John Deere 755K Crawler Loader Repair Service Manual (TM12052)
Complete repair technical 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.
TM12052 - John Deere 755K Crawler Loader Technical Manual - Repair.PDF
TM12052 - John Deere 755K Crawler Loader Technical Manual - Repair.PDF
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PRODUCT DETAILS:
Total Pages: 814 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Category: Repair
Language: Spanish English French
John Deere - Crawler - 1T0755KX_ _E192242—339206
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
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
Clean Debris from Machine...32
Add Cab Guarding for Special Uses...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 03: 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...105
Carrier Roller Remove and Install...106
Carrier Roller Disassemble and Assemble...108
Metal Face Seal Inspection...114
Carrier Roller Leakage Test...116
Track Roller Wear Inspection...118
Track Roller Remove and Install...120
Track Roller Disassemble and Assemble...122
Track Roller Leakage Test...133
Track Grouser Wear Inspection...136
Track Shoe Remove and Install...137
Pivot Shaft Remove and Install...139
Pivot Shaft Disassemble and Assemble...141
Crossbar Remove and Install...143
Crossbar Bushings and Seals Remove and Install...149
Track Link Height Inspection...152
Bushing Outside Diameter for Lubricated Track Chain Inspection...153
Track Pitch for Lubricated Track Chain Inspection...155
Track Chain Remove and Install...156
Lubricated Track Chain to Turn Bushings and Lubricate Chain Disassemble...161
Lubricated Track Chain to Turn Bushings and Lubricate Chain Assemble...165
Lubricated Track Chain to Turn Pins and Bushings and Not Lubricate Disassemble and Assemble...174
Track Sag Adjustment...182
Track Adjuster Cylinder and Recoil Spring Remove and Install...185
Track Adjuster Recoil Spring Disassemble and Assemble...187
Track Adjuster Cylinder Disassemble and Assemble...196
Track Frame Remove and Install...200
Front Idler Wear Inspection...206
Front Idler Remove and Install...207
Front Idler Disassemble and Assemble...215
Front Idler Adjustment...225
Front Idler Leakage Test...231
Sprocket Segment Remove and Install...233
Section 02: Axles and Suspension Systems...235
Group 0201: Drive Axle Housing and Support...235
Final Drive Remove and Install...242
Group 0250: Axle Shaft, Bearings and Reduction Gears...235
Planet Carrier Remove and Install...250
Planet Carrier Disassemble and Assemble...252
Ring Gear and Hub Remove and Install...254
Ring Gear and Hub Disassemble and Assemble...256
Final Drive Metal Face Seal Remove and Install...258
Inner Final Drive Housing Remove and Install...266
Inner Final Drive Housing Cover Disassemble and Assemble...269
Final Drive Seal Leakage Check...276
Section 03: Transmission...280
Group 0300: Remove and Install...280
Hydrostatic Pump and Motor Initial Start-Up Procedure...283
Hydrostatic Pump Remove and Install...285
Hydrostatic Motor Remove and Install...292
Group 0315: Control Linkage...280
Transmission Control Lever (TCL) Remove and Install...299
Transmission Control Lever (TCL) Adjustment...305
Decelerator/Brake Pedal Remove and Install...307
Decelerator/Brake Pedal Disassemble and Assemble...308
Steering Pedal Remove and Install—If Equipped...315
Steering Pedal Disassemble and Assemble—If Equipped...317
Group 0325: Input Drive Shafts and U-Joints...280
Dampener Drive Remove and Install...322
Group 0360: Hydraulic System...280
Hydrostatic Pump Disassemble...339
Charge Pump Disassemble and Assemble...353
Pump Displacement Control Valve (PDCV) Disassemble and Assemble...359
Multi-Function Valve Remove and Install...361
Multi-Function Valve Disassemble and Assemble...362
Hydrostatic Pump Assemble...366
Hydrostatic Motor Disassemble...386
Hydrostatic Motor Assemble...393
Hydraulic Integrated Circuit (HIC) Valve Remove and Install...412
Hydraulic Integrated Circuit (HIC) Valve Disassemble and Assemble...417
Hydrostatic Reservoir Remove and Install...421
Hydrostatic Cold Start Valve Remove and Install...427
Section 04: Engine...429
Group 0400: Removal and Installation...429
John Deere Engine...431
Engine Remove and Install...432
Engine Mounts Remove and Install...442
Belt Routing...444
Section 05: Engine Auxiliary Systems...445
Group 0505: Cold Weather Starting Aid...445
Engine Coolant Heater Remove and Install...448
Group 0510: Cooling System...445
Cooling Package Plenum Remove and Install...453
Cooling Package Remove and Install...456
Charge Air Cooler Remove and Install...464
Radiator Remove and Install...466
Hydraulic Oil Cooler Remove and Install...470
Hydrostatic Oil Cooler Remove and Install...473
Fuel Cooler Remove and Install...475
Group 0520: Intake System...445
Air Cleaner Remove and Install...480
Precleaner Remove and Install—If Equipped...483
Group 0530: External Exhaust Systems...445
Exhaust Tube Remove and Install...486
JDG11335 Bellows Alignment Fixture...488
Exhaust Bellows Alignment Procedure...495
Diesel Particulate Filter (DPF) Remove and Install...499
Exhaust Filter Remove and Install...501
Service Filter Cleaning...503
Group 0560: External Fuel Supply Systems...445
Fuel Tank Remove and Install...509
Fuel Tank Cover Remove and Install...514
Primary Fuel Filter and Water Separator Remove and Install...516
Final Fuel Filter Remove and Install...518
Auxiliary Fuel Filter and Water Separator Remove and Install—If Equipped...520
Fast Fill Fuel System Disassemble and Assemble...522
Section 11: Park Brake...523
Group 1100: Park Brake...523
Park Brake Remove and Install...526
Group 1115: Control Linkage...523
Park Lock Lever Remove and Install...530
Park Lock Lever Disassemble and Assemble...532
Group 1160: Hydraulic System...523
Park Brake Disassemble and Assemble...544
Section 15: Equipment Attaching...552
Group 1511: Drawbar...552
Retrieval Clevis Remove and Install...554
Retrieval Hitch Remove and Install—If Equipped...555
Section 17: Frame or Supporting Structure...556
Group 1740: Frame Installation...556
Welding Repair of Major Structure...559
Group 1746: Frame Bottom Guards...556
Bottom Guards Remove and Install...563
Group 1749: Chassis Weights...556
Rear Counterweight Remove and Install...567
Section 18: Operator’s Station...569
Group 1800: Removal and Installation...569
Cab/ROPS Remove and Install...578
Group 1810: Operator Enclosure...569
Windowpanes Remove and Install...588
Wiper Motor Remove and Install...591
Washer Pump Remove and Install...595
Hand Pump Bleed Procedure...596
Group 1821: Seat and Seat Belt...569
Seat Remove and Install...599
Seat Belt Remove and Install...601
Group 1830: Heating and Air Conditioning...569
Proper Refrigerant Handling...604
R134a Refrigerant Cautions...605
R134a Compressor Oil Charge Check...606
R134a Compressor Oil Removal...608
R134a Component Oil Charge...609
Leakage Testing...611
Refrigerant Hoses and Tubing Inspection...612
R134a Refrigerant Recovery, Recycling and Charging Station Installation Procedure...613
Recover R134a System...615
Evacuate R134a System...617
Charge R134a System...619
Air Conditioner System Cleaning Procedures...621
Purge R134a System...622
Flush R134a System...623
Evaporator or Heater Core Remove and Install...626
Expansion Valve Remove and Install...629
Air Conditioner Freeze Switch Remove and Install...631
Cab Heater Blower Motor and Blower Motor Speed Resistor Remove and Install...632
Cab Upper Heater Components...634
Cab or ROPS Under Seat Heater Disassemble and Assemble...636
Receiver-Dryer Remove and Install...639
Condenser Remove and Install...640
Compressor Remove and Install...642
Compressor Clutch Disassemble and Assemble...644
Clutch Hub Clearance Check...646
Section 19: Sheet Metal...647
Group 1910: Hood and Engine Enclosures...647
Engine Side Door Assembly Remove and Install...650
Hood Remove and Install...652
Group 1921: Grille and Grille Housing...647
Grille Remove and Install...656
Section 20: Safety and Convenience...657
Group 2004: Horn and Warning Devices...657
Backup Alarm Remove and Install...659
Backup Alarm Volume Adjustment...660
Section 21: Vehicle Main Hydraulic System...661
Group 2160: Hydraulic System...661
General Oil Cleanup Procedure...665
Hydraulic/Hydrostatic Component Failure Cleanup Procedure...668
Hydraulic Pump Remove and Install...672
Hydraulic Fan Motor Remove and Install...675
Hydraulic Fan Pump Remove and Install...678
Hydraulic Fan Reversing Valve Remove and Install...680
Hydraulic Fan Reversing Valve Disassemble and Assemble...682
Hydraulic Reservoir Remove and Install...684
Hydraulic Reservoir Cleanout Cover Remove and Install...691
Thermal Bypass Valve Remove and Install...695
Section 31: Loader...697
Group 3102: Bucket...697
NeverGrease™ Pin Joints...702
Standard and Multipurpose Bucket Remove and Install...706
Multipurpose Bucket and Lines Disassemble and Assemble...716
Shank and Tooth Remove and Install...788
Cracked Cutting Edge Repair...721
Group 3140: Frames...697
Boom Remove and Install...733
Boom Bushings and Seals Remove and Install...744
Group 3160: Loader Hydraulic System...697
Hydraulic Control Valve Remove and Install...751
Hydraulic Control Valve Disassemble and Assemble...756
System Relief Valve Remove and Install...765
Pilot Control Valve Remove and Install...767
Bucket Cylinder Remove and Install...769
Bucket Cylinder Disassemble and Assemble...772
Boom Cylinder Remove and Install...773
Boom Cylinder Disassemble and Assemble...775
Loader Start-Up Procedure (Hydraulic Cylinder Bleed Procedure)...776
Boom and Bucket Cylinder Position Sensor Calibration...777
Multipurpose Bucket Cylinder Disassemble and Assemble...778
Section 42: Ground Conditioning Tool...779
Group 4200: Remove and Install...779
Ripper Remove and Install—If Equipped...783
Group 4201: Blades, Teeth, and Shanks...779
Shank and Tooth Remove and Install...788
Group 4260: Hydraulic System...779
Auxiliary Control Valve Disassemble and Assemble...791
Ripper Pilot Control Valve Remove and Install...792
Ripper Cylinder Remove and Install...794
Ripper Cylinder Disassemble and Assemble...799
Section 9900: Dealer Fabricated Tools...800
Group 9900: Dealer Fabricated Tools...800
DF1063 Final Drive Lift Bracket...803
DF1065 Final Drive and Pump Adapter Bracket...805
DFT1167 Final Drive Lifting Bracket Adapter Spacer...806
DFT1243 Lifting Bracket Extension...807
DFT1250 Lifting Bracket...808
DFT1260 Final Drive Lifting Fixture...810
DFT1261 Rolling Torque Measurement Tool...812
DFT1302 Final Drive Pressure Test Adapter...813
John Deere 755K Crawler Loader Repair Service Manual (TM12052)
