John Deere 570 570A Repair Manual Motor Grader TM1001

TECHNICAL MANUAL
TM-1001 (Dec-87)
JD570 AND JD570-A MOTOR GRADERS
Technical Manual
TM-1001 (Dec-87)
CONTENTS Section 50 - POWER TRAIN
Group 5 - Engine Disconnect Clutch
Section 10 - GENERAL Group 10 - Transfer Drive
Group 5 - Specifications Group 15 - Power Shift Transmission
Group 10 - Predelivery, Delivery, and Group 20 - Differential, Differential Control and
After-Sale Services Valve
Group 15 - Tune-up and Adjustment Group 25 - Final Drive System
Group 20 - Lubrication Group 30 - Specifications and Special
Group 25 - Separation Tools
Group 30 - Specifications and Special
Tools Section 60 - POWER STEERING AND
BRAKES
Section 20 - ENGINE Group 5 - Power Steering Valve
Group 5 - Diagnosing Engine Malfunctions Group 10 - Brake Valve
Group 10 - Basic Engine Group 15 - Brake Cylinders and Disks
Group 15 - Engine Lubrication Group 20 - Parking Brake
Group 20 - Speed Control Linkage
Group 25 - Engine Cooling System Section 70 - HYDRAULIC SYSTEM
Group 5 - Components and Tests
Section 30 - FUEL SYSTEM Group 6 - System Testing (Analyzer) Serial No.
Group 5 - Diagnosing Malfunctions (001700- )
Group 10 - Fuel Tank, Filters, and Transfer Group 10 - Filters, Valves, and Accumulator
Pump Group 15 - Main Hydraulic Pump
Group 15 - Air Intake System Group 20 - Function Control Valves
Group 20 - Fuel Injection Pump Group 25 - Hydraulic Cylinders
Fuel Injection Nozzles Group 30 - Circle Drive Hydraulic Motor
(See SM-2045) Group 35 - Saddle Valve and Retaining Pins
Group 25 - Specifications and Special Tools Group 40 - Specifications and Special Tools
Section 40 - ELECTRICAL SYSTEM Section 80 - MISCELLANEOUS

K _ r^ £ se /"« rJrk fio n o r»H \ A /ir!n n D io n r o m e
\> < i v b / w v ii^ u v i i u i iu m i i m y L / ia y ia n ig
Group 10 - Charging System - Engine Group 10 - Drawbar, Circle and Moldboard

Serial No. ( -130705) f^rniin 1R - Saddle Mein Freme Front Axle end
Group 15 - Charging System - Engine Scarifier
Serial No. (130706- ) Group 20 - Specifications and Special Tools
Group 20 - Starting Motor
The specifications and design information contained

in this manual were correct at the time itw.as printed. It
is John Deere's policy to continually improve and up
date our machines. Therefore, the specifications and
design information are subject to change without no
tice.
C op yrigh t ® 1987
Previous Editions D E ER E & C O M P A N Y
Copyright ® 1980 Deere & Company Copyright 0 1974 Deere & Company M o lin e , Illin ois
Copyright ® 1979 Deere & Company Copyright ®1973 Deere & Company A ll rights reserved
OOA Copyright ® 1978 Deere & Company Copyright ®1972 Deere & Company
Copyright ° 1977 Deere & Company Copyright ®1971 Deere & Company
Copyright ® 1976 Deere & Company Copyright ®1969 Deere & Company
Copyright ® 1975 Deere & Company Copyright ®1967 Deere & Company
Litho in U.S.A.
Grader, Motor - JD570
2 TM-1001 (Feb-80)
INTRODUCTION
This technical manual is part of a twin concept of This technical manual was planned and written for
service: you— an experienced service technician. Keep it in a
permanent binder in the shop where it is handy. Refer
The two kinds of manuals work as a team to give you to it whenever in doubt about correct service proce
both the general background and technical details of dures or specifications.
shop service.
Some features of this technical manual:
• FOS Manuals— For Reference
• Table o f contents at front of manual
Fundamentals of Service (FOS) Manuals cover basic
theory of operation, fundamentals of trouble shooting, • Exploded views showing parts relationship
general maintenance, and basic types of failures and
their causes. FOS Manuals are for training new per • Photos showing service techniques
sonnel and for reference by experienced personnel.
• Specifications grouped for easy reference
— — i When a service technician should refer to a
res FOS Manual for more information, a FOS Using the technical manual as a guide will reduce error
symbol like the one at the left is used in the and costly delay. It will also assure you the best in
__ °J TM to identify the reference. finished service work.
JL
• Technical' Manuals—For Actuai Service idOntifiBS im p o rta n t
Ak safety messages in this manual. When you
Technical Manuals are concise service guides for a see this symbol, be alert to the possibility of personal
specific machine. Technical Manuals are on-the-job injury and carefully read the message that follows.
guides containing only the vital information needed by
an experienced service technician.
Litho in U.S.A.
Grader, M o to r - JD570 General 10
TM-1001 (Dec-87) S p e cifica tio n s 5-1
Section 10
GENERAL
CONTENTS OF THIS SECTION
Page Page
GROUP 5 - SPECIFICATIONS GROUP 25 - SEPARATION
JD570-A M achine S p e c ific a tio n s ................5-2,3 Separating Power Unit from Fram e... 25-1
JD570-A D im e n s io n s ......................................... 5-4 Separating Engine from Transmission 25-2
JD570 M achine S p e cifica tio n s ...................... 5-5 Separating Transfer Drive from
JD570 D im e n s io n s ............................................. 5-6 Transm ission.................................... 25-2
Separating Tandems from Power Unit 25-3
GROUP 10 - PREDELIVERY, DELIVERY,
Separating Clutch Housing from
AND AFTER-SALE SERVICES
Transm ission.................................. 25-3
Predelivery S e rv ic e ........................................... 10-1
Assembling Clutch Housing to
Delivery Service................................................ 10-16
Transm ission.................................... 25-3
After-Sale Inspection....................................... 10-16
Assembling Tandems to Power U n it.. 25-3
Assembling Transfer Drive to
GROUP 15 - TUNE-UP AND ADJUSTMENT
Transm ission.................................... 25-3
General Information ........................................ 15-1
Assembling Engine to Transmission .. 25-4
Preliminary Engine T e stin g............................ 15-1
Assembling Power Unit to Frame 25-4
Engine T une-up............................................... 15-1
Grader A d ju stm e n t.......................................... 15-2
GROUP 30 - SPECIFICATIONS AND SPECIAL
Hydraulic System Average Cycle
Tim es............................................................. 15-3 TOOLS
Making Special T o o ls ..................................... 30-1
GROUP 20 - LUBRICATION Torque V a lu e s ................................................. 30-1
Lubrication C h a rt............................................. 20-1 Special T o o ls ................................................... 30-1
Engine Lubricating O ils .................................. 20-2
Greases............................................................. 20-2
Fig. 1-JD570-A Motor Grader
Litho in U.S.A.
10 General Grader, M o to r - JDS70
5-2 S p e cifica tio n s TM-1001 (Dec-87)
Group 5
SPECIFICATIONS
(Specifications and design subject to change without notice. Wherever applicable, specifications are in accordance with ICED and SAE
Standards. Except where otherwise noted, these specifications are based on a unit equipped with 13.00-24, 8-ply-rating, tubeless tires and
standard equipment.)
JD570-A Final D riv e s .........................................................Inboard planetary
Pow er (« 2300 engine rpm): SA E DIN

Brakes:
G ro ss.......................................... 92 hp (68.6 kW*) Service................ Foot-operated, hydraulically actuated, wet-disk,
Net .............................................. 85 hp (63.4 kW) 86.2 PS effective on 4 tandem wheels
Parking.............Hand-operated, mechanical, expanding dry shoe,
Net engine flywheel power is for an engine equipped with fan, air effective on 4 tandem wheels
cleaner water pump, lubricating oil pump, fuel pump, alternator and
muffler. The gross engine power is without fan. Flywheel power S teering:
ratings are under SAE standard conditions of 500-ft. altitude and Front................................................... Full hydraulic power system
8 5 ^ . temperature, and DIN 70 020 conditions (non-corrected). No R e a r.................. Hydraulically articulated frame steering (22 deg.
derating is required up to 10,000 feet (3000 m) altitude. left or right)
*ln the international system of units (SI), power is expressed in Turning radius........................................................... 18 ft. (5.49 m)
kilowatts (kW). Range................................................................ 51 deg. left or right
E ng ine: John Deere turbocharged diesel, vertical 6-cylinder, H yd rau lic System : Closed-center
valve-in-head, 4-stroke cycle Pressure................................. 2000 psi (137.9 bar) (140.6 kg/cm2)
Bore and stroke................................. 4.02x4.33 in. (102x110 mm) P u m p ......... Variable displacement, 27 gpm (102 L/min) @ 2300
Piston displacement ................................... 329 cu. in. (5392 cm3) engine rpm
Compression ra tio ............................................................. 16.2 to 1
Maximum torque (i< 1300 rpm ... 238 Ib-ft (323 Nm) (32.8 kg-m) C ircle: 5.50x1 x4.62x1 in. (140x25x117x25 mm) welded angle, 4 ft. 6
NACC or AMA (U.S. Tax) horsepower......................................38.6 in. (1.37 m) dia.
Main bearings................................................................................. 7 Rotation............................................................................... 360 deg.
Lubrication...................................Pressure system w/full-flow filter D rive..............................................Hydraulic motor and worm gear
Cooling...................... Pressurized w/thermostat and fixed bypass
F a n ..........................................................................................Suction D ra w b a r ....... Tapered box, max. 3x7x0.375 in. (76x178x9.5 mm)
Air cleaner w/restriction indicator.............................................. Dry wall, w/universal swivel
Electrical system .............................................. 12-volt w/alternator
Batteries (2) ...................................Reserve capacity: 360 minutes B lade: S tandard Optional
Length ........................12 ft. (3.66 m) 12 ft. (3.66 m)
T ra n s m is s io n . .. Power Shift, 8 toward and 4 reverse selections Height......................... 22 in. (559 mm) 22 in. (559 mm)
Thickness................... 0.62 in. (15.8 mm) 0.75 in. (19.1 mm)
D ifferential L o c k .................Foot-operated, hydraulically actuated
B lade Lifting Mechanism :
T rav el Speeds (2300 engine rpm, no tire slip): C ontrol.............................................................Dual-lever, hydraulic
Cylinders (2 )....... 3 in. (76 mm) dia. bore; 42 in. (1.07 m) stroke
S hift Lever P osition m ph k m /h
Foward 1 2.0 3.3 B lade Range:
2 2.9 4.6 Lift above ground.................... . . . 1 ft. 1 in. (330 mm)
3 4.5 7.2 Blade side-shift:
4t 5.8 9.4 Right..................................... 2 ft. 2.75 in. (679 mm)
5 7.6 12.2 L e ft..................................... 2 ft. 7.25 in. (794 mm)
6 9.8 15.8 Shoulder reach outside wheels
7 12.8 20.6 Right..................................... . 5 ft. 11.5 in. (1.82 m)
8 21.6 34.8 L e ft....................................... . 6 ft. 5.25 in. (1.96 m)
Reverse 1 2.5 4.0 P itc h ........................................ ...............32 deg. total
2 3.5 5.6
3 5.5 8.8
4 7.1 11.4
Litho in U.S.A.
Grader, Motor • JD570 General 10
TM-1001 (Dec-87) Specifications 5-3
JD570-A Bulldozer ........ (Special Equipment): Mounts on scarifier linkage.

Angles 22 deg. left or right by articulating machine.
Saddle: Length ............................................................................... 93 in. (2.36 m)
R o tatio n ..................................... . . . 45 deg. right or left. 5 positions
H eight...........................................................................23.5 in. (597 mm)
C o n tro l.............Single foot-operated release hydraulically controls
Lift above ground.......................................................... 27 in. (686 mm)
tapered locking pins
P en e tratio n .......................................................................4 in. (102 mm)
Frame: Tapered box U.S. Imp Liters

Capacities:
Section size, m ax......................................... 16.5x8 in. (419x203 mm)
Fuel t a n k .................................................. . .5 0 gal. 41 .7 gal. 189.3
min.......................................... 12.5x8 in. (318x203 mm)
Cooling system ........................................ 4.7 gal. 21.2
Weight per ft. m ax..................................................99 lb. (147.3 kg/m )
Engine lubrication, including filter___ . .3 gal. 2.5 gal. 11.4
av..................................................... 91 lb. (135.4 kg/m )
Engine lubrication, without filte r ........ .. 10 qt. 2.1 gal. 9.5
Transmission and hydraulic system .. . .21 gal. 17.5 gal. 79.5
Tandems: Welded steel box section 1 ft. 9.75 in. (552 mm)x6.5 in.
Tandem housings (e a c h )..................... . .5 gal. 4.2 gal. 18.9
(165 mm)
Worm g e a rb o x ........................................ ..1 .5 qt. 1.3 qt. 1.4
D riv e ................................................1.75 in. (44 mm) pitch roller chain
Axle dia. at bearings..................................................3.25 in. (83 mm)
Additional Standard Equipment:
2.62 in. (67 mm)
Transistorized voltage Gauges:
regulator Coolant temperature
Front Axle: Fabricated steel A-frame with cast alloy-steel spindles. Lights Transmission temperature
tapered roller bearings
Turn signals Engine oil pressure
Diameter at bearing s e a ts ........................................2.62 in. (67 mm)
Electric hour meter Fuel
2.06 in. (52 mm)
Cigar lighter Cold weather starting aid
Total oscillation.............................................................................. 30 deg.
Horn Precleaner
Wheel lean (either direction)...................................................... 2 0 deg.
Deluxe seat ROPS cab and seat belt
Transmission bottom guard Work lights
Rear Drive Axle: Full floating with tapered roller bearings Cab heater
Diameter at bearings..................................................3.28 in. (83 mm)
Front windshield wiper
Rear windshield wiper
Scarifier (Special Equipment): V-type for 46 in. (1.17 m) cut with 3
manual pitch positions
Special Equipment:
Number of te e th ..................................................5 standard, 9 optional
Scarifier 12 ft. (3.66 m) heavy-duty blade
Lift above ground..............................................1 ft. 10.5 in. (572 mm)
Cab defroster fan Engine side shields
P enetratio n................................................................ 8.75 in. (222 mm)
Floor mat Overlay end bits
Maximum pressure— dow n............. 7000 lb. (31.37 kN) (3175 kg)
ROPS canopy and seat belt Bulldozer
u p ................. 20,000 lb. (89.64 kN) (9072 kg)
2 ft. (610 mm) moldboard Wheel weights for 24 in.
Shank size................................................................ 1x3 in. (25x76 mm)
extensions, right or left (610 mm) tires
Disconnect clutch Heavy-duty cutting edges
Automatic blade control
Litho in U.S.A.
10 General Grader, M o to r - JD570
JD570-A MOTOR GRADER DIMENSIONS
T62257N
Height to top of steering wheel ........................7 ft. 5 in. (2.26 m) SAE Operating Weight On Front On Rear
Wheels Wheels Total
Standard equipment.......................... ....... 5705 lb. 14,320 Ib. 20,025 Ib.
T ire s __ 13.00-24, 8-ply-rating; 15.5-25, 8-ply-rating; 13.00-24, Standard equipment (2608 kg) (6495 kg) (9083 kg)
and scarifier.................................. ....... 6755 lb. 14,148 Ib. 20,903 Ib.
10-ply-rating Standard equipment and (3063 kg) (6418 kg) (9481 kg)
wheel weights................................. ....... 5705 ib. 14,920 Ib. 20,625 Ib.
Standard equipment, scarifier, (2608 kg) (6768 kg) (9355 kg)
D IM EN SIO N S: and wheel weights ........................ ....... 6755 lb. 14,748 Ib. 21,503 Ib.
(3063 kg) (6690 kg) (9753 kg)
Wheel Tread Width Ground Clearance
Tire
Size Front Rear Front Rear (Front Axle)
13.00-24 78.75 in. 81.125 in. 7 ft. 10.75 in. 7 ft. 10.25 in. 1 ft. 11.5 in.
(2.00 m) (2.06 m) (2.41 m) (2.39 m) (597 mm)
15.5-25 81.375 in. 83.75 in. 8 ft. 3.75 in. 8 ft. 3.25 in. 1 ft. 10.9 in.
(2.07 m) (2.13 m) (2.53 m) (2.52 m) (582 mm)
IMPORTANT: Rear axle weight must not exceed

16,700 lb (7575 kg). If equipped with
ripper or snow wing, do not add full
liquid ballast. Maximum allowable
rear end weight could be exceeded
with full ballast.
Litho in U S.A.
TM-1001 (Dec-87) S pecification s 5-5
(Unit Equipped w/13.00 - 24, 8-ply Rating Tubeless Tires)
JD570
HORSEPOWER (at 2300 rpm) P a rk in g .............Hand-operated m echanical ex

Net engine flyw heel at 500 ft. panding dry-shoe type, effective
a ltitu d e and 85 deg. F. te m p e ra tu re ........ 83 on 4 tandem wheels
ENGINE CIRCLE
NACC or AM A taxable h o rs e p o w e r.......... 35.9 D ia m e te r.........................................................54 in.
Type of D riv e ..................... Hydraulic M otor and
C y c le ..................................................................... 4 Worm Gear
No. of C y lin d e r s ................................................ 6 R o ta tio n ....................................................360 deg.
Rated R P M ....................................................... 2300
Bore and Stroke ...................3.86 in. x 4.33 in. BLADE RANGE
Piston D is p la c e m e n t......................... 303 Cu. in. L ift above G ro u n d ........................................ 13 in.
E lectric S y s te m ...................................................12volts Blade Side S hift
S ta r tin g ...................................................... Electric R ig h t......................................................26.75 in.
L e f t ........................................................31.25 in.
TRANSMISSION Shoulder Reach, O utside Wheels
D e s c rip tio n ...............Power S h ift Transm ission R ig h t......................................................71.50 in.
Lock-Unlock D ifferential L e f t ........................................................77.25 in.
Bank C utting Angie (Right and Left) . .90 deg.
GROUND SPEEDS P itc h .............................................................32 deg.
1 s t .................................................................... 2.04mph
2 n d .................................................................... 2.88mph BLADE LIFTING MECHANISM
3 r d .................................................................... 4.49mph Saddle (H ydraulically
4 t h .................................................................... 5.81mph A c tu a te d )............... . . . .5 position - 22.5 deg.
5 t h .................................................................... 7.42mph Increment R otations
6 t h .................................................................... 9.67mph Total R otation Right
7 t h ........................................................ 12.80 mph or Left 45 deg.
8 t h ........................................................ 21.40 mph C y lin d e rs ................... 3 in. bore x 42 in. stroke
1st Rev.................................................... 2.36 mph
2nd Rev................................................... 3.36 mph BLADE ASSEMBLY
3rd Rev.................................................... 5.24 mph Length ....................... .....................10 ft. or 12 ft.
4th Rev.................................................... 6.77 mph H e ig h t....................... ....................................22 in.
T h ic k n e s s ................. ...............standard 0.62 in.
STEERING heavy-duty 0.75 in.
Type
Front .............Full H ydraulic Power Steering AXLE FRONT
R e a r............................... H ydraulic-Articulated Front Wheel Lean .. . . . .20 deg. left and right
Frame Steering Steering R a n g e ___ ___ 51 deg. left and right
Turning R a d iu s ..............................................18 ft. Ground Clearance
w ith 10.00-24 Tires
BRAKES (Early U n its )........... ............................. 21.75 in.
S e rvice................... Foot-operated, hydraulic-ac- w ith 13.00-24 Tires ............................... 23.5 in.
tuated, w et-disk type, effec w ith 15.50-25 Tires ................................23.0 in.
tive on 4 tandem wheels O s c illa tio n ................. ............................... 30 deg.
HYDRAULIC SYSTEM
T y p e ................................................ Closed center
P u m p ........ Variable displacem ent piston type
Litho in U.S.A.
JD570 SCARIFIER
W eight (w ithout T e e th )......................... 652 lbs.
CAPACITIES (with T e e th )................................ 878 lbs.
Fuel T a n k ................................................... 50 gal. No. o f T e e th ....................................................... 11
Cooling S y s te m ................................ 22.4 quarts L ift Above G ro u n d ................................ 22-1/2 in.
Crankcase (w ith Filter) ..................... 10 quarts P e n e tra tio n .............................................. 8-3/4 in.
Transm ission (w ith Filters) Pitch P o s itio n s ................................................... 3
(Includes H ydraulic S y s te m )............. 21 gal. C o n tro ls ................................................. H ydraulic
Tandem H ousings (E a ch ).................................. 5gal. Max. Force. 7,000 lbs. Down—20,000 lbs. Up
Worm Gear B o x ............................................... 1.5quarts W idth o f C u t................................................. 50 in.
Shank S iz e ...................................... 1 in. x 3 in.
Type ‘V’
© —©
Over-All Dimensions Inches Over-All Dimensions Inches
A. L e n g t h ............................................. 24 ft. 4.5 in. G. Tandem s (Center L in e ) ............... 4 ft. 8.75 in.
B. W idth (13.00-24 t ir e s ) ................. 7 ft. 10.75 in. H. H eight (Top L ift C y lin d e rs )........... 8 ft. 3.5 in.
(15.50-25 t ir e s ) ................... 8 ft. 3.75 in. J. H eight (Top A ir C leaner)............... 7 ft. 5.5 in.
C. H eight (with Cab) ............................ 10 ft. 6 in. K. Tread (Front) 13.00-24 tires) . . . . 6 ft. 6.75 in.
D. H eight (w ith o u t Cab - To Top of (Front) (15.50-25 tire s )........ 6 ft. 9.12 in.
Steering W h e e l)..................... 7 ft. 5 in. (Rear) (13.00-24 t ir e s ) ......... 6 ft. 9.12 in.
E. W h e e lb a s e ..................... r ................. 17 ft. 4 in. (Rear) (15.50-25 t ir e s ) ___ 6 ft. 11.75 in.
F. B la d e b a se......................... .................. 7 ft. 8 in. L. Length w ith S ca rifie r (In Up
P o s itio n )................................ 26 ft. 8.5 in.
L itho in U.S.A.
Grader, M o to r ■ JD570 General 10
TM-1001 (Dec-87) S p e cifica tio n s 5-7
JD570
WEIGHT On Rear W heels

O perating - Total (standard equipm ent
(standard equipm ent w ith o u t c a b ) .................................... 13120 lbs.
w ith o u t c a b ) ................................ 18625 lbs. (w ith c a b ) ............................................. 14220 lbs.
(standard equipm ent (standard equipm ent
w ith c a b )...................................... 19925 lbs. and s c a r ifie r ) .................................. 14048 lbs.
(standard equipm ent
and s c a r ifie r ) .............................. 20803 lbs.
On Front W heels
w ith o u t c a b ) ................................... 5505 lbs.
(with c a b ) ........................................... 5705 lbs.
and s c a r ifie r ) ................................. 6755 lbs.
(S pecification s and design are su b je ct to change w ith o u t notice. Wherever applicable, s p e cifica tio n s
are in accordance w ith ICED and SAE Standards.)
L ith o in U.S.A.
L itho in U.S.A.
Grader, Motor - JD570 General 10
TM-1001 (Nov-78) Predelivery, Delivery, and After-Sale Services 10-1
Group 10
PREDELIVERY, DELIVERY, AND AFTER-SALE SERVICES
TEMPORARY UNIT STORAGE PREDELIVERY SERVICE
After receiving your unit from the factory and before Because of the shipping factors involved, plus extra
putting the machine into temporary storage, perform finishing touches that are necessary to promote cus
the following checks and services. tomer satisfaction, proper predelivery service is of
prime importance to the dealer and the customer.
For long term storage (over 30 days) information,
consult your JD570-A operator's manual. If adjustments are required, procedures are found in
the after-sale section.
1. Check battery electrolyte level and charge the
battery, if necessary. Use the following list when preparing a motor grader
for delivery to the customer.
2. Check coolant level: Maintain 4 inches below the
top of the filler neck. 1. Pre-Cleaner
3. Fill the fuel tank.
4. Check crankcase oil level. Oil should be between

marks on dipstick after machine has been shut down
for 10 minutes.
5. Relieve hydraulic pressure by stopping engine,

lowering blade and operating control levers until sys
tem fails to respond.
6. Reduce shipping pressure of all tires to inflation

pressure shown on page 10-10-9.
7. Cover unit for protection and cleanliness.
Fig. 1-Pre-Cleaner
Check pre-cleaner bowl. Clean if necessary.
Pre-cleaner checked Yes No

10 General Grader, Motor - JD570
10-2 Predelivery, Delivery, and After-Sale Services TM-1001 (Nov-78)
O
£■»■
A iir
m
H a a ni aov ri
v i v m 3. Fuel Filter
Fig. 4-Fuel Filter

A—Oust Cap C—Primary Element
B—Wing Nut Check fuel filter for sediment. Drain if necessary.
Fig. 2-Air Cleaner
To bleed fuel system, see page 10-10-21.
Sediment present in filter Yes No
4. Batteries
Check battery electrolyte level. If distilled water is
not available, use clean soft water. Avoid use of hard
water. Remove foreign material from top of battery and
coat terminals with petroleum jelly.
IMPORTANT: Never add water to battery in

freezing weather unless engine will be run 2 to 3
hours.
Check battery connections.
A—Reset Button B— Red Signal Punch date code on battery.

Fig. 3-Restriction Indicator
Battery connections checked Yes No
Water added Yes No
Check air cleaner restriction indicator. If indicator
shows red, check elements. If only primary element is
dirty, clean the element. If safety element is dirty,
replace both elements.
Air cleaner checked Yes No

Elements replaced Yes No
Litho in U.S.A.
TM-1001 (Feb-80) Predelivery, Delivery, and After-Sale Services 10-3
5. Fuel Tank 7. Radiator
Fig. 7-Radiator Filler Cap
CAUTION: Remove radiator filler cap only
Fig. 5-Fuel Tank Filler Cap

A when coolant temperature is below boiling
point. Then loosen cap slightly to the stop to re
lieve pressure before removing the cap complete
Fill fuel tank with proper fuel. Check action of fuel
gauge. ly-
Check coolant level. Maintain 4 inches below the top

of the filler neck. Add permanent-type antifreeze if cold
weather is expected.
Radiator coolant level checked Yes No

Coolant or antifreeze added Yes No
Fig. 6-Fuel Gauge
Fuel tank filled Yes No

Fuel gauge checked Yes No
6. Fuel Tank Sump
IMPORTANT: Sediment will settle over extend

ed periods of transport or storage.
Open fuel tank drain cock. Drain liquid for several

seconds. Close drain cock.
NOTE: Fuel tank sump drain is located on the bot

tom o f the fuel tank.
Fuel sump drained Yes No
Litho in U.S.A.
10-4 Predelivery, Delivery, and After-Sale Services TM-1001 (Feb-80)
8. Tandem Drives 9. Crankcase Oil Level
A—Oil Level Plug B—Main Drive Sprocket

Retainer
A—Crankcase Dipstick B—Crankcase Filler Cap
Fig. 8-Tandem Drives
Fig. 10-Crankcase Oil Level
Check crankcase oil level with machine on level

ground and engine off. If oil level is at or below bottom
mark on dipstick, add oil specified on page 10-20-2 to
bring oil level to between marks on dipstick. Do not
operate engine with oil level below the bottom mark.
NOTE: There is a 3-1/2 quart difference between

the bottom mark and the top mark on the dipstick.
Crankcase oil level checked Yes No

Oii added, if any _______ qts.
Fig. 9-Tandem Drive Inspection Plate
Park grader on level surface. Remove inspection

plate from each tandem. Make sure oil reservoirs in
front and rear outboard hubs are full.
Remove oil level plug from each tandem. Oil should

be level with plug hole.
If oil is needed, use John Deere HY-GARD® Oil or

equivalent.
Install inspection plate and plug.
Tandem oil level checked Yes No

TM-1001 (Dec-87) Predelivery, Delivery, and After-Sale Services 10-5
10. Circle Drive Gear Box Alternator-fan belt should deflect 3/4-inch when 20
pounds of force is applied to the belt midway between
the two pulleys. Check front belt only. If a belt gauge is
used, tighten new alternator belt to 100 pounds strand
tension. After 3 minutes of operation, tension should be
90 pounds minimum.
IMPORTANT: Do not pry on the rear alternator

housing as this may damage the alternator.
Alternator-fan belt tension _______ lbs. strand tension

_______ inch deflection
12. Air Intake Hoses
A — V ent C— D rain Plug

B— Oil Level an d Filler Plug
Fig. 11-Circle Drive Gear Box
W ith the blade resting on level ground, check the

circle drive gear box oil level by removing the oil
level plug. Oil should be level w ith the plug hole.
If necessary, add John Deere SCL o il or equivalent.
(See page 10-20-2.) Replace fille r plug.
Circle drive gear box oil level checked Yes No A— A ir Intake Hose C— Tu rb o c h arg e r Inlet Hose
Oil added _______ qts. B— A ir Intake Hose Clam ps D— T u rb o c h arg e r Inlet Hose
C lam ps
11. Alternator - Fan Belts
Fig. 13-Air Intake Hoses and Clamps
Check hoses (A) for cracks. Tighten clamps (B).

Also check turbocharger inlet hose (C) and clamps (D).
Air intake hoses checked Yes No
A— A dju sting C ap S crew B— A lte rn ato r-F an B elts
Fig. 12-Alternator - Fan Belts
Litho in U.S.A.
10-6 Predelivery, Delivery, and A fter-S ale Services TM-1001 (Dec-87)
13. Transmission-Hydraulic System 15. Parking Brake

Oil Level
Fig. 15-Parking Brake Lever
Fig. 14-Transmission-Hydraulic System Filler Cap and Dipstick Check parking brake adjustment.
A lifting force of 75 lbs (minimum) is required to set
Be sure dipstick has been fully inserted before the parking brake lever. Check with spring scale at
checking oil level. Do not start engine, unless oil is near tached to adjustment knob on end of parking brake
top mark on dipstick. If oil level is low, add John Deere lever.
HY-GARD Oil or equivalent. Replace dipstick.
If adjustment is required, see page 10-10-26.
If the engine has been running and the transmission Parking brake operational Yes No
oil is warm, allow 10 minutes for oil to drain down
before checking. 16. Seat Operation
Check operation of seat.
NOTE: Overfilljng of the transmission-hydraulic
system may cause overheating during extended 8th
gear transport.
Transmission-hydraulic oil level checked Yes No

Transmission-hydraulic oil added _______ qts.
14. Engine Speeds

Warm up engine and attach a tachometer in the hour
meter drive plug hole to check engine speeds.
No-load, fa s t idle speed should be 2450 ± 50

rpm. Slow idle should be 900 ± 25 rpm.
If engine speeds need adjustment, see page 10-

10-25.
Engine speeds checked Yes No

A—Seat Position Selector C—Indicator
Lever D—Weight Adjusting
B—Seat Release Latch Screw
Fig. 16-Seat Operation
Move seat to upper rear position. Then sit down and

move seat position selector lever (A) left or right until
you reach desired position. Seat will always return to
this position when you sit down after you have moved
seat up and to rear for standing.
Litho in U.S.A.
D i/
w ^ iiZv/i/a
i s i ny,/ onW A i i d r _V
Ui IW /'If (Wl
C/U
a IV
/o W
C >oVfn »/IW
i r oW
of 10-7
Turn weight adjusting screw (D) clockwise or coun Turn signal switches (1) must be turned off after a
terclockwise until indicator (C) conforms to your turn. Turn both switches on for emergency flashers.
weight.
Dimmer switch on left floor panel controls high beam
To move seat up and back, stand up and lift seat- indicator light.
release latch (B). Seat will move automatically to upper
rear position. Sit down to return seat to normal preset Lights and switches checked Yes No
operating position.
18. Transmission Shifting
If seat does not move fully to the rear when un
latched, adjust counterbalance spring as follows:
Fig. 17-Seat Counterbalance Shaft
Move the seat to the upper rear position. Insert a

screwdriver in the slot in the counterbalance shaft,
A— Forw ard -R everse Lever B— T ran sm issio n S hift Lever
push in to unlatch the shaft, and turn the shaft coun
terclockwise. Align the latch in the end of the shaft with Fig. 19-Transmission Controls
the notches in the side of the seat support and pull the
screwdriver outward to latch the shaft. Check operation of motor grader in all gears.
Seat operation checked Yes No To move grader forward, release parking brake,
push forward-reverse lever into forward position, and
17. Light Operation move transmission shift lever to desired gear. Shift one
gear at a time.
Check operation of lights and switches.
Use the forward-reverse lever to change the direc
tion of travel “on the go” without declutching or shifting
gears.
Transmission checked Yes No
19. Reverser Operation

Check operation of forward-reverse lever.
NOTE: Parking brake must be released before for

ward-reverse lever can be shifted out of neutral.
To reverse grader, pull forward-reverse lever rear

ward to reverse position. With transmission shift lever
1— D irection Signal S w itches 4— W o rk Light S w itch in 5tn gear or higher, forward-reverse lever cannot be
2— B eacon Light S w itch 5— D rive Light Sw itch put in reverse position.
3— Panel Light S w itch 6— H i-B eam Indicator Light
Fig. 18-Light Switches
Push all switches forward to turn lights on. Pull

switches rearward to turn lights off.
Litho in U.S.A.
10-8 TM-1001 (Nov-78)
If light glows red while the engine is running, stop

engine and determine cause.
NOTE: Light glows when key switch is in start po
sition and engine off.
When the engine is running and this light is on:
1 - There is a restriction in the transmission oil
system.
2 - The pressure switch is not working. (This switch
is part of the engine oil pressure sending unit.)
3 - The engine oil pressure is low.
4 - The engine oil is cold.
NOTE: This light glows when the key switch is in

start position and the engine is off.
A— Fo rw ard -R ev ers e Lever B— Tran sm issio n Shift Lever
Fig. 20-Transmission Controls
Reverser operation checked Yes No
20. Indicator Lights and Gauges

Check operation of indicator lights and gauges.
During normal operations, the indicator hand should

be in the white zone. If the indicator hand goes into the
@ red-orange zone, stop the grader and check the engine
oil level. If oil level is not low, check for restrictions in oil
Fig. 21-Alternator Indicator Light lines or incorrect viscosity oil.
The alternator indicator light glows red when the

alternator is not charging. If the light goes on while the RED-ORANGE
engine is running, stop engine and determine cause.
NOTE: Light glows when key switch is in start po

sition and engine off.
■T6220411
Fig. 24-Engine Coolant

Temperature Gauge
Normal operating temperature is indicated by the

Fig. 22-Transmission Oil Filter Indicator Light light green zone. If indicator hand enters red-orange
zone, stop engine and determine the cause.
Litho in U.S.A.
22. Differential Lock Operation
If indicator hand enters the red-orange zone,

operate in a lower gear or speed. If hand remains in the
red-orange zone, check transmission oil level or in
spect for plugged oil cooler.
Indicator lights and gauges checked Yes No
21. Tire Pressure

Check the air pressure in all the tires with an accu
rate gauge having 1 psi graduations.
A— Fron t Pedal (Locked) B— R ear Pedal (U n locked)

IMPORTANT: All tires must be inflated to the
same pressure. Fig. 26-Differential Lock Pedal
Adjust pressure in tires to the following specifica Check differential lock operation.
tions:
1 - Lift all four rear wheels off the ground.
Inflation
Ply Pressures
2 - Move the transmission shift lever into first gear.
Tire size Rating psi
3 - Move the hand throttle to half-throttle position.
13.00-24 8 25 4 - Push down the front pedal (A, Fig. 26) to en
13.00-24 10 30 gage the differential lock.
15.5-25 8 25 5 - Push down the right (R.H.) brake pedal. If the
differential lock is working correctly, the engine will
Tire pressure checked Yes No
slow down immediately.
6 - Release the brake pedal.
7 - Follow the same procedure with the left (L.H.)
brake pedal.
8 - Push down the rear pedal (B, Fig. 26) to disen
gage the differential lock.
Litho in U.S.A.
IMPORTANT: Use first gear and half-throttle 24. Blade Lever Operation
ONLY.
Check operation of blade levers.
9 - Push down the right (R.H.) brake pedal. If
brakes engage correctly and the differential lock dis
engages correctly, the right (R.H.) wheels will stop and
the left (L.H.) wheels will keep turning (speed-up).
IMPORTANT: Hold the brake pedal down only

for a short time.
10 - Follow the same procedure with the left (L.H.)

brake.
Differential lock checked Yes No
23. Hydraulic Brakes
A— L eft B lade Lift Lever B— R ight B lade Lift Lever
Fig. 28-Blade Lift Levers
Move levers A and B forward to lower the blade and

rearward to raise the blade. Levers can be operated
individually to position the blade at the desired working
angle, or operated at the same time to lower the blade
to working depth.
Blade lever action checked Yes No
25. Inching Pedal Operation
Fig. 27-Brake Pedals
Check brake system for leaks or improper operation.
Put grader in gear and depress brake pedal. Mod

erate pedal force should hold grader in place.
If pedal force does not hold grader in place, pedal

feels spongy or bottoms out, repair is required, or
system may require bleeding (page 10-10-30).
Brakes operational Yes No
Fig. 29-lnching Pedal
Check inching pedal operation.
Litho in U.S.A.
While driving the motor grader, depress the inching

pedal completely. The transmission should disengage
the drive wheels.
Inching pedal checked Yes No
26. Steering
Start engine and turn steering wheel. Steering
should be free with engine running.
Steering operational Yes No
27. Lubrication
The motor grader was checked and lubricated be
fore it left the factory. However, to insure customer
satisfaction, check each lubrication point shown on the Fig. 32-Right Front Axle (7 points)
following pages. Lubricate with several strokes of John
Lubricant required Yes No
Deere Multi-Purpose Grease or equivalent, if neces
sary.
Fig. 30-Frame Pivot (2 points)
Fig. 31-Axle Pivot Pin (1 point)
Litho in U.S.A.
Fig. 37-Lift Cylinder Trunnions (6 points)
Fig. 35-Circle Side-Shift Cylinder (2 points)
Lubricant required Yes No Fig. 38-Yoke and Steering Cylinder (2 points)
Fig. 36-Lift Cylinders (2 points)
Litho in U.S.A.
93CSX
Fig. 39-Steering Arms (3 points)

Fig. 42-Steering Cylinders (4 points)
Fig. 40-Wheel Lean Cylinder and Pivot (2 points)

Fig. 43-Rear Axle Bearings (2 points)
Litho in U.S.A.
29. Check Accumulator Action

Check the accumulator reserve capacity as follows:
Start engine and run approximately one minute.

Stop engine. Operate brake pedal twenty applications.
After twenty applications, pedal travel should not be
p y n p s p iv p w ith• —a .............
------------ ' *
firm h u t |---------------------------
m n rlp ra tp n p rla---— l p■-ffn rt if th p
— - ' •• - •—
brake accumulator is functioning correctly.
Accumulator checked Yes No
30. Fluid Leakage

v ^ n e ^ r v u ic? iu iil / w ii l y o y o ic ? m o iv i ic a n o y c u u c puui
or faulty connections and broken hoses or lines.
Fig. 44-Locking Pin Holes A. Cooling system checked Yes No

B. Hydraulic system checked Yes No
C. Transmission system checked Yes No
Lubricate two locking pin holes. D. Fuel system checked Yes No
Lower blade to ground. Disengage locking pins from

holes. Apply John Deere Multi-Purpose Grease or
equivalent with brush to each hole.
Locking pin holes lubricated Yes No
28. Wheel Retaining Cap Screws
Fig. 4 5 -W h ee l Ftetaining Cap Screws
Check all wheel retainer cap screw torque. Tighten

to 300 Ib-ft.
Wheel retaining cap screws tightened Yes No

31. Accessible Hardware Torque Values The types of bolts and cap screws are identified by
head markings as follows:
Check all accessible bolts and nuts for proper tight
Plain Head: regular machine bolts and cap screws.
ness. If hardware is loose, tighten it to the proper
3-Dash Head: tempered steel high-strength bolts
torque. The table below gives correct torque values for
and cap screws.
various bolts and cap screws. Most hardware used is
6-Dash Head: tempered steel extra high-strength
high-strength (note dashes on hex. heads).
bolts and cap screws.
Machine bolts and cap screws 7/8-inch and larger
STANDARD TORQUE CHART are sometimes formed hot rather than cold, which
accounts for the lower torque.
All accessible hardware torqued Yes No
32. Final Check

The final predelivery procedure is the overall clean
up of the motor grader. Make the motor grader LOOK
like a new motor grader with the proper touch-up of
chipped paint and a good wash job. Deliver to the
customer a motor grader anyone would be proud to
own.
Litho in U.S.A.
DELIVERY SERVICE AFTER-SALE INSPECTION

A thorough discussion of the operation and service The purchaser of a new John Deere motor grader is
of this motor grader at the time of delivery helps to entitled to a free inspection at some mutually agree
assure complete customer satisfaction. Proper delivery able time within the warranty period after the equip
should be an important phase of a dealer’s program. A ment has been “ run in,” usually after 50 to 100 hours of
portion of the John Deere Delivery Receipt empha motor grader operation. The terms of this after-sale
sizes the importance of proper delivery service. inspection are outlined on the customer’s John Deere
Delivery Receipt.
Many complaints arise because the owner was not
shown how to operate and service the new motor The purpose of this inspection is to make sure that
grader properly. Devote enough time, at the custom the customer is receiving satisfactory performance
er’s convenience, to introduce the owner to the new from the motor grader. At the same time, the inspection
motor grader and explain how to operate and service it. should reveal whether or not the motor grader is being
operated, lubricated, and serviced properly.
The following procedure is recommended before the
service technician and owner complete the delivery If the recommended after-sale service inspection is
acknowledgments portion of the Delivery Receipt. followed, the dealer can eliminate a needless volume
of service work by preventing minor irregularities from
Use the operator’s manual as a guide to be sure that developing into serious problems later on. This will
the owner understands these points thoroughly. promote strong dealer-customer relations and present
the dealer an opportunity to answer questions that may
1. The importance of safety. have.?arisen during the first few days of operation.
2. The importance of lubrication and periodic ser
vices. During the inspection service, the dealer has the
3. The importance of the break-in period. further opportunity of promoting the possible sale of
4. Controls and instruments. other new equipment.
5. How to start and stop the engine.
6. All functions of the hydraulic system. Check operation of all controls and instruments for
freedom of movement and correct operation.
After explaining and demonstrating the above fea
tures, have the owner sign the Delivery Receipt and
give the owner the operator’s manual.
Litho in U.S.A.
1. Engine Crankcase Oil and Filter

NOTE: Check with the customer if oil has been
changed and filter replaced before performing this
service.
Normal sequence of service is as follows:
Oil and Filter Change - after first 100 hours
- every 200 hours thereafter
If changed, record information below:
Approximate hours at change
If not, change as follows:
A— Oil Filter C— Dipstick

B— Filler Cap
Fig. 48-Changing Crankcase Oil and Filter
Install crankcase drain plug.
Fill crankcase with new oil of proper viscosity (B, Fig.

48). Capacity is 12 quarts with filter.
Run engine a short time and check for leaks at filter

base and engine crankcase drain plug. Tighten filter if
required.
Stop engine. Check oil level (C, Fig. 48).

Fig. 47-Crankcase Drain Plug
Crankcase oil changed Yes No
Drain crankcase when the oil is hot. Remove the Oil filter changed Yes No
drain plug. Drain all oil.
While oil is draining, replace filter as follows:
Remove filter. (A, Fig 48) (turn counterclockwise).
Clean mounting surface.
Apply film of oil to sealing ring of new filter.
Tighten filter until sealing ring touches mounting

surface.
Turn an additional 1-1/2 turns.
Do not overtighten.
Litho in U.S.A.
2. Transmission-Hydraulic System Be sure dipstick has been fully inserted before

Oil Level and Filter Elements checking oil level. Do not start engine unless oil is near
top mark on dipstick.
NOTE: Before checking oil level find out if customer
has changed transmission filter element (first 50 hours
If oil is needed, add John Deere HY-GARD Oil or
service).
equivalent. Do not overfill.
If changed at an earlier date, record information
below: Transmission filter changed Yes No
Oil level checked Yes No
Approximate hours at change _______ Oil added ______ qts.
If not, change as follows:
A— Drain P lug B— Tran sm issio n Filter

C— H ydraulic Filter
A— Oil Level Plug B— Main D rive S procket
Fig. 49-Transmission-Hydraulic System Filters Retainer
Stop the engine. Remove the transmission oil filter Fig. 51-Tandem Drives
(B, Fig. 49) cover. Pull out the oil filter element and
install new filter element. Replace the filter cover gas With the grader on a level surface, check oil in both
ket. Install and tighten the filter cover to 55 Ib-ft (77 tandems by removing the oil level plug. Oil should be
Nm). Check the oil level. level with the check plug hole. If necessary, add John
Deere HY-GARD Oil or equivalent through one of the
holes under the inspection plates.
Fig. 50-Transmissicn-Hydraulic System Filler Cap and Dipstick
Litho in U.S.A.
TM-1001 (Dec-87)_______________________________________________________________________Predelivery, Delivery, and After-Sale Services 10-19
5. Precleaner
Fig. 52-Tandem Drive Inspection Plate
Tandem drives oil level checked Yes No

Oil added _____ qts.
4. Circle Drive Gear Box

Fig. 54-Precleaner
Check precleaner bowl. Clean if necessary.
Precleaner checked Yes No
6. Air Cleaner
A— V en t C— D rain Plug
B— O il Level an d Filler Plug
Fig. 53-Circle Drive Gear Box
W ith the blade resting on level ground, check the

A— D ust Cap C— P rim ary E lem ent
circle drive gear box oil level by removing the oil B— W ing Nut
level plug. Oil should be level w ith the plug hole.
If necessary, add John Deere SCL Gear Oil or Fig. 55-Air Cleaner
equivalent. Replace fille r plug.
Circle drive gear box
oil level checked Yes No
Oil added _____ qts.
Litho in U.S.A.
10 Generc.: Grader, Motor - JD570
8. Batteries
Remove foreign material from top of battery. Check
battery electrolyte level. If distilled water is not avail
able, use clean soft water. Coat terminals with petro
leum jelly. Check battery connections.
IMPORTANT: Never add water to battery in

freezing weather unless engine will be run 2 or 3
hours.
W ater added Yes No

Battery connections checked Yes No
9. Tire Pressure
Check the air pressure in all the tires with an accu
A—Reset Button B—Red Signal
rate gauge having 1 psi graduations.
Fig. 56-Restriction Indicator
Check air cleaner restriction indicator. If indicator IMPORTANT: All tires must be inflated to the
shows red, check elements. If only primary element is same pressure.
dirty, clean the element. If safety element is dirty,
replace both elements. Adjust pressure in tires to the following specifica
tions:
Air cleaner checked Yes No
Elements replaced Yes No Inflation
Ply Pressures
Tire size Rating psi
7. Radiator
13.00-24 8 25
13.00-24 10 30
15.5-25 8 25
Tire pressure checked Yes No
10. Fuel Tank
Fig. 57-Radiator Filler Cap
CAUTION: Remove the radiator filler cap

A only when the coolant temperature is
below the boiling point. Then loosen the cap
slightly to the stop to relieve pressure before re
moving the cap completely.
Check coolant level. Maintain 4 inches below the top
of the filler neck.
Radiator coolant level checked Yes No

Coolant or anti-freeze added qts.
Fig. 58-Fu el Tank Filler Cap
Bleed fuel system as follows:
Fig. 59-Fuel Gauge
Check fuel gauge. Turn on key switch and check for

movement of indicator on gauge. If no movement is
noted, add a small amount of fuel and repeat proce
dure.
Fig. 61-Bleeding Fuel System
If no indicator movement is noted, gauge is not
functioning. 1 - Be sure fuel tank has sufficient fuel.
2 - Loosen the bleed screw.
Fuel gauge functional Yes No 3 - Pump the primer lever until fuel without air
bubbles flows from the bleed screw.
11. Fuel Tank Sump 4 - Tighten the bleed screw.
5 - Push the primer lever down.
Open fuel tank drain cock. Drain liquid for several
seconds. Close drain cock. NOTE: If primer does not pump fuel and no resis
tance is felt at upper portion of lever stroke, turn engine
NOTE: Fuel tank sump drain is located on the bot slightly with starter to change fuel pump cam position.
tom o f the fuel tank.
Sediment present in filter Yes No
Fuel sump drained Yes No Fuel system bled Yes No
12. Fuel Filter 13. Lubrication

Check each lubrication point shown in the following
pages. Lubricate, if necessary, with several strokes of
John Deere Multi-Purpose Grease or equivalent.
Fig. 60-Fuel Filter
Fig. 62-Frame Pivot (2 points)

Check fuel filters for sediment. Drain if necessary.
Litho in U.S.A.
Fig. 63-Axle Pivot (1 point)

Fig. 65-Left Front Axle (8 points)
Fig. 64-Right Front Axle (7 points)

Fig. 66-Yoke and Retaining Pins (5 points)
Litho in U.S.A.
Fig. 67-Circle Side Shift Cylinder (2 points)
Fig. 69-Lift Cylinder Trunnions (6 points)
Fig. 68-Lift Cylinder (2 points)
Fig. 70-Yoke and Steering Cylinder (2 points)

Fig. 71-Steering Arms (3 points)

Fig. 74-Steering Cylinders (4 points)
Fig. 72-Wheel Lean Cylinder and Pivot (2 points)

Fig. 75-Rear Axle Bearings (2 points)
Fig. 73-Front Wheels (2 points)
Litho in U.S.A.
15. Alternator-Fan Belts
Fig. 76-Locking Pin Holes
Lubricate two locking pin holes.
Lower blade to ground. Disengage locking pins from A— A djusting C ap Screw B— A ltern ato r-F an Belts
holes. Apply John Deere Multi-Purpose Grease or

Fig. 78-Alternator-Fan Belts
equivalent with brush to each hole.
Alternator-fan belt should deflect 3/4-inch when 20
Locking pin holes lubricated Yes No
pounds of force is applied to the belt midway between
the two pulleys. Check front belt only. If a belt gauge is
14. Air Intake Hoses
used, tighten new alternator belt to 100 pounds strand
tension. After 3 minutes of operation, tension should be
90 pounds minimum.
IMPORTANT: Do not pry on the rear alternator

housing as this may damage the alternator.
Alternator-fan belt tension lbs strand tension

_____ inch deflection
16. Engine Speeds

Warm up engine and attach a tachometer in the hour
meter drive plug hole to check engine speeds.
No-load, fast idle speed should be 2450 rpm. Slow

idle should be 900 rpm.
A— Air Intake Hose C— Turb ocharger Inlet
B— A ir Intake Hose Hose If engine speeds do not agree with the above adjust
C lam ps D— Tu rbocharger Inlet as follows:
Hose Clam ps
Fig. 77-Air Intake Hoses and Clamps
Check hoses (A) for cracks. Replace if necessary.

Tighten clamps (B). Also check turbocharger inlet hose
(C) and clamps (D).
Air intake hoses checked Yes No
Litho in U.S.A.
17. Parking Brake
Fig. 80-Parking Brake Lever
Check parking brake adjustment.
A lifting force of 75 lbs (minimum) is required to set

the parking brake lever.
If parking brake adjustment is required, adjust as

follows:
The parking brake lever has a built-in adjustment

knob. Turn the knob clockwise to adjust the brake.
1— H and Th ro ttle Lever 5— Fo ot Th ro ttle Arm When the end of this adjustment is reached, turn the
2— T h ro ttle Lever 6— Foot T h ro ttle Pedal knob counterclockwise several turns to release the
3— Th ro ttle Rod an d C levis 7— Spring brake, and adjust the clevis linkage.
4— T h ro ttle Link
Fig. 79-Hand and Foot Throttle Linkage
With the foot throttle linkage in the slow idle position,

adjust the throttle cable so the lever on the pump
overrides the slow idle position by 1/4 inch.
Pull the hand throttle lever (1, Fig. 79) to the most
rearward position and adjust the throttle rod and clevis
linkage (3) on the hand throttle lever (1) to the shortest
length without moving the foot throttle linkage.
Put the hand throttle lever in the most forward posi

tion. The lever on the pump should be in the fast idle
Fig. 81-Parking Brake Adjustment
override position. Fast idle override is 1/4 inch.
Engine speeds checked Yes No

Remove the clevis from brake arm and back off lock
Adjustments required Yes No nuts. Turn clevis clockwise on brake cable to adjust
brake. Tighten lock nuts and install clevis.
Parking brake checked Yes No

Adjustment required Yes No
18. Circle Adjustment Place a wooden block (Fig. 83) between the end bit
and the front axle. Force the circle back by sideshifting
the moldboard against the wooden block.
The pinion tip-to-circle root distance should be a
maximum of 0.35 inch (see below).
A— W ear Plate C— C ircle

B— 0.02 to 0.08 Inch
Fig. 82-Circle Adjustment

A — Pinion Gear C— M axim um of 0.35 Inch
Wear Plate-Circle Clearance B— Circle
To adjust circle, position circle and blade assembly Fig. 84-Pinion Tip to Circle Adjustment
so blade is perpendicular to length of grader and Sideshift moldboard back away from the wooden
centered on the circle. Raise the blade a couple of block slightly to relieve some pressure from the front
inches from the ground. circle support bolts. Tighten bolts snug and recheck the
Adjust the circle support shim pack to obtain 0.02 to 0.35-inch maximum dimension.
0.08-inch clearance between the circle and each wear Adjust the rear support shoes uniformly until they
plate. Tighten support cap screws just enough so both just contact the circle teeth. Tighten each of the
support is firmly against shim pack. Check and adjust adjusting screws an additional 1/8 turn to snug the
one support at a time. support shoe up against the circle teeth.
NOTE: Wear plates may be replaced if no further Tighten hardware to 670 Ib-ft. and rotate circle 360
adjustment is possible. degrees in both directions. The 0.35-inch maximum
Position the blade under the machine in such a dimension should be maintained after rotation. If, after
manner that the moldboard can be sideshifted up initial adjustment, circle will not rotate a full 360 de
against the front axle. grees without binding, loosen the rear circle supports
and back them off slightly.
Loosen all circle support bolts.
NOTE: The circle support shoes will polish the tips
of the circle gear teeth and may initially peel small
ribbons of steel off the bottom of the circle.
Circle adjustments required Yes No
If yes, e xp la in _________________________________________
Fig. 83-Positioning Moldboard
Litho in U.S.A.
Fig. 85-Transmission Oil Filter Indicator Light Fig. 87-Engine Oil Pressure
Gauge
If light glows red while the engine is running, stop

During normal operations, the indicator hand should
engine and determine cause.
be in the white zone. If the indicator hand goes into the
red-orange zone, stop the grader and check the engine
When the engine is running and this light is on:
oil level. If oil level is not low, check for restrictions in oil
1 - There is a restriction in the transmission oil
lines or incorrect viscosity oil.
system.
2 - The pressure switch is not working. <This switch
is part of the engine oil pressure sending unit.)
3 - The engine oil pressure is low.
4 - The engine oil is cold.
NOTE: This light glows when the key switch is in

start position and the engine is off.
Normal operating temperature is indicated by the

light green zone. If indicator hand enters red-orange
zone, stop engine and determine the cause.
Fig. 86-Alternator Indicator Light
The alternator indicator light glows red when the

alternator is not charging. If the light goes on while the
engine is running, stop engine and determine cause.
NOTE: Light should glow when key switch is in start

position and engine off.
If indicator hand enters the red-orange zone,

operate in a lower gear or speed. If hand remains in the
red-orange zone, check transmission oil level or in
spect for plugged oil cooler.
Indicator lights and gauges checked Yes No
Litho in U.S.A.
20. Transmission Operation

Check operation of transmission in all gears.
A— C ircle S id e -S h ift C ylinder

B— Lift C ylin der Rod Ends
Fig. 91-Cylinder Ball and Socket
A — Forw ard -R everse Lever B— Tran sm issio n S h ift Lever Socket looseness OK Yes No
If no, number of shims removed _______
Fig. 90-Transmission Control Levers
23. Moldboard Retainers
Lever A - Release parking brake before shifting
out of neutral. Change direction of travel “ on the go”
without declutching or shifting gears.
Lever B - Shift one gear at a time. When in 5th

gear or higher, Lever A cannot be shifted into reverse.
Transmission operation checked Yes No
21. Charging System

When the motor grader is running and the alternator
indicator light (see page 10-10-28) is not lit, the
charging system is in proper working condition.
Charging system operational Yes No
22. Cylinder Bail and Socket Fig. 92-Blade Side-Shift Rail Shims
Assemblies
The ball and socket assemblies on the lift cylinder The two upper guides on the blade side-shift rail
rod ends and on the circle side-shift cylinder have have shims which may be removed to compensate for
shims which may be removed to compensate for wear. wear. Check the amount of looseness between the
guides and the rail by slightly raising and lowering the
Check looseness of sockets by lowering the blade to blade to the ground. If excessive looseness is noticed,
the ground and operating the cylinder back and forth remove shims accordingly. Retain enough shims to
without load. If movement exceeds 0.03 inch remove allow blade to side-shift completely without binding.
corresponding amounts of shims.
Shims removed Yes No
If yes, indicate amount _______
NOTE: Do not allow ball to bind in the socket.
Litho in U.S.A.
24. Saddle Retaining Pins Three adjustable guide shoes are located on the
saddle. Shims located between the three guide shoes
and the saddle can be removed or installed to control
the clearance (0.02 to 0.09 inch) of the saddle in the
guides.
25. Hydraulic Brakes
A— Saddle Pivot C— Locking Pin

B— Saddle Retaining Pins
Fig. 93-Saddle Retaining Pins (ROPS Canopy Removed

for Illustration Purposes Only)
Fig. 95-Brake Pedals

When the locking pin plunger (C, Fig. 93) is de
pressed the locking pins (B, Fig. 93) should retract Check brake system for leaks or improper operation.
from the holes in the saddle pivot (A, Fig. 93). The Put grader in gear and depress brake pedal. Mod
saddle may have to be “ rocked” slightly (using the lift erate pedal force should hold grader in place.
cylinders) to unload the locking pins. If pedal force does not hold grader in place, pedal
When the locking pin plunger is released the locking feels spongy or bottoms out, repair is required, or
pin should go back into the hole in the lift arm. system may require bleeding as follows:
Visually check if pin is in hole. Also check if the

locking pin plunger travels freely.
Check the torque on the clamp attaching bolts on the
locking pin barrel. Tighten to 35 Ib-ft.
A— Lock Nut B— Bleed Screw
Fig. 96-Bleed Screw
NOTE: This procedure requires two service techni

cians.
Fig. 94-Guide Shoes 1. Lower all equipment to ground.
2. Stop engine.
3. Loosen lock nut on each bleed screw. Open
Litho in U.S.A. bleed screw one turn .Tighten lock nut.
4. Hold brake pedals down to release accumulator Check the following cap screw torque values:
pressure. Release pedals.
Wheel retaining cap screws. Tighten to 300 Ib-ft.
5. Run engine at slow idle.
Wheel retaining cap screws tightened Yes No
6. Hold brake pedals down two minutes minimum.
7. Loosen lock nuts. Tighten bleed screws. Tighten Saddle to saddle mounting cap screws. Tighten to
lock nuts. Release pedals. 445 Ib-ft.
8. Pedal must feed solid. If not, bleed brakes again. Saddle to saddle mounting
cap screws tightened Yes No
Brake pedal action OK Yes No
Bleeding required Yes No
Circle supports to draft frame cap screws. Tighten to
670 Ib-ft.
26. Accumulator Action
Check the accumulator reserve capacity as follows: Circle supports to draft
frame cap screws tightened Yes No
Before starting engine, operate brake pedal several
times. Excessive pedal travel means the accumulator 28. Accessible Hardware Torque Values
has no reserve capacity.
If hardware is loose, tighten it to the proper torque.
Start engine and run approximately one minute. See page 10-10-15 for torque chart.
Stop engine. Operate brake pedal twenty applications.
After twenty applications, pedal travel should not be All accessible loose hardware torqued Yes No
excessive with a firm but moderate pedal effort if the
brake accumulator is functioning correctly. 29. Toe-In
Accumulator functioning OK Yes No Checking Toe-In

Check toe-in regularly.
27. Check Cap Screw Torque
1. Park the grader on a level surface.
NOTE: If the following torque values are higher than
your torque wrench is capable of measuring, use the 2. Use the blade or scarifier hydraulics to lift the
following formula to determine the correct values while front wheels off the ground. Block the front axle.
using a torque wrench extension.
TW = Ta X , L
L + A
TW = Torque wrench reading - Ib-ft

Ta = Required torque - Ib-ft A— Bell C rank C enterline B— A xle C enterline
L = Length (in feet) of torque wrench
A = Length (in feet) of extension Fig. 98-Aligning Centerlines
Fig. 97-Calculating Torque with an Extension 3. Line up the center mark on the bell crank with
centerline on axle as shown.
Litho in U.S.A.
Fig. 99-Measuring Lines Fig. 101-Measuring Lines
4. Distance C (axle centerline to left tie rod pin) 9. Turn tires 180° so G and H are at axle centerline
should be within 0.1 in. (2.5 mm) of distance D height in front of machine.
(centerline to right tie rod pin). 10. Measure distance L at G and H height.
11. Distance L must be 0 to 0.5 in. (0 to 13 mm) less
5. Measure distances E and F from floor to axle than distance K.
centerline.
Adjusting Toe-In
T?2014
Fig. 100-Drawing Lines
6. Draw lines G and H on rear of tires. Fig. 102-Adiusting Toe-In
7. Draw lines I and J at center of each tire. 12. Loosen tie rod nuts (M).
13. Turn tie rods (N) the same number of turns until
8. Measure distance K at G and H height. toe-in is correct.
14. Tighten nuts to 330 Ib-ft (462 N-m).
Toe-in checked Yes No
30. Fluid Leakage

Check the following systems for leakage due to poor
or faulty connections and broken hoses or lines.
A. Cooling system checked Yes No

B. Hydraulic system checked Yes No
C. Transmission system checked Yes No
D. Fuel system checked Yes No
Litho in U.S.A.
Grader, Motor - JD 570 G en eral 10
TM-1001 (Nov-78) T une-U p and A d ju stm ent 15-1
Group 15
TUNE-UP AND ADJUSTMENT
GENERAL IN FO RM ATION
Before tuning up an engine, determine if it is

in condition so that performance can be restored
by tune-up. Perform the following tests:
P R E D E LIV E R Y ENGINE TESTING

Operation S p e cifica tio n Reference
Vacuum test (at air cleaner) 8 to 25 inches of water at

fast idle
Check radiator for air bubbles
and indication of oil
Check cylinder compression
(minimum) 300 psi
Test engine power output Note and compare with output after
tune-up
ENGINE T U N E -U P
AIR INTAKE SYSTEM

Air cleaner - clean filter
element and dust cup .................................................................. Section 30, Group 10
Check breather pipe for restriction s............................................................................................................
Retighten cylinder head cap screws 110 ft-lbs torque Section 20, Group 10
Check valve clearances 0.014 in. intake Section 20, Group 10
0.018 in. exhaust
BATTERY
Check electrolyte level ............................................................................................................
Clean cables, terminals, and box ............................................................................................................
Tighten cable clamps ............................................................................................................
ALTERNATOR
Check belt tension 20 pounds at 3/4 in. ....................................
Replace brushes If less than 1/4 in. beyond holder Section 40, Group 10
FUEL SYSTEM
Check fuel tank and lines for
leaks or restrictions ............................................................................................................
Clean fuel transfer pump bowl
and strainer (JD570) ............................................................................................................
Replace fuel filter elements ............................................................................................................
Drain fuel tank sump .................................................................. See Operator's M a n u a l
Time injection pump .................................................................. Section 30, Group 15
Check injection pump advance .................................................................. Section 30, Group 15
Bleed fuel system ...............................................................................................................
Adjust speed control linkage
and check engine speeds .................................................................. Section 20, Group 20
ENGINE LUBRICATION SYSTEM
Check engine oil pressure 40 to 60 psi at 2300 rpm Section 20, Group 15
(180° to 220° F.)
L itho in U .S.A .
1H .9 T i m e .l l n a n H A rliiiG trruant TM-1Q01 (Dec-87)
ENGINE T U N E -U P -C o n tin u ed
O peration S p e c ific a tio n Reference
COOLING SYSTEM
Clean and flush system ...................................................................................... ........................
Inspect hoses ...............................................................................................................
Clean trash from radiator ...............................................................................................................
ADJUSTMENTS
BRAKES
Bleed brakes .................................................................. Section 60, Group 15
Check action of brake accumulator .................................................................. Section 60, Group 10
Check mechanical parking brake
jgyg.F effort .................................................................. Section 60, Group 20
Check service brake with no
accumulator pressure .................................................................. Operator's Manual
POWER-STEERING
Bleed steering system

♦Valve leakage (with oil at 140° F.,
cylinders against stops and 60 2-3 rpm max. Section 60, Group 5
in-lbs applied to steering 4 rpm indicates excessive
shaft). leakage
WHEELS
Check front and rear toe-in .................................................................. See Section 10, Group 10
Check front wheel bearings .................................................................. See Operator’s Manual
TIRES
Check tire inflation .................................................................. See Operator's Manual
TIGHTEN ACCESSIBLE BOLTS

AND CAP SCREWS See torque chart. Section 10, Group 25*
* U n its w ith s e r i a l n u m b e r s 1 4 4 1 , 1 4 4 7 - 1 4 5 0 a n d 1 4 7 0 - 1 4 7 5
Litho in U .S .A .
TM-1001 (Nov-78) T une-U p and A d justm ent 1 5 -3
HYDRAULIC SYSTEM AVERAGE CYCLE TIM ES

W ITH OIL T E M P E R A TU R E BETW EEN 65 AND 145 DEGREES FA H R EN H EIT
AND ENGINE AT F U L L TH R O TTLE
O peration S p e cifica tio n s
Blade pitch, forw ard.......................................................................... ... . 1.0-2.0 Seconds
Blade pitch, b a c k .................................................................................. . . 1.0-2.0 Seconds
Circle rotation, left (36 0 °)................................................................. , . 36.0-52.0 Seconds
Circle rotation, right (360°)................................................................ . 36.0-52.0 Seconds
Drawbar side shift, l e f t ....................................................................... 7.4-10.5 Seconds
Drawbar side shift, rig h t.................................................................... . 5.5-8.5 Seconds
Drift check, blade raised 6 in. movement is 1/16 inch maximum in 15 min.
Frame steer, right and left............................................................... . 3.0-7.0 Seconds
Lift cylinders, right and left, retract 12 inches (Early Units) . . 4.0-7.5 Seconds
(Early Units) . . 4.0-6.0 Seconds without orifice
retract 12 inches (Later Units) . . 3.5-4.5 Seconds with orifice
extend 12 inches. ......................... . 2.5-4.5 Seconds
Moldboard side shift, le ft .................................................................. . 7.5-10.2 Seconds
Moldboard side shift, right............................................................... . 5.5-8.0 Seconds
Scarifier, extend (Early U n its)....................................................... . 4.0-8.0 Seconds

(Later Units with o r ific e )................................. 2.5-6.0 Seconds
Scarifier, retract (Early Units)....................................................... . 6.5-9.7 Seconds

(Later Units with orifice)................................. 3.5-7.0 Seconds
Wheel lean, left or right..................................................................... 2.0-3.7 Seconds
Determine if engine is performing at its rated Compare output of engine with what it de-
horsepower (83 hpfor JD570, 85hpfor JD570-A). livered prior to tune-up.
Litho in U .S.A .
10 G en eral Grader, Motor - JD570
1 5 -4 T une-U p and A d ju stm ent TM-1001 (Nov-78)
Litho in U .S.A ,
Grader, Motor ■JD570 General 10
TM-1001 (Dec-87) Lubrication 20-1
Group 20
LUBRICATION
GENERAL INFORMATION
Carefully written and illustrated instructions have For your convenience, the following chart shows
been included in the operator’s manual furnished with capacities and types of lubricants for the machine’s
your customer’s machine. Remind your customer to various components and systems. Definitions of the
follow the recommendations in these instructions. lubricants follow the chart.
Component Capacity Type of Lubricant
Engine crankcase (including filter) 10 U.S. quarts (JD570) See page 20-2
12 U.S. quarts (JD570-A)
Transmission case 21 U.S. gallons John Deere HY-GARD Trans

(includes hydraulic mission and Hydraulic Oil
system and filters) or an equivalent
Circle drive 1.5 U.S. quarts John Deere SCL G ear Oil or
an equivalent
Tandems 5 U.S. gallons (each) John Deere HY-GARD Trans

filled to check mission and Hydraulic Oil
plug or an equivalent
Cylinders, trunnions, Several shots John Deere Multi-Purpose

draft frame, Grease or an equiva
front axle pivot lent
points, and frame
pivot
Grease fittings John Deere Multi-Purpose

Grease or an equiva
lent
Axle bearings 6 to 8 shots John Deere Multi-Purpose

Grease or an equiva
lent
Starter Saturate wicks Engine crankcase oil (SAE

10W)
Lubricate armature Engine crankcase oil (SAE

splines during 10W)
assembly
Litho in U.S.A.
20-2 Lubrication TM-1001 (Dec-87)
LUBRICANTS
Use only lubricants specified in this section. Apply Some increase in oil consumption may be expected
them according to instructions on the periodic service when SAE 5W-20 or SAE 5W oils are used. Check oil
chart. level more frequently.
ENGINE LUBRICATING OILS TANDEM DRIVES

Use John Deere HY-GARD Transm ission and
H ydraulic Oil (J20A) or an equivalent.
CIRCLE DRIVE GEARBOX

Use John Deere SCL Gear Oil or oils meeting API
X3377N service c la s sifica tio n GL-4 and co n ta in in g sulfur,
ch lorine and lead (SCL) additives as shown below:
John Deere TORQ-GARD® SUPREME Engine Oil
is recommended in engine crankcase. Never put addi- A ir V is c o s ity
tives in crankcase. Te m p eratu re SAE Num ber
If oil other than TORQ-GARD SUPREME is used, it 14°— 122°F 140

must conform to following specifications. ( - 1 0 ° — 50°C)
S IN G LE V IS C O SITY M U L T I-V IS C O S IT Y —4 ° — 122°F 90

O IL S O ILS ( —20°—50°C)
API Service CD-SD API Service CC/SD —22°—6 8 °F 80

MIL-L-2104C MIL-L-46152 ( —30°—20°C)
Series 3
—40°— 5 0 °F 75W
Use oil of viscosity as shown in following chart. ( —4 0 °— 10°C)
John D eere O ther Oils GREASES

A ir T O R Q -G A R D S ing le V is - M u lti-V is
Te m p eratu re SUPREME cosity O il co sity Oil Use John Deere Multi-Purpose Grease or equiva
lent for all grease fittings.
Above SAE 30 SAE 30 Not recom-
32°F (0CC) mended TRANSMISSION-HYDRAULIC SYSTEM
Above -15°F, use John Deere HY-GARD oil or an
* - 1 0 cF to SAE 10W-20 SAE 10W SAE 10W-30
equivalent.
32°F (—23°C to 0°C)
Use HY-GARD Winter Grade Oil when temperature
Below SAE 5W-20 SAE 5W SAE 5W-20
is below -15°F.
- 1 0 CF (—23°C)*
*SAE 5W-20 oil may also be used to insure optimum Continued use of HY-GARD Winter Grade Oil at
lubrication at starting, particularly when engine is sub temperatures above 32°F may result in increased
jected to -1 0 °F ( —23°C) or lower temperatures for transmission and hydraulic component wear and
shorter life.
several hours.
Litho in U.S.A.
Grader, Motor - JD 570 G en era l 10
TM-iOOi (Nov-78) S ep aration 25-1
Group 25
SEPARATION
SEPARATING POWER U N IT FROM FRAM E Unhook main wire harness (1, Fig. 1).
The power unit must be separated from the N O T E : U n its b e lo w s e r i a l n u m b e r 0 0 0 6 8 2

frame to service the final drives, transmission u s e a o n e - p i e c e m a in w i r e h a r n e s s . M a k e s u r e
or differential. If shop facilities are limited, it to ta g a l l c o n n e c tio n s w h e n r e m o v in g f o r i n s t a l l a
is advisable also to make this separation for tio n .
engine removal.
Break hydraulic line connections at clamp (2).
N O T E : O n c e s e p a r a tio n i s m a d e , th e p o w e r Tag all connections for installation.
u n it c a n o n ly b e m o v e d in a s t r a i g h t lin e . T h e r e
f o r e , b e s u r e m o t o r g r a d e r i s p o s i t io n e d c o r Disconnect park brake cable (3) from brake
r e c t l y b e f o r e m a k in g s e p a r a tio n . lever.
Use the following procedure to separate the

power unit from the engine frame.
N O T E : P o s i t i o n th e b la d e h o r iz o n ta l w ith th e
u n it, s o th e b la d e c a n s t a b i l i z e th e r e a r o f th e
e n g in e f r a m e .
Disconnect battery ground straps and battery -

to-battery connector cable.
Remove muffler, pre-cleaner, hood, grille and

fuel tank.
1 — A ccum u la tor 3 — H y d ra u lic Pump

2 — H y d ra u lic P u m p -to -P ria rity D rain L in e
V a lve L in e 4 — S p lit B a ffle
F ig . 2—H y d ra u lic Pump and A ccum u la tor
Remove accumulator (1, Fig. 2) from the unit.
Disconnect hydraulic pump-to-priority valve

line (2) from hydraulic pump.
Disconnect hydraulic pump drain line (3) from

the pump.
1 — M ain Wire H arness 2 — Clamp
3 - Park Brake C able Remove the split baffle (4) from under the
F ig . 1 -H y d ra u lic L in e s and radiator.
Main Wire H arness
L ith o in U .S.A .
10 G en era l Grader, Motor - JD 570
2 5 -2 S ep aration TM-1001 (Nov-78)
F ig . 4—Support B ar
Install support bar under tandem steps as

shown in Fig. 4. See "Making Special Tools,”
(Group 30 of this section) for construction
details of support bar.
CAUTION: The support bar prevents the

A transm ission and engine fro m oscillating
around the final drives once the connecting pins
are removed. Be sure support bar is snug against
1 — T h ro ttle P u sh -P u ll C oble 3 — Speed and D ire c tio n clutch housing.
2 - Hose B racke ts (2 used) C ables
4 — T h ro ttle C able B racke t Remove rear bumper and rear frame.
F ig . 3 - T h r o ttle C able and Speed
and D ire c tio n Cables
Attach hoist to main frame.
Disconnect throttle push-pull cable (1) from
injection pump and throttle cable bracket (4).
Disconnect speed and direction cables (3)

from transmission control valve.
Disconnect starting aid tube from intake

manifold.
Disconnect clutch disconnect cable from

lever.
F ia . 5 - P in P la te s
Remove the cap screws and retaining pin

plates (Fig. 5) from the connecting pins holding
the engine frame to the final drives. Use grease
gun to remove pins. Remove the grease fittings
from the pins to ease installation of pins. Re
install the fittings.
L itho in U .S.A .
TM-1001 (Feb-80) Separation 25-3
ASSEMBLING POWER UNIT TO FRAME

Hoist main frame so engine frame clears axle.
Roll power unit into position inside engine frame.
Clean excess grease out of mounting pin holes.
Coat mounting pins with PT505 or PT506 John

Deere Never-Seez Lubricant or an equivalent.
Attach rear frame and rear bumper. Remove support

bar.
Install split baffle under radiator. Attach hydraulic

lines at clamp and connect all cables.
Fig. 6-Power Unit Separated from Frame
Connect wiring harness. Be sure connectors are
attached to proper terminals. See Section 40, Group 5.
Use hoist to lift main frame. Roll power unit out from
under the engine frame (Fig. 6).
Install fuel tank, grille, hood, air cleaner, and muffler.
Connect battery-to-battery connector cable and

battery ground straps.
Litho in U.S.A.
25-4 Separation TM-1001 (Dec-87)
REMOVING ENGINE
Use the following procedure to separate the engine:
Disconnect battery ground straps.
Remove muffler, pre-cleaner, hood, grille, fuel tank
and fuel tank bracket.
Disconnect hydraulic lines from hydraulic pump, ac
cumulator, and pressure regulating valve.
Remove hose brackets (2, Fig. 3) from L.H. side of
engine.
Remove accumulator and R.H. bottom baffle plate.
Loosen L.H. bottom baffle plate.
Loosen the transmission oil cooler tube at the
transmission end.
Disconnect wiring harness connections. Tag all
connectors and terminals for easier installation. Re
move all wire harness clamps from engine.
Remove speed control push-pull cable (1, Fig. 3)
from injection pump.
1— S p read er B ar 2— JD244 Lifting Eyes
Remove throttle cable bracket (4, Fig. 3) with speed 3— Chain
control push-pull cable from engine.
Fig. 7-Engine Sling Attached to Engine
Disconnect starting aid tube from intake manifold.
NOTE: Hydraulic pump and radiator do not need to
Disconnect fuel transfer pump-to-fuel tank line from
be removed from engine. They will be lifted out with
pump.
engine. If radiator is removed before engine, readjust
Disconnect clutch disconnect linkage from lever. engine sling so engine is balanced to hang level.
Remove ventilator tube.
R e m o v e t r a n s f e r d r i ve. See “ R E M O V I N G
A tta ch JD244 o r JT01748 L iftin g Eyes to engine. TRANSFER DRIVE” in this group.
A tta ch spreader bar to liftin g brackets.
Disconnect oil drain hose from clutch housing.
Move engine forward until front engine mounts slide

off dowels.
Use hoist and lift engine out of unit.
Litho in U S A .
Grader, Motor - JD 570 G en era l 10
TM-1001 (Nov-78) S ep aration 2 5 -5
IN STA LLIN G ENGINE
Hoist engine over transmission and slide en

gine back over dowel pins.
Install transfer drive. Tighten engine-to-

transfer drive cap screws to 35 ft-lbs andtrans-
mission-to-transfer drive cap screws to 300
ft-lbs.
Install all parts removed.
Attach hydraulic lines to hydraulic pump,

accumulator and pressure control valve.
Connect all electrical connections.
Connect battery ground straps.

F ig . 8 —Removing T ra n sfe r D rive
REM OVING TRANSFER DRIVE
Attach hoist to eyebolt, remove the attaching
To remove the transfer drive from the power cap screws, and guide the transfer drive housing
unit, proceed as follows: back off the dowel pins.
N O T E : I f w o r k i s to b e d o n e on th e t r a n s f e r INSTALLING TRANSFER DRIVE

d r i v e a s s e m b l y , d r a in i t b e f o r e r e m o v a l.
N O T E : I f e n g in e h a s b e e n r e m o v e d , in s t a l l
Disconnect battery ground straps. e n g in e f i r s t .
Remove muffler, pre-cleaner, hood and fuel With hoist attached to eyebolt in top of transfer
tank. drive housing (Fig. 8), slide housing onto dowel pins.
Apply John Deere Never-Seez or an equivalent
Disconnect clutch disconnect cable from sparingly on splines of transmission drive shaft. Use
lever. care in aligning splines on transmission drive shaft
and transfer drive output gear.
Attach support bar to tandem steps. See Fig.
4. Tighten transfer drive-to-engine cap screws
to 35 ft-lbs and transfer drive-to-transmission
Remove rear bumper and rear frame. Tag to 300 ft-lbs.
light wire harness connections.
Connect pressure and return lines to transfer
If engine is not to be removed, use engine drive and transmission.
support brackets Fig. 8 to secure rear of engine
to engine frame. See "Making Special Tools," Install rear frame and bumper.
(Group 30 of this section) for construction de
tails. The use of these brackets will also aid in Remove support brackets from engine and
aligning shafts when installing the transfer drive. support bar from tandem steps.
Remove pressure and return tubes from Connect clutch disconnect cable to lever.
transfer drive and transmission.
Install fuel tank, hood, pre-cleaner and muf
Screw eyebolt into the top of the transfer fler.
drive housing as shown in Fig. 8. See "Making
Special Tools," (Group 30 of this section) for Connect battery ground straps.
construction details of eyebolt.
L itho in U .S.A .
10 G en era l Grader, Motor - JD 570
SEPARATING C LU TC H HOUSING FROM Disconnect transmission control valve inlet

TRANSMISSION CASE line (4) and transmission oil pump intake line (3).
To separate the clutch housing from the trans Disconnect speed and direction cables (1)
mission case when servicing the planetary pack, from shift bracket (2) and transmission control
reduction gear train, or differential, proceed as valve.
follows:
Disconnect 'wiring imrness connections.
Disconnect battery ground straps. all wires.
Drain transmission. Remove battery ground strap from clutch

housing.
Remove bottom guard and block up rear of
transmission. Remove R.H. batterv box.
Remove transfer drive. Remove clutch pack from clutch housing.
Disconnect the main hydraulic pump inlet tube Remove cap screws securing clutch housing
from the right side of the grader. to transmission case and swing away with hoist.
Disconnect clutch push-pull cable from clutch INSTALLING C LUTCH HOUSING

housing on right side.
N O T E : M a k e s u r e th e f i v e O - r i n g s a r e in
p l a c e in t r a n s m i s s i o n c a s e b e f o r e i n s ta llin g
c lu tc h h o u sin g .
Using a hoist, lift clutch housing into place on

transmission case.
Tighten internal cap screws to 170 ft-lbs and

external cap screws to 300 ft-lbs.
Install all other parts removed in reverse

procedure of removal.
2 - S h ift B racke t 5 - E ngine O il Drain Hose

3 — Transm issio n O il Pump Clamp
In ta ke L in e
F ig . 9 -T ra n s m is s io n C ontrol V a lve ,
C ables and H y d ra u lic L in e s
L itho in U .S.A .
TM-1001 (Nov-78) S ep aration 2 5 -7
SEPARATING TANDEM AND FIN A L

DRIVE HOUSING FROM POWER UNIT
To remove tandem drive and final drive hous

ings as a unit—for purposes of servicing the
brakes, sun gear, or final drive—proceed as fol
lows:
Drain transmission and differential case.
Separate power unit from engine frame.
N O T E : F ig . TO s h o w s e n g in e a n d t r a n s f e r
d r i v e r e m o v e d . I t i s n o t n e c e s s a r y to r e m o v e
th e m .
Before removing the tandem and final drive

housings from the transmission, attach support
V SJ26
stands (see "Special Tools," Group 30 of this
section) to each side of the clutch housing at the F ig . 10—Rem oving Tandems from P ow er U n it
rear of the power unit and to the transmission
case at the front.
ASSEMBLING TANDEM AND FIN A L DRIVE
NOTE: The su p p o rt b a r m u st be re m o v e d be HOUSING TO POWER UNIT
f o r e th e r e a r s ta n d s ca n b e m o u n te d . U s e a j a c k
to s u p p o r t th e r e a r o f th e p o w e r u n it. Hoist tandem and final drive into position
against transmission case (Fig. 10). Insert cap
Raise each end of the tandem separately and screws and tighten to 170 ft-lbs.
remove wheels from hubs.
Install wheels on hubs and tighten nuts to 300
Attach chain to tandems as shown in Fig. 10, ft-lbs.
and remove cap screws securing final drive
housing to transmission case. Support the rear of the power unit and remove
rear stands. Install support bar to tandem steps.
Swing tandem away from power unit.
Remove transmission case support stands and
lower unit onto wheels.
Assemble power unit to frame and fill trans

mission and differential case.
L itho in U .S.A .
10 G en eral Grader, Motor - JD 570
SEPARATING TA N DEM FROM TANDEM PIVOT
F ig . 11 —Rem oving Tandem from Tandem P iv o t
To remove the tandem drive for purposes of Swing tandem away from tandem pivot,
servicing the drive axles, sprockets or chain,
proceed as follows: INSTALLING TANDEM ON TANDEM PIVO T
Drain tandem. Hoist tandem into position against tandem

pivot (Fig. 11) and tighten cap screws.
Unhook tandem chain.
Attach tandem chain.
Jack up unit and place blocking under the final
drive housings. Install wheels on hubs, and tighten nuts to
300 ft-lbs.
Remove wheels from hubs.
Jack up unit and remove blocking from under
Attach chain to tandem as shown in Fig. 11, final drive housing and lower unit onto wheels.
and remove cap screws securing tandem to
tandem pivot. Fill tandems with proper amount of oil.
L itho in U .S.A .
TM-1001 (Nov-78) Separation 2 5 -9
REM OVING CAB
Use the following procedure when removing

cab from unit:
Disconnect battery ground straps.
Remove seat assembly from unit.
1 — Wire H arness C onnector
F ig . 13—D riv in g L ig h ts and Turn

S ignal 'Hire Harness C onnector
Disconnect driving lights and turn signal wire

1 - L .H . Steering 2 — R.H. Steering harness at connector (1). Remove harness from
V alve C over V alve Cover clamps under R.H. side of cab and remove wire
F ig . 12—S teering V alve Covers harness from main frame.
Remove R. H. steering valve cover (2, Fig. 12). Remove cab attaching cap screws from plat
form and lift cab off unit.
Loosen L. H. steering valve cover andposition
it so it will not interfere with cab when lifting INSTALLING CAB
cab off unit.
Lift cab up over unit and lower into position.
Fasten cab to platform.
Install driving lights and turn signal wire

harness in main frame and clamps under R.H.
side of cab. Connect wire harness at connector
( 1 ).
Install R.H. and L.H. steering valve covers

(Fig. 12).
Install seat assembly.
L itho in U .S.A .
10 G en era l Grader, Motor - JD570
2 5 -1 0 S ep aration TM-1001 (Nov-78)
L itho in U .S.A .
TM-1001 (Nov-78) S p e cifica tio n s and S p ecia l T o o ls 30-1
Group 3 0
SPECIFICATIONS AND SPECIAL TOOLS
TORQUE VALUES
Item Torque (ft-lb s )
Final drive housing-to-transmission c a s e ....................................... 170

Clutch housing-to-transmission case, external.............................. 300
Clutch housing-to-transmission case, internal.............................. 170
Rim retaining b o lts ................................................................................ 300
Hub retainer cap screw s........................................................................ 170
Transfer drive-to-engine unit, 3 /8 ” cap screw s............................ 35
Transfer drive-to-transmission unit, 3 /4 ” cap s c r e w s .............. 300
alie type© ua u u i l o <xiiu ect-p D u c w o a i c i u c u u -

fied by head markings as follows:
P la in Head: (B-strength) r e g u l a r machine

bolts and cap screws.
3-D ash Head: (D-strength) tempered s t e e l

high-strength bolts and cap screws.
6-D ash Head: (F-strength) tempered s t e e l

extra high-strength bolts and cap screws.
Machine bolts and cap screws 7/8 inch and

larger are sometimes formed hot rather than
cold, which accounts for the lower torque.
The standard torque requirements chart

(Fig. 1) is based on manufacturer's recommen
dations and should be observed in all cases where
specific requirements are not mentioned.
Litho in U .S.A .
10 G en eral Grader, Motor - JD 570
3 0 -2 S p e c ific a tio n s and S p e c ia l T o o ls TM-1001 (Nov-78)
SPECIAL TOOLS
MAKING SPECIAL TOOLS
Five special tools used in separating the E n g in e S u p p o r t B r a c k e t s

grader may be produced locally. Required ma Two engine support brackets are used to sup
terials and construction details are as follows: port the rear of the engine when only the transfer
drive is to be removed. The brackets are not
S u pport B a r required if the engine has been removed prior to
The support bar is used to prevent the trans removing the transfer drive.
mission and engine from oscillating around the
Cut a 4 x 3 x l/4 -in ch angle iron to a length F ig . 3 -C o n s tru c tio n o f E ngine Support B ra cke t
of 62-1/2 inches and drill two 3/16-inch holes
as indicated in Fig. 2.
To make each bracket, bend a 3-1/4 x 16-inch
piece of l/4 -in ch flat steel as shown in Fig. 3.
Add gussets as shown for extra strength.
L itiio in U .S.A .
TM-1001 (Feb-80) Specifications and Special Tools 30-3
SPECIAL TOOLS—Continued
Eyebolt Transmission Case Support Stand
24" x 4" x 1/2
The eyebolt provides an essential attaching point for
a hoist when removing the transfer drive.
T 1S923
Fig. 4-Construction of Eyebolt
To make the eyebolt, weld a 2-1/4 x 1-1/32 x

Fig. 6-Construction of Transmission Case
1/4-inch flat washer (24H1459) to a 1/2-13UNC x Support Stand
2-inch cap screw (19H1831) as shown in Fig. 4.
Use Fig. 6 as a guide to construct a front support
stand for the transmission case. Material required in
cludes two 4 x 1/2-inch pieces of flat steel in 24, 20,
and 16-inch pieces of flat steel in 24, 20, and 16-inch
lengths and a C-channel 33-3/4 x 5 x 1-3/4 inches.
Weld as in illustration.
Support Stands
Use Fig. 5 as a guide to construct the two clutch

housing support stands. Material required for each
stand includes two 6 x 1/2-inch pieces of flat steel in
25-1/2 and 12-inch lengths and one piece 22 x 4 x
1/2-inch. be careful. . . . .
'- avoid accidents
Litho in U.S.A.
30-4 Specifications and Special Tools TM-1001 (Feb-80)
^ ll U /\i • Ta m AAitiAf u n i t m U n n t n n /i A m n o a>n

w iu iv ii i fu u o in y wicai iu i \j o u y p v n fj v T v o t unit m i e n ic m u ^ m o cu c i c m u v c v i
JDG-1 or Engine Lifting Sling To lift engine from transmission
JDG-23
JD244 Lifting Eyes To lift engine from transmission
JDG-19 Lifting Bracket To lift engine from transmission
DO1043AA Load Positioning Sling To lift engine from transmission
Engine Support Brackets To support rear of engine when only the transfer drive is
removed
Eye Bolt To lift transfer drive housing from power unit
Support Bar To keep engine and transmission from oscillating around
final drive
Transmission Case Stand To support power unit when tandems are removed.
Litho in U.S.A.
Grader, Motor - JD570 Engine 20
TM-1001 (Feb-80) Diagnosing Engine Malfunctions 5-1
Section 20
ENGINE
Page
GROUP 5 - DIAGNOSING ENGINE GROUP 15 - ENGINE LUBRICATION—

M A L F U N C T IO N S ..................................5-2 Continued
Repair, Pump G e a rs ................................... 15-3
GROUP 10 - BASIC ENGINE Repair, Oil Pressure Regulating
Diagnosing Basic Engine M alfunctions............. 10-1 V a lv e ........................................................... 15-3
Cylinder Head, Valves, and Rocker Repair, Oil Filter .......................................... 15-3
Arms ....................................................................... 10-1 S pe cifica tio n s................................................ 15-4
Adjusting Valve Tappet Clearance .................. 10-3 Torque V a lu e s .............................................. 15-4
Cylinder Block, Liners, Pistons and Tune-up D a ta ................................................ 15-4
Rods ....................................................................... 10-4 Special T o o ls ................................................ 15-4
Crankshaft, Main Bearings and Fly-
| w h e e l....................................................................... 10-9 GROUP 20 - SPEED CONTROL
Tim ing Gear T ra in ................................................. 10-11 LINKAGE
C a m sh aft.................................................................. 10-13 Repair and A djustm ent............................... 20-1
S pecifications.......................................................... 10-15 Adjusting Fast Idle ..................................... 20-1
Torque V a lu e s ....................................................... 10-17 Adjusting Slow Id le ..................................... 20-2
Engine B re a k-in ..................................................... 10-17 Adjusting L in k a g e ........................................ 20-3
Tune-up D a ta ......................................................... 10-18 S pe cification s................................................. 20-4
Special T o o ls ......................................................... 10-18 Torques for Hardware ............................... 20-4
GROUP 15 - ENGINE LUBRICATION GROUP 25 - ENGINE COOLING

Oil P u m p ..................................................... 15-1 SYSTEM
Oil F ilte r....................................................... 15-1 R a d ia tor............................................... 25-1
Checking Engine Oil P re s s u re ........... 15-1 Crankcase Oil C o o le r.................... 25-1
Diagnosing Lubrication System W ater P u m p ..................................... 25-1
M alfunctions.......................................... 15-2 Diagnosing Cooling System
Repair, Pump Housing and C o v e r... 15-2 M a lfu nctio ns................................. 25-1
Repair, Pump Drive S h a ft.................... 15-2 Repair .................................................. 25-2
S pe cification s.................................. 25-5
Torque V a lu e s ................................. 25-5
Special T o o ls ................................. 25-5
Litho in U.S.A.
20 Engine Grader, Motor - JD570
n /o n n n p i’n n U
UIHÎ
Cn/iinzs
.l^fMC' IVIUMUI l^tlUf IO
Group 5
DIAGNOSING ENGINE MALFUNCTIONS
The following is a quick guide for diagnosing engine malfunctions. Diagnosis of each malfunction is elaborated
further in the section or group in this manual pertaining specifically to the com ponent or system.
Engine Starts Hard, Will Not Start Engine Speed is Erratic
Check fuel system (Section 30). Check fuel injection pump (Section 30).
Check electrical system (Section 40). Check speed control linkage (Group 20).
Check air intake system (Section 30).
Low com pression (Group 10). Engine Makes Abnormal Noise
Check fuel injection pump tim ing (Section 30).
Engine Starts, Won’t Continue To Run Improper fuel.
Check fuel system (Section 30). W orn or im p ro p e rly a d ju ste d e n gin e p a rts
Check electrical system (Section 40). (Group 10).
Check air intake system (Section 30). Plugged injection nozzles (Section 30).
Engine Lacks Power Engine Operating Temperature is
Too high viscosity oil in crankcase. Abnormal
Check fuel system (Section 30). Check cooling system (Group 25).
Check electrical system (Section 40). Check fuel injection timing (Section 30).
Low com pression (Group 10). Fuel Consumption is High
Engine Emits Black or Gray Exhaust

Check fuel system (Section 30).
Check air intake (Section 30).
Smoke Low compression (Group 10).
Check fuel system (Section 30). Engine Misses
Low com pression (Group 10). Low compression (Group 10).
Engine Gii Pressure is Low
Check fuel system (Section 30).
Check lubrication system (Group 15).
Litho in U.S.A.
Grader, Motor - JD570 E ngin e 20
TM-1001 (Nov-79) B a s ic E ngine 10-1
Group 10
BASIC ENGINE
DIAGNOSING BASIC ENGINE MALFUNCTIONS
ENGINE MAKES NOISE (VALVE TRAIN) LOW COMPRESSION

Improperly adjusted valve clearance.
Valve rotators not working. Worn rings.
Worn shaft or rocker arm bore. Burned valves.
Bent push rods. Damaged pistons.
Failed head gasket.
Worn camshaft or cam followers.
ENGINE MISSES
ENGINE MAKES NOISE (PISTON AND PINS)
Worn piston. Improperly adjusted valves.
Worn piston pin or bushings. Burned valves.
Broken piston. Weak valve springs.
Low compression on one or more cylinders.
ENGINE MAKES NOISE (BEARINGS) (Also see Fuel System, Section 30.)
Worn connecting rod bearings.
Excessive crankshaft end play. ENGINE LACKS POWER
Excessive main bearing clearance.
Low compression on some or all cylinders.
ENGINE MAKES NOISE (TIMING GEAR TRAIN) Improperly adjusted valves.
Burned valves (check compression).
Worn gears. Valves sticking.
ENGINE USES EXCESSIVE AMOUNT OF OIL (Also see Fuel System, Section 30.)
Worn valve guides. COOLANT GETS INTO CRANKCASE

Stuck piston rings or worn rings.
Excessive connecting rod bearing clearance T T o iln v * V
A o Vi.
rv f iiV
h n oUH
.Vi rr o o tr o f
Excessive oil pressure. Cracked head or block.

Crankcase oil dilutsd with fuol. a t P v* lin r lp r lin
***V » V < i.
p - r Wc pW Ma> *l '
O A M V *
Engine overloaded. Leaking crankcase oil cooler (early engines).
CYLINDER HEAD, VALVES, AND ROCKER ARMS

R EM O VAL INSPECTING CYLINDER HEAD
The engine need not be removed from grader Check to determine if cylinder head is flat and
to service cylinder head, valves, and related smooth. If it is necessary to resurface the bottom
parts. deck of the head, remove no more material than
absolutely necessary (not to exceed 0.030 inch).
Plug all open injection lines. Remove injec
tion nozzles from head. (Nozzle tips extend be Check distance from the bottom deck of the cyl
low face of cylinder head and may be accidental inder head to the valves when seated. The distance
ly damaged.) for intake valves must be 0.037±0.007 inch, the
distance for exhaust valves must be 0.057± 0.007
REPAIR inch.
Do not rotate crankshaft with cylinder head Measure inside diameter of valve guides.
removed unless all cylinder liners are bolted Valves are available with standard size or over
down. size stems.
L itho in U .s.A .
20 E ngine Grader, Motor - JD570
10-2 B a s ic E ngine TM-1001 (Nov-79)
&
1 9
I
3
T101SSK
1 — P lug (2 used) 7 — Washer (6 used) 13 — Push Rod (12 used)
2 - Rocker Arm Shaft 8 — V a lve Stem C over (12 used) 14 — Tappet (12 used)
3 — Washer (2 used) 9 — R etainer Lo ck (24 used) 15 — A d ju s tin g Screw (12 used)
4 - Spring (5 used) 10 — E xhaust V a lve Cap 16 — Support (6 used)
5 - Rocker Arm (12 used) 11 — V alve Spring (12 used) 17 — Intake V alve Cap (6 used)
6 — Cap Screw (6 used) 12 — Exhaust V a lve (6 used) 18 — Intake V a lv e '(6 used)
F ig . 1—E xploded V/ew o f R ocker Arm A ssem bly
Valve guides must be precision reamed to Clean holes in rocker arm mounting brackets.
matched oversized valves. Make sure valves fit This is especially important for the rear bracket,
freely in guides. because it is through this hole that oil is fed to
the rocker arm shaft.
Worn valve guides must be sized by knurling.
Use knurling tool exactly as recommended by If a valve has been replaced, the rocker arm
the manufacturer. arid push rod for that valve may also have to be
replaced.
REFACING VALVES
ASSEMBLY
Replace valve stem caps if worn or damaged.
ROCKER ARM ASSEMBLY
INSPECTING VALVE SPRINGS
Assemble parts to rocker arm shaft in se
Check compression strength of springs. quence that they were removed (Fig. 1).
INSPECTING ROCKER ARM ASSEMBLY Oil hole in rocker arm shaft to shaft support
must face downward when assembly is installed
Make sure that rocker arm oil holes are not on cylinder.
plugged.
Apply John Deere Valve Stem Lubricant
If ends of arms are worn, resurface them. (AR44402) or an equivalent to valve stems and
install valves in valve guides, working them back
and forth to make sure they slip through the ports
easily and seat properly. Be sure to use new valve
retainer locks (9, Fig. 1).
After assembly, "pop” each spring and valve as

sembly three or four times by tapping the end of
each valve stem with a soft mallet.
Litho in U .S.A .
Grader, M o to r - JD570 Engine 20
TM-1001 (Dec-87) Basic Engine 10-3
INSTALLATION Install rocker arm and shaft assem bly on cylinder

Install head gasket dry. head. Tighten cap screws to 35 Ib-ft torque.
ADJUSTING VALVE TAPPET CLEARANCE
The engine may be either hot or cold during valve
adjustment. Adjust as follows: Set No. 1 piston at
“TDC” of the compression stroke by turning
engine. Use JDE-81-1 Flywheel Rotation Tool on
later units. Remove the timing cover (early units)
and special screw from the flywheel housing, and
reversing the special screw, insert it into the
flywheel housing hole. Rock the flywheel until
special screw slides into hole in the flywheel rim.
Adjust valve clearance on No. 1, 3 and 5 exhaust
valves to 0.018-inch and No. 1 ,2 and 4 intake valves to
clearance of 0.014-inch. Using a feeler gauge to m ea
sure clearance, turn valve adjusting nut up or down
1— Cylinder Head Gasket 3— Equal Distance until clearance is corrected.
2— Cylinder Liner Within 0.040 In. (1.02 mm)
Remove special screw from flywheel. Rotate engine
Fig. 2-Cylinder Head Gasket flywheel 360 degrees and reinsert special screw into
hole on flywheel rim.
Position cylinder head gasket (1, Fig. 2) over dowels
on cylinder block. Check distance between cylinder
head gasket (1) and cylinder liner (2). Distance should
be equal within 0.040 in. (1.02 mm) around each
cylinder liner. If distance is not equal, make dowel
holes in cylinder head gasket larger.
Fig. 4-Adjusting Valve Tappet Clearance
Adjust valve clearance on No. 2, 4, and 6 exhaust

Fig. 3-Proper Sequence for Tightening and No. 3, 5, and 6 intake valves to clearances speci
Cylinder Head Cap Screws fied.
Use specified flat washers under all cap screws. Dip Remove special screw from flywheel. On early units
cap screws in oil prior to installation. Start cylinder reinstall timing cover.
head to cylinder block cap screws by hand and tighten
NOTE: If new piston rings have been installed, fol
evenly to 95 Ib-ft torque, following sequence in Fig. 3.
low instructions under “ Engine Break-In” (page 20-
Install push rods in same location as they were 10-19) for retorque of cylinder head cap screws. Oth
removed. erwise, run engine for 30 minutes, after warmup, at
one-half to full load. Then retorque cylinder head cap
Position valve stem caps over ends of valve stems.
Make certain the caps rotate freely on the stems. screws to 95 Ib-ft, and check and reset valve clear
ance.
Litho in U.S.A.
10-4 Basic Engine TM-1001 (Feb-80)
CYLINDER BLOCK, LINERS, PISTONS, AND RODS

GENERAL INFORMATION REPAIR
Cylinder block and crankcase are cast in one piece. Inspect all parts and compare with “ Specifications.”
Cylinder liners are of the replaceable wet-sleeve Note especially the following:
type, made of hardened alloy cast iron and are a slip fit Check ring grooves for excessive wear. Check key
in the cylinder block. The flange of each liner rests on a stone ring groove by inserting a JD E-62 Ring Groove
shoulder within the block and is sealed by a square W ear Gauge in keystone groove. If wear gauge
rubber packing on early models. Later m odels have shoulders contact the ring land the groove is exces
two additional packings in the engine block to seal the sively worn. Check other ring grooves by inserting a
lining. new ring in the proper groove at several points around
The top edge of the liner is sealed flush with the the piston. Measure clearance between ring and
cylinder block by the com pression of the cylinder head groove with a feeler gauge.
and gasket. Replace piston rings whenever they are removed
Pistons are alum inum -alloy, cam ground and weight from a piston.
controlled, with two com pression rings and one oil Check clearance between piston and cylinder liner
control ring. bore to determine if replacem ent is necessary. Mea
Connecting rods have a bronze bushing for the sure clearance with a feeler gauge at the bottom of
piston pin and a replaceable, steel-backed, alum i piston skirt 90° to pin bore. To establish taper and
num-lined bearing insert. out-of-round, check liner 1 inch from bottom and 1 inch
from top, lengthwise and crosswise. W ear limits are as
REMOVAL follows:
Rem ove the pistons and connecting rods noting the S pecificatio ns M easurem ent
following: Liner taper (m axim um ).......................................... 0.002 in.

1. Engine m ust be removed from grader to service Liner out-of-round (m a x im u m )...........................0.002 in.
pistons, connecting rods, and cylinder liners. See Maximum piston to liner clearance
a i uuuuni ui skiu (o.oo in. o o r e ) ........u.uuo in.
Section 10, Group 25 for engine removal.
(4.02 in. b o re )........0.008 in.
2. Do not rotate crankshaft with cylinder head re
moved unless all cylinder liners are bolted down. Bolt Piston pins must fit piston pin bore with a thumb
down cylinder liners before removing pistons. press fit.
3. Keep rod bearing inserts with their respective Replace piston if piston pin bore is worn.
rods and caps to assure correct reassembly. Measure piston pin outside diam eter at six places;
4. Each connecting rod and piston must be rein two m easurements 90° apart at each end, and two
stalled in the cylinder bore from which it was removed. m easurem ents 90° apart at center.
Observe the word “ FRO NT” stamped on the head of New piston pin O.D.
all pistons and in the rib of the connecting rods. These JD570 ( -200850) .. 1.1875 to 1.1879 in.
m ust face toward the front of the engine at the time of JD570 (200851- ) .. 1.3750 ± 0.0002 in.
assembly. J D 5 7 0 -A ................................. 1.3750 ± 0.0002 in.
5. Measure cylinder liners for clearance before re
moval from the cylinder block. See “ Repair” in this If piston pin size is not within specifications, install a
group. new one.
Litho in U.S.A.
TM-1001 (Feb-80) Basic Engine 10-5
Measure piston pin bushing inside diameter with Inspect oil pressure regulating valve bushing in front
bushing in connecting rod. end of cylinder block. If valve seating area is worn or
Piston pin bushing I.D.: damaged, remove bushing from block and install a new
h u s h in n nsinn . in94fi-A Hrivpr rFin 51
....................-------------V "C7•
P re s s— —
hu s h in n
JD570 ( -200850) .. 1.1886 to 1.1896 in. —/• • •
in until outer edge is flush with face of counterbore in
— — .........cr
JD570 (200851- ) . . . 1.376 to 1.377 inch block. Do not press on raised inner rim of bushing. This
J D 5 7 0 -A ................................... 1.376 to 1.377 inch is the seat for the oil pressure regulating valve.
Check piston pin size (above).
Find the difference, piston pin/bushing clearance,
between the piston pin size and the bushing size. The
clearance m ust be 0.0008 to 0.0022 in.
If bushing size is not within specifications, install a
new one.
Using JDE-88 Bushing Remover and Installer (for
6-329D engine), push bushing out of connecting rod.
IMPORTANT: Be sure oil hole in connecting rod
and oil hole in bushing are aligned.
Using JDE-88 Bushing Remover and Installer (for
6-329D engine), push bushing into connecting rod until
one side is flush with connecting rod.
Hone bushing to size shown above.
Replace connecting rod bearing inserts at every
major overhaul. Inserts are available in standard size
or undersizes of 0.002 in., 0.010 in., 0.020 in., and Fig. 5-Pressing in Oil Pressure Regulating Valve Bushing
0.030 in.
Clean block thoroughly with cleaning solvent or by If dipstick nipple has been removed, coat threads of
pressure steam cleaning. Make sure all passages and nipple with joint sealing compound and install in cylin
crevices are cleaned of sludge, rust, and grease. Be der block.
sure all coolant passages are cleaned of lime deposit
and scale. NOTE: If dipstick nipple has integral O-ring, be sure
O-ring is in good condition and does not shear or twist
NOTE: Diesel service blocks are furnished with when installing nipple.
both piston cooling orifices and plugs to be installed in
the tapped holes in the main bearing webs. If service If filter base nipple is damaged, remove it and press
block is being installed in engine with serial number up in a new nipple flush with face of bore in block. Position
to and including 248000, install plugs. Starting with nipple so that threaded boss is away from side of block
serial number 248001, install orifices. Tighten plugs or as far as possible.
orifices to 85 to 110 lb-in.
Inspect the oil sleeve in the lower right front bore of
cylinder block for damage or signs of oil leakage. This
sleeve plugs the drilled oil passage to the main oil
gallery and helps maintain engine oil pressure. The
sleeve can be replaced using JD249 tool without re
moving the engine from the grader. Press sleeve in
from the front of the engine until flush with cham fer on
rim of bore. Later units have a steel ball in oil passage.
If ball leaks, tap hole and plug.
Litho in U.S.A.
10-6 Basic Engine TM-1001 (Feb-80)
MEASURE T H I S HEIGH T
( C H E C K WI TH P A C K I N G Use a 180-grit honing stone with light pressure to
R E M O V E D FR OM L I N E R ) produce the desired 15 to 35 m icro-inch (r.m.s.) cylin
der wall finish.
Imm ediately after deglazing, clean liner bores with
hot water, soap and scrub brush. Rinse cylinder liner
bores with clean w ater until rinse w ater is clear. Wipe
liners dry with clean towels. Wipe bores with clean
engine oil.
IMPORTANT: Solvents will not remove honing
residue.
Fig. 6-Location of Liner in Cylinder Block ASSEMBLY
W hen installing new cylinder liners in block, use a Assembling Connecting Rod and Piston
depth gauge to m easure the height of the liner flange IMPORTANT: When installing new pistons be
above the block (Fig. 6). W ith packing removed from sure they are all of the same manufacture due to
the bottom of the liner, the top of the flange should be weight differences.
above the cylinder block 0.001 to 0.004 inch. On later
models, also rem ove two packings from grooves in Assem ble pistons and connecting rods. Be sure
cylinder bore. Check height at several places around identification marks on pistons and rods are in same
the liner to assure liner is squarely seated. relative position as they were at tim e of disassembly.
Be sure to pull cylinder liner and reinstall packings NOTE: On later units (002467- ) the piston
before final assem bly. pin diameter has been increased. The new pin also
requires the use of a new connecting rod, new piston,
Deglazing Cylinder Liners and new piston pin snap rings.
On units prior to the above serial number, the new

parts can be used; however, replacement must be
made for all engine cylinders. New parts cannot be
used along with old parts.
Install each connecting rod and piston in the cylinder

bore from which it was removed. Observe the word
“ FRO NT” on all piston heads and in ribs of connecting
rods. These m ust face toward the front of the engine.
Coat piston pins with a light film of oil. Insert them
into piston bores, through connecting rod bushings,
and on into opposite pin bores. Properly fitted piston
pins can be pressed into position with the thumb.
Installing Piston Rings On Piston
Coat the outside of the pistons and rings with a light
Fig. 7-Deglazing Cylinder Liner film of oil. Install rings in their respective grooves using
a JD E -45 Ring Expander on 4.02" bore engines, a
Cylinder liners m ay be deglazed (Fig. 7) with a JD -237 Ring Expander on 3.86" bore engines, or a
deglazing tool or honing stone, but do not rebore. JDE135 Universal Piston Ring Expander on both en
W hen the liner exceeds a 0.002 inch maximum taper or gines.
exceeds 0.002 inch out-of-roundness, the liner must
be replaced.
Litho in U.S.A.
TM-1001 (Nov-79) Basic Engine 10-7
1. Install the expander in the oil ring groove. Install Carefully install a new, dry black rectangular packing
the oil ring with “ TO P ” facing up towards the top of the over the bottom end of the cylinder liner. Slide packing
piston and position oil ring gap opposite expander gap firmly against the shoulder of the liner, making sure
(Fig. 8). that the packing is not twisted or crimped.
Later m odels have two additional O-rings in the

block. Dip these O -rings in AR54749 Soap Lubricant
and install into the grooves in the cylinder block. Check
that the O -rings are correctly retained in the grooves
and are not twisted.
NOTE: Install red O-ring in upper cylinder block
O-ring groove and black O-ring in lower cylinder block
O-ring groove.
Coat the liner packing, seating area of the liner, and

cylinder bore O-rings with AR54749 Soap Lubricant.
IMPORTANT: Do not soak the packing or O-
rings in oil prior to assembly. Soaking will cause
the packings to swell.
NOTE: If you suspect that a packing may have

sheared or displaced while lowering liner into position,
the liner and packing assembly should be removed and
examined.
Fig. 8-Ring Installation
W ork liners gently in place as far as possible by
2. Install the com pression rings in their respective hand. Finish seating liners by placing a wood block
grooves according to the num ber of pip marks on each over upper end and tapping block lightly with hammer.
with “ Top” toward the top of piston. If rings are not
marked install with either side up. Cylinder liners will protrude over the top of the
cylinder block more than normal due to the uncom
3. Be sure rings move freely in their grooves. pressed packing.
INSTALLATION Clean cylinder liner bores with waterless hand

cleaner after installation in block. W ipe dry with clean
Installing Cylinder Liners towels. Coat cylinder liner bores with engine oil just
before installing pistons.
New or deglazed cylinder liners should have bores
thoroughly cleaned. Scrub with a bristle brush, hot
water and soap before installation.
Before installing liners it is important to make sure
the counterbore, under the liner flange at top, is com
pletely free from dirt or nicks.
Litho in U.S.A.
10-8 Basic Engine TM-1001 (Nov-79)
Installing Pistons The tangs for locating the bearing inserts are on the
lower side of the connecting rod and cap. The cylinder
location number is also located on the lower side. The
lower side is installed toward the cam shaft side of the
engine.
Use new connecting rod cap screws. DO NOT reuse
cap screws.
NOTE: Dip connecting rod cap screws in oil before
installing.
IMPORTANT: Using pneumatic wrenches to in
stall cap screws may damage the threads.
Tighten each connecting rod cap screw to 150 lb-in.
IMPORTANT: Scribe two marks (1, Fig. 11) 60°
apart on the socket and one mark (2) on the con
necting rod cap to use as an indicator.
Fig. 9-lrtstalling Bearing Caps
Use short cap screws and large flat washers to

retain liners in position while pistons are installed.
Stagger ring gaps in pistons before installing them in
cylinder liners.
Be sure the word “ FRO NT” stam ped on the head of
the pistons faces toward the front of the engine before
installing them in liners. Be sure the word “ FRO NT” on
connecting rods (Fig. 9) also faces toward the front.
1—Two Marks 2—One Mark
Fig. 11-Rotation Indicator Marks
Tighten each cap screw an additional 60 degrees.

Installing Oil Pan
Apply Perm atex No. 3 to oil pan gasket and cylinder
block pan surface. Tighten oil pan-to-cylinder block
and tim ing gear cover cap screws to 35 Ib-ft torque.
Engine Break-In
Refer to specifications and perform the break-in
steps to assure proper run-in of new parts during the
Use com pressor tool JD239 (3.86 in. bore) or JD271 first hours of a rebuilt engine.
(4.02 in. bore) to install pistons (Fig. 10).
Apply light-weight oil to the bearing inserts and
crankshaft rod journals.
Litho in U.S.A.
TM-1001 (Feb-80) Basic Engine 10-9
CRANKSHAFT, MAIN BEARING, AND FLYWHEEL

GENERAL INFORMATION Check main bearing caps for identifying numbers. If
i ne cranKsnari is a one-piece steei rorging, sup in oneare
there no numbers, stam p corresponding numbers
oil pan rail and in main bearing cap. Stamp the
ported on seven main bearings. The bearings are number in each main bearing cap off center to the
replaceable, steel-backed, tin-plated, alum inum -lined same side as the number in the oil pan rail. This will
inserts. The rear main bearing has a thrust surface. assure correct indexing of main bearing caps during
The crankshaft is drilled for pressure lubrication from installation.
the main bearings to the connecting rod bearings.
" 'w""8
T h e r in n »
n VMI 1
e a r f' n r t*■h#w #53
o c t a r t i n n m n t n r #w
ic c h ..r i#-■
i n..X
k .#
in. n l a r e *
on the front outer rim of the flywheel. A “TDC bore” on

the front outer rim of the flywheel is used when tim ing
injection pump and valve tappets.
REMOVAL
Remove engine from grader to service crankshaft,
main bearings, and flywheel. See Group 25 of Section
10.
REPAIR
Examine all parts and repair or replace as neces
sary. Note the following:
To install new ring gear, heat gear evenly all the way
around and, while ring is hot, slip it onto flywheeL.
Install with chamfered edge of teeth toward front of
flywheel.
Use a knife-edge gear puller to pull crankshaft gear.
To install a new crankshaft gear, support crankshaft Determine crankshaft end play (Fig. 12). End play
under its first throw while pressing on gear. The gear should be no more than 0.0080 inch or less than
m ay be heated in hot oil to 300 degrees Fahrenheit, to 0.0020 inch.
aid in assembly.
CAUTION: Oil fumes or oil can ignite
A above 380°F. Use a thermometer and do not
exceed 360°F. Do not allow a flame or heating
element to be in direct contact with the oil. Heat the
oil in a well-ventilated area. Plan a safe handling
procedure to avoid burns.
Check the thrust surfaces on both sides of the
crankshaft rear main bearing.
If the crankshaft-journals are out-of-round or are
tapered, either grind crankshaft and install undersize
bearings or replace crankshaft. '
If any one main bearing insert needs replacing,
always replace both halves. Check clearance (0.0016
to 0.0060 inch) and condition of all main bearing inserts
at this time. W ear on the damaged insert may have
uGGn caused by another being out of specifications. If Fig. 13-Score Wear Ring
other inserts are within specifications, but show ex
cessive wear, replace them . New main bearing inserts Using a dull chisel, score the wear ring in several
should be installed at every major overhaul. places (Fig. 13).
Litho in U.S.A.
20 Engine Grader, M o to r - JD570
10-10 B asic Engine TM-1001 (Dec-87)
IMPORTANT: Do not score wear ring too deeply INSTALLATION

as it may damage the crankshaft surface.
1. Install inserts with thrust faces in rear main
W hen wear ring is loosened remove it from crank bearing bore. Install plain inserts in other main bearing
shaft. bores. Make sure that tangs on all inserts fit the locking
grooves in the bores and that the oil holes in inserts
Inspect crankshaft flange for nicks or burrs. If nec line up with oil passages in the block.
essary clean flange area with a fine cut file and fine
em ery cloth.
If abrasive was used to clean up crankshaft flange,
apply a thin coat of non-hardening gasket sealer to
crankshaft flange.
Crankshaft Damper
Service life of the crankshaft damper, located at the
front of the crankshaft, is affected by engine speed and
load variations as well as extreme heat or cold.
Replace the dam per at 4500 or more hours or every
five years, whichever occurs first.
A dam per is considered/failed when either run-out or
wobble of the outer ring exceeds 0.040 inch (1.02 mm)
total indicated run-out. Replace also if there are visible
signs that the outer ring has slipped relative to the
rubber m ember or drive hub.
Handle dam pers with care. They are sensitive to Fig. 14-Installing Main Bearing Caps
im pacts such as being dropped or hamm ered on. 2. If engine is equipped with piston cooling orifices,
Im pact dam age can im pair the “tuning effect” of the remove orifices from the top of the m ain bearing webs
dam per, which prevents torsional dam age to the en in the cylinder block. Inspect orifices for any evidence
gine. of blockage j>r dam age. Clean or replace as neces
Proper function of this damper is of major im por sary. Install orifices in cylinder block and tighten with
tance to crankshaft and tim jng gear life, but is often 85 to 110 lb-in/
ignored during engjna-setvicing. NOTE: Dip cap screws in engine oil before install
ing.
Litho in U.S.A.
TM-1001 (Dec-87) B asic Engine 10-11
4. Align upper and lower thrust flanges on rear main

bearing as follows: Tap the crankshaft to the rear to
line up the front flanges. Then tap the crankshaft to the
front to line up the rear flanges. Tighten main bearing
cap screws to 85 Ib-ft.
5. If c ra n k s h a ft end p la y has n o t been ch e cke d

w ith a ll re p a ir p a rts in s ta lle d , re fe r to F ig ure 10 o f
th is group. End play sh o u ld be 0.0020 to 0.0080 inch
w ith a m a xim um end p lay o f 0.0150 inch a llo w a b le .
6. Use th e fo llo w in g p re c a u tio n s fo r h a n d lin g
seal and w e a r sleeve:
— Seal and w e a r sleeve are a sse m b le d . DO NOT
SEPARATE. If p a rts be com e se p ara te d , d is c a rd
and replace w ith a new a sse m b ly. A tte m p ts to
re assem b le w ill ca u se th e w e a r sleeve to d a m
1— Number in Main Bearing Cap 3—Arrow
age th e seal a llo w in g engin e o il to leak p a st seal.
2— Number in Oil Pan Rail
— A lw ays in sta ll seal and w ear sleeve asse m b ly im
Fig. 15-Main Bearing Cap Positions m e dia te ly a fte r rem oval from p la s tic bag to avoid
p o s s ib le d irt c o n ta m in a tio n .
3. Install main bearing caps with numbers (1, Fig.
19) corresponding to numbers in oil pan rail (2). If there
is no arrow (3) machined on main bearing cap, install
— No lu b rica tio n o f any kind is to co n ta c t seal w hen
cap with number to same side as numbers in oil pan
in s ta llin g . Use o f a lu b ric a n t m ay re s u lt in pre
rail. If there is an arrow machined on main bearing cap,
m ature seal fa ilu re .
arrow must point toward camshaft side.
— In s ta ll o il se a l/w e a r sleeve a ss e m b ly w ith th e
open sid e o f seal and w e a r sleeve ID c h a m fe r
to w a rd th e en gin e . If seal is reversed, e n g in e o il
w ill be lo s t b e cau se groo ve s in o il seal lip w o u ld
be in c o rre c t w ith re sp e ct to d ire c tio n o f c ra n k
s h a ft ro ta tio n .
— O il seal and w e a r sleeve a s s e m b ly M UST be in
s ta lle d w ith th e JT30040 (fo rm e rly JD251 or
JD297) Seal and W e a r S leeve In s ta lle r Set. T ool
se t c o n s is ts o f a p ilo t and driver.
Litho in U.S.A.
10-12 B asic Engine TM -inni (Dec-87)
NOTE: Make sure that OD o f crankshaft flange

and ID of seal housing are free from nicks or burrs.
A p p ly a lig h t c o a tin g o f P e rm a te x N o. 3, o r
e q u iv a le n t; c o m p le te ly a ro u n d th e le a d in g e dge o f
c ra n k s h a ft fla n g e . W ipe aw a y any s e a la n t th a t m ay
have g o tte n on se a l h o u s in g bore.
In s ta ll p ilo t (A) on end o f c ra n k s h a ft u sin g tw o
hex-head cap scre w s. T ig h te n cap scre w s securely.
IMPORTANT: Handle seal and wear sleeve
assembly carefully. If assembly becomes sepa
rated, discard these parts and install a new
assembly. Chamfer on wear sleeve (A) and open
side of seal (B) must be on the same side.
C a re fu lly s ta rt oil seal/w ear sleeve asse m b ly over

p ilo t and c ra n k s h a ft fla n g e w ith o pen sid e o f seal
to w a rd engine.
L ith o in U.S.A.
A tta c h d riv e r and th ru s t w a sh e r to th e g u id e

p la te w ith ca p scre w . T ig h te n th e ca p sc re w u n til
d riv e r b o tto m s on p ilo t.
R em ove th e ca p scre w th ru s t w asher, driver, tw o
ca p scre w s and th e g u id e plate.
In s ta ll fly w h e e l on c ra n k s h a ft.
CAUTION: Flywheel is heavy. Plan proper
handling procedure to avoid injuries.
In s ta ll tw o g u id e s tu d s in c ra n k s h a ft cap scre w
th re a d e d h o le s. P lace fly w h e e l on s tu d s and s lid e
in to p o s itio n a g a in s t c ra n k s h a ft.
IMPORTANT: Always install new flywheel cap
screws when flywheel has been removed.
It is recom m ended th a t e a rlie r “ D” and “ F” grade

cap scre w s be replaced w ith new fla n ge d head high
s tre n g th cap scre w s w ith h ardened w a sh e rs.
S ta rt cap scre w s in c ra n k s h a ft. Do n ot tig h te n
u n til g u id e s tu d s are rem oved and a ll cap scre w s
sta rte d .
T ig hte n screw s to sp e c ific a tio n s . If high stre n g th
fla n g e d head cap scre w s are used, d ip in S A E 30
o il b e fo re in s ta llin g .
S P E C IF IC A T IO N S
“ D” g ra d e ca p s c re w s ....................................... 85 Ib -ft
“ F” grad e ca p s c re w s ..................................... 120 Ib -ft
F la ng e d head high
s tre n g th cap s c re w s .....................................40 Ib -ft
P lus a d d itio n a l 1/6 tu rn (60°)
L ith o in U.S.A.
10-14 Basic Engine TM-1001 (Dec-87)
7. Place crankshaft oil slinger over front end of

crankshaft with inside diameter of slinger against
front gear on crankshaft.
Install all parts removed.
Install engine in grader engine frame (Group 25
of Section 10).
TIMING GEAR TRAIN
T 14832
1— Inner Thrust Washer 5— Bushing 9— Outer Thrust Washer 13— Idler Gear Shaft
2— Idler Gear Shaft 6— Outer Thrust Washer 10— Bushing 14— Inner Thrust Washer
3— Spring Pin 7— Cap Screw 11— Lower Idler Gear 15— Washer
4— Upper Idler Gear 8— Cap Screw 12— Spring Pin 16— Special Bolt
Fig. 16-Idler G ea rs
Litho in U.S.A.
Grader, Motor ■ JD570 Engine 20
TM-1001 (Dec-87) Basic Engine 10-15
REMOVAL Idler Gears

To service gear train and related parts, with the Dt; su re uicu m e un nuie in m e uppei sn a il ( n y . £u) 15
exception of the crankshaft, engine norm ally need not open. Measure I.D. of bushing (1.7520 inches to
be removed. If removal is necessary, see Section 10, 1.7530 inches) and O.D. of shaft (1.7495 inches to
Group 25, of this manual. 1.7530 inches) to determ ine oil clearance of 0.0015
inch to 0.0035 inch. If bushing replacem ent is required
W henever an engine is being com pletely recondi- press in new bushing flush with either side of gear
t»in1n o r l n r t h n r r a n k c h a f t ic h o in n .^...w.ww,
PV .ww w' HIV VIWI.IWM-H IV
r o m n w o H t hIo o n n in o
W w..g...w using JD252 driver.
front plate with gear assem blies should be removed The upper idler gear is pressure lubricated. If there
from the engine using the following steps: are signs of oil starvation, make certain that the oil
delivery hole in cylinder block is open.
1. Remove tim ing gear cover.
If idler gear shaft replacem ent is necessary, press in
2. Remove hex nuts from the oil pump drive gears new spring pins to 0.200 inch to 0.2800 inch above
and cap screws from upper and lower idler gears. idler shaft.
3. Remove upper and lower idler gears from engine FRONT PLATE AND TIMING GEAR
front plate. Attach a puller to oil pump gear and pull COVER
gear from shaft. NEVER PRY GEAR FROM SHAFT. Never pry or press against tim ing gear cover with
excessive force. The cover is cast alum inum alloy and
4. Remove oil pump (Group 15). m ight be sprung or warped.
5. Remove fuel injection pump and drive gear
(Section 30, Group 20).
6. Remove camshaft.
REPAIR
For gear inspection and repair, refer to the Section
and Group in the m anual which covers the assemblies
which the gears drive. The cam shaft and crankshaft
m ust be removed from the engine to replace their
gears.
Checking Gear Train Backlash
If gear train noise is noted at the tim e of disassem bly
it usually indicates excessive gear lash or damaged
gear teeth.
During assem bly, measure gear train backlash or Fig. 17-lnstalling O il Seal in Timing Gear Cover
damaged gear teeth.
If there is evidence of oil leakage on outside of
tim ing gear cover, replace crankshaft front oil seal.
H
v wn va“t n n t o r we' n
- 1r f,w%ww
flr < a wn ,f WWW.,
Q o a l •»••■■■
ui/ith J iVnHi n.It WWW....
c o a l i n. yn w/?r*m
w . .. -
pound and inner surface with high temperature
grease. Support the oil seal bore area of timing gear
cover. Press in oil seal to bottom of bore with
spring-loaded lip facing inward (Fig. 17). Use a
JD250 Driver.
Litho in U.S.A.
20 Engine Grader, M otor - JD570
INSTALLATION With engine at “TDC,” use tool JD254 to align

the timing mark on the camshaft gear between
Installing and Timing the Gear Train centers of the crankshaft and camshaft (Fig. 18).
The cam shaft gear and injection pump gear m ust be
timed to the crankshaft when they are installed. Install 3. Install fuel injection pump and drive gear (Section
and time gear assem blies using the following steps: 30, Group 15).
1. Turn crankshaft until No. 1 piston is “ TD C ” of its
com pression stroke. Remove timing hole cover and
special screw on flywheel housing. Reversing the
special screw, insert the smooth end into the flywheel
housing bore. Rock the flywheel until the special screw
slides into hole in flywheel.
If engine is stripped, position crankshaft so that No.
1 connecting rod journal is at its highest point toward
the deck of the engine. The keyway in the crankshaft
front gear (not the pulley keyway) should point
straight up toward the top of the engine.
Do not rotate the crankshaft after “ TD C " setting has

been made.
2. Install camshaft.
Fig. 19-Timing the Injection Pump Gear (JD570)
With engine at “TDC,” use tool JD254 to align

the timing mark on the injection pump gear be
tween centers of crankshaft and injection pump
shaft (Fig. 19).
Fig. 18-Timing the Camshaft Gear
Litho in U.S.A.
Use the tim ing mark on the injection pump drive gear CAMSHAFT
which indicates the number of cylinders in the engine.
GENERAL INFORMATION
4. With camshaft and injection pump gears in
The cam shaft is alloy iron with all cams integral. A
stalled and timed, carefully install upper idler gear
lobe actuates the fuel transfer pump.
into position using care not to rotate the timing
gears. Be sure inner thrust washer and idler gear The cam shaft is driven at one-half engine speed by
shaft are in place on rear of idler gear shaft. Over the top idler gear and is supported by four pressure-
front of gear, install outer thrust washer and cap lubricated bores integral with the cylinder block. Cam
screw. Using a screwdriver between gears to pre
shaft thrust is taken by a thrust plate fastened to the
vent rotation, secure upper idler gear to front plate rear of the cylinder block.
and tighten to 65 ft-lbs.
VALVE LIFT CHECK
5. Install oil pump and drive gear (Group 15).
Tighten oil pump gear hex nut to 40 Ib-ft torque after
gears have been timed and lower idler gear installed so
that gears m ay be restrained with a screwdriver. Then
stake threads on shaft.
6. W ith oil pump gear installed, install lower idler
gear into position, using care not to rotate any gears.
Be sure special bolt, washer, inner thrust washer, and
idler gear shaft are in place on rear of idler gear shaft
(Fig. 17). Install outer thrust washer and cap screw
over front of gear. Tighten cap screw to 95 Ib-ft.
After all gears are locked in place, recheck all tim ing
marks with tool JD254. Make sure that marks still align
between the centers of the respective shafts and the
center of the crankshaft with the engine at “TD C .” Fig. 20-Checking Valve L ift
Then remove tim ing screw from flywheel and install
tim ing hole cover. Measuring valve lift can give an indication of wear on
cam lobes, cam followers, and push rods.
Final Installation
Apply a thin coat of high temperature grease to the Set exhaust valve clearance of 0.018 inch and in
inside lips of the front oil seal and install tim ing gear take valve clearance of 0.014 inch.
cover. Be careful not to invert lips of oil seal while Place dial indicator on valve rotator or valve spring
installing cover.
cap. (Be sure that valve is fully closed and the rocker
Before installing gear cover on engine be sure that arm moves freely.) Zero dial indicator.
oil slinger is securely positioned over end of crankshaft M anually turn engine in running direction. When
with inside diam eter in against gear. Also be sure oil rocker arm contacts valve, check indicator travel as the
pressure regulating valve and spring are in place under rocker arm moves valve to full open.
cover.
Exhaust valve lift should be 0.456 inch to 0.482 inch
and intake valve lift should be 0.460 inch to 0.490 inch.
Litho in U.S.A.
REMOVAL INSTALLATION
To service cam shaft and related parts, engine nor 1. C oat entire cam shaft with a light film of oil.
mally need not be removed from unit. If engine has to
be removed, see Section 10, Group 25. 2. W hen installing camshaft, do not perm it cam
lobes to drag on cam shaft bores.
Remove rocker arm and timing gear cover. Remove
rocker arm assem bly and push rods. 3. Turn the cam shaft gear until the cap screws and
locks which secure the thrust plate can be installed and
Remove fuel pump. tightened to 35 Ib-ft torque.
Using a wire with a 90-degree bend on the end, 4. C h e ck c a m sh a ft fo r 0.0025-inch to 0.0085-inch
reach down through top of cylinder head and raise cam end p la y (Fig. 21). (N ew c a m s h a ft and th ru s t p la te
followers off cam shaft lobes. Secure wires so that cam s h o u ld re sto re prop e r end play.)
followers will not drag on cam shaft during removal.
5. Before installing idler gear, set flywheel at “TD C ”
Remove top idler gear from engine front plate. This with No. 1 piston on the compression stroke. Align the
will allow cam shaft to rotate when lining up cam shaft timing mark on the cam shaft drive gear with the center
attaching cap screws. of the crankshaft, using timing tool JD254.
NOTE: If cylinder block is removed from machine 6. W ith timing marks aligned, install top idler gear
and secured on an engine stand upside down, cam and secure to front plate with fiat washers and cap
followers need not be wired up. screw. Tighten cap screw to 65 Ib-ft torque.
Repair
1. D e term ine if c a m s h a ft jo u rn a ls and bores are
w ith in 2.1997 in ch e s to 2.2007 in ch es.
2. M easure each c a m s h a ft lobe a t h ig h e s t p o in t
and a t n a rro w e st p o in t. S u b tra c t n a rro w e st d im e n
sio n fro m h ig h e s t d im e n s io n to fin d c a m s h a ft lobe
h e ig h t.
C a m s h a ft lobe h e ig h t is 0.266 to 0.286 in.
If h e ig h t is n o t c o rre c t on any lo be , in s ta ll a new
c a m s h a ft.
3. T h ru s t p la te m u s t be w ith in 0.1510 in ch to
0.1580 in c h as th e th ru s t p la te th ic k n e s s d e te r
m ine s c a m s h a ft end play.
4. R eplace c a m s h a ft d rive g e ar if n e ce s sa ry by
p re ss in g s h a ft fro m gear. P ress on gear u n til it is
tig h t a g a in s t fla n g e o n c a m s h a ft. T im in g m a rk
m u s t fa c e aw ay fro m c a m s h a ft. S u p p o rt c a m s h a ft
under its firs t b e arin g w h ile p re ss in g on gear. Fig. 21-Checking Camshaft End Play
5. C heck c a m s h a ft fo r 0.0025 in ch to 0.0085 inch

end p la y (new c a m s h a ft and th ru s t p la te s sh o u ld
re sto re th is).
6. If re p la c in g ta c h o m e te r drive, s u p p o rt c a m
s h a ft and press in new d rive w ith s lo t lo c a te d 180°
fro m ke yw a y in o p p o s ite end o f c a m s h a ft.
Litho in U.S.A.
TORQUE VALUES
Item Torque (Ib-ft)
111
orv»
V-/C ioi icii i
DIO +/-i Dln/% / 1
i i ii u o i r fc u ^ - iu ~ L Jtu i* r\............................................................................................................................................................................................
OC
Crankshaft Upper Idler G e a r.................................................................................................................... 65

Crankshaft Lower Idler G e a r.................................................................................................................... 95
Front P la te -to -B lo c k ................ 25
Rocker A rm -to -H e ad ................................................................................................................................... 35
Connecting Rod Cap Screws (dipped in o il) ............................................................... 150 lb-in plus 60°
Main Bearing Cap Screws ........................................................................................................................ 85
F lyw h e el-to -C ran ksha ft (“ D ” G rade Cap S cre w )...................................................................... 85
(“ F ” G rade Cap S cre w )....................................................................... 120
Flanged Head H igh S tre n g th Cap S c re w s ................................40 Ib-ft
P lus a d d itio n a l 1/6 tu rn (60°)
Flywheel Housing Cap Screw 3/8 in.................................................................................................. 35
5/8 in.................................................................................................. 170
H ead-to-B lock................................................................................................................................................ 95 (oiled)
Oil Pump Drive Gear ................................................................................................................................. 40
Oil Pan-to-Block and Timing Gear Cover ....................................................................................... 35
Fan Drive P ulley-to-C rankshaft............................................................................................................... 85
Fan Assem bly-to-Fan H ub........................................................................................................................ 20
Timing Gear C o v e r..................................................................................................................................... 35
Thermostat C o v e r....................................................................................................................................... 20
Injection Pump Drive Gear (middle) (Model C Only) ................................................................. 9
(outside three) (Models C and C B )................................................ 15
(nut) (ModelJ D B )................................................................................ 45
Injection N o zzle -to -H e a d .......................................................................................................................... 16
Injection Line-to-Injection P u m p ............................................................................................................. 35
Rocker Arm Cover Hex. Head Cap Screws (Later M odels)........................................................... 2
Piston Cooling Orifices or Plugs (Later M odels)............................................................. 85 to 110 lb-in
Exhaust Manifold Cap S c re w ............................................................................................................................. 35
ENGINE BREAK-IN
NOTE: Whenever possible, use a dynamometer to provide a more accurate break-in, assuring proper initial seating
of new piston rings.
Time Load* Engine Speed Remarks
5 Minutes No Load 900 rpm (Slow Idle) Check oil

5 Minutes No Load 1500 to 2000 rpm (1/2 Throttle) pressure,
5 Minutes 1/4 Load 1900 to 2200 rpm cooiant
10 Minutes 112 Load (3/4 Throttle) temperature,
10 Minutes 1/2 to 3/4 Load and leakage.
10 Minutes** 3/4 to Full Load
100 Hours+ All Loads Field Only
*Loads can be simulated in the field by controlled machine operation.
* *After this run, loosen cylinder head bolts 45 degrees; then tighten bolts one at a time, in sequence, to 95 Ib-ft. Loosen
rocker arm support cap screws; then tighten to 35 Ib-ft. Check and reset valve clearance. Loosen exhaust manifold
cap screws and nuts; then tighten to 35 Ib-ft.
+ Refer to the operator’s manual for proper operation and service. After break-in, drain crankcase oii, and remove
filter. Install new filter and fill crankcase with oil of proper viscosity and service classification.
Litho in U.S.A.
10-20 Basic Engine TM-1001 (Dec-87)
TUNE-UP DATA
M inim um Compression R ead in g s..........................................................................................................................350 psi

The m ost im portant factor in com pression readings is the difference between cylinders. This difference should bfe
no more than 50 psi.
Vacuum Tests
M in im u m ............................................................................................................................................................................ 8 in. water
M axim um ............................................................................................................................................................................ 25 in. water
Valve Clearance
Exhaust Valves .................................................................................................................................................................... 0.018 in.
Intake V a lv e s ........................................................................................................................................................................ 0.014 in.
A lte rn a to r............................................................................................................................................. 3/4 -in ch flex at 20 Ib-ft force
SPECIAL TOOLS
No. Name Use
Essential Tools
J D E -8 8 .................... PistonPin Bushing T o o l...............To remove and install piston pin bushings
(6-329D engine)
JDE-45..................... Limiting Piston Ring E xpander.. .To install piston rings on 3.86 and 4.02 in. bore
engines
JDE-135................... Universal Piston Ring Expander..To install piston rings
JD 239.....................Piston Ring Compressor...............Sleeve-type compressor for installing pistons
(3.86” bore)
JD 271.....................Piston Ring Compressor...............Sleeve-type compressor for installing pistons
(4.02” bore)
JD 248-A.................Oil Pressure Relief Valve................ To install relief valve bushing in cylinder block
Bushing Driver
D 20002W I............... Knurling T o o l.....................................To knurl engine valve guides
JD 249..................... Oil Sleeve Driver.............................. To install oil sleeve in lower right hand bore of
cylinder block
JD 250..................... Oil Seal Driver.....................................To install crankshaft front oil seal
JT 30040.................Rear Seal and W ear Sleeve............. To install crankshaft rear oil seal wear ring
Installer Set (Replaces JD 251 and JD 297) and to install seal
in flywheel housing
JD 252..................... Driver............................................. .To install idler gear bushings
JD 254..................... Gear Timing T o o l...............................To time engine front gear train
JDE-62......................Keystone Ring G auge...................... To check for wear in ring groove
JDE-81-1................. Flywheel Turning T o o l.....................To turn engine flywheel (laterunits)
Convenience Tool
No. Name Use
D 01062A A ..................C ylinder Liner P u lle r..............................To remove cylinder liners

or
DO1063AA
Litho in U.S.A.
TM-1001 (Dec-87) Engine Lubrication 15-1
GENERAL INFORM ATION Group 15

PRESSURE
ENGINE LUBRICATION
T79473
1—Oil Pump 5—Cooler Bypass Valve

2— Bypass Valve 6—Oil Filter Element
3— Pressure Control Valve 7— Filter Bypass Valve
4— Oil Cooler 8— Gallery
Fig. 2 -0 ilin g System (566498- )
The valve assembly consists of a valve body held

Fig. 1—Engine Lubrication System ( -566497) against a seat by a spring and plug. Pressure may
be adjusted by changing the number of shims
OIL PUMP behind the valve plug. When oil pressure is greater
than the valve setting, oil is bypassed to the
Oil enters the pump (Fig. 1 or 2) from the rear crankcase and desired pressure is maintained.
through the pump intake tube, and is discharged
at the oil outlet hole into an oil tube leading to the OIL FILTER
oil filter and engine oil gallery.
The oil filter (Fig. 1 or 2) is mounted on the right
A pressure regulating valve is located at the rear side of the cylinder block. It is a full-flow type with
of cylinder block in the oil gallery. The valve a spin-on type replaceable element. If the filter
regulates oil before it enters the oil filter and main clogs, a bypass valve in the element opens to keep
tains a constant oil pressure in the engine oil a full flow of oil to vital engine parts.
gallery.
L itho in U .S.A .
15-2 Engine L u b rica tio n TM-1001 (Dec-87)
CHECKING ENGINE O IL PRESSURE DIAGNOSING LUBRICATIO N SYSTEM

M ALFUNCTIO NS
If the oil pressure indicator gauge continues
to show low oil pressure after engine has been ENGINE OIL PRESSURE TOO HIGH
running for 10 seconds, the engine should be stop Pressure regulating valve seat not bottomed
ped and cause of low oil pressure determined. in block
(See below and Group 10 for further lubrication Incorrect oil viscosity
system diagnosis.) If indicator gauge shows low Engine oil pressure adjustment incorrect
oil pressure at any time while engine is being Pressure gauge inaccurate
operated, follow the same procedure immedi
ately. ENGINE OIL PRESSURE TOO LOW
Incorrect oil viscosity
Engine oil pressure adjustment incorrect
Worn parts (connecting rod bearings, main
bearings, camshaft bushings) allowing leak
age of oil
Plugged intake screen
Oil pressure regulating valve damaged or
stuck
Pressure regulating valve spring worn or
damaged
ENGINE CONSUMES EXCESSIVE AMOUNT OF

OIL
See diagnosis information in Group 10, "Basic
Engine''
Fig. 3 —Checking O il Pressure with M aster Gauge
Check oil pressure as follows:
Install master gauge (Fig. 3).
With engine warm and running at fast idle, oil

pressure reading should be 50 ± 15 psi. at 180-220°F.
If pressure is not correct, see “Diagnosing Basic

Lubrication System Malfunctions.”
L ith o in U.S.A.
1 — D rive Gear 8 — C over A ssem bly (early un its) 15 — Pipe P lug (early u n its)
2 — Jam Nut 9 - Groove Pin 16 — C over (la te r un its)
3 — 0 -R in g 10 — Gear 17 - Lo ck Washer (4 used) (la te r u n its)
4 — O utle t Tube 11 - D rive Shaft w ith Gear and Pin 18 — Cap Screw (2 used) (la te r u n its)
5 — Cap Screw (e arly u n its ) 12 - Id le r Shaft 19 — O il Pump Intake (la te r un its)
6 - Cap Screw (3 used) (e arly u n its ) 13 — Bushing (e arly un its) 20 — Cap Screw (2 used) (la te r un its )
7 - Lock Washer (4 used) (e arly units) 14 — Housing 21 - O-Ring (la te r units)
Fig. 4— Oii Pump
REMOVAL
Rem ove e n gin e as in s tru c te d in S ectio n 10,

G roup 25. Rem ove o il pan and o il pu m p assem bly.
R efer to Fig. 4 d uring repair.
REPAIR
1. M easure g e ar to h o u sin g side cle a ra n ce w ith a

fe e le r gauge and co m p a re to fo llo w in g s p e c ifi
ca tio n s :
G ear to h o u sin g sid e cle a ra n ce (1, Fig. 5) is
0.005 in.
M a xim um gear to h o u sin g sid e cle a ra n ce (1) is
0.007 in.
Lith o in U.S.A.
T798Q1 T79803
Fig. 6— Measure Gear End Clearance Fig. 8—Measure Drive Shaft H ousing Inside Diameter
2. Use a d e p th m ic ro m e te r o r s tra ig h t edge bar 5. M e asure d rive s h a ft h o u s in g in s id e d ia m e te r

w ith fe e le r gauge and m easure gear to h o u sin g end and co m p a re to fo llo w in g s p e c ific a tio n s :
cle a ra n ce and co m p are to fo llo w in g s p e c ific a tio n s : D rive s h a ft h o u sin g in s id e d ia m e te r (1, Fig. 8) is
G ear to h o u s in g end cle a ra n c e (1, Fig. 6) is 0.6327 in.
0.0037 in.
M a xim um d rive s h a ft h o u sin g in sid e d ia m e te r (1)
M a xim u m g e a r to h o u s in g end cle a ra n c e (1) is is 0.6332 in.
0.0062 in. 6. If any p a rts do n o t m e asure w ith in s p e c ific a
3. L ift drive g e a r and id le r g e a r o u t o f o il pum p tio n s , (ste p s 3, 4, 6, and 7), in s ta ll new p a rts.
h o u sin g . In sp e ct c o ve r fo r w ear. 7. In s p e c t h o u sin g fo r c ra cks, s c ra tc h e s , and
w ear. R eplace h o u s in g if d a m a g e d.
8. In s p e c t d rive ge ar and id le r gear fo r w ear, p it
tin g , c ra cks, and c h ip s . R eplace g e a r if d a m a g e d .
9. E xam ine screen on pu m p in le t tu b e to be sure
it is cle a n and w ire m esh scre e n is n o t d a m a g e d.
10. In s p e c t pu m p in le t tu b e and o u tle t tu b e fo r
c lo g g in g .
T79S02
Fig. 7—Measure Drive Shaft Outside Diameter
4. M e asure d rive s h a ft o u ts id e d ia m e te r and

c o m p a re to fo llo w in g s p e c ific a tio n s :
D rive s h a ft o u ts id e d ia m e te r (1, Fig. 7) 0.6310 in.
M in im u m d rive s h a ft o u ts id e d ia m e te r (1) is
0.6308 in.
L ith o in U.S.A.
Oil Pressure Regulating Valve Check pressure regulating valve plug threads for
damage.
IMPORTANT: When the latest oil pressure reg
ulating valve is installed, the latest pressure regu Oil Filter
lating spring and relief valve plug also must be
used. Discard filter element. Inspect oil passages at
mounting point on cylinder block for obstructions. If
Remove oil pressure regulating plug, shims, spring, filter base nipple in block is damaged, refer to Section
and valve. Save all shims for correct assembly. 20, Group 10, for replacement details.
Inspect regulating valve seat in front of cylinder
block for damage (especially at raised rim of bushing). ASSEMBLY
IMPORTANT: Put engine oil on gears before
assembling oil pump.
Press idler shaft (12, Fig. 4) into pump housing
until flush with outer surface of housing.
Using a JD253 tool, press bushing (13, Fig. 4)
into shaft bore of housing until flush with surface
inside housing.
Place gear and shaft in housing. Install pump
idler gear on idler shaft in housing. Check to see
that both gears rotate freely in housing.
Install new O-ring (3, Fig. 4) in oil outlet opening
in oil pump cover.
INSTALLATION
Oil Pump
Place pump housing with gears and drive shaft in
Fig. 9—Installing Pressure Regulating Valve Bushing
position in engine. Install drive gear on shaft. Tighten
hex. nut to 40 Ib-ft and then stake nut to shaft.
Press new bushing into block (Fig. 9) using a
Position oil pump cover and screen up against pump
JD 248 tool. Press in bushing until outer recessed
housing. Install pump outlet oil tube in cover. Fasten
edge is flush with bottom of counterbore in block.
cover in place with four cap screws and lock washers.
Do not press on raised inner rim of bushing. This
Tighten to 35 Ib-ft.
rim is the regulating valve seat.
Place valve and spring in valve hole in engine timing
Check oil pressure regulating spring for spring test gear cover. With an aluminum washer on valve plug
strength (Test Length— 1.68 in. at 15 ± 1.5 lbs.). and same number of shims in plug counterbore as
removed, install plug in timing gear cover. This is a
preliminary setting to be used until oil pressure can be
checked.
Oil Filter
Install new filter element. Turn elem ent down until
sealing ring just contacts mounting pad then turn down
an additional 1-1/2 turns.
Check for leaks around filter element. Retighten
if necessary, but do not overtighten.
The filter element has a special bypass valve to
protect the engine in case of filter clogging. Be sure
to replace only with a genuine John Deere filter
element.
Litho in U.S.A.
SPECIFICATIONS
Wear
Item Measurement New Part Tolerance
Oil Pump
Gear Side C learance................................................. n nng in _______ n n n 7 in
Gear End C le a ra n c e .................................... 0.0037 in............ ......... 0.0062 in.
Drive S h a ft.......................................... O.D, 0.6310 in............ ......... 0.6308 in.
Drive Shaft H o u sin g ......................... I.D.. 0.6327 in............ ......... 0.6332 in.
Oil Pressure Regulating Spring . . . Test Length @ 15 ± 1.5 lbs. 1.68 in.................
TORQUE VALUES
Item Torques (Ib-ft)
Oil pump assem bly cap s c re w s ...................... 35

Oil pump gear-to-drive shaft n u t .................... 40
Oil pan cap s c re w s ............................................... 35
Oil pan-to-clutch housing s c re w s .................... 170
Oil pressure regulating valve p lu g .................. 80
TUNE-UP DATA
Oil pressure (at fast idle) with engine at normal te m p e ra tu re ......... 50 ± 15 psi
SPECIAL TOOLS
No. Nam e Use
n OAQ
Ui !_/ iro
o rii
y uila
iu utin n
i ly
(seat)
JD 253 .................. D riv e r...................................... To install bushing in pump housing
................................. 0-200 psi Pressure Gauge To check engine oil pressure
Litho in U.S.A.
TM-1001 (Nov-79) Speed C ontrol Linkage 20-1
Group 20
SPEED CONTROL LINKAGE
1 - C ontrol Knob 12 - T h ro ttle C able B racket 24 - T h ro ttle L in k (Includes Bushings)

2 — Jam N ut (e a rly u n its) 13 — C otter Pin (2 used) 25 — T h ro ttle P iv o t Pin
3 — Lever 14 — Pin 26 — Yoke (2 used)
4 — Spring Pin 15 — Jam Nut 27 — Lo ck Nut
5 - T h ro ttle P late 16 - Sleeve 28 - Foot T h ro ttle L in k
6 - Facing P late (2 used) 17 — Spring Pin (2 used) 29 — Foot T h ro ttle Pedal
7 — Groove Pin (2 used) 18 — P ivo t 30 — Spring
8 — Lower Speed C ontrol D isk 19 - C otter Pin (2 used) 31 - Washer
9 - Spring 20 — Pin (2 used) 32 — T h ro ttle Rod
10 — T h ro ttle , P ush-P u ll Cable 21 - End Yoke 33 - L in k Coupler
11 — Cap Screw (2 used) 22 - Nut 34 — Lock Washer (2 used)
23 — Bushing 35 - Spring Pin
36 — Spring Pin
F ig. 7—Speed C ontrol L inka ge
REPAIR AND ADJUSTMENT SPEED ADJUSTMENTS
Speed control linkage is preset at the factory. Make all speed control adjustments in the
If repair or adjustment is necessary, refer to exact order given. Refer to Figs. 2, 3, 4, and 5
Fig, 1 for identification of parts and especially as a guide to adjusting points.
note the following:
F a s t Id le A d ju s tm e n t
Be sure engine is warm before making speed
control adjustments. Use a master tachometer. Model C Pump
Disconnect injection pump throttle cable from Remove slow idle screw from the pump throt
the pump lever. tle control cap (Fig. 2).
Adjust pump fast and slow idle speeds accord

ing to specifications.
Apply Never-Seez Lubricant, or equivalent, to

foot throttle pedal pivot.
Litho in U .S.A .
20-2 Speed C o n tro l Linkage TM-1001 (Dec-87)
Model JDB and DB2 Pump
Disconnect throttle cable (10, Fig. 1) from the

injection pump.
F ig . 2 -P u m p F a s t Id le A d ju s tm e n t (M odel " C ” Pump)
IM P O R TA N T: Never remove the throttle con

tro l cap from the ” C " pump sleeve while mak
ing any adjustment.
Insert a small-bladed screwdriver through

the threaded hole at the end of the cap and turn
the fast idle adjusting screw (Fig. 2).
F ig . 4 -P u m p Id le A d ju stm e n ts (M odel " J D B ” Pump)
Turn screw in (clockwise) to increase fast

idle speed or turn screw out (counterclockwise) Run engine and rotate pump throttle lever un
to decrease speed. til fast-idle stop screw (Fig. 4) contacts its stop.
Engine speed should be at fast idle of 2450 rpm.
Reinstall slow idle screw and make slow idle If not, adjust pump stop screw to correct. Lock
adjustment. screw with sealing wire.
S lo w I d l e A d j u s t m e n t
Model CB Pump
Model C and CB Pumps
F ig . 3 —Pump Id le A d ju stm e n ts.(M o d e l “ C B " Pump)
Remove throttle control cap and turn fast

idle adjusting screw out (counterclockwise) to
increase speed or in (clockwise) to decrease F ig . 5 -P u m p Slow Id le A djustm ent
speed (Fig. 3).

With slow idle adjusting screw installed, move
Install throttle control cap and tighten to 45 the throttle lever forward and check slow idle
to 50 in-lbs. speed (Fig. 5).
L ith o in U .S.A .
TM-1001 (Dec-87) Speed C ontrol Linkage 20-3
Turn the slow idle screw in to increase speed Remove and discard slow idle adjusting screw
qr out to decrease speed. Check to be sure that and nut (Fig. 7).
pump throttle lever is positioned 1/8 inch from
injection pump housing. With the foot throttle linkage in the slow idle
position, adjust the throttle cable so the lever on
Model JDB and DB2 Pump the pump overrides the slow idle position by 1/4-
inch.
Lightly rotate pump throttle lever to slow-idle posi
tion. Engine speed should be at slow idle of 900 ± Pull the hand throttle lever (Fig. 7) to the
25 rpm. If not, adjust slow-idle stop screw on top of most rearward position and adjust throttle rod
injection pump (Fig. 4). on the hand throttle lever to the shortest length
without moving the foot throttle linkage.
A d ju s tin g L in k a g e (JD 570)
Put the hand throttle lever in the most for
ward position. The lever on the pump should be
in the high idle override position. High idle over
ride is 1/4 inch.
A d ju s tin g L in k a g e (J D 5 7 0 -A )
F ig . 6 —In je c tio n Pump w ith T h ro ttle Cable
Override on pump throttle lever (1/4 in.)

should be preloaded at both fast and slow idle
positions.
1 — Hand T h ro ttle Le ver 5 —Foot T h ro ttle Arm

2 - T h ro ttle L e ver 6 - F oot T h ro ttle Pedal
3 — T h ro ttle Rod and C le v is 7 —Spring
4 — T h ro ttle L in k
F ig . 7 -H a n d and F o ot T h ro ttle L inka ge
F ig . 8 -H a n d and F o o t T h ro ttle L in ka g e
Litho in U .S.A .
20-4 Speed C ontrol Linkage TM-1001 (Dec-87)
With the foot throttle linkage in the slow idle rod and clevis linkage (3) on the hand throttle
position, adjust the throttle cable so the lever on lever (1) to the shortest length without moving
the pump overrides the slow idle position by 1/4 the foot throttle linkage. See Fig. 8.
inch.
Put the hand throttle lever in the most forward
Pull the hand throttle lever (1, Fig. 8) to the position. The lever on the pump should be in the
most rearward position and adjust the throttle high idle override position. High idle override is
1/4 inch.
SPECIFICATIONS
Item Measurement S p e c ific a tio n
Pump lever..................................................................... Override. 1/4 in.

J.UJ.UIL 1C IC V C i 1 JLU lll
pump housing (slow idle position)......................... Distance . 1/8 in.
T U N E -U P DATA
Injection Pump, Fast Idle Speed........................................................................................... 2450 ± 50 rpm

Injection Pump, Slow Idle Speed........................................................................................ 900 ± 25 rpm
TORQUES FOR HARDWARE
Item Torque(lb-in)
Injection Pump Slow Idle Adjusting N u t ..................................................................................... 25

Throttle Control C a p ......................................................................................................................... 45 to 50
Throttle Lever Screw ......................................................................................................................... 20 to 25
L itho in U .S.A .
TM-1001 (Nov-78) E ngine C ooling S y stem 25-1
Group 25
ENGINE COOLING SYSTEM
GENERAL INFORMATION DIAGNOSING COOLING SYSTEM

MALFUNCTIONS
RADIATOR ENGINE OVERHEATS
Coolant temperature is controlled by a thermo Low coolant level.

stat. A bypass line from the thermostat housing to Faulty thermostat.
the water pump allows fast engine warm up and a Leaking head gasket (Group 10).
uniform cooling temperature throughout the cylin Plugged radiator.
der block. The pressure-type radiator cap is Pump impeller broken.
equipped with a pressure valve which permits a Collapsed hoses.
pressure buildup in the cooling system. Scored pistons (Group 10).
CRANKCASE OIL COOLER WATER PUMP LEAKS
The crankcase oil cooler is connected direct Worn seal and/or shaft.
ly to the water pump by two external hoses.
ENGINE RUNS COLD
Coolant is pumped from the water pump
through a flexible hose connected to one end of Faulty thermostat.
the cooler. Heat generated in the crankcase is Defective temperature gauge.
conducted through the cooler tubes. The coolant
then absorbs this heat and is pumped through the ENGINE VIBRATES
radiator for final heat dissipation.
Bent fan blades.
WATER PUMP Worn pump shaft.
The centrifugal-type water pump attaches di OIL MIXES WITH COOLANT
rectly to the cylinder block and is driven by the
fan belt. A bellows-type seal assembly is pressed Defective crankcase oil cooler (early models).
into the pump housing between the pre-lubricated
ball bearing and impeller. COOLANT LEAKS INTO CRANKCASE
If the seal becomes worn or damaged, water Defective crankcase oil cooler (early models).
will escape through a drain hole near the bottom Failed cylinder liner packings.
of the pump housing.
L itho in U .S.A .
20 E ngine Grader, Motor - JD 570
2 5 -2 E ngine C oolin g S y ste m TM-1001 (Nov-78)
REPAIR
CRANKCASE OIL COOLER
14
10
3 — Cap Screw 10 — Clamp (8 used)

4 — B racket 11 - Hose (2 used)
5 — C ooler N ipple 12 — Water L in e Tubing
6 — O il C ooler With 13 - Hose
R e lie f V alve and 14 - Hose
1 — D riv e Screw 9 - Nut O-Ring 15 — Water L in e Tu bing
2 — Clamp 10 — Lo ck Washer 7 — R e lie f V alve
3 — O il C ooler 11 _ Washer
4 — P a cking (2 used) 12 - L in e F ig . 3 —O il C ooler
5 — P a cking Gland (2 used) 13 — Clamp (E ngine S erial No. 795490-248000)
6 - Hose Clamp (8 used) 14 — Cap Screw
7 — L in e 15 — Drain C ock (2 used)
8 — Hose (2 used) 16 — H ose (2 used)
F ig . 7—0 / / C ooler
(E n g in e S erial N o. -748738) 1-------
1 — N ut 10 — R etainer
2 — Clamp 11 — O-Ring (2 used)
3 — Cap Screw 12 — Washer (2 used)
4 — Bracket 13 — Water L in e
5 — C ooler N ip p le 14 — Water L in e
6 — Clamp (4 used) 15 - O-Ring
7 — Hose (2 used) 16 - R e lie f V a lv e
8 — Cap Screw 17 — Pipe P lug
9 — Lock Washer 18 — O il C oole r
F ig . 2 —0 / / C ooler
(E n g in e S e ria l No. 148139-195489)
9
T62664N
F ig . 4 - O i l C ooler
(E ng in e S erial N o. 248001- )
Litho in U .S.A .
e-— on
trader, Motor - Ju570 ciiym ct cm
TM-1001 (Dec-87) Engine Cooling System 25-3
1— Clamp (8 used) 9—Relief Valve Inspect impeller insert and cup. Replace if neces
2— Hose If?—Oii Cooler With Relief sary.
3— Hose Valve
4— Lower Tube 11— Cooler Nipple
5— Half Clamp 12— Screw
Assembling Pump
6— Cap Screw 13— Lock Washer Install a new seal in the pump housing. Coat outside
7— Hose (2 used) 14— Half Clamp
8— O-Ring 15— Washer
of pump seal metal retainer with joint sealing com
16— Upper Tube pound and wipe off any excess (spring-loaded type
seal only). Apply a thin coat of light oil to sealing lip of
Legend for Fig. 4 seal before installing.
If seal is a two-piece type, install by hand as shown
Drain oil from engine crankcase and coolant from in Fig. 5. Rubber sealing surface that contacts housing
radiator and oil cooler. If early model, remove engine should be clean and dry.
oil pan. If seal is a spring-loaded type, use a tubular type
Check to see that cooler is not plugged with lime or driver that contacts only the outer metal portion of the
other foreign material. Check for tube damage. See seal and press new seal (metal side first) into pump
Figs. 1, 2, 3 or 4 for relationship of cooler parts. housing. Press in until metal flange bottoms on hous
Position O-ring (8, Fig. 4) on bottom of oil cooler. ing.
Place oil cooler on cylinder block and install oil U sing a JD-262A w a te r pum p b e arin g d river or
cooler nipple (6). Tighten oil cooler nipple to 20 to 25 any tu bular-type d river th a t c o n ta c ts o n ly the o u te r
Ib-ft. race o f bearing, press s h a ft and b earing a sse m b ly
in to h ousing u n til o u te r m e ta l case is flu s h w ith
Radiator pum p housing.
Inspect and test radiator pressure cap for damage
which might impair its sealing power. See “ Specifica
tions.”
Water Pump
Drain coolant from radiator and engine block and
remove radiator and water pump from engine.
Disassembly
Remove the rear cover plate and gasket from the
pump housing (Fig. 5).
Select a drift which is slightly smaller than the bear
ing shaft and, supporting fan pulley, press pulley from
water pump.
S up p o rt w a te r pu m p ho usin g (Fig. 5) and a llo w
s u ffic ie n t cle a ra n ce fo r im p e lle r a t ce n te r o f su p
p o rt. U sing a JD-262A w a te r pum p bearing driver
o r any tu b u la r-typ e d river th a t c o n ta c ts o n ly the
o u te r race o f bearing, press bearing a sse m b ly from
housing.
Any leakage at the drain hole in bottom of housing
generally indicates a leaking seal.
Support impeller and press out bearing shaft using a
drift which is slightly smaller than the bearing shaft.
Remove seal from bearing shaft.
Litho in US. A.
25-4 Engine C ooling System TM-1001 (Dec-87)
1— Cap Screw (4 used) 9—Gasket 16— Cover

2— Fan 10— Bearing and Shaft 17— Housing
3— Fan Belt (2 used) 11— Seal 18— Tube (2 used) (Early Model)
4— Pulley 12— Insert 19— Stud
5— Cap Screw 13— Cup 20— Cap Screw (3 used)
6— Strap 14— Impeller 21— Lock Washer (7 used)
7— Plug 15— Gasket 22— Nut (6 used)
8— Elbow
Fig. 6-Water Pump
Install impeller insert and cup in impeller. Place Support pump assembly on end of bearing shaft and
insert in cup with vee groove on insert toward cup. Be press impeller (fins toward housing) into position. Im
sure parts are dry and clean. Dip cup and insert in oil peller should be pressed in until fins are flush (± 0.010
and install in impeller (cup to bottom of counter bore in in.) with metal rim of pump housing. Check with a
impeller). Insert should be flat and edge of cup uniform straightedge and feeler gauge as shown in Fig. 7.
around insert when installed in impeller.
Using a support smaller than the bearing shaft,
support impeller end of pump bearing shaft and press
fan pulley into position on opposite end of shaft.
A p p ly 2-3 d ro p s o f H ig h S tre n g th T hread L o ck

and S e a le r to fa n a tta c h in g scre w s. T ig h te n to 35
Ib-ft.
Fan surface on pulley to rear surface of pump
housing (without rear plate or gasket) should be 6.63
inch.
Using a new gasket, install pump rear cover on

pump assembly. Tighten attaching cap screws to 35
Ib-ft.
Install radiator and water pump on engine.
Fig. 7-lnstalling Impeller If the engine has been running too cool or too hot,
carefully inspect the thermostat for defects. If visual
inspection fails to disclose any defects, test the ther
mostat in hot water to check for proper closing.
Litho in U.S.A.
TM-1001 (Dec-87) Engine C oolant System 25-5
SPECIFICATIONS
Item Specification
RADIATOR
Coolant ca p a city............................................................. 7-1/2 U.S. gallons
Radiator cap relief pressure........................................... 6-1/4 to 7-1/2 psi
Therm ostat...................................................................... 195°F
WATER PUMP
Distance between impeller fins and rim of pump......... Flush (± 0.010-inch)
Fan surface on pulley to rear surface of pump housing
(without rear plate or gasket)..................................... 6.63 inch
OIL COOLER (External)
Relief valve se ttin g ......................................................... 12 to 15 psi
TORQUE VALUES
Item Torque (Ib-ft)
Fan-to-pulley............................ 35
Thermostat cover and housing 20
Water pump rear c o v e r......... 35
Oil cooler nipple...................... 20 to 25
SPECIAL TOOLS
No. Name Use
ESSEN TIAL TO O LS
JD-262A Driver To remove and install water pump bearing.
25-6 Engine Cooling System TM-1001 (Feb-80)
Litho in U.SA.
Grader, M o to r - JD570 Fuel System 30
TM-1001 (Dec-87) D iagnosing M a lfu n ctio n s 5-1
Section 30
FUEL SYSTEM
Page Page
GROUP 5 - DIAGNOSING MALFUNCTIONS MODEL CB

Diagnosing M alfunctions...................... 5-1 General Information.............................. 20-4
D iagnosis................................................. 20-4
GROUP 10 - FUEL TANK, FILTERS, AND Removal.................................................... 20-4
TRANSFER PUMP R epair...................................................... 20-4
Fuel Tank................................................. 10-1 Installation and T im ing......................... 20-4
F ilters...................................................... 10-2 Adjustm ents............................................ 20-5
Transfer P u m p ...................................... 10-3
MODEL JDB
GROUP 15 - AIR INTAKE SYSTEM General Information.............................. 20-5
Air Cleaner.............................................. 15-1 D iagnosis................................................. 20-5
Turbocharger (Altitude Compensating) 15-2 Removal.................................................... 20-5
General Information........................... 15-2 R epair....................................................... 20-6
Diagnosis........................ 15-2 Installation and Tim ing......................... 20-6
T e s t s .................................................... 15-3 Adjustment.............................................. 20-7
Repair.................................................... 15-4
Installation............................................ 15-7 FUEL INJECTION NOZZLES
(See SM-2045, "Testing and Servicing Fuel
GROUP 20 - FUEL INJECTION PUMP Injection Pumps and Nozzles.")
MODEL C
General Information.............................. 20-1 GROUP 25 - SPECIFICATIONS AND
D iagnosis................................................. 20-1 SPECIAL TOOLS................. 25-1
Removal.................................................... 20-1
R epair....................................................... 20-2
Installation and T im ing......................... 20-2
Adjustments.............................................. 20-3
Group 5
DIAGNOSIS
DIAGNOSING FUEL SYSTEM MALFUNCTIONS
The following is a guide for diagnosing fuel ENGINE STARTS HARD

system difficulties. For specific diagnosis of
fuel system components, refer to the groups Air leak on suction side of fuel system.
which cover complete servicing. Look for leaks at all connections.
Fuel too heavy at low temperatures.
FUEL IS NOT REACHING INJECTION PUMP See operator's manual for correct fuel.
Cranking speed too slow.
Fuel too heavy at low temperatures. Increase cranking speed. Check starting cir
See operator's manual for correct fuel. cuit.
Filters clogged. Injection nozzles faulty or sticking.
Remove and replace as necessary. Incorrect timing (Group 20).
See operator's manual. Electric shut-off sticking or failed
Fuel lines clogged or restricted. (see SM-2045).
Blow out all fuel lines with filtered air. Fuel tank screen or fuel filters dirty.
Replace damaged lines. Faulty fuel transfer pump.
Litho in U .S.A .
30 F u e l S y stem Grader, Motor - JD 570
5 -2 D ia g n o sin g M alfu n ction s TM-1001 (Nov-78)
Filters clogged. Injection nozzles sticking or faulty.

Remove and replace as necessary. Incorrect timing (Group 20).
See operator's manual. Fuel lines clogged or restricted.
Fuel lines clogged or restricted. Water in fuel.
Blow out all fuel lines with filtered air. Drain and refill fuel system. Prime andbleed
Replace damaged lines. system.
Water in fuel. Low cetane fuel.
Drain and refill fuel system. Injection nozzle return lines clogged.
Prime and bleed system. Remove and blow out with filtered air.
Low cetane fuel.
See operator's manual. ENGINE DOES NOT DEVELOP FULL POWER
ENGINE STARTS AND STOPS Electrical shut-off sticking.

Remove and inspect parts (see SM-2045).
Electrical shut-off failure. Air leak on suction side of fuel system.
Remove and inspect parts (see SM-2045). Look for leaks at all connections.
Check electrical circuit. Injection nozzles faulty or sticking.
Air leak on suction side of fuel system. Incorrect timing (Group 20).
Look for leaks at all connections. Speed control linkage out of adjustment (see Sec
Fuel tank screen or fuel filters dirty. tion 20, Group 20).
Fuel line clogged or restricted. Fuel tank screen or fuel filters dirty.
Water in fuel. Remove and clean or replace as necessary.
Drain and refill fuel system. Prime andbleed See operator's manual.
system. Fuel lines clogged or restricted.
Dirty check valves in transfer pump. Blow out with filtered air.
Faulty transfer pump. Water in fuel.
Drain and refill system. Prime and bleed
ENGINE OPERATION IS ERRATIC system.
Low cetane fuel.
Air leak on suction side of fuel system. See operator's manual.
Look for leaks at all connections. Dirty check valves in transfer pump.
Fuel too heavy at low temperatures. Faulty transfer pump.
See operator's manual for correct fuel. Injection nozzle return lines clogged.
Injection nozzles faulty or sticking. Remove and blow out with filtered air.
Incorrect timing (Group 20).
Fuel lines clogged or restricted. ENGINE SMOKES (BLACK)
Fuel tank screen or filters dirty.
Water in fuel. Injection nozzles faulty or sticking.
Drain and refill fuel system. Prime andbleed Replace or correct nozzles.
system. Incorrect pump timing (Group 20).
Low cetane fuel. Low cetane fuel.
See operator's manual. See operator’s manual.
Injection nozzle return lines clogged. Restriction or leak in air intake system.
Remove and clean parts. Inspect air intake system.
Restriction in exhaust system.
ENGINE IDLES POORLY Inspect exhaust system.
Electrical shut-off sticking.

Remove and inspect parts (see SM-2045).
Air leak on suction side of fuel system.
Look for leaking connections.
Fuel tank screen or fuel filters dirty.
Dirty check valves in transfer pump.
Faulty transfer pump.
Litho in U .S .A .
Grader, Motor - JD570 F u el S ystem 30
TM-1001 (Nov-78) F u el Tank, F ilte r s , and T ra n sfer Pump 10-1
Group 10
FUEL TANK, FILTERS, AND TRANSFER PUMP
1 — Cover IT — C onnector 22 — Lo ck Washer (9 used) 32 - L o ck Washer (2 used

2 — Machine Screw and Lock 12 — Return H ose 23 — Cap Screw w ith w arning lamp)
Washer (5 used) 13 - Connector (JD570) 24 - M ounting Pad (2 used) 33 - Fla sher (w ith w arning
3 — Gasket 14 — A dapter 25 — Clamp lamp)
4 — Sending U n it 15 - Tube 26 — Clamp 34 — Washer (2 used - w ith
5 — Cop 16 — Needle V alve (E arly U nits) 27 - Washer (4 used) w arning lamp)
6 - Cap Screw (6 used) 17 — Needle V a lve (L a te r U nits) 28 - Washer 35 - Cap Screw (2 used >
7 — Fuel Neclc 18 - Drain Cock 29 - Cap Screw w ith w arning lamp)
8 - Gasket 19 - Bracket 30 — F ilte r (L a te r U n its ) 36 — Emblem
9 - Cap Screw (4 used) 20 — Mounting Pad 31 — N ut (2 used - w ith
10 - Fuel Tank 21 - N ut (2 used) w arning lamp)
F rg. 1—F u e l Tank
GENERAL INFORM ATION REPAIR
The fuel tank is located behind and above the Refer to Fig. 1 during disassembly and
transfer drive housing at the extreme rear of the assembly. The filter (30) seldom needs cleaning
grader. because the sloshing of the fuel tends to wash
dirt particles from the filter screen.
IMPORTANT: Do not d rill holes in the back
protective shroud at the rear of the grader. This Refer to FOS Manual - Engines for de
is a wall of the fuel tank. tailed instructions for repair of fuel tanks.
Litho in U .S.A .
30 F u e l S y ste m Grader, Motor - JD 570
1 0 -2 F u el Tank, F ilt e r s , and T r a n s fe r Pum p TM-1001 (Nov-78)
FUEL FILTERS
GENERAL IN FO R M A TIO N 2. Be sure gaskets (7) are not crimped and
tighten filter screws (12) hand tight.
On graders with serial number before 002093
the fuel system has two fuel filters in parallel
Refer to the operator’s manual for filter re
located on the left side of the engine. Graders
placement information.
with serial number 002093 and after have a two
stage master filter located on the left side of
On graders starting with serial number
the engine.
002093, a two stage master filter is used.
Early units also have a strainer in the A.C.
fuel transfer pump. Later units with Airtex fuel Refer to Fig. 3 during disassembly and a s
transfer pumps have a strainer on the fuel tank sembly of the master filter.
needle valve (30, Fig. 1).
REPAIR
A complete diagnosis of the fuel system should

include an inspection of the filters and strainers
in the system.
Refer to Fig. 2 during disassembly and a s

sembly of fuel filters and note the following during
assembly.
1 — Cap Screw (2 used) 7 - Elbow

2 — Fuel F ilte r B racke t 8 — P ipe Plug
3 — S pecial Screw (2 used) 9 — Hex N ut (2 used)
4 — O -R ing (2 used) 10 — Cap Screw (2 used)
5 — Fuel F ilte r Body 11 - Fuel F ilte r E lem ent
6 — Connector 12 - R etaining Spring
F ig . 3 -M a s te r F ilte r
Refer to grader operator's manual for filter

element replacement information.
1 - Elbow 9 — Screen (e a rly models)
2 - Fuel L in e 10 - G lass B ow l (2 used)
3 - Plug (4 used) 11 — G asket (2 used)
4 — O -R ing (4 used) 12 — F ilte r Screw (2 used)
5 — F ilte r Head 13 — Fuel L in e
6 - O -R ing (2 used) 14 — Cap Screw
7 - G asket (4 used) 15 - E lbow (la te r models)
8 - Elem ent (2 used)
F ig . 2 —F u e l F ilte rs
1. On early units make sure filter screen (9)

is down on inner edge of bowl.
L itho in U .S .A .
Grader, Motor - JD570 Fuel System 30
TM-1001 (Feb-80) Fuel Tank, Filters, and Transfer Pump 10-3
FUEL TRANSFER PUMP

GENERAL INFORMATION
Early units have A.C. fuel transfer pumps. Later
units are equipped with Airtex fuel transfer pumps.
A.C. and Airtex pumps are a diaphragm type, ac

tuated by an eccentric lobe on the engine camshaft.
A hand primer lever on the fuel transfer pump is

used as an aid in bleeding the fuel system.
TESTING AND DIAGNOSIS
Suspected Low Fuel Delivery

Test fuel flow at transfer pump by installing a tee
fitting on fuel pump outlet side and connecting a low
pressure gauge into the tee. Pressure should be from
3.5 psi to 5.0 psi at 16 inches above outlet at 900
engine rpm.
1— Pump Cover 10— Screw
Fuel Flow Not To Specifications 2— Screw 11— Rocker Arm Parts Kit
3— Lock Washer 12— Pump Body
Primer lever is in upward position. 4— Diaphragm 13— Screen
Fuel screen inside pump sediment bowl is plugged 5— Cap Screw 14— Gasket
6— Elbow 15— Bowl
(A.C. only).
7— Spring 16— Bail Assembly
Fuel line from tank to transfer pump is clogged. 8— Spring 17— Gasket
Pump bowl gasket leaks. 9— Rocker Arm Bearing 18— Special Washer
Cover screws are loose (A.C. only). Retainer
Inspect rocker arm for wear.
Fig. 4-A.C. Fuel Transfer Pump
Inspect diaphragm for leaks (A.C. only).
Check pull rod for wear (A.C. only).
Inspect valve and cage assemblies (A.C. only). Refer to Fig. 4 and disassemble transfer pump.
Check rocker arm springs (A.C. only). Replace parts as necessary. Use the following as a
Inspect rocker arm link and pin (A.C. only). guide in checking pump parts.
REPAIR 1. Inspect rocker arm for wear.

2. Inspect diaphragm for leaks.
A.C. Pumps - Early Models 3. Check pull rod for wear.
4. Inspect valve and cage assemblies.
Two parts kits (1) a pump overhaul kit (7, 8, 14, and 5. Check rocker arm springs.
17, Fig. 4), and (2) a rocker arm parts kit (11) are used 6. Inspect rocker arm link and pin.
when repair is necessary.
Airtex Pumps - Later Models
Refer to Fig. 5 when disassembling the Airtex pump.
Litho in U.S.A.
30 Fuel System Grader, Motor - JD570
10-4 Fuel Tank, Filters, and Transfer Pump TM-1001 (Feb-80)
Further breakdown of the Airtex pump is not possi

ble. If a diagnosis of the system indicates a faulty
transfer pump, a new pump (5, Fig. 5) must be ordered.
NOTE: Be sure a fuel filter is installed at the fuel

outlet at the fuel tank to prevent contaminants from
entering the fuel pump.
ASSEMBLY
A.C. Pumps - Early Models
Be sure diaphragm pull rod is engaged with link
inside body (12, Fig. 4).
3— O-Ring
Tighten cover-to-body screws evenly to prevent
Fig. 5-Airtex Fuel Transfer Pump distortion.
To remove the primer lever, compress rocker arm Airtex Pumps - Later Models
and pull out lever. To install primer lever, place O-ring on lever, com
press rocker arm, and push lever into place.
Litho in U.S.A.
Grader, Motor - JD 570 F u el S y stem 30
TM-1001 (Nov-79) A ir Intake S y stem 15-1
Group 15
AIR INTAKE SYSTEM
AIR CLEANER
T26935
1 - B racket 8 - Weather Cap 15 — Body 21 — Elem ent

2 — Cap Screw 9 - Cover 16 — N ut 22 — R eta in ing Clamp
3 — Clamp 10 — Bow l 17 — Clamp (2 used) 23 — Clamp B o lt
4 - N at 11 - B ow l Base 18 - Cap Screw (2 used) 24 - B a ffle
5 — Cap Screw 12 — P re-C leaner 19 — Wing N u t (2 used) 25 — D ust Cup
6 — E xtension 13 - Hose Clamp (2 used) 20 — Safety Elem ent 26 — Hose (L a te r U n its)
7 — Grommet (E a rly U n its ) 14 - H ose (E a rly U n its) 27 — Seal (L a te r U n its)
F ig . 7—A ir C/eaner and P re-C leaner

(u n its w ith o u t turbocharger)
GENERAL INFO RM ATIO N REPAIR
The dry-type air cleaner (Fig. 5) consists of Refer to the operator’s manual when servic
the pre-cleaner, body assembly, safety element, ing the air cleaner.
primary filter element, baffle, and dust cup.
Replace primary filter element (1) if dam
Heavy particles of dirt are removed by the aged, (2) after one year of service, or (3), if
pre-cleaner. Air then enters the cleaner body element is not responding to cleaning, indica
and flows past the filter fins which separate dirt ted by excessive smoke or lo ss ofpower.
from the air and deposit the dirt in the dust cup.
Air is further filtered as it passes through the INSTALLATION
primary and safety elements before flowing out
to the engine. Tighten hose clamp on turbocharger inlet hose to
70 ± 5 lb-in.
Turbocharged units have a larger capacity air
cleaner that differs slightly from the one shown
in Fig. 1. It consists of the body assembly, pri
mary element, secondary element and cover.
L itho in U .S.A .
30 F u el S y stem Grader, Motor - JD 570
1 5 -2 A ir Intake S y stem TM-1001 (Nov-79)
TURBOCHARGER
GENERAL INFORMATION E n g in e W ill N o t D e l i v e r R a te d P o w e r

Clogged Manifold System
The turbocharger (Fig. 4) consists of a radial Clean air intake ducting.
inward-flow turbine (2), centrifugal impeller
(14), center housing (7), turbine housing (l),and Foreign Material Lodged in Compressor, Impel
compressor housing (17). ler, or Turbine
Disassemble and clean.
During engine operation, exhaust gases pass
through the turbine housing, rotating the turbine Excessive Dirt Build-Up in Compressor
wheel. The compressor wheel (mounted on same Thoroughly clean compressor assembly.
shaft as the turbine) rotates with the turbine. Clean air cleaner and check for leakage.
The compressor draws in ambient air, com
presses the air, and delivers it to the intake Leak in Engine Intake or Exhaust Manifold
manifold. As the power output of the engine in Tighten loose connections or replace manifold
creases, the flow of exhaust gases increases, gaskets as necessary.
and the speed and output of the rotating assem
bly increase proportionately. Rotating Assembly Bearing Seizure
Repair turbocharger.
Engine oil under pressure from the engine
lubrication system is pumped through passages O il on C o m p r e s s o r W h eel o r in C o m p r e s s o r
in the center housing and directed to bearings H o u sin g
and thrust washers through passages in the cen Oil Being Pushed or Pulled Through Center
ter housing and thrust plate. Oil is sealed from Housing
the compressor and turbine by seals at both ends Excessive back pressure - blocked exhaust.
of the center housing. Air intake restriction.
Clogged air cleaner element or collapsed in
Discharge oil drains by gravity from the cen let line.
ter housing to the engine crankcase.
O il in M a n ifo ld s o r D r ip p in g f r o m H o u sin g
DIAGNOSING MALFUNCTIONS Seal Failure
Damaged or worn journal bearings.
N o is e o r V ib r a tio n s (a) Unbalance of rotating assembly.
(Do not confuse the whine heard during run Damage to turbine or compressor wheel
down with noise which indicates a bearing fa il or blade. Dirt or carbon build-up on
ure.) wheel or wheels.
(b) Bearing wear
Bearings Not Lubricated. Oil starvation or insufficient lubrica
Engine oil pressure below 40 psi with oil at tion.
180° to 220° F.
Clean or replace oil line. D r a g in T u r b in e W h eel
Replace engine oil filter. Carbon Build-Up Behind Turbine Wheel
Coked oil or combustion deposits.
Leak in Engine Intake or Exhaust Manifold
Tighten loose connections or replace mani Dirt Build-Up Behind Compressor Wheel
fold gaskets if necessary. Air intake leaks.
Improper Clearance Between Turbine Wheel and Bearing Seizure, Dirty or Worn Bearings
Turbine Housing. Excessive temperatures, unbalanced wheel,
Check axial bearing for end play of 0.001 to dirty oil, oil starvation, insufficient lubri
0.004 inch. cation, or normal wear.
Litho in U .S.A .
Grader, M o to r ■ JD570 Fuel System 30
TM-1001 (Dec-87) A ir Intake S ystem 15-3
TESTS A x i a l E n d P l a y B e a r in g T e s t
Perform this test to determine if the rotating
R a d ia l B e a r in g T e s t assembly must be repaired or replaced.
Perform this test to determine whether it is.
necessary to replace or repair the thrust bear
ing, radial bearing, and/or rotating assembly of
the center housing assembly. The radial bear
ing check should be made with the turbocharger
removed from the engine.
F ig . 3 —E nd P la y B e a rin g T e st
Fasten a dial indicator to the backplate so

that the indicator tip rests on the end of the
shaft (Fig. 3).
Move the shaft axially back and forth by hand.

If the total indicator reading is more or le ss than
F ig . 2 —R ad ia l B earing Check
0.001 to 0.004 inch, the rotating assembly must
be repaired.
Fasten a dial indicator (plunger type with
one-inch travel) using a mounting adapter and I n ta k e M a n ifo ld P r e s s u r e T e s t
two-inch indicator extension rod to the turbo Remove starting fluid adapter or plug from
charger oil drain mounting flange (Fig. 2). The intake manifold and install an air pressure gauge.
mounting plate and indicator canbe/securedwith Run engine at 2300 rpm full load and check gauge
the bolts removed from the oil drain hole. (See for a reading of 5 to 7 psi.
"SPECIAL TOOLS” for dial indicator adapter.)
Move the rotating shaft forward (toward com

pressor) and away from the indicator (Fig. 2)
using care to move the shaft the same direction
as the dial indicator travels.
Equal pressures should be applied to the shaft

at both ends simultaneously. The total dial indi
cator movement should be 0.003 to 0.007 inch.
Any deviation from this movement is cause for
repair.
L itho in U .S.A .
30 Fuel System Grader, M o to r - JD570
15-4 A ir Intake System TM-1001 (Dec-87)
REPAIR
T6680AZ
1— Compressor Housing 9—Thrust Bearing 17— Shroud

2— Lock Nut 10— Bearing 18— Piston Ring
3— impeller 11— Snap Ring (4 used) 19— Turbine Wheel With Shaft
4— Back Plate 12— Bearing (2 used) 20— Special Bolt (6 used)
5— Clamp (3 used) 13— O-Ring 21— Lock Plate (3 used)
6— Lock Plate (3 used) 14— Center Housing 22— Clamp (3 used)
7— Cap Screw (6 used) 15— Lock Plate (2 used) 23— Turbine Housing
8— Piston Ring 16— Cap Screw (4 used) 24— Diffuser (Engine
Serial No. -387206)
Fig. 4— Turbocharger
R em ove th e c o m p re s s o r w heel fro m th e s h a ft.

Then rem ove th e tu rb in e w heel and s h a ft a sse m b ly
fro m th e c e n te r h o u sin g , kee pin g it ce n te red w ith
th e b e a rin g s u n til it is c le a r o f th e h o u sin g . Fig. 7
s h o w s th e tu rb in e w heel a sse m b ly rem oved fro m
th e c e n te r h o u sin g . The w heel sh ro u d and p is to n
p in s m ay be rem oved a t th is tim e .
R em ove th e back p la te -to -c e n te r h o u sin g ca p
scre w s and lo ck p la te s (16 and 15, Fig. 4). Then
rem ove th e b a ck p la te , by ta p p in g w ith a s o ft
m a lle t.
Fig. 5 — S h a ft a n d W h ee l A s s e m b ly
L ith o in U.S.A.
TM-1001 (Dec-87) A ir Intake System 15-5
R e p la ce a n y p a rt w h ic h fa ils to m eet th e re

q u ire m e n ts given in th e in s p e c tio n p roce d u res.
R e p la ce th e fo llo w in g p a rts: O -ring (13, Fig. 4),
lo c k p la te s (6, 15 and 21), p is to n rin g s (8 and 18)
a nd re ta in in g rin g s (11).
R ep la ce a ll d a m a g e d b o lts.
NOTE: If bearings and thrust washers show
signs of nicks, scores, shellac deposits, or foreign
material imbedment, replace them.
G eneral — P arts m u s t n o t s h o w s ig n s o f dam age,

co rro s io n , o r d e te rio ra tio n . T h re a d s m u st n ot be
n icke d , cro sse d , o r s trip p e d .
1— Rubber O-Ring 3— Piston Ring
2— Thrust Collar and Washer S h a ft and T u rb in e W heel — T u rb in e w heel m u st
Fig. 6 — R em oving Thrust C o lla r a n d Thrust W ash er s h o w no s ig n s o f ru b b in g , and vanes m u st not
be to rn o r w o rn to a fe a th e r edge. S h a ft m u st
R em ove th e th ru s t c o lla r and th ru s t w a s h e r as sh o w no sig n s o f sco rin g , s c ra tc h e s , o r seizure
sh o w n in F ig. 6. R em ove th e ru b b e r O -ring fro m w ith th e be arin gs.
h o u sin g .
R em ove b e a rin g s and re ta in e rs fro m th e c e n te r
h o u sin g .
Cleaning
B efore c le a n in g , in s p e c t p a rts fo r s ig n s o f b u rr

ing, ru b b in g , o r o th e r d a m a g e w h ic h m ig h t n o t be
e vid e n t a fte r cle a n in g .
S oa k a ll p a rts in clean c a rb o n s o lv e n t fo r a b o u t
25 m in u te s . A fte r so a kin g use a s tiff b ris tle brush
to rem ove a ll d irt p a rtic le s . D ry p a rts th o ro u g h ly .
NOTE: Normally, a light accumulation o f carbon
deposits will not affect turbine wheel operation.
Inspection
B urnish o r p o lish o u t m in o r su rfa ce dam age. Use

s ilic o n c a rb id e abra sive c lo th fo r a lu m in u m p a rts
and c ro c u s a b ra sive c lo th fo r th e ste e l p a rts.
Litho in LI.S-A.
30 F uel System Grader, M o to r - JD570
15-6 A ir Intake System TM-1001 (Dec-87)
C o m p re sso r W heel — M u s t sh o w no s ig n s o f
ru b b in g o r da m a g e fro m fo re ig n m a tte r. M u st be
c o m p le te ly fre e o f d irt o r o th e r fo re ig n m a te ria l.
Im p e lle r bore m u st n o t be g a lle d .
Seal P arts — M u st sh o w no s ig n s o f ru b b in g o r
s c o rin g o f th e running fa ce s.
H o u s in g s — M u st s h o w no s ig n s o f c o n ta c t w ith
ro ta tin g p a rts. O il and a ir p a ssa g e s m u st be
c le a n and fre e o f o b s tru c tio n s .
Assembly
Be sure each part is clean before a sse m b lin g . As

parts are a ssem bled, cover o p e n in g s to prevent en
try o f d irt o r o th e r fo re ig n m a te ria l.
1— Sleeve Tool 4— Inner Ring Sleeve (JD274-1)
NOTE: If any particle falls into the turbocharger 2— Retaining Ring 5— Retaining Ring Installed
3— Ring Installer 6— Bearing Installed
during assembly, remove the particle immediately, (JD274-3) 7— Outer Ring Sleeve (JD274-2)
A t/a n
w r w f i
i f wa vs \f»ownf ci w/ iVr fwl W / c a c c o m h / i / .#wc .r e n u ir a r l .
if
Fig. 7—Installing Retaining Rings
C heck p isto n ring cle a ra n ce in tu rb in e w heel ring In s ta ll p isto n ring on th ru s t c o lla r over s h a ft, and
groove. C h e ck fo r b u rrs o r fo re ig n m a tte r. fla t a g a in s t th e c e n te r h o u sin g , e n g a g in g th e p in s
In sta ll inboard re ta in in g rin g s (Fig.7) using re ta in
ing rin g a sse m b ly to o l (JD274). L u b ric a te b e a rin g s In s ta ll ru bb e r O -ring in groove in c e n te r h o u sin g .
w ith cle a n en gin e o il and in se rt in place. In sta ll tu r
bine s id e and c o m p re s s o r sid e b e arin g re ta in in g Ro sur© th a t th ru s t sp rin g is in sta !!6d in b a ck
ring s. p la te (F ig. 8).
In s ta ll p is to n ring o n tu rb in e w h e el s h a ft. W ith
tu rb in e w h e el s h a ft u p rig h t, g u id e th ro u g h th e
w heel s h ro u d and b e a rin g s . Do n o t use fo rc e to
co m p re s s p is to n rin g in to p lace. A g e n tle ro ckin g
and p u shin g a ctio n w ill a llo w th e p isto n ring to seat
and th e s h a ft to b o tto m . A th in to o l, su ch as a de n
ta l p ic k m a y be used as an a id in c o m p re s s in g th e
rin g if d iffic u lty is e n co u n te re d .
L ith o in U.S.A.
TM-1001 (Dec-87) A ir Intake System 15-7
C h e ck a xia l end p la y and ra d ia l m o ve m e n ts. If

n o t w ith in 0.003 to 0.006 in c h (b ea ring cle a ra n ce )
o r 0.001 to 0.004 in ch (b ea ring end play), re ch e ck
p a rts to d e te rm in e th e cause.
C h e ck cle a ra n ce betw een w heel sh ro u d and tu r
b in e w h e el. O rie n t c o m p re s s o r h o u s in g to c e n te r
h o u sin g . In s ta ll V-band c o u p lin g on e a rly u n its and
tig h te n w ith 40 to 80 lb-in. On la te r u n its in s ta ll
c la m p s and lo ck p lates.
In s ta ll c o m p re s s o r h o u sin g on c e n te r h o u sin g .
O n ly h and tig h te n cap s c re w s u n til tu rb o c h a rg e r
has been m o un ted .
A fte r a sse m b ly, push th e ro ta tin g a s s e m b ly as
fa r a w a y as p o s s ib le fro m th e tu rb in e end and
1— Spring 2—Back Plate c h e c k fo r b in d in g . R epeat check, p u sh in g fro m th e
c o m p re s s o r end.
Fig. 8 —Back Plate Assem bly
Installation
IMPORTANT: Back plate and spring are sold only
as an assembly. The installed depth of the spring J u s t p rio r to m o u n tin g th e tu rb o c h a rg e r, p rim e
is a controlled dimension. Therefore, do not remove th e lu b ric a tio n system . F ill th e c e n te r h o u sin g w ith
or replace the spring by itself. Cleaning can be new e n g in e o il th ro u g h th e o il d ra in hole. T urn th e
done without removing the spring from the back ro ta tin g asse m b ly by hand to lu b ric a te th e bearings
plate. and th ru s t w asher.
A lig n m o u n tin g holes o f ce n te r housing and back W hen in s ta llin g tu rb o c h a rg e r e x h a u s t a d a p te r
p la te and in s ta ll b a ck p la te over s h a ft and th ru s t and e x h a u s t e lb o w be c e rta in th a t th e in s ta lla tio n
c o lla r. Use ca re n o t to brea k p isto n rin g w hen en d o e s n o t a p p ly a fo rc e on th e tu rb in e h o u sin g . The
g a g in g seal in b a c k p la te bore. B ack p la te is e a sily e x h a u st a d ap te r m u st have 1/32-inch m in im u m end
in s ta lle d if o pen end o f p is to n ring is engaged in p la y and ro ta te fre e ly.
b a c k p la te bore firs t.
A lig n a ir in ta ke p ipe and th e a ir in ta k e m a n ifo ld
In s ta ll b a ck p la te -to -c e n te r h o u sin g ca p scre w s and tu rb o c h a rg e r o u tle t b e fo re tig h te n in g c la m p s
and lo c k p la te s . T ig h te n c a p scre w s to 40-60 lb-in. on e ith e r hose. T ig h te n tu rb o c h a rg e r a ir in le t hose
c la m p to 70 ± 5 lb-in.
IMPORTANT: Tighten impeller nut using a dou
ble universal joint to avoid side load, which may
cause shaft to bend.
In s ta ll c o m p re sso r w heel and tig h te n n u t w ith 18

to 20 lb-in th e n tig h te n th ro u g h an a n g le o f 90°.
L ith o in U.S.A.
30 Fuel System Grader, Motor - JD570
A!m> + /nissss OT\
smi /memc? uyoLan \LS&Lfw V //
A p p ly P erm a te x No. 1 J o in t S e a lin g C o m po u n d

o r an e q u iv a le n t to th e th re a d s o f th e tu rb o c h a rg e r
o il in le t lin e to o il in le t lin e a d a p te r. T h re a d s m u st
be fre e fro m o il to a ssu re an e ffe c tiv e seal.
NOTE: The portion o f air intake system between
the turbocharger and engine is not always
pressurized. Therefore, all connections in the
system must be tight.
W hen s ta rtin g e n g in e w ith a new o r re pa ired tu r

bocharger, d is c o n n e c t th e in je c tio n pum p e le c tric a l
s h u t-o ff s o le n o id w ire and c ra n k th e e n g in e w ith
th e s ta rte r u n til th e e n g in e o il p re ssu re g a ug e
p o in te r m oves o ff le ft in d e x m ark.
L ith o in U.S.A.
TM-1001 (Nov-78) F u el In jection Pum p 20-1
Group 20
FUEL INJECTION PUMPS
ROOSA MASTER, MODEL C PUMP E le c tr ic a l

(EARLY MODELS) Electrical system failure or low voltage at elec
tric solenoid shut-off.
GENERAL INFORMATION Test electric solenoid circuit.
Check electrical circuit.
The Roosa Master Model C Fuel Injection Electric solenoid failure.
Pump is mounted horizontally on the left side Test solenoid.
of the engine. The pump model and character Electric solenoid spring or plunger failure.
istics are shown in code form on the pump name Test solenoid.
plate. Plunger seal failure.
The pump is aspeed advance, single cylinder, Replace seal.
opposed plunger, internal bypass, distributor Fuel leaking at electric solenoid shut-off.
type. Tighten to specifications. Replace hole plug
seal or solenoid assembly if necessary.
DIAGNOSING INJECTION PUMP
MALFUNCTIONS M e c h a n ic a l
Pump timed incorrect to 6ngII16.
If fuel system diagnosis has isolated the mal- Correct timing, tighten pump mounting nuts.
■LLLUL/UXUU IU U1C XUC1 tliJCL/LUJli pUJ.li.pj U1C iU U U W lilg
guide may be used to determine injection pump Check installation and adjust linkage (Section
malfunction without r@movxng ttic injection pump on rvai *u u jj. on\
from the engine. Malfunctions are listed in three Automatic advance faulty or notoperating.
IT T T ? r ,f T ’D T r i A T
JU U U W > X i v x v n x i i
P V i a ,- I t t o m a q 1 r n i t
X' w u u , OUU 1UXJ ’ L'UCLXt CLUV UUU
CHANICAL. Slow and fast idle adjustment incorrect.

Adjust to specifications; tighten lock nut.
F uel
Fuel inlet line clogged or restricted. REMOVAL
Blow out inlet line with filtered air.
Fuel inlet line leaking. Before removing fuel injection pump thor
Tighten to specifications. Replace if damaged. oughly clean the pump, fittings, and all connec
Pump housing not full of fuel. tions to be disconnected.
Operate engine for approximately 5 minutes
until pump fills with fuel. IM PORTANT: Never spray cold water on or
Excessive air in pump housing. steam clean a warm injection pump.
Bleed injection pump.
Fuel injection line connected to wrong cylinder or Fuel injection pump and engine should be
leaking. static timed before injection pump is removed
Relocate lines for correct engine firing se (see "INSTALLATION").
quence, tighten to specifications and replace
if damaged. Drain radiator and remove lower radiator
One or more injection line connector screws ob hose.
structed.
Clean or replace. Remove solenoid shut-off wiring lead at pump.
Fuel return line clogged or restricted.
Blow out return line with filtered air. Remove access plate from engine timing gear
Fuel leaks at fittings in hydraulic head or drive cover (Fig. 1).
housing.
Tighten fittings to specifications and replace
seals where required.
Litho in U .S.A .
30 F u el S y ste m Grader, Motor - JD 570
2 0 -2 F u el In jectio n S y ste m TM-1001 (Nov-78)
F ig . 1—In je c tio n Pump D riv e Gear Cap Screws

Test Solenoid as Follows:
1. Test electrical system for failure or low
Remove gear mounting screw with retainer voltage (Section 40). See "Specifications" for
and three retaining screws (Fig. 1). voltage required to energize solenoid.
Disconnect all lines and control linkage. 2. With solenoid shut-off and all component parts
(Fig. 2) removed from injection pump, attach wiring
Cap or plug all line openings. lead to solenoid. Hold finger over plunger seat to
retain spring and plunger.
Mark position of pump mounting flange to
engine front plate. 3. Ground solenoid.
4. Turn key switch to "ON" position. If sole
Remove pump from engine. noid fails to partially retract the plunger, low
voltage or solenoid failure is indicated.
REPAIR
INSTALLATION AND TIMING
For detailed information and specifications
refer to John Deere Service Manual SM-2045, The fuel injection pump and engine must be
"Testing and Servicing Fuel Injection Pumps static timed!
and Nozzles."
D r iv e G ea r
If fuel injection pump drive gear requires
servicing, the engine timing gear cover must be
removed. See Section 20, Group 10 for gear re
moval and timing.
S o le n o id S h u t-O f f
Use special tool (solenoid screwdriver) and
remove solenoid shut-off from injection pump.
The solenoid shut-off is energized to run.

Electrical or solenoid failure will cause the
plunger to return to the "OFF” position.
F ig . 3 —T im in g In je c tio n Pump to E ngine
L itho in U .S.A .
TM-1001 (Nov-78) F u el Injection Pum p 2 0 -3
1. Set engine to TDC (see Section 20, Group ADJUSTMENTS

10) .
C am A d va n ce
2. Rotate pump drive shaft until pump timing 1. Be sure that injection pump is static
pin drops in place. timed to engine.
2. Install timing window (Fig. 4).
3. Position injection pump over mounting
studs and install hex. nuts and -washers, having 3. Bring engine to operating temperature.
hex. nuts loose enough to rotate the injection
4. Adjust cam advance by removing seal cup,
pump.
loosening lock nut, and turning advance trimmer
screw. Turn screw in to retard; turn screw out
4. Secure injection pump to drive gear with
to advance.
three new retaining screws and gear mounting
screw.
5. Align mounting flange and engine front

plate if marked before removal. Tighten mount
ing stud nuts.
6. If position of injection pump was not mark

ed before removal, reverse the timing pin and
slowly rotate the injection pump until the timing
pin drops into position. Engine should now be at
TDC. Tighten mounting stud nuts. Connect lines
as shown in Fig. 3.
7. Install radiator lower hose and fill radia

tor with specified coolant.
F ig . 4 —A d ju s tin g Cam Advance
BLEEDING INJECTION PUMP
Note the following.
1. Bleed the fuel system (see operator's
manual).
Each circle on the timing window equals 2
degrees advance. Use the hole in the center of
Additional bleeding, as follows, may be nec
the cam pin for reference.
essary to dispel all air from the injection pump.
When the hole in the center of the cam pin is
2. Use transfer pump primer until a quantity
directly in the center of the bull's-eye, the in
of air-free fuel flows from the injection pump in
jection pump is 5 degrees advanced.
let line. Fasten inlet to pump securely.
When checking cam advance start at the 5-
3. Continue priming until air-free fuel flows
degree advance position, working out from this
from the timing pin hole. Install and tighten the
timing pin. center point in both advance and retard direc
tions.
4. Loosen electric shut-off solenoid two full Cam advance positions are given in "Speci
turns and prime until air-free fuel flows from fications.”
this point.
5. Tighten lock nut and install seal cap and
5. Tighten solenoid and connect terminal
wire. seal.
If fuel injection pump cam advance cannot be
6. Crank the engine and tighten injection line
connector screws at the injection pump when fuel adjusted to specifications, remove pump for ad
flows from them. justment on test stand as described in Service
Manual SM-2045, "Testing and Servicing Fuel
7. Tighten ebnnector nuts at nozzles when Injection Pumps and Nozzles."
lines are filled.
L itho in U .S.A .
2 0 -4 F u el In jectio n Pum p TM-1001 (Nov-78)
ROOSA MASTER M ODEL CB PUM P REPAIR

(LA TE R MODELS)
For detailed disassembly procedures and
GENERAL INFORMATION specifications refer to service manualSM-2045,
"Testing and Servicing Fuel Injection Pumps
The Roosa Master Model CB Fuel Injection and Nozzles."
Pump is mounted horizontally on the left side of
the engine. The pump model and characteristics D r i v e G e a r a n d S h a ft
are shown in code form on the pump name plate. If the drive gear requires servicing, the en
gine timing gear cover must be removed. See
The pump is a speed advance, single cylinder, Section 20, Group 10 for timing gear removal
opposed plunger, inlet metering distributor type. and timing.
D iesel fuel is delivered from the fuel tank to If the drive shaft requires servicing, remove
the fuel filter by a diaphragm-type fuel pump. the engine timing gear cover access plate. Care
Fuel is pulled from the fuel filter by the vane- fully remove the access plate as thrust from the
type transfer pump in injection pump. pump thrust spring is applied to the access plate.
Use care not to drop thrust spring or retainer.
DIAGNOSING INJECTION PUMP
MALFUNCTIONS Remove the three cap screws retaining the
drive shaft to drive gear.
E n g in e W on’t S ta r t
Static timing 180 degrees off. The pump drive shaft can now be removed from
Check timing (see ' 'Installation and Timing"). the same side of the engine front plate that the
See page. 20-1 for additional diagnosing infor injection pump was removed.
mation.
S o le n o id S h u t-O f f
REMOVAL See page 20-2 for repair information.
Before removing the fuel injection pump, INSTALLATION AND TIMING

thoroughly clean the pump, fittings, and all con
nections to be disconnected. 1. Rotate pump drive shaft until timing pin
drops in place. Observe pin carefully as it
IM PO R TA N T: Never spray cold water on or drops - only 1/16 inch.
steam clean a w arm injection pump.
2. If engine has not been set on "top dead
Fuel injection pump and engine should be center" rotate engine in direction of rotation
static timed before the injection pump is re (counterclockwise) as viewed from flywheel end
moved (see "Installation and Timing"). until No. 1 cylinder is on compression stroke.
Insert engine timing pin in flywheel hole.
Remove solenoid shut-off wiring lead at pump.
3. If the drive shaft was removed from the
Disconnect all lines and control linkage. timing gear, install drive shaft to timing gear
using three new retainer screws, and tighten to
Cap or plug all line openings. specifications. Install thrust spring and guide.
Install access hole cover.
N O T E : It i s n o t n e c e s s a r y to r e m o v e th e a c
c e s s p la te f r o m th e e n g in e tim in g g e a r c o v e r 4. If the drive shaft was not removed from
to r e m o v e th e M o d e l C B F u e l I n je c tio n P u m p . the timing gear, install the injection pump making
sure that reference mark on the drive shaft aligns
Remove mounting stud nuts and remove pump with the ref erence mark on the rotor in the pump.
from engine.
5. Insert timing pin and slowly rotate the in
jection jpump until the timing pin again drops into
position. Tighten mounting stud nuts.
L itho in U .S.A .
TM-1001 (Dec-87) Fuel Injection Pumps 20-5
The engine and in je ctio n pump are now sta tic 10. If removed, install radiator lower hose and fill
timed. radiator w ith specified coolant.
6. Remove engine tim in g pin and pump tim in g BLEEDING INJECTION PUMP
pin.
See page 20-3.
7. Connect all lines and solenoid shut-off w iring
lead. ADJUSTMENTS
8. Bleed the fuel system (see operator’s manual). Cam Advance

See page 20-3.
9. Tighten fuei supply line and injection line
connectors.
ROOSA MASTER MODEL JDB PUMP
GENERAL INFORMATION Remove the pump m ounting nuts and slide the
pump in a straight iine away from the engine.
The Roosa M aster M odel JDB Fuel Injection
Pump is m ounted horizontally on the ieft side of The pump drive gear and shaft w ill remain on the
the engine. The pump m odel and characteristics engine fro n t plate.
are shown in code form on the pump name plate.
REMOVING AND INSTALLING INJECTION PUMP
The pump is a speed advance, single cylinder, DRIVE SHAFT
opposed plunger, inlet m etering, d istrib u to r type.
The injection pump drive shaft can be removed
DIAGNOSING INJECTION PUMP w ith o u t removing the tim ing gear cover. Remove
MALFUNCTIONS access plate, th ru st spring and pin from end of
shaft. Remove nut from the end of the drive shaft.
C n /i/r irt
U .I i y i I IC7
1A! n !+ O t o r f
VVW l I I U1CU L
S ta tic tim in g 180° off. Install JD303 injection pump shaft removal tool
rW
' hl I^
oVrS‘Lr t im in n / co o
IV mi l l i ng
“ IIIUlW
I n e + a lIIM
l a +ilVIl
ir m a n r l T.....i...m
MIIU
i n n ’^/•
........
r\n t i m i n n n o o r n nv/ar T i n h t o n n o n t o r n a n VVIVII
VII Ul I III 1^ ^wui WTVI ■ I 1^1 IIVI I W l IIVI
cnrovA/ U
ulnIII!
t il
(See page 20-1 fo r a d d itio n a l d ia g n o s in g tig h t against injection pump drive shaft.
inform ation.) Place tubular type driver over injection pump
drive shaft against injection pump gear. Use a (12
REMOVAL oz.) hammer to hit the end of driver.
If injection pump drive shaft does not come out
Before removing fuel injection pump, thoroughly of injection pump gear, hold a heavy bar or ham
clean the pump, fittin g s , and all connections to be mer against JD303 tool center screw, h ittin g driver
disconnected. harder.
If injection pump drive shaft s till does not come
IMPORTANT: Never spray cold water on or steam out of gear remove tim in g gear cover (Group 0402)
clean a warm injection pump. to remove shaft and gear.
To in stall shaft, place key in shaft. Place shaft
The fuel injection pum p and engine should be in gear and attach nut to shaft. Tighten nut to 35
s ta tic tim ed before the in je ctio n pump is removed ft-lbs.
(see “ Installation and T im in g ” ).
If it is desired to remove the pump drive gear with
Removing Injection Pump From Drive Shaft shaft from the engine, the tim ing gear cover m ust
D isconnect electric sh u t-o ff lead, fuel supply, be removed (see Section 20, Group 10).
fuel return and injection lines from the pump. Plug
all openings.
Disconnect the th ro ttle linkage and wire th ro ttle

lever in wide open position before removal of pump
to prevent loosening o f internal parts.
L ith o in U.S.A.
2 0 -6 F u el In jectio n P u m p s TM-1001 (Nov-78)
REPAIR
For detailed information and specifications

refer to John Deere Service Manual SM-2045,
"Testing and Servicing Fuel Injection Pumps and
Nozzles".
D r i v e S h a ft a n d G e a r
Remove thrust spring and pin from gear end
of shaft.
Loosen nut until flush with end of shaft and

press gear from shaft taper.
Remove nut and gear from shaft.
Inspect gear for wear or chipped teeth.
Inspect tang on drive shaft for wear. It must

be at least 0.305 in. thick.
F ig . 5 —Tim in g L in e s
Inspect wear surfaces on drive shaft.
If engine has not been set on "top dead cen
Check seals on drive shaft for hardness or ter" (No. 1 cylinder on compression stroke) ro
cracked condition. Examine seal grooves on shaft tate engine in direction of rotation (counterclock
for smooth finish. Any roughness at these points wise as viewed from flywheel end) until No. 1
will cause seal failure. cylinder is on compression stroke. Insert timing
pin in flywheel as the flywheel is rotated and
Apply a generous coat of lubriplate to the drive comes in registry. Engine is now set at "top
shaft seals and slide seals into grooves using dead center."
Drive Shaft Seal Installation Tool (13369). The
seals must face in the opposite directions. Apply Install pump over shaft, making sure that re
Lubriplate liberally around the shaft between the ference mark on drive shaft tang aligns with mark
seals. on the slot end of the distributor rotor in the
pump.
Install gear on shaft using key and keyway to
locate gear on shaft. Tighten hex. nut to 420 Incorrect assembly of shaft into pump w ill
in-lbs. result in tim ing e rro r of 180 degrees.
INSTALLATION AND TIMING Using Drive Shaft Seal Compressing Tool

(JD256 or 13371) compress seals on shaft and
If removed, install injection pump gear and slide pump in place (Fig. 6).
shaft on engine front plate. See Section 20, Group
10 for timing injection pump gear. IM PO RTANT: Do not turn drive shaft seals
m/Ai^ u rk i Ia v n c f n l 11 I'f i^ a e le tfiw r o Je f a I t e frtrt
v v c i v v i i i i^ i i i ^ v v i M i i i ^ t ii i w ^ i e t w n w w 19 i v i i )
Install engine timing gear cover (if removed). and check position of seals. If seals have been
forced back, replace seals.
With timing window (JD259 or 13366) in place,
check to be sure that timing line on governor Install hex. nuts and tignten finger tight. Ro
weight retainer hub registers with the line on the tate pump first in the direction of rotation and
c-------
a m \ -----
(E ioO--' R).
~ • then in the opposite direction and again register
timing lines to take up a ll backlash. Tighten
mounting nuts.
Recheck pump timing.
L ith o in U.S.A..
Grader, Motor - JD570 F u el S y stem 30
TM-1001 (Nov-78) F u el Injection Pum ps 2 0 -7
C am A dvan ce
1 — Mounting Studs 3 — Seal Compressing T ool

2 - Seals (JD256 or 13371)
F ig . 6 —Compressing D rive Shaft S e a ls .
Connect injection lines using new washers. F ig . 7 —A d ju s tin g Cam Advance
Tighten connections to 420 in-lbs. 1. Be sure that injection pump is static timed
to engine.
N O T E : B e s u r e e a c h in je c tio n lin e i s c o n
n e c te d to th e p r o p e r in je c tio n p u m p o u tle t. N o. 2. Install timing window (JD259 or 13366).
1 in je c tio n p u m p o u tle t i s a t f o u r o ’c lo c k p o s i
tio n ( v ie w e d f r o m en d p l a t e w ith g o v e r n o r h o u s Note the location of the cam timing line. Due
in g on to p ). F o llo w th e e n g in e f i r i n g o r d e r , m o v to slight variations in windows and hole loca
in g c o u n te r c lo c k w is e f r o m th e N o. 1 o u tle t. tions, cam line may not be exactly behind window
line. Adjust timing window to get best possible
Connect fuel supply and return lines. Tighten line up.
only enough to keep lines from leaking.
3. Bring engine to operating temperature.
Connect throttle linkage.
4. See "Specifications" for engine speeds
Remove timing window and install timing win and cam advance position.
dow cover.
5. Adjust cam advance by loosening lock nut
Bleed fuel system (see Operator's Manual). and turning advance trimmer screw.
ADJUSTMENT N O T E : E a c h lin e o n th e tim in g w in d o w e q u a ls
Modification or alteration of the injection pump, tw o p u m p d e g r e e s .
the injection pump timing, or the fuel injection
nozzles in ways not recommended by the manu
Turn screw in to retard timing, turn screw
facturer will terminate the warranty obligation to out to advance timing.
the purchaser.
6. Secure trimmer screw with lock nut and
S p e e d C o n tr o l L in k a g e install seal cap.
See Section 20, Group 20.
L itho in U .S.A .
30 Fuel System Grader, Motor - J D 5 7 0
20-8 Fuel Injection Pumps TM-1001 (N o v -7 8 )
A plug or rivet may be used to plug the leak-

off line (Fig- 8). Be sure it is fully inserted in
leak-off hose to prevent leakage.
Litho in U.S.A.
TM-1001 (Dec-87) S pecification s and S pecial Tools 25-1
Group 25
FUEL TANK, FILTERS, AND TRANSFER PUMP
SPECIFICATIONS
Item Specification
Fuel tank capacity...............................................................................50 U.S. Gallons
Fuel transfer pump flow (A.C.) .......................................................... 27 gallons per hour at 900 engine rpm with 2
psi fuel outlet pressure
(A irte x )........................................................ 45 gallons per hour at 900 engine rpm with 2
psi fuel outlet pressure
Fuel transfer pump static pressure (A.C. and Airtex) .....................3.5 psi min. to 5.0 psi max. at 16 inches above
outlet at 900 engine rpm
AIR INTAKE SYSTEM

SPECIFICATIONS
AIR CLEANER RESTRICTION INDICATOR
Item Specification
Indicator Rating .. 25 ± 2 inches of water
TURBOCHARGER
Radial bearing m ovem ent........................................... 0.003 in. to 0.006 in.

Axial end p la y .............................................................. 0.001 in. to 0.004 in.
Intake manifold pressure............................................. 5 psi to 7 psi at 2300 rpm at fu ll load.
Minimum oil flow per minute from turbocharger drain
at 2500 rpm engine sp e e d..................................... 0.5 gallons
Exhaust adapter end p la y ........................................... 0.03 in. (1/32 in.)
TORQUE VALUES
Item T o rq ue (lb-in)
Turbocharger inlet hose cla m p ...................................................................

V-band coupling....................................................................................................... 4
Turbine housing to center housing ..................................... , ............................................................... 100 to 130
Thrust plate bolts....................................................................................................................................... 40 to 60
Impeller n u t...................................................................................................................................... 18to20
Intake manifold cap screw ...................................................................................................................... 35 Ib-ft
ASSEMBLY NOTES
After installing impeller nut and tightening to 18 to 20 lb-in, continue to tighten through an angle of 90 degrees.
Litho in U.S.A.
30 F uel System Grader, M o to r - JD570
25-2 S p e cifica tio n s a n d S p e cia l Tools TM-1001 (Dec-87)
AIR INTAKE SYSTEM (Continued)

SPECIAL TOOLS
No. Nam e Use
Essential Tools
JD-274 Turbocharger Snap Ring Insta llin g retaining rings.
A ssem bly Tool Kit
Convenience Tools
D-05022ST Water Vacuum Gauge and Fittings Test air intake system
AR45035 Cleaning Gun Clean dry air cleaner element
.......... Holding Fixture To hold turbine wheel (See Fig. 6)
.......... Dial Indicator Adapter Radial bearing check (See Fig. 7)
1/8"1/8" 1/8“
Fig. 2-Dial indicator Adapter

(Radial Bearing Check)
Fig. 1-Turbine Wheel Holding Fixture
Litho in U.S.A.
Grader, Motor - JD570 Fuel System 30
TM-1001 (Nov-79) Specifications and Special Tools 25-3
FUEL INJECTION PUMPS

SPECIFICATIONS
Item M easurem ent W ear Lim its (in.)
Drive tang (Model CB) Distance between flats 0.4620 (min.)

(Model JDB) Distance between flats 0.3050 (min.)
TUNE-UP DATA
Model CDC 633-4DG

Total advance m ovem ent......................................................................................................6 degrees
Advance at 1600 rpm (no load)............................................................................................ 4 degrees
Model CDC 633-18DG

Total advance movement ..................................................................................................... 8 degrees
Model CDC 633-25DG

Total advance movement ..................................................................................................... 8 degrees
Advance at 1600 rpm (no load).............................................................................................5 degrees
Models CBC 633-11AL and CBC 633-40AL

Advance by 2400 rpm ........................................................................................................... 8 degrees
Model JDB 633-AL2440 (units without turbocharger only)

Total advance movement ..................................................................................................... 6 ± 1 /2 degrees
Advance at 1150 rpm (no load)............................................................................................ 4±1 degrees
Model JDB 633-AL2486 (units without turbocharger only)

Total advance movement ......................................................................................................6 ± 1 /2 degrees
Advance at 1150 rpm (no load)............................................................................................ 4±1 degrees
Model JDB 635-AL2558 or JDB 635-MD2804

Total advance movement ..................................................................................................... 6 -0 + 1 degrees
Model JDB 635-AL2446 (Service Replacement Pump)

Total advance movement........................................................................................................... 6 ± 1 /2 degrees
Model JDB 635-AL2723 (Service Replacement Pump)

Total advance movement........................................................................................................... 6 -0 + 1 degrees
Litho in U.S.A.
30 F u el S y stem Grader, Motor - JD570
2 5 -4 S p e c ific a tio n s and S p e c ia l T o o ls TM-1001 (Nov-79)
FUEL INJECTION PUMPS (Cont.)
TORQUE VALUES (LB-IN)
Model JDB Model C Model CB
Low idle adjusting lock n u t .................... 20-25 20 to 25 20 to 25

Drive gear retainer screw ( 3 ) ---------- --------- 170 to 180 170 to 180
Gear mounting screw (1 )......................... ............ 100 to 110
Solenoid assem bly.................................... ............ 20 to 25 20 to 25
Timing p in .................................................. ............ 45 to 50 45 to 50
Fuel inlet and outlet fitting screws . . . 240 225 to 250 200 to 220
Fuel line connectors (s c r e w s ).............. 420 420 420
(studs).................... ............ 420
Advance pin hole plug............................... ............ 70 to 80 70 to 80
Throttle control cap................................. ............ 45 to 50 45 to 50
Drive shaft hex. n u t................................. 540
TESTS
ELECTRIC SHUT-OFF SOLENOID
Voltage required to energize (Model C, CB, and JDB Pum ps)...................................... 8 to 12 volts
SPECIAL TOOLS
No. Name Use
ESSENTIAL TOOLS
M odel JD B
13369 Installation Tool Install drive shaft seal
JD256 (13371) Compressing Tool Compress drive shaft seal
JD259 (13366) Timing Window Adjust cam advance
M o d el C and CB
JD270 (17180) Timing Window Adjust cam advance
CONVENIENCE TOOL
M odel C a n d CB
18683 Solenoid Screwdriver Remove and install electric shut-off
(formerly 17358)
L ith o in U-S.A.
Grader, Motor - JD570 Electrical System 40
TM-1001 (Dec-87) Description and Wiring Diagrams 5-1
Section 40
ELECTRICAL SYSTEM
GROUP 5 - DESCRIPTION AND WIRING GROUP 15 - CHARGING SYSTEM—
DIAGRAMS Continued
General In fo rm a tio n .......................................5-1A Engine Ser. No. (130706- ) Page
Precautions .................................................... 5-1A Repair ............................................................... 15-3
W iring D ia g ra m s .............................................5-1A Disassembly..................................................... 15-4
Removing Body C onnectors from Assembly....................................................... 15-8
W ires (Early U n its )...................................... 5-25 Test After Assem bly....................................... 15-8
Removing Body C onnectors from Installation........................................................ 15-9
W ires (Later U n its ).......................................5-26 Specifications................................................... 15-9
Remove and Install A lte r n a to r -
GROUP 10 - CHARGING SYSTEM Later Units ................................................. 15-11
Engine Ser. No. ( -130705) Disassemble and Test A lte r n a to r -
Alternator and R egulator................................ 10-1 Later Units ................................................. 15-12
System T e s ts ................................................... 10-1 Assemble A lte r n a to r -
Diagnosis.......................................................... 10-2 Later Units ................................................. 15-14
Repair .............................................................. 10-3 A lternator S p e cification s—
Alternator T e s ts ............................................... 10-5 Later Units ................................................. 15-15
Assembly.......................................................... 10-7 A lternator Service Equipment
Batteries .......................................................... 10-7 and Tools— Later U n its ............................15-15
Battery Tests ................................................... 10-8
GROUP 20 - STARTING MOTOR
Specifications................................................... 10-9
Delco Remy Starting Motor............................. 20-1
General Inform ation..................................... 20-1
GROUP 15 - CHARGING SYSTEM
Diagnosis and Tests.................................... 20-1
Engine Ser. No. (130706- )
R e p a ir........................................................... 20-3
Diagnosis and T e stin g .................................... 15-1
A ssem bly..................................................... 20-6
Battery T e s ts ................................................... 15-1
Installation..................................................... 20-7
Wiring T e s ts ..................................................... 15-1
Specifications........................................... 20-14
Circuit T e s ts ..................................................... 15-1
John Deere Starting M o to r............................. 20-8
Regulator T e s ts ............................................... 15-3
General Inform ation..................................... 20-8
Testing........................................................... 20-8
R e p a ir...........................................................20-11
Assembly ..................................................... 20-12
Installation.................................................. 20-13
Specifications............................................... 20-15
GROUP 25 - MISCELLANEOUS COMPONENTS
Windshield Wiper Motor
General Inform ation.................................... 25-1
R em oval....................................................... 25-1
R e p a ir........................................................... 25-1
A d ju s tm e n t................................................. 25-2
Hour M e te r................................................. 25-2
Litho in U.S.A.
40 Electrical System Grader, Motor - JD570
5-2 Description and Wiring Diagrams TM-1001 (Dec-87)
Grader, Motor ■ JD570 Electrical System 40
TM-1001 (Dec-87) Description and Wiring Diagram 5-2A
Group 5
DESCRIPTION AND WIRING DIAGRAMS
GENERAL INFORMATION WIRING DIAGRAMS
The 12-volt, negative-grounded electrical system Two types of wiring diagrams are illustrated below
may be either of two different types. One system uses and on following pages. The first includes wiring har
two 12-volt, batteries connected in parallel; the other nesses which will assist you during installation of a new
uses two 6-volt, batteries connected in series. Both harness. The second includes schematic diagrams of
systems use a 55-ampere Motorola alternator, a volt the various electrical circuits. These will assist you in
age regulator, and a heavy-duty starter. trouble shooting or when replacing individual wires.
Dangers With Batteries The first type of wiring diagram includes three main
harnesses, Figs. 1, 2 and 3. The one-piece wiring
Keep all sparks or open flames away from batteries
harness in Fig. 1, which includes two 12-volt batteries
as gas from the electrolyte is highly flammable.
connected in parallel, is used on graders with serial
Whenever the electrical system is to be serviced,
numbers up to and including 000681. The two-piece
disconnect the battery ground cable.
harness in Fig. 2, which includes two 6-volt batteries
When replacing batteries, be sure to install only the connected in series, is used on graders beginning with
correct type of batteries for the particular system used serial number 000682 and up to and including 001699.
in the grader being serviced. See battery descriptions
The two-piece harness in Fig. 3, which includes two
on page 40-10-9.
6-volt batteries connected in series, is used on graders
beginning with serial number 001700. Harnesses for
Polarity Precautions headlights, work lights, signal lights and cab acces
Never polarize the alternator or regulator. Never sories are the same for all graders.
ground a terminal. If either the alternator or regulator is
disconnected, be sure it is reconnected before con
necting the batteries.
Disconnect positive battery terminals when charging
grader batteries. Disconnect negative battery ground
cable when arc welding on the grader.
Litho in U.S.A.
5-2B Description and Wiring Diagrams TM-1001 (Dec-87)
The second type of wiring diagram includes Figs. 8 If the battery has a specific gravity reading of 1.150
through 26. Figs. 8 through 15 illustrate 12-volt batter or lower, disconnect battery cables and charge it until
ies connected in parallel. Figs. 16 through 25 illustrate the specific gravity reading is 1.150 or above before
6-volt batteries connected in series. Fig. 26 illustrates using a battery charger as a booster.
cab wiring.
IMPORTANT: Do not attempt to jerk wires out of
John Deere battery chargers can be used as a body connectors. See page 40-5-25 for proper
booster to start the engine. procedure in removing connectors from wires.
IMPORTANT: A battery charger should not be
used as a booster if a battery has a very low charge
(1.150 specific gravity reading or lower). A low
charged battery greatly increases the possibility of
connecting the charger to the battery in reverse,
and it is possible to reverse the charge on a bat
tery. If this is done the alternator diodes or the wire
harness may be damaged.
Fig. 1-Main Wiring Harness - One Piece Type

(Used Below Unit Serial Number 000682)
Litho in U.S.A.
Grader, Motor - JD570
E le c tr ic a l S y stem 40
TM-1001 (Nov-78) D e sc r ip tio n and W irin g D ia g ra m s 5 -3
R/W
T2 422 9
F ig . 2 -M a in W iring H arness - Tw o-P iece Type

(U sed Above U n it S erial Number 000681)
R/W
R/W
R /W DBL
R BR/W
T2 3249 R/W
R IW
F ig . 3—Main W iring H arness — Tw o-P iece Type

(U sed A bove U n it S erial Number 0Q1$99)
Litho in U .S.A .
40 E le c tr ic a l S y stem Grader, Motor - JD570
5 -4 D e sc r ip tio n and W irin g D ia g ra m s TM-1001 (Nov-78)
WIRING COL OR CODE

B -BLACK OR -ORANGE
BL -BLUE OR/B - O R A N G E AND B L A C K
BR - BROWN P/B - P I N K AND B L A C K
BR/W - B R OWN AND WH I T E PR -PURPLE
DBL - D A R K BLUE PR/W - P U R P L E AND W H I T E
DG - D A R K GREEN R -RED
G -GREEN R/W - R E D AND WH I T E
LBL - L I G H T BLUE T -TAN
LBL/k - L I G H T B L U E AND WH I T E W -WHITE
LG - L I G H T GR EE N Y -YELLOW
LG/W - L I G H T G R E E N AND W H I T E Y/B - Y E L L O W AND B L A C K
F ig . 5 —F ro n i Work L ig h t W iring Harness
Litho in U .S.A .
Grader, Motor - JD 570 E le c tr ic a l S y stem 40
TM-1001 (Nov-78) D e sc r ip tio n and W irin g D ia g ra m s 5 -5
L itho in U .S .A .
5-6 Description and Wiring Diagrams TM-1001 (Dec-87)
W I R I N G COLOR CODE
B - B LA C K O R /B - ORANGE AND B LA C K
BR - BROWN P /B - P I N K AND B LA C K
B R /W - BROWN AND W H I T E PR - PURPLE
DBL - DARK B LU E P R /W - P U R P L E AND W H I T E
DG - DARK GREEN R RED
G - GREEN R /W - RED AND W H I T E
LBL - L I G H T B LU E T TAN
LB L /W - L I G H T B LU E AND W H I T E W W H ITE
LG - L I G H T GREEN Y Y E LLO W
L G /W - L I G H T GREEN AND W H I T E Y /8 - Y E L LO W AND B LA C K
OR - ORANGE US1$0
F ig . 8 -S ta rtin g and C harging C irc u its

(1 2 -V o lt B a tte rie s C onnected in P a ra lle l)
E ngine Ser. No. ( -130705)
Litho in U.S.A,
TM-1001 (Dec-87) ________________________________________ Description and Wiring Diagrams 5-7
F ig . 9 —S tartin g and Charging C irc u its

E ngine Ser. No. (130706- )
L itho in U .S.A .
40 E le c t r ic a l S y ste m Grader, Motor - JD 570
5 -8 D e sc r ip tio n and W irin g D ia g r a m s TM-1001 (Nov-78)
W I R I N G COLOR CODE'
B - B LA C K O R /B - ORANGE AND BLA CK
D6 - DARK GREEN R RED
L B L /W - L I G H T B LU E AND W H I T E W W HITE
L G /W - L I G H T GREEN AND W H I T E Y /B - Y E L LO W AND B LA CK
OR - ORANGE U6t60
H E A D L IG H T " " H E A D L IG H T
-Y / B -
-O R / B -
HIG H BEAM
IN D IC A T O R D R IV IN G
" f t LG
L IG H T
SWITCH
- T
_SJ
-B R -
-L B L -
LBL R
BR i — FUSE
f-TRl II IW1-W-
DIM M E R
SWITCH
B A T T E R Y ------^ A l L u ,
KEY SWITCH
o
LG
LG
LBL
LG
LG OR/B
-L G - — O R/B-
T Y/B -Y/B—1
■B R -
B A T T E R Y ------- -- ____________ i ______________________________

- BATTERY
—• “
H i- 4
BR
BR
DG-
R |
b |w
T A IL L IG H T T A IL L IG H T
F ig . 10—H e a d lig h t and T a illig h i C irc u its

Litho in U.S.A.
Grader, Motor - JD570 E le c tr ic a l S y stem 40
TM-1001 (Nov-78) D e sc r ip tio n and W irin g D ia g r a m s 5 -9
WORKLIGHT
Litho in U .S.A .
5 -1 0 D e sc r ip tio n and W irin g D ia g ra m s_________________________________________ TM-1001 (Nov-78)
B - BLA C K O R /B - ORANGE AND BLA CK
BR - BROWN P /B - P I N K AND BLA CK
B R /W - BROWN AND W H IT E PR - P U R P LE
DBL - DARK BLUE P R /W - P U R P L E AND W H I T E
DG - DARK GREEN R RED
G - GREEN R /W - RED AND W H ITE
LBL - L I G H T BLUE T TAN
L B L /W - L I G H T BLUE AND W H IT E W W HITE
LG - L I G H T GR-EEN Y YELLO W
LG /W - L I G H T GREEN AND W H IT E Y /B - YE LLO W AND BLA CK
OR - ORANG/ U6160
L E F T T U R N _ /- n
n -M jn e n ( - * ) „ __ RIGHT TURN L e ri IU K N HIGH I I UKN
IN D ICATOR ^ 7
INDICATOR LIGHT LIGHT
I
LBL
rA
U -rJ
TDBL2
,
Y— P &— -J
fp tS rt ’eh M i SWITCH
n
B iV :.
LBL SWITCH DBL1 fE 5
I I DG
Y
DBL2
DG DG
fi B Y____Y B 5
DBL1 DBL2 DBL2 DBdUf l
w | l b l |[ l b l | W DBL1
DBL2 1
LBL
-W — W -R-1
— DBL1- DBL 1 R .-R -1
GROUND
X T '
FUSE. -FUSE
DG
LBL
DBL2
R/W W
R/W R/W w
R/W
BATTERY
-KEY SWITCH
L-=P©>
W
-L B L - LBL G
-D B L 2 ■ DBL2 R
STOP LIGHT
PRESSURE
SWITCH
-DG ■
BATTERY
\
+*■ .BATTER Y
4|— -
BR>_,yI BR- #-i •

dg^ b
" Ilf
BIW B’’tW
TA ILLIG HT AILLIGHT
F ig . 12 -S ig n a l L ig h t C irc u it
(1 2 -V o lt B a tte rie s Connected in P a ra lle l)
Litho in U.S.A,
TM-1001 (Nov-78) ________________ D e sc r ip tio n and W irin g D ia g ra m s 5-11
T R A N S M IS S IO N
U 6708
F ig . 13—Gauge C irc u its
L itho in U .S.A .
40 E le c tr ic a l S y ste m Grader, Motor - JD 570
5 -1 2 D e sc r ip tio n and W irin g D ia g r a m s TM-1001 (Nov-78)
6 - B LA C K O R /B - ORANGE AND B LA C K
DG - DA RK GREEN R RED
LB L /W - L I G H T B LU E AND W H I T E W W HITE
LG - L I G H T GREEN Y Y ELLO W
L G /W - L I G H T GREEN AND W H I T E Y /B - Y E L LO W AND B LA C K
OR - ORANGE U 6I60
L itho in U.S.A,
TM-1001 (Nov-78) D e sc r ip tio n and W irin g D ia g ra m s 5 -1 3
OBL - DARK BLUE P R /W - P U R P L E AND W H I T E
tj - GREEN K /W - RED AND V I H l T t
L8L /W - L I G H T B LU E AND W H I T E W W HITE
LG - L I G H T GREEN Y Y ELLO W
L G /W - L I G H T GREEN AND W H I T E Y /B - Y E L LO W AND B LA C K
OR - ORANGE U SISO
FUSE
F ig . 75—A cce sso ry C irc u its

E ngine Ser. No. (130706- )
Litho in U.S.A.
40 E le c tric a l System Grader, M o to r - JD570
5-14 D escription and W iring D iagram s TM-1001 (Dec-87)
F ig . 1 6 -S ta rtin g and C harging C irc u its

(6 -V o lt B a tte rie s C onnected in Series)
E ngine Ser. No. f -130705)
Litho in U .S.A .
Grader, M o to r - JD570 E le ctrica l System 40
TM-1001 (Dec-87)______________________________________________ D escription and W iring D iagram s 5-15
Fig. 17-Starting a n d C h a rg in g C ircu its

(6-V olt B atte rie s C o n n e c te d in S eries)
E ng ine Ser. No. (130706- )
L ith o in U.S.A.
40 E le ctrica l System Grader, M o to r - JD570
T6707AE
Fig. 18-Starting a n d C h a rg in g C ircuits

(6-V olt B atteries C o n n e c te d in Series)
(U se d A bove U n it S e ria l No. 001699)
L ith o in U.S.A.
G - GREEN R /W - RED AND W H IT E
L B L /W - L I G H T B LU E AND WH-t£E W W HITE
LG /W - L I G H T GREEN AND W H I T E r/B - Y E L LO W AND B LA C K
OR - ORANGE U 6160
h e a d l ig h t ■ H E A D L IG H T
■W
-Y B -
- O R /B ^ -r-
H IG H BEAM
IN D IC A T O R D R IV IN G
L IG H T
' “ Bf L,G
t SW ITC H
-B R -
-L B L-
LBL
B -F U S E
R &
D IM M E R
SW ITC H
BATTERY'
key Sw it c h
O
LG
LG
LBL
Lm J
O R /B
-L G - IG — O R /B -
T Y /R -Y /B — 1
-B R -
BATTERY- -B A T T E R Y
4—
;1* 5 - STARTER
BR
-B R -
BR' r~ - B -
DG- 4
B BR —
t
B |W
r !
T A IL L IG H T I T A IL L IG H T
U S71I
F ig . 19—H e a d lig h t and T a illig h t C irc u it

(6 -V o lt B a tte rie s C onnected in S eries)
L itho in U.S.A,
40 E le c tr ic a l S y ste m Grader, Motor - JD570
BATTERY.
TAILLIGHT WORKLIGHT WORKLIGHT TAILLIGHT
F ig . 20 -W o rt L ig h t C ir c u it
( 6 - V o lt B a tte rie s C o n n e c te d in S e rie s )
Litho in U .S.A .
B - BLA C K O R /B - ORANGE ANO B LA C K
B R /W - BROWN AND W H IT E PR - P U R P LE
DBL - DARK BLU E P R /W - P U R P L E AND W H I T E
DG - DA RK GR EEN R RED
LBL - L I G H T BLUE T TAN
LBL/W - L I G H T B LU E AND W H I T E W W HITE
LG - L I G H T GR EEN Y YELLO W
LG/W - L I G H T GR EEN AND W H I T E Y /B - Y E LLO W AND BLA CK
OR - ORANGE U616Q
Fig. 2 ?—Signal L ig h t Circuit

( 6 - V o lt B a tte r ie s C o n n e c te d in S e rie s )
L itho in U.S.A.
40 E le c tr ic a l S y stem Grader, Motor - JD 570
WATER ENGINE OIL TRANSMISSION OIL TRANSMISSION

TEMPERATURE PRESSURE FILTER LIGHT OIL TEMPERATURE
r-Tfe
1W --Q ^F U E L
l_D
R/wl -R/W- - R IW - R/WJ
-Y / B -
DBL - B R/W — T
DG
L.
—
BR W -j—
- R IW - !±W
D BL
— rv
DG Y/B f
w
■FUSE
_l
r R W -w-
-R|W
-ACCESSORY
PR BATTERY—► _^K E Y SWITCH

REGULATOR J HOUR
DG -Y /B —1^ v
METER
„ T R A N S M IS S IO N
~BR/W - l _ p - ^ O IL T E M P E R A T U R E
S E N D IN G U N IT
B
WATER TEMPERATURE
SENDING UNIT
-Y / B -
DBL
I- — ] ENGINE OIL
W dg- I----- l * * ~ PRESSURE r \
SENDING UNIT T R A N S M IS S IO N O IL
o r /W F IL T E R B Y P A S S
S E N D IN G U N IT
FUEL SENDING
UNIT
P IB -
O IL P R E $ S U R E j 3 = . ■R |W -
SWITCH
- BATTERY
BATTERY-
-STARTER
- 5 0
F ig . 2 2 -G a u g e C ir c u its
( 6 - V o lt B a tte rie s C o n n e c te d in S e rie s )
(U s e d B e lo w U n it S e ria l N o . 0 0 1 7 0 0 )
Litho in U .S.A .
TM-1001 (Nov-78) D e sc r ip tio n and W irin g D ia g ra m s 5-21
W ATER E N G IN E O IL
T R A N S M IS S IO N O IL T R A N S M IS S IO N
TEM PERATURE PRESSU RE
F I L T E R L IG H T O IL T E M P E R A T U R E
FUEL
-f'-Tfr, IN J E C T IO N
PUMP
R/W R/W -F U E L
-R/W- J l -------R/W
D / W— I L . pR/W1
/ W*
-Y / B -
DG
DBL BR/W
T —1
□
BR W -R/W- ALTERNATOR
W E] R REG ULATO R
DBL
c|]-«— F U S E
DG Y/B
TT w OR PR G
R/VV
— R/W---------------- P R — =| h .
-A C C E SS O R Y
■L B L / W --------
KEY SW ITCH
BATTERY-
LBL/W
DG . HOUR
M ETER
_ T R A N S M IS S IO N
-B R / W - “ L P - * — O IL T E M P E R A T U R E
S E N D IN G U N IT
W A T ER T E M P E R A T U R E
S E N D IN G U N IT
-Y / B -
DBL
t h — E N G IN E O IL
PRESSU RE
S E N D IN G U N IT R/W T R A N S M IS S IO N O IL
F IL T E R BYP A SS
S E N D IN G U N IT
9
FUEL S E N D IN G
U N IT
O IL P R E S S U R E ____. D l
SW ITCH H J- -R/W-
BATTERY. -B A T T E R Y
-ST A R T E R
VT
F ig . 2 3 -G a u g e C irc u its
T2S2S1 (6 -V o lt B a tte rie s C onnected in Series)
(U sed Above U n it S e rial No. 001699)
Litho in U.S.A,
5-22 Description and Wiring Diagrams TM-1001 (Nov-78)
B -BLACK OR -O RANGE
BL -BLU E O R /B -ORAN GE AND BLA CK
BR -BROWN P /B - P I N K AND BLA CK
BR/W -BROWN AND W H IT E PR -PURPLE
DBL - D A R K BLUE PR/W - P U R P L E AND W H I T E
DG -D A R K GREEN R -R E D
G -G R E E N R/W - R E D AND W H IT E
LBL - L I G H T BLUE T -TAN
L B l/W - L I G H T BLU E AND W H I T E W -W H IT E
LG - L I G H T GREEN Y -Y E L L O W
LG /W - L I G H T GREEN AND W H I T E Y /B -Y E L L O W AND BLA C K
T 19667
PANEL LIGHT HORN BUTTON
FUSE
Fig. 24-Accessory Circuits

(6-Volt Batteries Connected in Series)
Engine Ser. No. ( -130705)
Litho in U.S.A.
TM-1001 (Feb-80) Description and Wiring Diagrams 5-23
M I R I N G COLOR CODE
B -BLACK OR -ORANGE
BL -B L U B O R /B -ORANGE AND BLACK
BR -BROWN P /B - P I N K AND BLACK
BR/W -BROWN AND W H ITE PR -P U R P L E
DBL -D AR K BLUE PR/W - P U R P L E AND WH ITE
DG -DARK GREEN R -R ED
G -G R E E N R/W -R E D AND WH ITE
LBL - L I G H T BLUE T -TA N
L B L /W - L I G H T BLUE AND WH ITE W -W H IT E
LG - L I G H T GREEN Y -Y E LL O W
LG/W - L I G H T GREEN AND WH ITE Y /B - Y E LL O W AND B L A C l /
T 196€7
PANEL LIGHT HORN BUTTON

[5 ]^
Bi--------------- ;----------R ------------
r
BEACON SWI TC H.
R — ^ ------------------------------ R --------
■D G ■
P/B ■
R R
- R/ W- EM E ------- R
- Y -
FUSE -fc.| 1 FUSE
DG
R / W __
K/VY
R/W ' -
W
YY
KI
w
R/W. ft/W w _J w
P/B R/V\f- ft/YY ____ I
YY
R/W
HORNS
HEATER - BA TT
-R/W-
/ \ \ R/ W
ACCESSORY
PR
KEY SWITCH
f_ T
R / W/ B
- P/B -R/W-
Y
R
■A L T E R N A T O R
- B ------------------ B -
- P R ------------------ P R - PR-
flb
r—R—1
T
REGULATOR
-* +
BATTERY- •B A T T E R Y
ff
STARTER
W
Fig. 25-Accessory Circuits
(6-Volt Batteries Connected in Series)
Litho in U.S.A.
5-24 Description and Wiring Diagrams TM-1001 (Feb-80)
MAIN WIRING HARNESS
Fig. 26-Cab Wiring
Litho in U.S.A.
Grader, M o to r - JD570 E lectrical System 40
TM-1001 (Dec-87) D escription and W iring Diagrams 5-25
WARNING LAMP
There are two suppliers of the AR38456 Warn

ing Lamp—Hobbs and Guide Lamp.
When a light bulb needs to be changed, BOTH

warning lamps will accept the AD2062 (General
Electric No. 1156) bulb.
Access to the bulb on the Guide Lamp warn

ing lamp is gained by removingthe three screws
on the lens face.
On the Hobbs warning lamp, remove the lock

screw and then remove the lens housing assembly Fig* 28—Removing Mo/e C onnector
by turning in direction indicated by arrow on base.
Using a knife or a screw driver, bend the
locking tang in as shown in Fig. 28. Remove wire
REMOVING BODY CONNECTORS
from connector.
FROM WIRES
Be sure to bend the locking tang out when as
To remove the body connectors is a very sembling new body connector.
simple job. DO NOT attempt to jerk the wires
out of the body connector. Use the following
procedures.
RESET
LOCKING TANG
T33S97N
F ig . 27—Removing Fem ale Connector
Insert a small screw driver orpaper clip into

the body connector and press the locking tang
down as shown in Fig. 27. Remove wire from
connector.
Be sure to bend the locking tang back up when

installing new body connector.
L ith o in U.S.A.
REPLACE WEATHER PACK™

CONNECTOR-
IM P O R TA N T: Id e n tify w ire c o lo r lo c a tio n s w ith

c o n n e c to r te rm in a l le tte rs .
1. Open connecto r body (A).
WEATHER PACK is trademark o f PACKARD ELECTRIC

TS0127
2. Insert JDG-364 Extraction Tool over term inal con

ta c t in co nnecto r body.
3. Hold extractor tool fu lly seated and pull wire from

conne cto r body.
NOTE: If terminal can not be removed, insert wire

or nail through extractor tool handle and push ter
minal contact from connector.
TS0129
L ith o in U.S.A.
Grader, M otor - JD570 E lectrical System 40
TM-1001 (Dec-87) Description and W iring Diagrams 5-27
IM PORTANT: C a refully spread contact lances to

assure good se a tin g in co n n e cto r body.
NOTE: Connector bodies are “keyed” for proper
contact mating. Be sure contacts are in proper
alignment.
4. Push contact into new connector body until

fu lly seated.
5. Pull on wire slig h tly to be certain contact is

locked in place.
TSOI 30
6. Transfer remaining wires to correct term inal

in new connector.
7. Close connector body.
INSTALL WEATHER PACK CONTACT
NOTE: Cable seals are color coded for three

sizes of wire:
a) Green - 18 to 20 gauge wire
b) Gray - 14 to 16 gauge wire
c) Blue - 10 to 12 gauge wire
1. Slip correct size cable seal on wire.
2. S trip insulation from wire to expose 6 mm (1/4

in.) and align cable seal w ith edge of insulation. TS0136
NOTE: Contacts have numbered identification

for two sizes of wire:
a) #15 for 14 to 16 gauge wire
b) #19 for 18 to 20 gauge wire
3. Place proper size contact on wire and use

JDG-144 Terminal A pplicator to crim p contact in
place w ith a “ W ” type crimp.
TS0137
Litho in U.S.A.
40 E lectrical System Grader, M otor - JD570
5-28 D escription and W iring Diagram TM-1001 (Dec-87)
4. Use JDG-144 Term inal A p p lica to r to secure

cable seal to contact as shown.
IM PO R TAN T: P roper c o n ta c t in s ta lla tio n fo r

“ sleeve” (A) and “ p in ” (B) is sh o w n .
SPECIAL TOOLS
No. Name
JDG-364 Extraction Tool

JDG-144 Terminal A pplicator
Litho in U.SA.
TM-1001 (Nov-78) Charging System 10-1
Group 10
CHARGING SYSTEM
Engine Ser. No. ( -130705)
GENERAL INFORMATION for broken wires, loose terminals, corroded or burnt
connection on the output stud, and corroded battery
The charging system consists of a 12-volt, 55-am-
posts.
pere-hour alternator, a sealed, solid-state regulator,
and either two 12-volt batteries connected in parallel,
or two 6-volt batteries connected in series.
The alternator, mounted on the right side of the
engine, has enclosed brushes and slip rings to prevent
damage from dirt entry.
The regulator is designed to compensate the alter
nator charging rate relative to temperature, giving a
higher charging rate in cold weather and a lower
charging rate in warm weather.
TESTING
When testing the alternator and regulator circuit,
note that the regulator’s function is to control only the
field current supplied to the alternator by sensing al
ternator voltage. The regulator does not contain a cut Fig. 1-Test No. 1
out relay or alternator output current limitation. Regu
lator failure will result in (1) no field current being Check voltage reading at the “ STA” terminal. If a
supplied to the alternator or (2) the alternator being voltage is read, a shorted positive diode is the cause.
given full field current without limitation.
NOTE: If voltage is read, it could also mean that
The alternator contains two completely independent insulation to the diode plate on the “STA" terminal is
circuits. One is the field circuit which is through the gone or ruined. Check for proper insulation before
brushes, slip rings, and rotor. This circuit provides the replacing a diode.
magnetic field which allows the alternator to charge.
The other, the output circuit, is through the stator and Test No. 2
diodes.
Turn key on, DO NOT start engine. Connect DC
The following tests are designed to isolate individual voltmeter to the field (FLD) terminal and to ground
circuits and check their operation. (GND) (Fig. 1).
Test No. 1 (A) If the voltage is higher than “ Specifications,” the

Make sure key is in “ OFF” position (Fig. 1). field circuit is defective; check brushes.
Check voltage from the alternator field (FLD) termi (B) If no voltage is read, check the regulator con
nal to the ground (GND). Any voltage reading indicates nections at the regulator and at the multiple connector
a faulty regulator. on the right side of the engine, and the red and white
Check voltage between OUTPUT terminal and (accessory) lead from the key switch.
ground (GND). It should be the same as that measured
at the positive (+) terminal of the battery. If voltage is To check the regulator circuit, disconnect the green
erratic or low, check the output connection. Also check field lead and insert the positive lead from the DC
voltmeter into the green lead terminal and the negative
voltmeter lead to ground.
Litho in U.S.A.
10-2 Charging System TM-1001 (Nov-78)
(C) If the voltage reads higher than “ Specifications,” Test No. 5 - Output Test
the trouble is in the alternator.
Use test 3 if readings are incorrect in test 2.
Test No. 3 - Field Draw Test

Make sure the key switch is in the “ OFF” position
and engine is stopped (Fig. 2). Disconnect the green
field wire at the alternator field terminal. Connect DC
ammeter from the output terminal to field terminal. This
test evaluates the complete field circuit, independent of
the voltage regulator. The circuit path is through the
brushes, slip rings, and field coil to ground. See
“ Specifications” for correct field current. If it is less than
this, check the brushes and slip rings.
Fig. 3-Output Test
Disconnect green wire from alternator field terminal

(Fig. 3). Disconnect regulator at the plug. Connect a
jumper wire from output terminal to field terminal.
Connect DC voltmeter to output terminal and to ground
terminal. Start engine and run at 1500 rpm.
This test isolates defects to either the alternator or

voltage regulator. If the voltage at the output terminal
rises to “ Specifications” when it did not with the regu
lator connected, the defect is in the regulator or key
switch and wiring to the regulator.
If the voltage does not rise at the output terminal and

Fig. 2-Field Draw Test
the field circuit checked out properly, the defect is in
the alternator stator or the rectifier diodes. For defects
It is necessary to use a field rheostate in series with
in the stator or diodes, remove the alternator.
the meter for protection of the meter. If the field is
shorted, excessive current will flow through the meter
CHECKING WIRING
and possibly damage it.
Clean corrosion from all connections and terminals
Test No. 4 - Running Test and inspect all wires for excessively frayed or worn
insulation.
Connect wiring, start engine, and run at approxi
mately 1500 rpm. Check voltage at the battery posts.
A regulator cannot function properly when a high
See “ Specifications” for correct voltage. Now connect
resistance is present in the charging system. Make
voltmeter to alternator output terminal and to ground.
sure regulator connections and battery connections
are clean and tight.
Correct voltage is the same as above. If the dif
ference between battery voltage and voltage at output
DIAGNOSING ALTERNATOR
terminal is greater than 1 volt, check wiring and termi
MALFUNCTIONS
nal to these points for corrosion or breaks.
Alternator fails to charge.
Alternator belts loose.
Stuck, excessively worn, open, or defective brushes.
Regulator doesn’t work.
Open rotor (field coil).
Litho in U.S.A.
TV1 o n + r i
WAVVIli 1VMA W
1 S t t c + ^ tvi
jr WV.V1U
A
—
fi
rw
Open or high resistance in charging or ground Replace brush assembly if brushes extend
return circuit or battery connections. less than 1/4-inch beyond the holder.
Low or unsteady charging rate. Remove pulley.

See ’’Alternator fails to charge.”
Also, check for shorted or open diode. Remove the four through bolts. Separate
Grounded or shorted turns in rotor (field front and rear housings, using two screwdrivers
coil).
Open, grounded, or shorted turns in stator.
Noisy alternator.
Loose pulley.
Misaligned or badly worn belt or pulley.
Worn bearings or shorted rectifier diodes.
R E P A IR
Disconnect battery ground straps first to pre

vent damage if leads removed from alternator
should be grounded.
Tag alternator wires to aid in installation.

Remove alternator.
Never immerse an alternator in cleaning solu

tion. Scrape off dirt and grease, then use a
stiff brush and solvent. Dry with compressed
air.
in stator slots between stator and front housing.
Never hammer or jar an alternator as the Remove rotor and front housing as an assembly.
diodes may be ruined.
To avoid damaging stator wiring do not in-
neier to rig. t as an aid wnenaisassemDimg sert screwdriver blades deeper than 1/16-inch.
and assembling the alternator.
To remove the slip ring end bearing, heat
Remove slip ring, brush dust cover, and and remove soldered rotor leads from slip ring
c ili n -v»4 w r r TToa IVwa A 9 1 C m i l l ft v
U1U911CD V-L' l g . *X/. V iC d ll LlU g,gCU U 1 UOilCO W ltll 0.1114 AClilW VC AAUg. C11C fA“ W1U
compressed air. Avoid using liquid as this in remove bearing. Install a new bearing, using
creases the possibility of dirt hardening in the tools A-208 and A-209 (Fig. 5). Also replace
brush cavity. O-ring bearing retainer in slip ring and frame.
Compress the ears of the front bearing re
tainer and lift washer to free it from the front
housing (Fig. 6). Remove frame by tapping on it
(use a block of wood) or, in stubborn cases, use
an A-216 puller. Pull off the front bearing.
Remove stator and diode assembly from the

rear housing. Carefully note locations of insula
tors and washers for proper reassembly. Do not
melt solder from stator-to-diode wire junctions.
Avoid bending stator wires at junction.
F ig . 4 - A lt e r n a t o r B ru s h e s a n d S lip R in g s
L itho in U .S.A .
1 0 -4 C harging S y stem TM-1001 (Nov-78)
In soldering and removing soldered leads

from diodes, grasp the diode lead with pliers
between the diode and the stator lead to be re
moved, This gives better heat dissipation and
protects the diode. Do not exert excessive stress
on diode lead.
Note the diode assembly in relation to stator

connections. Make certain replacement diode a s
sembly connections are the same. The positive
diode assembly has red printing and the negative
has black printing-DO NOT INTERCHANGE.
Use only rosin core solder when soldering

diode leads.
F ig . 6 - R e m o v in g F r o n t B e a rin g R e ta in e r
1 — No. 10 N u t (5 used) 11 - B o lt 21 — N ega tive D iode R ing

2 — No. 10 Lo ck Washer (7 used) 12 — No. 8 x 1 /2 ” S elf-T app in g Screw (2 used) 22 — R e c tify in g R ing Screw
3 — T e rm in a l 13 — In s u la to r 23 - S tator
4 - Washer (2 used) 14 — B rush Assem bly 24 — Cap Screw
5 — In s u la tin g Washer (5 used) 15 - A .C . Term inal 25 .— S lip R ing A ssem bly
6 - S e lf-T a p p in g Screw (2 used) 16 - Rear H ousing 26 - B earing (2 used)
7 — Rear H ousing C over 17 — Rear Bearing R etainer 27 — Rotor
8 — C over G asket 18 — In s u la to r Sleeve 28 — F ro n t Bearing R eta in er
9 — In s u la to r (2 used) 19 - C able A ssem bly 29 — F ront H ousing
10 - C able 20 — P o s itiv e D iode R ing 30 - Fan Spacer
F ig . 7 —E x p lo d e d V ie w o f A lte r n a to r
L itho in U .S.A .
Grader, Motor - JD 570 E le c tr ic a l S ystem 40
TM-1001 (Nov-78) Charging S ystem 1 0 -5
BRUSH ASSEMBLY INSULATION AND washers or sleeves on positive diode assembly

CONTINUITY TESTS would make diodes appear to be shorted.
In su la tio n T e s t: Connect ohmmeter or a test To check the negative diode assembly, con
lamp (12 to 120 volt) to field terminal and bracket nect tester to test points 1 and 2 as shown in
(test points A and B) as shown in Figure 8. Figure 9. Then successively check the two re
maining diodes in the same manner (ground
Resistance should be high (infinite) or test terminal and diode lead).
lamp should not light. If resistance is low or
test lamp lights, brush assembly is shorted and To check the positive diode assembly, con
must be replaced. nect tester to the output terminal and one of the
positive diode terminals. Repeat operation for
remaining two positive diodes.
RECTIFIER DIODE TEST USING A TEST LAMP
Test lamp will not indicate an open condition

unless ALL THREE DIODES of either assembly
are open. However, a shorted diode can be de
tected. This test is not 100 per cent effective
but can be used if so desired when an in-circuit
diode tester is not available.
IMPORTANT: DO NOT USE A 120-VOLT TEST

LAMP. USE A 12-VOLT DC TEST LAMP ONLY,
F ig . 8 - B r u s h In s u la tio n and C o n tin u ity
otherwise diodes will be damaged.
T e s t P o in ts
A . N e g a tiv e D io d e s - Connect t e s t lamp
C o n tin u ity Connect an ohmmeter to
T e s t: probes to test points 1 and 2 (Fig. 9), then re
field terminal and brush (test points A and C). verse test probes. The test lamp should light in
Use an alligator clip to assure good contact to one direction but not in the other. If the test
brush. Resistance reading should be "zero." lamp lights in both directions, one or more of
Move brush and brush lead wire to make certain the rectifier diodes of the assembly being tested
that the brush lead wire connections are not are shorted. If the test lamp does not light in
intermittent. Resistance reading should not vary either direction, ALL THREE DIODES IN THE
when brush and lead wire are being moved ASSEMBLY ARE OPEN. Recheck diodes indi
around. vidually after disassembly to ascertain findings
(Fig. 11).
Connect ohmmeter to bracket and grounded
brush (test points B and D, Fig. 8). Resistance A shorted stator coil to core would appear
reading should be ’’zero.” Repeat same test on as a shorted negative rectifier diode assembly.
brush lead wire as described in above para Also check stator for shorts after disassembly.
graph.
B . P o s i t i v e D io d e A s s e m b l y - Connect test
IN-CIRCUIT RECTIFIER DIODE TEST probes to auxiliary terminal and to terminal of
top position diode. Then reverse test probes.
Any commerical in-circuit diode tester will The same procedure and results apply as in
suffice to make this check. Follow tester manu paragraph "A."
facturer’s recommended testing procedure.
ROTOR LEAKAGE (SHORTS) TEST
If the in-circuit tester indicates that diodes
are faulty, recheck diodes individually after the This test checks the field coil for leakage
diode assemblies have been disconnected from or shorts to rotor poles. An ohmmeter or test
stator assembly (Fig. 11). lamp (12-volt or 120-volt) may be used.
Shorted stator coil or shorted insulating A. Remove the brush assembly.
L itho in U .S.A .
B. Connect ohmmeter or test lamp test If the test lamp lights in both directions, the
probes to one of the slip rings and ground stator winding is shorted to the stator, or one of
terminal. the negative rectifier diodes is shorted. Re
Ohmmeter resistance should be infinite or check stator and rectifier diode assembly (below)
test lamp should not light. If resistance is not after disassembly to ascertain findings.
infinite or test lamp lights, leakage or a short
exists between field coil and rotor. OUT-OF-CIRCUIT STATOR LEAKAGE
Repeat test after rotor has been removed (SHORTS) TEST
from alternator to ascertain findings. Connect
test probes to one of the slip rings and to rotor Disassemble alternator and remove the recti
shaft. fier diode plates and stator as an assembly as
shown in Figure 10.
IN-CIRCUIT STATOR LEAKAGE
(SHORTS) TEST
When making the "in-circuit" stator leakage

test, some consideration must be given to the
rectifier diodes that are connected to the stator
winding. The negative rectifier diode assembly
will conduct in one direction when properly
polarized. A shorted diode in the negative recti
fier diode assembly would make the stator appear
to be shorted. For this reason, the rectifier
diode plate assembly and stator must be checked
individually after alternator has been disassem
bled if the problem is localized to the stator.
DO NOT USE A 120-VOLT TEST LAMP. USE
A 12-VOLT DC TEST LAMP ONLY, or diodes An ohmmeter or test lamp (12-volt) may be
will be damaged. used.
A. Connect ohmmeter or test lamp probes to
one of the rectifier diode terminals and to stator
(test points A and B) as shown in Figure 10.
Resistance reading should be infinite or test
lamp should not light. If resistance reading is
not infinite or test lamp lights, high leakage or
a short exists between stator winding and stator.
In either case, stator should be replaced.
OUT-OF-CIRCUIT RECTIFIER DIODE TEST
If a commercial "Alternator Rectifier Diode

Tester" is used, follow the tester manufactur
er's recommended testing procedure.
If a commercial tester ohmmeter is not read
ily available, check diodes with a test lamp. DO
NOT USE A 120-VOLT TEST LAMP. USE A 12-
A. Connect the test lamp to a diode terminal VOLT DC TEST LAMP ONLY, or diodes will be
of the negative diode assembly and ground term i damaged.
nal (test points 1 and 2) as shown in Figure 9. When removing the solder from the stator
B. Then reverse test probes. The test lamp wires on the rectifier diode assembly, provide
should light in one direction but not in the other. a heat sink to the diode terminal with a pair of
If the test lamp does not light in either long-nosed pliers.
direction, this indicates that all three rectifiers
in the negative diode assembly are open.
L itho in U .S.A .
TM-1001 (Nov-78) C harging S ystem 10-7
Connect the test lamp probes to diode termi Press front housing onto rotor using tool
nal and diode plate stud (see Fig. 11) then re A-208, A-205, plain washers on top of A-205,
verse test lamp probes. The test lamp should and A-209 (Fig. 13). Install spacer and fan.
light in one direction but not in the other. Torque nut to '’Specifications.”
If the test lamp lights in both directions, the

diode is shorted. If the test lamp does not light
in either direction, the diode is open.
Test the remaining diodes of the assembly

in the same manner. Replace entire assembly if
one of the diodes is found to be faulty.
T IQS36
Fig- 1 2 - P r e s s in g in F r o n t B e a rin g
When testing with an ohmmeter, if a needle

deflection is observed with the positive lead to
the diode stem and negative lead to the case, the
diode is positive. The reverse is true for a nega
tive diode.
Positive diodes have red printing and nega

tive diodes have black printing. DO NOT INTER
CHANGE THEM.
ASSEM BLY
Assemble Stator and rear housing. Be sure F 'S- 1 3 - F r o n t H o u s in g a n d R o to r A s s e m b ly
insulators and washers are properly located. Be sure diode wires are properly positioned.
Assemble front and rear housings. Hand pres-
Press a new bearing into the front housing sure should be sufficient. The brush assembly
as shown in Figure 12. Install the bearing re- should be on the top. Torque through bolts to
tainer using a wooden dowel to compress the re- "Specifications.”
tainer waves, and seat with pliers.
BATTERIES
G E N E R A L IN F O R M A T IO N One battery box is located on each side of
the power unit.
The motor grader is equipped with two batteries.
Litho in U .S.A .
DANGERS WITH BATTERIES If any cell reads 1.95 volts or more and there
is a DIFFERENCE of 0.05 volt or more between
Gas from battery electrolyte is flammable; the highest and lowest cell, the battery is prob
keep away from all sparks or fires. ably defective.
Disconnect battery negative ( - ) ground straps If all cells test below 1.95 volts, the battery
when working on any part of the electrical sys charge condition is too low for this test. Boost-
tem or engine to avoid injury from sparks or a charge the battery by placing it on a charger at
short circuit. 60 amperes for 30 minutes and repeat the test.
Disconnect battery cables from positive (+) Disconnect positive battery terminals when
terminals before quick charging batteries on the charging batteries in the grader.
grader. Failure to do so may burn out the alter
nator diodes or the regulator. If charger will not charge 60 amperes, charge
at the highest rate available until battery has been
TESTS AND DIAGNOSIS charged 1,800 ampere-minutes. For example,
highest charger rate is 40 amperes; then charge
The electrical system in this unit is nega battery at 40 amperes for 45 minutes (40 amperes
tively grounded. When servicing the battery or x 45 minutes equal 1,800 ampere-minutes).
components, disconnect the negative ground
terminal first. SPECIFIC GRAVITY CELL COMPARISON TEST
LIGHT LOAD TEST Use this test only on batteries having one-
piece cell covers. Measure specific gravity of
Do not make light load tests on batteries each cell, regardless of state of charge.
with one-piece cell covers as this will damage
the cover. If specific gravity readings show a difference
between the highest and lowest cell of .050 (50
Inspect the battery visually. Add distilled points) or more, the battery is defective and
water to bring electrolyte to its proper level. must be replaced.
Remove battery surface charge by operating If the maximum difference between cell read
starter for three seconds (150-ampere load if ings is less than .050 (50 points) and the lowest
battery is off the unit). Prevent engine starting cell reading is 1.200 or above, corrected for
by disconnecting injection pump shut-off. temperature, the battery is in good condition
and may be returned to service.
Turn grader lamps on for one minute (10-
ampere load if battery is off the machine). If the maximum difference between cell read
ings is less than .050 (50 points) but the lowest
After one minute and with lights still on, cell reading is below 1.200, the battery is good
check individual cell voltages of the battery with but needs to be charged by the slow charge
an expanded scale voltmeter (calibrated one- method.
hundredths of a volt).
CONNECTING BATTERIES
On a good battery, sufficiently charged, the
voltmeter will read 1.95 volts or more, and the With key and light switch "OFF" and posi
difference between the highest and lowest cell tive terminals of batteries connected, tap the
will be less than 0.05 volt. negative battery strap to negative battery term
inal. No arcing should occur. If arcing occurs,
Readings above and below 1.95 volts and with do not make the connection. Check wiring sy s
a difference between cells of less than 0.05 volt tem for loose and corroded connections. Repeat
indicate a good battery that needs charging. the test.
Never attempt to polarize the alternator. To

do so may damage it.
L itho in U .S.A .
TM-1001 (Nov-78) C harging S y stem 10-9
Item Measurement
Alternator. . . . 55 amp.
Regulator . . . . Sealed, solid state
System Voltage 12-volt
Ground.............. Negative
Batteries
Specific gravity (corrected for 80° F. electrode temperature)........................... 1.215 to 1.270
Maximum variation between c e l l s ...................................................... 0.050 volts or 0.050 SP. GR.
When replacing the battery, use the John Deere battery or its equivalent shown in the following
chart.
Cold
C ranking Reserve
AMPS Ca pacify
John Deere BCI (M inutes at
P art Number Group 0 °F . -2 0 °F . 25 amps)
12 volts AR46115 (Serial Nos. up to 000681) 3ET 425 340 120

6 volts AR45450 (Serial Nos. 000682 up) 3EH 830 675 240
Fan Belt Tension

with gauge.......................................................................................... 80 to 85 lbs. strand tension
without gauge.................................................................................... 3/4-inch flex @ 20 lbs. force
A L T E R N A T O R AND R E G U LA TO R TESTS
Item Measurement
Test No. 2 - Key on, engine stopped . . (A). . 1-3 volts

(C) 8 volts maximum
Test No. 3 - Key off........................................... 2-2-1/2 amperes
Test No. 4 - Engine running @ 1500 rpm . . . 14.4 volts
Test No. 5 - Engine running @ 1500 rpm . . . 14-16 volts
TORQUES FOR HARDW ARE

Item Torques
Alternator pulley n u t ....................................................................... 40 to 50 ft--lbs
Alternator through b o lts ................................................................. .. 50 to 60 in--lbs
Brush mounting s c r e w s .................................................................. .. 16 to 20 in-lbs
Rear housing cover . ......................................................................... 20 to 30 in--lbs
Isolation diode lock n u ts.................................................................... 20 to 30 in--lbs
Litho in U .S.A .
40 E le c tr ic a l S y ste m Grader, Motor - JD570
1 0 -1 0 C harging S y stem _______________ TM-1001 (Nov-78)
S P E C IA L TOOLS
No. Name
A-201 Press Assembly

A-203 Drive End Bearing Installing Tool
A-205 Shaft Protector
A-207 Drive End Housing Support Tool
A-208 Rotor Holder
A-209 Bearing Removal and Pulley Installation Tool
A-216 Alternator Housing and Bearing Puller
L itho in U .S.A .
Group 15
CHARGING SYSTEM
GENERAL INFORMATION With the battery ground cable disconnected,
connect ammeter as shown in Fig. 1. Reconnect bat
The charging system consists of a 12-volt, 55-am-
tery ground.
pere-hour alternator, a sealed, solid-state regulator,
and two 6-volt batteries connected in series.
Start engine and obtain a charge rate of 10 amps. It
may be necessary to connect a carbon pile resistor
DIAGNOSIS AND TESTING
across the battery or to turn the lights on to obtain a 10
NOTE: The following test illustrate a later model amp. charge rate. With a voltmeter, check the system
alternator with an attached regulator. Refer to Group voltage drop between the points indicated in the chart
10 for early model alternators. in “ Specifications.”
The following tests isolate individual circuits Always use a pin connector to connect voltmeter to
res and check their operation. Refer to FOS-20 battery posts.
manual, Chapter 4, for additional diagnosis
e and tests. If voltmeter readings exceed the maximum listed in
thewiring test chart, high resistance usually exists in a
Battery Tests connection or component.
Make battery specific gravity test. See “ Specifica
When there is a high resistance present in the
tions.”
charging system, the regulator cannot control alterna
tor voltage and maintain the battery in a fully charged
If water is added more often than once every 200
condition.
hours, the system voltage is probably too high.
Circuit Tests
If specific gravity is low, the voltage may also be low.
Look for poor connections at the battery, starter, or - “ ““ I Make the following tests to isolate a faulty
alternator. F®6 component in the charging circuit. Follow the
test procedures explained in FOS-20 manu-
Wiring Tests ---®J al, Chapter 4.
T tt»77
Fig. 2-Voltmeter Connected to Regulator Terminal
Test No. 1
Connect a voltmeter to the regulator terminal and to
the ground terminal (Fig. 2).
Litho in U.S.A.
40 E lectrical System Grader, Motor - JD 570
15-2 Charging System TM-1001 (Nov-78)
With engine stopped and key switch and all With engine running at specified rpm, all ac
accessories off, the voltmeter should read cessories turned off, and the key switch on, the
specified voltage. See "Specifications." voltmeter should read specified voltage plus the
temperature corrected voltage listed in the chart
If reading is higher than specified voltage, under "Specifications."
the cause could be a shorted isolation diode, a
shorted key switch, a ground in the indicator Move the voltmeter lead from the regulator
lamp circuit, or a ground or slight electrical terminal to the output terminal (Fig. 3). The
leak in the key switch, light switch, or wire to voltmeter should now read approximately one
the light switch. volt less than it did at the regulator terminal. If
regulator terminal voltage is correct and output
T e s t N o. 2 terminal voltage is battery voltage, the isolation
Connect a voltmeter to the regulator terminal diode is open circuited.
and to the ground terminal (Fig. 2).
T e s t N o. 4
With the engine stopped and all accessories
off, turn the key switch on. The voltmeter should
read specified voltage. See "Specifications."
A reading above specified voltage usually

means a defective rotor field circuit. Loosen
fan belt and turn alternator. If reading is still
high, the trouble may be: an open circuit or high
resistance in alternator rotor field circuit,
defective brushes, disconnected regulator, or a
defective regulator.
A reading below specified voltage may be

caused by: a defective regulator, shorted rotor
field windings, or an open circuit in the indicator
lamp bulb.
F ig . 4 —A m m e te r C o n n e c te d to A lt e r n a t o r
If the voltage is not correct, make test num
ber 4. With the key switch off and engine stopped,
detach regulator and disconnect green wire from
T e s t N o. 3 alternator field terminal (Fig. 4).
Allow regulator to hang by red and black

wires. Do not allow regulator body to touch both
the grounded surface and the output term inal or
isolation diode assembly; to do so will probably
ruin wiring harness, alternator, or regulator.
Connect ammeter in series with a variable field
resistor to alternator field terminal and to out
put terminal.
The resistor prevents damage if field is

shorted. With all resistance eliminated, the am
meter should read specified amperes. See
"Specifications."
T 1692S
If reading is higher than specified, rotor field

F ig . 3 - V o lt m e t e r C o n n e c te d to O u tp u t T e rm in a l
windings or brushes may be shorted. If reading
is low, check brushes and slip rings for high
Connect a voltmeter to the regulator terminal resistance or an open circuit in rotor field
and to the ground terminal (Fig. 2). windings.
L itho in U .S.A .
TM-1001 (Nov-78) C harging S y ste m 1 5 -3
T e s t N o. 5 Connect a voltmeter with an accuracy of 0.1

volt to the alternator output terminal (Fig. 3).
Start the engine and turn the lights on (ap

proximately 10 amp. load). Run the engine for 15
minutes to stabilize regulator temperature.
Measure the regulator temperature and compare
the voltmeter reading with the temperature cor
rection chart under "Specifications."
N O T E : V o l tm e t e r r e a d in g a t r e g u l a t o r t e r
m in a l o f th e a l t e r n a t o r i s a p p r o x im a te ly 1 .0 v o lt
h ig h e r than a t th e o u tp u t te r m in a l.
If voltage is not within the lim its, stop engine

and with key switch off, replace the regulator. If
voltage with new regulator is not correct, the
1 — F ie ld Term inal 5 — R egulator
2 - V oltm eter 6 - Output Term inal difficulty must be in the grader wiring or the
3 — Ground Term inal 7 — R egulator Term inal isolation diode.
4 — R egulator D isconnected 8 — Jumper Wire
F ig , 5 —Jumper Wire d V oltm e ter C onnections
REPAIR
With key switch off and engine stopped, con BATTERIES

nect the jumper wire from alternator output ter
minal (Fig. 5) to field terminal (green wire was The electrical system in this unit is negative
disconnected in previous test). Do not allow reg ly grounded. When servicing the battery or
ulator to ground output term inal or isolation components, disconnect the negative ground
diode assembly; to do so will probably damage term inal firs t.
wiring harness, alternator, or regulator. Dis
connect regulator. Disconnect positive battery terminals when
charging batteries in the grader.
Connect voltmeter as shown in Fig. 5. Start
and run engine at specified rpm. If batteries are C o n n e c tin g B a t t e r i e s
fully charged, the voltmeter reading will be ap With key and light switch off and positive ter
proximately specified voltage. If grader batter minals of batteries connected, tap the negative
ies are not fully charged, it maybe necessary to battery strap to negative battery terminal. No
increase engine rpm slightly. arcing should occur. If arcing occurs, do not
make the connection. Check wiring system for
If specified reading was obtained in this test loose and corroded connections. Repeat the test.
(regulator disconnected), and if in test number 3
the voltage was below that specified (regulator WIRING
connected), then the regulator is probably defec
tive and should be replaced. Clean corrosion from all connections and ter
minals and inspect all wires for excessively
If voltage does not rise in this test, and the frayed and worn insulation.
field circuit checks OK in tests number 2 and 4,
then the trouble is in the stator or diodes and A regulator cannot function properly when a
the alternator should be removed for service. high resistance is present in the charging sys
tem. Make sure regulator connections and bat
REGULATOR TESTS tery connections are clean and tight.
The regulator must be checked with an alter

nator that is in good condition. If the alterna
tor is questionable, check it as previously in
structed.
L itho in U .S.A .
15-4 C harging System TM-1001 (Dec-87)
1 — Cap Screw 13 — Fan Spacer 25 — Screw

2 — Lock Washer 14 — Is o la tio n D iode A ssem b ly 26 — S lip Ring A ssem bly
3 — R egulator 15 — In s u la to r Sleeve 27 — Bearing (2 used)
4 - Gasket 16 — In s u la to r Washer 28 — R otor
5 — Screw 17 — In s u la to r Sleeve 29 — R etainer
6 — Brush A ssem bly 18 — C able Assem bly 30 — D rive End Frame
7 — Through B o lt 19 — P o s itiv e D iode A ssem b ly 31 - Nut
8 — In s u la to r 20 — N ega tive D iode A ssem b ly 32 — W oodruff Key
9 - N ut 21 — In s u la to r 33 — Fan
10 — Lock Washer 22 — Screw 34 — P u lle y
11 — in s u la tin g Washer 23 - Stator 35 - Lo ck Washer
12 — S lip Ring End Frame 24 — R etainer 36 — Jam Nut
Fig. 6 — A lte rn a to r A s s e m b ly — E a rly U n its — 5 5 A m p
DISASSEMBLY lution. Scrape off dirt and grease, then use a stiff
brush and solvent. Dry with compressed air.
Disconnect battery ground straps first to pre
vent damage if leads removed from alternator Never hammer or jar an alternator as the
should be grounded. diodes may be damaged.
res Refer to Fig. 6 and FOS-20, Chapter 4 Remove isolation diode, regulator, and brush
when disassembling and assembling the es. Remove through bolts. Pry stator and slip
a alternator and note the following: ring end frame from the rotor and drive end
frame. Inserting screwdriver deeper than 1 / 16-
Tag alternator wires to aid in installation and inch may damage windings.
remove alternator.
Never immerse an alternator in cleaning so-
L itho in U .S.A .
G rad er, M otor - JD570 E le c tr ic a l S ystem 40
T M -1001 (O ct-73) C harging S y stem 1 5-5
SLIP RING END BEARING S lip R in g I n s ta lla tio n
S lip R in g R e m o v a l Install slip rings with grooves for rotor

windings aligned. Tighten screw to 45 in-lbs.
Detach soldered rotor winding leads from slip With fiber washer in place on terminal for inside
ring and pull slip rings from rotor. If necessary, slip ring, solder leads to slip ring terminals
use a 1/4-28 cap screw 1-1/4 inches long as a (leads are interchangeable). Apply silicone
jack screw. Do not damage leads or small rubber or a glue to fasten wires. Check slip
fiber washer. rings and rotor windings for ground or short
circuit.
B e a r in g R e p la c e m e n t
DRIVE END FRAME BEARING
Figs. 9 through 13 illustrate drive end bear

ing replacement. Remove drive end frame by
tapping rotor shaft against a wood block or use
A-216 puller. RemovebearingwithA-216puller.
Compress the waves of the bearing retainer (Fig.
10) to seat it in its groove. Do not use a screw
driver or other small object that might slip off
and damage the bearing seal. A -209 presses
against the inside diameter of the bearing (Fig.
13). Position rotor leads away from A -205 holder
when installing bearing.
F ig . 7—Removing S lip Ring E nd Bearing
1 — W oodrufi Key 2 — P u lle y Nut

3 — Screwdriver
rim e A -202:
F ig . 9—Removing Woodruff K ey
F ig . 8 -P re s s in g on S lip R ing E nd Bearing
Figs. 7 and 8 illustrate bearing replacement.

Do not damage rotor leads when replacing the
bearing. Replace O-ring bearing retainer in slip
ring end frame.
itho in U.S.A.
15-6- C harging S y ste m TM-1001 (Nov-78)
1 - A-209 Tool
2 — A-205 Tool
F ig . 10—Removing D riv e End B earing R eta in er F ig . 13—In s ta llin g D rive End Frame
TESTS
A lte r n a to r Component Tests
If the circuit tests did not localize the

faulty component, perform one or more
of the following tests. For additional
information on testing alternator components,
see "Charging System" in FOS Manual -
ELECTRICAL SYSTEM.
B ru s h A sse m b ly Tests
1 - A -203 T o o l 2 - A-207 Tool Use an ohmmeter to test brush assembly for

insulation and continuity. If brushes do not meet
F ig . 1 1 -In s ta llin g D riv e E nd B earing
specifications, replace them.
Is o la tio n Diode T est
1 — Iso la tio n Diode A ssem bly 2 —O utput Term inal
F ig . 14—Is o la tio n D iode T e st P o in ts
Connect tester to the output terminal (Fig. 14)

1 — Bearing R etainer 2 — 3 /4 -ln c h Wooden Dowel and one of the exposed metal areas of the diode
F ig . 1 2 -ln s ta llin g B earing R eta in er frame and check diode.
L itho in U .S.A .
Grader, Motor - JD570 E le c tr ic a l S y stem 40
TMaOOl (Nov-78) C harging S y stem 1 5 -7
If available, use a diode tester and follow Disconnect "delta" connected stator leads
the manufacturer's instructions. Do not use (Fig. 16) and test windings using an armature
110-volt test lamp to check diodes. tester or test lamp. After testing, solder leads
A to B, C to AA, and BB to CC.
If using a 12-volt test lamp, the lamp should
light only when the diode is connected in a for Open C irc u it Tests
ward bias.
The test lamp should light when connected to
S ta to r Tests points: A to AA, B to BB, and C to CC.
Grounded Winding Test
The test lamp should not light when one lead

is connected to the metal frame and the other
lead to point A, then to point B, then to point C.
S h o rt-C irc u ite d T est
The test lamp should not light when connected

to points: A to B, Bto C, and A to C. An internal-
external growler may indicate shorted windings
within one phase but will not indicate two separate
F ig . 15—Stator Leakage T e st P oints phase coils shorted together.
Connect ohmmeter to points A and B (Fig. 15) DIODES
and check the stator. Leaving one test lead on
point B, move the other test lead from A to A humming or growling sound with consider
each of the remaining diode terminals in suc ably low output (6 to 10 amps) is caused by a
cession and check for grounded windings. shorted diode. If maximum output is slightly low
(35 amps) a diode may be open-circuited.
Examine stator for insulation failure or
defects. Shorted stator windings are usually If available, use a diode tester and follow
discolored and smell. Replace stator only after the manufacturer’s instructions. Donotuse 110-
other electrical components have been proven volt test lamp to check diodes.
to be satisfactory.
If using a 12-volt test lamp, the lamp should
light only when the diode is connected in a for
ward bias.
With a 1-1/2-volt ohmmeter, a good diode will

give both a high and a low reading. If the high and
low readings are identical, the diodes are good. A
slightly different reading indicates a defective
diode.
See Chapter 4 of FOS-20 "Electrical

Systems" for additional diode test in
formation.
F ig . 16—Stator Vliring T e st P o in ts
Litho in U.S.A.
15-8 C harging S y stem TM-1001 (Nov-78)
IM PORTANT: Isolation diode assembly is

mounted to both the positive and the negative
diode assembly term inals, so be sure that iso
lation diode assembly is insulated from the
negative (ground) term inal.
TESTS AFTER ASSEMBLY
1 - N ega tive Diode Assem bly 3 — Diode

2 - P o s itiv e Diode Assem bly
F ig . 1 7 -P lie rs Used as a H eat Sink
When soldering a diode lead, use pliers as a 3 - R e sisto r 5 - V oltm eter

6 — Jumper Wire
heat sink (Fig. 17).
F ig . 18—A lte rn a to r T e st Connections
If a diode is defective, replace the diode as

sembly. Note the insulator locations on the Mount alternator on electric servicer and
positive diode assembly to aid in correct as follow servicer instructions. If instructions are
sembly. The diode connections and polarity must not available, connect alternator as shown in
be correct. A positive diode has red printing Fig. 18. Run alternator at 3000 to 4000 rpm.
and a negative diode has black printing. Momentarily connect jumper wire between al
ternator output terminal and regulator terminal
ROTOR to excite alternator field. Adjust resistor to
obtain maximum output.
Check rotor for grounded, shorted, or
open field windings as instructed in FOS Open resistor and check regulator operation.
Manual 20-ELECTRICAL SYSTEMS. If battery is partially discharged, it may be
necessary to connect a 1/4-ohm resistor in
Polish slip rings with 400-grit silicon carbide series with the ammeter.
paper.
ASSEMBLY
Assemble stator and slip ring end frame. Be

sure insulators and washers are properly lo
cated.
Position stator leads to prevent interference

with rotor. Assemble stator and slip ring end
frame to the rotor and drive end frame. Tighten
through bolts to 50 to 60 in-lbs torque. Install
brush assembly.
Install regulator. Place insulating washer on

ground terminal. Install isolation diode assembly
using insulating bushing and washer.
Litho in U .S.A .
TM-1001 (Nov-78) C harging S y stem 15-9
INSTALLATIO N Connect alternator wires (Fig. 19). Making

sure all connections are clean and tight. Con
nect battery ground. Do not polarize.
( TO BRUSH
F ig . 19—A lte rn a to r and R egu lating Wiring
SPECIFICATIONS
Item S p e cifica tio n
Alternator output (m ax.)....................................................... 55 amp.
Alternator brushes.................................................................. l/4-in ch beyond holder (minimum)
System v o lta g e ....................................................................... 12-volt
Ground....................................................................................... Negative
Batteries (See page 40, 10-9 for battery specifications)
Fan belt tension (with gauge)............................................... 80 to 85 lbs. strand tension
(without gauge)......................................... 3/4-inch flex with 20 lbs. force
ALTERNATOR AND REGULATOR TEST SPECIFICATIONS

Test Reading
Circuit Tests
Test No. 1 Key o f f ..................................... . . . 0 to 0.1 volts
Test No. 2 Key on . . ................................. » . I. 5 to 2.0 volts
Test No. 3 Key on, engine running at 1500 rpm 0.8 to 1.2 volts plus
temperature correction
Test No. 4 - Key o ff..................................... .................... 2.0 to 3.0 amperes
Test No. 5 - Key on, engine running at 1500 rpm . =, 13 to 15 volts
Rotor T e s t .............................................................................. II. 0 to 14.0 ohms
TEMPERATURE CORRECTION CHART WIRING TEST CHART
Tem perature* V oltage Test P oints Maximum V oltm e ter Reading
40°F 14. 3-15. 1 volts B - E 0.3 volt

60°F 14.1 - 14.9 volts A - D 0.3 volt
80°F 14.0 - 14.8 volts D - F 0.1 volt
100°F 13. 8- 14. 6 volts B - C 1.3 volt
120°F 13.7 - 14.5 volts
140°F 13.6 - 14.3 volts
*M e a s u r e d 1 -in c h f r o m r e g u l a t o r c a s e .
L itho in U .S.A .
15-1 0 Charging S y stem TM-1001 (Nov-78)
TORQUES FOR HARDWARE

Item Torque
Alternator pulley nut........................................................................................................... 40 to 50 ft-lbs

Alternator through b o lt s ................................................ 25 to 30 in-lbs
Alternator pulley nut........................................................................................................... 40 to 50 ft-lbs
Alternator through b o lt s ................................................................................................... 25 to 30 in-lbs
Brush mounting screw s...................................................................................................... 16 to 20 in-lbs
Diode mounting nuts ............................................................................................................ 20 to 30 in-lbs
Regulator mounting s c r e w s .............................................................................................. 40 to 45 in-lbs
Regulator lead lock n u t s .......................................... 20 to 30 in-lbs
Slip ring cap screw.............................................................................................................. 45 in-lbs
SPECIAL TOOLS
N o. Name Use
ESSENTIAL TOOLS
A 200JD ............. Alternator Service Tool S e t........... Disassembly and Assembly of Alternator
A -205* .............. Shaft Protector

A-207* ................ Drive End HousingSupport Tool
A -208* .............. Rotor Holder
*Tools are p a rt of A200JD Alternator Service Tool Set and cannot be purchased individually.
Litho in U .S.A .
Grader, M o to r - JD570 E le c tric a l System 40
TM-1001 (Dec-87) C harging System 15-11
REMOVE AND INSTALL A LTER N A TO R -

LATER UNITS
1. D is c o n n e c t th e b a tte ry g round ca b le.

2. D is c o n n e c t w irin g leads.
3. R em ove ca p scre w s and b e lt to rem ove
a lte rn a to r.
4. In s ta ll a lte rn a to r. In s ta ll lo w er c a p scre w so T6680AW
head is to w a rd s fa n b elt.
5. In s ta ll b e lt on p u lle ys.
IMPORTANT: Force must be applied to front
housing only to prevent damaging alternator when
belt tension is adjusted.
6. A d ju s t b e lt te n s io n to 0.50 in. d e fle c tio n a t 15

lb fo rc e a p p lie d h a lfw a y betw een p u lle y s u sin g
d e fle c tio n ga ug e (A).
7. C o n n e ct w irin g leads. T ig h te n in d ic a to r lig h t
te rm in a l n u t to 20 lb-in. T ig h te n o u tp u t te rm in a l n ut
to 60 lb-in.
L ith o in U.S.A.
15-12 Charging System TM-1001 (Dec-87)
T6478AB
1— Nut (2 Used) 9—Voltage Regulator 16— Rectifier Diode Bridge 25 Bearing Retainer
2—Screw (2 Used) 10— Insulating Washer (2 Used) 17—Thru-Bolt (4 Used) Screw (3 Used)
3— Rear Cover 11—AC Tap Strap 18— Rear Housing 26 Front Bearing
4— Felt Gasket 12— B + Nut 19—O-Ring 27 Front Housing
5— Hut 13—Screw (4 Used) 20—Stator Assembly 28- Fan Spacer
6—D + Strap 14— Diode Field 21—Slip Ring 29 Fan
7—Brush Assembly 15—Screw (3 Used) 22— Rear Bearing 30 Pulley
8—Screw (2 Used) 23— Rotor Assembly 31 Lock Washer
24—Woodruff Key 32- Nut
Fig. 7— A lte rn a to r A s s e m b ly — L a te r U n its — 65 A m p
Litho in U.S.A.
Grader, M o to r - JD570 E lectrical System 40
TM-1001 (Dec-87) Charging System 15-13
1. In sp e ct and te s t b rush a ssem bly. B rush set

m ay be reused if b rush e s are 0.188 in. o r ionger.
B rushes m u st n o t be o il soaked, cra cke d o r
grooved.
T e st c o n tin u ity fro m A to B and C to D. T e st fo r
no c o n tin u ity fro m A o r B to C o r D.
T6478AC
2. In sp e ct and te s t d io d e -trio . T e st d io d e fro m

each o f th re e te rm in a ls (A) to D + stud (B).
3. In sp e ct and te s t re c tifie r bridge. T e st fo r c o n

tin u ity betw een (B) and each o f three te rm in a ls (A).
Then te s t fo r c o n tin u ity betw een (C) and each o f
th e th re e te rm in a ls (A). C o n tin u ity sh o u ld be
observed in one d ire c tio n o n ly and a ll d io d e s
sh o u ld c h e ck alike.
4. In sp e ct and te s t s ta to r. Test fo r c o n tin u ity be

tw e e n te rm in a ls (A, B and C). There sh o u ld be no
c o n tin u ity fro m any te rm in a ls (A, B, or C) and p o in t
(D) (lam in a tio ns).
T6478AF
L ith o in U S A .
15-14 C harging System TM-1001 (Dec-87)
5. In s p e c t a n d te s t ro to r a s s e m b ly . T e st
re s is ta n c e betw een each s lip ring (A). Then te s t fo r
no c o n tin u ity betw een each slip ring and p ole fin g e r
(B).
6. S tra ig h te n ro to r le ad s (A) and in s e rt a N o. 10

x 1 in. cap s c re w (B) in to c e n te r o f s lip ring
a sse m b ly. Rem ove s lip ring a sse m b ly using a bear
ing p u lle r.
7. If necessary, rem ove rear b e arin g using a bear
ing p u lle r.
NOTE: Replace bearing if removed.
T6486AH
ASSEMBLE ALTERNATOR— LATER

UNITS
F o r a lte rn a to r a sse m b ly , th e fo llo w in g is a lis t

o f s p e c ia l re a s s e m b ly re q u ire m e n ts .
R eplace b e a rin g s if rem oved.
G u id e ro to r le a d s th ro u g h o n e o f th e oval
p a ssa g e s in th e s lip rin g a sse m b ly . The oval
p a ssa g e m u st lin e up w ith th e groove in th e ro to r
s h a ft.
T ig h te n fro n t bearing re ta in e r s cre w s (B) to 25-35
lb-in.
P ress fro n t h o u s in g d o w n u n til in n e r b e a rin g (D)
race c o n ta c ts s h o u ld e r on th e s h a ft.
A p p ly a th in film o f h e a t s in k co m p o u n d to b a ck
o f d io d e re c tifie r b rid g e (A) and m a tin g s u rfa c e o f
rear h o u sin g . T6493BC
C h e ck to be s u re fe lt g a s k e t is in s ta lle d .
T ig h te n s h a ft n u t (C) to 35-50 Ib-ft.
T ig h te n th ru -b o lts (4 used) to 50-60 lb-in.
L ith o in U.S.A.
Grader. Motor - JD570 Electrical System 40
TM-1001 (Dec-87)____________________________________________________________ Charging System 15-15
ALTERNATOR SPECIFICATIONS— LATER UNITS—65 AMP
Ite m M e a s u re m e n t S n e c if ic a t io n
Brush ........................................ M inim um L e n g th ..................... 0.188 in.
Pulley-to-Shaft N u t................. T o r q u e ...................................... 35-50 Ib-ft.
Rear H ousing-to-Front
H ousing Cap S c re w ........... Torque ...................................... 50-60 lb-in.
Bearing Retainer S c re w s .. . . T o r q u e ...................................... 25-35 lb-in.
Term inal Nuts

O utput T e r m in a l................. Torque ...................................... 60 lb-in.
In d ica to r Light Term inal . . T o r q u e ...................................... 20 lb-in.
Fan Belt T e n s io n ................... D eflection at 15 lb fo r c e ___ 0.05 in.
ALTERNATOR SERVICE EQUIPMENT AND TO O LS -LA TER UNITS
NOTE: Order tools from your SERVICE— GARD catalog. Some tools may be available from a local supplier.
N am e i Ic e
Volt-Ohm -Am p M e t e r ............ ....................................Check resistance and co n tin u ity
Belt Tension G a u g e ...................................................Measure belt tension
No. 1 0 x 1 in. Cap S c re w . . , ....................................Remove slip ring
17-1/2-Ton Puller S e t...................................................Remove slip ring and bearings
Litho in U.S.A.
15-16 Charging System________________ _______________________________ ____________ TM-1001 (Dec-87)
Litho in U.SA.
TM-1001 (Nov-78) Starting M otor 20-1
Group 20
STARTING MOTOR
DELCO-REMY STARTING MOTOR
SOLENOID -L INKAGE "'SEAL LINKAGE
SHIFT LEVER
EVER"" H O U S I N G
NOSE HOUSING
:/
BRONZE
BUSHING
:I N S U L A T E D BRUSH BRONZE SPRAG

A R MA T U R i
BRUSH HOLDER BUSHING CLUTCH
•.POLE S H O E F I E L D ‘C O I L
ATTACHING
BOLT
F ig . 1—Cutaway V iew o f S tartin g Motor
GENERAL INFORMATION STARTER OPERATES SLOWLY

Low battery.
The starting motor has a totally enclosed shift High resistance in circuit.
lever and solenoid plunger to seal out dirt, ice, Excessive engine drag.
and water. Positive lubrication to the bushings Defective starter.
is provided by oil-saturated wicks.
VOLTMETER INDICATES BATTERY VOLT
When making tests, the battery voltage should AGE WHEN KEY IS TURNED ON AND START
not drop below 9 volts. Never run the start BUTTON DEPRESSED
ing motor more than twenty seconds at a time or Defective starter.
overheating will result. Allow motor to cool at Defective starter solenoid switch.
least two minutes before running it again.
VOLTMETER DOES NOT INDICATE BATTERY
Refer to "Starting Circuits" in FOSMan VOLTAGE WHEN KEY IS TURNED ON AND
ual - ELECTRICAL SYSTEMS for addi START BUTTON DEPRESSED
tional starting circuit information. Defective key switch.
Defective starter circuit relay.
DIAGNOSING M ALFUNCTIONS AND TESTING Defective wiring between key switch and
starter circuit relay.
SOLENOID SWITCH CHATTERS Defective wiring between battery and sole
Low battery. noid ” S" terminal.
Poor connections.
Open in solenoid hold-in circuit.
Litho in U .S.A .
20-2 Starting Motor TM-1001 (Dec-87)
HIGH RESISTANCE TEST
1— B attery 6— Ig n itio n S w itc h

2— S ta rte r 7— S ta rt B utton F ig . 3 -S o le n o id T e s t
3— S olenoid 8 — S ta rt S a fe ty S w itc h
4— S ta rte r R elay (E arly U n its — 1 used)
5— A lte rn a to r
T e stin g H o ld -In W indings. Disconnect so le
(L a te r U n its — 2 used)
noid. Connect ammeter in series with a switch to
F ig . 2 - H ig h R e s is ta n c e T e s t P o in ts
(JD 570-A S tartin g C irc u it Shown)
terminal S and to battery. Connect voltmeter to
terminal S and to solenoid ground. Connect
Disconnect wire from injection pump solenoid carbon pile resistor across the battery. Connect
shut-off terminal. other battery post to solenoid ground. Close the
switch and adjust carbon pile to obtain 10 volts.
Connect voltmeter to ground and to solenoid Ammeter should read 18 to 20 amps.
battery terminal. Operate starter and compare
voltage with a similar reading at battery. Always To prevent overheating, do not energize the
use a pin connector at battery post. If difference pull-in winding longer than 15 seconds. Current
is in excess of 0.8 volt, make the indicated test draw will decrease as the winding temperature
(Fig. 2). Check for defective wires or faulty con increases.
nections.
H igh A m m e te r R eading
H igh R esistan ce T e s t Values Windings are grounded or short circuited.
T e s t P oints Maximum V oltm e ter Reading L ow A m m e te r Reading

A-G 0 .2 Excessive resistance is present (usually in a
B-C 0 .2 connection).
C-D 1.0
B-E 0 .2
No A m m e te r Reading
C-F 0 .2
Windings are open circuited.
SOLENOID TESTS If the fault cannot be repaired and the sole

noid performance is questionable, replace the
T e s tin g P u ll- I n W indings. Disconnect f i e l d windings.
connector from solenoid motor terminal. Connect
ammeter in series Mrith a carbon pile resistor to
terminal S and to battery. Connect voltmeter to
terminal S and to solenoid motor terminal. With
carbon pile in the off position, connect other
battery post to solenoid motor terminal. Quickly
adjust the carbon pile to obtain 5 volts. Am
meter should read 26 to 29 amps.
Litho in U .S .A .
Grader IVIotor - «JD570 E le c tr ic a l S ystem 40
TM-1001 (Nov-78) Starting M otor 2 0 -3
NO LOAD TESTING 4. Failure to operate with no current draw

indicates:
a. Open field circuit. Check by inspecting

internal connections by tracing cir
cuit with a test lamp.
b. Open armature coils. Check commuta

tor for badly burned bars.
c. Broken brush springs, worn brushes,

high insulation between commutator
bars, or other causes preventing good
contact between brushes and commu
tator.
5. Low no-load speed and low current drag

indicates:
F ig . 4 -N o -L o a d T e st Hook-Up
a. High internal resistance due to poor
Make the hook-up as shown in Figure 4. Do connections, defective leads, dirty com
not run the motor for more than 20 seconds at mutator, and causes listed under item
a time as overheating will result. Allow motor
to cool at least 2 minutes before running it again.
No Load T e s t V alues (In c lu d in g Solenoid) 6. High free-speed and high current draw
indicates shorted fields. Replace field coil as
Test Min. Max.
V o lts
Min.
Amps.
Max.
Amps. RPM RPM
sembly and check for improved performance.
9.0 130 160 5000 7000 DISASSEMBLY
1. Rated current draw and no-load speed in Disassemble motor only as far as necessary
dicates normal condition of the motor. to make repairs. See Figures 1, and 5 to identify
components.
2. Low free-speed and high current drawin-
dicates: REPAIR
a. Bad bearings, bent armature shaft, or Mark relative position of solenoid, lever
loose pole shoes causing armature to housing, and nose housing so motor will be
drag. correctly assembled.
b. Shorted armature; check on a growler Disconnect field coil connector from solenoid
after disassembly. motor terminal and remove solenoid mounting
screws.
c. Grounded armature or fields. Check
after diassembly. Remove commutator endframe. Remove field
frame from lever housing. Then separate nose
3. Failure to operate with high current draw housing from lever housing.
indicates:
a. Direct ground in the terminal or fields.
b. Frozen bearings (determine by turning

armature by hand).
Litho in U .S.A .
2 0 -4 S tartin g M otor TM-1001 (Nov-78)
1 — F ie ld C o il A ssem bly 25 - Wick 48 — E xpansion P lug (2 used)

2 — P ole Shoe (4 used) 26 — L o ck Washer (2 used) 49 — P ip e P lug
3 — F ie ld C o il Insu lator 27 — Through B o lt (2 used) 50 - Wick
4 — F ie ld Te rm ina l Stud 28 - Expansion Plug 51 - L e ve r H ousing
5 — In s u la to r Bushing 29 - 0 -R in g P acking 52 — R e ta in in g Ring
6 — Dowel P in 30 — Washer (2 used)
53 - Spring R etainer
7 — Main Frame 31 - Bushing
54 - Spring
8 - Machine Screw (4 used) 32 - D rive H ousing
55 — Spring R etainer
9 — In s u la tin g Washer (2 used) 33 - Wick
10 — Washer 34 - Pipe Plug (2 used) 56 — B oot
11 — Connector 35 — R etaining R ing 57 - Washer
12 — L o c k Washer (2 used) 36 — P inion Stop 58 - P lunger
13 — Jam Nut (2 used) 37 - Bushing 59 - Screw
14 — Brush Ground Lead 38 — Motor D rive (C lu tch ) 60 — S olenoid Switch
15 — Brush Support (2 used) 39 — L o c k Wire (2 used) 61 — Spacing Washer
16 — Brush P in (2 used) 40 — Spring 62 - Arm ature
17 - Brush Spring (2 used) 41 — Motor D riv e C o lla r 63 — Spacer
18 - Brush H older (2 used) 42 —. Brake Washer 64 - B ushing
19 - Brush H older Ground (2 used) 43 - S hift Lever 65 — Cap Screw and Washer
20 — Brush 44 — Pin 66 — Gasket
21 - S pecial Tapping Screw (2 used) 45 - Spring R etainer
67 — 0 -R in g
22 — Bushing 46 — Expansion Plug (2 used)
68 — O-Ring
23 - Commutator Frame End 47 — S hift L e v e r Shaft 69 — O il Seal
24 - P ipe Plug
70 — Cap Screw and Washer {4 used)
F ig . 5—S tarting M otor
L ith o in U .S.A .
TM-1001 (Nov-78) S tartin g M otor 2 0 -5
CHECKING BRUSHES
Check brushes for wear. If they are exces

sively worn compared to a new brush, they should
be replaced. Be sure holders are clean and
brushes are not binding. The full brush surface
should ride on the commutator. Check brush
springs by hand to be sure they are giving firm
contact between brushes and commutator. If
springs are distorted or discolored, replace
them.
CHECKING FIELD COILS
The field coils can be checked for grounds and

opens by using a test lamp. Disconnect field coil
ground connections before checking for grounds.
F ig . 6 -R e m o v in g R eta in ing Ring Connect one lead of test lamp to field frame and
other lead to field connector. If lamp lights, at
Remove the retainer ring by sliding a half least one coil is grounded and must be repaired
inch pipe coupling onto the shaft so that it butts or replaced.
against the pinion stop (Fig. 6). Tap the coupling,
driving the pinion stop down and off the retaining To check for opens, connect test lamp leads to
ring. ends of field coils. If lamp does not light, field
coils are open.
If the retaining ring is badly distorted, re
place it when reassembling the clutch. Remove field coils from frame using a pole
shoe screwdriver. Use a pole shoe spreader to
Remove the armature and clutch from lever prevent distorting field frame.
housing and separate solenoid from the housing
(Fig. 1). Be careful when installing field coils to pre
vent shorting or grounding the coils as the pole
Do not clean any parts in grease dissolving shoes are tightened. Where the pole shoe has a
solvents. Wipe the drive with a clean cloth. long lip on one side and a short lip on the other,
assemble the long lip in direction of armature
The commutator may be cleaned with No. 00 rotation so that it is the trailing (not leading) edge
sand paper. Do not use emery cloth. of the pole shoe.
If the commutator is worn, dirty, out of round, BUSHINGS

or has high insulation it can be turned down in a
lathe. Do not undercut the insulation. Remove pipe plugs, expansion plugs and oil
wicks from housings. Press out old bushing.
CHECKING ARMATURE Press new bushing in to same depth as old bush
ing. Carefully drill bushing through oil wick hole
Check the armature for opens, short circuits, using same size drill as oil wick hole.
and grounds. Shorts between bars are sometimes
produced by brush dust or copper between the After drilling, ream bushing to maintain
bars. These shorts can be eliminated by cleaning proper oil clearance between shaft and bushing.
out the slots.
Soak new wicks in SAE 10 engine oil. Install
wicks, expansion plugs and pipe plugs.
Litho in U .S.A .
2 0 -6 S tartin g M otor TM-1001 (Nov-78)
REPAIRING SPRAG CLUTCH ASSEMBLY ASSEMBLY
To assemble starter, reverse the disassembly

procedures. Use an AR40174 Starting Motor
Sealing Kit to prevent entry of moisture or for
eign material.
N O TE : Use o nly the la te k its that have R11096

W asher, R40367 E nd F ra m e Gasket and R11120
O -R ing. In s ta ll the O -rin g between the d riv e end
housing and fra m e and the g asket between com
F ig . 7 —D isassem bled V ie w o f C lutch A ssem b ly m u ta to r end cap and fra m e .
To disassemble clutch assembly, remove the Lubricate splines and drive end of armature
lock wire, collar, and jump spring (Fig. 7). Re shaft with SAE 10 engine oil. Heavier oil may
move the pinion stop (36, Fig. 5) and large cause failure to mash at low temperature. Lubri
washers. Do not remove sleeve assembly or cate the bearing surfaces of the center bearing,
sprags from shell assembly. drive end frame, and commutator end frame with
Delco-Remy Lubricant No. 1960954.
Lubricate sprags and saturate felt washer
with No. 5W-20 oil. Do not use heavier oil.
Reassemble the clutch drive.
SOLENOID SWITCH
1 — L e v e r Housing 4 — Brake Washer

2 - Nose H ousing A tta c h in g Screws 5 - T h ru s t Washer
3 - C lu tc h 6 - Armature
F ig . 9 —Arm ature A ssem bly
With nose housing attaching screws in place

(Fig. 9) assemble armature to lever housing and
1 - Case and C o il 13 — Jam N ut (4 used) clutch.
2 — S w itch Te rm ina l Stud 14 - L o c k Washer (2 used)
3 — Term inal C lip 15 — S e aling Washer
4 — Motor Te rm ina l Stud 16 — L o c k Washer (2 used) Use the following procedure when assembling
5 - R e s is to r Stud 17 - N ut retaining ring and pinion stop to shaft:
6 — C ontact 18 - S e aling Washer
7 - C ontrol and Push Rod 19 — L o c k Washer
8 — Spring 20 - Nut 1. With the pinion stop placed over the shaft
9 — B attery T e rm ina l Stud 21 - Washer
(cupped surface facing the end of the shaft) force
10 — Gasket 22 — M achine Screw
11 — Cover 23 - Washer the retaining ring (Fig. 10) over the shaft with a
12 — S ealing Washer (2 used) 24 - Washer light hammer blow and slide ring into the groove.
25 — Washer
F ig . 8 -S o le n o id Switch
2. To force the pinion stop (Fig. 11) up and
Remove nuts and sealing washers from sole over the retaining ring, place a flat washer over
noid motor and "S" terminals when removing the shaft so that it rests on the retaining ring.
switch cover. Draw the pinion stop and the washer together
with pliers: Remove the washer.
Replacement ,TS" terminal clips and motor
terminal studs are soldered to winding leads. Use
new sealing washer when assembling the sole
noid.
L itho in U .S.A .
Grader, Motor - JD570 E le c tr ic a l S ystem 40
TM-1001 (Nov-78) Starting M otor 2 0 -7
1 — P inion 3 - F e e le r Gauge
2 - P inion Stop
F ig . 1 2 -C h e c k in g P inion Clearance
To check pinion clearance, disconnect field

coil from solenoid motor terminal. Connect bat
F ig . 10—F o rc in g R e ta in in g R ing Over Shaft
tery to solenoid frame and "S" terminal. Mo
mentarily connect a jumper wire between so
lenoid frame and motor terminal to pull sole
noid plunger in. Clearance between pinion and
pinion stop should be 0.010 to 0.140 inch when
pressing clutch toward commutator (Fig. 12).
IN S T A L L A T IO N
R ing
Carefully install field frame so that brush 1 — P o s itiv e Starter C able 5 — Red
2 — W iring Harness 6 — White (Up to Serial No.
holders are not broken. Align brushes with com 3 - Starter 001700) B lack and White
mutator and tighten brushes. 4 - Solenoid Switch (Serial No. 001700-Up)
F ig . 13—Starter C onnections
If it is necessary to seat brushes, use 00
sandpaper. Clean all dust from starter.
Install starter. Connect wiring harness and
p®s Check brush spring tension as instructed
positive battery cable (Fig. 13).
in Chapter 5 of FOS Manual 20-ELEC
Q TRICAL SYSTEMS.
Litho in U .S.A.
2 0 -8 S ta rtin g M otor TM-1001 (Nov-78)
JOHN DEERE STARTING MOTOR

3
1 — Plunger 7 — Bushing 13 — O il Seal 19 — P inion Stop

2 - Shunt F ie ld Term inal 8 — T h ru s t Washer 14 — B ushing 20 — B ushing
3 — Solenoid A ssem bly 9 — Commutator 15 - F e lt 21 - Snap Ring
4 — F ie ld C onnector 10 — F ie ld W indings 16 — Brake Washer 22 — D rive End H ousing
5 - End Frame Cover 1 1 — Armature 17 — Wear Pads 23 — S h ift Lever
6 — Brush 12 — P ole Shoe 18 — O verrunning C lutch
F ig . 14—S tarter
GENERAL IN FO R M A TIO N STARTER OPERATES SLOWLY

Low battery.
The starter essentially consists of a drive High resistance in circuit.
housing, overrunning clutch and pinion, drive Excessive engine drag.
lever, center bearing housing, magnetic switch, Defective starter.
armature, yoke and field windings, brushes and
commutator end frame. The shunt field winding VOLTMETER INDICATES BATTERY VOLT
is connected to the solenoid control circuit. AGE WHEN KEY IS TURNED ON AND START
BUTTON DEPRESSED
When making tests, the battery voltage should Defective starter.
not drop below 9 volts. Never run the starting Defective starter solenoid switch.
motor more than twenty seconds at a time or
overheating will result. Allpw motor to cool at VOLTMETER DOES NOT INDICATE BATTERY
least two minutes before running it again. VOLTAGE WHEN KEY IS TURNED ON AND
START BUTTON DEPRESSED
DIAGNOSING M A LFU N C TIO N S AND TESTING Defective key switch.
Defective starter circuit relay.
SOLENOID SWITCH CHATTERS Defective wiring between key switch and
Low battery. starter circuit relay.
Poor connections. Defective wiring between battery and sole
Open in solenoid hold-in circuit. noid "S" terminal.
L itho in U .S.A .
Grader, M o to r - JD570 E le ctrica l System 40
TM-1001 (Dec-87) S tarting M o to r 20-9
STARTER CIRCUIT RELAY DOES NOT H igh R esistan ce T e s t V alues

OPERATE
Defective key switch T e s t P o in ts Maximum V oltm e ter Reading
Defective neutral start switch A-G 0.2
Maladjusted neutral start switch B-C 0.2
Defective wiring between battery and starter C-D 1.0
circuit relay. B-E 0.2
C-F 0.2
N O TE: I f s t a r t e r continues to ru n a fte r key
s w itc h is rele a se d , check f o r open c irc u ite d shunt SOLENOID TESTS (Starter Removed)
w in d in g o r f o r s tu c k contact a t solenoid o r s ta r te r
c ir c u it re la y . To prevent damage, solenoid must be on
starter when testing the windings. Remove
HIGH RESISTANCE TEST terminal cover and field coil connector. Dis
connect shunt field winding lead from terminal on
field frame. Replace solenoid if it fails one of the
following tests.
Solenoid P u ll- In T est
1 — B atte ry 5 — A lte rn a to r
2 — S tarter 6 — Ig n itio n Switch
3 — Solenoid 7 - S tart Button
4 - S tarter Relay 8 — S tart Safety Switch
F ig . 1 5 - H ig h R e s is ta n c e T e s t P o in ts
(J D 5 7 0 -A S ta rtin g C ir c u it Shown)
F ig . 16- P u ll - I n T e s t
Disconnect wire from injection pump solenoid
shut-off terminal. Make connections shown (Fig. 16). With 8 volts
applied, the solenoid should push the pinion out
Connect voltmeter to ground and to solenoid to the pinion stop when the jumper wire is con
battery terminal. Operate starter and compare nected. Remove jumper wire. The drive should
voltage with a sim ilar reading at battery. Always remain out at pinion stop. Current through
use a pin connector at battery post. If difference jumper wire will be approximately 90 amps, so
is. in excess of 0.8 volt, make the indicated test use a heavy jumper wire and remove it soon after
(Fig. 15). Check for defective wires or faulty pinion is at stop.
connections.
L ith o in U .S.A .
40 E le c t r ic a l S y stem Grader, Motor - JD 570
2 0 - 10 S ta rtin g M otor TM-1001 (Nov-79)
Solenoid P u ll- In T e st No Load T e st D iagnosis
Fails to Operate, Low Current Draw

(Approx. 25 amps)
Open series field circuit.
Open armature coils.
Defective brush contact with commutator.
Fails to Operate, High Current Draw

Grounded terminal or fields.
Seized bearings.
Low Speed, Low Current Draw

High internal resistance.
1 - 12-V o lt B atte ry 2 - S w itch
Defective brush contact with commutator.
F ig . 17—R elurn T e s t
Low Sjpeed, High Current Draw
Make connections shown in Fig. 17. Close the Excessive friction.
switch and pull the drive out until the pinion con Shorted armature.
tacts the pinion stop. When released, the drive Grounded armature or fields.
should return without hesitation.
High Speed, Low Current Draw
No Lo a d T e st Open shunt field circuit.
High Speed, High Current Draw

Shorted series field coils.
REMOVAL
Disconnect battery ground cable.
Disconnect all cables and wires from solenoid.
A 9/16-inch crow foot wrench with a 3/8-inch

drive may be used to remove stud nut behind
starter.
F ig . 7 8 -N o L o a d T e s t
Make connections shown in Fig. 18. The start

er current draw should be 70 to 110 amps at 9.0
volts. The armature speed should be 2500 to
4500 rpm.
L itho in U .S.A .
Grader, Motor - JD 570 E le c tr ic a l S y ste m 40
TM -1001 (Nov-78) S ta rtin g M otor 20-11
R E P A IR
■e onno'7
r\
1 — D rive End B ushing 14 - O il Seal 27 — F ie ld C o il C onnector

no *r. • _l ____
2 — D rive End H ousin g 15 — C enter B earin g B ushing zo — i erm m ai c o ve r
3 - P acking 16 - O il F e lt 29 — Brush Ground Strap
4 — O verrunning C lu tc h 17 — B rake Washer 30 — End Frame C over
c
j
•/, i ___ o - __ x
— o n ITT u e v e r r iv o t
lO
io
Q: _ : C l
— i im u ti o iu p
31 _ QasL@
+
6 — O -R ing 19 — Snap R ing 32 — C om m utator End
7 — S h ift L e v e r 20 — Shunt W inding Ground Screw Frame B ushing
o n ___ d _-_:__ U ___
u — l v i i i c i u cu im y iiwusmy 2] _ p je ld W in d in - 33 _ Brush (4 used)
9 — S olenoid W inding 22 - P ole Shoe (4 used) 34 — Brush S pring (4 used)
10 — S olenoid S w itch C over 23 - Square Washer 35 - C om m utator End Frame
11 _ Shunt W inding Lead 24 — In s u la tin g B ushing 36 — B a k e lite Washer
12 — A rm ature 25 — Square in s u la to r 37 - T h ru s t Washer (0.008)
13 — B a k e lite Washer 26 — S pecial B o lt in . & 0.002 in . th ic k )
38 - F ie ld Frame
F i g . 19—S ta rte r A s s e m b ly
L itho in U .S .A .
2 0 -1 2 S tartin g M otor TM-1001 (Nov-78)
D isa sse m b ly
N O T E : S ta rte r has m e tr ic b o lts and nuts ex

cept f o r those on the sole n o id s w itc h c o v e r (10,
F ig . 19).
Disconnect shunt field lead (11). Remove ter

minal cover (28), field coil connector (27), and
solenoid assembly.
Remove end frame cover (30), gasket (31),

brushes (33), commutator end frame assembly
(35) and the brush ground strap (29). Slip thrust 1 — C enter Bearing H ousing 7 — Arm ature
2 — S h ift Le ver 8 - Brake Washer
washers (37) and bakelite washer (36) from 3 — Wear Pads 9 - B a k e lite Washer
armature. Remove field frame (38). 4 - O verrunning C lutch 10 — O -R ing
5 — Snap R ing 11 — S h ift L e ve r P iv o t
6 — P inion Stop
Remove drive end housing (2). Drive pinion F/'g. 2 0 -A rm a tu re and O verrunning C lutch
stop (18) toward pinion and remove snap ring
(19) and pinion stop (18). Remove armature (12) Comm utator and D rive End B ushing S p e c ific a tio n s *
from center bearing housing (8). Remove over
I.D. of bushing 0.6693 to 0.6704 in.
running clutch assembly (4), brake washer (17)
Oil clearance 0.0036 to 0.0070 in.
and shift lever wear pads (3, Fig. 20).
Maximum clearance 0.016 in.
Remove shift lever pivot (11, Fig. 20) and Bushing depth 0.008 to 0.022 in.
shift lever (2).
*R e a m in g m ay be necessary a fte r in s ta lla tio n .
Bushings C enter B ushing S p e cifica tio n s
Install a new oil seal (14, Fig. 19) and a new I.D. of bushing 1.182 to 1.184 in.
oil felt (16) saturated with engine oil when re
Maximum clearance 0.0236 in.
placing center bushing.
Bushing depth 0.017 to 0.032 in.
When replacing bushings, press the new bush A r m a tu re
ings in from the chamfered end. Make abushing ^ | For information on testing and servicing
driver as shown page 40-20-17 or use the follow
armature, see "Starting Circuits" inFOS
ing handle and disks from the OTC Universal
__ ?JManual - ELECTRICAL SYSTEMS.
Driver Set. Align hole in commutator and lubri
cation wick.
C h e c k a r m a t u r e for opens, s h o r t s and
Comm utator and D riv e End B ushing T o o ls grounds. Burned edge of commutator bar indi
cates an open circuit.
Component B ushing Removal B ushing In s ta lla tio n
Handle 27487 27487 Check armature for straightness. Runout
Disk (spacers) 27491 should not exceed 0.006 inch. Maximum com
27492 mutator runout is 0.016 inch. If necessary, turn
Disk 27494 27495 commutator and undercut insulation to l/32-inch.
Disk (pilot) 27493 27493 Undercut should never be less than 0.008 inch.
C enter B ushing Commutator O.D. must be 1.77 inches or more.
Clean copper dust from between the segments.
Component B ushing O il Seal
Handle 27487 27487
Disk 27505 27512
Disk (pilot) 27501 27501
Litho in U .S.A .
TM-1001 (Nov-78) Starting M otor 2 0 -1 3
O verru n n in g C lutch D riv e Remove nuts from solenoid "S" terminal (3)
res For overrunning clutch service informa and from pull-in terminal (6). Then remove
tion refer to "Starting Circuits” in FOS switch cover (1).
a Manual - ELECTRICAL SYSTEMS.
When installing switch cover (1), place gas
Field. C oils kets (7) on winding terminal, align main contact
Disconnect the grounded lead of the shunt vertically, and place packing (8) on switch cover.
field coil. The series field coil windings are of
copper strap and the shunt field coil windings are Solenoid contacts and plunger will be damaged
of small wire. Check the series windings and if current is applied to solenoid when it is re
the shunt windings for an open circuit and for moved from starter.
grounded windings. Check shunt windings for an
open circuit by connecting a carbon pile re ASSEM BLY
sistor in series with an ammeter to the large
field terminal and to the lead that was connected To assemble the starter reverse the disas
to the brushes. Adjust carbon pile resistor to ob sembly procedures. Use new seals and packings.
tain 50 amps. No magnetism at the pole shoe
indicates an open-circuited field winding. Lubricate the shift lever, overrunning clutch,
thrust washers, bushings, and armature bearing
Before removing pole shoes, scribe a mark surfaces with John Deere Multi-Purpose Lubri
on the pole shoe and the field frame to be sure cant.
they will be assembled in their original position.
Tighten pole shoe screws to 30 ft-lbs. If the shift lever was removed, tighten the
shift lever pivot screw to 30 ft-lbs. Bend wash-
B rushes ered edge of screw down to prevent loosening.
Replace brushes if they are oil soaked or if
they are worn shorter than 5/8 inch. Check brush NOTE: Do not in te rm ix e a rly and la te r s h ift
insulated holders for grounds. le ve rs (7, F ig . 19) and c e n te r bearing'housings
(8, F ig . 19). The la te s t s h ift le v e r has a black
Brush spring tension should be 40 ounces as oxide fin is h and the la te s t c e n te r bearing hous
the spring just leaves the brush holder. ing has the le tte r ” J ” stam ped on the top fr o n t
o f the housing.
Solenoid
Tighten center bearing housing to field frame
bolts to 6 ft-lbs. Tighten commutator end frame
bolts to 10 ft-lbs.
1 — Commutator End o f 2 — Commutator End o f

1 — Switch Cover 5 — P lunger Cover AR54994 AR66778 Armature
2 — Shunt W inding Lead 6 — P u ll-In Winding F ig . 2 2 -A R 5 4 9 9 4 a n d A R 66 7 7 8 A rm a tu re
3 — “ S” Term inal Term inal
4 — Solenoid W inding and 7 — Gaskets
Plunger A ssem bly 8*— P acking If starting motor has an AR54994 Armature
F ig . 2 1 —S o le n o id
(Fig. 22), install the bakelite washer and thick
or thin thrust washers to obtain 0.002 to 0.020
inch endplay (Fig. 23).
Litho in U .S.A .
2 0 -1 4 S tartin g M otor TM-1001 (Nov-78)
If starter has anAR66778 Armature (Fig. 22), Starting motor should rotate smoothly at a
install armature without bakelite washer or constant speed of at least3,100 rpmat 11.7 volts
thrust washers. It is not necessary to check end with a current draw of less than 110 amperes.
play of AR66778 Armature.
Tighten drive end housing bolts to 10 ft-lbs.
F ig . 23—C heckin g A rm ature E nd P la y
1 — B attery 5 — V oltm e ter

2 — R heostat 6 — S tartin g Motor
3 — Ammeter 7 — Tachom eter
4 — C ontrol Switch
F ig . 2 5 —N o L o a d T e s t ( A ft e r A s s e m b ly )
INSTALLATIO N
1 - Brush 3 - Brush Spring

2 — Brush Leads
F ig . 2 4 —B ru s h I n s ta lla t io n
When installing the brushes, twist brush leads

180 degrees (Fig. 24). Press the leads of the in
sulated brush down against the brush.
Give the assembled starter a no-load test.

Solenoid action during the test should be satis
factory.
NO LOAD TEST (After Assembly) 2 — W iring Harness 6 — W hite (Up to S erial No.
3 - S tarter 001700) B la ck and W hite
4 — Solenoid Switch (S erial N o. 001700-Up)
Connect a fully charged 12 volt battery with a
reserve capacity rating of 290 minutes, rheostat, F ig . 2 6 - S t a r te r C o n n e c tio n s
ammeter, control switch, voltmeter and tacho

meter to starting motor as shown in Fig. 25. Install starter. Connect wiring harness and
positive battery cable (Fig. 26).
L itho in U .S.A .
^ WA »* A^ ^ A *•
\JIC LU G If IV IV IV I t/ cru i/ / t/ c a / s j y o i c m
TM-1001 (Dec-87) Starting Motor 20-15
NEUTRAL START SWITCH Adjustment

These units are equipped with a neutral start switch.
(U nits w ith one n e utra l s ta rt s w itc h )
This switch prevents unit from starting with shift lever in
NOTE: On units with 2 neutral start switches, no
any gear.
adjustment is required.
The switch is mounted on the transmission control
valve.
P lace gear s e le c to r lever in n e u tra l p o s itio n . In
sure th a t s h ift lin k a g e is a d ju ste d co rre c tly .
E arly u n its have one s w itc h , la te r u n its have tw o Install neutral start switch with a minimum of one
s w itc h e s . washer.
Adjust switch by adding washers, one at a time, until

switch continuity is lost.
IMPORTANT: To insure correct adjustment of

the switch, tighten the switch to 20-25 Ib-ft EACH
TIME a washer is added or removed.
p
w Ai / n tin
i m i lii m
ii+w
y io i v o 1
io I n e t uv rvbi iac ni i tt-iA
u ic* ti c
aoo ti l i n M vA
/ in O n A h m m A tfir
i u i i v s iii i ii i ns «.c?r
indicates infinite resistance (no ohmmeter needle

m
i n nv t/
r voim
iio
vni it\
u ,
TS14S2
When continuity is lost, remove one washer and
1— Nipple 2—Aluminum Washer tighten switch to 20-25 Ib-ft.
(Units with one neutral
start switch)
Move the shift lever in and out of gear several times
Fig. 2 7 -N e u tra l S ta rt S w itch to insure the neutral start switch is closed only in the
neutral position.
T he sw itc h is n o rm a lly open. The s w itc h c lo se s
w hen nipple is depressed, th u s co m p le tin g th e c u r Connect wire leads to switch.
re nt path to s ta rte r w hen s ta rtin g u nit.
Litho in U.S.A.
20-16 S ta rtin g M o to r TM-1001 (Dec-87)
SPECIFICATIONS
HIGH RESISTANCE TEST VALUES
T e s t P oints Maximum V oltm e ter Reading

A-G 0.2
B-C 0.2
C-D 1.0
B-E 0.2
C-F 0.2
Maximum difference between starter voltage and

battery voltage..................................... 0.8 volts
1— B atteries 6— Ig n itio n S w itch

2— S ta rte r 7— S ta rt B utton
3— S olenoid 8 — N eu tra l S ta rt S w itc h
4— S ta rte r R elay (E arly U n its — 1 used)
5— A lte rn a to r an d R eg ulator
(L a te r U n its — 2 used)
Fig. 28-High Resistance Test Points
(JD570-A Starting Circuit Shown)
DELCO R E M Y STARTING MOTOR
STARTER NO LOAD TESTS
Test Min. Max. M in. Max.

Motor N o. V o lts V o lts Amps Amps RPM RPM
1113672 or 12 9.0 130 160 5000 7000

1113402
SOLENOID WINDING TEST
Windings, Pull In................................. . Current Draw. . . . . . 26 - 29 amps at 5 volts

Windings, Hold In................................. . Current Draw. . . . . . 18 - 20 amps at 10 volts
STARTER DELCO MODEL NO. 1113672 or 1113402

Item Measurement S p e cifica tio n Wear T o leran ce
Bushing, Overrunning Clutch. . . I.D..................................... 0.562 - 0.563 in . . 0.574 in.
Bushing, Nose Housing................. I.D..................................... 0.562 - 0.564 in . . 0.574 in.
Bushing, Nose Housing........... .. . Oil Clearance................. 0.002 - 0.005 in . . 0.017 in.
Bushing, Commutator End Frame I.D..................................... 0.562 - 0.564 in . . 0.573 in.
Bushing, Commutator End Frame Oil Clearance................. 0.002 - 0.005 in . . 0.016 in.
Bushing, Lever H ousing.............. I.D..................................... 0.757 - 0.758 in . . 0.772 in.
Bushing, Lever H ousing.............. Oil Clearance.................0.010 - 0.013 in . . 0.027 in.
Brush ............................................... Offset D irec tio n ........... To riser bars .
B ru sh ................................. .. . . . . Minimum Length........... 7/16 in. . . . . .
Spring, Brush................................. Minimum Tension . . . . 80 oz..................
Armature......................................... End P la y ......................... 0.050 in.............. 0.060 in.
Pinion................................................. C learan ce...................... 0.010 - 0.140 in
L ith o in U.S.A.
TM-1001 (Nov-79) Starting Motor 20-17
DELCO R E M Y STARTING MOTOR (Continued)
TORQUE VALUES
Item Torque
Nose housing attaching screws ....................................................................................................................11 lb-ft

Starting circuit relay 5/16 inch terminal n u t s ....................................................................................... 35 lb-in
Neutral start sw itc h ................................................................................................................................. 20-25 lb-ft
SPECIAL TOOLS
No. Nome Use
CONVENIENCE TOOLS
........... Pole shoe screw driver......................................... To remove field coils
........... Commutator turning to o l...................................... To turn commutator
Armature t e s t e r .....................................................To check armature for shorts, grounds,
or opens
Spring tension g a u g e ............................................ To check brush spring tension
Pre-lubricated bearing arbor (see Fig. 28). . .To install overrunning clutch bushings
--------3 / k " — ~
0. 6 05"
t
0. 5615"
--- 1S727
Fig. 29-Pre-Lubricated Bearing Adapter
JOHN DEERE STARTING MOTOR
SPECIFICATIO NS
SOLENOID
Wear
Item Measurement S p e cifica tio n Tolerance
Windings Pull I n .........................8 volts or less

Windings Return.........................12 volts..............
STARTER MODEL 028000-3290-ND

No Load Test (Before Disassembly) . . . Current D r a w ........... 70 to 110 amps at
9.0 volts.................
Armature RPM . . . . 2500 to 4500.................
Bushing, Commutator & Drive Housing. . I.D................................... 0.6693 to 0.6704 in. . . 0.6740 in.
Bushing, Commutator & Drive Housing. . Oil C learan ce........... 0.0036 to 0.0070 in .. . 0.016 in.
Bushing, Commutator & Drive Housing. . Depth............................ 0.008 to 0.022 in. . . .
Bushing, Center H ou sin g............................ I.D................................. 1.182 to 1.184 in. . . . 1.189 in.
Bushing, Center H ou sin g............................ Oil C learan ce...................................................... 0.0236 in.
Bushing, Center H ou sin g........................... Depth............................0.017 to 0.032 in. . . .
Brush............................................................... Minimum Length . . . 5/8 in............................
Spring, Brush.................................................. Minimum Tension. . . 40 oz..............................
A rm ature....................................................... End P l a y .................... 0.002-0.020 in.......
Pinion............................................................... Clearance....................0.012-0.185 in.........
No Load Test (After Assem bly)................. Current D r a w ........... 110 amps max. at
11.7 volts......................
Armature RPM . . . . 3100 min.......................
Litho in U .S.A .
20-18 Starting Motor TM-1001 (Nov-79)
JOHN DEERE STARTING MOTOR (Continued)
TORQUE VALUES
Item Torque
Center bearing housing field fr a m e ............................................................................................ 6 lb-ft

Commutator frame and drive housing attaching s c r e w s ......................................................... 10 lb-ft
Starting circuit relay 5/16 inch terminal nuts . . . .................................................................. 35 lb-in
SPECIAL TOOLS
No. Name Use
CONVENIENCE TOOLS
D-01045AA Universal Drive Set To remove and install bushings
MAKING SPECIAL TOOLS

D R IV E END HOUSING AN D COMMUTATOR
EN D FR AM E BUSHING D R IVER S
D rive r
D im ension Removal In s ta lla tio n
A 1" 1"
B 0.7324 - 0.736'T 0.732 - 0.736”
C 0.661 - 0.665" 0.661 - 0.665”
D 2" 3.94"
E 0.901 - 0.909" 0.018 - 0.022”
F 0.783 - 0.791" 0.783 - 0.791”
C E N T E R B E A R IN G BUSHING D R IVER S
Fig. 30-Bushing Driver D rive r

Dim ension Removal In s ta lla tio n
A 1.57" 1.57"
B 1.36 - 1.37" 1.36 - 1.37"
C 1.17 - 1.18" 1.17 - 1.18"
D 2” 2"
E 0.95 - 1.02" 0.018 - 0.022"
F 0.866 - 0.945" 0.996 - 1.000”
Litho in U .S.A .
TM-1001 (Feb-80) Miscellaneous Components 25-1
Group 25
MISCELLANEOUS COMPONENTS
WINDSHIELD WIPER MOTOR
—i To replace the drive gear in the front wiper motor,
remove the clip and washer (1, Fig. 1).
Remove connecting link (2) from drive arm (3).
Remove nut and washer (4), drive arm (3) and

bowed washer (5).
Remove three screws (6) and cap (7).
Remove two felt washers (8) from ears on housing

(9).
Move park adjusting plate (10) out of way and re
move drive gear (11).
1— C l ip a n d W a s h e r 7— Cap
2— C o n n e c t in g L i n k 8— F e lt W a s h e r ( 2 u s e d ) Do the following during installation of the drive gear:
3— D r iv e A r m 9— H o u s in g
A— N ut and W asher 10— P a r k A d j u s t i n g P la t e Coat the space between the bearings in the drive
5— B ow ed W asher 11— D r iv e G e a r
shaft bore with grease.
6— S c r e w (3 u s e d )
Fig. 1-Installing Drive Gear Put enough grease in the worn gear cavity to im
The rear wiper motor is serviceable only as an merse the lower 1/8 inch of the drive gear.
assembly.
Apply a thin film of grease to the portion of the
The front wiper motor drive gear (11, Fig. 1) is housing that contacts the drive gear and to the cam
serviceable as well as the motor assembly. and recessed portion of the gear face.
REMOVAL Complete the installation by reversing the drive gear

Remove wiper arm. removal procedure steps.
Disconnect wire leads and remove attaching hard Installation

ware. Remove wiper motor.
Use attaching hardware to install wiper motor. To
Testing connect wire leads see cab wiring schematic Section
40, Group 5. Install wiper arm.
With the key switch in the “ ACC” position and the
wiper switch ON, use a voltmeter to check the wiring Check wiper for proper operation.
harness for power to the wiper motor.
If there is none here but there is power to the switch,
the switch is defective.
If there is power to the motor, the motor is defective.
Litho in U.S.A.
25-2 M iscellaneous C om ponents TM-1001 (Dec-87)
ADJUSTMENTS 1. Loosen the three screws (1, Fig. 2) fastening the

cover to rear of wiper motor.
Adjust the park position on the front windshield wiper
to obtain maximum operator visibility.
2. If the drive collar parks before completing an
oscillation, turn the adjustment stud counterclock
CAUTION: Keep hands away from linkage
A when the motor is in operation. Do not
attempt to adjust parking when motor is in opera
wise.
3. If the drive collar parks after it has completed an

tion. Never start a windshield wiper when the blade
oscillation and has started the return swing, move the
is frozen to the windshield or manually stop the
adjustment stud clockwise.
blade when the wiper is operating.
4. Start the motor, shut it off and note the new
Use the following procedure:
parking position of the drive collar.
5. If the blade does not park in the required position

(1.5 to 2 inches [38 to 51 mm] from windshield mold
ing), readjust by following the procedure outlined in
Steps 1, 2 and 3 until the correct parking position is
obtained.
6. Tighten the cover screws to 18 to 22 lb-in (2.0 to

2.5 N-m).
1— Cover Screws 2— Park Adjusting Stud
Fig. 2-Windshield Wiper Adjustment
HOUR METER
TEST
A — A T 3 0 1 5 2 H o u r M e te r
( S e r ia l N o . 001699)
Fig. 3—Testing Hour Meter

T6680AO
Litho in U.S.A.
Grader, M o to r - JDS70 E le ctrica l System 40
TM-1001 (Dec-87) M iscellaneous Com ponents 25-3
If hour m eter fa ils to fu n ctio n , check to see if W hen applying voltage to the AT33995 Hour
electrical and ground w ire connections are secure. Meter, apply current to the connecting jo in t, not at
Make sure current is being supplied to hour m eter the wire hold down nut. Ground wire has a bare lead
when key sw itch is on. and can be used. If hour m eter registers when th is
is done, it is fu n ctio n in g norm ally and should not
If above te sts do not indicate a problem in w ir be replaced. This te st indicates a short or break in
ing, remove hour m eter from unit. Test by running the w iring to or from the meter.
ju m p e r w ires from a 12-volt battery through the
hour meter.
L ith o in U.S.A.
25-4 Miscellaneous Components TM-1001 (Dec-87)
Lit ho in U.S.A.
Grader, M o to r - JD570 Power Train 50
TM-1001 (Dec-87) Engine D isconnect C lutch 5-1
Section 50
POWER TRAIN
P age Page
GROUP 5 - ENGINE DISCONNECT GROUP 15 - POWER SHIFT
CLUTCH ......................... . .5-1 TRANSMISSION (Continued)
Speed Selector and D irection S elector
.10-1 L in k a g e ................................................... . .15-96
R em oval................................................... . .15-97
GROUP 15 ■ POWER SHIFT In s ta lla tio n ............................................ . .15-97
.15-1 A d ju s tm e n ts .......................................... . .15-98
15-18 C lutch Pedal Valve Linkage
15-26 R em oval................................................... ..15-99
15-30 In sta lla tio n ............................................ ..15-99
C lutch Oil Pressure Regulating Valve A djusting Pedal V a lv e ......................... .15-100
( -406497).................................... 15-32 A djusting Speed o f S h ift ................... .15-101
C lutch Oil Pressure Regulating Valve O il Filter and Pump In ta k e ..................... .15-102
(406498- ) .................................... 15-34
Transm ission C ontrol Valve A s s e m b ly .. .15-35 GROUP 20 - DIFFERENTIAL, DIFFERENTIAL
Transm ission Case and C o ve rs.................. 15-42 CONTROL AND VALVE
Transm ission C lutch H o u s in g .................... 15-44 D ifferential
C lutch Pack and O il M a n ifo ld .................... 15-46 General Inform ation ...................................20-1
Disassem bling High-Range Clutch R em oval..........................................................20-1
P a c k .......................................................... 15-50 D ifferential ....................................................20-2
A ssem bling High-Range C lutch P a c k ,.15-51 Installing New Ring G e a r ...................... 20-2
D isassem bling Low-Range C lutch Disassem bling and A s s e m b lin g .........20-3
P a c k .......................................................... 15-52 Testing and A d ju s tin g ............................ 20-6
D isassem bling M anifold and Oil In s ta llin g ....................................................20-6
P u m p ........................................................ 15-55 A d justing Bearing P re lo a d .................... 20-7
A ssem bling M anifold and Oil P u m p .. .15-58 A d justing B a c k la s h .................................20-7
A ssem bling Low-Range C lutch Pack . .15-60 Final In s ta lla tio n .....................................20-8
Hi-Lo C lutch and Oil M anifold D ifferential Drive S haft
A ssem bly A ir T e s t .................................15-61 D is a s s e m b lin g ............................................. 20-8
Planetary P a c k ................................................15-62 A d justing Cone P o in t .................................20-9
R em oving......................................................15-62 A s s e m b lin g ................................................. 20-10
R e p a irin g ......................................................15-63 M easuring End Play .................................20-13
A s s e m b lin g ..................................................15-82 Checking Rolling Drag T o rq u e ................20-14
In s ta llin g ......................................................15-86 Checking Tooth Bearing P a tte rn .............20-15
Planetary C a r r ie r ........................................... 15-73 D ifferential Control Valve
D is a s s e m b lin g ........................................... 15-74 Removal ( -001699) ....................... 20-15
A s s e m b lin g ..................................................15-78 Repair ( -0 0 1 6 9 9 )........................... 20-16
R eduction Gear S haft Removal (001700- ) ....................... 20-16
D is a s s e m b lin g ........................................... 15-87 Repair (001700- ) ........................... 20-17
A dju stin g Preload ..................................... 15-90 A djustm ent and T e s t.................................20-17
A s s e m b lin g ..................................................15-91
In s ta llin g ......................................................15-92
Tow D isconnect
R em oving......................................................15-93
Disassem bling and A ssem bling .......... 15-94
A d ju s tin g ................ 15-95
Litho in U.S.A.
50 Power Train Grader, M o to r - JD570
5-2 Engine D isconnect C lutch TM-1001 (Dec-87)
P age
GROUP 25 - FINAL DRIVE SYSTEM................25-1
General In fo rm a tio n .......................................25-1
R em oval.............................................................25-1
Repair
Tandem D rive............................................... 25-2
Tandem Pivot A s s e m b ly ............................ 25-4
Tandem Drive and Pivot Final
A s s e m b ly................................................... 25-6
Final Drive
Removing Final D rive ................................ 25-7
Disassem bling Final D rive........................ 25-8
A ssem bling Final D rive.............................. 25-9
In sta llin g Final D rive............................. ...2 5 -9
GROUP 30 - SPECIFICATIONS AND

SPECIAL TOOLS
D ifferential, D ifferential C ontrol and Valve
S p e c ific a tio n s ............................................... 30-1
Torque V a lu e s ............................................30-2
T o o ls .............................................................. 30-2
Engine D isconnect C lutch
S pecification s, Torque Values, and
T o o ls .......................................................... 30-2
Final Drive System
S p e cifica tio n s and Torque V a lu e s........ 30-2
Special T o o ls .................... ....3 0 - 4
Power S hift Transm ission
S p e c ific a tio n s ............................................... 30-5
Torque V a lu e s ............................................30-9
Special T o o ls ..............................................30-9
Transfer Drive
S pecification s and Torque V a lu e s----- 30-10
Dealer Fabricated Tools
JT38000 D ifferential L iftin g T o o l.......... 30-11
L itho in U.S.A.
TM-1001 (Dec-87) Engine D isconnect C lutch 5-3
T62S90N
1— S pecial Pin (4 used) 8— Lock W asher (2 used) 14— Cap S crew (2 used)
2— Y oke (2 used) 9— N ut (2 used) Lock W ash er (2 used)
3— C o tter Pin (6 used) 10— Clutch D isconn ect Cable 15— W ash er (2 used)
4— Jam N ut (2 used) 11— Clutch D isconn ect Lever 16— C lutch Lever
5— C ontrol Rod 12— C able C lam p (2 used) 17— Special Pin
6— C lutch D isconnect Bracket 13— C ap Screw 1 8 — W a s h e r (001144- )
7— Spring 19— C a p S crew
Fig. 1-Clutch Disconnect Linkage
REMOVAL Remove cotter pins and pins to remove control rod

(5, Fig. 1) with yokes (2) from clutch lever and clutch
Disassemble clutch control linkage using Figs. 1 and
fork shaft.
2 as a guide.
Remove cotter pin (3, Fig. 1) and pin (1) to discon

REPAIR
nect cable (10) from clutch disconnect lever (11). Inspect cable for wear, binding or broken strands.
Remove cotter pin (3) and pin (17) to remove lever. Inspect pivot points for wear.
Remove cotter pin and pin to disconnect cable from Replace parts as necessary,
clutch lever (16). Remove cable clamps (12) to remove
cable.
Litho in U.S.A.
50 Power Train Grader, Motor - JD570
5-4 Engine Disconnect du tch TM-iOOi (Feb-80)
Adjusting Clutch Lever Linkage

Position the clutch disconnect lever in cab so lever is
in the release position.
Disconnect upper yoke (5, Fig. 2) from clutch fork

shaft (7). Rotate clutch fork shaft counterclockwise as
far as possible so that the clutch release bearing is
resting firmly on the clutch fingers.
Adjust yoke until aligned with clutch fork shaft. Back

off yoke approximately half the hole diameter. Tighten
jam nut against yoke. Install pin and secure with cotter
pin.
After adjustment, start the engine and operate clutch

hand lever to be sure of complete clutch disengage
ment.
1— C lutch D isconnect 5— Upper Yoke

SERVICING RELEASE BEARING
Cable 6— C lutch Rod
AND LINKAGE
2— C lutch Lever 7— C lutch Fork
3— C lutch D isconnect Shaft Removal
B racket 8— Lower Yoke
4— Spring Separate the transfer drive housing from engine
Section 10, Group 25.
Fig. 2-Disconnect Clutch Controls
INSTALLATION
Coat all pivoted joints of clutch linkage with John
Deere High Temperature Grease or an equivalent.
Connect clutch rod (6, Fig. 2) and yokes (5 and 8)

assembly to clutch fork shaft (7) and clutch lever (2).
Secure with pins and cotter pins.
Connect clutch disconnect cable (1) to clutch lever

and disconnect clutch lever (11, Fig. 1). Secure with
pins, cotter pins, and cable clamps (12).
1— C lutch Fork 4— C lutch Fork

Install disconnect clutch lever (11) and secure with
S haft 5— Release Bearing
pin and cotter pin. 2— Pin 6— Release Bearing
3— C otter Pin C arrier
Operate rear steer to make sure that cable does not
pull tight when frames are articulated. Fig. 3-Clutch Release Bearing Assembly
Litho in U.S.A.
Grader, Motor - JD570 Power Train 50
TM-1001 (Feb-80) Engine Disconnect Clutch 5-5
Remove release bearing carrier (6, Fig. 3) from SERVICING CLUTCH AND
carrier sleeve and clutch fork (4). PRESSURE PLATE
Remove cotter pin (3) and pin (2) from dutch fork Removal
and remove clutch fork shaft (1) and clutch fork (4)
from transfer housing.
Repair
Inspect clutch fork shaft, clutch fork and release
bearing carrier for wear and damage.
Inspect clutch release bearing (5, Fig. 3) for wear.
Replace parts as necessary.
installation
Coat all pivoted joints of clutch assembly with John
Install clutch fork (4, Fig. 3) with cored holes to rear.
Pack bore of release bearing carrier (6) with John

Deere High Temperature Grease or an equivalent.
Install release bearing (5) with seal side toward clutch 1— C lutch Disk 4— Pressure Plate
2— Cap S crew s (6 used) A ssem bly
and flush with clutch side of hole.
3— Flywheel
Operate the clutch fork shaft (1) by hand several Fig. 4-Disconnect Clutch Assembly
times after assembly to be sure the bearing carrier
moves freely on the carrier sleeve. Separate the transfer drive housing from engine
Install the transfer drive housing as instructed in
Section 10, Group 25. Remove six cap screws (2, Fig. 4) securing clutch
pressure plate assembly (4) to engine flywheel.
Note location of spacers (11, Fig. 5) when removing

pressure plate assembly from flywheel. The spacers
are located between the pressure plate and the fly
wheel.
Remove clutch disk (1, Fig. 4) from flywheel hous

ing.
Remove pilot bearing (15, Fig. 6) if required.
Litho in U.S.A.
50 Power Train Grader, Motor - JDtj>70
5-6 Engine Disconnect Clutch TM-1001 (Feb->80)
Repair
1— P ressure Plate 5— P ivo t Pin (3 used) 9— A djusting Screw W asher

2— B racket 6— R eturn Clip (3 used) (3 used)
3— R elease Lever 7— A djusting S crew (3 used) 10— Spring Cup (6 used)
4— P ressure S pring (6 used) 8— A djusting S crew Lock N ut (3 used) 11— Spacer (6 used)
Fig. 5-Sectional View of Clutch Pressure Plate Assembly
Refer to Figs. 5 and 6 for identification of parts. Assemble release levers (3, Fig. 5) and bracket (2)
with new pivot pins (5). Peen over ends of pins (5) to
When cleaning clutch assemblies, do not immerse secure assembly.
clutch drive facings in any type of cleaning solution as it
will tend to glaze them. Make certain slots in bracket (2) align with the
pressure plate drive lugs.
Place the pressure plate assembly on a flat surface,
plate down, and centrally located. Depress the inner Apply lubriplate to sides of drive lugs to assure free
ends of the release levers (3, Fig. 5) as far as possible operation of clutch assembly.
without forcing against bracket (2). Use a hydraulic
press, applying the load through a steel plate repre Place assembly on a hydraulic press and apply
senting the clutch release bearing. pressure on the lever (3) directly above the pressure
spring (4) while forcing the spring into position in
Remove return clips (6), loosen lock nuts (8), and bracket (3).
back out the three adjusting screws (7) from pressure
plate. Install adjusting screws (7) with lock nuts (8) and
return clips (6). Release assembly from press.
Release assembly (by gradually releasing load on
press) and disassemble for inspection. To separate
release levers (3) from bracket (2), grind off peened
ends of pivot pins (5).
Inspect all parts for wear, rust and other damage.

Check pressure spring compression (1-11/16 in.
height at 149 to 165 lbs.).
Litho in U.S.A.
TM-1001 (Feb-80) Engine Disconnect Clutch 5-7
Installation
1— C ap Screw (6 used) 6— Release Lever (3 used) 9— Cap Screw (6 used) 13— Pressure Plate
2— R eturn C lip {3 used) 7— Spring (6 used) 10— Lock W ash er (6 used)14— C lutch D isk
3— Lock N ut (3 used) 8— Spring C up (6 used) 11— B racket 15— P ilot Bearing
4— W asher (3 used) ( -141262) 12— S pacer (6 used)
5— P ivot Pin (3 used) Spring C up (6 used)
(141263- )
Fig. 6-Pressure Plate Assembly
Pack bearing (15, Fig. 6) and fill cavity in crankshaft

with John Deere High Temperature Grease or an
equivalent.
Install bearing (15) with shielded side toward clutch

surface of flywheel. Drive the bearing on the outer race
only to prevent bearing damage. V J
SIR l V
j j OD-264
Use an old transmission drive shaft or a clutch
aligning tool (JDE 52-A), when installing clutch disk r
\
and clutch pressure plate assembly. L iJ
0.480
----- I u.aiu
Install clutch disk (14) with hub side facing flywheel.
_ T 3 864 0N ______
Align clutch disk assembly with clutch shaft bearing
when assembling clutch assembly to flywheel. Fig. 7-Modifying Clutch Adjustment Gauge
Insert spacers between flywheel and pressure plate Place the legs of modified gauge against flywheel
bracket (11). with the cutout portion over the lever to be adjusted.
Tighten pressure plate-to-flywheel cap screws (9) to

35 ± 4 Ib-ft.
Litho in U.S.A.
5-8 Engine Disconnect Clutch TM-1001 (Feb-80)
Reguiate adjusting screw (7, Fig. 5) and iock nut (8) iMPUH i A n t : The variation in adjusted height of
to properly place release levers. Clutch release levers release levers should not exceed 0.015 inch.
adjusted height is 2.198 to 2.258 in.
Install the transfer drive housing as instructed in
After release levers are adjusted and lock nuts se Section 10, Group 25.
cured, install the return clips. Exercise the levers sev-
abrlU
o ll tlllll&
i m oOc UIIU
o n H Ir &
o rwnv>vr\
' h o r l / UUJUOUH^fl
a r J i u e t m a n Ik.
t
Litho in U.S.A.
TM-1001 (Nov-78) Transfer Drive 10-1
Group 10
TRANSFER DRIVE
GENERAL INFORMATION
1— Input G ear 3— Low er Idler Gear

2— U pper Idler Gear 4— O u tpu t G ear
Fig. 2-Transfer Drive Unit with Upper

and Lower Quills Removed
REMOVAL
Inspect rear bearings in the input and output gear
1— H ub C ap (2 used) 2— Oil Inlet shafts by removing hub caps (1, Fig. 1). This inspection
Fitting can be done without removing the unit from grader.
Fig. 1-Transfer Drive Unit

Remove transfer drive unit as instructed in Section
10, Group 25.
The transfer drive unit (Fig. 1) located at the rear of
the grader, transmits power from the engine to the Refer to page 50-5-3 and remove engine disconnect
transmission. clutch shaft and carrier.
Engine power is transferred from the crankshaft, Use exploded views (Fig. 3 through Fig. 6, page
through the input gear (1, Fig. 2), the two idler gears, 50-10-2 and page 50-10-3) as guides for disassem
and the output gear shaft to the transmission drive bling and assembling the transfer drive unit.
shaft.
Transmission drive shaft and engine crankshaft

speeds are the same. Gear reduction speeds are
regulated by the transmission, differential, and final
drive.
Litho in U.S.A.
50 P o w er T ra in Grader, Motor - JD570
1 0 -2 T r a n sfe r D r iv e TM-1001 (Nov-78)
1 - Cop Screw 14 — Shim (.0 0 5 ” ) (as required) 27 - Id le r Shaft

2 - Sealing Washer 15 - Shim (.0 0 3 ” ) (as required) 28 - Bearing Cone (2 used)
3 — Hub Cap 16 — Shim (.0 1 0 ” ) (as required) 29 - B earing Cup (2 used)
4— P ipe Plug 17 - Upper Q u ill 30 — Snap R ing (2 used)
5— C lutch Shaft 18 — Cap Screw (6 used) 31 - Spacer
6 — Transfe r D riv e H ousing 19 — C lutch D rive Shaft 32 — Shim (.0 0 4 ” ) (as required)
7 — Dowel P in (2 used) 20 — Dowel Pin (2 used) 33 — Upper Id le r Gear
8 — Bearing Cup (2 used) 21 — C lu tch Throw O ut B earing C arrier 34 — Cap Screw (10 used)
9 - Bearing Cone (2 used) 22 — C lu tch Fork 35 — Lo ck Washer (10 used)
10 — Pipe Plug 23 - Pin 36 — Cap Screw (6 used)
11 — Input Gear 24 - B earing 37 — L o ck Washer (6 used)
12 - O il Seal 25 — C otter Pin 38 — Cap Screw (4 used)
13 — O -Ring 26 — O-Ring 39 - Lo ck Washer (4 used)
40 — N ut (4 used)
Fig. 3-Upper Assembly of Transfer Drive ( -003133)
1 — Hub Cap 12 — Bearing Cup (2 used) 23 — C lu tch Throw Out 33 - Snap Ring (2 used)
2 - Cap Screw 13 — B earing Cone (2 used) B earing C arrier 34 — Shim (.0 04” ) (as required)
3 — Washer 14 - Inp ut Gear 24 — Dowel P in (2 used) 35 — Shim (.0 0 6 ” ) (as required)
4 — Spacer 15 — O -R ing 25 — B earing 36 - Spacer
5 — P ipe Plug 16 — Shim (.0 0 5 ” ) (as required) 26 - C lu tch Fork 37 — Upper Id le r Gear
6 — Cap Screw (10 used) 17 — Shim (.0 0 3 ” ) (as required) 27 - Pin 38 - N u t (4 used)
7 — Lo ck Washer (10 used) 18 — Shim (.0 1 0 ” ) (as required) 28 — C otter Pin 39 — L o c k Washer (4 used)
8 — A d ju s ta b le Elbow 19 - O il Seal 29 — O -R ing 40 — Cap Screw (4 used)
9 — O-Ring 20 - Upper Q u ill 30 — Id le r Shaft 41 — L o ck Washer (6 used)
10 — T ra n s fe r D riv e H ousing 21 - Cap Screw (6 used) 31 — B earing Cone (2 used) 42 — Cap Screw (6 used)
11 — Dowel P in (2 used) 22 — C lutch D riv e Shaft 32 - B earing Cup (2 used) 43 — O -R ing
44 — Washer
45 — Cap Screw
Fig. 4-Upper Assembly of Transfer Drive (003134- )
Litho in U .S.A .
Grader, motor - JD570 Pow er Train w'/
TM-1001 (Nov-78) T ransfer D rive 1 0 -3
1- Cap Screw 9 - Lo w e r Id le r Gear 17 — O-Ring

2— S ealing Washer 10 - Id le r Shaft 18 - O il Seal
3- Hub Cap 11 - O-R ing 19 — Bearing Cup (2 used)
4- B earing Cone (2 used) 12 - Cap Screw (6 used) 20 - Bearing Cone (2 used)
5- B earing Cup (2 used) 13 — Low er Q u ill 21 — P ipe Plug
6 - Snap Ring (2 used) 14 - Shim (.0 1 0 ") (as required) 22 — O utput Gear
7 - Shim (.0 0 4 " ) (as required) 15 - Shim (.0 0 3 ") (as required) 23 — P ipe Plug
8 — Spacer 16 - Shim (.0 0 5 ") (as required)
Fig. 5-Lower Assembly of Transfer Drive ( -003133)
1 — Pipe Plug 8 — Lower Id le r Gear 15 - Shim (.0 1 0 ") (as required) 22 — B earing Cup
2 — Bearing Cone (2 used) 9 — Idle r Shaft 16 — Shim (.0 0 3 ") (as required) 23 — Pipe Plug
3 — Bearing Cup (2 used) 10 — O-R ing 17 - Shim (.0 0 5 ” ) (as required) 24 — O-Ring
4 — Snap Ring (2 used) 11 — Cap Screw (6 used) 18 — O-Ring 25 - Plug
5 — Shim (.0 0 4 ") (as required) 12 - O il Seal 19 — Bearing Cone (2 used) 26 — Hub Cap
6 — Shim (.0 0 6 ") (as required) 13 ~ Bearing Cup 20 - P ipe Plug 27 — Cap Screw
7 — Spacer 14 — Low er Q u ill 21 — O utput Gear 28 — Washer
29 — O-R ing
Fig. 6-Lower Assembly of Transfer Drive (003134- )
L itho in U .S.A .
10-4 Transfer Drive TM-1001 (Dec-87)
Remove six cap screws (21, Fig. 4) securing upper NOTE: Transfer drive output gear (21, Fig. 6) may
quill (20) to transfer drive housing (10). be serviced without removing transfer drive input gear
and upper and lower idler gears.
Remove upper quill, clutch drive shaft and input gear
as a unit from transfer drive housing. Be careful not to Remove six cap screws (11, Fig. 6) securing lower
damage shim pack. quill (14) to transfer drive housing.
Remove cap screw (2, Fig. 4) securing input gear to Remove lower quill and output gear assembly from
clutch drive shaft and separate parts. transfer drive housing. Be careful not to damage shim
pack.
Remove cap screws (45, Fig. 4 and 27, Fig. 6)
securing upper and lower idler shafts (30, Fig. 4 and 9, IMPORTANT: After removing transfer drive unit,
Fig. 6) to transfer housing and remove idler shaft and do not disengage clutch disconnect as clutch disk
gears. will fall out of alignment.
Care must be taken to prevent loss of shims as the NOTE: The input shaft can be used to align the
idler gears are removed. clutch.
Litho in U.S.A.
TM-1001 (Dec-87) Transfer Drive 10-5
REPAIR Remove bearing cup (1, Fig. 7) from upper quill (2).
Input Gear Assembly Remove bearing cones (3) from both ends of input
gear (4).
Disassembly
Remove other bearing cup (1) from transfer drive
housing.
Remove oil seal (5) from upper quill.
Inspect O-ring (6) for cuts or other damage. Replace

if necessary.
Refer to page 50-10-8 for inspecting, cleaning and

handling of parts.
1— B earing C up (2 used) 4— Input Gear

2— U pper Ouifl 5 — O il Seal
3— B earing C one (2 used)6— O-Ring
Fig. 7-Input Gear Assembly
Litho in U.S.A.
50 Power Train Grader, M otor - JD570
Assembly On early units, apply TY6299 John Deere Gasket

Maker to the outer diam eter of oil seal (C, Fig. 7A).
Drive bearing cups (1, Fig. 7); one in transfer drive
Install oil seal tig h t against shoulder, w ith spring
housing and the other in upper quill (2) until cups
side o f seal tow ard bearing cup.
bottom out.
On later units, cored hole (B, Fig. 7B) in quill
casting is shortened. This elim inates po ssib ility of
oil leaking past the press fit o f oil seal (C).
Therefore, a sealer is not required. Install o il seal
tig h t against shoulder, w ith spring side o f seal
tow ard bearing cup.
Install O-ring (6, Fig. 7) on upper quill if replaced.
Press bearing cones (3) tight against shoulders on

input gear (4). Cones may be heated in oil (approxi
mately 5 to 10 minutes) to not more than 250°F to ease
assembly.

exceed 360CF. Do not allow a flame or heating
procedure to avoid burns.
C — O il S eal
Fig. 7A-Upper Q uill Assembly- Protect assembly from damage and contamination.
Early Units
A — Q u ill
B — C ored H ole
C — O il S eal
Fig. 7B-Upper Q uill Assembly-

Later Units
Litho in U.S.A.
TM-1001 (Dec-87) Transfer Drive 10-6A
Upper and Lower Idler Gear Assembly Remove idler shaft (8, Fig. 8) from idler gear as
sembly.
D isassem bly
Remove bearing cones (1) from idler shaft and idler
gear (6). NOTE: Keep respective shim pack (2) with
bearing cone when removed.
Spacer (3) will be free for removal.
Remove bearing cups (4) from idler gear.
Remove snap rings (5).
Inspect O-ring (7) and replace if necessary.

handling of parts.
A sse m bly
Install snap rings (5, Fig. 8) in snap ring grooves of
idler gear (6).
Drive or press bearing cups (4) in idler gear tight

against snap rings.
Install bearing cone (1) with respective shim pack

(2). Place spacer (3) next to shim pack.
Install other bearing cone and shim pack.
NOTE: Shims may be replaced on either side of

spacer or all shims may be placed on one side of
spacer.
1— Bearing C on e (4 used) 6— Upper Idler Gear

2— Shim (as required) Lower Idler Gear
3— Spacer (2 used) 7— O -R in g (2 used)
4— Bearing C up (4 used) 8— Idler S haft (2 used)
5— Snap Ring (4 used)
Fig. 8-Upper and Lower Idler Gear Assembly
Litho in U.S.A.
10-6B Transfer Drive TM-1001 (Dec-87)
Adjust upper and lower idler gear bearings outside

of transfer drive housing.
Install idler shaft (2, Fig. 9) in idler gear assembly

(1). Place a 2 in. diameter pipe (3), 2 in. long over idler
shaft. Install a long bolt (6) with a 2 in. diameter washer
(5) through idler shaft. Install another washer on end of
bolt and secure assembly with nut (7). Place idler
assembly in a vise.
Start with a shim pack that provides a measurable

amount of end play.
Tighten nut and adjust end play to 0.002 ± 0.002 in.

by removing or adding shims. Rotate idler gear while
tightening.
After adjustment keep shim pack with respective

idler gear for installation.
1— Idler G ear A ssem b ly 4— B earing C on e

2— Idler S h aft 5— W ash er (2 used)
3— 2 in. x 2 in. 6— B olt
(51 m m ) P ipe 7— Nut
Fig. 9-Adjusting Idler Gear End Play
L ith o in U.S.A.
Output Gear Assembly Remove oil seal (6, Fig. 10) from lower quill.
Disassembly Inspect O-ring (4) for cuts or other damage. Replace

if necessary.

handling of parts.
Assembly
Drive bearing cups (1, Fig. 10) one in transfer
housing and the other in lower quill (5) until cups
bottom out.
Install oil seal (6) in lower quill tight against shoulder

with spring side of seal toward bearing cup.
Install O-ring (4) on lower quill if replaced.
Press bearing cones (2) tight against shoulders on

gear (3). Cones may be heated in oil (approximately 5
to 10 minutes) to not more than 250°F to ease assem
bly.

exceed 360°F. Do not allow a flame or heating
1— Bearing C up (2 used) 5— Lower Quill procedure to avoid burns.
2— Bearing C on e (2 used) 6— Oil Seal
3— O utput Gear 7— Pipe Plug Install pipe plug (7) in end of output gear using a
4— O -R ing
non-hardening pipe joint compound. Remove excess
Fig. 10-Output Gear Assembly compound.
Remove bearing cups (1, Fig. 10) from lower quill (5) Protect assembly from damage and contamination.
and transfer housing.
Remove bearing cones (2) from both ends of output

gear (3).
Remove pipe plug (7) from end of output gear.
Litho in U.S.A.
10-8 Transfer Drive TM-1001 (Nov-79)
Cleaning, Handling and Inspecting Inspect bearings for roughness of rotation. Replace
a bearing if its rotation is still rough after cleaning and
Parts which have close operating tolerances must
oiling.
be handled carefully to prevent nicking, scratching, or
denting. The slightest damage to these parts can result
Inspect bearings for scored, pitted, scratched,
in erratic operation and possible malfunction of the
cracked or chipped races, and for indication of exces
transfer drive. These parts should be carefully handled
sive wear of rollers. If one of these defects is found,
and protected during removal, cleaning, inspection,
replace the bearing.
and installation.
Inspect the defective bearing’s housing and shaft for
All parts must be clean to permit effective inspection.
grooved, burred, or galled conditions that indicate the
During assembly, it is very important that no dirt or
bearing has been turning in its housing or on its shaft. If
foreign matter enters the transfer drive. Even minute
the damage cannot be repaired with crocus cloth,
particles can cause the malfunction of close-fitting
replace the defective parts.
parts.
Inspect lip-type oil seals for cuts and hardness.
All metallic parts (except bearings) should be
Replace the oil seals if these defects are found.
cleaned thoroughly with volatile mineral spirits, or by
the steam-cleaning method. Do not use a caustic soda
When replacing lip-type oil seals, make sure the lip
solution for steam cleaning. Gum and varnish deposits
of each oil seal is toward the oil to be sealed (toward
should be removed by allowing the parts to soak in
the inside of the unit). Use a nonhardening seal com
varnish remover.
pound on the outside of the seal to help prevent oil
leaks. Coat the inside of the seal with high temperature
Parts should be dried with compressed air. Steam-
grease (AT30408 or equivalent) to protect the seal
cleaned parts should be oiled immediately after drying.
during shaft installation and to provide lubrication dur
ing initial operation.
Clean oil passages by working a piece of soft wire
back and forth through the passages and flushing with
Inspect gears for scuffed, nicked, burred, or broken
spirits. Dry the passages with compressed air.
teeth. If the defect cannot be removed with a soft
honing stone, replace the gear.
After cleaning, examine the parts and especially the
oil passages to make certain they are entirely clean.
Inspect gear teeth for wear that may have destroyed
Reclean them, if necessary.
the original tooth shape. If this condition is found,
replace the gear.
Bearings that have been in service should be
thoroughly washed in volatile mineral spirts.
Inspect the thrust faces of gears for scores,
scratches, and burrs. Remove such defects with a soft
Before inspection, oil the bearings with the same
honing stone.
type of oil that will be used in the transfer drive.
Lubricate all O-rings with John Deere Multi-Purpose
NOTE: Never spin dry bearings with compressed
Grease or an equivalent before installing.
air. Do not rotate bearings while they are not lubricat
ed.
Litho in U.S.A.
1— O utput G ear A ssem bly

2— Tran sfe r Drive Housing
3— S him s (use as required)
4— Lo w er Quill
5— Cap Screw (6 used)
6— Low er Idler Gear A ssem bly
U pp er Idler Gear A ssem b ly
7— Id ler Shaft (2 used)
8— O -R in g (2 used)
9— S pecial W asher (2 used)
10— C ap Screw (2 used)
11— C lutch Drive Input S haft
12— Input Gear A ssem bly
13— S pacer
14— W asher
15— S pecial Cap Screw
16— S him s (use as required)
17— U pp er Quill
19— O -R in gs (2 used)
20— H ub Cap (2 used)
Fig. 11-Installing Gears, Shafts and Bearings
Litho in U.S.A.
50 Pow er Train Grader, M o to r - JD570
INSTALLATION Input Gear Assembly

Install clutch drive input shaft (11, Fig. 11) in input
Output Gear Assembly
gear assembly (12). Install spacer (13).
Install the output gear assembly (1, Fig. 11) into
transfer drive housing (2). A p p ly John Deere LOCTITE h ig h -stre n g th th re ad
lo c k and se a le r o r e q u iv a le n t to ca p s cre w (15)
Start with a shim pack (3) between housing and th re a d s. S ecure c lu tc h d rive in p u t s h a ft to in p u t
lower quill (4) that provides a measurable amount of g e a r w ith w a sh e r (14) and ca p scre w (15). T ig h te n
end play. ca p scre w to 35 Ib-ft.
IMPORTANT: To avoid damaging O-ring (19) Install input gear and clutch drive shaft and upper
remove it from lower quill while adjusting end play. quill (17) in transfer drive housing.
Tighten lower quill cap screws (5) securely. Start with a shim pack between housing and quill
that provides a measurable amount of end play.
Adjust end play to 0.002 ± 0.002 in. by removing or
adding shims between housing and quill. IMPORTANT: To avoid damaging O-ring (19)
remove it from upper quill while adjusting end play.
Install O-ring (19) on lower quill and tighten cap
screws (5) to 35 Ib-ft. A p p ly Jo h n Deere LO C TITE m e d iu m -s tre n g th
th re a d lo c k and se a le r o r e q u iv a le n t to ca p scre w
Idler Gear Assemblies (18) th re a d s . T ig h te n u p p e r q u ill ca p scre w s (18)
Install lower idler gear assembly (6, Fig. 11) and its se cu re ly.
shims in transfer drive housing. Care must be taken to
prevent shims from dropping out of position. Adjust end play to 0.002 ± 0.002 in. by adding or
subtracting shims between housing and quill.
Install idler shaft (7) with a twisting motion to aid in
starting shims onto shaft. If shaft does not go in easily, Install O-ring (19) on quill and tighten cap screws
remove shaft and check for shims out of alignment or (18) to 35 Ib-ft.
burrs on end of shaft.
Coat outside surface of hub caps (20) with Permatex
IMPORTANT: Do not drive shafts into position. No. 2 Sealer or an equivalent before assembly. Press
hub caps into transfer drive housing.
A p p ly Jo h n Deere LO C TITE m e d iu m -s tre n g th
th re a d lo c k and se a le r o r e q u iv a le n t to ca p scre w Install bearing tube (2, Fig. 12) on clutch drive input
(10) th re a d s. In s ta ll O -ring (8) on ca p scre w (10) and shaft (3) per dimension (1) to insure that end of tube
se cu re id le r s h a ft w ith w a sh e r (9) and cap scre w . does not rupture oil seal.
T ig h te n ca p screw .
Using the same procedure, install the upper idler
gear assembly.
Litho in U.S.A.
Grader, M o to r ■ JD570 Power Train 50
TM-1001 (Dec-87) Transfer Drive 10-11
The flow of lubricating oil into the transfer drive is

metered by an orifice in the inlet line fitting. Be sure to
use correct fitting if replacement is necessary. See oil
inlet fitting (2, Fig. 1).
Pour 5 qts. of recommended hydraulic oil into

transfer drive housing before installing both quills. This
will insure lubrication of the transfer drive during initial
minutes of operation following assembly.
Install transfer drive to transmission and engine

(Section 10, Group 25).
1— 2.91 ± 0.04 in. 3— C lutch Drive Input

2— Bearing Tube Shaft
Fig. 12-lnstalling Bearing Tube
Pack spline bore of output gear (1, Fig. 11) with John
Refer to page 50-5-4 and install engine disconnect

clutch shaft and carrier.
L ig h tly c o a t e xte rn a l s p lin e end o f c lu tc h drive

in p u t s h a ft (11) end w h ich enga g e s d is c o n n e c t
c lu tc h a sse m b ly, w ith John Deere LOCTITE high-
s tre n g th th re a d lo c k and se a ler o r an e q uiva le nt.
Litho in U.S.A.
50 Power Train Grader, Motor - JD 5 7 0
10-12 Transfer Drive TM-1001 (N ov-79)
Litho in U.S.A.
TM-1001 (Nov-78) Power Shift Transmission 15-1
Group 15
POWER SHIFT TRANSMISSION
1— Transfer Drive 3— P lanetary Packs 5— Differential

2— Clutch Pack 4— Parking Brake 6— Tandem Drive
Fig. 1-Power Shift Transmission
GENERAL INFORMATION
The Power Shift is similar to other John Deere The transmission consists of a clutch pack located in
Power Shift transmissions except that it is turned 180 the clutch housing and a planetary pack located in the
degrees and it does not contain a PTO, park pawl, or transmission case.
the idler gear in the reduction gear train. The unit
includes a parking brake mounted on top of the trans A tow disconnect lever can be engaged to discon
mission case. nect the transmission from the differential for towing
the grader.
The Power Shift provides eight forward and four
reverse speeds. Speed ranges are controlled by the
speed selector lever on the shifting pedestal. Shifting
on-the-go and under load is accomplished by two
compound planetary pinion sets which are controlled
by three clutches and four brakes. These are hydrauli
cally actuated by pressure oil from the transmission
pump.
Litho in U.S.A.
50 P o w e r T ra in Grader, Motor - JD570
1 5 -2 P o w e r Shift T r a n s m is s io n TM-1001 (Nov-78)
CLUTCH PACK
ASSEMBLED CLUTCH PACK
1 — C lutch D riv e Shaft 6 — O il Passage

2 - C lutch Pack 7 — C lutch P iston
3 - C l C lutch 8 — C lutch P isto n Return Spring
4 - C2 C lutch 9 — O utput Shafts ( C l and C2)
5 — C l and C2 C lutch P ressure P late 10 — T ransm issio n O il Pump
F i g . 2 - C l u t c h Pack and Trans missio n O i l Pump
Engine power is transmitted from the engine the clutch plates tanged in to the clutch drum
disconnect clutch to the clutch pack (Fig. 2). transmit engine power to the clutch disks
The clutch pack contains two hydraulically splined to the clutch output shaft. The clutch
operated clutches (Cl and C2). The low range output shaft is forced to rotate in the same
clutch is Cl and the high range clutch is C2. direction at engine speed.
The internal-gear type transmission oil pump
is also located in the clutch pack. The clutches in the clutch pack operate
independently of each other. Either or both
When a clutch is engaged, oil from the trans clutches may be engaged ort disengaged at any
mission oil pump is admitted by the transmission time.
control system to an oil passage in the clutch
drum. Pressure oil enters the cavity behind When a clutch is disengaged, oil pressure
the clutch piston, to compress the clutch disks on the clutch piston is relieved by the trans
and clutch plates against the clutch pressure mission control system. The clutch piston re
plate. turn spring returns the clutch piston to the dis
engaged position, interrupting the flow of engine
Since the clutch drum is rotating at engine power to the clutch output shaft. Oil from the
speed and in the same direction as the engine, clutch piston cavity is returned to the reservoir.
L itho in U .S.A .
TM-1001 (Nov-78) Power Shift Transmission 15-3
Planetary Pack
T40680N
1— B4 5— P lanet Pinions 9— C om pound Planetary S et

2— C3 6— B2 10— Planet Pinion Carrier
3— B3 7— B1 11— O verdrive and Reverse
4— S un P inions 8— Ring Gear P lanetary Set
Fig. 3-Planetary Pack
The planetary pack (Fig. 3) is mounted in the trans The planetary pack contains four disk-type brakes
mission case. It contains four planetary systems com for the planetary systems as follows:
bined into two sets of two each. All the planet pinions
are mounted on shafts in a single carrier which rotates B1 - 1st planetary reduction brake
as a solid unit. B2 - 2nd planetary reduction brake
B3 - Reverse brake
Engine power from the clutch pack output shafts is B4 - Overdrive brake
transmitted by the planetary pack at different speeds
and direction of rotation to the reduction gear train. A clutch (C3) is provided for direct drive applications.
This clutch operates independently of the clutches in
the clutch pack.
Litho in U.S.A.
50 P o w e r T rain Grader, Motor - JD 570
15_4 P o w e r Shift T r a n s m is s io n TM-1001 (Nov-78)
TORQUE PATHS THROUGH TRANSMISSION
Fig. 4—Flow o f Engine P ow er in F i r s t Speed Forward
Fig. 17, page 50-15-19 (chart) shows the clutches The flow of engine power is from the engine
and brakes which must be engaged to obtain the disconnect clutch to Cl in the clutch pack. The
various transmission speeds. The transmission hy Cl clutch shaft transmits power from Cl to the
draulic control system controls the actual engage Cl sun pinion in the planetary pack.
ment of clutches and brakes.
Since B1 restrains one ring gear from turn
F i r s t Speed F o rw a rd ing, the planet pinions "walk around” the ring
When the transmission control lever is placed gear, forcing the planet pinion carrier to rotate
in the first speed forward position, the hydraulic in the same direction as the sun pinion, but at a
transmission control system engages Cl in the slower rate of speed. The planet pinion carrier
clutch pack and B1 and C3 in the planetary pack transmits power to the overdrive and reverse
(Fig. 4). planetary set.
CLUTCH PLANETARY When C3 is engaged, both sun pinions in the

PACK PACK overdrive and reverse planetary set are locked
Cl C2 B1 B2 B3 B4 C3 together. Since the planet pinions cannot rotate
X X X at different speeds the planetary set rotates as
a solid unit and acts as a direct drive to the
Fig. 5 - C l u t c h e s and Brakes Engaged transmission reduction gears.
for 1st Speed Forward
L itho in U .S.A .
Grader, Motor - JD570 P o w er T ra in 50
TM-1001 (Nov-78) P o w er Shift T r a n s m is s io n 15-5
T h ir d S p e e d R e v e r s e
Fig ure 6 —F lo w o f E ngine P ow er in T h i r d Speed Reverse
When the transmission control lever is placed Since B1 restrains one ring gear from turn
in the third speed reverse position, the hydraulic ing, the planet pinions ’’walk around" the ring
transmission control system engages C2 in the gear, forcing the planet pinion carrier to rotate
clutch pack and B1 and B3 in the planetary pack in the same direction as the sun pinion, but at a
(Fig. 6). slower rate of speed. The planet pinion carrier
transmits power to the overdrive and reverse
CLUTCH PLANETARY planetary set.
PACK PACK
Cl C2 B1 B2 B3 B4 C3 When B3 is engaged, one ring gear is restrain
X X X ed from turning. As the planet pinion carrier ro
Fig. 7—Clutches and Brakes Engaged
tates, the planet pinions in mesh with the ring
for 3rd Speed Reverse gear are forced to rotate on their axes, driving
the inner planet pinions, which in turn force the
The flow of engine power is from the engine sun pinion to rotate in the opposite direction
disconnect clutch to C2 in the clutch pack. The from the planet pinion carrier. The sun pinion
C2 clutch shaft transmits power at engine speed which is driven by the planet pinions drives the
from C2 to the C2 sun pinion in the planetary transmission reduction gears.
pack.
L itho in U .S.A .
50 Power Train Grader, Motor - J D 5 7 0
15 -6 Power Shift Transmission TM-1001 (N o v -7 8 )
TRANSMISSION CONTROL SYSTEM
1— Pressure Oil (175 psf) 8— To Main Hydraulic Pump 15— Orifice (2 used)
2— Low Pressure Oil 9— From Hydraulic Oil Filter 16— Rear Accumulator
3— Pressure Free Oil 10— From Oil Cooler 17— Front Accumulator
4— Pedal Valve 11— Transmission Lubrication 18— Sump Strainer
5— Oil Pressure Regulating Valve 12— Priority Lube Orifice 19— Speed Selector Valve
6— Return Pressure Check Valve 13— Plug 20— Transmission Oil Filter
7— Oil Cooler Relief Valve 14— Transmission Oil Pump 21— Oil Filter Relief Valve
Fig. 8-Transmission Control System - Dual Accumulator (1700- )

(Neutral Forward Illustrated)
Litho in U.S.A.
Grader, Motor - JDo70 Power Train 50
TM-1001 (Aug-72) Power Shift Transmission 15-7
T he tr a n s m is s io n h yd rau lic s y s te m g e n e r ing. The v a lv e h ou sin g r e c e iv e s o il under p r e s

a te s , d ir e c ts , and c o n tr o ls the p r e s s u r e and flow su r e fro m the tr a n s m is s io n o il pump and p e r
of o il w ithin the tr a n s m is s io n . H yd rau lic s y s te m fo r m s the fo llo w in g functions:
oil lu b r ic a te s and c o o ls the tr a n s m is s io n p a rts
and a p p lie s the c lu tc h e s and b ra k es. 1. O il F ilte r R e lie f V a lv e
If the tr a n s m is s io n o il filte r b e c o m e s
Oil i s drawn fro m the tr a n s m is s io n sum p clo g g ed w ith slu d g e o r i s o th e r w ise o b stru cted ,
through a w ir e -m e s h str a in e r . the o il filte r r e lie f v a lv e op en s to retu rn p r e s
su r e o il to the r e s e r v o ir .
( -1699)
The pump d e liv e r s it s en tir e output to a f u l l- 2. A ccu m u lator C harging O rific e
flow o il filte r . The accu m u la to r ch argin g o r ific e i s co m
p o se d o f a fix ed o r ific e to g iv e a m inim um a c
(17 0 0 - ) cu m u lator ch argin g ra te .
The pump d e liv e r s 1.2 gpm to the tr a n s m is sio n
lu b rica tio n c ir c u it and r em a in d er to tlje o il filte r . ( -1 699)
E a r ly u n its have an ad ju stab le o r ific e w hich
T he tr a n s m is s io n co n tro l s y s te m (F ig . 8, page p r o v id e s a m ean s of v a r y in g the sh ift ra te .
5 0 -1 5 -6 ) c o n s is ts of the fo llo w in g com ponents: 1.
tr a n s m is s io n o il pump; 2. o il p r e s s u r e r e g u la t (1 7 0 0 - )
ing va lv e; 3. dual accu m u lator; 4 . tr a n s m is s io n L a ter u n its have 2 fix e d o r if ic e s w hich are
con tro l v a lv e; and 5. p ed a l v a lv e . fa c to r y adjusted.
W hen the s e le c to r le v e r i s m oved fro m one 3. P r e s s u r e R egu latin g V alve

tr a n s m is s io n sp e e d to an oth er, co n tro l is a - The o il p r e s s u r e reg u la tin g v a lv e su p p lies
ch iev ed by o p eratin g the follo w in g com ponents: o il to the tr a n s m is s io n co n tro l sy s te m .
Transmission Oil Pump 4. R eturn P r e s s u r e Check V alve

The tr a n s m is s io n pump is lo ca ted in the r e a r The ch eck v a lv e a llo w s retu rn o il from
se c tio n o f the clu tch h ou sin g. It is d riv en by the h y d ra u lic fu n ction s to go to the c o o le r and r e s
output sh aft in the tr a n sfe r d riv e h ou sin g. The e r v o ir , w h ile p rev en tin g p r e s s u r e o il fro m
pump is a p o s itiv e -d is p la c e m e n t, g e a r -ty p e unit en te r in g the h yd rau lic retu rn s y s te m and " b a ck
(r e fe r to FOS H y d ra u lics). in g up" through the h y d ra u lic filte r .
( -1699) 5. O il C oo ler R e lie f V alve

T r a n sm issio n o il pump d e liv e r s ap p ro x i The o il c o o le r r e lie f v a lv e lim its the p r e s
m ately 13 gpm at 1900 rp m with 170 to 180 p s i su r e o f o il to the o il c o o le r and the m ain h y
at ap p ro x im a tely 120° F. d ra u lic pump. W henever o il p r e s s u r e in the v a lv e
h ou sin g e x c e e d s the v a lv e se ttin g , the o il c o o le r
(170 0 - ) r e lie f v a lv e op en s to retu rn p r e s s u r e o il to the
T r a n sm issio n o il pump d e liv e r s a p p ro x i r e s e r v o ir .
m ately 15 gpm at 1900 rpm w ith 170 to 180 p si
at ap p ro x im a tely 120° F . (1.2 gpm to p r io r ity Accumulator
lu b e, 13.8 gpm fro m o il p r e s s u r e reg u la tin g ( -1699)
v a lv e ). E a r lie r u n its have a sin g le a ccu m u la to r s y s
te m w ith the a ccu m u la to r lo c a te d in the le ft-h a n d
The pump c ir c u la te s o il to lu b r ic a te the tr a n s w a ll of the clu tch h ou sin g.
m is s io n clu tch , p la n eta ry p a c k s, g e a r s , and b e a r
in g s. It a ls o lu b r ic a te s and c h a r g e s the m ain h y (1 7 0 0 - )
d ra u lic pum p, fo r c e s o il through the o il c o o le r L ater u n its have a dual accu m u la to r s y s te m
to co o l the e n tir e h yd rau lic s y s te m , and su p w ith the a c c u m u la to rs lo c a te d in the tr a n s m is
p lie s p r e s s u r e o il to o p era te the tr a n s m is sio n . sio n co n tro l v a lv e h ou sin g (F ig . 8, page 5 0 -1 5 -
6).
Oil Pressure Regulating Valve
The o il p r e s s u r e reg u la tin g v a lv e h ou sin g is In e ith e r s y s te m the a ccu m u la to r s con trol
lo c a te d on the righ t-h an d sid e o f the clu tch h o u s o il p r e s s u r e during a sh ift and p ro v id e the f o l
lo w in g functions:
Litho in U.S.A.
50 P o w e r T r a in Grader, Motor - JD 570
1 5 -8 P o w e r S h ift T ra n s m is s io n TM -1001 (N ov-78)
1. Maintain a supply of oil in reserve to pro Accumulator pressure returns to normal as

vide a volume of oil to assist in moving the clutch clutch or brake engagement is completed. The
or brake pistons rapidly toward engagement dump valve is returned by accumulator pressure
during a shift. to its normal open position, and the released ele
ments are permitted to complete their cycle by
2. Provide a low system pressure at the time releasing oil to the reservoir through the dump
of initial clutch or brake engagement. This pro valve.
vides smoother shifting just as "slipping” the
clutch does when operating a dry disk clutch. Pedal Valve
3. Give a gradual pressure build-up as the A foot-controlled pedal valve is provided for
shift is accomplished, and provide for a low emergency stops and for inching. This valve con
restriction when the shift is completed and the trols the supply of pressure oil to the Cl and C2
grader is in motion to reduce the pressure drop clutches. When the pedal is depressed, oil pres
in the hydraulic control system. sure is cut off from the clutch elements.
Transmission Control Valve H y d r a u lic C o n tro l S y s te m F la w (F ig s. 9, 10, 11, 1 2

The transmission control valve consists of the a n d 13)
transmission control valve housing and the shift The illustrations on the following pages show
valve housing which are assembled together and the transmission control system elements en
located on the left-hand side of the transmission gaged for each of the twelve grader speeds.
case.
1. Transmission Control Valve Housing The accumulator, pedal valve, and oil pres
The transmission control valve housing sure regulating valve housing are not illustrated
receives oil from the transmission pump and as their function in the transmission control sys
routes it to the proper valves in the shift valve tem is constant relative to grader speed and di
housing to engage the clutches and brakes for the rection.
selected transmission speed.
The direction selector valve has a forward, For example: To obtain the first speed forward,
neutral, and reverse position. clutches Cl and C3, and brake Bl must be engaged
The speed selector valve has nine detented (Fig. 9, page 50-15-10).
positions. Five positions (neutral and first-
through-fourth) are common for forward and The direction selector valve routes pilot oil
reverse speeds. The fifth-through-eighth posi to the No. 4shiftvalve. Pilot oil pressure against
tions are forward speeds only. the valve head compresses the valve spring open
2. Shift Valve Housing ing the C3 port to allow pressure oil to flow to
The shift valves direct pressure oil to the the C3 clutch piston and engage the C3 clutch.
selected brake and clutch pistons. Each valve
has two positions and is actuated in one direc Pilot oil is also routed to the head of the No.
tion by oil pressure from the speed selector 2 shift valve, allowing pressure oil from the pedal
valve, and in the opposite direction by a return valve to pass through the ports in shift valves
spring. Each shift valve works independently. No. 1 and No. 2 to engage the Cl clutch.
The dump valve is located in the shift valve
housing. The dump valve controls the flow of oil Pressure oil from the accumulator is routed
returning to the reservoir from the clutches and through shift valve No. 2 to continue through shift
brakes during a shift. The valve is controlled by valve No. 3 to engage the B l brake.
oil pressure from the accumulator.
During a shift, the accumulator oil pressure Figs. 9,10,11,12 and 13 on the following pages
is reduced due to the volume of oil required for are keyed as follows:
the engagement of the clutches and brakes. As 1, 2, 3, 4 - Shift Valves
accumulator pressure is reduced, the dump valve B l, B2, B3, B4, C3 — Planetary Pack Ele
spring forces the dump valve to the closedposi- ments
tion. When the valve is in the closed position, the C l, C2 — Clutch Pack Elements
return oil passage from the released clutch or — Pressure Oil
brake is closed and the flow of oil from the ele I I- Pilot Oil
ment being released is temporarily prevented ------- ► — Direction of Flow
from returning to the reservoir.
L ith o in U .S .A .
Grader, M otor - J D 5 7 0 Pow er Train 50
T M -1001 (N ov-78) Pow er Shift Transmission 15-9
N e u tr a l ( N o t I llu s tr a t e d ) Shift valve number 4 is pushed to the “ down” posi

tion by pilot oil from the speed selector valve. In this
The transmission pump draws oil through a suction
position it directs pressure oil from the C3 B4 B3
strainer and sends it on through a filter. The oil flow
accumulator to the C3 direct drive clutch.
branches into three power shift circuits:
The transmission requires engagement of only one

1. The speed selector valve
more element to be in gear.
2. The pedal valve, and

F ir s t S p e e d F o rw a rd ( F ig . 9 )
3. The accumulators W hen the speed selector lever is in the first speed
forward position, the C1 low range clutch, B1 low range
Oil flow up to this point will be the same in all brake, and C3 direct drive clutch are engaged.
speeds. In the neutral position, shift valves number 1 ,2
and 3 are in the “ up” position. This allows the oil to flow Pressure oil from the speed selector valve is routed
around the number 1 and 2 shift valves to shift valve to the head of the number 2 shift valve, moving the
number 3. Shift valve number 3 directs the pressure oil valve to the “ down” position. Pressure oil from the
to engage the B1 brake. It is important to note that B1 pedal valve passes through a port in the number 1 shift
is engaged by pressure oil from the clutch pedal valve valve, which is in the “ up” position, and flows to the
circuit when in the neutral position. number 2 shift valve.
Since it takes engagement of three elements in Before reaching the shift valve, on the way to C1
order for power to flow through the transmission, the clutch, the oil passes through the C1 accumulator,
grader cannot move. which modulates the engagement of C1 clutch.
N e u tr a l F o r w a r d ( N o t Illu s tr a t e d ) A port in the number 2 shift valve directs pressure oil

to the C1 clutch.
W hen the speed selector lever is placed in the
“ neutral” position on the forward side of the shift
With the number 2 shift valve in the “ down" position,
quadrant, two elements are engaged: B1 and C3.
oil from the B1 B2 accumulator is routed through it to
the number 3 shift valve. This valve is in the “ up”
Shift valves number 1, 2, and 3 are in the “ up”
position and routes pressure oil to engage the B1
position. In neutral oil flows around the number 1 and 2
brake.
shift valves to the number 3 shift valve. From here it is
directed to engage the B1 brake. Again, it should be
The speed selector valve also directs pilot oil to the
emphasized that B1 is being engaged by pressure oil
head of the number 4 shift valve, moving it to the
from the clutch pedal valve circuit. This occurs only in
“dow n” position. Pressure oil coming from the C3 B4
neutral.
B3 accumulator flows through the direction selector
valve to the number 4 shift valve. In the “ dow n” posi
tion, the shift valve directs pressure oil to engage the
C3 clutch.
Litho in U.S.A.
1 5 -1 0 Power Shift Transmission TM-1001 (Nov-78)
T27144
2nd Speed Forward
Fig. 9-Hydraulic Control System Flow for 1st and 2nd Forward Speeds
Second Speed Forward (Fig. 9) The valve directs pressure oil out the C1 port.
When the speed selector is in the second speed
The speed selector valve also routes pilot oil to the
forward position, the C1 low range clutch, the B2 high
head of the number 3 shift valve, pushing it to the
range brake, and the C3 direct drive clutch are en
“down” position. This allows pressure oil that has been
gaged.
routed from the B1 B2 accumulator and the number 2
shift valve, to flow through a port in the number 3 shift
Pressure oil from the speed selector valve is routed
valve to engage the B2 brake. Pilot oil also causes the
to the head of the number 2 shift valve, moving the
number 4 shift valve to move to the “down” position.
valve to the “down” position. Pressure oil from the
This allows pressure oil from the C3 B4 B3 accumula
pedal valve passes through a port in the number 1 shift
tors and the direction selector valve to flow through a
valve, which is in the “up” position, and flows to the
port in the number 4 shift valve to engage the C3
number 2 shift valve.
clutch.
Litho in U.S.A.
Grader, Motor - J D 5 7 0 Pow er Train 50
T M -1001 (N ov-78) Pow er Shift Transmission 15-11
T h ir d Speed F o rw a rd ( F ig . 1 0 ) Pressure oil is routed from the clutch pedal valve

and through the number 1 shift valve to engage the C2
W ith the speed selector lever in the third speed
high range clutch.
forward position, pressure oil from the control circuit
engages the C2 high range clutch, B1 low range brake,
Pressure oil from the B1 B2 accumulator is routed
and C3 direct drive clutch.
through the number 2 shift valve and out a port in the
number 3 shift valve leading to the B2 brake, engaging
Pilot oil from the speed selector valve is routed to the
the brake.
head of the number 1 shift valve, moving it to the
“ down” position. This opens the valve to the passage
Pressure oil from C3 B4 B3 accumulator is sent by
leading to the C2 clutch. Pressure oil can now flow
the direction selector valve to the number 4 shift valve.
from the clutch pedal valve and through the shift valve
Since it is in the “ dow n” position, the shift valve routes
to engage the C2 clutch.
the pressure oil to engage the C3 clutch.
Pilot oil has also moved the number 2 shift valve to

F ifth Speed F o rw a rd ( F ig . 1 0 )
the “ down” position. This allows pressure oil to flow
from the B1 B2 accumulator and through the valve to W ith the speed selector lever in the fifth speed
number 3 shift valve. The number 3 shift valve is in the forward position, pressure oil from the control circuit
“ up” position, with the port leading to B1 open. The engages the C2 high range clutch, the B1 low range
valve directs the pressure oil through this port,engag brake and the B4 overdrive brake.
ing the B1 brake.
The speed selector valve sends pilot oil to the head
Pressure oil from the C3 B4 B3 accumulator is of the number 1 shift valve, pushing it to the "dow n”
routed by the direction selector valve to the number 4 position. Pressure oil can now flow from the clutch
shift valve. The shift valve is in the "dow n” position due pedal valve and through a port in the shift valve to
to pilot oil from the speed selector valve acting on the engage the C2 high range clutch.
head of the valve. A port leading to the C3 clutch is
open, allowing pressure coming from the direction Pilot oil from the speed selector valve also acts on
selector valve to engage the clutch. the head of the number 2 shift valve and pushes it to
the down position. Pressure oil from the B1 B2 ac
F o u rth Speed F o rw a rd ( F ig . 1 0 ) cumulator is directed through the valve to the number 3
shift valve. The pressure oil is then routed out the shift
With the speed selector lever in the fourth speed
valve connected to the B1 brake and engages the
forward position, pressure oil from the control circuit
brake.
engages the C2 high range clutch, the B2 high range
brake and the C3 direct drive clutch.
When the number 4 shift valve is in the “ up" posi
tion, it opens a port leading to the B4 overdrive brake.
In this speed, the speed selector valve routes pilot
Pressure oil from the C3 B4 B3 accumulator flows
oil to the heads of all four shift valves, forcing them to
through the direction selector valve and is routed by
the "dow n" position.
this port in the shift valve to engage the brake.
Litho in U.S.A.
3 rd S p e e d F o rw a rd
T27146
4 th S p e e d F o rw a rd
T27147
5 th S p e e d F o rw a rd
Fig, 10-Hydraulic Control System Flow for 2nd Through 5th Speed Forward
Litho in U.S.A.
Grader, Motor - JD 570 Pow er Train 50
T M -1001 (N ov-78) Pow er Shift Transmission 1 5 -13
S ix th Speed F o rw a rd ( F ig . 1 1 ) Being in the “ down" position, shift valve number 4 is

connected to the C3 port. Pressure oil from the C3 B4
The C2 clutch and B2 and B4 brakes are engaged
B3 accumulator and the direction selector valve is
when the speed selector lever is placed in the sixth
routed through the C3 port in the shift valve to engage
speed forward position.
in the C3 clutch.
Pilot oil from the speed selector valve is directed to

E ig h th Speed F o rw a rd ( F ig . 1 1 )
the heads of number 1, 2, and 3 shift valves.
The C1 and C2 clutches plus the B4 brake are
Pressure oil from the clutch pedal valve is routed engaged when the speed selector lever is placed in the
through the C2 port in the number 1 shift valve, en eighth speed forward position.
gaging the C2 clutch.
Pilot oil from the speed selector valve acts on the
The number 2 shift valve directs pressure oil from head of the number 1 shift valve, forcing it to the
the B1 B2 accumulator to the number 3 shift valve. The “ dow n” position. The shift valve receives pressure oil
B2 port in the number 3 shift valve routes the pressure from the clutch pedal valve and routes it in two direc
oil to engage the B2 brake. tions. A portion of the oil is routed out the C2 port to
engage the C2 clutch. The rest of the oil is directed to
The number 4 shift valve remains as it was in fifth the number 2 shift valve. Since it is in the “ up" position,
speed, directing pressure oil from the C3 B4 B3 ac the valve directs the pressure oil out the C1 port.
cumulators and direction selector valve to the B4
brake. In the "u p" position, shift valve number 4 is con
nected to the B4 port. Pressure oil from the C3 B4 B3
S e v e n th Speed F o rw a rd ( F ig . 1 1 ) accumulator flows through the direction selector valve
and is routed out of the B4 port in the shift valve to
The C 1, C2, and C3 clutches are engaged when the
engage the B4 brake.
speed selector lever is placed in the seventh speed
forward position.

heads of the number 1 and 4 shift valves, pushing them
to the “ down” position.
The number 1 shift valve receives pressure oil from

the clutch pedal valve and routes it in two directions. A
portion of the pressure oil is routed out the C2 port to
engage the C2 clutch. The rest of the pressure oil is
routed to the number 2 shift valve. Since it is in the “ up”
position, the valve directs the oil out the C1 port.
Litho in U.S.A.
T27148
6th Speed Forward
T27149
7th Speed Forward
T27150
8th Speed Forward
Fig. 11 -Hydraulic Control System Flow for 6th Through 8th Speed Forward
Litho in U.S.A.
Grader, Motor - J D 5 7 0 P ow er Train 50
T M -1001 (N ov-78) P ow er Shift Transmission 15 -1 5
N e u tr a l P o s it io n - R e v e rs e ( N o t Illu s tr a t e d ) S econd Speed R e v e rs e ( F ig . 1 2 )
When the speed selector lever is in the neutral The C1 clutch plus the B2 and B3 brakes are en
position on the reverse side of the shift quadrant, B1 gaged when the speed selector lever is placed in the
and B3, are engaged. second speed reverse position.
Shift valves number 1, 2, and 3 are in the "u p ” Pilot oil from the speed selector valve acts on the
position. Shift valve number 4 is in the "dow n" position. heads of the number 2, 3, and 4 shift valves, pushing
In neutral, pressure oil from the clutch pedal valve is them to the “ down" position.
routed around the number 1 and 2 shift valves and
flows on to shift valve number 3. From here it is Shift valve number 1, in the "u p ” position, routes
directed to engage B1. pressure oil from the clutch pedal valve to the number
2 shift valve. The C1 port in the shift valve directs the
Pressure oil from the C3 B4 B3 accumulator is pressure oil to the C1 clutch.
routed by the direction selector valve directly to the B3
reverse brake. The reverse brake is the only element A second port in the number 2 shift valve directs
not controlled by a shift valve. pressure oil from the B1 B2 accumulator to the number
3 shift valve. The number 3 shift valve, also being in the
F ir s t S p e e d R e v e rs e ( F ig . 1 2 ) “ down" position, allows the pressure oil to flow out the
B1 port and engage the B1 brake.
The C1 clutch plus the B1 and B3 brakes are en
gaged when the speed selector lever is placed in the
Pressure oil from the C3 B4 B3 accumulator is
first speed reverse position.
routed directly by the direction selector valve to engage
the B3 brake.
The number 1 shift valve is in the “ up" position and
directs the flow of pressure oil from the clutch pedal
T h ir d Speed R e v e rs e ( F ig . 1 2 )
valve to the number 2 shift valve. Pressure oil from the
speed selector valve acts on the head of the number 2 The C2 clutch plus the B1 and B3 brakes are en
shift valve, pushing it to the “ down” position and gaged when the speed selector lever is placed in the
opening the C1 port. Pressure oil is directed out this third speed reverse position.
port to the C1 clutch.
Another passage in the number 2 shift valve directs heads of the numbers 1 ,2 , and 4 shift valves, pushing
pressure oil from the B1 B2 accumulator to the number them to the “ down” position.
3 shift valve. In the “ up” position, the B1 port of the
number 3 shift valve is open, allowing pressure oil to The number 1 shift valve, in the “ down” position,
engage the B1 brake. routes pressure oil from the clutch pedal valve out the
C2 port to engage the C2 clutch.
routed by the direction selector valve directly to the B3 Shift valve number 2, also in the “ down” position,
brake. routes the pressure oil from the B1 B2 accumulator to
the number 3 shift valve. Since it is in the “ up” position,
the number 3 shift valve directs the pressure oil out the
B1 port to engage the B1 brake.

routed through the direction selector valve directly
engaging the B3 brake.
Litho in U.S.A.
15 -1 6 Power Shift Transmission TM-1001 (Nov-78)
T27151
1st Speed Reverse
2nd Speed Reverse
T27153
3rd Speed Reverse
Fig. 12-Hydraulic Control System for 1st, 2nd, and 3rd Speed Reverse
Litho in U.S.A.
Grader, M otor - JD570 Power Train 50
TM-1001 (Feb-80) Power Shift Transmission 15-17
4th Speed Reverse
Fig. 13-Hydraulic Control System for 4th Speed Reverse
F o u rth S p e e d R e ve rs e (F ig. 13) Shift valve number 2 routes pressure oil from the B1
B2 accumulator to the number 3 shift valve. The
The C2 clutch plus B2 and B3 brakes are engaged
number 3 shift valve routes the pressure oil out of the
when the speed selector lever is placed in fourth speed
B2 port to engage the B2 brake.
reverse position.

routed by the direction selector valve directly to the B3
heads of the four (4) shift valves, pushing them to the
brake.
“ down” position.
The number 1 shift valve routes pressure oil from the

clutch pedal valve and out the C2 port to engage the
C2 clutch.
Litho in U.S.A.
50 P o w er Train G rader ; M otor - JD 570
*IE_HQ
I V ' I U /D /WVVGI
M j/A r O M /f# T M n e m i e e l r t n
KJII tIL 1 1Gil l*JI 1ll\J\JIKSt 1
Ti ihnA -i iunvmr ji / u u 'u / /
T r f 'T H I
1CO I
n \ / n n a ■■■ i/% a i i m a naa n n n n A r t P i M i m ?

n iu n M u i. iV / w il . w M n m -u r r n u u c u u n c
1. Cover oil cooler with paper or cardboard.
O D im
n u n
A n / i m ^ *■*+
u i 1 1 c u
-fi qo o
o i
+ iSHI a
v jic.
3. Put tow disconnect in the “ TO W ” position.
4. Operate transmission in 8th forward.
5 . Operate circle rotate to heat oil to specifi

cation.
6. Cycle all functions to distribute warm oil.
Litho in U.S.A
TM-1001 (Dec-87) Power S h ift Transm ission 15-19
If transm ission m alfu n ctio n is detected or 4. Depress clu tch pedal. W ith pedal depressed,
suspected, check the condition of the transmission pressure m ust be zero.
oil filte r before conductin g any tests. Be sure that
the filte r bypass valve is operating properly. The. 5. Slowly release the pedal. The pressure should
transm ission control system m ust be supplied with rise at a sm ooth increasing rate u n til the pedal is
an adequate volum e o f clean o il if transm ission 1/2 to 1 inch from the top. A t th is position, the
te sts are to be accurate. pressure should be about 80 psi. Any further move
ment of the pedal should cause the pressure to
P ressure A nd Leakage T e st jum p to approxim ately fu ll clutch pressure. If no
rise in pressure is noticed when the pedal is re
Use the fo llo w in g procedure to te st fo r a leased, check pedal control cable fo r bent or worn
m alfu n ctio n in the transm ission control system or condition.
excessive o il leakage.
1. Put to w disconne ct lever in “ TOW” position.

Block both tandem s so th a t all fo u r drive wheels
are free to rotate.
2. S ta rt engine and operate at fa st idle u n til a

transm ission oil tem perature o f 140 to 150 degrees
Fahrenheit is obtained.
NOTE: Blocking airflow through the grille with a

rug or cardboard can help heat the oil faster.
Fig. 15-Oil Pressure Test Points ( -1699)
Fig. 14-Pump Pressure Test Point
3. Stop engine. Remove return spring and

bypass cap nut. Install a 0 to 300 psi oil pressure
gauge in the “ CLUTCH” te st port (Fig. 14). Start
engine and run at 1900 rpm. Measure pump
pressure. Pressure m ust be 175 ± 10 psi. If
necessary, ad ju st the o il pressure regulating valve
to obtain correct pressure (see page 50-15-64).
Fig. 16-Oil Pressure Test Points
IM P O R TA N T: If th e to w d is c o n n e c t lever is not (1700- ) (4 Gauge Test Setup)
p u t in to th e “ TO W ” p o s itio n , b lo c k in g o n ly one set
o f ta n d e m s o ff th e g ro u n d and o p e ra tin g m a ch in e
a t fa s t id le above firs t g e a r can ca u se dam age to
th e d iffe re n tia l.
Litho in U.S.A.
15-20 Power S h ift Transm ission TM-1001 (Dec-87)
6. Remove te st plugs. If the pressure on engaged clutch and brake ele

m ents is more than 15 psi below pump pressure
( -1699) (Fig. 15) (see step 3), excessive leakage is indicated.
Install 0 to 300 psi oil pressure gauges at B1, B2,
B3, B4, C1, C2, and C3. If pressure is observed on any element when that
element should not be engaged, the trouble is prob
(1700- ) ably a sticking valve or leakage w ith in the control
Test points B1, B2, B3, B4, and C2 are the same valve housing.
as early units. C1 and C3 test points are located
as shown. NOTE: When using the four gauge test method,
the gauges in the B1, B2 and C3, B3, B4 test ports
The C3 gauge w ill register pressure in every posi will show a pressure reading in all gear positions
tion of the speed sele cto r because the te st port is NN through 4R. The gauges are reading ac
at the accum ulator co n tro llin g C3, B3 and B4. C3 cumulator pressure and not the actual pressure at
can be checked in neutral forw ard through 4th the dutch or brake packs.
speed forward as well as 7th speed forward. B3 can
be checked in 5th, 6th and 8th speed forward. 8. Position gear selector lever in 5th gear. Try to
s h ift the forward-reverse lever into reverse. B3
7. W ith the engine running at 1900 rpm, record pressure m ust not exceed 6 psi when reverse lever
pressure on the gauges shown in Fig. 17. is held against the interlock fo r 5 seconds. Repeat
fo r gears 6 through 8.
GEAR CLUTCH a n d / o r BRAKE S H IF T VALVE POSIT ION

Cl C2 B1 B2 B3 B4 C3 N O .1 NO.2 NO. 3 N O .4
NEUTRAL X up up up Down
NEUTRAL Forward X X up up up Down
1st Forward X X X up Down up Down
2nd Forward X X X up Down Down Down
3rd Forward X X X Down Down up Down
4th Forward X X X Down Down Down Down

5th Forward X X X Down Down up up
6th Forward X X X Down Down Down up
7th Forward X X X Down up up Down
8th Forward X X X Down up up up
NEUTRAL Reverse X X* up up up Down

1st Reverse X X X* up Down up Down
2nd Reverse X X X* up Down Down Down

3rd Reverse X X X* Down Down up Down
4th Reverse X X X* Down Down Down Down
4fB3 r e c e i v e s o i l d i r e c t l y from the direc t i o n selector valve without
p a s s i n g t hrough the shift valve assembly.
OIL
VALVE POSITION DIRECTED TO BY WA Y OF
1 up Cl Through Shift Valve N o . 2 from Foot Valve
Down C2 Direct from Foot Valve
2 up Cl From Shift Valve No.l if No.l is Down
Down Cl From Shift Valve No.l if No.l is up
up B1 From Shift Valve No.2 if No.2 is Down

3 Down From Shift Valve No.2 if No.2 is Down
B2
up B4 Direct from Direction Valve

4 Direct from Direction Valve
Down C3
T 24234
Fig. 17-Clutch and Brake Engagement
X Indicates engaged elements
Litho in U.S.A.
Grader, M o to r - JD570 P ow er Train 50
TM-1001 (Dec-87) Pow er S h ift Transm ission 15-21
Lube R e lie f V alve P ressure T e st (1700- )
S P E C IF IC A T IO N S NOTE: If engine speed is increased too much,

Oil Tem perature..........................................................100 ± 10°F
lube pressure can start increasing again due to
Engine Speed......................................................Slow to fast idle restriction through the lube relief valve.
Lube Relief Pressure..................................................... 45-55 psi
E S S E N T IA L T O O LS
If lube pressure is high, lube relief valve may be
stickin g in bore or passages may be restricted.
B—JT01608 Coupler (1/8 x 7/16-20 F 37°)
C—JT05489 Connector (7/16 M 37° x 1/2 M ORB)
If lube pressure is low, do the fo llo w in g :
S E R V IC E E Q U IP M E N T A N D T O O LS W ith gearshift lever in neutral, depress clutch
pedal. If lube pressure increases to sp ecification ,
Tachometer/Temperature Reader
A— Gauge 0—60 psi
leakage is indicated in B1 brake circu it.
NOTE: If temperature is too high, lube pressure Destroke main hydraulic pump. If lube pressure
may not increase to lube relief specification. increases to sp ecification , leakage is indicated in
a hydraulic system non-return com ponent (saddle
1. Check transm ission o il level. lock pin valve, brake valve, diffe re n tia l lock, or
hydraulic filte r relief valve).
2. Connect tachom eter/tem perature reader.
Remove and inspect lube relief valve and spring.
3. Make te s t connectio n.
Remove transm ission filte r and suction screen
4. Heat oil to te st specification s. (See Hydraulic to inspect fo r m etal particles in filte r and bottom
System Warm-Up Procedure in th is group.) of transm ission case. Low lube pressure can
be caused by excessive wear in transm ission
5. Slow ly increase engine speed from slow idle bushings.
u n til lube pressure stops increasing (relief valve
opens).
L ith o in U.S.A.
15-22 Power Shift Transmission TM-1001 (Dec-87)
Lube Pressure Test (1700- )
S P E C IF IC A T IO N S Remove and inspect lube relief valve and spring.

Engine Speed.................................................................. Fast idle Remove transm ission filte r and suction screen
Lube Pressure (m inim um )....................................................35 psi to inspect fo r m etal particles in filte r and bottom
o f transm ission case. Low lube pressure can be
E S S E N T IA L T O O L S
caused by exce ssive w ear in tra n s m is s io n
B—JT01608 Coupler (1/8 x 7/16 — 20 F 37°) bushings or worn transm ission charge pump.
C—JT05489 Connector (7/16 — 20 M 37° x 1/2 — 20 M ORB)
S E R V IC E E Q U IP M E N T A N D T O O L S
A—Gauge 0—60 psi
1. Make te s t connections.
2. If lube pressure is low, move g e a rsh ift lever

to neutral and depress clu tch pedal. If lube
pressure increases to sp e cifica tio n , leakage is in
dicated in B1 brake circu it.
Litho in U.S.A.
TM-1001 (Dec-87) Power Shift Transmission 15-23
Cooler Relief Valve Pressure Test (1700- )
S P E C IF IC A T IO N S 1. C onnect tachom eter/tem perature reader.

Oil Temperature............................................................100 ± 7°F
Engine Speed....................................................... 1000 ± 10 rpm 2. Make te st connections.
Relief Pressure....................................................... 116 ± 18 psi
3. Heat transm ission oil up to test specification.
(See H ydraulic System Warm-Up Procedure in th is
A —JT03022 Cap (1-1/16 — 12 F 37°)(Parker No. 06CP— 12) group.)
B—JT03178 Plug (1-1/16 — 12 M 37°)(Parker No. 03CP— 12)
D—JT05489 Connector (7/16 — 20 M 37° x 1/2 — 20 M ORB)
E—JT01608 Coupler (1/8 x 7/16 — 20 F 37°) IMPORTANT: DO NOT run test for an extended
period of time or at a higher rpm with flow to main
S E R V I C E E Q U IP M E N T A N D T O O L S pump blocked off.
C—Gauge 0—150 psi 4. Run te s t at sp e cification s.
A low pressure setting can be caused by a weak,

broken, or wrong spring or a valve spool th a t does
not slid e freely in its bore.
Litho in U.S.A.
50 Power Train Grader, Motor ■JD570
Oil Cooler Restriction Test (1700- )
S P E C IF IC A T IO N S 1. C onnect tachom eter/tem perature reader.

Engine Speed........................................................1500 ± 25 rpm 2. Make te st connections.
Cooler Pressure.................................................................... 75 psi
3. Heat transm ission oil up to test specification.
(See H ydraulic System Warm-Up Procedure in th is
B—JT01608 Coupler (1/8 x 7/16 — 20 F 37°) group.)
C—JT05489 Connector (7/16 — 20 M 37° x 1/2 — 20 M ORB)
S E R V IC E E Q U IP M E N T A N D T O O L S
4. Check cooler pressure.
Tachometer/Temperature Reader If cooler pressure reaches test sp e cifica tio n s, a

A —Gauge 0— 150 psi
restricted oil cooler is indicated. Back flush oil
cooler.
Litho in U S A .
Drag Test 3. To check clutch C1, place the speed selector

lever in third speed forward. W ith the grader mov
Use the follow ing te s t to decide whether or not ing in third speed forward, depress the clutch
any of the clutches or brakes have been damaged pedal. If C l is dragging, the grader w ill keep mov
by heat. Disks damaged by heat, can cause ex ing forward but at a slow er speed than before
cessive drag. The person running the test should depressing the clutch pedal.
be fa m ilia r w ith typ ica l Power S h ift Transm ission
drag levels. 4. To check clutch C2, place the speed selector
lever in second speed forward. W ith the grader mov
Power S hift Transm issions norm ally display ing in second speed forward, depress the clutch
some drag in the clutches and brakes. This drag pedal. If C2 is dragging, the grader w ill keep mov
is due to the presence of lubricating oil in the ing forward but at a faster speed than before
clu tch and brake packs. Such drag w ill decrease depressing the clutch pedal.
as engine rpm and oil tem perature increase. Ex
cessive drag due to warped disks w ill increase as 5. To check clutch C3, brake B4 and brake B3,
engine rpm increases. Therefore, it is very im por place the direction selector lever in the neutral posi
tant that proper oil level, oil temperature and engine tion. W ith the grader standing still, place the speed
rpm be attained before running the test. selector lever in firs t speed forward. DO NOT
depress the clutch pedal fo r th is test. If C3 or B4
It is som etim es d iffic u lt to decide whether the is dragging, the grader w ill move forward. If B3 is
drag can be considered excessive. When testing a dragging, the grader w ill move backward.
failed clutch or brake pack, the engine w ill labor
when the clutch pedal is depressed and the grader NOTE: In S t e p s 3 , 4 a n d 5, if d r a g is e v id e n t, p r o
service brakes are applied. When the service brakes c e e d a s fo llo w s:
and clutch pedal are released, the grader w ill ac
celerate q u ickly to its form er ground speed. A . If lu b e o il is c a u s in g th e d ra g , in c r e a s
in g th e e n g in e rp m fro m 1500 rp m to h igh
When testing a clutch or brake pack in good con id le w ill c a u s e th e g r a d e r to s lo w d o w n .
ditio n , the engine w ill not labor when the clutch
pedal is depressed and the service brakes are ap B. If w a r p e d d i s k s a re c a u s in g th e d ra g , in
plied. When the service brakes and clutch pedal are c r e a s in g th e e n g in e rp m fro m 1500 to h igh
released, the grader w ill accelerate slow ly or not id le w ill c a u s e th e g r a d e r to s p e e d up.
at all.
6. There is no ready check to see if brake B1 or
NOTE: Tire p r e s s u r e w ill a f f e c t te s t. T h erefo re, brake B2 is dragging. These brakes are visible when
b e f o r e m a k in g te s t, c h e c k tire p r e s s u r e in e a c h o f the transm ission rear cover is removed.
th e tir e s to b e s u r e th e y a re p r o p e r ly in fla te d .
Remove transm ission case cover and visually
1. Run the test on a hard, level area such as dry check fo r clearance in disengaged packs. Lack of
com pacted clay or a hard surfaced road. clearance indicates brake warpage or a piston
w hich has not com pletely returned.
2. W ith engine speed set at 1500 rpm, transm is
sion oil tem perature should be 100 to 160°F. If the disks are warped, they w ill usually be tight
on the B1 and B2 ring gear and thus feel tig h t to
NOTE: M a k e s u r e e n g in e rp m a n d o il te m p e r a finger pressure. If the disks are in good condition,
tu re a re a tta in e d a n d re m a in c o n s ta n t d u rin g th e the disk and plates can easily be moved back and
te s t. forth w ith finger pressure.
This visual test can be made for all brakes in the

planetary brake pack.
Litho in U.S.A.
Diagnose Powershift Transmission Malfunctions
NOTE: Diagnose malfunction charts are arranged from most probable and simplest to verify, to least likely
more difficult to verify.
Problem Possible Cause Verification/Solution
Transmission Slippage Low oil level Check and add oil.
R estricted oil filte r Remove, inspect and replace filte r.
C lutch pedal linkage o u t o f A djust,

adjustm ent
W eak or broken pressure Do Transm ission Pressure and

regulating valve spring Leakage Test (See Group 50-15.)
F ilte r relief valve stu ck open Remove filte r relief valve and
inspect.
Excessive clu tch or brake Do Transm ission Pressure and

elem ent leakage or s h ift valve Leakage test. (See Group 50-15.)
housing gasket leakage Remove s h ift valve housing and in
spect gasket
Low transm ission pum p flo w Do Transm ission Pump Flow Test.
due to worn transm ission (See Group 70-5.)
pump
Pressure regulating valve Remove and inspect,

housing gasket leakage
Transmission Shifts Too Low oil level (aeration o f Check and add oil.
Slow (unit stops when oil)
changing gears under load)
M isadjusted speed of s h ift A d ju st (See Group 50-15.)
o rifice
Low transm ission system Do Transm ission Pressure and

pressure Leakage Test. (See Group 50-15.)
Transm ission pump su ctio n Remove and clean screen,

screen restricted
Low transm ission pum p flo w Do Transm ission Pump Flow Test.
(See Group 70-5.)
Excessive clu tch or brake Do Transm ission Pressure and

c irc u it leakage (gaskets, piston Leakage Test. (See Group 50-15.)
seals)
B1— B2, o r B3— B4— C3 Remove and inspect accum ulators,

accu m u la to r piston stu ck
Continued on next page
Litho in U.S.A.
Transmission Shifts Too Oil passages restricted Remove control valve and inspect
Slow (units stops when between control valve and oil passages.
changing gears under load)— clutch or brake elem ent
Continued
Erratic Shift (wrong C ontrol valve cables or lever Inspect cable and linkage.
gears or no gear change pivots binding
when gearshift lever is
moved) S hift valve stuck Do Transm ission Pressure and
Leakage Test. (See Group 50-15.)
Remove and inspect valve.
Dump valve stickin g or Do Transm ission Pressure and

transm ission control valve, Leakage Test. (See Group 50-15.)
s h ift valve gaskets failed Remove and inspect gaskets.
Return passage in Remove transm ission control valve

transm ission case restricted and inspect.
Unit Will Not Move In Any No system pressure Check oil level. Add. Do
Gear (no load put on engine Transm ission Pressure and Leakage
when shifted into gear) Test.
C lutch control valve linkage Inspect and repair linkage.

m alfunction
D irection control valve or Inspect and repair linkage.

gearshift linkage m alfunction
M echanical failure in reduction Remove top cover and inspect

and drop train gear area reduction gearbox com ponents.
M echanical failure in Disassem ble and inspect

transm ission transm ission com ponents.
Unit Will Not Move (load put Brake valve m alfunction Destroke main hydraulic pump.
on engine or engine stalls (inlet valve stuck open) If unit w ill now move, repair brake
when shifted into gear) valve.
Park brake dragging Remove, inspect and repair.
Transm ission control valve Do Transm ission Pressure and

gasket leakage or stu ck sh ift Leakage Test.
valve
M echanical failure in Remove, inspect tra nsm ission

transm ission or d iffe re n tia l suction screen fo r m etal particles.
Litho in U.S.A.
Unit Creeps in Neutral Transm ission overfilled w ith Check oil level. Correct.
(Load put on engine when oil
system brakes are applied)
W arped disks and plates Do T ransm ission Drag Test.
in transm ission (See Group 50-15.)
Transmission Hydraulics Transm ission overfilled w ith Check o il level. Correct.

System Overheats (slow oil.
hydraulic functions and
transmission slippage T ransm ission/hydraulic filte rs Remove. Inspect. Replace.
may occur) restricted
F ilte r relief valve or surge Remove and inspect. Check spring

relief valve stu ck open or tension.
spring broken
Low air flo w through oil Inspect radiator, oil cooler for
coo le r and/or radiator debris. Check fan to ensure fan
restricted installed correctly. Check shroud
and b a ffles to ensure b a ffles are in
correct position.
Excessive drag in transm ission Do T ransm ission Drag Test (See

Group 50-15.)
C ooler relief valve s tu c k open Remove and inspect. Check spring

or spring broken tension.
Leakage in main hydraulic Test hydraulic system. (See Group

system 70-6.)
Leakage in transm ission Do T ransm ission Pressure and

hydraulic system Leakage Test. (See Group 50-15.)
Low transm ission pum p output Do T ransm ission Pump Flow Test.
(See Group 70-5.)
Transmission Shifts System pressure too high Do T ransm ission Pressure and
too Fast Leakage Test. (See Group 50-15.)
M isadjusted speed of A djust. (See Group 50-15.)

s h ift o rifice
B1 — B2, o r B3— B4— C3 Remove and inspect accum ulators

accu m u la to r piston s tu ck and/ and s h ift control valve.
or s h ift control valve o rifices
m issing
Loss of 1st, 2nd, 3rd, C3 elem ent failure, C3 circu it Do T ransm ission Pressure and
4th, and 7th Forward leakage, or broken sealing Leakage Test, (See Group 50-15.)
Speeds rings or reduction gear shaft Remove reduction gear sh a ft and
inspect sealing rings.
Litho in U.S.A.
Problem P ossible C au se V e rifica tio n /S o lu tio n
Loss Of All Reverse B3 elem ent failure, B3 Do Transm ission Pressure and
I o 's l / 'a n o T a e t /C n o C ir A im \
o pccuo U C G U \ a ^ ^ / I WII V U ) ^ X^V/~ I \J.J
Fast Shift From 6th to 7th, 8th C3 a ir bleed ball stu ck closed Disassemble and inspect C3 clutch,
to 7th, And 5th to 4th, and or C3 piston return
Engine Lugs Down In 4th springs broken
Reverse
Fast Shift From Forward S tuck B3-B4-C3 Remove and inspect,

To Reverse Or Reverse a ccum ulator piston
To Forward
Unit Moves Suddenly When C lutch valve sticking or spring Remove and inspect valve.
Releasing Clutch Pedal in clu tch valve broken
Lube Pressure Low, Lube relief valve stuck open, Inspect lube relief valve and spring.
Transmission Pressure And broken spring or regulating
Charge Pressure Normal valve housing gasket failed
Excessive wear in bushings Remove transm ission filte r and

in transm ission suction screen to inspect fo r metal
particles in filte r and bottom of
transm ission case.
Lube Pressure Low, Main hydraulic system, non Check fo r leakage at brake valve
Transmission Pressure Normal return leak and differential lock valve return
And Charge Pressure Low ports.
Excessive Transmission Noise Engine slow, idle to low Check engine slow idle speed.
(under load or no load)
Parts worn or damaged in Remove transm ission suction
transm ission. Repair as screen. Inspect for m etal particles.
necessary (See Group 0360.)
Low or no lube flow Check pump fio w to check for worn

transm ission pump. Do Transm is
sion Pump Fiow Tesi. (See Group
70-5.)
Litho in U.S.A.
TRANSMISSION CLUTCH VALVE

The transmission clutch valve is used for emergency Use Fig. 18 for identification of parts and for refer
stops and for inching the unit. This valve controls the ence during disassembly and assembly.
supply of pressure oil to the C1 and C2 clutches. When
the pedal is depressed, oil pressure is cut off from the Remove special pin (23, Fig. 19) holding clutch
clutch elements. valve control shaft (21) to clutch control shaft link (22).
REMOVAL Remove special plug (32) from housing and pull

clutch valve assembly from housing.
Disassemble valve.
Remove control shaft (21) and remove oil seal (19).
Inspect all parts for wear or damage. Replace parts

if necessary.
Check clutch valve and housing bore for excessive

scoring.
Check valve springs.
Spring (26) free length is 2 ± 0.03 in. (51 ± 8 mm)

T70639
and test length is 1.41 at 13 ± 1 lb. force.
1— H ousing 8— Yoke
2— V alve O perating Rod 9— Pin and C otter Pin
Spring (27) free length is 1.3 ± 0.03 in. and test
3— Jam Nut 10— Pin and C otter Pin
4— C lutch Valve 11— Cap S crew (5 used)
length is 1.09 in. at 17 ± 2 lbs. force.
C ontrol Lever 12— Spring
5— Lock W asher (7 used) 13— C otter Pin Spring (28) free length is 0.5 ± 0.03 in. and test
6— Cap Screw (2 used) 14— V alve O perating Arm length is 0.34 in. at 4 ± 0.4 lbs. force.
7— C lutch Pedal Cable
Fig. 18-Clutch Valve Removal
Disconnect spring (12, Fig. 18) from clutch valve

control lever (4) and clutch housing.
Remove cotter pin and pin (10) and disconnect
clutch pedal cable (7).
Remove cap screws (6 and 11) and lock washers
(5).
Remove clutch valve from clutch housing.
Litho in U.S.A.
T2 961 SN
1— Snap Ring 13— Cap Screw (5 used) 25— Shim (as required)
2— W asher 14— Cap Screw (2 used) 26— Pedal V alve Top Spring
3— Control Lever 15— Plug (3 used) 27— Pedal V alve M iddle Spring
4— Spring 16— O-Ring (3 used) 28— Pedal V alve Bottom Spring
5— Pin 17— Control Lever Pivot Shaft 29— Spring Pin
6— Spring Pin 18— Dowel Pin (2 used) 30— C lutch Valve
7— O perating Arm 19— O il S e a l 31— O-Ring
8— Cotter Pin (2 used) 20— Clutch Valve Housing 32— Special Plug
9— O perating Rod 21— Control Shaft 3 3 — G asket ( -406497)
10— Jam Nut 22— Link 3 3 — G as ket (406498— )
11— Yoke 23— Special Pin (2 used) 34— G asket P late ( -406497)
34— G as ket P late (406498- )
12— Pin 24— Pedal Valve Shaft
35— G asket
Fig. 19-Pedal Valve Components
Check clutch valve and housing bore for excessive Install control shaft (21) into housing.
scoring.
Assemble clutch valve and shaft assembly and in
Compare O.D. of clutch valve (30) with new part stall in housing. Connect valve shaft to control shaft
dimension of 0.6861 to 0.6865 inch. link with pin (23).
Replace all O-rings, and seals in assembly. Lightly Press shaft (17) into housing with snap ring
oil all internal parts prior to assembly. groove end protruding 1.34 in.
Install seal (19) even with housing (20) with lips of
seal toward bottom of seal bore (metal side out).
CLUTCH 0 !L PRESSURE REGULATING VALVE
GENERAL INFORMATION REMOVAL
The transm ission o il pressure regulating valve is D isconnect tw o lines from clu tch oil pressure
located on the right side o f clu tc h housing. regulating valve housing. Remove cap screw s and
remove valve.
The pressure regulating valve housing contains
tra nsm issio n o il filte r re lie f valve, lube relief valve,
oil pressure regulating valve and o il cooler relief
valve.
REPAIR
1— Cap Screw (5 used) 13— Plug 24— O rifice M etering Screw 35— G asket
2— W ash er (7 used) 14— C heck V alve Spring ( -*1 6 9 9 ) 36— G asket Plate
3— Cap Screw (2 used) 15— R eturn P ressure C heck 25— 0 -R in g ( -*1 6 9 9 ) 37— G asket
4— H yd rau lic Oil B ypass V alve 26— O -R in g 38— O il Filter R elief V alve
Screw 16— O -R in g 27— Plug 39 — B ypass V alve S pring
5— A lum inum W asher 17— Plug 28— Oil Filter Relief 40— S pring G uide
6— Cap N ut 18— O il P ressu re R egulating V alve ( -*1 7 1 0 ) 41— S pring (*1 7 1 1 - )
7— Cap Screw V alve 29— S pring ( -*1 7 1 0 ) 42— S pring (*1 7 1 1 - )
8— V alve Housing 19— P ressure V alve Spring 30 — Spring G uide 43— 0 -R in g
9— T em p eratu re S ending 2 0 — S him (as requ ired) ( -*1 7 1 0 ) 44 — B ypass V alve P lug
U nit 21— A lum in um W asher 31— S pring ( -*1 7 1 0 ) 45— N ut
10— Oil C oo ler Relief 0 0 — Plnn 0.0___ n .R in n l .*17101 45— w a s h e r
V alve 23 — A d ju sta b le M etering 33— Bypass V alve P lug 47— O -R in g
11— R elief V alve Spring O rifice ( -*1 6 9 9 ) ( -*1 7 1 0 ) 48— Lock W ash er (7 used)
12— A lum inum W asher 34— N ut ( -*1 7 1 0 )
"Transm ission S erial No. Fig. 20-Oil Pressure Regulating Valve—( -406497)
L ith o in U.S.A.
NOTE: On later models, correct valve location Replace all O-rings w ith new.
and position is shown by a symbol and letter cast
on the valve housing (8, Fig. 20). “R ” is oil cooler Put clean hydraulic oil on all internal parts prior
relief valve, “C” is return pressure check valve, “P ” to assem bly.
is oil pressure regulating valve, and “F ” is oil filter
relief valve. IMPORTANT: Hydraulic oil bypass screw (4, Fig.
20) must be installed tight against the seat.
Refer to Fig. 20 d u rin g d isa sse m b ly and
assem bly o f pressure regulating valve. Install the accum ulator o rifice m etering screw
(24) in o rifice to fu ll depth and back o ff 5 turns.
During disassem bly tag valves and springs so
they can be installed in the bore from w hich they When in sta llin g valves in housing, use the same
were removed. number of shim s (20, Fig. 20) under the valve spring
(19) as were removed.
Note the num ber o f a d ju stin g shim s (20, Fig. 20)
under valve spring (19) when removing valve from IMPORTANT: Install clutch oil check valve (15,
housing. Fig. 20) with drilled end facing bottom of bore.
Inspect all parts fo r w ear or damage. Replace

parts if necessary.
Check valve and housing fo r excessive scoring.
Measure O.D. of valve (38, Fig. 21). New valve O.D.

is .6845 ± .0005 in.
Test springs and compare the results with the fol

lowing specifications.
Bypass Valve Spring (39)

(free le n g th )..............................................2.32 in.
(test le n g th ).............................................. 1.58 in.
at 21 ± 2.1 lbs.
Spring (42)
(free le n g th )........................................2 ± .03 in.
(test length) ............................................. 1.41 in.
at 13 ± 1.3 lbs.
Pressure Valve Spring (19)

(free le n g th )..............................................3.94 in.
(test length) ..............................................3.44 in.
at 65 ± 6.5 lbs.
Check Valve Spring (14)

(free length) .............. 2.31 in.
(test le n g th )............... ..................75 in.
at 12 ± 1.2 lbs.
Relief Valve Spring (11)
(free le n g th )............... .............. 3.78 in.
(test length) ............... .............. 3.22 in.
at 37 ± 3.7 lbs.
L ith o in U.SA.
SERIAL NO. (406498- ) Filter Bypass Valve, Upper (S):

Free le n g th ............................... 0.93 in. (24 mm)
Test le n g th ......................... 0.51 in. at 37-45 lb.
(13 mm at 81-91 N)
Filter Bypass Valve, Lower (Q):

Free le n g th ............................... 2.59 in. (66 mm)
(52 mm at 109-133 N)
Lube Relief Valve (N):

Free le n g th ............................... 2.80 in. (71 mm)
(52 mm at 39-48 N)
Pressure Regulating Valve (J):

Free le n g th ............................. 5.61 in. (143 mm)
Test le n g th ........................... 4.27 in. at 57-70 lb
(109 mm at 124-153 N)
Check Valve (H)

Free le n g th ............................... 2.06 in. (53 mm)
Test le n g th ............................... 0.75 in. at 4-5 lb
(19 mm at 8.6-10.3 N)
Cooler Relief Valve (D):

Free le n g th ............................. 4.55 in. (116 mm)
R38061 Test le n g th ........................... 3.53 in. at 37-44 lb
(90 mm at 81-96 N)
A — S ender K — Shim s
B — V alve H ousing L— Plug W ith W ash er
Use same number o f shim s (K, Fig. 21) as were
C — C o o ler R e lie f V alve M — Lube R e lie f V alve
D — C oo ler R e lie f V alve N — Lube R e lie f Spring removed.
Spring O — Plug W ith O-Ring
E— Plug and W a s h e r P — Plug W ith O-Ring
Q — F ilte r B yp ass Low er
INSTALLATION
F — C h e ck V alve Plug
G — C h e ck V alve Spring
H — C h e ck V alve S pring R — Spring G u id e G askets m ust be replaced w henever the
I— Pressure R e g u latin g V alve S — F ilte r B yp ass Upper
Spring
regulating valve is removed. To accom plish this, it
J — Pressure R e g u latin g V alve
Spring T — F ilter B yp ass V alve w ill be necessary to remove the transm ission
clutch valve.
Fig. 21-Oil Pressure Regulating Valve—(406498- ) If removed, install clutch valve.
1. Remove plugs from valve bores. Install pressure regulating valve assem bly on
transm ission clu tch housing and tighten cap
2. Remove valve parts. screws to 45 Ib-ft. (61 N-m).
3. Inspect valve springs. Connect return lines.
ADJUSTMENT
Check setting (Section 70, Group 5) o f pressure

regulating valve. If pressure setting is low add
shim s (20, Fig. 20) or (K, Fig. 21). Remove shim s if
pressure setting is high.
Litho in U.S.A.
TRANSMISSION CONTROL VALVE ASSEMBLY

The transmission control valve assembly consists of Disconnect harness (14, Fig. 22) from neutral start
the transmission control valve housing, accumulators, switch (13).
and shift valve housing, all of which are located on the
left-hand side of the transmission case. Remove cotter pins (2) and pins (3) from speed
selector arm (1) and direction selector arm (5) and
REMOVAL disconnect cables (4).
Disconnect oil tube (10) from control valve (20) and

clutch housing (7) and remove tube.
Remove necessary cap screws.
Remove control valve.
1— Speed Selector Arm 5— G asket

2— D irection S elector Arm 6— S hift V alve Housing
3— Cover 7— Cover
4— Cap Screw (5 used) 8— Cap S crew (6 used)
Fig. 23-Transmission Control Valve Removed

T70641
1— Speed Selector Arm 11— C onnector

Remove cap screws (4, Fig. 23) to remove cover
2— C otter Pin (2 used) 12— Special W asher assembly. See Transmission Control Valve Cover
3— Pin (2 used) 13— Neutral S tart Switch Assembly in this group to disassemble and assem
4— Speed and Direction 14— W iring Harness ble cover.
Cable (2 used) 15— Lock W asher (12 used)
5— Direction S elector Arm16— Cap Screw, 3 /8 x 3 -1 /4
6— Control Valve Cover 17— Cap Screw, 3 /8 x 6 -1 /4
Remove cap screws (8) to separate shift valve
7— Clutch Housing (4 used) housing (6) from control valve.
6— O -R ing (2 used) 18— Cap Screw, 3 /8 x 1 -1 /4
9— Elbow, 90° (6 used)
10— Tube 19— Cap Screw, 3 /8 x 3
20— Housing
Fig. 22-Transmission Control Valve

(JD570A)
Litho in U.S.A.
15-36 Pow er S h ift Transm ission TM-1001 (Dec-87)
1— C a p S c r e w (6 u s e d ) 18— Plug 38— Speed V alve Arm

2— S h i f t V a lv e C o v e r 19— Steel Ball 39— C over G asket
3— G asket 20— 0-Ring (3 used) 40— Oil Seal (2 used)
4— S p e c ia l S c r e w 21— Plug (2 used) 41— Control V alve S h aft (2 used)
5— D u m p V a lv e S p r i n g 22— Cap Screw (2 used) 42— Felt W ash er (2 used)
6— D u m p V a lv e 23— Cap Screw 43— W asher (2 used)
7— S h i f t V a lv e H o u s in g 24— O-Ring (2 used) 44— S pring (2 used)
8— S h i f t V a lv e ( 4 u s e d ) 25— Plug (2 used) 45— Speed V alve Arm
9— S h i f t V a lv e S p r i n g ( 4 u s e d ) 26— Cap Screw (2 used) 46— Spring Pin (2 used)
10— Washer (4 used) 27— Lock Washer (14 used) 47— Cover
11— R e t a i n in g R i n g ( 4 u s e d ) 28— Cap Screw 48— Cap Screw
12— S h i f t V a lv e G a s k e t 29— Cap Screw 49— Cap Screw (5 used)
1 3 — G a s k e t P la t e 30— Direction Selector Valve 50— Spring (*2 1 1 3 - ) (2 used)
14— C o n t r o l V a lv e G a s k e t 31— Spring Pin (2 used) 51— Ball (*2 1 1 3 - ) (2 used)
15— C o n t r o l V a lv e H o u s in g 32— Speed Selector Valve 52— Lock W asher (2 used)
16— S p r in g ( -*2 1 1 2 ) (4 u s e d ) 33— Control Link (2 used) 53— 0 -R in g (4 used)
S p rin g (*2 1 1 3 - ) (2 u s e d ) 34— Washer (2 used) 54— Starter S afety Sw itch
17— D e te n t ( -* 2 1 1 2 ) (4 u s e d ) 35— Cotter Pin (2 used) 55— Special W asher (as required)
D e te n t (* 2 1 1 3 - ) (2 u s e d ) 36— Direction Valve Arm 56— Reverse V alve O perating Arm
37— Spring Pin (2 used) 57— Spring Pin (1 700- ) (2 used)
'T ra n s m is s io n Serial No.
Fig. 24-Transmission Control Valve Components ( -001699)
Refer to Fig. 24 to disassem ble and assem ble

transm issio n co n tro l valve on JD570.
Litho in U.S.A.
JD570A
1— G asket 10A — S w itch ( -010567) 23— C ap S crew (4 used) ( -503989)

2— Plate 10 B — S w itc h (010568- ) C ap S crew (4 used) (503990- )
3— G as ket ( -006903) 11— O -R ing (9 used) 24— F ittin g Plug (2 used)
G asket (006904- ) 12— Plug (9 used) 25— 0 -R in g (2 used)
4— Spring (2 used) 13— O-Ring 26— O rific e (2 used)
5 A — Ball (2 used) 14A — Fittin g ( -406497) 2 7 — C ap ( -010567)
5 B — D ete n t (2 used) 14B — Fittin g (406498- ) Plug (010568- )
6 —-Spring (2 used) 15— C a p S crew (4 used) 28— W ash er
7— D etent (2 used) 16— Piston (2 used) 29— B olt (12 used)
8— Housing 17— S pring (2 used) 30— O-Ring
9 A — Shim (As Required) 18— S pring (2 used) 31— Fittin g Plug
( -010567) 19— G asket
9 B — O-R ing (2 used) 20— C over ( -503989)
(010568- ) C over (503990- )
21— Ball
22— C ap S crew (4 used) ( -503989)
C ap S crew (4 used) (503990- )
Fig. 25-Transmission Control Valve (001700- )
Litho in U.S.A.
3— Oil Seals (2 used) 11— Link (2 used) 19— Speed S elector Arm
4— C over 12— Felt W asher (2 used) 20— Shim (as required)
5— G asket 13— W asher (2 used) 21— Control V alve Arm
6— Reverse Valve Arm 14— Spring (2 used) 22— Spring
7— Spring Pin (2 used) 15— W asher (2 used) 23— Detent
8— Spring 16— C otter Pin (2 used) 24— Speed Control V alve
Fig. 26-Transmission Control Valve Cover Linkage
Remove valves (10 and 24, Fig. 26).

Drive out spring pins (7) to remove valves (10 and
24).
Inspect valves for scoring, wear or damage.
0. D. of new valves (10 and 24) is 0.7480 to 0.7490
in.1
1. D. of valve bores in a new housing is 0.7495 to
0.7505 in.
Inspect cover (4) for cracks or other damage.
If cover (4) or oil seals (3) must be replaced, drive
out spring pins (17 and 18) and remove shafts (2).
Litho in U.S.A.
Grader, M o to r - JD570 Pow er Train 50
NOTE: Detent springs (8 and 22, Fig. 26) will be Check springs (5 and 6) for damage and proper
released when gasket plate (2, Fig. 25) is removed. strength. Free length of outer springs (5) is 4.09 in.
Test length is 2.91 in. at 205 ± 20 lbs. force.
Free length of inner spring (6) is 3.78 in. Test length

is 2.91 in. at 111 ± 11 lb. force.
Inspect pistons (3) and piston bores for wear, scor

ing and damage.
O.D. of new pistons is 1.8090 to 1.8096 in.
Piston bore diameter in new housing (7) is 1.8115 to

1.8125 in.
Replace parts as necessary.
1— Cover 6— Inner Spring Use new O-rings, seals and gaskets in assembly.
2— G asket 7— C ontrol Valve H ousing Put a light coat of oil on all internal parts to aid in
3— Piston 8— S tart Safety Sw itch
assembly.
4— W asher 9— Orifice
5— O uter Spring
Assemble accumulator parts in the order shown in
Fig. 27-Accumulator Assembly
Fig. 27.
Remove cover (1, Fig. 27) to remove accumulators
from control valve housing. Install a new gasket (2). Install cover (1) and tighten
cap screws to 35 Ib-ft.
Litho in U.S.A.
Inspect valve bores in housing (7) for scoring and

wear I.D. of dump valve bore in new housing (7) is
0.6245 to 0.6255 in. I.D. of shift valve bore in new
housing is 0.4995 to 0.5005 in.
Inspect springs for damage and proper strength.
Free length of shift valve spring (12) is 1.39 in. Test
length is 0.81 in. at 6.8 to 8.4 lb. force.
Free length of dump valve spring (2) is 1.12 inch.
Test length is 0.84 inch at 32 to 38 lb. force.
Replace parts if necessary.
IMPORTANT: Install snap rings (10) with rounded

edge toward valve.
Install dump valve (3) with the open end toward the
outside of housing.
Install spring (2) and special screw (1). Stake special
screw in two places.
Coat all parts with the same type of oil used in the
transmission before assembly.
Replace all O-rings and gaskets.
Refer to Fig. 28 during assembly.
1— Special Screw 8— G asket
2— Spring 9— C over Install shift valves (13) into the housing (7) with the
3— Dum p Valve 10— R etaining Ring (4 used) open end toward the outside of housing.
4— G asket 11— W asher (4 used)
5— Plate 12— S pring (4 used)
6— G asket 13— S h ift Valve (4 used)
7— S h ift V alve Housing 14— O -R in g (4 used)
Fig. 28-Shift Valves
Remove special screw (1, Fig. 28) to remove dump

valve (3).
Remove retaining rings (10), to remove washers
(11), springs (12) and shift valves (13).
Inspect valve spools (3 and 13) for wear and scor
ing.
O.D. of new dump valve (3) is 0.6227 to 0.6233 in.
O.D. of new shift valve spool (13) is 0.4977 to
0.4983 in.
Litho in U.S.A.
Install springs (12, Fig. 28), washers (11), and re INSTALLATION
taining rings (10).
Install new gasket (5, Fig. 26) on control valve
Install steel ball (9, Fig. 25), detent (23) and springs cover. Install cover w ith valves on control valve
(8 and 22) into detent bores in the control valve hous housing. Install and tig h te n cap screws.
ing.
Install new gasket (8, Fig. 28) and plate (9) on
Install gaskets (4 and 6, Fig. 28) and plate (5) onto s h ift valve housing (7). Install s h ift valve on control
the control valve housing. Take special care to see that valve housing. Tighten cap screws to 20 Ib-ft.
they are positioned correctly when assembling shift
valve to control valve housing. Install transm ission control valve to transm is
sion case. Install cap screws and tighten to 45 Ib-ft.
Coat lips o f seals (3, Fig. 26) w ith clean hydraulic
o il and in sta ll in cover (4) w ith lips toward bottom Install oil tube from clutch housing to control
o f seal. valve.
Install control arms (6 and 21) in cover with bearing Install pins and c o tte r pins connecting speed
against machine boss in cover. selector arm and direction selector arm to push-pull
Use shims (20) to fill the gap between arm (21) and control cables.
cover (4).
Connect w iring harness to neutral sta rt sw itch
When installing spring pins (17 and 18) in arms (6 on control valve.
and 21) make sure slot on inner spring pin (17) aligns
with slot on outer spring pin (18).
Attach control valves (10 and 24) to links (11) with
spring pin (7).
Litho in U.S.A.
TRANSMISSION CASE AND COVERS

The transmission case, located below the engine in Refer to Section 10, Group 25 for removal of Engine,
the power unit, consists of two compartments. The Transfer Drive Assembly, Transmission or Tandem
forward compartment contains the differential assem Drive Assembly.
bly and the rearward compartment contains the plane
tary pack. REPAIR
All parts must be clean to permit effective inspection.
The transmission mounts to the engine frame and
supports the engine and final drive systems. The
All metallic parts of the transmission clutch housing
transmission clutch housing is fastened directly to the
should be cleaned thoroughly with volatile mineral
rear of the transmission case.
spirits, or by the steam-cleaning method. Do not use a
caustic soda solution for steam cleaning. Gum and
varnish deposits can be removed by allowing the parts
to soak in varnish remover.
T70645
1— Cap Screw (12 used) 6— Lock W asher (21 used) 11— Cap Screw (12 used)
2— Lock W asher (12 used) 7— Stud (6 used) 12— Front Cover
3— Dowel Pin (2 used) S— Filler Tube 13— Gasket
4— Rear Cover 9— Dipstick 14— Gasket
5— N ut (9 used) 10— Special W asher (15 used)
Fig. 29-Transmission Case Top Covers
Litho in U.S.A.
Dry parts with compressed air. Steam-cleaned parts Check clutch housing and transmission housing
must be oiled immediately after drying. for cracks and other possible dam age.
Clean oil passages by working a piece of soft wire

Replace aii defective parts as necessary.
back and forth through the passages and flushing with
spirits. Dry the passages with compressed air. Replace all O-rings.
After cleaning, inspect the parts and especially the Lubricate O-rings with clean hydraulic oil before
oil passages to make sure they are entirely clean. installation.
Reclean, if necessary.
1— Special Plug 11— Dowel Pin (2 used) 20— Special Pin

2— Special W asher 12— Plug 21— O -R ing
3— Retainer 13— O -R in g (3 used) 22— Plug
4— O -R ing 14— O -R ing (6 used) 23— Lock W asher (6 used)
5— S pecial Plug (2 used) 15— Plug (6 used) 24— Cap Screw (4 used)
6— Stud (7 used) 16— Pipe Plug (2 used) 25— Nut (2 used)
7— Dowel Pin (2 used) 17— Dowel Pin 26— Rear C over
8— Stud (3 used) 18— Special W ash er (2 used) 27— G asket
9— Dowel Pin (2 used) 19— Drain Plug (2 used) 28— D ow el Pin (2 used)
10— O -R ing (2 used) 29— C ase ( -406497)
C a s e <406498- )
r iy . 30-Transm ission Case
Litho in U.S.A.
TRANSMISSION CLUTCH HOUSING

The transmission clutch housing, located at the rear Refer to Section 10, Group 25 for removal of Engine,
of the power unit, contains the transmission oil pump Transfer Drive Assembly, Transmission or Tandem
and clutch pack assembly. Drive Assembly.
The transmission clutch housing fastens directly to
the rear of the transmission case.
REPAIR
Use Fig. 31 or Fig. 32 as a reference for disas
sembly and assembly of the clutch housing.
T6692AO
1 — G as ket 10— G asket 19— G as ket

2 — S pring ( -001699)* 11— C over 20— S tud (2 used)
3 — Piston ( -001699)* 12— S crew (2 used) 21— C ap S crew (10 used)
4 — Pipe Plug ( -001699)* 13— D ow el Pin (2 used) 22— G as ket
5— D ow el Pin (2 used) 14— C ap S crew (6 used) 23— C lam p
6— D ow el Pin 15— Cover 24— C ap S crew (2 used)
7— C ap S crew (2 used) 16— Lock W a s h e r (4 used) Lock W ash er (2 used)
8— Pin 17— N u t (2 used) 25— S eal (001700- )*
9— H ousing 18— C ap S crew (2 used) 26— P iston (001700- )*
Fig. 31-Transmission Clutch Housing

( -406497)
Transmission Serial No.
Pow er Train 50
Grader, M o to r - JD570
Power S h ift Transmission 15-45
TM-1001 (Dec-87)
T6692AK
5— H ousing 9 — D rain Plug

1— G asket
6— C ap S crew (2 used) 10— C ap S crew (12 used)
2— O-Ring (2 used)
7— Dowel Pin (2 used) 11— O -R ing (3 used)
3— Dowel Pin (2 used)
4— Dowel Pin 8— O-Ring
Fig. 32-Transmission Clutch Housing

(406498- )
Litho in U.S.A.
SERVICING CLUTCH PACK AND OIL MANIFOLD
1— O il Pum p 12— T h ru st W ash er 28— C 2 C lu tch H ub

2— C a p S c re w 13— S n ap Ring 29— Spring R eta in e r
3— G a s k e t ( -406497) 14— Drive S h a ft ( -406497) 30— C lu tc h P isto n R eturn S p rin g
G a s k e t (406498- ) Drive S h a ft (406498- ) 3 1 — C 2 C lutch P iston
4— S te e l B all (2 used) 15— Bushing 32— B ushing
5— M a n ifo ld (0.1285 G rooves) 16— S n ap R ing (2 used) 33— C 2 C lu tch Drum
( -1742)* 17— C1 C lu tch Drum ( -004010) 34— C a p S c re w (6 used)
M a n ifo ld (0.1595 G rooves) C1 C lu tch Drum (004011- ) 35— B earin g w ith S n ap R ing ( -406497)
(1743- )* 18— D ow el P in (2 used) 3 6 — C lu tc h G e a r ( -406497)
M a n ifo ld (0.1595 G rooves) 19— S e a lin g R ing (2 used) 37— B earin g ( -406497)
(406498- ) 20— S ealin g Ring (2 used) 38— S n a p R ing
6— C a p S c re w (6 used) 2 1 — C1 C lu tc h P iston 3 9 — B earin g S p ac er ( -406497)
7— S e a lin g R ing (4 used) 22— S pring W ash ers (4 used) 40— T h ru st W a s h e r
(1/8 in. W id e ( -1742)* 23— S n a p R ing (2 used) 41— S n ap R ing
S e a lin g Ring (4 used) 24— C1 C lu tch H ub 42— T h ru st W a s h e r
(5/32 in . W ide)<1743- )* 25— C lu tc h P late (3 used) 43— Bushing
8— G a s k e t ( -406497) 26— C lu tc h D isk (3 used) 4 4 — C 2 C lu tc h S h a ft ( -406497)
G a s k e t (406498- ) 27— C1 an d C 2 C lutch C 2 C lu tch S h a ft (406498- )
9— S e a lin g Ring (2 used) P ressure P late 45— C1 C lu tc h S h a ft (-004010)
10— S n a p Ring C1 C lu tch S h a ft ( -406497)
11— B all B earin g C1 C lu tc h S h a ft (406498- )
46— C lu tch P la te (5 used)
47— C lu tc h D isk (5 used)
48— C lu tc h D rum S up port (406498- )
49— S pring Pin
Fig. 33-Clutch Pack Components
L ith o in U.S.A.
1 — C 2 C lutch (H ig h -R a n g e ) 3 — C1 C lu tc h (Low -R ange) 5 — C lu tc h O il P um p H o u sin g 7 — C lu tch Drive S h a ft

2 — C lu tch S e p a ra to r P late 4 — C lu tch O il M a n ifo ld 6 — C lu tch O il P um p
Fig. 34-Clutch Pack and O il M anifold
L ith o in U.S.A.
15-48 Power S hift Transm ission TM-1001 (Dec-87)
R39970
1— H igh-R ange C lutch Drum 5 — Thrust W ash er (Bonded to 3) 9 — Retainer 12— O u ter Seal
2— C lutch S eparator P late 6— Disk (5 used) to—Spring 13— Inner Seal
3— H igh-R ange Clutch H ub 7 — P late (5 used) 11— H igh-R ange C lutch 14— Bushing
4— Thrust W ash er (B onded to8 —
3) S nap Ring Piston
Fig. 35-C2 High-Hange Clutch Pack
Litho in U.S.A.
TM-1001 (Dec-87)______________________________________________________ Power S h ift Transm ission 15-49
1— Low -R ange C lu tch H ub 4— Disk (3 used) 7 — Low -R ange C lu tch Drum 10— Low -R ange C lu tch P iston
2— T h ru st W ash er (B onded to 1)5 — P late (3 used)8 — S nap Ring 11— O u te r Packing
3— T h ru st W a s h e r (B onded to 1)6 — S nap R ing 9— B ellv ille Spring (4 used) 12— In ner P acking
Fig. 36-C1 Low-Range Clutch Pack
L ith o in U.S.A.
N O T E : S e e s e p a ra tio n in s tru c tio n s (S e c tio n 10,

G ro u p 25) fo r re m o v a l o f en g in e a n d tra n s fe r drive
h o using.
Disassembling High-Range Clutch Pack
Fig. 37-High-Range Clutch Pack
Remove parts in the order they are numbered.
L ith o in U.S.A.
2. Inspect bonded thrust washer on hub (B). Re

place hub if thrust w asher is dam aged.
3. Inspect disks (D).
4. Replace the disk if disk facing m aterial chips,

flakes or scratches with a fingernail (or equivalent:)
Replace disks when oil grooves are worn smooth.
Replace plates if burned, cracked, or coned.
A — H ou sin g C2
B -H u b
C — P late (6 used)
D — D isk (6 used)
E — Pressure P late
Assembling High-Range Clutch

1. Soak all clutch disks in clean transm ission oil
before installing.
2. Install three disks and three plates. A lternate

plates and disks starting with a plate next to piston.
Install wavy separator plates so punch marked
sides of plates (A) alternate. Make sure notches (B)
in tangs are not in sam e housing slots.
3. Install clutch pressure plate. Ends of dowel pins

(C) should be 0.22 in. from surface of plate.
L ith o in U.S.A.
50 P ow er Train Grader, M o to r - JD570
4. Install JDT-24A Spring C om pressor and tighten

just enough to remove snap ring. Remove spring
retainer and com pression spring.
5. Remove piston with packing.
6. Inspect two oil bleed holes (B). Inspect and clean

drum and piston contact surfaces. Inspect and
clean metal to m etal seal for pressure port (A) to
clutch pressure plate.
A — Pressure Port to C 2 Piston

B — Bleed H o le (2 used)
Disassembling Low-Range Clutch
Fig. 38-Low-Range Clutch Pack
1. Remove parts in the order they are numbered.
L ith o in U.S.A.
2. Remove hub (A), disks (C), and plates (D).
NOTE: T h ere is a b o n d e d th r u s t w a s h e r o n b o th
s id e s .
3. Inspect bonded thrust washers (B) on hub.

Replace hub if either thrust washer is dam aged.
4. Inspect disks (C) for excessive wear or damage.
A — Hub
B — Bonded T h ru st W ash er
C — Disks (6 used)
D — P late (6 used)
E — H ousing - C1
5. Install JDT-24A Spring Compressor and tighten

just enough to remove snap ring.
6. Remove four conical Belleville spring washers.
7. Clean and inspect metal-to-metal pressure ports

(A) for seal.
Litho in U.S.A.
8. Remove piston with packing.
9. Inspect two oil bleed holes (A).
10. Inspect and clean drum and piston contact

surfaces.
Litho in U.S.A.
TM-1001 (Dec-87) ____________________________________________________ Power S h ift Transm ission 15-55
Disassembling Manifold and Oil Pump
La
R39968
1 — S ealin g Ring (4 used) 6— Bearing 10— C lutch O il M a n ifo ld 14— P acking

2— S nap Ring 7— T h ru st W ash er 11— G asket 15— G e a r (Driven)
3— S nap Ring 8— S ealin g Rings (2 used) 12— C lutch O il P um p H ousing 16— G ear
4— C lu tch Drive S h a ft 9— Bushing 13— B ushing 17— O il S eal
5— S nap Ring 18— C lu tch O il Pum p Body
Fig. 39-Manifold and Oil Pump

50 Power Train Grader, M o to r ■ JD570
1— G asket 9 — S pecial C ap S crew (2 used) 14— O il Seal

2— S ealin g Ring (4 used) 10— S pecial C ap S crew 15— Packing
( -*004010) 11— S pecial C ap S crew (3 used) 16— Pum p Body
S ealin g Ring (4 used) 12— Pum p Drive G ea r 17— S ealing Ring (2 used)
(004011- ) ( -002237) 18— Snap Ring
3— S p ec ial C ap S crew (6 used) Pum p Drive G ear 19— Ball Bearing
4— C lutch O il M anifo ld (002238- ) 20— Thrust W asher
(001743*-406497) 13— Pum p In ternal G ear 21— Snap Ring
C lu tch O il M a n ifo ld ( -002237) 22— Bushing
(406498- ) Pum p Internal G ear 23— C lutch Drive S haft
5— S te e l Ball (2 used) (002238- ) ( -406497)
6— G asket C lutch Drive S haft
7— C a p Screw (406498- )
8— Pum p Housing
transmission Serial Number

Fig. 40-Transmission M anifold and O il Pump
The fixed displacement gear-type transmission The five functions of this pump are: (1) to supply
pump, located in the clutch housing runs whenever the pressure oil to operate the power shift transmission, (2)
engine is running, except when the disconnect clutch is to lubricate and charge the main pump, (3) to circulate
disengaged. oil through the oil cooler to cool the system, (4) to
lubricate transmission and bearings, and (5) to lubri
cate the transfer drive gears and bearings.
Litho in U.S.A.
Grader, M o to r ■ JD570 Pow er Train 50
TM-1001 (Dec-87 Power S h ift Transm ission 15-57
1. Inspect sealing rings for scratches or grooves on

the sealing surfaces. Inspect the locks on the end
of the sealing rings.
2. Inspect the sealing ring grooves in manifold for

wear or dam age. During normal operation, rings
and grooves wear only on the side opposite the
pressure side near the outer edge.
3. Inspect sealing ring patterns in housing. During

normal operation, patterns will be smooth and
polished. Inspect patterns for skips, nicks, or
scratches.
4. Install the four rings in housing. Check to be sure

there is a gap between locks on ends of rings. If
there is no gap, remove rings and install new rings.
Check new rings for gap. If there is no gap replace
housing.
$__rro u j \
5. Separate housing from manifold and gasket.

Care must be taken so C1 and C2 air bleed valve
balls (A) are not lost.
R39251
6. Inspect bearing. If replacem ent is necessary,

remove snap rings (A).
7. Remove bearing using a press and bearing puller.
8. Remove thrust washer (C).
9. Inspect shaft splines for excessive wear or

damage. Inspect area between lubrication holes (B)
for cracks.
Litho in U S A .
10. Refer to Fig. 40 fo r disassem bly of transm ission

oil pump.
11. Remove cap screw (7, Fig. 40) holding pump

housing to pump body. Remove parts from pump.
12. Check pump gears fo r chipped or grooved teeth.

Check oil grooves in bushing fo r build-up th a t may
restrict oil flow. Inspect pump body fo r scoring and
wear.
Assembling Manifold and Oil Pump
1. Refer to Fig. 40 fo r assem bly o f o il pump.
2. Install oil seal (14) w ith spring side facin g driver.
IMPORTANT: Thoroughly coat all sides and faces

of pump gears (12 and 13) with clean hydraulic oil
prior to assembly. Failure to do so could lead to
premature pump failure.
3. A pply hydraulic oil to pump gears.
4. Install oil pump internal gear (13) w ith chamfered

side in pump body.
5. Install bushing using 40 mm and 43 mm disks

flush w ith surface o f housing.
6. Put clean transm ission oil on all parts.
L itho in U.S.A.
7. Install bushing in m anifold even w ith top surface

o f bore, using 40 mm and 43 mm disks.
8. Install shaft (B).
9. Install snap ring (A) w ith cham fered side away

from bearing.
10. Install tw o balls (A) in m anifold. Install new

gasket in place.1
11. Carefully install housing on m anifold and shaft.

Care must be taken not to damage the oil pump
seal.
12. Turn the housing m anifold assem bly over and

install in bench fixture. Install six cap screws and
tighten to 20 Ib-ft.
13. Insta ll fo u r sealing rings. Coat w ith petroleum

jelly. Be sure ring locks are not lined up and turn
freely in th e ir grooves.
14. Turn shaft to make sure all gears move freely.
Assembling Low-Range Clutch

1. Install new seals (A and B) w ith sealing lip toward
housing. Put petroleum je lly on seals.
2. Install piston.
3. Install fo u r conical Belleville spring washers.
Litho in U.S.A.
TM-1001 (Dec-87)________________________________ Power S h ift Transm ission 15-61
4. Install hub (C).
NOTE: If some clutch disks are color coded with

a yellow stripe and some with a white stripe, make
sure that only disks with a white stripe are used
in the C1 clutch.
5. Install five disks and five plates. A lternate

plates and disks starting w ith a plate next to clutch
pressure plate. Install wavy separator plates so
punch m arks (A) alternate. Make sure notches (B)
in tangs are not in same housing slots.
6. Align dowel pin holes in drum with dowel pins

in clutch pressure plate, and in stall drum in place
over disk pack.
7. Install cap screws and tighten to 20 Ib-ft.
Hi-Lo Clutch and Oil Manifold

Assembly Air Test
Turn sh a ft several turns to be sure all parts move

freely.
NOTE: Some air leakage is normal past the seal

ing rings and the dutch drive shaft bearing O.D.
Test clutch pack w ith compressed air using

JDG185 A irT e s t Plug. Use 50—80 psi air pressure.
Piston should move when air pressure is applied
to corresponding passage.
Check fo r leakage past the piston seals.
If piston seals leak, repeat disassem ble and

assem ble procedures.
L ith o in U.S.A.
PLANETARY CARRIER
Removing Planetary Pack

Remove engine and tra n sfe r drive. See Section
10
, rirn
-w, , wim
w.!•" —
Remove clu tch pack from clu tch housing and

separate clutch housing from transm ission case.
Be sure tran sm issio n case is adequately sup
ported.
Remove parking brake and cover from the trans

m ission case as an assembly.
Fig. 42-Removing Reduction Gear Shaft
Remove reduction gear sh a ft bearing container

from inside the case. Use a long brass d rift to reach
through bore o f the planetary pack from the rear.
Drive reduction gear shaft back enough to free
bearing cup and sh a ft (Fig. 42).
Remove cap screws securing planetary pack to

transm ission case.
Fig. 41-Removing Clutch Gear ( -406497)
On units Serial No. ( -406497), remove clutch

gear assem bly (Fig. 41) from rear o f transm ission
case.
On units Serial No. (406498- ), remove

clutch drum support (48, Fig. 33) and spring pin (49)
from rear o f transm ission case.
Fig. 43-Removing Planetary Pack
CAUTION: Planetary assembly weighs ap-

A p iu A im m eiy
4 7 A
mu
Ik
iu .
I l »
use
IT A 4 7 J O
uiuiiho
I i l l ! . .
u iu iiy
Brackets and chain to avoid personal injury.
Attach JT01748 Lifting Brackets, chain and chain

I IW IO I G il I I I I d 1IU |JICLI I t s l C l l y .
L ith o in U.S.A.
Grader, M o to r - JD570 Power Train
50
TM-1001 (Dec-87)_____________________________________________________ Power S h ift Transm ission
15-63
Repairing Planetary Pack
Fig. 44-Planetary Pack Components
Lithoin U.S.A.
50 P ow er Train Grader, M o to r - JD570
1 — B2 Ring Gear 24— S e p a r a to r P la te (2 u s e d ) 39— H o u sin g S ealin g Ring

2— B1 and B2 Brake Backing Plate 25— C 3 C lu tc h H u b ( -0 0 4 0 1 0 ) 40— P isto n S ealin g Ring
3— Planet Pinion Carrier Assembly C 3 C lu tc h H u b (0 0 4 0 1 1 - ) 41— B4 B rake Piston
4— B1 Ring Gear 26— C 3 C lu t c h P la te (4 u s e d ) 42— B rake Piston R eturn P late
5— Separator Plate (2 used) ( -0 0 4 0 1 0 ) 43— B rake Disk (2 used)
6— Brake Disk (3 usedM -406497) C 3 C lu t c h P la te (5 u s e d ) 44— S e p a ra to r P la te (1 used)
Brake Disk (3 used)(406498- ) (0 0 4 0 1 1 - ) 45— Bushing
7— Brake Piston Return Plate 27— C 3 C lu t c h D is k (4 u s e d ) 46— C 3 C lutch P iston H o u sin g
8— Spring (8 used in B1, B2, and B4) ( -0 0 4 0 1 0 ) ( -004010)
9— B1 Brake Piston C 3 C lu t c h D is k (5 u s e d ) C 3 C lutch P iston H o u sin g
10— Piston Sealing Ring (0 0 4 0 1 1 -4 0 6 4 9 7 ) (004011-008464)
11— Housing Sealing Ring C 3 C l u t c h D i s k (5 u s e d ) C 3 C lutch P iston H o u sin g
12— Dowel (4 used) (4 0 6 4 9 8 - ) (008465-010567)
13— B1 Brake Piston Housing 28— C 3 C lu tc h D ru m ( -0 0 4 0 1 0 ) C 3 C lu tch P iston H ou sin g
14— Brake Disk (4 used) ( -406497) C 3 C lu t c h D r u m (0 0 4 0 1 1 - ) (010568- )
Brake Disk (4 used) (406498- ) 29— D o w e l P in ( 6 u s e d ) 47— H ou sin g S ealin g Ring
15— Separator Plate (3 used) 3 0 — B 3 B ra k e P is to n H o u s in g 48— P isto n S ealing Ring
16— B3 Ring Gear ( -004010) 31— B u s h in g 49— C 3 C lutch P iston
B3 Ring Gear (004011- ) 32— D o w e l P in ( 2 u s e d ) ( -004010)
17— B2 Brake Piston Housing 33— H o u s in g S e a lin g R in g C 3 C lutch Piston
18— Housing Sealing Ring 34— P i s t o n S e a li n g R i n g (004011-010567)
19— Piston Sealing Ring 35— B 3 B ra k e P is to n C 3 C lutch Piston
20— B2 Brake Piston 36— B r a k e P is to n R e tu r n P la te (010568- )
21— Brake Piston Return Plate 37— C a p S c r e w (5 u s e d ) 50— P isto n R eturn Spring
22— Spring (8 used in B3) 38— B 4 B r a k e P is to n H o u s in g 51— S pring R etainer
23— Brake Disk (3 used) 52— S n a p Ring
53— B ushing
54— D ow el Pin
55— C ap S crew (4 used)
56— S p e c ia l C ap S crew (6 used)
57— 0 -R in g Seal (2 used)
5 8 — S e a t (008465- )
5 9 — B all (008465- )
6 0 — D ow el Pin (008465- )
Fig. 44-Planetary Pack Components
L ith o in U.S.A.
R39960
1— B4 Brake 3 — B3 Brake 5 — S ep a ra to r P late

2 — P lan etary C lutch P ack 4 — B2 Brake 6 — B1 Brake
Fig. 45-Planetary Pack
NOTE: if facing material chips, flakes or scratches

with a fingernail (or equivalent), the disk should be
replaced. Replace disks when oil grooves are worn
smooth. Replace plates if burnt, cracked, or coned.
Litho in U.S.A.
15-66 P ow er S h ift Transm ission TM-1001 (Dec-87)
Repairing Planetary Pack
® G) 0)0)
1— C ap S crew (5 used)
2— B4 H ou sin g
3— Piston 6 — P iston R eturn P late 9 — Piston Return S prings (8 used)
Fig. 46-B4 Planetary Pack
B4 P LA N E TA R Y PA CK S P E C IF IC A T IO N S
Item M e asu rem en t S p ec ific atio n
Cap Screw (5 u s e d )............................. T o rq u e .................................................... 35 Ib-ft
Piston Return P la te ............................. Thickness (New) .................................. 0.117— 0.123 in.
Disks (2 used) ...................................... Thickness (New) .................................. 0.117— 0.123 in.
Separator P la t e .................................... Thickness (New) .................................. 0.117— 0.123 in.
Return Spring (8 u s e d )....................... Free Length (a p p ro x .)......................... 0.62 in.

Test Length at 26.6— 32.5 lb force
L itho in U.S.A.
R39963
1 — B3 H ousing 4 — O u te r S eal 6 — Springs (8 used) 8— S e p a ra to r P lates (3 used)

2— Piston 5 — Piston Return P late 7 — D isks In n e r S plin ed (4 used) 9 — R ing G e a r
3— Inner S eal 1 0 — B ushing
B3 P LA N E TA R Y P A C K S P E C IF IC A T IO N S
Ite m M e a s u re m e n t S p e c ific a tio n
Piston Return P la te ............................. Thickness (New) .................................. 0.117—0.123 in.
Return Spring Free Length (a p p ro x .)......................... 1.0 in.

Test Length at 22.5— 27.5 lb force
Disks Inner Splined (4 u s e d ) ............. Thickness (New) .................................. 0.117— 0.123 in.
S eparator Plates (3 u sed)................... Thickness (New) .................................. 0.117— 0.123 in.
L ith o in U.S.A.
0 ® 0 )0 )0 )
R39965
— B2 H ousing 4 — In n er S eal 6 — R eturn Springs (8 used) 8 — S ep a ra to r P lates (2 used)

ro
— Piston 5 — Piston R eturn P late 7 — Disks - In ner S plined (3 used) 9 — Ring G e a r • S econd Planet
gj
— O u te r S eal 1 0 — B i-5 2 S ep a ra to r P ia ie
B2 P LA N E TA R Y P A CK S P E C IF IC A T IO N S
Piston Return Plate Thickness (New) 0.117— 0.123 in.
Return Springs (8 used) Free Length (approx.) 0.62 in.

ic o i
I ~ ~ ~ +U ^4- Ob C
u cn ym c u * :u .O —
OO C IU
o ti.u iu M jru t;
illC I o ^ /lll ICU

\ n A r O »•%I ! r»/"m -J /O i
\^ j UOCU ) iinum icoo
Q o iv a r o + n r D to + a o
v u ^ u i u i v i i i u i u o
/O 1 1 coH \
yttm f •
Thi^l/nAPp /Nl /t\« A
i 111 v-» r v i i c o o y i ’i c v v /
B1-B2 Separator Plate I Thickness (New) .. 0.307— 0.317 in.
! j.t_
_
uI in u_!_inI uI .o .mA .
R39966
1— Ring Gear-First Planet 4 — Return Spring (8 used) 6— Piston 8— Inner Seal

2 — Disks-lnner Spline (3 used) 5— Piston Return Plate 7— Outer Seal 9— Pins (4 used)
3— Separator Plates (2 used) 10— B1 Housing
B1 PLANETARY PACK SPECIFICATIONS
Item Measurement Specification
Disks - Inner Splined (3 used) Thickness (New) ................... 0.117— 0.123 in.
Separator Plates (2 used) Thickness (New) ................... 0.117— 0.123 in.
Return Springs (8 u s e d )........ Free Length (a p p ro x .)........... 0.62 in.

T _ -i I n 4 OiC* o o o C IK
ItJSL L-fcMigiM CU *1U.U — lU
Piston Return P la te ................ Thickness (New) ................... 0.117— 0.123 in.
Litho in U.S.A.
1
I
I
U J
/ 0o,
1— Cap Screw 5— Spring 10— Bushing 14— Seat

(6 used) 6— Piston 11— Dowel Pin 15— Hub
2— Housing 7— Outer Seal (Anti-Rotation) 16— Clutch Plate (4 used) ( -004010)*
3— Snap Ring 8— Inner Seal 12— Dowel Pin Clutch Plate (5 used) (004011- )*
4— Retainer 9— Bushing 13— Ball 17— Clutch Disk (4 used) ( -004010)*
Clutch Disk (5 used) (004011- )*
18— Drum
Fig. 50-C3 Planetary Clutch Pack
1. Remove parts in the order they are numbered.
C3 CLUTCH SPECIFICATIONS
Cap Screw (6 u s e d ).............................. T o rq u e ..................................................... 20 Ib-ft
S p r in g ..................................................... Free Length (a p p ro x .)......................... 0.270 in.

Test Length .......................................... 1.12 in.
247— 302 lb force
C lutch Plate (4 or 5 u s e d ) ................. Thickness (New) 0.117— 0.123 in.
Disks (4 or 5 u s e d ) .............................. Thickness (New) 0.112— 0.118 in.
tran sm is s io n Serial Number
L itho in U.S.A.
Grader, M otor - JD570 Power Train 50
2. Install JDT-24A Spring Compressor and

tighten just enough to remove snap ring.
3. Remove snap ring (A).
4. Remove spring compressor.
5. Remove compression spring and retainer.
6. Inspect bushing (A) and replace if necessary.
7. Remove packing (B) and inspect housing sur

face for nicks and burrs.
8. Shake housing to be sure bleed ball in

assembly (C) moves freely. If not, use air pressure
to free ball.
9. If pressure does not free bleed ball, remove

and clean or replace bleed ball assembly.
1— Clutch Piston Housing

2— Pin
3— Ball
4— Seat
Fig. 51-C3 A ir Bleed Ball and Plug
Litho in U.S.A.
10. Install piston com pression spring and re

tainer as shown.
11. Install JDT-24A Spring Com pressor and

tighten ju s t enough to install snap ring.
12. Install snap ring (A).
13. Remove spring compressor.
14. Install clutch cover and cap screws. Tighten
Litho in U.S.A.
SERVICING PLANETARY CARRIER
1— 4th P lan et Sun Pinion 1G0ea — r Th ru st W ash er (3 used) 19— 3rd P lan et Sun Pinion 28— R oller B earings (62 used)
2— C ap S crew (3 used) 11— Th ru st W ash er (3 used) 2 0 — T h ru st W ash er (B onded to 19) 29— S p ac er (3 used)
3— Lock P late (3 used) 12— S h a ft (3 used) 21— R ear C over 30— T h ru st W a s h e r (3 used)
4— R ear P inion S haft R eta1in3—er A nti-R otatio n B all 22— C ap Screw (3 used) 31 — T h ru st W a s h e r (3 used)
5— S h a ft (3 used) (3 used) 23— Lock P late (3 used) 32— 1st P lan et Sun Pinion
6— 14—
A nti-R o tatio n Bail (3 used) R oller Bearing (62 used)2 4 — Front P inion S h a ft R eta in e r 3 3 — 2nd P lanet Sun Pinion
7— 15—
3rd P lan et Pinion (3 used) S pacer 25— S h a ft (3 used) 34— Fron t C over
8— R oller Bearings (62 used) 16— Thrust W ash er (3 used) 2 6 — A n ti-R o tatio n Ball (3 used) 3 5 — B ushing
3 — S p ac er (3 used) i# — i m u s t w a s i i e i (o u s e u j
n-r a«a o n _ j
i a i ct a n u r i & u c i r i m u i i
1 8 — 4th P lan et Pinion (3 used)
(3 used)
Fig. 52-Planet Pinion Carrier
P LA N E TA R Y C A R R IE R S P E C IF IC A T IO N S
Item M e asu rem en t S p e c ific a tio n

Cap Screw (3 used) Front C over-to-Carrier........ Torque .......................................... 35 Ib-ft
Cap Screw (3 used) Rear C o ve r-to -C a rrie r........ Torque .......................................... 35 Ib-ft
L ith o in U.S.A.
Disassembling Planetary Carrier
T6692AS
1 — C ap S crew (3 used) 11 — Fourth P lanet Sun Pinion 17— D ow el Pin (3 used)

2— Lock P late (3 used) ( -004010) 18— S p ac er (3 used)
3— R ear R etainer Fourth P lanet Sun Pinion 19— First and Second P lan et Pinion
4— S tee l Ball (9 used) (004011- ) (3 used)
5— R ear Cover 12— Third P lan et Sun Pinion 20— S h a ft (3 used)
6— S h a ft (6 used) ( -004010) 21 — Second P lanet Sun Pinion
7— Th ru st W ash er (18 used) 12— Third P lan et Sun Pinion 22— First P lanet Sun Pinion
8— Th ird P lan et Pinion (3 used) (004011- ) 23— Front End Plate
( -004010) 13— Thrust W ash er (2 used) 24— Bushing
Th ird P lan et Pinion (3 used) 14— Fourth P lan et Pinion (3 used) 25— Front R etainer
(004011- ) ( -004010) 26— Lock P late (3 used)
9 — R o ller B earing (558 used) Fourth P lan et Pinion (3 used) 27— C ap S crew (3 used)
10— S p ac er (6 used) (004011- ) 28— Thrust W ash er
15— Bushing ( -004010)
1 6 — C arrier Fram e ( -004010)
C arrier Fram e (004011- )
Fig. 53-Planet Pinion Carrier Components
transm ission Serial Number
Litho in U.SA.
1. Straighten retaining tabs (A) and remove cap

screws (B).
2. Remove fro n t retainer (C).
3. Remove firs t planet ring gear (D).
A — Lock P late (3 used)

B — C ap Screw s (3 used)
41
j
C — R etainer
D — Ring G ear-First Planet R40001
4. Turn assem bly over and remove cover plate.
5. Remove th ru st washers (A and B).
R40018
6. Remove second planet sun pinion gear (A).
7. Remove firs t and second planet pinion gears

(B), bearings (C) and bearing spacers (D).
8. Inspect bearings. Replace all bearings if one

is damaged.
A — S eco n d P ian et Sun Pinion G ear

B — First and S econd P ian et Pinion
G e a r (3 used)
C — R o ller B earings (62 used)
D — Bearing S pacer R40021
Litho in U.S.A.
9. Remove thrust washer (A). Inspect and replace

if worn or damaged.
10. Inspect pinion sh a ft (B) and replace if worn

or damaged. Drive sh a fts through plate. DO NOT
lose a nti-rotation ball (C) out ou te r end o f shaft.
R40022
11. Straighten retainer tabs (A) and remove cap

screws (B).
12. Remove rear retainer (C).
13. Remove fourth planet pinion shafts (B) using

JDT-22-1 Stacked Dummy Shafts (A) to prevent loss
or displacem ent of bearing rollers. Do not lose ball
(C).
14. Remove th ru st washers, pinion gears and
bearing rollers. Inspect all parts and replace as re
quired. Make sure oil passages in pinion shafts are
clean and free of obstructions.
N O T E : R e p la c e a ll b ea rin g ro lle rs i f o ne is
d am ag ed .
R40024
Litho in U.S.A.
15. Remove th ird planet pinion sh a fts (B) using

JDT-22-1 Stacked Dummy S haft (A) to prevent loss
or displacem ent o f bearing rollers. Do not lose ball
■(C).
16. Remove th ru st washers, pinion gears and
bearing rollers. Inspect all parts and replace as re
quired. Make sure oil passages in pinion shaft are
clean and free o f o bstructions.
17. Inspect carrier fo r dam age or wear and

replace as required.
NOTE: Replace ail bearing rollers if one is

damaged.
18. Remove th ird planet pinion sun gear (A).
19. inspect bonded th ru s t washer (B). Replace

gear and th ru st washer if required.
R40026
L ith o in U.S.A.
Assembling Planetary Carrier
1. Apply petroleum je lly to bore of third planet

pinion. Install one row of 31 bearing rollers, spacer,
and final row o f 31 bearing rollers.
NOTE: Use JDT-22-2 Dummy Shaft to retain roller

bearings in position during assembly.
2. A pply petroleum je lly to one side of thrust

washer and position on ends o f third planet pinion.
A llow Dummy S haft JDT-22-2 to extend for aid in
positioning thrust washer gear end.
3. Install two, third planet pinion gears (A), bear

ings and thrust washers in carrier.
4. Install shaft (B) and balls (C) then drive dummy

shaft (A) through carrier wall.
5. Install third planet pinion sun gear (A) with

thrust washer (B) against center face of carrier.
6. Install last, third planet pinion gear, bearings

and thrust washers in carrier.
7. Install shaft and ball.
Litho in U.S.A.
TM-1001 (Dec-87) Power S h ift Transm ission 15*79
8. A pply petroleum je lly to bore o f fourth planet

pinion. Install one row o f 31 bearing rollers, spacer
and final row o f 31 bearing rollers.
NOTE: Use JDT-22-1 Dummy Shaft to retain roller

9. A pply petroleum je lly to one side o f thrust

w asher and p osition on ends o f fo u rth planet pi
nion. A llow Dummy Shaft JDT-22-2 to extend for aid
in p o sitio n in g th ru s t w asher on gear end.
10. In sta ll fourth planet pinion gears, bearings

and th ru s t w ashers in carrier.
11. In sta ll sh a ft (B) and balls (C) and drive

dum m y s h a ft (A) through carrier center web.
R40024
12. Install rear retainer (C).
13. In sta ll cap screw retainer (A).
14. Install cap scew s (B) and tig h te n to 35 Ib-ft.

(35 Ib-ft).
15. Bend corners o f cap screw lock plates up on

cap screw heads and down over edge of rear
retainer.
16. Install pinion s h a fts (B) and anti-rotation

balls (C).
17. Install th ru s t w asher (A).
L ith o in U.S.A.
18. Install firs t planet sun pinion gear (A).
19. Install second planet sun pinion gear (B).
R40028
20. Install th ru s t washers (A).
21. A pply petroleum je lly to bore of firs t and se

cond planet pinion gear (A). Install one row of 31
bearing rollers (B), spacer (C) and second row o f 31
bearing rollers (6).
NOTE: Use JDT22-2 Dummy Shaft to retain roller

A — First and S eco nd P lan et

Pinion G ear
B — R oller B earings
C — B earing S pacer
D — R oller Bearing
22. Install firs t and second planet pinion gear

w ith bearings and bearing spacer on pinion shafts.
23. A lign tim in g m arks (A) on firs t and second

planet pinion gears w ith a tooth on second planet
sun pinion gear.
R40031
Litho in U.S.A.
24. Install th ru st w asher (A and B).
25. Install previously assem bled carrier parts

over pinion shaft.
26. Hold carrier parts securely together and turn

assem bly over.
27. Install firs t planet ring gear (A).
28. Install fro n t retainer (C).
29. Install lock plates (A).
30. Install cap screws (B) and tighten to 35 Ib-ft.

(35 Ib-ft).
31. Bend corners o f cap screw lock plates up on

cap screw heads and down over edge o f front
retainer.
32. Turn assem bly over. Install fourth planet sun

pinion gear w ith sm all gear diam eter up.
L ith o in U.S.A.
50 Power Train Grader, M o to r ■ JD570
Assembling Planetary Pack
1. Install new seals w ith sealing lips toward

housing.
2. Put petroleum je lly on seals.
3. Install piston into all brake housings w ith

sealing lips tow ard closed end o f housing.
B1 Brake Shown
4. Install fo u r pins (A).
5. Install four 3/8 in. ready rods (B) approxim ately

250 mm (10 in.) long.
6. Install piston return plate and eight piston

return springs (C).
R E TU R N S P R IN G S P E C IF IC A T IO N S
Free L e n g th ....................................................................................0.86 in.

T e st Length at 26 .6— 32.5 lb f o r c e ..................................... 0.62 in.
7. Install three disks (D) and two separator plates

(E). A lternate plates and disks s ta rtin g w ith a disk.
A — Pins (4 used)
B — 3/8 in. R eady Rod
(4 used)
C — R eturn S pring (8 used)
D — Disk (3 used)
E — S ep a ra to r P late (2 used)
8. Install planet pinion carrier assem bly (A) and

firs t planet ring gear.
NOTE: M a k e c e r ta in g e a r te e th o n fir s t p la n e t
ring g e a r align a n d e n g a g e w ith g e a r te e th o n b ra k e
d is k s .
Litho in U.S.A.
9. Install separator plate (A).
10. Install second planet ring gear (B).
11. Install eight piston return springs (A).
RETU R N S P R IN G S S P E C IF IC A T IO N S
Free Length (a p p ro x.)....................................................... 0.86 in.

Test Length at 26.6—32.5 lb f o r c e .................................0.62 in.
12. Install three disks (B) and tw o separator

plates (C). A lternate plates and disks starting w ith
a disk.
13. Install piston return plate (D).
A — R eturn Spring (8 used)

B — D isk (3 used)
C — S e p a ra to r P late (2 used)
D — P iston Return P late
14. Install B2 housing and piston.
Litho in U.S.A.
R ETURN S P R IN G S S P E C IF IC A T IO N S
Free Length (a p p ro x.)....................................................... 1.22 in.

Test Length at 22.5—27.5 lb f o r c e ...................................1.0 in.
16. Install fo u r disks (B) and three separator

plates (C). A lternate plates and d isks starting w ith
a disk.
A — R eturn Springs (8 used)

C — S e p a ra to r P late (3 used)
D — P isto n Return P late
18. Install B3 housing (A) and piston.
♦'-V*
19. Install C3 clutch (A).
Litho in U.S.A.
P IS TO N R E TU R N S P R IN G S P E C IF IC A T IO N S
Free Length (a p p ro x .)........................................................0.86 in.

Test Length at 26.6—32.5 lb f o r c e ................................. 0.62 in.
21. Install tw o disks (B) and one separator plate

(C). A lternate disks and plates sta rting w ith a disk.
A — Piston Return S pring (8 used)

C — S e p a ra to r P late
D — Piston Return P late
23. Install B4 housing (A) and brake piston.
24. Remove fo u r 3/8 in. ready-rods (B).
NOTE: Make certain all return springs are se

cured when cap screws are assembled.
25. Install five cap screw s (A) and tighten to 35

Ib-ft.
L ith o in U.S.A.
T■o e t i n n D l a nbav ti u
■ aui
a imj D a n lr
■u v n
Test planetary brake packs w ith compressed air us-

ing JDG-185 A ir Test Plug. Use 50— 80 psi air pres
sure at each o f the brake housing inlet passages.
Pistons should move when air pressure is applied

to corresponding passage.
Check fo r leakage past piston seals.
If piston seals leak, repeat disassem ble and assem

ble procedures.
Install reduction gear shaft and high and low range

clutch sh afts. Turn sha fts several tu rn s to be sure
all parts turn freely. Remove shafts.
Installing Planetary Pack
Install new O-ring seals in the brake control oil

passages in the bottom o f the transm ission case.
Be careful not to move these O-rings out o f posi
tion when in sta llin g the planetary pack.
Install planetary pack and tig h te n planetary

pack-to-transm ission case cap screw s to 55 ± 6
Ib-ft.
Install reduction gear shaft.
Install transm ission case fro n t cover and park

ing brake assembly.
Install high- and low-range drive sha fts into

planetary pack.
Tighten d u tc h housing to transm ission case in

ternal cap screws to 170 Ib-ft. and external cap
screws to 300 ib-ft.
Install clutch pack and oil pump assem bly into

transm ission clu tch housing. Tighten special
screws w ith 50 Ib-ft.
Install transm ission case rear cover.
Refer to Section 10, Group 25 to in sta ll engine

and tra n sfe r drive.
L ith o in U.s.A.
SERVICING REDUCTION GEAR TRAIN
Removing Reduction Gear Shaft
To service reduction gear shaft, remove following components:
Engine (See Section 10, Group 25)

Transfer drive (See Section 10, Group 25)
Clutch pack with transmission pump
Planetary pack (included in this group)
Disassembling Reduction Gear Shaft
1— R etainer 5— Piston Ring 9 — G ear 13— S ealin g Ring

2— C heck Ball 6— Bearing Cup 10— Snap Ring 14 — Bushing
3— Shim s 7— Bearing C one 11— Bearing Cup 15 — R eduction S h a ft
4— R etainer 8— S h ift C ollar 12— Bearing C one
Fig. 54-Reduction Gear Shaft
L ith o in U.S.A.
R40037
1— R eta in e r ( -003826)* 10— S nap Ring

R eta in e r (003827-406497)* 11— B earing Cup
2— S tee l Ball 12— B earing Cone
3— S him (As R equired) 13— S ealin g R ing (2 used)
4— R eta in e r (406498- ) 14— B ushing
5— R ing ( -406497) 15— R ed uction G e a r S h aft
Ring (406498- )
6— Bearing C up ( -003826)*
B earing C up (003827*- )
7— B earing C on e ( -003826)*
Bearing C on e (003827*- )
8— D isc o n n ect S h ifte r C o llar
9— R eduction G ea r
*Transmission Serial Number

Fig. 55-Reduction Gear Shaft
1. Refer to Fig. 55 to disassem ble parts.
L ith o in U S A .
TM-1001 (Dec-87) __________________________ Power S h ift Transm ission 15-89
2. Remove sealing rings (A).
3. Inspect sealing rings fo r scratches or grooves on

the sealing surfaces. Inspect the locks on the ends
o f the sealing rings.
4. Inspect the sealing ring grooves in shaft for wear

or damage. During norm al operation rings and
grooves wear only on the side opposite the
pressure side near the outer edge.
5. Inspect sealing ring patterns in C3 housing. Dur

ing normal operation patterns w ill be sm ooth and
polished. Inspect patterns fo r skips, nicks, or
scratches.
6. Make sure all oil passages in shaft are clean and

free o f obstructions. Inspect sh a ft (C) and replace
if required.
A — S ealin g Ring (2 Used)

B — O il P assage
C — R ed uction G e a r S h aft
D — G ear
E — B earing Cone
F — Bearing Cup
7. Inspect sealing ring pattern in shaft ID (A). Dur

ing normal operation, pattern w ill be sm ooth and
polished. Inspect patterns fo r skips, nicks, or
scratches. Replace shaft as required.
8. Make sure oil passage (B) is clean and free of

obstructions.
9. Inspect spline teeth (C) fo r wear or damage.

Replace as required.
10. Remove tow disconne ct shafts. Remove clevis

(A), to w disconnect gear (B), and pins (C) as a unit.
NOTE: Pins are not retained in clevis and fall out

if not handled carefully.1
11. Inspect pins (C), clevis (A), and gear (B) for
damage or wear and replace as required.
Litho in U.S.A.
12. Remove snap ring behind o utput planetary wall

bearing cup.
13. Drive bearing cup out o f case using 102 mm disk

and driving handle.
14. Inspect cup and replace as required.
NOTE: Bearing cone must be replaced if bearing

cup is replaced.
Adjusting Reduction Gear

Shaft Preload
1. Install bearing cup on planetary side using 102

mm d isk and driving handle. Drive the cup into the
case fa r enough to allow in s ta lla tio n o f snap ring.
2. Install snap ring (A) and drive cone back against

snap ring using 102 mm d isk and driving handle.
3. Insta ll reduction aear (B) and fro n t bearina cone

(A).
4. install reduction year shaft (A), front bearing

cone (B), reduction gear (C), rear cone (D) and rear
cup
A — R eduction G ea r S haft
B — Front Bearing Cone
C — R ear C one
D — R ear B earing Cone
E — R ear C up
L ith o in U.SA.
5. Install bearing retainer (A) with enough shims (B)

to establish end play.
6. Install three cap screws and tighten to 55 Ib-ft.
7. Install dial indicator as shown and measure end

play.
8. Remove enough shim s to provide 0.000—0.002

in. preload.
NOTE: Shims are available in nominal thicknesses

of 0.003, 0.005 and 0.010 in.
Assembling Reduction Gear Shaft
1. Remove com ponents th a t were assembled to ad

ju s t preload.
2. Assem ble yoke (A), shoes (C), and collar (B) and
position in case. Relief on co lla r (B) should be
tow ards reduction gear. Install tow disconnect
shafts.
NOTE: Make sure shoes (C) remain in place during

assembly to prevent gear failure.
3. Install reduction gear(B) in case with tow discon

nect teeth tow ards d iffe re n tia l side o f housing.
4. Install bearing cone (A) and position reduction

gear on centerline of bore to retain bearing cone.
L ith o in U.S.A.
5. In sta ll oil seal 2— 3 mm below s h a ft end using

27 and 18 mm disks and driver.
N OTE: M e ta l f a c e o f s e a l m u s t b e a g a in s t d isk .
6. Install sealing rings (A) on sh a ft. Make sure they

are hooked.
A — S e a lin g R ing (2 used)

B — O il P assage
C — R ed uction G ear S h aft
D — G ea r
E — B earin g Cone
F — B earin g Cup
R39346
Installing Reduction Gear Shaft
1. Install planetary pack.
2. Install reduction gear shaft and gear (A) into case

through reduction gear (C) and bearing cone (B).
3. Install fro n t bearing cone and cup.
4. In sta ll new sealing ring (A) on reduction sh a ft

bearing retainer. Make sure ends are hooked.
L ith o in U.S.A.
5. In s ta ll re d u c tio n s h a ft b e arin g re ta in e r and

p red e te rm in e d sh im pack. (See p rocedure in th is
group.)
6. In s ta ll cap scre w (A).
7. In s ta ll o il line (B).
8. In s ta ll is o la to r (C).
9. In s ta ll re m a in ing cap scre w s.
10. T ig h te n a ll cap scre w s to 55 Ib-ft.
11. In s ta ll fo llo w in g co m p o n e n ts:
C lu tc h pack w ith tra n s m is s io n pum p
T ra n s fe r drive (See S ectio n 10, G roup 25)
E ngine (See S e c tio n 10, G roup 25)
SERVICING TOW DISCONNECT
Removing Tow Disconnect

To service to w d is c o n n e c t, rem ove fo llo w in g
co m p o n e n ts:
E ngine (See S e ctio n 10, G roup 25)
T ra n s fe r drive (See S ectio n 10, G roup 25)
C lu tc h pa ck w ith tra n s m is s io n pum p
P la n e ta ry p a ck (inclu d e d in th is group)
Litho in U.S.A.
50 Pow er Train Grader, M o to r ■ JD570
Disassembling and Assembling Tow Disconnect
T6692AV
1— S p rin g Pin 6— O-Ring 10— W ash er

2— W asher 7— Yoke 11— Shaft
3— Lever 8— A d ju sting S crew 12— C ap Screw (2 used)
4— R e ta in e r ( — *002321) 13— Lock W ash er (2 used)
5— S h a ft 9— Pin 14— W ash er (2 used)
Fig. 57-Disconnect Lever Adjustm ent
R e fe r to Fig. 56 to d is a s s e m b le and a sse m b le

to w d is c o n n e c t.
tran sm issio n Serial Number
L ith o in U.S.A.
TM-1001 (Dec-87)_______________________________ Power S h ift Transm ission 15-95
Adjusting Tow Disconnect

(Transmission Serial Number -002321)
W hen in s ta llin g lever s h a ft (3, Fig. 55), p u t d is

co n n e ct c o lla r in th e engaged p o s itio n . Lever m u st
be ve rtica l.
W ith th e tra n s m is s io n d is c o n n e c t s h ifte r yoke
assem bled on sh a fts , a d ju st screw (8) to give 0.030
p lus o r m in u s 0.020 cle a ra n ce betw een s h ifte r c o l
la r and tra n s m is s io n re d u ctio n ge ar w ith gear
a g a in st fro n t bearing cone. Index th e tra n sm issio n
d isco n n e ct s h ifte r yoke s h a ft (11) so th e hole in the
s h a ft s lo p e s a p p ro x im a te ly tw e lve degrees from
h o rizo n ta l to w a rd s rear o f grader.
In s ta ll tra n s m is s io n d is c o n n e c t s h ifte r lever (3)
on s h a ft w ith h u b fa c in g o u tw a rd .
Adjusting Tow Disconnect (Transmission
Serial Number 002322- )
W ith th e tra n s m is s io n d is c o n n e c t s h ifte r c o lla r 1— C ap S crew (2 used) 3 — D isc o n n ect S hifter

fu lly engaged w ith th e re d u ctio n gear, a sse m b le 2— D isc o n n ect Lever S top Lever
th e tra n s m is s io n d is c o n n e c t s h ifte r yoke (7) to the Fig. 57-Disconnect Lever Adjustm ent
s h a ft so hole in s h a ft is a p p ro xim a te ly ten degrees
dow n from h o rizo n ta l to w a rd rear o f grader.
Loosen ca p scre w s (1, Fig. 57) on d is c o n n e c t
In sta ll re ta in e r (4), d is c o n n e c t lever sto p (14) and lever s to p (2).
lever (3). S ecure lever w ith sp rin g pin (1).
R otate d is c o n n e c t s h ifte r lever (3) fo rw a rd
around th e d is c o n n e c t lever sto p u n til lever stop s.
A lig n a d ju s tm e n t m a rk o n d is c o n n e c t lever sto p
w ith rearw ard edge o f s h ift lever (as in d ic a te d by
arrow).
T ig h te n cap scre w s (1).
Litho in U.S.A.
SPEED SELECTOR AND DIRECTION SELECTOR LINKAGE

O ' 1
1— Knob (2 used) 12— Washer 23— Parking Brake Lever

2— S hift Lever 13— Washer (2 used) 24— S hift Lock Lever
3— Bushing (2 used) 14— Snap Ring (2 used) 25— Pin
4— Lever 15— Yoke (2 used) 26— C otter Pin
5— Pin 16— Nut (4 used) 27— Yoke
6— C otter Pin 17— Cable (2 used) 28— Special Pin
7— D irection Lever 18— Cfevis (2 used) 29— Nut
8— dam N ut 19— Pin (2 used) 30— Rod
9— Pin 20— Cotter Pin (2 used) 31— Spring Pin
10— C otter Pin 21— Valve Operating Arm 32— Yoke
11— Lever 22— Valve Operating Arm 33— Spring
Fig. 58-Speed Selector and Direction Selector Linkage
Litho in U.S.A.
D isa sse m b le Speed S e le c to r and D ire c tio n Assemble speed selector lever (4) and bushing (3).
S e le c to r L inkage using Fig. 58 as a reference. Install lever (4) and push-pull cable (17).
Remove shift lock rod assem bly (30) from shift lock Attach cable (17) to lever (4) and transm ission con
lever (24) by removing special pin (28) from yoke (27). trol valve operating arm (22). Install push-pull cable
clamping.
Disconnect direction selector push-pull cable (17)
from shift lever (11) by removing pin (9) from yoke (15). Assemble direction selector lever (11) and bushing
(3). Install lever (11) and push-pull cable (17).
Remove shift lever (11) and inspect bushing (3) for
wear or damage. Replace bushing (3) if necessary. Fasten cable (17) to lever (11) and transmission
control valve operating arm (21). Install push-pull cable
Disconnect speed selector push-pull cable (17) from clamping.
speed shifting lever (4) by removing pin (9) from yoke
(15). Assemble shift lock rod (30), yoke (32) and yoke
(27).
Disconnect both push-pull cables (17) from the
transmission control valve operating arms (21 and 22). Install shift lock rod assem bly securing yoke (27) to
shift lock lever (24) using special pin (28) and cotter pin
Remove push-pull cable (17) clamping and remove (26).
cablos from unit.
I rv■ R r-taill aiÛIa in H 7\ fa Ra Art A Ai» isitAlsi-s
I I I O |J d s l J J U O IP “ JJU II L O U I C 3 V( / / l '- / l ^ K L IO Ul TV11 I (N O .
Replace if necessary.
Remove speed selector lever (4) and inspect bush
ing (3) for wear or damage. Replace if necessary.
Litho in U.S.A.
ADJUSTMENTS
Adjusting Speed Selector and Direction S crew th e yokes 5/8-inch (a pp ro xim a tely 17 turns)
Selector Linkages o n to th e th re a d e d e n ds o f th e ca b les.
Use the following procedure to adjust the speed
selector and the direction, selector linkages. P lace th e speed s e le c to r arm on th e tra n s m is
sio n c o n tro l valve (Fig. 60) in th e u p p e rm o s t d e te n t
Lock the speed selector lever in the neutral position p o s itio n (neutral). There are nine speed s e le c to r de
and block the direction selector lever in the neutral te n t p o s itio n s .
position.
P lace th e d ire c tio n se le c to r arm on th e tra n s m is
sion co n tro l valve (Fig. 60) in the m id d le d e te n t p o si
tio n . There are th re e d ire c tio n s e le c to r d e te n t
p o s itio n s .
Fig. 60-Transmission Control Valve (JD570 Shown)
sition. There are three direction selector detent posi

tions.
Fig. 59-Transmission Control Linkage A d ju s t yo ke s to a lig n h o le s in yo ke s w ith h o le s

in th e arm s. T here s h o u ld be 1/4-inch o f ca b le
C h e ck th e ja m n u t a d ju s tm e n t on ea ch ca b le th re a d s in yo ke s. If not, re a d ju s t th e ja m n u ts (Fig.
(Fig. 59). T here s h o u ld be a p p ro x im a te ly th e sam e 59).
n u m b e r o f e xp o se d th re a d s on e ach sid e o f the
n u ts.
Litho in U.S.A.
CLUTCH PEDAL VALVE LINKAGE
15 17
1— Clevis 7— Bushing 12— Pin

2— N u t (2 used) 8— Arm 13— Spring Pin
3— W asher 9— Pedal 14— Pin
4— C lam p (2 used) 10— Cap Screw (2 used) 15— C otter Pin (2 used)
5— Cable 11— Lock W asher (3 used) 16— Cap Screw
6— Yoke 17— Pin
Fig. 61-Clutch Pedal Linkage
D isa sse m b le C lu tch Pedal Linkage using Fig. 61 Install bushing (7) into clutch pedal arm (8).
as a reference.
Position arm and drive pin (12) in arm.
D isco n n e ct ca b le (5, Fig. 61) fro m th e c lu tc h Install spring pin (13) in pin (12).
pedal arm (8). Rem ove cable cla m p s (4) and d is c o n
n e ct c a b le fro m c lu tc h pedal valve lever. Connect pedal (9) to arm (8) using two cap screws
Inspect push-pull cable (5) for bends or kinks. Re (10) and two lock washers (11).
place if necessary. Install push-pull cable (5) and connect yoke (6) to
Remove clutch pedal (9) from clutch pedal arm (8). arm (8) using pin (14) and cotter pin (15). Connect
clevis (1) using pin (17) and cotter pin (15).
Remove spring pin (13) and drive pin (12) from Clamp cable (5) to clutch housing using two clamps
clutch pedal arm (8). (4), washer (3), lock washer (11) and cap screw (16).
Remove clutch pedal arm (8) with bushing (7).
Inspect bushing (7) for wear or damage. Replace if
necessary.
Litho in U.S.A.
Adjusting Pedal Valve W ith the operating arm and the bell crank lever
against the stops, adjust the yoke on the operating arm
so that the hole in the yoke aligns with the hole in the
bell crank lever. Then turn yoke 1/2 turn counter
clockwise to lengthen the rod.
Replace the return spring and block the clutch pedal
in its uppermost position. Adjust the yoke on the cable
to connect cable to the bell crank lever.
IMPORTANT: Insure that the clevis from the
clutch cable at the transmission is pinned into the
lower hole in the bell crank lever. Position the clevis
from the valve operating rod in the upper hole.
Refer to Fig. 62.
Be sure to tighten jam nuts against the yokes.
Fig. 62-Pedal Valve Adjustm ent
Remove return spring from the bell crank lever

and disconnect the cable yoke (Fig. 62). Rotate both
the valve operating arm and the bell crank lever
counterclockw ise until they h it the stops.
Litho in U.S.A.
Adjusting Speed Of Shift ( -1699) Speed Of Shift (1700- )
Fig. 63-Adjustment Parts
The adjustable accum ulator charging orifice con Fig. 64-Dual A ccum ulator Housing
tro ls the speed w ith w hich transm ission sh ifts take
place. To adjust the orifice (JD570 only), remove the The dual accum ulator system of the JD570A is
plug (Fig. 63) and turn the orifice screw in or out. adjusted at the factory to provide a satisfactory speed
Make a djustm ents in 1/2-turn increm ents, testing of shift for the w idest variety of jobs.
a fte r each adjustm ent.
Adjusting Oil Pressure Regulating Valve
To make the shift quicker, turn the screw out to open
the orifice. Opening the orifice increases the rate of oil To adjust the oil pressure regulating valve, install a 0
pressure rise at the clutches and brakes during a shift to 300 psi oil pressure gauge in the test port marked
and reduces the tendency to drop torque when shifting “ C LU TC H ” in the pedal valve housing. Remove return
under load, but makes shifts sharper under no load. spring and bypass cap nut to install gauge.
To make the shift slower, turn the screw in, closing W ith oil at operating tem perature and engine set at
the orifice. Closing the orifice decreases the rate of oil 1900 rpm, oil pressure gauge should read 175 ± 10
pressure rise at the clutches and brakes during a shift, psi. If oil pressure is more than 185 psi, stop engine
and sm ooths shifts under no load, but increases the and remove one or more of the shims under the oil
tendency to drop torque when shifting under load. pressure regulating valve spring to obtain correct
pressure.
If oil pressure is less than 165 psi, stop engine and
add one or more shims under the oil pressure regulat
ing valve spring to obtain correct oil pressure.
Litho in U.S.A.
DISASSEMBLE AND ASSEMBLE OIL FILTER AND OIL PUMP SUCTION SCREEN
1— C ap S crew ( -002161) 11 — F ilte r Elem ent (2 used) 22— Spring ( -406497)

2— O -R ing (2 used) 12— C ap Screw ( -002161) 23— Valve ( -406497)
3— C over C a p Screw 24— Fitting
4— W a s h e r (2 used) 13— H yd rau lic O il F ilte r Cover 25— Washer
5— Spring (2 used) 14— C ap Screw (2 used) 26— Oil Pump Intake Screen
6— W a s h e r (2 used) 15A — H yd rau lic O il F ilte r Valve 27— Gasket
7— O -R ing (Round Cross Section) ( -406497) 28— Cap Screw (2 used)
O-R ing (Square Cross Section) 15B — H yd rau lic Oil F ilte r Valve 29— Adapter
8— R eta in e r (Use w ith Round Cross (406498- ) 30— O-Ring (2 used) ( -406497)
S ection O-R ing) 16— O-Ring O-Ring (1 used) (406498- )
R eta in e r (Use w ith S qu are Cross 17 — F ilte r R elief Valve 31—Tube ( -406497)
S ectio n O-Ring) 18 — Spring 32— Adapter ( -406497)
9— C lam p 19— F ittin g ( -406497) 33— Cap Screw ( -406497)
10— S nap Ring (2 used) 2 0 — Plug ( -4322) 34— Cap Screw ( -406497)
F ittin g (4323-406497) 35— Gasket
21— Lock P late ( -4322) 36— 0-Ring
Lock P late (4323-406497) 37— Washer (406498- )
38— Snap Ring (406498- )
39— Oil Tube (406498- )
40— Cap Screw (2 used) (406498-
41— Lock Washer (4 used)
Fig. 65-Transmission Oil F ilter and O il Pump Suction Screen

Litho in U.S.A.
R efer to Fig. 65 to d isa sse m b le and a ssem ble

filte r a sse m b lie s.
T O R Q U E S P E C IF IC A T IO N S
H yd ra u lic o il filte r
co ve r cap scre w (12, Fig. 6 5 ) ................... 45 Ib-ft
T ra n s m iss io n o il filte r
cover cap scre w (1, Fig. 6 5 ) ......................45 Ib-ft
L ith o in U.S.A.
15-104 Power S h ift Transm ission____________________________________________________ TM-1001 (Dec-87)
L ith o in U.S.A.
Grader, M o to r - JD57G Dq V/QT Trajn 50
TM-1001 (Dec-87) D ifferential, D iffe re n tia l C ontrol and Valve 20-1
v ii v s v a |« r
OH
fc v
DIFFERENTIAL, DIFFERENTIAL CONTROL AND VALVE

rM C C C D C K IT I A I
uirrLntn i iml
GENERAL INFORMATION Refer to Section 10, Group 25 to remove the trans
mission case.
Remove the differential housing cover.
Remove oil line from transmission case to left-hand
bearing quill. Remove the differential lock line connec
tor from the left-hand bearing quill.
if differential pinion shaft requires service, refer to

Section 50, Group 15 to remove transm ission plane
tary pack.
Fig. 1-Differential Control and Final

Drive Assemblies
The differential is located in the forward portion of R39977
the one-piece transmission and differential case. A — JT38000 L iftin g To ol

B — Q uill
C — Shim s
Differentials are equipped with lock. The drive axles Fig. 2-Removing Differential
may be iocked together to rotate at the same speed.
The differential control pedal actuates a control valve CAUTION: Differential assembly weighs ap
which provides a convenient means of releasing the proximately 150 lbs.
drive axles so that they may rotate at different speeds
IUI LUIMO. install JT38000 Liftin g Tool (A). (See Section 50,
Group 30.) Connect hoist and raise d ifferential
REMOVAL enough to relieve w eight on bearing quills.
IMPORTANT: If the external differential pres Remove q uill (B) and shim s (C) from botl
sure line is removed, care must be taken to keep o f differential case. Keep shim s with correct quills.
bulkhead fitting from turning. If the fitting is not
held while removing the outside flare nut, the fit
Remove d iffe re n tia l assembly.
ting may turn and twist off the internal line.
Remove both final drive and tandem assemblies as

instructed (page 50-25-1).
Litho in U.S.A.
20-2 D ifferential, D iffe re n tia l C ontrol and Valve TM-1001 (Dec-87)
SERVICING DIFFERENTIAL
Installing New Ring Gear
R39978
Fig. 3-Ring Gear
IMPORTANT: If differential ring gear is replaced,

pinion shaft must also be replaced.
Ring gear and pinion shaft are sup
plied as a matched set. Be sure
number stamped on ring gear and
pinion end of shaft are same before
assembly. Adjust cone point when
replacing ring gear and pinion shaft.
CAUTION: Heat parts in a bearing heater.

Use a thermometer and do not exceed
360°F. Plan a safe handling procedure to
avoid burns.
1. R em ove 12 cap scre w s (A) to rem ove ring gear

fro m h o usin g .
2. H eat ring ge ar to 300°F , b u t n o t m ore th a n
360°F , and in s ta ll on h o u sin g .
IMPORTANT: DO NOT use a petroleum base sol
vent, such as gasoline, to degrease
cap screws and ring gear.
3. Degrease cap screw s and threads (A) in ring gear

u sin g la c q u e r th in n e r o r ch lo ro e th e n e .
4. A p p ly AT38226 E poxy to lo w e r 0.75 in. o f cap
s cre w th re a d s.
5. In s ta ll cap scre w s and w ashers. T ig h te n 6 cap
C A r a u / e in o n r i e o r m c c
v;vi uvvu hi u ui moui wgu |ûuvni
n a t + o r n trk
iv
IK. ft
i ii•
6. R epeat tig h te n in g p a tte rn three tim e s.
L itho in U.S.A.
TM-1001 (Dec-87) Differential, Differential Control and Valve 20-3
Disassembling and Assembling Differential
5 6 e s 'S 10
11
t l § l 12
lr 34 ,
23 24
........... y ? ~ \ 2,6
[V J J ! ( \ M M 7 K T ^ I
1— C a p S c r e w (1 2 u s e d ) 1 0 — H o u s in g C o v e r ( -0 0 2 1 1 3 ) 20— O - R in g
2— L o c k P la t e (1 2 u s e d ) (0 0 2 1 1 4 - ) 21— C a p S c e w (1 2 u s e d )
3— B e a r in g Q u ill ( -0 0 2 1 1 3 ) 11— S p r in g (3 u s e d ) 22— L o c k P la te (6 u s e d )
B e a r in g Q u ill (0 0 2 1 1 4 -0 0 4 1 6 6 ) 12— D r iv e D i s k ( 4 u s e d ) 23— H o u s in g
B e a r in g Q u ill (0 0 4 1 6 7 - ) 13— S e p a r a to r P la te (3 u s e d ) 24— B e v e l P in io n S h a ft
4— N u t (2 u s e d ) 14— B a c k in g P la te 25— L o c k P la te
5— B e a r in g C u p ( -0 0 2 1 1 3 ) 15— Bevel Lock G ear ( -0 0 2 1 1 3 ) 26— C a p S c re w
B e a r in g C u p (0 0 2 1 1 4 - ) B e v e l L o c k G e a r (0 0 2 1 1 4 - ) 27— S e a lin g R in g (2 u s e d )
6— B e a r in g C o n e ( -0 0 2 1 1 3 ) 16— B e v e l P in io n (2 u s e d ) 28— B e a r in g Q u ill
B e a r in g C o n e (0 0 2 1 1 4 - ) 17— Bevel G ear ( -0 0 2 1 1 3 ) 29— B e a r in g C u p
7— S h im ( a s r e q u i r e d ) B e v e l G e a r (0 0 2 1 1 4 - ) 30— Cone
8— C a p S c r e w (1 2 u s e d ) 18— P iston 31— D r iv e G e a r S h a f t
9— P in (3 u s e d ) 19— O - R in g 32— R in g G e a r
33— G e a r a n d S h a ft A s s e m b ly
34— T h r u s t W a s h e r ( 2 u s e d ) (0 0 2 1 1 4 -
Fig. 4-Differential and D ifferential Control Components
Litho in U.S.A.
20-4 Differential, Differential Control and Valve TM-1001 (Dec-87)
1. Remove cap screws from d iffe re n tia l lock cover

to housing.
2. Remove cover by supporting d iffe re n tia l approx

im ately 3-1/2 in. o ff of table, inserting brass d rift
or wood dowel through center o f housing, and tap
ping lig h tly on cover.
3. Remove bevel gear (A).
4. Remove th ru st washer under bevel gear.
5. Inspect disks. Replace if:

a) Peening is evident o r sp lin e s have
backlash.
b) Warpage or coning exceeds 0.030 in.
c) Friction m aterial is flaked, pitted or looks
burned.
d) Less than 0.100 in. thick.
e) Oil groove depth is less than 0.006 in. R39981
6. Inspect separator plates. Replace if:

a) Scored or galled.
b) Tangs are worn.
c) Warpage or coning exceeds 0.030 in.
S E P A R A T O R P L A T E S P E C IF IC A T IO N
New Part Thickness .0.120 in.
N O T E : There is o ne 12-tang p la te a n d three 9 -ta n g

p la te s .
7. Remove and inspect three sm all springs (B).
N E W S P R IN G S P E C IF IC A T IO N S
Free Length (approximate)................................................ 1.16 in.

Test Length at 45—55 lb force......................................... 0.74 in.
8. Inspect three pins and replace if damaged.
9. Insta ll new pins to 0.47 in. above cover surface.
Litho in U.S.A.
10. Apply petroleum je lly to piston seals and install

piston in housing.
11. Install bevel gear.
12. Install 12-tang separator plate.
13. Install three separator plates w ith nine tangs

and fo u r clu tch drive disks. A lternate in stallation
sta rtin g w ith a clu tch drive disk. Make sure
separator plate tan g s are aligned.
14. Install th ru s t w asher to face o f bevel gear.
15. A pply grease to ID o f three return springs and

in s ta ll over pins on cover.
16. C arefully turn cover over and in sta ll on hous

ing m aking sure springs remain in place.
17. Install 12 cover-to-housing cap screws (A) and

tig h te n to 56 Ib-ft.
18. Install new sealing rings (A) making sure the

ends are locked.
Litho in U S A .
Test and Adjust Differential

1. insta ll new cup, using 110 mm disk if lock side
bearing cone was replaced.
2. Clean outer bearing cup surface and inside of

quill using a clean and cure primer.
3. Put a high strength thread lock and sealer on the

outside surface of the bearing cup.
4. Install bearing cup tig h t against shoulder in quill

using 110 mm disk.
IMPORTANT: Care must be taken not to damage

sealing ring surface with locking
pliers.
5. Check fo r leakage and pressure (inlet) passage

behind bearing cup by blocking passage using a
piece of O-ring w ith a large cross section and a pair
o f locking pliers.
6. Put a generous am ount of clean hydraulic oil

around bearing cup. Check fo r air leakage using
JDG-185 A ir Test Plug and 14.5 psi regulated
pressure. If leakage is present, replace bearing cup
and/or quill.
Install Differential
1. Install lock quill w ith m ating shim s on ring gear
side o f case. Position oil port (A) towards rear of
case approxim ately 45°.
IMPORTANT: Avoid damage to sealing rings (B).
2. Install quill and m ating shim s on opposite side

o f case.
3. Install six cap screws to each bearing quill and

tighten to 85 Ib-ft. Top cap screw requires square
nut.
4. A djust bearing preload and differential backlash.
Litho in U.S.A.
Adjust Differential Bearing Preload
If possible, turn differential case on its side and at

tach diai in d ic a to r.
Use a pry bar under ring gear to check end play.

Remove or add shim s (m aintaining backlash) to ob
tain 0.002—0.004 in. bearing preload.
NOTE: S h im s a re a v a ila b le in n o m in a l t h ic k n e s s e s
o f 0.003, 0.0 0 5 a n d 0.0 1 0 in. M e a s u r e s h im s
in d iv id u a lly fo r a c c u r a te m e a s u r e m e n t.
Adjust Differential Backlash

IMPORTANT: Adjust backlash only after making
preload and cone point adjustments.
Install dial in d ica to r on case w ith contact point

against ring gear tooth.
W hile holding the pinion shaft stationary, move ring

gear noting backlash. Check at three places, 120°
apart. Use average o f three readings to determ ine
backlash adjustm ent.
IMPORTANT: In order to maintain proper differen

tial bearing preload, shims must not
be added or removed. Shims should
be moved from one side to the other
to adjust backlash.
A d ju st backlash to 0.007— 0.015 in. If backlash is

low, move shim(s) from le ft q u ill to right qu ill. If
backlash is high, move shim(s) from right q u ill to
L ith o in U.S.A.
Final Installation Of Differential

1. Insta ll d iffe re n tia l assem bly into tra n sm issio n
case using JT38000 L iftin g Tool.
2. Install bearing q u ills w ith respective shim packs.
3. Tighten bearing q u ill cap screw s to 85 Ib-ft.
4. Bend up corners o f lock plates to lock cap screws

in positio n .
5. C onnect o il line and d iffe re n tia l lo ck line.
DIFFERENTIAL DRIVE SHAFT
Disassembling Differential Drive Shaft
R39816
1— Lock N ut ( -0 0 4 2 3 8 ) 7— Spacer
L o c k N u t (0 0 4 2 3 9 - ) 8— B e a r in g C o n e
2— S h a ft 9— B e a r in g C u p
3— Bearing Cone 10— > S h im { A s R e q u ir e d )
4— S h i m ( A s R e q u ir e d ) ( .0 0 3 in . , .0 0 5 in . , . 0 1 0 in . )
( .0 0 3 in , .0 0 5 in . , . 0 1 0 in . ) ( -0 0 4 2 3 8 ) 11— B e a r in g C u p
( .0 0 7 in . , . 0 1 0 in . , . 0 1 2 i n . , .0 1 5 in . ) ( 0 0 4 2 3 9 - )
5— Spacer
6— G ear
Fig. 5-D ifferentiai Drive Shaft
Remove d iffe re n tia l drive sh a ft parts (Fig. 5) in the

order the y are numbered.
Unstake special lock nut (B).
Insert m echanics pry bar (A) between the driven

gear and idler gear from the bottom side to prevent
sh a ft from tu rn in g when removing special lock nut
(B).
Litho in U.S.A.
IM P O R TAN T: A h y d ra u lic ja c k is th e s a fe s t w a y to
re m o ve th e d riv e s h a ft w ith o u t
d a m a g in g b e arin g o r s h a ft.
Press drive s h a ft through fro n t bearing cone using
a hydraulic jack. Use a sm all driver d isk between
ja c k and shaft to protect end o f shaft from possi
ble damage.
NOTE: There is a shim pack behind the front bear

ing cone and then a spacer. Do not lose or
misplace these parts.
Adjust Cone Point
IM P O R TAN T: If an y b e a rin g cups, co n es, d iffe re n

tia l drive s h a ft o r bearin g q u ill w ere
in s ta lle d new , check and a d ju st cone
p o in t.
1. O btain and record the dim ension etched on the
face o f the bevel pinion.
2. Add to th is dim ension, 1.752 in. bearing mean

overall w idth and add 0.0015 in. to allow for in
crease in length when cup is pressed into the case.
3. To determ ine the shim pack to be installed be

hind the bearing cup, sub tra ct the to ta l o f steps 1
and 2 from the dim ension stam ped on the top sur
face o f the d iffe re n tia l com partm ent. If the dim en
sion is not stam ped there, use the case mean bore
depth given in the exam ple to calculate the shim
pack.
NOTE: Shims are available in thicknesses of 0.003,

0.005, and 0.010 in.
L itho in U.SA.
Example for Finding Cone Point Shim Pack
8.287 in. Dimension on bevel pinion shaft

1.752 in. Bearing mean overall w idth
0.002 in. Increase in w idth of cup when pressed into case
10.041 Sum of Steps 1 and 2
10.08 in. Case mean bore depth (stamped on top o f case)
10.041 in. Sum o f Steps 1 and 2
0.039 in. Cone point shim pack required
Assembling Differential Drive Shaft
1— S p ec ial Nut 4— S him Pack 7— G ea r 10— S him P ack

2— Bevel Pinion S h a ft 5— S pacer 8— S pacer 11— B earing Cup
3— B earing Cone 6— Bearing Cone 9— Bearing Cup
Fig 6-Differential Drive Shaft
L itho in U.S.A.
1. Put shim pack (A) between bearing cup and

transm ission case on d iffe re n tia l side o f case.
2. Seat cup on d iffe re n tia l side o f case using a

brass ham m er or Porta-Power w ith 124 mm disk.
3. Seat bearing cup on planetary side o f hous

ing using hydraulic ja ck and 95 mm disk.
4. Install bearing cone on shaft.
5. S tart sh a ft and bearing assem bly (A and B)

into case, in sta ll rear spacer (E), driven gear (F),
fro n t spacer (G) and enough shim s (H) to pro
vide end play as sh a ft is installed in case.
A — B evel P inion G e a r
B— B earin g Cone
C — B earin g C up
D — S him s
E — R ear S p ac er
F — Driven G ear
G — Front S pacer
H — S him s
J — B earing C up
K— B earing C one
L — S p ec ial N ut
R39226
20-12 D ifferential, D iffe re n tia l C on tro l and Valve TM-1001 (Dec-87)
6. Install hydraulic ja c k as shown. Use bar stock

(A), 1-1/2 in. diam eter and a m inim um o f 24 in. long
to support ja c k press.
^ C A U TIO N : P lan a s a fe h a n d lin g p roce d u re

n io a vo id b u rn s.
7. Heat bearing in a bearing heater. Use ther
m om eter and do not exceed 300° F. In sta ll bear
ing on shaft.
8. In sta ll bearing cone using a piece o f pipe 2-1/8

in. m inim um ID and a m axim um OD o f 2-3/8 in.,
hydraulic ja c k backing to o l and hydraulic jack.
Make sure bearing is seated firm ly.
9. Place 3/8 in. diam eter rod o r bo lt between gears.
10. Install special nut and tig h te n to 400 Ib-ft.
i :.
jl._ i i r* a
LIUIU Ifl U.&.H.
Measuring Differential Drive Shaft

End Play
1. M ount a dial indicator as shown so the pointer

rests on end o f shaft.
2. Mark the nut and the case wall so end play can
be checked at the same point on the shaft.
3. Grasp the pinion end of the drive shaft and rotate

it in each direction several tim es w hile pushing it
forward to seat the rear bearings.
4. A lign the m arks and w hile holding the shaft fo r

ward, set the dial in d ica to r to zero.
5. Rotate the s h a ft several tim es in each direction

w hile pulling it rearward to seat the fro n t bearing
rollers.
6. Align the m arks and w hile holding the shaft rear

ward note the in d ica to r reading.
7. Remove dial in d ica to r and nut.
8. Press drive shaft through fro n t bearing cone us

ing a hydraulic jack.
9. Remove d iffe re n tia l drive shaft front bearing

cone.
10. Remove or add enough shim s to provide 0.001

in. end play to 0.001 in. preload.
NOTE: Front bearing shims come in nominal thick

nesses o f 0.007, 0.010, 0.012 and 0.015 in.
Measure shims individually for accurate
measurement.
11. Install shim pack determined in the above steps

and repeat procedure u n til proper preload is
achieved.
Litho in U.S.A.
Check Rolling Drag Torque
1. Tie a string approxim ately 6 ft. long tig h tly

around d ifferential drive shaft bevel pinion at fla t
area (as close to rear bearing as possible).
2. Rotate shaft to wrap string around shaft.
3. A ttach a JDT-42 Spring Scale (A). Be sure scale

is set to zero.
4. Pull the spring scale up rotating the shaft a max

imum of one revolution per second w hile reading
the spring scale. Repeat several tim e s fo r an ac
curate reading.
5. Spring scale reading m ust be 2.5— 7.5 lb.
NOTE: The 2.5— 7.5 lb. spring scale reading pro

vides the specified rolling drag torque of
5 — 15 lb-in.
6. If rolling drag torque is not w ithin specification,

repeat the entire assemble drive shaft components
and check rolling drag torque procedures. Make
sure shaft is free from nicks and burrs.
IM PO RTANT: A fte r a ll ch e cks and a d ju s tm e n ts are

m ade, a new drive s h a ft re ta in in g nut
scre w m u st be in s ta lle d and to rq ue d
as s p e c ifie d .
7. If rolling drag torque is w ithin specification,
remove the retaining nut and install a new nut.
8. Tighten nut to 400 Ib-ft.
9. Stake special nut to shaft in tw o places (B).
Litho in U.S.A.
TM-1001 (Dec-87) D ifferential, D iffe re n tia l C ontrol a n d Valve 20-15
Checking Tooth Bearing Pattern Differential Control Valve

When the hydraulic tube and hose from the dif
Check the tooth bearing pattern (Fig. 7) of the dif
ferential lock function is to be removed, identify the
ferential spiral bevel gear (2) with the bevel pinion
loose end of this hose with tape or other positive
(1). End of the tooth pattern (3) must be located 0.38
means. Insure when connecting plumbing that this
± 0.12 in. from toe end of pinion. Length of pattern
hose is connected only to the differential lock valve.
should be 1.38 to 0.24 in. (This is for new parts only.)
NOTE: The differential lock function can be dam
aged, if it is inadvertently connected to the brake valve.
Removal ( -001699)
1— D ifferential Spiral 4— 0.3 8 ± 0.12 in.

Bevel Pinion (9 .7 ± 3.0 m m )
2— Spiral Bevel Gear 5— 1.38 ± 0.24
3— T o o th B earing P attern (35.1 ± 6.1 m m )
Fig. 7-Tooth Bearing Pattern
Install the differential cover with parking brake as Fig. 8-Differential Control Valve (Early Model Shown)
instructed on page 60-20-3.
Install both final drive and tandem assemblies as

instructed (page 50-25-1).
Install engine and power unit as instructed (page

10-25-1).
Litho in U.S.A.
1— 90° E lbow (2 used) 9— Link (2 used) 17— Spring

2— O -R in g (3 used) 10— Retaining Ring (2 used) 18— Shim (as required)
3— Spring 11— Pin (2 used) 19— Flow Control V alve
4— C heck Valve 12— Pedal 20— O-Ring
5— Cap Screw 13— C otter Pin (2 used) 21— N ut (2 used)
6— Cap Screw 14— Pin 22— W asher (2 used)
7— Plug (2 used) 15— S et Screw 23— Connector
8— Housing 16— Return Valve
Fig. 9-Differential Control Valve Components (Serial No. -001699)
Before removing the differential control valve (Fig. control valve (22), shims (23), spring (24), plunger (25),
8), relieve hydraulic oil accumulator pressure from the and O-ring (26).
system by operating the steering valve with engine
stopped. Remove adjustable 90° elbow (3) from housing (28).
Refer to Fig. 9 and remove the pedal (12) from the Inspect O-ring (4), spring (5), steel ball (6) and roller
valve assembly before removing the valve from the bearing (7). Check connector (8) and O-rings (9).
mounting bracket.
Repair ( -001699)
Refer to Fig. 9 and remove the elbow fitting (1) from
the valve housing (8). Remove the following parts from D IF F E R E N T IA L
lO N IR C L VALVE
the housing bore and inspect for damage and wear:
flow control valve spring (17), shims (18), flow control
valve (19), check valve spring (3), and check valve (4).
Prior to assembling the valve according to Fig. 9,
coat components with clean hydraulic oil.
Removal (001700- )
Before removing the differential control valve (Fig.
10), relieve hydraulic oil accumulator pressure from the
system by operating the steering valve with engine
stopped.
Refer to Fig. 11, page 50-20-9 and remove the
pedal (29) from the valve assembly before removing
the valve from the mounting bracket. T 2 ‘S 2 6 ? .n ~
Remove the plug (15) from the valve housing (28). Fig. 10-Differential Control Valve (Later Model Shown)
Remove the following parts from the housing bore and
inspect for damage and wear: O-ring (16), spring (17), Prior to assembling the valve according to Fig. 11,
coat components with clean hydraulic oil.
Litho in U.S.A.
TM-1001 (Dec-87) D ifferential, D iffe re n tia l C ontrol a n d Valve 20-17
Repair (001700- )
1— H eaded Pin 11— Lock W ash er (2 used) 21— Link (2 used)

2— C otter Pin 12— W asher (4 used) 22— C ontrol Valve
3— 90° Elbow 13— Cap Screw 23— Shim (6 used)
4— O -R in g 14— Cap Screw 24— S pring
5— Spring 15— Plug 25— P lunger
6— Steel Bali 16— O -R in g 26— 0 -R in g
7— Roller B earing 17— Spring 27— Spring Pin
8— C onnector 18— 90° Elbow 28— H ousing
9— O -R in g (2 used) 19— H eaded Pin (2 used) 29— P edal
10— N ut (2 used) 20— R etaining Ring (2 used) 30— S p rin g Pin
Fig. 11-Differential Control Valve Components (Serial No. 001700- )
In sta ll spring pin (27, Fig. 11) in housing so pin

protrudes approxim ate ly 0.24 inch (6 mm) to o u t
side o f housing. Drive spring pin (30) into spring pin
(27) until ends are flush. S lot in sm aller spring pin
m ust be 90° relative to s lo t in larger spring pin.
Adjustment and Test (All Units)

Conduct the test using recommended oil. The oil
temperature range should be 90° to 110° F and with a
pressure of 2250 psi applied to the valve.
To test, remove test plug at the oil manifold (Fig. 12)

and install an oil pressure gauge of sufficient capacity.
( -001699)
With the engine running at rated speed, and with the
axles locked together, oil pressure should be 400 to
450 psi.
Fig. 12-Checking Oil Pressure (Early Model Shown)
(001700- )
Adjust to correct pressure by adding or deducting
W ith the pedal in the on position, the pressure
differential lock flow control valve shims on top of the
measured at the differential lock valve housing con
valve.
nector m ust be 635 ± 25 psi at 2450 rpm.
Litho in U.S.A.
20-18 D ifferential, D iffe re n tia l C on tro l and Valve TM-1001 (Dec-87)
Pedal Adjustment (001700- )

No pedal adjustment of the differential lock valve
( -001699)
can be made.
When the correct oil pressure has been obtained,
adjust the pedal as follows:
Depress the rear portion of the pedal until heavy

spring resistance can be felt. Release the pedal and
turn the adjusting screw so that it does not quite touch
the pedal arm when the pedal is released.
Litho in U.S.A.
TM-1001 (Nov-78) Final Drive System 25-1
Group 25
FINAL DRIVE SYSTEM
T62564N
1— Hub 6— D rive Sprocket 10— Tandem Pivot

2— Outboard Hub 6— Chain 11— Main Axle
3— D riven Axle 8— D riven S procket 12— Axle Housing
4— O il Seal 9— H ub Cap 13— Oil Seal
5— Tandem Drive Housing
Fig. 1-Final Drive System (Early Unit Shown)

The final drive system is composed of an axle drive For removal of axle drive housing and tandem pivot
housing, tandem pivot assembly and tandem drive. assemblies; refer to Section 10, Group 25.
The axle drive housing contains an axle mounted on
tapered roller bearings and a planetary gear system.
The tandem drive housings oscillate to allow both sets
of rear wheels to remain on the ground when traveling
over uneven terrain.
Power from the drive sprocket on the main axle is

transmitted through chains in the tandem drive housing
to the driven sprockets. The driven sprockets are bolt
ed to the driven axle.
All internal components including the bearings,

sprockets, and chains are splash lubricated by the
lubricant in the tandem housing.
Litho in U.S.A.
50 P o w er T ra in Grader, Motor - JD 570
2 5 -2 F in a l D r iv e S y ste m TM-1001 (Nov-78)
REPAIR
TANDEM DRIVE
1 — Cap Screw (36 used) 13 — Gasket (4 used) 27 — Outboard Hub (2 used)

2 - Hub Cap (2 used) 14 - P ipe Cap ( -002210) 28 — O il Seal (2 used)
3 - O-R ing (2 used) 15 - F ille r Tube ( -002210) 29 — Hub R etainer (2 used)
4 - Bearing Cup (2 used) Inspection P la te (002211- ) 30 - S e lf-L o c k in g Cap Screw (4 used)
5 - Bearing Cone (2 used) 16 — A ir Vent 31 - Wheel B o lt (20 used)
6 - Shim (as required) 17 - Cover
18 — Tandem H ousing
32 — Hub (2 used)
7 - Shim (as required) 33 - G asket
8 - Shim (as required) 19 - N ut (18 used)
20 — Driven A xle (2 used)
34 — Inspection P la te
9 — Cap Screw (40 used) ( -002210) 35 - P ip e Plug
Cap Screw (34 used) (002211- ) 21 - D rive C hain (2 used) 36 - S p e cia l Washer (2 used)
10 — Inspection P late (2 used) 22 - S p ro c k e t(2 used) 37 — S pecial Plug (2 used)
11 - Gasket (3 used) ( -002210) 23 - Cap Screw (18 used) 38 — R epair L in k
Gasket (2 used) (002211- ) 24 — Bearing Cone (2 used) 39 _ Wheel N ut (20 used)
12 — Cover (3 used) 25 - Bearing Cup (2 used) 40 — S pecial Washer (20 used)
26 — O -R ing (2 used) (0 0 2 3 6 6 - )
F ig, 2 —E x p l o d e d V i e w o f R i g h t T a n d e m Com ponents
Refer to Fig. 2 when servicing the tandem Attach a pulling attachment (Fig. 3, page 50-
drive. 25-3) with a hydraulic push puller to hub (32).
Remove plug (37) and drain lubricant from the Remove inspection plates (10, Fig. 2) from
tandem housing. Raise and block the rear of the the tandem housing. Disconnect the drive chains
motor grader so all four tandem drive wheels are (21) in the tandem housing (18).
clear of the ground.
Rotate the driven axle (20) until the master
Remove wheels from hub (32). chain links appear through the inspection plate
(10) opening. Remove the cotter pins from the
Remove the hub retainer (29) from the driven master links and drive out the master link pins.
axle (20).
L itho in U .S.A .
TM-1001 (Nov-79) Final D rive System 25-3
Remove the outboard hub from the driven axle

shaft being careful not to damage the seal (28, Fig.
2) in the hub.
Bolt the tandem axle lifting tool (Fig. 4) (if avail

able in shop) to the driven axle shaft. Remove the
cap screws (1, Fig. 2) holding the outboard hub (27)
to the tandem housing. Use an overhead hoist at
tached to the lifting tool to remove the driven axle
F ig . 5 —R e m o v in g B e a rin g s Fro m th e A x le D r iv e
(20) with the outboard hub (27) from the tandem
housing.
Remove the outer and inner bearing cones (5 and
24, Fig. 2) from the driven axle shaft (Fig. 5).
Remove hub cap (2, Fig. 2) and shims (6, 7, and 8).
NOTE: Keep shims with hub cap.
Attach chains to the tandem housing and an

overhead hoist. Remove the tandem housing by
removing the cap screws (15) on the tandem
pivot housing (Fig. 6, page 50-25-4).
Fig. 4-Removing Axle Drive with Outboard Hub

(JD-1001 and 1002 no longer available)
Litho in U.S.A.
25-4 Final Drive System TM-1001 (Nov-79)
TANDEM PIVOT ASSEMBLY Remove cap screw (5, Fig. 6) and thrust retainer
(6). Shims (7, 8, and 9) and thrust washer (10) can
Disassembly now be removed.
Refer to Fig. 6 for identification of tandem Bushings (11) in the tandem pivot can now be
pivot assembly parts. serviced as necessary.
Assembly
1 - Cop Screw (2 used) 8 - Shim (as required)

2 - R etaining Hub 9 - Shim (as required)
3 - Tandem D rive Sprocket 10 - T hrust Washer (2 used)
4 — O-Ring 11 — Bushing (2 used)
5 — Cop Screw (8 used) 12 - Tandem P iv o t
6 - Thrust Washer 13 - Grease F ittin g
7 - Shim (as required) 14 — O-Ring
15 — Cap Screw (20 used)
F ig . 6~Tandem P iv o t A ssem bly
F ig . 8 —B u s h in g s In s ta lle d in Tandem P iv o t
Remove cap screws (1, Fig. 6) and retaining hub
(2). Pull tandem drive sprocket (3) as shown in Fig. if removed, install bushings (11) in tandem
7. pivot as shown in Fig. 8.
N02\b: Two relieved areas on the drive Install new O-rings on the axle housing and
sprocket will accommodate a pulling attachment tandem pivot. Lubricate O-rings withSAE multi
with a 10-1/4-inch span. purpose-type grease before installing.
Lubricate bushings (11, Fig. 6) and bushing bores

with SAE multi-purpose grease.
Position thrust washers (10) and tandem pivot

(12) with assembled bushings (11) on final drive
housing, and seat firmly against the inboard
thrust washer.
Install thrust retainer (6) without shims.
Tighten cap screws (5) finger tight only.

Measure the gap between the thrust retainer and
the end of the axle housing (Fig. 9, page 50-25-
F ig , 7 -R e m o v in g Tandem D riv e S p ro cke t
5). Select a shim pack (7, 8 and 9, Fig. 6) which
will permit 0.010 to 0.015-inch end play.
Litho in U. S. A.
TM-1001 (Nov-79) Final Drive System 25-5
1— D rive Plate 3— Tandem S procket

2— S crew s (2 used)
Fig. 9-Shim Pack Measurement
Install shim pack, and thrust retainer. Tighten “ F” Fig. 11-JDG-30, Tandem Drive Sprocket Installation Tool
Grade cap screws (5) to 120 Ib-ft. (drive plate installed)
NOTE: The tandem pivot assembly should oscillate Install drive plate (1, Fig. 11) on the m ain axle with
without excessive binding. two screws (2). Tighten the screws to 170 to 190 Ib-ft.
Lubricate tandem pivot after assembly. See page Install the tandem sprocket (3) on the main axle.
10-20-1.
Press the tandem drive sprocket (Fig. 10) onto the

drive axle using a force of 20 tons. Use a threaded
adapter and sleeve if available in shop, or use JDG -30
Tandem Drive Sprocket Installation Tool (Fig. 11 and
12 ).
Litho in U.S.A.
Heat bearing cones (5 and 24) to 250°F in a suitable

oil bath before installing on driven axles.
Install driven sprocket (22) on driven axle shaft and
tighten cap screws (23) to 350 ± 50 Ib-ft.
NOTE: Rear sprocket (22) is installed on inside of
axle drive shaft. Front sprocket (22) is installed on
outside of axle drive shaft.
Install outboard hub (27) containing bearing cup (25)
on driven axle (20). NOTE: Outboard hub is marked
“T O P .”
Use axle lifting tool (Fig. 4, page 50-25-3) (if avail

able in shop), and install the driven axle and outboard
hub into the tandem housing using T43512 John Deere
Loctite or equivalent on all cap screws (1) (outboard
hub). Tighten cap screws from 78 to 92 Ib-ft.
Use the following procedure to obtain proper drag
1— Drive Cup 3— H ex Nut
torque.
2— B earing R ace Add sufficient am ount of shims (7, 8, and 9) (Fig. 6,
Fig. 12-JDG-30 Tandem Drive Sprocket Installation Tool
page 50-25-4) to the hub cap (2) to produce a slight
(drive cup installed) end play on the driven axle. Tighten cap screws (1).
Install the drive cup (1, Fig. 12), bearing race (2) and
hex nut (3).
Lubricate all sliding surfaces, including threads, with
clean oil.
Press the tandem drive sprocket onto the main axle
by tightening the hex nut to 350 Ib-ft.
Install retainer hub (2, Fig. 6) and retainer cap
screws (1). Tighten to 170 to 190 Ib-ft.
TANDEM DRIVE AND PIVOT FINAL
ASSEMBLY
Fig. 13-Checking Drag Torque on Driven Axle
Refer to Fig. 2, page 50-25-2 for assem bly.
NOTE: Lubricate all O-rings and O-ring grooves
Check drag torque (without preload) on shaft using
with SAE multipurpose-type grease before installing.
JD -6 axle bearing torque adapter (see “ SPECIAL
TO O LS,” page 50-30-3) and torque wrench (Fig. 13)
Secure tandem housing to final drive pivot using w ithout seal in place. Deduct enough shims to provide
T43512 John Deere Loctite or equivalent on all cap 15 to 25 lb-in more drag torque than obtained in
screws. Tighten cap screws, 78 to 90 Ib-ft. previous step.
Apply T43512 John Deere Loctite or equivalent to
cap screws (1) (hub cap) and tighten to 80 Ib-ft.
Litho in U.S.A.
TM-1001 (Dec-87) Engine D isco n n e ct C lutch 25-7
Lubricate seal (28, Fig. 2, page 50-25-2) lips with FINAL DRIVE
John Deere m ultipurpose-type grease or an equiva
lent. Removing Final Drive
Install the seal into outboard hub so lip of seal Separate the power unit from the engine frame
(spring side) is toward bottom of bore. (Section 10, Group 25).
Connect drive chains (21) to sprockets (22). Raise and support the transm ission adequately to
prevent the power unit from tipping.
Install inspection plates (10) and access covers (12 Remove the tandem housing from the tandem pivot
and 17). Use T43512 John Deere Loctite or equivalent assem bly (see page 50-25-2).
on all cap screws.
Press the wheel hub on the driven axle using a
JDG-30 S procket In sta lle r to apply a force o f 20
tons.
Add lubricant to tandem housing (see page

10-20-1). Be sure th a t the cavity in rear of outboard
hub is filled w ith oil.
Litho in U.S.A.
25-8 Final Drive System TM-1001 ('Nov-79)
DISASSEMBLING FINAL DRIVE
1 - Cap Screw (2 used) 14 — Snap Ring 26 - P lanet P inion Shaft (3 used)

2 — R etaining Hub 15 — Snap Ring R etainer 27 - T h rust Washer (6 used)
3 — Tandem D rive Sprocket 16 — Bearing Cone 28 — P la n e t P inion (3 used)
4 — O-Ring 17 — Bearing Cup (2 used) 29 — R o lle r Bearing (99 used)
5 — Cap Screw (8 used) 18 — Main A x le 30 - Snap Ring
6 — T h rust R etainer 19 — O-Ring 31 — P lanet P inion C arrier
7 — Shim (as required) 20 — A x le Housing 32 — Washer
8 — Shim (as required) 21 — Gasket 33 — Cap Screw
9 — Shim (as required) 22 - O il Seal 34 — Lo ck P late
10 — T h ru s t Washer (2 used) 23 — Bearing Cone 35 — Sun P inion and F in a l D rive Shaft
11 — Bushing (2 used) 24 - Dowel Pin (3 used) 36 — Washer (22 used)
12 — Tandem P iv o t 25 - Cap Screw (12 used) 37 - T h rust Washer (000843- )
13 — Grease F ittin g 38 — Cap Screw (20 used)
Fig. 14-Finai Drive
Refer to Fig. 14 for identification of final drive Remove lock plate (34) and cap screw (33).
parts. Lift planet pinion carrier assembly from axle
housing (20).
Pull the tandem drive sprocket (page 50-
25-4). Each planet pinion shaft (26) can be removed
as snap ring (30) is expanded to clear groove
Remove thrust retainer. Pull tandem pivot. in planet carrier (31).
Remove axle housing (20) with final drive Press main axle (18) and bearing (16) out of
assembly from the transmission case. housing (20).
Pull sun pinion and final drive shaft (35) Replace entire set of bearing rollers (29) if
from the differential or drive coupling. any are found to be defective.
Litho in U .S.A .
TM-1001 (Dec-87)___________________ _________________________________________ F inal Drive System 25-9
Assembling Final Drive

Refer to Fig. 14, page 50-25-8 when assembling
final drive.
Coat bores of planet pinions (28) with John Deere
m ultipurpose-type grease or an equivalent to retain
roller bearings (29).
Mount planet pinion (28) and rollers (29) in carrier
(31). Using thrust washers (27), insert shafts (26) far
enough to secure roller bearing (29) in position. Install
snap ring (30).
T6514BH
Coat the bore of the axle housing oil seal (22) with Fig. 15-Adjusting Axle Bearings
John Deere multipurpose-type grease or equivalent.
Adjust special cap screw to obtain a final drag torque
NOTE: If new bearings (16) are required, heat the reading of 20 to 50 lb-in greater than the drag torque
bearing cones not to exceed 300°F and install on axle measured with end play in the bearings.
(18) while hot. Make certain parts are properly seated.
Install lock plate (34). If necessary, tighten the cap
Install axle through housing. screw (33) the minimum additional amount required to
permit installation and to lock plate in position. Use
Heat inner bearing cone (23) not to exceed 300 John Deere m ulti-purpose-type grease or equivalent to
degrees F and install on axle. retain the lock piate until the axle housing has been
installed on the transmission case.
Place planet pinion carrier assembly, special washer
and cap screw on axle. Installing Final Drive
Install sun pinion and final drive shaft (35, Fig. 14,
Pull bearing cone (23) into position by tightening page 50-25-8) in transmission.
special cap screw (33) against washer (32). Tighten
cap screw to 70 Ib-ft to properly seat bearings. This Assemble brake components (page 60-15-1).
should be done while the bearing cone is still hot.
Use a new gasket (21) and join the assembled final
Loosen special cap screw 1/16 turn and tap on cap drive unit to the transmission case. Tighten cap screws
screw lightly (with a soft hammer) to release preload. to 170 Ib-ft.
A d ju st bearings by firs t measuring the drag Install tandem pivot assembly (see page 50-25-4).
torque (Fig. 15) w ith planet carrier assembled in
place and w ith end play in bearing. Install tandem drive assem bly (see page 50-25-5).
Litho in U.S.A.
Litho in U.S.A.
TM-1001 (Dec-87) S p e cifica tio n s and S pecial Tools 30-1
Group 3 0
DIFFERENTIAL, DIFFERENTIAL CONTROL AND VALVE
SPECIFICATIONS
Wear
Bearings, differential quill Preload 0.002 to 0.004 in.

Disk (4 used) Thickness 0.125 in. 0.100 in. min.
Cone height (maximum) 0.030 in.
Gear, bevel ( -002113*) O.D. of hub 2.9995 to 3.0005 in.
Gear bevels (002114*- ) O.D. of hub 2.9690 to 2.9790 in.
Gear, bevel lock
( -002113*) O.D. of inner hub 2.995 to 3.005 in.
Gear, bevel lock
( -002113*) O.D. of splines 5.980 to 5.990 in.
Gear, bevel lock
(002114*- ) O.D. of inner hub 2.9690 to 2.9790 in.
Gear, bevel lock
(002114*- ) O.D. of splines 5.980 to 5.990 in.
Gear, ring, differential Backlash 0.007 to 0.015 in.
Housing I.D. of pinion shaft bore 1.233 to 1.235 in.
Housing O.D. of sealing ring hub 4.478 to 4.482 in.
Housing O.D. of bearing hub 3.0025 to 3.0045 in.
Housing I.D. of piston bore 9.013 to 9.017 in.
Housing cover ( -002113*) I.D. of bevel gear hub bore 3.0025 to 3.0045 in.
Housing cover (002114*- ) I.D. of bevel gear hub bore 3.0050 to 3.0150 in.
Oil manifold ( -1699) Pressure 400 to 450 psi
(1700- ) Pressure 535 ± 25 psi
Pinion, bevel I.D. 1.2335 to 1.2365 in.
Piston, clutch O.D. 8.999 to 9.005 in.
Piston, clutch I.D. 7.073 to 7.076 in.
Piston, clutch Thickness 0.700 to 0.710 in.
Plate, clutch backing (1 used) Thickness, new 0.120 in.
Plate, clutch backing No. of tangs 12
Plates, clutch separator
(3 used) Thickness, new 0.120 in.
Cone height (maximum) 0.030 in.
Plates, clutch separator No. of tangs 9
Shaft, differential drive End play 0.000 to 0.001 in.
Shaft, differential drive,
journal (small) Diameter 2.0080 to 2.0086 in.
bearing cups and cones O.D. and I.D. Press fit
rolling drag torque Force 5-15 lb-in.
Shaft, pinion O.D. 1.2295 to 1.2305 in.
♦Transmission Serial Number
L it ho in U.S.A.
30-2 S p e cifica tio n s and S pecial Tools TM-1001 (Dec-87)
DIFFERENTIAL, DIFFERENTIAL CONTROL AND VALVE (Continued)
SPECIFICATIONS
Wear
Spring, check valve

( -1699) Free length 1.75 in.
Compressed at 12-1/4 to 1.31 in.
15 lbs.
(1700- ) Free length .62 in.

Compressed at 4 to 5 oz. .38 in.
Spring, clutch piston return Free length 1.16 in.
Compressed at 45 to 55 lbs. 0.740 in.
Spring, flow control
valve ( -1699) Free length 1.275 in.
Compressed at 180 to 220
lbs. 1.13 in.
(1700- ) Free length 2.28 in.
Compressed at 103 to 125
lbs. 1.92 in.
d/\t«T /t/\M Trnlirn
L 7 p im g t u v w uuuuui v<uvc
return (1700- ) Free length 2.56 in.

P
VW
om
U
np
A
rloV
ctfeOoVÛ U
aV
f Q
V
K f nV 11
tV V
R
J. x«v
lbs. 1.31 in.
TORQUE VALUES
Item Torque (ft-lbs)
Differential housing cover to housing cap screws 55

Differential ring gear to housing cap screws (with epoxy adhesive) 85
Differential bearing quill cap screws 85
Differential drive shaft bearing retainer to case special nut 400
TOOLS
JDG-185 Air Test Plug Check for leakage of differential lock

quill
JDT-42 Spring Scale Read rolling drag torque on drive shaft
JT38000* Differential Lifting Tool Remove and install differential from
transmission case.
*See Page 50-30-11
L itho in U .S.A .
TM-1001 (Dec-87) Specifications and Special Tools 30-3
ENGINE DISCONNECT CLUTCH
SPECIFICATIONS
Wear
Levers, clutch release Adjusted height 2.198 to 2.258 in.

Adjustment variation 0.010 in.
Springs, clutch pressure Pressure at 1-11/16 in. height 149 to 165 lbs.
TORQUE VALUES
Item Torque (ft-lbs)
Pressure plate assembly-to-flywheel 35
SPECIAL TOOLS
No. Name Use
Essential Tool
JD264 Clutch adjustment gauge To obtain proper release lever adjustment
FIN A L DRIVE SYSTEM
SPECIFICATIONS
Wear
Item Measurement New P art To leran ce
Drive Axle O.D. at outer bearing 3.144 to 3.152 in.

Drive Axle O.D. at inner bearing 3.2515 to 3.2525 in.
Driven Axle O.D. at outer bearing 3.2515 to 3.2525 in.
Driven Axle O.D. at inner bearing 2.6260 to 3.6270 in.
Thrust Washer Thickness 0.008 to 0.012 in.
Thrust Washer Thickness 0.003 to 0.009 in.
Planet Pinion O.D. 2.0838 to 2.0844 in.
Shaft
Roller Bearing O.D. at center 0.2186 to 0.2188 in.
Planet Pinion Thickness 1.507 to 1.517 in.
I.D. 2.5226 to 2.5240 in.
Drive axle and driven axle
New b ea rin g .....................................................................
Torque increase on axle when tightening -
20 to 70 in-lbs.
Old bearing....................................................................... Torque increase on axle when tightening -
10 to 35 in-lbs.
Tandem hub-to-driven a x le............................................... Press fit - 20 tons
Tandem drive sprocket-to-drive a x le ............................ Press fit - 20 tons
End play between axle housing and tandem pivot a sse m b ly .................................... 0.010 to 0.015 in.
Litho in U.S.A.
50 Power Train Grader, Motor ■JD570
30-4 Specifications and Special Tools TM-1001 (Dec-87)
FINAL DRIVE SYSTEM (Continued)

TORQUE VALUES
Item Torque (Ib-ft)
T an dem D r iv e
Hub cap-to-tandem drive hou sing.............. 78 to 92
Outboard hub-to-tandem drive housing. . . 78 to 92
Driven sprocket-to-driven axle................... 300 to 400
Inspection plates-to-tandem drive housing 35
Wheel b olts...................................................... 300
Hub retainer-to-driven axle......................... 170 to 190
T andem P iv o t
Thrust retainer-to-final drive housing (” F,T grade cap screw s). 120
Tandem pivot-to-tandem drive housing............................................ 78 to 92
F in a l D r i v e
Hub retainer-to-drive axle......................... 170 to 190
Final drive housing-to-transmission case 170
SPECIAL TOOLS
No. Name Use
Essential Tools
JD-1000* Grader Tool Set Contains tools essential for servicing the JD570
and JD570-A motor grader. Includes a service
board for storing the tools.
938-4 Thrust Washer Use with pulling attachment.
938-1A Cross Block Use with pulling attachment.
939-5 Sliding Plate Use with pulling attachment.
939-B -l Leg, 18” Use with pulling attachment.
Y-525* Thread Adapter TTco u r it h
——
1 ft ” lp c r s
10220 Hex Nut Use with pulling attachment.

953 Pulling Attachment Removing tandem drive sprocket, wheel hub, and
bearings from the axle drive.
13138* Clevis Use with "L" bracket.
JD-1001* Guide Tube Assembly Use with '’L” bracket.
JD-1003* Adapter Plug Use with "L" bracket.
JD-1004* Seal Protector Use with "L" bracket.
Y-1012* Lock-on Pin Use with "L" bracket.
JD-1002* ” L” Bracket Remove and attach axle drive to hub.
JD-244 Engine Lifting Eyes Lifting and handling engine.
JD-264 Clutch Adjusting Gauge Adjust engine clutch fingers.
D-01043AA Engine Lifting Sling Lifting engine.
Y-30-12 Ram Adjusting Screw Use with ram.
Y-30-13 Adjusting Crank Use with adjusting screw.
JDG-30 Tandem Drive Press tandem drive sprocket and wheel hub on driven
Sprocket Installation Tool axle.
Y-30-A Ram With Half Coupler Separate and assemble tandem components.
JD-1000-B* Service Board Storing contents of set.
*Tools no longer available.
Litho in U .S.A .
G rad er, M o to r - J D 5 7 0 Power Train 50
TM-1G01 (Dec-87) Specifications and Special Toois 30-5
POWER SHIFT TRANSMISSION

SPECIFICATIONS
Wear
Clutch Pack
Bushing, C2 clutch drum I.D. 2.0025-2.0035 in.
Bushing, C2 clutch shaft I.D. (installed) 1.1265-1.1295 in.
Bushing, clutch drive shaft I.D. 0.8765-0.8795 in.
Disk, clutch Thickness 0.112-0.118 in. 0.100 in. min.
Dowel pui positioning Height above plate A AA A A i
V . 4 V ‘ V.4<k 1X1.
Piston, Cl clutch I.D. 3.125-3.126 in.
Piston, C2 clutch I.D. 3.125-3.126 in.
Piston bore, Cl clutch I.D. (Early JD570) 6.030-6.040 in.
I.D. (Late JD570, JD570A) 6.6245-6.6255 in.
Piston bore, C2 clutch I.D. (Early JD570) 6.030-6.040 in.
I.D. (Late JD570, JD570A) 6.6245-6.6255 in.
Plate, clutch Thickness 0.117-0.123 in.
Plate, pressure,
Cl and C2 clutch Thickness 0.300-0.310 in.
Shaft, clutch drive O.D. at bearing 1.3778-1.3784 in.
O.D. at pilot bearing 0.6684-0.6690 in.
Sleeve, clutch oil pump
housing I.D. (installed) 1.3750-1.3760 in.
Spring, piston, Cl clutch Free length (approx.) 0.117 in.
Test length at
352-528 lb. force 0.075 in.
Spring, piston, C2 clutch Free length (approx.) 2.70 in.
Test length at
247-302 lb. force 1.12 in.
P lan e ta ry Pack
Bushing, B3 brake piston
housing I.D. 3.7555-3.7570 in.
Bushing, C3 clutch piston
housing, front I.D. 1.909-1.911 in.
Bushing, C3 clutch piston
housing, rear I.D. (installed) 1.8565-1.8585 in.
Bushing, front plate, planet
pinion carrier I.D. (installed) 2.130-2.132 in.
Thickness ( -1699) 11/16 in.
Thickness (1700- ) 3/4 in.
Disk brake, B l, B2, B3, B4 Thickness 0.117-0.123 in.
Disk, brake, C3 Thickness 0.112-0.118 in.
L itho in U .S.A .
Power Shift Transmission (Continued)
SPECIFICATIONS
Item Measurement New Part
Pinion, planet, 1 and 2 I.D. 1.0220-1.0230 in.

Thickness at hub 1.735-1.741 in.
Pinion, planet, 3 I.D. 1.0220-1.0230 in.
O.D. ( -1699) 1.966-1.976 in.
O .D .(1700- ) 1.989-1.999 in.
Pinion, planet, 4 I.D. 1.0220-1.0230 in.
O.D. ( -1699) 2.935-2.945 in.
O.D. (1700- ) 2.977-2.987 in.
Piston, C3 dutch I.D. 3.125-3.126 in.
Plate, brake, return, B l, B2,
B3, B4 Thickness 0.118-0.122 in.
Plate, brake, return, C3 Thickness 0.118-0.122 in.
Plate, brake, separator,
B l, B2, B3, B4 Thickness 0.117-0.123 in.
Plate, brake, separator,
B1-B2 Thickness 0.307-0.317 in.
Shaft-Clutch & Planetary
Support ( -406497)
Clutch support O.D. 2.1245-2.1255 in.
Planetary support O.D. 1.9967-1.9983 in.
Shaft-Clutch & Planetary
Support (406498- )
Clutch support O.D. 2.2470-2.2480 in.
Planetary support O.D. 2.4995-2.5005 in.
Shaft, pinion O.D. 0.8336-0.8340 in.
Spacer, roller bearing, 1 and
2 planet pinion Thickness 0.102-0.108 in.
Spacer, roller bearing, 3 and
4 planet pinion Thickness 0.341-0.347 in.
Spring, B l pack Free length (approx) 0.86 in.
Test length at
26.6-32.5 lb force 0.62 in.
Spring, B2 pack Free length (approx) 0.86 in.
Test length at
26.6-32.5 lb force 0.62 in.
Test length at
22.5-27.5 lb force 1.00 in.
Test length at
26.6-32.5 lb force 0.62 in.
Spring, C3 pack Free length (approx) 0.270 in.
Test length at
24.7-30.2 lb force 1.12 in.
Litho in U.SA.
POWER SHIFT TRANSMISSION (Continued)

Wear
Item Measurement New Part T o leran ce
Washer, thrust, planet pinion Thickness 0.033-0.039 in.

Washer, thrust, sun pinion Thickness 0.056-0.068 in.
O il P r e s s u r e R e g u la tin g V a lve ( -406497)

Spring, regulating valve,
oil pressure Approximate free length 3-15/16 in.
Compressed at 58.5 to 71.5 lbs. 3-7/16 in.
Spring, relief valve, oil
cooler Approximate free length 3-51/64 in.
Spring, relief valve, oil
filter Approximate free length 2-3/4 in.
Compressed at 27 to 33 lbs. 1-13/16 in.
Approximate free length
( -*1710) 3/4 in.
Compressed at 12 to 14 lbs.
( -*1710) 1/2 in.
(*1711- ) 57/64 in.
(*1711- ) 1/2 in.
(*1711- ) 2 in.
(*1711- ) 1-13/32 in.
(*1711- ) 2-5/16 in.
Compressed at 18.9 to 23.1 lbs
(*1711- ) 1-37/64 in.
Spring, relief, transmission
filter Approximate free length 47/64 in.
Compressed at 12.1to 14.91bs. 1/2 in.
Pedal Valve
Spring, bottom Approximate free length 1/2 in.

Compressed at 3.33 to 4.07 lbs. 11/32 in.
Spring, middle Approximate free length 1-5/16 in.
Spring, top Approximate free length 2 in.
Compressed at 11.7 to 14.31bs. 1-13/32 in.
t r a n s m i s s i o n S e r ia l N u m b e r
L ith o in U .S.A .
O il P r e s s u r e R e g u la tin g
V a lv e (406498- )
Spring, filter bypass valve,
upper Approximate free length 0.93 in.
Compressed at 37-45 lb. 0.51 in.
Spring, filter bypass valve,
lower Approximate free length 2.59 in.
Spring, lube relief valve Approximate free length 2.80 in.
Spring, pressure regulating
valve Approximate free length 5.61 in.
Spring, check valve Approximate free length 2.06 in.
Spring, cooler relief valve Approximate free length 4.55 in.
R e d u c tio n G e a r T r a in
Bearing, bevel pinion shaft Preload 0.004-0.006 in.
Bearing, reduction gear shaft Preload 0.000-0.002 in.
Reduction gear and disconnect
collar Clearance between 0.005-0.010 in.
Mean dimension of pinion shaft cup and cone................... .. 1.754 in.
T r a n s m is s io n C o n tr o l V a lv e
Spring, accumulator piston,
inner (JD570A) Approximate free length 3.78 in.
Compressed at 100.0 to
122.0 lbs. 2.91 in.
Spring, accumulator piston,
outer (JD570A) Approximate free length 4.09 in.
Compressed at 184.8 to
224.8 lbs. 2.91 in.
Spring, detent (inboard side) Approximate free length 1.16 in.
Compressed at 5.85 to 7.15 lbs. 0.83 in.
Spring, detent (outboard side) Approximate free length 1.12 in.
Compressed at 14.4-17.6 lbs. 0.80 in.
Spring, shaft, control valve Approximate free length 1-1/2 in.
Compressed at 1.3-1.9 lbs. 7/8 in.
Spring, valve, dump Approximate free length 1.23 in.
Spring, valve, shift Approximate free length 1.44 in.
T r a n s m is s io n O il P u m p
Gear, drive pump O.D. 3.3195-3.3205 in.
Gear, internal, pump I.D. 3.5695-3.5705 in.
TORQUE VALUES
Item Torque (ft-lb s
unless o th e rw ise no ted)
Accumulator piston cover-to-transmission control valve housing cap screws. . . 35

Clutch backing plate-to-clutch front drum cap s c r e w s ............................................... 20
Clutch oil manifold-to-clutch housing cap s c r e w s ........... ........................................... 45
Clutch oil pump body-to-housing cap s c r e w s ............................................................... 20
Clutch housing-to-transmission case external cap s c r e w s ...................................... 300
Clutch housing-to-transmission case internal cap screw s......................................... 170
Cover to control valve cap s c r e w s ................... .............................................................. 45
Planet brake piston housing cap screw s......................................................................... 35
Planetary clutch piston housing-to-drum cap screw s................................................. 20
Shift valve housing-to-control valve housing cap screw s............................................ 20
Control valve housing-to-case................................................. ......................................... 35
Differential bevel pinion shaft nut..................................................................................... 400
Differential bevel pinion shaft rolling torque (stake 2 places).......................................... 17 to 27 in. lbs.
High-range to low range cap screws.................................................................................... 18
Reduction gear shaft retainer-to-case cap screws.............................................................. 58
B1 to B4 housing cap screw................................................................................................. 35
Planetary front and rear cover cap screws......................................................................... 35
C3 cover-to-housing cap screws............................................................................................ 20
Planetary assembly-to-transmission case............................................................................ 51
Hydraulic oil filter relief valve cover cap screw................................................................. 45
Transmission oil filter cover cap screw............................................................................... 45
SPECIAL TOOLS
No. Name Use
Convenience Tools
JDG185 Air Test Plug Testing Power Shift

Transmission.
JT01748 Lifting Brackets Remove planetary pack.
JDT-24A Spring Compressor Compress clutch pack conical
spring washers.
JDT-22 Stacked Dummy Shaft Set Remove and install planet
pinion shaft.
Litho in U .S.A .
TRANSFER DRIVE
SPECIFICATIONS
Item Measurement New P art
Gear assembly, input ( -3133) End play .000-.004

(3134- ) .002 ± .0 0 2
Gear assembly, output ( -3133) End play .000-.004
(3134- ) .002 ± .0 0 2
Gear, lower idler ( -3133) End play .000-.004
(3134- ) .002 ± .0 0 2
Gear, upper idler ( -3133) End play .000-.004
(3134- ) .002 ± .0 0 2
Shaft, input gear:
Inner bearing shoulder O.D. 1.7975-1.7985
Outer bearing shoulder O.D. 1.7975-1.7985
Shaft, output gear:
Inner bearing shoulder O.D. 1.7975-1.7985
Outer bearing shoulder O.D. 1.747 -1.753
Shaft, upper idler O.D. 1.6240-1.6250
Shaft, lower idler O.D. 1.6240-1.6250
Transfer drive, inlet Oil Flow 1/2 to 1 gpm
TORQUE VALUES
Item Torque (Ib-ft)
Upper and lower quill cap screws 35

Input and output gear shaft bolts 35
Housing 3/8" cap screws 35
Housing to engine - transmission 3/4" bolts 300
Input gear to clutch drive shaft (3134- ) 35
L itho in U .S.A .
DEALER FABRICATED TOOLS

JT38000 Differential Lifting Tool
D ifferential Lifting Tool is used to remove and install Material required:

differential housing from differential case.
1020 mold steel
Two 1/2-13 UNC nuts
One piece of (13 x 305 mm) 1/2 x 12 in. round bar
stock
One piece of 1/2-13 UNC x 9.5 in. ready rod
One piece of (7 x 51 x 25 mm) 1/4 x 2 x 1 in. flat
steel
One piece of (13 x 51 x 292 mm) 1/2 x 2 x 11-1/2
in. flat steel
L itho in U .S.A .
30-12 Specifications and Special Tools_____________________________________________TM-1001 (Dec-87)
Litho in U.S.A.
Grader, Motor - JD570 Power Steering and Brakes 60
TM-1001 (Dec-87) ______ Power Steering Valve 5-1
Section 6 0
POWER STEERING AND BRAKES
Page Page
GROUP 5 - POWER STEERING VALVE GROUP 10 - BRAKE VALVE CONT.
JD570 and JD570-A Repair............................................................. 10-3
General Information.................................. 5-1 Specifications................................................. 10-4
Diagnosing Malfunctions.......................... 5-4
Repair......................................................... 5-6 GROUP 15 - BRAKE CYLINDERS AND DISKS
Units with Serial Nos. 1441, 1447-1450, General Information..................................... 15-1
and 1470-1475, and 2366-6724 Repair............................................................. 15-1
General Information.................................. 5-10 Specifications..... ........................................... 15-2
Repair......................................................... 5-15 GROUP 20 - PARKING BRAKE
Units with Serial No. 006725-Up General Information..................................... 20-1
Repair......................................................... 5-17 Diagnosing Malfunctions............................. 20-1
Specifications............................................... 5-21 iepair............................................................. 20-2
Specifications................................................. 20-4
GROUP 10 - BRAKE VALVE
General Information.................................. 10-1
CAUTION: Escaping fluid under pressure can have sufficient force to penetrate the skin causing
A serious personal injury. Before disconnecting lines, be sure to relieve all pressure. Before apply
ing pressure to the system, be sure all connections are tight and that lines and hoses are not damaged.
Fluid escaping from a very small hole can be almost invisible. Use a piece of cardboard or wood, rather
than the hands, to search for suspected leaks.
Group 5
POWER STEERING VALVE
JD570 AND JD570-A
GENERAL INFORMATION Forward shaft advance causes operating c o lla r
The steering system co n sists of a closed center (5) to m echanically pivot lever (7), forcing valves (14
steering valve and tw o steering cylinders. This and 15) open.
system is o f the h yd ro sta tic type. Refer to Figs. 1 Pressure oil flo w s through valve (15) past valve
and 2 and study the fo llo w in g before attem pting to (9) to fro n t end o f steering valve cylinder, forcing
diagnose steering d iffic u ltie s : piston to the rear.
Rotation of the steering wheel causes a mechani Displaced oil from the rear o f the steering valve
cal im balance between the valve operating shaft (1) piston (3) flow s to the piston side of the left-hand
and the steering valve piston (3). When th is im steering cylinder and pressure oil flow s dire ctly
balance occurs, the control valves (8 and 9 or 14 and from the valve (9) to the rod side o f the right-hand
15) in the steering valve are m echanically opened, steering cylinder, turning the wheels to the right.
perm itting pressure oil to activate the steering Return oil from the right-hand cylinder flow s
cylinder pistons. When steering wheel rotation is through the left-hand steering cylinder and enters
stopped, the valves remain in operation until equal the steering valve. It then passes through the steer
pressures are achieved on both sides of the steer ing valve and is discharged through the check valve
ing valve piston (3), closing the operating valves. The seat (11) to the reservoir.
grader wheels are held rigid by trapped oil. W hen rotation o f the steering valve shaft stops,
RIGHT HAND TURN (Fig. 1) the valve operating collar (5) and shaft (1) are pulled
back by rearward movem ent o f the piston and rod
Right-hand rotation o f valve operating shaft (1),
assem bly (3) when pressures are equalized on both
advances screw end o f sh a ft through piston rod,
collar, roller, spring and nut assem bly (4). sides o f piston. This closes valves (14 and 15) and
stops steering cylinder piston movement.
Litho in U.S.A.
60 P o w e r S te e r in g and B r a k e s G rader, M otor - J D 5 7 0
5 -2 P o w e r S te e r in g V a lv e T M -1001 (N ov-78)
1 - Valve Operating Shaft 8 — Pressure Valve 15 - Pressure Valve

2 - Trapped Oil Circuit 9 - Return Valve 16 - Pressure Line from Main Pump
3 - Steering Valve Piston 10 - Check Valve Piston 17 - Return to Reservoir
4 — Collar, Roller, Spring and Nut Assembly 11 - Check Valve Seat 18 - Right Steering Cylinder
5 - Valve Operating Collar 12 - Check Valve Piston Shaft 19 - Left Steering Cylinder
6 - Upper Valve Operating Lever 13 - Check Valve 20 - Inlet Check Valve
7 — Lower Valve Operating Lever 14 — Return Valve
F ig . 1—P o w e r S te e r in g - R ig h t H a n d T u rn
L ith o in U. S. A.
G rader, M otor - J D 5 7 0 P o w e r S te e r in g and B r a k e s 60
T M -1001 (N ov-78)__________________________________________________________ P o w e r S te e r in g V a lv e 5 -3
■ RETURN OIL
■ TRAPPED OIL
T18944
1- Valve Operating Shaft 8 - Pressure Valve 15 - Pressure Valve

2 - Trapped Oil Circuit 9 - Return Valve 16 - Pressure Line from Main Pump
3 - Steering Valve Piston 10 — Check Valve Piston 17 — Return to Reservoir
4 - Collar, Roller, Spring and Nut Assembly 11 - Check Valve Seat 18 - Right Steering Cylinder
5 - Valve Operating Collar 12 - Check Valve Piston Shaft 19 — L eft Steering Cylinder
6 - Upper Valve Operating Lever 13 - Check Valve 20 - Inlet Check Valve
7 - Lower Valve Operating Lever 14 — Return Valve
Fig. 2 -P o w e r Steering ■ L e f t Hand Turn
L ith o in U . S. A,
60 P o w er S te e r in g and B raises Grader, Motor - JD570
5-4 P ow er S te e r in g V alve______ TM-1001 (Nov-78)
L E F T HAND TURN (F ig . 2) ju stm en t is in d icated . W hen the s te e r in g w h eel

is h eld f i r s t as fa r righ t and then as fa r le ft as
L eft-hand rotation of the v a lv e op eratin g it can be turned e a s ily with the engine running,
sh a ft (1) r e tr a c ts s c r e w end of sh a ft through in tern a l lea k a g e is in d icated by the h eatin g of
p isto n rod, c o lla r , r o lle r , sp r in g and nut a s the p r e s s u r e in le t lin e and the retu rn lin e. T h is
se m b ly (4). m ay a lso be accom p an ied by the sound of o il
ru sh in g through the lin e s and the lo s s of engine
R earw a rd sh aft advance c a u se s v a lv e o p e r sp eed .
ating c o lla r (5) to m ech a n ica lly p ivot le v e r (6),
fo r c in g open v a lv e s (8 and 9). In tern al lea k a g e with ste e r in g w h eel turned to
right.
P r e s s u r e o il flo w s p a st v a lv e (15) through U pper p a ir of v a lv e s , b a lls , or s e a t leak in g.
v a lv e (8) and out to the rod end of the le ft
ste e r in g c y lin d er and the p isto n end o f the righ t In tern al leak age with s te e r in g w h eel turned to
ste e r in g cy lin d er. T he c y lin d e r s then turn the left.
grad er w h eels to the left. L ow er p a ir of v a lv e s , b a lls, o r s e a t leaking.
D isp la c e d o il fro m the p isto n sid e o f the le f t- If lea k a g e is v e r ifie d , alw ays ch eck p r e ss u r e
hand ste e r in g cy lin d er e n te r s at the r e a r of the in le t ch eck v a lv e fo r dam age. T h is dam age w ill
ste e r in g v a lv e p isto n , fo r c in g the p isto n down r e s t r ic t o il flow and c a u se slo w ste e r in g .
and d isp la c in g o il fro m the bottom s id e of the
p isto n through the v a lv e (9). R eturn o il fro m If no leak age is in d icated , turn the w h e e ls
the rod s id e of the righ t-h an d ste e r in g cylin d er to the str a ig h t ahead p osition ; sh u t off the en
a lso flow s to v a lv e (9). R eturn o il is then d is gine, and m ake the follow in g ch eck s: Turn the
ch arged through the c e n te r of the ch eck v a lv e s te e r in g w h eel in both d ir e c tio n s and note
(13) to the r e s e r v o ir . w hether the fr e e play is e x c e s s iv e . T hen apply
a stead y torque to the ste e r in g w h eel in each
When rotation of the w h eel sto p s, the v a lv e d irectio n . N ote w hether r e s is ta n c e is so lid and
o p eratin g c o lla r (5) and sh aft (1) a re pulled if ste e r in g w heel c r e e p s. D isc o n n e c t the s t e e r
forw ard by m ovem en t of p isto n and rod a sse m b ly ing v a lv e retu rn lin e at the ste e r in g v a lv e.
(3) when p r e s s u r e s a re equal on both s id e s of Apply a stea d y torque to the w h eel in each
p iston . T h is c lo s e s v a lv e s (8 and 9), and sto p s d ir e c tio n to ch eck fo r leak age.
s te e r in g cy lin d er p isto n m ovem ent.
S teerin g w h eel fr e e p lay e x c e e d s 60 d e g r e e s of
DIAGNOSING STEERING VALVE rotation.
MALFUNCTIONS V a lv e o p era tin g c o lla r is lo o s e .
To test the steering valve, refer to hydraulic
system tests, Section 70, Group 5. Spongy f e e l when turning w h eel to right.
B le e d a ir fr o m sy ste m .
D IF FIC U L T , INTERM ITTENT, SLOW, OR NO
POWER STEERING S teerin g w h eel c r e e p s but no lea k a g e noted.
Check fo r d e fe c tiv e ste e r in g v a lv e p iston ,
T o quickly d eterm in e the d ifficu lty, m ake the O -rin g , or sy n ch ro n izin g v a lv e.
follow in g ch eck s in the o rd er given. If su ffic ie n t Check p isto n rod c o lla r sp rin g loaded nut
h yd rau lic o il flow and p r e s s u r e are av a ila b le, (s e e " S p ecification s" ).
in tern a l leak age or im p ro p er s te e r in g v a lv e ad
Litho in U .S.A .
Grader, Motor - JD 570 P ow er S tee rin g and B ra k es 60
TM-1001 (Nov-78) ______P ow er S tee rin g V a lv e 5 -5
Leakage from steering valve when turning to SYNCHRONIZING VALVE LEAKAGE

right.
Defective piston rod O-ring in cylinder, Leakage past the synchronizing valves will be
c iV'oôVyl ’ il n
O l irgr » W.AV V v»ic?+nn f 'i —v in
* 1o^r in
A.** Pvtl* 1i 1n*H
V »V * U U l XXXg, pw YYc X OlCCXXXlg
r i l l v * i n o ’ v\/"\nrr\ v* +
\_>pcx
-
CXCXUXX XXX CXU1CX
i v f i r i n ir s
avu iv i
cover, or small square section packing in direction. Leakage would be most noted during
counterbore on face of cylinder. manual steering in either direction because of
the pressure drop across the piston caused by
T . o o l rQcro frn m til© mechanical fence of the manual steening
^ ^ * * > ✓- - ■* ^c t p p r~i n
“ o* 0* v a lv p
" ~ whpn
----------- * t------------------O
i i r n i n o * t.n
—
left.
Check for defective piston rod O-ring in Upper synchronizing ball.
cylinder cover or steering valve check valve Leakage at the upper ball would occur dur
ball seating improperly. ing a left-hand turn and would synchronize
(oil will leak out of trapped oil circuit)
If no difficulty has been found, check valve during the left-hand turn.
operating collar for looseness, valve operating
levers for excessive end play, and adjust valves Lower synchronizing ball.
as specified. Leakage would occur during the right-hand
turn and would synchronize (oil will leak
Shut down engine, turn steering wheel from into the trapped oil circuit) during the
right to left, and discharge accumulator until right-hand turn.
moderate effort will allow less than one-half
turn of wheel. It might appear that leakage would occur only
under the upper synchronizing ball, but it is
If steering wheel turns more than this, check possible that the system is synchronizing in both
for the following: directions.
1. Leakage of oil past the steering cylinder UNEQUAL STEERING RESPONSE

piston.
Piston rod collar improperly adjusted.
2. Air in the trapped oil circuit (in right Operating levers opening valves at wrong
turn only). time causing possible intermittent steering
response.
FREQUENT SYNCHRONIZATION
Steering control valve improperly adjusted.
Continual synchronization is caused by leaks If the control valve was improperly adjusted,
in the system. External leaks are obvious. the pressure valve would open before the
discharge valve when • tu• r n in go e-----------
it h e r w•• a—jv •
Possible internal leakage points are listed below:
The discharge valve would act as a restric
tion.
Defective piston rod O-ring in left steering
cylinder. STEERING WANDER AND EXCESSIVE
Leakage past this O-ring would be slight and STEERING WHEEL BACKLASH
at about the same rate. Therefore, synchro
nization would be the same in both directions. Lost motion in steering valve.
Check for loose valve operating collar, ex
Defective steering piston seal. cessive valve operating lever end play, or
Leakage past this packing will be slight incorrect valve adjustment. Also check for
U U i xug, pX-/WCX
c5i m i «/v
CIVXU11 XXX XJ\JCX1
v\r>TiTAw rtf AAvti«n> Av\nwofi An in Via VVi d i r in
<*** e ve +woxmi i r\v*
x u kaj wx i n o n f f i <-* -i n n f f > iiv \ v » lT T
xxxx7uxxx^xt^m . ou-pj^/xj U i p i C D ™
a -P m m a a
directions. Leakage would be most noted sure oil.

during manual steering in both directions
because of the pressure drop across the
m c+rm
■ n sm cp rl Vrcr m e r * h a n ir » f ll fr*y»r»P rvf f h p
manual steering.
Litho in U .S.A .
60 Pow er S teering a n d Brakes Grader, M o to r - JD570
5-6 Pow er S teering Valve______ TM-1001 (Dec-87)
REPAIR
81
T6680AN
Fig. 3-Steering Valve (JD570 and JD570-A)
Litho in U.S.A.
Grader, M o to r - JD570 Power Steering and Brakes 60
TM-1001 (Dec-87) ______ Power S teering Valve 5-7
1 — Steering Wheel Emblem 29 — Steering V alve P iston 58 — O-R ing 86 — Low er V alve O perating
2 — O-Ring 30 - P iston 59 — M etering Shaft w ith Guide Le ve r
3 — Jam N ut 31 — C otte r Pin 60 — Cap Screw 87 - S pecial Set Screw
4 — S pecial Lo ck Washer 32 - V alve Operating Shaft 61 — Jam Nut 88 — S lotted N ut
5 — Steering Wheel 33 — Spring Pin 62 — O-R ing 89 - Spring
6 — Snap Ring 34 - C oupling 63 — A d ju s ta b le Tee 90 - Snap Ring
7 — Washer 35 — Steering Shaft 64 — E lbow 91 _ V a lve Operating Shaft
8 - O il Seal 36 — A d ju s ta b le Tee 65 — O -R ing B earing Race
9 — Snap Ring 37 — O-Ring 66 — Steering V a lve H ousing 92 - Steel B a ll
10 — Washer 38 — Packing 67 - P lug 93 — V a lve O perating C o lla r
11 — Bushing 39 — Steering V alve C y lin d e r 68 — O-Ring 94 — Plug
12 — Machine Screw C over 69 — O-R ing 95 — O-R ing
13 — Bleed Screw 40 — R oller 70 — B ack-U p Ring 96 — Spring
14 - Nut 41 - Pin 71 — C heck V alve Seat 97 - Snap Ring
15 — Steel B a ll 42 — P acking 72 — Check V alve Shaft '98 — B ack-U p Ring
16 — Steering V alve C y lin d e r 43 - O-Ring 73 — Check V a lve Seat Spring 99 — O-R ing
17 — T h ru st Bearing 44 - Back-U p Ring 74 — C heck V a lve P iston Stop 100 - Washer
18 — Dowel Pin 45 - Steering Check V a lve P iston 75 — In le t C heck V a lve Seat 101 - Plug
19 — Back-Up Ring 46 — P iston Rod C o lla r 76 — Back-U p Ring 102 — O-R ing
20 — O-Ring 47 — Spring 77 — O-R ing 103 — Cap Screw and Lo ck
21 - Elbow 48 — V alve Operating Shaft N ut 78 - Steel B a ll Washer
22 — O-Ring 49 - O-Ring 79 — Spring 104 — Cap Screw and Lo ck
23 — P acking 50 - Plug 80 — Spring Guide Washer
24 — Synchronizing V a lve 51 — Back-Up Ring 81 — C over 105 — Cap Screw and Lock
Guide 52 — O-Ring 82 — Jam Nut Washer
25 — O-Ring 53 — Spring 83 — Upper V alve O perating 106 — P acking
26 — Synchronizing V a lve 54 - Steel B a ll Le ver 107 - Plug
Shaft 55 — C ontrol V alve 84 — S pecial Set Screw
27 — Steel B a ll 56 - Plug 85 — Jam Nut
28 — Spring 57 - E lbow
Le gend fo r F ig u re 3
Detach steering wheel, frame steer control Examine spring (47) for damaged coils. Spring
levers, and sleeve. Remove hydraulic oil line test length should be 3/4 in. when compressed
from steering valve and cylinder and plug ports. with 90 to 110 lbs. of force.
Remove steering valve support. Slide valve, cyl
inder, and steering wheel shaft out front of the Check piston rod collar (46), pins (41), and
instrument panel. rollers (40) and replace rollers on pins if rollers
do not turn freely.
Refer to exploded view (Fig. 3) and replace
worn or defective parts as indicated by diagnosis. Check synchronizing valves to see that valve
Be especially careful to note the following: balls are not sticking and that they return to
their seats properly.
Separate steering column top from steer
ing valve cylinder. Separate steering shafts. Examine valve operating shaft (32) for wear on
splines and worm gear. Check spring (89) for
Remove cover from bottom of steering valve damaged coils. Spring test length should be 9/16
housing. in. whencompressedwithl53to 187 lbs. of force.
Remove cotter pin (31), nut (88), and coil Inspect control valves (55) for wear, espe
spring (89) from valve operating shaft. cially in the valve seating area on small end of
valve. Included angle of valves and their seating
Remove cap screws securingvalvehousingto area in the valve housing are mismatched (valves
steering valve cylinder. - 100°; seating area - 90°) so that the valve
gives line contact between the liner and outer
Remember to remove outer snap ring and edges of valve seat.
washer from steering shaft (35) before attempt
ing to pull shaft from housing. Inspect steering valve housing (66). The valve
metering shafts and guides (59) are serviced as a
Discard and replace all O-rings and seals. matched set. Remove all guides and drive in new
guides (using care not to damage hole in center
of guide) until guide bottoms in housing.
L itho in U .S.A .
60 P ow er S teerin g and B ra k es Grader, Motor - JD570
5 -8 P ow er S teerin g V alve TM-1001 (Nov-78)
ASSEMBLY
Wash, all parts in solvent and dip in hydraulic
oil before assembly. This includes O-rings and
backup washers.
STEERING CYLINDER ASSEMBLY
Install shaft bushing (11), O-ring (20) and
backup ring (19) in cylinder. Using tool JDH-23,
install inner oil seal (8) to bottom of oil seal
bore in cylinder with sealing lips facing inward.
Install washers, snap ring (9), and press in outer
seal with sealing lips facing outward using tool
JDH-23. Install metal washer (7) and outer snap
ring.
If removed, install dowel pins (18) with 1/8 in.

protruding from surface of cylinder. Install cover on steering valve cylinder. Be
sure steering shafts are splined to coupling.
STEERING PISTON AND CYLINDER COVER
ASSEMBLY Attach piston rod collar (46) to piston rod
with pins (41) and position rollers (40) on pins.
VALVE AT ONE 0-CL0CK Install valve operating shaft spring (47) on shaft
and position nut (48) 1/8 in. away from rod collar
(Fig. 5).
STEERING VALVE ASSEMBLY
Install check valve seat (71), shaft (72), spring
(73), and check valve piston stop (74).
Install operating levers (86 and 83) and turn in

cap screws (60) until 0.003 in. maximum end play
is obtained. Lock with jam nuts. Levers must op
erate freely after adjustment.
Install metering shafts (59),valves (55),balls

(54), springs (53), and control valve plugs (50)
in housing. Install springs with small end toward
steel ball.
Install two plugs (56) with new O-rings and

T !US3 HOLES HORIZONTAL
backup rings.
F ig . 4 —P is to n a n d S yn c h ro n iz in g "Valve
Install check valve seat (71) and shaft (72)
Install piston rod (29) in piston (30) so that in check valve bore.
synchronizing valve is at one o'clock position
Place O-ring (49) on steering valve housing.
when centerlines of the rod holes are horizontal
Insert valve operating collar (93) with bearings
(Fig. 4).
in valve housing (narrow ridge inward) and at
tach valve housing to cylinder. Tighten attaching
Screw valve operating shaft (32) through
cap screws to 110 ft-lbs.
piston rod and install assembly in steering valve
cylinder.
Install coil spring (89) and special hex. nut
(88). Tighten nut to 5 ft-ibs., loosen if required
Install check valve piston (45) in cover (39)
to insert cotter pin. Check to see that operating
so that flat side of piston faces outward.
collar turns freely by hand on shaft.
Litho in U .S.A .
Grader, Motor - JD570 P o w er S tee rin g and B ra k es 60
TM-1001 (Nov-78) P o w er S tee rin g V alve 5 -9
ADJUSTMENT BLEEDING THE SYSTEM
1. Machine must have been idle for at least

one hour (overnight is better) with steering in
left or straight ahead position.
2. Do not start the engine. Remove steering
valve cover and machine screw from bleed
screw.
3. Install one end of the transparent 5/16-
inch I.D. bleed tube over the bleed screw, and
place the other end in the transmission filler tube.
Loosen bleed screw jam nut and open bleed
screw one to two turns.
F ig . 6 —A d ju s tin g Steering C ontrol V alve
Attach gauge plates (JDH-3C) as shown in Fig.

6 with thin lip of plates positioned against the
valve operating collar. (Use side of tool with
0.030 in. step.)
Mount a dial indicator needle directly on the

end of each adjusting screw as each valve is set.
Turn steering wheel all the way to the right F ig . 7 -P o w e r S teering B le e d Screw
and hold in this position by hanging a weight on
the wheel. Adjust the control valves using the 4. Without starting the engine, slowly turn
sequence outlined in specifications. the steering wheel to full right turn.
5. With steering wheel full right, hold bleed
While making adjustments on the valves, place tube in position, start the engine and run at a
a stiff wire hook behind the operating lever shaft slow idle. The wheels should not turn from their
of the valve being adjusted and pull outward with original position during this step.
slight pressure. This helps to eliminate any side 6. When the oil flowing through the tube is free
play in the operating levers and gives a more of air, close bleed screw. Wheels will turn right.
accurate valve adjustment. 7. When wheels reach a full right turn, rotate
the steering wheel very slowly (5 rpm) to full
Remove dial indicator and gauge plates. Place left.
packing in housing groove and secure cover to 8. With both steering wheel and steered
steering valve housing. Tighten attaching cap wheels turned full left, open bleed screw one to
screws to 20 ft-lbs. two turns and slowly turn the steering wheel to
full right. Make sure the vehicle wheels are not
IN STA LLA TIO N turning during this time.
9. Close bleed screw and allow the wheels to
Be sure to place fram e steer sleeve on steer turn full right.
ing wheel shaft before inserting shaft through 10. Repeat steps 7, 8, and 9 until no air
instrument panel. bubbles are visible in the tube during step 8.
Attach oil lines to their respective fittings. 11. Be sure to allow vehicle to synchronize
Install steering valve support. Connect frame full right before stopping the engine. Tighten
steering linkage from control valve to swivel on bleed screw lock nut, remove tube, install ma
frame steer sleeve. chine screw and replace steering valve cover.
Fasten frame steer controls to frame sleeve.
Install steering wheel and lock plate on shaft.
Tighten nut to 50 ft-lbs.
L itho in U .S.A .
60 P ow er S teerin g and B ra k es Grader, Motor - JD570
5 -1 0 P ow er S teerin g V alve TM-1001 (Nov-78)
UNITS WITH SERIAL NOS. 001441, 001447-001450, 001470-001475,
and 002366-UP
GENERAL INFORMATION 1. It forces oil out of the gerotor into outlet
passages in the housing, back through the sleeve
and spool, and out the left outlet port (marked
"L").
This oil is directed to the rod end of the left

steering cylinder and the head end of the right
steering cylinder. Return oil from the cylinders
is forced back through the valve and out to the
sump.
2. The rotation of the gerotor gear also turns

the gerotor drive which is connected to and turns
the valve sleeve.
When rotation of the steering wheel stops, the

1 — To Sump 3 — To R ight Steering gerotor gear continues to move turning the valve
2 — To L e ft Steering C y linde r sleeve until the sleeve is in the correct relation
C y lin d e r 4 — From Pump
ship with the spool to stop the flow of oil to the
F ig . 8 —Steering Vo/ve (U n its w ith
S erial Nos. 001441, 001447-001450, 001470-001475 gerotor. At this point the valve is in the neutral
and 002366- ) position and will remain there until the steering
The steeringvalve (F ig . 8) consists of a rotary wheel is again moved.
spool and sleeve assembly located inside the
valve housing with a gerotor at the end of the RIGHT-HAND TURN (FIG. 10)
assembly.
When the steering wheel is turned to the right,
Refer to Figs. 9 and 10 and study the following movement takes place in the valve which is
before attempting to diagnose steering difficul similar to the movement occuring during a left
ties. hand turn.
NEUTRAL POSITION The movement of the spool, however, isinthe

opposite direction to a left turn and oil is routed
Whenever the steering wheel is not moving, through different ports and passages in the sleeve
the steering valve assumes the neutral position. and spool, directing oil out the right outlet port
In this position the spool and sleeve are lined up (marked ” R").
in such a way that oil flow through the valve is
blocked. Oil can neither flow from the pump MANUAL STEERING
through the valve nor can it flow from the steer
ing cylinders through the valve. If there is no power to supply pressure oil to
the valve, the unit can be steered manually. When
LEFT HAND TURN (FIG. 9) the steering wheel is turned, the spool directs oil
as described above. If no pressure oil is avail
As the steering wheel is turned to the left, the able, the spool will come into contact with the
spool is turned by means of its direct connection cross pin. The pin then provides a direct me
to the steering shaft. This movement aligns the chanical connection to the gerotor gear. As the
spool passages with the sleeve ports and pres gerotor is turned it pumps oil to the steering
sure oil begins to flow in the valve. cylinders. Return oil from the cylinders is drawn
through a check valve between the inlet and out
The oil flows through the sleeve, into spool let ports to provide oil for manual steering op
passages, and back out of the sleeve into the valve eration. Thus the unit can be steered manually
housing. The passages in the housing direct oil until the grader is brought to a stop.
to one side of the gerotor moving the gerotor
gear. As the gear is rotated it performs the
following functions:
Litho in U .S.A .
G rader, M otor - J D 5 7 0 P o w e r S te e rin g and B ra k e s 60
T M -1001 (N ov-78) P o w e r S te e rin g V a lv e 5 -1 1
T23264
1 - Pump Pressure Oil 5 - Sleeve and Housing 9 - From Pump

2 - Steering Pressure Oil 6 - Spool 10 - L.H . Steering Cylinder
3 - Return Oil 7 - Steering Column 11- Steering Arm
4 - Gerotor Assembly 8 - To Sump 12 - R.H. Steering Cylinder
F i g ■ 9 - P o w e r S te e r in g - L e f t T u rn
60 P o w e r S te e r in g and B r a k e s G rader, Motor - JD570
5 -1 2 P o w e r S te e r in g V a lv e TM -1001 (Nov-78)
d>
© != □
© n
©■
© □
T23265
1 - Pump Pressure Oil 5 - Sleeve and Housing 9 - From Pump
2 - Steering Pressure Oil 6 - Spool 10 - L .H . Steering Cylinder
3 - Return Oil 7 - Steering Column 11 - Steering Arm
4 - Gerotor Assembly 8 - To Sump 12 - R.H. Steering Cylinder
F ig . 1 0 - P o w e r S te e r in g - R ig h t T u rn
Grader, Motor - JD570 Power Steering and B rakes 60
TM-1001 (Nov-78) Pow er Steering Valve 5-13
STEERING VALVE TEST 4. Operate steering wheel to extreme right and

apply a 60 in-lbs torque to steering shaft. Record
Perform the following service checks on the rpm. If the rpm recorded exceed 20 rpm in either
steering system if steering functions become direction, valve is unserviceable and must be re
erratic or if it is suspected that the grader has placed or rebuilt.
been operating with highly contaminated hydrau
lic oil. VALVE SPOOL LEAKAGE WITH VALVE IN
NEUTRAL POSITION
GEROTOR LEAKAGE TEST
1. Operate valves so wheels are positioned
1. Operate the machine to obtain a transmis approximately s t r a i g h t . Raise front axle off
sion oil temperature of approximately 150° F. ground with blade functions.
(road machine in eighth gear, or operate trans
mission in eighth gear with all four drive wheels Run engine at half throttle with steering valve
off the ground, or with transmission in tow). in neutral position. Record steering rod move
ment during a five minute period. If cylinder rod
2. Cycle steering valve from lock to lock ap travel exceeds 1.50 inches in five minutes, valve
proximately 15 times to bring oil temperature in is unserviceable and must be replaced or rebuilt.
the v a l v e to approximate temperature in the
transmission sump. NOTE: Before removing valve from machine,
verify that steering cylinders and lines are not
3. Operate steering wheel to extreme left and leaking.
apply 60 in-lbs torque to steering s haft. Record
rpm's.
Litho in U.S.A.
60 Pow er Steering and Brakes Grader, Motor - JD 570
5 -1 4 Power Steering Valve TM-1001 (Nov-78)
DIAGNOSING MALFUNCTIONS
STEERING WHEEL DOES NOT CENTER OR NO RESPONSE

STEERING IS ERRATIC
Sleeve and spool locked.
Binding in valve linkage. Disassemble, repair or replace.
Re-align valve.
Pump failure.
Gerotor gear splines misaligned. See Section 70.
Re-align valve.
Hose or filter clogged.
Broken centering springs. Check and correct.
Replace springs.
Check valve stuck.
NO RESPONSE OR EXCESSIVE FORCE RE Drain, flush and refill.
QUIRED WHEN STEERING WHEEL IS TURNED
Steering column shaft broken or not engaged in
Low pump pressure. spool splines.
See Section 70. Replace shaft.
Dirt in system. Shaft splines not engaged in spool splines.

Drain, flush, and refill with clean oil.
Disassemble valve and clean parts. External leakage.
Wear on sleeve and spool. Transmission oil level low.

Replace. Fill to proper level.
Transmission oil level low. Steering cylinder leakage.

Fill to proper level. Repair cylinders.
Stoppage in lines or steering cylinders. Wear in metering valve.

Check and correct. Repair.
WRONG RESPONSE TO STEERING STEERING WHEEL KICKBACK
Lines hooked up to wrong ports. Check valve in pressure line not functioning.
Reconnect. Repair check valve.
Gerotor gear splines misaligned. UNIT STEERS WHEN STEERING WHEEL

Disassemble and readjust. IS NOT MOVED
CONTINUOUS STEERING WHEEL ROTATION Sleeve, spool, or gerotor set worn or broken.
Disassemble and repair.
Dirty fluid.
Drain, flush, and refill. Excessive internal leakage.
Disassemble and replace worn parts.
Perform steering valve test.
Broken centering springs.
Replace. STEERING WHEEL CONTINUES TO TURN AT
A RAPID RATE WHEN STEERING LINKAGE IS
Input linkage binding. AGAINST STOPS
Realign.
Excessive internal leakage.
Burr on sleeve or spool. Disassemble and replace worn parts.
Repair. Perform steering valve test.
Litho in U.S.A.
TM-1001 (Nov-78) Power Steering Valve 5-15
REPAIR
(Serial Nos. 001441, 001447-001450, 001470-001475, and 002366-006724)
1— Drive 8— C om pression Spring 15— Special Screw (4 used) 21— O -R ing

2— Spacer 9— Ball 16— Oil Seal 22— C entering Pin
3— Plate 10— Check Seat 17— M ounting Plate 23— C ontrol Parts A ssem bly
4— Gerotor Set 11— Seal Plug 18— Quad Ring Seal 24— Spring (6 used)
5— End Cap 12— O-Ring 19— Bushing 25— S leeve*
6— Special Screw (7 used) 13— S pool* 20— T h ru st Bearing
7— Housing* 14— Bearing R ace
Cannot be replaced separately.

Fig. 11-Steering Valve Breakdown (Serial Nos. 001441, 001447-001450, and 001470-001475)
1— Drive
2— Spacer
3— Plate 8— Snap Ring 13— Bearing 19— Insert
4— G erotor Set 9— Seal 14— S p o o l* 20— Ball
5— Cap 10— Seal 15— Pin 21— Spring (6 used)
16— S leeve* 22— Control Parts A ssem bly
*Cannot be replaced separately.

Fig. 12-Steering Valve (002366-006724)
Litho in U.S.A.
60 Pow er Steering and B rakes Grader, Motor - JD 570
5 -1 6 P ow er Steering Valve TM-1001 (Nov-78)
Refer to Figs. 11 or 12 during disassembly grit. The ends of the meter gear can be used for
and assembly of the steering valve and note the this purpose. Then smooth both sides of the ring
following: gear, both sides of the plate, and 14-hole end of
the housing and the flat side of the end cap.
DISASSEMBLY
Stroke each surface across the abrasive
Mark mounting plate (001441, 001447-001450, several times and observe the part. Any small
and 001470-001475) before removing from valve bright area near an edge indicates a burr which
housing to insure that the ports will be in must be removed. Hold part so that contact with
the proper direction when reassembled. the abrasive is as flat as possible. Check each
part after 6 to 10 strokes across the abrasive.
NOTE: Remove spool and sleeve assembly
only when necessary. Tolerances in this area After polishing each part, rinse clean in
are very close and when replacement is neces solvent and blow dry. Keep these parts absolutely
sary the housing, spool, and sleeve must be or clean until they are assembled.
dered as a matched set.
NOTE: Do not wipe with shop rag. Lint from
If it is necessary to disassemble the housing, rag may prevent proper seal or prevent assembly
spool, and sleeve assembly, be careful to prevent o f spool, sleeve and housing.
these parts from binding. They are very closely
fitted and must usually be rotated slightly as they ASSEMBLY
are withdrawn.
Install a check valve spring into check hole
I M P O R T A N T : Always remove spool and with large end down so spool splines pass through
sleeve assembly through the end opposite the sleeve (001441, 001447-001450 and 001470-
gerotor set. Remove the spool fro m the re a r of 001475). Make certain check ball rests on top of
the sleeve. the small end of the spring before installing check
valve.
Use a small bent wire to remove check valve
seal plug (001441, 001447-001450, and 001470- Tighten check valve seat to 150 in-lbs (001441,
001475). Dislodge valve from seat by pushing on 001447-001450, and 001470-001475).
it through the outlet port. Do not pry on edge of
hole in housing bore. Install spool through the rear of the sleeve.
Rotate spool gently during assembly. Spool should
Inspect all parts for wear or damage and re rotate freely in sleeve with fingertip force ap
place as necessary. Clean all parts carefully in plied at splined end.
clean solvent.
Insert spring installation tool (60057) through |
NOTE: It is a good idea to replace all seals both spool and sleeve spring slots. Enter one end of
when repairing the valve. spring set into tool. Compress the other end of
spring set and draw into place through the spool and
Inspect all moving surfaces to insure that they sleeve.
have not been scored or abraded by dirt parti
cles or otherwise disrupted. Smooth burnished Install cross pin until it is flush or slightly
surfaces are normal in any areas. Slightly below diameter of sleeve.
scored parts can be cleaned with 600 grit
abrasive paper by hand rubbing only. Install spool and sleeve assembly so the
splined end of the spool enters the fourteen hole
Prepare surfaces of the meter section for end of the housing first. Rotate spool and sleeve
reassembly by placing a piece of 600 grit abra assembly gently during assembly.
sive paper on an extremely flat clean hard sur
face. If the paper is new it should be first rub Install mounting plate and tighten cap screws
bed down with a scrap steel part to remove sharp .evenly and gradually to 250 in-lbs (001441,
001447-001450, and 001470-001475).
Litho in U.S.A.
TM-1001 (Nov-78) Power Steering Valve 5-17
When assembling drive within the meter gear, be Install meter gear ring with chamfer toward valve
certain that the slot at the control end of the drive is in housing.
alignment with the valleys between the meter gear
teeth. Tighten end cap screws evenly and gradually to 250
in-lbs.
NOTE: If the slot of the drive is not aligned with
valleys on the meter gear, the valve will be out of time Install steering column making sure to align the
and function will be erratic or operate in opposite marks made during disassembly (001441, 001447-
direction. 001450 and 001470-001475). Tighten cap screws to
250 in-lbs.
REPAIR
(Serial No. 006725- )
Disassembly NOTE: Remove spool and sleeve assembly only

when necessary. Tolerance in this area is very close
IMPORTANT: Before starting to disassemble
and when replacement is necessary the housing, spool
the steering valve be sure that the working area
and sleeve must be ordered as a matched set.
and tools are absolutely clean.
IMPORTANT: Always remove spool and sleeve
The steering valve itself should be free of dirt and
assembly from the 14-hole end of the housing.
grease. Use a solvent to clean oil and grease from
valve. Also clean all paint from metering end of valve
If it is necessary to disassemble the housing, spool,
so that no paint flakes will enter these closely fitting
and sleeve assembly, be careful to prevent these parts
parts during assembly.
from binding. They are very closely fitted and must be
rotated slightly as they are withdrawn.
Do not use a shop cloth to clean parts. Lint deposits
can disrupt a function or cause leaks. The parts should
Remove centering pin (10).
be rinsed clean in solvent and blown dry with an air
hose. Then place all parts on a clean paper towel.
Push the spool (11) so that it moves toward the
splined end and remove it carefully from sleeve (12).
Remove the seven special screws (27, Fig. 13) and
Rotate the spool slightly as you remove it. Push the
remove end cap (26).
centering spring set (13) out of the spring slots in the
spool.
Carefully lift gerotor (25) and drive shaft (20) from
valve assembly.
Remove set screw (19) to remove check ball seat
(17), check ball (15) and check ball retainer (14).
Remove snap ring (2) and remove gland bushing

(3), thrust races and needle bearings (6 and 7).
Litho in U.S.A.
60 Pow er Steering and Brakes Grader, M otor - JD570
5-18 Power Steering Valve______ TM-1001 (Dec-87)
T6678AC
1— O il Seal 10— Pin 18— O -R ing

2— S nap Ring 11— C ontrol Spool 19— S et Screw
3— Seal Gland Bushing 12— Control Sleeve 20— Drive Shaft
4— Q uad Ring Seal 13— C en tering Spring (6 used) 21— Th in Spacer
5— O -R ing 14— C heck Ball Retainer 22— Th ick Spacer
6— T h ru st Race (2 used) 15— C heck Ball 23— S eal (3 used)
7— N eedle Thrust Bearing 16— O -R ing 24— S p ac er P late
8— C ontrol Parts A ssem bly 17— C heck Ball Seat 25— G eroter A ssem bly
9— V alve Housing 26— E nd Cap
Fig. 13-Steering Valve Assembly

(006725- )
Litho in U.S.A.
TM-1001 (Dec-87) ______ Power Steering Valve 5-19
Assembly (006725- )
NOTE: Replace all seals when assembling valve.
Clean valve parts thoroughly before assembly.
Install check ball retainer (14, Fig. 13), ball (15), and
ball seat (17) with new O-rings into housing (9). Install
set screw (19), flush or below mounting surface, and
tighten to 100 lb-in.
Install O-ring (5, Fig. 13) into housing.
Install gland bushing (3) with quad ring seal (4) and
oil seal (1). Install snap ring (2).
1— G eroter Star Gear 3— D rive Shaft S lot
2— C enter Pin End
Install thrust races (6) and needle bearings (7) in
housing. Fig. 14-Timing Geroter Star Gear And
Drive Shaft
If spool and sleeve assembly were disassembled,
install spool (11) in sleeve (12) carefully so that the Place the splined end of the drive shaft within the
spring slots of both parts are at the same end. Coat geroter star gear so that the slot at the control end of
both parts with a film of oil and rotate while sliding parts the drive is in alignment with the valleys between the
together. Check spool and sleeve for free rotation. The geroter star teeth. See Fig. 14.
spool should rotate smoothly in sleeve when fingertip
force is applied at the splined end. Push the splined end of the drive shaft partially
through the geroter star so that the spline extends
Insert spring installation tool (60057) through both about one-half its length beyond the geroter star and
spool and sleeve spring slots. Enter one end of spring hold it in this position while installing it into the housing.
set into tool. Compress the other end of spring set and Chamfer on gear teeth must be toward the housing.
draw into place through the spool and sleeve.
Note the position of the spool sleeve centering pin.
Install cross pin until it is flush or slightly below Install the geroter star with drive into the geroter ring.
diameter of sleeve. Wiggle the parts slowly into position so the drive shaft
does not become disengaged from the geroter star.
Install spool and sleeve assembly so the splined end Hold the spacer plate and geroter ring in position on
of the spool enters the fourteen hole end of the housing the housing while the star is being installed. Rotate the
first. Rotate spool and sleeve assembly gently during geroter star slightly to bring the cross slot of the drive
assembly. shaft into engagement with the centering pin.
Install new seals on housing. NOTE: Alignment of the cross slot in the drive shaft
with the valleys between the teeth of the geroter star
Place the spacer plate on the steering motor hous determines the proper valve timing of the unit. There
ing so that the bolt holes in the plate align with the are twelve teeth on the splined and six pump lobes on
tapped holes in the housing. Install new O-ring in the star. This means there are six possible correct
geroter. Place the geroter section outer gear on the timing positions. If the parts slip during assembly re
spacer plate so that the bolt holes align. peat timing procedure.
Litho in U.S.A.
60 Pow er S teering and Brakes Grader, M o to r - JD570
5-20 Pow er Steering Valve______ TM-1001 (Dec-87)
Place the two spacers (21 and 22, Fig. 13) in the end installation (006725- )
of the geroter star. If the spacers do not drop flush with
Position steering valve assembly against the upper
the gear surface, the drive has not properly engaged
steering tube in the unit. Rotate the steering wheel
centering pin.
while bringing the steering valve into contact with the
mounting surface. Install four cap screws and tighten to
Install seals (23) on geroter assem bly.
250 lb-in.
Place the end cap (26) over the assembly. Install
Connect all the hydraulic lines to the valve.
two cap screws finger tight to maintain alignment of the
parts. Install the remaining cap screws and tighten
Start the engine. Cycle steering and check for leaks
them uniformly and alternately to 250 lb-in.
at the line connections and in the steering valve hous
ing joints.
Litho in U.S.A.
TM-1001 (Nov-79) _______ Power Steering Valve 5-21
SPECIFICATIONS
STEERING VALVE (Units with Serial Nos. up to 001440, 001442-001446, 001451-001469, and
001476-002365)
Item New P art Tolerance
O.D. steering valve p isto n .............................. . . 3.370 to 3.372 in. —
I.D. steering valve cylinder........................... . . 3.3740 to 3.3770 in. —
O.D. piston r o d ................................................. . . 1.1220 to 1.1230 in. —
I.D. cylinder cover piston rod......................... . . 1.126 to 1.128 in. —
O.D. control valves............................................ . . 0.7480 to 0.7490 in. —
I.D. control valve bore in valve housing . . . . . 0.750 to 0.752 in. —
I.D. steering shaft bushing - installed. . . . . . 0.880 to 0.884 in. 0.003 in.
O.D. steering shaft at bushing......................... . . 0.874 to 0.876 in. —
Included angle of control v a lv e ...................... . . 100° —
Included angle of control valve se a t.............. . . 90° —
O.D. steering shaft at oil seal......................... . . 0.874 to 0.876 in. —
Steering valve operating shaft spring (test le n g th ).............................. 90 to 110 lbs at 3/4 in.
Steering valve operating bearing race spring (test length)................ 153 to 187 lbs at 9/16 in.
Dowels protruding from surface of cy lin d e r......................................... 1/8 in.
Synchronizing valve position in housing with centerline of piston rod
horizontal to ground.................................................................................. One o’clock
Distance between valve operating shaft nut and piston rod collar. . . 1/8 in.
Steering valve operating lever shaft maximum end play...................... 0.003 in.
STEERING VALVE (Units with Serial Nos. 001441, 001447-001450, 001470-001475, and
002366- )
Item S p e cifica tio n
Valve leakage (with oil at 150 'F., cylinders against
stops, and 60-in-lbs applied to steering shaft).......................................... 1.5 revolutions per minute
maximum.
Steering cylinder rod travel with steering valve in
neutral position...................................................................................................... 1.50 inches maximum,
ADJUSTMENT
(Units with Serial Nos. up to 001440, 001442-001446, 001451-001469, and 001476-002365)

Valve operating shaft (fore and aft movement) . . . 0.060 in. (0.030 in. either way from center)
Specifications sequence for adjusting steering control valves:
Adjusting screw location with Valve operating lever movement
valve operating collar on top measured on adjusting screw
Upper l e f t ................... . . . 0.0030 ± 0.0005 in.
Upper rig h t........... . . . . . 0.0010 ±.0.0005 in.
Lower right................. . . . 0.0030 ±_ 0.0005 in.
Lower le ft................... . . . 0.0010 ±.0.0005 in.
Litho in U.S.A.
60 Power Steering and Brakes Grader, Motor - JD570
5-22 Power Steering Valve TM-1001 (Nov-79)
TORQUE VALUES

Item T o rq u e (Ib -ft)
Steering valve housing-to-cylinder housing............................................................................ 110
Valve housing-to-cover cap s c r e w s ......................................................................................... 20
Valve operating collar slotted n u t ............................................................................................ 5
Steering wheel-to-steering wheel shaft.................................................................................... 50
Steering cylinder rod guides....................................................................................................... 500 to 700
Steering cylinder pivot pin lock nuts......................................................................................... 300
Steering cylinder piston-to-cylinder rod n u t .............................. .......................................... 350 to 500
(Units with Serial Nos. 001441, 001447-001450, 001470-001475 and 002366- )

Item T o rq u e (lb -in )
Check valve seat (001441, 001447-001450, and 001470-001475)....................................................... 150

Mounting plate cap screws (001441, 001447-001450, 001470-001475,
and 006725- ) .............................................................................................................................. 250
End plate cap screw s.................................................................................................................................. 250
Column-to-mounting plate (001441, 001447-001450, and 001470-001475)................................... 280
Check valve set screw (006725- ) ................................................................................................ 100
SPECIAL TOOLS
No. Nome Use

(JD570 and JD570-A)
JDH-23 Oil Seal Driver Protect steering wheel shaft oil seal
JDH-3D Steering Valve Adjusting Gauge* Adjust steering valve
(formerly JDH-3C)
(Units with Serial Nos. 001441, 001447-001450, 001470-001475, and 002366- )

60057 + Spring Installation Tool Install steering valve centering springs
*Use side of tool with 0.030 in. step.

+Order from: Char-Lyn Co., 15151 H ighway 5, Eden Prairie, Minn. 55343
L itho in U .S.A .
G rad er, M o to r - J D 5 7 0 P o w e r S te e rin g and B ra k e s 60
T M -1 0 0 1 (N ov-78) P o w e r B ra k e V a lv e 10-1
Group 10
POWER BRAKE VALVE
GENERAL INFO RM ATIO N
□ PRESSURE OIL
T18946 □ LOW-PRESSURE OIL
1 - Inlet Check Valve (early units) 4 _ Equalizing Valve 7 - Check Valve Disk
2 - Operating Rod Guide 5 - Brake Valve Plunger 8 - Brake Valve (Later Models)
3 - Equalizing Valve Pin 6 - Brake Valve (Early Models)
F ig . 7 -P o w e r Brake Operation
The brake valve assembly contains operating brake valve plunger (5) down and open the brake
valves to direct the flow of hydraulic oil to the valve (6).
brake cylinders. The ope rating valves can be op
erated separately or together. Pressure oil through the open brake valve
forces the check valve disk (7) open and aids in
Equalizing valves between the operating keeping the applied brake equalizing valve closed.
valves assure equal pressure to the brakes when
both operating valves are open. The upper end of the brake valve seats in the
brake valve plunger to prevent pressure oil flow
into the reservoir area.
INDIVIDUAL BRAKING (Fig. 1)
The pressure oil enters the wheel brake
As one brake is applied, the equalizing valve cylinders forcing the brake pistons and pressure
opposite of it is opened in the first 3/4 inch plate against the brake disk. The disk is splined
of pedal travel. to the final drive shaft and sun pinion of the
planetary assembly. The pressure plates move
Further travel of the pedal of approximately the brake disk against the brake backing plate to
1/8 inch causes the operating rod (2) to move provide the braking action.
60 P o w e r S te e rin g and B ra k e s G rader, M otor - J D 5 7 0
1 0 -2 P o w e r B ra k e V a lv e T M -1001 (N ov-78)
T18947 □ TRAPPED OIL
1 _ Inlet Check Valve (early units) 4 - Brake Valve (E arly Models) 6 - Reservoir Check Valve
2 - Operating Rod Guide 5 - Manual Brake Piston 7 - Brake Valve (Later Models)
3 - Brake Valve Plunger
F ig . 2 -M a n u a l Brakes Operation
EQUALIZED BRAKING The upper end of the brake valve seats,

stopping flow to the brake reservoir. Spring
When both brakes are applied, one brake valve pressure closes pressure check valve (1) and
may open before the other; however, both equaliz reservoir check valve (6) trapping oil in the
ing valves open in the first 3/4 inch of pedal operating valve. Manual brake piston then forces
travel. This allows pressure oil through the oil to the brake cylinders.
equalizing valves and assures equal braking to
both rear wheels, As the pedal is released, the valve plunger,
valve, and manual piston return to their original
ACCUMULATOR ASSISTED AND MANUAL positions. Oil then flows from the brake reservoir
BRAKES (Fig. 2) to manual piston area and return oil flows from
the wheel cylinders back into the reservoir
The accumulator, provides normal power through a metering orifice.
brakes for the first few applications (see
specifications). Eventually, however, this pres The brake pedal is again depressed and the
sure will diminish requiring more manual cycle repeats.
pressure on the brakes.
Additional pressure on the pedal causes the

operating guide (2) to move the brake valve
plunger (3), brake valve (4), and manual brake
piston (5) down.
Grader, Motor - JD 570 Pow er Steering and B rakes 60
TM-1001 (Nov-78) Pow er Brake V alve 10-3
DIAGNOSING M ALFUNCTIONS and plug brake tubes at valve. Remove valve

from mounting bracket.
MALFUNCTION OF BRAKES
Inspect all parts for wear or breakage and re
Loss of brake capacity due to internal leakage. place parts as required.
Remove return pipe. There should be no flow
of oil with brakes fully applied. When removing brake pedal bracket from
valve housing, be careful not to lose equalizing
Both brakes applied with one pedal. valve pins.
Replace defective O-rings on equalizing valve
shaft guide. Check to see if brake pedals are
binding on equalizing valve shaft.
Check for other causes of restricted move

ment of brake operating rod. Remove dirt,
which is packed around operating rod, from
failed boot.
One tandem braking before the other with both
brakes applied evenly.
Check for excessive wear on equalizing valve
pin or brake operating rod guide.
Incomplete brake releasing.

Clean restriction from 0.030-inch bleed ori
fice.
Brake pedal bounces.
Inspect brake pressure outlet check valve
disk.
External leakage around brake boot.
Replace leaking O-ring on operating rod
guide.
Leakage past pipe connectors. 1 - G asket 19 - Spring
2 — Paper Washer 20 — O -R ing
Replace O-ring packings. 21 - Plug
3 — 0 -R in g
4 - P isto n 22 - Plug
EXCESSIVE BRAKE CHATTER 5 - P lunger 23 — F ilte r Screen
6 - Spring 24 - O -R ing
7 - In le t V alve N ipple 25 — Spring
Incorrect or contaminated oil in hydraulic sy s 8 - 0 -R in g 26 — Steel B a ll
tem. 9 - Spring 27 — V a lve H ousing
Drain and refill with clean oil of proper 10 - Spring Guide P in 28 — Spring
11 - Backup R ing 29 - O -R ing
specification. 12 - O-R ing 30 — E q u a liz in g V a lve Shaft G uide
13 — C heck V alve Stop 31 - O-R ing
14 - Spring 32 — P acking Washer
NO MANUAL BRAKES 33 - E q u a lizin g V a lve Shaft Sleeve
15 — Steel B a ll
16 - 0 -R in g 34 — E q u a lizin g V a lve Shaft
Hydraulic brake lines broken. 17 — C onnector 35 — E q u a liz in g V a lve P in
36 — Washer
Replace lines as necessary. 18 - Check V a lve D isk
F ig . 3 - V a l v e H ousing A ssem bly

Inlet check valve or reservoir check valve in
correctly assembled or not in brake valve a s Use a deep-well socket to remove inletvalve
sembly. nipples from valve housing.
REPAIR Clean filter screen thoroughly. Remove any

dirt buildup around operating rod guide.
Remove spring pin from pedal and drive out
pedal shaft. Detach pedal from yoke. Disconnect
Litho in U.S.A.
60 P ow er S te e r in g and B r a k e s Grader, Motor - JD 570
1 0 -4 P o w er B rak e V a lv e________ TM-1001 (Nov-78)
ASSEMBLY
When installing brake valve and inlet valve

nipple assembly over valve return spring,
tighten nipples to valve housing to 40 ft-lbs.
Use new O-rings and a new valve housing

gasket.
IN S T A L L A T IO N
Attach brake valve to mounting bracket. Con
nect hydraulic tubes and brake pedals.
IM P O R T A N T : The d iffe re n tia l lo c k o p e ra te s

a t a p re s s u re of 500 p s i and the b ra k e v a lv e o p
e ra te s a t 2000 p s i. The d iffe r e n tia l lo c k fu n c tio n
can be dam aged if the b ra k e v a lv e lin e is co n
ne cte d to the d iffe r e n tia l lo c k .
A D JU S T M E N T 1 — Ppdal B racket 12 — Cap Screw

2 — O -R ing 13 — Lo ck Washer
The only adjustment on the brake operating 3 - O perating Rod Guide 14 - Hex. N ut
4 — Operating Rod 15 — R etainer
valve is a lock nut and screw arrangement on 5 - Operating Rad Stop 16 — Cap Screw
the brake operating rod. 6 — Spring 17 — O-Ring
7 — 0 -R in g 18 - 9 0 ° Elbow
8 — O perating Rod Stop R etainer 19 - Jan Nut
Adjust brake operating rod and yoke so that 9 - O perating Rod Boot 20 — R etaining Ring
the center line in the yoke is 3 inches from the 10 — O perating Rod Sleeve 21 - Y oke
surface of the boot retainer when the rod is 11 — Spring P i n 22 - Pin
in line with the valves.

Fig. 4 —Peda l B ra cke t and Operating Rod Ass em bly
This adjustment is for aligning the two brake

pedals and has no bearing on the operating valves.
Item N ew P a rt T olerance
I.D. of brake pedal b u s h in g ................................. 0.6880 to 0.6920 in.

0 . D. of check valve d i s k s .................................. 0.6410 in.
Width of check valve d i s k ..................................... 0.0470 in. flat within 0.001 in.
1. D. of valve housing piston b o r e .................... 0.9365 to 0.9375 in.
Maximum pedal e f f o r t ......................................... 70 lbs. at 2000 psi
0 . D. of brake p i s t o n .......................................... 0.9330 to 0.9350 in.
1. D. of piston plunger b o r e ................ .... 0.5610 to 0.5360 in.
O.D. of brake valve p lu n g er............................... 0.5595 to 0.5605 in.
O.D. of brake pedal s h a f t ................................... 0.6880 in.
Brake valve spring (test s tr e n g th )...................0.6 to 0.8 lbs. at 2-3/16 in.
Brake valve plunger spring (test strength). . . 39 to 47 lbs. at 1-11/16 in.
Pressure line valve spring (test strength) . . . 7 to 9 oz. at 1 in.
O.D. of brake valve (upper e n d ) ....................... 0.1200 to 0.1300 in.
(lower end) . ..................... 0.1200 to 0.1300 in.
TO R Q U E V A L U E S
Brake valve nipple (in h o u s i n g ) .......................................................................... 40
Litho in U .S.A .
TM-1001 (Dec-87) Brake Cylinders and Disks 15-1
Group 15
BRAKE CYLINDERS AND DISKS
GENERAL INFORMATION
1— Backing Plate 6— Piston (3 used)

2— Brake Disk 7— Paper W asher (3 used)
Fig. 1-Brake Backing Plate 3— Special Rivet (18 used) 8— O -R ing (3 used)
4— Brake Facing (3 used) 9— Pressure Plate (early
5— Pressure Plate A ssem bly units)
The brakes are hydraulically-actuated, wet-disk (3 used)
type, similar to those used on John Deere tractors.
Braking action is achieved when the brake pistons Fig. 2-Brake Components
force the revolving disk against the stationary backing
plate (Fig. 1). Replaceable brake facings are used on Replace all worn parts, O-rings (8), and paper
both the piston pressure plates and the backing plate. washers (7).
Remove each tandem and drive axle assembly Refer to Figure 2 and install parts noting the
to gain access to the brake backing plate and follow ing:
related parts. See Section 10, Group 25.
Install brake piston paper washers in O-ring
REPAIR grooves toward open end of piston bores. Brake
Use exploded view (Fig. 2) for identification of parts piston paper washers are to be soaked in the same
and for references when disassembling and assem type of oil used in the transm ission for softening
bling components. Also note the following: before assembly.
Pistons and early pressure plates are pressed as Do not allow sun gear to move outward as the brake
semblies. disk may drop behind the teeth.
Align dowel lugs on edge of plate (1) with indenta

tions in mounting flange housing when installing back
ing plate. See Figure 1.
Litho in U.S.A.
15-2 Brake Cylinders and Disks TM-1001 (Feb-80)
BLEEDING THE BRAKES

NOTE: This brake bleeding procedure requires two
service technicians.
IM PORTANT: B efore b leeding th e brakes, m ake

sure the o il side o f the brake a c cu m u la to r has zero
pressure.
1 - Lower all equipment to the ground. Stop the
engine.
2 - Loosen lock nuts on both bleed screws (Fig. 3).

Open bleed screws one full turn. Tighten lock nuts.
3 - Push both brake pedals down and hold to re Fig. 3-Brake Bleed Screw
lease the hydraulic pressure from the accumulator. (Left Side Shown)
Release brake pedals.
NOTE: The oil is released internally into the trans

mission housing.
4 - Start the engine and run at slow idle.
5 - Push both brake pedals down and hold a min-

imurn of two minutGS.
I I fho
Irtrteon II IC
lock nuts and tighten bleed screws. Tighten lock nuts.
Release the brake pedals.
7 - Push each brake pedal once. Pedal must feel

solid, if not, do the bleed procedure again.
SPECIFICATIONS
Item M easurem ent New Part Tolerance
Early brake pistons O.D. 2.9980 to 3.0010 in. .—
Later brake pistons O.D. 2.24995 to 2:25005 in. —
Brake cylinder in transmission case I.D. 2.253 to 2.256 in. —
Brake disk Flat within per in. of O.D. 0.004 in.
Litho in U.S.A.
TM-1001 (Nov-78) _____________ P ark in g B rak e 20-1
Group 20
PARKING BRAKE
F i g . 1—Park in g Brake
G E N E R A L IN F O R M A T IO N Excessive linkage friction.

The parking brake is a dry shoe expanding Check linkage pivot points for rust, bind
type, mounted on the transmission cover. The ing, or lack of lubrication.
brake contains a pinion shaft connecting the
brake drum to the differential ring gear. BRAKE GRABS
When the brake is applied, pressure from the Brake lubricant or transmission oil on lining.
brake lining against the brake drum locks the Replace linings. Clean oil or lubricant
shaft, which in turn locks the differential ring from brake and drum. Replace faulty oil
gear. When the brake is released, the shaft and seal.
drum are free to rotate with the differential.
The brake assembly is lubricated by return BRAKE DOES NOT HOLD
oil from the hydraulic oil block and also by Clearance preventing complete braking.
splash lubrication. Adjust lining to drum clearance. Take up
D IA G N O S IN G M A L F U N C T IO N S slack in linkage.
BRAKE SQUEALS OR GROANS Grease soaked linings.
Glazed lining. Repair oil leak and install new linings.
Remove glaze from lining. Excessive linkage friction.
Misalignment of parts. Check for linkage binding and misalign
Tighten loose brake or drum mounting ment.
bolts.
Dirt in drum. BRAKE IS WEARING EXCESSIVELY
BRAKE IS NOISY Brake drag.
Worn out lining. Brake lever and camshaft adjustment too
Bent or misaligned shoe. tight.
BRAKE CLICKS Inspect for broken or missing shoe return
Excessive clearance. springs.
Eccentric or wobbling drum. Rough drum surface or abrasive dirt in drum.
Inspect drum runout. Check for worn or Smooth drum with emery paper or replace
loose bearing on main shaft. drum if badly scored.
L itho in U .S.A .
60 P o w er S te e r in g and B r a k e s Grader, Motor - JD570
2 0 -2 P ark in g B rak e_____________ ___ TM-1001 (Nov-78)
1 - Cap Screw (6 used) 9 - Support P la te 17 - Spacer

2 — Drum 10 — Spring 18 — Cap Screw (3 used)
3 — Drum Support 11 — L e ve r C am shaft 19 — Spacer P la te
4 - Spring P in 12 - Pin 20 - Spacer (2 used)
5 — Spring Pirn 13 — C o tte r Pin 21 — B rake Le ver
6 — Shoe and L in in g (2 used) 14 - C able Clamp (2 used) 22 - Hex N ut
7 — Return Spring (2 used) 15 — Cap Screw (2 used) 23 - Yoke
8 — Cap Screw (4 used) 16 — Broke C able
F i g . 2 —Brake L i n i n g Components
R E P A IR Install drum (2) and torque cap screws (1)

to 85 ft-lbs.
REPLACING BRAKE LININGS
BRAKE ADJUSTMENT
N O T E : T h e e n g in e m u s t b e r e m o v e d b e f o r e
p a r k in g b ra k e can be d is a s s e m b le d . The parking brake is adjusted by either turn
ing the knob on the end of the parking brake lever
Refer to Figure 2 when disassembling, re (21) or adjusting the yoke (23) on the end of the
pairing, and assembling the parking brake. Note cable. Turning the knob clockwise will tighten the
the following: brake.
Apply a light film of lubricant to the sur Attach a spring scale directly behind the knob
faces of the brake support plate (9) and to the on the brake lever and at right angles to the lever.
anchor pins which contact the brake shoes.
L itho in U .S.A .
Grader, M o to r ■ JD570 Power Steering and Brakes 60
TM-1001 (Dec-87) Parking Brake 20-3
When the brake is properly adjusted, a force of

at least 75 pounds will be required to fully en
gage the brake.
REPLACING BEARINGS AND SHAFT

Refer to Fig. 3 when disassembling, repairing
and assembling parking brake bearing and shaft
components. Particularly note the following.
Refer also to Fig. 4 when assembling thrust
washers (8, Fig. 3) and bearings (9) on thrust ring (10).
Install assembly on the brake shaft (14). Secure with
retaining snap ring (7).
Install retaining ring (7) with chamfer facing away

from spiral bevel gear.
Support lower housing and thrust ring assemblies

with a piece of pipe (see Special Tools). Press shaft
into the assemblies.
V 5973
F i g . 4 —In s t a l l in g Brake Shaft in L o w e r

Housing
1 — Cap Screw 9 — B earing (2 used)
2 - Q i! Seal 10 - T h ru st Ring
3 - Bearing 11 — L o w e r Housing
4 — Upper Housing 12 - Bearing
5 — Shim 13 — Snap Ring
6 — 0 -R in g 14 - Shaft
7 — R etaining Ring 15 - Shims
8 — T h ru st Washer (2 used)
Fig . 3 —Bearing and Shaft Components
Litho in U.S.A.
60 Power Steering and Brakes Grader, M o to r ■ JD570
20-4 Parking Brake_____________ TM-1001 (Dec-87)
F i g . 6 - C h e c k i n g Backlash
N O T E : W h en in s ta llin g tr a n s m is s io n b r a k e
a s s e m b ly o n to tra n sm issio n c a se co v er, m a k e su re
0 .5 in. oil lin e co n n e c to r h o le p o in ts to w a rd re a r o f
tra n sm issio n case.
Fig. 5 - C h e c k in g End P lo y
Refer to Fig. 1 and remove cap screws (8)
Attach the upper housing to the lower housing and mount support plate (9). Reinstall capscrews
with sufficient amount of shims (5) to provide a and tighten to 85 ft-lbs.
measurable amount of end play. Tighten cap screws
(1) to 85 ft-lbs. Mount a dial indicator (Fig. 5) to deter Install shoes and lining (6), drum support (3),
mine the shim pack needed to provide 0.002 in. end spring pins (4 and 5), and drum (2). Tighten cap
play. screws to 85 ft-lbs.
INSTALLATION
Install brake assembly using one 0.010 in., two
0.005 in., and one 0.003 in. shims between the brake
assembly and the transmission case. Insert tapered
pin into hole in top of brake shaft and check backlash
with differential spiral bevel gear using dial indicator.
Indicator reading is to be taken on pin within 1/4 in.
of the edge of brake shaft. Backlash should measure
0.007 to 0.017 in. Adjust backlash if necessary by ad
ding or removing shims.
Tighten parking brake housing to case cover stud

nuts to 35 lb-ft. torque.
T J 1„ TT Cl A
.U1.U.IU i n u .p .a .
TM-1001 (Nov-78) P a rk in g B ra k es 2 0 -5
Item Measurement S p e cifica tio n
Differential ring gear Backlash measured 1/4 in. from edge of shaft 0.007 to 0.017 in.
Brake shaft End play
Parking brake lever Force required to move lever to engaged position. 75 lbs. min.
Drum to drum support 85
T T r v n o r h n u e H n o - t n Irvurpr h n u s i n c r ftS
Lower housing to transmission case 35
S P E C IA L TO O LS
No. Name Use
CONVENIENCE TOOL
Fig. 7* Pipe Support Support lower housing and thrust ring as
sem blies when installing shaft.
1 - A p p ro xim a te ly 4 Inches 3 - Pipe

2 — 2 Inch es—I.D .
Fig . 7 —Pipe Support
* C o n s tr u c t in d e a l e r ’s sh o p .
Litho in U .S.A .
20-6 Parking Brake TM-1001 (Nov-78)
Litho in U .S.A .
G ra d er, M o to r - JD 5 7 0 H y d ra u lic S y s t e m 70
/r s ~ ~
[LSCtJm
O//
o*7i \SWIm11M rtnI l&l
[SW + o CoUnIKW
n n 11*? J Trtff
I +P 5-1
Section 70
HYDRAULIC SYSTEM
Page Page
GRO UP 5 - C O M P O N E N TS A N D T E S T S ...........5-1 GRO UP 25 - H Y D R AU LIC C Y LIN D E R S ..............25-1
GRO UP 6 - SYSTEM TE STIN G (AN ALYZER ) GRO UP 30 - C IR C LE DRIVE H Y D R AU LIC
S erial No. (001700- ) M O TO R ....................................................30-1
GRO UP 10 - FILTERS, V ALV E S , A N D GRO UP 35 - SAD D LE V A LV E AN D
AC C U M U LA TO R R ETAIN IN G P IN S ............................... 35-1
F ilte r R e lie f V a lv e s ..................................................10-1 GRO UP 40 - S P E C IFIC A TIO N S A N D
H y d ra u lic O il A c c u m u la to r (E arly U n its ).....10-2 S P E C IA L T O O L S ................................ 40-1
H y d ra u lic O il A c c u m u la to r (L a te r U n its ).....10-4
P ressure C o n tro l V a lv e ......................................... 10-7
GRO UP 15 - M AIN H Y D R A U LIC P U M P .............. 15-1
GRO UP 20 - FU N C TIO N C O N TR O L VALVES..20-1
uroup o
COM PONENTS AND TE STS
GENERAL INFORMATION “ C lo se d -ce n te r” m eans th a t o il d o e s n o t flo w

+h(
'/
■ mink +k»AnnAmflnn wnliiAnssl fkn hucii'Ai i IS
^nAAm
u ii v u y i i Li cuii v a i v c o u i u i^ i l y u i a u n u v u i 1 1 "
CAUTION: Escaping fluid under pressure p o n e n ts w hen th e o p e ra tin g valves are in n e u tra l
n an
V M M
haua
M M * V
e n ffln la n t
V M I I I V I V I ■I I V I W
tn
IV
n a n e tro fa Ih o
|# V M V II« IV IIIV p v o iit11!/-\r\
w i i.
skin, causing serious personal injury. Before dis
connecting lines, be sure to relieve all pressure. “ C o n sta n t-p re ssu re ” m eans th a t as long as th e
Before applying pressure to system, be sure all con- e n gin e and pum p are running, a s ta n d b y o il pres-
n o n tin n c V
a r.V
a t*>
in h f. M
9 M
anH t hIM
..MM
a tI lin
»«
aV
"V
eJ r
nTin V
oV
e an H .h.W
nW
cW
aW
c ew
v u ir vo n
v if fa
Ow ^n
wnw tr\ 0AC\C\ n e i i c m a i n t a i n o r ! in i h o c \ / o to m
iv f e - r v v ^ w i i v iiimmi iui i i v w 11 i u i v v j v i v i i
are not damaged. Fluid escaping from a very small

h n le rtan
W —
hV
«V
e a lm n
*""a V
c t«.....V
W
S n v ic.V
ih.V
lo . «
l iV
cV
e M
a n io r»o V
o f. V
oa
M
rH
.M
. A n o in h t.n
' '*• '-'■»*
i c tlw
K'w
n n"> rW
n .nIV
cV
t aM
n in
t . r.n«n..n
.M
i nl ig
n, n r oV
f/IV
c i* r o . r n m .
cV
board or wood, rather than hands, to search for pensated, va riable-displacem ent pum p, m ounted in
jiu s n u c te H le a k s f r o n t o f thr> r a d i a t n r a n d d r iv e n d ir e o t lv h v t h e
If injured by escaping fluid, see a doctor at once. e n gin e cra n k sh a ft, su p p lie s pressure o il fo r th e e n
Serious infection or reaction can Hevelnn if nroner tire h y d ra u lic system .
medical treatment is not administered immediately.
T he M o to r G ra d e r h y d ra u lic s ys te m (Fig. 1) c o n V ery little e n gin e h o rse p o w e r is required to d rive
s is ts o f a reservoir (tra n sm issio n case), m ain pum p, th e pum p w hen th e h y d ra u lic c o m p o n e n ts are in
tra n s m is s io n p um p, p re ss u re c o n tro l valve, ju n c neutral. W hen pressure o il is needed to operate one
tio n b lo c k, p o w er s te e rin g valve, up to n in e fu n c o f th e h y d ra u lic c o m p o n e n ts, th e a p p ro p ria te
tio n c o n tro l valves, a ro ta ry m a n ifo ld , sa d d le c o n o p e ra tin g valve is opened m a nu a lly, a llo w in g p res
tro l valve, d iffe re n tia l c o n tro l valve, tw o p o w er su re o il to a c tiv a te th a t c o m p o n e n t. T h is re du ce s
brake va lves, an o il c o o le r, h y d ra u lic m o to r, a c o il p ressure in th e pum p cra n kca se , c a u s in g th e
c u m u la to r, c y lin d e rs an d filte rs . These in d iv id u a l p u m p to g o “ in s tro k e .” A s th e o il p re ss u re b u ild s
co m p o n e n ts are co n n e c te d by e xte rn a l stee l tu b e s up in th e h y d ra u lic syste m and p u m p cra n k ca se ,
o r re in fo rc e d ru b b e r hose. th e pum p g o e s “ o u t o f s tro k e .”
T he h y d ra u lic sys te m is a clo se d -ce n te r, c o n
s ta n t pressure system . O il is n o t pum ped u n til there The te rm p ressure -co m pe n sa te d , v a ria b le -d is
is a d e m a n d fo r o il fro m on e o f th e in d iv id u a l p la c e m e n t m eans th a t th e pum p s u p p lie s o n ly as
co m p o n e n ts . m u ch o il as is required to o p era te th e h y d ra u lic
c o m p o n e n ts a t any one tim e .
L ith o in U.S.A.
70 Hydraulic System Grader, Motor - JD570
5 -2 Components and Tests TM-1001 (Feb-80)
© -*-
>7)
□ Q
T29624N
□ ©
m ®
1— Pressure Oil 10— >Junction Block 19— Transmission Pump

2— Low Pressure Oil 11— Differential Lock Valve (Transmission 001743- )
3— Pressure Free Oil 12— Pressure Control Valve 20— To Transfer Drive
4— Steering Valve 13— Accumulator 21— From Transfer Drive
5— Steering Valve* 14— Function Return Filter 22— Transmission Pump
6— Function Control Valve 15— Pressure Regulating Valve (Transmission -001742)
7— Saddle Pin 16— To Transmission Control Valve 23— Reservoir
8— Saddle Pin Valve 17— Transmission Filter 24— Parking Brake
9— Brake Valve 18— Priority Lube Orifice 25— Oil Cooler
26— Main Hydraulic Pump
*S e ria l Nos. 1441, 1 4 47-1 450 , an d 1 4 7 0 -1 4 7 5
Fig. 1-Hydraulic System
Litho in U.S.A.
Grader, Motor - JD570 Hydraulic System 70
TM-1001 (Nov-78). Components and T est 5 -3
Litho in U. S. A.
70 H ydraulic S y stem Grader, Motor - JD570
5 -4 Com ponents and T e s ts___________________ TM-1001 (Nov-78)
SYSTEM TESTING Partially close the gate valve to restrict oil

flow until a reading of 50 psi is recorded on the
Make a preliminary check of the hydraulic oil gauge. Discharge should be three gallons every
supply, oil lines, and cylinders, and the usual in 15 seconds. If oil discharge rate falls off, re
spection for leaks, prior to testing. Whenever move and check the transmission pump gaskets.
testing the hydraulic system , new transmission See Section 50, Group 15.
and hydraulic filter elements should be in
stalled. Remove low pressure gauge and gate valve.
Connect main pump inlet oil pipe to connector on
TRANSMISSION PUMP CHECK ( -1699) oil filter relief valve housing and tighten.
Checking with Gate Valve and Pressure Gauge Checking with Flow Meter
Disconnect inlet line to main pump. Plug the

line to the main hydraulic pump to prevent oil P L A C E IN T R A N S M I S S I O N C O N N E C T TO 90° F I T T I N G
from leaking back from the main pump and oil OIL FILLER HOLE AT TRAN. CLUTCH VALVE
cooler.
Fig. 4 —In s t a l l in g H ydr aulic Tester
Connect hydraulic tester as shown in Fig. 4.

Block off line to main hydraulic pump to prevent
Fig . 3 —Transm ission Pump F lo w Check
oil from leaking back.
Turn the connector until its opening points Open hydraulic tester pressure loading valve,
down and tighten jam nut. Install low pressure start engine and adjust to specified engine speed.
gauge with gate valve as shown in Fig. 3. Place Refer to "Specifications" for pump flow.
clean container under assembly and open gate
valve.
With disconnect clutch disengaged, start the

grader engine and run at 1900 rpm.
Engage the disconnect clutch and with gate

valve open check quantity of' oil discharged in
15 seconds. Discharge should be approximately
three gallons during this period.
Litho in U.S.A.
Grader, M o to r - JD570 H ydraulic System 70
TM-1001 (Dec-87) Com ponents and Tests 5-5
Transmission Pump Check Destroke the main hydraulic pump by turning in the
(/ aI -?nA
l uu- destroke screw (pump shut-off screw).
The following customer complaints may result from
a faulty transmission pump: loading valve before starting the engine.
1) Transmission slippage, W ith the transm ission in neutral and engine at 1900
2) Cavitation of the main hydraulic pump, ± 5 rpm, the output from the transm ission pump should
3) Slow hydraulic functions, or be a minimum of 15.8 gpm. Oil temperature must be
4) Low transmission lube pressure. 120 to 140°F.
Once the transmission filter, pressure regulating If the minimum flow specification cannot be met,
valve, filter relief valve, cooler relief valve, and sump suspect a suction problem. Check that the filter relief
screen have been eliminated as the possible problem, valve is properly seated.
next check the output of the transmission pump.
IMPORTANT: Do not completely close the flow
Before making test connections, heat the oil in the meter loading valve. Pressure in excess of 250 psi
transmission to approxim ately 150°F (66°C). This can will damage the transmission pump.
be quickly done by operating the transm ission in 8th
speed forward with the unit in the TOW position. Slowly close the flow meter loading valve until 175
psi is reached. The output from the transm ission pump
CAUTION: Block one set of tandem wheels
should be 11 gpm minimum.
A off the ground for an extra margin of safety.
If the pressure flow minimum specification cannot be
IUI p ui Hill/ tIIk 1AC T! AV/V
\» f
V
position, running machine at W.O.T. above 1st gear
met, be sure the filter relief valve is seated. Do not
remove the transm ission pump before checking the
with only one set of tandems off the ground can
filter relief valve and pressure regulating valve housing
cause damage to the differential.
gaskets.
Shut off engine. Quickly perform test connections NOTE: Some leakage from hole in plug (B, Fig.
(Fig. 5). 4A) is acceptable. If oil leakage is under pressure,
stop test. This indicates filter relief valve is not
Remove the transm ission filte r. Install the properly seated.
transm ission tool kit (JD-293) (Fig. 4B). Connect the
inlet hose of the flow m eter to the transm ission too!
kit output connector. Run the o utlet hose from the
flo w meter to the filte r tube.
NOTE: Secure the return hose with tape to pre

vent back pressure from pushing hose out of filter
tube.
Use the JD-293-5 plug (B, Fig. 4A) and JD-293-6

sleeve (A) to block the filte r relief valve to prevent
any oil from being dumped from the circuit, caus
ing a fa u lty te st reading.
A — J D - 2 9 3 - 6 S le e v e
B — J D -2 9 3 -5 P lu g
Fig. 4A-Filter Relief Valve Plug
Litho in U.S.A.
70 Hydraulic System Grader, M otor - JD570
5-6 Components and Tests TM-1001 (Dec-87)
\\\w \\\
W w
U
T6139D11
1— JD-293-1 Filter Housing Cover A ssem bly 3 — JD-293-3 Tube Extension
2 — O-Ring (2 used) 4 — JD-293-2 Filter Assem bly
Fig. 4B-Transmission Pump Tool Kit
1— OTC Flow M eter 6— Used H ydraulic Tube 1 1 — D-96 Double Fem ale Union
2— Flow M e ter Loading H andle 7— Transm ission Tool Filter 12— D-91 Flow M e ter Inlet H ose
3— Y-2110 Flow M e ter In let Hose 8— Transm ission F ilter Extension 13— Flow M e ter Loading H andle
4— Y-2110 Flow M eter O u tlet Hose 9— Transm ission Tool Filter Cover 1 4 — N uD ay Flow M eter
5— Pipe Coupling 1 0 — D-88 Union A dapter 15— D-91 Flow M e ter O utlet
Hose
Fig. 5-Transmission Oil Pump Flow Setup

Using Nuday or OTC Flow Meter
TM-1001 (Dec-87) C om ponents and Tests 5-7
Transmission Pump Pressure Main Hydraulic Pump

The test for checking transm ission pump pressure is Remove transmission temperature sending unit
included in Section 50, Group 15, under the Power from oil pressure regulating valve and install a pres
Shift Transmission. sure gauge.
Differential Control Valve

Test the differential control valve as outlined in
Standby Pressure Check
Fig. 7-Main Hydraulic Pump Charge Pressure
Discharge hydraulic system by operating steering

Fig. 6-Checking Standby Pressure and brakes with engine off.
Install a 3000 psi gauge in the lower port of the Install a 0 to 5000 psi pressure gauge in the upper
manifold block (Fig. 6). W ith the grader engine running test port of the stroke control valve to m onitor main
at 2450 rpm, the gauge reading should be to specifi pressure.
cations.
Connect the outlet of the flow meter as shown in Fig.
If gauge reading is not within specifications, adjust 8.
stroke control valve on the main hydraulic pump to
achieve the desired pressure. Remove the elbow from the pressure control valve
Fig. 9. Connect the flow meter inlet to the line from the
Pressure Control Valve main pump.
Install a 5000 psi gauge in the lower manifold block C onnect gauge (Fig. 7) to m onitor main pump
port as shown in Fig. 6. Operate the circle with engine o- h a rn fi n ra s s iire
operating at 900 rpm (low idle). •-— o - r ------------------ —
A pressure reading of 1600 to 1900 psi should be

obtained during circle rotation. If the gauge does not
register pressure within this range, add or deduct
washers on the pressure control valve shaft as ex-
^ lf^ in A / J i n ocolivii
O n n + iA *■» "7/ O ■ ■n
piaiticu mi u, vjiuufj
is obtained.
Litho in U.S.A.
70 H y d ra u lic S y s t e m G rader, M o to r - J D 5 7 0
C.fi
w~w P o m r i n n o n f c a n H T a c -tc
W / H ^ / V I I V I I I W MMW I T u .m m
I IVI I \S\S l
/n*r>.R7\
jk / W L /f y
Open flow meter loading valve completely before

starting engine.
Run engine at 3/4 throttle. Close flow meter loading

valve to obtain approximately 2000 psi at the flow
meter gauge. Run until oil temperature reaches 140 to
150°F.
Close flow meter loading valve. Run engine at 2375

± 5 rpm. Standby pressure at the stroke control valve
should be 2300 to 2400 psi. Adjust stroke control valve
if necessary.
Run engine at 2375 ± 5 rpm. Open flow meter

loading valve until a minimum pressure of approxi
mately 250 psi is indicated.
Flow must be 29.5 gpm minimum. Low flow can

indicate a charge problem, defective flow meter, or
incorrect engine speed.
Slowly close loading valve until 2000 psi is regis

tered on the pressure gauge at the main pump. Main
tain engine speed of 2375 ± 5 rpm.
Main pump output should be 21.6 gpm minimum.
If flow is low:
Check main pump charge pressure.
Charge pressure m ust be 14 psi m inim um . If

charge pressure is less than 14 psi, main pump flow
te s t resuits w iii be invalid. Correct charge c irc u it
problem and retest.
Check pump standby pressure in th is group.

i'c?£56'*jV*
Reduce pressure to 1500 psi and record flow . In
Fig 9-Remove This Elbow and Connect Flow Meter Inlet to Line
crease pressure in 100 psi increm ents up to 2100
From Main Pump
psi. If flow decreases more than 2 gpm w ith a 100
psi change in pressure, a stroke control valve
m alfunction is indicated.
Remove pistons at random and check pistons,

piston bores, and springs fo r wear or damage.
Remove and inspect stroke control valve and
crankcase o u tle t valve. Repair as necessary.
Clean hydraulic system before putting unit back

into service.
Litho in U.S.A.
TM-1001 (Dec-87) Com ponents and Tests 5-9
Hydraulic Circuit Tests Operate a grader control valve and hold valve in a
power position (piston in cylinder at the end of its
Remove function control valve pressure line from
stroke). Move only one control valve spool to a power
pressure control valve and install hydraulic tester “ in
position at any one time.
line” as shown in Fig. 10.
With control valve spool held in a power position
Open hydraulic tester pressure loading valve.
there should be no indication of oil flow on the hydraulic
tester.
S tart engine and run at 2375 rpm un til normal
operating tem perature o f 65° to 145°F. is reached.
If oil flow is noted, leakage is either within the control
valve or in the cylinder.
PRESSURE LINE
FROM PRESSURE
TO FUNCTION
CONTROL VALVE CONTROL VALVE Repeat test for all control valve power positions.
Make all tests at operating temperatures. If temper

ature is too high from previous circuit test, keep hy
Y - 21- 10
draulic tester loading valve closed and work grader
D - 91 control valve to circulate oil through the system.
To determine whether leakage is in the control valve

V-3018 or cylinder, remove cylinder return line while the control
d - 96 frn is in a power position. If no oil is leaking out of cylinder
return port, the control valve is at fault. If leakage is
noted, the cylinder is at fault and must be repaired.
HYDRAULIC TESTER
T3SS14N
Fig. 10-Connecting Tester for Circuit Test
Litho in U.S.A.
70 H ydraulic System Grader, M o to r - JD570
5-10 C om ponents and Tests TM-1001 (Dec-87)
DIAGNOSING SYSTEM M ALFU N C TIO N S
HYDRAULIC FUNCTIONS SLOW LOW OR NO HYDRAULIC PRESSURE
Slow hydraulic response. No oil in system.

Increase engine speed. Fill with proper oil. (See Section 10, Group 20).
Worn transmission charge pump. Oil of wrong viscosity.

Check output. Check oil specifications. (Section 10, Group
20) .
Improper oil in system.
Drain and fill system with proper oil. See Pump out of stroke.
Section 10, Group 20. Check pump shut-off screw.
Stroke control valve out of adjustment Low transmission charge pump pressure.
Check for foreign material or damaged seat. Pump not charging. Repair pump (see Sec
tion 50).
Internal leaks in functions. Oil cooler relief valve dumping. Allow oil to
Refer to "System T ests” to pinpoint leaks. warm up.
Transmission filter dirty or plugged.
Worn main hydraulic pump. Transmission oil filter relief valve not func
Check output. tioning.
Check valve for plugged condition. Test spring
Filters dirty or plugged. (Section 50).
Replace elements.
External oil line leaks.
Hydraulic oil bypass valve not turned in all the way. Tighten or replace lines.
Turn in bypass valve until it bottoms.
Main pump worn or damaged.
OIL IN SYSTEM HEATS Check pump output.
Wrong oil viscosity. HYDRAULIC FUNCTIONS DRIFTING

Use proper viscosity. See Section 10, Group
20 . Cylinder packings failed.
Test and replace as necessary.
Low oil supply.
Check oil supply. Foreign material under valve lockout seat.
Remove and clean lockouts.
Oil cooler malfunctioning.
Clean or repair cooler. Lockout seat damaged or lockout assembly
broken.
Engine running too fast. Replace lockout.
Reset engine speed (Section 20).
Valve spool sticking or scored.
OIL IN SYSTEM FOAMS Loosen tie bolts and then tighten with 20 to
25 ft-lbs.
Kinks or dirt in line. Repair valve section.
Clean or replace.
Valve stack tie bolts loose.
Low oil level. Tighten bolts with 20 to 25 ft-lbs.
Check oil supply.
Wrong viscosity of oil.

Drain and refill with proper oil (Section 10,
Group 20).
L itho in U .S.A .
TM-1001 (Nov-78) System Testing (Analyzer) 6-1
HYDRAULIC SYSTEM ANALYZER

Group 6
SYSTEM TESTING (Analyzer)
1— M aster H ydraulic 2— T a c h o m e te r/
S ystem A nalyzer T em p eratu re Reader
Fig. 1-Hydraulic System Analyzer
GENERAL INFORMATION a dual purpose 0 to 30 in. Hg (0 to 1 016 m bar) vacuum

The hydraulic system analyzer consists of a m aster or a 0 to 150 psi (0 to 10 bar) (0 to 11 kg/cm 2) pressure
hydraulic system analyzer, a tachom eter/tem perature gauge, a 0 to 30 in. Hg (0 to 1 016 m bar) vacuum
reader and a construction equipm ent accessory kit. gauge and four 0 to 400 psi (0 to 28 bar) (0 to 28
The m aster hydraulic system analyzer contains a kg /cm 2) pressure gauges. Each gauge uses quick
0 to 5000 psi (0 to 345 bar) (0 to 352 kg/cm 2) gauge, coupling connectors. The quick coupling connectors
are numbered the sam e as the gauges.
Litho in U.S.A.
6-2 System Testing (Analyzer) TM-1001 (Nov-78)
The tachom eter/tem perature reader is used to re Connect the tachom eter/tem perature reader and
cord engine rpm and hydraulic system oil temperature. start the engine. Bottom function with orifice installed
It is powered by the grader’s electrical system. and hold. W atch the oil temperature. W hen the oil
reaches the specified temperature, adjust engine rpm
The construction equipm ent accessory kit contains to obtain the specified test pressure, if it takes more
the necessary quick connectors and adapters to in engine rpm than specified to obtain the test pressure,
strum ent the hydraulic circuits for easy hook-up of the the circuit has a leak or the hydraulic pump is defective.
analyzer.
The hydrauiic sysiem pretest check sheet provides a
The hydraulic system analyzer is designed to test • general listing of problems in the hydraulic system.
hydraulic systems.
The symptom index is a table that lists the sym p
The hydraulic system analyzer measures pump and tom s that the operator may report. From the sym p
circuit conditions by recording pressures at specified tom s, it points out the probable faulty com ponent and a
engine rpm and oil temperature. An orifice is installed test to verify it.
into the circuit so all the hydraulic pump flow is directed
through it. The procedure for testing the hydraulic system fo l
lows:
T r * H - u a r lf the» h v / r t r a u lir c \ / c t » m in c t f l ll t h o c n o r i f i o H
orifice, then install the pressure gauges into the test 1. Fill out the hydraulic system pretest check sheet
ports of the hydraulic pump stroke control valve. (Fig. 2).
----------------
? I nr.atfi svm |-------- s from
- j - - ntnm ---- - tho
-• - - j-nrotoRt
— ---------r.hor.k
---- - phppt
-- - - -
on the symptom index, pages 70-6-5 to 70-6-8.
3. Perform verification tests.
Litho in U.S.A.
CAUTION: Escaping fluid under pressure OPERATIONAL CHECKS

A can have sufficient force to penetrate the
skin, causing serious personal injury. Before dis
1. Record following information on the Hydraulic
connecting lines, be sure to relieve all pressure.
System Test Record.
Before applying pressure to system, be sure all
Machine description
connections are tight and that lines, pipes and
hoses are not damaged. Fluid escaping from a very
Test specifications
small hole can be almost invisible. Use a piece of
Circuit relief settings
cardboard or wood, rather than hands to search for
suspected leaks.
2. Start engine.
If injured by escaping fluid, see a doctor at once.

3. Cycle a function until hydraulic oil is warm.
Serious infection or reaction can develop if proper
medical treatment is not administered immediate
4. W ith engine at fast idle, cycle functions. Record
cycle times on Hydraulic System Test Record. O b
ly- serve operation of functions.
PRETEST INSPECTION 5. Compare recorded cycle times with specification
1. Record machine identification information on cycle times.
Hydraulic Systems Pretest Check Sheet. (Form M-
5107-Stock-5-76) 6. Check applicable symptoms on Check Sheet.
2. Record customer description of problem. 7. Inspect hydraulic oil for bubbles.
3. Clean machine as required for visual inspection. 8. Inspect filters for plugging and particles.
4. Inspect following items: (Record findings on 9. Go to Symptom Index, pages 70-6-5 to 70-6-8.
Check Sheet) Select probable faulty component(s). Select com po
nent test.
Hydraulic oil
Transm ission filter
Function return filter
Transm ission oil cooling system
Hydraulic lines and fittings
Cylinders
5. Correct problems noted.
6. Perform operational checks.
Litho in U.S.A.
HYDRAULIC SYSTEM PRETEST

CHECK SHEET
Custom er Com m ents:
Machine Identification
PRETEST INSPECTION
h. C le a n m a c h in e a s r e q u i r e d . 3. C o r r e c t a n y p r o b le m s .
|2. P e r f o r m a l l in s p e c t io n s . 4. P e r f o r m O p e r a t i o n a l C h e c k .
Hydraulic Oii Yes No Oii Cooier Yes No
C o rre c t ty p e □ □ C le a r o f d ir t , d e b r is □ □
C o r r e c t le v e l □ □ F an o r s h ro u d d a m a g e d a □
B u b b le s in o il □ □ B e lt t e n s io n a n d c o n d i t i o n □ □
O th e r □ □ L e a k in g c o o l e r o r li n e s □ □
Control Valve(s) Yes No Hydraulic System Yes No

B e n t li n k a g e □ Z2 B e n t o r d a m a g e d li n e s □ □
P r o p e r l y a d j u s t e d li n k a g e □ E x t e r n a l o i l le a k s □ □
C y lin d e r R o d (s ) B e n t a □
F r e q u e n tly b lo w n s e a ls a n d f it t in g s □ □
Filters: Transmission Return Hydraulic
Yes No Yes No Yes No
R u p tu r e d F ilt e r □ □ □ □ □ □
P lu g g e d F ilt e r □ □ □ □ □ □
M e t a l P a r t ic l e s □ □ □ □ □ □
P a c k in g P a r t ic l e s □ □ □ □ □ □
N e w F i l t e r I n s t a l le d □ □
OPERATIONAL CHECK
1. S tart engine. W arm the hydraulic oil as described 3. Record cycle tim es. C heck ap p lic ab le sym ptom s
in the m ach ine T e ch n ica l M anual. 4. R einspect hydraulic oil for bubbles.
2. W ith engine at sp ecified fast idle, cy cle each cir 5. Go to Sym ptom Index in m ach ine Techn ical M a n
cuit. ual to select and verify faulty com ponent.
No hydraulics □
No pow er in hydraulics □
S low hydraulics, general □
S low hydraulics in circu it □ (N am e of circu it)
S low c ircu it in one direction □ (N am e of circuit)
C hattering hydraulics, general □
C hattering hydraulics in circu it n (N am e of circu it)
C ircu it initially m oves in opposite direction □ (N am e of circuit)
W rong circu it op erates □ (N am e of circuit)
D rift or leakdow n in circu it □ (N am e of circu it)
S ticky op eratio n o f control valves □
Noisy pum p □
Filter w arning in d ica to r on □
Slipping transm ission □
COMMENTS:
M-5107-STOCK-5-76
T490S2N
Fig. 2-Hydraulic System Pretest Check Sheet
Litho in U.S.A.
SYMPTOM INDEX
PROBABLE FAULTY
SYMPTOMS COMPONENTS VERIFICATIONS
Circuit drifts or leaks down from Cylinder(s) Perform Cylinders Leakage Test on
loaded position. applicable cylinder, page 70-6-19.
Possible: Lack of power in a Rotary manifold for blade tilt Inspect for leaks between work
function and blade sideshift circuits. circuits.
Lockouts Faulty or dirty lockouts (Section 70,
G roup 20)
Function control valves Perform Function Leakage Test, page
70-6-18
Circle is slow or will not rotate. Circle drive motor Inspect circle drive motor. Repair or
replace as necessary (Section 70,
Group 30).
Circle rotates in wrong direction. Motor incorrectly timed. Refer to
Section 70, G roup 30, to time motor.
Sluggish or no non-priority Pressure control valve Perform Pressure Control Valve Test,
function operation. page 70-6-24.
Hard steering while operating a Pressure control valve Perform Pressure Control Valve Test,
non-priority function. page 70-6-24.
Hydraulics respond slowly to Crankcase outlet valve Crankcase outlet valve rem ains
control lever movement. closed, stuck or is incorrectly
adjusted. Repair or replace as
necessary (Section 70, G roup 15).
Litho in U.S.A.
SYMPTOM INDEX
PROBABLE FAULTY
No differential lock operation or Differential lock valve Perform Differential Lock Valve
slipping Pressure Test, page 70-6-26. Adjust
if necessary (Section 50, Group 20).
If pressure cannot be adjusted,
inspect differential lock valve (Section
50, Group 20).
Slow, jerky or overheating Sealing rings or piston seals If problem not corrected perform
hydraulics when operating leaking in differential housing. Function Leakage Test, page
differential lock. 70-6-18.
Slow hydraulics, general These general com plaints have Perform System Test, page 70-6-9.
m any possible causes.
Chattering hydraulics, general
Overheating hydraulic oil,
general
Transm ission slipping or no Pressure regulating valve Perform Transmission Pressure Test,
transm ission operation. page 70-6-23.
Erratic or no operation of Transm ission filter or function Filters ruptured or plugged. Replace
various hydraulic function. Dirt return filter as necessary (Section 70, Group 10).
and contam ination in hydraulic Perform System Test, page 70-6-9.
system.
Overheating hydraulic oil. Oil cooler Core plugged with debris. Clean as
necessary.
Litho in U.S.A.
SYMPTOM INDEX
PROBABLE FAULTY
SYMPTOMS COMPONENTS VERIFICATION
Frequent failure of O-rings, High standby pressure Perform Standby Pressure Test, page
hoses and fittings. 70-6-28.
Plugged filter screen in stroke Inspect screen. Clean or replace as
control valve assem bly necessary (Section 70, Group 15).
System accum ulator Perform Accum ulator Test, page
70-6-27.
Oil leaking between stroke Steering valve check valve. Inspect check valve. Replace as
control valve and pum p housing. necessary (Section 60, G roup 5).
Steering is slow Steering valve Refer to Section 60, G roup 5 to
check steering valve.
Steering wheel continues to turn Steering cylinders Perform Cylinder Leakage Test, page
at a fast rate at end of stop. 70-6-19, before rem oving steering
valve. Repair or replace as necessary
(Section 60, G roup 5).
Steering wanders in neutral.
No steering.
Steering wheel kicks back. Check valve in steering valve. Inspect check valve for leakage
Brakes dragging Brake valve Perform Brake Valve Leakage Test,
page 70-6-25.
Brakes will not release.
No manual brakes Brake bleed screws. Inspect bleed screws for dam aged
seats.
Settling of brakes w hen applied. Brake valve Perform Brake Valve Leakage Test,
page 70-6-25.
Brake piston seals. Inspect piston seal for leakage
Litho in U.S.A.
SYMPTOM INDEX
PROBABLE FAULTY
Lift arm locking pin will not Lift arm locking pin valve Check that locking pin valve is
engage. assembled correctly. Inspect for
Lift arm locking pin damaged seat in valve, plugged oil
passage, roll pin in valve bent,
binding or too long. Inspect for
binding of locking pin in its bore.
Lift arm locking pin will not Disconnect return hose from locking
disengage. pin valve. Depress valve.
NOTE: Approximately 3 gpm (11
L/min) of flow may come from open
port.
No flow, missing or bent roll pin in

valve or plugged passage. If flow is
observed, sealing ring on locking pin
may be missing or broken. Repair or
replace as necessary (Section 70,
Group 35).
Litho in U.S.A.
TESTING AND ADJUSTMENT

SYSTEM TEST (JD570-A ONLY)
1— Red C lip, Positive 2— B lack C lip, G rou nd

Post
Fig. 4-Electrical Hookup
Fig. 3-Tachometer Generator Hookup
Install tachom eter generator (2, Fig. 3) and drive

cable (3) to tachom eter drive (4) on engine.
Connect pow er/rpm cable (1) to tachom eter gener
ator and Tachom eter/Tem perature Reader (2, Fig. 5).
Set thum b dials (1) to read 030. Attach red clip (1, Fig.
4) to positive post on battery and black clip (2) to
ground on engine frame.
1— T h um b D ials 4— P o w e r/R P M Cable

2— T a c h o m e ter/T e m p eratu re 5— Pum p O utlet P ressure
Reader 6— P um p Inlet Pressure
3— Tem p eratu re Sensor 7— Tran sm issio n Pum p
C able O u tlet Pressure
Fig. 5-Hydraulic Analyzer
Litho in U.S.A.
6-10 System Testing (Analyzer) TM-1001 (Dec-87)
1— 202867 Straight Connector

2— 202852 Swivel Elbow 45°
3— 202850 Q uick Coupler Adapter
4— 36952 Hose Assem bly 144 in. (3 658 m m) 1— 202853 S traight C onnector (Pum p Outlet Pressure)
5— Tem perature Sensor 2— 202853 S traight C onnector (Pum p Inlet Pressure)
3— 202851 Swivel Elbow 90°
Fig. 6-Transmission Outlet Pressure Hookup 4— 202852 Swivel Elbow 45°
5— 202850 Q uick C oupler Adapter (2 used)
Install fittings (1 to 3, Fig. 6) and hose assembly (4) 6—
7—
36953
36952
Hose A ssem bly W ith Valve 144 in. (3 658 m m )
Hose A ssem bly 144 in. (3 658 m m )
to test port in clutch pedal valve housing. Connect hose
assembly to No. 3 test port on Hydraulic Analyzer (7, Fig. 7-Main Pump Hookup
Fig. 5).
Remove hood from unit to gain access to test ports
Using plastic strap, install temperature sensor (5, on main pump.
Fig. 6) to main hydraulic pump charge line. Connect
temperature sensor cable to Tachom eter/Tem perature CAUTION: Relieve hydraulic pressure in
Reader (2, Fig. 5). A system by operating steering valve and
brake valve until no response is felt.
NOTE: To assure good contact apply a layer of
grease between temperature sensor and tube. Cover Slowly remove plugs from test ports on main pump
with a shop towel to decrease effect of outside air (Fig. 7) to relieve any pressure left in system.
temperature.
Install fittings (1 to 4) and hose assemblies (5 and 6)
to test ports. Connect hose assembly (6) to No. 1 test
port on Hydraulic Analyzer (5, Fig. 5). Connect hose
assembly (7, Fig. 7) to No. 2 test port on Hydraulic
Analyzer (6, Fig. 5).
Litho in U.S.A.
1— W ire Lead fo r Tem p eratu re Sender

2— 203654 S traight C on nector (Pum p Inlet P ressure)
3— 202852 S w ivel Elbow 45° 1— Pressure Control V alve 3— V alve Spool
4— 202850 Q u ick C oupler A dapter
2— Spring
5— 36952 Hose A ssem bly 144 in. (3 658 m m )
Fig. 9-Remove Pressure Control Valve Spring
Fig. 8-Alternate Pump Inlet Pressure Hookup
Rem ove spring (2, Fig. 9) from pressure control

On units with no test port on main pump for pump /I \ Dr>inr<1<^ll n o lim
\sjf
ZO\ o n rl 1r»n
inlet pressure proceed as follows: v a iv c V1
hoses to tee.
i i o n lo i e u i v a iv c a n u ic c .
Remove wire lead from tem perature sender (1, Fig.

8) in pressure regulating housing. Tape wire lead so it
does not ground out on unit. Rem ove tem perature
sender.
Install fittings (2 to 4) and hose assem bly (5) to test
port. Connect hose assem bly to No. 2 test port on
Hydraulic Analyzer (6, Fig. 5).
Litho in U.S A.
1—Circle Drive Motor 3—203093 Cap (2 used) 1— Lower Hose

2— Upper Hose 2— 203595 Reducer (2 used)
3—203223 Double Swivel (2 used)
Fig. 10-Disconnect Circle Drive Motor 4— 203663 Orifice 0.156 in. (3.96 mm)
5— Direction of Flow
The 203663 orifice (4, Fig. 11) will be installed in the Fig. 11-Orifice Installation
circle rotation circuit.
Disconnect circle drive motor (1, Fig. 10) upper hose Install fittings (2 and 3) and 203663 orifice to lower
(2) at connection by clamp on main frame. Cap (3) hose and tube in main frame.
upper hose. IM P O R TA N T: Be sure o rifice is installed w ith
arrow (FLO W ) pointing tow ard th e tube.
Disconnect lower hose (1, Fig. 11) from lower fitting
on circle drive motor. Cap fitting (3, Fig. 10).
Litho in U.S.A.
HYDRAULIC OIL TEMPERATURE: 1 4 0 to 1 5 0 ° F (60 to 66 ° C )

O R I F I C E USED: Part No. 2 0 3 6 6 3 , 0 . 1 5 6 in. (3 . 9 6 m m ) i n s t a l l e d in b l a d e r o t a t i o n c i r c u i t .
MAIN PUMP O U T L E T PRESSURE MA I N PUMP INLET PRESSURE TRANS. PUMP OUTLET

ENGINE
RPM
IN S T R O K E STANDBY IN S T R O K E STANDBY STANDBY
5 5 0 psi min. 2 2 0 0 to 2 3 0 0 psi 5 to 25 psi 10 to 30 psi 1 5 5 to 175 psi

1000 (38 bar m i n .) (152 to 159 bar) (0.34 to 1.7 bar) (0.68 to 2.1 bar) (11 to 12 bar)
2 3 0 0 to 2 4 0 0 psi 25 to 50 psi 70 to 110 psi

1 6 5 to 1 8 5 psi
2200 (159 to 165 bar) (1.7 to 3.4 bar) (4.8 to 7.5 bar) (11 to 1 2 . 8 bar)
2 0 0 0 psi
2150
(138 bar) HIGH PRESSURE C I RCUIT TEST
MAX
T69764
Fig. 12-JD570-A (001700- ) Test Specifications
Record test specifications (Fig. 12) on Closed- Hold engine speed at 1000 rpm and obtain the
Center Hydraulic Test Record (Fig. 13) (Form M5112, following readings:
Stock 8-76).
N O T E : To p e rfo rm th e in s tro k e test, o p e ra te circle
Start engine and warm hydraulic oil to 140 to 150°F ro ta te c o n tro l h a n d le in c lo c k w is e d ire c tio n .
(60 to 66°C) using orifice flow. If necessary, block air
flow through oil cooler to maintain tem perature. W ith main pump in stroke, record m ain pump outlet
pressure.
IM P O R T A N T : For a cc u rate resu lts it is im p o r
tan t to m a in ta in th is tem p e ratu re fo r all te s t re a d W ith main pump in standby, record main pump
ings. outlet pressure.
For orifice flow turn the circle rotate control handle in W ith main pump in stroke, record m ain pump inlet
a clockwise direction. Oil flow will be from the hose pressure.
through the orifice into the tube. At the same time
operate other function to reduce extreme heat buildup W ith main pump in standby, record m ain pump inlet
at function control valve that can damage O-rings and pressure.
packings.
W ith main pump in standby, record transm ission
IM P O R T A N T : A lw ays o p era te circle rotate c o n pump outlet pressure.
tro l handle in clo ck w is e d ire ctio n so oil flow
th ro u g h o rifice is from hose into th e tub e. T he hose Hold engine speed at 2200 rpm and obtain the
m ay be d am ag ed if flo w is from tu b e th ro u g h o ri following readings:
fic e into hose.
W ith main pump in standby, record main pump
outlet pressure.
W ith main pump in stroke, record m ain pump inlet
pressure.
W ith main pump in standby, record m ain pump inlet
pressure.
W ith main pump in standby, record transm ission
pump outlet pressure.
Litho in U.S.A.
70 H y d ra u lic S y s te m G ra d e r, M o to r - J D 5 7 0
oC - 4ihA O. __ Ti&sufiy
oy*ie?r// __ ________ —..l
/ A ~ ~ t
(SMicuy^vij T» i -4 r \ r \ - t
I ivi- I U U I
/a , ffli
{I VUV- / VJ
C L O S E D -C E N T E R H Y D R A U L IC S Y S T E M T E S T R E C O R D n at„
Work Order No.

(Attach to Hydraulic System Pretest Check Sheet I
TEST SPECIFICATIONS:
Hydraulic Oil Temoerature: /4® 1° ID O F ( bo -to 66 C)
Hiqh Pressure Circuit Test: While main DumD outlet oressure is at J -O O O f r s i ennine sneeri must not he
areater than 2 IS O . rnm
Transmission Pump Test: Use orifice. Part No. . With transmission pump pressure at PRl
(Bar) en9'ne sPeed mus* no1 exceed RPM
MAIN PUMP O UTLE T PRESSURE MAIN PUMP INLET PRESSURE TRANS. PUMP O UTLET
ENGINE RPM
In Stroke Standby In Stroke Standby Standby
1000 5 5 0 p5< min. 22 OO A> 1AOO ?*>'< 5 -b 2 -5 P*>' (0 4o 5 0 p H p$t
2200 2 500 4© 2400 p*i 26 -fa 50 p b 10 -h I/O pbt 16,5 H> (S 5 p * <
2 t5 0
may- 2460 f * * H IG H P R E S S U R E C IR C U IT T E S T
j T R A N S M IS S IO N P U M P T E S T
TEST RECORD
ENGINE RP m
MAIN PUMP DllTI FT PPPSSIIRP________ j________ MAIN PUMP INI PT PPCCCIJPC TRANS. PUMP O UTLET
In Stroke Standby j In Stroke Standby Standby
1000 5 2 - 5 ? * '< L. Z500 p *i -y pt>i L. 8 poi t- ISO p ti N

TEST
2200 2 4 0 0 ffe i # j 2 4 - L- 6 5 poi L- / 8 0 p>t>i Af
1
Z200 ft ZOOO pvi H IG H P R E S S U R E C IR C U IT T E S T
T R A N S M IS S IO N PUM P TEST
T69765
1—Test Specifications 2—Test Readings
Fig. 13-Closed-Center Hydraulic System Test Record Sample

(Sample Does Not Reflect Actual Test Data)
W ith main pump in stroke, start at low idle and H - High pressure or High rpm
increase engine rpm to maintain 2000 psi (138 bar) at N - Normal pressure or Normal rpm
main pump outlet. Record rpm in high pressure circuit L - Low pressure or Low rpm
test slot on Test Record (Fig. 13). P - Pulsing pressure. Pulsing is combined with
other classifications. For example NP means
Compare test readings (2) to test specifications (1). pressure is normal but unsteady.
Mark classification next to each reading. Use following
classifications: Determine probable cause by comparing test pat
tern with test pattern(s) on Test Pattern Analysis Chart,
pages 70-6-15 to 70-6-17.
Litho in U.S.A.
TEST PATTERN ANALYSIS CHART

PATTERN PROBABLE CAUSE VERIFICATION A N D /O R
CORRECTION
L N L L N Transmission oil filter plugged. Remove filter and inspect. Replace

N L L N as necessary (Section 70, Group
H 10). RETEST.
Manual bypass valve open or seat Remove bypass valve and inspect.
damaged. Repair or replace as necessary
(Section 70, Group 15). RETEST.
Transmission oil filter relief valve Inspect valve, spring and bore.
stuck open or spring broken. Repair or replace as necessary
Transmission oil cooler relief valve Inspect valve, spring and bore.
spring broken. Repair or replace as necessary
Transmission oil pump intake screen Remove screen and inspect. Clean
plugged. or replace as necessary (Section
70, Group 15). RETEST.
Transmission oil pump worn. Perform Transmission Pump Test,
page 70-6-21.
Leaking gaskets or seals in Inspect gaskets and seals. Repair
transmission, transm ission clutch or replace as necessary (Section
pedal valve, transm ission oil 70, Group 15).
pressure regulating valve or
transmission control valve.
N N L L L Transmission oil filter plugged or Replace filter (Section 70, Group
N L L L collapsed. 10). RETEST.
N
Transmission oil filter relief valve Inspect valve spring and bore.
spring weak or broken. Valve stuck Repair or replace as necessary
open in bore. Damaged valve seat (Section 70, Group 15).
in valve housing.
Leaking transm ission oil pressure Replace gaskets (Section 70,
regulating valve housing gaskets. Group 15).
Litho in U.S.A.
TEST PATTERN ANALYSIS CHART

PATTERN PROBABLE CAUSE VERIFICATION AN D/O R
CORRECTION
L L L L L Transmission oil filter plugged or Replace filter (Section 70, Group
L L L L collapsed. 10) RETEST.
H
L N L L L/N Leaking brake or clutch elements. Refer to Testing Transmission
N L L L/N (Section 50, Group 15).
N
Incorrect or leaking gasket.
N N L L N Transmission oil cooler relief valve Inspect valve spring and bore.
N L L N spring weak or broken. Valve stuck Repair or replace as necessary
H/N in bore. Valve seat in transmission (Section 50, Group 15).
oil pressure regulating valve housing
damaged.
L N N N N Oil cooler plugged internally. Repair or replace as necessary.
N N N N
H
N N L L N Function return filter plugged or Replace filter (Section 70, Group
N L L N collapsed. 10) RETEST.
H
Function return filter relief valve Inspect valve, spring and bore.
spring weak or broken. Valve seat in Repair or replace as necessary
hydraulic oil filter valve housing (Section 70, Group 10).
damaged or worn. Valve stuck in
housing.
Litho in U.S.A.
TEST PATTERN ANALYS S CHART

PATTERN PROBABLE CAUSE VERIFICATIO N A N D /O R
CORRECTION
N N N N N Main hydraulic pump worn or Remove and inspect pump for

N N N N defective. worn or sticking piston. Broken
H piston springs. Broken or leaking
inlet and outlet valves. Leaking
seals. Repair or replace as
necessary (Section 70, Group 15).
N L N N N Low standby pressure Perform Standby Pressure Test,
L N N N page
H
Worn, fatigued or incorrectly If standby pressure cannot be
adjusted stroke control valve parts. adjusted inspect stroke control
valve (Section 70, Group 15).
N H N N N High standby pressure Perform Standby Pressure Test,
H N N N page 70-6-28.
N
Filter screen in stroke control valve Inspect filter screen. Clean or
plugged. replace as necessary (Section 70,
Group 15).
N N N N L Transmission pressure regulating Perform Transmission Pressure
N N N L valve spring weak or broken. Test, page 70-6-23.
N
Valve stuck (open) in bore. Adjust, replace or repair as
L N L N N Surge pressure relief valve spring Inspect valve spring and bore.
N L N N weak or broken. Valve seat Repair or replace as necessary
H damaged. Valve stuck in bore. (Section 70, Group 10).
Litho in U.S.A.
FUNCTION LEAKAGE TEST

(JD570-A ONLY)
HYDRAULIC SYSTEM TEST RECORD
HYDRAULIC TEST SPECIFICATIONS: USE ( _____________ ) O R IFIC E , PART N O ___________________________
W H IL E PR E SS U R E IS A T _____________ PSI ( ______________ BAR)
M A X IM U M E N G IN E SPEED M U S T BE LESS T H A N ______________RPM .
H Y D R A U LIC O IL T E M P E R A TU R E M U ST BE _____________ ° F ( _______:___________________ °C )
SYSTEM RELIEF VALVE SETTING: S P E C ______________ PSI ( ______________BAR)
A C T U A L _____________ PSI ( ______________BAR)
C IR C U IT
C YC LE C YC LE R pm at Rpm at R pm at Rpm at R pm at R pm at R pm at R pm at R pm at R pm at
R E L IE F
T IM E T IM E 17 b a r 34 bar 52 b a r 69 bar 86 bar 103 b a r 120 b a r 138 b a r 155 b a r 172 b a r
C IR C U I T S E T T IN G
SPEC ACTUAL 250 PSI 500 PSI 750 PSI 1000 PS I 1250 PSI 1 5 0 0 PSI 1 7 5 0 PSI 2000 PS I 2250 PSI 2500 PSI
SPEC
(}) /3 ? o //.O S ' / “7 / o / f / o
y .j- (V) U VO /3 9 o /■/?» /d o o /7 /o /v o o
/ ‘/ j o A S 'L T O /7 o o /F J O /9 S -o
/.o u te r * _ 0 _-
CO
T62461N
1— Pressure at Which Circuit Condition is Checked 3—Blade Raise, Normal Circuit

2— Circle Rotate, Standard Circuit 4— Blade Lower, Indicating a Leak
Fig. 14-Hydraulic System Test Record Sample

(Sample Does Not Reflect Actual Test Data)
Oil leakage in each of the functions can be checked Activate function with orifice installed to put pump
by using the following general procedure. Check each into stroke and to warm hydraulic oil. W arm hydraulic
function in both directions. oil as described in System Test, page 70-6-9.
NOTE: Refer to Fig. 15 for functions cycle times. IM PO R TA N T: For accurate results, m aintain oil
tem perature at 140 to 150°F (60 to 66°C) fo r all test
Connect Hydraulic Analyzer as described in System readings.
Test, page 70-6-9. The hookup for transmission and
main pump inlet pressure need not be connected for
this test.
Litho in U.S.A.
Function Leakage Test—Continued Possible causes are cylinder leakage or leakage in

fiI U inr'tirvn/-'/*Nn+rr»l P oV rI fI rV irMmI I P S /MllinI W
rld r I o a l r d n o TI o ot
Bottom function to be checked in one direction. I I V I I V I I V W 1 111 V/ I V VII V V • I
page 70-6-19, to isolate problem to cylinder or control

VI W M U U ^ V W l )
Return control lever to neutral. valve. Repair or replace as necessary (Section 70,
W ith pump in stroke, adjust engine rpm to maintain Group 20 and 25).
2000 psi (138 bar) (141 kg /cm 2). Immediately bottom To check differential lock leakage proceed as fo l
function being checked and observe pressure gauge. lows.
A pressure drop indicates leakage in that function.
Note function on Hydraulic System Test Record (Fig. W ith pump in stroke increase engine speed to obtain
14) for later test (Form M -5107-Stock-5-76). 2000 psi (138 bar) (141 kg /cm 2). Record engine rpm
Bottom function in opposite direction and repeat on Test Record.
test. W ith pump in stroke engage differential lock valve
and record engine rpm to obtain 2000 psi (128 bar)
Test all functions as described above. Note all (141 kg/cm 2).
functions indicating leakage.
The difference in engine rpm indicates am ount of
W ith pump in stroke adjust engine rpm to maintain differential lock leakage. The difference should be no
2000 psi (138 bar) (141 kg /cm 2) to 750 psi (52 bar) (53 more than 75 rpm.
kg /cm 2) in 250 psi (17 bar) (18 kg/cm 2) increments.
Record engine rpm for each pressure setting on Test CYLINDER LEAKAGE TEST
Record. This will be the standard circuit.
1. Bottom a cylinder.
Bottom function (the one noted before leaking) and
hold. W ith pump in stroke, adjust engine rpm to main 2. Disconnect hydraulic oil line from cylinder at end
tain 2000 psi (138 bar) (141 kg /cm 2) to 750 psi (52 bar) where cylinder is bottomed.
(53 kg/cm?) in-250 psi (17 bar) (18 kg/cm 2) increments.
Record engine rpm for each pressure setting on Test 3. Cap line.
Record.
4. W hile observing open cylinder port for a flow of
Com pare test readings to standard circuit. If all oil, reactivate circuit in the same direction that cylinder
engine rpms in a circuit are greater than rpm in stan is bottomed.
dard circuit leakage is indicated. As pressure is in
creased variation becomes greater at an increasing but 5. If oil flows from open port in a continuous stream ,
steady rate (4, Fig. 14). The difference in engine rpm remove and repair cylinder (Section 70, Group 25).
indicates am ount of leakage. The difference should be
no more than 40 rpm at 2000 psi (138 bar) (141 6. If oil does not flow in a continuous stream , check
kg/cm 2). applicable section of control valve. Repair or replace
as necessary (Section 70, G roup 20).
Litho in U.S.A.
70 H ydraulic System Grader, M otor - JD570
CYCLE
M O TOR GRADER C H E C K BALL ORIFICE
TIME LOCKOUTS
FUNCTIONS (LIFT C H E C K PLATES
,S E C O N D S *
Bl a d e Lift
E xtend 12 in. (305 mm) 2 . 5 to 4 . 5 YES No. 351 - 0 . 0 9 3 5 in. (2.37 mm) YES
R e t r a c t 12 in. (305 m m ) 4 . 0 to 6.0. YES N ONE (001861 - 0022 2 6 ) YES
R e t r a c t 12 in. (305 m m ) 3.5 to 4 . 5 YES No. 3 4 0 - 0 . 0 6 2 5 in. (1.59 mm) YES
C i r c l e S ide Sh i f t
E xtend 7.4 to 1 0.5 YES No. 346 - 0 . 0 7 8 5 in. (1.99 mm) YES
Retract 5.5 to 8 . 5 YES No. 3 4 0 - 0 . 0 6 2 5 in. (1.59 mm) YES
Blade Side Shift

L eft s ide sh i f t 7.5 to 10.2 YES N ONE YES
Rig h t s ide s h i f t 5.5 to 8 . 0 YES N ONE YES
Bl a d e Til t
Extend 1.0 to 2 . 0 YES N ONE YES
Retract 1.0 to 2 . 0 YES N ONE YES
Bl a d e R o t a t i o n
Clockwise 36 to 52 NON E N ONE NONE
Counterclockwise 36 to 52 NONE N ONE NONE
Wheel Lean
E x tend 2 . 0 to 3.7 YES No. 3 4 6 - 0 . 0 7 8 5 in. (2.37 mm) YES
Retract 2 . 0 to 3.7 YES No. 3 4 0 - 0 . 0 6 2 5 in. (1.59 mm) YES
R e a r St e e r
L eft o r rig h t 3 . 0 to 7.0 YES NONE YES
Front M o u n t E q u i p m e n t
E x tend ( -0 0 2 2 2 6 ) 4.0 to 8.0 YES NONE YES
E x tend (002227- ) 3.0 to 5.0 YES NONE YES
Retract ( - 0 0 2226) 6.5 to 9.7 YES NONE YES
R e t r a c t ( 0 02227- ) 2.5 to 4.0 YES No. 3 6 7 - 0 . 1 4 0 5 in. (3.56 mm) YES
Dr i f t S p e c i f i c a t i o n 0.0 6 in. (1.5 m m ) m a x i m u m in 15 m i n u t e s wit h e n g i n e at l o w

idl e or e n g i n e o ff, m o l d b o a r d 6 in (152 mm) a b o v e g r o u n d
a n d all o t h e r c y l i n d e r s a p p r o x i m a t e l y m i d - s t r o k e .
*N0TE: Cycle times are with transmission oil temperature at

65° to 1 4 5 ° F (18 to 63°C) a n d engine at 2 4 7 5 ± 25 rpm.
T62462N
NOTE: Cycle times given are to be used only as guidelines. Therefore, when a unit does not perform according to
the cycle times given, the mechanic must decide if the difference is great enough to indicate a malfunction of some
component in the system.
Fig. 15-JD570-A (001700- ) Motor Grader

Functions Test Specifications
Litho in U.S.A.
TRANSMISSION PUMP TEST

(JD570-A Only)
1 — T r a n s m i s s i o n F i lt e r R e lie f V a lv e P lu g
2— J D - 2 9 3 - 5 P lu g
3 — J D - 2 9 3 - 6 S le e v e
Fig. 17-Block Transmission Filter

Relief Valve
1— J D -2 9 3 -1 F i lt e r H o u s i n g C o v e r A s s e m b l y
2— 3 6 9 5 2 H o s e A s s e m b l y 1 4 4 in . ( 3 6 5 8 m m )
3— 2 0 2 8 5 0 Q u i c k C o u p le r A d a p t e r
4— 2 0 2 8 5 3 S t r a ig h t C o n n e c t o r
5— 2 0 3 6 5 8 R e tu r n H o s e
6— 2 0 3 6 6 5 O r i f i c e 0 . 1 8 7 in . ( 4 .7 5 m m )
7 — T e m p e ra tu re S e n s o r
8— 1 7 5 0 2 S p e c ia l F i t t i n g
9 — T r a n s m i s s i o n F i l t e r R e lie f V a lv e P l u g
Fig. 16-Transmission Pump Test Hookup
Connect Tachom eter/Tem perature Reader as de

scribed in System Test, page 70-6-9.
W arm hydraulic oil to 150°F (66°C) using orifice flow
as described in System Test, page 70-6-9.
If orifice is not installed warm hydraulic oil to 150°F
(66°C) by operating transm ission in eighth gear with
| transm ission in TO W position. Block both sets of tan
dem wheels off the ground for an extra safety margin. 1— T r a n s m i s s i o n D i p s t i c k T u b e 2— 2 0 3 6 5 8 R e tu r n H o s e
Also block the air flow through oil cooler and operate
the main hydraulic functions. Fig. 18-Return Hose
IMPORTANT: If the unit is not put into the TOW

position, running machine at W.O.T. above 1st gear Connect hose assem bly (2, Fig. 16) to No. 3 test port
with only one set of tandems off the ground can on Hydraulic Analyzer.
cause damage to the differential. Route return hose (5) to transm ission dipstick tube
Once the hydraulic oil has been warmed, shut off (1, Fig. 18). Be sure return hose is pushed to the
engine and remove transm ission filter and cover. In bottom of transm ission case to prevent aeration and a
stall the transm ission pump tool kit (Fig. 19), fittings faulty test. Secure return hose to dipstick tube so it is
(Fig. 16), No. 203665 orifice (6) and hose assemblies not blown out during test.
(2 and 5).
Litho in U.S.A.
6-22 System Testing (Analyzer) TM-1001 (No\r-79)
Transmission Pump Test—Continued
1— J D -2 9 3 -1 F i lt e r H o u s i n g C o v e r A s s e m b l y 3 — J D - 2 9 3 -3 T u b e E x te n s io n
2 — O - R in g ( 2 u s e d ) 4 — J D - 2 9 3 - 2 F ilt e r A s s e m b ly
Fig. 19-Transmission Pump Tool Kit
Using plastic strap, attach tem perature sensor (7, W ith transm ission in neutral increase engine rpm to
Fig. 16) to special fitting. m aintain 175 psi (12 bar) on pressure gauge. Record
engine rpm and tem perature on Test Record.
NOTE: To assure good contact, apply a layer of
grease between temperature sensor and fitting. Cover Engine speed should not exceed 2050 rpm with oil
with a shop towel to decrease effect of outside air temperature at 120°F (49°C) minimum and pressure at
temperature. 175 psi (12 bar).
Rem ove transm ission filter relief valve plug (1, Fig. IMPORTANT: Pressure in excess of 250 psi (17
17) and spring. Install plug (2) and sleeve (3) to block bar) may permanently damage the transmission oil
filter relief valve to prevent any oil loss from the circuit, pump. Do not exceed the pressure required to
causing a faulty test reading. perform the pump test.
NOTE: Do not over tighten the plug as it does not If the engine rpm are above specifications check the
have to be turned all the way in. pressure regulating valve housing gaskets for leakage
before removing transm ission oil pump assembly.
Destroke main pump by turning in manual destroke
valve. Keep test short because main pump does not
receive any charge oil during test.
Start engine and check for leaks.
NOTE: If oil leaks from JD-293-5 plug stop test and
check filter kit for proper installation of components or
transmission filter relief valve not seated.
Litho in U.S.A.
Grader, M o to r - JD570 H yd ra u lic System 70
TM-1001 (Dec-87) System Testing (Analyzer) 6-23
TRANSMISSION PRESSURE TEST Start the engine and operate at 1900 rpm.
W ith the oil tem perature at 90 to 110°F (32 to 43°C)
the pressure should be 175 ± 10 psi (12 ± 0.68 bar).
Add or deduct shims as necessary to bring the
pressure within specifications (Section 50, Group 15).
If pressure cannot be adjusted, it will be necessary
to check for one of the other conditions (see below).
Depress clutch pedal. W ith pedal depressed, pres
sure should drop to zero.
Slowly release the clutch pedal. The pressure
should rise at a sm ooth rate until the pedal is approxi
m ately 1 inch (25 mm) from the top. At this point the
pressure should be approxim ately 80 psi (6 bar) (6
kg /cm 2). From this point, pressure should jum p and
m ust return to 175 ± 1 0 psi (12 ± 0.68 bar) when the
1— 2 0 2 6 6 7 S t r a ig h t C o n n e c t o r pedal reaches the end of its travel.
2 — 2 0 2 8 5 2 S w iv e l E l b o w 4 5 °
3 — 2 0 2 8 5 0 Q u i c k C o u p le r A d a p t e r
4 — 3 6 9 5 2 H o s e A s s e m b l y 1 4 4 in . ( 3 6 5 8 m m )
cations given, a sticking or faulty pedal valve is indi
Fig. 20-Transmission Pressure Test Port cated or the clutch pedal linkage is out of adjustm ent,
bent or worn. Repair or replace as necessary (Section
Install fittings (1 and 2, Fig. 20) and hose assem bly 50, Group 15).
(3) to test port. Connect hose assem bly to No. 3 test
port on Hydraulic Analyzer.
Install Tachom eter/Tem perature Reader as de
Place tow disconnect lever in “ TO W ” position.
Litho in U.S.A.
PRESSURE CONTROL VALVE TESTS
O perational T est
NOTE: If spring was removed from pressure control
valve for System Test replace before checking valve.
Run the engine at 900 rpm with the differential lock

valve disengaged.
Operate steering valve and note response.
Again operate steering valve and at the same time
turn the circle. There should be no change in steering
response.
If a change in steering response is noted, pressure
control valve is out of adjustment.
NOTE: Do not attempt to adjust pressure control
valve using the above test. Test and adjustment pres
sure control valve using a pressure gauge as de
1 — 2 0 2 8 5 4 S t r a ig h t C o n n e c t o r
scribed below. 2— 2 0 2 8 5 0 Q u ic k C o u p le r A d a p t e r
3 — 3 6 9 5 3 H o s e A s s e m b l y W it h V a lv e 1 4 4 in . (3 6 5 8 m m )
P ressure T est
Fig. 21-Standby Pressure Test Port
CAUTIO N: R elieve p re ssu re in h yd ra u lic
A system b y o p era tin g ste e rin g va lve and
brake valve u n til no response is fe lt.
Start and run engine at 900 rpm.
Operate the circle. At the same time note the read
NOTE: The connection to main pump outlet pres ing on the pressure gauge. Pressure should be 1600 to
sure (1, Fig. 7) from System Test can be used. 1900 psi (110 to 131 bar).
Slowly remove plug from test port in manifold block If pressure is not to specifications, adjust pressure
to relieve any pressure left in system. control valve by adding or deducting shims (Section
70, Group 10).
Install fittings (1 and 2, Fig. 21) and hose assembly
Litho in U.S.A.
BRAKE VALVE LEAKAGE TEST W ith engine off, disconnect brake valve return line
(1, Fig. 22) ai manifoid biock. Cap fitting on manifold
block.
CAUTION: Do not operate brake valve with
A return line disconnected.
Start engine and observe valve return line. If there is

a steady stream of oil flowing from the line, brake valve
is defective. Repair or replace as necessary (Section
60, Group 10).
1— B r a k e V a lv e 2 — B r a k e V a lv e
R e tu r n L in e
Pig, 2 2 -Brake Waive Leakage Test
Litho in U.S.A.
DIFFERENTIAL LOCK VALVE Install adapter assembly (1, Fig. 23) and hose as
PRESSURE TEST sembly (2) to valve. Connect hose assembly to No. 1
test port on Hydraulic Analyzer.
Install Tachometer/Tem perature Reader as de
Start and run unit until transmission temperature is
90 to 110°F (33 to 44°C). With engine speed at 2450
rpm engage differential lock valve and observe reading
on pressure gauge.
P ressure reading m u st be 566-667 psi w ith oil
te m p e ra tu re less th a n 122°F. P ressure reading
m u st be 595-653 psi w ith o il tem perature m ore than
122° F. A d ju s t valve by a dding o r d e d u ctin g sh im s
(S ection 50, G roup 20).
If differential lock valve cannot be adjusted, inspect
valve. Repair or replace valve as necessary (Section
50, Group 20).
1— 2 0 2 8 4 0 A d a p t e r A s s e m b l y
Refer to Function Leakage Test, page 70-6-18, to
2— 369 52 H o s e A s s e m b l y 1 4 4 in . ( 3 6 5 8 m m )
test for differential lock leakage.
Fig. 23-Differential Lock Valve Test Port
(001700- )
CAUTION: R elieve pressure in h yd ra u lic

A system by op era tin g steering valve, brake
valve and d iffe re n tia l lo ck valve u n til no response
is fe lt.
Slowly remove plug from end of differential lock
valve to relieve any pressure left in system and to
relieve spring located behind plug. Leave spring in
valve.
Litho in U.S.A.
SYSTEM ACCUMULATOR TEST Install fittings (1 and 2, Fig. 24) and hose assem bly
Start and run engine to charge accum ulator to
standby pressure, 2350 ± 50 at 2450 rpm. Shut off
engine.
If pressure immediately drops to zero, accumulator
has no precharge. Recharge, repair or replace as
If pressure holds, slowly turn steering wheel back
and forth to discharge accumulator. The pressure
should drop gradually to 500 ± 25 psi (93 bar) (95 kg 1
cmr) and then drop quickly to zero. The point at which
pressure drops to zero is the precharge in accum ula
tor. Recharge, repair or replace as necessary (Section
70, Group 10).
1— 2 0 2 8 5 4 S t r a ig h t C o n n e c t o r
2 — 2 0 2 8 5 0 Q u ic k C o u p le r A d a p t e r
3— 3 6 9 5 3 H o s e A s s e m b l y W it h V a lv e 1 4 4 in .
(3 6 5 8 m m )
CAUTIO N: Relieve p re ssu re in h y d ra u lic

A system by o p erating stee ring va lve and
brake valve u n til no re spo n se is fe lt.
NOTE: The connection to main pump outlet pres
sure (1, Fig. 7) from System Test can be used.
Slowly remove plug from test port in manifold block

to relieve any pressure left in system.
Litho in U.S.A.
STANDBY PRESSURE TEST
Fig. 26-S tandby Pressure Adjustment Screw

Location
(Grille Screen Removed)
1— 2 0 2 8 5 4 S t r a ig h t C o n n e c t o r Install fittings (1 and 2, Fig. 25) and hose assem bly

2— 2 0 2 8 5 0 Q u ic k C o u p le r A d a p t e r (3) to test port. C onnect hose assem bly to No. 1 test
3— 3 6 9 5 3 H o s e A s s e m b l y W it h V a lv e 1 4 4 in . port on Hydraulic Analyzer.
(3 6 5 8 m m )

C AUTIO N: R elieve p ressure in h y d ra u lic
A syste m by o p e ra tin g ste e rin g valve and
brake va lve u n til no re spo n se is fe lt.
Start and run unit until transm ission oil tem perature
is 90 to 110°F (33 to 44°C).
NOTE: The connection to main pump outlet pres Run engine at 2450 rpm and check standby pres
sure (1, Fig. 7) from System Test can be used. sure on gauge. Standby pressure should be 2350 ± 50
psi (162 ± 3 bar) (165 ± 4 kg/cm 2).
Slowly remove plug from test port in manifold block
to relieve any pressure left in system. If necessary, adjust standby pressure (Fig. 26) to
specification. Then cycle blade lift function three times
and readjust if necessary.
Litho in U.S.A.
LIST OF PARTS FOR TESTS

SYSTEM TEST TRANSMISSION PUMP TEST
1. 202850 Quick Coupler Adapter (3 used) 1. 202850 Quick Coupler Adapter
2. 202851 Swivel Elbow 90° 2. 202853 Straight Connector
3. 202852 Swivel Elbow 45° (2 used) 3. 203658 Return Hose
4. 202853 Straight Connector (2 used) 4. 203665 Orifice 0.187 in. (4.75 mm)
5. 202867 Straight Connector 5. 17502 Special Fitting
6. 203093 Cap (2 used) 6. 36952 Hose Assembly 144 in. (3 658 mm)
7. 203223 Double Swivel (2 used) 7. JD-293 Transmission Pump Tool Kit
8. 203595 Reducer (2 used) 8. Temperature Sensor Cable and Strap
9. 203654 Straight Connector 9. Power/RPM Cable
10. 203663 Orifice 0.156 in. (3.96 mm) 10. Tachometer Generator and Drive Cable
11 . 36952 Hose Assembly 144 in. (3 658 mm) (2 11. D-01080AA Master Hydraulic System Analyzer
used) 12. D-01084AA Tachom eter/Tem perature Reader
12 . 36953 Hose Assembly with Valve 144 in. (3 658
mm) TRANSMISSION PRESSURE TEST
13. Temperature Sensor Cable and Strap 1. 202850 Quick Coupler Adapter
14. Power/RPM Cable 2. 202852 Swivel Elbow 45°
15. Tachometer Generator and Drive Cable 3. 202867 Straight Connector
16. D-01080AA Master Hydraulic System Analyzer 4. 36952 Hose Assembly 144 in. (3 658 mm)
17. D-01084AA Tachometer/Tem perature Reader 5. Temperature Sensor Cable and Strap
6. Power/RPM Cable
FUNCTION LEAKAGE TEST 7. Tachometer Generator and Drive Cable
1. 202850 Quick Coupler Adapter 8. D-01080AA Master Hydraulic System Analyzer
2. 202851 Swivel Elbow 90° 9. D-01084AA Tachom eter/Tem perature Reader
3. 202853 Straight Connector
4. 203093 Cap (2 used) PRESSURE CONTROL VALVE TEST
5. 203223 Double Swivel (2 used) 1. 202850 Quick Coupler Adapter
6. 203595 Reducer (2 used) 2. 202854 Straight Connector
7. 203663 Orifice 0.156 in. (3.96 mm) 3. 36953 Hose Assembly W ith Valve 144 in. (3 658
8. 36953 Hose Assembly with Valve 144 in. (3 658 mm)
mm) 4. Temperature Sensor Cable and Strap
9. Temperature Sensor Cable and Strap 5. Power/RPM Cable
10. Power/RPM Cable 6. Tachometer Generator and Drive Cable
11. Tachometer Generator and Drive Cable 7. D-01080AA Master Hydraulic System Analyzer
12 . D-01080AA Master Hydraulic System Analyzer 8. D-01084AA Tachom eter/Tem perature Reader
13. D-01084AA Tachom eter/Tem perature Reader
Litho in U.S.A.
r t i r r m r u T i a i i a / n i/ i# a i i / P
L /ir r c n c iM i im l v m l v c
PRESSURE TEST 1. 202850 Quick Coupler Adapter

1. 202840 Adapter Assem bly 2. 202854 Straight Connector
2. 36952 Hose Assem bly 144 in. (3 658 mm) 3. 36953 Hose Assem bly With Valve 144 in. (3 658
3. Tem perature Sensor Cable and Strap mm)
4. Power/RPM Cable 4. Tem perature Sensor Cable and Strap
5. Tachom eter Generator and Drive Cable 5. Power/RPM Cable
6. D-01080AA Master Hydraulic System Analyzer 6. Tachom eter Generator and Drive Cable
7. D-01084AA Tachometer /Tem perature Reader 7. D-01080AA Master Hydraulic System Analyzer
8. D-01084AA Tachom eter/Tem perature Reader
SYSTEM ACCUMULATOR TEST
1. 202850 Quick Coupler Adapter
2. 202854 Straight Connector
3. 36953 Hose Assem bly W ith Valve 144 in. (3 658
mm)
4. Temperature Sensor Cable and Strap
5. Power/RPM Cable
6. Tachom eter Generator and Drive Cable
7. D-01080AA Master Hydraulic System Analyzer
8. D-01084AA Tachometer /Tem perature Reader
Liiho in U.S.A.
Grader, Motor - JD570 H ydraulic S y stem 70
TM-1001 (Nov-78) F ilte r s , V a lv es and A ccu m ulator 10-1
Group 10
FILTERS, VALVES, AND ACCUMULATOR
TRANSMISSION FILTER
RELIEF VALVE
GENERAL INFORMATION
The transm ission filter relief valve (Fig. 1)

is incorporated into the hydraulic system to allow
oil to return to the transm ission case if the oil
is heavy during the warm-up period or if the
transm ission filter becomes clogged.
F ig . 2 -F u n c tio n R eturn F ilte r and Surge Pressure R e lie f V alve s
REMOVAL AND INSTALLATION
Remove oil filter cap (Fig. 2), rubber pack

ing, and filter element.
Remove two cap screw s securing oil filter

valve housingto transm ission case. Liftoutvalve
housing with both valves.
Remove retaining plugs (Fig. 3) and springs

and valves from the oil filter valve housing.
F ig . 7-T ra n s m is s io n F ilte r R e lie f V alve Reverse the above procedures for assembly.
NOTE: See Group 15 of Section 50 for repair

of the transmission filter relief valve.
FUNCTION RETURN AND SURGE

PRESSURE RELIEF VALVE
GENERAL INFORMATION
The function return filter relief valve (Fig.

2) allows oil to return to the transm ission case
if the function return filter becomes clogged. A F ig . 3 —Fu nction Return and Surge Pressure
R e lie f V alves Removed
surge pressure relief valve (Fig. 2) is incor (E a rly U nits)
porated into the sam e housing to lim it return oil
from the functions to 100 psi. NOTE: Later units have an O-ringassembled
on the function return relief valve.
Apply two or three drops of John Deere Loc-

tite Sealant or an equivalent to function return
relief valve plug and tighten to 70 ft-lbs.
Tighten surge pressure relief valve plug to

70 ft-lbs.
Litho in U .S.A .
10-2 Filters, Valves and A c c u m u la to r TM-1001 (Dec-87)
HYDRAULIC OIL ACCUMULATOR
1— Gas Valve (Early Accu 3— Pin 7— Ball 11— Spring

mulators) 4— Washer 8— Pin 12— Valve
2— Gas Valve) Later Ac 5— Spring Guide 9— Cap 13— Packing
cumulators with Re- 6— Valve Body 10—Spring Guide 14— Plug
moveabie End)
Fig. 4-Accumulator Gas Valves

The accum ulator is connected into the main hy CAUTION: Before removing accumulator,
draulic pump pressure line at the hydraulic pump out
let.
A relieve hydraulic oil accumulator pressure
from the system by actuating the steering valve.
With engine stopped, turn steering wheel back and
The rear portion of the accumulator is charged with forth until pressure is expended. Also actuate the
dry nitrogen to a pressure of 500 ± 25 psi and the front service brakes until no response is felt to insure
portion is filled with hydraulic oil from the main hy that pressure is expended.
draulic pump. A floating piston in the accumulator Open accumulator pressure lines slowly because
keeps the dry nitrogen and hydraulic oil from coming in accum ulators m ay be slightly charged. Remove ac
contact with each other. cum ulator from unit.
The following three types of accum ulators have CAUTION: Before disassembly, nitrogen
been used on the Motor Grader: gas must be bled from accumulator.
1. Early accumulators with a removable cap and a Refer to Fig. 4 and bleed the accumulators as fol
gas valve mounted on the outside of the non-rem ov lows:
able end (1, Fig. 4). 1, Fig. 4 — Bleed gas from accum ulator by installing
charging valve and turning valve depressing lever,
2. Later accum ulators with a removable cap and an clockwise. This opens the gas valve steel ball, allowing
improved gas valve mounted on the inside of the gas to escape.
non-rem ovable end. 2, Fig. 4 — To bleed gas from accum ulator, remove
plug from end of cylinder and insert steel rod to unseat
3. Later accum ulators with a removable cap and a gas valve.
gas valve of the sam e design as used in number two Refer to Fig. 5 and service accumulators as follows:
above mounted on a removable end. Disassembly
Early Accumulators - Remove gas valve body as
sem bly from cylinder. Push cap into cylinder and re
move retaining ring. Pull cap with O-ring from cylinder.
Remove piston with U-cup packing.
Litho in U.S.A.
TM-1001 (Dec-87) Filters, Valves, and A ccu m u la to r 10-3
1— C ap * 10— Cylinder*** 19— V a lv e ** 28— A ccum ulator Cap

2— O -R ing (2 used)* 11— Plug** 20— Special W ash ert 29— Retaining Cap
3— V alve Body* 12— 0-R in g ** 21— S p rin g ** 30— O-Ring
4— Spring Pin* 13— O-Ringt 22— Spring G u id e** 31— Elbow
5— Valve Pin* 14— Backup Ringt 23— U -C up P a c k in g tt 32— Cap Screw (2 used)
6— Steel Ball* 15— Accumulator Endt 24— P is to n tt 33— Lock W asher (2 used)
7— Spring* 16— Retaining Ringt 25— O -R ing 34— Orifice
o r u « » i,
o — ^ iic v iv
\v/ aAi.,A
iv c
■ if
■ /— v y im u c i i a u —
a d :.< .
w * n ii t y
o c
w —
o . . : . # .
m y
9— Special W asher* 18— Packing** 27— Backup Ring 36— P is to n ttt

‘ Serial No. ( -000976) tSerial No. (001255- ) 37— O -R in g ttt
‘ ‘ Serial No. (000977- ) ttS erial No. ( -001431) 38— Backup Ring (2 used)
“ ‘ Serial No. ( -001254) tttS e ria l No. (001432- ) (later units)
39— Backup Ring (later units)
Fig. 5-Hydraulic Oil Accum ulator—Early Units
Remove roll pin from gas valve body and remove Coat O-rings with oil before assembly.
check valve stop, spring, steel ball, and gas valve pin.
Later accumulators (with non-removable end) - Re On early units install new U-cup packing (23) on
move cylinder cap and piston. See Making Special piston (24) with open end of packing facing away from
Tools when removing gas valve assembly. O-ring groove.
Later accumulators (with removable end) - Remove On later units, install new O-rings and backup rings
cylinder cap and piston. Remove cylinder end and on pistons. The single spiral backup rings go on both
disassemble gas valve. sides of the O-ring toward the gas end of the cylinder
Inspect accumulator and note the following: and the double spiral backup ring goes on the outside
of the O-ring toward the oil side of the cylinder.
1. I.D. of cylinder (10 and 17, Fig. 5) must be from
2.9980 to 3.0010 in. NOTE: Some later unit pistons may not have the
backup rings; however, these pistons will accommo
2. O.D. of piston (24) must be from 2.9930 to date the rings. Be sure to install backup rings on these
2.9960 in. pistons.
3. O.D. of cap and end (28 and 15) must be from
2.9940 to 2.9980. Install piston in cylinder with open end toward oil
side and small counterbore toward gas side.
Assembly
Install gas valve assembly in cylinder end. Install O-rings on accumulator end (later units) and
cap, and place in cylinder. Push in far enough to allow
NOTE: See “Making Special Tools” when installing retaining ring to be installed.
gas valve assembly into later accumulators with non
removable ends. Install accumulator in unit and connect pressure
lines.
Litho in U.S.A.
10-4 Filters, Valves, and A cc u m u la to r TM-1001 (Dec-87)
DISASSEMBLE AND ASSEMBLE ACCUM ULATOR-

LATER UNITS
NEW SPRING SPECIFICATION
Spring (12, Fig. 7)
Free length (approximate) 1.10 in.
Test length at 1.5 ± 0.2 lb force 0.59 in.
T84501
Fig. 6-R eieasing G as From A c c u m u la to r
CAUTK^N: Before disassembly, nitrogen

gas rriust be bled from accumulator.
Remove plug (A) from accum ulator end. Connect

D-15041NU Nitrogen C harging Kit to accum ulator.
Turn handle o f gas petcock clockw ise to open gas
valve o f accum ulator and release gas.
Refer to Fig. 7 fo r disassem bly and assem bly o f

parts.
Thoroughly clean parts. Inspect fo r w ear or

damage. Replace as necessary.
L ith o in U.S.A.
TM-1001 (Dec-87) Filters, Valves, and A ccu m u la to r 10-5
T6680AV
1— C ap 5— O -R ing (2 used) 9 — S eal 14— P acking

2— In le t Port 6— C ylin d e r 10— Piston 15— End
3— R eta in in g Ring 7— B ackup Ring 11— Spring G u id e 16— Plug
4— B ackup Ring (2 used) 8— O -R ing 12— Spring 17— O-Ring
13— G as V alve 18— S p ec ial W a s h e r
Fig. 7-Hydraulic O il A ccum ulator—Later Units
L ith o in U.SA.
10-6 Filters, Valves and A c c u m u la to r TM-1001 (Dec-87)
I ■ A M A ■■■■■■■ A M
U n M m a C A U U U IV IU L A IU H 1. Remove piug from the accum ulator end.
IMPORTANT; use dry nitrogen oniy io charge the 2. in sta ii adapter assem bly (A) and O-ring washer.
accumulator. Dry nitrogen DOES
NOT mix with oil. It is non-com 3. Turn handle of gas cock fu lly counterclockwise.
bustible. It will not cause oxidation Install gas cock on adapter assembly.
or condensation inside the ac
cumulator and is not harmful to the 4. Connect high pressure hose assem bly to the
piston seal. DO NOT use air or any pressure regulator valve.
combustible gas as these can cause
oxidation and condensation. Oxida 5. Open the control valve of the nitrogen tank.
tion and condensation are harmful
to the oil piston seal and the IMPORTANT: DO NOT over charge the accumula
accumulator. tor.
6. A djust the pressure regulator valve to 100 ± 10

psi.
7. Turn needle of gas cock clockw ise to open gas

valve of accum ulator and charge accum ulator.
8. Turn needle of gas cock fu lly counterclockw ise

so gas valve can close.
9. Close the control valve o f the nitrogen tank.
10. Slowly loosen the connection at pressure

T88799
regulator valve to release pressure from hose.
Fig. 8‘Charging Accumulator
11. Remove the gas cock and adapter assem bly
j. CAUTION: For safety reasons, a pressure from accumulator. Install the plug into accum ulator
A regulator valve and gauge must be ordered end.
from your local nitrogen gas supplier.
The accum ulator can be charged either on or o ff

the unit using the D-15041NU N itrogen A ccum u
lator Charging Kit.
NOTE: To charge an a ccu m u la to r on the unit,

make sure the o il side o f a ccu m u la to r has
zero pressure. Operate steering valve dur
ing the charging operation to release
hyd ra u lic pressure and to m ake sure the
p isto n goes to o il end o f the accum ulator.
NOTE: When m easuring the charge pressure o f an

a ccu m u la to r on a unit, make sure the o il
side o f a c cu m u la to r has zero pressure to
g e t an accurate reading.
To charge an accum ulator, fo llo w th is procedure:
L itho in U.S.A.
TM-1001 (Dec-87) Filters, Valves, and A c c u m u la to r 10-7
PRESSURE CONTROL VALVE
T24242
1— High Pressure Oil 4— Bleed Line 7— To Steering Valve

2— Low Pressure Oil 5— Spring 8— From Main Hydraulic Pump
3— To Function Control Valves 6— Valve Orifice 9— Pressure Control Valve
Fig. 6-Pressure Control Valve A t 1800 - 1850 PSI
GENERAL INFORMATION W hen a hydraulic fu n ctio n is used, a pressure

drop occurs in the system . This pressure drop
The pressure control valve m aintains pressure oil allow s the spring to move the pressure co n tro l
to the steering and brakes regardless of demands valve forward. When the valve is in th is position,
made by o ther hydraulic functions. the flo w of oil to the fu n ctio n co n tro l valves is
restricted w hile the flo w to the steering and brakes
Pressure oil overcom es spring force and pushes remains the same (Fig. 6).
the valve to the rear of the housing. Pressure oil
also goes to the back side o f the valve through an W hen the main pum p rebuilds to system
o rific e and equalizes pressure on both sides of the pressure, the valve is again moved against its
valve. spring to the rear of the housing. A t th is tim e, fu ll
flo w is again restored to all hydraulic functions.
Oil leakage past the valve is returned to the low
pressure side o f the system through the steering — i Refer to “ Hydraulic Valves” in FOS Manual
valve. This bleed port is incorporated in the pres res - HYDRAULICS for a d dition al description
sure control valve to prevent hydraulic lock. and theory o f operation.
L ith o in U.S.A.
10-8 Filters, Valves, and A ccu m u la to r TM-1001 (Dec-87)
1 — C ap S crew 7— V alve Body 13— O-Ring

2— O-Ring 8— Spring 14— E lbow Fitting
3— C o n n ec to r 9— S him (.030”) 15— E lbow F ittin g (JD570)
4— Nut 10— O rifice 16— S pacer
5— O -R ing (3 used) 11— V alve 17— Lock W ash er
6— Plug 12— In let C o n n ec to r 18— C heck V alve *
*Serial Nos. 1441, 1447-1450, and 1470-1475
Fig. 7-Pressure Control Valve
REPAIR Check the outside diam eter of the pressure con

trol valve. The fro n t of the valve should be 0.7497
NOTE: Before rem oving the pressure co n tro l to 0.7503 in. The center should be 0.7040 to 0.8140
valve, relieve hydraulic a ccu m u la to r pressure from in. The rear should be 0.7257 to 0.7263 in.
the system b y actuating the steering valve with the
engine stopped. The valve spring should have a free length of
4-5/8 in. and its test strength should be 1-3/4 in.
Refer to Fig. 7 for id e n tifica tio n o f parts and se when compressed w ith 50 lbs.
quence o f assembly. A lso note the fo llo w in g
sp e cific instructions. Assembly
Note the number o f shim s (9) removed during Use the same number o f shim s (9) as were
disassem bly. It w ill be necessary to use the same removed, to obtain correct spring pressure setting.
number when assem bling to obtain the correct
pressure setting. Assemble orifice (10) shim s (9) and spring (8) into
valve (11) before valve is installed into valve body
Check the inside diam eter o f the pressure con (13).
trol valve bore in the valve body. The fro n t o f the
bore should be 0.7508 to 0.7518 in. The rear should ADJUSTMENTS
be 0.7268 to 0.7278 in.
Check the pressure control valve as recom
mended in “ Testing the Hydraulic System” Section
70, Group 5.
L itho in U.S.A.
TM-1001 (Dec-87) Filters, Valves, and A ccu m u la to rs 10-9

SPECIAL TOOLS
Essential Tools
Tool Tool N um ber Use
D-15041NU To charge the accumulators

CAUTION: For safety reasons, pressure
A regulator valve and gauge m ust be ordered
from your local nitrogen gas supplier.
TS9340
1— Gas Cock 3— A dapter A ssem b ly

2— High Pressure 4— O -R in g W asher
Hose A ssem b ly 5— T ru-S eal Nut
Fig. 8-Nitrogen Accumulator Charging Kit
Litho in U.S.A.
10-10 Filters, Valves, and A ccu m u la to r TM-1001 (Dec-87)

Convenience Tools
Tool Tool Num ber Use
* See Tubing (1, Fig. 10) and Rod

( 2 ).
T2 3731
1— Tubing 5— I.D. - 0.40 In.

2— Rod 6— 18 In.
3— 17 In. 7— O.D. - 0.125 In.
4— O.D. - 0.50 In.
Fig. 9-Removal and Installation Tools
3 4 5 6 For removing and installing the gas

valve assembly in accumulators
with non-removable ends.
1— Tubing (Rem oval and 4— Spring

Installation) 5— Valve
2— Red (In stallation) 6— Packing
3— Spring Guide 7— A ccum ulator End
Fig. 10-Use of Tools

Make in dealers shop
TM-1001 (Dec-87) M ain H ydraulic Pump 15-1
Group 15
MAIN HYDRAULIC PUMP
For complete repair information on the 40 cm3 (3
cu. in.) (Serial No. -405250) and the 50 cm3 (3 cu.
in.) (Serial No. 405251- ) main hydraulic pumps,
see component technical manual CTM-7.
L ith o in U.S.A.
70 H ydraulic System Grader, Motor - JD570
15-2 M ain H yd rau lic Pum p TM-1001 (Dec-87)
HYDRAULIC PUMP DRIVE AND ENGINE SUPPORT

(Serial No. -010078)
T6680AP
A—Lock Nut (2 used) D—Cap Screw (4 used) G—Special Screw

B— Bushing (4 used) E—Support (2 used)
C—Cap Screw (2 used) F—Cap Screw (2 used) H—Special Screw
(2 used)
I—Locking Wire
/\ F
—a r- l-vj U n it e )/
Fig. 1-Pump D rive a n d E ng ine S upport
REMOVAL Loosley install hydraulic pump on pump support.

Install pump drive shaft on hydraulic pump shaft.
Remove main hydraulic pump.
Then tighten hydraulic pump-to-pump support
screws to 85 lb-ft.
Refer to Fig. 1 to disassemble.
REPAIR Install bushings (B) on spocial screws (G and H),
and position coupler halves on bushings.
Inspect all parts for wear or d a m a g e . Replace parts
as necessary. Adjust pump drive shaft to relieve any axial strain
on bushings.
INSTALLATION
IMPORTANT: There must be a minimum clear
If support (E, Fig. 1) is removed, install on unit. ance of 0.08 in. between the ends of the special
Tighten pump support cap screws (D) to 85 lb-ft. screws (G and H).
Apply two to three drops of T43513 John Deere Early Units — Tighten cap screws (F) to 25 lb-ft.
Thread Lock and Sealer (High Strength) or an equiva Insert locking wire (I) through cap screw heads and
lent to special screws (G). Tighten to 35 lb-ft. tie ends of wire together.
Tighten special screws (H) to 75 lb-ft.
L ith o in U.S.A.
TM-1001 (Dec-87) H ydraulic Pump Drive and Engine S upport 15-3
Later Units — Tighten cap screws (F, Fig. 1) to

30 Ib-ft. Check and retorque coupler screws in same
~~ ^~
d c q u c i iu c l i 11 l i i
ma un o u ic w o i c i a n i 4k/s on
u ic o u
ik f*
il t i i. ilm l j u c .
^
Hold cap screws (F) and tig h te n lock nut (A) to

30 Ib-ft.
HYDRAULIC PUMP DRIVE AND ENGINE SUPPORT

fSerial No. 010079- \,
v — ------------------ -------------------- ---------------------------- ------
T6S14DT
A— Rear Coupler D— Front Coupler F—Cap Screws (4 used) H— Hydraulic Pump

B— Hex Screws (2 used) E—Pump Drive Shaft G—Cap Screws (2 used) I —Cap Screws
C—Cushion (4 used)
Fig. 2-H y d rau lic P um p D rive a n d E ngine S u p p o rt
1. Loosen cap screws (F). AA* A r v.r »V

1J
lir t fV r r o o r l I n n lr
u VUU
o o o l o r /ViicrVt Ul/lVUgVll)
U11U UVU1VA 1**
ofrorterf-Vi^ fV
nV
2. Remove parts (A-I). threads of cap screws (G) and install pump drive shaft
(E) to front coupler (D). Tighten cap screws to 35 lb-ft.
IMPORTANT: To avoid overloading pump bear
ings do not apply an axial force 5. Install cushion between couplers while slipping in
against the crankshaft. put shaft of hydraulic pump onto drive shaft. Install
cap screws (I) and lock washers, and tighten to 85
3. Apply thread lock and sealer (high strength) to lb-ft.
the threads of cap screws (B) and install rear
coupler (A) to crankshaft pulley. Tighten cap
screws to 85 lb-ft.
L ith o in U.S.A.
70 H y d ra u lic S yste m G rader, M o to r - J D 5 70
/ n ~ ~ . o~7\
io “ f m am n y u iau u u r u m p [UGU’Of )
6. Apply thread lock and sealer (high strength) to

threads of cap screws. (F, Fig. 2) and tighten rear
screw, then front to 35 lb-ft. Rotate shaft 180
degrees, tightening other two cap screws (front, then
rear) to 35 lb-ft. Repeat sequence on each side several
times.
TORQUE VALUES
Hydraulic Pump Drive

and Engine Support
(Serial No. -010078)
Pump Support Cap Screws.... Torque.... 85 lb-ft.
Pump Drive Shaft Screws..... . Torque.... 35 lb-ft.
Pulley Drive Screws................. Torque.... 75 lb-ft.
Coupler Half Cap Screws

(Early Units)......................... Torque.... 25 lb-ft.
Coupler Half Cap Screws

(Later Units)......................... Torque.... 30 lb-ft.
Drive Shaft Clamping Screws Torque.... 30 lb-ft.
Hydraulic Pump Drive

and Engine Support
(Serial No. 010079- )
Pump Drive Shaft-to-Front

Coupler Cap Screws............ Torque 35 lb-ft.
Rear Coupler-to-Crankshaft
Pulley Cap Screws............. Torque. 85 lb-ft.
Pump Drive Shaft Clamping

Cap Screws.......................... Torque 35 lb-ft.
Pump-to-Support Torque ,85 lb-ft.

TM-1001 (Nov-78) Function C ontrol V a lv es 20-1
Group 20
FUNCTION CONTROL VALVES
GENERAL INFO RM ATION Oil flow to operate all hydraulic functions of
the grader is controlled by the function control
valves (Fig. 1), with the exception of the power
steering, power brakes, hydraulic saddle pins,
and differential control.
The control valve assem bly consists of a port

plate, nine double-acting valve assem blies, and
an end plate, assem bled into a unit (Fig. 2).
Each double-acting valve assem bly is of the

closed-center design. Each valve incorporates
two internal valves called lockouts, with the ex
ception of the circle rotation valve. Lockouts
prevent any possible oil flow from the cylinder
back through the hydraulic valve.
Fig . 1—Function Control Valve

(JD570 Shown)
ROD END l . - H . C Y L .
ROD: end
P I S T n END R .H PI STM z m ,
FRAME STEER c ir c l e s im - : ,.
? 1 S70.M END SHM'-CYt. : «
WHEEL LEAN .MOyETID .
lND cv
t FT :CYL
':
Bt AO. EI
„CW7
' S ston' eSs ;
S C A R IF IE D C Y L .;
: ROD END
R .H . U r
ROD . END., ..
SCA.RT F IE R :‘
ROB: £
WHEEL
:C Y L:. . ROD I
ROD END R .H .C Y L . C IR C L E / iC I I S e L E
P IS T O N E N D : i . HLGY R O T A T IO N S H IF T C
■FRAME STEER ■ LE FT
Fig . 2 - V a l v e Func tion s

(E arly V alv e Shown)
L itho in U .S .A .
20-2 Function Control Valves TM-1001 (Dec-87)
T33896N
1— Pressure Oil 4— Standard Lockout (open) 7— Spool Orifice 10— Inlet Passage
2— Return Pressure Oil 5— Spring 8 — Check Ball 11— Check Balls
3— Pressure Free Oil 6— Outlet Passage 9— Spool 12— Pressure Cavity
F ig . 3 -W h e e l L e a n C o n tro l V alve - S ta n d a r d L o c k o u ts (P o w e r P o s itio n )
Two kinds of lockouts are used in the JD570 and Return oil from the cylinders flows through the
JD570-A, SPECIAL and STANDARD. The blade other open lockout (4) and out the spool orifice (7) to
lift, scarifier, circle sideshift, and blade pitch valve the outlet passage.
sections have the SPECIAL type in valve ports go
ing to the rod end of the cylinders. The blade sideshift By returning the spool (9) to neutral, oil pressure
valve section has the SPECIAL type in valve port to cavity (12) is stopped and the springs (5) force and
going to head end of the cylinder. The STANDARD hold the lockouts (4) closed. With the lockouts closed,
type is used in ports going to the piston ends. Wheel there is no possibility of spool leakage getting to the
lean and early model frame steer sections have cylinders and causing drift.
STANDARD lockouts in both ports.
SPECIAL LOCKOUTS
STANDARD LOCKOUTS
The SPECIAL lockouts (5, Fig. 4) are different
Fig. 3 illustrates how the STANDARD lockouts from the standard type. They are designed to utilize
work. return oil to help hold themselves open. This is
necessary because return oil pressure in some of the
When the spool (9) is placed in power position, circuits often exceeds system pressure. If a STAN
pressure oil enters the spool and unseats the check DARD lockout were used here, oil returning from the
bail (8). Oil then flows to cavity (12), seats the two cylinder could close it and prevent oil from return
check balls there, and pushes open both lockouts (4). ing through the valve.
Simultaneously, oil in the inlet passage (10) flows by
the spool, through the open lockout (4), and on the This high pressure return oil is created by small
cylinders. spool orifice. Restricting the oil flow creates a
smoother cylinder piston movement in the direction
of the rod side of the piston.
L ith o In U .S .A .
G rader, M otor - J D 5 7 0 H y d ra u lic S ystem 70
T M -1001 (N ov-78) F u n c tio n C o n tro l V a lv e s 2 0 -3
H ©
□ ©
□ © T33897N
1 - Pressure Oil 5 - Special Lockout (open) 8 - Check Ball 11 - Standard Lockout (open)
2 - Return Pressure Oil 6 — Outlet Passage 9 — Spool 12 - Check Balls
3 - Pressure Free Oil 7 - Spool Orifice 10 - Inlet Passage 13 - Pressure Cavity
4 - Restrictor
F ig . 4 -C o n tro l V olvo - Standard and Special L o cko u ts (Pow er P o sitio n )
Oil flow through avalve section with SPECIAL The SPECIAL lockout stays open because of its
lockouts is basically the same as that in a valve design. Notice in the Fig. 4 inset how low pressure
with STANDARD lockouts. The main difference oil is introduced in the spring area of the lockout
is the way the lockouts work. Fig. 4 with inset instead of higher pressure oil as in the standard
illustrates the difference. lockout.
REMOVAL
When spool (9) is placed in power position,
pressure oil enters the spool and unseats the N O T E : W hen in te rn a l valve leakage is indicated,
check ball (8). Oil then flows to cavity (13), rem ove a n d inspect lockouts. I f lockouts are in good
seats the two check balls, and pushes open both condition and valve leakage continues, rem ove and
lockouts (5 and 11). Simultaneously, oil in the re p a ir valve.
inlet passage (10) flows by the spool, through E x te rn a l o il leakage between sections o f the con
the open lockout (11), and on to the cylinder. tro l valve indicates th a t th e O -rings (2, F ig . 5) are
n o t p ro p e rly compressed o r the through bolts are n o t
Return oil from the rod side of the cylinder p ro p e rly torqued. Check bolts fo r a torque o f 20 - 25
piston begins to move and build pressure. It ft-lb s. I f re -to rq u in g bolts does n o t stop leakage,
flows through the SPECIAL lockout (5). The small replace O -rings (2, Fig. 5) and add special washers
spool orifice (7) restricts the return oil and in (18) between valve sections to control compression o f
creases its pressure around the SPECIAL lock the O-rings.
out. N O T E : I t is n o t necessary to rem ove the e n tire
control valve assem bly to service in d iv id u a l valve
At this point, a STANDARD lockout in this sections.
situation would be overcome by the high-pres If necessary, remove cab, steering valve, cylinder
sure oil and close. and shaft assembly. Disconnect oil tubes at control
valve assembly.
70 Hydraulic System Grader, M otor - J D 5 7 0
2 0 -4 Function Control Valves TM -1001 (N ov-78)
T62572N
1— Port Plate, L.H. 7— Orifice Plate (0.0625 in.) 12— End Plate
2— 0-Ring (20 used) (4 used) 13— Tie Bolt (4 used)
3— 0-Ring (10 used) 8— Valve (Circle and Blade 14— Valve Spacer
4— Valve (Blade Lift and Side Shift) (2 used) 15— Cap Screw (3 used)
Scarifier) (3 used) 9— Valve (Circle Rotation) 16— Lock Washer (3 used)
5—Valve (Blade Pitch) 10— Valve (Wheel Lean and 17— Orifice Plate (0.1405 in.)
6— Orifice Plate (0.0785 in.) Frame Steer) (2 used) Serial No. 002227- )
(2 used) 11— Orifice Plate (0.0935 in.) 18— Special Washer (20 used)
(Serial No. -001860 and 19— Lock Washer (8 used)
002227- )(2 used) 20—Nut (8 used) (5518- )
Fig. 5-Nine-Section Control Valve Assembly
Loosen (do not remove) cap screws holding valve inserted into their respective valves as shown in Fig.
panel plate to floor bracket. T ilt panel plate backward to 12. Slotted sides of orifice plates should face out.
clear the tubes. Attach hoist to valve assembly.
IMPORTANT: If all orifice plates are removed at
Disconnect control lever-to-valve linkage. Remove
once, tag and mark them to insure installation in
three cap screws securing control valve assembly to
correct ports. Installation in incorrect port could
panel plate, and lift valve assem bly from grader.
result in unsatisfactory operation of functions in
volved.
REPAIR
Refer to exploded views (Figs. 5 through 11) when To remove lockouts from a valve, remove upper and
servicing the function control valves. Particularly note lower lockout plugs and loose inner parts. Place small
the following: brass rod through lockout port and carefully drive out
parts. Lockouts and valve spools vary with each valve
Be careful not to lose orifice plates when
according to the function served (Fig. 6 through 11).
servicing valves. Also be sure orifice plates are
Litho in U .S .A .
TM-1001 (Dec-87) Function Control Valves 20-5
The SPECIAL lockout is a one piece assembly At Serial No. (406926- ) redesigned lockouts
whereas the STANDARD is not. Be sure STAND were used. When replacing an old lockout with a new
ARD lockouts are not installed in control valve lockout, all parts in AT74667 Kit must be used. Parts
ports requiring SPECIAL lockouts. are not interchangeable.
N O T E : S T A N D A R D lo c k o u ts in e a r ly m o d e l
fr a m e s t e e r v a lv e s ( -0 0 1 6 9 9 ) s h o u ld he
r e p la c e d w ith S P E C IA L lo c k o u ts a s u s e d in f r a m e
s t e e r v a lv e s (0 0 1 7 0 0 -0 0 2 2 2 6 ) w h e n e v e r th e s e
v a l v e s e c ti o n s a r e s e r v i c e d . F r a m e s t e e r v a lv e s
(0 0 2 2 2 7 - ) r e q u i r e S T A N D A R D lo c k o u ts .
12
2 — M achine Screw 7 — Valve Housing 12 — P lug Assem bly 17 — Spool Spacer

3 — D ust Seal Retainer 8 — Plunger 13 — Cap Assem bly 18 — Bushing
4 - Breather Washer 9 — 0 -R in g 14 - Spool Screw 19 — 0 -R in g
5 — Spool 10 — Backup Washer 15 — Steel Washer
Fig. 6-B/a</e Rotation Control Valve
21
1 — D ust Seal 8 — O-Ring 15 — Seat Assem bly 22 — Cap A ssem bly

2 — M achine Screw 9 — 0 -R in g 16 — Poppet 23 — Spool Screw
3 - D ust Seal R etainer 10 - Spool Plug 17 — Spring 24 — Steel Washer
4 - Breather Washer 11 — 0-R in g 18 — O-Ring 25 — Spool C entering Spring
5 — Spool 12 — V alve H ousing 19 — Backup Washer 26 Spool Spacer
6 — Steel Bal I 13 — Plunger Assem bly 20 — O-Ring 27 — Bushing
7 — Spring 14 — O-Ring 21 — P lug Assem bly 28 — O-Ring
Fig. 7-W h eel Lean and Fram e Steer

(Serial No. -0 0 1 6 9 9 a n d 0 0 2 2 2 7 - ) Control Valves
L itho in U .S.A .
70 H ydraulic S y stem Grader, Motor - JD 570
2 0 -6 F unction C ontrol V a lv es TM-1001 (Nov-78)
29
1 - D ust Seal 11 — O -Ring 20 — P lug Assem bly 29 - P lug A ssem bly

2 — Machine Screw 12 - Poppet 21 - P lug 30 — Spring
3 — Dust Seal R etainer 13 — P lunger Assem bly 22 - N ylon B a ll 31 - Cap A ssem bly
4 — Breather Washer 14 — O-Ring 23 — Spring Pin 32 - D etent Screw
5 — Spool 15 — Seat A ssem bly 24 - O -R ing 33 — Spring
6 — Steel B all 16 — Spring 25 — O-Ring 34 — Spool Washer
7 - Spring 17 — O-Ring 26 - P lunge r and Poppet 35 — Steel Washer
8 — 0 -R in g 18 — Backup Washer A ssem bly 36 — Bushing
9 - O-Ring 19 — O-Ring 27 — O -R ing 37 — O -R ing
10 — Spool Plug 28 — Backup Washer 38 — V a lve H ousing
Fig. 8 - B l a d e L i f t and Scarifier Control Valves
Valves for the scarifier and blade lift con- screwdriver attachment on torque wrench. Apply
tain detents (Figs. 2 and 8) which will permit Loctite to threads and tighten with 5 to 8 ft-lbs
operators to lock levers in float position. When torque.
installing detents in end of valve spool, use a
30
27 282 ? ' 2 2 ^ 1
12 26 17
\ 31
}
A A 32
35
37 36 33
1 — D ust Seal 11 — O -Ring 19 - Spring 28 - Poppet

2 - M achine Screw 12 - V a lve H ousing 20 - O -R ing 29 - Spring
3 — D ust Seal Retainer 13 - P lug 21 — Backup Washer 30 - P lug A ssem bly
4 — Breather Washer 14 — N ylon B all 22 — O -R ing 31 — Cap A ssem bly
5 — Spool 15 — Spring Pin 23 - Backup Washer 32 — Spool Screw
6 - Steel B all 16 — O -Ring 24 — O -R ing 33 — Steel Washer
7 — Spring 17 — O -R ing 25 — P lug A ssem bly 34 — Spool C entering Spring
8 — O-Ring 18 - P lunger and Poppet 26 — P lunge r Assem bly 35 — Spool Spacer
9 — O-Ring A ssem bly 27 — Seat Assem bly 36 — Bushing
10 — Spool Plug 37 — O -Ring
Fig. 9 —Blade P i tc h Control Valve
Litho in U .S.A .
TM-1001 (Nov-78) Function C ontrol V alv es 2 0 -7
30
1 — Dust Seal 10 — Spool Plug 19 - Backup Washer 28 — O-R ing

2 — Machine Screw 11 — O-Ring 20 — O-Ring 29 - Backup Washer
3 — Dust Seal R etainer 12 — V alve Housing 21 - Plug Assem bly 30 — Plug A ssem bly
4 — Breather Washer 13 - P lunger Assem bly 22 - P lug 31 - Cap A ssem bly
5 — Spool 14 - O-Ring 23 - Spring Pin 32 — Spool Screw
6 - Steel B all 15 - Seat A ssem bly 24 — N ylon B all 33 — Steel Washer
7 — Spring 16 - Poppet 25 — O-Ring 3.4 — Spool C entering Spring
8 — O-Ring 17 — Spring 26 — P lunger and Poppet 35 — Spool Spacer
9 — O-Ring 18 - O-Ring A ssem bly 36 - Bushing
27 - Spring 37 — O -R ing
F i g . 10—C i r c l e a n d B l a d e S i d e - S h i f t C o n t r o l V a l v e s
1 - Dust Seal 9 — Backup Washer (2 used) 17 — Plug (2 used) 25 - O-Ring

2 — Screw (2 used) 10 — O-R ing (2 used) 18 — V alve Body 26 — O-Ring
3 — Retainer IT - Spring (2 used) 19 — Cap A ssem bly 27 - Spool Plug
4 — Breather Washer 12 — O-Ring (2 used) 20 — Spool Screw 28 — O-Ring
5 — Plug A ssem bly (2 used) 13 — Plunger and Poppet (2 used) 21 — Steel Washer (2 used) 29 — O-Rtng
6 — O-Ring (2 used) 14 - O-Ring (2 used) 22 — C entering Spring 30 — Spring
7 - Backup Washer (2 used) 15 - Spring Pin (2 used) 23 — Spool Spacer 31 - Steel B a ll
8 — O-Ring (2 used) 16 - Nylon B a ll (2 used) 24 — Bushing 32 — Spool
F i g . I I - F r a m e Steer C o n t r o l V a l v e ( S e r ia l N o . 001 7 0 0- 0 0 2 22 6 )
L itho in U .S.A .
70 Hydraulic System Grader, Motor ■JD570
20-8 Function Control Valves TM-1001 (Dec-87)
in correct valve ports (Fig. 12).
N O T E : I f o n e b la d e l i f t c y li n d e r o p e r a te s a t a
d if f e r e n t s p e e d f r o m th e o th e r , c h e c k o r i f i c e f o r
f r e e d o m o f m o v e m e n t. I f o r if ic e m o v e m e n t is
n o t r e s t r i c t e d w h en h y d r a u lic lin e s a r e c o n n e c t
ed , i t i s p o s s i b le to a d d o r r e m o v e an o r if ic e
p l a t e (1 , F ig . 12) to o b ta in eq u a l s p e e d o f o p e r a
tio n . D if f e r e n t s i z e o r i f i c e p l a t e s m a y a ls o be
xi$Qd to c o w e d b la d e l i f t v jie v e ? ie s s .
INSTALLATION
Mount control valve assembly to panel plate

brackets and connect control lever linkage.
1— 0 .0 935 O rifice P lates 3— 0 .0 6 2 5 O rific e P late s
(S erial No. -0 0 i8 6 0 ) 4— 0.1 405 O rific e P iate
(S erial No. 002227- ) (S erial N o. 0 0 2 2 2 7 - ) Connect bottom tubes to their respective fit
2— 0 .0 785 O rific e P lates tings, beginning with middle tube. This offers
Fig. 1 2 -C orr ect Location o f Res tricto rs greater convenience when tightening connections.
Attach upper tubes in same manner. Tighten cap
On other valves clean thoroughly, apply Loc- screws holding valve panel plate to floor bracket.
tite to threads of spool screw, and tighten to 5 to
8 ft-lbs. Be sure breather in cap assembly is
free of paint.
When reassembling control valve assembly,

be sure to install O-ring and steel backup ring
in valve next to port plate (Fig. 13). Install
washers (18, Fig. 5) withO-rings (2) andO-rings
(3) between all sections.
Install control valve tie bolts.
IMPORTANT: Torque all tie bolts to 20-25 ft-lb.

An improper torque may distort valve bodies caus
ing the valve spools to stick or cause leakage be
tween valve sections.
L it ho in U.S.A.
TM-1001 (Dec-87) H ydraulic Cylinders 25-1
Group 25
HYDRAULIC CYLINDERS
GENERAL IN FO RM ATION REPAIR
All hydraulic cylinders used are double-acting. All CAUTION: Be sure the blade is on the
cylinders on early units have V-packings with the ex A ground and the engine stopped before at
tempting to remove a cylinder. Before discon
ception of the front wheel steering cylinders, which
have O-ring seals. necting the hydraulic lines, p a rtia lly crack con
nections to relieve the hydraulic pressure. When
On later units, if scarifier and snowplow lift cylin removing wheel lean cylinder, be sure to block
der or blade lift cylinder is replaced, a new cylinder up the entire front axle so wheels w ill not fall
with cap seals will be furnished. to a leaning position.
Replaceable non-metallic wear rings are used

on the piston retainers and in the rod guides to
prevent scoring of the barrels and piston rods.
Rod ends are welded to piston rods.
TESTING
Use the following procedure to test for in

ternal leakage.
Fully extend or retract the cylinder to be

tested. If the cylinder is extended, remove the
hydraulic hose or tube from the rod end of the
cylinder. If the cylinder is retracted, remove the
hydraulic hose or tube from the head end of the
cylinder. Cap the end of the hose or tube which
was disconnected.
IM PO R TA N T: To prevent oil from beingdis- 1 — Barrel 10 — Wear Ring

charged from the disconnected hose, be sure to 2 — P iston Rod Nut 11 — Rod Guide
3 — Wear Ring 12 — O-R ing
operate the cylinder inthe same direction chosen 4 — P iston R etainer 13 — B ackup Washer
in the previous paragraph. F o r example, if hose 5 — V -P acking 14 — Snap Ring
is disconnected from the rod end, operate the 6 - O-Ring 15 — Wiper Seal
7 — Piston 16 — Spanner N ut
valve lever to extend the cylinder 8 — Snap Ring 17 — P iston Rod
9 - V -P acking
Examine the open port on the cylinder. If any
oil is leaking from the port, the cylinder packings F ig . 1-H ydraulic C y lin d e r C o m p o n e n ts — E arly U nits
are defective and should be replaced.
Refer to Fig. 1 for disassembly and assem

bly and note the following:
Use spanner wrench (474) to remove spanner

nut (16).
Use all new parts provided in repair kit when

reassembling cylinder.
L itho in U .S.A .
25-2 H ydraulic C ylinders TM-1001 (Dec-87)
BLADE LIFT CYLINDER (LATER UNITS)
T6692AH
Fig. 2 -B la d e L ift C y lin d e r C o m p o n en ts
L ith o in U.S.A.
TM-1001 (Dec-87) H ydraulic Cylinders 25-3
A — Barrel J — S eal T — S n ap R ing

B — Lock N u t K — W e a r R ing U — B ack-U p Ring
C — W e a r Ring L— G u ide V — O -R ing
D — P iston M — C a p S crew (2 used) W — C ap S crew (2 used)
E -S e a l N — Lu b rica tio n Fittin g X — Lock W a s h e r (2 used)
F — B ack Up Ring (2 used) (N o lo n g e r required) Y — P o sitio n R ad ius o f
G — O-Ring 0 — C ap B ack-U p R ings
H — Piston P — S him (A s required) as S ho w n
I — S nap R ing Q -R o d
R -N u t
S -S e a l
L e g en d fo r Fig. 2-B la d e L ift C y lin d e r C om po nen ts
TORQUE SPECIFICATIONS
Nut (E, Fig. 2 ) .................................. 600-700 Ib-ft.

Nut(R, Fig. 2 )........................................... 150 Ib-ft.
See page 70-25-6 for installation procedure of

piston cap seal.
L ith o in U.S.A.
25-4 H ydraulic Cylinders TM-1001 (Dec-87)
SCARIFIER AND SNOW PLOW LIFT CYLINDER (LATER UNITS)
T6692AG
Fig. 3 -S c a rifie r an d S no w P low L ift C ylin d e r C om po nen ts
Litho in U.S.A.
TM-1001 (Dec-87) H ydraulic C ylinders 25-5
A — C a p S crew J — B ack-U p Ring R — S p an n e r N u t

L o ck W ash er (2 used) S — S eal
W ash er K — P iston T — S n ap Ring
B — Tu b e L— S nap R ing U —-B ack-U p Ring
C — F ittin g M — S eal V — O-R ing
D — O-R ing N — W e a r Ring W — Bushing
E— Lock N u t O — H y d ra u lic C ylin d e r W — H y d ra u lic C ylin d e r
F — W e a r Ring Rod G u ide Barrel
G — P iston P — Bushing (2 used) Y — P osition R adius o f B ackup
H — S eal Q — Rod Rings A s S how n
I— O -R ing
Le g en d fo r Fig. 3 -S c a rifie r an d S n o w p lo w L ift C y lin d e r C o m p o n en ts
TORQUE SPECIFICATIONS
Nut (B, Fig. 3 ) ...................................... 150-250 Ib-ft.

Nut (R, Fig. 3 ) ...............................................150 Ib-ft.
See page 70-25-6 fo r in sta lla tio n procedure of

piston cap seal.
L ith o in U.S.A.
25-6 Hydraulic Cylinders TM-1001 (Dec-87)
installing Piston cap seal IMPORTANT: For proper fit, the backup rings
must be installed with the radius
toward seal expander.
3. Install backup rings (C) w ith radius toward seal

expander (B).
T6514AA
A — P iston C — B ackup B ings (2 used)

R_ __Oa s I C vnaniiar n _ P a n Caal
H ----WWHI tan^BIIWWI * * -------WVHI
Fig. 4-P iston Cap S e a l
N O T E : U se a cylin d e r re p a ir k it when a s s e m b lin g

re b u iid ab le cylinder. B efo re assem b ling ,
a p p ly clean h y d ra u lic o il to a ll in te rn a l
parts.
1. Install seal expander (B) on end of piston (A).
IMPORTANT: Cap seal must fit tight against seal

expander to prevent seal damage
during assembly into barrel.
2. Install cap seal (D) onto seal expander (B). If

necessary, sh rin k cap seal to its original size us
ing a ring com pressor or hose clam p w ith shim
stock.
Litho in U .S.A .
TM-1001 (Nov-78) C ir c le D rive H ydraulic M otor 30-1
Group 3 0
CIRCLE DRIVE HYDRAULIC MOTOR
GENERAL INFORMATION Plugged filter.
Clean or replace filter element.
MOTOR WILL NOT TURN
Large contaminating particles in fluid.

Check filter and replace oil.
MOTOR RUNS WITHOUT TURNING CIRCLE
Broken shaft.
Replace shaft. Check housing for wear.
MOTOR TURNS IN WRONG DIRECTION
F i g . 1 - C i r c l e D ri ve H ydra ulic Motor Improper tube connection.

Reverse connections.
The circle drive hydraulic motor (Fig. 1)
operated by the T-shaped control lever, is de Wrong timing.
signed to deliver high torque at slow usable Remove geroter from splines on drive and
speeds. move one spline tooth in either direction.
Turning the T-shaped lever to the right LEAK AT SHAFT

activates the circle drive function control valve,
which in turn supplies oil pressure to the circle Worn or cut quad-ring.
drive hydraulic motor, turning the circle and Replace ring and polish shaft at seal area
blade in the same direction as the control lever. with No. 600 wet or dry standing cloth.
Likewise turning the lever to the left results in
the circle and blade turning left. LEAK BETWEEN PLATE AND HOUSING
Although the motor is precision-built, it is Loose plate.

relatively simple, having only three moving Tighten to proper tor q u o .
parts—the geroter, drive, and output shaft.
»s e a l.
The output shaft, which is coupled to a worm Replace. Check housing surface at seal for
gear in the circle drive gear box, drives the sharp nicks or deep scratches.
circle drive gear.
Leak in body plug seal.
DIAGNOSING M ALFUNCTIONS
LEAK AT WEAR PLATES
SLOW OPERATION
End cap screws loose.
Worn pump or motor. Tighten to proper torque. If threads are
Replace worn parts. accidentally stripped in housing, drill and
tap hole deeper. Reassemble with longer
Extremely high fluid temperature causing motor bolts.
to slip.
Use proper hydraulic fluid.
L itho in U .S.A .
70 H ydraulic S y stem Grader, Motor - JD570
3 0 -2 C ir c le D r iv e H ydraulic M otor TM-1001 (Nov-78)
(S e r. No. -3 7 4 7 )
1 — C oupling 7 - Backup Washer 13 — Spacer 18 - End Cap

2 — Special Cop Screw 8 — Quad Seal 14 — D rive 19 — Seal Washer
3 — Internal Lock Washer 9 — 0 -R in g 15 — Spacer P late 20 - Cap Screw (7 used)
4 — O il Seal 10 - Bearing Race 16 — Gerotor 21 — O -Ring
5 — Spring Pin (4 used) 11 — T h ru s t Bearing (2 used) 17 — Spacer 22 - P lug
6 — Mounting P late 12 — H ousing and Shaft
F i g . 2 —C ircl e D riv e H ydr aulic Motor Components
LEAK BETWEEN GEROTER AND END CAP When disassembling motor, make a timing
mark on geroter (16) and drive splines (14) so
Dirt between surfaces. that these parts can be assembled with the same
Clean and dry parts. tooth alignment. Failure to do this can result
in the operating levers causing reverse rotation
Scratches or nicks on surfaces. of the circle.
Polish very carefully on a flat, hard sur
face. Use No. 600 or finer abrasive cloth Should the levers operate in a reverse man
with very little pressure. Avoid rounding ner, remove end cap (18) and geroter. Move
edges. geroter one spline tooth in either direction on
drive.
CRACKED MOUNTING PLATE
To replace oil seal (4) remove mountingplate
Installation bolts too long. (6) and install new seal. Install plate on motor
Replace plate. Use proper size bolts. and tighten to 250 ^ 25 in-lbs.
LEAK AT OIL PORTS Prior to assembly, wash all parts in clean

solvent and air dry. Keep all foreign material
Poor fittings. out of motor.
Replace fittings. Use new O-rings.
MOTOR R U N -IN
Damaged threads.
Replace housing or use nut such as a true When a new motor is started a slight clicking
seal. sound may be heard or the motor may stall
momentarily. Neither of these situations is
REMOVAL harmful or critical, and both will correct them
selves.
Disconnect and plug hydraulic tubes. Remove
mounting cap screws. The clicking sound is produced at low speeds
under no-load conditions and is due to a slight
REPAIR backlash in the drive linkage. The sound will
stop as flow is increased.
When servicing the circle drive motor, refer
to the exploded view (Fig. 2). Particularly note If the motor stalls it is probably due to a
the following: thermal expansion of the shaft. The motor will
start again after a few seconds when the system
temperatures have equalized.
L itho in U .S.A .
TM-1001 (Nov-78) Circle Drive Hydraulic Motor 30-3
(Ser. No. 3748- )
10
11
12
I
§
0
1— O utput Shaft 8— G eroter 15— O -R ing

2— O-Ring 9— Spacer 16— Quad Seal
3— Plug 10— End Cap 17— Dust Seal
4— Housing 11— Seal W asher 18— M ounting Plate
5— Drive 12— C ap Screw 19— Internal Lock W asher
6— Oil Seal 13— T h ru st Bearing 20— C ap Screw
7— Spacer Plate 14— Bearing R ace
Fig. 3-Circle Drive Hydraulic Components
Litho in U.S.A.
30-4 C ircle Drive H ydraulic M o to r TM-1001 (Dec-87)
ROTARY MANIFOLD
Lower blade to the ground.
Relieve pressure in h y d ra u lic system by

operating steering valve, brake valve and control
levers. Slowly crack fittin g on rotary m anifold to
relieve any pressure trapped in lines due to lock
outs in main control valve.
Remove cover, bracket and rod assembly.
Disconnect, mark and cap lines on front and bot

tom o f rotary m anifold.
Remove rotary m anifold from unit.
Fig. 4-R o tary M a n ifo ld
The rotary m anifold is m ounted on the draft

fram e (Fig. 4).
The m anifold body rem ains s ta tio n a ry w hile the

m anifold spool is turned by a bracket and rod
assem bly th a t is attached to the spool and the cir
cle and blade assembly.
The rotary m anifold allow s fo r 360° rotation of

circle and blade assem bly.
L itho in U.S.A.
TM-1001 (Dec-87) Circle Drive H ydraulic M o to r 30-5
REPAIR
^ K .
© — o
© — o
(D— " C Z 5
T6679AB
A — S upport C — 0 -R in g (5 used) E — W ash er

B — Back-Up R ing (2 used) D — S w ivel F — S nap Ring
Fig. 5-R o tary M a n ifo ld A sse m b ly (S erial N o. -004643)
Refer to Fig. 5 during disassem bly and assembly

o f rotary m anifold (Serial No. -004643).
L ith o in U.SA.
70 H ydraulic System Grader, M otor - JD570
30-6 C ircle Drive H ydraulic M o to r TM-1001 (Dec-87)
1 — C ap S crew (4 used) 4 — F e lt W ash er (2 used) 7 — W ash er

2 — Lock W a s h e r (4 used) 5 — M a n ifo ld Body 8 — M a n ifo ld Spool
3— R e ta in e r 6 — S eal (5 used)
Fig. 6-R o tary M a n ifo ld A sse m b ly (S erial N o. 004644- )
Refer to Fig. 6 during disassem bly and assembly Measure O.D. of m anifold spool and I.D. of
of rotary m anifold. m anifold body. Replace parts as necessary.
Scribe a mark on m anifold body and spool to aid M anifold Spool O.D................ 3.6210 ± 0.0015 in.
in reassembly.
M anifold Body I.D.................. 3.6260 ± 0.0015 in.
Remove the four cap screws (1) and retainer (3).
Install washer (7) on m anifold spool.
Press m anifold spool (8) from m anifold body (5).
Install seals (6) on m anifold spool (8) afte r soak
Check m anifold body and spool fo r damage. ing in oil.
Remove m inor nicks and scratches w ith crocus
cloth.
L itho in U.S.A.
TM-1001 (Dec-87) C ircle Drive H ydraulic M o to r 30-7
NOTE: One seal replaces tw o backup rings and INSTALLATION

one O-ring packing.
A lign marks made during removal and install
Install new felt washers (4) in manifold body after rotary m anifold on the unit,
soaking in oil.
Connect hydraulic lines and hoses.
Coat the m anifold spool and inside of m anifold
body w ith oil. Install spool into m anifold body be- Install drive bracket,
ing careful not to damage seals.
Install cover.
Position retainer on rotary m anifold and install
lock washers (2) and cap screws (1).
Litho in U.S.A.
30-8 C ircle Drive H ydraulic M o to r________________ _____________________________ TM-1001 (Dec-87)
L ith o in U.S.A.
G rader, M otor - J D 5 7 0 H y d ra u lic S ystem 70
T M -1001 (N ov-78) Saddle V a lv e and R e ta in in g P in s 3 5 -1
Group 35
SADDLE VALVE AND RETAINING PINS ( -0 0 3 9 2 5 )
PRESSURE OIL □ PRESSURE OIL
□ RETURN OIL □ RETURN OIL

T18955 T18956
D ise n g a g e d P o s itio n E n g ag ed P o s itio n
Fig. 1—Saddle Retaining Pin
GENERAL INFORMATION E n g a g ed P o s itio n

When the foot plunger is released, the check
Movement of the saddle on the saddle pivot ball in the return channel of the valve is unseated.
is controlled by the foot-operated valve on the Hydraulic pressure seats the bottom check ball
right underside of the operator's platform. cutting off pressure oil to the outside of the saddle
pin. The unseated upper check ball permits r e
D is e n g a g e d P o s itio n turn oil from this area to flow to sump and the
Depressing the foot plunger places the pin in pin is forced to the engaged position by pressure
the retracted position. Foot pressure on the oil in the cavity inside the pin.
plunger unseats the lower check ball permitting
pressure oil to flow to the pin housing. Increased When the foot plunger is not depressed, the
foot pressure on the plunger seats the upper lower check ball is seated and return oil p res
check ball, closing the return channel of the sure exists on the outside of the (pin. Pressure
valve. The pressure oil is directed to the out oil remains inside the pin which hydraulically
side of the saddle pin. Although the pressure on retains pin in the engaged position.
both outside piston and the interior of the pin
is the same, the difference in area forces the
pin to retract.
35-2 Saddle Valve and Retaining Pins TM-1001 (Dec-87)
REPAIR
T66B0AY
1— Backup Washer (4 used)9—Piston (2 used)
2— O-Ring (4 used) 10— Snap Ring (2 used)
3— Snap Ring (2 used) 11— Snap Ring (4 used)
4— Backup Washer (4 used)
12— Plug (2 used)
5— O-RIng (4 used) 13— Return Pin (2 used)
6— Saddle Pin (2 used) 14— Tube (2 used)
7— O-Ring (2 used) 15— Pin (2 used)
8— Backup Washer <2 used)
Fig. 2 — Lo ckin g Pin A ssem bly

( -003925)
Disassemble and assemble the saddle valve and

saddle pin assembly using Figs. 2 and 3. Pay par
ticular attention to the following:
Remember, the blade must be on the ground

before retracting the saddle retaining pins.
Be sure saddle pins (6, Fig. 2) are completely

disengaged before attempting to change operating
angle. Likewise, be sure pins are completely en
gaged before operating the grader.
The saddle pin housing is pressed into the sad

1— 90-Degree Adapter (2 used)7— O-Ring
2— O-Ring (3 used) 8— Plug dle with hole in pin in down position. To install,
3— Steel Ball (2 used) 9— O-Ring press to 30 tons; removal press requirements will
4— Spring Pin 10— Plunger vary with condition of machine.
5— Straight Adapter 11— Valve Body
6— Snap Ring 12— Jam Nut
Fig. 3 — Saddle Valve Com ponents ( -003925)
Litho in U.S.A.
TM-1001 (Dec-87) Saddle Valve and Retaining Pins 35-3
Fig. 4-Snap R ing Installed
When removing tube (14, Fig. 2) from saddle pin

(6), release snap ring (3) by using a screwdriver to
start the flat end of snap ring up the slotted incline
in tube. Turn tube and snap ring will rotate out of
its groove.
Fig. 5-Saddle Shims
To install same snap ring, hooked end of ring

through slot in tube. Turn rod and tube in opposite Add or remove shims as needed to obtain
direction as above and ring will seat itself as shown clearance of 0.020 to 0.090 in. between saddle and
in Figure 4. saddle pivot (Fig. 5).
Litho in U.S.A.
3 5 -4 Saddle Valve and Retaining Pins TM-1001 (Feb-80)
SADDLE VALVE AND RETAINING PINS (003926- )

GENERAL INFORMATION
1— Pressure Oil 7— From Main Pump 1' -Pressure Oil 7— From Main Pump
2— Return Oil 8— Crossbar 2— Return Oil 8— Crossbar
3— Check Ball 9— Locking Pin 3—Check Ball 9— Locking Pin
4— Spring Pin 10— Locking Pin Barrel 4—Spring Pin 10— Locking Pin Barrel
5— Plunger 11— Piston 5— Plunger 11— Piston
6— To Return 12— Piston Ring Seal 6—To Return 12— Piston Ring Seal
Fig. 6-Locking Pin Disengaged Fig. 7-Locking Pin Engaged

(003926-007141) Shown (003926-007141) Shown
Disengagement of the saddle locking pins is con Engaging Locking Pin

trolled by a manually operated valve on the right un (Fig. 7)
derside of the operator’s platform. When the plunger (5) is released, the check ball (3)
seats in the return passage of the saddle locking valve.
Disengaging Locking Pin Due to the orifice slot in the piston seal ring (12),
(Fig. 6) pressure on each side of the piston (11) equalizes. The
Depressing the plunger (5) will disengage the lock difference in areas on each side of the piston forces the
ing pin (9). Pressure on the plunger unseats the check locking pin to engage.
ball (3) permitting the oil on the back side of the piston
(11) to flow to and through the saddle pin locking valve
to return (6). The difference in pressure on each side of
the piston (11) forces the locking pin (9) back, disen
gaging it.
Litho in U.S.A.
Grader, M otor - JD570 Hydraulic System 70
TM-1001 (Dec-87) Saddle Valve and Retaining Pins 35-5
SADDLE LOCKING VALVE
1— C on nector 8 — P lunger (007142- ) 14— Snap Ring (2 used)

2— O-Ring 8A — P lunger (003926-007141) 15— O-Ring
3— Center-B onded M ounting 9 — Boot 16— 9 0 ° Elbow
(2 used) 10 — S nap Ring (007142- ) 17— 0 -R in g
4— W ash er (2 used) 11 — S pecial W ash er (007142- ) 18— Bail
5— N u t (2 used) 12 — Spring (007142- ) 19— Spring Pin
6— O-Ring 13 — W ash er (003926-007141) 20— V alve Body
7— Plug S pacer (007142- ) 21 — C ap Screw (2 used)
Fig. 8-Saddle Valve (003926- )
REPAIR
REMOVAL
Refer to Fig. 8 during disassembly and assembly
Lower blade to the ground.
of saddle locking valve.
Operate steering valve and brake valve with
Remove plug (7, Fig. 8) and pull plunger assembly
engine o ff to relieve hydraulic system pressure.
from body (20).
Disconnect and cap hoses from lift arm locking
Remove snap ring (14) a n d slide plunger (8) out
valve.
ui jJiuy /~7\
— X . 1 . . .
Remove fastening cap screws and remove valve.

Remove elbow (16) and remove ball (18) and
spring pin (19).
Inspect all parts and replace as necessary.
When assem bling the valve, use new O-rings in

all locations.
Litho in U.S.A.
35-6 Saddle Valve and R etaining Pins TM-1001 (Dec-87)
INSTALLATION Refer to Fig. 9 during disassem bly and assem bly

o f locking pin assem bly.
M ount valve w ith inlet c onnecto r (1, Fig. 8) p o in t
ing tow ard rear o f grader. Fasten w ith cap screws Slide locking pin (6) and piston (4) out of barrel (1).
and connect hose to m ain fram e over brake pedal
arms to prevent any interferences o f hose w ith Remove retaining ring (2) and slide piston (4) o ff
pedal arms. o f locking pin (6).
LOCKING PIN ASSEMBLY Inspect all parts and replace as necessary.
Replace all O-rings.

REMOVAL
NOTE: Insure th a t large cham fer o f p isto n is
H ydra u lica lly retract the locking pin using the
tow ard tapered end o f pin.
valve u n til the pin is retracted. Turn the m otor
grader o ff. Hold the valve in the retracted position
Before installation of pin into housing, coat bore
m om entarily w hile tu rn in g the steering wheel to
o f locking pin w ith John Deere Never-Seez or an
bleed o ff any pressure in the system . Release the
equivalent.
valve; the pin should stay in the retracted position.
Measure the I.D. o f the barrel (1) I.D. o f the lo ck
D isconnect and cap hoses from locking pin
ing pin housing, and O.D. o f the locking pin (6). Use
housing.
the fo llo w in g sp e cification s.
Remove tapped h a lf clam p.
Barrel I.D........................................ 2.998 ± 0.002 in.
Mark the position o f locking pin on the saddle.
H ousing I.D....................................2.005 ± 0.002 in.
A tta ch chain wrench to barrel (1, Fig. 9).
Pin O.D........................................2.0000 ± 0.0015 in.
Revolve barrel and remove snap ring (9).
Note the follow ing when assem bling the locking
pin.
Remove locking pin from unit.
W hen assem bling use new seals and O-rings in
REPAIR
all locations.
Assem ble piston (4) on locking pin (6) w ith large

cham fer tow ard snap ring (9).
1— B a rre l 7— O - R in g
2— R e t a i n i n g R in g 8— B a c k u p R in g
3— P is to n R in g S e a l 9— S n a p R in g
4— P is to n 10— O - R in g (2 u s e d )
5— B a c k u p R i n g (2 u s e d ) 11— L o c k i n g P in H o u s i n g
6— L o c k i n g P in
Fig. 9-Lockin g P in (003926- )
L ith o in U .SA.
TM-1001 (Feb-80) Saddle Valve and Retaining Pins 35-7
INSTALLATION
Install locking pin on the saddle.
Install snap ring (9, Fig. 9).
Using chain wrench, revolve barrel (1) to marked
position.
Connect hoses.
After assembly, check saddle to saddle pivot clear
ance (Fig. 5) and readjust if required.
Install half clamp around barrel (1, Fig. 9).
Refer to Figs. 10 and 11. 1— Tapped Half Clamp 4— Port Weld
2— Locking Pin Barrel 5— Port
3— Main Frame Relief Hole 6— Half Clamp
7—Cap Screw
Fig. 11-Location of Locking Pin Clamps
N O T E : A fte r 1 0 0 h o u rs o f s e rv ic e , tig h te n lo c k in g
p in c la m p c a p s c re w s a g a in .
Tighten cap screws to 35 Ib-ft.
1 4 7 1 9 S i!
1— Tapped Half Clamp 5— Locking Pin

2— Small Clamp Gap, Barrel
0.12 in. min. 6— 3/8" x 3"
to 0.20 in. max. Cap Screw
3— Half Clamp 7— Port
4— 3/8" x 2-1/2" 8— Port Weld
Cap Screw 9— Large Gap Centered
Fig. 10-Location of Locking Pin Clamp
Litho in U.S.A.
70 Hydraulic System Grader, Motor - JD 570
35-8 Saddle Valve and Retaining Pins TM-1001 (F eb-80)
Litho in U.S.A.
TM-1001 (Dec-87) S pecifications and S pecial Tools 40-1
v < ■V U | ^ -Ar vt \/
Q P F r i F i r A T I O M Q AMD Q P F r i A l TOOI Q
HYDRAULIC SYSTEM
SPECIFICATIONS
Hydraulic System Temperature 65° F to 145° F
Engine Speed...... RPM Fast Idle
Cycle Times
L ift c y lin d e r..... Retract (12 in.) (Early Units) 4.0 - 7.5 sec.
(Early Units) 4.0 - 6.0 sec. w ith o u t o rific e
Retract (12 in.) (Later Units) 3.5 - 4.5 sec. w ith o rific e
Extend (12 in.) 2.5 - 4.5 sec.
D ra w b a r.......................................... Left side s h ift 7.4 - 10.5 sec.
Right side sh ift 5.5 - 8.5 sec.
W h e e l.............................................. Left or right lean 2.0 - 3.7 sec.
Rear steering (with d ifferential
unlocked )................................... Left or right 3.0 - 7.0 sec. fa s t idle
M o ld b o a rd ..................................... Left side s h ift 7.5 - 10.2 sec.
Right side sh ift 5.5 - 8.0 sec.
C irc le ............................................... Left or right rotation (360°) 36.0 - 52.0 sec.
B lad e ............................................... Forward or backward pitch 1.0 - 2.0 sec.
S c a rifie r.......................................... Retract (Early Units) 6.5 - 9.7 sec.
(Later Units) 2.5 - 4.0 sec. w ith o rific e
Extend (Early Units) 4.0 - 8.0 sec.
(Later Units) 3.0 - 5.0 sec. w ith o rific e
Drift check (blade raised 6 in. and
engine at slow id le )................. Movement up or down 1/16-in. m ax. in 15 m in.
Drift check (blade raised 6 in. and
engine o ff)................................. Movement down 1/16-in. m ax. in 5 m in.
Transm ission p u m p ..................... Flow (with gate valve) 3 gal. per 15 sec. a t 50 psi (1900
en g in e rpm)
Flow (with flow meter) 10 gpm at 70 psi (1900 en gin e
S.N. ( -1699) rpm
Flow (with flow meter) 11 gpm a t 175 psi (1900 en gin e
S.N. (1700- ) rpm
Main H ydraulic Pump Displacem ent 3.01 cu. in. per re vo lu tio n
Standby pressure 2300 to 2400 psi a t 2375 rpm
M inim um flow 29.5 gpm at 250 psi (2375 rpm )
21.6 gpm at 2000 psi (2375 rpm )
70% e ffic ie n c y o r g rea ter
Saddle Pins Locked to Retract 7 ± 3 sec.
(Both)
Retracted to Lock 7 ± 3 sec.
Litho in U.S.A.
40-2 Specifications and Special Tools TM-1001 (Nov-78)
HYDRAULIC SYSTEM
SPECIFICATIONS—Continued
Pressure Control V alve.......................... Pressure during circle

rotation 1600 to 1900 psi at 900 rpm
Pressure change with one
shim 35 to 40 psi
Differential Control V a lv e ...................... Pressure (JD570) 420 to 480 psi at 2300 rpm
Pressure (JD570-A) 635 ± 25 psi at 2450 rpm
SPECIAL TOOLS
No. Name
Convenience Tools
OTC Nuday
Transmission Pump Test
Y3001 D -9 6 ................................................................................................. Adapter
Y21-10 D-91 ..................................................................................................Hose (2 used)
Y-90 ND-1575 .........................................................................................Hydraulic Tester
Main Hydraulic Pump Test
Y3013 D -9 2 .............. Tee
Y3023 D -1 0 3 .............. Connector
Y3017 Connector
Y21-10 D-91 ............... Hose (3 used)
Y3018 (2 used) D-96 (3 used) Adapter
Y3020 D-94 ............... Plug
Y3019 D-93 ................ Cap
Y90 N D -1 5 7 5 .... Hydraulic Tester
JD-293 .................................................................................................................................Transm ission Pump Tool Kit
Litho in U.S.A.
HYDRAULIC SYSTEM, ANALYZER

SPECIFICATIONS
System Test
Tachom eter/Tem perature Reader thumb dial s e ttin g ......................................................................................................030
HYDRAULIC OIL TEMPERATURE: 14 0 to 1 5 0 ° F (60 to 66°C)

O R I F I C E US E D : Part No. 2 0 3 6 6 3 , 0. 1 5 6 in. (3.96 m m) i n s t a l l e d in b l a d e r o t a t i o n c i r c u i t .
M A I N PUMP O U T L E T P R E S S U R E M A I N PUMP I N L E T P R E S S U R E TRANS. PUMP OUTLET

ENGINE
RPM
IN S T R O K E STANDBY IN S T R O K E STANDBY STANDBY
550 psi min. 2 2 0 0 to 2 3 0 0 psi 5 to 25 psi 10 to 30 psi 1 55 to 175 psi

1000 (38 bar m i n .) (152 to 15 9 bar) (0.34 to 1.7 bar) (0.68 to 2 .1 bar) (11 to 12 bar)
2 3 0 0 to 2 4 0 0 psi 25 to 50 psi 7 0 to 1 10 psi

165 to 185 psi
2200 (159 to 165 bar) (1.7 to 3 .4 bar) (4.8 to 7.5 bar) (11 to 1 2 . 8 bar)
2000 psi
2150
(138 bar) HIGH PRESSURE CIRCUIT TEST
MA X
T69764
Fig. 1-JD570-A (001700- ) Test Specifications
Function Leakage Test

Hydraulic oil tem perature..................................................................................................................................... 140 to 150°F
(60 to 66°C)
Orifice used (installed in blade rotation circuit)..........................................................., ....................... Part No. 203663
0.156 in. (3.96 mm)
Function leakage
The rpm difference between pump in stroke at 2000 psi (138 bar)
and pump in stroke with differential lock valve engaged at
2000 psi (138 bar) must be no more th a n ........................................................................................................... 40 rpm
Differential lock leakage
The rpm difference between pump in stroke at 2000 psi (138 bar)
and pump in stroke with a function bottomed at
2000 psi (138 bar) m ust be no more th a n ........................................................................................................... 75 rpm
Litho in U.S.A.
40-4 S p e cifica tio n s and S pecial Tools TM-1001 (Dec-87)
HYDRAULIC SYSTEM, ANALYZER (Continued)

SPECIFICATIONS(Continued)
CYCLE
MOTOR GRADER TIME CHE C K BALL ORIFICE
LOCKOUTS
FUNCTIONS (L I F T C H E C K PLATES
SECONDS*
B l a d e Lift
E x t e n d 12 in. (305 m m ) 2 . 5 to 4 . 5 YES No. 351 - 0 . 0 9 3 5 in. (2.37 mm) YES
R e t r a c t 12 in. (305 m m ) 4 . 0 to 6 . 0 YES NONE (001861 - 002226) YES
R e t r a c t 12 in. (305 mm) 3 . 5 to 4.5 YES No. 3 4 0 - 0 . 0 6 2 5 in. (1 . 5 9 mm) YES
Circle Side Shift

Extend 7 . 4 to 1 0 . 5 YES No. 3 4 6 - 0 . 0 7 8 5 in. (1 . 9 9 mm) YES
Retract 5.5 to 8 . 5 YES No. 3 4 0 - 0 . 0 6 2 5 in. (1 . 5 9 mm) YES
Blade Side Shift

Left side shift 7 . 5 to 1 0 . 2 YES NONE YES
Right side shift 5 . 5 to 8 . 0 YES NONE YES
Blade Tilt
Extend 1 . 0 to 2 . 0 YES NONE YES
Retract 1 . 0 to 2 . 0 YES NONE YES
Blade Rotation
Clockwise 36 to 52 NONE NONE NONE
Counterclockwise 36 to 52 NONE NONE NONE
Wheel Lean
Extend 2 . 0 to 3.7 YES No. 346 - 0.0785 in. (2.37 mm) YES
Retract 2 . 0 to 3.7 YES No. 340 - 0.0625 in. (1.59 mm) YES
R e a r St e e r
L e f t or r i g h t 3 . 0 to 7 . 0 YES NONE YES
Front Mount Equipment

Extend ( -002225) 4.0 to 8.0 YES NONE YES
Extend (002227- ) 3.0 to 5.0 YES NONE YES
Retract ( -002226) 6.5 to 9.7 YES NONE YES
Retract (002227- ) 2.5 to 4.0 YES No. 3 6 7 - 0 . 1 4 0 5 in. (3.56 mm) YES
Drift Specification 0 . 0 6 in. (1.5 m m ) m a x i m u m in 15 m i n u t e s w i t h e n g i n e a t l o w

i u i e u r eiiuine u t t , m u i a u o a r a o i r i mm; aDOve grouna
a n d all o t h e r c y l i n d e r s a p p r o x i m a t e l y m i d - s t r o k e .
*NOTE: Cycle times are with transmission oil temperature at

6 5 to 1 4 5 ° F (18 to 63°C) a n d engine at 2 4 7 5 ± 2 5 rpm.
T62462N
N O T E : C y c le tim e s g iv e n a r e to b e u s e d o n ly a s g u id e lin e s . T h e re fo re , w h e n a u n it d o e s n o t p e rfo rm a c c o rd in g

to th e c y c le tim e s g iv e n , th e m e c h a n ic m u s t d e c id e if th e d iffe re n c e is g r e a t e n o u g h to in d ic a te a m a lfu n c tio n o f
s o m e c o m p o n e n t in th e s y s te m .
Fig. 2-JD 570-A (0 01700- j Motor Grader Functions Test

Specifications
Litho in U.S.A.
HYDRAULIC SYSTEM, ANALYZER (Continued)

SPECIFICATIONS (Continued)

Hydraulic oil temperature
Warm hydraulic oil t o ............................................................................................................................................150°F (66°C)
Orifice used, installed to transmission pump tool k it............................................................................ Part No. 203665
0.187 in. (4.75 mm)
With transmission filter relief valve blocked, transmission
pump pressure at 175 ± 10 psi (12 ± 0.68 bar) and oil temperature at 120°F (49°C) minimum,
engine speed must not e x c e e d ...................................................................................................................................2050 rpm
NOTE: Remaining specifications for pressure test using Hydraulic Analyzer hookups will be the same as those
listed under HYDRAULIC SYSTEM.
HYDRAULIC SYSTEM, ANALYZER

SPECIAL TOOLS
Convenience Tools
Tool Tool Number Use
D-01080AA Master Hydraulic System Analyzer

- Used when testing hydraulic sys
tem.
D-01084AA Tachom eter/Tem perature Reader
- Used to measure engine rpm and
oil temperature.
D-01088AA Construction Equipment Accessory
Kit - Fittings used to make hydraulic
connections.
T465U3
1— Master Hydraulic System Analyzer

2—Tachometer/Temperature Reader
Fig. 3-Hydraulic System Analyzer
JD -293 Transmission Pump Tool Kit - This

tool kit is used to isolate transm is
sion pump flow for transm ission
pump test.
Fig. 4-Transmission Pump Filter Kit
Litho in U.S.A.
PRESSURE CONTROL VALVE

V alve.................................... 0.7497 to 0.7503 in.

O.D. (rear) 0.7257 to 0.7263 in.
O.D. (center) 0.7040 to 0.8140 in.
Valve b o r e ......................... 0.7508 to 0.7518 in.
I.D. (rear) 0.7268 to 0.7278 in.
Valve sp rin g ...................... 4 -5 /8 in.
Test strength 50 lbs. at 1-3/4 in.
ACCUMULATOR
Dry nitrogen........................ 475 to 525 psi

Cylinder.............................. ..................... I.D. 2.9980 to 3.0010 in.
Piston ................................... ................... O.D. 2.9930 to 2.9960 in.
C ap............................................................ O.D. 2.9940 to 2.9980 in.
Removable end................... ..................... O.D. 2.9940 to 2.9980 in.
S P E C IA L TOOLS
No. Name Use
Essential Tools
D-15041NU Nitrogen Accumulator To charge the accumulator
Charging Kit
CAUTION: For safety reasons, pressure

regulator valve and gauge must be or
dered from your local nitrogen gas suppli
er.
OIL FILTER
Item Measurement Sp e c ific a tio n
Relief v a lv e ........... ........................ 50 psi (differential)

Valve spring.................................... 2 -3/4 in.
Test strength 30 lbs. at 1-13/16 i:
Surge pressure relief valve. . . . 100 psi
Valve spring.................................... 3 -3/4 in.
Test strength 37 lbs. at 3-1/4 in.
Item Torque (Ib-ft)
Filter relief valve plugs 70
Litho in U.S.A.
MAIN HYDRAULIC PUMP
SPECIFICATIONS
Item Dimension New P art Tolerance
Cam, pump shaft . ............................................................ 0. D. 1.9632 to 1.9638 in.

Housing, pump:
Bearing b o r e s .............................................................. 1. D. 3.3755 to 3.3765 in.
Discharge valve bore................................................... I.D. 0.6245 to 0.6255 in.
Finished face to bottom of inlet valve bore . . . . Depth 3.851 to 3.861 in.
Finished face to bottom of discharge valve b o re. Depth 1.214 to 1.222 in.
Inlet valve b o r e ............................................................ I.D. 0.9995 to 1.0005 in.
Piston b o r e .................................................................... I.D. 0.8747 to 0.8753 in.
Pump shaft oil seal b o r e .......................................... I.D. 1.999 to 2.001 in.
Pump shaft O-ring b o r e ............................................. I.D. 1.385 to 1.396 in.
Housing, stroke control valve:
Crankcase outlet valve b o r e ..................................... I.D. 0.7485 to 0.7495 in.
Stroke control valve b o r e ........................................... I.D. 0.7485 to 0.7495 in.
Race, cam :.................................................................... . . I.D. 2.3400 to 2.3406 in.
0 . D. 2.870 to 2.880 in.
Shim, adjusting, stroke control valve housing . . . . Thickness 0.006 to 0.010 in.
Sleeve, crankcase outlet valve:
Lower end..................................... .. .............................. 1. D. 0.4684 to 0.4690 in.
Upper e n d ............................ ......................................... I.D. 0.4374 to 0.4380 in.
O.D. 0.7481 to 0.7485 in.
Sleeve, stroke control valve:
L a r g e ................................................ I.D. 0.418 to 0.422 in.
Small................................................... I.D. 0.2667 to 0.2673 in.
O.D. 0.7481 to 0.7485 in.
Springs, piston (early units) . . . . Test strength 1 -3 /8 -in . with 34.2 to 40.2 lbs.
(force required by each of the
eight springs must not vary
more than 0.2 lbs.)
(later units -
color coded). . . . Test strength 1 -5 /8 -in . with at least 33 lbs.
(force required by each of the
eight springs must not vary
more than 1.5 lbs.)
Valve, crankcase outlet:
Lower e n d ........................................ O.D. 0.4678 to 0.4682 in.
Upper end............................ .............. O.D. 0.4368 to 0.4372 in.
Valve, in let:........................................ O.D. 1.001 to 1.002 in.
Lift 0.060 to 0.082 in.
Valve, stroke control....................... O.D. 0.2661 to 0.2665 in.
Pump shaft. . ..................................... End play 0.001 to 0.003 in.
Litho in U .S.A .
MAIN HYDRAULIC PUMP (Continued)

SPECIFICATIONS (Continued)
TORQUE VALUES
Pump drive coupler screw s (units with lock w i r e ) .......................................................................... 25

(units with lock n u t s ) .......................................................................... 30
Pump drive coupler lock n u ts................................................................................................................. 30
Cap screw s, pump-to-support................................................................................................................. 85
Cap screw s, spline s h a ft......................................................................................................................... 30
Cap screw s, stroke control valve to pump.......................................................................................... 85
Drive screw s, pulley.................................................................................................................................. 85
Drive screw s, pump drive s h a f t ........................................................................................................... 35
Piston plugs in pump housing................................................................................................................. 100
SPECIAL TOOLS
No. Name Use
Essential Tools
JDH-18 Driver To install oil seal

JDH-19B Crankcase outlet valve adjusting tool To adjust crankcase outlet valve pressure
JDH-19
JDH-40 Seat Puller To remove outlet valve seats from pump hous
ing.
JDH-39A Seat Driver To install outlet valve seats to the correct
depth in pump housing.
Convenience Tool
r r i T T r>i
dLJn-4± Pump parts tray r I 'n
X KJ X .V J U C C li J .1
v w iw + r >
p d l VS
» i •*»* « r v
U U llU g V A X O C tO O C ilJ l
*Make in dealer shop (see Group 15, Fig. 9)
Litho in U.S.A.
FUNCTION CONTROL VALVE

SPECIFICATIONS
Item Measurement New P art T o leran ce
Restrictor, piston end, of lift cylinders............................ ............. I.D. 0.0935
Restrictor, rod end of lift cylin d ers................................ ............. I.D. 0.0625
Restrictor, piston end of wheel lean cylinder................ ............. I.D. 0.0785
Restrictor, rod end of wheel lean cylinder..................... ............. I.D. 0.0625
Restrictor, piston end of circle side-shift cylinder......... ............. I.D. 0.0785
Restrictor, rod end of circle side-shift cylinder.............. ............. I.D. 0.0625
Restrictor, rod end of scarifier cylinder (2227- ). . . ............. I.D. 0.1405
TORQUE VALU ES
Item T o rq u e (Ib -ft)
Tie bolts, 3 /8 ” x 16” UNC (4 u s e d ) ............................. 20-25

Detent, valve (with sc re w d r iv e r )................................... 5-8 with Loctite
Screw, s p o o l ........................................................................ 5-8 with Loctite
SPECIAL TOOLS
No. Name Use
Convenience Tool
JDH-6 O-ring seal hook To remove and install O-rings in small
bore in valve.
HYDRAULIC CYLINDER
TORQUE VALUES
Cylinder Piston Rod Nut (Ib-ft) Spanner Nut (Ib-ft)
Blade Lift . . . . . . . 250-350. . . . 125-175

Blade Tilt . . . . . . . 250-350. . . . 150-175
Blade Side-Shift . . . 250-350. . . . 125-175
Circle Side-Shift . . . 250-350. . . . 500-700
Front Steering . . . . 150-210. . . . 150-210
Rear Steering. . . . . 250-350. . . . 125-175
S carifier........... . . . 500-600. . . . 150-175
L itho in U .S.A .
CIRCLE DRIVE HYDRAULIC MOTOR
SPECIFICATIONS
Wear
Item Measurement New P a rt Tolerance
Shaft, output............................................. O.D. 1.000 inch
TORQUE VALUES
Item Torque (in -lb s )
Mounting Plate Cap S crew s................................................................. 225-275

End Plate Cap Screws................... ......................................................... 150-180
SADDLE VALVE
SPECIFICATIONS
Saddle pin guide b o r e ......................... .............. I.D. 2.9960 to 2.9980 in.

Saddle pin guide.................................... .............. O.D. 2.9930 to 2.9950 in.
Saddle pin housing.............................. 2.0030 to 2.0070 in.
Saddle pin.............................................. .............. O.D. 1.9785 to 2.0015 in.
Saddle pin guide to sa d d le................ 30 tons
Saddle to saddle pivot......................... 0.020 to 0.090 in.
Litho in U .S.A .
70 Hydraulic System Grader, Motor - JD 570
40-12 Specifications and Special Tools TM-1001 (N ov-78)
Litho in U.S.A.
Grader, M o to r - JD570 M iscellaneous 80
TM-1001 (Dec-87) Circle Drive Gearbox 5-1
Qo
W Wrtin
t I V In■ w
AO
M IQ C F I I A M F D I I Q
Page Page
GROUP 5 - CIRCLE DRIVEGEARBOX 5-1 GROUP 15 - SADDLE, MAIN FRAME,
FRONT AXLE, SCARIFIER
GROUP 10 - DRAWBAR, CIRCLE, AND AND ENGINE
MOLDBOARD FRAME— Continued
D raw bar.............................................................. 10-1 Front A x le .......................................................... 15-4
Moldboard C ircle...............................................10-2 S c a rifie r.............................................................. 15-5
Circle A d ju s tm e n t.................... ....................... 10-2 B u lld o ze r............................................................ 15-7
Moldboard Extension In s ta lla tio n .................. 10-3 Rear Frame and Main Fram e...........................15-8
M o ld b o a rd .......................................................... 10-4
GROUP 20 - SPECIFICATIONS AND
GROUP 15 - SADDLE, MAIN FRAME, SPECIAL TOOLS
FRONT AXLE, SCARIFIER, C ircle Drive G e a rb o x....................................... 20-1
AND ENGINE FRAME Drawbar, M oldboard Circle and Mold-
S addle................................................................. 15-1 board............................................................... 20-1
Main Fram e........................................................ 15-3 Saddle, Main Frame, Front Axle and
S c a rifie r.......................................................... 20-1
CIRCLE DRIVE GEARBOX

Machines ( -003939):
1. Disconnect the hydraulic lines from the motor
(see Fig. 1).
Put caps or plugs on the lines and in the motor.
2. Remove the circle drive pinion (36, Fig. 2).
the draft frame.
motor assembly (Fig. 1) and lift it from the ma-
Machines (003940- ):
1. Disconnect the hydraulic lines from the motor
(see Fig. 1).
Fig. 1-Circle Drive Gearbox and Motor
Put caps or plugs on the lines and in the motor.
2. Put a wood block below the pinion on the drive
The circle drive gearbox (Fig. 1) transmits power shaft (16, Fig. 2).
from hydraulic motor through the worm gear to rotate
the circle.
The worm gear allows the blade to stay in a station
ary position while under load.
NOTE: It is not necessary to remove the gearbox
(11, Fig. 2) from the machine for disassembly, repair,
and adjustment of gearbox components.
Litho in U.S.A.
80 M iscellaneous Grader, M o to r - JD570
5-2 Circle Drive G earbox TM-1001 (Dec-87)
T6680AX
Fig. 2 -C irc le Drive G ea rb o x A s s e m b ly
L ith o in U.S.A.
TM-1001 (Dec-87) C ircle Drive Gearbox 5-3
1— C ap S crew and Lock W a s h e r (6 used) 1 5 — F e lt W ash er 27— C ap S crew (4 used)

2— B reath er V e n t 1 6 — Drive S h a ft (003940- ) 2 8 — G a s k e t (007213- )
3— G earb ox Cover 17— B ushing (2 used) 29— C o u p le r
4— G as ket 18— Bronze W a s h e r (2 used) 30— H yd rau lic M o to r
5— C ap S crew (3 used) (003940- ) ( 002210- ) 31— B olt Lock (3 used)
6— R eta in e r 19— S tee l W a s h e r (4 used) ( -002209)
7— S p ac er W a s h e r (use as required) ( -002209) 3 2 — W orm G ea r ( -002209)
8 — W orm G e a r (003940- ) (2 used) (002210- ) 3 3 — Pin (2 used) ( -002209)
9 A — Expansion Plug (E arly U nits) 20— W orm D ow el (6 used)
9 B — T h readed Plug (L a te r U nits) 21— O il S eal ( -007212) (002210-003939)
10— Pipe Plug (2 used) 22— G asket 3 4 — Drive S h a ft ( -002209)
11— G earb ox ( -003939) 23— M o to r A d a p te r ( -007212) 35— Drive S h a ft (002210-003939)
G earb ox (003940-010464) M o to r A d a p te r (007213- ) 36— C ircle Drive Pinion (
G earb ox (010465- ) 24— C ap S crew (4 used) 003939)
12— Dowel Pin 2 5 — W a s h e r (3 used) (003940- ) 37— W asher ( -003939)
13— O-Ring 26— W ash er (4 used) 3 8 — C o tte r Pin ( -003939)
14— W ash er 39— Nut ( -003939)
40— O -R ing (L ate r U nits)
Fig. 2-C ircle D rive G ea rb o x A ss e m b ly
3. Remove the gearbox cover (3, ig. 2).

REPAIR
4. Remove the cap screw s (5), retainer (6), and
spacer w ashers (7). Note the num ber o f spacer Refer to Fig. 2 fo r assem bly and disassem bly of
washers (7) fo r reassem bly. the c *rcle drive gearbox.
5. Remove the drive sh a ft (16) from the bottom of NOTE: In s ta ll the p in io n (36) o r drive s h a ft (16)
the gearbox assembly. and cover (3) a fte r the gearbox is in s ta lle d on the
m achine.
6. Remove cap screws holding the gearbox (11) to
the dra ft frame. Inspect the bushings (17), worm (20), and coupler
(29) fo r wear. Inspect the gaskets (4,22, and 28) and
7. A tta ch a h o ist to the circle drive gearbox and w ashers (14 and 15) fo r any damage or wear;
m otor assem bly (see Fig. 1) and lift it from the replace parts if necessary.
machine.
Inspect the drive shaft (34,35, or 16) and the bore
in the gearbox housing. Some scoring on the shaft
and bore below the O-ring (13) is normal; if there
is any scoring on the shaft or in the bore above the
O-ring, remove the scoring using emery clo th or
replace parts.
Put a pipe sealant (Permatex #1, L octite PS/T, or

an equivalent) on the threads o f the pipe plugs (10)
before installation .
Install a steel w asher (19) on each end o f the

worm shaft against the shoulder portion o f the
worm. Install a bronze washer (18) on each end o f
the worm (20) between the steel w asher and the
gearbox (11) and the m otor adapter (23). If neces
sary, add addition al steel washers (19) to take up
end play of the worm.
L it ho in U.S.A.
5-4 C ircle Drive Gearbox TM-1001 (Dec-87)
Put clean oil on the O-ring (13). Install O-ring (13) Machines (003940- )
into O-ring groove in the bore o f the circle drive
gearbox. 3. Install the drive shaft (16) from under the dra ft
fram e into the gearbox assembly. Install the
NOTE: I f you have a circle drive gearbox with two worm gear (8), spacer washer(s) (7), retainer (6),
O-ring grooves, it is n o t necessary to in s ta ll two and cap screws (5) with washers. Tighten the cap
O-rings. In s ta ll one O-ring in the upper groove. screws (5) to standard torque.
Early Units: Check the end play of the shaft (16). The end play
m ust be 0.005 to 0.040 inch (0.13 to 1.01 mm). If
Clean surfaces of expansion plug (9) counterbore necessary, add or remove spacer washers (7) to get
in gearbox w ith solvent. A pply silico n e rubber to the correct end play.
lip o f counterbore shoulder, m aking a 0.12 in. (3
mm) fille t around bore. Tap in plug (9). 4. Install the gearbox cover (3).
Later Units: 5. Connect the hydraulic lines to the motor.
Install new O-ring (40) and threaded plug (9B). 6. Fill the circle drive gearbox w ith the correct type
of oil (see Section 10, Group 20) before operation.
INSTALLATION
1. If the gearbox (11) is removed, reinstall it on the

machine.
Machines ( -003939)
2. Install the drive shaft (34 or 35) and pinion (36);

tighten nut (39) until all end play in shaft and gear
assem bly is taken up. Back o ff nut to firs t slo t
and install co tte r pin (38).
L itho in U S A .
Grader, Motor - JD 570 M iscellaneous 80
TM-1001 (Nov-78) D ra w b a r, C irc le And M oldboard 10-1
Group 10
DRAWBAR, CIRCLE, AND MOLDBOARD
GENERAL INFORMATION
The drawbar is used to pull and control the The circle, used to rotate the blade 360 de
blade. It is fastened to the front of the main grees, is part of the blade assembly. The circle
frame by a universal type swivel. The drawbar is carried by the drawbar and held in place by
is supported at the rear by the blade lift four wear supports. The front supports require
cylinders. clearance adjustment, while the rear supports
are adjusted for both clearance and gear teeth
wear.
REPAIR
1 - R etaining R ing (2 used) 9 — Washer 17 - C irc le Support (4 used) 25 — Cop Screw (2 used)
2 - R etaining Pin 10 - F e lt Washer 18 — Shim (.0 60 in .) 26 — R otary M a nifold
3 — P iv o t C o lla r 11 — Pinion 19 — Shim (.036 in .) 27 — Lo ck Washer (2 used)
4 - P iv o t Washer (2 used) 12 - Washer 20 - F la t Washer (8 used) 28 — Hex. N ut (2 used)
5 — Bushing (2 used) 13 — C otte r P in 21 — Lock Washer (8 used) 29 — Cap Screw (2 used)
6 - Y oke 14 — Hex. N ut (8 used) 22 — Hex. N ut (8 used) 30 - Spacer (2 used)
7 — Grease F ittin g 15 - Cap Screw (4 used) 23 - Hex. N ut (4 used) 31 — Hose S hield
8 — Frame 15 — Cap Screw (8 used) 24 — Cap Screw (4 used) 32 — Wear P late (4 used)
F ig . 1- D r a w b a r
Litho in U .S .A .
80 Miscellaneous Grader, M otor - JD570
10-2 Dra wbar, Circle and M oldboard TM-1001 (Dec-87)
Check reta in in g ring (D, Fig. 1A) for p ro p er

seating. On units Serial No. ( -008763) retaining
ring may not seat in retaining pin groove. If nec
essary, grind pivot collar to provide clearance for
proper seating of retaining pin.
T6680A Q
A — Grind R elief Here C — Pivot C ollar

B— Retaining Ring D — Retaining Ring
Fig. 1A-Drawbar Pivot C ollar
Litho in U.S.A.
TM-1001 (Dec-87) Drawbar, Circle and M oldboard 10-3
1— C o tte r Pin (2 used) 4— Pivot Rod 8— C ap S crew (2 used) 12— C ircle

2— H ex N u t (2 used) 5— T ilt Rod (2 used) 9— C ap S crew (2 used) 13— Pin (2 used)
3— F iat W ash er (2 used) 6— T u be (2 used) 10— Lock W ash er (2 used) 14— C ap S crew (2 used)
7— Pivot Pin (2 used) 11— H ex. N u t (2 used) 15— S pecial W ash er (2 used)
Fig. 3-M o ld b o ard C ircle
Refer to Figs. 1 and 2 for identification of parts and Adjust the circle support shim pack (3, Fig. 7) to
sequence of assembly. obtain 0.020 to 0.080 inch clearance between the cir
cle and each wear plate. Tighten support cap screws
CIRCLE ADJUSTMENT just enough so support is firmly against shim pack.
Check and adjust one support at a time.
The purpose of the circle adjustment is two-fold:
Position the blade under the machine in such a
1. To hold a 0.020 to 0.080 inch clearance between manner that the moldboard can be sideshifted up
the wear plate and the circle. against the front axle.
2. To hold radial clearance to permit the circle rota Loosen all circle support bolts.
tion and to hold a 0.350 inch maximum distance be
tween the circle drive pinion tip and the circle root.
Fig. 5-P o sitionin g W ooden B lock
Place a wooden block (Fig. 5) between the end bit

and the front axle. Force the circle back by side-
Fig. 4-C h ecking C lea ran ce B etw een shifting the moldboard against the wooden block.
C ircle a n d W ear P late s
To adjust circle, position circle and blade assembly

so blade is perpendicular to length of grader and
centerline on the circle (Fig. 4). Raise the blade a
couple of inches from the ground.
L ith o in U.S.A.
10-4 Drawbar; C ircle and M oldboard TM-1001 (Dec-87)
Tighten circle support-to-drawbar cap screws to
670 ft-ibs. and rotate circle 360 degrees in both direc
tions. The 0.350 inch maximum dimension should be
maintained after rotation. If, after initial adjustment,
circle will not rotate a full 360 degrees without stall
ing, loosen the rear circle supports and back them
off slightly.
N O TE : The circle supports w ill polish the tip s o f

the circle gear teeth and m ay in itia lly peel sm all rib
bons o f steel o ff the bottom o f the circle.
MOLDBOARD EXTENSION
1— C ircle Drive 3— INSTALLATION
D istance B etw een P inion 126950
Pinion Tip T ip and C ircle Root
2— C ircle 4— R uler
Use the following procedure when installing mold-
Fig. 6-C h eck in g C ircle Drive P inion board extensions:
Tip-To-C ircle R o o t D istan c e
The circle drive pinion tip-to-circle root distance (3)

should be 0.350 inch maximum.
S irlo o R ift-. m nlrlV inprr) V iarlr n w a v f r n m f h p w n n H e n
block slightly to relieve some pressure from the front
circle support bolts. Tighten bolts snug and recheck
distance between pinion tip and circle root. T2616S T26163
1— M o ldb oard 5— N ut, 3/8-inch (3 used)

2— C ap S crew 6— Plow Bolt, 5/8 x 2-1/2-inch
5/8 x 2-1 /2-inch 7— M oldboard Extension
3— W ash er, 21/32 x 8— Plow B olt, 5/8 x 2-inch
1-1/4” x .250-inch 9— M oldboard S tiffe n e r
4— Lock W ash er, 5/8-inch
Fig. 8-Top M o ld b o ard S tiffe n e r In s ta lla tio n
1. Install a 5/8 x 1/2-inch cap screw (2), flat washer

(3), lock washer (4), and nut (5) on top stiffener as
shown in Fig. 8. Tighten nut (5) to 105 ft-lbs.
N O TE: Cap screw (2) is used to stabilize the

m oldboard extension.
2. Refer to Fig. 10 and install moldboard exten

I2 B 9 S 1
T26951 sions. Install moldboard extensions completely be
1 — D raw bar 4 — C ircle S upport fore tightening the hardware.
2 — A d ju stin g S crew 5 — C ircle
3— S him P ack
N O T E : Top and bottom moldboard stiffeners are
Fig. 7-R ear C ircle S u p p o rt A d ju s tm e n t interchangeable.
Adjust the rear support shoes uniformly until they
both just contact the circle teeth. Tighten each of the
adjusting screws (2) an additional 1/8 turn to snug
the rear supports (4) up against the circle teeth.
L ltho in U.S.A.
TM-1001 (Dec-87) Drawbar, C ircle and M oldboard 10-5
1— End B it (2 used) 8— M o ldb oard 15— C a p S crew (2 used) 20— B lad e S h ift R eta in e r
2— C u ttin g E dge (2 used) 9— Lock W a s h e r (25 used)16— S p a c e r (2 used) 21— C ap S crew
3— P low Bolt (24 used) 10— N u t (25 used) 17— S to p B racket (M a n u a l sid e 22— Lock W ash er
4— C a p S crew (12 used) 11— Pin s h ift - JD 570 only) 23— Nut
5— 12—
B lad e S h ift R eta in e rs (4 used) B racket 1 8 — M a n u a l Side S h ift (JD 570 24— L o ck W a s h e r (14 used)
6— S him 13— Spring Pin O nly) 25— W a s h e r (2 used)
7— S him 14— T ilt Pivot 19— C a p S crew
Fig. 9-M o ld b o ard a n d C u ttin g E dge
3. Install top stiffeners (2) in the second set of holes

from the top using only two holes to attach stiffeners
to moldboard and moldboard extensions.
N O T E : I f the top s tiffener is assembled in the top

set o f holes o r in an upside-down position, the s tif
fener w ill h it the blade p itc h cylinder when side s h ift
in g the blade, causing damage to the cylinder.
4. Install the bottom stiffeners (5) using all the

holes to attach stiffeners to moldboard and mold-
board extensions.
5. Spread stiffeners apart on the moldboard end of

the stiffeners to obtain clearance between the stif
feners and blade retainers. Tighten all hardware to
Fig. 10 -M o ldb oard E xte n sio n A s s e m b le d
170 ft-lbs.
1— C ap Screw 4— P low B olt, 5/8 x 2-inch
5/8 x 2-1/2-in c h N u ts (5 used) 6. After the moldboard extensions have been as
2— T o p S tiffe n e r 5— B ottom S tiffe n e r
3— P low B olts, 5/8 x 6— M o ld b o ard E xtensio n sembled, carefully side shift the blade and check to
2-1/2-inch, N u t (4 used) make sure stiffeners clear blade shift retainers.
L ith o in U.S.A.
80 M iscellaneous Grader, M otor - JD570
10-6 Drawbar, C ircle and M oldboard_________________________________________ TM-1001 (Dec-87)
Litho in U.S.A.
Grader, Motor - JD 570 M is c e lla n e o u s 80
TM -1001 (Nov-78) Saddle, M ain fr a m e , F ron t A xle and S c a r ifie r 15-1
Group 15
SADDLE, MAIN FRAME, FRONT AXLE AND SCARIFIER
GENERAL INFORMATION
4 - L ift C ylinder Yoke (2 used) 16 — Saddle Retaining Pin (2 used) 27 - Cap Screw (2 used)
5 — Boom P ivo t Washer (4 used) 17 — 0-Ring (2 used) 28 — Lock Washer (10 used)
6 — Bushing (4 used) 18 - Backup Washer (2 used) 29 - Nut (2 used)
7 — Lock N ut (2 used) 19 — Piston (2 used) 30 - Bushing (4 used)
8 — Boom P ivot C ollar (2 used) 20 - Snap Ring (2 used) 31 - Cop Screw (9 used)
9 - Cap Screw (2 used) 21 — Return Pin (2 used) Lock Washer (9 used)
10 - Saddle 22 - Snap Ring (4 used) 32 - Keeper (3 used)
11 — Backup Washer (4 used) 23 — Pin (2 used) 33 — Shims (as required)
12 - 0-R ing (4 used) 34 - Plug (2 used) (L.H.
saddle pin)
Fig. 1-Saddle ( -3925)
L itho in U .S.A .
15-2 Saddle, M ain Frame TM-1001 (Dec-87)
dee
T6680AR
TM-1001 (Dec-87) Saddle, M ain Frame 15-2A
A — S trap (3 used) F — B ack-U p Ring (4 used) K — R ing (2 used) 0 — C lam p (2 used)

B — S trap (As R equired) G — O -R ing (4 used) L— P isto n (2 used) P— S n ap Ring (2 used)
C — S add le H — Back-U p Ring (2 used) M — S n a p Ring (2 used) Q — Pivot
D — Pad (W eld ed on sa d d le ear I— O -R ing (2 used) N — C y lin d e r Barrel R — H ousing
fo r use w ith 3.64 in. J — Pin (2 used) S — Pivot Ball
[92 m m ] pivot ball) (4.65 in. [118 m m] used
E — Pivot Ball (used w ith key D) w ith o u t pad [key D])
T — A sse m b le w ith c h a m fe r on
th is side
Fig. 2-Saddle (Serial No. 3926- )
REPAIR When assem bling saddle pivot (26, Fig. 1 or 4,

Fig. 2) to saddle (10, Fig. 1 or 6, Fig. 2) use as many
Refer to Fig. 1 or 2 fo r id e n tifica tio n of parts and
shim s (33, Fig. 1 or 17, Fig.2) as required to obtain
sequence fo r disassem bly and assembly. Also note
0.020 to 0.090 inch clearance between saddle pivot
the fo llo w in g sp e cific in stru ctio n .
and saddle.
Coat saddle retaining pin (16, Fig. 1 or 11, Fig.
2) w ith J13E3 non-seizing grease before installation.
L ith o in U.S.A.
15-2B Saddle, M ain Fram e TM-1001 (Dec-87)
L itho in U.S.A.
Grader, Motor - JD570 Miscellaneous 80
3 6 ___<3 >— 10
9 ----- 1 * — 20
1— G rom m et 12— Pin 23— C ap S crew (2 used) 3 4 — W a s h e r (4 used)
2— G rease F ittin g 13— B ushing (2 used) 24— Lock P late 35— N u t (2 used)
3— Pin 14— Pin 25— Lock P late 36— Lo ck W a s h e r (7 used)
4— C ap S crew 15— C over C lam p P late (2 used)
26— Low er Pivot Pin 37— C ap S crew
5— Lock N u t 16— C over P late (2 used) 27— Spacer 38— S him (as required)
6— M a in F ram e 17— Lock W ash er (2 used) 28— 39—
Pivot Pin W a s h e r (2 used) S him (as required)
7— Cover P late 18— S pring Pin (2 used) 29— C a p S crew (0.04 in.)
8— C ap S crew (4 used)1 9 — Pin (2 used) 30— G reas e Fittin g 40— S him (as required)
9— C ap S crew (6 used)2 0 — G rease F ittin g (3 used) 31— G reas e F ittin g E xtensio n (0.10 in.)
10— Pin R eta in e r (2 used)
21— B ushing (2 used) 32— C a p S crew (2 used)
11— Shim (2 used) 22— B ushing (2 used) 33— Lock W a s h e r (6 used)
Fig. 3-Main Frame
Refer to Fig. 3 fo r id e n tific a tio n o f parts and se

quence fo r disassem bly and assembly.
Assem ble lower engine fram e to main fram e pin

(A), and spacers (B, C, and D). Rap top of pin using
a hammer, u n til it is seated. A d ju st shim pack, as
necessary, until there is 0.010-0.040 in. clearance
between low er spacer and retainer.
Tighten cap screws (23) to 100 ft-lbs. Loosen cap

screws one-half turn and bend ears on lock plates
(24) to lock cap screw (Fig. 4).
Attach saddle to main frame. W ith the grader s it

tin g on a fla t surface, saddle m ust be parallel to
ground w ith in .75 inches measured at the center
lines o f the lift cylin d e r m ounting holes.
A — Lo w er Pivot Pin F — R eta in e r
If necessary, ad ju st by in sta llin g shim (38) be B — S p ac er G — C a p S crew (2 used)
tween saddle and m ounting plate o f main frame. C — E ngine F ram e H — S him Pack
D — S p ac er I — 0.010-0.040 in. C lea ran ce
Use a m axim um of three shim s w ith existing hard E— Spacer
ware to insure adequate thread engagement. Fig. 4-Lower Pivot Pin Adjustm ent
L ith o in U.S.A.
80 M iscellaneous Grader, Motor - JD570
15-4 Saddle, Main Fram e, Front A xle and Scarifier TM-1001 (Nov-78)
1 - L.H. Spindle 13 — Bushing 25 — King Pin (2 used)

2 - Bushing (10 used) 14 — Bushing (2 used) 26 — Cap Screw (2 used)
3 — Grease F ittin g (6 used) 15 — Cap Screw (2 used) 27 — Lock N ut (2 used)
4 - L .H . Wheel Lean P iv o t 16 - P iv o t P in (2 used) 28 - P in (2 used)
5 — Bushing (4 used) 17 — Stop N ut (2 used) 29 - Pin (2 used)
6 - L in k 18 — Pin 30 — Grease F ittin g (3 used)
7 — Pin 19 - Cap (3 used) 31 - Pin
8 - Cap Screw (2 used) 20 - R .H . Wheel Lean P iv o t 32 - Cap Screw
9 - Lock N ut (2 used) 21 - T h ru s t Washer (2 used) (E a rly U n its) 33 — A xle
10 — Pin 22 — T h ru s t Washer (2 used) (E a rly U n its ) 34 — Grease F ittin g
11 — Spacer 23 - R.H. Spindle 35 — Washer (4 used)
12 - Cap Screw, L o c k Washer and 24 — Hub Cap (2 used) (E a rly U n its ) 36 — Washer (as re quire d)
Washer 37 — T h ru st Washer (2 used)
(L a te r U n its)
Fig. 5-Front Axle
TS0387N
1 - Oil Seal 6 — Wheel Hub 1 1 — Special Washer 16 - Cap Screw (3 used)

2 — Retainer 7 — Pipe Plug 12 — Slotted Nut 17 - Cotter Pin
3 — Bearing Cone 8 — Bearing Cup 13 — Gasket 18 — Cap Screw (10 used) (Later Units)
4 — Bearing Cup 9 — Bearing Cone 14 — Hub Cap 19 — Special Washer (10 used) (Later
5 — Wheel Bolf (10 used) 10 - Wheel Nut 15 — Lock Washer (3 used) Units)
(Early Units)
Fig. 6-Front Wheel Hub
Litho in U .S.A .
TM-1001 (Nov-78) Saddle, Main Frame, Front Axle and Scarifier 15-5
Refer to Figs. 5 and 6 for identification of parts and Make sure steering cylinder grease fittings face up
sequence for disassembly and assembly. Also note the when cylinders are assembled,
following instructions.
Tighten wheel hub cap screws (18, Fig. 6) to 270 to
Use as many washers (36, Fig. 5) as required to 330 ft-lbs.
obtain a 0.120 inch maximum play between front axle
and main frame.
1— Scarifier Frame 10— Lock W ash er (4 used) 19— Pin

2— Nut (4 used) 11— N ut (4 used) 20— Cap Screw
3— Lock W asher (4 used) 12— C otter Pin (4 used) 21— L.H. Mast
4— R.H. M ast 13— N ut (4 used) 22— Low er Pivot Pin (2 used)
5— Pin (2 used) 14— Shank T ip (11 used) 23— Pin (2 used)
6— Cap S crew (4 used) 15— W asher (4 used) 24— C ap Screw (2 used)
7— Parallel Link (2 used) 16— S pacer (4 used) 25— K eeper ( -001699)
8— Cap Screw 17— Boom 26— Shank (11 used)
9— Upper Cylinder Pin 18— Special B olt (4 used) 27— S han k Retainer (11 used)
Fig. / - Scarifier and Buiiaozer Linkage (Early Units)
Refer to Figs. 7, 8 and 9 for identification of parts When assembling scarifier or bulldozer to main
and sequence for disassembly and assembly. Also frame, tighten mounting bolts to 300 ft-lbs. Then ad
note the following specific instructions. vance nut to next castellation and install cotter pin.
Litho in U.S-A.
80 Miscellaneous Grader, Motor - JD570
15-6 Saddle, Main Frame, Front Axle and Scarifier TM-1001 (Nov-78)
TZ0S88N
1— S h an k Retainer (9 used) 8— Parallel Link (2 used) 15— Nut (4 used)

2— N ut (4 used) 9— C ap Screw 16— W asher (4 used)
3— W ash er (8 used) 10— U pper Cylinder Pin 17— Spacer (4 used)
4— Pin (4 used) 11— Lock W asher (4 used) 18— Special B olt (4 used)
5— S h an k (5 used) 12— N ut (2 used) 19— Pin
6— S h an k T ip (5 used) 13— Boom 20— C ap Screw
7— C ap S crew (4 used) 14— C otter Pin (4 used) 21— S carifier Fram e
Fig. 8-Scarifier and Linkage (Later Units)
Litho in U.S.A.
TM-1001 (Nov-78) Saddle, Main Frame, Front Axle and Scarifier 15-7
1— B u lld o ze r Blade 8— Parallel Link (2 used) 1 5 - N u t (4 used)

2— N ut (4 used) 9— C ap S crew 1 5 —W ash er (4 used)
3— W ash er (4 used) 10— U pper C ylin der Pin 17— S p a c e r (4 used)
4— End B it (2 used) 11— Lo ck W ash er (4 u sed) 18— S pecial B olt (4 used)
5— P in (4 used) 12— N u t (2 u sed) 19— P in
6— C ap S crew (4 used) 13— B oom 20— C a p S crew
7 — C u ttin g E dge 14— C o tter Pin (4 used) 21— P lo w Bolt, L o ck W ash er
a n d Nut
Fig. 9-Bulldozer and Linkage (Later Units)
Litho in U.S.A.
15-8 Saddle, M ain Frame, F ro n t A xle and S ca rifie r TM-1001 (Dec-87)
A — C a p S crew (4 used)
Fig. 10-Rear Frame and Engine Frame
T ighten rear-to-engine fram e cap screw s (A) to

170 Ib-ft.
L ith o in U.S.A.
TM-1001 (Dec-87) S pecification s and S pecial Tools 20-1
Group 20
DRAWBAR, CIRCLE AND MOLDBOARD
SPECIFICATIONS
Drive shaft, circle drive gearbox ...........................End p la y ............................................. 0.005 to 0.040 in.
C ircle-to-circle s u p p o rt.............................................. C le a ra n c e ........................................... 0.020 to 0.080 in.
Pinion tip-to-circle root ............................................ C le a ra n c e ........................................... 0.350 in. (max.)
TORQUE VALUES
Item Torque (Ib-ft)
C ir c le ......................................................................................................................................................................... 670
M oldboard extension stabilizing cap s c r e w .................................................................................................... 105
SADDLE, MAIN FRAME, FRONT AXLE, SCARIFIER, AND ENGINE FRAME
SPECIFICATIONS
Front axle-to-main fr a m e ..........................................C le a ra n c e .......................................... 0.120 in. (max.)

Saddle p iv o t-to -s a d d le .............................................. C le a ra n c e .......................................... 0.020 to 0.090 in.
TORQUE VALUES
Item Torque (Ib-ft)
Bulldozer-to-main f r a m e ........................................................................................................................... 300

Scarifier-to-m ain fr a m e ............................................................................................................................. 300
Engine fram e-to-m ain fram e (lower pivot p in )....................................................................................... 100
Wheel hub cap s c r e w s ............................................................................................................................. 270 - 330
Rear fram e-to-engine cap s c r e w s ........................................................................................................... 170
L ith o in U.S.A.
80 M isc e lla n e o u s Grader, Motor - JD570
2 0 -2 S p e c ific a tio n s and S p e cia l T o o ls TM-1001 (Nov-79)
Litho in U .S.A .
I
I
I
SAFETY
livewithit

John Deere 570 570A Repair Manual Motor Grader TM1001

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

John Deere 570 570A Repair Manual Motor Grader TM1001

Uploaded by

Copyright:

Available Formats

TECHNICAL MANUAL

Section 40 - ELECTRICAL SYSTEM Section 80 - MISCELLANEOUS

Group 10 - Charging System - Engine Group 10 - Drawbar, Circle and Moldboard

The specifications and design information contained

Fig. 1-JD570-A Motor Grader

JD570-A Final D riv e s .........................................................Inboard planetary

Pow er (« 2300 engine rpm): SA E DIN

JD570-A Bulldozer ........ (Special Equipment): Mounts on scarifier linkage.

Frame: Tapered box U.S. Imp Liters

JD570-A MOTOR GRADER DIMENSIONS

IMPORTANT: Rear axle weight must not exceed

(Unit Equipped w/13.00 - 24, 8-ply Rating Tubeless Tires)

HORSEPOWER (at 2300 rpm) P a rk in g .............Hand-operated m echanical ex­

Over-All Dimensions Inches Over-All Dimensions Inches

WEIGHT On Rear W heels

3. Fill the fuel tank.

4. Check crankcase oil level. Oil should be between

5. Relieve hydraulic pressure by stopping engine,

6. Reduce shipping pressure of all tires to inflation

7. Cover unit for protection and cleanliness.

Check pre-cleaner bowl. Clean if necessary.

Pre-cleaner checked Yes No

Fig. 4-Fuel Filter

Sediment present in filter Yes No

IMPORTANT: Never add water to battery in

Check battery connections.

A—Reset Button B— Red Signal Punch date code on battery.

Air cleaner checked Yes No

5. Fuel Tank 7. Radiator

Fig. 7-Radiator Filler Cap

CAUTION: Remove radiator filler cap only

Fig. 5-Fuel Tank Filler Cap

Check coolant level. Maintain 4 inches below the top

Radiator coolant level checked Yes No

Fig. 6-Fuel Gauge

Fuel tank filled Yes No

6. Fuel Tank Sump

IMPORTANT: Sediment will settle over extend­

Open fuel tank drain cock. Drain liquid for several

NOTE: Fuel tank sump drain is located on the bot­

Fuel sump drained Yes No

8. Tandem Drives 9. Crankcase Oil Level

A—Oil Level Plug B—Main Drive Sprocket

Check crankcase oil level with machine on level

NOTE: There is a 3-1/2 quart difference between

Crankcase oil level checked Yes No

Fig. 9-Tandem Drive Inspection Plate

Park grader on level surface. Remove inspection

Remove oil level plug from each tandem. Oil should

If oil is needed, use John Deere HY-GARD® Oil or

Install inspection plate and plug.

Tandem oil level checked Yes No

IMPORTANT: Do not pry on the rear alternator

Alternator-fan belt tension _______ lbs. strand tension

12. Air Intake Hoses

A — V ent C— D rain Plug

Fig. 11-Circle Drive Gear Box

W ith the blade resting on level ground, check the

Check hoses (A) for cracks. Tighten clamps (B).

Air intake hoses checked Yes No

A— A dju sting C ap S crew B— A lte rn ato r-F an B elts

Fig. 12-Alternator - Fan Belts

13. Transmission-Hydraulic System 15. Parking Brake

Fig. 15-Parking Brake Lever

HORSEPOWER (at 2300 rpm) P a rk in g .............Hand-operated m echanical ex

IMPORTANT: Sediment will settle over extend

NOTE: Fuel tank sump drain is located on the bot

NOTE: Parking brake must be released before for

To reverse grader, pull forward-reverse lever rear

NOTE: Light glows when key switch is in start po

Put grader in gear and depress brake pedal. Mod