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John Deere 655K Crawler Loader Repair Technical Manual TM12721 – PDF DOWNLOAD
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John Deere 655K Crawler Loader Repair Technical Manual TM12721 – PDF DOWNLOAD
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Description
John Deere 655K Crawler Loader Repair Technical Manual TM12721 – PDF DOWNLOAD
FILE DETAILS:
John Deere 655K Crawler Loader Repair Technical Manual TM12721 – PDF DOWNLOAD
Language : English
Pages : 470
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
John Deere 655K Crawler Loader Repair Technical Manual TM12721 – PDF DOWNLOAD
- 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.
- 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 problems 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.
TABLE OF CONTENTS:
John Deere 655K Crawler Loader Repair Technical Manual TM12721 – PDF DOWNLOAD
Contents................................................................................................................ 5 General Information................................................................................................. 7 Safety.......................................................................................................... 9 Recognize Safety Information................................................................................ 9 Follow Safety Instructions.................................................................................. 9 Operate Only If Qualified................................................................................... 9 Wear Protective Equipment................................................................................... 10 Avoid Unauthorized Machine Modifications.................................................................... 10 Inspect Machine............................................................................................. 10 Stay Clear of Moving Parts.................................................................................. 10 Avoid High-Pressure Fluids.................................................................................. 11 Avoid High-Pressure Oils.................................................................................... 11 Work In Ventilated Area..................................................................................... 12 Prevent Fires............................................................................................... 12 Prevent Battery Explosions.................................................................................. 13 Handle Chemical Products Safely............................................................................. 13 Decommissioning — Proper Recycling and Disposal of Fluids and Components.................................... 14 Exhaust Filter Ash Handling and Disposal.................................................................... 14 Prepare for Emergencies..................................................................................... 14 Clean Debris from Machine................................................................................... 15 Add Cab Guarding for Special Uses........................................................................... 15 Use Steps and Handholds Correctly........................................................................... 15 Start Only From Operator's Seat............................................................................. 15 Use and Maintain Seat Belt.................................................................................. 16 Prevent Unintended Machine Movement......................................................................... 16 Avoid Work Site Hazards..................................................................................... 17 Keep Riders Off Machine..................................................................................... 17 Avoid Backover Accidents.................................................................................... 18 Avoid Machine Tip Over and Machine Damage................................................................... 18 Operating or Traveling On Public Roads...................................................................... 19 Inspect and Maintain ROPS................................................................................... 19 Add and Operate Attachments Safely.......................................................................... 19 Park and Prepare for Service Safely......................................................................... 20 Service Cooling System Safely............................................................................... 20 Remove Paint Before Welding or Heating...................................................................... 21 Make Welding Repairs Safely................................................................................. 21 Drive Metal Pins Safely..................................................................................... 21 Clean Exhaust Filter Safely................................................................................. 22 Torque Values................................................................................................... 23 Metric Bolt and Cap Screw Torque Values..................................................................... 23 Additional Metric Cap Screw Torque Values................................................................... 24 Unified Inch Bolt and Cap Screw Torque Values............................................................... 25 Service Recommendations for 37° Flare and 30° Cone Seat Connectors.......................................... 26 Service Recommendations for O-Ring Boss Fittings............................................................ 26 O-Ring Boss Fittings In Aluminum Housing Service Recommendations—Excavators................................. 28 Service Recommendations for Flared Connections—Straight or Tapered Threads.................................. 29 Service Recommendations For Flat Face O-Ring Seal Fittings.................................................. 30 O-Ring Face Seal Fittings With SAE Inch Hex Nut And Stud End For High Pressure Service Recommendations...... 31 O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For Standard Pressure Service Recommendations.... 33 O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For High Pressure Service Recommendations........ 35 Service Recommendations for Metric Series Four Bolt Flange Fitting.......................................... 37 Service Recommendations For Inch Series Four Bolt Flange Fittings........................................... 38 Inch Series Four Bolt Flange Fitting For High Pressure Service Recommendations.............................. 39 Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings...................................... 40 Service Recommendations For O-Ring Boss Fittings With Shoulder.............................................. 41 Metric 24° O-Ring Seal DIN 20078 Service Recommendations.................................................... 43 Tracks.............................................................................................................. 45 Track System.................................................................................................... 47 Welding On Machine.......................................................................................... 47 Track Guides and Rock Guards Remove and Install............................................................. 48 Carrier Roller Wear Inspection.............................................................................. 50 Carrier Roller Remove and Install........................................................................... 50 Carrier Roller Disassemble and Assemble..................................................................... 52 Metal Face Seal Inspection.................................................................................. 54 Carrier Roller Leakage Test................................................................................. 55 Track Roller Wear Inspection................................................................................ 57 Track Roller Remove and Install............................................................................. 58 Track Roller Disassemble and Assemble....................................................................... 59 Track Roller Leakage Test................................................................................... 67 Track Grouser Wear Inspection............................................................................... 69 Track Shoe Remove and Install............................................................................... 70 Pivot Shaft Remove and Install.............................................................................. 71 Crossbar Remove and Install................................................................................. 72 Crossbar Bushings and Seals Remove and Install.............................................................. 74 Track Link Height Inspection................................................................................ 76 Bushing Outside Diameter for Lubricated Track Chain Inspection.............................................. 77 Track Pitch for Lubricated Track Chain Inspection........................................................... 78 Track Chain Remove and Install.............................................................................. 79 Lubricated Track Chain to Turn Bushings and Lubricate Chain Disassemble..................................... 83 Lubricated Track Chain to Turn Bushings and Lubricate Chain Assemble........................................ 85 Lubricated Track Chain to Turn Pins and Bushings and Not Lubricate Disassemble and Assemble................. 92 Track Sag Adjustment........................................................................................ 97 Track Adjuster Cylinder and Recoil Spring Remove and Install................................................ 98 Track Adjuster Recoil Spring Disassemble and Assemble.......................................................100 Track Adjuster Cylinder Disassemble and Assemble............................................................108 Track Frame Remove and Install..............................................................................110 Front Idler Wear Inspection.................................................................................113 Front Idler Remove and Install..............................................................................114 Front Idler Disassemble and Assemble........................................................................119 Front Idler Vertical Movement Adjustment....................................................................125 Front Idler Leakage Test....................................................................................126 Sprocket Segment Remove and Install.........................................................................127 Axles and Suspension Systems........................................................................................129 Drive Axle Housing and Support..................................................................................131 Final Drive Remove and Install.............................................................................131 Axle Shaft, Bearings and Reduction Gears........................................................................137 Planet Carrier Remove and Install...........................................................................137 Planet Carrier Disassemble and Assemble.....................................................................138 Ring Gear and Hub Remove and Install........................................................................141 Ring Gear and Hub Disassemble and Assemble..................................................................142 Final Drive Metal Face Seal Remove and Install..............................................................143 Final Drive Seal Leakage Check..............................................................................149 Inner Final Drive Housing Remove and Install................................................................151 Inner Final Drive Housing Disassemble and Assemble..........................................................154 Transmission........................................................................................................159 Remove and Install..............................................................................................161 Hydrostatic Pump and Motor Initial Start-Up Procedure.......................................................161 Hydrostatic Pump Remove and Install.........................................................................162 Hydrostatic Motor Remove and Install........................................................................168 Control Linkage.................................................................................................169 Transmission Control Lever (TCL) Remove and Install.........................................................169 Decelerator/Brake Pedal Remove and Install..................................................................171 Decelerator/Brake Pedal Disassemble and Assemble............................................................172 Steering Pedal Remove and Install—If Equipped...............................................................176 Steering Pedal Disassemble and Assemble—If Equipped.........................................................177 Input Drive Shafts and U-Joints.................................................................................179 Damper Drive Remove and Install.............................................................................179 Hydraulic System................................................................................................181 Hydrostatic Pump Disassemble................................................................................181 Charge Pump Disassemble and Assemble........................................................................194 Pump Displacement Control Valve (PDCV) Disassemble and Assemble.............................................198 Multi-Function Valve Remove and Install.....................................................................198 Multi-Function Valve Disassemble and Assemble...............................................................199 Hydrostatic Pump Assemble...................................................................................201 Hydrostatic Motor Disassemble...............................................................................218 Hydrostatic Motor Assemble..................................................................................224 Hydraulic Integrated Circuit (HIC) Valve Remove and Install.................................................236 Hydraulic Integrated Circuit (HIC) Valve Disassemble and Assemble...........................................240 Hydrostatic Reservoir Remove and Install....................................................................242 Hydrostatic Cold Start Valve Remove and Install.............................................................246 Engine..............................................................................................................247 Removal and Installation........................................................................................249 John Deere Engine...........................................................................................249 Engine Remove and Install...................................................................................250 Engine Mounts Remove and Install............................................................................256 Belt Routing................................................................................................257 Engine Auxiliary Systems............................................................................................259 Cold Weather Starting Aid.......................................................................................261 Engine Coolant Heater Remove and Install....................................................................261 Cooling System..................................................................................................263 Cooling Package Plenum Remove and Install...................................................................263 Cooling Package Remove and Install..........................................................................265 Charge Air Cooler Remove and Install........................................................................268 Radiator Remove and Install.................................................................................269 Hydraulic Oil Cooler Remove and Install.....................................................................271 Hydrostatic Oil Cooler Remove and Install...................................................................272 Fuel Cooler Remove and Install..............................................................................273 Intake System...................................................................................................275 Air Cleaner Remove and Install..............................................................................275 Precleaner Remove and Install—If Equipped...................................................................275 External Exhaust Systems........................................................................................277 Exhaust Tube Remove and Install.............................................................................277 Diesel Particulate Filter (DPF) Remove and Install..........................................................278 Exhaust Filter Remove and Install...........................................................................279 Service Filter Cleaning.....................................................................................279 External Fuel Supply Systems....................................................................................281 Fuel Tank Remove and Install................................................................................281 Fuel Tank Covers Remove and Install.........................................................................284 Primary Fuel Filter and Water Separator Remove and Install..................................................285 Final Fuel Filter Remove and Install........................................................................286 Auxiliary Fuel Filter and Water Separator Remove and Install—If Equipped....................................287 Park Brake..........................................................................................................289 Park Brake......................................................................................................291 Park Brake Remove and Install...............................................................................291 Control Linkage.................................................................................................293 Park Lock Lever Remove and Install..........................................................................293 Park Lock Lever Disassemble and Assemble....................................................................294 Hydraulic System................................................................................................297 Park Brake Disassemble and Assemble.........................................................................297 Equipment Attaching.................................................................................................303 Drawbar.........................................................................................................305 Retrieval Clevis Remove and Install.........................................................................305 Retrieval Hitch Remove and Install—If Equipped..............................................................305 Frame or Supporting Structure.......................................................................................307 Frame Installation..............................................................................................309 Welding Repair of Major Structure...........................................................................309 Frame Bottom Guards.............................................................................................311 Bottom Guards Remove and Install............................................................................311 Chassis Weights.................................................................................................313 Rear Counterweight Remove and Install.......................................................................313 Operator’s Station..................................................................................................315 Removal and Installation........................................................................................317 Cab/ROPS Remove and Install.................................................................................317 Operator Enclosure..............................................................................................323 Windowpanes Remove and Install..............................................................................323 Wiper Motor Remove and Install..............................................................................326 Washer Pump Remove and Install..............................................................................327 Hand Pump Bleed Procedure...................................................................................328 Seat and Seat Belt..............................................................................................329 Seat Remove and Install.....................................................................................329 Seat Belt Remove and Install................................................................................330 Heating and Air Conditioning....................................................................................331 Proper Refrigerant Handling.................................................................................331 R134a Refrigerant Cautions..................................................................................331 R134a Compressor Oil Charge Check...........................................................................331 R134a Compressor Oil Removal................................................................................332 R134a Component Oil Charge..................................................................................333 Leakage Testing.............................................................................................334 Refrigerant Hoses and Tubing Inspection.....................................................................334 R134a Refrigerant Recovery, Recycling and Charging Station Installation Procedure...........................334 Recover R134a System........................................................................................335 Evacuate R134a System.......................................................................................336 Charge R134a System.........................................................................................337 Air Conditioner System Cleaning Procedures..................................................................338 Purge R134a System..........................................................................................338 Flush R134a System..........................................................................................339 Evaporator or Heater Core Remove and Install................................................................340 Expansion Valve Remove and Install..........................................................................341 Air Conditioner Freeze Switch Remove and Install............................................................342 Cab Heater Blower Motor and Blower Motor Speed Resistor Remove and Install..................................342 Cab Upper Heater Components.................................................................................344 Cab or ROPS Under Seat Heater Disassemble and Assemble......................................................345 Receiver-Dryer Remove and Install...........................................................................347 Condenser Remove and Install................................................................................348 Compressor Remove and Install...............................................................................349 Sheet Metal.........................................................................................................351 Hood and Engine Enclosures......................................................................................353 Engine Side Door Assembly Remove and Install................................................................353 Hood Remove and Install.....................................................................................354 Grille and Grille Housing.......................................................................................355 Grille Remove and Install...................................................................................355 Safety and Convenience..............................................................................................357 Horn and Warning Devices........................................................................................359 Backup Alarm Remove and Install.............................................................................359 Backup Alarm Volume Adjustment..............................................................................359 Vehicle Main Hydraulic System.......................................................................................361 Hydraulic System................................................................................................363 General Oil Cleanup Procedure...............................................................................363 Hydraulic/Hydrostatic Component Failure Cleanup Procedure...................................................365 Hydraulic Pump Remove and Install...........................................................................368 Hydraulic Fan Motor Remove and Install......................................................................369 Hydraulic Fan Pump Remove and Install.......................................................................371 Hydraulic Fan Reversing Valve Remove and Install............................................................372 Hydraulic Fan Reversing Valve Disassemble and Assemble......................................................373 Hydraulic Reservoir Remove and Install......................................................................374 Hydraulic Reservoir Cleanout Cover Remove and Install.......................................................379 Thermal Bypass Valve Remove and Install.....................................................................382 Loader..............................................................................................................383 Bucket..........................................................................................................385 Standard and Multipurpose Bucket Remove and Install.........................................................385 Multipurpose Bucket and Lines Disassemble and Assemble......................................................392 Shank and Tooth Remove and Install..........................................................................395 Cracked Cutting Edge Repair.................................................................................395 Frames..........................................................................................................397 Boom Remove and Install.....................................................................................397 Boom Bushings and Seals Remove and Install..................................................................406 Loader Hydraulic System.........................................................................................409 Hydraulic Control Valve Remove and Install..................................................................409 Hydraulic Control Valve Disassemble and Assemble............................................................414 System Relief Valve Remove and Install......................................................................427 Pilot Control Valve Remove and Install......................................................................428 Bucket Cylinder Remove and Install..........................................................................430 Bucket Cylinder Disassemble and Assemble....................................................................431 Boom Cylinder Remove and Install............................................................................432 Boom Cylinder Disassemble and Assemble......................................................................432 Loader Start-Up Procedure (Hydraulic Cylinder Bleed Procedure)..............................................433 Boom and Bucket Cylinder Position Sensor Calibration........................................................433 Multipurpose Bucket Cylinder Disassemble and Assemble.......................................................433 Ground Conditioning Tool............................................................................................435 Remove and Install..............................................................................................437 Ripper Remove and Install—If Equipped.......................................................................437 Blades, Teeth, and Shanks.......................................................................................439 Shank and Tooth Remove and Install..........................................................................439 Hydraulic System................................................................................................441 Auxiliary Control Valve Disassemble and Assemble............................................................441 Ripper Pilot Control Valve Remove and Install...............................................................441 Ripper Cylinder Remove and Install..........................................................................442 Ripper Cylinder Disassemble and Assemble....................................................................445 Dealer Fabricated Tools.............................................................................................447 Dealer Fabricated Tools.........................................................................................449 DF1063 Final Drive Lift Bracket.............................................................................449 DF1065 Final Drive and Pump Adapter Bracket.................................................................450 DFT1167 Final Drive Lifting Bracket Adapter Spacer..........................................................451 DFT1243 Lifting Bracket Extension...........................................................................452 DFT1250 Lifting Bracket.....................................................................................453 DFT1260 Final Drive Lifting Fixture.........................................................................456 DFT1261 Rolling Torque Measurement Tool.....................................................................457 DFT1302 Final Drive Pressure Test Adapter...................................................................457 Page Number............................................................................................................. 5 Section 00.......................................................................................................... 7 Group 0001...................................................................................................... 9 Group 03........................................................................................................ 23 Section 01.......................................................................................................... 45 Group 0130...................................................................................................... 47 Section 02..........................................................................................................129 Group 0201......................................................................................................131 Group 0250......................................................................................................137 Section 03..........................................................................................................159 Group 0300......................................................................................................161 Group 0315......................................................................................................169 Group 0325......................................................................................................179 Group 0360......................................................................................................181 Section 04..........................................................................................................247 Group 0400......................................................................................................249 Section 05..........................................................................................................259 Group 0505......................................................................................................261 Group 0510......................................................................................................263 Group 0520......................................................................................................275 Group 0530......................................................................................................277 Group 0560......................................................................................................281 Section 11..........................................................................................................289 Group 1100......................................................................................................291 Group 1115......................................................................................................293 Group 1160......................................................................................................297 Section 15..........................................................................................................303 Group 1511......................................................................................................305 Section 17..........................................................................................................307 Group 1740......................................................................................................309 Group 1746......................................................................................................311 Group 1749......................................................................................................313 Section 18..........................................................................................................315 Group 1800......................................................................................................317 Group 1810......................................................................................................323 Group 1821......................................................................................................329 Group 1830......................................................................................................331 Section 19..........................................................................................................351 Group 1910......................................................................................................353 Group 1921......................................................................................................355 Section 20..........................................................................................................357 Group 2004......................................................................................................359 Section 21..........................................................................................................361 Group 2160......................................................................................................363 Section 31..........................................................................................................383 Group 3102......................................................................................................385 Group 3140......................................................................................................397 Group 3160......................................................................................................409 Section 42..........................................................................................................435 Group 4200......................................................................................................437 Group 4201......................................................................................................439 Group 4260......................................................................................................441 Section 99..........................................................................................................447 Group 9900......................................................................................................449
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