Case 770 EX Service Manual
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Case 770 EX Service Manual

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

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Summary of Contents for Case 770 EX

  • Page 1 770 EX 770 EX MAGNUM Tractor Loader SERVICE MANUAL Part number 48190544 English September 2017 © 2017 CNH Construction Equipment (India) Pvt. Ltd. All rights reserved.
  • Page 2 Contents INTRODUCTION Engine..................10 [10.001] Engine and crankcase ............. 10.1 [10.254] Intake and exhaust manifolds and muffler .
  • Page 3 [35.104] Fixed displacement pump ............35.3 [35.359] Main control valve .
  • Page 4 [90.150] Cab ................. 90.1 [90.154] Cab doors and hatches .
  • Page 5 INTRODUCTION 48190544 26/09/2017 Find manuals at https://best-manuals.com...

  • Page 6: Table Of Contents

    Contents INTRODUCTION Safety rules ..................3 Safety rules .
  • Page 7 INTRODUCTION Safety rules Personal safety This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible death or injury. Throughout this manual you will find the signal words DANGER, WARNING, and CAUTION followed by special in- structions.

  • Page 8: Safety Rules

    NOTICE: Extreme working and environmental conditions require shortened service intervals. Use Case fluids, lubricants, and filters for the best protection and performance of your machine. All fluids, lubricants, and filters must be disposed of in compliance with environmental standards and regulations. Contact your Dealer with any questions regarding the service and maintenance of this machine.

  • Page 9: Safety Rules - Ductile Iron

    INTRODUCTION Safety rules - Ductile iron DANGER Altering cast ductile iron can cause it to weaken or break. Before you weld, cut, or drill holes on any part of this machine, make sure that the part is not cast ductile iron. Failure to comply will result in death or serious injury.
  • Page 10 INTRODUCTION Safety rules - Ductile iron DANGER Improper operation or service of this machine can result in an accident. Any unauthorized modifications made to this machine can have serious consequences. Consult an authorized dealer on changes, additions, or modifications that may be required for this machine. Do not make any unauthorized modifications.

  • Page 11: Safety Rules

    INTRODUCTION Safety rules Unless otherwise instructed, always perform these steps before you service the machine: 1. Park the machine on a flat, level surface. 2. Place the loader bucket on the ground, with the bottom of the loader bucket parallel to the surface. 3.

  • Page 12: Safety Rules - Ecology And The Environment

    INTRODUCTION Safety rules - Ecology and the environment Soil, air, and water are vital factors of agriculture and life in general. When legislation does not yet rule the treatment of some of the substances required by advanced technology, sound judgment should govern the use and disposal of products of a chemical and petrochemical nature.

  • Page 13: Basic Instructions - Important Notice Regarding Equipment Servicing

    In any case, no warranty is given or attributed on the product manufactured or marketed by the manufacturer in case of damages caused by parts and/or components not approved by the manufacturer.

  • Page 14: Basic Instructions

    INTRODUCTION Basic instructions WARNING Explosive gas! Batteries emit explosive hydrogen gas and other fumes while charging. Ventilate the charging area. Keep the battery away from sparks, open flames, and other ignition sources. Never charge a frozen battery. Failure to comply could result in death or serious injury. W0005A WARNING Hazardous chemicals!

  • Page 15: Basic Instructions - Fuse And Relay Locations

    INTRODUCTION Basic instructions - Fuse and relay locations The machine is equipped with a fuse located on the side console. Side console box 1. Turn the thumb screws (1) to loosen the panel cover (2) for the fuse box. Remove the panel cover. 2.

  • Page 16: Basic Instructions

    INTRODUCTION Basic instructions WARNING Crushing hazard! If you service the machine with the loader lift arms raised, always use the support strut. Remove the retaining pin and place the support strut onto the cylinder rod. Install the retaining pin into the support strut.
  • Page 17 INTRODUCTION Lower supported loader lift arms: 1. Raise the lift arms so that the end of the support strut no longer rests on the cylinder. 2. Shut down the engine. PTIL17TLB0173AA 3. Remove the retaining pin from the support strut. 4.

  • Page 18: Basic Instructions

    INTRODUCTION Basic instructions Open the hood: 1. Shut down the engine. 2. Turn the handle (1) counter-clockwise to release the hood latch. PTIL13TLB1558AB 3. Lift the hood and rotate forward. PTIL17TLB0164AA NOTICE: To avoid damage to the hood parts, always close the hood before moving the loader. Close the hood: 1.

  • Page 19: Basic Instructions - Shop And Assembly

    Only use CNH Original Parts or CASE CONSTRUCTION Original Parts. Only genuine spare parts guarantee the same quality, duration, and safety as original parts, as they are the same parts that are assembled during standard production. Only CNH Original Parts or CASE CONSTRUCTION Original Parts can offer this guarantee.
  • Page 20 Failure to comply could result in death or serious injury. W0111A The special tools that CASE CONSTRUCTION suggests and illustrate in this manual have been specifically re- searched and designed for use with CASE CONSTRUCTION machines. The special tools are essential for reliable repair operations.

  • Page 21: Torque - Minimum Tightening Torques For Normal Assembly

    INTRODUCTION Torque - Minimum tightening torques for normal assembly METRIC NON-FLANGED HARDWARE NOM. LOCKNUT LOCKNUT SIZE CL.8 CL.10 CLASS 8.8 BOLT and CLASS 10.9 BOLT and W/CL8.8 W/CL10.9 CLASS 8 NUT CLASS 10 NUT BOLT BOLT PLATED PLATED UNPLATED UNPLATED W/ZnCr W/ZnCr 2.2 N·m (19 lb...
  • Page 22 INTRODUCTION METRIC FLANGED HARDWARE NOM. CLASS 8.8 BOLT and CLASS 10.9 BOLT and LOCKNUT LOCKNUT SIZE CLASS 8 NUT CLASS 10 NUT CL.8 CL.10 W/CL8.8 W/CL10.9 BOLT BOLT PLATED PLATED UNPLATED UNPLATED W/ZnCr W/ZnCr 2.4 N·m (21 lb 3.2 N·m (28 lb 3.5 N·m (31 lb 4.6 N·m (41 lb 2.2 N·m (19 lb...
  • Page 23 INTRODUCTION 1. Manufacturer's Identification 2. Property Class 3. Clock Marking of Property Class and Manufacturer's Identification (Optional), i.e. marks 60° apart indicate Class 10 properties, and marks 120° apart indicate Class 8. INCH NON-FLANGED HARDWARE LOCKNUT LOCKNUT NOMINAL SAE GRADE 5 BOLT SAE GRADE 8 BOLT GrB W/ Gr5 GrC W/ Gr8...
  • Page 24 INTRODUCTION INCH FLANGED HARDWARE NOM- LOCKNUT LOCKNUT SAE GRADE 5 BOLT and SAE GRADE 8 BOLT and INAL GrF W/ Gr5 GrG W/ Gr8 SIZE BOLT BOLT UNPLATED PLATED UNPLATED PLATED or PLATED W/ZnCr or PLATED W/ZnCr SILVER GOLD SILVER GOLD 12 N·m (106 lb 13 N·m (115 lb...
  • Page 25 INTRODUCTION Inch Lock Nuts, All Metal (Three optional methods) 20090268 Grade Identification Grade Corner Marking Method (1) Flats Marking Method (2) Clock Marking Method (3) Grade A No Notches No Mark No Marks Grade B One Circumferential Notch Letter B Three Marks Grade C Two Circumferential Notches...

  • Page 26: Torque - Standard Torque Data For Hydraulics

    INTRODUCTION Torque - Standard torque data for hydraulics INSTALLATION OF ADJUSTABLE FITTINGS IN STRAIGHT THREAD O RING BOSSES 1. Lubricate the O-ring by coating it with a light oil or petroleum. Install the O-ring in the groove adjacent to the metal backup washer which is assembled at the extreme end of the groove (4).
  • Page 27 INTRODUCTION PIPE THREAD FITTING TORQUE PIPE THREAD FITTING Torque (Maximum) Thread Size Before installing and tightening pipe fittings, clean the 1/8-27 13 N·m (10 lb ft) threads with a clean solvent or Loctite cleaner and ap- 1/4-18 16 N·m (12 lb ft) ply sealant for all fittings including stainless steel or for 3/8-18 22 N·m (16 lb ft)

  • Page 28: Abbreviation - Measurements

    INTRODUCTION Abbreviation - Measurements Typical applications Metric unit Imperial unit Name Symbol Name Symbol Area (Land area) acre hectare square meter m² square foot ft² square inch in² square millimeter mm² square inch in² Electricity ampere ampere volt volt microfarad µF microfarad µF...
  • Page 29 INTRODUCTION Typical applications Metric unit Imperial unit Name Symbol Name Symbol Temperature (other than Thermodynamic) degrees Celsius °C degrees Fahrenheit °F Time hour hour minute minute second second Torque (includes Bending moment, Moment of force, and Moment of a couple) newton meter pound foot lb ft...

  • Page 30: Capacities

    INTRODUCTION Capacities For 770 EX/EX Magnum S.N. Usage Specification Brand 770 EX/EX Magnum Transmission oil 2WD SAE 15W30 CASE TRANSPOWER 16.00 l (4.23 US gal) 18.50 l (4.89 US gal) Transmission oil 4WD SAE 15W30 CASE TRANSPOWER Rear axle oil...
  • Page 31 SERVICE MANUAL Engine 770EX Magnum 770EX 48190544 26/09/2017...
  • Page 32 Contents Engine - 10 [10.001] Engine and crankcase ............. . . 10.1 [10.254] Intake and exhaust manifolds and muffler .
  • Page 33 Engine - 10 Engine and crankcase - 001 770EX Magnum 770EX 48190544 26/09/2017 10.1 [10.001] / 1...
  • Page 34 Contents Engine - 10 Engine and crankcase - 001 TECHNICAL DATA Engine General specification ............... 3 Torque .
  • Page 35 0.120 mm (0.005 in) wear 0.400 – 0.800 mm (0.016 – 0.031 in) Liner inner diameter oversize Camshaft bush seat diameters (For 770 EX/EX Magnum) • Front 54.780 – 54.805 mm (2.157 – 2.158 in) • Intermediate C33 54.280 – 54.305 mm (2.137 – 2.138 in) 53.780 –...
  • Page 36 Engine - Engine and crankcase Exhaust valves (For 770 EX/EX Magnum) 41.00 – 41.25 mm (1.61 – Valve head diameter 1.62 in) 7.985 – 8.000 mm (0.314 – Valve stem diameter 0.315 in) Face angle 45° 30’±7’ Tappet clearance (Cold) 0.300 mm (0.012 in)
  • Page 37 Adopter for tachometer cable (S2) ® 243™ OCTITE Flywheel housing to engine block (S3) ® 510™ OCTITE Timing gear case studs (S4) ® 270 OCTITE Timing gear cover dowel pin (S5) ® 270 OCTITE Starter motor to flywheel housing (S6) ®...
  • Page 38 Engine - Engine and crankcase 380000301 Engine stand PTIL14TLB0102AA 380200415 Support PTIL14TLB0103AA 380000302 Cylinder head valve spring compressor PTIL14TLB0104AA 380200447 Puller ( FIP gear & crank pulley hub) PTIL14TLB0105AA 48190544 26/09/2017 10.1 [10.001] / 6...
  • Page 39 Engine - Engine and crankcase 380200448 Sump locating pin PTIL14TLB0106AA 380200449 Adaptor FIP timing PTIL14TLB0107AA 380000232 Tappet adjusting screw driver PTIL14TLB0108AA 380200450 Crankshaft front seal installer PTIL14TLB0109AA 48190544 26/09/2017 10.1 [10.001] / 7...
  • Page 40 Engine - Engine and crankcase 380200396 Oil pressure gauge with adaptor PTIL14TLB0110AA 380000215 Nozzle tester PTIL14TLB0111AA 380200451 Installer main oil seal PTIL14TLB0112AA 380000549 Sliding hammer - Injector removal PTIL14TLB0113AA 48190544 26/09/2017 10.1 [10.001] / 8...
  • Page 41 Engine - Engine and crankcase 380200452 Remover filters PTIL14TLB0114AA 380200453 Wrench to remove solenoid switch PTIL14TLB0115AA 380200454 FIP nut remover PTIL14TLB0116AA 380200471 Injector sleeve puller PTIL14TLB0124AA 48190544 26/09/2017 10.1 [10.001] / 9...
  • Page 42 Engine - Engine and crankcase 380000830 Guide socket PTIL14TLB0117AA 380000228 Dial gauge PTIL14TLB0123AA 380000834 Injector sleeve installer PTIL14TLB0118AA 380000833 Cutter - Injector holder seat PTIL14TLB0119AA 48190544 26/09/2017 10.1 [10.001] / 10...
  • Page 43 Engine - Engine and crankcase 380000219 Valve guide installer/remover PTIL14TLB0120AA 380000242 Valve guide installer PTIL14TLB0121AA 380000229 Dial gauge holder tool - Pump timing PTIL14TLB0122AA 48190544 26/09/2017 10.1 [10.001] / 11...
  • Page 44 Engine - Engine and crankcase Crankcase - General specification Crank gear Crankshaft - Bearings Main journal diameter 79.791 – 79.810 mm (3.141 – 3.142 in) 0.254 mm (0.010 in) 0.508 mm (0.020 in) Main journal undersize 0.762 mm (0.030 in) 1.016 mm (0.040 in) Main bearing wall thickness 2.168 –...
  • Page 45 Engine - Engine and crankcase Connecting rods 41.846 – 41.884 mm (1.647 – 1.649 in) Small end bore diameter Small end bushing outer diameter 41.979 – 42.017 mm (1.647 – 1.649 in) Bushing interference fit in small end 0.095 – 0.171 mm (0.0037 – 0.0067 in) Small end bushing fitted ID 38.004 –...
  • Page 46 Engine - Engine and crankcase Valve gear Valve timing gears Timing gear backlash 0.160 mm (0.006 in) Idler gear jack shaft diameter 36.975 – 37.000 mm (1.456 – 1.457 in) Idler gear bushing fitted ID after reaming 37.050 – 37.075 mm (1.459 – 1.460 in) Jack shaft journal clearance in bushing 0.050 –...
  • Page 47 Engine - Engine and crankcase Rockers Rocker bushing O D 21.006 – 21.031 mm (0.827 – 0.828 in) 20.939 – 20.972 mm (0.824 – 0.826 in) Rocker bore diameter Bushing interference fit in rocker 0.034 – 0.092 mm (0.001 – 0.004 in) Rocker bracket bore diameter 18.016 –...
  • Page 48 Engine - Engine and crankcase Engine - Static description The S8000 is a 4 cylinder turbo charged and after cool diesel engine. It features a cross flow cylinder head, with the inlet and exhaust manifolds on opposite sides of the cylinder head. The fuel and air combustion process, takes place in the specially designed bowel in the crown of the pistons.
  • Page 49 Engine - Engine and crankcase The connecting rods are heavy beam construction and are assembled as a matched set to each engine, attached to the crankshaft, by means of insert type bearings. They are retained in position by the connecting rod big end cap and secured by two bolts per rod. The small end of the connecting rod is fitted with a replaceable bronze bushing, through which the free floating piston pin is fitted.
  • Page 50 Engine - Engine and crankcase This enables precise timing being maintained during the life of the engine. The crankshaft gear drives the idler gear, which is attached to the front of cylinder block. The idler gear then drives the camshaft and the injection pump via meshing helical gears. The camshaft gear is bolted to the front of the shaft and is keyed to maintain position of the gear on the camshaft.
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