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John Deere 450J, 550J & 650J Crawler Dozer Repair Technical Manual TM10722 – PDF DOWNLOAD
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John Deere 450J, 550J & 650J Crawler Dozer Repair Technical Manual TM10722 – PDF DOWNLOAD
450J (Serial No. 159987 – 216242) 550J, 650J (Serial No. 159987 – ) Crawler Dozer Repair
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Description
John Deere 450J, 550J & 650J Crawler Dozer Repair Technical Manual TM10722 – PDF DOWNLOAD
FILE DETAILS:
John Deere 450J, 550J & 650J Crawler Dozer Repair Technical Manual TM10722 – PDF DOWNLOAD
Language : English
Pages : 418
Downloadable : Yes
File Type : PDF
450J (Serial No. 159987 – 216242) 550J, 650J (Serial No. 159987 – ) Crawler Dozer Repair
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
John Deere 450J, 550J & 650J Crawler Dozer Repair Technical Manual TM10722 – 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.
- 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.
- Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair.
- Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.
TABLE OF CONTENTS:
John Deere 450J, 550J & 650J Crawler Dozer Repair Technical Manual TM10722 – 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 Oils.................................................................................... 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 Prevent Unintended Detonation of Explosive Devices.......................................................... 17 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 Lubricated Track Chain (Saw Tooth Master Split Link) Remove and Install..................................... 53 Lubricated Track Chain Disassembly (Turn Bushings and Lubricate Chain)...................................... 56 Lubricated Track Chain Assembly (Turn Bushings and Lubricate Chain)......................................... 58 Lubricated Track Chain Disassemble and Assemble (Turn Pins and Not Lubricate)............................... 65 Front Idler Remove and Install.............................................................................. 70 Front Idler Disassemble, Inspect, and Assemble.............................................................. 71 Front Idler Adjustment...................................................................................... 73 Front Idler Oil Level Check................................................................................. 74 Track Tension Adjuster Remove and Disassemble............................................................... 76 Track Tension Adjuster Assemble and Install................................................................. 78 Track Idler Recoil Spring Remove and Install................................................................ 79 Track Idler Recoil Spring Disassemble and Assemble.......................................................... 80 Sprocket Remove and Install................................................................................. 84 Track Frame Remove and Install.............................................................................. 84 Track Frame Disassemble and Assemble........................................................................ 85 Frame Wear Strips Remove and Install........................................................................ 88 Axles and Suspension Systems........................................................................................ 91 Drive Axle Housing and Support.................................................................................. 93 Final Drive Remove and Install.............................................................................. 93 Axle Shaft, Bearings, and Reduction Gear........................................................................ 97 Final Drive Disassemble and Assemble........................................................................ 97 Transmission........................................................................................................109 Removal and Installation........................................................................................111 Hydrostatic Pump Remove and Install.........................................................................111 Hydrostatic Motor Remove and Install........................................................................121 Controls Linkage................................................................................................123 Transmission Control Lever (TCL) Remove and Install.........................................................123 Transmission Control Lever (TCL) Disassemble and Assemble...................................................124 Hydrostatic System..............................................................................................141 Hydrostatic Pumps Disassemble...............................................................................141 Hydrostatic Charge Pump Disassemble and Assemble............................................................148 Pump Displacement Control Valve (PDCV) Disassemble and Assemble.............................................153 Multi-Function Valve Disassemble and Assemble...............................................................155 Neutral Charge Relief Valve Disassemble and Assemble........................................................156 Hydrostatic Pump Assemble...................................................................................157 Hydrostatic Motor Disassemble...............................................................................164 Hydrostatic Motor Assemble..................................................................................170 Oil Cooler Thermal Bypass Valve Remove and Install..........................................................182 Hydrostatic Filter Remove and Install.......................................................................182 Hydrostatic Filter Disassemble and Assemble.................................................................184 Hydrostatic Reservoir Remove and Install....................................................................185 Engine..............................................................................................................189 Removal and Installation........................................................................................191 Engine Remove and Install...................................................................................191 Engine Auxiliary Systems............................................................................................201 Cold Weather Starting Aids......................................................................................203 Engine Coolant Heater Remove and Install....................................................................203 Start Aid Remove and Install................................................................................204 Starting Aid Solenoid Remove and Install....................................................................205 Radiator and Fan Shroud.........................................................................................207 Fan Blade and Shroud Remove and Install.....................................................................207 Cooling Package Remove and Install..........................................................................208 Engine Speed Control............................................................................................211 Decelerator/Brake Pedal Remove and Install..................................................................211 Decelerator/Brake Pedal Disassemble and Assemble............................................................212 Intake System...................................................................................................217 Air Cleaner Remove and Install..............................................................................217 External Exhaust System.........................................................................................219 Muffler Remove and Install..................................................................................219 Mounting Frame..................................................................................................220 Engine and Power Train Mounting.............................................................................220 External Fuel Supply System.....................................................................................223 Fuel Tank Remove and Install................................................................................223 Dampener Drive......................................................................................................225 Elements........................................................................................................227 Dampener Drive Remove and Install...........................................................................227 Park Brake..........................................................................................................229 Removal and Installation........................................................................................231 Park Brake Valve Remove and Install.........................................................................231 Park Brake Remove and Install...............................................................................231 Control Linkage.................................................................................................235 Park Lock Linkage Remove and Install........................................................................235 Park Lock Linkage Disassemble and Assemble..................................................................236 Hydraulic System................................................................................................239 Park Brake Valve Disassemble and Assemble...................................................................239 Park Brake Disassemble and Assemble.........................................................................240 Equipment Attaching.................................................................................................245 Ripper..........................................................................................................246 Ripper Remove and Install...................................................................................246 Operator's Station..................................................................................................251 Removal and Installation........................................................................................253 Cab or ROPS Remove and Install..............................................................................253 Operator's Enclosure............................................................................................261 Slide Glass Remove and Install..............................................................................261 Stationary Glass Remove and Install.........................................................................262 Sliding Window Remove and Install ..........................................................................264 Front Window Wiper Remove and Install.......................................................................266 Door Window Wipers Remove and Install.......................................................................268 Rear Window Wiper Remove and Install........................................................................270 Window Washer Pumps Remove and Install......................................................................271 Seat and Seat Belt..............................................................................................273 Standard Seat Remove and Install (Old)......................................................................273 Deluxe Seat Remove and Install..............................................................................277 Air Suspension Seat Remove and Install......................................................................287 Heating and Air Conditioning....................................................................................289 R134a Refrigerant Cautions..................................................................................289 R134a Compressor Oil Charge Check...........................................................................289 R134a Compressor Oil Removal................................................................................289 R134a Component Oil Charge..................................................................................290 Leakage Testing.............................................................................................291 R134a Refrigerant Recovery, Recycling and Charging Station Installation Procedure...........................291 Recover R134a System........................................................................................292 Evacuate R134a System.......................................................................................293 Charge R134a System.........................................................................................294 Air Conditioner System Cleaning Procedures..................................................................295 Purge R134a System..........................................................................................295 Flush R134a System..........................................................................................296 Evaporator or Heater Core Remove and Install................................................................297 Expansion Valve Remove and Install..........................................................................299 A/C Freeze Switch Remove and Install........................................................................299 Upper Cab Heater Blower Motor and Heater Blower Resistor Remove and Install.................................300 Cab Upper Heater Disassemble and Assemble...................................................................302 Cab or ROPS Under Seat Heater Disassemble and Assemble......................................................304 Receiver-Dryer Remove and Install...........................................................................306 Condenser Remove and Install................................................................................306 Compressor Remove and Install...............................................................................307 Compressor Clutch Disassemble and Assemble..................................................................309 Clutch Hub Clearance Check..................................................................................310 Compressor Manifold Inspect.................................................................................310 Compressor Disassemble and Assemble.........................................................................311 Sheet Metal and Styling.............................................................................................315 Hood and Engine Enclosure.......................................................................................316 Hood Remove and Install.....................................................................................316 Hood Support and Engine Side Shields Remove and Install.....................................................318 Grille and Grille Housing.......................................................................................319 Grille and Grille Housing Removal...........................................................................319 Grille and Grille Housing Installation......................................................................322 Main Hydraulic System...............................................................................................327 Hydraulic System................................................................................................329 Hydraulic Pump Remove and Install...........................................................................329 Hydraulic Pump (With Winch Option) Disassemble and Assemble.................................................331 Hydraulic Pump (Without Winch Option) Disassemble and Assemble..............................................335 Hydraulic Reservoir Remove and Install (S.N. —243763).......................................................337 Hydraulic Reservoir Remove and Install (S.N. 243764— )......................................................340 Hydraulic Reservoir and Hydrostatic Reservoir Cleanout Cover Remove and Install.............................343 Hydraulic Reservoir Disassemble and Assemble................................................................346 Hydraulic Filter Remove and Install.........................................................................347 Hydraulic Filter Disassemble and Assemble...................................................................348 Bulldozer...........................................................................................................349 Blades..........................................................................................................351 Blade Remove and Install (S.N. —178254).....................................................................351 Blade Remove and Install (S.N. 178255— )....................................................................353 Blade Retainer Split Bearing Installation...................................................................355 Cutting Edges and End Bits Remove and Install...............................................................357 Control Linkage.................................................................................................358 Hydraulic Control Lever Linkage Remove and Install..........................................................358 Auxiliary Hydraulic Control Lever Linkage Remove and Install................................................360 Frames..........................................................................................................363 C-Frame Remove and Install..................................................................................363 C-Frame Remove and Install (New)............................................................................365 Hydraulic System................................................................................................369 Hydraulic Control Valve Remove and Install..................................................................369 Hydraulic Control Valve Disassemble and Assemble............................................................370 Hydraulic Control Valve Disassemble and Assemble—IGC........................................................371 Wiper Seals and Lip Seals on Hydraulic Control Valve Remove and Install.....................................373 Auxiliary Control Valve Section Disassemble and Assemble....................................................379 Angle Control Valve Section Disassemble and Assemble........................................................380 Tilt Control Valve Section Disassemble and Assemble.........................................................382 Lift Control Valve Section Disassemble and Assemble.........................................................383 System and Angle Circuit Relief Valve Disassemble and Assemble..............................................384 Integrated Grade Control (IGC) Lever Remove and Install.....................................................385 Integrated Grade Control (IGC) Lever Disassemble and Assemble...............................................387 Tilt Cylinder Remove and Install............................................................................388 Angle Cylinder Remove and Install...........................................................................389 Lift Cylinder Remove and Install............................................................................390 Angle, Lift, and Tilt Cylinders Disassemble and Assemble (John Deere 120 Series Cylinders)..................390 Dealer Fabricated Tools.............................................................................................391 Dealer Fabricated Tools.........................................................................................393 DF1041 Track Nut Removal Tool...............................................................................393 DF1063 Final Drive Lift Bracket.............................................................................394 DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool.............................................395 DFT1119 Pump Support........................................................................................396 DFT1130 Adapter.............................................................................................397 DFT1132 Hydrostatic Motor Removal and Installation Tool.....................................................398 DFT1137 Hydrostatic Motor Removal and Installation Tool.....................................................399 DFT1165 Left Hand Hydrostatic Motor Lifting Bracket.........................................................400 DFT1166 Final Drive Lifting Bracket Adapter.................................................................401 DFT1167 Final Drive Lifting Bracket Adapter Spacer..........................................................402 DFT1168 Right Hand Hydrostatic Motor Lifting Bracket........................................................403 DFT1211 Final Drive Lifting Bracket Adapter.................................................................404 DFT1278 30 mm Wrench with 3/4 in. Drive.....................................................................404 DFRW20 Compressor Holding Fixture...........................................................................405 ST4920 Track Recoil Spring Disassembly and Assembly Tool....................................................406 Page Number............................................................................................................. 5 Section 00.......................................................................................................... 7 Group 01........................................................................................................ 9 Group 03........................................................................................................ 19 Section 01.......................................................................................................... 41 Group 0130...................................................................................................... 43 Section 02.......................................................................................................... 91 Group 0201...................................................................................................... 93 Group 0250...................................................................................................... 97 Section 03..........................................................................................................109 Group 0300......................................................................................................111 Group 0315......................................................................................................123 Group 0360......................................................................................................141 Section 04..........................................................................................................189 Group 0400......................................................................................................191 Section 05..........................................................................................................201 Group 0505......................................................................................................203 Group 0510......................................................................................................207 Group 0515......................................................................................................211 Group 0520......................................................................................................217 Group 0530......................................................................................................219 Group 0540......................................................................................................220 Group 0560......................................................................................................223 Section 07..........................................................................................................225 Group 0752......................................................................................................227 Section 11..........................................................................................................229 Group 1100......................................................................................................231 Group 1115......................................................................................................235 Group 1160......................................................................................................239 Section 15..........................................................................................................245 Group 1540......................................................................................................246 Section 18..........................................................................................................251 Group 1800......................................................................................................253 Group 1810......................................................................................................261 Group 1821......................................................................................................273 Group 1830......................................................................................................289 Section 19..........................................................................................................315 Group 1910......................................................................................................316 Group 1921......................................................................................................319 Section 21..........................................................................................................327 Group 2160......................................................................................................329 Section 32..........................................................................................................349 Group 3201......................................................................................................351 Group 3215......................................................................................................358 Group 3240......................................................................................................363 Group 3260......................................................................................................369 Section 99..........................................................................................................391 Group 9900......................................................................................................393
S.S 19/02/2025
