Complete service repair manual for John Deere 450G, 455G, 550G, 555G, 650G Crawler Dozer, with all the workshop information to maintain, repair, and service like professional mechanics.

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

TM1404 (EN) - John Deere 450G, 455G, 550G, 555G, 650G Crawler Dozer Technical Manual (Repair).PDF
TM1404 (EN) - John Deere 450G, 455G, 550G, 555G, 650G Crawler Dozer Technical Manual (Repair).epub

Total Pages: 981 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality) & EPUB/MOBI/AZW for Kindle/iPad/iPhone/Android.
Language: English

MAIN SECTIONS
   Foreword
   Help!! Help!! Help!! Help!!
   General Information
      Safety Information
      General Specifications
      Torque Values
      Fuels and Lubricants
   Tracks
      Track System
      Dealer Fabricated Tools
   Axles and Suspension Systems
      Axle Shaft, Bearings, and Reduction Gears
      Hydraulic System
      Dealer Fabricated Tools
   Transmission
      Control Linkage
      Input Drive Shafts and U-Joints
      Gears, Shafts, Bearings and Clutch
      Hydraulic System
      Dealer Fabricated Tools
   Engine
      Removal and Installation
   Engine Auxiliary Systems
      Cold Weather Starting Aid
      Cooling System
      Speed Controls and Fuel Shut-Off Linkage
      Intake System
      External Fuel Supply System
   Torque Converter
      Removal and Installation
      Turbine, Gears and Shaft
   Dampener Drive
      Removal and Installation
   Steering Systems
      Power Steering Linkage
      Hydraulic System
   Electrical System
      Batteries, Support and Cables
      Alternator, Regulator, and Charging System Wiring
      Lighting System
      Wiring Harness and Switches
      Instruments and Indicators
      Motors and Actuators
   Frames, Chassis, or Supporting Structure
      Frame Installation
      Chassis Weights
      Dealer Fabricated Tools
   Operator`s Station
      Removal and Installation
      Seat and Seat Belt
   Sheet Metal and Styling
      Hood and Engine Enclosure
      Miscellaneous Guards
      Grille and Grille Housing
      Fenders
   Safety, Convenience and Miscellaneous
      Horn and Warning Devices
   Main Hydraulic System
      Hydraulic System
   Loader
      Bucket
      Controls Linkage
      Frames
      Hydraulics
   Bulldozer
      Blades
      Controls Linkage
      Frames
      Hydraulic System
   Backhoe
      Removal and Installation
   Backhoe
      Buckets
      Controls Linkage
      Frames
      Hydraulic System

Total Pages: 970 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

tm1404 - 450G, 455G, 550G, 555G, 650G Crawler

Table of Contents

Foreword

Help!! Help!! Help!! Help!!

Section 00: General Information

Group 0001: Safety Information

Handle Fluids Safely—Avoid Fires

Prevent Battery Explosions

Prepare for Emergencies

Prevent Acid Burns

Handle Chemical Products Safely

Avoid High-Pressure Fluids

Park Machine Safely

Support Machine Properly

Wear Protective Clothing

Work in Clean Area

Service Machines Safely

Work In Ventilated Area

Illuminate Work Area Safely

Replace Safety Signs

Use Proper Lifting Equipment

Remove Paint Before Welding or Heating

Avoid Heating Near Pressurized Fluid Lines

Keep ROPS Installed Properly

Service Tires Safely

Avoid Harmful Asbestos Dust

Practice Safe Maintenance

Use Proper Tools

Dispose of Waste Properly

Live With Safety

Group 0002: General Specifications

450G Crawler Dozer Specifications

450G Drain and Refill Capacities

450G—LT Crawler Dozer Specifications

450G—LT Drain and Refill Capacities

450G—LGP Crawler Dozer Specifications

450G—LGP Drain and Refill Capacities

455G Crawler Loader Specifications

455G Crawler Loader Specifications—cont.

455G Drain and Refill Capacities

550G—LT Crawler Dozer Specifications

550G—LT Drain and Refill Capacities

550G—LGP Crawler Dozer Specifications

550G—LGP Drain and Refill Capacities

555G Crawler Loader Specifications

555G Drain and Refill Capacities

650G Crawler Dozer Specifications

650G Drain and Refill Capacities

650G—LGP Crawler Dozer Specifications

650G—LGP Drain and Refill Capacities

9310 Backhoe Specifications

9310 Backhoe Lift Capacity (G Series Loaders)

9310 Backhoe Lift Capacity (G-Series Dozers)

Group 0003: Torque Values

Specifications

Hardware Torque Specifications

ROPS Torque Specifications

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

Service Recommendations for 37° Flare and 30° Cone Seat Connectors

Service Recommendations for O-Ring Boss Fittings

Service Recommendations For Flat Face O-Ring Seal Fittings

Service Recommendations For Inch Series Four Bolt Flange Fittings

Service Recommendations for Metric Series Four Bolt Flange Fitting

Group 0004: Fuels and Lubricants

Fuel Specifications

Storing Fuel

Do Not Use Galvanized Containers

Diesel Engine Oil

Final Drive Oil

Track Roller, Front Idler, and Carrier Roller Oil

Transmission, Steering Clutches, Hydraulic and Winch Oil

Grease

Heavy Duty Diesel Engine Coolant

Alternative and Synthetic Lubricants

Lubricant Storage

Section 01: Tracks

Group 0130: Track System

Special or Essential Tools

Service Equipment and Tools

Other Material

Specifications

Measure Carrier Roller Wear

Remove and Install Carrier Roller Assembly

Disassemble and Assemble Carrier Roller

Check Carrier Roller Oil Level

Measure Track Roller Wear

Remove and Install Track Rollers

Disassemble and Assemble Track Roller (S.N. —XXXXXX)

Disassemble and Assemble Track Roller (S.N. XXXXXX— )

Checking Track Roller Oil Level (S.N. —XXXXXX)

Checking Track Roller Oil Level (S.N. XXXXXX— )

Adding Oil to the Roller (S.N. —XXXXXX)

Adding Oil to the Roller (S.N. XXXXXX— )

Measure Track Shoe Grouser Wear

Remove and Install Track Shoe

Measure Link Height

Measure Track Bushing Outer Diameter

Measure Track Pitch

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—Interlock Master Link

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

Disassemble Lubricated Track Chain to Turn Bushings and Relubricate Chain

Assemble Lubricated Track Chain to Turn Bushings and Relubricate Chain

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

Measure Front Idler Wear

Remove and Install Front Idler Assembly

Disassemble and Inspect Front Idler Assembly

Assemble Front Idler Assembly

Idler Adjustment Procedure

Check Front Idler Oil Level

Remove and Disassemble Hydraulic Track Tension Adjuster (S.N. —745426)

Assemble and Install Hydraulic Track Tension Adjuster (S.N. —745426)

Remove and Disassemble Hydraulic Track Tension Adjuster (S.N. 745427—781708)

Remove and Disassemble Hydraulic Track Tension Adjuster (S.N. 781709— )

Assemble and Install Hydraulic Track Tension Adjuster (S.N. 745427—)

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

DF1067 Lubricated Track Split Master Link Separator Tool—Earlier Machines

DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool

ST4920 Track Recoil Spring Disassembly and Assembly Tool

Section 02: Axles and Suspension Systems

Group 0250: Axle Shaft, Bearings, and Reduction Gears

Service Equipment and Tools

Other Material

Specifications

Remove and Install Final Drive

Disassemble and Assemble Final Drive

Adjust Pinion Shaft Preload

Adjust Idler Shaft Preload for Double Reduction Drives

Adjust Axle Shaft Preload

Remove and Install Steering Clutch

Disassemble and Assemble Steering Clutch (S.N. —770807)

Disassemble and Assemble Steering Clutch (S.N. 770808— )

Disassemble and Assemble Steering Brake Anchor (S.N. —770807)

Disassemble and Assemble Steering Brake Anchor (S.N. 770808— )

Disassemble and Assemble Steering Brake Linkage (S.N. —770807)

Disassemble and Assemble Steering Brake Linkage (S.N. 770808— )

Adjust Steering Brake Linkage

Adjust Steering Brake Self-Adjuster Linkage (S.N. —770807)

Manual Steering Brake Adjustment (S.N. —770807)

Manual Steering Brake Adjustment (S.N. 770808— )

Adjust Steering Brakes Linkage—Pedal Steer

Adjust Steering Brakes Linkage—Lever Steer (S.N. —770807)

Adjust Steering Brakes Linkage—Lever Steer (S.N. 770808—)

Engage Tow Disconnect Pins Manually

Group 0260: Hydraulic System

Other Material

Specifications

Remove and Install Steering Clutch Valve

Disassemble and Assemble Steering Clutch Valve (S.N. —770807)

Disassemble and Assemble Steering Clutch Valve (S.N. 770808— )

Adjust Steering Clutch Valve

Remove and Install Steering Brake Cylinder

Group 0299: Dealer Fabricated Tools

DF1030 Brake Assembly Tool

DF1063 Final Drive Lift Bracket

DF1063A Single Reduction Adapter Plate

DF1063B Double Reduction Adapter Plate

Section 03: Transmission

Group 0315: Control Linkage

Other Material

Specifications

Disassemble and Assemble Transmission Linkage (S.N. —768272)

Disassemble and Assemble Transmission Linkage (S.N. 768273— )

Transmission Control Linkage Adjustment

Group 0325: Input Drive Shafts and U-Joints

Remove and Install Drive Shaft

Group 0350: Gears, Shafts, Bearings and Clutch

Special or Essential Tools

Service Equipment and Tools

Other Material

Specifications

Remove and Install Transmission

Disassemble Transmission

Check Backing Plates Movement

Disassemble and Assemble Transmission Cover

Disassemble and Assemble First/Second and Third/Fourth Clutch Packs

Disassemble and Assemble Forward/Reverse Clutch Pack

Replace Ring Gear

Adjust Cone Point

Adjust Ring Gear Bearing Preload

Adjust Output Shaft Bearing Preload

Assemble Transmission

Transmission Air Test

Disassemble and Assemble Transverse Housing

Group 0360: Hydraulic System

Service Equipment and Tools

Other Material

Specifications

Remove and Install Transmission Control Valve

Disassemble and Assemble Transmission Control Valve

Disassemble and Assemble Transmission Control Valve Manifold

Adjust Rate of Shift

Disassemble and Assemble Transmission Decelerator Assembly

Remove and Install Transmission Oil Pump—Torque Converter Machines

Remove and Install Transmission Oil Pump—Direct Drive Machines

Disassemble and Assemble Transmission Oil Pump—Torque Converter Machines

Disassemble and Assemble Transmission Oil Pump—Direct Drive Machines

Charge Transmission Accumulator

Remove and Install Transmission Oil Filter

Remove and Install Transverse Case Suction Screen

Remove and Install Transmission Oil Cooler

Group 0399: Dealer Fabricated Tools

DF1126 Bearing Installer

DF1127 Support Tubing

DF1128 Bearing Installer

DF1031 Clutch Assembly Tool

DFT1121 Rivet Forming Tool

JT38000 Differential Lifting Tool

Section 04: Engine

Group 0400: Removal and Installation

4276 John Deere Engine Repair—Use CTM4 (S.N. —299999)

4045 John Deere Engine Repair—Use CTM8 (S.N. 300000—840460)

Engine Accessories—Use CTM11

PowerTech 4.5 L Engine Repair—Use CTM104 (S.N. 840461— )

Special or Essential Tools

Specifications

Remove Engine—With Torque Converter

Install Engine—With Torque Converter

Remove Engine—With Direct Drive

Install Engine—With Direct Drive

Bleed Fuel System

Section 05: Engine Auxiliary Systems

Group 0505: Cold Weather Starting Aid

Specifications

Other Material

Remove and Install Coolant Heater

Remove and Install Starting Aid Nozzle

Remove and Install Starting Aid Solenoid

Group 0510: Cooling System

Service Equipment and Tools

Specifications

Check and Adjust V-Belt Tension (S.N. —840460)

Checking Serpentine Belt Tensioner Spring Tension and Belt Wear (S.N. 840461— )

Remove and Install Sand Screens

Remove and Install Fan

Adjust Reversible Fan Blade Angle

Remove and Install Radiator

Group 0515: Speed Controls and Fuel Shut-Off Linkage

Remove and Install Speed Control Cable

Remove and Install Speed Control Linkage—Without Declutch

Remove and Install Speed Control Linkage—With Declutch

Group 0520: Intake System

Disassemble and Assemble Air Cleaner

Group 0560: External Fuel Supply System

Specifications

Remove and Install Fuel Tank

Section 06: Torque Converter

Group 0600: Removal and Installation

Special or Essential Tools

Other Material

Specifications

Remove and Install Torque Converter

Group 0651: Turbine, Gears and Shaft

Special or Essential Tools

Other Material

Specifications

Torque Converter Cross Section

Replace Torque Converter Rear Seal and Turbine Shaft

Disassemble and Assemble Torque Converter

Air Test Torque Converter

Disassemble and Assemble Torque Converter Housing

Section 07: Dampener Drive

Group 0700: Removal and Installation

Other Material

Specifications

Remove and Install Dampener Drive—Direct Drive Machines Only

Section 09: Steering Systems

Group 0920: Power Steering Linkage

Specifications

Remove and Install Steering Linkage—Pedal Steer

Adjust Stops—Pedal Steer

Adjust Linkage—Pedal Steer

Remove and Install Steering Linkage—Lever Steer

Adjust Stops—Lever Steer (S.N. —770807)

Adjust Stops—Lever Steer (S.N. 770808— )

Adjust Linkage—Lever Steer

Group 0960: Hydraulic System

Hydraulic System

Section 16: Electrical System

Group 1671: Batteries, Support and Cables

Specifications

Battery Safety

Check Battery Electrolyte Level and Terminals

Procedure for Testing Batteries

Using Booster Batteries—12-Volt System

Remove and Install Batteries

Group 1672: Alternator, Regulator, and Charging System Wiring

John Deere Engine Accessories—Use CTM11

Service Equipment and Tools

Specifications

Remove and Install Alternator

Group 1673: Lighting System

Replace Halogen Bulbs

Work Light Adjustment

Group 1674: Wiring Harness and Switches

Special or Essential Tools

Specifications

Replace DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Connectors

Install DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Contact

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

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

Remove Connector Body from Blade Terminals

Remove and Install Battery Disconnect Switch

Remove and Install Transmission Low Pressure, Reverse Warning Alarm and Neutral Start Switches

Remove and Install Start Circuit Relay (S.N. —768317)

Remove and Install Start Circuit Relay (S.N. 768318— )

Remove and Install Return-to-Dig Switch

Remove and Install Return-to-Dig Switch Assembly

Return-to-Dig Adjustment

Group 1676: Instruments and Indicators

Remove and Install Logic Module or Circuit Breaker (S.N. —768317) (Module Package)

Remove and Install Logic Module or Circuit Breaker (S.N. 768318— ) (Module Package)

Remove and Install Display Monitor

Remove and Install Display Monitor Lights

Remove and Install Switch, Gauge, Hour Meter or Indicator Light

Group 1677: Motors and Actuators

John Deere Engine Accessories—Use CTM11

Remove and Install Starting Motor (S.N. —742459)

Remove and Install Starting Motor (S.N. 742460— )

Section 17: Frames, Chassis, or Supporting Structure

Group 1740: Frame Installation

Other Material

Specifications

Welding Repair of Major Structures

Remove and Install Transverse Housing

Group 1749: Chassis Weights

Service Equipment and Tools

Specifications

Remove and Install Sprocket Counterweight

Remove and Install Rear Counterweights

Remove and Install Front Counterweight

Group 1799: Dealer Fabricated Tools

JT38022 Sprocket Weight Lifting Tool

Section 18: Operator's Station

Group 1800: Removal and Installation

Other Material

Specifications

Remove and Install Roll-Over Protective Structure (ROPS) or Cab

Remove and Install ROPS/Cab Supports

Repair Foam Headliner

Group 1821: Seat and Seat Belt

Disassemble and Assemble Non-Suspension Seat

Disassemble and Assemble Deluxe Seat (ROPS)

Disassemble and Assemble Arm Rest

Exploded View of Suspension Seat

Section 19: Sheet Metal and Styling

Group 1910: Hood and Engine Enclosure

Other Material

Disassemble and Assemble Hood and Engine Side Shields

Disassemble and Assemble Cowl

Group 1913: Miscellaneous Guards

Remove and Install Bottom Guards and Access Covers

Group 1921: Grille and Grille Housing

Disassemble and Assemble Grille Housing

Group 1927: Fenders

Disassemble and Assemble Side Fenders

Disassemble and Assemble Back Fender (S.N. —763492)

Disassemble and Assemble Back Fender (S.N. 763493— )

Section 20: Safety, Convenience and Miscellaneous

Group 2004: Horn and Warning Devices

Remove and Install Horn

Remove and Install Reverse Warning Alarm—If Equipped

Adjust Reverse Warning Alarm Volume—If Equipped

Section 21: Main Hydraulic System

Group 2160: Hydraulic System

Other Material

Specifications

Remove and Install Hydraulic Pump and/or Drive Shaft—Direct Drive Machines

Disassemble and Assemble Hydraulic Pump—Direct Drive Machines

Remove and Install Hydraulic Pump—Torque Converter Machines

Disassemble and Assemble Hydraulic Pump—Torque Converter Machines

Remove and Install Hydraulic Oil Filter

Disassemble and Assemble Hydraulic Oil Filter

Remove and Install Hydraulic Oil Cooler

Remove and Install Hydraulic Reservoir

Section 31: Loader

Group 3102: Bucket

Specifications

Remove and Install Bucket Tooth Shanks

Remove and Install Bucket Tooth Tips

Remove and Install Loader Bucket

Repair Cracked Cutting Edge

Replace Cutting Edge

Group 3115: Controls Linkage

Other Material

Disassemble and Assemble Loader Control Linkage

Group 3140: Frames

Specifications

Remove Loader Boom

Install Loader Boom

Group 3160: Hydraulics

Other Material

Specifications

Loader Hydraulic Component Location

Remove and Install Loader Control Valve

Disassemble and Assemble Loader Control Valve

Disassemble and Assemble Bucket Section

Disassemble and Assemble Boom Section

Disassemble and Assemble Auxiliary Section

Cross Section of System Relief Valve

Inspect System Relief Valve

Inspect Anti-Cavitation Bucket Circuit Relief Valve

Inspect Bucket and Boom Adjusting Circuit Relief Valves

Disassemble and Inspect Boom and Bucket Cylinders

Cross Section of Bucket and Boom Cylinder

Assemble Boom and Bucket Cylinders

Disassemble and Assemble Ripper Cylinder

Section 32: Bulldozer

Group 3201: Blades

Other Material

Specifications

Remove and Install Dozer Blade (S.N. —785733)

Remove and Install Dozer Blade (S.N. 785734— )

Remove and Install Cutting Edges and End Bits

Group 3215: Controls Linkage

Other Material

Disassemble and Assemble Two Lever Control Linkage (S.N. —763492)

Disassemble and Assemble Two Lever Control Linkage (S.N. 763493— )

Disassemble and Assemble T-Bar Control Linkage (S.N. —763492)

Disassemble and Assemble T-Bar Control Linkage (S.N. 763493— )

Group 3240: Frames

Service Equipment and Tools

Remove and Install Dozer C-Frame

Disassemble and Assemble Blade Pitch Strut

Group 3260: Hydraulic System

Specifications

Dozer Hydraulic Component Location (S.N. —834560)

Dozer Hydraulic Component Location (S.N. 834561— )

Remove and Install Dozer Control Valve

Disassemble and Assemble Dozer Control Valve

Inspect System Relief Valve

Inspect Lift Checks

Disassemble and Assemble Angle, Tilt and Auxiliary Sections

Disassemble and Assemble Blade Section

Repair Cylinders

Section 33: Backhoe

Group 3300: Removal and Installation

Remove Backhoe Assembly

Install Backhoe Assembly

Group 3302: Buckets

Service Equipment and Tools

Remove and Install Bucket and Bucket Links

Remove and Install Bucket Bushings

Remove and Install Tooth Shank

Remove and Install Cutting Edges

Group 3315: Controls Linkage

Specifications

Remove, Install, and Adjust Backhoe Control Valve Linkage

Remove, Install, and Adjust Stabilizer Valve Linkage

Group 3340: Frames

Service Equipment and Tools

Other Material

Specifications

Remove and Install Dipperstick

Remove and Install Boom

Remove and Install Swing Frame

Remove and Install Stabilizer

Remove and Install Valve Box

Group 3360: Hydraulic System

Other Material

Specifications

Disassemble Bucket, Crowd, Boom, Swing and Stabilizer Cylinder

Cross Section of Bucket Cylinder—9300G, 9310G and Boom Cylinder—9300G

Cross Section of Boom Cylinder—9310G

Cross Section of Crowd Cylinder—9300G

Cross Section of Crowd Cylinder—9310G

Cross Section of Stabilizer Cylinder—9300G, 9310G

Cross Section of Swing Cylinder—9300G, 9310G

Assemble Bucket, Crowd, Boom, Swing and Stabilizer Cylinder

Remove and Install Backhoe Control Valve

Disassemble and Assemble Backhoe Control Valve

Disassemble and Assemble Circuit Relief Valve With Anti-Cavitation

Disassemble and Assemble Circuit Relief Valve

Disassemble and Assemble Crowd and Bucket Valve Section

Disassemble and Assemble Boom Valve Section

Disassemble and Assemble Swing Valve Section

Disassemble and Assemble Outlet Valve Section (With Low Pressure Regenerative Relief Valve)

Backhoe Relief Valve Specifications

Remove and Install Stabilizer Valve

Cross Section View of Stabilizer Control Valve

Disassemble Stabilizer Control Valve

Assemble Stabilizer Control Valve

John Deere Crawler Dozer 450G, 455G, 550G, 555G, 650G Repair Service Manual (TM1404)