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New Holland FORD 555A User manual

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FORD
Service Manual
Tractor-Loader-Backhoe
555A, 5558 and 655A
Part 1 - Engine Systems
Part 2 - Fuel Systems
Part 3 - Electrical Systems
Part 4 - Clutches
Part 5 - Transmission Systems
Part 6 - Cab, Heating and Air Conditioning
Vol. 1
40055540A , ·
FORO
N:WHOLLAI\D
I
Reprinted I
FOREWORD
This manual provides information for the proper servicing and overhaul of the Ford Model 555A
& Band 655A Tractor-Loader-Backhoe and is an essential publication for all service personnel car-
rying out repairs and maintenance procedures.
The model 555Adesignates three cylinder engine units produced from January 1984through June
1985. The model 555B designates units produced from July 1985and later.
The model 655A designates four cylinder engine units produced from June 1985 and later.
Special service instructions are identified by tractor model number or applicable production date
code throughout the text.
The Manual isdivided into twelve PARTS, each sub-divided into Chapters. EachChapter contains
information on generaloperating principles, detailed inspection and overhaul and, where applicable,
trouble shooting, special tools and specifications.
The material contained in this Manual was correct at the time of printing, but Ford policy is one
of continuous improvement and the right to change prices, specifications, equipment or design
at anytime without notice is reserved. All data in this Manual is subject to production variations,
so overall dimensions and weights should be considered as approximate only and the illustrations
do not necessarily depict the unit to standard build specification.
Ford New Holland, Inc.
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CONTENTS
Part 1- Engine Systems . . . . . . . . . . . . . . . . . . Vol. 1
Part 2 - Fuel Systems . . . . . . . . . . . . . . . . . . . . . Vol. 1
Part 3 - Electrical Systems . . . . . . . . . . . . . . . . Vol. 1
Part 4 - Clutches . . . . . . . . . . . . . . . . . . . . . . . . . Vol. 1
Part 5 - Transmission Systems . . . . . . . . . . . . . Vol. 1
Part 6 - Cab, Heating and Air Conditioning... . Vol. 1
Part 7- Rear Axle & Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vol. 2
Part 8- Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vol. 2
Part 9 - Steering Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vol. 2
Part 1O- Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vol. 2
Part 11- Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vol. 2
Part 12- Separating the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vol. 2
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PRODUCTION DATE CODES AND
SERIAL NUMBERS
A vehicle identification plate is located on the steering console on the left hand side. Whenever
effecting repairor overhaulof the FordTractor, the relevantinformation should benoted and used
when referring to service bulletins or ordering parts.
This plate is stamped with the following information:
• TRACTOR NUMBER - Serial number prefixed by • ENGINE- Engine production date code.
the letter 'A', 'B' or 'C'.
• MODEL - Production model code. • TRANSMISSION - Transmissionproduction date
code.
• UNIT - Production unit date code.
PRINTEDIN U.S.A.
• REARAXLE - Rearaxle production date code.
iii
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iv
MODEL NUMBER -CODE
H.P. Series Chassis Series Fuel Power Transmission
Type (Prod. Stage) Type Take-Off Type
I I I I
4x4
Ind. Design Stage No- Torque
H.P. Flat Deck 1 thru 7 Diesel PTO Converter
DF711F
KEYTO PRODUCTION DATE CODES
First Number First Letter Second Number Second Letter
YEAR MONTH DAY OF MONTH PRODUCTION SHIFT
4 - 1984 A-Jan. H-Aug. 01-32 A-Midnight
5 - 1985 8-Feb. J-Sept. 8-Day
6 - 1986 C-March K-Oct. C-Afternoon
7 - 1987 D-April L-Nov.
8 - 1988 E-May M-Dec.
9 - 1989 F-June
0 - 1990 G-July
Exampleof Production Unit Date Code 4 C 0 3 B
'-....,---'
\
Year of Final
Assembly (19841 Month of Year
(Marchi Day of Month
(Third) Shift Period
(Day)
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A SAFETY PRECAUTIONS A
Practically all servicework involvesthe needto drive the tractor. The Operator's Manual, supplied with each tractor,
contains detailed safety precautions relating to driving, operating and servicing that tractor. These precautions are
as applicable to the service technician as they are to the operator, and should be read, understood and practiced
by all personnel.
Prior to undertaking any maintenance, repair, overhaul, dismantling or re-assembly operations, whether within a
workshop facility or out "in the field," consideration should be given to factors that may have an effect upon safety,
not only upon the mechanic carrying out the work, but also upon bystanders.
PERSONAL CONSIDERATIONS
• The wrong clothes or carelessnessin dress can cause accidents. Check to see that you are suitably clothed.
Some jobs require special protective equipment.
• Skin Protection
Used engine oil may cause skin cancer. Follow work practices that minimize the amount of skin exposed and
the length of time used oil remains on the skin.
• Eye Protection
The smallest eyeinjury may causeloss of vision. Injury can be avoided by wearing eyeprotection when engaged
in chiselling, grinding, discing, welding, painting, etc.
• Breathing Protection
Fumes,dust and paint sprayareunpleasantand harmful. Thesecan beavoidedby wearing respiratoryprotection.
• Hearing Protection
Loud noisemay damageyour hearing and the greater the exposure the worse the damage. If you feel the noise
is excessive, wear ear protection.
• Hand Protection
It is advisable to use a protective cream before work to prevent irritation and skin contamination. After work
clean your hands with soap and water. Solvents such as white spirit, paraffin, etc., may harm the skin.
• Foot Protection
Substantial or protective footwear with reinforcedtoe-capswill protect your feet from falling objects. Additionally,
oil-resistant soles will help to avoid slipping.
• Special Clothing
For certain wor~ it may be necessary to wear flame or acid-resistant clothing.
• Avoid injury through incorrect handling of components. Make sure you are capable of lifting the object. If in
doubt get help.
EQUIPMENT CONSIDERATIONS
• Machine Guards
Before using any machine, be sure the machine guards are in position and serviceable. These guards not only
prevent body and clothing from coming in contact with the moving parts of the machine, but also ward off
objects that might fly off the machine and cause injury. •
• Lifting Appliances
Always ensure that lifting equipment, such as chains, slings, lifting brackets, hooks and eyes are thoroughly
checked before use. If in doubt, select stronger equipment than is necessary.
Never stand under a suspended load or a raised implement.
• Compressed Air
The pressurefrom a compressed air line is often as high as 100 psi (6.9 bar) 7 (kgf/cm 2). It is perfectly safe
if used correctly. Any misuse may cause injury.
PRINTED IN U.S.A. V
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Never use compressed air to blow dust, filing, dirt, etc., away from your work area unless the correct type of
nozzle is fitted.
Compressed air is not a cleaning agent, it will only move dust, etc., from one place to another. Look around
before using an air hose as bystanders may get grit into their eyes, ears or skin.
• Hand Tools
Many cuts, abrasions and injuries are caused by defective tools. Never use the wrong tool for the job, as this
generally leads either to some injury, or to a poor job.
Never use
- A hammer with a loose head or split handle.
- Spanners or wrenches with splayed or worn jaws.
- Spanners or files as hammers; or drills, clevis pins or bolts as punches.
For removing or replacing hardened pins use a copper or brass drift rather than a hammer.
For dismantling, overhaul and assembly of major and sub components, always use the Special Service Tools
recommended. They will reduce effort, labor and repair cost.
Always keep tools clean and in good working order.
• Electricity
Electricity has become so familiar in day to day usage, that it s potentially dangerous properties are often over-
looked. Misuse of electrical equipment can endanger life.
Before using any electrical equipment - particularly portable applicances - make a visual check to make sure
that the cable is not worn or frayed and that the plugs, sockets, etc., are intact. Make sure you know where
the nearest isolating switch for your equipment is located.
GENERAL CONSIDERATIONS
• Solvents
Use only cleaning fluids and solvents that are known to be safe. Certain types of fluids can cause damage to
components such asseals,etc., and can causeskin irritation. Useonly solvents that are suitable for the cleaning
of components and parts, and that do not affect the personal safety of the user.
• Housekeeping
Many injuries result from tripping or slipping over, or on, objects or material left lying around by a carelessworker.
Prevent these accidents from occurring. If you notice a hazard, don't ignore it - remove it.
A clean, hazard-free place of work improves the surroundings and daily environment for everybody.
• Fire
Fire has no respect for persons or property. The destruction that a fire can cause is not always fully realized.
Everyone must be constantly on guard.
- Extinguish matches/cigars/cigarettes, etc., before throwing them away.
- Work cleanly, disposing of waste material into proper containers.
Locate the fire extinguishers and find out how to operate them.
Do not panic - warn those near and raise the alarm.
Do not allow or use an open flame near the tractor fuel tank, battery or component parts.
• First Aid
vi
In the type of work that mechanics are engaged in, dirt, grease, fine dusts, etc., all settle upon the skin and
clothing. If a cut, abrasion or burn is disregarded it may be found that a septic condition has formed within
a short time. What appearsat first to be trivial could become painful and injurious. It only takes a few minutes
to have a fresh cut dressed, but it will take longer if you neglect it. Make sure you know where the First Aid
box is located.
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• Cleanliness
Cleanlinessof the tractor hydraulic system is essential for optimum performance. When carrying out service
and repairs plug all hose ends and component connections to prevent dirt entry.
Cleanthe exterior of all components before carrying out any form of repair. Dirt and abrasive dust can reduce
the efficiency and working life of a component and lead to costly replacement. Useof a high pressurewasher
or steam cleaner is recommended.
OPERATIONAL CONSIDERATIONS
• Stop the engine, if at all possible, before performing any service.
• Placea warning sign on tractors which, due to service or overhaul, would be dangerous to start. Disconnect
the battery leads if leaving such a unit unattended.
• Do not attempt to start the enginewhile standing besidethe tractor or attempt to by-passthe neutralstart switch.
• Avoid prolonged running of the engine in a closed building or in an areawith inadequate ventilation as exhaust
fumes are highly toxic.
• Always turn the radiator capto the first stop to allow pressureinthe systemto dissipatewhen the coolant ishot.
• Neverwork beneath a tractor which is on soft ground. Always take the unit to an areawhich hasa hard working
surface - concrete for preference.
• If it is found necessaryto raisethe tractor for easeof servicing or repair, make surethat safe and stable supports
are installed beneath axle housings, casings, etc., before commencing work.
• Certainrepairor overhaulproceduresmay necessitate"separating the tractor," eitherat the engine/front transmis-
sion or front transmission/rear transmission locations. Theseoperations aresimplified by the useof the Tractor
Splitting Kit/Stands. Should this equipment not be available, then every consideration must be given to stabili-
ty, balance and weight of the components, especially if a cab is installed.
• Use footsteps or working platforms when servicing those areas of a tractor that are not within easy reach.
• Before looseningany hosesor tubes connecting implements to remote control valves, etc., switch off the engine,
remove all pressure in the lines by operating leversseveraltimes. This will remove the danger of personal injury
by oil pressure.
• Prior to pressuretesting, make sure all hoses and connectors not only of the tractor, but also those of the test
equipment, arein good condition and tightly sealed. Pressurereadingsmust betaken with the gaugesspecified.
The correct procedure should be rigidly observed to prevent damage to the system or the equipment, and to
eliminate the possibility of personal injury.
• When equipment or implements are required to be attached to the hydraulic linkage, either for testing purposes
or for transportation, then "position control" should be used.
• Always lower equipment to the ground when leaving the tractor.
• If high lift attachments are installed on a tractor beware of overhead power, electric or telephone cables when
traveling. Drop attachment near to ground level to increase stability and minimize risks.
• Do not park or attempt to service a tractor on an incline. If unavoidable, take extra care and block all wheels.
• Escaping hydraulic/diesel fluid under pressure can penetrate the skin causing serious injury. Do not use your
hand to check for leaks. Use a piece of cardboard or paper to search for leaks. Stop the engine and relieve
the pressurebefore connecting or disconnecting oil lines. Tighten all connections before starting the engine or
pressurizingthe lines. If fluid is injected into the skin, obtain medicalattention immediately or gangrenemay result.
PRINTED IN U.S.A. vii
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• Observe recommended precautions as indicated in this Repair Manual when dismantling the air conditioning
system as escaping refrigerant can cause frostbite.
• Priorto removingwheelsand tiresfrom a tractor, check to determinewhether additional ballast(liquid or weights)
has been added. Seek assistance and use suitable equipment to support the weight of the wheel assembly.
• When inflating tires beware of over inflation - constantly check the pressure. Overinflation can causetires to
burst and result in personal injury.
Safety precautions are very seldom the figment of someone's imagination. They are the result of sad experience,
where most likely someone has paid dearly through personal injury.
Heed these precautions and you will protect yourself accordingly. Disregard them and you may duplicate the sad
experience of others.
viii
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