Description
John Deere 770G, 770GP, 772G, and 772GP Motor Grader Repair Manual TM11207 PDF
This is the complete John Deere 770G, 770GP, 772G, and 772GP Motor Grader Repair Manual TM11207, dated 11MAY09, written for technicians who service these grading machines in the field or in the shop. If you’re searching for a dependable 770G 770GP 772G 772GP Motor Grader Repair Manual, this technical manual walks through removal, installation, disassembly, assembly, and specification data for every major system on the machine, organized exactly as John Deere structured it for dealer technicians.
File Details
- Manual type: Technical/Repair Manual (John Deere ILLUSTRUCTION Manual)
- Brand/Models: John Deere 770G, 770GP, 772G, and 772GP Motor Graders
- Document number: TM11207
- Publication date: 11MAY09 (May 2009)
- Language: English
- Page count: 610 pages
- File format: PDF, instant digital download
Chapters Covered
The 770G 770GP 772G 772GP Repair Manual is broken into numbered sections and groups covering the machine end to end:
- General Information — Safety, Torque Values
- Section 01 — Wheels: Powered Wheels and Fasteners
- Section 02 — Axles and Suspension Systems: Input Drive Shafts and U-Joints, Non-Powered Wheel Axles, Powered Wheel Axles, Axle Shafts/Bearings/Reduction Gears, Hydraulic System
- Section 03 — Transmission: Removal and Installation, Hydraulic System
- Section 04 — Engine: Removal and Installation (PowerTech Plus 9.0L / 6090 John Deere engine, Tier 3/Stage IIIA and Stage II)
- Section 05 — Engine Auxiliary System: Cooling System, External Fuel Supply Systems
- Section 07 — Torsional Isolator: Elements
- Section 09 — Steering System: Power Steering, Hydraulic System
- Section 10 — Service Brakes: Active Elements, Hydraulic System
- Section 11 — Park Brake: Active Elements
- Section 17 — Frame, Chassis or Supporting Structure: Frame Installation
- Section 18 — Operator’s Station: Removal and Installation, Operator Enclosure, Pedal Assembly, Steering Tilt Console, Seat and Seat Belt, Heating and Air Conditioning
- Section 19 — Sheet Metal and Styling: Grille and Grille Housing
- Section 21 — Main Hydraulic System
- Section 34 — Grading Device: Controls Linkage, Frames, Circle Gearbox, Hydraulic System
- Section 42 — Ground Conditioning Tool: Frames
- Section 99 — Dealer Fabricated Tools
Taken together, this gives a technician a full service path through the driveline, hydraulics, engine, operator’s station, and grading components of the 770G/770GP/772G/772GP line, with the diagnostic and repair depth needed to move from problem to fix without guessing at procedures.
What’s Inside
Each service group in this John Deere manual opens with the essential tools, service equipment, specifications, wear tolerances, and torque values needed before starting the job, then walks through the actual remove, disassemble, inspect, assemble, and install steps with numbered illustrations. Component-specific torque and weight specifications (for example, hub torque and hub weight callouts on the axle groups) are called out inline so a technician isn’t hunting through a separate spec sheet mid-repair. The manual also cross-references companion publications for the operator’s manual, the PowerTech 9.0L engine, the DF180 Series Powershift Transmission, TeamMate II inboard planetary axles, 120 Series hydraulic cylinders, and the JDLink/ZXLink monitoring system, so the scope here is specifically the grader’s own chassis, drivetrain, hydraulic, and structural systems.
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the “John Deere 770G 770GP 772G 772GP Motor Grader Repair Manual TM11207 PDF” are as follows:
+Contentsp. 3
+General Informationp. 7
+Safetyp. 9
Recognize Safety Informationp. 9
Follow Safety Instructionsp. 9
Operate Only If Qualifiedp. 10
Wear Protective Equipmentp. 10
Avoid Unauthorized Machine Modificationsp. 10
Inspect Machinep. 11
Stay Clear of Moving Partsp. 11
Avoid High-Pressure Oilsp. 11
Beware of Exhaust Fumesp. 12
Prevent Firesp. 12
Prevent Battery Explosionsp. 12
Handle Chemical Products Safelyp. 13
Dispose of Waste Properlyp. 13
Prepare for Emergenciesp. 13
Use Steps and Handholds Correctlyp. 14
Start Only From Operator's Seatp. 14
Use and Maintain Seat Beltp. 14
Prevent Unintended Machine Movementp. 15
Avoid Work Site Hazardsp. 15
Keep Riders Off Machinep. 16
Avoid Backover Accidentsp. 16
Avoid Machine Tip Overp. 17
Operating Or Traveling On Public Roadsp. 17
Inspect and Maintain ROPSp. 18
Add and Operate Attachments Safelyp. 18
Park And Prepare For Service Safelyp. 19
Service Cooling System Safelyp. 19
Remove Paint Before Welding or Heatingp. 20
Make Welding Repairs Safelyp. 20
Drive Metal Pins Safelyp. 21
+Torque Valuesp. 23
+Torque Valuep. 23
Metric Bolt and Cap Screwp. 23
Additional Metric Cap Screw Torque Valuesp. 24
+Torque Valuep. 26
Unified Inch Bolt and Cap Screwp. 26
Service Recommendations for 37° Flare and 30° Cone Seat Connectorsp. 27
Service Recommendations for O-Ring Boss Fittingsp. 28
Service Recommendations For Flared Connections—Straight or Tapered Threadsp. 30
Service Recommendations For Flat Face O-Ring Seal Fittingsp. 31
+Service Recommendationp. 33
O-Ring Face Seal Fittings with SAE Inch Hex Nut and Stud End for High Pressurep. 33
O-Ring Face Seal Fittings with Metric Hex Nut and Stud End for Standard Pressurep. 35
O-Ring Face Seal Fittings with Metric Hex Nut and Stud End for High Pressurep. 37
Service Recommendations for Metric Series Four Bolt Flange Fittingp. 39
Service Recommendations For Inch Series Four Bolt Flange Fittingsp. 40
Inch Series Four Bolt Flange Fitting For High Pressure Service Recommendationsp. 41
Service Recommendations For Non-Restricted Banjo (Adjustable) Fittingsp. 42
Service Recommendations For O-Ring Boss Fittings With Shoulderp. 44
+Service Recommendationp. 47
Metric 24 O-Ring Seal DIN 20078p. 47
+Wheelsp. 49
+Powered Wheels and Fastenersp. 51
Wheel Remove and Installp. 51
Tire Remove and Installp. 52
+Axles and Suspension Systemsp. 55
+Input Drive Shafts and U-Jointsp. 57
Transmission-to-Rear Axle Drive Shaft Remove and Installp. 57
Transmission-to-Rear Axle Drive Shaft Disassemble and Assemblep. 58
+Non-Powered Wheel Axlesp. 59
Front Wheel Hub and Spindle Remove and Install—Non 6WDp. 59
Front Wheel Hub and Spindle Disassemble and Assemble—Non 6WDp. 62
Front Axle Remove and Install—Non 6WDp. 65
+Powered Wheel Axlesp. 69
Front Wheel Hub and Spindle Remove and Install—6WDp. 69
Front Wheel Hub and Spindle Disassemble and Assemble—6WDp. 73
Front Wheel Hub and Spindle Disassemble and Assemble with Steering Angle Sensor—6WDp. 79
6WD Drive Hub Disassemble and Assemblep. 86
Planetary Drive Disassemble and Assemblep. 88
Planetary Brake Disassemble and Assemblep. 92
6WD Bearings Remove and Installp. 97
6WD O-Ring Metal Face Seal Remove and Installp. 102
Front Axle Remove and Install—6WDp. 110
+Axle Shafts, Bearings, and Reduction Gearsp. 117
TEAMMATE™ II 1400 Series Inboard Planetary Axle—Use CTM43p. 117
Rear Axle Remove and Installp. 117
Rear Axle Disassemble and Assemblep. 122
Tandem and Wheel Axle Assembly Remove and Installp. 123
Tandem Wheel Axle Assembly Remove and Installp. 126
Tandem Wheel Axle Assembly Disassemble and Assemblep. 128
Tandem Pivot Disassemble and Assemblep. 134
Final Drive Axle Remove and Installp. 138
Final Drive Axle Disassemble and Assemblep. 145
Brake Component Remove and Installp. 149
Planet Pinion Carrier Remove and Installp. 150
Tandem Drive Shaft Remove and Installp. 152
Drive Chain Remove and Installp. 157
+Hydraulic Systemp. 161
6WD Pump Remove and Installp. 161
6WD Pump Disassemblep. 164
6WD Pump Assemblep. 182
6WD Charge Pump Remove and Installp. 202
6WD Engagement Manifold Remove and Installp. 202
Differential Lock Pump Remove and Installp. 205
6WD Motor Remove and Installp. 206
6WD Motor Disassemble and Assemblep. 208
+Transmissionp. 213
+Removal and Installationp. 215
DF180 Transmissionp. 215
Transmission Remove and Installp. 217
+Hydraulic Systemp. 223
Transmission Charge Pump Remove and Installp. 223
+Enginep. 225
+Removal and Installationp. 227
PowerTech Plus™ 9.0L (6090) John Deere Engine—9.0L Tier 3/Stage IIIAp. 227
PowerTech Plus™ 9.0L (6090) John Deere Engine—9.0L Stage IIp. 227
Engine Remove and Install—9.0L Tier 3/Stage IIIAp. 228
Engine Remove and Install—9.0L Stage IIp. 237
+Engine Auxiliary Systemp. 239
+Cooling Systemp. 241
Fan Blade Remove and Installp. 241
Radiator Remove and Installp. 243
Hydraulic and Differential Oil Cooler Remove and Installp. 248
Transmission Oil Cooler Remove and Installp. 250
Fuel Cooler Remove and Install—9.0Lp. 253
Charge Air Cooler Remove and Installp. 254
+External Fuel Supply Systemsp. 257
Fuel Tank Remove and Installp. 257
Fast Fill Fuel System Disassemble and Assemble—If Equippedp. 262
+Torsional Isolatorp. 265
+Elementsp. 267
Torsional Isolator Remove and Installp. 267
+Steering Systemp. 269
+Power Steeringp. 271
Toe-In Check and Adjustmentp. 271
+Hydraulic Systemp. 273
Steering Wheel, Column, and Valve Remove and Install—Standard Controlsp. 273
Steering Wheel, Column, and Valve Remove and Install—EH Controlsp. 276
EH Controls Steering Canceling Valve Remove and Installp. 278
Steering Cylinder Remove and Installp. 280
Hydraulic Cylinder Disassemble and Assemblep. 283
Wheel Lean Cylinder Remove and Installp. 284
Secondary Steering Accumulator Remove and Install—If Equippedp. 289
+Service Brakesp. 291
+Active Elementsp. 293
Service Brake Repairp. 293
+Hydraulic Systemp. 295
Service Brake Valve Remove and Installp. 295
Service Brake Bleedingp. 297
Brake Accumulator Remove and Installp. 298
+Park Brakep. 301
+Frame, Chassis or Supporting Structurep. 305
+Frame Installationp. 307
Welding On Machinep. 307
Welding Repair of Major Structurep. 308
Separate Frames at Articulation Jointp. 309
Articulation Bearing Replacementp. 316
+Operator's Stationp. 321
+Removal and Installationp. 323
Cab Remove and Installp. 323
Cab Remove and Install—GP Machine Onlyp. 331
+Operator Enclosurep. 339
Windowpanes Remove and Installp. 339
Cab Door Handle Remove and Installp. 340
Cab Door Latch Remove and Installp. 341
Rivet Nut Installationp. 343
+Pedal Assemblyp. 347
Inching Pedal Remove and Installp. 347
+Steering Tilt Consolep. 350
Steering Support Console Remove and Install—Standard Controlsp. 350
Steering Support Console Remove and Install—EH Controlsp. 352
Console Tilt Remove and Installp. 354
Steering Tilt Assembly Remove and Installp. 356
+Seat and Seat Beltp. 357
Seat Remove and Installp. 357
Seat Belt Remove and Installp. 359
Armrest Remove and Installp. 361
Armrest Remove and Install—EH Controlsp. 362
Armrest Disassemble and Assemble—EH Controlsp. 364
Standard Seat Disassemble and Assemblep. 366
Deluxe Seat Disassemble and Assemblep. 368
Air Suspension Disassemble and Assemblep. 370
+Heating and Air Conditioningp. 373
Refrigerant Cautions and Proper Handlingp. 373
Flush and Purge Air Conditioner Systemp. 375
R134a Refrigerant Oil Informationp. 380
R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedurep. 382
R134a System Recoverp. 383
R134a System Evacuatep. 384
R134a System Chargep. 386
Expansion Valve Remove and Installp. 387
Freeze Control Switch Remove and Installp. 389
Air Conditioning High-Low Pressure Switch Remove and Installp. 391
Heater Control Valve Remove and Installp. 392
Heater Control Valve Leak Checkp. 393
Blower Motor Assembly Remove and Installp. 393
Compressor Remove and Install—6.8Lp. 394
Compressor Remove and Install—9.0Lp. 396
Condenser Remove and Installp. 398
Heater and Air Conditioner Remove and Installp. 400
Receiver-Dryer Remove and Installp. 405
Accumulator Remove and Installp. 406
Compressor Clutch Disassemble and Assemblep. 407
Compressor Manifold Inspectp. 408
Compressor Relief Valve Remove and Installp. 409
+Sheet Metal and Stylingp. 411
+Grille and Grille Housingp. 413
Grille Housing Remove and Installp. 413
+Main Hydraulic Systemp. 417
+Hydraulic Systemp. 419
Vacuum Pump Installationp. 419
Hydraulic Pump Remove and Installp. 419
Hydraulic Pump Disassemble and Assemblep. 422
Hydraulic System Manifold Remove and Installp. 428
Hydraulic System Manifold Disassemble and Assemblep. 430
Soft Start Valve Remove and Installp. 431
Soft Start Valve Disassemble and Assemblep. 434
Hydraulic Fan Pump Remove and Installp. 435
Hydraulic Fan Motor Remove and Installp. 436
Hydraulic Fan Valve Remove and Installp. 437
General Oil Cleanup Procedurep. 441
Hydraulic/Hydrostatic Component Failure Cleanup Procedurep. 444
+Grading Devicep. 449
+Controls Linkagep. 451
Control Linkage Remove and Installp. 451
+Framesp. 453
NeverGrease™ Pin Jointsp. 453
Lift Arms Remove and Installp. 458
Saddle Locking Cylinder Remove and Installp. 462
Saddle Frame Remove and Installp. 465
Blade Pitch Frame Remove and Installp. 468
Draft and Circle Frame Remove and Installp. 472
Circle Adjustmentp. 476
Blade Side Shift Wear Inserts Remove and Installp. 481
+Circle Gearboxp. 485
Circle Drive Gearbox Remove and Installp. 485
Circle Drive Gearbox Disassemble and Assemblep. 488
Circle Drive Gearbox (With Slip Clutch) Disassemble and Assemblep. 494
+Hydraulic Systemp. 509
Grader Control Valve Remove and Installp. 509
Draft Frame Mount Grader Control Valve Remove and Install—EH Controlsp. 513
Cab Mount Grader Control Valve Remove and Install—EH Controlsp. 517
Grader Control Valve Disassemble and Assemblep. 520
Midmount Scarifier Valve Section Disassemble and Assemblep. 522
Midmount Scarifier Valve Section Disassemble and Assemble—EH Controlsp. 524
Blade Lift Valve Section Disassemble and Assemblep. 526
Blade Lift Valve Section Disassemble and Assemble—EH Controlsp. 528
Auxiliary (With Float) Valve Section Disassemble and Assemblep. 530
Auxiliary (Without Float) Valve Section Disassemble and Assemblep. 532
Auxiliary Valve Section Disassemble and Assemble—EH Controlsp. 534
Wheel Lean, Articulation, Circle Side Shift, Blade Pitch, and Blade Side Shift Valve Section Disassemble and Assemblep. 536
Wheel Lean, Articulation, Circle Side Shift, Blade Pitch, Blade Side Shift, and Steering Valve Section Disassemble and Assemble—EH Controlsp. 538
Circle Rotate Valve Section Disassemble and Assemblep. 540
Circle Rotate Valve Section Disassemble and Assemble—EH Controlsp. 542
Return Check Poppets Disassemble and Assemblep. 544
Rotate Motor Disassemble and Assemblep. 545
Rotary Manifold Remove and Installp. 547
Blade Lift, Blade Pitch, and Circle Side Shift Cylinders Remove and Installp. 550
Blade Side Shift Cylinder Remove and Installp. 552
Articulation Cylinders Remove and Installp. 555
+Ground Conditioning Toolp. 559
+Framesp. 561
NeverGrease™ Pin Jointsp. 561
Scarifier/Blade Remove and Installp. 565
Midmount Scarifier Remove and Installp. 567
Midmount Scarifier Cylinder Remove and Installp. 574
Ripper Remove and Installp. 576
Ripper Cylinders Remove and Installp. 579
Balderson™ Style Front Lift Group Remove and Installp. 581
+Dealer Fabricated Toolsp. 583
+Dealer Fabricated Toolsp. 585
DF1017—Axle Lift Eyep. 585
DF1057—Axle Adjusting Toolp. 586
DFRW20 Compressor Holding Fixturep. 587
DFRW103—Yoke Holding Tool1p. 588
DFT1101 Cab and ROPS Lift Bracketp. 589
DFT1151—Outboard Bearing Driverp. 590
DFT1152—Inboard Bearing Driverp. 591
DFT1153—Oil Seal Driverp. 591
DFT1225—Rolling Torque Measurement Toolp. 592
DFT1250 Lifting Bracketp. 593
DFT1282—King Pin Torque Adapterp. 594
DFT1308 Transmission Support Bracketp. 596
DFT1310—Cab Mount Control Valve Support Bracketp. 598
DFT1311—Extension for DFT1250p. 600
+Page Numbersp. 3
+Sectionp. 7
+Group 001p. 9
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+Section 02p. 55
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+Group 0260p. 161
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50p. 558
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52p. 560
+Section 42p. 559
+Group 4240p. 561
1p. 561
2p. 562
3p. 563
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21p. 581
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24p. 584
+Section 99p. 583
+Group 9900p. 585
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16p. 600
Why Technicians Rely on This Manual
With this John Deere 770G 770GP 772G 772GP Motor Grader Repair Manual, a shop can diagnose and repair wheel and axle issues, transmission and driveline faults, engine removal and installation, steering and brake hydraulic problems, operator’s station repairs, and grading circle/moldboard hydraulics using the exact torque values, clearances, and procedures John Deere published for this equipment — instead of relying on guesswork or generic references. Getting the correct specification matters here: undertightened or overtightened hub nuts, incorrect torque on structural fasteners, or missed hydraulic system steps can lead to premature wear or unsafe operation, and this manual is written to prevent exactly that. The file downloads instantly after purchase as a PDF, works on any laptop, tablet, or phone, needs no shipping or waiting, and can be printed for shop use whenever a page is needed at the bench.
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