JOHN DEERE 670C, 670CH, 672CH, 770C, 770CH, 772CH MOTOR GRADER TM1606 SERVICE MANUAL

670C, 670CH, 672CH, 770C, 770CH, 772CH Motor Graders Diagnostic

OPERATION AND TEST MANUAL Graders models 670C, 670CH, 672CH; HFWD models 672CH, 770CH, 772CH TM1606 22 FEB 05 (ENGLISH)

For complete service information also see: 120 Series Hydraulic Cylinders

TM-H120A

670C, 670CH, 672CH 770C, 770CH, 772CH Motor Graders Repair

TM1607

PowerTech 8.1 L Diesel Engines Base Engine

CTM86

Alternators and Starting Motors

CTM77

TeamMate II 1200, 1400,and 1600 Series Inboard Planetary Axles

CTM43

PowerTech 8.1L Diesel Engines Mechanical Fuel Systems

CTM243

PowerTech 6.8L and 8.1L, 6068 and 6081 Diesel Engines (Level 3 Electronic Fuel Systems with Bosch In-Line Pump)

CTM134

PowerTech 4.5L & 6.8L Diesel Engines Tier 1/Stage I, Tier 2/Stage II, Tier 3/Stage IIIA, Tier 3/Stage IIA Tier 3/Stage III, (Base Engine)

CTM104

John Deere Construction and Forestry

Pinted by Belgreen

tm1606-OPERATION AND TEST MANUAL

(g) by Belgreen v2.5

Table of contents FOREWORD HELP!! HELP!! HELP!! HELP!!

Section 9000 - GENERAL INFORMATION Group 01 - Safety Group 02 - General Specifications Group 03 - Torque Values Group 04 - Fuels And Lubricants Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10 - Operational Checkout Procedure Section 9010 - ENGINE Group 05 - Theory Of Operation Group 15 - Diagnostic Information Group 20 - Adjustments Group 25 - Tests Section 9015 - ELECTRICAL SYSTEM Group 05 - System Information Group 10 - System Diagrams Group 15 - Sub-System Diagnostics Group 20 - Diagnostic Trouble Codes Group 25 - References And Tests Section 9016 - HYDRAULIC FRONT WHEEL DRIVE Group 05 - Theory Of Operation Group 15 - Diagnostic Information Group 20 - Adjustments And Checks Group 25 - Tests Section 9020 - POWER TRAIN Group 05 - Theory Of Operation Group 15 - Diagnostic Information Group 20 - Adjustments Group 25 - Tests Section 9025 - HYDRAULIC SYSTEM Group 05 - Theory Of Operation Group 15 - Diagnose Malfunctions Group 20 - Adjustments Group 25 - Tests Section 9031 - HEATING AND AIR CONDITIONING Group 05 - Theory Of Operation Group 10 - System Operational Checks Group 15 - Diagnostic Information Group 20 - Adjustments Group 25 - Tests

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tm1606-OPERATION AND TEST MANUAL

For the full PDF version of this manual, Please click on the above download PDF button.

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tm1606-OPERATION AND TEST MANUAL

tm1606-OPERATION AND TEST MANUAL

(g) by Belgreen v2.5

Foreword This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use.

Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.

This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury.

Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components.

Operation and tests sections help you identify the majority of routine failures quickly.

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

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

Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.

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tm1606-OPERATION AND TEST MANUAL

tm1606-OPERATION AND TEST MANUAL

(g) by Belgreen v2.5

HELP!! HELP!! HELP!! HELP!!

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tm1606-OPERATION AND TEST MANUAL

tm1606-OPERATION AND TEST MANUAL

(g) by Belgreen v2.5

Section 9000 - GENERAL INFORMATION Table of contents Group 01 - Safety ..................................................................................................................................... 1 Handle Fluids Safely-Avoid Fires ........................................................................................................... 1 Prevent Battery Explosions ................................................................................................................... 1 Prepare for Emergencies ...................................................................................................................... 1 Prevent Acid Burns ............................................................................................................................... 3 Handle Chemical Products Safely ......................................................................................................... 3 Avoid High-Pressure Fluids ................................................................................................................... 4 Park Machine Safely ............................................................................................................................. 4 Support Machine Properly .................................................................................................................... 5 Wear Protective Clothing ...................................................................................................................... 6 Work in Clean Area ............................................................................................................................... 6 Service Machines Safely ....................................................................................................................... 6 Work In Ventilated Area ........................................................................................................................ 7 Illuminate Work Area Safely ................................................................................................................. 7 Replace Safety Signs ............................................................................................................................ 8 Use Proper Lifting Equipment ............................................................................................................... 8 Remove Paint Before Welding or Heating ............................................................................................. 8 Avoid Heating Near Pressurized Fluid Lines ........................................................................................ 10 Keep ROPS Installed Properly ............................................................................................................. 10 Service Tires Safely ............................................................................................................................ 11 Avoid Harmful Asbestos Dust ............................................................................................................. 11 Practice Safe Maintenance ................................................................................................................. 13 Use Proper Tools ................................................................................................................................. 13 Dispose of Waste Properly .................................................................................................................. 14 Live With Safety ................................................................................................................................. 14 Group 02 - General Specifications ....................................................................................................... 16 670C, 670CH, and 672CH Specifications ............................................................................................ 16 Drain and Refill Capacities - 670C, 670CH and 672CH ....................................................................... 18 770C, 770CH, and 772CH Specifications ............................................................................................ 19 Drain and Refill Capacities - 770C, 770CH and 772CH ....................................................................... 21 Group 03 - Torque Values ..................................................................................................................... 22 Hardware Torque Specifications ......................................................................................................... 22 Unified Inch Bolt and Cap Screw Torque Values ................................................................................. 23 Metric Bolt and Cap Screw Torque Values .......................................................................................... 24 Additional Metric Cap Screw Torque Values ....................................................................................... 25 Check Oil Lines And Fittings ............................................................................................................... 26 Service Recommendations for O-Ring Boss Fittings ........................................................................... 27 Service Recommendations for Flat Face O-Ring Seal Fittings ............................................................ 29 Service Recommendations For Inch Series Four Bolt Flange Fittings ................................................. 30 Service Recommendations for Metric Series Four Bolt Flange Fitting ................................................. 31 Service Recommendations For Flared Connections-Straight or Tapered Threads .............................. 32 Group 04 - Fuels And Lubricants ......................................................................................................... 34 Diesel Fuel .......................................................................................................................................... 34 Lubricity of Diesel Fuel ....................................................................................................................... 34 Diesel Fuel Storage ............................................................................................................................. 34 Low Sulfur Diesel Fuel Conditioner ..................................................................................................... 35 Do Not Use Galvanized Containers ..................................................................................................... 35 Fuel Tank ............................................................................................................................................ 35 Diesel Engine Oil, Hydraulic Reservoir And Wheel Motor Oil .............................................................. 36 Transmission, Differential Housing, Tandem Drive, And Circle Drive Gear Box Oil ............................. 38

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tm1606-OPERATION AND TEST MANUAL

tm1606-OPERATION AND TEST MANUAL

(g) by Belgreen v2.5

Grease ................................................................................................................................................

39 Alternative and Synthetic Lubricants .................................................................................................. 39 Lubricant Storage ............................................................................................................................... 39 Mixing of Lubricants ........................................................................................................................... 40 Diesel Engine Coolant ......................................................................................................................... 40

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tm1606-OPERATION AND TEST MANUAL

Section 9000 - GENERAL INFORMATION

Group 01: Safety

Group 01 - Safety Handle Fluids Safely-Avoid Fires

Avoid Fires When you work around fuel, do not smoke or work near heaters or other fire hazards.

Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers.

Make sure machine is clean of trash, grease, and debris.

Do not store oily rags; they can ignite and burn spontaneously.

Prevent Battery Explosions

Battery Explosions Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode.

Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer.

Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).

Prepare for Emergencies

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Section 9000 page 1

tm1606-OPERATION AND TEST MANUAL

Section 9000 - GENERAL INFORMATION

Group 01: Safety

First Aid Kit Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.

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Section 9000 page 2

tm1606-OPERATION AND TEST MANUAL

Section 9000 - GENERAL INFORMATION

Group 01: Safety

Prevent Acid Burns

Acid Burns Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.

Avoid the hazard by: 1.Filling batteries in a well-ventilated area.

2.Wearing eye protection and rubber gloves.

3.Avoiding breathing fumes when electrolyte is added.

4.Avoiding spilling or dripping electrolyte.

5.Use proper jump start procedure.

If you spill acid on yourself: 1.Flush your skin with water.

2.Apply baking soda or lime to help neutralize the acid.

3.Flush your eyes with water for 15-30 minutes. Get medical attention immediately.

If acid is swallowed: 1.Do not induce vomiting.

2.Drink large amounts of water or milk, but do not exceed 2 L (2 quarts).

3.Get medical attention immediately.

Handle Chemical Products Safely

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Section 9000 page 3

tm1606-OPERATION AND TEST MANUAL

Section 9000 - GENERAL INFORMATION

Group 01: Safety

Material Safety Data Sheet Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere equipment include such items as lubricants, coolants, paints, and adhesives.

A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques.

Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and recommended equipment.

(See your John Deere dealer for MSDS’s on chemical products used with John Deere equipment.)

Avoid High-Pressure Fluids

High-Pressure Fluids Escaping fluid under pressure can penetrate the skin causing serious injury.

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids.

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A.

Park Machine Safely

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Section 9000 page 4

tm1606-OPERATION AND TEST MANUAL

Section 9000 - GENERAL INFORMATION

Group 01: Safety

Remove the Key Before working on the machine: Lower all equipment to the ground.

Stop the engine and remove the key.

Disconnect the battery ground strap.

Hang a "DO NOT OPERATE" tag in operator station.

Support Machine Properly

Support Properly Always lower the attachment or implement to the ground before you work on the machine. If you must work on a lifted machine or attachment, securely support the machine or attachment. If left in a raised position, hydraulically supported devices can settle or leak down.

Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. Follow recommended procedures in this manual.

When implements or attachments are used with a tractor, always follow safety precautions listed in the implement operator′s manual.

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Section 9000 page 5

tm1606-OPERATION AND TEST MANUAL

For the full PDF version of this manual, Please click on the above download PDF button.