John Deere 450G, 455G, 550G, 555G, 650G Crawler Operation & Test Technical Manual (TM1403)

Complete technical Operation & Test Manual with electrical wiring diagrams for John Deere 450G, 455G, 550G, 555G, 650G Crawler. It's the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

John Deere 450G, 455G, 550G, 555G, 650G Crawler 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.

TM1403 (EN) - John Deere 450G, 455G, 550G, 555G, 650G Crawler Technical Manual (Operation & Test).pdf
612 pages, bookmarked, Searchable, Printable, high quality PDF

MAIN SECTIONS
SECTION 9000—General Information
Group 01—Safety Information
Group 02—General Specifications
Group 03—Torque Values
Group 04—Fuels and Lubricants
9005
SECTION 9005—Operational Checkout Procedure
Group 10—Operational Checkout Procedure
SECTION 9010—Engine
Group 05—Theory of Operation
Group 10—System Operational Checks
Group 15—System Diagnostic Information
Group 20—Adjustments
Group 25—Tests
9010
9015
SECTION 9015—Electrical System
Group 05—System Information
Group 10—System Diagrams
Group 15—Sub-System Diagnostics
Group 20—References
9020
SECTION 9020—Power Train
Group 05—Theory of Operation
Group 10—System Operational Checks
Group 15—Diagnostic Information
Group 20—Adjustments
Group 25—Tests
9025
SECTION 9025—Hydraulic System
Group 05—Theory of Operation
Group 10—System Operational Checks
Group 15—Diagnostic Information
Group 20—Adjustments
Group 25—Tests
...

TABLE OF CONTENTS...1
Section 9000: General Information...17
  Group 01: Safety Information...17
    Handle Fluids Safely-Avoid Fires...21
    Prevent Battery Explosions...22
    Prepare For Emergencies...23
    Prevent Acid Burns...24
    Handle Chemical Products Safely...26
    Avoid High-Pressure Fluids...27
    Park Machine Safely...28
    Support Machine Properly...29
    Wear Protective Clothing...30
    Work In Clean Area...31
    Service Machines Safely...32
    Work In Ventilated Area...33
    Illuminate Work Area Safely...34
    Replace Safety Signs...35
    Use Proper Lifting Equipment...36
    Remove Paint Before Welding or Heating...37
    Avoid Heating Near Pressurized Fluid Lines...38
    Keep ROPS Installed Properly...39
    Practice Safe Maintenance...40
    Dispose of Waste Properly...41
    Live With Safety...42
  Group 02: General Specifications...17
    450G Crawler Dozer Specifications...17
    450G Drain and Refill Capacities...17
    450G-LT Crawler Dozer Specifications...17
    450G-LT Drain and Refill Capacities...17
    450G-LGP Crawler Dozer Specifications...17
    450G-LGP Drain and Refill Capacities...17
    455G Crawler Loader Specifications...17
    455G Operating Information...17
    455G Drain and Refill Capacities...17
    550G-LT Crawler Dozer Specifications...18
    550G-LT Drain and Refill Capacities...18
    550G-LGP Crawler Dozer Specifications...18
    550G-LGP Drain and Refill Capacities...18
    555G Crawler Loader Specifications...18
    555G Drain and Refill Capacities...18
    650G Crawler Dozer Specifications...18
    650G Drain and Refill Capacities...18
    650G-LGP Crawler Dozer Specifications...18
    650G-LGP Drain and Refill Capacities...18
    9310 Backhoe Specifications...18
    9310 Backhoe Lift Capacity (G Series Loaders)...18
    9310 Backhoe Lift Capacity (G-Series Dozers)...18
  Group 03: Torque Values...18
    Hardware Torque Specifications...92
    Keeping ROPS Installed Properly...93
    Checking Track Shoe Cap Screw Torque...94
    Unified Inch Bolt and Cap Screw Torque Values...96
    Metric Bolt and Cap Screw Torque Values...97
    Additional Metric Cap Screw Torque Values...98
    Check Oil Lines and Fittings...100
    Service Recommendations for 37° Flare and 30° Cone Seat Connectors...101
    Service Recommendations for O-Ring Boss Fittings...103
    Service Recommendations for Flat Face O-Ring Seal Fittings...105
    Service Recommendations for Inch Series Four Bolt Flange Fittings...107
    Service Recommendations for Metric Series Four Bolt Flange Fitting...109
  Group 04: Fuels and Lubricants...18
    Fuel Specifications...112
    Storing Fuel...113
    Do Not Use Galvanized Containers...114
    Diesel Engine Oil...115
    Final Drive Oil...116
    Track Roller, Front Idler, and Carrier Roller Oil...117
    Transmission, Steering Clutches, Hydraulic and Winch Oil...118
    Grease...119
    Diesel Engine Coolant...120
    Alternative and Synthetic Lubricants...121
    Lubricant Storage...122
Section 9005: Operational Checkout Procedure...170
  Group 10: Operational Checkout Procedure...170
    Operational Checkout Procedure...170
Section 9010: Engine...216
  Group 05: Theory of Operation...216
    General Engine Description...220
    Engine-Sectional View...222
    Cold Weather Starting Aid Operation...224
    Air Cleaner Operation...225
  Group 10: System Operational Checks...231
    4276 John Deere Engine-Use CTM4...216
    4045 John Deere Engine-Use CTM8...216
    John Deere PowerTech PowerTech is a registered trademark of Deere & Company 4045 Engine-Use CTM104...216
    John Deere Engine Accessories-Use CTM11...254
    System Operational Checks...231
  Group 15: System Diagnostic Information...216
    4276 John Deere Engine-Use CTM4...216
    4045 John Deere Engine-Use CTM8...216
    John Deere PowerTech PowerTech is a registered trademark of Deere & Company 4045 Engine-Use CTM104...216
    John Deere Engine Accessories-Use CTM11...254
    Make Visual Inspection of Engine and Supporting Systems...255
    Diagnose Engine Malfunctions...257
  Group 20: Adjustments...216
    4276 John Deere Engine-Use CTM4...216
    4045 John Deere Engine-Use CTM8...216
    John Deere PowerTech PowerTech is a registered trademark of Deere & Company 4045 Engine-Use CTM104...216
    JT07158 TIME TRAC TIME TRAC is a registered trademark of Standyne Automotive Corp. Installation...216
    Fan V-Belt Tension Adjustment (S.N. -840460)...273
    Fan Belt Tension Adjustment (S.N. 840461- )...275
    Engine Speed Adjustment...276
    Engine Speed Control Linkage Adjustment Without Declutch...278
    Engine Speed Control Linkage Adjustment With Declutch...280
    Injection Pump Dynamic Timing...283
    Injection Pump Static Timing Adjustment...286
  Group 25: Tests...217
    4276 John Deere Engine-Use CTM4...217
    4045 John Deere Engine-Use CTM8...217
    John Deere PowerTech PowerTech is a registered trademark of Deere & Company 4045 Engine-Use CTM104...217
    JT05801 Clamp-On Electronic Tachometer Installation...870
    JT05800 Digital Thermometer Installation...871
    Cooling System...294
    Engine Oil Pressure Test...296
    Fuel Supply Pump Pressure Test...298
    Air Filter Restriction Indicator Switch Test...300
    Air Intake System Leakage Test...302
    Radiator Air Flow Test...304
    Turbocharger Boost Pressure Test (S.N. -840460)...308
    Turbocharger Boost Pressure Test (S.N. 840461- )...311
Section 9015: Electrical System...313
  Group 05: System Information...313
    Battery Operation...318
    Battery Specifications...319
    Diagnose Battery Malfunctions...320
    Check Battery Electrolyte Level and Terminals...321
    Procedure for Testing Batteries...324
    Using Booster Batteries-12 Volt System...326
    Visually Inspect Electrical System...328
    Electrical Circuit Malfunctions...329
    High Resistance Circuit...331
    Open Circuit...333
    Grounded Circuit...335
    Shorted Circuit...337
    Multimeter...339
    Seven Step Electrical Test Procedure...340
    Wiring Diagram and Schematic Information...342
    Reading a System Functional Schematic...358
    Reading a Wiring Diagram...344
    Electrical Schematic Symbols...346
  Group 10: System Diagrams...313
    Component Identification Table...351
    Circuit Breaker Specifications...353
    Wiring and Schematic Diagrams Legend...354
    System Functional Schematic Section Legend...357
    System Functional Schematic...358
    Front Console Harness (W5) Wiring Diagram-Modules...360
    Front Console Harness (W5) Component Location-Modules...361
    Front Console Harness (W5A) Wiring Diagram-Gauges...362
    Front Console Harness (W5A) Component Location-Gauges...363
    Engine Harness (W6) Wiring Diagram...364
    Engine Harness (W6) Component Location...365
    Rear Harness (W7) Wiring Diagram...366
    Rear Harness (W7) Component Location...367
    Return-to-Dig Harness (W8) Wiring Diagram...368
    Return-to-Dig Harness (W8) Component Location...369
    Work Light Harness (W9) Wiring Diagram...370
    Work Light Harness (W9) Component Location...371
    Horn Harness (W10) Wiring Diagram...372
    Horn Harness (W10) Component Location...373
    Declutch Harness (W11) Wiring Diagram...374
    Declutch Harness (W11) Component Location...375
    Cab Harness (W12) Wiring Diagram...376
    Cab Harness (W12) Component Location...377
    Pressurizer Harness (W13) Wiring Diagram...378
    Pressurizer Harness (W13) Component Location...379
    Blower Harness (W14) Wiring Diagram...380
    Blower Harness (W14) Component Location...381
    Roof Harness (W15) Wiring Diagram...382
    Roof Harness (W15) Component Location...383
  Group 15: Sub-System Diagnostics...314
    Power Circuit Operational Information...385
    Power Circuit Theory of Operation...386
    Power Circuit Schematic...387
    Start Circuit Operational Information...392
    Start Circuit Theory of Operation...393
    Start Circuit Schematic...394
    Charging Circuit Operational Information...399
    Charging Circuit Theory of Operation...400
    Charge Circuit Schematic...401
    Display Module and Logic Module Circuit Operational Information...406
    Display Module and Logic Module Circuit Theory of Operation...407
    Display Module and Logic Module Circuit Schematic...408
    Logic Module...411
    Indicator Circuit Specifications...412
    Fuel Gauge Sender Specifications...413
    Indicator Circuit Operational Information...414
    Indicator Circuit Theory of Operation...415
    Indicator Circuit Theory of Operation (Fuel Gauge)...416
    Indicator Circuit Schematic...417
    Indicator Circuit Schematic (Fuel Gauge)...418
    Gauge Circuit Specifications...430
    Gauge Circuit Operational Information...433
    Gauge Circuit Theory of Operation...434
    Gauge Circuit Schematic...435
    Start Aid Circuit Operational Information...447
    Start Aid Circuit Theory of Operation...448
    Start Aid Circuit Schematic...449
    Light Circuit Operational Information...452
    Light Circuit Theory of Operation...453
    Light Circuit Schematic...454
    Horn Circuit Operational Information...457
    Horn Circuit Theory of Operation...458
    Horn Circuit Schematic...459
    Reverse Alarm Circuit Operational Information...462
    Reverse Alarm Circuit Theory of Operation...463
    Reverse Alarm Circuit Schematic...464
    Declutch Circuit Operational Information...467
    Declutch Circuit Theory of Operation...468
    Declutch Circuit Schematic...469
    Return-to-Dig Circuit Operational Information...472
    Return-to-Dig Circuit Theory of Operation...473
    Return-to-Dig Circuit Schematic...474
    Hourmeter Circuit Operational Information...477
    Hourmeter Circuit Theory of Operation-with Modules...478
    Hourmeter Circuit Theory of Operation-with Gauges...479
    Hourmeter Circuit Schematic-with Modules...480
    Hourmeter Circuit Schematic-with Gauges...481
    Blower Circuit Operational Information...484
    Blower Circuit Theory of Operation...485
    Blower Circuit Schematic...486
    Dome Light Circuit Operational Information...489
    Dome Light Circuit Theory of Operation...490
    Dome Light Circuit Schematic...491
    Wiper/Washer Circuit Operational Information...493
    Wiper/Washer Circuit Theory of Operation...494
    Wiper/Washer Circuit Schematic...495
  Group 20: References...316
    John Deere Alternator and Starting Motors-Use CTM77...500
    Alternator Operation-95 Amp Bosch...502
    Alternator Operation-95 Amp Bosch...502
    Logic Module Test in Machine...503
    Logic Module Bench Test...506
Section 9020: Power Train...508
  Group 05: Theory of Operation...508
    Transmission Drive and Pump-Direct Drive...513
    Torque Converter...514
    Transmission Hydraulic Components-Direct Drive Machine (S.N. -803600)...516
    Transmission Hydraulic Components-Direct Drive Machine (S.N. 803601- )...517
    Transmission Hydraulic Components-Torque Converter Machine (S.N. -803600)...518
    Transmission Hydraulic Components-Torque Converter Machine (S.N. 803601- )...519
    Transmission-Thrust Washer/Bushing Design...520
    Transmission-Ball Bearing Design...522
    Power Flow-First Speed Forward...524
    Power Flow-Second Speed Reverse...526
    Transmission Oil Routing...528
    Transmission Lubrication...530
    Direction Clutch Pack...532
    Speed Clutch Pack...533
    Transmission Charge Circuit...534
    Pressure Regulating Valve...535
    Cooler and Lubrication Relief Valves...536
    Speed Control Valve and Detent Spool...537
    Speed Pack Orifices...538
    Sump Valve Drain Port...539
    Park Position...540
    Steering Brake Control Linkage...542
    Transmission Oil Flow-Direct Drive...544
    Transmission Oil Flow-Torque Converter...547
    Transmission Control Valve...550
    Steering Brake Priority...559
    Pedal Steering-Straight Travel...561
    Pedal Steering-Right Steer...562
    Pedal Steering-Both Pedals Depressed...563
    Pedal Steering Linkage-(S.N. -770807)...565
    Pedal Steering Linkage-(S.N. 770808- )...567
    Lever Steering-Right Turn...568
    Lever Steering-Both Levers Pulled...569
    Lever Steering-(S.N. -770807)...570
    Lever Steering-(S.N. 770808- )...572
    Final Drives...573
  Group 10: System Operational Checks...231
    System Operational Procedure...841
  Group 15: Diagnostic Information...509
    Diagnose Transmission Malfunctions...610
    Diagnose Undercarriage Malfunctions...616
    Measure Track Bushing Outer Diameter...618
    Measure Track Pitch-Sealed Chain...620
    Measure Track Pitch for Lubricated Track Chain...621
    Measure Grouser Bar Height...622
    Measure Front Idler Wear...623
    Measure Track Roller Wear...625
    Measure Upper Track Carrier Roller Wear...626
    Measure Link Height...627
    Hydraulic Oil Filter Inspection Procedure...857
  Group 20: Adjustments...509
    Engage Tow Disconnect Pins Manually...631
    Adjust Steering Brake Self-Adjuster Linkage-(S.N. -770807)...633
    Manual Steering Brake Adjustment-(S.N. -770807)...636
    Manual Steering Brake Adjustment-(S.N. 770808- )...639
    Procedure for Complete Steering Adjustment...642
    Loosen Brake Bands (S.N. -770807)...643
    Loosen Brake Bands (S.N. 770808- )...645
    Adjust Linkage Inside Transverse Housing...647
    Adjust Stops-Pedal Steer...650
    Adjust Linkage-Pedal Steer...652
    Adjust Steering Valve-Pedal Steer-Direct Drive Machine (S.N. -770807)...653
    Adjust Brakes...688
    Adjust Steering Valve-Pedal Steer-Direct Drive Machine (S.N. 770808- )...658
    Adjust Brakes...688
    Adjust Steering Valve-Pedal Steer-Torque Converter Machine...663
    Adjust Brakes...688
    Adjust Stops-Lever Steer (S.N. -770807)...668
    Adjust Stops-Lever Steer (S.N. 770808- )...670
    Adjust Linkage-Lever Steer...672
    Adjust Steering Valve-Lever Steer (S.N. -770807)...674
    Adjust Brakes...688
    Adjust Steering Valve-Lever Steer (S.N. 770808- )-Direct Drive Machine...679
    Adjust Brakes...688
    Adjust Steering Valve-Lever Steer-Torque Converter Machine...684
    Adjust Brakes...688
    Power Control Pedal Adjustment-Direct Drive Machine...689
    Rate of Shift Adjustment...692
    Transmission Control Linkage Adjustment...693
    Declutch Switch Adjustment-Direct Drive Machine...696
    Track Sag Adjustment...698
    Idler Height Adjustment...701
    Charge Transmission Accumulator-Direct Drive Machine...706
  Group 25: Tests...510
    JT05801 Clamp-On Electronic Tachometer Installation...870
    JT05800 Digital Thermometer Installation...871
    Transmission Air Test (In Transverse Housing)...711
    Transmission Warm-Up Procedure-Direct Drive Machine...713
    Transmission Pump Flow Test-Direct Drive Machine...715
    Transmission Pressure Regulating Valve Test-Direct Drive Machine...718
    Cooler Relief Valve Pressure Test-Direct Drive Machine...720
    Lube Relief Valve Pressure Test-Direct Drive Machine...722
    Steering Circuit Pressure Test-Direct Drive Machine...724
    Complete Transmission System Test (S.N. -770807)-Direct Drive...726
    Complete Transmission System Test Checkout Sheet (S.N. -770807)-Direct Drive...732
    Complete Transmission System Test Specifications and Analysis (S.N. -770807)-Direct Drive...733
    Complete Transmission System Test (S.N. 770808- )-Direct Drive...734
    Complete Transmission System Test Checkout Sheet (S.N. 770808- )-Direct Drive...739
    Complete Transmission System Test Specifications and Analysis (S.N. 770808- )-Direct Drive...741
    Transmission and Steering Clutch Leakage Test Using Cooler Pressure (S.N. -770807)-Direct Drive...742
    Transmission and Steering Clutch Leakage Chart Using Cooler Pressure (S.N. -770807)-Direct Drive...745
    Analysis of Transmission and Steering Clutch Using Cooler Pressure (S.N. -770807)-Direct Drive...747
    Transmission and Steering Clutch Leakage Test Using Cooler Pressure (S.N. 770808- )-Direct Drive...749
    Transmission and Steering Clutch Leakage Chart Using Cooler Pressure (S.N. 770808- )-Direct Drive...753
    Analysis of Transmission and Steering Clutch Test Using Cooler Pressure (S.N. 770808- )-Direct Drive...755
    Transmission Oil Cooler Restriction Test-Direct Drive...757
    Transmission Warm-Up Procedure-Torque Converter...759
    Transmission Pump Flow Test-Torque Converter...760
    Transmission Pressure Regulating Valve Test-Torque Converter...763
    Cooler Relief and Converter-In Valve Pressure Test-Torque Converter...765
    Lube Relief Valve Pressure Test-Torque Converter...767
    Steering Circuit Pressure Test-Torque Converter...769
    Complete Transmission System Test-Torque Converter...771
    Complete Transmission System Test Checkout Sheet-Torque Converter...775
    Transmission Complete System Test Specifications and Analysis-Torque Converter...776
    Transmission and Steering Clutch Leakage Test Using Cooler Pressure-Torque Converter...777
    Transmission and Steering Clutch Leakage Chart Using Cooler Pressure-Torque Converter...781
    Analysis of Transmission and Steering Clutch Leakage Test Using Cooler Pressure-Torque Converter...783
    Stall Speed Test-Torque Converter...785
    Drain Leakage Test-Torque Converter...787
    Transmission Oil Cooler Restriction Test-Torque Converter...789
Section 9025: Hydraulic System...791
  Group 05: Theory of Operation...791
    Dozer Hydraulic System Operation...797
    Dozer Hydraulic System Operation...797
    Loader Hydraulic System Operation...798
    Hydraulic Reservoir Operation...800
    Hydraulic Filter Operation...801
    Hydraulic Pump Operation-Direct Drive...803
    Hydraulic Pump Operation-Torque Converter...805
    Dozer Blade Lift Valve Operation...806
    Dozer Angle, Tilt, and Auxiliary Valve Operation...808
    Dozer System Relief Valve Operation...810
    Loader Control Valve Operation...811
    Loader Valve Inlet Section Operation...813
    Loader System Relief Valve Operation...814
    Loader Bucket Dump Operation...816
    Loader Bucket Regenerative Dump Operation...818
    Loader Bucket Roll-back Operation...819
    Loader Boom Raise Operation...820
    Loader Boom Lower Operation...821
    Loader Boom Float Operation...823
    Loader Auxiliary Valve Operation...825
    Hydraulic Cylinder Operation...827
    Hydraulic Oil Cooler Operation...828
  Group 10: System Operational Checks...231
    System Operational Procedure...841
  Group 15: Diagnostic Information...791
    Use These Seven Basic Steps to Diagnose and Test the Hydraulic System...854
    Make a Pretest Inspection and an Operation Check of the Machine...855
    Hydraulic System Pretest...856
    Hydraulic Oil Filter Inspection Procedure...857
    Diagnose Hydraulic System Malfunction...858
  Group 20: Adjustments...792
    T-Bar Linkage Adjustment-(S.N. 763493- )...864
    Return-to-Dig Adjustment...866
  Group 25: Tests...792
    JT05801 Clamp-On Electronic Tachometer Installation...870
    JT05800 Digital Thermometer Installation...871
    Hydraulic Oil Warm-Up Procedure...872
    Main Hydraulic Pump Flow Test...873
    Loader Circuit Relief Valve Test...877
    Backhoe Circuit Relief Valve Test w/Flow Regulator-If Equipped (9300/9310)...881
    Backhoe Circuit Relief Valve Test w/Remote Pump-If Equipped (9300/9310)...886
    Hydraulic System Relief Valve Test...889
    Cycle Time Test...891
    Cylinder Drift Test...896
    Cylinder Leakage Test...898
    Hydraulic Oil Cooler Restriction Test...900
    Component Location-Loader...902
    Component Location-Dozer (S.N. -834560)...903
    Component Location-Dozer (S.N. 834561- )...904