John Deere 655K Crawler Loader Repair Service Manual (TM12721)

TM12721 - John Deere 655K Crawler Loader Technical Manual - Repair.PDF

Complete service repair manual for John Deere 655K Crawler Loader, with all the shop information to maintain, diagnostic, repair, refurbish/rebuild like professional mechanics.

John Deere 655K Crawler Loader workshop service 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.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* 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.

Total Pages: 806 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

MAIN SECTIONS
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
      Hydraulic 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
   Frame 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 and Convenience
      Horn and Warning Devices
   Vehicle Main Hydraulic System
      Hydraulic System
   Loader
      Bucket
      Frames
      Loader Hydraulic System
   Ground Conditioning Tool
      Remove and Install
      Blades, Teeth, and Shanks
      Hydraulic System
   Dealer Fabricated Tools

tm12721 - 655K Crawler Loader (PIN: 1T0655KX_ _E233169— )

Table of Contents

Foreword

Technical Information Feedback Form

Section 00: General Information

Group 0001: Safety

Recognize Safety Information

Follow Safety Instructions

Operate Only If Qualified

Wear Protective Equipment

Avoid Unauthorized Machine Modifications

Inspect Machine

Stay Clear of Moving Parts

Avoid High-Pressure Fluids

Avoid High-Pressure Oils

Work In Ventilated Area

Prevent Fires

Prevent Battery Explosions

Handle Chemical Products Safely

Decommissioning — Proper Recycling and Disposal of Fluids and Components

Exhaust Filter Ash Handling and Disposal

Prepare for Emergencies

Clean Debris from Machine

Add Cab Guarding for Special Uses

Use Steps and Handholds Correctly

Start Only From Operator's Seat

Use and Maintain Seat Belt

Prevent Unintended Machine Movement

Avoid Work Site Hazards

Keep Riders Off Machine

Avoid Backover Accidents

Avoid Machine Tip Over and Machine Damage

Operating or Traveling On Public Roads

Inspect and Maintain ROPS

Add and Operate Attachments Safely

Park and Prepare for Service Safely

Service Cooling System Safely

Remove Paint Before Welding or Heating

Make Welding Repairs Safely

Drive Metal Pins Safely

Clean Exhaust Filter Safely

Group 03: Torque Values

Metric Bolt and Cap Screw Torque Values

Additional Metric Cap Screw Torque Values

Unified Inch Bolt and Cap Screw Torque Values

Service Recommendations for 37° Flare and 30° Cone Seat Connectors

Service Recommendations for O-Ring Boss Fittings

O-Ring Boss Fittings In Aluminum Housing Service Recommendations—Excavators

Service Recommendations for Flared Connections—Straight or Tapered Threads

Service Recommendations For Flat Face O-Ring Seal Fittings

O-Ring Face Seal Fittings With SAE Inch Hex Nut And Stud End For High Pressure Service Recommendations

O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For Standard Pressure Service Recommendations

O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For High Pressure Service Recommendations

Service Recommendations for Metric Series Four Bolt Flange Fitting

Service Recommendations For Inch Series Four Bolt Flange Fittings

Inch Series Four Bolt Flange Fitting For High Pressure Service Recommendations

Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings

Service Recommendations For O-Ring Boss Fittings With Shoulder

Metric 24° O-Ring Seal DIN 20078 Service Recommendations

Section 01: Tracks

Group 0130: Track System

Welding On Machine

Track Guides and Rock Guards Remove and Install

Carrier Roller Wear Inspection

Carrier Roller Remove and Install

Carrier Roller Disassemble and Assemble

Metal Face Seal Inspection

Carrier Roller Leakage Test

Track Roller Wear Inspection

Track Roller Remove and Install

Track Roller Disassemble and Assemble

Track Roller Leakage Test

Track Grouser Wear Inspection

Track Shoe Remove and Install

Pivot Shaft Remove and Install

Pivot Shaft Disassemble and Assemble

Crossbar Remove and Install

Crossbar Bushings and Seals Remove and Install

Track Link Height Inspection

Bushing Outside Diameter for Lubricated Track Chain Inspection

Track Pitch for Lubricated Track Chain Inspection

Track Chain Remove and Install

Lubricated Track Chain to Turn Bushings and Lubricate Chain Disassemble

Lubricated Track Chain to Turn Bushings and Lubricate Chain Assemble

Lubricated Track Chain to Turn Pins and Bushings and Not Lubricate Disassemble and Assemble

Track Sag Adjustment

Track Adjuster Cylinder and Recoil Spring Remove and Install

Track Adjuster Recoil Spring Disassemble and Assemble

Track Adjuster Cylinder Disassemble and Assemble

Track Frame Remove and Install

Front Idler Wear Inspection

Front Idler Remove and Install

Front Idler Disassemble and Assemble

Front Idler Vertical Movement Adjustment

Front Idler Leakage Test

Sprocket Segment Remove and Install

Section 02: Axles and Suspension Systems

Group 0201: Drive Axle Housing and Support

Final Drive Remove and Install

Group 0250: Axle Shaft, Bearings and Reduction Gears

Planet Carrier Remove and Install

Planet Carrier Disassemble and Assemble

Ring Gear and Hub Remove and Install

Ring Gear and Hub Disassemble and Assemble

Final Drive Metal Face Seal Remove and Install

Inner Final Drive Housing Remove and Install

Inner Final Drive Housing Cover Disassemble and Assemble

Final Drive Seal Leakage Check

Section 03: Transmission

Group 0300: Remove and Install

Hydrostatic Pump and Motor Initial Start-Up Procedure

Hydrostatic Pump Remove and Install

Hydrostatic Motor Remove and Install

Group 0315: Control Linkage

Transmission Control Lever (TCL) Remove and Install

Decelerator/Brake Pedal Remove and Install

Decelerator/Brake Pedal Disassemble and Assemble

Steering Pedal Remove and Install—If Equipped

Steering Pedal Disassemble and Assemble—If Equipped

Group 0325: Input Drive Shafts and U-Joints

Damper Drive Remove and Install

Group 0360: Hydraulic System

Hydrostatic Pump Disassemble

Charge Pump Disassemble and Assemble

Pump Displacement Control Valve (PDCV) Disassemble and Assemble

Multi-Function Valve Remove and Install

Multi-Function Valve Disassemble and Assemble

Hydrostatic Pump Assemble

Hydrostatic Motor Disassemble

Hydrostatic Motor Assemble

Hydraulic Integrated Circuit (HIC) Valve Remove and Install

Hydraulic Integrated Circuit (HIC) Valve Disassemble and Assemble

Hydrostatic Reservoir Remove and Install

Hydrostatic Cold Start Valve Remove and Install

Section 04: Engine

Group 0400: Removal and Installation

John Deere Engine

Engine Remove and Install

Engine Mounts Remove and Install

Belt Routing

Section 05: Engine Auxiliary Systems

Group 0505: Cold Weather Starting Aid

Engine Coolant Heater Remove and Install

Group 0510: Cooling System

Cooling Package Plenum Remove and Install

Cooling Package Remove and Install

Charge Air Cooler Remove and Install

Radiator Remove and Install

Hydraulic Oil Cooler Remove and Install

Hydrostatic Oil Cooler Remove and Install

Fuel Cooler Remove and Install

Group 0520: Intake System

Air Cleaner Remove and Install

Precleaner Remove and Install—If Equipped

Group 0530: External Exhaust Systems

Exhaust Tube Remove and Install

Diesel Particulate Filter (DPF) Remove and Install

Exhaust Filter Remove and Install

Service Filter Cleaning

Group 0560: External Fuel Supply Systems

Fuel Tank Remove and Install

Fuel Tank Covers Remove and Install

Primary Fuel Filter and Water Separator Remove and Install

Final Fuel Filter Remove and Install

Auxiliary Fuel Filter and Water Separator Remove and Install—If Equipped

Section 11: Park Brake

Group 1100: Park Brake

Park Brake Remove and Install

Group 1115: Control Linkage

Park Lock Lever Remove and Install

Park Lock Lever Disassemble and Assemble

Group 1160: Hydraulic System

Park Brake Disassemble and Assemble

Section 15: Equipment Attaching

Group 1511: Drawbar

Retrieval Clevis Remove and Install

Retrieval Hitch Remove and Install—If Equipped

Section 17: Frame or Supporting Structure

Group 1740: Frame Installation

Welding Repair of Major Structure

Group 1746: Frame Bottom Guards

Bottom Guards Remove and Install

Group 1749: Chassis Weights

Rear Counterweight Remove and Install

Section 18: Operator’s Station

Group 1800: Removal and Installation

Cab/ROPS Remove and Install

Group 1810: Operator Enclosure

Windowpanes Remove and Install

Wiper Motor Remove and Install

Washer Pump Remove and Install

Hand Pump Bleed Procedure

Group 1821: Seat and Seat Belt

Seat Remove and Install

Seat Belt Remove and Install

Group 1830: Heating and Air Conditioning

Proper Refrigerant Handling

R134a Refrigerant Cautions

R134a Compressor Oil Charge Check

R134a Compressor Oil Removal

R134a Component Oil Charge

Leakage Testing

Refrigerant Hoses and Tubing Inspection

R134a Refrigerant Recovery, Recycling and Charging Station Installation Procedure

Recover R134a System

Evacuate R134a System

Charge R134a System

Air Conditioner System Cleaning Procedures

Purge R134a System

Flush R134a System

Evaporator or Heater Core Remove and Install

Expansion Valve Remove and Install

Air Conditioner Freeze Switch Remove and Install

Cab Heater Blower Motor and Blower Motor Speed Resistor Remove and Install

Cab Upper Heater Components

Cab or ROPS Under Seat Heater Disassemble and Assemble

Receiver-Dryer Remove and Install

Condenser Remove and Install

Compressor Remove and Install

Section 19: Sheet Metal

Group 1910: Hood and Engine Enclosures

Engine Side Door Assembly Remove and Install

Hood Remove and Install

Group 1921: Grille and Grille Housing

Grille Remove and Install

Section 20: Safety and Convenience

Group 2004: Horn and Warning Devices

Backup Alarm Remove and Install

Backup Alarm Volume Adjustment

Section 21: Vehicle Main Hydraulic System

Group 2160: Hydraulic System

General Oil Cleanup Procedure

Hydraulic/Hydrostatic Component Failure Cleanup Procedure

Hydraulic Pump Remove and Install

Hydraulic Fan Motor Remove and Install

Hydraulic Fan Pump Remove and Install

Hydraulic Fan Reversing Valve Remove and Install

Hydraulic Fan Reversing Valve Disassemble and Assemble

Hydraulic Reservoir Remove and Install

Hydraulic Reservoir Cleanout Cover Remove and Install

Thermal Bypass Valve Remove and Install

Section 31: Loader

Group 3102: Bucket

Standard and Multipurpose Bucket Remove and Install

Multipurpose Bucket and Lines Disassemble and Assemble

Shank and Tooth Remove and Install

Cracked Cutting Edge Repair

Group 3140: Frames

Boom Remove and Install

Boom Bushings and Seals Remove and Install

Group 3160: Loader Hydraulic System

Hydraulic Control Valve Remove and Install

Hydraulic Control Valve Disassemble and Assemble

System Relief Valve Remove and Install

Pilot Control Valve Remove and Install

Bucket Cylinder Remove and Install

Bucket Cylinder Disassemble and Assemble

Boom Cylinder Remove and Install

Boom Cylinder Disassemble and Assemble

Loader Start-Up Procedure (Hydraulic Cylinder Bleed Procedure)

Boom and Bucket Cylinder Position Sensor Calibration

Multipurpose Bucket Cylinder Disassemble and Assemble

Section 42: Ground Conditioning Tool

Group 4200: Remove and Install

Ripper Remove and Install—If Equipped

Group 4201: Blades, Teeth, and Shanks

Shank and Tooth Remove and Install

Group 4260: Hydraulic System

Auxiliary Control Valve Disassemble and Assemble

Ripper Pilot Control Valve Remove and Install

Ripper Cylinder Remove and Install

Ripper Cylinder Disassemble and Assemble

Section 99: Dealer Fabricated Tools

Group 9900: Dealer Fabricated Tools

DF1063 Final Drive Lift Bracket

DF1065 Final Drive and Pump Adapter Bracket

DFT1167 Final Drive Lifting Bracket Adapter Spacer

DFT1243 Lifting Bracket Extension

DFT1250 Lifting Bracket

DFT1260 Final Drive Lifting Fixture

DFT1261 Rolling Torque Measurement Tool

DFT1302 Final Drive Pressure Test Adapter