John Deere 4475 5575 6675 7775 Skid Steer Loader Technical Manual TM1553 PDF

CONTENTS
SPECIFICATIONS & INFORMATION
GENERAL VEHICLE SPECIFICATIONS 2
UNIFIED INCH TORQUE VALUES 7
METRIC TORQUE VALUES 8
DIESEL FUEL SPECIFICATIONS 9
DIESEL FUEL STORAGE 9
LUBRICANT SPECIFICATIONS 10
ENGINE OIL 10
GREASE 10
TRANSMISSION AND HYDRAULIC OIL 11
CHAIN CASE OIL 11
GEARBOX OIL 11
ALTERNATIVE LUBRICANTS 11
SYNTHETIC LUBRICANTS11
OIL FILTERS 11
LUBRICANT STORAGE 11
ENGINE COOLANT 12
SERIAL NUMBER LOCATION 12
SKID STEER LOADER PRODUCT IDENTIFICATION NUMBER 12
ENGINE SERIAL NUMBER 12

DIESEL ENGINE
SPECIFICATIONS — 3015D001 (3TNE84) 5
GENERAL SPECIFICATIONS 5
REPAIR SPECIFICATIONS 5
CHECKS, TESTS AND ADJUSTMENTS 11
OPERATIONAL TESTS 12
SPECIFICATIONS – 4020D001 (4TNE84) 13
GENERAL SPECIFICATIONS 13
REPAIR SPECIFICATIONS 13
CHECKS, TESTS AND ADJUSTMENTS 19
OPERATIONAL TESTS 20
SPECIFICATIONS – 3017D001 (3TNE88) 21
GENERAL SPECIFICATIONS 21
REPAIR SPECIFICATIONS 22
CHECKS, TESTS AND ADJUSTMENTS 28
OPERATIONAL TESTS 29
SPECIFICATIONS – 4022D001 (4TNE88) 30
GENERAL SPECIFICATIONS 30
REPAIR SPECIFICATIONS 30
CHECKS, TESTS AND ADJUSTMENTS 36
OPERATIONAL TESTS 37
ENGINE COMPONENT LOCATION 38
THEORY OF OPERATION 39
COOLING SYSTEM OPERATION 39
LUBRICATION SYSTEM OPERATION 40
FUEL AND AIR SYSTEM OPERATION 42
TROUBLESHOOTING 44
ENGINE SYSTEM DIAGNOSIS 46
CHECKS, TESTS AND ADJUSTMENTS 48
CYLINDER COMPRESSION PRESSURE TEST 48
THROTTLE CONTROL ADJUSTMENT 48
FUEL SHUTOFF SOLENOID ADJUSTMENT 49
SLOW IDLE ADJUSTMENT 49
FAST IDLE ADJUSTMENT 50
INJECTION PUMP TIMING ADJUSTMENT 50
VALVE CLEARANCE CHECK AND ADJUSTMENT 51
CONNECTING ROD SIDE PLAY CHECK 52
CONNECTING ROD BEARING CLEARANCE CHECK 52
CRANKSHAFT END PLAY CHECK 53
CRANKSHAFT MAIN BEARING CLEARANCE CHECK 54
VALVE LIFT CHECK 54
CAMSHAFT END PLAY CHECK 55
TIMING GEAR BACKLASH CHECK 55
FUEL INJECTION NOZZLE TEST (HOLE-TYPE) 56
THERMOSTAT OPENING TEST 58
INJECTION PUMP STATIC TIMING ADJUSTMENT 59
FAN/ALTERNATOR DRIVE BELT ADJUSTMENT 60
RADIATOR BUBBLE TEST 61
COOLING SYSTEM PRESSURE TEST 61
RADIATOR CAP PRESSURE TEST 62
ENGINE OIL PRESSURE TEST 62
AIR INTAKE SYSTEM LEAKAGE TEST 63
FUEL SUPPLY PUMP PRESSURE TEST 63
FUEL SYSTEM LEAKAGE TEST 64
BLEED FUEL SYSTEM 64
ENGINE REMOVAL 65
ENGINE REMOVAL WITH CAB TILTED 65
ENGINE REMOVAL WITHOUT CAB TILTED 66
CYLINDER HEAD, VALVES AND MANIFOLDS 67
SPECIAL OR ESSENTIAL TOOLS 67
SERVICE PARTS KITS 67
ROCKER ARM COVER 68
ROCKER ARM ASSEMBLY 69
INSPECTION 71
CYLINDER HEAD AND VALVES 72
REMOVAL/INSTALLATION 72
EXHAUST MANIFOLD 78
INTAKE MANIFOLD 79
GRIND VALVE SEATS 79
LAP VALVES 80
MEASURE PISTON-TO-CYLINDER HEAD CLEARANCE 80
PISTONS, RODS AND CYLINDER BLOCK 81
SERVICE PARTS KITS 81
PISTON AND CONNECTING ROD 81
ASSEMBLY 82
CYLINDER BORE 87
REBORING 88
CRANKSHAFT, MAIN BEARINGS AND FLYWHEEL 89
OTHER MATERIALS 89
SERVICE PARTS KITS 89
CRANKCASE EXTENSION HOUSING 89
CRANKSHAFT REAR OIL SEAL 90
CRANKSHAFT FRONT OIL SEAL 90
CRANKSHAFT AND MAIN BEARINGS 90
FLYWHEEL 96
FLYWHEEL HOUSING 96
CAMSHAFT AND TIMING GEAR TRAIN 97
SPECIAL OR ESSENTIAL TOOLS 97
OTHER MATERIALS 97
SERVICE PARTS KITS 97
CAMSHAFT 97
CAM FOLLOWERS 100
TIMING GEAR COVER 101
IDLER GEAR 103
TIMING GEAR COVER MOUNTING PLATE 104
LUBRICATION SYSTEM 105
OTHER MATERIALS 105
OIL PAN AND STRAINER 105
OIL PUMP 106
OIL PRESSURE REGULATING VALVE 108
COOLING SYSTEM 109
THERMOSTAT AND WATER PUMP 109
FUEL SYSTEM 110
SPECIAL OR ESSENTIAL TOOLS 110
SERVICE PARTS KITS 110
FUEL FILTER ASSEMBLY 111
FUEL INJECTION PUMP 112
FUEL INJECTION NOZZLES 114
STARTER – NIPPONDENSO 117
MOTOR ASSEMBLY 118
MOTOR INSPECTION/TEST 119
STARTER GEAR TRAIN 120
STARTER SOLENOID 122
VOLTAGE REGULATOR – HITACHI 40A 123
ALTERNATOR – HITACHI 40A 123
DISASSEMBLY 123
ASSEMBLY 125
INSPECTION/TEST 125

ELECTRICAL
SPECIFICATIONS 3
ELECTRICAL DIAGNOSTIC INFORMATION 4
READING ELECTRICAL SCHEMATICS4
THEORY OF OPERATION INFORMATION 5
DIAGNOSTIC INFORMATION5
COMMON CIRCUIT TESTS 5
WIRE COLOR ABBREVIATION CHART 5
ELECTRONIC INSTRUMENT PANEL MODULE OPERATION 6
TROUBLESHOOTING CHART12
COMPONENT LOCATION 13
ELECTRICAL SCHEMATIC 14
WIRING HARNESS17
POWER CIRCUIT OPERATION 18
CIRCUIT OPERATION AND DIAGNOSIS 19
POWER CIRCUIT OPERATION 19
UNSWITCHED POWER CIRCUITS 19
SWITCHED POWER CIRCUIT 19
POWER CIRCUIT DIAGNOSIS20
CRANKING CIRCUIT OPERATION 22
CRANKING CIRCUIT DIAGNOSIS 24
CHARGING CIRCUIT, VOLTMETER, AND BATTERY LIGHT OPERATION26
TACHOMETER CIRCUIT OPERATION26
HOURMETER CIRCUIT OPERATION 26
CHARGING CIRCUIT, VOLTMETER, AND BATTERY LIGHT DIAGNOSIS 28
TACHOMETER CIRCUIT DIAGNOSIS 30
FUEL SHUTOFF SOLENOID CIRCUIT OPERATION32
FUEL SHUTOFF SOLENOID CIRCUIT DIAGNOSIS 34
FUEL SHUTOFF SOLENOID CIRCUIT DIAGNOSIS (CONTINUED)35
GLOW PLUG AND LIGHT CIRCUIT OPERATION 36
GLOW PLUG/MANIFOLD HEATER AND LIGHT CIRCUIT DIAGNOSIS
MANUAL PREHEAT38
GLOW PLUG/MANIFOLD HEATER AND LIGHT CIRCUIT DIAGNOSIS
AUTOMATIC PREHEAT 40
HYDRAULIC CHARGE PRESSURE LIGHT CIRCUIT OPERATION 42
ENGINE OIL PRESSURE LIGHT CIRCUIT OPERATION 42
HYDRAULIC CHARGE PRESSURE LIGHT CIRCUIT DIAGNOSIS44
ENGINE OIL PRESSURE LIGHT CIRCUIT DIAGNOSIS 46
ENGINE COOLANT TEMPERATURE LIGHT OPERATION 48
HYDRAULIC OIL TEMPERATURE LIGHT CIRCUIT OPERATION48
ENGINE COOLANT TEMPERATURE LIGHT DIAGNOSIS 50
HYDRAULIC OIL TEMPERATURE LIGHT DIAGNOSIS 52
HYDRAULIC OIL FILTER RESTRICTION LIGHT CIRCUIT OPERATION 54
AIR FILTER RESTRICTION LIGHT CIRCUIT OPERATION 54
FUEL LEVEL DISPLAY CIRCUIT OPERATION 54
HYDRAULIC OIL FILTER RESTRICTION LIGHT CIRCUIT DIAGNOSIS 56
AIR FILTER RESTRICTION LIGHT CIRCUIT DIAGNOSIS 58
FUEL LEVEL DISPLAY CIRCUIT DIAGNOSIS 60
HYDRAULIC BOOM AND BUCKET LOCKOUT CIRCUIT OPERATION 62
HYDRAULIC BOOM AND BUCKET LOCKOUT CIRCUIT DIAGNOSIS 64
ROAD/WORK LIGHT/ACCESSORY CIRCUIT OPERATION 66
ROAD/WORK LIGHT/ACCESSORY CIRCUIT DIAGNOSIS 68
TESTS & ADJUSTMENTS 70
BATTERY TEST 70
CHARGE BATTERY 70
BATTERY LOAD TEST71
REGULATED AMPERAGE AND VOLTAGE TEST 72
STARTER LOADED AMPERAGE DRAW TEST 72
STARTER NO-LOAD AMPERAGE AND RPM TESTS 73
STARTER SOLENOID TEST 74
ELECTRICAL SWITCH TESTS 75
ELECTRICAL RELAY / SOLENOID TESTS 77
FUEL GAUGE SENDER 79
ELECTRONIC INSTRUMENT PANEL MODULE TEST 80
GROUND CIRCUIT TEST 86
BLOWN FUSE SYMPTOMS87

GEAR POWER TRAIN
SPECIFICATIONS-6675/7775 2
GEAR DRIVE COMPONENT LOCATION-6675/7775 3
THEORY OF OPERATION-6675/7775 4
GEARBOX 4
CHAIN CASE 4
DRIVE CHAINS 4
DRIVE AXLES 4
TROUBLESHOOTING-6675/7775 5
DIAGNOSIS-6675/7775 6
GEAR POWER TRAIN REPAIR-6675/7775 8
GEARBOX OIL LEVEL CHECK 8
CHAIN CASE OIL LEVEL CHECK 8
CHAIN CASE OIL CHANGE 8
CHAIN CASE SIDE COVER REMOVAL & INSTALLATION 8
AXLE HOUSING REMOVAL & INSTALLATION 9
AXLE DISASSEMBLY & ASSEMBLY 9
DRIVE CHAIN AND SPROCKET REMOVAL & INSTALLATION 11
GEARBOX REMOVAL 13
GEARBOX DISASSEMBLY 14
GEARBOX ASSEMBLY 14
GEARBOX INSTALLATION 16
SPECIFICATIONS-4475 17
THEORY OF OPERATION-4475 18
CHAIN CASE 18
DRIVE MOTOR 18
INTERMEDIATE DRIVE SHAFT 18
FINAL DRIVE CHAINS 18
DRIVE AXLES 18
COMPONENT LOCATION-4475 19
TROUBLESHOOTING-4475 20
DIAGNOSIS-4475 21
GEAR POWER TRAIN REPAIR-4475 22
CHAIN CASE OIL LEVEL 22
CHAIN CASE OIL CHANGE 22
CHAIN CASE SIDE COVER REMOVAL & INSTALLATION 22
AXLE HOUSING REMOVAL & INSTALLATION 22
AXLE DISASSEMBLY & ASSEMBLY 23
DRIVE CHAIN AND SPROCKET REMOVAL & INSTALLATION 25
INTERMEDIATE DRIVE SHAFT REMOVAL & INSTALLATION 27

HYDROSTATIC POWER TRAIN
SPECIFICATIONS 3
HYDROSTATIC SYSTEM OPERATION 4
HYDROSTATIC COMPONENT LOCATION 5
HYDROSTATIC SYSTEM SCHEMATIC 6
COMPONENT LOCATION 7
HYDROSTATIC HOSES 7
HYDROSTATIC CASE DRAIN 8
REAR HYDROSTATIC PUMP 9
FRONT HYDROSTATIC PUMP 10
HYDROSTATIC MOTOR – 6675/7775 11
HYDROSTATIC MOTOR – 4475/5575 11.1
MOUNTING HARDWARE 12
TROUBLESHOOTING 13
DIAGNOSTICS 14
TEST AND ADJUSTMENT 15
HYDROSTATIC PUMP EFFICIENCY TEST 15
HYDROSTATIC PUMP CASE DRAIN TEST 16
HYDROSTATIC PUMP CASE DRAIN PRESSURE TEST 17
HYDROSTATIC PUMP HIGH PRESSURE RELIEF TEST 19
HYDROSTATIC MOTOR EFFICIENCY TEST 20
HYDROSTATIC MOTOR CASE DRAIN TEST21
REPAIR 23
HYDROSTATIC PUMP REMOVAL 23
HYDROSTATIC PUMP DISASSEMBLY24
HYDROSTATIC PUMP INSPECTION 27
HYDROSTATIC PUMP ASSEMBLY 28
HYDROSTATIC PUMPS INSTALLATION 31
HYDROSTATIC MOTOR REMOVAL 33
HYDROSTATIC MOTOR DISASSEMBLY – 6675/7775 35
HYDROSTATIC MOTOR INSPECTION – 6675/7775 36
HYDROSTATIC MOTOR ASSEMBLY – 6675/7775 37
HYDROSTATIC MOTOR SHIMMING PROCEDURE – 6675/7775 41
HYDROSTATIC MOTOR DISASSEMBLY – 4475/5575 42.1
HYDROSTATIC MOTOR INSPECTION – 4475/5575 42.2
HYDROSTATIC MOTOR ASSEMBLY – 4475/5575 42.3
HYDROSTATIC MOTOR INSTALLATION – 6676/7775 43
HYDROSTATIC MOTOR INSTALLATION – 4475/5575 44
START-UP PROCEDURE AFTER PUMP OR MOTOR REPLACEMENT 46

BRAKES
SPECIFICATIONS 2
THEORY OF OPERATION 3
COMPONENT LOCATION 4
BRAKE SYSTEM EXPLODED VIEW 5
DIAGNOSIS 6
TROUBLESHOOTING 8
TESTS AND ADJUSTMENTS 9
PARK BRAKE LINKAGE ADJUSTMENT 9
PARK BRAKE HANDLE ADJUSTMENT 9
REPAIR 10
PARK BRAKE HANDLE & LINKAGE REMOVAL & INSTALLATION 10
PARK BRAKE FRICTION PAD & CALIPER REPAIR 10

HYDRAULICS
SPECIFICATIONS 2
HYDRAULIC SYSTEM COMPONENTS AND OPERATION 4
HYDRAULIC SYSTEM COMPONENT LOCATION 5
HYDRAULIC SYSTEM SCHEMATIC 6
COMPONENT LOCATION 7
CYLINDERS 7
MISCELLANEOUS 8
CONTROL VALVE 9
CHARGE PUMP 10
BUCKET CYLINDER 11
LIFT CYLINDER 12
TROUBLESHOOTING 13
DIAGNOSTICS 14
TEST AND ADJUSTMENT 15
BOOM OPERATION CHECK 15
BUCKET OPERATION CHECK 15
BOOM AND BUCKET LOCKOUT SOLENOIDS CHECK 15
CHARGE PUMP SYSTEM PRESSURE TEST 16
SYSTEM RELIEF VALVE PRESSURE TEST 16, 18
PUMP FLOW TEST 17, 18
BOOM DRIFT DOWN CHECK 19
BOOM LIFT CHECK TEST 19
BOOM DRIFT UP CHECK 19
BUCKET DRIFT DUMP POSITION CHECK 19
BUCKET DRIFT ROLLBACK POSITION CHECK 20
BOOM LOCK CHECK (mechanical) 20
REPAIR 21
CHARGE PUMP REMOVAL 21
CHARGE PUMP DISASSEMBLY 22
CHARGE PUMP COMPONENT INSPECTION 23
CHARGE PUMP ASSEMBLY 24
CHARGE PUMP INSTALLATION 26
MAIN CONTROL VALVE REMOVAL 27
MAIN CONTROL VALVE DISASSEMBLY 28
MAIN CONTROL VALVE INSPECTION 29
MAIN CONTROL VALVE ASSEMBLY 31
MAIN CONTROL VALVE INSTALLATION 33
LIFT ARM CYLINDERS REMOVAL 34
LIFT ARM CYLINDER REPAIR 34
LIFT ARM CYLINDERS INSTALLATION 36
BUCKET CYLINDERS REMOVAL 36
BUCKET CYLINDER REPAIR 36
BUCKET CYLINDERS INSTALLATION 38
START-UP PROCEDURE AFTER COMPONENT REPLACEMENT 38