John Deere 450J, 550J, 650J Crawler Dozer Repair Technical Manual (TM10294)

TM10294 - 450J, 550J, 650J Crawler Dozer (S.N. 141667—159986) Repair Manual.pdf
662 pages, bookmarked, Searchable, Printable, high quality PDF

Complete technical repair Manual for John Deere 450J, 550J, 650J Crawler Dozer. It's the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

John Deere 450J, 550J, 650J Crawler Dozer Operation & Test Technical Manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

MAIN SECTIONS
00 - General Information
01 - Tracks
02 - Axles and Suspension Systems
03 - Transmission
04 - Engine
05 - Engine Auxiliary Systems
07 - Dampener Drive
11 - Park Brake
15 - Equipement Attaching
18 - Operator's Station
19 - Sheet Metal and Styling
21 - Main Hydraulic System
32 - Bulldozer
9900 - Dealer Fabricated Tools
...

TABLE OF CONTENTS....1
Section 00: General Information....11
  Group 01: Safety....11
    Recognize Safety Information....14
    Follow Safety Instructions....15
    Operate Only If Qualified....16
    Wear Protective Equipment....17
    Avoid Unauthorized Machine Modifications....18
    Inspect Machine....19
    Stay Clear of Moving Parts....20
    Avoid High-Pressure Fluids....21
    Avoid High-Pressure Oil....22
    Beware of Exhaust Fumes....23
    Prevent Fires....24
    Prevent Battery Explosions....25
    Handle Chemical Products Safely....26
    Dispose of Waste Properly....27
    Prepare for Emergencies....28
    Add Cab Guarding For Special Uses....29
    Start Only From Operator's Seat....30
    Prevent Unintended Machine Movement....31
    Avoid Work Site Hazards....32
    Keep Riders Off Machine....34
    Avoid Backover Accidents....35
    Avoid Machine Tip Over....36
    Park And Prepare For Service Safely....38
    Service Cooling System Safely....39
    Remove Paint Before Welding or Heating....40
    Make Welding Repairs Safely....41
    Drive Metal Pins Safely....42
  Group 03: Torque Values....11
    Metric Bolt and Cap Screw Torque Values....45
    Additional Metric Cap Screw Torque Values....47
    Unified Inch Bolt and Cap Screw Torque Values....49
    Service Recommendations for 37° Flare and 30° Cone Seat Connectors....51
    Service Recommendations for O-Ring Boss Fittings....53
    O-Ring Boss Fittings In Aluminum Housing Service Recommendations—Excavators....55
    Service Recommendations for Flared Connections—Straight or Tapered Threads....58
    Service Recommendations For Flat Face O-Ring Seal Fittings....60
    O-Ring Face Seal Fittings With SAE Inch Hex Nut And Stud End For High Pressure Service Recommendations....62
    O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For Standard Pressure Service Recommendations....64
    O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For High Pressure Service Recommendations....67
    Service Recommendations for Metric Series Four Bolt Flange Fitting....70
    Service Recommendations For Inch Series Four Bolt Flange Fittings....72
    Inch Series Four Bolt Flange Fitting For High Pressure Service Recommendations....74
    Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings....76
    Service Recommendations For O-Ring Boss Fittings With Shoulder....79
    Metric 24° O-Ring Seal DIN 20078 Service Recommendations....82
Section 01: Tracks....86
  Group 0130: Track System....86
    Rock Guards and Chain Guides Remove and Install....89
    Carrier Roller Remove and Install....91
    Carrier Roller Disassemble and Assemble....95
    Metal Face Seals Inspection....98
    Track Roller Remove and Install....100
    Track Roller Disassemble and Assemble....102
    Track Roller Leakage Test....104
    Track Shoe Remove and Install....105
    Sealed Track Chain Removal....108
    Sealed Track Chain Disassemble and Assemble....113
    Sealed Track Chain Installation....114
    Lubricated Track Chain (Saw Tooth Master Split Link) Remove and Install....117
    Lubricated Track Chain Disassembly (Turn Bushings and Lubricate Chain)....122
    Lubricated Track Chain Assembly (Turn Bushings and Lubricate Chain)....126
    Lubricated Track Chain Disassemble and Assemble (Turn Pins and Not Lubricate)....135
    Front Idler Remove and Install....142
    Front Idler Disassemble, Inspect, and Assemble....144
    Front Idler Adjustment....147
    Front Idler Oil Level Check....149
    Track Tension Adjuster Remove and Disassemble....151
    Track Tension Adjuster Assemble and Install....153
    Track Idler Recoil Spring Remove and Install....155
    Track Idler Recoil Spring Disassemble and Assemble....157
    Sprocket Remove and Install....163
    Track Frame Remove and Install....165
    Track Frame Disassemble and Assemble....167
    Frame Wear Strips Remove and Install....170
Section 02: Axles and Suspension Systems....172
  Group 0201: Drive Axle Housing and Support....172
    Final Drive Remove and Install....178
  Group 0250: Axle Shaft, Bearings, and Reduction Gear....172
    Final Drive Disassemble and Assemble....199
Section 03: Transmission....215
  Group 0300: Removal and Installation....215
    Hydrostatic Pump Remove and Install....228
    Hydrostatic Motor Remove and Install....240
  Group 0315: Controls Linkage....215
    Transmission Control Lever (TCL) Remove and Install....245
    Transmission Control Lever (TCL) Disassemble and Assemble (S.N. —130885)....247
    Transmission Control Lever (TCL) with Integrated Grade Control (IGC) Disassemble and Assemble (S.N. 130886—)....271
  Group 0360: Hydrostatic System....215
    Hydrostatic Pumps Disassemble....286
    Hydrostatic Charge Pump Disassemble and Assemble....299
    Pump Displacement Control Valve (PDCV) Disassemble and Assemble....305
    Multi-Function Valve Disassemble and Assemble....309
    Neutral Charge Relief Valve Disassemble and Assemble....312
    Hydrostatic Pump Assemble....313
    Hydrostatic Motor Disassemble....326
    Hydrostatic Motor Assemble....332
    Oil Cooler Thermal Bypass Valve Remove and Install....349
    Hydrostatic Filter Remove and Install....351
    Hydrostatic Filter Disassemble and Assemble....352
    Hydrostatic Reservoir Remove and Install....354
Section 04: Engine....358
  Group 0400: Removal and Installation....358
    Engine Remove and Install....367
Section 05: Engine Auxiliary Systems....375
  Group 0505: Cold Weather Starting Aids....375
    Engine Coolant Heater Remove and Install....379
    Start Aid Remove and Install....382
    Starting Aid Solenoid Remove and Install....384
  Group 0510: Radiator and Fan Shroud....375
    Fan Blade and Shroud Remove and Install (450J, 550J)....387
    Fan Blade and Shroud Remove and Install (650J)....389
    Cooling Package Remove and Install (450J, 550J)....392
    Cooling Package Remove and Install (650J)....395
    Sand Shield Remove and Install....400
  Group 0515: Engine Speed Control....375
    Decelerator/Brake Pedal Remove and Install....402
    Decelerator/Brake Pedal Disassemble and Assemble....403
  Group 0520: Intake System....375
    Air Cleaner Remove and Install 550J and 650J....412
  Group 0530: External Exhaust System....375
    Muffler Without Turbocharger Remove and Install....415
    Muffler With Turbocharger Remove and Install....416
  Group 0540: Mounting Frame....375
    Engine and Power Train Mounting....419
  Group 0560: External Fuel Supply System....375
    Fuel Tank Remove and Install....423
Section 07: Dampener Drive....425
  Group 0752: Elements....425
    Dampener Drive Remove and Install....428
Section 11: Park Brake....430
  Group 1100: Removal and Installation....430
    Park Brake Valve Remove and Install....432
    Park Brake Remove and Install....433
  Group 1115: Control Linkage....430
    Park Lock Linkage Remove and Install....439
    Park Lock Linkage Disassemble and Assemble....441
  Group 1160: Hydraulic System....430
    Park Brake Valve Disassemble and Assemble....448
    Park Brake Disassemble and Assemble....451
Section 15: Equipment Attaching....456
  Group 1540: Ripper....456
    Ripper Remove and Install....461
Section 18: Operator's Station....465
  Group 1800: Removal and Installation....465
    Cab or ROPS Remove and Install....477
  Group 1810: Operator's Enclosure....465
    Slide Glass Remove and Install....489
    Stationary Glass Remove and Install....491
    Sliding Window Remove and Install....493
    Front Window Wiper Remove and Install....495
    Door Window Wipers Remove and Install....497
    Rear Window Wiper Remove and Install....499
    Window Washer Pumps Remove and Install....501
  Group 1821: Seat and Seat Belt....465
    Standard Seat Remove and Install (Old)....506
    Deluxe Seat Remove and Install....510
    Air Suspension Seat Remove and Install....519
  Group 1830: Heating and Air Conditioning....465
    R134a Refrigerant Cautions....523
    R134a Compressor Oil Charge Check....524
    R134a Compressor Oil Removal....525
    R134a Component Oil Charge....526
    Leakage Testing....528
    R134a Refrigerant Recovery, Recycling and Charging Station Installation Procedure....529
    Recover R134a System....531
    Evacuate R134a System....533
    Charge R134a System....535
    Air Conditioner System Cleaning Procedures....537
    Purge R134a System....538
    Flush R134a System....539
    Evaporator or Heater Core Remove and Install....542
    Expansion Valve Remove and Install....546
    A/C Freeze Switch Remove and Install....547
    Upper Cab Heater Blower Motor and Heater Blower Resistor Remove and Install....548
    Cab Upper Heater Disassemble and Assemble....549
    Cab or ROPS Under Seat Heater Disassemble and Assemble....551
    Receiver-Dryer Remove and Install....554
    Condenser Remove and Install....555
    Compressor Remove and Install....556
    Compressor Clutch Disassemble and Assemble....558
    Clutch Hub Clearance Check....560
    Compressor Manifold Inspect....561
    Compressor Disassemble and Assemble....562
Section 19: Sheet Metal and Styling....566
  Group 1910: Hood and Engine Enclosure....566
    Hood Remove and Install....569
    Hood Support and Engine Side Shields Remove and Install....571
  Group 1921: Grille and Grille Housing....566
    Grille and Grille Housing Removal....575
    Grille and Grille Housing Installation....578
Section 21: Main Hydraulic System....582
  Group 2160: Hydraulic System....582
    Hydraulic Pump Remove and Install....587
    Hydraulic Pump (With Winch Option) Disassemble and Assemble....591
    Hydraulic Pump (Without Winch Option) Disassemble and Assemble....596
    Hydraulic Reservoir Remove and Install....599
    Hydraulic Reservoir and Hydrostatic Reservoir Cleanout Cover Remove and Install....603
    Hydraulic Reservoir Disassemble and Assemble....607
    Hydraulic Filter Remove and Install....609
    Hydraulic Filter Disassemble and Assemble....610
Section 32: Bulldozer....612
  Group 3201: Blades....612
    Blade Remove and Install....617
    Blade Retainer Split Bearing Installation....621
    Cutting Edges and End Bits Remove and Install....623
  Group 3215: Control Linkage....612
    Hydraulic Control Lever Linkage Remove and Install....627
    Auxiliary Hydraulic Control Lever Linkage Remove and Install....630
  Group 3240: Frames....612
    C-Frame Remove and Install....636
    C-Frame Remove and Install (New)....640
  Group 3260: Hydraulic System....612
    Hydraulic Control Valve Remove and Install....651
    Hydraulic Control Valve Disassemble and Assemble....654
    Hydraulic Control Valve Disassemble and Assemble—IGC....656
    Wiper Seals and Lip Seals on Hydraulic Control Valve Remove and Install....659
    Auxiliary Control Valve Section Disassemble and Assemble....667
    Angle Control Valve Section Disassemble and Assemble....669
    Tilt Control Valve Section Disassemble and Assemble....671
    Lift Control Valve Section Disassemble and Assemble....673
    System and Angle Circuit Relief Valve Disassemble and Assemble....676
    Integrated Grade Control (IGC) Lever Remove and Install (S.N. 130886—)....678
    Integrated Grade Control (IGC) Lever Disassemble and Assemble (S.N. 130886—)....681
    Tilt Cylinder Remove and Install....683
    Angle Cylinder Remove and Install....685
    Lift Cylinder Remove and Install....687
    Angle, Lift, and Tilt Cylinders Disassemble and Assemble (John Deere 120 Series Cylinders)....689
Section 9900: Dealer Fabricated Tools....690
  Group 0999: Dealer Fabricated Tools....690
    DF1041 Track Nut Removal Tool....692
    DF1063 Final Drive Lift Bracket....693
    DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool....695
    DFT1119 Pump Support....696
    DFT1130 Adapter....697
    DFT1132 Hydrostatic Motor Removal and Installation Tool....698
    DFT1137 Hydrostatic Motor Removal and Installation Tool....699
    DFT1165 Left Hand Hydrostatic Motor Lifting Bracket....700
    DFT1166 Final Drive Lifting Bracket Adapter....701
    DFT1167 Final Drive Lifting Bracket Adapter Spacer....702
    DFT1168 Right Hand Hydrostatic Motor Lifting Bracket....703
    DFT1211 Final Drive Lifting Bracket Adapter....704
    DFRW20 Compressor Holding Fixture....705
    ST4920 Track Recoil Spring Disassembly and Assembly Tool....706