PDF Service Manual Ford 455 555 655 555C 655C Loader Backhoe - 21 MB
This comprehensive service and repair manual covers the Ford 455, 555, 655, 555C, and 655C loader backhoe tractors.
It is the definitive guide for performing maintenance and repairs, from simple adjustments to complex engine work.
The manual provides detailed specifications, torque values, and troubleshooting charts to help you diagnose and fix problems efficiently.
This is an essential document for keeping your versatile Ford backhoe in top working condition.
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classicmachinery.net
Appropriate service methods and proper repair procedures are essential for the safe, reliable
operation of all equipment as well as the personal safety of the individual doing the work. This
Repair Manual provides general directions for accomplishing service and repair work with
tested, effective techniques. Following them will help assure reliability.
There are numerous variations in procedures. techniques, tools, and parts for servicing
equipment, as well as in the skill of the individual doing the work. This manual cannot possibly
anticipate all such variations and provide advice 'or cautions as to each. Accordingly, anyone
who departs from the instructions provided in this Manual must first establish that he does not
compromise his own personal safety nor the safety of others by his choice of methods or tools.
As you read through this manual, you will come across NOTES and WARNINGS. Each one is
there for a specific purpose. NOTES are given to prevent you from making an error that could
damage the vehicle. WARNINGS remind you to be especially careful in those areas where
carelessness can cause personal injury.
The Manual is divided into eleven Parts each sub-divided in turn into Chapters. Each Chapter
contains information on general operating principles, detailed inspection and overhaul and,
where applicable, specific trouble shooting, special tools and specifications. Any reference in
this Manual to right, left, rear, front, top or bottom is as viewed from the operator's seat looking
forward towards the loader.
The material contained in this Manual was correct at the time of going to print but Ford New
Holland policy is one of continuous improvement and the right to change prices, specifications,
equipment or design at any time 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 built specification.
Measurement details in this Manual are tabled with the British standard first. with the metric
equivalent following in brackets.
(i)
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------------CHAPTER1------------
The intake manifolds are connected through
tubing to the air cleaner. The diese! engine
intake manifold is provided with a tapped
hale for installation of a thermostart or an
ether cold starting aid kit.
NOTE: On tractors where co/d start
equipment is not instal/ed, the plug in the
manifold should remain securely installed at
al/ times, since considerable damage to the
cylinder bores could result from its absence.
R-1-1 ·
The cylinder bores can a/so be damaged by
Figure 2
Conventíonal Píston and Ríngs
grit and other foreign matter passing through
the air c/eaner hose connections if they are
1. Notch to Front of Engíne not proper/y secured.
2. Expander for Oíl Control Ríng
3. Oíl Control Ríng
4. 1 st Compressíon Ríng
5. 2nd Compressíon Ríng
6. Top Compressíon Ríng
Pistons
Pistons are an aluminium alloy with
combustion chambers recessed into the pistan
crowns. Each pistan, Figure 2, has three
compression rings and one oil control ring, all
of which are located above the pistan pin.
Cylinder Block Assembly
Connecting Rods The cylinder block is alloy cast iron with
heavy webbing and deep cylinder skirts. The
The pistan connecting rods are of T section, block features full length water jackets for
with replaceable bronze pistan pin bushings. cooling the cylinders, which are bored
Full-floating pistan pins are retained by two integral with the block. Cylinders are in-line
snap rings in each pistan. and vertical, and numbered from 1 to 3, front
to rear.
Manifolds
The cast iron intake and exhaust mariifolds
are on opposite sides of the cylinder head for The oíl pan is attached to the bottom of the
better heat distribution in the head, and less cylinder block and is the sump for the
heat transfer to the intake manifold. Ali lubrication system. The engine front cover is
tractors are fitted with vertical exhaust attached to the front engine adapter plate
systems. forming a cover for the timing gears.
3
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R-1- 1-15 .Q R-1-1 -16 .Q
Figure 14 Figure 15
Raising/ Lowering Valve Seats Critica! Valve Measurements and lnspection Checks
1. Use 30• grinding wheel for lowering the seat 1. Valve Head Edge 4. Valve Face
2. Use 60º grinding wheel for raising the seat 2. Valve Head 5. Valve Stem
3. Valve Face Angle 6. Valve Tip
(4s.s·)
Valves 4. Any valve refacing operation should be
closely coordinated with the valve seat
1. The critica! inspection points of the refacing operation so that the finished
valves are shown in Figure 16. lnspect angle of the valve is 0,5º less than the
the valve tace and the edge of the valve valve seat to provide an interference
head for pits, grooves, seores, or other angle for better seating. Adjust the valve
defects. lnspect the stem for a bent refacing tool to obtain a tace angle of
condition and the end of the stem for 45,5º, Figure 15.
grooves or seores. Check the valve head
for cracks, erosion, warpage, or bum.
Minor defects such as small pits or
grooves, can be removed. Check the
valve tip for pits or grooves and replace
the valve if such a condition exists.
5. Remove only enough stock to clean up
Discard valves that are severely
the pits and grooves. Check the edge of
damaged.
the valve head; if less than the specified
figure, see " Specifications" - Chapter 4,
install a new valve.
2. Check for bent stems and correct
diameter.
6. Remove all grooves or score marks from
the valve stem tip, then chamfer as
necessary. Do not remove more than
3. Check maximum valve tace eccentricity. 0,01 O in. (0,25 mm) from the tip.
13
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Q.
R· 1· 1·33
Figure 31 Figure 32
Oil Pump and Filter Screen Oil Pump Drive Gear Removal
1. Filter Screen 1. Retaining Bolt
2. lntermediate Shaft 2. Proofmeter Driveshaft Adapter
3. Oil Pump Retaining Bolts 3. Oil Pump Driveshaft and Gear Assembly
4. Oil Pump 4. Driveshaft Adapter Mounting Base
OIL PUMP 4. Slacken the retaining bolt then withdraw
the driveshaft adapter assembly where
fitted or remove the welch plug from
engine block and the oil pump drive gear,
Figure 32.
REMOVAL
1. Remove the oil pan sump as previously
described in this Chapter.
DISASSEMBLY
With reference to Figure 33.
2. Remove the oil pump with the filter
screen, Figure 31. Withdraw the inter-
mediate shaft. 1. Remove the spring clip and detach the
pump screen.
2. Withdraw the retaining screw and
3. Disconnect the proofmeter drive cable washer assemblies then separate the
from the driveshaft adapter, where fitted, inner and outer covers from the body and
and remove the engine oil filter. extract the rotor and shaft assembly.
23
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-------------CHAPTER1-------------
4. Use an expander to install the piston
rings Figure 49, starting with the oil
control ring in the bottom groove and
working upwards.
The service ring set comprises:
• 1 Coiled Wire Expander or "Rail" type
Expander for the Oil Control Ring
• 1 Oil Control Ring
R-1- 1-51
Figure49
• 3 Compression Rings Pistan Ring lnstallatian
1. Pistan Ring Expander
2. Pistan Ring
Oil Control Ring
Open the coiled wire expander to fully reveal
2nd Compression Ring
the inner guide wire. Position the coiled
expander in the oil groove and insert the
Bright chrome finish on the outside diameter
inner guide wire into the open end of the coi l.
with a chamfer or step on the outside
Clase the coil until the ends abut.
diameter which must tace upwards on
assembly.
Postion a "rail" type expander in the oil
groove ensuring the ends do not overlap.
Attempting to install a ring with overlapping
ends will result in a broken ring and/or
damaged cylinder bore. ~ Do not cut the
expander if it appears to be too large. The
rings will compress to size if the correct ring NOTE: To faci/itate assembly, the 2nd and
compressor is used, Figure 49. 3rd compression rings are marked with a
punched dot or the letters 'TOP' engraved on
their upper surfaces.
lnstall the cast iron ring (either side up) with
the inside groove over the coiled rail
expander. Position the ring gap diametrically
opposite the coiled wire ends.
3rd Compression Ring Top Compression Ring
Dull finish with a step or chamfer on the Bright chrome finish with a chamfer on the
inside diameter which must tace downwards outside diameter which must face upwards
ora step on the outside diameter which must and a step on the outside diameter which
tace upwards on assembly. must tace downwards on assembly.
33
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------------CHAPTER1------------
R-1-1-65
Figure 62 Figure 63
Crankshaft Oil Seal lnstallation Checking Rear Main Beari ng Crankshaft Oil Seal
Run-Out
1. Crankshaft Oil Seal 1. Dial lndicator Gauge
2. Tool No. FT 6212 2. Crankshaft
3. Crankshaft Oil Seal
4. Cylinder Block
(vi) lnstall the centre stock of tool No. (viii) Mount a dial indicator gauge on the
FT 6212 to the crankshaft flange and end of the crankshaft, Figure 63, rotate
secure with the two screws, Figure 62. the crankshaft and check the run out of
Assemble the cylinder end plate the seal does not exceed 0.015 in.
assembly to the centre stock and (0.38 mm).
secure with the nut and washer as
shown in Figure 62. Gradually tighten 9. lnstall the correct bearing liners in the
the nut until the outer diameter of the connecting rod and cap. lf the journals
tool abuts the retainer. The tool must are standard size select the correct
not be overtightened as stress and bearing liners as for main bearings in
distortion could be imposed on the Steps 1 and 2. Ensure the bearing liner
retainer. tangs locate in the slots of the rod and
cap.
1 O. lnstall the connecting rod bearing cap, as
previously detailed in this Chapter, with
NOTE: The fírst sea/ replacement should be the number on the cap on the same side
pushed ínto the retaíner wíth the plaín end of as the number on the rod. lnstall new
the too/ and the second and subsequent nuts and tighten to the specified torque,
sea/s wíth the stepped end of the too/ whích see "Specifications" - Chapter 4.
wí/1 reposítíon the sea/ 0.060 in. (1 .52 mm)
further ín.
INSTALLATION
1. lnstallation of the components to effect
complete re-assembly of the engine
(vii) Remove the tool follows the removal procedure in reverse.
43
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------------CHAPTER 2------------
Figure 5 Figure 6
Turbocharger lnstalled Fuel lnjector Removal
1. Turbocharger to lntake Manifold Tube 1. Fuel lnjector Assembly
2. Oil Supply Tube 2. Fuel lnjector Mounting Bolts
3. Oil Return Tube 3. Copper Washer
4. Exhaust Manifold 4. Cork Washer
5. Exhaust Outlet Pipe
6. Air Cleaner to Turbocharger Tube
11 . Shut-otf the fuel tank tap then 14. Disconnect and remove the rocker cover
disconnect the low pressure fuel lines ventilation tube.
and remove the fuel filters from the inlet
manifold and cap the exposed openings.
15. Disconnect the cold start equipment and
plug the exposed openings (where
fitted) .
12. Disconnect and remove the injector fuel
pipes from the fuel injection pump and
the injectors. Cap the exposed openings
in the pump, injectors and tubes. 16. Disconnect the alternator, oil pressure,
coolant temperature sender, air cleaner
restriction indicator, fuel injection pump
solenoid, horn and cold start wiring
harness connections (where fitted).
13. Disconnect the thermostart fuel pipe at
the intake manifold and plug the exposed 17. Remove the turbocharger, where fitted,
openings. see "FUEL SYSTEMS" - Part 2.
7
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------------cHAPTER2------------
Figure 21 Figure 22
Setting Valve Lash Fuel lnjector lnstallation
1. Adjuster Screw 1. Fuel lnjector Assembly
2. Rocker Arm 2. Fuel lnjector Mounting Bolts
3. Valve Stem 3. Copper Washer
4. Feeler Gauge 4. Cork Washer
• Tighten the cylinder head retaining bolts • 1nstall the injectors with new seat
in the sequence shown in Figure 20 and washers and cork seals, Figure 22.
progressively in three steps as follows:
• lnstall the injector lines and leak-off pipe
with new washers.
(i) Torque to 115 lbf.ft. (156 Nm)
(ii) Torque to 140 lbf.ft. (190 Nm)
(iii) Torque to 160 lbf.ft. (217 Nm) NOTE: Hold the leak-off plastic tube
securely to prevent pivoting when tightening
the banjo fitting bo/ts to the specified torque.
See "Specifications" - Chapter 4.
Do NOT oil the bolts befare installation.
• Use new lock tabs for the exhaust
manifold retaining bolts and bend the
tabs to effect retention.
NOTE: The cylinder head bolts should be
torqued only when the engine is co/d.
• Tighten ali nuts and bolts to the specified
torques. See "Specifications" - Chapter 4.
• Rotate the engine and set the valve
lash, Figure 21 . See "Specifications" - • Operate the engine and check for fluid
Chapter 4. leaks.
17
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------------CHAPTER2------------
R- 1· 1·41
Figure 38 Figure 39
Piston Ring Removal Piston and Connecting Rod Disassembled
, . Piston 5. Bearing Liners
2. Pin Retainers 6. Bearing Cap
3. Piston Pin 7. Retaining Nuts
4. Connecting Rod 8. Piston Rings
2. With the piston at the bottom of the 3. ldentify each piston and rod for
stroke, remove the nuts from the bearing reassembly, Figure 39
cap bolts and remove the bearing cap and
liner, Figure 37.
3. Use the handle end of a hammer to push
the piston and rod assembly out of the
top of the block. Remove the bearing
INSPECTION ANO REPAIR
liner from the connecting rod.
1. Wash the piston and connecting rod
assembly in a suitable solvent and dry
4. Turn the crankshaft to bring each piston
with a clean lint free cloth or compressed
to the bottom of its stroke and repeat this
air.
procedure. Keep the bearing caps and
liners with their respective connecting
rods.
2. lnspect the piston ring lands, skirts and
DISASSEMBLY pin bosses for damage.
1. Remove the piston pin retainer (snap
ring) from each side of the piston and
remove the pin. 3. Clean the ring grooves and using a new
ring and feeler gauge check the piston ring
lands for wear, Figure 40. Fer maximum
2. Use an expander to remove the piston ring clearance see "Specifications" -
rings, Figure 38. Chapter 4.
27
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-------------CHAPTER2-------------
O◄
A2 - 4 - J5
Figure 54
Dynamic Balancer Components
1. Roll Pins 6. Plugs
2. Housing 7. Shafts
3. Thrust Washers 8. Orive Gear
4. Driven Gear 9. Plug
5. Thrust Washers 1 O. Gasket
3. Position a dial indicator gauge
perpendicular to the tooth of one gear
and hold the other gear firmly.
Rock the free gear to measure the
backlash.
Take the backlash readings at 90º inter-
vals around the gear.
A2-4-J7
lf the end float or backlash exceeds the Figure 55
Balancer Gear Assembly
specified limits, see "Specifications" -
Chapter 4, replace one or both of the 1. Balancer Gear Timing Marks
gears and re-check. 2. Roll Pins
37
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-------------CHAPTER2-------------
Q
Figure 68 Figure 69
Camshaft Rear Cover Plate Removal Camshaft Bearing Removal and Installation
1. Rear Cover Plate 1. Bearing
2. Sealant 2. Oil Hole
3. Hydraulic Pump Drive Gear 3. Tool No. FT 6203 or 1255
4. Punch 4. Tool No. N 6261 - A or 1443
6. Withdraw the bolts and lockwashers and 2. Inspect the oil pump drive gear on the
remove the camshaft thrust plate. camshaft for broken or worn teeth. Check
the mating gear on the oil pump drive
shaft. If any damage is apparent, install a
7. For engines without a gear on the rear new camshaft and/or oil pump drive
end of the camshaft, the camshaft can be gear.
withdrawn from the front of the engine. If
the camshaft is equipped with a gear, the
flywheel and rear cover plate must be
removed and the camshaft rear cover
driven out with a punch, Figure 68.
Remove the key and spacer from the front
of the camshaft and carefully withdraw 3. Check each tappet for signs of chipping
the camshaft from the rear of the engine. or other damage. Measure the diameter
and renew tappets if worn beyond the
limits specified see "Specifications" -
8. Lift out the tappets and place in a Chapter 4.
numbered rack to facilitate re-assembly.
INSPECTION AND REPAIR
4. Measure the diameter and out-of-round
1. Inspect the camshaft journals and lobes of the bearing journals. If the journals
for damage, pitting or heat discolour- exceed the specified limits, see
ation. If any of these conditions exist, "Specifications" - Chapter 4, install a
install a new camshaft. new camshaft.
47
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------------CHAPTER 3 - - - - - - - - - - - -
TRACTOR-MANUALS-UK.COM
'
7. Install a new gasket and assemble the INSTALLATIO N
front and rear halves of the pump
together and tighten the bolts to the 1. Installation of the water pump fqllows
specified torque, see 'Specifications· - the removal procedure in reverse. On
Chapter 4 . installation observe the following
requirements.:
• Install a new pump gasket.
• Adjust the alternator drive belt
tension, see PART 3, 'Electrical
Systems' .
8. Install the fan on the pulley and tighten • After installation ofthe radiator, fill the
the bolts to the specified torque, see cooling system and run the engine to
'Specifications' - Chapter 4. check for leaks.
9
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------------CHAPTER4------------
TRACTOR-MANUALS-UK.COM
ROCKER ARM SHAFT
Shaft Diameter 1.000-1.001 in (25.40-25.43 mm)
Support Diameter (Internal diameter) 1.002-1.004 in (25.45-25.20 mm)
ROCKER ARM
Inside Diameter 1.003-1.004 in (25.48 - 25.50 mm)
TAPPETS
Clearance to Bore 0.0006--0.0021 in (0.015-0.053 mm)
Tappet Diameter 0.9889-0.9894 in (25.118-25.130 mm)
Tappet Bore Diameter 0.9900-0.9910 in (25.15-25.17 mm)
CAMSHAFT
Bearing Journal Diameter 2.3895-2.3905 in (60.696-60.719 mm)
Bearing Clearance 0.0010-0.0030 in (0.025-0.076 mm)
End Play 0.0010-0.0070 in (0.025-0.18 mm)
CONNECTING RODS
Small End Bushing (Internal Diameter)
Normally Aspirated 1.5003-1 .5006 in (38.108-38.115 mm)
Turbocharged 1.6253-1.6256 in (41 .283-41.290 mm)
Clearance Bushing-to-Piston-Pin 0.0005-0.0007 in (0.013-0.018 mm)
Side Float 0.0070-0.01 30 in (0.18-0.33 mm)
Maximum Twist 0.0120 in (0.30 mm)
Maximum Bend 0.0040 in (0.10 mm)
PISTON PIN
Outside Diameter
Normally Aspirated Engine 1.4997-1.5000 in (38.092- 38.100 mm)
Turbocharged Engine 1.6247-1 . 6250 in (41 .267-41.275 mm)
9
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TRACTOR-MANUALS-UK.COM
~ABrt: 2
- ..., " : ' I "l l 'l
FUEL SYSTE MS
Chapter 1
FUEL SYSTEM - GENERA L
Section Page
A. FUEL SYSTEM - DESCRIPTION AND OPERATION 1
B. FUEL SYSTEM - ADJUSTMENT S DPA DISTRIBUTOR TYPE FUEL
INJECTION PUMP 6
C. FUEL SYSTEM - ADJUSTMENT S OPS DISTRIBUTOR TYPE FUEL
INJECTION PUMP 8
D. FUEL SYSTEM - FUEL TANKS, FILTERS AND FUEL LINES OVERHAUL 11
Chapter 2
FUEL INJECTIO N PUMP - DPA DISTRIB UTOR TYPE
Section Page
A. FUEL INJECTION PUMP - DESCRIPTION AND OPERATION 1
B. FUEL INJECTION PUMP - OVERHAUL 4
C. FUEL INJECTION PUMP - ISO TEST CONDITIONS 21
D. FUEL INJECTION PUMP - TEST PROCEDURES 30
Chapter 3
FUEL INJECTIO N PUMP - DPS DISTRIB UTOR TYPE
Section Page
A. FUEL INJECTION PUMP - DESCRIPTION AND OPERATION 1
B. FUEL INJECTION PUMP - OVERHAUL 17
C. FUEL INJECTION PUMP - ISO TEST CONDITIONS 47
D. FUEL INJECTION PUMP - TEST PROCEDURE 56
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MAXIMUM NO-LOAD SPEED
ADJUSTMENT
IMPORTANT: The maximum no-load
speed screw is adjusted and sealed at the
factor for correct fuel delivery and maximum
no-load speed. If the maximum no-load
speed is above or below the specified range,
see "Specifications" - Chapter 8, then
adjustment may be made as follows:-
1. With the engine running and at normal
operating temperature, disconnect the
throttle linkage at the fuel injection
pump, Figure 12.
Figure 12
Injection Pump Adjustment Screws
1. Throttle Cable Connection 2. Cut and remove the maximum no-load
2. Idle Speed Adjustment Screw speed stop screw sealing wire and
3. Idle Speed Adjustment Screw Locknut remove the locking sleeve.
IDLE SPEED ADJUSTMENT
3. Set the throttle lever at the injection
1. With the engine running and at normal pump to the maximum no- load speed
operating temperature, disconnect the position then loosen the locknut and
throttle linkage at the injection pump, adjust the screw until the specified
Figure 12. maximum no-load speed is obtained.
Tighten the locknut to the specified
torque, see "Specifications" - Chapter 8,
and secure the adjustment with a new
sealing wire and locking sleeve.
4. Ensure the throttle linkage can be
2. Loosen the locknut and adjust the idle reconnected to the injection pump and
speed stop screw until the specified idle adjust the linkage length, if necessary.
speed is obtained, see "Specifications" -
Chapter 8, and reconnect the throttle
linkage.
5. Reconnect the throttle linkage and re-
check the maximum no-load and idle
speeds can be obtained using the hand