Complete Operation & Test manual with electrical wiring diagrams for John Deere Crawler Dozers / Loaders 450G, 455G, 550G, 555G, 650G, with all the shop information to maintain, diagnose, and service like professional mechanics.

John Deere Crawler Dozers / Loaders 450G, 455G, 550G, 555G, 650G workshop Diagnostics & 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.

tm1403 - 450G, 455G, 550G 555G, 650G Crawler Operation and Test Technical Manual.pdf
tm1403 - 450G, 455G, 550G 555G, 650G Crawler Operation and Test Technical Manual.epub

Total Pages: 902 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
   Operational Checkout Procedure
      Operational Checkout Procedure
   Engine
      Theory of Operation
      System Operational Checks
      System Diagnostic Information
      Adjustments
      Tests
   Electrical System
      System Information
      System Diagrams
      Sub-System Diagnostics
      References
   Power Train
      Theory of Operation
      System Operational Checks
      Diagnostic Information
      Adjustments
      Tests
   Hydraulic System
      Theory of Operation
      System Operational Checks
      Diagnostic Information
      Adjustments
      Tests

Total Pages: 931 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

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

tm1403 - 450G, 455G, 550G 555G, 650G Crawler Operation and Test

Table of Contents

Foreword

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

Section 9000: General Information

Group 01: 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

Practice Safe Maintenance

Dispose of Waste Properly

Live With Safety

Group 02: 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 Operating Information

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 03: Torque Values

Hardware Torque Specifications

Keeping ROPS Installed Properly

Checking Track Shoe Cap Screw Torque

Unified Inch Bolt and Cap Screw Torque Values

Metric Bolt and Cap 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 04: 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

Diesel Engine Coolant

Alternative and Synthetic Lubricants

Lubricant Storage

Section 9005: Operational Checkout Procedure

Group 10: Operational Checkout Procedure

Operational Checkout Procedure

Section 9010: Engine

Group 05: Theory of Operation

General Engine Description

Engine-Sectional View

Cold Weather Starting Aid Operation

Air Cleaner Operation

Group 10: System Operational Checks

4276 John Deere Engine-Use CTM4

4045 John Deere Engine-Use CTM8

John Deere PowerTech PowerTech is a registered trademark of Deere & Company 4045 Engine-Use CTM104

John Deere Engine Accessories-Use CTM11

System Operational Checks

Group 15: System Diagnostic Information

4276 John Deere Engine-Use CTM4

4045 John Deere Engine-Use CTM8

John Deere PowerTech PowerTech is a registered trademark of Deere & Company 4045 Engine-Use CTM104

John Deere Engine Accessories-Use CTM11

Make Visual Inspection of Engine and Supporting Systems

Diagnose Engine Malfunctions

Group 20: Adjustments

4276 John Deere Engine-Use CTM4

4045 John Deere Engine-Use CTM8

John Deere PowerTech PowerTech is a registered trademark of Deere & Company 4045 Engine-Use CTM104

JT07158 TIME TRAC TIME TRAC is a registered trademark of Standyne Automotive Corp. Installation

Fan V-Belt Tension Adjustment (S.N. -840460)

Fan Belt Tension Adjustment (S.N. 840461- )

Engine Speed Adjustment

Engine Speed Control Linkage Adjustment Without Declutch

Engine Speed Control Linkage Adjustment With Declutch

Injection Pump Dynamic Timing

Injection Pump Static Timing Adjustment

Group 25: Tests

4276 John Deere Engine-Use CTM4

4045 John Deere Engine-Use CTM8

John Deere PowerTech PowerTech is a registered trademark of Deere & Company 4045 Engine-Use CTM104

JT05801 Clamp-On Electronic Tachometer Installation

JT05800 Digital Thermometer Installation

Cooling System

Engine Oil Pressure Test

Fuel Supply Pump Pressure Test

Air Filter Restriction Indicator Switch Test

Air Intake System Leakage Test

Radiator Air Flow Test

Turbocharger Boost Pressure Test (S.N. -840460)

Turbocharger Boost Pressure Test (S.N. 840461- )

Section 9015: Electrical System

Group 05: System Information

Battery Operation

Battery Specifications

Diagnose Battery Malfunctions

Check Battery Electrolyte Level and Terminals

Procedure for Testing Batteries

Using Booster Batteries-12 Volt System

Visually Inspect Electrical System

Electrical Circuit Malfunctions

High Resistance Circuit

Open Circuit

Grounded Circuit

Shorted Circuit

Multimeter

Seven Step Electrical Test Procedure

Wiring Diagram and Schematic Information

Reading a System Functional Schematic

Reading a Wiring Diagram

Electrical Schematic Symbols

Group 10: System Diagrams

Component Identification Table

Circuit Breaker Specifications

Wiring and Schematic Diagrams Legend

System Functional Schematic Section Legend

System Functional Schematic

Front Console Harness (W5) Wiring Diagram-Modules

Front Console Harness (W5) Component Location-Modules

Front Console Harness (W5A) Wiring Diagram-Gauges

Front Console Harness (W5A) Component Location-Gauges

Engine Harness (W6) Wiring Diagram

Engine Harness (W6) Component Location

Rear Harness (W7) Wiring Diagram

Rear Harness (W7) Component Location

Return-to-Dig Harness (W8) Wiring Diagram

Return-to-Dig Harness (W8) Component Location

Work Light Harness (W9) Wiring Diagram

Work Light Harness (W9) Component Location

Horn Harness (W10) Wiring Diagram

Horn Harness (W10) Component Location

Declutch Harness (W11) Wiring Diagram

Declutch Harness (W11) Component Location

Cab Harness (W12) Wiring Diagram

Cab Harness (W12) Component Location

Pressurizer Harness (W13) Wiring Diagram

Pressurizer Harness (W13) Component Location

Blower Harness (W14) Wiring Diagram

Blower Harness (W14) Component Location

Roof Harness (W15) Wiring Diagram

Roof Harness (W15) Component Location

Group 15: Sub-System Diagnostics

Power Circuit Operational Information

Power Circuit Theory of Operation

Power Circuit Schematic

Start Circuit Operational Information

Start Circuit Theory of Operation

Start Circuit Schematic

Charging Circuit Operational Information

Charging Circuit Theory of Operation

Charge Circuit Schematic

Display Module and Logic Module Circuit Operational Information

Display Module and Logic Module Circuit Theory of Operation

Display Module and Logic Module Circuit Schematic

Logic Module

Indicator Circuit Specifications

Fuel Gauge Sender Specifications

Indicator Circuit Operational Information

Indicator Circuit Theory of Operation

Indicator Circuit Theory of Operation (Fuel Gauge)

Indicator Circuit Schematic

Indicator Circuit Schematic (Fuel Gauge)

Gauge Circuit Specifications

Gauge Circuit Operational Information

Gauge Circuit Theory of Operation

Gauge Circuit Schematic

Start Aid Circuit Operational Information

Start Aid Circuit Theory of Operation

Start Aid Circuit Schematic

Light Circuit Operational Information

Light Circuit Theory of Operation

Light Circuit Schematic

Horn Circuit Operational Information

Horn Circuit Theory of Operation

Horn Circuit Schematic

Reverse Alarm Circuit Operational Information

Reverse Alarm Circuit Theory of Operation

Reverse Alarm Circuit Schematic

Declutch Circuit Operational Information

Declutch Circuit Theory of Operation

Declutch Circuit Schematic

Return-to-Dig Circuit Operational Information

Return-to-Dig Circuit Theory of Operation

Return-to-Dig Circuit Schematic

Hourmeter Circuit Operational Information

Hourmeter Circuit Theory of Operation-with Modules

Hourmeter Circuit Theory of Operation-with Gauges

Hourmeter Circuit Schematic-with Modules

Hourmeter Circuit Schematic-with Gauges

Blower Circuit Operational Information

Blower Circuit Theory of Operation

Blower Circuit Schematic

Dome Light Circuit Operational Information

Dome Light Circuit Theory of Operation

Dome Light Circuit Schematic

Wiper/Washer Circuit Operational Information

Wiper/Washer Circuit Theory of Operation

Wiper/Washer Circuit Schematic

Group 20: References

John Deere Alternator and Starting Motors-Use CTM77

Alternator Operation-95 Amp Bosch

Alternator Operation-95 Amp Bosch

Logic Module Test in Machine

Logic Module Bench Test

Section 9020: Power Train

Group 05: Theory of Operation

Transmission Drive and Pump-Direct Drive

Torque Converter

Transmission Hydraulic Components-Direct Drive Machine (S.N. -803600)

Transmission Hydraulic Components-Direct Drive Machine (S.N. 803601- )

Transmission Hydraulic Components-Torque Converter Machine (S.N. -803600)

Transmission Hydraulic Components-Torque Converter Machine (S.N. 803601- )

Transmission-Thrust Washer/Bushing Design

Transmission-Ball Bearing Design

Power Flow-First Speed Forward

Power Flow-Second Speed Reverse

Transmission Oil Routing

Transmission Lubrication

Direction Clutch Pack

Speed Clutch Pack

Transmission Charge Circuit

Pressure Regulating Valve

Cooler and Lubrication Relief Valves

Speed Control Valve and Detent Spool

Speed Pack Orifices

Sump Valve Drain Port

Park Position

Steering Brake Control Linkage

Transmission Oil Flow-Direct Drive

Transmission Oil Flow-Torque Converter

Transmission Control Valve

Steering Brake Priority

Pedal Steering-Straight Travel

Pedal Steering-Right Steer

Pedal Steering-Both Pedals Depressed

Pedal Steering Linkage-(S.N. -770807)

Pedal Steering Linkage-(S.N. 770808- )

Lever Steering-Right Turn

Lever Steering-Both Levers Pulled

Lever Steering-(S.N. -770807)

Lever Steering-(S.N. 770808- )

Final Drives

Group 10: System Operational Checks

System Operational Procedure

Group 15: Diagnostic Information

Diagnose Transmission Malfunctions

Diagnose Undercarriage Malfunctions

Measure Track Bushing Outer Diameter

Measure Track Pitch-Sealed Chain

Measure Track Pitch for Lubricated Track Chain

Measure Grouser Bar Height

Measure Front Idler Wear

Measure Track Roller Wear

Measure Upper Track Carrier Roller Wear

Measure Link Height

Hydraulic Oil Filter Inspection Procedure

Group 20: Adjustments

Engage Tow Disconnect Pins Manually

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

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

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

Procedure for Complete Steering Adjustment

Loosen Brake Bands (S.N. -770807)

Loosen Brake Bands (S.N. 770808- )

Adjust Linkage Inside Transverse Housing

Adjust Stops-Pedal Steer

Adjust Linkage-Pedal Steer

Adjust Steering Valve-Pedal Steer-Direct Drive Machine (S.N. -770807)

Adjust Brakes

Adjust Steering Valve-Pedal Steer-Direct Drive Machine (S.N. 770808- )

Adjust Brakes

Adjust Steering Valve-Pedal Steer-Torque Converter Machine

Adjust Brakes

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

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

Adjust Linkage-Lever Steer

Adjust Steering Valve-Lever Steer (S.N. -770807)

Adjust Brakes

Adjust Steering Valve-Lever Steer (S.N. 770808- )-Direct Drive Machine

Adjust Brakes

Adjust Steering Valve-Lever Steer-Torque Converter Machine

Adjust Brakes

Power Control Pedal Adjustment-Direct Drive Machine

Rate of Shift Adjustment

Transmission Control Linkage Adjustment

Declutch Switch Adjustment-Direct Drive Machine

Track Sag Adjustment

Idler Height Adjustment

Charge Transmission Accumulator-Direct Drive Machine

Group 25: Tests

JT05801 Clamp-On Electronic Tachometer Installation

JT05800 Digital Thermometer Installation

Transmission Air Test (In Transverse Housing)

Transmission Warm-Up Procedure-Direct Drive Machine

Transmission Pump Flow Test-Direct Drive Machine

Transmission Pressure Regulating Valve Test-Direct Drive Machine

Cooler Relief Valve Pressure Test-Direct Drive Machine

Lube Relief Valve Pressure Test-Direct Drive Machine

Steering Circuit Pressure Test-Direct Drive Machine

Complete Transmission System Test (S.N. -770807)-Direct Drive

Complete Transmission System Test Checkout Sheet (S.N. -770807)-Direct Drive

Complete Transmission System Test Specifications and Analysis (S.N. -770807)-Direct Drive

Complete Transmission System Test (S.N. 770808- )-Direct Drive

Complete Transmission System Test Checkout Sheet (S.N. 770808- )-Direct Drive

Complete Transmission System Test Specifications and Analysis (S.N. 770808- )-Direct Drive

Transmission and Steering Clutch Leakage Test Using Cooler Pressure (S.N. -770807)-Direct Drive

Transmission and Steering Clutch Leakage Chart Using Cooler Pressure (S.N. -770807)-Direct Drive

Analysis of Transmission and Steering Clutch Using Cooler Pressure (S.N. -770807)-Direct Drive

Transmission and Steering Clutch Leakage Test Using Cooler Pressure (S.N. 770808- )-Direct Drive

Transmission and Steering Clutch Leakage Chart Using Cooler Pressure (S.N. 770808- )-Direct Drive

Analysis of Transmission and Steering Clutch Test Using Cooler Pressure (S.N. 770808- )-Direct Drive

Transmission Oil Cooler Restriction Test-Direct Drive

Transmission Warm-Up Procedure-Torque Converter

Transmission Pump Flow Test-Torque Converter

Transmission Pressure Regulating Valve Test-Torque Converter

Cooler Relief and Converter-In Valve Pressure Test-Torque Converter

Lube Relief Valve Pressure Test-Torque Converter

Steering Circuit Pressure Test-Torque Converter

Complete Transmission System Test-Torque Converter

Complete Transmission System Test Checkout Sheet-Torque Converter

Transmission Complete System Test Specifications and Analysis-Torque Converter

Transmission and Steering Clutch Leakage Test Using Cooler Pressure-Torque Converter

Transmission and Steering Clutch Leakage Chart Using Cooler Pressure-Torque Converter

Analysis of Transmission and Steering Clutch Leakage Test Using Cooler Pressure-Torque Converter

Stall Speed Test-Torque Converter

Drain Leakage Test-Torque Converter

Transmission Oil Cooler Restriction Test-Torque Converter

Section 9025: Hydraulic System

Group 05: Theory of Operation

Dozer Hydraulic System Operation

Dozer Hydraulic System Operation

Loader Hydraulic System Operation

Hydraulic Reservoir Operation

Hydraulic Filter Operation

Hydraulic Pump Operation-Direct Drive

Hydraulic Pump Operation-Torque Converter

Dozer Blade Lift Valve Operation

Dozer Angle, Tilt, and Auxiliary Valve Operation

Dozer System Relief Valve Operation

Loader Control Valve Operation

Loader Valve Inlet Section Operation

Loader System Relief Valve Operation

Loader Bucket Dump Operation

Loader Bucket Regenerative Dump Operation

Loader Bucket Roll-back Operation

Loader Boom Raise Operation

Loader Boom Lower Operation

Loader Boom Float Operation

Loader Auxiliary Valve Operation

Hydraulic Cylinder Operation

Hydraulic Oil Cooler Operation

Group 10: System Operational Checks

System Operational Procedure

Group 15: Diagnostic Information

Use These Seven Basic Steps to Diagnose and Test the Hydraulic System

Make a Pretest Inspection and an Operation Check of the Machine

Hydraulic System Pretest

Hydraulic Oil Filter Inspection Procedure

Diagnose Hydraulic System Malfunction

Group 20: Adjustments

T-Bar Linkage Adjustment-(S.N. 763493- )

Return-to-Dig Adjustment

Group 25: Tests

JT05801 Clamp-On Electronic Tachometer Installation

JT05800 Digital Thermometer Installation

Hydraulic Oil Warm-Up Procedure

Main Hydraulic Pump Flow Test

Loader Circuit Relief Valve Test

Backhoe Circuit Relief Valve Test w/Flow Regulator-If Equipped (9300/9310)

Backhoe Circuit Relief Valve Test w/Remote Pump-If Equipped (9300/9310)

Hydraulic System Relief Valve Test

Cycle Time Test

Cylinder Drift Test

Cylinder Leakage Test

Hydraulic Oil Cooler Restriction Test

Component Location-Loader

Component Location-Dozer (S.N. -834560)

Component Location-Dozer (S.N. 834561- )

John Deere Crawler Dozers / Loaders 450G, 455G, 550G, 555G, 650G Operation & Test Service Manual (TM1403)