John Deere 755K Crawler Loader Repair Service Manual (TM12269)
Complete repair manual for John Deere 755K Crawler Loader, with all the workshop information to maintain, repair, and rebuild like professional mechanics.
John Deere 755K Crawler Loader workshop repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
TM12269 - John Deere 755K Crawler Loader Technical Manual - Repair.PDF
TM12269 - John Deere 755K Crawler Loader Technical Manual - Repair.epub
PRODUCT DETAILS:
Total Pages: 818 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English
MAIN SECTIONS
Description
Foreword
Technical Information Feedback Form
General Information
Safety
Torque Values
Tracks
Track System
Axles and Suspension Systems
Drive Axle Housing and Support
Axle Shaft, Bearings and Reduction Gears
Transmission
Remove and Install
Control Linkage
Input Drive Shafts and U-Joints
Hydrostatic System
Engine
Removal and Installation
Engine Auxiliary Systems
Cold Weather Starting Aid
Cooling System
Intake System
External Exhaust Systems
External Fuel Supply Systems
Park Brake
Park Brake
Control Linkage
Hydraulic System
Equipment Attaching
Drawbar
Frames, Chassis, or Supporting Structure
Frame Installation
Frame Bottom Guards
Chassis Weights
Operator’s Station
Removal and Installation
Operator Enclosure
Seat and Seat Belt
Heating and Air Conditioning
Sheet Metal
Hood and Engine Enclosures
Grille and Grille Housing
Safety, Convenience and Miscellaneous
Horn and Warning Devices
Main Hydraulic System
Hydraulic System
Bulldozer
Blade
Frames
Hydraulic System
Ground Conditioning Tool
Ripper
Blades, Teeth, and Shanks
Hydraulic System
Dealer Fabricated Tools
TABLE OF CONTENTS...1
Section 00: General Information...13
Group 0001: Safety...13
Recognize Safety Information...16
Follow Safety Instructions...17
Operate Only If Qualified...18
Wear Protective Equipment...19
Avoid Unauthorized Machine Modifications...20
Inspect Machine...21
Stay Clear of Moving Parts...22
Avoid High-Pressure Fluids...23
Avoid High-Pressure Oils...24
Work In Ventilated Area...25
Prevent Fires...26
Prevent Battery Explosions...27
Handle Chemical Products Safely...28
Decommissioning — Proper Recycling and Disposal of Fluids and Components...29
Exhaust Filter Ash Handling and Disposal...30
Prepare for Emergencies...31
Add Cab Guarding For Special Uses...32
Clean Debris from Machine...33
Use Steps and Handholds Correctly...34
Start Only From Operator's Seat...35
Use and Maintain Seat Belt...36
Prevent Unintended Machine Movement...37
Avoid Work Site Hazards...38
Keep Riders Off Machine...40
Avoid Backover Accidents...41
Avoid Machine Tip Over and Machine Damage...42
Operating or Traveling On Public Roads...44
Inspect and Maintain ROPS...45
Add and Operate Attachments Safely...46
Park and Prepare for Service Safely...47
Service Cooling System Safely...48
Remove Paint Before Welding or Heating...49
Make Welding Repairs Safely...50
Drive Metal Pins Safely...51
Clean Exhaust Filter Safely...52
Group 0003: Torque Values...14
Metric Bolt and Cap Screw Torque Values...57
Additional Metric Cap Screw Torque Values...59
Unified Inch Bolt and Cap Screw Torque Values...61
Service Recommendations for 37° Flare and 30° Cone Seat Connectors...63
Service Recommendations for O-Ring Boss Fittings...65
O-Ring Boss Fittings In Aluminum Housing Service Recommendations—Excavators...67
Service Recommendations for Flared Connections—Straight or Tapered Threads...70
Service Recommendations For Flat Face O-Ring Seal Fittings...72
O-Ring Face Seal Fittings With SAE Inch Hex Nut And Stud End For High Pressure Service Recommendations...74
O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For Standard Pressure Service Recommendations...76
O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For High Pressure Service Recommendations...79
Service Recommendations for Metric Series Four Bolt Flange Fitting...82
Service Recommendations For Inch Series Four Bolt Flange Fittings...84
Inch Series Four Bolt Flange Fitting For High Pressure Service Recommendations...86
Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings...88
Service Recommendations For O-Ring Boss Fittings With Shoulder...91
Metric 24° O-Ring Seal DIN 20078 Service Recommendations...94
Section 01: Tracks...98
Group 0130: Track System...98
Welding On Machine...101
Track Guides and Rock Guards Remove and Install...102
Carrier Roller Wear Inspection...107
Carrier Roller Remove and Install...108
Carrier Roller Disassemble and Assemble...110
Metal Face Seals Inspection...116
Carrier Roller Leakage Test...118
Track Roller Wear Inspection...120
Track Roller Remove and Install...123
Track Roller Disassemble and Assemble...126
Track Roller Leakage Test...138
Track Shoe Grouser Wear Inspection...140
Track Shoe Remove and Install...142
Pivot Shaft Remove and Install...145
Pivot Shaft Disassemble and Assemble...147
Crossbar Remove and Install...149
Crossbar Bushings and Seals Remove and Install...155
Track Link Height Inspection...158
Bushing Outside Diameter for Lubricated Track Chain Inspection...159
Track Pitch for Lubricated Track Chain Inspection...161
Lubricated Track Chain Remove and Install...163
Lubricated Track Chain to Turn Bushings and Lubricate Chain Disassemble...169
Lubricated Track Chain to Turn Bushings and Lubricate Chain Assemble...173
Lubricated Track Chain to Turn Pins and Bushings and Not Lubricate Disassemble and Assemble...182
Track Sag Adjustment...190
Track Adjuster Cylinder and Recoil Spring Remove and Install...193
Track Adjuster Recoil Spring Disassemble and Assemble...195
Track Adjuster Cylinder Disassemble and Assemble...208
Track Frame Remove and Install...213
Front Idler Wear Inspection...220
Front Idler Remove and Install...221
Front Idler Disassemble and Assemble...229
Front Idler Adjustment...240
Front Idler Oil Leakage Test...246
Sprocket Segment Remove and Install...248
Section 02: Axles and Suspension Systems...250
Group 0201: Drive Axle Housing and Support...250
Final Drive Remove and Install...256
Group 0250: Axle Shaft, Bearings and Reduction Gears...250
Planet Carrier Remove and Install...263
Planet Carrier Disassemble and Assemble...265
Ring Gear and Hub Remove and Install...267
Ring Gear and Hub Disassemble and Assemble...269
Final Drive Metal Face Seal Remove and Install...271
Inner Final Drive Housing Remove and Install...279
Inner Final Drive Housing Cover Disassemble and Assemble...282
Final Drive Seal Leakage Check...289
Section 03: Transmission...293
Group 0300: Remove and Install...293
Hydrostatic Pump and Motor Initial Start-Up Procedure...296
Hydrostatic Pump Remove and Install...298
Hydrostatic Motor Remove and Install...306
Group 0315: Control Linkage...293
Transmission Control Lever (TCL) Remove and Install...312
Transmission Control Lever (TCL) Disassemble and Assemble...314
Decelerator/Brake Pedal Remove and Install...338
Decelerator/Brake Pedal Disassemble and Assemble...339
Group 0325: Input Drive Shafts and U-Joints...293
Damper Drive Remove and Install...349
Group 0360: Hydrostatic System...293
Hydrostatic Pump Disassemble...363
Charge Pump Disassemble and Assemble...374
Pump Displacement Control Valve (PDCV) Disassemble and Assemble...380
Multi-Function Valve Remove and Install...382
Multi-Function Valve Disassemble and Assemble...383
Hydrostatic Pump Assemble...387
Hydrostatic Motor Disassemble...407
Hydrostatic Motor Assemble...414
Hydraulic Integrated Circuit (HIC) Valve Remove and Install...433
Hydraulic Integrated Circuit (HIC) Valve Disassemble and Assemble...436
Hydrostatic Reservoir Remove and Install...439
Hydrostatic Cold Start Valve Remove and Install...442
Section 04: Engine...444
Group 0400: Removal and Installation...444
John Deere Engine...446
Engine Remove and Install...447
Engine Mounts Remove and Install...455
Belt Routing...457
Section 05: Engine Auxiliary Systems...459
Group 0505: Cold Weather Starting Aid...459
Engine Coolant Heater Remove and Install...462
Group 0510: Cooling System...459
Cooling Package Plenum Remove and Install...467
Cooling Package Remove and Install...470
Charge Air Cooler Remove and Install...476
Radiator Remove and Install...478
Hydraulic Oil Cooler Remove and Install...479
Hydrostatic Oil Cooler Remove and Install...481
Fuel Cooler Remove and Install...482
Group 0520: Intake System...459
Air Cleaner Remove and Install...486
Strata Strata is a trademark of Donaldson Company Inc. Cap Precleaner Remove and Install—If Equipped...459
Large Debris Precleaner Remove and Install—If Equipped...489
Group 0530: External Exhaust Systems...459
Exhaust Tube Remove and Install...494
JDG11335 Bellows Alignment Fixture...497
Exhaust Bellows Alignment Procedure...504
Diesel Particulate Filter (DPF) Remove and Install...509
Exhaust Filter Remove and Install...512
Service Filter Cleaning...515
Group 0560: External Fuel Supply Systems...459
Fuel Tank Remove and Install...519
Primary Fuel Filter and Water Separator Remove and Install...522
Secondary Fuel Filter Remove and Install...524
Auxiliary Fuel Filter and Water Separator Remove and Install—If Equipped...526
Fast Fill Fuel System Disassemble and Assemble...528
Section 11: Park Brake...529
Group 1100: Park Brake...529
Park Brake Remove and Install...532
Group 1115: Control Linkage...529
Park Lock Linkage Remove and Install...537
Park Lock Linkage Disassemble and Assemble...540
Group 1160: Hydraulic System...529
Park Brake Disassemble and Assemble...552
Section 15: Equipment Attaching...560
Group 1511: Drawbar...560
Extended Rigid Drawbar Remove and Install...565
Rigid Drawbar Remove and Install...565
Section 17: Frames, Chassis, or Supporting Structure...566
Group 1740: Frame Installation...566
Welding Repair of Major Structures...569
Group 1746: Frame Bottom Guards...566
Bottom Guards Remove and Install...572
Group 1749: Chassis Weights...566
Front Counterweight Remove and Install...575
Rear Counterweight Remove and Install...577
Section 18: Operator’s Station...579
Group 1800: Removal and Installation...579
Cab/ROPS Remove and Install...584
Group 1810: Operator Enclosure...579
Slide Glass Remove and Install...589
Stationary Glass Remove and Install...591
Windowpanes Remove and Install...593
Window Wiper Motor Remove and Install...596
Window Washer Pumps Remove and Install...606
Hand Pump Bleed Procedure...607
Group 1821: Seat and Seat Belt...579
Seat Remove and Install...611
Seat Belt Remove and Install...614
Group 1830: Heating and Air Conditioning...579
R134a Refrigerant Cautions and Proper Handling...617
R134a Refrigerant Cautions...618
R134a Compressor Oil Removal...619
R134a Component Oil Charge...620
Refrigerant Leakage Testing...622
Refrigerant Hoses and Tubing Inspection...623
R134a Refrigerant Recovery, Recycling and Charging Station Installation Procedure...624
Recover R134a System...626
Evacuate R134a System...627
Charge R134a System...629
Air Conditioner System Cleaning Procedures...630
Flush and Purge Air Conditioner System...631
Evaporator or Heater Core Remove and Install...634
Expansion Valve Remove and Install...637
Cab Heater Blower Motor and Heater Blower Resistor Remove and Install...639
Cab Heater Disassemble and Assemble...640
Cab or ROPS Under Seat Heater Disassemble and Assemble...642
Receiver-Dryer Remove and Install...644
Condenser Remove and Install...645
Compressor Remove and Install...646
Section 19: Sheet Metal...649
Group 1910: Hood and Engine Enclosures...649
Hood Remove and Install...652
Engine Side Shields Remove and Install...654
Rear Hood Support Remove and Install...655
Front Hood Support Remove and Install...657
Group 1921: Grille and Grille Housing...649
Grille Remove and Install...663
Section 20: Safety, Convenience and Miscellaneous...666
Group 2004: Horn and Warning Devices...666
Remove and Install Reverse Alarm...668
Adjust Reverse Warning Alarm Volume...669
Section 21: Main Hydraulic System...670
Group 2160: Hydraulic System...670
General Oil Cleanup Procedure...674
Hydraulic Component Failure Cleanup Procedure...677
Hydraulic Pump Remove and Install...681
Hydraulic Pump Disassemble and Assemble...686
Hydraulic Pump Control Valve Disassemble and Assemble...688
Hydraulic Fan Motor Remove and Install...691
Hydraulic Fan Pump Remove and Install...694
Hydraulic Fan Reversing Valve Remove and Install...696
Hydraulic Fan Reversing Valve Disassemble and Assemble...698
Hydraulic Reservoir Remove and Install...699
Hydraulic Reservoir Cleanout Cover Remove and Install...703
Hydraulic Oil Cooler Bypass Valve Remove and Install...707
Section 32: Bulldozer...708
Group 3201: Blade...708
Cutting Edges and End Bits Remove and Install...711
Blade Remove and Install...713
Group 3240: Frames...708
Outside Dozer Push Beams Remove and Install...733
C-Frame Remove and Install...749
Group 3260: Hydraulic System...708
Hydraulic Control Valve Remove and Install...754
Hydraulic Control Valve Disassemble and Assemble...756
Hydraulic Control Valve Disassemble and Assemble—IGC...759
Pilot Control Valve Remove and Install...762
Pilot Control Valve Disassemble and Assemble...765
Integrated Grade Control (IGC) Lever Remove and Install...768
Integrated Grade Control (IGC) Lever Disassemble and Assemble...770
Quick-Drop Valve Remove and Install...771
Power Angle Tilt (PAT) Cylinder Remove and Install...773
Angle Cylinder (PAT) Remove and Install...774
Hydraulic Cylinder Repair...776
Section 42: Ground Conditioning Tool...777
Group 4200: Ripper...777
Ripper Remove and Install—If Equipped...783
Group 4201: Blades, Teeth, and Shanks...777
Shank and Tooth Remove and Install...790
Group 4260: Hydraulic System...777
Auxiliary Joystick Remove and Install—IGC...794
Auxiliary Pilot Control Valve Remove and Install...796
Ripper Cylinder Remove and Install...798
Section 99: Dealer Fabricated Tools...801
Group 9900: Dealer Fabricated Tools...801
DF1041 Track Nut Removal Tool...803
DF1063 Final Drive Lift Bracket...804
DF1065 Final Drive and Pump Adapter Bracket...806
DFT1132 Hydrostatic Motor Removal and Installation Tool...807
DFT1137 Hydrostatic Motor Removal and Installation Tool...808
DFT1167 Final Drive Lifting Bracket Adapter Spacer...809
DFT1243 Lifting Bracket Extension...810
DFT1250 Lifting Bracket...811
DFT1260 Final Drive Lifting Fixture...813
DFT1261 Rolling Torque Measurement Tool...815
DFT1302 Final Drive Pressure Test Adapter...816
John Deere 755K Crawler Loader Repair Service Manual (TM12269)
