John Deere 755K Crawler Loader Workshop Repair Manual TM12269 PDF - MJODTM12269.zip

A thorough service guide for the John Deere 755K Crawler Loader, containing every bit of workshop data needed to service, fix, and overhaul the machine the way expert technicians do.

The John Deere 755K Crawler Loader service repair manual contains:

* 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