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John Deere 450J, 550J, 650J Crawler Dozer Repair Technical Manual TM10294 – PDF DOWNLOAD
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John Deere 450J, 550J, 650J Crawler Dozer Repair Technical Manual TM10294 – PDF DOWNLOAD
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Description
John Deere 450J, 550J, 650J Crawler Dozer Repair Technical Manual TM10294 – PDF DOWNLOAD
FILE DETAILS:
John Deere 450J, 550J, 650J Crawler Dozer Repair Technical Manual TM10294 – PDF DOWNLOAD
Language : English
Pages : 426
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
John Deere 450J, 550J, 650J Crawler Dozer Repair Technical Manual TM10294 – PDF DOWNLOAD
- 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.
- 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 operation and tests. Repair sections tell how to repair the components. Operation and tests 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.
TABLE OF CONTENTS:
John Deere 450J, 550J, 650J Crawler Dozer Repair Technical Manual TM10294 – PDF DOWNLOAD
Contents.................................................................................................................... 5 General Information..................................................................................................... 7 Safety.............................................................................................................. 9 Recognize Safety Information.................................................................................... 9 Follow Safety Instructions...................................................................................... 9 Operate Only If Qualified....................................................................................... 9 Wear Protective Equipment....................................................................................... 10 Avoid Unauthorized Machine Modifications........................................................................ 10 Inspect Machine................................................................................................. 10 Stay Clear of Moving Parts...................................................................................... 10 Avoid High-Pressure Fluids...................................................................................... 11 Avoid High-Pressure Oil......................................................................................... 11 Beware of Exhaust Fumes......................................................................................... 12 Prevent Fires................................................................................................... 12 Prevent Battery Explosions...................................................................................... 12 Handle Chemical Products Safely................................................................................. 13 Dispose of Waste Properly....................................................................................... 13 Prepare for Emergencies......................................................................................... 13 Add Cab Guarding For Special Uses............................................................................... 14 Start Only From Operator's Seat................................................................................. 14 Prevent Unintended Machine Movement............................................................................. 14 Avoid Work Site Hazards......................................................................................... 15 Keep Riders Off Machine......................................................................................... 15 Avoid Backover Accidents........................................................................................ 16 Avoid Machine Tip Over.......................................................................................... 16 Park And Prepare For Service Safely............................................................................. 17 Service Cooling System Safely................................................................................... 17 Remove Paint Before Welding or Heating.......................................................................... 18 Make Welding Repairs Safely..................................................................................... 18 Drive Metal Pins Safely......................................................................................... 18 Torque Values....................................................................................................... 19 Metric Bolt and Cap Screw Torque Values......................................................................... 19 Additional Metric Cap Screw Torque Values....................................................................... 20 Unified Inch Bolt and Cap Screw Torque Values................................................................... 21 Service Recommendations for 37° Flare and 30° Cone Seat Connectors.............................................. 22 Service Recommendations for O-Ring Boss Fittings................................................................ 22 O-Ring Boss Fittings In Aluminum Housing Service Recommendations—Excavators..................................... 24 Service Recommendations for Flared Connections—Straight or Tapered Threads...................................... 25 Service Recommendations For Flat Face O-Ring Seal Fittings...................................................... 26 O-Ring Face Seal Fittings With SAE Inch Hex Nut And Stud End For High Pressure Service Recommendations.......... 27 O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For Standard Pressure Service Recommendations........ 29 O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For High Pressure Service Recommendations............ 31 Service Recommendations for Metric Series Four Bolt Flange Fitting.............................................. 33 Service Recommendations For Inch Series Four Bolt Flange Fittings............................................... 34 Inch Series Four Bolt Flange Fitting For High Pressure Service Recommendations.................................. 35 Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings.......................................... 36 Service Recommendations For O-Ring Boss Fittings With Shoulder.................................................. 37 Metric 24° O-Ring Seal DIN 20078 Service Recommendations........................................................ 39 Tracks ................................................................................................................. 41 Track System........................................................................................................ 43 Rock Guards and Chain Guides Remove and Install................................................................. 43 Carrier Roller Remove and Install............................................................................... 44 Carrier Roller Disassemble and Assemble......................................................................... 47 Metal Face Seals Inspection..................................................................................... 48 Track Roller Remove and Install................................................................................. 49 Track Roller Disassemble and Assemble........................................................................... 50 Track Roller Leakage Test....................................................................................... 51 Track Shoe Remove and Install................................................................................... 51 Sealed Track Chain Removal...................................................................................... 53 Sealed Track Chain Disassemble and Assemble..................................................................... 56 Sealed Track Chain Installation................................................................................. 56 Lubricated Track Chain (Saw Tooth Master Split Link) Remove and Install......................................... 58 Lubricated Track Chain Disassembly (Turn Bushings and Lubricate Chain).......................................... 61 Lubricated Track Chain Assembly (Turn Bushings and Lubricate Chain)............................................. 63 Lubricated Track Chain Disassemble and Assemble (Turn Pins and Not Lubricate)................................... 70 Front Idler Remove and Install.................................................................................. 74 Front Idler Disassemble, Inspect, and Assemble.................................................................. 75 Front Idler Adjustment.......................................................................................... 77 Front Idler Oil Level Check..................................................................................... 78 Track Tension Adjuster Remove and Disassemble................................................................... 80 Track Tension Adjuster Assemble and Install..................................................................... 82 Track Idler Recoil Spring Remove and Install.................................................................... 83 Track Idler Recoil Spring Disassemble and Assemble.............................................................. 84 Sprocket Remove and Install..................................................................................... 88 Track Frame Remove and Install.................................................................................. 89 Track Frame Disassemble and Assemble............................................................................ 89 Frame Wear Strips Remove and Install............................................................................ 92 Axles and Suspension Systems............................................................................................ 95 Drive Axle Housing and Support...................................................................................... 97 Final Drive Remove and Install.................................................................................. 97 Axle Shaft, Bearings, and Reduction Gear............................................................................101 Final Drive Disassemble and Assemble............................................................................101 Transmission............................................................................................................113 Removal and Installation............................................................................................115 Hydrostatic Pump Remove and Install.............................................................................115 Hydrostatic Motor Remove and Install............................................................................124 Controls Linkage....................................................................................................127 Transmission Control Lever (TCL) Remove and Install.............................................................127 Transmission Control Lever (TCL) Disassemble and Assemble (S.N. —130885)........................................128 Transmission Control Lever (TCL) with Integrated Grade Control (IGC) Disassemble and Assemble (S.N. 130886—)....146 Hydrostatic System..................................................................................................149 Hydrostatic Pumps Disassemble...................................................................................149 Hydrostatic Charge Pump Disassemble and Assemble................................................................156 Pump Displacement Control Valve (PDCV) Disassemble and Assemble.................................................161 Multi-Function Valve Disassemble and Assemble...................................................................163 Neutral Charge Relief Valve Disassemble and Assemble............................................................164 Hydrostatic Pump Assemble.......................................................................................165 Hydrostatic Motor Disassemble...................................................................................172 Hydrostatic Motor Assemble......................................................................................178 Oil Cooler Thermal Bypass Valve Remove and Install..............................................................190 Hydrostatic Filter Remove and Install...........................................................................190 Hydrostatic Filter Disassemble and Assemble.....................................................................192 Hydrostatic Reservoir Remove and Install........................................................................193 Engine..................................................................................................................197 Removal and Installation............................................................................................199 Engine Remove and Install.......................................................................................199 Engine Auxiliary Systems................................................................................................207 Cold Weather Starting Aids..........................................................................................209 Engine Coolant Heater Remove and Install........................................................................209 Start Aid Remove and Install....................................................................................210 Starting Aid Solenoid Remove and Install........................................................................211 Radiator and Fan Shroud.............................................................................................213 Fan Blade and Shroud Remove and Install (450J, 550J)............................................................213 Fan Blade and Shroud Remove and Install (650J)..................................................................214 Cooling Package Remove and Install (450J, 550J).................................................................215 Cooling Package Remove and Install (650J).......................................................................216 Sand Shield Remove and Install..................................................................................220 Engine Speed Control................................................................................................221 Decelerator/Brake Pedal Remove and Install......................................................................221 Decelerator/Brake Pedal Disassemble and Assemble................................................................222 Intake System.......................................................................................................227 Air Cleaner Remove and Install 550J and 650J....................................................................227 External Exhaust System.............................................................................................229 Muffler Without Turbocharger Remove and Install.................................................................229 Muffler With Turbocharger Remove and Install....................................................................230 Mounting Frame......................................................................................................232 Engine and Power Train Mounting.................................................................................232 External Fuel Supply System.........................................................................................235 Fuel Tank Remove and Install....................................................................................235 Dampener Drive..........................................................................................................237 Elements............................................................................................................239 Dampener Drive Remove and Install...............................................................................239 Park Brake..............................................................................................................241 Removal and Installation............................................................................................243 Park Brake Valve Remove and Install.............................................................................243 Park Brake Remove and Install...................................................................................243 Control Linkage.....................................................................................................247 Park Lock Linkage Remove and Install............................................................................247 Park Lock Linkage Disassemble and Assemble......................................................................248 Hydraulic System....................................................................................................251 Park Brake Valve Disassemble and Assemble.......................................................................251 Park Brake Disassemble and Assemble.............................................................................252 Equipment Attaching.....................................................................................................257 Ripper..............................................................................................................258 Ripper Remove and Install.......................................................................................258 Operator's Station......................................................................................................263 Removal and Installation............................................................................................265 Cab or ROPS Remove and Install..................................................................................265 Operator's Enclosure................................................................................................273 Slide Glass Remove and Install..................................................................................273 Stationary Glass Remove and Install.............................................................................274 Sliding Window Remove and Install ..............................................................................276 Front Window Wiper Remove and Install...........................................................................278 Door Window Wipers Remove and Install...........................................................................280 Rear Window Wiper Remove and Install............................................................................282 Window Washer Pumps Remove and Install..........................................................................283 Seat and Seat Belt..................................................................................................285 Standard Seat Remove and Install (Old)..........................................................................285 Deluxe Seat Remove and Install..................................................................................289 Air Suspension Seat Remove and Install..........................................................................299 Heating and Air Conditioning........................................................................................301 R134a Refrigerant Cautions......................................................................................301 R134a Compressor Oil Charge Check...............................................................................301 R134a Compressor Oil Removal....................................................................................301 R134a Component Oil Charge......................................................................................302 Leakage Testing.................................................................................................303 R134a Refrigerant Recovery, Recycling and Charging Station Installation Procedure...............................303 Recover R134a System............................................................................................304 Evacuate R134a System...........................................................................................305 Charge R134a System.............................................................................................306 Air Conditioner System Cleaning Procedures......................................................................307 Purge R134a System..............................................................................................307 Flush R134a System..............................................................................................308 Evaporator or Heater Core Remove and Install....................................................................309 Expansion Valve Remove and Install..............................................................................311 A/C Freeze Switch Remove and Install............................................................................311 Upper Cab Heater Blower Motor and Heater Blower Resistor Remove and Install.....................................312 Cab Upper Heater Disassemble and Assemble.......................................................................314 Cab or ROPS Under Seat Heater Disassemble and Assemble..........................................................316 Receiver-Dryer Remove and Install...............................................................................318 Condenser Remove and Install....................................................................................318 Compressor Remove and Install...................................................................................319 Compressor Clutch Disassemble and Assemble......................................................................321 Clutch Hub Clearance Check......................................................................................322 Compressor Manifold Inspect.....................................................................................322 Compressor Disassemble and Assemble.............................................................................323 Sheet Metal and Styling.................................................................................................327 Hood and Engine Enclosure...........................................................................................328 Hood Remove and Install.........................................................................................328 Hood Support and Engine Side Shields Remove and Install.........................................................330 Grille and Grille Housing...........................................................................................331 Grille and Grille Housing Removal...............................................................................331 Grille and Grille Housing Installation..........................................................................334 Main Hydraulic System...................................................................................................339 Hydraulic System....................................................................................................341 Hydraulic Pump Remove and Install...............................................................................341 Hydraulic Pump (With Winch Option) Disassemble and Assemble.....................................................343 Hydraulic Pump (Without Winch Option) Disassemble and Assemble..................................................347 Hydraulic Reservoir Remove and Install..........................................................................349 Hydraulic Reservoir and Hydrostatic Reservoir Cleanout Cover Remove and Install.................................351 Hydraulic Reservoir Disassemble and Assemble....................................................................354 Hydraulic Filter Remove and Install.............................................................................355 Hydraulic Filter Disassemble and Assemble.......................................................................356 Bulldozer...............................................................................................................357 Blades..............................................................................................................359 Blade Remove and Install........................................................................................359 Blade Retainer Split Bearing Installation.......................................................................361 Cutting Edges and End Bits Remove and Install...................................................................362 Control Linkage.....................................................................................................364 Hydraulic Control Lever Linkage Remove and Install..............................................................364 Auxiliary Hydraulic Control Lever Linkage Remove and Install....................................................366 Frames..............................................................................................................369 C-Frame Remove and Install......................................................................................369 C-Frame Remove and Install (New)................................................................................371 Hydraulic System....................................................................................................375 Hydraulic Control Valve Remove and Install......................................................................375 Hydraulic Control Valve Disassemble and Assemble................................................................376 Hydraulic Control Valve Disassemble and Assemble—IGC............................................................377 Wiper Seals and Lip Seals on Hydraulic Control Valve Remove and Install.........................................379 Auxiliary Control Valve Section Disassemble and Assemble........................................................385 Angle Control Valve Section Disassemble and Assemble............................................................386 Tilt Control Valve Section Disassemble and Assemble.............................................................388 Lift Control Valve Section Disassemble and Assemble.............................................................389 System and Angle Circuit Relief Valve Disassemble and Assemble..................................................390 Integrated Grade Control (IGC) Lever Remove and Install (S.N. 130886—)..........................................391 Integrated Grade Control (IGC) Lever Disassemble and Assemble (S.N. 130886—)....................................394 Tilt Cylinder Remove and Install................................................................................395 Angle Cylinder Remove and Install...............................................................................396 Lift Cylinder Remove and Install................................................................................397 Angle, Lift, and Tilt Cylinders Disassemble and Assemble (John Deere 120 Series Cylinders)......................397 Dealer Fabricated Tools.................................................................................................399 Dealer Fabricated Tools.............................................................................................401 DF1041 Track Nut Removal Tool...................................................................................401 DF1063 Final Drive Lift Bracket.................................................................................402 DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool.................................................403 DFT1119 Pump Support............................................................................................404 DFT1130 Adapter.................................................................................................405 DFT1132 Hydrostatic Motor Removal and Installation Tool.........................................................406 DFT1137 Hydrostatic Motor Removal and Installation Tool.........................................................407 DFT1165 Left Hand Hydrostatic Motor Lifting Bracket.............................................................408 DFT1166 Final Drive Lifting Bracket Adapter.....................................................................409 DFT1167 Final Drive Lifting Bracket Adapter Spacer..............................................................410 DFT1168 Right Hand Hydrostatic Motor Lifting Bracket............................................................411 DFT1211 Final Drive Lifting Bracket Adapter.....................................................................412 DFRW20 Compressor Holding Fixture...............................................................................413 ST4920 Track Recoil Spring Disassembly and Assembly Tool........................................................414 Page Number................................................................................................................. 5 Section 00.............................................................................................................. 7 Group 01............................................................................................................ 9 Group 03............................................................................................................ 19 Section 01.............................................................................................................. 41 Group 0130.......................................................................................................... 43 Section 02.............................................................................................................. 95 Group 0201.......................................................................................................... 97 Group 0250..........................................................................................................101 Section 03..............................................................................................................113 Group 0300..........................................................................................................115 Group 0315..........................................................................................................127 Group 0360..........................................................................................................149 Section 04..............................................................................................................197 Group 0400..........................................................................................................199 Section 05..............................................................................................................207 Group 0505..........................................................................................................209 Group 0510..........................................................................................................213 Group 0515..........................................................................................................221 Group 0520..........................................................................................................227 Group 0530..........................................................................................................229 Group 0540..........................................................................................................232 Group 0560..........................................................................................................235 Section 07..............................................................................................................237 Group 0752..........................................................................................................239 Section 11..............................................................................................................241 Group 1100..........................................................................................................243 Group 1115..........................................................................................................247 Group 1160..........................................................................................................251 Section 15..............................................................................................................257 Group 1540..........................................................................................................258 Section 18..............................................................................................................263 Group 1800..........................................................................................................265 Group 1810..........................................................................................................273 Group 1821..........................................................................................................285 Group 1830..........................................................................................................301 Section 19..............................................................................................................327 Group 1910..........................................................................................................328 Group 1921..........................................................................................................331 Section 21..............................................................................................................339 Group 2160..........................................................................................................341 Section 32..............................................................................................................357 Group 3201..........................................................................................................359 Group 3215..........................................................................................................364 Group 3240..........................................................................................................369 Group 3260..........................................................................................................375 Section 9900............................................................................................................399 Group 0999..........................................................................................................401
S.S 23/02/2025
