John Deere 655/755/756/855/856/955 Compact Utility Tractors OEM Service & Repair Manual

TECHNICAL MANUAL Litho in U.S.A John Deere Lawn & Grounds Care Division 655, 755, 855, 955, 756 and 856 Compact Utility Tractors TM1360 (June 1996)

FOREWORD This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use. LIVE WITH SAFETY: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual. P This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury. Technical manuals are divided in two parts: repair and diagnostics. Repair sections tell how to repair the components. Diagnostic sections help you identify the majority of routine failures quickly. Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values. Binders, binder labels, and tab sets can be ordered by John Deere dealers direct from the John Deere Distribution Service Center. This manual is part of a total product support program. FOS MANUALS—REFERENCE TECHNICAL MANUALS—MACHINE SERVICE COMPONENT MANUALS—COMPONENT SERVICE Fundamentals of Service (FOS) Manuals cover basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes. FOS Manuals are for training new personnel and for reference by experienced technicians. Technical Manuals are concise guides for specific machines. Technical manuals are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair. Component Technical Manuals are concise service guides for specific components. Component technical manuals are written as stand-alone manuals covering multiple machine applications. NOTE: The 756 and 856 tractors are identical to the 755 and 855 tractors; therefore, all information pertaining to the 755 also pertains to the 756 and the same is true for the 855 and the 856 tractors. The 655, 756 and 856 tractors were all discontinued before the late model 755 and 855 tractors and the new 955 tractors were produced. Therefore, any late model references do not include the 655, 756, and 856 tractors. MX,TM1360,IFC -19-16OCT91 Introduction TM1360 (16OCT91) 55, 56 Series Tractors 010395

Contents SECTION 10—GENERAL INFORMATION Group 05—Safety Group 10—Repair Specifications Group 15—Repair Information Group 20—Fuels, Lubricants, and Coolants Group 25—Serial Number Locations SECTION 20—DIESEL ENGINE REPAIR Group 05—Yanmar Diesel Engine Repair Group 10—Remove and Install Oil Cooler Group 15—Remove and Install Radiator Group 20—Remove and Install Diesel Engine SECTION 30—FUEL AND AIR REPAIR Group 05—Fuel Transfer Pump Group 10—Fuel Tank Group 15—Fuel Tank Tube and Sender Group 20—Air Cleaner SECTION 40—ALTERNATOR REPAIR Group 05—Alternator Repair Specifications Group 10—Alternator Installation SECTION 50—POWER TRAIN REPAIR Group 05—Hydrostatic Transmission Group 10—Transaxle Group 15—Final Drives Group 20—Mechanical Front Wheel Drive (MFWD) Group 25—Power Train Gears and Shafts Group 30—Speed Control Linkage SECTION 60—STEERING AND BRAKES REPAIR Group 05—Standard Front Axle Group 10—Steering Valve Group 15—Brake Linkage SECTION 70—HYDRAULICS REPAIR Group 05—Hydraulic Pump Group 10—Flow Divider and Selective Control Valves (SCV’s) Group 15—Rockshaft Group 20—Hydraulic Hoses SECTION 80—MISCELLANEOUS REPAIR Group 15—Operator’s Seat Group 20—European Roll-Gard ® Group 25—German Rear Hitch Group 30—3-Point Hitch SECTION 210—MACHINE OPERATIONAL CHECKOUT PROCEDURE Group 05—Machine Operational Checkout Procedure SECTION 220—ENGINE/FUEL OPERATION AND TESTS Group 05—Engine Systems Operational Checkout Procedure Group 10—Engine System Diagnosis SECTION 240—ELECTRICAL OPERATION AND TESTS Group 05—Electrical System Checkout Group 10—Electrical System Diagnosis Group 15—Theory of Operation SECTION 250—POWER TRAIN OPERATION AND TESTS Group 05—Power Train System Checkout Group 10—Power Train Tests and Adjustments Group 15—Theory of Operation SECTION 260—STEERING AND BRAKE OPERATION AND TESTS Group 05—Steering and Brakes System Checkout Group 10—Steering and Brakes Tests and Adjustments Group 15—Theory of Operation SECTION 270—HYDRAULIC OPERATION AND TESTS Group 05—Hydraulic System Checkout Group 10—Hydraulic System Tests and Adjustments Group 15—Theory of Operation INDEX All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice. TM 1360-19-01Jun 96 i 10 40 20 70 30 50 60 80 210 220 COPYRIGHT©1996 DEERE & COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION Manual Previous Editions Copyright© 1991, 1990, 1986 Deere & Company

Contents ii 240 250 260 270 INDX

Contents Page Page Section 10 General Information Group 05—Safety Safety Items . . . . . . . . . . . . . . . . . . . . . . . . . 10-05-1 Group 10—Repair Specifications General Tractor Specifications . . . . . . . . . . . 10-10-1 Group 15—Repair Information Metric Fastener Torque Values. . . . . . . . . . . 10-15-1 Inch Fastener Torque Values . . . . . . . . . . . . 10-15-2 O-Ring Face Seal Fittings . . . . . . . . . . . . . . 10-15-3 O-Ring Boss Fittings . . . . . . . . . . . . . . . . . . 10-15-4 Group 20—Fuels, Lubricants, and Coolants Diesel Fuel—North America. . . . . . . . . . . . . 10-20-1 Diesel Fuel Lubricity—North America . . . . . 10-20-1 Diesel Fuel Storage—North America . . . . . . 10-20-1 Diesel Fuel—Europe . . . . . . . . . . . . . . . . . . 10-20-2 Diesel Fuel Lubricity—Europe . . . . . . . . . . . 10-20-2 Diesel Fuel Storage—Europe . . . . . . . . . . . 10-20-2 Engine Oil—North America . . . . . . . . . . . . . 10-20-3 Engine Oil—Europe . . . . . . . . . . . . . . . . . . . 10-20-4 Break-in Engine Oil—North America . . . . . . 10-20-5 Break-in Engine Oil—Europe . . . . . . . . . . . . 10-20-6 Hydrostatic Transmission and Hydraulic Oil— North America. . . . . . . . . . 10-20-7 Hydrostatic Transmission and Hydraulic Oil— Europe . . . . . . . . . . . . . . . 10-20-8 Gear Case Oil (MFWD)—North America . . .10-20-9 Gear Case Oil (MFWD)—Europe. . . . . . . . 10-20-10 Grease—North America . . . . . . . . . . . . . . . 10-20-11 Grease—Europe . . . . . . . . . . . . . . . . . . . . 10-20-12 North America Alternative Lubricants. . . . . . . . . . . . . . . . . 10-20-13 Synthetic Lubricants . . . . . . . . . . . . . . . . . . 10-20-13 Lubricant Storage . . . . . . . . . . . . . . . . . . . . 10-20-13 Mixing of Lubricants . . . . . . . . . . . . . . . . . . 10-20-13 Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-13 Europe Alternative Lubricants. . . . . . . . . . . . . . . . . 10-20-14 Synthetic Lubricants . . . . . . . . . . . . . . . . . . 10-20-14 Lubricant Storage . . . . . . . . . . . . . . . . . . . . 10-20-14 Mixing of Lubricants . . . . . . . . . . . . . . . . . . 10-20-14 Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-14 Diesel Engine Coolant—North America . . .10-20-15 Diesel Engine Coolant—Europe . . . . . . . . 10-20-16 Group 25—Serial Number Locations Product Serial Number . . . . . . . . . . . . . . . . 10-25-1 Engine Serial Number . . . . . . . . . . . . . . . . . 10-25-1 Transaxle Serial Number . . . . . . . . . . . . . . 10-25-1 Mower Deck Serial Number . . . . . . . . . . . . 10-25-1 10-1 10

Contents TM1360 (16OCT91) 10-2 55, 56 Series Tractors 010395 10

HANDLE FLUIDS SAFELY—AVOID FIRES When you work around fuel, do not smoke or work near heaters or other fire hazards. Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers. Make sure machine is clean of trash, grease, and debris. Do not store oily rags; they can ignite and burn spontaneously. TS227 -UN-23AUG88 PREVENT BATTERY EXPLOSIONS Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode. Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer. Do not charge a frozen battery; it may explode. Warm battery to 16˚C (60˚F). TS204 -UN-23AUG88 PREPARE FOR EMERGENCIES Be prepared if a fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone. TS291 -UN-23AUG88 DX,FLAME -19-04JUN90 DX,SPARKS -19-04JUN90 DX,FIRE2 -19-04JUN90 Group 05 Safety TM1360 (16OCT91) 10-05-1 55, 56 Series Tractors 010395 10 05 1

PREVENT ACID BURNS Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. Avoid the hazard by: 1. Filling batteries in a well-ventilated area. 2. Wearing eye protection and rubber gloves. 3. Avoiding breathing fumes when electrolyte is added. 4. Avoiding spilling or dripping electrolyte. 5. Use proper jump start procedure. If you spill acid on yourself: 1. Flush your skin with water. 2. Apply baking soda or lime to help neutralize the acid. 3. Flush your eyes with water for 10—15 minutes. Get medical attention immediately. If acid is swallowed: 1. Drink large amounts of water or milk. 2. Then drink milk of magnesia, beaten eggs, or vegetable oil. 3. Get medical attention immediately. TS203 -UN-23AUG88 DX,POISON -19-04JUN90 Safety TM1360 (16OCT91) 10-05-2 55, 56 Series Tractors 010395 10 05 2

AVOID HIGH-PRESSURE FLUIDS Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. X9811 -UN-23AUG88 PARK MACHINE SAFELY Before working on the machine: • Lower all equipment to the ground. • Stop the engine and remove the key. • Disconnect the battery ground strap. • Hang a “DO NOT OPERATE” tag in operator station. TS230 -UN-24MAY89 DX,FLUID -19-09AUG91 DX,PARK -19-04JUN90 Safety TM1360 (16OCT91) 10-05-3 55, 56 Series Tractors 010395 10 05 3

SUPPORT MACHINE PROPERLY Always lower the attachment or implement to the ground before you work on the machine. If you must work on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. Follow recommended procedures in this manual. TS229 -UN-23AUG88 WEAR PROTECTIVE CLOTHING Wear close fitting clothing and safety equipment appropriate to the job. Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises. Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine. TS206 -UN-23AUG88 SERVICE MACHINES SAFELY Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result. Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts. TS228 -UN-23AUG88 DX,LOWER -19-04JUN90 DX,WEAR -19-10SEP90 DX,LOOSE -19-04JUN90 Safety TM1360 (16OCT91) 10-05-4 55, 56 Series Tractors 010395 10 05 4

John Deere 655/755/756/855/856/955 Compact Utility Tractors OEM Service & Repair Manual

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