Complete service repair manual for John Deere Crawler Dozers 450H, 550H, 650H, with workshop information to maintain, repair, and service like professional mechanics.

John Deere Crawler Dozers 450H, 550H, 650H workshop service repair 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.
* 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.

TM1744 - John Deere 450H, 550H, 650H Crawler Dozers Technical Manual - Repair.pdf
TM1744 - John Deere 450H, 550H, 650H Crawler Dozers Technical Manual - Repair.epub

Total Pages: 930 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English

MAIN SECTIONS
Foreword
   Technical Information Feedback Form
   General Information
      Safety
      General Specifications
      Torque Values
      Fuels and Lubricants
   Tracks
      Track System
      Dealer Fabricated Tools
   Axles and Suspension Systems
      Drive Axle Housing and Support
      Axle Shaft, Bearings, and Reduction Gear
      Dealer Fabricated Tools
   Transmission
      Removal and Installation
      Controls Linkage
      Hydrostatic System
      Dealer Fabricated Tools
   Engine
      Removal and Installation
      Dealer Fabricated Tools
   Engine Auxiliary Systems
      Cold Weather Starting Aids
      Radiator and Fan Shroud
      Engine Speed Control
      Intake System
      External Exhaust System
      Mounting Frame
      External Fuel Supply System
   Dampener Drive
      Elements
   Park Brake
      Removal and Installation
      Control Linkage
      Hydraulic System
   Equipment Attaching
      Drawbar
   Electrical System
      Batteries, Support, and Cables
      Alternator, Regulator and Charging System Wiring
      Wiring Harness and Switches
      System Controls
      Instruments and Indicators
      Motors and Actuators
   Frames, Chassis, or Supporting Structure
      Frame Installation
      Chassis Weights
   Operator`s Station
      Removal and Installation
      Operator`s Enclosure
      Seat and Seat Belt
      Heating and Air Conditioning
      Dealer Fabricated Tools
   Sheet Metal and Styling
      Hood and Engine Enclosure
      Grille and Grille Housing
   Safety, Convenience and Miscellaneous
      Horn and Warning Devices
   Main Hydraulic System
      Hydraulic System
      Dealer Fabricated Tools
   Bulldozer
      Blades
      Control Linkage
      Frames
      Hydraulic System

tm1744 - 450H, 550H, 650H Crawler Dozer

Table of Contents

Foreword

Technical Information Feedback Form

Section 00: 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

Safety Signs

Instrument Panel with Gauge Package—If Equipped (Earlier Machines)

Instrument Panel Functions (Earlier Machines)

Instrument Panel (Later Machines)

Instrument Panel Functions (Later Machines)

Transmission Controller Display Window

Air Conditioning and Cab Heater—If Equipped

Windshield Wiper and Washer Controls

Windshield Washer Reservoir

Horn Switch

Auxiliary Power Outlet—If Equipped

Side Windows—Secondary Exits

Adjust Non-Suspension Seat

Adjust Suspension Seat—If Equipped

Adjust Armrest

Seat Belt

Live With Safety

Group 02: General Specifications

450H and 450H-LT Crawler Dozer Dimensions

450H-LGP Crawler Dozer Dimensions

450H Crawler Dozer Specifications

450H Other Information

450H Crawler Dozer Weights

450H Crawler Dozer Drain and Refill Capacities

550H Crawler Dozer Dimensions

550H Crawler Dozer Specifications

550H Crawler Dozer Weights

550H-LGP Crawler Dozer Dimensions

550H-LGP Crawler Dozer Specifications

550H-LGP Crawler Dozer Weights

550H and 550H-LGP Other Information

550H and 550H-LGP Crawler Dozer Drain and Refill Capacities

650H Crawler Dozer Dimensions

650H Crawler Dozer Specifications

650H Crawler Dozer Weights

650H-LGP Crawler Dozer Dimensions

650H-LGP Crawler Dozer Specifications

650H-LGP Crawler Dozer Weights

650H and 650H-LGP Other Information

650H and 650H-LGP Crawler Dozer Drain and Refill Capacities

Maximum Cable Capacities

Group 03: Torque Values

Hardware Torque Specifications

Keeping ROPS Installed Properly

Checking Track Shoe Cap Screw Torque

Unified Inch Bolt and Screw Torque Values

Metric Bolt and Screw Torque Values

Additional Metric Cap Screw Torque Values

Check Oil Lines And Fittings

O-Ring Groove Connections

Service Recommendations For Flat Face O-Ring Seal Fittings

Service Recommendations for O-Ring Boss Fittings

Service Recommendations for Inch Series Four Bolt Flange Fittings

Service Recommendations for Metric Series Four Bolt Flange Fitting

Group 04: Fuels and Lubricants

Diesel Fuel

Low Sulfur Diesel Fuel Conditioner

Diesel Fuel Storage

Fuel Tank

Diesel Engine Oil

Track Rollers, Front Idler and Carrier Roller Oil

Transmission and Hydraulic Oil

Winch Oil

Inner and Outer Final Drive Oil

Grease

Lubricant Storage

Alternative and Synthetic Lubricants

Mixing of Lubricants

Heavy Duty Diesel Engine Coolant

Section 01: Tracks

Group 0130: Track System

Essential Tools

Service Equipment and Tools

Other Material

Specifications

Remove and Install Rock Guards and Chain Guides

Measure Carrier Roller Wear

Remove and Install Carrier Roller Assembly

Disassemble and Assemble Carrier Roller

Inspect Carrier Roller Metal Face Seals

Check Carrier Roller Oil Level

Measure Track Roller Wear

Remove and Install Track Roller

Disassemble and Assemble Track Roller

Check Track Roller Oil Level

Adding Oil to The Roller

Test Track Roller for Leakage

Inspect Track Roller Metal Face Seals

Measure Track Shoe Grouser Wear

Remove and Install Track Shoe

Measure Link Height

Measure Track Bushing Outer Diameter

Measure Track Pitch

Check Track Sag

Adjust Track Sag

Remove Sealed Track Chain

Turn Sealed Track Chain Pins and Bushings

Disassemble and Assemble Sealed Track Chain Using Track Press

Install Sealed Track Chain

Remove and Install Lubricated Track Chain—Saw Tooth Master Split Link

Disassemble Lubricated Track Chain to Turn Bushings and Lubricate Chain

Assemble Lubricated Track Chain to Turn Bushings and Lubricate Chain

Disassemble and Assemble Lubricated Track Chain to Turn Pins and Not Lubricate

Measure Front Idler Wear

Remove and Install Front Idler

Disassemble, Inspect, and Assemble Front Idler

Idler Adjustment Procedure

Check Front Idler Oil Level

Remove and Disassemble Hydraulic Track Tension Adjuster

Assemble and Install Hydraulic Track Tension Adjuster

Remove and Install Track Idler Recoil Spring

Disassemble and Assemble Recoil Spring

Remove and Install Sprocket

Remove and Install Track Frame

Remove and Install Frame Wear Strips

Group 0199: Dealer Fabricated Tools

DF1041 Track Nut Removal Tool

DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool

ST4920 Track Recoil Spring Disassembly and Assembly Tool

Section 02: Axles and Suspension Systems

Group 0201: Drive Axle Housing and Support

Service Equipment and Tools

Other Material

Specifications

Remove and Install Final Drive

Group 0250: Axle Shaft, Bearings, and Reduction Gear

Essential Tools

Other Material

Specifications

Disassemble and Assemble Final Drive

Group 0299: Dealer Fabricated Tools

DF1063 Final Drive Lift Bracket

DFT1166 Final Drive Lifting Bracket Adapter

DFT1167 Final Drive Lifting Bracket Adapter Spacer

Section 03: Transmission

Group 0300: Removal and Installation

Service Equipment and Tools

Other Material

Specifications

Hydrostatic Component Location

Remove and Install Hydrostatic Pump

Remove and Install Hydrostatic Motors

Group 0315: Controls Linkage

Essential Tools

Other Material

Specifications

Single Lever Control (SLC) Exploded View (With Speed Lever, If Equipped)

Single Lever Control (SLC) Exploded View (With Speed In Grip, If Equipped)

Remove and Install Single Lever Control (SLC) (With Speed Lever, If Equipped)

Remove and Install Single Lever Control (SLC) (With Speed In Grip, If Equipped)

Disassemble and Assemble Single Lever Control Linkage (SLC)

Remove and Install Transmission Speed Lever Assembly (If Equipped)

Disassemble and Assemble Transmission Speed Lever Assembly (If Equipped)

Group 0360: Hydrostatic System

Essential Tools

Service Equipment and Tools

Specifications

Hydrostatic Pump Exploded View

Disassemble Hydrostatic Pumps

Charge Pump and Pump Controls Exploded View

Disassemble and Assemble Hydrostatic Charge Pump

Pump Displacement Control Valve (PDCV) Remove and Install

Disassemble and Assemble Displacement Control Valve

Disassemble and Assemble Multi-Function Valve

Disassemble and Assemble Neutral Charge Relief Valve

Assemble Hydrostatic Pump

Remove and Install Hydrostatic Motor Speed Sensor

Adjust Hydrostatic Motor Speed Sensor

Disassemble Hydrostatic Motor

Disassemble and Assemble Motor Shift Solenoid Valve

Disassemble and Assemble Charge Pressure Relief Valve

Disassemble and Assemble Loop Flushing Valve

Assemble Hydrostatic Motor

Remove and Install Oil Cooler Thermal Bypass Valve

Disassemble and Assemble Oil Cooler Thermal Bypass Valve

Remove and Install Hydrostatic Filter

Disassemble and Assemble Hydrostatic Filter

Remove and Install Hydrostatic Reservoir

Remove and Install Diagnostic Plumbing

Group 0399: Dealer Fabricated Tools

DFT1063 Pump Lifting Bracket

DFT1130 Adapter

DFT1132 Hydrostatic Motor Removal and Installation Tool

DFT1165 Left Hand Hydrostatic Motor Lifting Bracket

DFT1168 Right Hand Hydrostatic Motor Lifting Bracket

Section 04: Engine

Group 0400: Removal and Installation

Service Equipment and Tools

Other Material

Specifications

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

Remove and Install Engine (450H, 550H S.N. —910011) (650H S.N. —924717)

Remove and Install Engine (450H, 550H S.N. 910011—) (650H S.N. 924718—)

Bleed Fuel System

Group 0499: Dealer Fabricated Tools

DFT1119 Pump Support

Section 05: Engine Auxiliary Systems

Group 0505: Cold Weather Starting Aids

Specifications

PowerTech PowerTech is a registered trademark of Deere & Company 4.5L (4045) John Deere Engine—Use CTM104

Remove and Install Engine Coolant Heater

Remove and Install Starting Aid—If Equipped

Remove and Install Starting Aid Solenoid—If Equipped

Group 0510: Radiator and Fan Shroud

Other Material

Specifications

Remove and Install Fan Blade and Shroud (450H, 550H) (650H S.N.—924717)

Remove and Install Fan Blade and Shroud (650H S.N 924718— )

Remove Radiator and Oil Cooler (450H, 550H) (650H S.N.—924717)

Install Radiator and Oil Cooler (450H, 550H) (650H S.N.—924717)

Cooling Package Remove and Install (650H S.N. 924718— )

Remove and Install Sand Shield—If Equipped

Group 0515: Engine Speed Control

Other Material

Specifications

Remove and Install Engine Speed Control and Decelerator

Group 0520: Intake System

Specifications

Remove and Install Air Cleaner with Turbocharger or Naturally Aspirated 450H, (550H and 650H S. N. —893112)

Remove and Install Air Cleaner 550H and 650H (S.N. 893113 — )

Group 0530: External Exhaust System

Specifications

Remove and Install Muffler Without Turbocharger

Remove and Install Muffler With Turbocharger

Group 0540: Mounting Frame

Specifications

Engine and Power Train Mounting

Group 0560: External Fuel Supply System

Specifications

Remove and Install Fuel Tank

Section 07: Dampener Drive

Group 0752: Elements

Other Material

Specifications

Remove and Install Dampener Drive

Section 11: Park Brake

Group 1100: Removal and Installation

Other Material

Remove and Install Brake Valve

Remove and Install Park Brake

Group 1115: Control Linkage

Service Equipment and Tools

Other Material

Specifications

Remove and Install Brake Pedal Control Linkage

Remove and Install Park Lock Linkage

Group 1160: Hydraulic System

Other Material

Specifications

Disassemble and Assemble Brake Valve

Disassemble and Assemble Park Brake

Section 15: Equipment Attaching

Group 1511: Drawbar

Remove and Install Drawbar

Remove and Install Tow Hook

Section 16: Electrical System

Group 1671: Batteries, Support, and Cables

Service Equipment and Tools

Specifications

Battery Safety

Service Batteries Carefully

Procedure for Testing Batteries

Check Battery Electrolyte Specific Gravity

Check Battery Electrolyte Level

Using Booster Batteries—12—Volt System

Remove and Install Batteries

Group 1672: Alternator, Regulator and Charging System Wiring

Specifications

Alternators and Starting Motors—Use CTM77

Remove and Install Alternator

Group 1674: Wiring Harness and Switches

Essential Tools

Service Equipment and Tools

Cab and ROPS Component Location 1 of 8

Engine Harness Component Location

Transmission Harness Component Location

Radio Harness (W9) Component Location

Air Conditioning and Heater Harness Component Location

Explanation Of Wire Markings

Fuse and Relay Color Codes

Replace DEUTSCH DEUTSCH is a trademark of Deutsch Co. Connector

Install DEUTSCH DEUTSCH is a trademark of Deutsch Co. Contact

Replace WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Connectors

Install WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Contact

Replace (Pull Type) Metri-Pack™ Connectors

Replace (Push Type) Metri-Pack™ Connectors

Remove Connector Body from Blade Terminals

Group 1675: System Controls

Specifications

Welding Procedure

Remove and Install Transmission Controller

Remove and Install Display Monitor

Group 1676: Instruments and Indicators

Remove and Install Dash, Switches and Gauges

Group 1677: Motors and Actuators

John Deere Starting Motor—Use CTM77

Remove and Install Starting Motor

Section 17: Frames, Chassis, or Supporting Structure

Group 1740: Frame Installation

Specifications

Welding Repair of Major Structure

Remove and Install Frame and Bottom Guards

Remove and Install Pivot Shafts

Remove and Install Crossbar

Group 1749: Chassis Weights

Remove and Install Counterweight

Section 18: Operator's Station

Group 1800: Removal and Installation

Service Equipment and Tools

Specifications

Remove Cab or ROPS

Install Cab or ROPS

Group 1810: Operator's Enclosure

Remove and Install Slide Glass

Remove and Install Stationary Glass

Remove and Install Windowpanes

Remove and Install Front Window Wiper

Remove and Install Door Window Wipers (Left Shown)

Remove and Install Window Washer Pumps

Group 1821: Seat and Seat Belt

Remove and Install Standard Seat

Remove and Install Deluxe Seat

Remove and Install Air Suspension Seat

Group 1830: Heating and Air Conditioning

Essential Tools

Service Equipment and Tools

Other Material

Specifications

R134a Refrigerant Theory of Operation

Proper Refrigerant Handling

R134a Refrigerant Cautions

R134a Compressor Oil Charge Check

R134a Compressor Oil Removal

R134a Component Oil Charge

R134a Refrigerant Recovery, Recycling and Charging Station Installation Procedure

Recover R134a System

Evacuate R134a System

Charge R134a System

Leakage Testing

Air Conditioner System Cleaning Procedures

Purge Air Conditioner System

Flush Air Conditioner System

Air Conditioning Electrical and Component Location

Air Conditioning Electrical and Component Location—Continued

Remove and Install Compressor

Disassemble and Assemble Compressor Clutch

Check Clutch Hub Clearance

Inspect Compressor Manifold

Disassemble, Inspect and Assemble Compressor

Remove and Install Receiver-Dryer

Remove and Install Evaporator or Heater Core

Remove and Install Expansion Valve

Remove and Install Condenser

Remove and Install A/C Freeze Switch

Remove and Install Upper Cab Heater Blower Motor or Heater Blower Resistor

Disassemble and Assemble Cab Upper Heater

Disassemble and Assemble Cab or ROPS Under Seat Heater

Group 1899: Dealer Fabricated Tools

DFRW20 Compressor Holding Fixture

Section 19: Sheet Metal and Styling

Group 1910: Hood and Engine Enclosure

Specifications

Remove and Install Hood

Remove and Install Hood Support and Engine Side Shields

Group 1921: Grille and Grille Housing

Specifications

Remove Grille and Grille Housing

Install Grille and Grille Housing

Section 20: Safety, Convenience and Miscellaneous

Group 2004: Horn and Warning Devices

Remove and Install Reverse Warning Alarm

Adjust Reverse Warning Alarm Volume

Section 21: Main Hydraulic System

Group 2160: Hydraulic System

Service Equipment and Tools

Specifications

Remove and Install Hydraulic Pump

Disassemble and Assemble Hydraulic Pump (With Winch Option)

Disassemble and Assemble Hydraulic Pump (Without Winch Option)

Remove and Install Hydraulic Reservoir

Hydraulic Reservoir (S.N. 925789— ) And Hydrostatic Reservoir (S.N. 925855— ) Cleanout Cover Remove and Install

Disassemble and Assemble Hydraulic Reservoir

Remove and Install Hydraulic Filter

Disassemble and Assemble Hydraulic Filter

Group 2199: Dealer Fabricated Tools

DFT1132 Hydrostatic Motor and Hydraulic Pump Removal and Installation Tool

Section 32: Bulldozer

Group 3201: Blades

Specifications

Remove and Install Dozer Blade (S.N. —903158)

Remove and Install Dozer Blade (S.N. 903159— )

Remove and Install Cutting Edges and End Bits

Group 3215: Control Linkage

Specifications

Remove and Install T-Bar Control Linkage

Remove and Install Auxiliary Linkage

Group 3240: Frames

Specifications

Remove and Install Dozer C-Frame (S.N. —903158)

Remove and Install Dozer C-Frame (S.N. 903159— )

Group 3260: Hydraulic System

Essential Tools

Service Equipment and Tools

Other Material

Specifications

Hydraulic System Component Location

Remove and Install Hydraulic Control Valve

Disassemble and Assemble Hydraulic Control Valve

Remove and Install Wiper Seals and Lip Seals on Hydraulic Control Valve Sections

Disassemble and Assemble Auxiliary Control Valve Section

Disassemble and Assemble Angle Control Valve Section (S.N. —902404)

Disassemble and Assemble Angle Control Valve Section (S.N. 902405— )

Disassemble and Assemble Tilt Control Valve Section

Disassemble and Assemble Lift Control Valve Section

Disassemble and Assemble System and Angle Circuit Relief Valve

Tilt Cylinder-To-Control Valve Component Location

Remove and Install Tilt Cylinder

Angle Cylinder-To-Control Valve Component Location

Remove and Install Angle Cylinder

Lift Cylinder-To-Control Valve Component Location

Remove and Install Lift Cylinder

Disassemble and Assemble Angle, Lift and Tilt Cylinders (John Deere 120 Series Cylinders)

John Deere Crawler Dozers 450H, 550H, 650H Service Repair Service Manual (TM1744)