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Technical Repair Manual for John Deere 450K 550K 650K Dozer PDF
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John Deere 450K, 550K & 650K Crawler Dozer Repair Technical Manual TM14163X19 – PDF DOWNLOAD
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Description
John Deere 450K, 550K & 650K Crawler Dozer Repair Technical Manual TM14163X19 – PDF DOWNLOAD
FILE DETAILS:
John Deere 450K, 550K & 650K Crawler Dozer Repair Technical Manual TM14163X19 – PDF DOWNLOAD
Language : English
Pages : 474
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
John Deere 450K, 550K & 650K Crawler Dozer Repair Technical Manual TM14163X19 – 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 test sections help to quickly 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.
TABLE OF CONTENTS:
John Deere 450K, 550K & 650K Crawler Dozer Repair Technical Manual TM14163X19 – PDF DOWNLOAD
Contents................................................................................................................ 5 General Information................................................................................................. 7 Safety.......................................................................................................... 9 Information for European Union Directives and Eurasian Economic Union Technical Regulations Compliance...... 9 Recognize Safety Information................................................................................ 10 Follow Safety Instructions.................................................................................. 11 Operate Only If Qualified................................................................................... 11 Wear Protective Equipment................................................................................... 11 Avoid Unauthorized Machine Modifications.................................................................... 12 Inspect Machine............................................................................................. 12 Stay Clear of Moving Parts.................................................................................. 12 Avoid High-Pressure Fluids.................................................................................. 13 Avoid High-Pressure Oils.................................................................................... 13 Work In Ventilated Area..................................................................................... 13 Avoid Static Electricity Risk When Refueling................................................................ 14 High Debris Applications.................................................................................... 14 Prevent Fires............................................................................................... 15 In Case of Machine Fire..................................................................................... 15 Prevent Battery Explosions.................................................................................. 16 Handle Chemical Products Safely............................................................................. 16 Handle Starting Fluid Safely................................................................................ 16 Decommissioning — Proper Recycling and Disposal of Fluids and Components.................................... 17 Exhaust Filter Ash Handling and Disposal.................................................................... 17 Prepare for Emergencies..................................................................................... 17 Clean Debris from Machine................................................................................... 18 Add Cab Guarding for Special Uses........................................................................... 18 Use Steps and Handholds Correctly........................................................................... 18 Start Only From Operator's Seat............................................................................. 18 Use and Maintain Seat Belt.................................................................................. 19 Prevent Unintended Machine Movement......................................................................... 19 Avoid Work Site Hazards..................................................................................... 20 Keep Riders Off Machine..................................................................................... 20 Avoid Backover Accidents.................................................................................... 21 Avoid Machine Tip Over and Machine Damage................................................................... 22 Use Special Care When Operating............................................................................. 22 Inspect and Maintain ROPS................................................................................... 23 Travel Safely............................................................................................... 23 Prevent Acid Burns.......................................................................................... 24 Add and Operate Attachments Safely.......................................................................... 24 Park and Prepare for Service Safely......................................................................... 25 Service Machines Safely..................................................................................... 25 Service Cooling System Safely............................................................................... 25 Remove Paint Before Welding or Heating...................................................................... 26 Make Welding Repairs Safely................................................................................. 26 Drive Metal Pins Safely..................................................................................... 26 Use Proper Lifting Equipment................................................................................ 27 Clean Exhaust Filter Safely................................................................................. 28 Torque Values................................................................................................... 29 Metric Bolt and Cap Screw Torque Values..................................................................... 29 Additional Metric Cap Screw Torque Values................................................................... 30 Unified Inch Bolt and Cap Screw Torque Values............................................................... 31 Service Recommendations for 37° Flare and 30° Cone Seat Connectors.......................................... 32 Service Recommendations for O-Ring Boss Fittings............................................................ 32 O-Ring Boss Fittings in Aluminum Housing Service Recommendations—Excavators................................. 34 Service Recommendations for Flared Connections—Straight or Tapered Threads.................................. 35 Service Recommendations for Flat Face O-Ring Seal Fittings.................................................. 36 O-Ring Face Seal Fittings With SAE Inch Hex Nut and Stud End for High-Pressure Service Recommendations...... 37 O-Ring Face Seal Fittings With Metric Hex Nut and Stud End for Standard Pressure Service Recommendations.... 39 O-Ring Face Seal Fittings With Metric Hex Nut and Stud End for High-Pressure Service Recommendations........ 41 Service Recommendations for Metric Series Four Bolt Flange Fitting.......................................... 43 Service Recommendations For Inch Series Four Bolt Flange Fittings........................................... 44 Inch Series Four Bolt Flange Fitting for High-Pressure Service Recommendations.............................. 45 Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings...................................... 46 Service Recommendations For O-Ring Boss Fittings With Shoulder.............................................. 47 Metric 24° O-Ring Seal DIN 20078 Service Recommendations.................................................... 49 Tracks.............................................................................................................. 51 Track System.................................................................................................... 53 Welding On Machine.......................................................................................... 53 Track Guides and Rock Guards Remove and Install............................................................. 53 Carrier Roller Wear Inspection.............................................................................. 56 Carrier Roller Remove and Install........................................................................... 56 Carrier Roller Disassemble and Assemble..................................................................... 58 Metal Face Seals Inspection................................................................................. 60 Carrier Roller Leakage Test................................................................................. 62 Track Roller Wear Inspection................................................................................ 63 Track Roller Remove and Install............................................................................. 64 Track Roller Disassemble and Assemble....................................................................... 65 Track Roller Leakage Test................................................................................... 74 Track Shoe Grouser Wear Inspection.......................................................................... 75 Track Shoe Remove and Install............................................................................... 76 Track Link Height Inspection................................................................................ 77 Bushing Outside Diameter for Lubricated Track Chain Inspection.............................................. 78 Track Pitch for Lubricated Track Chain Inspection........................................................... 79 Lubricated Track Chain Remove and Install................................................................... 80 Lubricated Track Chain to Turn Bushings and Lubricate Chain Disassemble and Assemble........................ 84 Lubricated Track Chain to Turn Pins and Bushings and Not Lubricate Disassemble and Assemble................. 93 Track Sag Adjustment........................................................................................ 98 Front Idler Wear Inspection.................................................................................100 Front Idler Remove and Install..............................................................................101 Front Idler Disassemble and Assemble........................................................................102 Front Idler Adjustment......................................................................................109 Front Idler Oil Level Check.................................................................................110 Track Tension Adjuster Repair...............................................................................111 Track Idler Recoil Spring Remove and Install................................................................114 Track Idler Recoil Spring Disassemble and Assemble..........................................................115 Track Frame Remove and Install..............................................................................119 Frame Wear Strips Remove and Install........................................................................120 Sprocket Remove and Install.................................................................................121 Axles and Suspension Systems........................................................................................123 Drive Axle Housing and Support..................................................................................125 Final Drive Remove and Install..............................................................................125 Axle Shaft, Bearings, and Reduction Gears.......................................................................127 Final Drive Disassemble and Assemble........................................................................127 Transmission........................................................................................................139 Removal and Installation........................................................................................141 Hydrostatic Pump and Motor Initial Start-Up Procedure.......................................................141 Hydrostatic Pump Remove and Install.........................................................................142 Hydrostatic Motor Remove and Install........................................................................146 Controls Linkage................................................................................................149 Transmission Control Lever (TCL) Remove and Install.........................................................149 Transmission Control Lever (TCL) Disassemble and Assemble...................................................150 Decelerator/Brake Pedal Remove and Install..................................................................167 Decelerator/Brake Pedal Disassemble and Assemble............................................................168 Input Drive Shafts and U-Joints.................................................................................173 Damper Drive Remove and Install.............................................................................173 Hydrostatic System..............................................................................................175 Hydrostatic Pump Disassemble................................................................................175 Charge Pump Disassemble and Assemble........................................................................183 Pump Displacement Control Valve (PDCV) Disassemble and Assemble.............................................187 Multi-Function Valve Remove and Install.....................................................................189 Multi-Function Valve Disassemble and Assemble...............................................................189 Hydrostatic Pump Assemble...................................................................................191 Neutral Charge Relief Valve Disassemble and Assemble........................................................198 Hydrostatic Motor Disassemble...............................................................................199 Hydrostatic Motor Assemble..................................................................................211 Hydrostatic Thermal Bypass Valve Remove and Install.........................................................226 Hydrostatic Charge Oil Filter Assembly Remove and Install...................................................227 Hydrostatic Charge Oil Filter Assembly Disassemble and Assemble.............................................228 Hydrostatic and Hydraulic Oil Reservoir Cleanout Cover Remove and Install...................................229 Hydraulic Oil Reservoir Remove and Install..................................................................229 Engine..............................................................................................................233 Removal and Installation........................................................................................235 John Deere Engine...........................................................................................235 Engine Remove and Install...................................................................................235 Engine Mounts Remove and Install............................................................................240 Engine Auxiliary System.............................................................................................243 Cold Weather Starting Aids......................................................................................245 Engine Coolant Heater Remove and Install....................................................................245 Cooling Systems.................................................................................................247 Fan Blade Remove and Install................................................................................247 Cooling Package Remove and Install..........................................................................250 Charge Air Cooler Remove and Install........................................................................255 Radiator Remove and Install.................................................................................255 Hydrostatic Oil Cooler Remove and Install...................................................................256 Intake System...................................................................................................257 Air Cleaner Remove and Install..............................................................................257 Precleaner Remove and Install—If Equipped...................................................................257 External Exhaust Systems........................................................................................259 Exhaust Tube Remove and Install.............................................................................259 JDG11340 Bellows Alignment Fixture..........................................................................260 Exhaust Bellows Alignment Procedure.........................................................................264 Diesel Oxidation Catalyst (DOC) Remove and Install..........................................................269 Diesel Particulate Filter (DPF) Remove and Install..........................................................270 Exhaust Filter Remove and Install...........................................................................271 Aftertreatment Assembly Remove and Install..................................................................272 Service Filter Cleaning.....................................................................................274 Selective Catalyst Reduction (SCR) Remove and Install.......................................................275 Diesel Exhaust Fluid (DEF) Tank Remove and Install..........................................................276 Diesel Exhaust Fluid (DEF) Tank Header Remove and Install...................................................277 Diesel Exhaust Fluid (DEF) Tank Header Disassemble and Assemble.............................................278 Diesel Exhaust Fluid (DEF) Tank Cleaning Procedure..........................................................279 Diesel Exhaust Fluid (DEF) Dosing Unit Remove and Install...................................................280 Diesel Exhaust Fluid (DEF) Dosing Injector Remove and Install...............................................281 Diesel Exhaust Fluid (DEF) Decomposition Tube Remove and Install............................................281 External Fuel Supply Systems....................................................................................283 Primary Fuel Filter and Water Separator Remove and Install..................................................283 Final Fuel Filter Remove and Install........................................................................284 Auxiliary Fuel Filter and Water Separator Remove and Install—If Equipped....................................284 Fuel Tank Remove and Install................................................................................285 Park Brake..........................................................................................................287 Removal and Installation........................................................................................289 Park Brake Remove and Install...............................................................................289 Park Brake Valve Remove and Install.........................................................................291 Controls Linkage................................................................................................293 Park Lock Linkage Remove and Install........................................................................293 Park Lock Linkage Disassemble and Assemble..................................................................295 Hydraulic System................................................................................................297 Park Brake Disassemble and Assemble.........................................................................297 Park Brake Valve Disassemble and Assemble...................................................................301 Equipment Attaching.................................................................................................303 Drawbar.........................................................................................................305 Drawbar Remove and Install..................................................................................305 Extended Drawbar Remove and Install.........................................................................306 Electrical System...................................................................................................307 Removal and Installation........................................................................................309 Integrated Grade Control (IGC) Lever Remove and Install.....................................................309 Integrated Grade Control (IGC) Lever Disassemble and Assemble...............................................310 Auxiliary Joystick Remove and Install—IGC...................................................................311 Exhaust Filter Sensor Installation..........................................................................312 Rotary Sensor Remove and Install............................................................................312 Air Conditioner Freeze Control Switch Remove and Install....................................................313 Controller Remove and Install...............................................................................315 Replace (Pull-Type) Metri-Pack® Connectors..................................................................315 Replace (Push-Type) Metri-Pack® Connectors..................................................................316 Replace Metri-Pack® Connectors..............................................................................316 Replace Weather Pack™ Connector.............................................................................317 Install Weather Pack™ Contact...............................................................................318 Replace DEUTSCH® Rectangular or Triangular Connectors.......................................................319 Replace DEUTSCH® Circular Connectors........................................................................321 Replace DEUTSCH® Connectors.................................................................................322 Install DEUTSCH® Contact....................................................................................323 Replace Cinch™ Connectors...................................................................................324 Install Cinch™ Contact......................................................................................326 Repair 32 and 48-Way Cinch™ Connectors......................................................................327 Remove Connector Body From Blade Terminals..................................................................329 Repair Molex Connectors.....................................................................................330 Replace TYCO™ Connectors....................................................................................331 Frame, Chassis, or Supporting Structure.............................................................................333 Frame Installation..............................................................................................335 Welding Repair of Major Structures..........................................................................335 Frame Bottom Guards.............................................................................................337 Bottom Guards Remove and Install............................................................................337 Chassis Weights.................................................................................................339 Front Counterweight Remove and Install......................................................................339 Rear Counterweight Remove and Install.......................................................................340 Operator's Station..................................................................................................341 Removal and Installation........................................................................................343 Operator’s Station Remove and Install.......................................................................343 Operator Enclosure..............................................................................................349 Windowpanes Remove and Install..............................................................................349 Window Wiper Motor Remove and Install.......................................................................352 Window Washer Pumps Remove and Install......................................................................358 Seat and Seat Belt..............................................................................................359 Seat Remove and Install.....................................................................................359 Replacing Seat Belt.........................................................................................359 Heating and Air Conditioning....................................................................................361 R134a Refrigerant Cautions and Proper Handling..............................................................361 R134a Refrigerant Oil Information...........................................................................362 R134a Refrigerant Recovery, Recycling, and Charging Station Installation Procedure..........................363 Recover R134a Refrigerant...................................................................................363 Flush and Purge Air Conditioning System.....................................................................364 Evacuate R134a System.......................................................................................365 Charge R134a System.........................................................................................366 Evaporator or Heater Core Remove and Install................................................................367 Expansion Valve Remove and Install..........................................................................371 Blower Motor and Blower Motor Speed Resistor Remove and Install.............................................372 Heater Disassemble and Assemble.............................................................................373 Under Seat Heater Remove and Install........................................................................374 Under Seat Heater Disassemble and Assemble..................................................................375 Receiver-Dryer Remove and Install...........................................................................376 Condenser Remove and Install................................................................................377 Compressor Remove and Install...............................................................................378 Sheet Metal and Styling.............................................................................................379 Hood or Engine Enclosure........................................................................................381 Hood Remove and Install.....................................................................................381 Engine Side Shields Remove and Install......................................................................382 Miscellaneous Shields...........................................................................................383 Rear Sheet Metal Remove and Install.........................................................................383 Grille and Grille Housing.......................................................................................385 Grille Remove and Install...................................................................................385 Safety, Convenience, and Miscellaneous..............................................................................387 Horn and Warning Devices........................................................................................389 Backup Alarm Remove and Install.............................................................................389 Backup Alarm Volume Adjustment..............................................................................389 Main Hydraulic System...............................................................................................391 Hydraulic System................................................................................................393 General Oil Cleanup Procedure...............................................................................393 Hydraulic Component Failure Cleanup Procedure...............................................................394 Hydraulic Pump Remove and Install...........................................................................395 Hydraulic Pump (With Winch Option) Disassemble and Assemble.................................................396 Hydraulic Pump (Without Winch Option) Disassemble and Assemble..............................................400 Hydraulic Fan Pump Remove and Install.......................................................................402 Hydraulic Fan Motor Remove and Install......................................................................403 Bulldozer...........................................................................................................405 Blades..........................................................................................................407 Cutting Edges and End Bits Remove and Install...............................................................407 Blade Remove and Install....................................................................................408 Control Linkage.................................................................................................411 Blade Control Lever Linkage Remove and Install..............................................................411 Auxiliary Control Lever Linkage Remove and Install..........................................................414 Frames..........................................................................................................417 C-Frame Remove and Install..................................................................................417 Hydraulic System................................................................................................419 Hydraulic Control Valve Remove and Install..................................................................419 Hydraulic Control Valve Remove and Install—IGC..............................................................420 Hydraulic Control Valve Disassemble and Assemble............................................................422 Wiper Seals and Lip Seals on Hydraulic Control Valve Remove and Install.....................................423 Auxiliary Control Valve Section Disassemble and Assemble....................................................429 Angle Control Valve Section Disassemble and Assemble........................................................430 Tilt Control Valve Section Disassemble and Assemble.........................................................432 Lift Control Valve Section Disassemble and Assemble.........................................................433 System Relief Valve Disassemble and Assemble................................................................434 Hydraulic Control Valve Disassemble and Assemble—IGC........................................................436 Lift Cylinder Remove and Install............................................................................437 Tilt Cylinder Remove and Install............................................................................438 Angle Cylinder Remove and Install...........................................................................438 Hydraulic Cylinder Repair...................................................................................439 Ground Conditioning Tool............................................................................................441 Ripper..........................................................................................................443 Ripper Remove and Install—If Equipped.......................................................................443 Blades, Teeth, and Shanks.......................................................................................445 Shank and Tooth Remove and Install..........................................................................445 Hydraulic System................................................................................................447 Ripper Cylinder Remove and Install..........................................................................447 Dealer Fabricated Tools.............................................................................................449 Dealer Fabricated Tools.........................................................................................451 DF1041 Track Nut Removal Tool...............................................................................451 DF1063 Lift Bracket.........................................................................................452 DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool.............................................453 DFT1119 Pump Support........................................................................................454 DFT1130 Adapter.............................................................................................455 DFT1132 Hydrostatic Motor/Hydraulic Pump Tool...............................................................456 DFT1137 Hydrostatic Motor Removal and Installation Tool.....................................................457 DFT1166 Final Drive Lifting Bracket Adapter.................................................................458 DFT1167 Final Drive Lifting Bracket Adapter Spacer..........................................................459 DFT1211 Final Drive Lifting Bracket Adapter.................................................................460 DFT1278 30 mm Wrench With 3/4-in Drive......................................................................460 ST4920 Track Recoil Spring Disassembly and Assembly Tool....................................................461 Page Number............................................................................................................. 5 Section 00.......................................................................................................... 7 Group 0001...................................................................................................... 9 Group 0003...................................................................................................... 29 Section 01.......................................................................................................... 51 Group 0130...................................................................................................... 53 Section 02..........................................................................................................123 Group 0201......................................................................................................125 Group 0250......................................................................................................127 Section 03..........................................................................................................139 Group 0300......................................................................................................141 Group 0315......................................................................................................149 Group 0325......................................................................................................173 Group 0360......................................................................................................175 Section 04..........................................................................................................233 Group 0400......................................................................................................235 Section 05..........................................................................................................243 Group 0505......................................................................................................245 Group 0510......................................................................................................247 Group 0520......................................................................................................257 Group 0530......................................................................................................259 Group 0560......................................................................................................283 Section 11..........................................................................................................287 Group 1100......................................................................................................289 Group 1115......................................................................................................293 Group 1160......................................................................................................297 Section 15..........................................................................................................303 Group 1511......................................................................................................305 Section 16..........................................................................................................307 Group 1600......................................................................................................309 Section 17..........................................................................................................333 Group 1740......................................................................................................335 Group 1746......................................................................................................337 Group 1749......................................................................................................339 Section 18..........................................................................................................341 Group 1800......................................................................................................343 Group 1810......................................................................................................349 Group 1821......................................................................................................359 Group 1830......................................................................................................361 Section 19..........................................................................................................379 Group 1910......................................................................................................381 Group 1913......................................................................................................383 Group 1921......................................................................................................385 Section 20..........................................................................................................387 Group 2004......................................................................................................389 Section 21..........................................................................................................391 Group 2160......................................................................................................393 Section 32..........................................................................................................405 Group 3201......................................................................................................407 Group 3215......................................................................................................411 Group 3240......................................................................................................417 Group 3260......................................................................................................419 Section 42..........................................................................................................441 Group 4200......................................................................................................443 Group 4201......................................................................................................445 Group 4260......................................................................................................447 Section 99..........................................................................................................449 Group 9900......................................................................................................451
S.S 26/02/2025
