Complete Operation and Test manual with Electrical Wiring Diagrams for John Deere Crawler Dozers 450J, 550J, 650J (S.N.before 141666), with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.

John Deere Crawler Dozers 450J, 550J, 650J workshop Diagnostics and Test manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

TM2257 - John Deere 450G, 455G, 550G, 555G, 650G Crawler Dozer Technical Manual (Operation and Test).PDF

Total Pages: 397 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

MAIN SECTIONS
Foreword
   General Information
      Safety
   Operational Checkout Procedure
      System Operational Checks
   Engine
      Theory Of Operation
      System Diagnostic Information
      Tests
   Electrical System
      System Information
      System Diagrams
      Sub-System Diagnostics
      References
   Hydraulic System
      Theory of Operation
      Diagnostic Information
      Adjustments
      Tests
   Hydrostatic System
...

tm2257 - 450J, 550J, 650J Crawler Dozer (S.N. —141666)

Table of Contents

Foreword

Technical Information Feedback Form

Section 9000: General Information

Group 01: Safety

Recognize Safety Information

Follow Safety Instructions

Operate Only If Qualified

Wear Protective Equipment

Avoid Unauthorized Machine Modifications

Inspect Machine

Stay Clear of Moving Parts

Avoid High-Pressure Fluids

Beware of Exhaust Fumes

Prevent Fires

Prevent Battery Explosions

Handle Chemical Products Safely

Dispose of Waste Properly

Prepare for Emergencies

Add Cab Guarding For Special Uses

Start Only From Operator's Seat

Prevent Unintended Machine Movement

Avoid Work Site Hazards

Keep Riders Off Machine

Avoid Backover Accidents

Avoid Machine Tip Over

Park And Prepare For Service Safely

Service Cooling System Safely

Remove Paint Before Welding or Heating

Make Welding Repairs Safely

Drive Metal Pins Safely

Section 9005: Operational Checkout Procedure

Group 10: System Operational Checks

Operational Checkout

Section 9010: Engine

Group 05: Theory Of Operation

POWERTECH POWERTECH is a trademark of Deere & Company 4.5 L (4045) John Deere Engine

Cold Weather Starting Aid Operation

Group 15: System Diagnostic Information

Diagnose Engine Malfunctions

Group 25: Tests

Slow and Fast Idle Test

Fuel System Test

Turbocharger Boost Pressure Test

Section 9015: Electrical System

Group 05: System Information

Electrical Diagram Information

Group 10: System Diagrams

Fuse and Relay Specifications

System Functional Schematic, Wiring Diagram, and Component Location Legend

System Functional Schematic and Schematic Legend

Canopy Harness (W4) Component Location

Canopy Harness (W4) Wiring Diagram

Cab Harness (W5) Component Location

Cab Harness (W5) Wiring Diagram

Engine Harness (W6) Component Location

Engine Harness (W6) Wiring Diagram

Transmission Harness (W7) Component Location

Transmission Harness (W7) Wiring Diagram

A/C Harness (W8) Component Location (S.N. —102598)

A/C Harness (W8) Component Location (S.N. 102599— )

A/C Harness (W8) Wiring Diagram

Radio Harness (W9) Component Location

Radio Harness (W9) Wiring Diagram

Canopy Auxiliary Light Harness (W11) Component Location

Canopy Auxiliary Light Harness (W11) Wiring Diagram

Grill Harness (W13) Component Location

Grill Harness (W13) Wiring Diagram

Group 15: Sub-System Diagnostics

Starting and Charging Circuit Theory of Operation

Controller Area Network (CAN) Theory of Operation

Engine Control Unit (ECU) Circuit Theory of Operation

Monitor Display Unit (MDU) Circuit Theory of Operation

Transmission Control Unit (TCU) Circuit Theory of Operation

Group 20: References

Service ADVISOR™ Diagnostic Application

Service ADVISOR™ Connection Procedure

Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application

Access Diagnostic Trouble Codes (DTCs)

Engine Control Unit (ECU) Diagnostic Trouble Codes

Monitor Display Unit (MDU) Diagnostic Trouble Codes

Transmission Control Unit (TCU) Diagnostic Trouble Codes

Battery Electrolyte Level And Terminals Check

Battery Test Procedure

Alternator Test Procedure

CAN Circuit Test

Electrical Component Specifications

Transmission Control Unit (TCU) Calibration

Change Units on Monitor Display Unit (MDU)

Decelerator/Brake Pedal Adjustment

Engine Speed Control Remove and Install

Rotary Sensor Remove and Install

Transmission Control Lever (TCL) Adjustment

Section 9025: Hydraulic System

Group 05: Theory of Operation

Hydraulic System Operation

Hydraulic Pump Operation

Hydraulic Pump and Reservoir Operation

Hydraulic Filter Operation—Normal

Hydraulic Filter Operation Continued—Restricted

Control Valve Operation

System Relief Valve (S.N. —108980) And Blade Angle Circuit Relief Valve Operation

System Relief Valve (S.N. 108981— )

Inlet Valve Operation

Auxiliary Valve Operation

Blade Lift Valve Operation

Blade Angle Valve Operation

Blade Tilt Valve Operation

Outlet Valve Cover Operation

Hydraulic Cylinder Operation

Group 15: Diagnostic Information

Hydraulic System Schematic

Hydraulic Component Location

Diagnose Hydraulic System

Group 20: Adjustments

Hydraulic Control Lever Linkage Adjustment

Auxiliary Lever Linkage Adjustment

Blade Pitch Linkage Adjustment

Group 25: Tests

Hydraulic Oil Warm-Up Procedure

Hydraulic Pump Flow Test

Hydraulic System Relief Valve Test

Circuit Relief Valve Test—With Remote Pump

Hydraulic Pump Cycle Time Test

Lift Cylinder Drift Test

Cylinder Leakage Test

Oil Clean-up Procedure

Section 9026: Hydrostatic System

Group 05: Theory of Operation

Hydrostatic System

Transmission Control Circuit—Flow Chart

Charge Pump Operation

Hydrostatic Filter Operation

Neutral Charge Relief Valve Operation

Park Brake Operation

Multi-Function Valve Operation

Oil Cooler Bypass Valve Operation

Pump Pressure Control Pilot (PCP) Operation

Pump Displacement Control Valve (PDCV) Operation

Hydrostatic Pump Operation

Flushing Valve and Operating Charge Relief Valve Operation

Hydrostatic Motor Operation

Group 15: Diagnostic Information

Hydrostatic Schematic—Neutral (Park Brake ON)

Hydrostatic System Component Location

Hydrostatic System Diagram—Park Brake On (Neutral)

Hydrostatic System Diagram—Forward (Slow Speed)

Hydrostatic System Diagram—Reverse (Fast Speed)

Overheating - Flow Chart

High/Low Charge Pressure - Flow Chart

Mistrack/Indexes - Flow Chart

Machine Will Not Reach Full Speed - Flow Chart

Low Power - Flow Chart

TCU Won't Calibrate And One Of The Following Codes Are Displayed During Calibration - Flow Chart

Group 25: Test

JT05800 Digital Thermometer Installation

Digital Pressure And Temperature Analyzer Installation

Hydraulic Oil Cleanup Procedure

Ultra Clean® Hand Launcher

Transmission Oil Warm-Up Procedure

Releasing Park Brake to Tow the Machine

Hydrostatic Pump and Motor Initial Start-Up Procedure

Hydrostatic Pump Flushing Procedure

Pressure Control Pilot (PCP) Manual Override Test

Pressure Control Pilot (PCP) Test

Pressure Control Pilot (PCP) Internal Adjustment

Multi-Function Relief Valve Test

Transmission Efficiency Test

Neutral Charge Relief and Operating Charge Relief Pressure Test

Pump Displacement Control Valve (PDCV) Neutral (Null) Adjustment

Pump Servo Pressure Test

Hydrostatic Motor Min./Max. Angle Servo Piston Pressure Test

Hydrostatic Motor Min. Angle Stop Adjustment

Charge Pump Flow Test

Cooler Bypass Valve Test

Section 9031: Heating and Air Conditioning

Group 05: Theory of Operation

Air Conditioner System Cycle Of Operation

Group 15: Diagnostic Information

Diagnose Air Conditioning System Malfunctions

Diagnose Heater System Malfunctions

Group 25: Test

Proper Refrigerant Handling

R134a Refrigerant Cautions

R134a Oil Charge Capacity

R134a Refrigerant Charge Capacity

Refrigerant Hoses And Tubing Inspection

Operating Pressure Diagnostic Chart

Air Conditioner Low Pressure Switch Test (S.N. —102598)

Air Conditioner High Pressure Switch Test (S.N. —102598)

Air Conditioner High/Low Pressure (Binary) Switch Test (S.N. 102599— )

Freeze Control Switch Test

Leak Testing

John Deere Crawler Dozers 450J, 550J, 650J Operation and Test Service Manual (TM2257)