New Holland 555E, 575E, 655E & 675E Backhoe Loader Service Manual (2000–2010)

New Holland service manual for the 555E, 575E, 655E, and 675E loader backhoes, covering system diagnosis, component overhaul, and major repair work.

PDF Bookmarks, Search Limits, and Diagram Detail

Search and navigation: Text search is available through much of the manual, but the introduction and engine chapters lack searchable text. Embedded bookmarks cover system sections and repair subsections; the “Table of Contents” bookmark opens the introduction. Small wiring labels require zooming, and some circuit lines are faint.

One English-language, printable PDF contains 936 pages: 935 manual pages plus one added front page, already included in the total.

Engine, Drivetrain, and Backhoe Repair

The selected topics below outline the main workshop coverage. Other subjects include air-cleaner servicing and ether cold-start equipment installation.

• Engine overhaul: Engine removal, cylinder-head repair, piston and crankshaft inspection, timing gears, lubrication-system repairs, water-pump overhaul, and turbocharger inspection.

• Fuel-system service: DPS injection-pump timing and test plans, injector testing and overhaul, lift-pump repairs, throttle adjustment, and fuel-system troubleshooting.

• Transmission repair: Power Shuttle and Powershift disassembly, clutch-pack service, hydraulic pressure checks, model-specific stall tests, and electronic fault diagnosis.

• Electrical troubleshooting: System wiring diagrams, harness and connector identification, starter-circuit testing, starter overhaul, and alternator testing and repair.

• Axles, brakes, and steering: Rear-axle overhaul, bearing-preload adjustment, differential-lock diagnosis, brake bleeding, hydrostatic steering repairs, and four-wheel-drive front-axle service.

• Loader and backhoe hydraulics: Tandem-pump overhaul, control-valve repairs, cylinder servicing, swing-system diagnosis, pressure and flow testing, and extendable-dipper maintenance.

• Cab service: Heater troubleshooting, air-conditioning testing and component service, bonded-glass replacement, interior trim work, and cab removal procedures.

Suited to experienced service technicians with hydraulic test equipment and facilities for supported lifting and major component disassembly.

Engine Rebuilding and Fuel-Injection Service

The engine chapter distinguishes work possible with the engine installed from repairs requiring removal and separation from the transmission. Inspection data cover cylinder bores, pistons, crankshaft journals, bearings, and valve gear.

The turbocharger section separates housing service from the factory-balanced center housing and rotating assembly (CHRA). Dismantling the CHRA destroys its balance and requires assembly replacement.

Fuel System Schematic — Engine Cranking and Fuel System Schematic — Engine Running explain the DPS pump’s operating circuits. Pump test plans accompany the timing information; the manual reserves DPS pump dismantling, assembly, testing, and adjustment for an authorized CAV dealer.

Transmission Tests and Electrical Fault Tracing

Powershift diagnosis includes LED fault indications, shift-lever input checks, speed-sensor faults, and solenoid-output tests. The Powershift Microprocessor Circuit links the controller to its switches, connectors, and control valves.

Both transmission types use sealed torque converters. Converter coverage includes testing, cleaning, inspection, and replacement rather than internal component rebuilding.

The electrical section’s Start Circuit diagram is supported by connector views and wire-color identification. Starter no-load and armature tests, plus alternator rotor, stator, and rectifier checks, extend the coverage beyond wiring diagrams.

Rear-Axle Setup, Brakes, and Steering

Separate rear-axle sections address Power Shuttle and Powershift arrangements, including their different differential-lock controls. Pinion, axle-shaft, and differential-bearing adjustments are supported by shim-selection tables.

The axle-shaft preload procedure warns that excessive shaft movement during measurement can damage the seal. Brake documentation also distinguishes bleed-screw orientation between transmission variants.

Hydraulic Diagnosis and Attachment Repairs

The front- and rear-pump troubleshooting charts help distinguish a loader/backhoe supply problem from a stabilizer or extendable-dipper fault before teardown. Pressure-test locations, flow tests, and the E-Series Hydraulic Testing Worksheet support comparison of measured results with the relevant specifications.

Oil Flow Through Backhoe Control Valve Sections illustrates circuit operation. Mechanical repair coverage extends to sideshift carriage clamps, swing cylinders, boom and dipper removal, and step-by-step procedures for extendable-dipper wear-pad replacement.

Loader adjustments cover self-leveling linkage and the return-to-dig sensor. Raised-loader and backhoe service requires the support and boom-lock precautions described in the introduction, with hydraulic pressure relieved before line disconnection.

Cab Equipment and Accessory Conversions

Air-conditioning coverage includes R134a system diagnosis, leak testing, refrigerant recovery, charging, and compressor service. These procedures require certified air-conditioning personnel and suitable recovery equipment.

Accessory instructions cover standard, ISO, three-lever, and four-lever backhoe controls, plus hammer, HED, loader-auxiliary, and hand-tool hydraulic circuits. Kit-selection tables and approximate installation times support conversion planning.

Sample Valve-Lash and Return-to-Dig Settings

For cold-engine valve-lash checks, the engine specifications list intake clearance of 0.014–0.018 in (0.36–0.46 mm) and exhaust clearance of 0.017–0.021 in (0.43–0.53 mm).

The loader’s return-to-dig adjustment specifies a 3–6 mm gap between the sensor face and the pointer on the self-leveling linkage. These settings accompany the relevant inspection and adjustment procedures.