Case 770 EX User manual

SERVICE MANUAL
English
September 2017
Part number 48190544
© 2017 CNH Construction Equipment (India) Pvt. Ltd. All rights reserved.
770 EX
770 EX MAGNUM
Tractor Loader

Contents
INTRODUCTION
Engine.......................................................................................10
[10.001]Engineandcrankcase.............................................................10.1
[10.254]Intakeandexhaustmanifoldsandmufer.........................................10.2
[10.400]Enginecoolingsystem.............................................................10.3
Transmission..............................................................................21
[21.100]Mechanicaltransmissionhydrauliccomponents...................................21.1
[21.112]Powershuttletransmission.........................................................21.2
[21.134]Powershuttletransmissionexternalcontrols......................................21.3
[21.154]Powershuttletransmissioninternalcomponents..................................21.4
[21.700]Torqueconverter...................................................................21.5
Frontaxlesystem.......................................................................25
[25.100]Poweredfrontaxle.................................................................25.1
[25.102]Frontbevelgearsetanddifferential...............................................25.2
[25.108]Finaldrivehub,steeringknuckles,andshafts.....................................25.3
[25.400]Non-poweredfrontaxle............................................................25.4
Rearaxlesystem........................................................................27
[27.100]Poweredrearaxle..................................................................27.1
[27.106]Rearbevelgearsetanddifferential................................................27.2
[27.124]Finaldrivehub,steeringknuckles,andshafts.....................................27.3
Brakesandcontrols....................................................................33
[33.202]Hydraulicservicebrakes...........................................................33.1
[33.110]Parkingbrakeorparkinglock......................................................33.2
Hydraulicsystems.......................................................................35
[35.000]Hydraulicsystems..................................................................35.1
[35.300]Reservoir,cooler,andlters........................................................35.2
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[35.104]Fixeddisplacementpump..........................................................35.3
[35.359]Maincontrolvalve..................................................................35.4
[35.724]Frontloaderhydraulicsystemcontrol..............................................35.5
[35.701]Frontloaderarmhydraulicsystem.................................................35.6
[35.723]Frontloaderbuckethydraulicsystem..............................................35.7
[35.AAA]Hydraulicsystemsgenericsub-group.............................................35.8
Framesandballasting.................................................................39
[39.140]Ballastsandsupports..............................................................39.1
Steering.....................................................................................41
[41.101]Steeringcontrol....................................................................41.1
[41.200]Hydrauliccontrolcomponents......................................................41.2
[41.216]Cylinders...........................................................................41.3
Wheels......................................................................................44
[44.511]Frontwheels........................................................................44.1
[44.520]Rearwheels........................................................................44.2
[44.AAA]Wheelsgenericsub-group........................................................44.3
Cabclimatecontrol.....................................................................50
[50.100]Heating.............................................................................50.1
[50.200]Airconditioning.....................................................................50.2
Electricalsystems.......................................................................55
[55.100]Harnessesandconnectors.........................................................55.1
[55.201]Enginestartingsystem.............................................................55.2
[55.301]Alternator...........................................................................55.3
[55.518]Wiperandwashersystem..........................................................55.4
Frontloaderandbucket...............................................................82
[82.100]Arm.................................................................................82.1
[82.300]Bucket..............................................................................82.2
Platform,cab,bodywork,anddecals.............................................90
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[90.150]Cab.................................................................................90.1
[90.154]Cabdoorsandhatches............................................................90.2
[90.156]Cabwindshieldandwindows......................................................90.3
[90.100]Enginehoodandpanels...........................................................90.4
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INTRODUCTION
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Contents
INTRODUCTION
Safetyrules.....................................................................................3
Safetyrules.....................................................................................4
Safetyrules-Ductileiron.......................................................................5
Safetyrules-Ductileiron.......................................................................6
Safetyrules.....................................................................................7
Safetyrules-Ecologyandtheenvironment....................................................8
Basicinstructions-Importantnoticeregardingequipmentservicing...........................9
Basicinstructions.............................................................................10
Basicinstructions-Fuseandrelaylocations.................................................11
Basicinstructions.............................................................................12
Basicinstructions.............................................................................14
Basicinstructions-Shopandassembly......................................................15
Torque-Minimumtighteningtorquesfornormalassembly...................................17
Torque-Standardtorquedataforhydraulics.................................................22
Abbreviation-Measurements................................................................24
Capacities.....................................................................................26
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INTRODUCTION
Safetyrules
Personalsafety
Thisisthesafetyalertsymbol.Itisusedtoalertyoutopotentialpersonalinjuryhazards.Obeyall
safetymessagesthatfollowthissymboltoavoidpossibledeathorinjury.
ThroughoutthismanualyouwillndthesignalwordsDANGER,WARNING,andCAUTIONfollowedbyspecialin-
structions.Theseprecautionsareintendedforthepersonalsafetyofyouandthoseworkingwithyou.
Readandunderstandallthesafetymessagesinthismanualbeforeyouoperateorservicethemachine.
DANGERindicatesahazardoussituationthat,ifnotavoided,willresultindeathorseriousinjury.
WARNINGindicatesahazardoussituationthat,ifnotavoided,couldresultindeathorseriousinjury.
CAUTIONindicatesahazardoussituationthat,ifnotavoided,couldresultinminorormoderateinjury.
FAILURETOFOLLOWDANGER,WARNING,ANDCAUTIONMESSAGESCOULDRESULT
INDEATHORSERIOUSINJURY.
Machinesafety
NOTICE:Noticeindicatesasituationthat,ifnotavoided,couldresultinmachineorpropertydamage.
ThroughoutthismanualyouwillndthesignalwordNoticefollowedbyspecialinstructionstopreventmachineor
propertydamage.ThewordNoticeisusedtoaddresspracticesnotrelatedtopersonalsafety.
Information
NOTE:Noteindicatesadditionalinformationthatclariessteps,procedures,orotherinformationinthismanual.
ThroughoutthismanualyouwillndthewordNotefollowedbyadditionalinformationaboutastep,procedure,or
otherinformationinthemanual.ThewordNoteisnotintendedtoaddresspersonalsafetyorpropertydamage.
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INTRODUCTION
Safetyrules
DANGER
Improperoperationorserviceofthismachinecanresultinanaccident.
Donotoperatethismachineorperformanylubrication,maintenance,orrepaironituntilyouhave
readandunderstoodtheoperation,lubrication,maintenance,andrepairinformation.
Failuretocomplywillresultindeathorseriousinjury.D0010A
WARNING
Maintenancehazard!
Alwaysperformallserviceprocedurespunctuallyattheintervalsstatedinthismanual.Thisensures
optimumperformancelevelsandmaximumsafetyduringmachineoperation.
Failuretocomplycouldresultindeathorseriousinjury.W0132A
NOTICE:Extremeworkingandenvironmentalconditionsrequireshortenedserviceintervals.
UseCaseuids,lubricants,andltersforthebestprotectionandperformanceofyourmachine.Alluids,lubricants,
andltersmustbedisposedofincompliancewithenvironmentalstandardsandregulations.ContactyourDealerwith
anyquestionsregardingtheserviceandmaintenanceofthismachine.
Usethismanualwiththeoperator'smanualtounderstandandperformthecompleteserviceprocedures.Readthe
safetydecalsandinformationdecalsonthemachine.ReadtheOperator’sManualandsafetymanual.Understand
theoperationofthemachinebeforeyoustartanyservice.
Beforeyouservicethemachine,puta“DoNotOperate”tagonthesteeringwheeloroverthekeyswitch.Ensurethe
tagisatalocationwhereeveryonewhomightoperateorservicethemachinemayseeclearly.
Plasticandresinparts
•Avoidusinggasoline,paintthinner,etc.whencleaningplasticparts,console,instrumentcluster,etc.
•Useonlywater,mildsoap,andasoftclothwhenyoucleantheseparts.
•Usinggasoline,thinners,etc.cancausediscoloration,cracking,ordeformationofthepartbeingcleaned.
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INTRODUCTION
Safetyrules-Ductileiron
DANGER
Alteringcastductileironcancauseittoweakenorbreak.
Beforeyouweld,cut,ordrillholesonanypartofthismachine,makesurethatthepartisnotcast
ductileiron.
Failuretocomplywillresultindeathorseriousinjury.D0148A
Alteringcastductileironcancauseittoweakenorbreak.Unauthorizedmodicationstocastductileironpartscan
causedeathorseriousinjury.Donotweld,cut,drill,repair,orattachitemstocastductileironpartsonthismachine.
Beforeyouweld,cut,ordrillholesonanypartofthismachine,makesurethepartisnotcastductileiron.Seeyour
dealerifyoudonotknowifapartiscastductileiron.
Thefollowingitemsareexamplesofcastductileironparts.Theremayalsobeotherpartsmadeofcastductile
ironthatarenotonthelistbelow.
•two-wheeldrivesteeringlink
•dumplinks
•frontaxle
•swingtower
•bucketlinkage
•Air-Conditioning(A/C)compressormountingbracket
Donotmakeanyunauthorizedmodications.Consultanauthorizeddealerbeforemakinganychanges,additions,
ormodicationstothismachine.
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INTRODUCTION
Safetyrules-Ductileiron
DANGER
Improperoperationorserviceofthismachinecanresultinanaccident.
Anyunauthorizedmodicationsmadetothismachinecanhaveseriousconsequences.Consultan
authorizeddealeronchanges,additions,ormodicationsthatmayberequiredforthismachine.Do
notmakeanyunauthorizedmodications.
Failuretocomplywillresultindeathorseriousinjury.D0030A
Beforeyouweld,cut,ordrillholesonanypartofthismachine,makesurethepartisnotcastductileiron.Seeyour
dealerifyoudonotknowifapartiscastductileiron.Thefollowingarecastductileironparts:
•twowheeldrivesteeringlink
•dumplinks
•frontaxle
•bucketlinkage
•Airconditioning(A/C)compressormountingbracket
Unauthorizedmodicationstocastductileironpartscancauseinjuryordeath.Welding,cutting,ordrillingcancause
castductileirontobreak.Donotweld,cut,ordrilltorepairortoattachitemstocastductileironpartsonthismachine.
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INTRODUCTION
Safetyrules
Unlessotherwiseinstructed,alwaysperformthesestepsbeforeyouservicethemachine:
1.Parkthemachineonaat,levelsurface.
2.Placetheloaderbucketontheground,withthebottomoftheloaderbucketparalleltothesurface.
3.Placethedirectioncontrolleverandthetransmissioninneutral.
4.Ifyouneedtoopenthehoodtoperformservice,raisetheloaderarmsandinstallthesupportstrut.
5.Shutdowntheengine.
6.Placea'DoNotOperate'tagonthekeyswitchsothatitisvisibletootherworkersorremovethekey.
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INTRODUCTION
Safetyrules-Ecologyandtheenvironment
Soil,air,andwaterarevitalfactorsofagricultureandlifeingeneral.Whenlegislationdoesnotyetrulethetreatment
ofsomeofthesubstancesrequiredbyadvancedtechnology,soundjudgmentshouldgoverntheuseanddisposalof
productsofachemicalandpetrochemicalnature.
NOTE:Thefollowingarerecommendationsthatmaybeofassistance:
•Becomeacquaintedwithandensurethatyouunderstandtherelativelegislationapplicabletoyourcountry.
•Wherenolegislationexists,obtaininformationfromsuppliersofoils,lters,batteries,fuels,antifreeze,cleaning
agents,etc.,withregardtotheireffectonmanandnatureandhowtosafelystore,use,anddisposeofthese
substances.
Helpfulhints
•Avoidllingtanksusingcansorinappropriatepressurizedfueldeliverysystemsthatmaycauseconsiderable
spillage.
•Ingeneral,avoidskincontactwithallfuels,oils,acids,solvents,etc.Mostofthemcontainsubstancesthatmaybe
harmfultoyourhealth.
•Modernoilscontainadditives.Donotburncontaminatedfuelsandorwasteoilsinordinaryheatingsystems.
•Avoidspillagewhendrainingoffusedenginecoolantmixtures,engine,gearboxandhydraulicoils,brakeuids,etc.
Donotmixdrainedbrakeuidsorfuelswithlubricants.Storethemsafelyuntiltheycanbedisposedofinaproper
waytocomplywithlocallegislationandavailableresources.
•Moderncoolantmixtures,i.e.antifreezeandotheradditives,shouldbereplacedeverytwoyears.Theyshouldnot
beallowedtogetintothesoil,butshouldbecollectedanddisposedofproperly.
•Repairanyleaksordefectsintheenginecoolingorhydraulicsystemimmediately.
•Donotincreasethepressureinapressurizedcircuitasthismayleadtoacomponentfailure.
•Protecthosesduringweldingaspenetratingweldsplattermayburnaholeorweakenthem,allowingthelossof
oils,coolant,etc.
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INTRODUCTION
Basicinstructions-Importantnoticeregardingequipmentservicing
Allrepairandmaintenanceworklistedinthismanualmustbecarriedoutonlybyqualieddealershippersonnel,
strictlycomplyingwiththeinstructionsgiven,andusing,wheneverpossible,thespecialtools.
Anyonewhoperformsrepairandmaintenanceoperationswithoutcomplyingwiththeproceduresprovidedherein
shallberesponsibleforanysubsequentdamages.
Themanufacturerandalltheorganizationsofitsdistributionchain,including-withoutlimitation-national,regional,
orlocalCASEDealers,rejectanyresponsibilityfordamagescausedbypartsand/orcomponentsnotapprovedby
themanufacturer,includingthoseusedfortheservicingorrepairoftheproductmanufacturedormarketedbythe
manufacturer.
Inanycase,nowarrantyisgivenorattributedontheproductmanufacturedormarketedbythemanufacturerincase
ofdamagescausedbypartsand/orcomponentsnotapprovedbythemanufacturer.
Theinformationinthismanualisup-to-dateatthedateofthepublication.Itisthepolicyofthemanufacturerfor
continuousimprovement.Someinformationcouldnotbeupdatedduetomodicationsofatechnicalorcommercial
type,orchangestothelawsandregulationsofdifferentcountries.
Incaseofquestions,refertoyourCaseNewHollandConstructionEquipmentsSalesandServiceNetworks.
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INTRODUCTION
Basicinstructions
WARNING
Explosivegas!
Batteriesemitexplosivehydrogengasandotherfumeswhilecharging.Ventilatethechargingarea.
Keepthebatteryawayfromsparks,openames,andotherignitionsources.Neverchargeafrozen
battery.
Failuretocomplycouldresultindeathorseriousinjury.W0005A
WARNING
Hazardouschemicals!
Batteryelectrolytecontainssulfuricacid.Contactwithskinandeyescouldresultinsevereirritation
andburns.Alwayswearsplash-proofgogglesandprotectiveclothing(glovesandaprons).Wash
handsafterhandling.
Failuretocomplycouldresultindeathorseriousinjury.W0006A
•Donotruntheenginewiththealternatorwiresdisconnected.
•Beforeusinganelectricwelder,disconnectthealternatorwires,instrumentclusterandbatteries.
•Donotuseasteamcleaneroracleaningsolventtocleanthealternator.
•Keepthebatteryventsclean.Ensurethebatteryventsarenotrestricted.
Disconnectbattery
1.Openthebatterycompartmentcoverontherighthand
sidestepofthevehicle,usingthekey.
2.Disconnectthenegativebatterycable(1)fromthe
negativebatteryterminal.
PTIL13TLB1199AB1
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INTRODUCTION
Basicinstructions-Fuseandrelaylocations
Themachineisequippedwithafuselocatedonthesideconsole.
Sideconsolebox
1.Turnthethumbscrews(1)toloosenthepanelcover
(2)forthefusebox.Removethepanelcover.
2.Removethefuseboxcoversasneeded.
3.Refertothedecalontopofthepanelcoverforfuse,
relay,and/ordiodefunctions.
PTIL13TLB0302AB1
SlNo.FuseratingFusedetails
115AFrontworklight
210A12Vpoweroutput
315ARearworklight
415AHorn,hazardlightcontrol
510ACabin,fan,radio
610AInstallerignition
710AWiper
815ADrivinglampLOW
915ADrivinglampHIGH
1010ACabindomelight
1120AHVAC(Iftted)
1210ALoaderselflevel
1310ASideshiftlock
1410ACluster
1510ASpeedometer
1610AStoplamps
1710AHazardlightscontrolignition
1810AFuelshutoff
1910A4WD(Iftted)
2010AShuttlecontrol
ThefusesarearrangedaspertheFig.2
PTIL12TLB0441AA2
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INTRODUCTION
Basicinstructions
WARNING
Crushinghazard!
Ifyouservicethemachinewiththeloaderliftarmsraised,alwaysusethesupportstrut.Removethe
retainingpinandplacethesupportstrutontothecylinderrod.Installtheretainingpinintothesupport
strut.Lowertheliftarmsontothesupportstrut.
Failuretocomplycouldresultindeathorseriousinjury.W0230A
Raiseandsupportloaderliftarms:
1.Emptytheloaderbucket.
2.Raisetheloaderliftarmstothemaximumheight.
3.Shutdowntheengine.
PTIL17TLB0173AA1
4.Removetheretainingpin.
5.Lowerthesupportstrutontothecylinderrod.
6.Installtheretainingpin.
PTIL17TLB0174AA2
7.Starttheengine.
8.Slowlylowertheliftarmssothattheendofthesupport
strutrestsonthecylinder.
PTIL17TLB0172AA3
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INTRODUCTION
Lowersupportedloaderliftarms:
1.Raisetheliftarmssothattheendofthesupportstrut
nolongerrestsonthecylinder.
2.Shutdowntheengine.
PTIL17TLB0173AA4
3.Removetheretainingpinfromthesupportstrut.
4.Raisethesupportstrutuptothestoragepositionand
securewiththeretainingpin,asshown.
PTIL17TLB0174AA5
5.Starttheengine.
6.Lowertheloadertotheground.
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INTRODUCTION
Basicinstructions
Openthehood:
1.Shutdowntheengine.
2.Turnthehandle(1)counter-clockwisetoreleasethe
hoodlatch.
PTIL13TLB1558AB1
3.Liftthehoodandrotateforward.
PTIL17TLB0164AA2
NOTICE:Toavoiddamagetothehoodparts,alwaysclosethehoodbeforemovingtheloader.
Closethehood:
1.Lowerthehood.
2.Turnthehandle(1)clockwisetolockthehoodlatch.
PTIL13TLB1558AB3
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INTRODUCTION
Basicinstructions-Shopandassembly
Shimming
Foreachadjustmentoperation,selectadjustingshimsandmeasuretheadjustingshimsindividuallyusingamicrom-
eter,thenadduptherecordedvalues.Donotrelyonmeasuringtheentireshimmingset,whichmaybeincorrect,or
theratedvalueshownoneachshim.
Rotatingshaftseals
Forcorrectrotatingshaftsealinstallation,proceedasfollows:
1.Beforeassembly,allowthesealtosoakintheoilitwillbesealingforatleastthirtyminutes.
2.Thoroughlycleantheshaftandcheckthattheworkingsurfaceontheshaftisnotdamaged.
3.Positionthesealinglipfacingtheuid.
NOTE:Withhydrodynamiclips,takeintoconsiderationtheshaftrotationdirectionandpositionthegroovessothat
theywillmovetheuidtowardstheinnersideoftheseal.
4.Coatthesealinglipwithathinlayeroflubricant(useoilratherthangrease).Fillthegapbetweenthesealinglip
andthedustlipondoublelipsealswithgrease.
5.Insertthesealinitsseatandpressdownusingaatpunchorsealinstallationtool.Donottapthesealwitha
hammerormallet.
6.Whileyouinserttheseal,checkthatthesealisperpendiculartotheseat.Whenthesealsettles,makesurethat
thesealmakescontactwiththethrustelement,ifrequired.
7.Topreventdamagetotheseallipontheshaft,positionaprotectiveguardduringinstallationoperations.
O-ringseals
LubricatetheO-ringsealsbeforeyouinsertthemintheseats.ThiswillpreventtheO-ringsealsfromoverturningand
twisting,whichwouldjeopardizesealingefciency.
Sealingcompounds
Applyasealingcompoundonthematingsurfaceswhenspeciedbytheprocedure.Beforeyouapplythesealing
compound,preparethesurfacesasdirectedbytheproductcontainer.
Spareparts
OnlyuseCNHOriginalPartsorCASECONSTRUCTIONOriginalParts.
Onlygenuinesparepartsguaranteethesamequality,duration,andsafetyasoriginalparts,astheyarethesame
partsthatareassembledduringstandardproduction.OnlyCNHOriginalPartsorCASECONSTRUCTIONOriginal
Partscanofferthisguarantee.
Whenorderingspareparts,alwaysprovidethefollowinginformation:
•Machinemodel(commercialname)andProductIdenticationNumber(PIN)
•Partnumberoftheorderedpart,whichcanbefoundinthepartscatalog
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INTRODUCTION
Protectingtheelectronicand/orelectricalsystemsduringchargingandwelding
Toavoiddamagetotheelectronicand/orelectricalsystems,alwaysobservethefollowingpractices:
1.Nevermakeorbreakanyofthechargingcircuitconnectionswhentheengineisrunning,includingthebattery
connections.
2.Nevershortanyofthechargingcomponentstoground.
3.Alwaysdisconnectthegroundcablefromthebatterybeforearcweldingonthemachineoronanymachine
attachment.
•Positiontheweldergroundclampasclosetotheweldingareaaspossible.
•Ifyouweldincloseproximitytoacomputermodule,thenyoushouldremovethemodulefromthemachine.
•Neverallowweldingcablestolieon,near,oracrossanyelectricalwiringorelectroniccomponentwhileyou
weld.
4.Alwaysdisconnectthenegativecablefromthebatterywhenchargingthebatteryinthemachinewithabattery
charger.
NOTICE:Ifyoumustweldontheunit,youmustdisconnectthebatterygroundcablefromthemachinebattery.
Theelectronicmonitoringsystemandchargingsystemwillbedamagedifthisisnotdone.
5.Removethebatterygroundcable.Reconnectthecablewhenyoucompletewelding.
Specialtools
WARNING
Batteryacidcausesburns.Batteriescontainsulfuricacid.
Avoidcontactwithskin,eyesorclothing.Antidote(external):Flushwithwater.Antidote(eyes):ush
withwaterfor15minutesandseekmedicalattentionimmediately.Antidote(internal):Drinklarge
quantitiesofwaterormilk.Donotinducevomiting.Seekmedicalattentionimmediately.
Failuretocomplycouldresultindeathorseriousinjury.W0111A
ThespecialtoolsthatCASECONSTRUCTIONsuggestsandillustrateinthismanualhavebeenspecicallyre-
searchedanddesignedforusewithCASECONSTRUCTIONmachines.Thespecialtoolsareessentialforreliable
repairoperations.Thespecialtoolsareaccuratelybuiltandrigorouslytestedtoofferefcientandlong-lastingoper-
ation.
Byusingthesetools,repairpersonnelwillbenetfrom:
•Operatinginoptimaltechnicalconditions
•Obtainingthebestresults
•Savingtimeandeffort
•Workinginsafeconditions
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