John Deere 450K, 550K, and 650K Crawler Dozer Repair Service Manual (TM14163X19)

tm14163x19 - 450K, 550K, and 650K Crawler Dozer Technical Manual.pdf

Complete Repair Service Technical Manual for John Deere 450K, 550K, and 650K Crawler Dozer, with all the shop information to maintain, repair, rebuild like professional mechanics.

John Deere 450K, 550K, and 650K Crawler Dozer workshop technical manual (repair) 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.

Total Pages: 856 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

tm14163x19 - 450K, 550K, and 650K Crawler Dozer

Table of Contents

Foreword

Manual Identification—READ THIS FIRST!

Section 00: General Information

Group 0001: Safety

Information for European Union Directives and Eurasian Economic Union Technical Regulations Compliance

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

Avoid High-Pressure Oils

Work In Ventilated Area

Avoid Static Electricity Risk When Refueling

High Debris Applications

Prevent Fires

In Case of Machine Fire

Prevent Battery Explosions

Handle Chemical Products Safely

Handle Starting Fluid Safely

Decommissioning — Proper Recycling and Disposal of Fluids and Components

Exhaust Filter Ash Handling and Disposal

Prepare for Emergencies

Clean Debris from Machine

Add Cab Guarding for Special Uses

Use Steps and Handholds Correctly

Start Only From Operator's Seat

Use and Maintain Seat Belt

Prevent Unintended Machine Movement

Avoid Work Site Hazards

Keep Riders Off Machine

Avoid Backover Accidents

Avoid Machine Tip Over and Machine Damage

Use Special Care When Operating

Inspect and Maintain ROPS

Travel Safely

Prevent Acid Burns

Add and Operate Attachments Safely

Park and Prepare for Service Safely

Service Machines Safely

Service Cooling System Safely

Remove Paint Before Welding or Heating

Make Welding Repairs Safely

Drive Metal Pins Safely

Use Proper Lifting Equipment

Clean Exhaust Filter Safely

Group 0003: Torque Values

Metric Bolt and Cap Screw Torque Values

Additional Metric Cap Screw Torque Values

Unified Inch Bolt and Cap Screw Torque Values

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

Service Recommendations for O-Ring Boss Fittings

O-Ring Boss Fittings in Aluminum Housing Service Recommendations—Excavators

Service Recommendations for Flared Connections—Straight or Tapered Threads

Service Recommendations for Flat Face O-Ring Seal Fittings

O-Ring Face Seal Fittings With SAE Inch Hex Nut and Stud End for High-Pressure Service Recommendations

O-Ring Face Seal Fittings With Metric Hex Nut and Stud End for Standard Pressure Service Recommendations

O-Ring Face Seal Fittings With Metric Hex Nut and Stud End for High-Pressure Service Recommendations

Service Recommendations for Metric Series Four Bolt Flange Fitting

Service Recommendations For Inch Series Four Bolt Flange Fittings

Inch Series Four Bolt Flange Fitting for High-Pressure Service Recommendations

Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings

Service Recommendations For O-Ring Boss Fittings With Shoulder

Metric 24° O-Ring Seal DIN 20078 Service Recommendations

Section 01: Tracks

Group 0130: Track System

Welding On Machine

Track Guides and Rock Guards Remove and Install

Carrier Roller Wear Inspection

Carrier Roller Remove and Install

Carrier Roller Disassemble and Assemble

Metal Face Seals Inspection

Carrier Roller Leakage Test

Track Roller Wear Inspection

Track Roller Remove and Install

Track Roller Disassemble and Assemble

Track Roller Leakage Test

Track Shoe Grouser Wear Inspection

Track Shoe Remove and Install

Track Link Height Inspection

Bushing Outside Diameter for Lubricated Track Chain Inspection

Track Pitch for Lubricated Track Chain Inspection

Lubricated Track Chain Remove and Install

Lubricated Track Chain to Turn Bushings and Lubricate Chain Disassemble and Assemble

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

Track Sag Adjustment

Front Idler Wear Inspection

Front Idler Remove and Install

Front Idler Disassemble and Assemble

Front Idler Adjustment

Front Idler Oil Level Check

Track Tension Adjuster Repair

Track Idler Recoil Spring Remove and Install

Track Idler Recoil Spring Disassemble and Assemble

Track Frame Remove and Install

Frame Wear Strips Remove and Install

Sprocket Remove and Install

Section 02: Axles and Suspension Systems

Group 0201: Drive Axle Housing and Support

Final Drive Remove and Install

Group 0250: Axle Shaft, Bearings, and Reduction Gears

Final Drive Disassemble and Assemble

Section 03: Transmission

Group 0300: Removal and Installation

Hydrostatic Pump and Motor Initial Start-Up Procedure

Hydrostatic Pump Remove and Install

Hydrostatic Motor Remove and Install

Group 0315: Controls Linkage

Transmission Control Lever (TCL) Remove and Install

Transmission Control Lever (TCL) Disassemble and Assemble

Decelerator/Brake Pedal Remove and Install

Decelerator/Brake Pedal Disassemble and Assemble

Group 0325: Input Drive Shafts and U-Joints

Damper Drive Remove and Install

Group 0360: Hydrostatic System

Hydrostatic Pump Disassemble

Charge Pump Disassemble and Assemble

Pump Displacement Control Valve (PDCV) Disassemble and Assemble

Multi-Function Valve Remove and Install

Multi-Function Valve Disassemble and Assemble

Hydrostatic Pump Assemble

Neutral Charge Relief Valve Disassemble and Assemble

Hydrostatic Motor Disassemble

Hydrostatic Motor Assemble

Hydrostatic Thermal Bypass Valve Remove and Install

Hydrostatic Charge Oil Filter Assembly Remove and Install

Hydrostatic Charge Oil Filter Assembly Disassemble and Assemble

Hydrostatic and Hydraulic Oil Reservoir Cleanout Cover Remove and Install

Hydraulic Oil Reservoir Remove and Install

Section 04: Engine

Group 0400: Removal and Installation

John Deere Engine

Engine Remove and Install

Engine Mounts Remove and Install

Section 05: Engine Auxiliary System

Group 0505: Cold Weather Starting Aids

Engine Coolant Heater Remove and Install

Group 0510: Cooling Systems

Fan Blade Remove and Install

Cooling Package Remove and Install

Charge Air Cooler Remove and Install

Radiator Remove and Install

Hydrostatic Oil Cooler Remove and Install

Group 0520: Intake System

Air Cleaner Remove and Install

Precleaner Remove and Install—If Equipped

Group 0530: External Exhaust Systems

Exhaust Tube Remove and Install

JDG11340 Bellows Alignment Fixture

Exhaust Bellows Alignment Procedure

Diesel Oxidation Catalyst (DOC) Remove and Install

Diesel Particulate Filter (DPF) Remove and Install

Exhaust Filter Remove and Install

Aftertreatment Assembly Remove and Install

Service Filter Cleaning

Selective Catalyst Reduction (SCR) Remove and Install

Diesel Exhaust Fluid (DEF) Tank Remove and Install

Diesel Exhaust Fluid (DEF) Tank Header Remove and Install

Diesel Exhaust Fluid (DEF) Tank Header Disassemble and Assemble

Diesel Exhaust Fluid (DEF) Tank Cleaning Procedure

Diesel Exhaust Fluid (DEF) Dosing Unit Remove and Install

Diesel Exhaust Fluid (DEF) Dosing Injector Remove and Install

Diesel Exhaust Fluid (DEF) Decomposition Tube Remove and Install

Group 0560: External Fuel Supply Systems

Primary Fuel Filter and Water Separator Remove and Install

Final Fuel Filter Remove and Install

Auxiliary Fuel Filter and Water Separator Remove and Install—If Equipped

Fuel Tank Remove and Install

Section 11: Park Brake

Group 1100: Removal and Installation

Park Brake Remove and Install

Park Brake Valve Remove and Install

Group 1115: Controls Linkage

Park Lock Linkage Remove and Install

Park Lock Linkage Disassemble and Assemble

Group 1160: Hydraulic System

Park Brake Disassemble and Assemble

Park Brake Valve Disassemble and Assemble

Section 15: Equipment Attaching

Group 1511: Drawbar

Drawbar Remove and Install

Extended Drawbar Remove and Install

Section 16: Electrical System

Group 1600: Removal and Installation

Integrated Grade Control (IGC) Lever Remove and Install

Integrated Grade Control (IGC) Lever Disassemble and Assemble

Auxiliary Joystick Remove and Install—IGC

Exhaust Filter Sensor Installation

Rotary Sensor Remove and Install

Air Conditioner Freeze Control Switch Remove and Install

Controller Remove and Install

Replace (Pull-Type) Metri-Pack® Connectors

Replace (Push-Type) Metri-Pack® Connectors

Replace Metri-Pack® Connectors

Replace Weather Pack™ Connector

Install Weather Pack™ Contact

Replace DEUTSCH® Rectangular or Triangular Connectors

Replace DEUTSCH® Circular Connectors

Replace DEUTSCH® Connectors

Install DEUTSCH® Contact

Replace Cinch™ Connectors

Install Cinch™ Contact

Repair 32 and 48-Way Cinch™ Connectors

Remove Connector Body From Blade Terminals

Repair Molex Connectors

Replace TYCO™ Connectors

Section 17: Frame, Chassis, or Supporting Structure

Group 1740: Frame Installation

Welding Repair of Major Structures

Group 1746: Frame Bottom Guards

Bottom Guards Remove and Install

Group 1749: Chassis Weights

Front Counterweight Remove and Install

Rear Counterweight Remove and Install

Section 18: Operator's Station

Group 1800: Removal and Installation

Operator’s Station Remove and Install

Group 1810: Operator Enclosure

Windowpanes Remove and Install

Window Wiper Motor Remove and Install

Window Washer Pumps Remove and Install

Group 1821: Seat and Seat Belt

Seat Remove and Install

Replacing Seat Belt

Group 1830: Heating and Air Conditioning

R134a Refrigerant Cautions and Proper Handling

R134a Refrigerant Oil Information

R134a Refrigerant Recovery, Recycling, and Charging Station Installation Procedure

Recover R134a Refrigerant

Flush and Purge Air Conditioning System

Evacuate R134a System

Charge R134a System

Evaporator or Heater Core Remove and Install

Expansion Valve Remove and Install

Blower Motor and Blower Motor Speed Resistor Remove and Install

Heater Disassemble and Assemble

Under Seat Heater Remove and Install

Under Seat Heater Disassemble and Assemble

Receiver-Dryer Remove and Install

Condenser Remove and Install

Compressor Remove and Install

Section 19: Sheet Metal and Styling

Group 1910: Hood or Engine Enclosure

Hood Remove and Install

Engine Side Shields Remove and Install

Group 1913: Miscellaneous Shields

Rear Sheet Metal Remove and Install

Group 1921: Grille and Grille Housing

Grille Remove and Install

Section 20: Safety, Convenience, and Miscellaneous

Group 2004: Horn and Warning Devices

Backup Alarm Remove and Install

Backup Alarm Volume Adjustment

Section 21: Main Hydraulic System

Group 2160: Hydraulic System

General Oil Cleanup Procedure

Hydraulic Component Failure Cleanup Procedure

Hydraulic Pump Remove and Install

Hydraulic Pump (With Winch Option) Disassemble and Assemble

Hydraulic Pump (Without Winch Option) Disassemble and Assemble

Hydraulic Fan Pump Remove and Install

Hydraulic Fan Motor Remove and Install

Section 32: Bulldozer

Group 3201: Blades

Cutting Edges and End Bits Remove and Install

Blade Remove and Install

Group 3215: Control Linkage

Blade Control Lever Linkage Remove and Install

Auxiliary Control Lever Linkage Remove and Install

Group 3240: Frames

C-Frame Remove and Install

Group 3260: Hydraulic System

Hydraulic Control Valve Remove and Install

Hydraulic Control Valve Remove and Install—IGC

Hydraulic Control Valve Disassemble and Assemble

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

Auxiliary Control Valve Section Disassemble and Assemble

Angle Control Valve Section Disassemble and Assemble

Tilt Control Valve Section Disassemble and Assemble

Lift Control Valve Section Disassemble and Assemble

System Relief Valve Disassemble and Assemble

Hydraulic Control Valve Disassemble and Assemble—IGC

Lift Cylinder Remove and Install

Tilt Cylinder Remove and Install

Angle Cylinder Remove and Install

Hydraulic Cylinder Repair

Section 42: Ground Conditioning Tool

Group 4200: Ripper

Ripper Remove and Install—If Equipped

Group 4201: Blades, Teeth, and Shanks

Shank and Tooth Remove and Install

Group 4260: Hydraulic System

Ripper Cylinder Remove and Install

Section 99: Dealer Fabricated Tools

Group 9900: Dealer Fabricated Tools

DF1041 Track Nut Removal Tool

DF1063 Lift Bracket

DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool

DFT1119 Pump Support

DFT1130 Adapter

DFT1132 Hydrostatic Motor/Hydraulic Pump Tool

DFT1137 Hydrostatic Motor Removal and Installation Tool

DFT1166 Final Drive Lifting Bracket Adapter

DFT1167 Final Drive Lifting Bracket Adapter Spacer

DFT1211 Final Drive Lifting Bracket Adapter

DFT1278 30 mm Wrench With 3/4-in Drive

ST4920 Track Recoil Spring Disassembly and Assembly Tool