This is the Ford New Holland D Series Backhoe Loader Repair Manual 40045541. It covers the 455D, 555D, 575D, 655D and 675D.
The 455D's 3-cylinder engine is in here. So are the 4-cylinder engines in the 555D to 675D, turbo versions included. It also covers the DPA and DPS pumps, the 4x4 and 8x8 powershuttles, the rear axle, steering, the front-drive axle and the cab air. The full hydraulic system is covered, with relief settings and pressure tests.
What's Inside This Ford 455D–675D Repair Manual
| System | Pages | Key Topics |
|---|---|---|
| Introduction and Safety | 1-10 | Spine Labels, Contents, Introduction, Production Date Codes and Unit Serial Numbers, Precautionary Statements, Safety Precautions |
| Cylinder Diesel Engine (455D) | 11-59 | Description and Operation, Engine Overhaul, Cylinder Head, Crankshaft, Pistons and Camshaft |
| Cylinder Diesel Engine (555D to 675D) | 60-142 | Description and Operation of Naturally Aspirated and Turbo Engines, Overhaul, Troubleshooting, Specifications and Special Tools |
| Fuel Systems | 143-242 | Fuel System, Fuel Filter, DPA and DPS Injection Pumps and Overhaul, Injectors for 455D and 555D to 675D, Air Cleaners, Turbocharger, Fuel System Troubleshooting |
| Electrical Wiring, Lights and Controls | 243-284 | Harnesses and Instruments, Troubleshooting and Repair, Wiring Diagrams Figures 3-24 to 3-38 |
| Battery, Starting and Charging Systems | 285-332 | Battery, Starting System, Alternator and Charging System, Troubleshooting Guides, Electrical Specifications and Special Tools |
| 4x4 Transmission | 333-397 | Four Speed Powershuttle with Torque Converter: Description and Operation, Solenoid Control Valve, Service |
| 8x8 Transmission | 398-471 | Eight Speed Transmission Description and Operation, Transmission Electrical Operation and Wiring Figure 4-200 |
| Transmission Troubleshooting and Specifications | 472-512 | Transmission Troubleshooting, Troubleshooting Guide, Transmission Specifications with Gear Ratios and Pressures, Special Tools |
| Rear Axle and Brakes | 513-544 | Rear Axle and Wheel Brakes, Differential Lock, Axle, Differential, Brake Pedal, Specifications and Special Tools |
| Power Take-Off | 545-576 | Independent PTO Description and Operation, PTO Troubleshooting, Specifications and Special Tools |
| Hydrostatic Steering | 577-630 | Steering Description and Operation, Steering Specifications and Special Tools, Steering Troubleshooting |
| Front-Wheel Drive Front Axle | 631-690 | Front-Wheel Drive Axle, Transfer Gear Assembly and Overhaul, Special Tools |
| Hydraulic Circuits, Reservoir and Pump | 691-715 | Hydraulic Circuits with Figures 8-1 to 8-6, Reservoir, Filter and Oil Cooler, Hydraulic Pump |
| Backhoe Control Valve | 716-755 | Backhoe Control Valve Assembly, Circuit Relief Valves, Sideshift Hydraulic Clamping System |
| Loader Control Valve | 756-792 | Loader Hydraulic Control Valve Assembly Removal, Overhaul and Installation |
| Hydraulic Cylinders | 793-820 | Flow Restrictor Valves, Cylinder Overhaul |
| Backhoe Frame, Boom and Controls | 821-873 | Backhoe Frame, Boom, Dipstick and Buckets, Control System, Hoses and Tubes |
| Hydraulic Troubleshooting and Pressure Testing | 874-891 | Whole Unit, Backhoe and Loader Troubleshooting, Hydraulic Pressure Testing |
| Hydraulic Specifications | 892-900 | Cylinder Dimensions, Relief Valves and Pressure Settings, Special Tools |
| Cab and Air Conditioning | 901-982 | Cab Glass Installation, Air Conditioning Process, Compressor, Condenser, Troubleshooting and Service, Diagnosis Chart, Manifold Gauges, Refrigerant Recovery |
| Separating the Tractor | 983-1010 | Front Cover or Oil Pan Removal, Separating the Transmission, Torque Specifications |
| Accessories | 1011-1107 | Cold Start Kit, Heavy-Duty Seat Suspension, Third Valve Section Kit, Cutting Edges, Bucket Forks, Lever and Dipperstick Conversion Kits, Stabilizer Pads, Coolant Inhibitor and Filter Kit |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Net horsepower, 455D / 555D / 575D / 655D / 655D Turbo / 675D | 60 / 65 / 75 / 75 / 75 / 85 | p. 128 |
| Compression ratio | 16.3:1 | p. 128 |
| Rated engine speed | 2200 rev/min | p. 128 |
| Valve clearance, exhaust (cold) | 0.017” - 0.021” (0.43 mm - 0.53 mm) | p. 129 |
| Valve clearance, intake (cold) | 0.014” - 0.018” (0.36 mm - 0.46 mm) | p. 129 |
| Oil pump relief valve pressure | 60-70 lbf/in² (4.1 bar - 4.8 bar) at 2000 rev/min | p. 136 |
| Engine oil without filter, 555D, 575D, 655D, 675D | 8 U.S. qts (7.6 L) | p. 137 |
| Engine oil with filter, 555D, 575D, 655D, 675D | 9 U.S. qts (8.5 L) | p. 137 |
| Cooling system, 555D, 575D, 655D, 675D | 4.0 U.S. gals (15.2 L) | p. 137 |
| Thermostat opening temperature | 168° F. (76° C.) | p. 137 |
| Cylinder head bolts (engine cold), ft. lb / N·m / Kgf m | 160 / 217 / 22 | p. 139 |
| Injector opening pressure, 455D / 555D to 675D | 3240 PSI / 3381 PSI | p. 237 |
| Battery | 800 CCA/80 AH, 12 V | p. 327 |
| Voltage regulator setting | 13.6-14.4V | p. 327 |
| Transmission oil capacity | 4.5 US Gal. (18 litres) (31.7 Imp Pts) | p. 505 |
| Transmission line pressure at 800 RPM | 130 PSI (8.83 bar) (9 kgf/cm²) | p. 506 |
| Wheel securing nuts, ft. lb / N·m / kgm | 400 / 540 / 48 | p. 540 |
| Brake pedal free travel | 1.0-2.5” (50-63 mm) with 15 lbs. (67 N) applied to pedals | p. 540 |
| PTO speed | 540 RPM @ 1850 engine RPM | p. 573 |
| Steering relief valve pressure | 2030 - 2100 PSI at 1100 rev/min | p. 612 |
| Main system relief valve, 455D/555D | 2450 lbf/in² +100 / -0 | p. 879 |
| Hydraulic system total, backhoe loader | 21.0 US Gal. (79.6 ltrs) (17.5 Imp. Gal) | p. 892 |
| Backhoe lift cylinder rod end circuit relief | 4600 lbf/in² +150/-0 (317 bar +10.5/-0) at 1400 RPM | p. 886 |
Ford 455D–675D Common Problems This Manual Covers
Engine overheats
Check the cheap causes first. Look for a leaking hose connection and tighten it. If the thermostat is faulty, replace it. A radiator cap that is defective or not sealing also gets replaced. If the fan belt adjustment is wrong, readjust it. The engine troubleshooting chart lists all four causes with their fixes.
Manual Section: Engine troubleshooting p. 125Low engine oil pressure
Check the dipstick before you do anything else, and top up if the level is low. If pressure is still low, clean the oil pump sump screen, since a blocked screen starves the pump. If neither helps, install a new oil pressure relief valve. The engine troubleshooting tables walk through these steps in that order.
Manual Section: Engine troubleshooting p. 126No steering or excessive effort required to steer
First make sure the reservoir has the correct grade and quantity of oil. If steering is still heavy, a faulty pump relief valve is the likely cause. Check system pressure against the 2030 - 2100 PSI at 1100 rev/min steering relief figure. If pressure won't come up, inspect the pump for wear and repair it.
Manual Section: Steering troubleshooting p. 629Backhoe lift fails to operate, is slow, loses power or will not hold
Run the lift circuit relief valve pressure test first, because the valve may be stuck open or set low. If relief pressure is good, run the cylinder leakage test to check for piston seal leakage. If the cylinder holds, look for valve spool leakage in the lift section of the backhoe control valve.
Manual Section: Backhoe troubleshooting p. 875Frequently Asked Questions
Does this manual cover my Ford 455D, 555D, 575D, 655D or 675D backhoe loader?
Yes, if it is a D Series machine. This is Ford New Holland Repair Manual 40045541 for the 455D, 555D, 575D, 655D and 675D. The 455D runs the 3-cylinder engine. The 555D to 675D use 4-cylinder engines, with turbo engines on the 575D, 655D and 675D. Net horsepower is 60 for the 455D and 65 for the 555D. The 575D, 655D and 655D Turbo are each rated at 75, and the 675D at 85. C Series machines are not covered. p. 128
What are the Ford 555D to 675D valve clearances and engine oil capacity?
Set the valves with the engine cold. Exhaust is 0.017” - 0.021” (0.43 mm - 0.53 mm) and intake is 0.014” - 0.018” (0.36 mm - 0.46 mm). On the 555D, 575D, 655D and 675D, engine oil is 8 U.S. qts (7.6 L) without the filter and 9 U.S. qts (8.5 L) with it. Those same four models hold 4.0 U.S. gals (15.2 L) in the cooling system. The thermostat opens at 168° F. (76° C.). p. 129
What are the Ford D Series hydraulic relief valve settings?
On the 455D and 555D the main system relief valve is 2450 lbf/in² +100 / -0. The backhoe lift cylinder rod end circuit relief is 4600 lbf/in² +150/-0 (317 bar +10.5/-0) at 1400 RPM. Steering relief valve pressure is 2030 - 2100 PSI at 1100 rev/min. Total hydraulic capacity for the backhoe loader is 21.0 US Gal. (79.6 ltrs) (17.5 Imp. Gal). p. 879
What are the Ford D Series transmission oil capacity and line pressure?
On these D Series machines, transmission oil capacity is 4.5 US Gal. (18 litres) (31.7 Imp Pts). Line pressure should read 130 PSI (8.83 bar) (9 kgf/cm²) at 800 RPM. The book covers both the 4x4 and the 8x8 transmissions. Gear ratios and the by-pass valve and cooler pressures are in the transmission specifications. p. 505
Does the manual include wiring diagrams, hydraulic schematics and troubleshooting?
Yes. The electrical section has wiring diagrams for the engine cranking circuit, the instrumentation circuit and the air conditioner, plus the transmission electrical operation diagram. Hydraulic circuit schematics cover both sideshift and center pivot backhoes, along with schematics for individual components. Troubleshooting tables cover the engine, fuel system, turbocharger, electrical system, transmission, PTO, steering, hydraulics and air conditioning. Hydraulic pressure testing procedures are included too. p. 264
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