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John Deere 450K, 550K & 650K Crawler Dozer Repair Technical Manual TM14163X19 – PDF DOWNLOAD
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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 : 476
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.
- 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 450K, 550K & 650K Crawler Dozer Repair Technical Manual TM14163X19 – PDF DOWNLOAD
Contents................................................................................................................ 7 General Information................................................................................................. 9 Safety.......................................................................................................... 11 Information for European Union Directives and Eurasian Economic Union Technical Regulations Compliance...... 11 Recognize Safety Information................................................................................ 12 Follow Safety Instructions.................................................................................. 13 Operate Only If Qualified................................................................................... 13 Wear Protective Equipment................................................................................... 13 Avoid Unauthorized Machine Modifications.................................................................... 14 Inspect Machine............................................................................................. 14 Stay Clear of Moving Parts.................................................................................. 14 Avoid High-Pressure Fluids.................................................................................. 15 Avoid High-Pressure Oils.................................................................................... 15 Work In Ventilated Area..................................................................................... 15 Avoid Static Electricity Risk When Refueling................................................................ 16 High Debris Applications.................................................................................... 16 Prevent Fires............................................................................................... 17 In Case of Machine Fire..................................................................................... 17 Prevent Battery Explosions.................................................................................. 18 Handle Chemical Products Safely............................................................................. 18 Handle Starting Fluid Safely................................................................................ 18 Decommissioning — Proper Recycling and Disposal of Fluids and Components.................................... 19 Exhaust Filter Ash Handling and Disposal.................................................................... 19 Prepare for Emergencies..................................................................................... 19 Clean Debris from Machine................................................................................... 20 Add Cab Guarding for Special Uses........................................................................... 20 Use Steps and Handholds Correctly........................................................................... 20 Start Only From Operator's Seat............................................................................. 20 Use and Maintain Seat Belt.................................................................................. 21 Prevent Unintended Machine Movement......................................................................... 21 Avoid Work Site Hazards..................................................................................... 22 Keep Riders Off Machine..................................................................................... 22 Avoid Backover Accidents.................................................................................... 23 Avoid Machine Tip Over and Machine Damage................................................................... 24 Use Special Care When Operating............................................................................. 24 Inspect and Maintain ROPS................................................................................... 25 Travel Safely............................................................................................... 25 Prevent Acid Burns.......................................................................................... 26 Add and Operate Attachments Safely.......................................................................... 26 Park and Prepare for Service Safely......................................................................... 27 Service Machines Safely..................................................................................... 27 Service Cooling System Safely............................................................................... 27 Remove Paint Before Welding or Heating...................................................................... 28 Make Welding Repairs Safely................................................................................. 28 Drive Metal Pins Safely..................................................................................... 28 Use Proper Lifting Equipment................................................................................ 29 Clean Exhaust Filter Safely................................................................................. 30 Torque Values................................................................................................... 31 Metric Bolt and Cap Screw Torque Values..................................................................... 31 Additional Metric Cap Screw Torque Values................................................................... 32 Unified Inch Bolt and Cap Screw Torque Values............................................................... 33 Service Recommendations for 37° Flare and 30° Cone Seat Connectors.......................................... 34 Service Recommendations for O-Ring Boss Fittings............................................................ 34 O-Ring Boss Fittings in Aluminum Housing Service Recommendations—Excavators................................. 36 Service Recommendations for Flared Connections—Straight or Tapered Threads.................................. 37 Service Recommendations for Flat Face O-Ring Seal Fittings.................................................. 38 O-Ring Face Seal Fittings With SAE Inch Hex Nut and Stud End for High-Pressure Service Recommendations...... 39 O-Ring Face Seal Fittings With Metric Hex Nut and Stud End for Standard Pressure Service Recommendations.... 41 O-Ring Face Seal Fittings With Metric Hex Nut and Stud End for High-Pressure Service Recommendations........ 43 Service Recommendations for Metric Series Four Bolt Flange Fitting.......................................... 45 Service Recommendations For Inch Series Four Bolt Flange Fittings........................................... 46 Inch Series Four Bolt Flange Fitting for High-Pressure Service Recommendations.............................. 47 Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings...................................... 48 Service Recommendations For O-Ring Boss Fittings With Shoulder.............................................. 49 Metric 24° O-Ring Seal DIN 20078 Service Recommendations.................................................... 51 Tracks.............................................................................................................. 53 Track System.................................................................................................... 55 Welding On Machine.......................................................................................... 55 Track Guides and Rock Guards Remove and Install............................................................. 55 Carrier Roller Wear Inspection.............................................................................. 58 Carrier Roller Remove and Install........................................................................... 58 Carrier Roller Disassemble and Assemble..................................................................... 60 Metal Face Seals Inspection................................................................................. 62 Carrier Roller Leakage Test................................................................................. 64 Track Roller Wear Inspection................................................................................ 65 Track Roller Remove and Install............................................................................. 66 Track Roller Disassemble and Assemble....................................................................... 67 Track Roller Leakage Test................................................................................... 76 Track Shoe Grouser Wear Inspection.......................................................................... 77 Track Shoe Remove and Install............................................................................... 78 Track Link Height Inspection................................................................................ 79 Bushing Outside Diameter for Lubricated Track Chain Inspection.............................................. 80 Track Pitch for Lubricated Track Chain Inspection........................................................... 81 Lubricated Track Chain Remove and Install................................................................... 82 Lubricated Track Chain to Turn Bushings and Lubricate Chain Disassemble and Assemble........................ 86 Lubricated Track Chain to Turn Pins and Bushings and Not Lubricate Disassemble and Assemble................. 95 Track Sag Adjustment........................................................................................100 Front Idler Wear Inspection.................................................................................102 Front Idler Remove and Install..............................................................................103 Front Idler Disassemble and Assemble........................................................................104 Front Idler Adjustment......................................................................................111 Front Idler Oil Level Check.................................................................................112 Track Tension Adjuster Repair...............................................................................113 Track Idler Recoil Spring Remove and Install................................................................116 Track Idler Recoil Spring Disassemble and Assemble..........................................................117 Track Frame Remove and Install..............................................................................121 Frame Wear Strips Remove and Install........................................................................122 Sprocket Remove and Install.................................................................................123 Axles and Suspension Systems........................................................................................125 Drive Axle Housing and Support..................................................................................127 Final Drive Remove and Install..............................................................................127 Axle Shaft, Bearings, and Reduction Gears.......................................................................129 Final Drive Disassemble and Assemble........................................................................129 Transmission........................................................................................................141 Removal and Installation........................................................................................143 Hydrostatic Pump and Motor Initial Start-Up Procedure.......................................................143 Hydrostatic Pump Remove and Install.........................................................................144 Hydrostatic Motor Remove and Install........................................................................148 Controls Linkage................................................................................................151 Transmission Control Lever (TCL) Remove and Install.........................................................151 Transmission Control Lever (TCL) Disassemble and Assemble...................................................152 Decelerator/Brake Pedal Remove and Install..................................................................169 Decelerator/Brake Pedal Disassemble and Assemble............................................................170 Input Drive Shafts and U-Joints.................................................................................175 Damper Drive Remove and Install.............................................................................175 Hydrostatic System..............................................................................................177 Hydrostatic Pump Disassemble................................................................................177 Charge Pump Disassemble and Assemble........................................................................185 Pump Displacement Control Valve (PDCV) Disassemble and Assemble.............................................189 Multi-Function Valve Remove and Install.....................................................................191 Multi-Function Valve Disassemble and Assemble...............................................................191 Hydrostatic Pump Assemble...................................................................................193 Neutral Charge Relief Valve Disassemble and Assemble........................................................200 Hydrostatic Motor Disassemble...............................................................................201 Hydrostatic Motor Assemble..................................................................................213 Hydrostatic Thermal Bypass Valve Remove and Install.........................................................228 Hydrostatic Charge Oil Filter Assembly Remove and Install...................................................229 Hydrostatic Charge Oil Filter Assembly Disassemble and Assemble.............................................230 Hydrostatic and Hydraulic Oil Reservoir Cleanout Cover Remove and Install...................................231 Hydraulic Oil Reservoir Remove and Install..................................................................231 Engine..............................................................................................................235 Removal and Installation........................................................................................237 John Deere Engine...........................................................................................237 Engine Remove and Install...................................................................................237 Engine Mounts Remove and Install............................................................................242 Engine Auxiliary System.............................................................................................245 Cold Weather Starting Aids......................................................................................247 Engine Coolant Heater Remove and Install....................................................................247 Cooling Systems.................................................................................................249 Fan Blade Remove and Install................................................................................249 Cooling Package Remove and Install..........................................................................252 Charge Air Cooler Remove and Install........................................................................257 Radiator Remove and Install.................................................................................257 Hydrostatic Oil Cooler Remove and Install...................................................................258 Intake System...................................................................................................259 Air Cleaner Remove and Install..............................................................................259 Precleaner Remove and Install—If Equipped...................................................................259 External Exhaust Systems........................................................................................261 Exhaust Tube Remove and Install.............................................................................261 JDG11340 Bellows Alignment Fixture..........................................................................262 Exhaust Bellows Alignment Procedure.........................................................................266 Diesel Oxidation Catalyst (DOC) Remove and Install..........................................................271 Diesel Particulate Filter (DPF) Remove and Install..........................................................272 Exhaust Filter Remove and Install...........................................................................273 Aftertreatment Assembly Remove and Install..................................................................274 Service Filter Cleaning.....................................................................................276 Selective Catalyst Reduction (SCR) Remove and Install.......................................................277 Diesel Exhaust Fluid (DEF) Tank Remove and Install..........................................................278 Diesel Exhaust Fluid (DEF) Tank Header Remove and Install...................................................279 Diesel Exhaust Fluid (DEF) Tank Header Disassemble and Assemble.............................................280 Diesel Exhaust Fluid (DEF) Tank Cleaning Procedure..........................................................281 Diesel Exhaust Fluid (DEF) Dosing Unit Remove and Install...................................................282 Diesel Exhaust Fluid (DEF) Dosing Injector Remove and Install...............................................283 Diesel Exhaust Fluid (DEF) Decomposition Tube Remove and Install............................................283 External Fuel Supply Systems....................................................................................285 Primary Fuel Filter and Water Separator Remove and Install..................................................285 Final Fuel Filter Remove and Install........................................................................286 Auxiliary Fuel Filter and Water Separator Remove and Install—If Equipped....................................286 Fuel Tank Remove and Install................................................................................287 Park Brake..........................................................................................................289 Removal and Installation........................................................................................291 Park Brake Remove and Install...............................................................................291 Park Brake Valve Remove and Install.........................................................................293 Controls Linkage................................................................................................295 Park Lock Linkage Remove and Install........................................................................295 Park Lock Linkage Disassemble and Assemble..................................................................297 Hydraulic System................................................................................................299 Park Brake Disassemble and Assemble.........................................................................299 Park Brake Valve Disassemble and Assemble...................................................................303 Equipment Attaching.................................................................................................305 Drawbar.........................................................................................................307 Drawbar Remove and Install..................................................................................307 Extended Drawbar Remove and Install.........................................................................308 Electrical System...................................................................................................309 Removal and Installation........................................................................................311 Integrated Grade Control (IGC) Lever Remove and Install.....................................................311 Integrated Grade Control (IGC) Lever Disassemble and Assemble...............................................312 Auxiliary Joystick Remove and Install—IGC...................................................................313 Exhaust Filter Sensor Installation..........................................................................314 Rotary Sensor Remove and Install............................................................................314 Air Conditioner Freeze Control Switch Remove and Install....................................................315 Controller Remove and Install...............................................................................317 Replace (Pull-Type) Metri-Pack® Connectors..................................................................317 Replace (Push-Type) Metri-Pack® Connectors..................................................................318 Replace Metri-Pack® Connectors..............................................................................318 Replace Weather Pack™ Connector.............................................................................319 Install Weather Pack™ Contact...............................................................................320 Replace DEUTSCH® Rectangular or Triangular Connectors.......................................................321 Replace DEUTSCH® Circular Connectors........................................................................323 Replace DEUTSCH® Connectors.................................................................................324 Install DEUTSCH® Contact....................................................................................325 Replace Cinch™ Connectors...................................................................................326 Install Cinch™ Contact......................................................................................328 Repair 32 and 48-Way Cinch™ Connectors......................................................................329 Remove Connector Body From Blade Terminals..................................................................331 Repair Molex Connectors.....................................................................................332 Replace TYCO™ Connectors....................................................................................333 Frame, Chassis, or Supporting Structure.............................................................................335 Frame Installation..............................................................................................337 Welding Repair of Major Structures..........................................................................337 Frame Bottom Guards.............................................................................................339 Bottom Guards Remove and Install............................................................................339 Chassis Weights.................................................................................................341 Front Counterweight Remove and Install......................................................................341 Rear Counterweight Remove and Install.......................................................................342 Operator's Station..................................................................................................343 Removal and Installation........................................................................................345 Operator’s Station Remove and Install.......................................................................345 Operator Enclosure..............................................................................................351 Windowpanes Remove and Install..............................................................................351 Window Wiper Motor Remove and Install.......................................................................354 Window Washer Pumps Remove and Install......................................................................360 Seat and Seat Belt..............................................................................................361 Seat Remove and Install.....................................................................................361 Replacing Seat Belt.........................................................................................361 Heating and Air Conditioning....................................................................................363 R134a Refrigerant Cautions and Proper Handling..............................................................363 R134a Refrigerant Oil Information...........................................................................364 R134a Refrigerant Recovery, Recycling, and Charging Station Installation Procedure..........................365 Recover R134a Refrigerant...................................................................................365 Flush and Purge Air Conditioning System.....................................................................366 Evacuate R134a System.......................................................................................367 Charge R134a System.........................................................................................368 Evaporator or Heater Core Remove and Install................................................................369 Expansion Valve Remove and Install..........................................................................373 Blower Motor and Blower Motor Speed Resistor Remove and Install.............................................374 Heater Disassemble and Assemble.............................................................................375 Under Seat Heater Remove and Install........................................................................376 Under Seat Heater Disassemble and Assemble..................................................................377 Receiver-Dryer Remove and Install...........................................................................378 Condenser Remove and Install................................................................................379 Compressor Remove and Install...............................................................................380 Sheet Metal and Styling.............................................................................................381 Hood or Engine Enclosure........................................................................................383 Hood Remove and Install.....................................................................................383 Engine Side Shields Remove and Install......................................................................384 Miscellaneous Shields...........................................................................................385 Rear Sheet Metal Remove and Install.........................................................................385 Grille and Grille Housing.......................................................................................387 Grille Remove and Install...................................................................................387 Safety, Convenience, and Miscellaneous..............................................................................389 Horn and Warning Devices........................................................................................391 Backup Alarm Remove and Install.............................................................................391 Backup Alarm Volume Adjustment..............................................................................391 Main Hydraulic System...............................................................................................393 Hydraulic System................................................................................................395 General Oil Cleanup Procedure...............................................................................395 Hydraulic Component Failure Cleanup Procedure...............................................................396 Hydraulic Pump Remove and Install...........................................................................397 Hydraulic Pump (With Winch Option) Disassemble and Assemble.................................................398 Hydraulic Pump (Without Winch Option) Disassemble and Assemble..............................................402 Hydraulic Fan Pump Remove and Install.......................................................................404 Hydraulic Fan Motor Remove and Install......................................................................405 Bulldozer...........................................................................................................407 Blades..........................................................................................................409 Cutting Edges and End Bits Remove and Install...............................................................409 Blade Remove and Install....................................................................................410 Control Linkage.................................................................................................413 Blade Control Lever Linkage Remove and Install..............................................................413 Auxiliary Control Lever Linkage Remove and Install..........................................................416 Frames..........................................................................................................419 C-Frame Remove and Install..................................................................................419 Hydraulic System................................................................................................421 Hydraulic Control Valve Remove and Install..................................................................421 Hydraulic Control Valve Remove and Install—IGC..............................................................422 Hydraulic Control Valve Disassemble and Assemble............................................................424 Wiper Seals and Lip Seals on Hydraulic Control Valve Remove and Install.....................................425 Auxiliary Control Valve Section Disassemble and Assemble....................................................431 Angle Control Valve Section Disassemble and Assemble........................................................432 Tilt Control Valve Section Disassemble and Assemble.........................................................434 Lift Control Valve Section Disassemble and Assemble.........................................................435 System Relief Valve Disassemble and Assemble................................................................436 Hydraulic Control Valve Disassemble and Assemble—IGC........................................................438 Lift Cylinder Remove and Install............................................................................439 Tilt Cylinder Remove and Install............................................................................440 Angle Cylinder Remove and Install...........................................................................440 Hydraulic Cylinder Repair...................................................................................441 Ground Conditioning Tool............................................................................................443 Ripper..........................................................................................................445 Ripper Remove and Install—If Equipped.......................................................................445 Blades, Teeth, and Shanks.......................................................................................447 Shank and Tooth Remove and Install..........................................................................447 Hydraulic System................................................................................................449 Ripper Cylinder Remove and Install..........................................................................449 Dealer Fabricated Tools.............................................................................................451 Dealer Fabricated Tools.........................................................................................453 DF1041 Track Nut Removal Tool...............................................................................453 DF1063 Lift Bracket.........................................................................................454 DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool.............................................455 DFT1119 Pump Support........................................................................................456 DFT1130 Adapter.............................................................................................457 DFT1132 Hydrostatic Motor/Hydraulic Pump Tool...............................................................458 DFT1137 Hydrostatic Motor Removal and Installation Tool.....................................................459 DFT1166 Final Drive Lifting Bracket Adapter.................................................................460 DFT1167 Final Drive Lifting Bracket Adapter Spacer..........................................................461 DFT1211 Final Drive Lifting Bracket Adapter.................................................................462 DFT1278 30 mm Wrench With 3/4-in Drive......................................................................462 ST4920 Track Recoil Spring Disassembly and Assembly Tool....................................................463 Page Number............................................................................................................. 7 Section 00.......................................................................................................... 9 Group 0001...................................................................................................... 11 Group 0003...................................................................................................... 31 Section 01.......................................................................................................... 53 Group 0130...................................................................................................... 55 Section 02..........................................................................................................125 Group 0201......................................................................................................127 Group 0250......................................................................................................129 Section 03..........................................................................................................141 Group 0300......................................................................................................143 Group 0315......................................................................................................151 Group 0325......................................................................................................175 Group 0360......................................................................................................177 Section 04..........................................................................................................235 Group 0400......................................................................................................237 Section 05..........................................................................................................245 Group 0505......................................................................................................247 Group 0510......................................................................................................249 Group 0520......................................................................................................259 Group 0530......................................................................................................261 Group 0560......................................................................................................285 Section 11..........................................................................................................289 Group 1100......................................................................................................291 Group 1115......................................................................................................295 Group 1160......................................................................................................299 Section 15..........................................................................................................305 Group 1511......................................................................................................307 Section 16..........................................................................................................309 Group 1600......................................................................................................311 Section 17..........................................................................................................335 Group 1740......................................................................................................337 Group 1746......................................................................................................339 Group 1749......................................................................................................341 Section 18..........................................................................................................343 Group 1800......................................................................................................345 Group 1810......................................................................................................351 Group 1821......................................................................................................361 Group 1830......................................................................................................363 Section 19..........................................................................................................381 Group 1910......................................................................................................383 Group 1913......................................................................................................385 Group 1921......................................................................................................387 Section 20..........................................................................................................389 Group 2004......................................................................................................391 Section 21..........................................................................................................393 Group 2160......................................................................................................395 Section 32..........................................................................................................407 Group 3201......................................................................................................409 Group 3215......................................................................................................413 Group 3240......................................................................................................419 Group 3260......................................................................................................421 Section 42..........................................................................................................443 Group 4200......................................................................................................445 Group 4201......................................................................................................447 Group 4260......................................................................................................449 Section 99..........................................................................................................451 Group 9900......................................................................................................453
S.S 20/02/2025
