John Deere C Series II Motor Graders Operation & Test Manual TM1914

Description

John Deere C Series II Motor Graders Operation & Test Manual TM1914

This John Deere C Series II Motor Graders Operation and Test Manual (TM1914) is the technical reference for diagnosing, testing and understanding the complete machine on 670C, 670CH, 672CH, 770C, 770CH and 772CH motor graders. Written for the experienced technician, it organizes every major system into theory of operation, diagnostic information, adjustments and tests, so a complete machine operational checkout or a single fault isolation can be worked from the same volume.

File Details

• Manual type: Operation and Test Technical Manual
• Brand: John Deere
• Models covered: 670C, 670CH, 672CH, 770C, 770CH, 772CH
• Engines referenced: 6068 (6.8 L) and 6081 (8.1 L)
• Serial number breakdowns: S.N. —589368 and S.N. 589369—
• Language: English
• Page count: 849
• File format: PDF
• Document number: TM1914

Chapters Covered

• General Information — Safety — operator qualification, protective equipment, high-pressure fluid hazards, exhaust fumes, fire prevention, battery explosions, chemical handling, ROPS inspection and safe service procedures
• Operational Checkout Procedure — complete machine operational checkout with engine-off checks, engine-running checks and stored diagnostic trouble code retrieval
• Engine — theory of operation, diagnostic information, adjustments and tests for 6068 and 6081 engines, including surge tank operation, air intake and exhaust system operation, cold start theory, engine air heater theory, ether start aid, and diagnostic procedures B1 and B2
• Electrical System — system information, system diagrams, sub-system diagnostics, references and tests, with complete wiring diagrams for every machine harness, diagnostic trouble code reference lists, stored code retrieval and detailed component checks
• Hydrostatic Front Wheel Drive (HFWD) — theory of operation, diagnostic information, adjustments and checks, tests covering pump and displacement control, charge pump, charge filter, flushing valve, multi-function valve, engagement valve, front wheel motor and power flow
• Power Train — theory of operation, diagnostic information, adjustments and tests for the DF180 powershift transmission, park brake and differential lock control valve, park brake operation and manual release, differential lock operation, and rear axle and tandem operation
• Hydraulic System — theory of operation, diagnose malfunctions, adjustments and tests for the main hydraulic system, main pump, return filter, system relief valve, service brake, brake accumulator, steering, priority control valve, grader control valve and all valve sections
• Heating and Air Conditioning — theory of operation, diagnostic information and tests for the R134a air conditioning system and heater system

The John Deere C Series II Motor Graders Operation and Test Manual goes well beyond a list of specifications. It gives the technician structured diagnostic procedures for every major system on the machine — from the engine controller and electrical harnesses through the DF180 powershift transmission, hydrostatic front wheel drive, main hydraulic system and HVAC. Each section begins with theory of operation, then builds into diagnostic information, adjustments and tests so the reader understands not just what to check but why a failure produces the symptom it does.

Diagnostic trouble codes are covered in depth. The manual lists HFWD codes F213 through F274, transmission codes F301 through F398, and engine codes F401 through F487, each with symptom, probable cause and repair path. Stored diagnostic trouble code retrieval is explained for the monitor display. The electrical section provides complete wiring diagrams for the roof harness (W2), map light harness (W3), A/C roof harness (W7), under seat heater harness (W8), engine harnesses (W9 and W10), platform harness (W11), transmission harness (W13), side console harnesses (W15, W16 and W17), front console harness (W18), A/C compressor harness (W20), ripper harness (W21), 24V radio harness (W31), and HFWD front and rear harnesses (W34 and W35).

The engine section covers both the 6068 (6.8 L) and 6081 (8.1 L) engines, with separate diagnostic procedures for machines built before and after serial number 589369. Topics include surge tank operation, air intake and exhaust system operation, cold start theory, ether start aid, engine air heater with and without ether start aid, and specific diagnostic procedures for hard starting and low power complaints. Engine tests include fuel line leakage, air intake system leakage, air filter restriction indicator switch, intake manifold pressure (turbocharger boost), injection pump rack position voltage, fuel supply pump leakage, fuel pressure and throttle potentiometer tests. The JT05801 clamp-on electronic tachometer installation, engine belt tensioner spring check, fan belt tensioner spring check, engine speed linkage adjustment for both 670C and later models, primary fuel filter drain valve procedures and fuel system bleeding for all model variants are also included.

The powertrain section explains the DF180 powershift transmission in detail — hydraulic system operation, control valve port identification, clutch pack operation, clutch and gear operation, park brake and differential lock control valve, park brake engaged and manual release operation, differential lock operation, and rear axle and tandem operation. Each transmission and axle test is included, from pump flow and system pressure through clutch pressure, park brake pressure and differential lock pressure tests. Transmission diagnostics include troubleshooting tips for F301 through F319 transmission gear solenoid codes and inching pedal codes, with guidance on limp-home mode behaviour when solenoid circuits fail. The transmission controller calibration procedure, transmission solenoid resistance test and transmission proportional solenoid valve test are all included, along with the transmission control and park brake lever test and the park/not neutral gear position switch module bench test.

The hydraulic section covers the main hydraulic system, main hydraulic pump, main hydraulic return filter, system relief valve, service brake operation, brake accumulator operation, steering system operation, priority control valve, grader control valve, control valve orifice operation, blade lift and scarifier and ripper valve operation, wheel lean and rear steer and circle side shift and blade tilt and blade side shift valve operation, counterbalance valve operation, circle rotate valve operation, locking pin circuit operation, ripper valve operation, and circle drive gearbox operation both with and without slip clutch.

Beyond diagnostics, the manual includes a full set of component checks for relays, diodes, the key switch, the aggressiveness switch, solenoid coils, transmission shaft speed pickups and the inching potentiometer, along with connector service procedures for METRI-PACK, DEUTSCH and WEATHER PACK connectors. Calibration procedures are provided for the tachometer, transmission controller (TCU), HFWD controller (HCU), inching pedal and articulation potentiometer. Fuse and relay specifications are broken out by serial number range, and the functional schematic and wiring diagram master legend is included to help trace any circuit.

The HFWD section covers pump and displacement control operation, forward operation, pump and motor flushing pump, charge pump, charge filter operation, flushing valve and operating charge relief valve, multi-function valve, engagement valve operation, front wheel motor operation and HFWD power flow, followed by the full set of HFWD tests — start-up procedure, pump control neutral adjustment, planetary brake leakage, neutral and operating charge regulating valve pressure, charge pressure balance, pump leakage, motor leakage, pressure override and multi-function relief valve, motor flushing pump relief valve, charge pump flow and cooler bypass valve pressure.

Component location diagrams are provided for the roof harness, map light harness, A/C roof harness, under seat heater harness, engine harnesses, platform harness, transmission harness, side console harnesses, front console harness, A/C compressor harness, ripper harness, 24V radio harness, and HFWD front and rear harnesses, with separate diagrams for pre-589369 and post-589369 machines where the harness or routing changed.

What This Manual Enables

With the John Deere C Series II Motor Graders Operation and Test Manual on hand, a technician can perform a complete machine operational checkout from the operator’s seat, isolate faults across the engine, electrical, powertrain, hydraulic and HVAC systems, retrieve and interpret diagnostic trouble codes, run the full range of pressure, flow, leakage and cycle-time tests, calibrate the tachometer, transmission controller, HFWD controller and inching pedal, and reference the exact wiring diagram for any harness on the machine. The procedures are written so a repair can be planned and verified rather than guessed at — which matters on a grader where a misdiagnosed hydraulic or transmission fault can mean days of downtime.

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