve Remove and Install. . . .10-1060-1
Service Brake Bleeding . . . . . . . . . . . . . . . . .10-1060-3
Brake Accumulator Remove and Install. . . . .10-1060-4

10

TM2256 (09JAN07) 10-1 D Series Motor Grader Repair

020207
PN=1
 Contents

10

TM2256 (09JAN07) 10-2 D Series Motor Grader Repair

020207
PN=2
 Group 1011
Active Elements

Service Brake Repair

For repair information on service brake components, see

1400 Multiple Disk Brakes. (CTM43.)

TX19495,0000171 –19–10JAN05–1/1

10
1011
1

TM2256 (09JAN07) 10-1011-1 D Series Motor Grader Repair

020207
PN=297
 Active Elements

10
1011
2

TM2256 (09JAN07) 10-1011-2 D Series Motor Grader Repair

020207
PN=298
 Group 1060
Hydraulic System

Service Brake Valve Remove and Install

CAUTION: Escaping fluid under pressure can

penetrate the skin causing serious injury. Avoid
the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten

–UN–23AUG88
all connections before applying pressure.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure
fluids.

X9811
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be
surgically removed within a few hours or
gangrene may result. Doctors unfamiliar with
this type of injury should reference a
knowledgeable source. Such information is
available from Deere & Company Medical
Department in Moline, Illinois, U.S.A.

CAUTION: Prevent possible injury from

unexpected machine movement. Install
articulation lock pin when machine is raised or
when working in articulation joint area.

1. Install articulation lock pin. See Locking Machine

Frame. (Operator’s Manual.)

2. Apply brake pedal and observe feedback. Pedal is

spring loaded away from brake valve actuator tube.
Reach under pedal to feel feedback on actuator tube.
When feedback is no longer observed (approximately
20 applications with a full accumulator), accumulator is
discharged.

Continued on next page TX19495,0000172 –19–19JAN05–1/3

10
1060
1

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020207
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 Hydraulic System

8
3

7
4

–UN–07DEC04
5

T204868
1 2
T204868
Brake Valve and Pedal

1—Electrical Connectors (2 2—Brake Valve 4—Spring 7—U-Bolt

used) 3—Cap Screw (3 used) 5—Pivot 8—Brake Pedal Assembly

3. Remove lines and seal openings from inner two 10. Remove hex nuts from U-bolt (7) at the brake
grader control valves at the right control valve valve pivot and remove U-bolt.
assembly to gain access to brake valve. Mark lines
for ease of assembly. 11. Remove cap screw (3) holding brake pedal
assembly (8) to the floor and lift pedal assembly
4. Disconnect both electrical connectors (1) from the from machine.
brake valve.
12. Remove brake valve (2) from the machine.
5. Disconnect all hydraulic lines from the brake valve
(2). Cap and plug lines. Mark lines for ease of IMPORTANT: Brake valve is not serviceable.
assembly.
13. Repair or replace parts as necessary.
6. Remove screws holding floor mat in place.
10
1060
14. Install brake pedal assembly (8) and tighten cap
2 7. Remove floor mat from around the brake valve. screws (3).

8. Remove spring (4) from pivot (5). 15. Align brake valve with pedal tube and install U-bolt
and install and tighten hex nuts and washers.
9. Remove lower link pin from the brake valve pivot.

Continued on next page TX19495,0000172 –19–19JAN05–2/3

TM2256 (09JAN07) 10-1060-2 D Series Motor Grader Repair

020207
PN=300
 Hydraulic System

16. Install all lines to the brake valve. 19. Install floor mat.

17. Install electrical connectors. 20. Remove articulation lock pin.

18. Install link pin from pedal to brake valve pivot with 21. Bleed brakes if necessary. See Service Brake
hardware. Bleeding. (Group 1060.)

TX19495,0000172 –19–19JAN05–3/3

Service Brake Bleeding

NOTE: Service brakes are bled at bleed screws on the

brake housing when ever components are
replaced or repaired.

–UN–03NOV00
Bleed service brakes when ever main system components
have been repaired or replaced. A bleed screw (A—Right
side shown) is located on left and right top side of the
brake housing. It can be accessed by opening the left and

T135024B
right engine side doors.

1. Place a clear plastic tube on bleed screw to route

hydraulic oil to hydraulic oil tank or other suitable 1—Bleed Screw—Service Brake (Right Side
Shown)
container.

2. Apply hydraulic pressure to the brake system with

brake pedal until hydraulic oil starts flow. Close brake
bleed screw when air bubbles disappear.

TX04577,000041C –19–10JAN05–1/1

10
1060
3

TM2256 (09JAN07) 10-1060-3 D Series Motor Grader Repair

020207
PN=301
 Hydraulic System

Brake Accumulator Remove and Install

CAUTION: Escaping fluid under pressure can

penetrate the skin causing serious injury. Avoid
the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten

–UN–23AUG88
all connections before applying pressure.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure
fluids.

X9811
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be
surgically removed within a few hours or
gangrene may result. Doctors unfamiliar with
this type of injury should reference a
knowledgeable medical source. Such
information is available from Deere & Company
Medical Department in Moline, Illinois, U.S.A.

IMPORTANT: Perform Brake Accumulator Precharge

Test before removing accumulator. If
accumulator does not meet test
specification, replace it. See Brake
Accumulator Precharge Test. (Group
9025-25.)

CAUTION: Prevent possible injury from

unexpected machine movement. Install
articulation lock pin when machine is raised or
when working in articulation joint area.

1. Install articulation lock pin. See Locking Machine

Frame. (Operator’s Manual.)

2. Apply brake pedal and observe feedback. Pedal is

spring loaded away from brake valve actuator tube.
Reach under pedal to feel feedback on actuator tube.
When feedback is no longer observed (approximately
20 applications with a full accumulator), accumulator is
discharged.

10
1060
4

Continued on next page TX,10,DU2415 –19–10JAN05–1/2

TM2256 (09JAN07) 10-1060-4 D Series Motor Grader Repair

020207
PN=302
 Hydraulic System

3. Slowly disconnect lines (2) from accumulator (1).

4. Remove cap screws (3) and clamps (4). Remove brake

accumulator (1).

5. Replace parts as necessary.

–UN–20NOV04
NOTE: Accumulator is not rechargeable or repairable.
Replace as necessary.

T204871A
6. Position accumulator (1) in place and install clamps (4)
and cap screws (3).
Brake Accumulator
7. Connect lines (2).
1—Brake Accumulator
2—Hydraulic Line (2 used)
8. Remove articulation lock pin. 3—Cap Screw (2 used)
4—Clamp (2 used)

TX,10,DU2415 –19–10JAN05–2/2

10
1060
5

TM2256 (09JAN07) 10-1060-5 D Series Motor Grader Repair

020207
PN=303
 Hydraulic System

10
1060
6

TM2256 (09JAN07) 10-1060-6 D Series Motor Grader Repair

020207
PN=304
 Section 11
Park Brake
Contents

Page

Group 1111—Active Elements

Park Brake Repair. . . . . . . . . . . . . . . . . . . . .11-1111-1

11

TM2256 (09JAN07) 11-1 D Series Motor Grader Repair

020207
PN=1
 Contents

11

TM2256 (09JAN07) 11-2 D Series Motor Grader Repair

020207
PN=2
 Group 1111
Active Elements

Park Brake Repair

For additional information on Funk transmissions and park

brake components, see the following Component
Technical Manuals.

• DF180 Series Powershift Transmission Repair Manual.

(CTM308.)
• DF230 Series Transmission Repair Manual. (CTM362.)

TX19495,0000173 –19–10JAN05–1/1

11
1111
1

TM2256 (09JAN07) 11-1111-1 D Series Motor Grader Repair

020207
PN=307
 Active Elements

11
1111
2

TM2256 (09JAN07) 11-1111-2 D Series Motor Grader Repair

020207
PN=308
 Section 17
Frame, Chassis or Supporting Structure 17

Contents

Page

Group 1740—Frame Installation

Welding On Machine . . . . . . . . . . . . . . . . . . .17-1740-1
Welding Repair of Major Structure. . . . . . . . .17-1740-2
Separate Engine and Equipment Frame . . . .17-1740-3

TM2256 (09JAN07) 17-1 D Series Motor Grader Repair

020207
PN=1
 Contents

17

TM2256 (09JAN07) 17-2 D Series Motor Grader Repair

020207
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 Group 1740
Frame Installation

Welding On Machine

IMPORTANT: Disconnect battery ground strap or WELD METAL SPECIFICATIONS 17

1740
turn battery disconnect switch to 1
OFF (if applicable). Item Specification
Tensile Strength 482.6 mPa (70 000 psi)
Disconnect both negative and
Yield Strength 413.7 mPa (60 000 psi)
positive battery cables and
microprocessor unit (if applicable). Elongation 22%

IMPORTANT: Have only a qualified welder do this Use one of the following weld processes:
job. Connect welder ground clamp
close to each weld area so electrical • AWS-E-7018 covered electrode with shielded metal
current does not pass through any arc welding (SMAW) process.
bearings. • AWS-ER-70S-3f wire electrode with gas metal arc
welding (GMAW) process.
Remove or protect all parts that can • AWS-E70T-1 or E71T-1 wire electrode with flux core
be damaged by heat or weld splatter. arc welding (FCAW) process.

TX,WELD,II –19–11APR95–1/1

TM2256 (09JAN07) 17-1740-1 D Series Motor Grader Repair

020207
PN=311
 Frame Installation

Welding Repair of Major Structure

17 • AWS-ER-70S-3 wire electrode with gas metal arc
1740 CAUTION: Avoid potentially toxic fumes and
welding (GMAW) process.
2 dust. Hazardous fumes can be generated
• AWS-E70T-1 or E71T-1 wire electrode with flux
when paint is heated by welding, soldering,
core arc welding (FCAW) process.
or using a torch. Do all work outside or in a
well ventilated area. Dispose of paint and Welding Repair of Major Structure—Specification
solvent properly. Weld Metal—Tensile Strength ............................................482.6 mPa
70,000 psi
If you sand or grind paint, avoid breathing Yield Strength ..................................................................... 413.7 mPa
the dust. Wear an approved respirator. If you 60,000 psi
Elongation ..................................................................................... 22%
use solvent or paint stripper, remove
stripper with soap and water before welding.
Remove solvent or paint stripper containers
and other flammable material from area.
Allow fumes to disperse at least 15 minutes
IMPORTANT: Area to be repaired must be
before welding or heating.
preheated to allow better weld
penetration.
1. Remove paint before welding or heating.
3. To repair weld metal failure, remove failed weld
IMPORTANT: Electrical current traveling from the
metal using arc or grinding equipment. Thoroughly
welder through the machine
clean area to be welded. Preheat structural
electrical system may damage the
assemblies to a minimum of 38°C (100°F). Preheat
machine electrical system, including
ground engaging tools (cutting edges, skid shoes,
battery, machine information center,
and teeth shanks) to 177°C (350°F).
and pump and valve controller.
Disconnect battery ground cable,
To repair base metal failure remove enough
machine information center, and
material to allow weld to penetrate to the bottom of
pump and valve controller electrical
crack. Preheat structural assemblies to a minimum
connectors before welding on the
of 38°C (100°F). Preheat ground engaging tools
machine.
(cutting edges, skid shoes, and teeth shanks) to
177°C (350°F).
Have only a qualified welder do this
job. Connect welder ground clamp Welding Repair of Major Structure—Specification
close to each weld area so electrical Structural Assemblies—Preheat
current does not pass through any Temperature ................................................................................ 38°C
bearings. Remove or protect all parts 100°F
that can be damaged by heat or weld Ground Engaging Tools—
Preheat Temperature................................................................. 177°C
splatter. 350°F

2. Use one of the following weld processes:

• AWS-E-7018 covered electrode with shielded

metal arc welding (SMAW) process.

LD30992,0000008 –19–17FEB03–1/1

TM2256 (09JAN07) 17-1740-2 D Series Motor Grader Repair

020207
PN=312
 Frame Installation

Separate Engine and Equipment Frame

1. Park machine on smooth level surface and align 17

1740
frames. 3

2. Lower blade to floor.

CAUTION: Equipment frame will tip if not

properly supported. Stabilize frame before
removing pivot pins.

3. Stop engine.

4. Activate hydraulic functions to relieve system pressure.

AK49222,0000010 –19–23AUG05–1/5

5. Install a shortened cylinder locking bar (E) or length of

angle iron secured with a hose clamp on each blade lift
cylinder.

6. Install 10-ton shop stand (D) under equipment frame

ahead of pivot.

CAUTION: If not supported, the engine frame

will tip to the rear when pivot pins are removed.

7. Attach hoist with lifting straps to rear of engine frame.

8. Disconnect engine linkages:

• Speed control lever-to-injection pump cable

• Fuel shut-off lever-to-injection pump cable

9. Remove wire harness cover on rear of cab.

–UN–18NOV89

D—10-Ton Shop Stand

E—Shortened Cylinder Locking Bar
T6401CK

Continued on next page AK49222,0000010 –19–23AUG05–2/5

TM2256 (09JAN07) 17-1740-3 D Series Motor Grader Repair

020207
PN=313
 Frame Installation

10. Disconnect wire harness connectors 1,2, and 3.

17 11. Disconnect wire harness clamps (4).

1740
4
12. Disconnect HFWD lines (if equipped). See HFWD
System Component Location (Group 9016-15)

–UN–25AUG05
13. Disconnect park brake lines. See Power Train
Component Location (Group 9020-15)

T213853A
14. Disconnect service brake lines. See Hydraulic System
Component Location (Group 9025-15)
Wire Harness Connectors Rear Cab
15. Disconnect hydraulic lines. See Hydraulic System
1—Engine Wire Harness Connector
Component Location (Group 9025-15) 2—Rear Platform Wire Harness Connector
3—Transmission Wire Harness Connector
NOTE: Recover air conditioner refrigerant before doing
any disassembly. See R134a Refrigerant
Recovery/Recycling and Charging Station
Installation Procedure (Group 1830)

16. Disconnect air conditioner and heater lines. Air

Conditioner and Heater Component Location (Group
9031-15)

17. Remove articulation cylinder rod end pins to

disconnect articulation cylinders.

Continued on next page AK49222,0000010 –19–23AUG05–3/5

TM2256 (09JAN07) 17-1740-4 D Series Motor Grader Repair

020207
PN=314
 Frame Installation

17
1740
5

TM2256 (09JAN07) 17-1740-5 D Series Motor Grader Repair

020207
PN=315
 Frame Installation

17
1740
6

–UN–08SEP05
T213917

T213917
Assemble Engine and Equipment Frames

Continued on next page AK49222,0000010 –19–23AUG05–4/5

TM2256 (09JAN07) 17-1740-6 D Series Motor Grader Repair

020207
PN=316
 Frame Installation

1—Screw 5—Equipment Frame 9—Engine Frame 13—Cotter Pin

2—Washer 6—Bushing 10—Bushing 14—Shim
3—Spacer 7—Bushing 11—Washer 15—Lower Pivot Pin 17
4—Upper Pivot Pin 8—Bushing 12—Nut 1740
7
18. Remove upper and lower pivot pins. Roll engine Specification
frame back from equipment frame. Lower Pin Nut—Torque .........................................................407 N•m
300 lb-ft

19. Replace parts as necessary

25. Back off nut to align slot on nut with hole in lower
pin (15).
20. To assemble engine frame (9) to equipment frame
(5), align bushing holes in each frame member.
26. Install cotter pin (13).
21. Install upper pin (4) through upper bushing in
27. Connect all hydraulic hoses, electrical harnesses,
equipment frame (7) and through upper bushing
and linkages.
(6) in engine frame (5).
28. Charge air conditioning. See Charge R134a
22. Install lower pin (15) and washers through lower
System (Group 1830)
bushing in equipment frame (6), lower bushing (8),
and lower shims (14) in engine frame (9).
29. Connect steering cylinders.
23. Install cap screw (1), washer (2) and spacer (3).
30. Start machine and check for leaks.
24. Install bushing (10), washer (11), and nut (12) on
lower pin (15) and tighten to specification.

AK49222,0000010 –19–23AUG05–5/5

TM2256 (09JAN07) 17-1740-7 D Series Motor Grader Repair

020207
PN=317
 Frame Installation

17
1740
8

TM2256 (09JAN07) 17-1740-8 D Series Motor Grader Repair

020207
PN=318
 Section 18
Operator’s Station
Contents

Page 18

Group 1800—Removal and Installation

Cab Remove and Install . . . . . . . . . . . . . . . .18-1800-1

Group 1810—Operator Enclosure

Windowpanes Remove and Install . . . . . . . .18-1810-1
Cab Door Handle Remove and Install . . . . . .18-1810-2
Cab Door Latch Remove and Install . . . . . . .18-1810-3
Rivet Nut Installation . . . . . . . . . . . . . . . . . . .18-1810-6

Group 1821—Seat and Seat Belt

Seat Remove and Install . . . . . . . . . . . . . . . .18-1821-1
Seat Belt Remove and Install . . . . . . . . . . . .18-1821-2
Air Suspension Seat Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . . .18-1821-4
Air Seat Suspension Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . . .18-1821-6
Mechanical Suspension Seat Disassemble
and Assemble . . . . . . . . . . . . . . . . . . . . . .18-1821-8
Mechanical Seat Suspension Disassemble
and Assemble . . . . . . . . . . . . . . . . . . . . .18-1821-10

Group 1830—Heating and Air Conditioning

Refrigerant Cautions and Proper
Handling . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-1
Flush and Purge Air Conditioner System. . . .18-1830-3
R134a Refrigerant Oil Information . . . . . . . . .18-1830-6
R134a Refrigerant Recovery/Recycling
and Charging Station Installation
Procedure . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-7
Recover R134a Refrigerant . . . . . . . . . . . . . .18-1830-8
Evacuate R134a System . . . . . . . . . . . . . . . .18-1830-9
Charge R134a System . . . . . . . . . . . . . . . .18-1830-10
Compressor Remove and Install . . . . . . . . .18-1830-10
Condenser Remove and Install . . . . . . . . . .18-1830-11
Heater and Air Conditioner Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-13
Receiver/Dryer Remove and Install . . . . . . .18-1830-15
Accumulator Remove and Install . . . . . . . . .18-1830-16
Compressor Clutch Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .18-1830-18
Compressor Manifold Inspect . . . . . . . . . . .18-1830-20
Compressor Relief Valve Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-20

TM2256 (09JAN07) 18-1 D Series Motor Grader Repair

020207
PN=1
 Contents

18

TM2256 (09JAN07) 18-2 D Series Motor Grader Repair

020207
PN=2
 Group 1800
Removal and Installation

Cab Remove and Install

1. Park machine on flat level surface. Lower all

implements to ground.

2. Disconnect power to machine using manual battery

disconnect switch.
18
3. Drain engine coolant. See Draining The Cooling 1800
System. (Operator’s Manual.) 1

4. Recover air conditioning system refrigerant. See

Recover R134a Refrigerant. (Group 1800.)

5. Remove harness connectors and ground from back of

cab.

6. Remove harness connectors, ground strap, and

harness clamps from under right side of cab.

7. Remove cover over frame in front of cab.

8. Remove hydraulic steering lines from front of cab. Note

location of lines. Cap and plug all lines.

9. Disconnect harness from front lower wiper, front lower

window switches and remove harness clamp from cab,
if equipped.

10. Disconnect heater hot water lines from cab after

engine cooling system has drained.

11. Disconnect air conditioner lines from cab.

12. Remove cab floor mat.

Continued on next page AK49222,000000E –19–13OCT06–1/7

TM2256 (09JAN07) 18-1800-1 D Series Motor Grader Repair

020207
PN=321
 Removal and Installation

13. Remove cap screws (6 and 7) and cover plates (8

and 9) over control valves.

6—Cap Screw (8 used)

7—Cap Screw (4 used)
8—Dust Cover
9—Cover Plate

18
1800
2

–UN–03DEC04
T205814A
Cover Plate Over Valve

Continued on next page AK49222,000000E –19–13OCT06–2/7

TM2256 (09JAN07) 18-1800-2 D Series Motor Grader Repair

020207
PN=322
 Removal and Installation

CAUTION: To avoid injury from escaping fluid

under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.

–UN–03DEC04
14. Remove cap screw (12) to disconnect control valve
linkages (11) at control valve (13). 18
1800
3

T205813A
15. Disconnect control valves from under cab.

16. Remove hydraulic lines from service brake valve. Control Linkage On Control Valve
Note location of lines. Cap and plug all lines.
11—Linkage Rod
17. Disconnect roof harness from cab harness connector. 12—Cap Screw
13—Control Valve
18. Disconnect heated mirrors (if equipped) from roof
harness.

19. Remove cap screws holding roof to cab. Note location

of spacers and washers.

20. Attach lifting straps to cab roof.

CAUTION: Avoid crushing injury. Use

appropriate lifting device when removing cab
roof.

21. Using an appropriate lifting device, attach lifting straps

to DF1101 Cab and ROPS Lifting Bracket and
remove cab roof.

Specification
Cab Roof—Weight.............................................................................55 kg
121 lb

Continued on next page AK49222,000000E –19–13OCT06–3/7

TM2256 (09JAN07) 18-1800-3 D Series Motor Grader Repair

020207
PN=323
 Removal and Installation

IMPORTANT: Route chains to prevent chains from

making contact with rear and side
window.

22. Attach lifting straps (15) to front cab hand rail (16)
and attach chains (20) to rear lifting bracket (19).

18 23. Attach lifting straps and chains to DF1101 Cab and

1800 ROPS Lifting Bracket.
4
24. Remove cab isolator cap screws.

–UN–03DEC04
CAUTION: Avoid crushing injury. Use
appropriate lifting device when removing cab.

T205812A
25. Using an appropriate lifting device, remove cab with
DF1101 Cab and ROPS Lifting Bracket. Front Cab Lifting Point

Specification
Cab—Weight .................................................................................1035 kg
2280 lb

26. Repair or replace parts as necessary.

27. Install cab to frame.

Cab Isolators—Specification
Front Isolator—Torque ........................................................500—748 N•m
368—552 lb-ft
Rear Isolator—Torque .......................................................857—1285 N•m

–UN–03DEC04
632—948 lb-ft

15—Lifting Strap
16—Front Cab Hand Rail

T205811A
17—DF1101 Cab and ROPS Lifting Bracket
19—Rear Lifting Bracket
20—Chain Rear Cab Lifting Point
21—DF1101 Cab and ROPS Lifting Bracket

Continued on next page AK49222,000000E –19–13OCT06–4/7

TM2256 (09JAN07) 18-1800-4 D Series Motor Grader Repair

020207
PN=324
 Removal and Installation

IMPORTANT: Cab roof is an integral part to heater

and air conditioner external air intake.
Cab roof must seal correctly to prevent
contaminants from entering the system.

28. Inspect seal (23) around left rear cab corner post.
Replace if necessary.
18
29. Align left rear cab corner post with opening in cab 1800
roof. 5

–UN–03DEC04
23—Foam Seal
24—Cab Fresh Air Duct

T205810A
Cab Fresh Air Duct Seal

AK49222,000000E –19–13OCT06–5/7

IMPORTANT: Spacers must be installed with cap

screws and washers to prevent
crushing roof when cap screws are
tightened.

30. Install spacers (29), washers (28), and cap screws

–UN–03DEC04
(27) to cab roof.

31. Connect heated mirrors and cab roof harness

connector.

T205809A
32. Install hydraulic lines to brake valve.
Cab Roof Cap Screws and Spacers
33. Install hydraulic control valves under cab.
27—Cap Screw
28—Washer
34. Install control linkages, control valve cover plates, and 29—Spacer
cap screws.

IMPORTANT: When installing floor mat, ensure floor

mat does not interfere with control
levers, boots or pedal.

35. Install floor mat and cap screws.

36. Move steering console to forward position.

Continued on next page AK49222,000000E –19–13OCT06–6/7

TM2256 (09JAN07) 18-1800-5 D Series Motor Grader Repair

020207
PN=325
 Removal and Installation

IMPORTANT: The length specification for linkage

boots is critical and can cause lever
effort complaints from operator if these
boots are installed wrong.

37. Adjust linkage boots so neck (2) is above floor plate

–UN–01JUN05
to specification.
18
1800 Specification
6 Floor Plate to Top of Linkage

T211816A
Boots—Length .................................................................................50 mm
2 in.

Linkage Boot
38. Connect air conditioner and heater lines.
2—Boot Neck
Specification
Refrigerant High Pressure Inlet
Line—Torque ...........................................................................14—20 N•m
123—177 lb-in.
Refrigerant Low Pressure Outlet
Line—Torque ...........................................................................40—47 N•m
30—35 lb-ft

39. Connect front lower wiper and switches to harness.

40. Connect hydraulic steering lines.

41. Install cowl cover over frame in front of cab.

42. Install harness connectors, ground strap, and harness

clamps to right under side of cab.

43. Install harness connectors and ground to back of cab.

44. Evacuate and charge air conditioning system. See

Evacuate R134a System and See Charge R134a
System. (Group 1800.)

45. Fill cooling system with coolant. See Filling The

Cooling System. (Operator’s Manual.)

46. Connect power to machine using manual battery

disconnect switch.

47. Operate machine and verify functions. See

Operational Checkout. (Group 9005-10.)

AK49222,000000E –19–13OCT06–7/7

TM2256 (09JAN07) 18-1800-6 D Series Motor Grader Repair

020207
PN=326
 Group 1810
Operator Enclosure

Windowpanes Remove and Install

The adhesive used to hold the windowpanes in place 3. Scrape broken glass off existing adhesive. Do not
is a urethane adhesive that is used on most remove adhesive from window frame or cab.
automobile windshields. Urethane adhesive
manufactured by Loctite Corporation or equivalent is IMPORTANT: Adhesive will not stick to bare metal.
recommended. Do not use any other type of adhesive.
It is also recommended that an auto glass dealer 4. If existing adhesive is removed from frame and 18
install the windowpanes. paint is scraped off window frame, paint window 1810
frame. Paint must be fully cured before installing 1
IMPORTANT: Windowpanes must have an windowpane.
ultra-violet barrier around the edge
of the glass since ultra-violet rays 5. Trim existing adhesive so it has a smooth surface.
will deteriorate the adhesive.
Windowpanes ordered through John 6. Follow the manufacturer’s instructions for using the
Deere Parts have the ultra-violet adhesive.
barrier. If the windowpane is
purchased through a glass dealer, 7. Apply a 6 mm (1/4 in.) bead of adhesive on top of
the dealer must put an ultra-violet the existing adhesive.
barrier on the glass. Do not apply
paint to the border of the glass. 8. Put a new windowpane into position. Use hand
pressure to force windowpane down around the
If an auto glass dealer is not installing the edges until even with metal frame.
windowpanes, use the following procedure:
9. If windowpane is installed directly on cab, use duct
1. Purchase urethane adhesive from your local auto tape to hold it in place while adhesive cures.
glass dealer.
10. Allow adhesive to cure for 24 hours before
2. If window frame is removable, remove frame from operating machine.
cab.

T52,1810,C19 –19–05JUN98–1/1

TM2256 (09JAN07) 18-1810-1 D Series Motor Grader Repair

020207
PN=327
 Operator Enclosure

Cab Door Handle Remove and Install

1. Remove clip (2) and pin (3) from clevis (5).

2. Remove clevis (5) from door handle.

3. Remove cap screws (4) and door handle.

18
1810 4. Repair or replace parts as necessary.
2

–UN–03DEC04
1—Bracket
2—Clip
3—Pin
4—Cap Screw (3 used)
5—Clevis

T205821A
Cab Door Handle Inside

LD30992,0000100 –19–03DEC04–1/2

5. Install handle (6), gasket (7) and spacer (8).

IMPORTANT: Do not over torque cap screws. Over

torquing cap screws may break cab
door glass.

–UN–03DEC04
6. Apply T43512 Thread Lock and Sealer (medium
strength) to cap screws and install through bracket into
handle.

T205820A
Specification
Door Handle Cap Screw—Torque ........................................5.6—6.7 N•m
49—59 lb-in.
Door Handle Parts

7. Install clevis to door handle. 4—Cap Screw (3 used)

5—Clevis
8. Install pin and clip to clevis. 6—Handle
7—Gasket
8—Spacer

LD30992,0000100 –19–03DEC04–2/2

TM2256 (09JAN07) 18-1810-2 D Series Motor Grader Repair

020207
PN=328
 Operator Enclosure

Cab Door Latch Remove and Install

1. Remove cap screws (6) and cover plate (7).

6—Cap Screw (2 used)

7—Cover Plate
8—Door Latch
18
1810
3

–UN–03DEC04
T205823A
Door Latch Cover Plate

Continued on next page LD30992,0000101 –19–03DEC04–1/3

TM2256 (09JAN07) 18-1810-3 D Series Motor Grader Repair

020207
PN=329
 Operator Enclosure

18
1810
4

–UN–03DEC04
T205825A
Door Latch Components

1—Cap Screw (2 used) 10—Bushing (4 used) 12—Latch Lever 14—Nut (2 used)

3—Cab Door Latch 11—Spacer (2 used) 13—Washer (2 used)

NOTE: Cap screws (1 and 2) are threaded into door 2. Remove nuts (14) from cap screw (1) and remove
latch (3). Lock nut (14) is also threaded on cap washers (13), bushings (10), spacers (11), and
screw (1). latch lever (12).

Continued on next page LD30992,0000101 –19–03DEC04–2/3

TM2256 (09JAN07) 18-1810-4 D Series Motor Grader Repair

020207
PN=330
 Operator Enclosure

3. Remove cap screws (1 and 2) and remove latch (3).

4. Repair or replace parts as necessary.

5. Install latch and cap screws (1 and 2) to door.

Specification
Cab Door Latch Cap Screw—
Torque ......................................................................................... 15.3 N•m 18
135 lb-in. 1810
5

–UN–03DEC04
6. Install washers (13), bushings (10), spacers (11), and
latch lever (12) to latch (3).

7. Use a wrench to hold cap screws (1) from turning and

T205824A
install nuts (14).

Specification
Cab Door Latch Cap Screws
Cab Door Latch Nut—Torque .....................................................10.4 N•m
92 lb-in.
1—Cap Screw (2 used)
2—Cap Screw (2 used)
NOTE: Cap screws (1) may loosen when installing nuts 3—Cab Door Latch
(14).

8. Verify torque on cap screws (1 and 2).

Specification
Cab Door Latch Cap Screw—
Torque ......................................................................................... 15.3 N•m
135 lb-in.

9. Install cover plate (7) and cap screws (6).

LD30992,0000101 –19–03DEC04–3/3

TM2256 (09JAN07) 18-1810-5 D Series Motor Grader Repair

020207
PN=331
 Operator Enclosure

Rivet Nut Installation

Remove Rivet Nut

Remove flange of rivet nut using a hammer and chisel.

Use care not to damage equipment’s surface under the

–UN–19JUL94
flange or the hexagonal hole.
18
1810 Use a punch to remove threaded portion of fastener.
6

T8287AJ
Install Rivet Nut

NOTE: It is not necessary to drill and broach when

replacing a rivet nut.

1. Locate and mark position for new fastener.

IMPORTANT: DO NOT use drill bit larger than

specified. Fastener will not hold
securely. A smaller drill bit may be
substituted, but will increase broaching
effort.

2. Use appropriate drill bit for fastener size being installed

and drill hole.

Rivet Nut Size Drill Bit Size

M6 8 mm
M6 21/64 in.
M8 10 mm
M8 27/64 in.
M10 13 mm
M10 33/64 in.

IMPORTANT: Do not let broach pop out of hole while

driving in broach. Broach will not create
a clean hexagonal hole if it pops out.

3. Broach rivet nut hole using appropriate broach for

fastener size being installed.

Rivet Nut Size Rivet Nut Broach

M6 JDG1829
M8 JDG1832
M10 JDG936

Continued on next page LD30992,0000102 –19–03DEC04–1/5

TM2256 (09JAN07) 18-1810-6 D Series Motor Grader Repair

020207
PN=332
 Operator Enclosure

NOTE: Hardware fastened to rivet nut fastener must have

full thread engagement to rivet nut when
installation is complete.

4. Select appropriate rivet nut fastener for thickness of

material being installed to. Fasteners are color-coded
as well as stamped on the flange surface. (Coding
indicates the nominal plate thickness for which the 18
fastener can be used.) 1810
7
Material Thickness Flange Color Code
Stamp
M6 RIVET NUT LENGTH SELECTION
2.50—5.00 mm (0.098—0.197 in.) 4.5 Silver
5.00—7.00 mm (0.197—0.276 in.) 6.0 Yellow
M8 RIVET NUT LENGTH SELECTION
2.50—5.00 mm (0.098—0.197 in.) 4.5 Silver
5.00—7.00 mm (0.197—0.276 in.) 6.0 Yellow
M10 RIVET NUT LENGTH SELECTION
2.50—4.50 mm (0.098—0.177 in.) 4 Yellow
5.74—7.09 mm (0.226—0.279 in.) 6 Yellow
7.75—9.09 mm (0.305—0.358 in.) 8 Red
9.75—11.10 mm (0.384—0.437 in.) 10 Black
11.73—13.08 mm (0.462—0.515 in.) 12 Olive Drab

LD30992,0000102 –19–03DEC04–2/5

IMPORTANT: DO NOT force or drive fastener into

hole. Fastener can be damaged and
may not hold securely.

5. Make sure fastener fits easily into hexagon hole (A). If

necessary, use a small file to clean edges of hole.
–UN–17OCT94

A—Hexagon Hole
T8287AK

Continued on next page LD30992,0000102 –19–03DEC04–3/5

TM2256 (09JAN07) 18-1810-7 D Series Motor Grader Repair

020207
PN=333
 Operator Enclosure

IMPORTANT: Use only specified installation tool for

rivet nut. Use of other materials to
install rivet nut may result in fastener
failure.

6. Lubricate large threads (A) of the appropriate

–UN–19JUL94
installation tool for the fastener size being installed.
18
1810 Rivet Nut Size Rivet Nut Installation Tool
8 M6 JDG1830

T8287AL
M8 JDG1295
M10 JDG894

A—Large Threads
7. Install rivet nut fastener (C) on tool: B—Tool Shoulder
C—Rivet Nut Fastener
• Small threads (D) of installation tool must extend D—Small Threads
past fastener.
• Flange of fastener must contact shoulder (B) of tool.

Continued on next page LD30992,0000102 –19–03DEC04–4/5

TM2256 (09JAN07) 18-1810-8 D Series Motor Grader Repair

020207
PN=334
 Operator Enclosure

8. Install fastener with installation tool in hexagon hole.

Make sure flange (C) is flat against mounting surface.

IMPORTANT: NEVER turn or tighten installation tool

socket head screw. Damage to threads
of fastener can occur.

9. While holding socket head screw (A) stationary, tighten 18

large nut (B) to specifications using a crowsfoot 1810
wrench. 9

Specification
Rivet Nut Fastener
—Torque—M6 .........................................................................20—27 N•m
180—240 lb-in.

–UN–17OCT94
Torque—M8 .............................................................................39—46 N•m
29—34 lb-ft
Torque—M10 ...........................................................................68—74 N•m
50—55 lb-ft

T8287AM
10. Loosen large nut to remove tool.

A—Socket Head Screw

B—Nut
C—Flange

Rivet Nut Size Drill Bit Size Broach Tool Installation Tool
M6 8 mm JDG1829 JDG1830
M6 21/64 in. JDG1829 JDG1830
M8 10 mm JDG1832 JDG1295
M8 27/64 in. JDG1832 JDG1295
M10 13 mm JDG936 JDG894
M10 33/64 in. JDG936 JDG894

LD30992,0000102 –19–03DEC04–5/5

TM2256 (09JAN07) 18-1810-9 D Series Motor Grader Repair

020207
PN=335
 Operator Enclosure

18
1810
10

TM2256 (09JAN07) 18-1810-10 D Series Motor Grader Repair

020207
PN=336
 Group 1821
Seat and Seat Belt

Seat Remove and Install

1. Park machine on flat level surface. Lower all

implements to ground.

2. Remove seat arm rests.

3. Remove seat belt tethers, if equipped. 18

1821
4. Lift seat cushion and remove. 1

TX19495,0000104 –19–18JUN04–1/2

5. Remove cap screws (1—3) and remove seat back from

machine.

Specification
Seat Back—Weight ...........................................................................19 kg
42 lb

6. Disconnect harness to seat suspension if equipped

with air ride seat.

7. Remove cap screws from under seat suspension.

–UN–05JAN05
CAUTION: Avoid crushing injury. Use
appropriate lifting device when removing seat
suspension.

T206685A
8. Use appropriate lifting device and remove seat
Seat Back
suspension.
1—Cap Screw (2 used)
Specification 2—Cap Screw (2 used)
Seat Suspension—Weight.................................................................31 kg 3—Cap Screw (2 used)
68 lb

9. Repair or replace parts as necessary.

10. Install seat suspension and connect harness.

11. Install seat back and cushion.

12. Install seat belt tethers.

13. Install arm rests.

TX19495,0000104 –19–18JUN04–2/2

TM2256 (09JAN07) 18-1821-1 D Series Motor Grader Repair

020207
PN=337
 Seat and Seat Belt

Seat Belt Remove and Install

1. Park machine on flat level surface. Lower all

implements to ground.

2. Remove seat belt tether (mechanical suspension seat.)

18
1821
2

LD30992,0000112 –19–20DEC04–1/3

3. Remove cap screw (1) and seat belt buckle (2).

1—Cap Screw
2—Seat Belt Buckle

–UN–05JAN05
T206686A
Seat Belt Buckle

Continued on next page LD30992,0000112 –19–20DEC04–2/3

TM2256 (09JAN07) 18-1821-2 D Series Motor Grader Repair

020207
PN=338
 Seat and Seat Belt

4. Remove cap screws (5 and 6) and seat belt (4).

5. Repair or replace parts as necessary.

6. Install seat belt and cap screws.

Specification
Seat Belt—Torque ...................................................................32—46 N•m
24—34 lb-ft 18
1821
3
7. Install seat belt buckle and cap screws.

–UN–05JAN05
Specification
Seat Belt Buckle—Torque .......................................................32—46 N•m
24—34 lb-ft

T206687A
8. Install seat tether (mechanical suspension seat.)

Specification Seat Belt

Seat Belt Tether—Torque .......................................................58—87 N•m
43—64 lb-ft 4—Seat Belt
5—Cap Screw
6—Cap Screw

LD30992,0000112 –19–20DEC04–3/3

TM2256 (09JAN07) 18-1821-3 D Series Motor Grader Repair

020207
PN=339
 Seat and Seat Belt

Air Suspension Seat Disassemble and Assemble

18
1821
4

–UN–10NOV04
T204097

Air Suspension Seat

Continued on next page LD30992,0000113 –19–05JAN05–1/2

TM2256 (09JAN07) 18-1821-4 D Series Motor Grader Repair

020207
PN=340
 Seat and Seat Belt

1—Cap Screw (4 used) 10—Kit 19—Recliner Knob 27—Clip (4 used)

2—Cap Screw (2 used) 11—Snap Ring (4 used) 20—Cap Screw 28—Cushion
3—Seat Belt 12—Spring 21—Kit 29—Grommet
4—Washer (4 used) 13—Spring 22—Spring Pin (2 used) 30—Seat Suspension
5—Cover 14—Torsion Spring 23—Kit 31—Control Lever
6—Seat 15—Kit 24—Nut (3 used) 32—Seat Base
7—Right Arm Rest 17—Lumbar Knob 25—Cushion 33—Nut (4 used)
8—Left Arm Rest 18—Spring Pin 26—Cushion 34—Cap Screw (4 used)
9—Slide
18
1821
5

LD30992,0000113 –19–05JAN05–2/2

TM2256 (09JAN07) 18-1821-5 D Series Motor Grader Repair

020207
PN=341
 Seat and Seat Belt

Air Seat Suspension Disassemble and Assemble

18
1821
6

–UN–25SEP03
T195125

Air Seat Suspension

Continued on next page LD30992,0000114 –19–05JAN05–1/2

TM2256 (09JAN07) 18-1821-6 D Series Motor Grader Repair

020207
PN=342
 Seat and Seat Belt

1—Seat Suspension 12—Clip 23—Nut 34—Nut (2 used)

2—Shaft 13—Kit 24—Spacer 35—Cap Screw (2 used)
3—Bearing 14—Compressor 25—Valve 36—Wiring Harness
4—Tether Belt 15—Wiring Harness 26—Knob 37—Tie Band (4 used)
5—Base Plate 16—Bumper 27—Nut 38—Compressor
6—Seat Plate 17—Shaft (2 used) 28—Washer 39—Spring Pin (2 used)
7—Arm 18—Nut (2 used) 29—Clip (23 used) 40—Rivet (4 used)
8—Spring 19—Bushing (4 used) 30—Rivet (3 used) 41—Clamp
9—Kit 20—Shock Absorber 31—Rivet (3 used) 42—Pipe
10—Air Valve 21—Bearing 32—Boot 43—Tab Connector 18
11—Kit 22—Locking Collar 33—Bumper (2 used) 44—Fitting 1821
7

LD30992,0000114 –19–05JAN05–2/2

TM2256 (09JAN07) 18-1821-7 D Series Motor Grader Repair

020207
PN=343
 Seat and Seat Belt

Mechanical Suspension Seat Disassemble and Assemble

18
1821
8

–UN–21DEC04
T204659

Mechanical Suspension Seat

Continued on next page LD30992,0000115 –19–05JAN05–1/2

TM2256 (09JAN07) 18-1821-8 D Series Motor Grader Repair

020207
PN=344
 Seat and Seat Belt

1—Cap Screw (4 used) 11—Snap Ring (4 used) 22—Spring Pin (2 used) 32—Seat Base
2—Cap Screw (2 used) 12—Spring 23—Kit 33—Nut (4 used)
3—Seat Belt 13—Spring 24—Nut (3 used) 34—Cap Screw (4 used)
4—Washer (4 used) 14—Torsion Spring 25—Cushion 35—Seat Back
5—Cover 15—Kit 26—Cushion 36—Tether (2 used)
6—Seat 17—Lumbar Knob 27—Clip (4 used) 37—Nut (2 used)
7—Right Arm Rest 18—Spring Pin 28—Cushion 38—Cap Screw (2 used)
8—Left Arm Rest 19—Recliner Knob 29—Grommet 39—Washer (4 used)
9—Slide 20—Cap Screw 30—Seat Suspension 40—Spacer (2 used)
10—Kit 21—Kit 31—Control Lever 18
1821
9

LD30992,0000115 –19–05JAN05–2/2

TM2256 (09JAN07) 18-1821-9 D Series Motor Grader Repair

020207
PN=345
 Seat and Seat Belt

Mechanical Seat Suspension Disassemble and Assemble

18
1821
10

–UN–29DEC04
T206425

Mechanical Seat Suspension

Continued on next page LD30992,0000116 –19–05JAN05–1/2

TM2256 (09JAN07) 18-1821-10 D Series Motor Grader Repair

020207
PN=346
 Seat and Seat Belt

1—Bearing 4—Kit 7—Kit 10—Boot

2—Spring 5—Spring Pin 8—Bushing (2 used) 11—Plug (25 used)
3—Spring 6—Knob 9—Seat Suspension 12—Bumper (2 used)

LD30992,0000116 –19–05JAN05–2/2

18
1821
11

TM2256 (09JAN07) 18-1821-11 D Series Motor Grader Repair

020207
PN=347
 Seat and Seat Belt

18
1821
12

TM2256 (09JAN07) 18-1821-12 D Series Motor Grader Repair

020207
PN=348
 Group 1830
Heating and Air Conditioning

Refrigerant Cautions and Proper Handling

R134a is used in the air conditioning

CAUTION: DO NOT allow liquid refrigerant to
system. Because it does not contain
contact eyes or skin. Liquid refrigerant will
chlorine, R134a is not detrimental to
freeze eyes or skin on contact. Wear
the ozone in the atmosphere.
goggles, gloves and protective clothing.
However, it is illegal to discharge
any refrigerant into the atmosphere. 18
If liquid refrigerant contacts eyes or skin, DO
It must be recovered using the 1830
NOT rub the area. Splash large amounts of 1
appropriate recovery stations.
COOL water on affected area. Go to a
physician or hospital immediately for
Use correct refrigerant recovery,
treatment.
recycling and charging stations.
Never mix refrigerants, hoses,
DO NOT allow refrigerant to contact open
fittings, components or refrigerant
flames or very hot surfaces such as electric
oils.
welding arc, electric heating element and
lighted smoking materials.
Use only John Deere approved
R134a refrigerant products. Mixing of
DO NOT heat refrigerant over 52°C (125°F) in
products not compatible will cause
a closed container. Heated refrigerant will
system damage and contaminate
develop high pressure which can burst the
recovery, recycling and charging
container.
station equipment. Care must be
taken to identify and use equipment,
Keep refrigerant containers away from heat
refrigerant oil and refrigerant
sources. Store refrigerant in a cool place.
designed only for R134a refrigerant
systems. Refrigerant should be
DO NOT handle damp refrigerant container
tested for type and purity before
with your bare hands. Skin may freeze to
recovery, recycling or charging of
container. Wear gloves.
system. JT02167A refrigerant test
instrument should be used before
If skin freezes to container, pour COOL
any testing or repair to system is
water over container to free the skin. Go to a
preformed.
physician or hospital immediately for
treatment.

IMPORTANT: To meet government standards

relating to the use of refrigerants,

Continued on next page TX,9031,DY5073 –19–21JUL06–1/2

TM2256 (09JAN07) 18-1830-1 D Series Motor Grader Repair

020207
PN=349
 Heating and Air Conditioning

Prism Pro Refrigerant Identification

Instrument . . . . . . . . . . . . . . . . . . . . . . . JT02167A

To safely identify type and check purity of refrigerant

prior to recovery, recycling and recharging of A/C
systems.

18
1830
2

TX,9031,DY5073 –19–21JUL06–2/2

TM2256 (09JAN07) 18-1830-2 D Series Motor Grader Repair

020207
PN=350
 Heating and Air Conditioning

Flush and Purge Air Conditioner System

a. Remove compressor and measure oil drained

CAUTION: Liquid refrigerant will freeze eyes
from both manifold ports.
or skin on contact. Wear goggles, gloves
and protective clothing.
b. Connect flusher outlet hose to inlet end of
compressor discharge line using JT02102
See Refrigerant Cautions and Proper
Adapter. 18
Handling. (Group 1830.)
1830
c. Pour flushing solvent into suction port and 3
NOTE: Flushing can be performed on machine.
discharge port. Plug both ports in compressor
manifold, using JT02099 and JT03194 Caps.
1. Perform Recover R134a Refrigerant. (Group 1830.)
Specification
Add flushing solvent to system with JT02075 Flushing Solvent in Suction
Flusher and JT02098 Flusher Fitting Kit. Port—Volume...........................................................................240 mL
8 fl oz
2. Remove and discard receiver/dryer. Flushing Solvent in Discharge
Port—Volume...........................................................................120 mL
4 fl oz
3. Connect flusher outlet hose to inlet end of
compressor discharge line using JT02102 Adapter.

4. Fill flusher tank with solvent and fasten all d. Turn compressor end for end and roll it side to
connections. Dispose of solvent properly. side.
Specification
Flusher Tank—Capacity .................................................................4 L e. Remove both plugs from manifold ports and
1 gal drain solvent from compressor.

NOTE: Air pressure must be at least at specification f. Connect battery power to compressor clutch coil.
for flushing and purging. Rotate pulley at least five revolutions to move
solvent out of cylinders.
Specification
Air Pressure—Minimum g. Invert compressor. Roll end for end and side to
Pressure........................................................ 620 kPa for flushing and
side. Drain thoroughly.
purging
90 psi for flushing and purging
6.2 bar for flushing and purging h. Repeat previous two steps at least three times.

5. Connect supply line of moisture-free compressed 8. Divide system into two circuits:
air or dry nitrogen to flusher air valve.
• Condenser circuit, including inlet and outlet
6. Open air valve to force flushing solvent into hoses.
condenser circuit. Flusher tank is empty when hose • Evaporator circuit, including inlet and outlet
pulsing stops. Additional flushing cycles are hoses.
required if system is heavily contaminated with
burned oil or metal particles. 9. Condenser:

7. Clean compressor as follows:

Continued on next page TX,18,DU2461 –19–04MAR03–1/3

TM2256 (09JAN07) 18-1830-3 D Series Motor Grader Repair

020207
PN=351
 Heating and Air Conditioning

IMPORTANT: DO NOT attempt to flush through Put nozzle in container to collect flushing
compressor or receiver/dryer. solvent.
Flushing through expansion valve is
acceptable if refrigerant oil has a NOTE: Purging the condenser circuit takes 10—12
normal odor and appearance. minutes to thoroughly remove solvent.

a. Flush/Purge Condenser: h. Disconnect hose from aeration nozzle to check

18 circuit for solvent. Hold hose close to piece of
1830 b. Remove and discard receiver/dryer. cardboard; continue purging until cardboard is
4 dry.
c. Connect flusher outlet hose to inlet end of
compressor discharge line using JT02102 10. See flush evaporator, if evaporator requires
Adapter. flushing.

d. Fill flusher tank with solvent and fasten all If system is contaminated with burned refrigerant
connections. oil or debris, remove and bench flush evaporator.
See following steps to flush evaporator through
Specification expansion valve, if oil appears normal.
Flusher Tank—Capacity .................................................................4 L
1 gal
11. Flush evaporator:

a. Remove evaporator and expansion valve. See

Air Conditioner and Heater Remove and Install.
NOTE: Air pressure must be at least to specification
(Group 1830.)
for flushing and purging.

Specification
b. Force flushing solvent through evaporator inlet
Air Pressure—Minimum with compressed air.
Pressure........................................................ 620 kPa for flushing and
purging. c. Purge system until dry.
90 psi for flushing and purging.
6.2 bar for flushing and
purging.
d. Install evaporator and then go to step 13.

e. Connect supply line of moisture-free compressed 12. Flush evaporator through expansion valve:
air or dry nitrogen to flusher air valve.
a. Connect flusher outlet hose to connection of
f. Open air valve to force flushing solvent into receiver/dryer outlet hose using JT03188
condenser circuit. Flusher tank is empty when adapter.
hose pulsing stops. Additional flushing cycles are
required if system is heavily contaminated with b. Fill flusher tank and fasten all connections.
burned oil or metal particles.
Specification
Flusher Tank—Capacity .................................................................4 L
g. Attach return hose and aerator nozzle to end of 1 gal
receiver/dryer inlet hose using JT03197 Adapter.

Continued on next page TX,18,DU2461 –19–04MAR03–2/3

TM2256 (09JAN07) 18-1830-4 D Series Motor Grader Repair

020207
PN=352
 Heating and Air Conditioning

NOTE: Air pressure must be at least to specification 13. Disconnect hose from aeration nozzle to check
for flushing and purging. circuit for solvent. Hold hose close to piece of
cardboard and continue purging until cardboard is
Specification dry.
Air Pressure—Minimum
Pressure........................................................ 620 kpa for flushing and
purging.
14. Install new receiver/dryer compatible with R134a
90 psi for flushing and purging. refrigerant. Fasten connections and mounting
6.2 bar for flushing and bracket. See Receiver-Dryer Remove and Install. 18
purging. (Group 1830.) 1830
5
c. Connect supply line of moisture-free 15. Add required oil. See R134a Refrigerant Oil
compressed air or dry nitrogen to flusher air Information. (Group 1830.)
valve.
16. Install compressor and connect refrigerant lines to
d. Attach hose and aerator nozzle to compressor manifold.
inlet line using JT02101 adapter. Put nozzle in
container to collect solvent. 17. Connect clutch coil wire and install drive belt.

NOTE: Purging evaporator circuit takes 12—15

minutes to thoroughly remove solvent.

TX,18,DU2461 –19–04MAR03–3/3

TM2256 (09JAN07) 18-1830-5 D Series Motor Grader Repair

020207
PN=353
 Heating and Air Conditioning

R134a Refrigerant Oil Information

Specification
CAUTION: All new compressors are charged Oil—Total System Volume ......................................................180 mL
with a mixture of nitrogen, R134a refrigerant 6.09 fl oz
and TY22025 (R134a) refrigerant oil. Wear R134a—Weight..............................................................1100—1200 g
safety goggles and discharge the 2.43— 2.65 lb
compressor slowly to avoid possible injury.
18 If any section of hose is removed and flushed or
1830 replaced, measure length of hose and use formula 3
6
IMPORTANT: Do not add any more oil than
required or maximum cooling will be mL per 30 cm (0.1 fl oz per ft ) to determine correct
reduced. amount of oil to be added.

DO NOT leave system or R134a Drain compressor oil into graduated container while
compressor oil containers open. rotating compressor shaft and record amount.
Refrigerant oil easily absorbs
moisture. DO NOT spill R134a If oil drained from compressor removed from operation
compressor oil on acrylic or ABS is very black or amount of oil is less than 6 mL (0.2 fl
plastic. This oil will deteriorate these oz), perform the following and discard oil properly:
materials rapidly. Identify R134a oil
containers and measures to ❒ Determine if R134a leakage was detected, remove
eliminate accidental mixing of component and repair or replace component. See
different oils. Refrigerant Leak Test. (Group 9031-25.)
❒ Remove and discard receiver-dryer. See
New compressor from parts depot contains new oil. Oil Receiver-Dryer Remove and Install. (Group 1830.)
level visible through suction port normally is below ❒ Flush complete system with TY16134 Air
drive shaft. Conditioning Flushing Solvent. See Flush and
Purge Air Conditioner System. (Group 1830.)
Normal operating oil level of compressor removed from
operation cannot be seen through suction port of If component is serviceable, pour flushing solvent in
compressor. ports and internally wash out old oil and discard oil
properly.
Compressors can be divided into three categories
when determining correct oil charge for system. 1. Install new receiver-dryer. See Receiver-Dryer
Remove and Install. (Group 1830.)
• New compressor from parts depot
• Used compressor removed from operation 2. Pour required amount of TY22025 Refrigerant Oil in
• Compressor internally washed with flushing solvent compressor.

Determining amount of system oil charge prior to 3. Connect all components. Perform Evacuate R134a
installation of compressor on machine. System. (Group 1830.)

When complete system, lines, and components are 4. Perform Charge R134a System. (Group 1830.)
flushed add correct amount of oil as described.

LD30992,0000011 –19–01AUG06–1/1

TM2256 (09JAN07) 18-1830-6 D Series Motor Grader Repair

020207
PN=354
 Heating and Air Conditioning

R134a Refrigerant Recovery/Recycling and

Charging Station Installation Procedure

CAUTION: Liquid refrigerant will freeze eyes or

skin on contact. Wear goggles, gloves and
protective clothing.
18
See Refrigerant Cautions and Proper Handling. 1830
(Group 1830.) 7

IMPORTANT: Use only John Deere approved R134a

refrigerant products. Mixing of products
not compatible will cause system
damage and contaminate recovery,
recycling and charging station
equipment.

CAUTION: Do not remove high pressure relief

valve (D). Air conditioning station will discharge

–UN–06DEC93
rapidly causing possible injury.

IMPORTANT: Use only John Deere approved

refrigerant recovery/recycling and

T8118AG
charging stations. DO NOT mix
refrigerant, hoses, fittings, components
or refrigerant oils.
A—High Pressure Hose Charge Port Cap
1. Follow procedures. See Refrigerant Cautions and B—Red Hose
Proper Handling. (Group 1830.) C—Blue Hose
D—High Pressure Relief Valve
E—Refrigerant Recovery/Recycling and Charging
2. Close both high-side and low-side valves on refrigerant Station
recovery/recycling and charging station (E).

3. Remove cap from low-side charge port.

4. Connect blue hose (C) from refrigerant

recovery/recycling and charging station (E) to low-side
test port.

5. Remove cap (A) from charge port on high pressure

hose and connect red hose (B).

6. Follow the manufacturers’ instructions when using

refrigerant recovery/recycling and charging station.

TX,9031,DU1693 –19–04MAR03–1/1

TM2256 (09JAN07) 18-1830-7 D Series Motor Grader Repair

020207
PN=355
 Heating and Air Conditioning

Recover R134a Refrigerant

CAUTION: Liquid refrigerant will freeze eyes or

skin on contact. Wear goggles, gloves and
protective clothing.

See Refrigerant Cautions and Proper Handling.

18 (Group 1830.)
1830
8
CAUTION: Do not remove high pressure relief
valve. Air conditioning system will discharge
rapidly causing possible injury.

IMPORTANT: Use correct refrigerant

recovery/recycling and charging
stations. DO NOT mix refrigerant,
hoses, fittings, components or
refrigerant oils.

1. Run air conditioning system for three minutes to help in

recovery process. Turn air conditioning system off
before proceeding with recovery steps.

2. With engine OFF identify refrigerant type using

JT02167A Refrigerant Identification Instrument.

3. Connect refrigerant recovery system. See R134a

Refrigerant Recovery/Recycling and Charging Station
Installation Procedure. (Group 1830.)

4. Follow manufacturers’ instructions when using

refrigerant recovery/recycling and charging station.

TX,9031,DU1694 –19–04MAR03–1/1

TM2256 (09JAN07) 18-1830-8 D Series Motor Grader Repair

020207
PN=356
 Heating and Air Conditioning

Evacuate R134a System

4. Evacuate system until low-side gauge registers 98

CAUTION: Liquid refrigerant will freeze eyes
kPa (980 mbar) (29 in. Hg) vacuum.
or skin on contact. Wear goggles, gloves
and protective clothing. Specification
Evacuate System—Vacuum .....................................................98 kPa
See Refrigerant Cautions and Proper 980 kPa
Handling. (Group 1830.) 29 in. Hg 18
1830
9
Do not remove high pressure relief valve. Air If above specification vacuum cannot be obtained in 15
conditioning system will discharge rapidly minutes, test the system for leaks. See Refrigerant
causing possible injury. Leak Test. (Group 9031-25.)

1. Connect refrigerant recovery system. See R134a 5. When vacuum reaches above specification, close
Refrigerant Recovery/Recycling and Charging low-side and high-side valves. Turn vacuum pump
Station Installation Procedure. (Group 1830.) off.

2. Open low-side and high-side valves on refrigerant 6. If vacuum decreases more than specification in 5
recovery/recycling and charging station. minutes, there is a leak in system.

3. Follow manufacturers’ instructions and evacuate Specification

Evacuate System—Vacuum ....................................................3.4 kPa
system. 34 mbar
1 in. Hg
NOTE: Vacuum specifications listed are for sea level
conditions. Subtract 3.4 kPa (34 mbar) (1 in. 7. Repair leak.
Hg) from 98 kPa (980 mbar) (29 in. Hg) for
each 300 m (1000 ft) elevation above sea 8. Evacuate system for 30 minutes after 98 kPa (980
level. mbar) (29 in. Hg) vacuum is reached.
Specification
9. Close low-side and high-side valves. Stop
Evacuate System—Vacuum ................Subtract 3.4 kPa from 98 kPa
for each 300 m elevation above evacuation.
sea level
Subtract 34 mbar from 980 10. Perform Charge R134a System. (Group 1830.)
mbar for each 300 m elevation
above seal level
Subtract 1 in. Hg from 29 in.
Hg for each 1000 ft elevation
above sea level

OUOE054,0000031 –19–04MAR03–1/1

TM2256 (09JAN07) 18-1830-9 D Series Motor Grader Repair

020207
PN=357
 Heating and Air Conditioning

Charge R134a System

level). Subtract 3.4 kPa (34 mbar) (1 in. Hg)

CAUTION: Liquid refrigerant will freeze eyes
from 98 kPa (980 mbar) (29 in. Hg) for each
or skin on contact. Wear goggles, gloves
300 m (1000 ft) elevation above sea level.
and protective clothing.
Specification
See Refrigerant Cautions and Proper Evacuate System—Vacuum ................Subtract 3.4 kPa from 98 kPa
18 Handling. (Group 1830.) for each 300 m elevation above
1830 sea level
10 Subtract 34 mbar from 980
IMPORTANT: Use only John Deere approved
mbar for each 300 m elevation
refrigerant recovery/recycling and above seal level
charging stations. DO NOT mix Subtract 1 in. Hg from 29 in.
refrigerant, hoses, fittings, Hg for each 1000 ft elevation
components or refrigerant oils. above sea level

1. Identify refrigerant type using JT02167A Refrigerant 4. Follow manufacturer’s instructions and charge
Identification Instrument. system.

2. Connect R134a Refrigerant Recovery/Recycling 5. Add refrigerant to system.

and Charging Station. See R134a Refrigerant
Recovery/Recycling and Charging Station Specification
Air Conditioning System
Installation Procedure. (Group 1830.) Refrigerant—Refrigerant
Quantity..................................................................................... 2495 g
3. Perform Evacuate R134a System . (Group 1830.) 5.5 lb

NOTE: Before beginning to charge air conditioning 6. Check air conditioning for proper function. See
system, the following conditions must exist: Diagnose Air Conditioning System Malfunctions.
Engine STOPPED, the pump must be capable (Group 9031-25.)
of pulling at least 28.6 in. Hg vacuum (sea

OUOE054,000002E –19–04MAR03–1/1

Compressor Remove and Install

1. Park machine on flat level surface. Lower all

implements to ground.

2. Recover refrigerant. See Recover R134a Refrigerant.

(Group 1800.)

3. Disconnect harness from air conditioner compressor.

Continued on next page LD30992,00000EF –19–07OCT04–1/2

TM2256 (09JAN07) 18-1830-10 D Series Motor Grader Repair

020207
PN=358
 Heating and Air Conditioning

4. Remove refrigerant lines (2 and 3) from compressor.

5. Remove engine accessory belt.

NOTE: Note location of spacers when removing

compressor.

6. Remove cap screws (1) and compressor (4). 18

1830
7. Repair or replace parts as necessary. 11

–UN–10DEC04
8. Install compressor and cap screws.

9. Install refrigerant lines to compressor.

T206123A
Specification
Accumulator-to-Compressor Low
Pressure Line—Torque ..................................................................32 N•m Air Conditioner Compressor
24 lb-ft
1—Cap Screw (3 used)
Specification 2—High Pressure Refrigerant Line
Compressor-to-Condenser High 3—Low Pressure Refrigerant Line
Pressure Line—Torque ..................................................................27 N•m 4—Air Conditioner Compressor
20 lb-ft

10. Install engine accessory belt and connect harness.

11. Evacuate and charge air conditioning system. See

Evacuate R134a System, See Charge R134a System.
(Group 1800.)

LD30992,00000EF –19–07OCT04–2/2

Condenser Remove and Install

1. Park machine on flat level surface. Lower all

implements to ground.

2. Recover refrigerant. See Recover R134a Refrigerant.

(Group 1800.)

Continued on next page LD30992,00000F0 –19–07OCT04–1/2

TM2256 (09JAN07) 18-1830-11 D Series Motor Grader Repair

020207
PN=359
 Heating and Air Conditioning

3. Remove refrigerant lines (4 and 5) from air conditioner

condenser (1).

NOTE: Air conditioner condenser is supported by fan

finger guards.

4. Remove fan finger guard (3) from left side of machine.

18
1830 5. Support air conditioner condenser and remove
12 remaining cap screws from right side fan finger guard.
Remove air conditioner condenser.

6. Repair or replace parts as necessary.

7. Support air conditioner condenser and install to right

side finger guard.

8. Install refrigerant lines.

Specification

–UN–10DEC04
Compressor-to-Condenser High
Pressure Line—Torque ..................................................................27 N•m
20 lb-ft

Specification

T206125A
Condenser-to-Receiver/Dryer
High Pressure Line—Torque ..........................................................16 N•m
144 lb-in.
Air Conditioner Condenser

9. Install left side finger guard and cap screws to air 1—Air Conditioner Condenser
conditioner condenser. 2—Cap Screw (6 used)
3—Fan Finger Guard
10. Evacuate and charge air conditioning system. See 4—Compressor-to-Condenser High Pressure Line
5—Condenser-to-Receiver/Dryer High Pressure
Evacuate R134a System, See Charge R134a System.
Line
(Group 1800.)

LD30992,00000F0 –19–07OCT04–2/2

TM2256 (09JAN07) 18-1830-12 D Series Motor Grader Repair

020207
PN=360
 Heating and Air Conditioning

Heater and Air Conditioner Remove and

Install

1. Park machine on flat level surface. Lower all

implements to ground.

2. Drain engine coolant. See Draining The Cooling

System. (Operator’s Manual.) 18
1830
3. Recover refrigerant. See Recover R134a Refrigerant. 13
(Group 1800.)

4. Remove seat. See Seat Remove and Install. (Group

1800.)

5. Remove floor mat.

6. Loosen cover over transmission control and park brake

lever. See Park/Not Neutral Gear Position Switch
Module (S6) And Forward/Reverse Switch Module
Remove and Install. (Group 9015-20.)

LD30992,00000F1 –19–07OCT04–1/5

7. Loosen front air duct (2) and lift to gain access to seat
base (1) cap screw.

8. Remove cap screws and seat base.

1—Seat Base
2—Front Air Duct

–UN–05JAN05
T206690A

Front Air Duct and Seat Base

Continued on next page LD30992,00000F1 –19–07OCT04–2/5

TM2256 (09JAN07) 18-1830-13 D Series Motor Grader Repair

020207
PN=361
 Heating and Air Conditioning

9. Remove cap screws (5—9) and air intake duct (4) with
filters.

4—Air Intake Duct

5—Cap Screw
6—Cap Screw
7—Cap Screw (2 used)
8—Cap Screw (2 used)
18 9—Cap Screw
1830
14

–UN–05JAN05
T206691A
Air Intake Duct

LD30992,00000F1 –19–07OCT04–3/5

10. Disconnect refrigerant lines from expansion valve

(15). Cap and plug lines.

11. Disconnect heater hot water lines (16) from heater

core.

12. Disconnect harness from blower motor, blower motor

resistor, and air conditioner freeze switch.

15—Expansion Valve

–UN–06JAN05
16—Heater Hot Water Lines

T206739A
Heater Hot Water Lines and Refrigerant Lines

Continued on next page LD30992,00000F1 –19–07OCT04–4/5

TM2256 (09JAN07) 18-1830-14 D Series Motor Grader Repair

020207
PN=362
 Heating and Air Conditioning

13. Remove cap screws (11 and 12).

14. Remove heater and air conditioner.

15. Repair or replace parts as necessary.

–UN–05JAN05
16. Install heater and air conditioner.
18
17. Connect harness, heater hot water lines, and 1830
refrigerant lines to heater and air conditioner. 15

T206692A
18. Install air intake duct.
Air Conditioner and Heater
19. Install seat base and front air duct.
11—Cap Screw (2 used)
12—Cap Screw
20. Install cover around transmission control and park
brake lever. See Park/Not Neutral Gear Position
Switch Module (S6) And Forward/Reverse Switch
Module Remove and Install. (Group 9015-20.)

21. Install seat. See Seat Remove and Install. (Group

1800.)

22. Evacuate and charge air conditioning system. See

Evacuate R134a System, See Charge R134a System.
(Group 1800.)

LD30992,00000F1 –19–07OCT04–5/5

Receiver/Dryer Remove and Install

1. Park machine on flat level surface. Lower all

implements to ground.

2. Recover refrigerant. See Recover R134a Refrigerant.

(Group 1800.)

Continued on next page LD30992,00000F2 –19–07OCT04–1/2

TM2256 (09JAN07) 18-1830-15 D Series Motor Grader Repair

020207
PN=363
 Heating and Air Conditioning

3. Remove refrigerant lines (3 and 4) from receiver/dryer

(1).

4. Remove cap screws (5) and receiver/dryer.

5. Repair or replace parts as necessary.

18 6. Install receiver/dryer and cap screws.

1830
16 7. Install refrigerant lines.

–UN–10DEC04
Specification
Condenser-to-Receiver/Dryer
High Pressure Line—Torque ...................................................14—20 N•m
124—178 lb-in.

T206130A
Specification
Receiver/Dryer-to-Evaporator
High Pressure Line—Torque ...................................................14—20 N•m Receiver/Dryer and Accumulator
124—178 lb-in.
1—Receiver/Dryer
2—Accumulator
8. Evacuate and charge air conditioning system. See 3—Condenser-to-Receiver/Dryer High Pressure
Evacuate R134a System, See Charge R134a System. Line
(Group 1800.) 4—Receiver/Dryer-to-Evaporator High Pressure
Line
5—Cap Screw (2 used)
6—Accumulator-to-Compressor Low Pressure
Line
7—Evaporator-to-Accumulator Low Pressure Line
8—Cap Screw (2 used)

LD30992,00000F2 –19–07OCT04–2/2

Accumulator Remove and Install

1. Park machine on flat level surface. Lower all

implements to ground.

2. Recover refrigerant. See Recover R134a Refrigerant.

(Group 1800.)

Continued on next page LD30992,00000F3 –19–07OCT04–1/2

TM2256 (09JAN07) 18-1830-16 D Series Motor Grader Repair

020207
PN=364
 Heating and Air Conditioning

3. Remove refrigerant lines (6 and 7) from accumulator

(2).

4. Remove cap screws (8) and accumulator.

5. Repair or replace parts as necessary.

6. Install accumulator and cap screws. 18

1830
7. Install refrigerant lines. 17

–UN–10DEC04
Specification
Evaporator-to-Accumulator Low
Pressure Line—Torque ..................................................................39 N•m
29 lb-ft

T206130A
Specification
Accumulator-to-Compressor Low
Pressure Line—Torque ..................................................................42 N•m Receiver/Dryer and Accumulator
31 lb-ft
1—Receiver/Dryer
2—Accumulator
8. Evacuate and charge air conditioning system. See 3—Condenser-to-Receiver/Dryer High Pressure
Evacuate R134a System, See Charge R134a System. Line
(Group 1800.) 4—Receiver/Dryer-to-Evaporator High Pressure
Line
5—Cap Screw (2 used)
6—Accumulator-to-Compressor Low Pressure
Line
7—Evaporator-to-Accumulator Low Pressure Line
8—Cap Screw (2 used)

LD30992,00000F3 –19–07OCT04–2/2

TM2256 (09JAN07) 18-1830-17 D Series Motor Grader Repair

020207
PN=365
 Heating and Air Conditioning

Compressor Clutch Disassemble and

Assemble

18
1830
18

–UN–24JUN92
RW21157
–UN–09MAY97
T107716

A—JDG747 Compressor C—Clutch Hub E—Pulley G—Clutch Coil

Clutch Spanner D—Pulley Snap Ring F—Clutch Coil Snap Ring H—Shims
B—Clutch Shaft Bolt

1. Follow refrigerant cautions and proper handling

procedures. See See Refrigerant Cautions and
Proper Handling. (Group 1800.)

Continued on next page TX19495,0000179 –19–21JAN05–1/3

TM2256 (09JAN07) 18-1830-18 D Series Motor Grader Repair

020207
PN=366
 Heating and Air Conditioning

2. Remove compressor and mount on DFRW20 7. Disconnect clutch coil lead wire. Remove and
Compressor Holding Fixture using two 6 in. x 1/4 in. discard snap ring (F) and remove clutch coil (G).
eye bolts with nuts as illustrated. See Compressor
Remove and Install (Group 1800.) and See NOTE: The bearing in pulley is NOT serviceable.
DFRW20 Compressor Holding Fixture. (Group
9900.) 8. Check pulley bearing operation. Replace pulley and
bearing as required.
3. Remove dust cover. 18
9. Install clutch coil and new snap ring with flat side of 1830
4. Hold clutch hub using JDG747 Compressor Clutch snap ring down. Connect clutch coil lead wire. 19
Spanner (A) and remove clutch shaft bolt (B).
10. Install pulley with new snap ring flat side down.
5. Remove clutch hub (C). Remove shims (H) from
clutch hub and save for installation. 11. Apply grease to shims (H) and install in clutch
hub.
6. Remove and discard snap ring (D). Remove pulley
(E) using a plastic hammer or JDG220 Puller,
JDG748 Jaws, and JDG771 Hub Protector.

TX19495,0000179 –19–21JAN05–2/3

12. Check pulley-to-clutch hub clearance using a dial

indicator. Mount gauge to pulley as illustrated and
connect a set of jumper wires from compressor to a
12V battery.

13. Rotate pulley and check clearance in three equally

spaced locations around clutch hub. Add or remove
shims as required.

Specification
Pulley-to-Clutch Hub—Clearance......................................0.35—0.65 mm
0.014—0.026 in

14. Install clutch hub and tighten shaft bolt to

specification. Install dust cover.

Specification
Clutch Hub and Shaft Bolt—
Torque ............................................................................................ 14 N•m
120 lb-in.
–UN–24JUN92
RW21159

TX19495,0000179 –19–21JAN05–3/3

TM2256 (09JAN07) 18-1830-19 D Series Motor Grader Repair

020207
PN=367
 Heating and Air Conditioning

Compressor Manifold Inspect

1. Remove cap screws (A) and manifold (B).

2. Remove and discard seal (C). Inspect porting surfaces.

3. Lubricate and install a new seal (C).

18
1830 4. Install manifold and tighten cap screws to specification.
20
Specification
Manifold Cap Screws—Torque ......................................................26 N•m
228 lb-in.

–UN–24JUN92
A—Manifold Cap Screw
B—Manifold
C—Manifold Seal

RW21160
TX19495,000017A –19–21JAN05–1/1

Compressor Relief Valve Remove and Install

CAUTION: High pressure may exist at discharge

fitting. If this pressure is released too rapidly,
there may be considerable discharge of
refrigerant and oil.

1. Follow refrigerant cautions and proper handling

procedures. See Refrigerant Cautions and Proper
Handling. (Group 1800.)

Continued on next page TX,18,DU2467 –19–10JUL01–1/2

TM2256 (09JAN07) 18-1830-20 D Series Motor Grader Repair

020207
PN=368
 Heating and Air Conditioning

2. Do system refrigerant recovery. See Recover R134a

Refrigerant. (Group 1800.)

3. Slowly remove relief valve (A) from compressor

manifold.

–UN–26MAR97
NOTE: The relief valve is not serviceable. Replace valve
as required. 18
1830
4. Install relief valve and tighten to specification. 21

T107718
Specification
Compressor Relief Valve—
Torque ................................................................................... 12—16 N•m A—Relief Valve
108—144 lb-in.

5. Evacuate and charge air conditioning system. See

Evacuate R134a System, See Charge R134a System.
(Group 1800.)

TX,18,DU2467 –19–10JUL01–2/2

TM2256 (09JAN07) 18-1830-21 D Series Motor Grader Repair

020207
PN=369
 Heating and Air Conditioning

18
1830
22

TM2256 (09JAN07) 18-1830-22 D Series Motor Grader Repair

020207
PN=370
 Section 19
Sheet Metal and Styling
Contents

Page

Group 1921—Grille and Grille Housing

Grille Housing Remove and Install . . . . . . . .19-1921-1

19

TM2256 (09JAN07) 19-1 D Series Motor Grader Repair

020207
PN=1
 Contents

19

TM2256 (09JAN07) 19-2 D Series Motor Grader Repair

020207
PN=2
 Group 1921
Grille and Grille Housing

Grille Housing Remove and Install

1. Park machine on flat level surface. Lower all

implements to ground.

TX19495,0000108 –19–18JUN04–1/2

2. Remove left and right rear access doors (1).

3. Remove upper and lower grilles (6 and 7).

4. Remove cap screws from top of grille housing.

19
CAUTION: Avoid crushing injury. Use 1921
appropriate lifting device when removing grille 1
housing.

–UN–08DEC04
5. Attach appropriate lifting device to grille housing.

Specification
Grille Housing—Weight ...................................................................103 kg

T206000A
227 lb

6. Remove cap screws (3) and grille housing.

Rear Access Doors, Grille Housing and Grille

7. Repair or replace parts as necessary. 1—Rear Access Door

2—Grille Housing
8. Install grille housing and cap screws. 3—Cap Screw (4 used)
4—Cap Screw (4 used)
5—Cap Screw (4 used)
9. Install upper and lower grilles.
6—Upper Grille
7—Lower Grille
10. Install rear access doors.

TX19495,0000108 –19–18JUN04–2/2

TM2256 (09JAN07) 19-1921-1 D Series Motor Grader Repair

020207
PN=373
 Grille and Grille Housing

19
1921
2

TM2256 (09JAN07) 19-1921-2 D Series Motor Grader Repair

020207
PN=374
 Section 21
Main Hydraulic System
Contents

Page

Group 2160—Hydraulic System

Hydraulic Pump Remove and Install . . . . . . .21-2160-1
Hydraulic Pump Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . . .21-2160-4
Hydraulic System Manifold Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .21-2160-9
Hydraulic System Manifold Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .21-2160-11
Hydraulic Oil Tank Remove and Install . . . .21-2160-13
Attenuator Remove and Install . . . . . . . . . .21-2160-15 21
Soft Start Valve Remove and Install . . . . . .21-2160-16
Soft Start Valve Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .21-2160-18

TM2256 (09JAN07) 21-1 D Series Motor Grader Repair

020207
PN=1
 Contents

21

TM2256 (09JAN07) 21-2 D Series Motor Grader Repair

020207
PN=2
 Group 2160
Hydraulic System

Hydraulic Pump Remove and Install

CAUTION: Prevent possible injury from

unexpected machine movement. Install
articulation lock pin when machine is raised or
when working in articulation joint area.

1. Install articulation lock pin. See Locking Machine

Frame. (Operator’s Manual.)

2. Remove left rear side door.

3. Drain hydraulic tank. See Drain and Refill Capacities.

(Operator’s Manual.)

4. Loosen front hydraulic tank mounting cap screws.

21
TX,21,DU2559 –19–10OCT03–1/3 2160
1

5. Support hydraulic tank with supporting jack (2).

Remove hydraulic tank support leg mounting screws
and remove leg.

6. Disconnect all lines at hydraulic pump and HFWD

charge pump (if equipped). Mark lines for ease of

–UN–04DEC04
assembly. Cap and plug all openings.

7. Remove hydraulic pump mounting cap screws (5).

T205757A
1—Hydraulic Tank
2—Supporting Jack
3—Hydraulic Pump Hydraulic Pump Remove and Install
4—HFWD Charge Pump
5—Hydraulic Pump Mounting Cap Screws (4 used)

Continued on next page TX,21,DU2559 –19–10OCT03–2/3

TM2256 (09JAN07) 21-2160-1 D Series Motor Grader Repair

020207
PN=377
 Hydraulic System

CAUTION: Heavy component. Prevent crushing

injury, use lifting device.

8. Slide pump back to disengage coupler and remove

assembly from machine.

–UN–04DEC04
Specification
Hydraulic Pump—Weight ..................................................................36 kg
80 lb
Hydraulic Pump with HFWD

T205759A
Charge Pump—Weight...................................................................50.3 kg
111 lb

9. Remove HFWD charge pump from rear of hydraulic 1—Hydraulic Tank

pump (if equipped), and lay aside. See HFWD Charge 2—Pump Supporting Device
Pump Remove and Install. (Group 0260.) 3—Hydraulic Pump
4—HFWD Charge Pump
10. Repair pump as necessary.

21 NOTE: Fill pump case with oil before startup.

2160
2
11. Install charge pump to hydraulic pump. See HFWD
Charge Pump Remove and Install. (Group 0260.)

12. Install pump assembly into transmission charge pump

while engaging coupler. Tighten hydraulic pump
mounting screws to specification.

Specification
Hydraulic Pump-to-Transmission
Charge Pump Cap Screws—
Torque .......................................................................................... 237 N•m
175 lb-ft

13. Install hydraulic tank support leg using cap screws.

Remove jack, tighten front support cap screws.

14. Fill hydraulic tank. See Drain and Refill Capacities.

(Operator’s Manual.)

15. Remove articulation lock pin.

TX,21,DU2559 –19–10OCT03–3/3

TM2256 (09JAN07) 21-2160-2 D Series Motor Grader Repair

020207
PN=378
 Hydraulic System

21
2160
3

TM2256 (09JAN07) 21-2160-3 D Series Motor Grader Repair

020207
PN=379
 Hydraulic System

Hydraulic Pump Disassemble and Assemble

21
2160
4

–UN–10DEC04
T201567

Hydraulic Pump Assembly

Continued on next page CED,OUOE027,212 –19–15SEP03–1/6

TM2256 (09JAN07) 21-2160-4 D Series Motor Grader Repair

020207
PN=380
 Hydraulic System

1—Cap Screw (4 used) 10—Fitting Plug (2 used) 23—Sleeve (used with 52—Spool
2—Washer (4 used) 11—O-Ring auxiliary drive) 53—O-Ring
3—O-Ring (used with auxiliary 12—Bearing Kit 24—Seal 54—O-Ring (4 used)
drive) 13—Valve Plate 25—Snap Ring 55—Screw (4 used)
4—Cap Screw (4 used with 14—Rotate Group 26—Snap Ring (used with 57—O-Ring (2 used)
auxiliary drive) 15—Drive Shaft auxiliary drive) 58—Plug Fitting (2 used)
5—Adapter Plate (auxiliary 16—Swashplate 30—O-Ring 59—O-Ring (2 used)
drive) 17—Bearing Kit 40—Backup Ring 60—Plug (2 used)
6—Coupler (4 used with 18—Bias Piston Assembly 41—O-Ring 61—Spring
auxiliary drive) 19—Swashplate Bearing (2 42—O-Ring 62—O-Ring
7—Plug (3 used) used) 48—Load Sense Control 63—O-Ring
8—Screw (4 used with 20—Plug Assembly 70—Hydraulic Pump Assembly
auxiliary drive) 21—O-Ring 49—Cap Screw 71—Seal Assembly
9—Seal Kit 22—O-Ring (6 used)

21
CED,OUOE027,212 –19–15SEP03–2/6 2160
5

1. Mark pump housing as shown to show orientation to

pump end cap (9) and location of control piston.

IMPORTANT: Loosen set screw before removing

components.

–UN–16NOV01
2. Remove load sense control valve (48). Replace parts
as necessary.

3. Position pump upright on table. Remove pump end

T146629B
cover (9) for pump.

Locating Marks on Pump

9—Pump End Cover
31—Pump Housing
30—Control Piston Cap

Continued on next page CED,OUOE027,212 –19–15SEP03–3/6

TM2256 (09JAN07) 21-2160-5 D Series Motor Grader Repair

020207
PN=381
 Hydraulic System

IMPORTANT: Mark orientation of valve plate before

disassembly.

4. Remove valve plate (13) carefully. Make sure that gap

in timing pin (32) faces either directly towards or
directly away from center of end cover.

–UN–16NOV01
5. Inspect valve plate of cracks or scratches. Valve plate
thickness must be no less than specification.

T146607B
Specification
Valve Plate—Thickness..............................................................4.950 mm
0.195 in
Valve Plate and Timing Pin

6. Remove bias piston assembly (18). Replace parts as 13—Valve Plate

necessary. 32—Dowel Pin

7. Remove control piston. Inspect for damage in the bore

and on the piston. If it is damaged. Replace pump
21 assembly.
2160
6

Continued on next page CED,OUOE027,212 –19–15SEP03–4/6

TM2256 (09JAN07) 21-2160-6 D Series Motor Grader Repair

020207
PN=382
 Hydraulic System

8. Position pump on its side. Slowly remove drive shaft

(15) and rotate group so that pistons (33) do not come
out of cylinder block (14).

9. Remove drive shaft from rotate group. Inspect splines

for wear or damage.

–UN–16NOV01
10. Inspect rotate group. Check slippers for wear and
excessive end play. Check cylinder block height.

T146620B
Specification
Piston Slipper Foot Thickness—
Thickness (minimum) ................................................................... 2.23 mm
Rotate Group and Shaft
0.127 in.
14—Cylinder Block
Specification 15—Drive Shaft
Slipper End Play—Thickness 33—Pistons
(minimum) ................................................................................... 0.102 mm
0.004 in.

Specification 21
Cylinder Block Height—Thickness .............................................62.23 mm 2160
2.450 in. 7

NOTE: Mark swash plate orientation before disassembly.

11. Position pump upright. Remove swash plate (16).

IMPORTANT: Mark orientation and location of swash

plate bearings before disassembly.

12. Remove swash plate bearings (19). Replace if

necessary.

13. Remove and inspect all bearing and bearing cups.

Replace as needed.

14. Remove retaining ring (25) and shaft seal (24).

Replace if necessary.

15. Clean and lubricate all pump components before

assembly.

16. Install front bearing kit (17).

17. Install swash plate bearings in original location and

orientation.

18. Install swash plate in its original orientation.

Continued on next page CED,OUOE027,212 –19–15SEP03–5/6

TM2256 (09JAN07) 21-2160-7 D Series Motor Grader Repair

020207
PN=383
 Hydraulic System

19. Install pump drive shaft.

20. Install control piston. Tighten plug to specification.

Specification
Control Piston Plug—Torque........................................................230 N•m
170 lb-ft

21. Install bias piston assembly (18). Tighten plug to

specification.

Specification
Bias Piston Assembly Plug—
Torque .......................................................................................... 230 N•m
170 lb-ft

22. Position pump on side. Install rotate group.

NOTE: Rotate group should be flush with shoulder of

21
drive shaft when installed.
2160
8 23. Install bearing kit (12).

24. Install valve plate (13) in its original orientation.

25. Install end cap (9). Tighten cap screws (7) to

specification.

Specification
Main Hydraulic Pump End
Cap-to-Pump Housing Cap
Screw—Torque ...............................................................................96 N•m
71 lb-ft

26. Install load sense control valve assembly (48).

CED,OUOE027,212 –19–15SEP03–6/6

TM2256 (09JAN07) 21-2160-8 D Series Motor Grader Repair

020207
PN=384
 Hydraulic System

Hydraulic System Manifold Remove and

Install

CAUTION: Prevent possible injury from

unexpected machine movement. Install
articulation lock pin when machine is raised or
when working in articulation joint area.

1. Install articulation lock pin. See Locking Machine

Frame. (Operator’s Manual.)

2. Install vacuum pump to hydraulic tank. See Vacuum

Pump Installation. (Group 9025-25.)

3. Locate hydraulic system manifold under the right side

of the cab. See Hydraulic System Component
Location. (Group 9025-05.)
21
4. Remove lines and mark for ease of assembly. 2160
9
5. Cap all lines and plug all openings.

Continued on next page MX10672,0000149 –19–14JAN05–1/2

TM2256 (09JAN07) 21-2160-9 D Series Motor Grader Repair

020207
PN=385
 Hydraulic System

6. Remove electrical connector (2) from lock pin solenoid

(3).

7. Remove three hydraulic system manifold mounting

bracket (6) cap screws and pull manifold out and away
from frame to access two lines to left control valve

–UN–08DEC04
assembly.

8. Remove remaining lines from the hydraulic system

manifold. Cap lines and plug openings.

T205920A
9. Replace or repair parts as needed.
Hydraulic System Manifold
10. Support hydraulic system manifold and connect two
1—Hydraulic System Manifold
hydraulic lines from left control valve assembly to left 2—Electrical Connector
side of manifold. 3—Lock Pin Solenoid
4—Lock Pin Pressure Reducing Valve
11. Install three mounting cap screws through manifold 5—Hydraulic System Relief Valve
6—Hydraulic System Manifold Mounting Bracket
21 bracket to frame.
2160
10 12. Install the remaining hydraulic lines to manifold.

13. Install electrical connector to lock pin solenoid.

14. Remove vacuum pump from hydraulic tank.

15. Check hydraulic oil level. See Checking Hydraulic

Tank Oil Level. (Operator’s Manual.)

16. Remove articulation lock pin.

MX10672,0000149 –19–14JAN05–2/2

TM2256 (09JAN07) 21-2160-10 D Series Motor Grader Repair

020207
PN=386
 Hydraulic System

Hydraulic System Manifold Disassemble and

Assemble

CAUTION: Escaping fluid under pressure can

penetrate the skin causing serious injury. Avoid
the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure
fluids.

If an accident occurs, see a doctor immediately.

Any fluid injected into the skin must be
surgically removed within a few hours or
gangrene may result. Doctors unfamiliar with
this type of injury may call the Deere &
Company Medical Department in Moline, Illinois,
21
or other knowledgeable medical source. 2160
11

–UN–11JAN05
1. Install vacuum pump to hydraulic [Link] Vacuum
Pump Installation. (Group 9025-25.)

2. Locate hydraulic system manifold under the right side

T206602
of the cab. See Hydraulic System Component
Location. (Group 9025-05.)
1—Lock Pin Pressure Reducing Valve
3. Remove hydraulic system relief valve (3) and lock pin 2—Seal Kit
pressure reducing valve (1) from hydraulic system 3—Hydraulic System Relief Valve
manifold (9). 4—Seal Kit
5—Saddle Lock Pin Valve
6—Seal Kit
NOTE: Hydraulic system relief valve and lock pin
7—Saddle Lock Pin Solenoid
pressure reducing valve are not serviceable. 8—Nut
9—Hydraulic Systems Manifold
4. Install new hydraulic system relief valve and lock pin
pressure reducing valve as needed.

5. Disconnect wiring from saddle lock pin solenoid.

6. Remove nut (8) from saddle lock pin solenoid (7).

7. Remove saddle lock pin solenoid from saddle lock pin

valve (5).

8. Remove saddle lock pin valve.

Continued on next page JL45346,000000F –19–19JAN05–1/2

TM2256 (09JAN07) 21-2160-11 D Series Motor Grader Repair

020207
PN=387
 Hydraulic System

NOTE: Lock pin valve and solenoid are not serviceable.

9. Replace as needed.

10. Install saddle lock pin valve into hydraulic system

manifold and tighten to specification.

Specification
Saddle Locking Pin Valve to
Manifold—Torque ..............................................................25.8—28.5 N•m
228—252 lb-in.

11. Install saddle lock pin solenoid.

12. Tighten solenoid retaining nut to specification.

Specification
Saddle Lock Pin Solenoid
Retaining Nut—Torque ..........................................................5.4—6.8 N•m
48—60 lb-in
21
2160
12 13. Remove vacuum pump from hydraulic tank.

14. Check hydraulic oil level in tank. See Drain and Refill
Capacities. (Operator’s Manual.)

JL45346,000000F –19–19JAN05–2/2

TM2256 (09JAN07) 21-2160-12 D Series Motor Grader Repair

020207
PN=388
 Hydraulic System

Hydraulic Oil Tank Remove and Install

CAUTION: Prevent possible injury from

unexpected machine movement. Install
articulation lock pin when machine is raised or
when working in articulation joint area.

1. Install articulation lock pin. See Locking Machine

Frame. (Operator’s Manual.)

2. Drain hydraulic oil tank. See Drain and Refill

Capacities. (Operator’s manual.)

CAUTION: Avoid crushing injury. Use lifting

device.

3. Remove hood covering fuel tank and hydraulic oil tank.

21
Specification 2160
Hydraulic Tank Cover—Weight ......................................................34.5 kg 13
76 lb

Continued on next page DW09104,0000065 –19–30MAY03–1/2

TM2256 (09JAN07) 21-2160-13 D Series Motor Grader Repair

020207
PN=389
 Hydraulic System

4. Remove clamping hardware (2) from intercooler hose

(3) and upper radiator hose (4) on right side of
hydraulic tank.

5. Remove electrical harness and tank vent tubes from

top left side of hydraulic oil tank.

–UN–09DEC04
6. Remove all hoses from tank. Mark all lines for ease of
assembly. Cap and plug all openings.

T206039A
7. Remove hydraulic tank mounting hardware from both
sides and top of tank.
Hydraulic Oil Tank Hose Clamps

CAUTION: Avoid possible crushing injury, use 1—Hydraulic Oil Tank

appropriate lifting device. 2—Clamping Hardware
3—Intercooler Hose
4—Upper Radiator Hose
Specification
Hydraulic Oil Tank—Weight ............................................................. 90 kg
21 200 lb
2160
14 8. Remove hydraulic tank by moving it to the left to clear
hoses over the right side of tank.

9. Replace or repair as necessary.

10. Install tank and mounting hardware.

11. Connect all hydraulic hoses.

12. Install electrical harness and tank vent tubes to top

left side of hydraulic oil tank.

13. Install air and coolant supply tube clamping hardware

on right side of hydraulic oil tank.

CAUTION: Avoid crushing injury. Use lifting

device.

14. Install hood covering fuel tank and hydraulic oil tank.

15. Fill hydraulic oil tank. See Drain and Refill Capacities.
(Operator’s manual.)

16. Remove articulation lock pin.

DW09104,0000065 –19–30MAY03–2/2

TM2256 (09JAN07) 21-2160-14 D Series Motor Grader Repair

020207
PN=390
 Hydraulic System

Attenuator Remove and Install

CAUTION: Prevent possible injury from

unexpected machine movement. Install
articulation lock pin when machine is raised or
when working in articulation joint area.

1. Install articulation lock pin. See Locking Machine

Frame. (Operator’s Manual.)

2. Install vacuum pump to hydraulic tank. See Vacuum

Pump Installation. (Group 9025-25.)

CAUTION: Prevent possible injury from

crushing. Use appropriate lifting device.

3. Remove rear access plate mounting hardware and

remove plate. 21
2160
Specification 15
Rear Access Plate—Weight ...........................................................22.7 kg
50 lb

4. Locate attenuator below the cooling package. See

Hydraulic System Component Location. (Group
9025-05.)

5. Remove two hydraulic lines. Cap and plug all

openings. Remove attenuator mounting hardware and
remove attenuator.

6. Replace attenuator.

7. Install mounting hardware.

8. Install rear access plate.

9. Remove vacuum pump from hydraulic tank.

10. Check hydraulic oil level in tank. See Drain and Refill
Capacities. (Operator’s Manual.)

11. Remove articulation lock pin.

OUT3035,0000427 –19–19JAN05–1/1

TM2256 (09JAN07) 21-2160-15 D Series Motor Grader Repair

020207
PN=391
 Hydraulic System

Soft Start Valve Remove and Install

CAUTION: Prevent possible injury from

unexpected machine movement. Install
articulation lock pin when machine is raised or
when working in articulation joint area.

1. Install articulation lock pin. See Locking Machine

Frame. (Operator’s Manual.)

2. Install vacuum pump to hydraulic [Link] Vacuum

Pump Installation. (Group 9025-05.)

3. Remove hydraulic lines to the soft start valve. Mark for

ease of assembly. Cap and plug all openings.

4. Disconnect electrical harness at connector.

21 5. Remove two mounting cap screws and remove valve

2160
16
assembly.

6. Replace or repair as [Link] Soft Start Valve

Disassemble and Assemble. (Group 2160.)

7. Mount valve with two cap screws.

8. Connect electrical harness to solenoid.

9. Install all hydraulic lines to valve.

10. Remove vacuum pump from hydraulic tank.

11. Check hydraulic oil level in tank. See Drain and Refill
Capacities. (Operator’s Manual.)

12. Remove articulation lock pin.

MX10672,0000150 –19–19JAN05–1/1

TM2256 (09JAN07) 21-2160-16 D Series Motor Grader Repair

020207
PN=392
 Hydraulic System

21
2160
17

TM2256 (09JAN07) 21-2160-17 D Series Motor Grader Repair

020207
PN=393
 Hydraulic System

Soft Start Valve Disassemble and Assemble

21
2160
18

–UN–29NOV04
T205434

Soft Start Valve

Continued on next page MX10672,0000151 –19–14JAN05–1/2

TM2256 (09JAN07) 21-2160-18 D Series Motor Grader Repair

020207
PN=394
 Hydraulic System

1—Solenoid Valve 4—Seal Kit 6—Mounting Parts 8—Housing

2—Solenoid 5—Electrical Proportional 7—Solenoid Kit
3—Nut Valve

1. Remove solenoid retaining nut (3) from valve 5. Replace valve seals (4) and install valve into
assembly. housing.

2. Slide solenoid from valve (1). 6. Install solenoid (2) over valve and install solenoid
retaining nut (3).
3. Unscrew valve (1) from housing.

4. Inspect valve for damage, replace if scratched or

damaged.

21
MX10672,0000151 –19–14JAN05–2/2 2160
19

TM2256 (09JAN07) 21-2160-19 D Series Motor Grader Repair

020207
PN=395
 Hydraulic System

21
2160
20

TM2256 (09JAN07) 21-2160-20 D Series Motor Grader Repair

020207
PN=396
 Section 34
Grading Device
Contents

Page Page

Group 3415—Controls Linkage Blade Lift, Blade Tilt and Circle Side Shift
Steering Support Console Remove and Cylinders Remove and Install . . . . . . . . .34-3460-21
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .34-3415-2
Steering Tilt Assembly Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .34-3415-4
Console Tilt Remove and Install . . . . . . . . . .34-3415-5

Group 3440—Frames
Lift Arms, Saddle Frame and Locking Pin
Bracket Remove and Install . . . . . . . . . . . .34-3440-2
Draft, Circle, and Blade Tilt Frame Remove
and Install . . . . . . . . . . . . . . . . . . . . . . . . .34-3440-6
Circle Adjustment . . . . . . . . . . . . . . . . . . . . .34-3440-9
Blade Side Shift Wear Inserts Install and
Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . .34-3440-12
34
Blade Side Shift Clearance Measure and
Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . .34-3440-15

Group 3450—Circle Gearbox

Circle Drive Gearbox Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . . .34-3450-2
Circle Drive Gearbox (With Slip Clutch)
Disassemble and Assemble. . . . . . . . . . . .34-3450-6

Group 3460—Hydraulic System

Grader Control Valve Remove and Install . . .34-3460-1
Grader Control Valve Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . . .34-3460-4
Midmount Scarifier Valve Section
Disassemble and Assemble. . . . . . . . . . . .34-3460-6
Blade Lift Valve Section Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . . .34-3460-8
Scarifier or Ripper Valve Section
Disassemble and Assemble. . . . . . . . . . .34-3460-10
Blade Side Shift, Blade Tilt, Articulation,
Wheel Lean, or Circle Side Shift Valve
Section Disassemble and Assemble . . . .34-3460-12
Circle Rotate Valve Section Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .34-3460-14
Return Check Poppets Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .34-3460-15
Rotate Motor Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .34-3460-16
Rotary Manifold Remove and Install . . . . . .34-3460-19
Rotary Manifold Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .34-3460-20

TM2256 (09JAN07) 34-1 D Series Motor Grader Repair

020207
PN=1
 Contents

34

TM2256 (09JAN07) 34-2 D Series Motor Grader Repair

020207
PN=2
 Group 3415
Controls Linkage

34
3415
1

TM2256 (09JAN07) 34-3415-1 D Series Motor Grader Repair

020207
PN=399
 Controls Linkage

Steering Support Console Remove and Install

34
3415
2

–UN–18DEC04
T204228

Steering Support
Continued on next page T55,33415,J3 –19–19JAN05–1/2

TM2256 (09JAN07) 34-3415-2 D Series Motor Grader Repair

020207
PN=400
 Controls Linkage

1—Screw (4 used) 14—Control Support 25—Washer (4 used) 38—Isolator

2—Screw (6 used) 15—Bushing (8 used) 26—Adapter 39—Nut (4 used)
3—Cotter Pin (2 used) 16—Bracket 27—Lever 40—Nut (4 used)
4—Flange Nut (9 used) 17—Plate 28—Pin Fastener 41—Self-Locking Screw (4
5—Screw (8 used) 18—Bushing (8 used) 29—Extension Spring (2 used) used)
6—Screw 19—Bracket 32—Shaft 42—Self-Locking Screw (4
7—Set Screw (5 used) 20—Plate (2 used) 33—Spacer (5 used) used)
9—Washer (9 used) 21—Cover 34—Spacer 43—Screw (4 used)
10—Spring Pin 22—Lever 35—Grommet 44—Nut (4 used)
11—Control Support 23—Gas Operated Cylinder 36—Cap 45—Cover
12—Control Support 24—Nut 37—Pin Fastener (2 used) 46—Cover
13—Bracket

1. Disconnect control rods at upper ball joints. 8. Remove control supports, and steering brackets.

2. Remove console cover (46), side cover (21) and 9. Inspect and replace parts as necessary.
side cover (45).
10. Install steering supports, steering brackets, control
3. Disconnect electrical switches connected to console lever shaft, gas operated cylinder, and inching
cover. pedals.

4. Remove steering valve. See Steering Wheel, 11. Install steering valve. See Steering Wheel,
Column, and Valve Remove and Install. (Group Column, and Valve Remove and Install. (Group
0960.) 0960.)

5. Remove control levers and shaft (32). 12. Install control levers.
34
3415
6. Remove inching pedal. 13. Connect electrical switches to console cover. 3

NOTE: Position steering column so the gas cylinder is 14. Install console cover and side covers.
in the most compressed position. This will aid
in the assemble of the steering console. 15. Connect control rods at upper ball joints.

7. Remove gas operated cylinder (13).

T55,33415,J3 –19–19JAN05–2/2

TM2256 (09JAN07) 34-3415-3 D Series Motor Grader Repair

020207
PN=401
 Controls Linkage

Steering Tilt Assembly Remove and Install

–UN–14JAN05
34
3415
4

T206946
T206946
Tilt Steering

Remove console assembly and steering supports to Thoroughly clean and inspect all parts for wear or
remove steering tilt assembly. See Steering Support damage. Replace parts as necessary.
Console Remove and Install. (Group 3415.)
T55,3415,M2 –19–21JAN05–1/1

TM2256 (09JAN07) 34-3415-4 D Series Motor Grader Repair

020207
PN=402
 Controls Linkage

Console Tilt Remove and Install

NOTE: Position steering column so the gas cylinder is in

the retracted position. This will aid in the
assemble of the tilt console.

Replace gas operated cylinder and gas release lever as

necessary.

–UN–14JAN05
T206947
34
3415
5
Console Tilt

T55,3415,M3 –19–12JAN05–1/1

TM2256 (09JAN07) 34-3415-5 D Series Motor Grader Repair

020207
PN=403
 Controls Linkage

34
3415
6

TM2256 (09JAN07) 34-3415-6 D Series Motor Grader Repair

020207
PN=404
 Group 3440
Frames

34
3440
1

TM2256 (09JAN07) 34-3440-1 D Series Motor Grader Repair

020207
PN=405
 Frames

Lift Arms, Saddle Frame and Locking Pin Bracket Remove and Install

34
3440
2

–UN–08DEC04
T203298

Lift Arms, Saddle Frame and Locking Pin Bracket

Continued on next page CED,OUOE027,226 –19–19JAN05–1/5

TM2256 (09JAN07) 34-3440-2 D Series Motor Grader Repair

020207
PN=406
 Frames

1—Nut (4 used) 12—Bracket 25—Lubrication Fitting (8 33—Rear Saddle Pin

2—Nut 14—Angle used) 34—Saddle Frame
3—Cap Screw (4 used) 15—Left Saddle Arm Kit 26—Lubrication Fitting (2 35—Saddle Lock Pin Bracket
4—Cap Screw (8 used) 16—Saddle Arm Kit Bushing used) 36—Washer (4 used)
5—Cap Screw (4 used) 17—Right Saddle Arm Kit 27—Saddle Lock Index Pointer 37—Bushing (4 used)
6—Cap Screw (2 used) 18—Saddle Lock Bar 28—Washer (8 used) 38—Pin Fastener
7—Cap Screw (2 used) 20—Bushing (2 used) 29—Pin (2 used) 39—Ball
8—Cap Screw (8 used) 21—Yoke (2 used) 30—Washer (4 used) 40—Shim (as required)
9—Washer (4 used) 22—Lock Washer (4 used) 31—Retainer (2 used) 41—Thrust Washer (2 used)
10—Washer (8 used) 23—Cap Screw (4 used) 32—Front Saddle Pin 42—Cap Screw (4 used)
11—Washer (4 used) 24—Lubrication Fitting (2
used)

4. Disconnect hydraulic lines at saddle lock pin

CAUTION: To avoid injury from escaping
cylinder. Cap and seal lines.
fluid under pressure, stop engine and relieve
the pressure in the system before
5. Disconnect electrical connector to saddle lock pin
disconnecting or connecting hydraulic or
cylinder.
other lines. Tighten all connections before
applying pressure.
6. Remove hydraulic cylinders.
1. Lower blade to ground and relieve hydraulic
7. Remove cap screws (5), retainer (31) and yoke
pressure.
(21).

CAUTION: Avoid crushing injury. Use a 8. Remove cap screws (6 and 7), pin fastener (38),
lifting device. ball (39) and saddle locking bar (18).
34
3440
2. Retract saddle locking pin. 9. Remove cap screws (4), pins (29) and saddle arms 3
(15 and 17).
Specification
Lift Arm—Approximate Weight .................................................132 kg
10. Remove saddle locking pin cylinder.
291 lb

Specification 11. Remove cap screws (8) and saddle locking pin
Locking Crossbar— bracket (35).
Approximate Weight ................................................................... 44 kg
97 lb 12. Remove cap screws (42), saddle pins (32 and 33)
and saddle frame (34).
Specification
Saddle Frame—Approximate
Weight ....................................................................................... 106 kg 13. Inspect and replace parts as necessary.
234 lb
14. Install cylinder bore bushings (16) even with end
Specification of bore.
Lock Pin Bracket—Approximate
Weight ......................................................................................... 55 kg
15. Install saddle frame, saddle pins (32 and 33) and
121 lb
cap screws (42).
3. Support lift arms (15 and 17), locking crossbar (18),
16. Install saddle locking pin bracket and cap screws
saddle frame (34) and locking pin bracket (35) with
(8).
lifting straps and hoist.

Continued on next page CED,OUOE027,226 –19–19JAN05–2/5

TM2256 (09JAN07) 34-3440-3 D Series Motor Grader Repair

020207
PN=407
 Frames

17. Tighten rear then front cap screws (8) to initial 24. Install saddle locking bar (18), ball (39), pin
torque specification. Repeat sequence and tighten fastener (38) and cap screws (6 and 7).
to final torque specification.
25. Install hydraulic cylinders.
Specification
Saddle Lock Bar Cap Screws— 26. Connect hydraulic lines and electrical connector to
Initial Torque ............................................................................ 28 N•m
21 lb-ft
saddle lock pin cylinder.
Final Torque........................................................................... 229 N•m
169 lb-ft 27. Apply John Deere NEVER-SEEZ Lubricant or an
equivalent to saddle locking pin.
18. Install saddle arms (15 and 17), pins (29) and cap
screws (4). 28. Put saddle locking pin in center hole of locking
crossbar. Assemble pointer (27) to specification.
19. Install thrust washer (41) with chamfer toward Put pointer in middle drill point on saddle.
yoke shaft radius for clearance.
Specification
20. Install yoke (21), retainer (31) and cap screws (5). Rear Face of Saddle
Frame-to-Pointer—Clearance .........................................6.4—9.5 mm
1/4—3/8 in.
21. Check function of saddle locking pin cylinder
before installing on machine.

22. Install saddle locking pin cylinder and shims (40).

23. Apply a heavy coat of John Deere NEVER-SEEZ

34 Lubricant or an equivalent to locking crossbar
3440
4
holes.

NEVER-SEEZ is a trademark of Emhart Chemical Group. CED,OUOE027,226 –19–19JAN05–3/5

29. Move lift arm (3) past locking pin bracket (4) and
install locking pin into saddle lock bar.

1—Saddle Locking Pin Cylinder

2—Saddle Lock Bar
3—Lift Arm
–UN–10DEC04

4—Saddle Lock Pin Bracket

T206113A

Lift Arms, Saddle Frame and Saddle Lock Pin Assembly

Continued on next page CED,OUOE027,226 –19–19JAN05–4/5

TM2256 (09JAN07) 34-3440-4 D Series Motor Grader Repair

020207
PN=408
 Frames

30. Remove or install shims (40) to provide correct saddle

locking pin cylinder-to-saddle lock bar gap
specification.

Specification
Saddle Locking Pin

–UN–24MAY89
Cylinder-to-Saddle Lock Bar
Gap—Gap ................................................................................0.3—2 mm
0.01—0.08 in.

T6451BM
A—Lift Arm Pad
B—Specified Gap
C—Shim (As required)
D—Locking Pin Cylinder Saddle Locking Pin Gap Adjustment

CED,OUOE027,226 –19–19JAN05–5/5

34
3440
5

TM2256 (09JAN07) 34-3440-5 D Series Motor Grader Repair

020207
PN=409
 Frames

Draft, Circle, and Blade Tilt Frame Remove and Install

34
3440
6

–UN–24JAN05
T206927

Draft, Circle, and Blade Tilt Frame

Continued on next page CED,OUOE027,230 –19–21JAN05–1/3

TM2256 (09JAN07) 34-3440-6 D Series Motor Grader Repair

020207
PN=410
 Frames

1—Lock Washer (10 used) 12—Bushing (12 used) 23—Cap Screw (2 used) 34—Shim
2—Nut (12 used) 13—Bushing (6 used) 24—Cap Screw (18 used) 35—Shim
3—Cap Screw (2 used) 14—Bolt (12 used front) 25—Insert (6 used) 36—Bushing (6 used)
4—Cap Screw (10 used) 15—Retainer 26—Plate (6 used) 37—Blade Tilt Frame
5—Cap Screw (6 used) 16—Retainer 27—Washer (12 used) 38—Cap Screw (6 used)
6—Cap Screw (12 used) 17—Washer (8 used) 28—Cap Screw (12 used) 39—Washer (6 used)
7—Draft Frame 18—Shim 29—Washer (18 used) 40—Cap Screw (24 used)
8—Ball (3 used) 19—Circle Frame 30—Pin (2 used) 41—Insert (8 used)
9—Lubrication Fitting 20—Insert (15 used) 31—Lock Nut (2 used) 42—Support (6 used)
10—Washer (6 used rear) 21—Washer (2 used) 32—Washer (2 used) 43—Retainer (2 used)
11—Cap Screw (6 used) 22—Bushing (4 used) 33—Washer

1. Move draft frame (7) to one side and then lower 5. Remove moldboard from tilt frame.
blade to the ground.
6. Remove hydraulic lines.
CAUTION: To avoid injury from escaping
7. Remove hydraulic tilt cylinder and hydraulic side
fluid under pressure, stop engine and relieve
shift cylinder.
the pressure in the system before
disconnecting or connecting hydraulic or
8. Remove cap screws (23), lock nuts (31) and pin
other lines. Tighten all connections before
(30) holding blade tilt frame-to-circle frame.
applying pressure.
9. Remove tilt frame (37) from circle frame (19).
2. Relieve hydraulic pressure.
10. Disconnect hydraulic cylinders at balls (8).
CAUTION: Avoid crushing injury. Use lifting
34
device. 11. Remove retainer (16). 3440
7
3. Support components using lifting straps and a hoist. 12. Inspect retainer (15) for wear and replace as
needed. Lubricate and torque retainer cap screws
Specification (5).
Draft Frame—Approximate
Weight ....................................................................................... 615 kg
Specification
1356 lb
Retainer-to-Draft Frame Cap
Screws—Torque ...........................................................488—597 N•m
Specification 360—440 lb-ft
Circle Frame—Approximate
Weight ....................................................................................... 560 kg
1235 lb 13. Remove rotary manifold and circle drive gear box.
.
Specification
Blade Tilt Frame—Approximate 14. Position draft frame and circle frame so circle
Weight ....................................................................................... 140 kg frame is on top.
308 lb

15. Remove cap screws (24) and supports (42).

Specification
Moldboard—Approximate
Weight ...................................................................................... 953 kg 16. Clean and inspect parts. Repair or replace parts
2100 lb as necessary.

4. Remove retainers (43) from blade tilt frame.

Continued on next page CED,OUOE027,230 –19–21JAN05–2/3

TM2256 (09JAN07) 34-3440-7 D Series Motor Grader Repair

020207
PN=411
 Frames

17. To replace bushings (36) use 30-ton hydraulic NOTE: Shims (34) are used to center the tilt frame
pusher/puller. between the circle frame. Washers (33) are
used to reduce the excess play in the pins
18. Install support (42) and cap screw (24). Tighten to (30). Shims and washers should be able to
specification. rotate freely.

Specification 25. Install pin (30) through circle frame, shims (34), tilt
Support-to-Draft Frame Cap frame and washers (33).
Screws—Torque ......................................................................54 N•m
40 lb-ft
26. Install cap screws (23), washers (20), washers
19. Reposition circle frame and draft frame so draft (22) and nuts (31).
frame is on top.
Specification
Blade Tilt Frame-to-Circle
20. Install rotary manifold and circle drive gear box. Frame Cap Screw Nut—Torque ............................................800 N•m
590 lb-ft
21. Install shims (17) and retainer (16) to draft frame
ball assembly to permit turning by hand. Lubricate 27. Install hydraulic tilt cylinder and hydraulic side shift
assembly. Apply John Deere NEVER-SEEZ cylinder.
Lubricant or an equivalent to retainer (15).
28. Place moldboard onto tilt frame and install retainer
22. Adjust ball assembly end play to specification. and cap screws.

Specification 29. Adjust circle frame to draft frame. See Circle

Draft Frame Ball Assembly— Adjustment. (Group 3440.)
34 Maximum End Play.................................................................. 1.5 mm
3440 0.059 in.
8 30. Adjust blade side shift. See Measure and Adjust
23. Connect hydraulic cylinders to draft frame balls Blade Side Shift Clearance. (Group 3440.)
(8).

24. Apply John Deere NEVER-SEEZ Lubricant or an

equivalent to the inside bore of tilt frame and circle
frame.

NEVER-SEEZ is a trademark of Emhart Chemical Group. CED,OUOE027,230 –19–21JAN05–3/3

TM2256 (09JAN07) 34-3440-8 D Series Motor Grader Repair

020207
PN=412
 Frames

Circle Adjustment

–UN–23FEB89

–UN–28JUN90
T6949AY

T7316AE
–UN–28JUN90

34
T7316AD

3440
9

–UN–28JUN90
T7316AF

A—C-Clamp E—Circle I—Support M—Pinion-to-Circle Clearance

B—Draft Frame F—Horizontal Clearance J—Nut N—Locating Hole-to-Circle
C—Vertical Wear Strip (15 G—Horizontal Wear Strip (6 K—Cap Screw Dimension
used) used) L—Shim (As Required) P—Locating Hole
D—Vertical Clearance H—Support-to-Draft Frame
Cap Screw

NOTE: It may be easier and less time consuming to 1. Measure the thickness of all wear strips before
replace wear strips rather than adjust circle. adjusting circle clearance. If wear strips are worn to
Replacing wear strips should adjust circle back less than minimum thickness, replace strips.
to original specifications.

Continued on next page TX,90,DH1283 –19–20JAN05–1/3

TM2256 (09JAN07) 34-3440-9 D Series Motor Grader Repair

020207
PN=413
 Frames

Specification 8. Center the circle within the draft frame using a pry
Vertical Wear Strips (C)—New
bar or C-clamps. Measurements (N) from locating
Thickness .................................................................................. 16 mm
0.63 in. hole (P) to the circle must be within 3 mm (0.12 in.)
Minimum Thickness ................................................................. 11 mm from side to side.
0.433 in.
Horizontal Wear Strips (G)— 9. Tilt the top of the blade forward. Lower the blade to
New Thickness ........................................................................... 8 mm push rear of circle up against draft frame wear
0.31 in.
Minimum Thickness .................................................................... 2 mm
strips.
0.08 in.
10. Measure and adjust each support individually. Add
2. If all wear strips are within specification, raise blade or remove shims (L) to adjust vertical clearance
and rotate 90° to main frame. Turn pinion until a (D) to specification. Shims are available in 1 mm
tooth is pointed directly forward and into the root of (0.04 in.) and 1.5 mm (0.06 in.) thickness.
the circle gear as shown on the drawing illustrating
clearance (M).. Specification
Support-to-Circle—Vertical
Clearance (D) ................................................................. 0.2—1.0 mm
3. Using a pry bar, move circle rearward as far as it 0.01—0.04 in.
will go.
11. With the circle pulled back against the two front
4. If the pinion-to-circle clearance (M) is less than the supports, adjust the horizontal clearance (F) on
minimum specification and the circle is tight against rear supports. Loosen nuts (J) and support cap
the front supports, adjust the two front supports. screws (H). Move rear supports to achieve
(See Step 6.) support-to-circle clearance (F).
34
3440
5. If the pinion-to-circle clearance (M) is less than the Specification
minimum specification, there is clearance between Support-to-Circle—Horizontal
10
the two front supports and the circle, and the point Clearance (F) .............................................................. 0.25—0.76 mm
0.010—0.030 in.
of the front pinion tooth is tight against the root of
the circle gear, adjust the two front supports. (See
12. Check for adequate clearance between shims and
Step 6.)
circle teeth. Tighten support cap screws (H).
6. To adjust the two front supports, loosen nuts (J) Specification
and cap screws (H). Use cap screws (K) to move Support Cap Screw—Torque ...........................................27—55 N•m
supports up against circle and to achieve the 20—40 lb-ft
minimum pinion-to-circle clearance (M).
NOTE: If cap screws (H) are overtightened, support
Specification will not move when cap screw (K) is adjusted.
Circle Drive-to-Circle—Minimum
If cap screws (H) are too loose, support will
Clearance (M) ........................................................................... 76 mm
3.0 in. move excessively when final torque is applied.
Circle Drive-to-Circle—
Maximum Clearance (M) .......................................................... 79 mm 13. Tighten the support-to-draft frame cap screws to
3.11 in. specification.

7. Install a C-clamp to pull front of circle up against

draft frame wear strips.

Continued on next page TX,90,DH1283 –19–20JAN05–2/3

TM2256 (09JAN07) 34-3440-10 D Series Motor Grader Repair

020207
PN=414
 Frames

Specification procedure.
Support-to-Draft Frame Cap
Screw—Torque ......................................................................850 N•m
Specification
625 lb-ft
Support-to-Circle—Vertical
Clearance (D) .................................................................... 0.2—1 mm
14. Using a pry bar, move circle forward as far as it 0.01—0.04 in.
will go. Horizontal Clearance (F) ............................................ 0.25—0.76 mm
0.010—0.030 in.
15. If the pinion-to-circle clearance (M) is greater than
the maximum specification and the circle is tight 17. After adjusting the clearance, rotate the blade
against the rear supports, repeat step 11 and through working range in both directions to check
reduce the support-to-circle clearance (F) for the for binding. If circle binds, stop circle at the tight
two rear supports. spot.

16. With circle pulled back against front supports, 18. Adjust any supports that are binding until circle
check horizontal and vertical clearance (D and F). rotates freely.
If clearance is not to specification, repeat

TX,90,DH1283 –19–20JAN05–3/3

34
3440
11

TM2256 (09JAN07) 34-3440-11 D Series Motor Grader Repair

020207
PN=415
 Frames

Blade Side Shift Wear Inserts Install and

Adjust

1. Before installing new inserts (D), be sure the V-shaped

mounting pockets in retainers (A and H) are clean. If
they are not, the new inserts will not seat properly in
the mounting pockets.

CAUTION: Do not remove retainer-to-tilt frame

cap screws. Blade may tilt forward and cause
personal injury if the top retainers are removed.
Chock or secure blade prior to loosening
retainer-to-tilt frame cap screws.

2. Initially mount eight new inserts (D) to retainers (A and

H) with insert mounting cap screws (F) installed “finger
tight” or just tight enough to hold the inserts on the
retainer mounting surfaces. The inserts must be able to
slip under the cap screw heads and seat with
application of a load from the moldboard.

3. Before tightening the insert mounting cap screws (F),

set the machine up as follows:
34
3440 a. Route the circle so the moldboard is approximately
12 perpendicular to the grader mainframe.

b. Adjust the moldboard so it is approximately

centered in it’s blade side shift travel range.

c. Center the circle side shift so the blade lift cylinders

are approximately vertical with the cutting edge on
the ground.

d. Adjust blade pitch so the top moldboard slide bar is

directly above the bottom moldboard slide bar when
the cutting edge is on the ground. (The cutting edge
should be on the ground over it’s entire length.)
A—Retainer (2 used)
B—Retainer-to-Tilt Frame Cap Screw (6 used)
C—Shim (As Required)
D—Insert (8 used)
E1—Insert-to-Blade Rail Clearance
E2—Insert-to-Blade Rail Clearance
F—Insert Mounting Cap Screw (24 used)
G—Blade Tilt Frame
–UN–23SEP99

H—Retainer (Welded)
T124779

Continued on next page CED,OUOE003,7595 –19–20JAN05–1/3

TM2256 (09JAN07) 34-3440-12 D Series Motor Grader Repair

020207
PN=416
 Frames

4. With the cutting edge on the ground, push the blade lift
control levers forward enough to load the cutting edge
against the ground and securely force the top inserts
(D) into their respective retainers (A).

5. With the top inserts (D) securely held in their retainers

(A), tighten and apply John Deere NEVER-SEEZ
Lubricant or an equivalent to the 12 top insert
mounting cap screws (F) ..

Specification
Insert Mounting Cap Screw—
Torque ............................................................................................ 58 N•m
43 lb-ft

6. Pull the blade lift control levers back to lift the cutting
edge slightly off the ground to force the bottom inserts
into their respective mounting pockets using the weight
of the moldboard. With the weight of the moldboard on
the bottom inserts, “jiggle” the moldboard back and
forth approximately ± 12 mm (1/2 in.) 8—10 times
using the blade side shift control lever to ensure that
the inserts are securely seated into their mounting
pockets. Stop engine.
34
7. With the bottom inserts (D) securely held in retainers 3440
(H) by the weight of the moldboard, tighten and apply 13
John Deere NEVER-SEEZ Lubricant or an equivalent
to the 12 bottom insert mounting cap screws (F).

Specification
Bottom Insert Mounting Cap
Screw—Torque ...............................................................................58 N•m
43 lb-ft

8. With the moldboard off the ground, side shift the

moldboard full stroke both directions 3—4 times.

9. Measure the clearances (E1 and E2) between the

blade rail and the insert. Add the clearances together.
This is the total insert-to-blade rail clearance.

NEVER-SEEZ is a trademark of Emhart Chemical Group. Continued on next page CED,OUOE003,7595 –19–20JAN05–2/3

TM2256 (09JAN07) 34-3440-13 D Series Motor Grader Repair

020207
PN=417
 Frames

NOTE: Clearance will vary slightly as moldboard is side

shifted back and forth. To determine how much
shim can be removed, to reduce the clearance to
the desired amount, the technician will have to
shift the moldboard to find the minimum clearance
point and remove shim relative to that point.

CAUTION: Do not remove retainer-to-tilt frame

cap screws. Blade may tilt forward and cause
personal injury if the top retainers are removed.
Shims are slotted. Loosen retainer-to-tilt frame
cap screws only enough to slide shims in or
out. Chock or secure blade prior to loosening
retainer-to-tilt frame cap screws

10. Note points of minimum clearance between the top

inserts and top moldboard rail. If the moldboard will
not side shift freely without binding, add shim (C)
between the top moldboard retainers and the blade tilt
frame to achieve unrestricted movement and the
desired minimum clearance. If the minimum clearance
observed is greater than desired, remove shim from
between the top moldboard retainers and the blade tilt
34 frame to achieve the proper insert-to-blade rail
3440 clearance. See Measure and Adjust Blade Side Shift
14 Clearance. (Group 3440).

Specification
Insert-to-Blade Rail—Clearance
(E1 + E2) .............................................................................. 0.5—6.0 mm
0.02—0.25 in.

11. Tighten and apply John Deere NEVER-SEEZ

Lubricant or an equivalent to cap screws (B).

Specification
Retainer-to-Tilt Frame Cap
Screw—Torque ............................................................................637 N•m
470 lb-ft

NEVER-SEEZ is a trademark of Emhart Chemical Group. CED,OUOE003,7595 –19–20JAN05–3/3

TM2256 (09JAN07) 34-3440-14 D Series Motor Grader Repair

020207
PN=418
 Frames

Blade Side Shift Clearance Measure and

Adjust

1. Inspect insert (D) before adjusting clearance. If wear

strip retainer (A) is in contact with blade rail, wear strip
must be replaced.

2. To measure insert clearances (E1 and E2), raise blade

off ground. Tilt blade top rearward and stop engine.

3. Measure the clearances (E1 and E2) between the

blade rail and the insert. Add the clearances together.
This is the total insert-to-blade rail clearance.

Specification
Insert-to-Blade Rail—Clearance
(E1 + E2) .............................................................................. 0.5—6.0 mm
0.02—0.25 in.

CAUTION: Do not remove retainer-to-tilt frame

cap screws. Blade may tilt forward and cause
personal injury if the top retainers are removed.
Shims are slotted. Loosen retainer-to-tilt frame
cap screws only enough to slide shims in or
out. Chock or secure blade prior to loosening 34
3440
retainer-to-tilt frame cap screws. 15

4. If clearance is not within specification, loosen three

retainer-to-tilt frame cap screws (B) on one side.

5. Add or remove shims (C) to adjust clearance on this

side. Clearance will change approximately 1 mm (0.04
in.) for each shim added or removed.

6. Finger tighten retainer-to-tilt frame cap screws (B)

securing retainer.

7. Lower blade to align retainers.

A—Retainer
B—Retainer-to-Tilt Frame Cap Screw
C—Shim
D—Insert
E1—Insert-to-Blade Rail Clearance
E2—Insert-to-Blade Rail Clearance
–UN–23SEP99
T124782

Continued on next page TX,90,DH2936 –19–20JAN05–1/2

TM2256 (09JAN07) 34-3440-15 D Series Motor Grader Repair

020207
PN=419
 Frames

8. Tighten and apply John Deere NEVER-SEEZ

Lubricant or an equivalent to cap screws (B).

Specification
Retainer-to-Tilt Frame Cap
Screw—Torque .............................................................................637 N•m
470 lb-ft

9. Raise blade off ground. Measure the clearances (E1

and E2) between the blade rail and the wear strip at all
top guides. If clearance is not within specification on
retainer on opposite side, loosen retainer-to-tilt frame
cap screws on that retainer and repeat steps 4—9.

NOTE: Clearance will vary slightly as the moldboard is

side shifted back and forth. To determine how
much shim can be removed to reduce the
clearance to the desired amount, the technician
will have to shift the moldboard to find the
minimum clearance point and remove shim
relative to that point.

10. Move blade side shift through full travel to check for
binding. If blade binds, stop at the tight spot.
34
Determine which retainer is too tight. Add shims to
3440 adjust retainer to the minimum clearance
16 specification.

11. Tighten and apply John Deere NEVER-SEEZ

Lubricant or an equivalent to cap screws (B).

Specification
Retainer-to-Tilt Frame Cap
Screw—Torque ............................................................................637 N•m
470 lb-ft

NEVER-SEEZ is a trademark of Emhart Chemical Group. TX,90,DH2936 –19–20JAN05–2/2

TM2256 (09JAN07) 34-3440-16 D Series Motor Grader Repair

020207
PN=420
 Group 3450
Circle Gearbox

34
3450
1

TM2256 (09JAN07) 34-3450-1 D Series Motor Grader Repair

020207
PN=421
 Circle Gearbox

Circle Drive Gearbox Disassemble and Assemble

34
3450
2

–UN–24JUN04
T201069

Circle Drive Gearbox

Continued on next page TX19495,000017B –19–25JAN05–1/3

TM2256 (09JAN07) 34-3450-2 D Series Motor Grader Repair

020207
PN=422
 Circle Gearbox

1—Bearing Cone 10—Gear Case 23—Retaining Washer 32—Cap Screw (15 used)
2—Seal 11—Shaft 24—Thrust Washer (2 used) 33—Adapter
3—Breather 12—Cover 25—O-Ring 34—O-Ring
4—Bearing Cone 13—Shaft 26—Cap 35—Splined Coupling
5—Bearing Cone (2 used) 14—Flange 27—Pipe Plug 36—Circle Drive Gear Box
6—Bearing Cup (2 used) 15—Gear 28—O-Ring (2 used) 37—Cap Screw (2 used)
7—Bearing Cup 16—Shim (As required) 29—Pipe Plug (2 used) 38—Cap Screw
8—Bearing Cup 19—Shim (As required) 30—Washer (5 used) 39—Nut (2 used)
9—O-Ring 22—Plug 31—Cap Screw (4 used)

1. Drain circle gearbox. 10. Pull bearing cup (7) from cover (12) and bearing
cup (8) from gear case (10).
Specification
Circle Gearbox—Approximate 11. Remove seal (2) from gear case (10).
Capacity ....................................................................................... 5.5 L
1.5 gal
12. Remove cap screws (31) and flange (14) from
2. Remove three cap screws (37 and 38) holding gear case (10).
gearbox to draft frame.
13. Remove shims (16) and O-ring (25).

CAUTION: Prevent crushing injury. Use 14. Remove shaft (13) with bearing cones (5).
lifting device.
15. Pull bearing cones (5) from shaft (13).
Specification
Circle Gearbox—Approximate
Weight ....................................................................................... 124 kg NOTE: If inner bearing cups (6) are replaced, plug
275 lb (22) must be tapped out of gear case (10) to 34
drive bearing cup out. 3450
3. Install hoist with straps to circle gearbox. Remove 3
circle gearbox. 16. Pull bearing cups (6) from gear case (10) and
flange (14).
4. Remove cap (26).
17. Replace parts as necessary.
5. Remove cap screws (32), retaining washer (23) and
shims (19) from end of shaft. 18. Drive in bearing cups (6) and press bearing cones
(5) on shaft (13).
6. Remove cap screws (32) from cover (12).
19. Install shaft (13) into gear case (10).
CAUTION: Make sure the pinion shaft does 20. Install shims (16) on flange (14) and install flange
not fall out of the bottom of the gearbox in gear case (10).
when removing the cover and bearing cone.
21. Install cap screws (31) and tighten to specification.
7. Install three cap screws in tapped holes in cover
(12) and pull bearing cone (4) with cover (12) from Specification
shaft (11). Flange-to-Gear Case Cap
Screw—Torque ......................................................................130 N•m
8. Remove O-ring (9), thrust washers (24), gear (15) 95 lb-ft
and shaft (11) with bearing cone (1).
22. Check for end play with dial indicator and record
9. Pull bearing cone (1) from shaft (11). reading for setting up preload.

Continued on next page TX19495,000017B –19–25JAN05–2/3

TM2256 (09JAN07) 34-3450-3 D Series Motor Grader Repair

020207
PN=423
 Circle Gearbox

Specification 33. Remove cap screws (32) and retaining washer

Shaft (Worn) Bearing Preload—
(23).
End Gap............................................................................. 0.0675 mm
0.0025 in.
34. Install shims (19), retaining washer (23), cap
23. Remove flange (14). Add and subtract shims (16) screws (32) and check for end play with dial
to obtain bearing preload specification. indicator.

24. Install flange (14) with shims (16) and O-ring (25). 35. Add and subtract shims as required to set preload
to specification.
25. Install cap screws (31) and tighten to specification.
Specification
Shaft (Worn) Bearing Preload—
Specification End Gap............................................................................. 0.0675 mm
Flange-to-Gear Case Cap 0.0025 in.
Screw—Torque ......................................................................130 N•m
95 lb-ft
36. Install retaining washer (23) and cap screws (32).
26. Drive bearing cup (7) into cover (12). Tighten cap screws to specification.

Specification
27. Drive bearing cup (8) into gear case (10). Retaining Washer-to-Shaft
(Ring) Cap Screw—Torque .....................................................70 N•m
28. Drive bearing cone (1) onto shaft (11). 51 lb-ft

29. Install shaft (11) with bearing cone (1), thrust 37. Apply high strength gasket to cap (26). Install cap.
washers (24) and gear (15) into gear case (10)
34 aligning with shaft (13). IMPORTANT: Be careful when installing oil seal
3450 because it is a cassette type and
4 NOTE: Apply thread lock and sealer (medium needs to be pushed on the outer and
strength) to threads of cap screws that inner case at the same time. Use
protrude through the cover into the oil cavity of JDG1009 Seal Installer to ensure
gear case. correct installation.

30. Install O-ring (9) and cover (12) with cap screws 38. Install seal (2) in gear case (10) around shaft (11)
(30). Tighten cap screws to specification. from bottom of gearbox using JDG1009 Seal
Installer.
Specification
Cover-to-Gear Case Cap 39. Install circle gearbox onto machine with three cap
Screw—Torque ........................................................................70 N•m
51 lb-ft
screws.

31. Place bearing cone (4) and retaining washer (23) 40. Fill housing with oil through pipe plug (27) to level
onto shaft (11). of upper pipe plug (29).

Specification
32. Pull bearing cone (4) onto shaft (11) using cap Circle Gearbox—Approximate
screws (32) and tighten to specification Capacity ....................................................................................... 5.5 L
1.5 gal
Specification
Retaining Washer-to-Shaft
(Ring) Cap Screw—Torque .....................................................70 N•m
51 lb-ft

TX19495,000017B –19–25JAN05–3/3

TM2256 (09JAN07) 34-3450-4 D Series Motor Grader Repair

020207
PN=424
 Circle Gearbox

34
3450
5

TM2256 (09JAN07) 34-3450-5 D Series Motor Grader Repair

020207
PN=425
 Circle Gearbox

Circle Drive Gearbox (With Slip Clutch) Disassemble and Assemble

34
3450
6

–UN–04DEC04
T201073

Circle Drive Gearbox with Slip Clutch

Continued on next page CED,OUOE003,7584 –19–18JAN05–1/26

TM2256 (09JAN07) 34-3450-6 D Series Motor Grader Repair

020207
PN=426
 Circle Gearbox

1—Bearing Cone 14—Motor Mounting Flange 27—Plug 40—Shim (As Required)

2—Oil Seal 15—Worm Gear 28—O-Ring (2 used) 41—Shim (As Required)
3—Pressure Relief Fitting 16—Shim (As Required) 29—Plug (2 used) 42—O-Ring
4—Bearing Cone 17—Washer 30—Cap Screw (12 used) 43—Cap Screw (6 used)
5—Bearing Cone (2 used) 18—Nut 31—Cap Screw (4 used) 44—Belleville Spring
6—Bearing Cup (2 used) 19—Shim (As Required) 32—Cap Screw (3 used) 45—Plate (13 used)
7—Bearing Cup 20—Shim (As Required) 33—Adapter 46—Clutch disk (14 used)
8—Bearing Cup 21—Shim (As Required) 34—O-Ring 47—Cap Screw (3 used)
9—O-Ring 22—Plug 35—Splined Hub 48—O-Ring
10—Housing 23—Retaining Washer 36—Backing Plate 49—Coupling
11—Circle Pinion Shaft 24—Thrust Washer (2 used) 37—Pressure Plate 50—Gear Case
12—Cover 25—O-Ring 38—Bearing Quill 51—Cap Screw
13—Worm 26—Cover 39—Shim (As Required) 52—Cap Screw (2 used)

Determine worm (13) preload as follows:

1. Install bearing cups (6) in housing (10) and motor

mounting flange (14).

CED,OUOE003,7584 –19–18JAN05–2/26

2. Install bearing cones (5) on worm (13).

3. Install worm (13) with bearings in housing (10). 34

3450
4. Position shims (16) removed during disassembly. 7

5. Install O-ring (25) on motor mounting flange (14).

6. Install motor mounting flange (14).

7. Tighten cap screws (31) finger tight.

NOTE: Shims come in 0.1 mm (0.004 in.) 0.2 mm (0.008

in.) and 0.5 mm (0.020 in.) thickness.

–UN–27SEP99
8. Add or remove shims (16) to obtain specified worm
end play.

T123980
Specification
Worm—End Play ..................................................................0—0.125 mm
0—0.005 in.
5—Bearing Cone (2 used)
10—Housing
13—Worm

Continued on next page CED,OUOE003,7584 –19–18JAN05–3/26

TM2256 (09JAN07) 34-3450-7 D Series Motor Grader Repair

020207
PN=427
 Circle Gearbox

9. Install plug (22).

10. Assemble gearbox as follows:

Install bearing cup (8) in housing (10).

11. Press bearing cone (1) on circle pinion shaft (11).

12. Install circle pinion shaft (11) in housing (10).

22—Plug

–UN–16SEP99
T123982
34
3450
8
CED,OUOE003,7584 –19–18JAN05–4/26

13. Install seal (2) in housing (10) with seal driver until
seal is seated flush with edge of housing.

2—Oil Seal
10—Housing

–UN–16SEP99
T123983

Continued on next page CED,OUOE003,7584 –19–18JAN05–5/26

TM2256 (09JAN07) 34-3450-8 D Series Motor Grader Repair

020207
PN=428
 Circle Gearbox

14. Install backing plate (36).

36—Backing Plate

–UN–16SEP99
T123984
34
3450
9
CED,OUOE003,7584 –19–18JAN05–6/26

NOTE: Make sure thrust washer (24) is centered and

seated on lower surface of backing plate.

15. Install thrust washer (24).

24—Thrust Washer

–UN–16SEP99
T123985

Continued on next page CED,OUOE003,7584 –19–18JAN05–7/26

TM2256 (09JAN07) 34-3450-9 D Series Motor Grader Repair

020207
PN=429
 Circle Gearbox

NOTE: Worm gear (15) and/or worm (13) may have to be

manually rotated to allow worm gear to fall into
position.

16. Install worm gear (15).

17. Tighten cap screws (31) to specification.

Specification
Motor Mounting Flange Cap
Screw—Torque ............................................................................130 N•m
96 lb-ft

15—Worm Gear

–UN–16SEP99
T123986
34
3450
10
CED,OUOE003,7584 –19–18JAN05–8/26

18. Install splined hub (35) with inside recessed section

towards gear end of circle pinion shaft (11).

35—Splined Hub

–UN–16SEP99
T123987

Continued on next page CED,OUOE003,7584 –19–18JAN05–9/26

TM2256 (09JAN07) 34-3450-10 D Series Motor Grader Repair

020207
PN=430
 Circle Gearbox

19. Starting with a clutch disk, install 14 clutch disks (46)

and 13 separator plates (45).

45—Plate (13 used)

46—Clutch disk (14 used)

–UN–16SEP99
T123989
34
3450
11

–UN–16SEP99
T123988
Continued on next page CED,OUOE003,7584 –19–18JAN05–10/26

TM2256 (09JAN07) 34-3450-11 D Series Motor Grader Repair

020207
PN=431
 Circle Gearbox

20. Install pressure plate (37).

37—Pressure Plate

–UN–16SEP99
T123990
34
3450
12
CED,OUOE003,7584 –19–18JAN05–11/26

NOTE: Make sure thrust washer is centered and seated

on lower surface of backing plate.

21. Install thrust washer (24).

24—Thrust Washer

–UN–16SEP99
T123991

Continued on next page CED,OUOE003,7584 –19–18JAN05–12/26

TM2256 (09JAN07) 34-3450-12 D Series Motor Grader Repair

020207
PN=432
 Circle Gearbox

22. Install Belleville spring (44) concave side down.

23. Install bearing cup (7) in cover (12).

24. Install O-ring (9) on cover (12).

25. Install cover (12).

44—Belleville Spring

–UN–16SEP99
T123992
34
3450
13
Continued on next page CED,OUOE003,7584 –19–18JAN05–13/26

TM2256 (09JAN07) 34-3450-13 D Series Motor Grader Repair

020207
PN=433
 Circle Gearbox

26. Apply cure primer to threads of two cap screws (30).

Apply pipe sealant to threads of two cap screws (30).
Install cap screws.

27. Install remaining cap screws (30) and tighten

specification.

Specification
Cover-to-Housing Cap Screw—
Torque ............................................................................................ 70 N•m
52 lb-ft

30—Cap Screw (12 used)

–UN–16SEP99
T123993
34
3450
14

–UN–16SEP99
T123994

Continued on next page CED,OUOE003,7584 –19–18JAN05–14/26

TM2256 (09JAN07) 34-3450-14 D Series Motor Grader Repair

020207
PN=434
 Circle Gearbox

28. Determine Belleville spring (44) preload and circle

pinion shaft (11) end play as follows:

Install bearing cone (4) on bearing quill (38).

4—Bearing Cone
38—Bearing Quill

–UN–16SEP99
T123995
34
3450
15
CED,OUOE003,7584 –19–18JAN05–15/26

29. Install bearing cone (4) and quill (38). Tap quill into
position.

30. Install cap screws (47) and tighten to specification.

Specification
Quill-to-Circle Pinion Shaft Cap
Screw—Torque ...............................................................................36 N•m
27 lb-ft

31. Retighten cap screws (47).

4—Bearing Cone
38—Bearing Quill
–UN–16SEP99

47—Cap Screw (3 used)

T123996

Continued on next page CED,OUOE003,7584 –19–18JAN05–16/26

TM2256 (09JAN07) 34-3450-15 D Series Motor Grader Repair

020207
PN=435
 Circle Gearbox

32. Measure distance from top of quill to top of pinion

shaft through hole in center of quill.

NOTE:

Specification
Shim—Thickness ..........................................................................0.10 mm
0.004 in.
.015 mm
0.006 in.
0.50 mm
0.020 in.

33. Subtract 10 mm (0.394 in.) from measurement made

in previous step to obtain shim pack thickness. Build

–UN–16SEP99
shim pack.

T123997
34
3450
16
CED,OUOE003,7584 –19–18JAN05–17/26

34. Remove cap screws (47), install shim pack (39, 40,
41) determined in step 33 under bearing quill (38).

39—Shim (As Required)

40—Shim (As Required)
41—Shim (As Required)

–UN–16SEP99
T123998

Continued on next page CED,OUOE003,7584 –19–18JAN05–18/26

TM2256 (09JAN07) 34-3450-16 D Series Motor Grader Repair

020207
PN=436
 Circle Gearbox

35. Install cap screws (47). Tighten to specification in a

circular pattern.

Specification
Quill-to-Circle Pinion Shaft Cap
Screw—Final Torque ....................................................................240 N•m
177 lb-ft

36. Retighten cap screws (47) in a circular pattern.

37. Install retaining washer (23).

38. Install cap screws (32) and tighten to specification

Specification

–UN–16SEP99
Retaining Washer-to-Circle Pinion
Shaft Cap Screw—Torque .............................................................70 N•m
52 lb-ft

T123999
.

34
3450
17
CED,OUOE003,7584 –19–18JAN05–19/26

NOTE:

Specification
Shim—Thickness ..........................................................................0.10 mm
0.004 in.
.015 mm
0.006 in.
0.50 mm
0.020 in.

39. Measure distance from top of bearing to top of quill.

Subtract 0.1 mm (0.004 in.) from measurement and
build shim pack. –UN–07MAR00
T124001

Continued on next page CED,OUOE003,7584 –19–18JAN05–20/26

TM2256 (09JAN07) 34-3450-17 D Series Motor Grader Repair

020207
PN=437
 Circle Gearbox

40. Install shims (19, 20, 21).

19—Shim (As Required)

20—Shim (As Required)
21—Shim (As Required)

–UN–16SEP99
T124002
34
3450
18
CED,OUOE003,7584 –19–18JAN05–21/26

41. Install retaining washer (23).

23—Retaining Washer

–UN–16SEP99
T124627

Continued on next page CED,OUOE003,7584 –19–18JAN05–22/26

TM2256 (09JAN07) 34-3450-18 D Series Motor Grader Repair

020207
PN=438
 Circle Gearbox

42. Install cap screws (32) and tighten to specification.

Specification
Retaining Washer-to-Circle Pinion
Shaft Cap Screw—Torque .............................................................70 N•m
52 lb-ft

32—Cap Screw (3 used)

–UN–16SEP99
T124628
34
3450
19
CED,OUOE003,7584 –19–18JAN05–23/26

43. Install O-ring (42).

42—O-Ring

–UN–16SEP99
T124629

Continued on next page CED,OUOE003,7584 –19–18JAN05–24/26

TM2256 (09JAN07) 34-3450-19 D Series Motor Grader Repair

020207
PN=439
 Circle Gearbox

44. Position cover (26).

45. Install cap screws (43) and tighten to specification.

Specification
Cover-to-Cover Cap Screw—
Torque ............................................................................................ 40 N•m
30 lb-ft

26—Cover
43—Cap Screw (6 used)

–UN–16SEP99
T124630
34
3450
20
CED,OUOE003,7584 –19–18JAN05–25/26

46. Install adapter (33).

47. Apply cure primer to threads of vent (3).

48. Apply pipe sealant to threads of vent (3). Install vent.

3—Pressure Relief Fitting

33—Adapter

–UN–16SEP99
T124003

CED,OUOE003,7584 –19–18JAN05–26/26

TM2256 (09JAN07) 34-3450-20 D Series Motor Grader Repair

020207
PN=440
 Group 3460
Hydraulic System

Grader Control Valve Remove and Install

60 62 63
61 64
59 122
55 57
53 65
56 58
52 54
121
115
114

131

124

131 42
131 123

131
40 44

–UN–07DEC06
123

41 34

TX1014875
3460
TX1014875 42 1

40—Hydraulic System 54—Ripper Valve (Optional) 64—Right Auxiliary Valve 1 122—Right Control Valve
Manifold 55—Blade Lift Valve l—Left (Optional— Plow Angle 1) Assembly Mid-inlet
41—Pressure Reducing Valve 56—Blade Side Shift Valve 65—Right Auxiliary Valve 2 123—Work Port Relief Valve (2
42—System Relief Valve 57—Circle Rotate Valve (Optional—Plow Angle 2) used, one on each blade
44—Saddle Locking Pin 58—Blade Tilt Valve 114—Left Control Valve lift circuit)
Solenoid Valve 59—Articulation Valve Assembly 124—Circuit Relief—Midmount
52—Left Auxiliary Valve 2 60—Circle rotate Valve 115—Right Control Valve Scarifier Only
(Optional—Wing Lift) 61—Wheel Lean Valve Assembly 131—Control Valve End Cap (4
53—Left Auxiliary Valve 1 62—Blade Lift Valve 121—Left Control Valve used)
(Optional—Wing Tilt) 63—Scarifier Valve (Optional— Assembly Mid-inlet
Plow Angle 1)

1. Rotate the blade away from the control valve the pressure in the system before
assembly you are going to remove. disconnecting or connecting hydraulic or
other lines. Tighten all connections before
2. Tilt blade all the way forward. Lower all equipment applying pressure.
to the ground.
4. To release pressure in the system, slowly loosen
3. Install vacuum pump to hydraulic tank. See Vacuum fittings on lines at control valve.
Pump Installation. (Group 9025-25.)
5. Remove all hydraulic lines from control valve
assembly and mark for ease of assembly. Cap and
CAUTION: To avoid injury from escaping
plug all openings.
fluid under pressure, stop engine and relieve

Continued on next page CP94658,0000037 –19–07DEC06–1/5

TM2256 (09JAN07) 34-3460-1 D Series Motor Grader Repair

020207
PN=441
 Hydraulic System

6. Remove floor mat retaining screws from the side of 9. Remove cap screws connecting linkage rods to
the cab the control valve assembly is being control valves at the valve levers.
removed.
10. Tie strap linkage rods away from opening.
7. Remove linkage boots and slide them up on the
linkage rods.

8. Remove cover plate retaining cap screws and slide

the cover up on the linkage rods.

CP94658,0000037 –19–07DEC06–2/5

CAUTION: Avoid crushing injury. Use a lifting

device.

11. Connect hoist to valve using lifting strap (1).

–UN–11DEC04
1—Lifting Strap
2—Grader Control Valve Right Side

T206140A
34
3460
2
Control Valve Removal Right Side

Continued on next page CP94658,0000037 –19–07DEC06–3/5

TM2256 (09JAN07) 34-3460-2 D Series Motor Grader Repair

020207
PN=442
 Hydraulic System

12. Remove control valve mounting hardware (4) and

lower control valve assembly from machine.

13. Repair grader control valve as needed.

–UN–11DEC04
CAUTION: Avoid crushing injury. Use lifting
device.

14. Lift assembly into machine and install control valve

T206144A
mounting hardware.

15. Connect linkage rods to the control valve assembly. Right Grader Control Valve Mounting Bracket and Hardware

16. Install cover plate over control valve assembly. 1—Lifting Strap
2—Right Grader Control Valve Assembly
3—Control Valve Mounting Bracket
IMPORTANT: When installing floor mat, make sure
4—Control Valve Mounting Hardware (3 used)
floor mat does not interfere with control
levers, boots or pedal.

17. Install floor mat and cap screws.

18. Move steering console to forward position.

34
3460
3
CP94658,0000037 –19–07DEC06–4/5

IMPORTANT: The length specification for linkage

boots is critical and can cause lever
effort complaints from operator if these
boots are not in the correct position.

19. Adjust linkage boots so neck (2) is above floor plate

–UN–01JUN05
to specification.

Specification
Floor Plate to Top of Linkage

T211816A
Boots—Length .................................................................................50 mm
2 in.

Linkage Boot
20. Connect all lines.
2—Boot Neck
21. Remove vacuum from hydraulic tank.

22. Check hydraulic oil level in tank. See Drain and Refill
Capacities. (Operator’s Manual.)

CP94658,0000037 –19–07DEC06–5/5

TM2256 (09JAN07) 34-3460-3 D Series Motor Grader Repair

020207
PN=443
 Hydraulic System

Grader Control Valve Disassemble and Assemble

34
3460
4

–UN–16NOV04
T204807

Continued on next page TX,34,DU2443 –19–18JAN05–1/2

TM2256 (09JAN07) 34-3460-4 D Series Motor Grader Repair

020207
PN=444
 Hydraulic System

1—Cap Screw (2 used) 3—Stud (2 used) 5—Stud 7—Nut (2 used)

2—Cap Screw 4—Stud 6—Stud (2 used) 8—Nut (4 used)

1. Mark the valve sections configuration to aid 4. Clean and inspect parts. Repair or replace parts as
assembly. See Control Valve Operation—Left . necessary.
(Group 9025-05.) See Control Valve Operation—
Right. (Group 9025-05.) 5. Tighten control valve nuts accordingly.

NOTE: Depending on the number of valve sections, Specification

cap screws might be used in place of the Control Valve Nut (Small)—
Torque...................................................................................... 19 N•m
studs and nuts. 168 lb-in
Control Valve Nut (Large)—
2. Remove nuts from each side of control valve. Torque...................................................................................... 45 N•m
33 lb-ft
3. Separate valve sections.

TX,34,DU2443 –19–18JAN05–2/2

34
3460
5

TM2256 (09JAN07) 34-3460-5 D Series Motor Grader Repair

020207
PN=445
 Hydraulic System

Midmount Scarifier Valve Section Disassemble and Assemble

34
3460
6

–UN–09NOV04
T203541

Blade Lift Valve Section

Continued on next page CP94658,0000034 –19–07DEC06–1/2

TM2256 (09JAN07) 34-3460-6 D Series Motor Grader Repair

020207
PN=446
 Hydraulic System

1—Screw 7—O-Ring 12—O-Ring 18—Seal

2—Pressure Relief Valve 8—Disk 13—Spool 19—O-Ring
3—Seal Kit 9—Spring 14—Housing 20—O-Ring
4—Check Valve 10—O-Ring 15—Cover Housing 21—Spring
5—Spool 11—O-Ring 16—Actuator 22—Control Valve
6—Spring

1. Remove check valve (4) and spool (13). 8. Tighten parts to specification.

2. Remove actuator assemble (16) and spring (9). Specification

Check Valve-to-Valve Body—
Torque...................................................................................... 65 N•m
3. Remove housing (14), spool (5) and cover housing 48 lb-ft
(15). Pressure Relief Valve-to-Valve
Body—Torque ..........................................................................45 N•m
4. Slide spool out of valve body. 33 lb-ft
Housing-to-Cover
Housing-to-Valve Body—
5. Remove pressure relief valve (2). Torque..................................................................................... 9.5 N•m
84 lb-in.
6. Clean and inspect parts. Repair or replace parts as Actuator-to-Valve Body—
necessary. Torque..................................................................................... 9.5 N•m
84 lb-in.
7. Replace all O-rings, seals and assemble valve.

34
3460
7
CP94658,0000034 –19–07DEC06–2/2

TM2256 (09JAN07) 34-3460-7 D Series Motor Grader Repair

020207
PN=447
 Hydraulic System

Blade Lift Valve Section Disassemble and Assemble

34
3460
8

–UN–09NOV04
T203541

Blade Lift Valve Section

Continued on next page TX,3460,DV2415 –19–12DEC06–1/2

TM2256 (09JAN07) 34-3460-8 D Series Motor Grader Repair

020207
PN=448
 Hydraulic System

1—Screw 7—O-Ring 12—O-Ring 18—Seal

2—Pressure Relief Valve 8—Disk 13—Spool 19—O-Ring
3—Seal Kit 9—Spring 14—Housing 20—O-Ring
4—Check Valve 10—O-Ring 15—Cover Housing 21—Spring
5—Spool 11—O-Ring 16—Actuator 22—Control Valve
6—Spring

1. Remove check valve (4) and spool (13). 8. Tighten parts to specification.

2. Remove actuator assemble (16) and spring (9). Specification

Check Valve-to-Valve Body—
Torque...................................................................................... 65 N•m
3. Remove housing (14), spool (5) and cover housing 48 lb-ft
(15). Pressure Relief Valve-to-Valve
Body—Torque ..........................................................................45 N•m
4. Slide spool out of valve body. 33 lb-ft
Housing-to-Cover
Housing-to-Valve Body—
5. Remove pressure relief valve (2). Torque..................................................................................... 9.5 N•m
84 lb-in.
6. Clean and inspect parts. Repair or replace parts as Actuator-to-Valve Body—
necessary. Torque..................................................................................... 9.5 N•m
84 lb-in.
7. Replace all O-rings, seals and assemble valve.

34
3460
9
TX,3460,DV2415 –19–12DEC06–2/2

TM2256 (09JAN07) 34-3460-9 D Series Motor Grader Repair

020207
PN=449
 Hydraulic System

Scarifier or Ripper Valve Section Disassemble and Assemble

34
3460
10

–UN–08DEC04
T203546

Scarifier and Ripper Valve Section

Continued on next page TX,3460,DV2415 –19–18JAN05–1/2

TM2256 (09JAN07) 34-3460-10 D Series Motor Grader Repair

020207
PN=450
 Hydraulic System

1—Screw 6—Spring 11—Fitting (Scarifier Only) 16—Stud

2—Check Valve 7—O-Ring 12—Spring 17—Housing
3—Detent 8—Disk 13—O-Ring 18—Cover Housing
4—Plug 9—Plug (Scarifier Only) 14—O-Ring 19—Actuator
5—Seal 10—O-Ring (Scarifier Only) 15—O-Ring 20—Control Valve

1. Remove plugs (4 and 9), check valves (2), and Fitting-to-Valve Body—Torque ................................................50 N•m
studs (16). 37 lb-ft
Plug-to-Valve Body—Torque ...................................................45 N•m
33 lb-ft
2. Remove housing (17), detent (3), and cover Housing-to-Cover
housing (18). Housing-to-Valve Body—
Torque..................................................................................... 9.5 N•m
3. Remove actuator assemble (19) and spring (12). 84 lb-in.
Actuator-to-Valve Body—
Torque..................................................................................... 9.5 N•m
4. Remove spool. 84 lb-in.

5. Inspect and replace worn parts.

6. Replace all O-rings, seal and assemble valve.

7. Tighten parts to specification.

Specification
Check Valve-to-Valve Body—
Torque...................................................................................... 65 N•m
48 lb-ft 34
3460
11

TX,3460,DV2415 –19–18JAN05–2/2

TM2256 (09JAN07) 34-3460-11 D Series Motor Grader Repair

020207
PN=451
 Hydraulic System

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

34
3460
12

–UN–09NOV04
T203404

Continued on next page TX,34,DU2537 –19–18JAN05–1/2

Blade Side Shift, Blade Tilt, Articulation, Wheel Lean, or Circle Side Shift Valve Section
TM2256 (09JAN07) 34-3460-12 D Series Motor Grader Repair
020207
PN=452
 Hydraulic System

1—Screw 5—Disk 9—O-ring 12—Cover Housing

2—Check Valve 6—Screw 10—O-ring 13—Actuator
3—Spring 7—Spring 11—Stud 14—Control Valve
4—O-ring 8—O-ring

1. Remove check valves (2) and studs (11). 7. Tighten parts to specification.

2. Remove actuator assemble (13) and spring (7). Specification

Check Valve-to-Valve Body—
Torque...................................................................................... 65 N•m
3. Remove cover housing (12). 48 lb-ft
Cover Housing-to-Valve Body—
4. Slide spool out of valve body. Torque..................................................................................... 9.5 N•m
84 lb-in.
5. Inspect and replace worn parts. Actuator-to-Valve Body—
Torque..................................................................................... 9.5 N•m
84 lb-in.
6. Replace all O-rings and assemble valve.

TX,34,DU2537 –19–18JAN05–2/2

34
3460
13

TM2256 (09JAN07) 34-3460-13 D Series Motor Grader Repair

020207
PN=453
 Hydraulic System

Circle Rotate Valve Section Disassemble and Assemble

34
3460
14

–UN–09NOV04
T203405

Circle Rotate Valve Section

Continued on next page TX,34,DU2538 –19–18JAN05–1/2

TM2256 (09JAN07) 34-3460-14 D Series Motor Grader Repair

020207
PN=454
 Hydraulic System

1—Screw 5—O-ring 9—O-ring 13—Cover Housing

2—Fitting 6—Disk 10—O-ring 14—Actuator
3—O-ring 7—Screw 11—O-ring 15—Control Valve
4—Spring 8—Spring 12—Stud

1. Remove Fittings (2) and studs (12). 6. Tighten parts to specification.

2. Remove actuator assemble (14), spring (8) and Specification

cover housing (13). Fitting-to-Valve Body—Torque ................................................65 N•m
48 lb-ft
Cover Housing-to-Valve Body—
3. Remove Spool. Torque..................................................................................... 9.5 N•m
84 lb-in.
4. Inspect and replace worn parts. Actuator-to-Valve Body—
Torque..................................................................................... 9.5 N•m
84 lb-in.
5. Replace all O-rings and assemble valve.

TX,34,DU2538 –19–18JAN05–2/2

Return Check Poppets Disassemble and

Assemble
34
NOTE: Poppets are serviced as an assembly except 3460
O-rings and back-up rings. 15

–UN–03NOV88
A—Back-Up Ring
B—O-Ring
C—Poppet Body
D—O-Ring

T6266AE
E—Check Poppet
F—Spring
G—O-Ring Disassemble and Inspect Return Check Poppets
H—Plug

T55,3460,C9 –19–05JAN05–1/1

TM2256 (09JAN07) 34-3460-15 D Series Motor Grader Repair

020207
PN=455
 Hydraulic System

Rotate Motor Disassemble and Assemble

34
3460
16

–UN–18JUN97
T110029

Rotate Motor

1—Cap Screw (4 used) 6—Packing 10—Cap Screw (7 used) 14—Plate

2—Seal 7—Bearing Race 11—Cap 15—Drive Shaft
3—Flange 8—Shaft 12—Seal 16—Housing
4—Shim 9—Shaft 13—Housing 17—Check Valve (2 used)
5—Seal

Continued on next page TX19495,0000176 –19–11JAN05–1/3

TM2256 (09JAN07) 34-3460-16 D Series Motor Grader Repair

020207
PN=456
 Hydraulic System

1. Remove cap screws (1 and 10) to disassemble 2. Clean and inspect parts. Repair or replace parts as
motor. necessary.

Continued on next page TX19495,0000176 –19–11JAN05–2/3

34
3460
17

TM2256 (09JAN07) 34-3460-17 D Series Motor Grader Repair

020207
PN=457
 Hydraulic System

3. Install shim (4) and seal (5) even with face of flange
(3) and with seal tip toward top of bore.

4. Install packing (6), bearing race (7) and bearing (8) on

shaft (9) and insert in housing (16).

5. Install seal (2) even with face of flange (3) and with
seal tip toward top of bore.

6. Apply T43512 Thread Lock and Sealer (Medium

Strength) to cap screws (1) and cap screw holes on
housing (16).

7. Install flange assembly to housing assembly with cap

screws (1). Tighten cap screws to specification using
criss-cross pattern.

Specification
Mounting Plate Cap Screw—
Torque ............................................................................................ 28 N•m
250 lb-in.

–UN–11JUL97
IMPORTANT: The relationship of valve, valve plate,
and gerotor is critical. These parts must
be correctly timed at assembly. If timing

T110377
34
3460 is not correct the motor will run
18 backwards.
Assemble Motor

8. Time the valve as follows:

Align timing mark (18) on shaft (9) with any threaded

hole in housing.

9. Install drive shaft (15), seal (12) and plate (14).

–UN–24FEB89
10. Align a gerotor star point (19) with previously aligned
threaded hole and install housing (13).

T6997AD
11. Install seal (12), cap (11) and cap screws (10).

Tighten cap screws in two steps in sequence shown. Timing Valves

Specification 9—Shaft
End Cap-to-Housing Cap 13—Housing
Screws—Initial Torque ..........................................................1.7—4.5 N•m 15—Drive Shaft
15—40 lb-in. 16—Housing
Final Torque ................................................................................... 23 N•m 18—Timing Mark
200 lb-in. 19—Gerotor Star Point

TX19495,0000176 –19–11JAN05–3/3

TM2256 (09JAN07) 34-3460-18 D Series Motor Grader Repair

020207
PN=458
 Hydraulic System

Rotary Manifold Remove and Install

1. Disconnect lines (E—H and J—M).

2. Remove cap screw and nut (A).

3. Remove cap screws (B) and washers (C).

4. Remove rotary manifold (D) from bracket (I).

5. Repair or replace parts as necessary.

6. Position rotary manifold (D) in bracket (I).

–UN–18JUN97
7. Install cap screw and nut (A), cap screws (B) and
washers (C).

8. Connect lines (E—H and J—M).

T109913
A—Cap Screw and Nut
B—Cap Screw (4 used)
Rotary Manifold Components
C—Washer (4 used)
D—Rotary Manifold
E—To Moldboard Tilt Control Valve Port Line
F—To Moldboard Tilt Control Valve Port Line
G—To Moldboard Sideshift Control Valve Port Line
34
H—To Moldboard Sideshift Control Valve Port Line
3460
I—Bracket
19
J—To Moldboard Tilt Cylinder—Up Port Line
K—To Moldboard Sideshift Cylinder—Right Port Line
L—To Moldboard Tilt Cylinder—Down Port Line
M—To Moldboard Sideshift Cylinder—Left Port Line

–UN–18JUN97
T109914

Rotary Manifold Lines

TX,34,DU2364 –19–05JAN05–1/1

TM2256 (09JAN07) 34-3460-19 D Series Motor Grader Repair

020207
PN=459
 Hydraulic System

Rotary Manifold Disassemble and Assemble

–UN–18JUN97
34
3460
20

T109912
Rotary Manifold

1—Cap Screw (2 used) 4—Thrust Washer 7—Housing 10—Spool

2—Lock Washer (2 used) 5—Ring 8—Seal (5 used) 11—Cap Screw (4 used)
3—Plate 6—Wear Ring (2 used) 9—Seal 12—Washer (4 used)

1. Scribe mark on housing (7) and spool (10). 5. Install parts (5, 6, 8 and 9) on spool (10).

2. Press spool from housing. 6. Align scribe marks on spool and housing (7) and
install.
3. Replace parts as necessary.

4. Soak seals (8 and 9) and wear rings (6) in oil.

TX,34,DU2365 –19–05JAN05–1/1

TM2256 (09JAN07) 34-3460-20 D Series Motor Grader Repair

020207
PN=460
 Hydraulic System

Blade Lift, Blade Tilt and Circle Side Shift

Cylinders Remove and Install

CAUTION: The approximate weights of

cylinders are:

• Blade Lift Cylinder:

Specification
Blade Lift Cylinder—Weight—
Approximate....................................................................................... 50 kg
110 lb

• Blade Tilt Cylinder:

Specification
Blade Tilt Cylinder—Weight—
Approximate....................................................................................... 26 kg
58 lb

• Circle Sideshift Cylinder: 34

3460
Specification 21
Circle Sideshift Cylinder—
Weight—Approximate ........................................................................33 kg
72 lb

If rebuilding a blade lift cylinder on the

machine, it must be held while lowering, or it
may swing down and cause injury.

1. Disconnect lines and remove cylinder.

2. Repair or replace parts as necessary. See Hydraulic

Cylinder Repair. (Group 0960.)

3. Install cylinder and connect lines.

4. The ball and socket assemblies on the lift cylinder rod

ends and on the circle sideshift cylinder rod and head
end are to be shimmed to 1.1 mm (0.045 in.) to
provide maximum travel relative to the stationary ball
without binding.

Continued on next page TX19495,0000175 –19–11JAN05–1/2

TM2256 (09JAN07) 34-3460-21 D Series Motor Grader Repair

020207
PN=461
 Hydraulic System

Specification
Ball and Socket, Lift Cylinder Rod
End and Circle Sideshift Cylinder
Rod and Head End—Shimmed ......................................................1.1 mm
0.045 in.

TX19495,0000175 –19–11JAN05–2/2

34
3460
22

TM2256 (09JAN07) 34-3460-22 D Series Motor Grader Repair

020207
PN=462
 Section 42
Ground Conditioning Tool
Contents

Page

Group 4240—Frames
Scarifier Remove and Install . . . . . . . . . . . .42-4240-2
Midmount Scarifier Remove and Install . . . .42-4240-4
Ripper Remove and Install . . . . . . . . . . . . .42-4240-16

42

TM2256 (09JAN07) 42-1 D Series Motor Grader Repair

020207
PN=1
 Contents

42

TM2256 (09JAN07) 42-2 D Series Motor Grader Repair

020207
PN=2
 Group 4240
Frames

42
4240
1

TM2256 (09JAN07) 42-4240-1 D Series Motor Grader Repair

020207
PN=465
 Frames

Scarifier Remove and Install

42
4240
2

–UN–19NOV04
T204191

Scarifier
Continued on next page TX,42,DU2372 –19–19JAN05–1/2

TM2256 (09JAN07) 42-4240-2 D Series Motor Grader Repair

020207
PN=466
 Frames

1—Nut (10 used) 9—Bushing (4 used) 17—Lubrication Fitting (2 23—Retainer (5 used)

2—Cap Screw (4 used) 10—Scarifier Attachment used) 24—Bracket
3—Cap Screw (3 used) 11—Link (2 used) 19—Pin Fastener 25—Pin (4 used)
4—Cap Screw (10 used) 12—Bushing (4 used) 20—Pin 26—Washer (23 used)
5—Washer (16 used) 13—Cap Screw 21—Lubrication Fitting (8 27—Snap Ring (8 used)
6—Shank (5 used) 14—Washer (2 used) used) 28—Pin Fastener
7—Tooth (5 used) 15—Snap Ring (2 used) 22—Lock Nut (4 used) 29—Scarifier Assemble
8—Scarifier Boom 16—Hydraulic Cylinder

CAUTION: Avoid crushing injury. Use

appropriate lifting device.

Item Measurement Specification

Scarifier Approximate Weight 850 kg

1874 lb

TX,42,DU2372 –19–19JAN05–2/2

42
4240
3

TM2256 (09JAN07) 42-4240-3 D Series Motor Grader Repair

020207
PN=467
 Frames

Midmount Scarifier Remove and Install

CAUTION: To prevent possible crushing injury

from heavy component. Use appropriate lifting
device.

–UN–01DEC06
1. Lower midmount scarifier to ground use wood block to
support midmount frame.

TX1014518A
Specification
Midmount Frame—Approximate
Weight.............................................................................................. 306 kg
675 lb Lift Cylinder

2. Turn engine off and move control levers to relieve 7—Cap Screw (2 used)
13—Bellcrank
hydraulic pressure. 15—Head End Pin
23—Front Mount
3. Support cylinder with lifting strap and hoist to prevent 46—Cylinder Rod
injury when removing. 48—Hydraulic Hose Head End
49—Hose Guide
Specification 50—Clamp
Cylinder Head and Rod End— 51—Hydraulic Hose Rod End
Approximate Weight ......................................................................... 43 kg 52—Cylinder Head End
95 lb 53—Rod End Pin

4. Remove clamp (50) and hose guide (49) from cylinder

head end (52).

5. Remove hydraulic hose head end (48) and rod end

(51) from cylinder. Close all openings using cap and
42 plugs.
4240
4

Continued on next page CP94658,0000033 –19–08DEC06–1/11

TM2256 (09JAN07) 42-4240-4 D Series Motor Grader Repair

020207
PN=468
 Frames

–UN–04DEC06
TX1014923
Cylinder Pin and Washer

7—Cap Screw (2 used) 13—Bellcrank 46—Cylinder Rod 53—Rod End Pin

11—Washer (2 used) 15—Head End Pin 52—Cylinder Head End 56—Washer (4 used)
12—Spacer (2 used) 23—Front Mount
42
6. Remove cap screw, washer, and spacer (7, 11, and 9. Remove head end pin (15) from front mount (23). 4240
12) from rod end pin (53). 5
10. Remove cylinder and washer (56) from bellcrank
7. Remove rod end pin (53) from bellcrank (13). and front mount (13 and 23).

8. Remove cap screw, washer, and spacer (7, 11, and

12) from head end pin (15).

Continued on next page CP94658,0000033 –19–08DEC06–2/11

TM2256 (09JAN07) 42-4240-5 D Series Motor Grader Repair

020207
PN=469
 Frames

–UN–04DEC06
TX1014845
Bellcrank, Strut, and Pillow Block

CAUTION: To prevent possible crushing injury

42 from heavy component. Use appropriate lifting
4240 device.
6

11. Support strut (29) right side.

1—Cap Nut (8 used)

13—Bellcrank
16—Midmount Frame
18—Tooth (11 used)

–UN–05DEC06
19—Shank (11 used)
24—Cap Screw (8 used)
25—Lower Pillow Block (2 used)
26—Upper Pillow Block (2 used)
TX1014548A

27—Washer (16 used)

28—Cap Screw (8 used)
29—Strut (2 used)
30—Upper and Lower End Cover (4 used)
31—Fitting (4 used) Mounting Plate
32—Shim Thick .05 (12 used)
33—Shim Thin .015 (16 used)
35—Retainer (11 used)
38—Upper and Lower Bushing (2 used)
47—Mounting Plate
57—Ball (4 used)

Continued on next page CP94658,0000033 –19–08DEC06–3/11

TM2256 (09JAN07) 42-4240-6 D Series Motor Grader Repair

020207
PN=470
 Frames

12. Remove lower cap screw, end cover, and shims (28,
30, 32, and 33) from strut right side.

13. Remove upper cap screw, end cover, and shims (28,
30, 32, and 33) from strut right side.

14. Remove strut (29) right side.

Specification
Strut—Approximate Weight ...............................................................66 kg
145 lb

15. Support strut (29) left side.

16. Remove lower cap screw, end cover, and shims (28,
30, 32, and 33) from strut left side.

IMPORTANT: To prevent possible injury when

removing strut left lower with hoist to
allow bellcrank to move downward.

17. Remove upper cap screw, end cover, and shims (28,
30, 32, and 33) from strut right side.

18. Remove strut (29).

Specification
Strut—Approximate Weight ...............................................................66 kg
145 lb

19. Support bellcrank (13). 42

4240
20. Remove cap screw, washer, and cap nut (24, 27, and 7
1) from upper and lower pillow block (26 and 25).

21. Remove upper pillow blocks (26) from bellcrank (13).

22. Remove bellcrank (13) from lower pillow blocks (25).

Specification
Bellcrank—Approximate Weight ......................................................172 kg
380 lb

23. Remove bushing (38) from bellcrank and lower pillow

block.

24. Remove lower pillow blocks (25) from mounting plate

(47).

Continued on next page CP94658,0000033 –19–08DEC06–4/11

TM2256 (09JAN07) 42-4240-7 D Series Motor Grader Repair

020207
PN=471
 Frames

25. Remove shank and retainer (19 and 35) from

midmount frame (16). See Replacing Scarifier Shank.
(Operator’s Manual).

26. Remove tooth (18) from shank (19). See Replacing

Scarifier Tooth. (Operator’s Manual).

Continued on next page CP94658,0000033 –19–08DEC06–5/11

42
4240
8

TM2256 (09JAN07) 42-4240-8 D Series Motor Grader Repair

020207
PN=472
 Frames

–UN–04DEC06
TX1014534
Radial Arms, Seals, and Bushing

3—Cap Nut (2 used) 9—Washer (8 used) 21—Bushing (2 used) 37—Retainer (2 used)

5—Cap Screw (4 used) 10—Washer (4 used) 22—Seal (4 used) 54—Cap Nut (4 used)
6—Cap Screw (2 used) 16—Midmount Frame 23—Front Mount 55—Washer (2 used)
8—Hex Socket Set Screw (2 20—Radial Arm (2 used) 36—Pin
42
used)
4240
9
27. Remove cap screw, and cap nut (6 and 3) from 32. Remove radial arm from pin, front mount, and
retainer (37) right and left side. midmount frame (36, 23, and 16).

28. Remove retainer and washer (37 and 10) from pin Specification
(36) right and left side. Radial Arm—Approximate
Weight ....................................................................................... 147 kg
325 lb
29. Remove cap screw, washer, and cap nut (5, 9,
and 54) from radial arm, and midmount frame (20 33. Remove seal, and bushing (22 and 21) from radial
and 16) right side. arm (20).
30. Remove cap screw, washer, and cap nut (5, 9, 34. Inspect seal and bushing replace as needed.
and 54) from radial arm, and midmount frame (20
and 16) left side. 35. Remove washer (55) from pin (36) right and left
side.
31. Support radial arm (20).
36. Remove hex socket set screw (8) from front mount
CAUTION: To prevent possible crushing (23).
injury from heavy component. Use
appropriate lifting device. 37. Remove pin (36) from front mount.

Continued on next page CP94658,0000033 –19–08DEC06–6/11

TM2256 (09JAN07) 42-4240-9 D Series Motor Grader Repair

020207
PN=473
 Frames

–UN–04DEC06
TX1014534
Radial Arm, Seal, and Bushing

3—Cap Nut (2 used) 9—Washer (8 used) 21—Bushing (2 used) 37—Retainer (2 used)

5—Cap Screw (4 used) 10—Washer (4 used) 22—Seal (4 used) 54—Cap Nut (4 used)
6—Cap Screw (2 used) 16—Midmount Frame 23—Front Mount 55—Washer (2 used)
8—Hex Socket Set Screw (2 20—Radial Arm (2 used) 36—Pin
42
used)
4240
10
38. Clean and inspect parts, replace parts as needed. 43. Install radial arm (20) to pin (36).
See Hydraulic Cylinder Repair. (Group 0960).
44. Install washer, and retainer (10 and 37) to pin (36)
39. Install pin (36) to front mount (23). right and left side.

40. Install hex socket set screw (8) to front mount 45. Install cap screw, and cap nut (6 and 3) to retainer
(23). (37) right and left side.

NOTE: Center pin in front mount and tighten hex 46. Install cap screw, washer, and cap nut (5, 9, and
socket set screw. 54) to radial arm, and midmount frame (20 and
16) right side.
41. Install washer (55) to pin (36) right and left side.
47. Install cap screw, washer, and cap nut (5, 9, and
IMPORTANT: Orientation of seal lip must be 54) to radial arm, and midmount frame (20 and
correct, lip to face away from 16) left side.
bushing.

42. Install seal and bushing (22 and 21) to radial arm
(20).

Continued on next page CP94658,0000033 –19–08DEC06–7/11

TM2256 (09JAN07) 42-4240-10 D Series Motor Grader Repair

020207
PN=474
 Frames

–UN–04DEC06
TX1014845
Bellcrank, Strut, and Pillow Block

48. Install lower pillow blocks (25) to mounting plate (47).

42
49. Install lower bushing (38) to lower pillow block right 4240
and left side. 11

1—Cap Nut (8 used)

13—Bellcrank
16—Midmount Frame
18—Tooth (11 used)
19—Shank (11 used)
24—Cap Screw (8 used)

–UN–05DEC06
25—Lower Pillow Block (2 used)
26—Upper Pillow Block (2 used)
27—Washer (16 used)
28—Cap Screw (8 used)
TX1014548A

29—Strut (2 used)
30—Upper and Lower End Cover (4 used)
31—Fitting (4 used)
32—Shim Thick .05 (12 used)
33—Shim Thin .015 (16 used) Mounting Plate
35—Retainer (11 used)
38—Upper and Lower Bushing (2 used)
47—Mounting Plate
57—Ball (4 used)

Continued on next page CP94658,0000033 –19–08DEC06–8/11

TM2256 (09JAN07) 42-4240-11 D Series Motor Grader Repair

020207
PN=475
 Frames

IMPORTANT: Lower pillow blocks are not anchored to

mounting plate so carefully lower
bellcrank down onto lower pillow
blocks.

50. Install bellcrank (13) to lower pillow blocks (25).

51. Install upper bushing (38) to top of bellcrank.

52. Install upper pillow blocks (26) to bellcrank.

53. Install cap screw, washer, and cap nut (24, 27, and 1)
to upper and lower pillow blocks and mounting plate
(47).

54. Install upper shims, end cover and cap screw (32, 33,
30, and 28) to bellcrank and strut (13 and 29) right
and left side.

55. Check upper and lower end covers and ball (30 and
57) socket area for excessive looseness. The ball and
socket assemblies on the strut ends are to be
shimmed to 1.1 mm (0.045 in.) to provide maximum
travel relative to the stationary ball without binding.

Specification
Ball and End Cover, Strut—
Maximum Clearance....................................................................... 1.1 mm
.045 in.

42 56. Install lower shims, end cover and cap screw (32, 33,
4240 30, and 28) to midmount frame and strut (16 and 29).
12

57. Grease the upper and lower fitting (31) on end cap
(30).

58. Install tooth (18) to shank (19). See Replacing

Scarifier Tooth. (Operator’s Manual).

59. Install shank and retainer (19 and 35) to midmount

frame (16). See Replacing Scarifier Shank.
(Operator’s Manual).

Continued on next page CP94658,0000033 –19–08DEC06–9/11

TM2256 (09JAN07) 42-4240-12 D Series Motor Grader Repair

020207
PN=476
 Frames

–UN–04DEC06
TX1014923
Cylinder, Pin, and Washer

7—Cap Screw (2 used) 13—Bellcrank 46—Cylinder Rod 53—Rod End Pin

11—Washer (2 used) 15—Head End Pin 52—Cylinder Head End 56—Washer (4 used)
12—Spacer (2 used) 23—Front Mount
42
60. Install head end pin, washer, and cylinder head 62. Install rod end pin, washer and cylinder rod end 4240
end (15, 56, and 52) to front mount (23). (53, 56 and 46) to bellcrank (13). 13

NOTE: Install washers as required to take up the play NOTE: Install washers as required to take up the play
between cylinder head end and front mount. between cylinder rod end and bellcrank.

61. Install washer, spacer, and cap screw (11, 12, and 63. Install washer, spacer, and cap screw (11, 12, and
7) to front mount (23). 7) to bellcrank (13).

Continued on next page CP94658,0000033 –19–08DEC06–10/11

TM2256 (09JAN07) 42-4240-13 D Series Motor Grader Repair

020207
PN=477
 Frames

64. Install hose guide (49) to hydraulic hose rod end (51).

65. Install clamp (50) to hose guide and cylinder head

end (49 and 52).

–UN–01DEC06
66. Install hydraulic hose head end (48) to cylinder head
end (52).

67. Install hydraulic hose rod end (51) to cylinder rod end.

TX1014518A
7—Cap Screw (2 used)
13—Bellcrank
15—Head End Pin Lift Cylinder
23—Front Mount
46—Cylinder Rod
48—Hydraulic Hose Head End
49—Hose Guide
50—Clamp
51—Hydraulic Hose Rod End
52—Cylinder Head End
53—Rod End Pin

CP94658,0000033 –19–08DEC06–11/11

42
4240
14

TM2256 (09JAN07) 42-4240-14 D Series Motor Grader Repair

020207
PN=478
 Frames

42
4240
15

TM2256 (09JAN07) 42-4240-15 D Series Motor Grader Repair

020207
PN=479
 Frames

Ripper Remove and Install

42
4240
16

–UN–03DEC04
T204198

Ripper
Continued on next page TX,42,DU2373 –19–19JAN05–1/2

TM2256 (09JAN07) 42-4240-16 D Series Motor Grader Repair

020207
PN=480
 Frames

1—Cap Screw (8 used) 11—Snap Ring (8 used) 19—Frame 29—Reflector (2 used)

2—Cap Screw (2 used) 12—Lubrication Fitting (10 21—Quick Lock Pin 30—Reflector (2 used)
3—Cap Screw (16 used) used) 22—Shank (3 used) 31—Pin (3 used)
4—Cap Screw (6 used) 13—Lubrication Fitting (6 23—Tooth (3 used) 32—Pin (3 used)
5—Washer (22 used) used) 24—Retainer (3 used) 33—Hydraulic Cylinder (2
6—Spacer (8 used) 14—Washer (10 used) 25—Pin (3 used) used)
7—Bushing (2 used) 15—Plate (4 used) 26—Pin Fastener 34—Side Boom
8—Pin (4 used) 16—Pin (4 used) 27—Spring Pin 35—Frame
9—Pin (6 used) 17—Spacer (2 used) 28—Spring Pin 36—Ripper Assemble
10—Bracket (2 used) 18—Plate (2 used)

CAUTION: Avoid crushing injury. Use

appropriate lifting device.

Item Measurement Specification

Ripper Approximate Weight 1361 kg

3000 lb

TX,42,DU2373 –19–19JAN05–2/2

42
4240
17

TM2256 (09JAN07) 42-4240-17 D Series Motor Grader Repair

020207
PN=481
 Frames

42
4240
18

TM2256 (09JAN07) 42-4240-18 D Series Motor Grader Repair

020207
PN=482
 Section 99
Dealer Fabricated Tools
Contents

Page

Group 9900—Dealer Fabricated Tools

DFT1151—Outboard Bearing Driver . . . . . . .99-9900-1
DFT1152—Inboard Bearing Driver . . . . . . . .99-9900-2
DFT1153—Oil Seal Driver. . . . . . . . . . . . . . .99-9900-2
DF1017—Axle Lift Eye . . . . . . . . . . . . . . . . .99-9900-3
DF1057—Axle Adjusting Tool . . . . . . . . . . . .99-9900-4
DFRW103—Yoke Holding Tool1 . . . . . . . . . .99-9900-5
DFT1225—Rolling Torque Measurement
Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99-9900-6
DFT1253 Transmission Support Bracket . . . .99-9900-7
DFRW20 Compressor Holding Fixture. . . . . .99-9900-8
DFT1101 Cab and ROPS Lift Bracket . . . . . .99-9900-9
DFT1282—King Pin Torque Adapter . . . . . .99-9900-10

99

TM2256 (09JAN07) 99-1 D Series Motor Grader Repair

020207
PN=1
 Contents

99

TM2256 (09JAN07) 99-2 D Series Motor Grader Repair

020207
PN=2
 Group 9900
Dealer Fabricated Tools

DFT1151—Outboard Bearing Driver

–UN–21JUL97
T110629
Material Required: • Steel tubing or equivalent

• 114.4 mm OD x 9.5 mm wall (4.50 in. OD x 0.375

in. wall)

TX,02,DU2626 –19–06JAN05–1/1

99
9900
1

TM2256 (09JAN07) 99-9900-1 D Series Motor Grader Repair

020207
PN=485
 Dealer Fabricated Tools

DFT1152—Inboard Bearing Driver

–19–21JUL97
T110630
Material Required: • Barrel—114.4 mm OD x 9.5 mm wall (4.50 in. OD x
0.375 in. wall)
• Cap—20 mm (0.75 in.) mild steel plate • Steel tubing or equivalent
TX,02,DU2626 –19–06JAN05–1/1

DFT1153—Oil Seal Driver

99
9900
2

–19–21JUL97
T110631

Materials Required: • Driver—152 mm (6.0 in.) mild steel bar

• Handle—51 mm (2.0 in.) mild steel bar
• Driver—38 mm (1.50 in.) mild steel plate, or
TX,02,DU2627 –19–18JUL97–1/1

TM2256 (09JAN07) 99-9900-2 D Series Motor Grader Repair

020207
PN=486
 Dealer Fabricated Tools

DF1017—Axle Lift Eye

–19–22MAY89
99

T6401FS
9900
3

Axle Lift Eye is used for removal and installation of • 12.7 mm (0.50 in.) 1020 mild steel.
axle housing.

Material required:

T29,9900,M3 –19–06JAN05–1/1

TM2256 (09JAN07) 99-9900-3 D Series Motor Grader Repair

020207
PN=487
 Dealer Fabricated Tools

DF1057—Axle Adjusting Tool

–UN–22OCT91
RW18932
99
9900
4 A—660.4 mm (26 in.) G—250.8 mm (9.87 in.) L—0.187 5 x 2 x 2 in. Tube S—355.6 mm (14 in.)
B—225.4 mm (8.87 in.) H—223.8 mm (8.81 in.) M—25.4 mm (1 in.) T—425.2 mm (16.74 in.)
C—1/2 in. Drilled Hole (2 I—25.4 mm (1 in.) N—25.4 mm (1 in.) U—25.4 mm (1 in.)
places) J—0.25 x 1 x 1.38 in. Each O—11/16 in. Drilled Hole V—3/4 in. Drilled Hole (2
D—Welded Nut (Centered) Chain Link P—104.7 mm (4.13 in.) places)
E—300 mm (11.81 in.) K—3/4 in. Drilled Hole (8 Q—50.8 mm (2 in.) W—25.4 mm (1 in.)
F—274.1 mm (10.79 in.) Places) R—307.9 mm (12.12 in.) X—88.9 mm (3.5 in.)

Material Required: Use an odd number of links in the section of chain.

• 2 x 2 in. Steel Tube Tool is used to remove axle shaft and adjust axle
• 2 x 1/2 in. Flat Steel bearings.

RX,DF1057 –19–06JAN05–1/1

TM2256 (09JAN07) 99-9900-4 D Series Motor Grader Repair

020207
PN=488
 Dealer Fabricated Tools

DFRW103—Yoke Holding Tool1

–UN–14JUN95
RW25384
Material Required: Tool is used to retain input shaft during yoke retaining
nut remove and installation.
• 3/8 in. Flat Steel

Fabricate holding tool as illustrated.

1
Tool may be purchased. Order JDG924.
TX19495,000016E –19–06JAN05–1/1

99
9900
5

TM2256 (09JAN07) 99-9900-5 D Series Motor Grader Repair

020207
PN=489
 Dealer Fabricated Tools

DFT1225—Rolling Torque Measurement Tool

–UN–16NOV01
T148180
A—580 mm (23 in) (minimum) D—262 mm (10.3 in) F—10 mm (3/8 in) threaded rod H—10 mm (3/8 in) cap screw
B—523 mm (20.6 in) E—10 mm (3/8 in) nut and G—230 mm (9 in)
C—10 mm (3/8 in) flat steel bar washer (8 used)

Material Required: • 10 mm (3/8 in) cap screw (H)

99 • 10 mm (3/8 in) flat steel bar (C) Tool is used to measure rolling torque on HFWD wheel
9900 • 10 mm (3/8 in) threaded rod (F) drive hubs.
6
• 10 mm (3/8 in) nuts and washers (E) (8 used)

TX19495,000016F –19–06JAN05–1/1

TM2256 (09JAN07) 99-9900-6 D Series Motor Grader Repair

020207
PN=490
 Dealer Fabricated Tools

DFT1253 Transmission Support Bracket

205.0 MM
(8.1 IN.)

140.0 MM
(5.5 IN.)
101.6 MM
(4.0 IN.)
3/4 - 10 UNC
UNPLATED NUT
50.8 MM
(2.0 IN.) 55
WELD

WELD

25.0 MM
WELD
125.0 MM (0.98 IN.)
(4.9 IN.) DRILL 35
25.4 MM
(1.0 IN.)
9.52 MM
(0.375 IN.) 105 MM
(4.1 IN.)
105.0 MM
45.0 MM (4.1 IN.)
191.0 MM (1.8 IN.)
(7.5 IN.)
99
174.0 MM 9900
(6.85 IN.) 7

15.8 MM
4 x 18.00 MM 28.5 MM
(0.625 IN.)
(0.7 IN.) DRILL (1.1 IN.)

57.0 MM TRANSMISSION SUPPORT BRACKET IS USED TO HOLD

(2.2 IN.) TRANSMISSION IN CHASSIS WHEN ENGINE IS REMOVED.

MATERIAL REQUIRED:
–19–04JAN05

15.88 MM (0.625 IN.) IDM 1020 HR STEEL.

9.57 MM (0.375 IN.) IDM 1020 HR STEEL.
T206134

T206134
DFT1253 Transmission Support Bracket
TX19495,000016D –19–17DEC04–1/1

TM2256 (09JAN07) 99-9900-7 D Series Motor Grader Repair

020207
PN=491
 Dealer Fabricated Tools

DFRW20 Compressor Holding Fixture

–UN–20SEP89
RW13619
A—102 mm (4 in.) D—6.4 mm (0.25 in.) G—254 mm (10 in.) J—Weld
B—76 mm (3 in.) E—19 mm (0.75 in.) H—114 mm (4.5 in.) K—Two Holes
C—70 mm (2.75 in.) F—152 mm (6 in.) I—178 mm (7 in.)

This tool is used to hold the air conditioning • Two pieces of threaded rod, 13 mm (1/2 in.) threads
compressor during disassembly and assembly. x 178 mm (7 in.) long and four lock washers and
nuts.
MATERIALS:
99
9900 • Two pieces of steel plate, approximately 70 x 120
8 mm (2-3/4 x 4 in.) and 152 x 254 mm (6 x 10 in.).

NX,19905,F –19–06JAN05–1/1

TM2256 (09JAN07) 99-9900-8 D Series Motor Grader Repair

020207
PN=492
 Dealer Fabricated Tools

DFT1101 Cab and ROPS Lift Bracket

–UN–23SEP98
T117366
A—Drill Six Holes (0.625 in.) B—Weld C—U46161 Lift Eyes Welded to
Tube with 0.25 in. Fillet
Weld

Used to remove and install cab or ROPS. • U46161 U-Bolts (4 used)

• JT01748 Lift Brackets (2 used)
Material: • 0.625 in. x 3.00 in. "F" Grade Cap Screws (2 used) 99
9900
9
• 2.0 in. x 2.0 in. x 0.250 in. Square Tube

TX,18,QQ9298 –19–01SEP06–1/1

TM2256 (09JAN07) 99-9900-9 D Series Motor Grader Repair

020207
PN=493
 Dealer Fabricated Tools

DFT1282—King Pin Torque Adapter

B C
D

E G

–UN–19DEC06
J

TX1016357
TX1016357

A—173 mm (6.8 in.) D—70.5 mm (2.78 in.) G—24 mm Nut J—19 mm (0.750 in.)
B—70.5 mm (2.78 in.) E—Weld H—13 mm (0.5 in.) K—38 mm (1.5 in.)
C—86.5 mm (3.41 in.) F—6 mm (0.25 in.)

Material Required: Tool is used to measure rolling torque of lean yoke on

lower king pin of front hubs.
• 6 mm (1/4 in.) flat steel bar
• 24 mm Nut
99
9900
10

AC12469,000003C –19–19DEC06–1/1

TM2256 (09JAN07) 99-9900-10 D Series Motor Grader Repair

020207
PN=494
 Index
Page Page

A Rear, tandem and wheel assembly, remove and

install. . . . . . . . . . . . . . . . . . . . . . . . .02-0250-16
Accumulator Tandem and wheel assembly, remove and
Air conditioner, remove and install . . . .18-1830-16 install. . . . . . . . . . . . . . . . . . . . . . . . .02-0250-11
Brake, remove and install . . . . . . . . . . . .10-1060-4 Tandem wheel assembly, disassemble and
Transmission, remove and install . . . . . .03-0360-3 assemble . . . . . . . . . . . . . . . . . . . . . .02-0250-20
Adjustment Axle adjusting tool
Circle clearance . . . . . . . . . . . . . . . . . . .34-3440-9 DF1057. . . . . . . . . . . . . . . . . . . . . . . . . .99-9900-4
Air conditioner Axle lift eye
Accumulator remove and install . . . . . .18-1830-16 DF1017. . . . . . . . . . . . . . . . . . . . . . . . . .99-9900-3
Compressor relief valve remove and
install. . . . . . . . . . . . . . . . . . . . . . . . .18-1830-20
Compressor remove and install. . . . . . .18-1830-10
Condener remove and install . . . . . . . .18-1830-11 B
Receiver/dryer remove and install . . . . .18-1830-15
Air conditioner and heater Battery explosions
Remove and install . . . . . . . . . . . . . . . .18-1830-13
Prevent . . . . . . . . . . . . . . . . . . . . . . . . . . .00-001-4
Air conditioner system
Bearing
Flush and purge . . . . . . . . . . . . . . . . . . .18-1830-3
HFWD, remove and install . . . . . . . . . .02-0240-28
Refrigerant cautions and proper
Blade lift
handling. . . . . . . . . . . . . . . . . . . . . . . .18-1830-1
Cylinder, disassemble and assemble . . .09-0960-8
R134a refrigerant oil information . . . . . . .18-1830-6
Cylinder, remove and install . . . . . . . . .34-3460-21
Air conditioning
Valve section, disassemble and
Charge R134a system . . . . . . . . . . . . .18-1830-10
assemble . . . . . . . . . . . . . . . . . . . . . . .34-3460-8
Evacuate R134a system . . . . . . . . . . . . .18-1830-9
Blade side shift
Recover R134a refrigerant . . . . . . . . . . .18-1830-8
Valve section, disassemble and
R134a station installation . . . . . . . . . . . .18-1830-7
Air suspension seat assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-12
Seat disassemble and assemble. . . . . . .18-1821-4 Blade side shift clearance
Suspension disassemble and Measure and adjust . . . . . . . . . . . . . . .34-3440-15
assemble . . . . . . . . . . . . . . . . . . . . . . .18-1821-6 Blade side shift wear inserts
Articulation Install and adjust. . . . . . . . . . . . . . . . . .34-3440-12
Cylinder, disassemble and assemble . . .09-0960-8 Blade slide
Valve section, disassemble and Cylinder, disassemble and assemble . . .09-0960-8
assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-12 Blade tilt
Attachments Cylinder, disassemble and assemble . . .09-0960-8
Adding safely . . . . . . . . . . . . . . . . . . . . .00-001-10 Cylinder, remove and install . . . . . . . . .34-3460-21
Operating safely . . . . . . . . . . . . . . . . . . .00-001-10 Valve section, disassemble and
Attenuator assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-12
Indx
Remove and install . . . . . . . . . . . . . . . .21-2160-15 Blade tilt frame 1
Axle Remove and install . . . . . . . . . . . . . . . . .34-3440-6
Final drive, disassemble and Brake
assemble . . . . . . . . . . . . . . . . . . . . . .02-0250-36 Components, remove and install . . . . . .02-0250-39
Final drive, remove and install . . . . . . .02-0250-30 Park, Disassemble and assemble . . . . . .11-1111-1
Front, HFWD, remove and install . . . . .02-0240-41 Park, remove and install . . . . . . . . . . . . .11-1111-1
Front, non HFWD, remove and install . . .02-0230-4 Planetary, disassemble and
Front, tandem wheel assembly, remove and assemble . . . . . . . . . . . . . . . . . . . . . .02-0240-22
install. . . . . . . . . . . . . . . . . . . . . . . . .02-0250-17 Service, bleeding . . . . . . . . . . . . . . . . . .10-1060-3
Planet pinion carrier, remove and Service, disassemble and assemble . . . .10-1011-1
install. . . . . . . . . . . . . . . . . . . . . . . . .02-0250-40 Service, remove and install . . . . . . . . . . .10-1011-1
Rear, disassemble and assemble . . . . .02-0250-10 Brake accumulator
Rear, remove and install . . . . . . . . . . . . .02-0250-2 Remove and install . . . . . . . . . . . . . . . . .10-1060-4

TM2256 (09JAN07) Index-1 D Series Motor Grader Repair

020207
PN=1
 Index

Page Page

C Oil cooler remove and install. . . . . . . . .05-0510-10

Radiator remove and install . . . . . . . . . .05-0510-8
Cab Cylinder
Remove and install . . . . . . . . . . . . . . . . .18-1800-1 Articulation, disassemble and
Cab door assemble . . . . . . . . . . . . . . . . . . . . . . .09-0960-8
Handle remove and install. . . . . . . . . . . .18-1810-2 Blade lift, disassemble and assemble . . .09-0960-8
Latch remove and install . . . . . . . . . . . . .18-1810-3 Blade lift, remove and install . . . . . . . . .34-3460-21
Chain Blade slide, disassemble and
Drive, remove and install. . . . . . . . . . . .02-0250-53 assemble . . . . . . . . . . . . . . . . . . . . . . .09-0960-8
Charge air cooler Blade tilt, disassemble and assemble . . .09-0960-8
Remove and install . . . . . . . . . . . . . . . .05-0510-13 Blade tilt, remove and install . . . . . . . . .34-3460-21
Charge pump Circle sideshift, disassemble and
HFWD, disassemble and assemble. . . .02-0260-33 assemble . . . . . . . . . . . . . . . . . . . . . . .09-0960-8
HFWD, remove and install . . . . . . . . . .02-0260-32 Circle sideshift, remove and install . . . .34-3460-21
Charge R134a system . . . . . . . . . . . . . . .18-1830-10 Disassemble and assemble . . . . . . . . . .09-0960-8
Circle Front steering, disassemble and
Clearance adjust . . . . . . . . . . . . . . . . . . .34-3440-9 assemble . . . . . . . . . . . . . . . . . . . . . . .09-0960-8
Circle drive gearbox Ripper, disassemble and assemble. . . . .09-0960-8
Disassemble and assemble . . . . . . . . . .34-3450-2 Scarifier, disassemble and assemble . . .09-0960-8
(with slip clutch), disassemble and Wheel lean, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . . .34-3450-6 assemble . . . . . . . . . . . . . . . . . . . . . . .09-0960-8
Circle frame Wheel lean, remove and install . . . . . . . .09-0960-9
Remove and install . . . . . . . . . . . . . . . . .34-3440-6
Circle rotate
Valve section, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-14 D
Circle side shift
Cylinder, remove and install . . . . . . . . .34-3460-21 Dealer fabricated tool
Valve section, disassemble and DFRW20 compressor holding fixture. . . .99-9900-8
assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-12 DFT1151 outboard bearing driver . . . . . .99-9900-1
Circle sideshift DFT1152 inboard bearing driver . . . . . . .99-9900-2
Cylinder, disassemble and assemble . . .09-0960-8 DFT1153 oil seal driver. . . . . . . . . . . . . .99-9900-2
Clutch DFT1225 rolling torque measurement
Compressor, disassemble and tool . . . . . . . . . . . . . . . . . . . . . . . . . . .99-9900-6
assemble . . . . . . . . . . . . . . . . . . . . . .18-1830-18 DFT1253 transmission support
Compressor bracket . . . . . . . . . . . . . . . . . . . . . . . .99-9900-7
Air conditioner, remove and install . . . .18-1830-10 DFT1282 king pin torque adapter . . . . .99-9900-10
Clutch, disassemble and assemble . . . .18-1830-18 DF1017 axle lift eye . . . . . . . . . . . . . . . .99-9900-3
Manifold, inspect . . . . . . . . . . . . . . . . . .18-1830-20 DF1057 axle adjusting tool . . . . . . . . . . .99-9900-4
Indx Relief valve remove and install . . . . . . .18-1830-20 DFRW103
2 Compressor holding fixture Yoke holding tool . . . . . . . . . . . . . . . . . .99-9900-5
DFRW20 . . . . . . . . . . . . . . . . . . . . . . . . .99-9900-8 DFRW20
Condenser Compressor holding fixture . . . . . . . . . . .99-9900-8
Air conditioner, remove and install . . . .18-1830-11 DFT1151
Console Outboard bearing driver . . . . . . . . . . . . .99-9900-1
Remove and install . . . . . . . . . . . . . . . . .34-3415-2 DFT1152
Console tilt linkage Inboard bearing driver . . . . . . . . . . . . . . .99-9900-2
Remove and install . . . . . . . . . . . . . . . . .34-3415-5 DFT1153
Control valve Oil seal driver . . . . . . . . . . . . . . . . . . . . .99-9900-2
Disassemble and assemble . . . . . . . . . .34-3460-4 DFT1225
Remove and install . . . . . . . . . . . . . . . . .34-3460-1 Rolling torque measurement tool. . . . . . .99-9900-6
Cooling package DFT1253
Charge air cooler remove and install. . .05-0510-13 Transmission support bracket . . . . . . . . .99-9900-7

TM2256 (09JAN07) Index-2 D Series Motor Grader Repair

020207
PN=2
 Index

Page Page

DFT1282 Fan belt

King pin torque adapter. . . . . . . . . . . . .99-9900-10 Tensioner, remove and install . . . . . . . . .05-0510-5
DF1017 Fan drive assembly
Axle lift eye . . . . . . . . . . . . . . . . . . . . . . .99-9900-3 Remove and install . . . . . . . . . . . . . . . . .05-0510-6
DF1057 Fan pulley
Axle adjusting tool. . . . . . . . . . . . . . . . . .99-9900-4 Disassemble and assemble . . . . . . . . . .05-0510-3
DF180 transmission . . . . . . . . . . . . . . . . . .03-0300-1 Remove and install . . . . . . . . . . . . . . . . .05-0510-2
DF230 transmission . . . . . . . . . . . . . . . . . .03-0300-1 Filter
Differential lock pump Transmission oil, remove and install . . . .03-0360-2
Remove and install . . . . . . . . . . . . . . . .02-0260-37 Final drive axle
Differential oil cooler Disassemble and assemble . . . . . . . . .02-0250-36
Remove and install . . . . . . . . . . . . . . . .05-0510-10 Remove and install . . . . . . . . . . . . . . . .02-0250-30
Door handle Fire prevention . . . . . . . . . . . . . . . . . . . . . . .00-001-4
Remove and install . . . . . . . . . . . . . . . . .18-1810-2 Flush air conditioner system . . . . . . . . . . . .18-1830-3
Door latch Frames
Remove and install . . . . . . . . . . . . . . . . .18-1810-3 Remove and install . . . . . . . . . . . . . . . . .34-3440-6
Draft frame Front axle
Remove and install . . . . . . . . . . . . . . . . .34-3440-6 HFWD, remove and install . . . . . . . . . .02-0240-41
Drive chain Non HFWD, remove and install. . . . . . . .02-0230-4
Remove and install . . . . . . . . . . . . . . . .02-0250-53 Front steering
Drive hub Cylinder, disassemble and assemble . . .09-0960-8
disassemble and assemble . . . . . . . . . . .05-0510-7 Front wheel
HFWD, disassemble and assemble. . . .02-0240-15 HFWD hub and spindle, disassemble and
Drive shaft assemble . . . . . . . . . . . . . . . . . . . . . . .02-0240-6
Tandem, Remove and install. . . . . . . . .02-0250-42 HFWD hub and spindle, disassemble and
Transmission-to-rear axle, disassemble and assemble with steering angle
assemble . . . . . . . . . . . . . . . . . . . . . . .02-0225-2
sensor . . . . . . . . . . . . . . . . . . . . . . . .02-0240-11
Transmission-to-rear axle, remove and
HFWD hub and spindle, remove and
install. . . . . . . . . . . . . . . . . . . . . . . . . .02-0225-1
install. . . . . . . . . . . . . . . . . . . . . . . . . .02-0240-1
Driving metal pins. . . . . . . . . . . . . . . . . . . .00-001-12
Non HFWD hub and spindle, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . . .02-0230-2
E Non HFWD hub and spindle, remove and
install. . . . . . . . . . . . . . . . . . . . . . . . . .02-0230-1
Emergency preparation . . . . . . . . . . . . . . . .00-001-5 Fuel tank
Engagement manifold Remove and install . . . . . . . . . . . . . . . . .05-0560-1
HFWD, Disassemble and assemble . . .02-0260-36 Funk transmission . . . . . . . . . . . . . . . . . . .03-0300-1
HFWD, remove and install . . . . . . . . . .02-0260-33
Engine
Remove and install—6.8 L . . . . . . . . . . .04-0400-2
Remove and install—8.1 L . . . . . . . . . . .04-0400-8 G Indx
Engine and equipment frame 3
Separate . . . . . . . . . . . . . . . . . . . . . . . . .17-1740-3 Grader control valve
Engine coupler Disassemble and assemble . . . . . . . . . .34-3460-4
Remove and install . . . . . . . . . . . . . . . . .07-0752-1 Remove and install . . . . . . . . . . . . . . . . .34-3460-1
Evacuate R134a system. . . . . . . . . . . . . . .18-1830-9 Grille housing
Exhaust fumes . . . . . . . . . . . . . . . . . . . . . . .00-001-4 Remove and install . . . . . . . . . . . . . . . . .19-1921-1
Explosion
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . .00-001-4
H
F
Handhold use . . . . . . . . . . . . . . . . . . . . . . . .00-001-6
Fan Heater and air conditioner
Remove and install . . . . . . . . . . . . . . . . .05-0510-1 Remove and install . . . . . . . . . . . . . . . .18-1830-13

TM2256 (09JAN07) Index-3 D Series Motor Grader Repair

020207
PN=3
 Index

Page Page

HFWD Hydraulic oil tank

Bearings, remove and install . . . . . . . . .02-0240-28 Remove and install . . . . . . . . . . . . . . . .21-2160-13
Charge pump, disassemble and Hydraulic pump
assemble . . . . . . . . . . . . . . . . . . . . . .02-0260-33 Disassemble and assemble . . . . . . . . . .21-2160-4
Charge pump, remove and install . . . . .02-0260-32 Remove and install . . . . . . . . . . . . . . . . .21-2160-1
Drive hub, disassemble and Hydraulic system manifold
assemble . . . . . . . . . . . . . . . . . . . . . .02-0240-15 Disassemble and assemble . . . . . . . . .21-2160-11
Engagement manifold, disassemble and Remove and install . . . . . . . . . . . . . . . . .21-2160-9
assemble . . . . . . . . . . . . . . . . . . . . . .02-0260-36
Engagement manifold, remove and
install. . . . . . . . . . . . . . . . . . . . . . . . .02-0260-33
I
Front wheel hub and spindle, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . . .02-0240-6
Inboard bearing driver
Front wheel hub and spindle, disassemble and
DFT1152. . . . . . . . . . . . . . . . . . . . . . . . .99-9900-2
assemble with steering angle
Inch bolt and cap screw
sensor . . . . . . . . . . . . . . . . . . . . . . . .02-0240-11
Torque value. . . . . . . . . . . . . . . . . . . . . .00-0003-4
Front wheel hub and spindle, remove and
Inch series four bolt flange fitting
install. . . . . . . . . . . . . . . . . . . . . . . . . .02-0240-1
Service recommendation, torque value for high
Motor flushing pump, remove and
pressure . . . . . . . . . . . . . . . . . . . . . .00-0003-18
install. . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-1
Inspect machine . . . . . . . . . . . . . . . . . . . . . .00-001-3
Motor, disassemble and assemble . . . .02-0260-44
Intercooler
Motor, remove and install . . . . . . . . . . .02-0260-42
Remove and install . . . . . . . . . . . . . . . .05-0510-13
O-ring metal face seal, remove and
install. . . . . . . . . . . . . . . . . . . . . . . . .02-0240-33
Planetary brake, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . .02-0240-22 K
Planetary drive, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . .02-0240-18 King pin torque adapter
Pump, disassemble and assemble . . . . .02-0260-4 DFT1282. . . . . . . . . . . . . . . . . . . . . . . .99-9900-10
Pump, remove and install . . . . . . . . . . . .02-0260-1
High-pressure oils
Avoid . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-001-3
L
Hub
Fan drive, disassemble and assemble . .05-0510-7
Lift arms
HFWD front, disassemble and
Remove and install . . . . . . . . . . . . . . . . .34-3440-2
assemble . . . . . . . . . . . . . . . . . . . . . . .02-0240-6
Locking pin bracket
HFWD front, disassemble and assemble with
Remove and install . . . . . . . . . . . . . . . . .34-3440-2
steering angle sensor . . . . . . . . . . . .02-0240-11
HFWD front, remove and install . . . . . . .02-0240-1
Indx Non HFWD front, disassemble and
4 assemble . . . . . . . . . . . . . . . . . . . . . . .02-0230-2 M
Non HFWD front, remove and install. . . .02-0230-1
Hydraulic Machine inspection. . . . . . . . . . . . . . . . . . . .00-001-3
Fittings, 30° cone seat. . . . . . . . . . .00-0003-5 Manifold
Fittings, 37° flare . . . . . . . . . . . . . . .00-0003-5 Hydraulic system, disassemble and
Hydraulic cylinder assemble . . . . . . . . . . . . . . . . . . . . . .21-2160-11
Disassemble and assemble . . . . . . . . . .09-0960-8 Hydraulic system, remove and install . . .21-2160-9
Hydraulic fitting Rotary, disassemble and assemble. . . .34-3460-20
Flared connections . . . . . . . . . . . . . . . . .00-0003-8 Rotary, remove and install . . . . . . . . . .34-3460-19
Non-restricted banjo (adjustable). . . . . .00-0003-19 Mechanical suspension seat
O-ring boss with shoulder . . . . . . . . . . .00-0003-21 Seat disassemble and assemble. . . . . . .18-1821-8
Hydraulic oil cooler Suspension disassemble and
Remove and install . . . . . . . . . . . . . . . .05-0510-10 assemble . . . . . . . . . . . . . . . . . . . . . .18-1821-10

TM2256 (09JAN07) Index-4 D Series Motor Grader Repair

020207
PN=4
 Index

Page Page

Metal face seals Valve, disassemble and assemble . . . .02-0260-40

Inspection . . . . . . . . . . . . . . . . . . . . . . .02-0250-54 Valve, remove and install . . . . . . . . . . .02-0260-39
Metal face seals, HFWD Planet pinion carrier
Remove and install . . . . . . . . . . . . . . . .02-0240-33 Remove and install . . . . . . . . . . . . . . . .02-0250-40
Metal pins. . . . . . . . . . . . . . . . . . . . . . . . . .00-001-12 Planetary brake
Metric bolt and cap screw Disassemble and assemble . . . . . . . . .02-0240-22
Torque value. . . . . . . . . . . . . . . . . . . . . .00-0003-1 Planetary drive
Midmount Disassemble and assemble . . . . . . . . .02-0240-18
Scarifier valve section, disassemble and Protective equipment . . . . . . . . . . . . . . . . . .00-001-2
assemble . . . . . . . . . . . . . . . . . . . . . . .34-3460-6 Pump
Scarifier, remove and install . . . . . . . . . .42-4240-4 HFWD motor flushing, remove and
Motor install. . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-1
HFWD, disassemble and assemble. . . .02-0260-44 HFWD, disassemble and assemble. . . . .02-0260-4
HFWD, remove and install . . . . . . . . . .02-0260-42 HFWD, remove and install . . . . . . . . . . .02-0260-1
Rotate, disassemble and assemble. . . .34-3460-16 Hydraulic, disassemble and assemble. . .21-2160-4
Moving parts Hydraulic, remove and install . . . . . . . . .21-2160-1
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-001-3 Transmission charge, remove and
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . .00-001-3 install. . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-1
Purge air conditioner system . . . . . . . . . . .18-1830-3

O-ring boss fittings . . . . . . . . . . . . . . . . . . .00-0003-6 R

O-ring face seal fitting
Inch hex nut and stud end for high pressure torque Radiator
values . . . . . . . . . . . . . . . . . . . . . . . .00-0003-10 Remove and install . . . . . . . . . . . . . . . . .05-0510-8
Metric hex nut and stud end for high pressure Rear axle
torque values. . . . . . . . . . . . . . . . . . .00-0003-14 Disassemble and assemble . . . . . . . . .02-0250-10
Metric hex nut and stud end for standard pressure Final drive, disassemble and
torque values. . . . . . . . . . . . . . . . . . .00-0003-12 assemble . . . . . . . . . . . . . . . . . . . . . .02-0250-36
O-ring seal, metric 24° Final drive, remove and install . . . . . . .02-0250-30
Service recommendation. . . . . . . . . . . .00-0003-24 Planet pinion carrier, remove and
Oil cooler install. . . . . . . . . . . . . . . . . . . . . . . . .02-0250-40
remove and install. . . . . . . . . . . . . . . . .05-0510-10 Remove and install . . . . . . . . . . . . . . . . .02-0250-2
Oil filter Receiver/dryer
Transmission, remove and install . . . . . .03-0360-2 Air conditioner, remove and install . . . .18-1830-15
Oil information Recover R134a refrigerant . . . . . . . . . . . . .18-1830-8
R134a refrigerant . . . . . . . . . . . . . . . . . .18-1830-6 Refrigerant
Oil seal driver Cautions and proper handling . . . . . . . . .18-1830-1 Indx
DFT1153. . . . . . . . . . . . . . . . . . . . . . . . .99-9900-2 Recover R134a, air conditioning . . . . . . .18-1830-8 5
Operation qualification . . . . . . . . . . . . . . . . .00-001-2 Refrigerant oil information
Operator enclosure R134a . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-6
Remove and install . . . . . . . . . . . . . . . . .18-1800-1 Refrigerant recovery/recycling and charging
Outboard bearing driver Charging station installation
DFT1151. . . . . . . . . . . . . . . . . . . . . . . . .99-9900-1 procedure . . . . . . . . . . . . . . . . . . . . . .18-1830-7
Remove and install
Steering angle sensor (S.N. 611296—
P ). . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0240-48
Reservoir
Park brake Fuel, remove and install . . . . . . . . . . . . .05-0560-1
Disassemble and assemble . . . . . . . . . .11-1111-1 Return check poppets
Remove and install . . . . . . . . . . . . . . . . .11-1111-1 Disassemble and assemble . . . . . . . . .34-3460-15

TM2256 (09JAN07) Index-5 D Series Motor Grader Repair

020207
PN=5
 Index

Page Page

Ripper Service brake

Cylinder, disassemble and assemble . . .09-0960-8 Bleeding . . . . . . . . . . . . . . . . . . . . . . . . .10-1060-3
Remove and install . . . . . . . . . . . . . . . .42-4240-16 Components, remove and install . . . . . .02-0250-39
Valve section, disassemble and Disassemble and assemble . . . . . . . . . .10-1011-1
assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-10 Remove and install . . . . . . . . . . . . . . . . .10-1011-1
Rolling torque measurement tool Service brake valve
DFT1225. . . . . . . . . . . . . . . . . . . . . . . . .99-9900-6 Remove and install . . . . . . . . . . . . . . . . .10-1060-1
Rotary manifold Service recommendation
Disassemble and assemble . . . . . . . . .34-3460-20 Inch series four bolt flange fitting for high
Remove and install . . . . . . . . . . . . . . . .34-3460-19 pressure . . . . . . . . . . . . . . . . . . . . . .00-0003-18
Rotate motor O-ring face seal fittings with inch hex nut and
Disassemble and assemble . . . . . . . . .34-3460-16 stud end for high pressure. . . . . . . . .00-0003-10
R134a refrigerant recovery . . . . . . . . . . . . .18-1830-8 O-ring face seal fittings with metric hex nut and
R134a refrigerant recovery and charging station stud end for high pressure. . . . . . . . .00-0003-14
Installation procedure . . . . . . . . . . . . . . .18-1830-7 O-ring face seal fittings with metric hex nut and
R134a system charge. . . . . . . . . . . . . . . .18-1830-10 stud end for standard pressure . . . . .00-0003-12
R134a system evacuate . . . . . . . . . . . . . . .18-1830-9 O-ring seal, metric 24° . . . . . . . . . . . . .00-0003-24
Soft start valve
Disassemble and assemble . . . . . . . . .21-2160-18
Remove and install . . . . . . . . . . . . . . . .21-2160-16
S Spindle
HFWD front, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . . .02-0240-6
Saddle frame
HFWD front, disassemble and assemble with
Remove and install . . . . . . . . . . . . . . . . .34-3440-2 steering angle sensor . . . . . . . . . . . .02-0240-11
Safety HFWD front, remove and install . . . . . . .02-0240-1
Operator’s seat . . . . . . . . . . . . . . . . . . . . .00-001-6 Non HFWD front, disassemble and
Safety equipment . . . . . . . . . . . . . . . . . . . . .00-001-2 assemble . . . . . . . . . . . . . . . . . . . . . . .02-0230-2
Safety information Non HFWD front, remove and install. . . .02-0230-1
Recognizing . . . . . . . . . . . . . . . . . . . . . . .00-001-1 Steering angle sensor
Safety symbols . . . . . . . . . . . . . . . . . . . . . . .00-001-1 Remove and install (S.N. 611296—
Scarifier ). . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0240-48
Cylinder, disassemble and assemble . . .09-0960-8 Steering column
Midmount valve section, disassemble and Remove and install . . . . . . . . . . . . . . . . .09-0960-1
assemble . . . . . . . . . . . . . . . . . . . . . . .34-3460-6 Steering cylinder
Midmount, remove and install . . . . . . . . .42-4240-4 Remove and install . . . . . . . . . . . . . . . . .09-0960-7
Remove and install . . . . . . . . . . . . . . . . .42-4240-2 Steering support
Valve section, disassemble and Remove and installl. . . . . . . . . . . . . . . . .34-3415-2
assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-10 Steering support and console
Seals Remove and install . . . . . . . . . . . . . . . . .34-3415-2
Indx Metal face, inspection . . . . . . . . . . . . . .02-0250-54 Steering tilt assembly
6 Seat Remove and install . . . . . . . . . . . . . . . . .34-3415-4
Air seat suspension, disassemble and Steering valve
assemble . . . . . . . . . . . . . . . . . . . . . . .18-1821-6 Disassemble and assemble . . . . . . . . . .09-0960-2
Air suspension seat, disassemble and Remove and install . . . . . . . . . . . . . . . . .09-0960-1
assemble . . . . . . . . . . . . . . . . . . . . . . .18-1821-4 Steering wheel
Belt remove and install . . . . . . . . . . . . . .18-1821-2 Remove and install . . . . . . . . . . . . . . . . .09-0960-1
Mechanical seat suspension, disassemble and Steps use . . . . . . . . . . . . . . . . . . . . . . . . . . .00-001-6
assemble . . . . . . . . . . . . . . . . . . . . . .18-1821-10
Mechanical suspension seat, disassemble and T
assemble . . . . . . . . . . . . . . . . . . . . . . .18-1821-8
Remove and install . . . . . . . . . . . . . . . . .18-1821-1 Tandem
Seat belt Front wheel axle assembly, remove and
Use and maintenance . . . . . . . . . . . . . . . .00-001-6 install. . . . . . . . . . . . . . . . . . . . . . . . .02-0250-17

TM2256 (09JAN07) Index-6 D Series Motor Grader Repair

020207
PN=6
 Index

Page Page

Pivot, disassemble and assemble . . . . .02-0250-26 V

Rear wheel axle assembly, remove and
install. . . . . . . . . . . . . . . . . . . . . . . . .02-0250-16 Valve
Wheel axle assembly, disassemble and Articulation section, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . .02-0250-20 assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-12
Wheel axle assembly, remove and Blade lift section, disassemble and
install. . . . . . . . . . . . . . . . . . . . . . . . .02-0250-11 assemble . . . . . . . . . . . . . . . . . . . . . . .34-3460-8
Tandem drive shaft Blade side shift section, disassemble and
Remove and install . . . . . . . . . . . . . . . .02-0250-42 assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-12
Tank Blade tilt section, disassemble and
Fuel, remove and install . . . . . . . . . . . . .05-0560-1 assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-12
Tensioner Circle rotate, disassemble and
Fan belt, remove and install . . . . . . . . . .05-0510-5 assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-14
Tire Circle side shift section, disassemble and
Remove and install . . . . . . . . . . . . . . . . .01-0110-1 assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-12
Toe-in (HFWD or non-HFWD) Grader control, disassemble and
Check and adjustment . . . . . . . . . . . . . .09-0920-1 assemble . . . . . . . . . . . . . . . . . . . . . . .34-3460-4
Torque value Grader control, remove and install . . . . .34-3460-1
Flared connections . . . . . . . . . . . . . . . . .00-0003-8 Midmount scarifier section, disassemble and
Flat face O-ring seal fitting . . . . . . . . . . .00-0003-9 assemble . . . . . . . . . . . . . . . . . . . . . . .34-3460-6
Inch SAE four bolt flange fitting. . . . . . .00-0003-17 Park brake, disassemble and
Inch series four bolt flange fitting for high assemble . . . . . . . . . . . . . . . . . . . . . .02-0260-40
pressure . . . . . . . . . . . . . . . . . . . . . .00-0003-18 Park brake, remove and install . . . . . . .02-0260-39
Metric bolt and cap screw . . . . . . . . . . . .00-0003-1 Ripper section, disassemble and
Metric cap screw. . . . . . . . . . . . . . . . . . .00-0003-2 assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-10
Metric four bolt flange fitting . . . . . . . . .00-0003-16 Scarifier section, disassemble and
Non-restricted banjo fittings. . . . . . . . . .00-0003-19 assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-10
O-Ring boss fitting . . . . . . . . . . . . . . . . .00-0003-6 Service brake, remove and install . . . . . .10-1060-1
O-ring boss fittings with shoulder . . . . .00-0003-21 Soft start, disassemble and
O-ring face seal fittings with inch hex nut and assemble . . . . . . . . . . . . . . . . . . . . . .21-2160-18
stud end for high pressure. . . . . . . . .00-0003-10 Soft start, remove and install. . . . . . . . .21-2160-16
O-ring face seal fittings with metric hex nut and Wheel lean section, disassemble and
stud end for high pressure. . . . . . . . .00-0003-14 assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-12
O-ring face seal fittings with metric hex nut and
stud end for standard pressure . . . . .00-0003-12
O-ring seal, metric 24° . . . . . . . . . . . . .00-0003-24
Unified inch bolt and cap screw . . . . . . .00-0003-4
30° cone seat hydraulic fittings . . . .00-0003-5 W
37° flare hydraulic fittings . . . . . . . .00-0003-5
Torsional isolator Waste disposal . . . . . . . . . . . . . . . . . . . . . . .00-001-5 Indx
7
Remove and install . . . . . . . . . . . . . . . . .07-0752-1 Wear inserts
Transmission Blade side shift, install and adjust . . . . .34-3440-12
Accumulator, remove and install . . . . . . .03-0360-3 Welding repairs . . . . . . . . . . . . . . . . . . . . .00-001-12
Charge pump, remove and install . . . . . .03-0360-1 Wheel
Disassemble and assemble . . . . . . . . . .03-0300-1 HFWD front hub and spindle, disassemble and
Oil filter, remove and install. . . . . . . . . . .03-0360-2 assemble . . . . . . . . . . . . . . . . . . . . . . .02-0240-6
Remove and install . . . . . . . . . . . . . . . . .03-0300-3 HFWD front hub and spindle, disassemble and
Transmission coupler assemble with steering angle
Remove and install . . . . . . . . . . . . . . . . .07-0752-1 sensor . . . . . . . . . . . . . . . . . . . . . . . .02-0240-11
Transmission oil cooler HFWD front hub and spindle, remove and
Remove and install . . . . . . . . . . . . . . . .05-0510-10 install. . . . . . . . . . . . . . . . . . . . . . . . . .02-0240-1
Transmission support bracket Non HFWD front hub and spindle, disassemble
DFT1253. . . . . . . . . . . . . . . . . . . . . . . . .99-9900-7 and assemble . . . . . . . . . . . . . . . . . . .02-0230-2

TM2256 (09JAN07) Index-7 D Series Motor Grader Repair

020207
PN=7
 Index

Page

Non HFWD front hub and spindle, remove and

install. . . . . . . . . . . . . . . . . . . . . . . . . .02-0230-1
Wheel axle
Front, tandem assembly, remove and
install. . . . . . . . . . . . . . . . . . . . . . . . .02-0250-17
Rear, tandem assembly, remove and
install. . . . . . . . . . . . . . . . . . . . . . . . .02-0250-16
Tandem assembly, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . .02-0250-20
Tandem assembly, remove and
install. . . . . . . . . . . . . . . . . . . . . . . . .02-0250-11
Wheel lean
Cylinder, disassemble and assemble . . .09-0960-8
Remove and install . . . . . . . . . . . . . . . . .09-0960-9
Valve section, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-12
Windowpanes
Remove and install . . . . . . . . . . . . . . . . .18-1810-1

Yoke holding tool

DFRW103 . . . . . . . . . . . . . . . . . . . . . . . .99-9900-5

Indx
8

TM2256 (09JAN07) Index-8 D Series Motor Grader Repair

020207
PN=8