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John Deere 550K & 650K Crawler Dozer Repair Technical Manual TM13357X19 – PDF DOWNLOAD
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John Deere 550K & 650K Crawler Dozer Repair Technical Manual TM13357X19 – PDF DOWNLOAD
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Description
John Deere 550K & 650K Crawler Dozer Repair Technical Manual TM13357X19 – PDF DOWNLOAD
FILE DETAILS:
John Deere 550K & 650K Crawler Dozer Repair Technical Manual TM13357X19 – PDF DOWNLOAD
Language : English
Pages : 470
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
John Deere 550K & 650K Crawler Dozer Repair Technical Manual TM13357X19 – PDF DOWNLOAD
- This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use.
- Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.
- Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components. Operation and test sections help to quickly identify the majority of routine failures quickly.
- Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values.
TABLE OF CONTENTS:
John Deere 550K & 650K Crawler Dozer Repair Technical Manual TM13357X19 – PDF DOWNLOAD
Contents................................................................................................................ 3 General Information................................................................................................. 5 Safety.......................................................................................................... 7 Recognize Safety Information................................................................................ 7 Follow Safety Instructions.................................................................................. 7 Operate Only If Qualified................................................................................... 7 Wear Protective Equipment................................................................................... 8 Avoid Unauthorized Machine Modifications.................................................................... 8 Inspect Machine............................................................................................. 8 Stay Clear of Moving Parts.................................................................................. 8 Avoid High-Pressure Fluids.................................................................................. 9 Avoid High-Pressure Oils.................................................................................... 9 Work In Ventilated Area..................................................................................... 9 Prevent Fires............................................................................................... 10 Prevent Battery Explosions.................................................................................. 10 Handle Chemical Products Safely............................................................................. 11 Decommissioning — Proper Recycling and Disposal of Fluids and Components.................................... 11 Exhaust Filter Ash Handling and Disposal.................................................................... 11 Prepare for Emergencies..................................................................................... 12 Add Cab Guarding for Special Uses........................................................................... 12 Clean Debris from Machine................................................................................... 12 Use Steps and Handholds Correctly........................................................................... 12 Start Only From Operator's Seat............................................................................. 13 Use and Maintain Seat Belt.................................................................................. 13 Prevent Unintended Machine Movement......................................................................... 13 Avoid Work Site Hazards..................................................................................... 14 Keep Riders Off Machine..................................................................................... 14 Avoid Backover Accidents.................................................................................... 15 Avoid Machine Tip Over and Machine Damage................................................................... 16 Operating or Traveling On Public Roads...................................................................... 16 Inspect and Maintain ROPS................................................................................... 17 Add and Operate Attachments Safely.......................................................................... 17 Park and Prepare for Service Safely......................................................................... 17 Service Cooling System Safely............................................................................... 18 Remove Paint Before Welding or Heating...................................................................... 18 Make Welding Repairs Safely................................................................................. 18 Drive Metal Pins Safely..................................................................................... 19 Clean Exhaust Filter Safely................................................................................. 20 Torque Values................................................................................................... 21 Additional Metric Cap Screw Torque Values................................................................... 21 Inch Series Four Bolt Flange Fitting for High-Pressure Service Recommendations.............................. 22 Metric 24° O-Ring Seal DIN 20078 Service Recommendations.................................................... 23 Metric Bolt and Cap Screw Torque Values..................................................................... 24 O-Ring Boss Fittings in Aluminum Housing Service Recommendations—Excavators................................. 25 O-Ring Face Seal Fittings With Metric Hex Nut and Stud End for High-Pressure Service Recommendations........ 27 O-Ring Face Seal Fittings With Metric Hex Nut and Stud End for Standard Pressure Service Recommendations.... 29 O-Ring Face Seal Fittings With SAE Inch Hex Nut and Stud End for High-Pressure Service Recommendations...... 31 Service Recommendations for 37° Flare and 30° Cone Seat Connectors.......................................... 32 Service Recommendations for Flared Connections—Straight or Tapered Threads.................................. 33 Service Recommendations for Flat Face O-Ring Seal Fittings.................................................. 34 Service Recommendations For Inch Series Four Bolt Flange Fittings........................................... 35 Service Recommendations for Metric Series Four Bolt Flange Fitting.......................................... 36 Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings...................................... 37 Service Recommendations for O-Ring Boss Fittings............................................................ 38 Service Recommendations For O-Ring Boss Fittings With Shoulder.............................................. 39 Unified Inch Bolt and Cap Screw Torque Values............................................................... 41 Tracks.............................................................................................................. 43 Track System.................................................................................................... 45 Welding On Machine.......................................................................................... 45 Track Guides and Rock Guards Remove and Install............................................................. 45 Carrier Roller Wear Inspection.............................................................................. 49 Carrier Roller Remove and Install........................................................................... 50 Carrier Roller Disassemble and Assemble..................................................................... 51 Metal Face Seals Inspection................................................................................. 53 Carrier Roller Leakage Test................................................................................. 55 Track Roller Wear Inspection................................................................................ 56 Track Roller Remove and Install............................................................................. 57 Track Roller Disassemble and Assemble....................................................................... 59 Track Roller Leakage Test................................................................................... 68 Track Shoe Grouser Wear Inspection.......................................................................... 69 Track Shoe Remove and Install............................................................................... 70 Track Link Height Inspection................................................................................ 71 Bushing Outside Diameter for Lubricated Track Chain Inspection.............................................. 72 Track Pitch for Lubricated Track Chain Inspection........................................................... 74 Lubricated Track Chain Remove and Install................................................................... 75 Lubricated Track Chain to Turn Bushings and Lubricate Chain Disassemble and Assemble........................ 79 Lubricated Track Chain to Turn Pins and Bushings and Not Lubricate Disassemble and Assemble................. 88 Track Sag Adjustment........................................................................................ 93 Front Idler Wear Inspection................................................................................. 95 Front Idler Remove and Install.............................................................................. 96 Front Idler Disassemble and Assemble........................................................................ 97 Front Idler Adjustment......................................................................................104 Front Idler Oil Level Check.................................................................................105 Track Tension Adjuster Repair...............................................................................106 Track Idler Recoil Spring Remove and Install................................................................109 Track Idler Recoil Spring Disassemble and Assemble..........................................................110 Track Frame Remove and Install..............................................................................114 Frame Wear Strips Remove and Install........................................................................115 Sprocket Remove and Install.................................................................................116 Axles and Suspension Systems........................................................................................117 Drive Axle Housing and Support..................................................................................119 Final Drive Remove and Install..............................................................................119 Axle Shaft, Bearings, and Reduction Gears.......................................................................123 Final Drive Disassemble and Assemble........................................................................123 Transmission........................................................................................................135 Removal and Installation........................................................................................137 Hydrostatic Pump and Motor Initial Start-Up Procedure.......................................................137 Hydrostatic Pump Remove and Install.........................................................................138 Hydrostatic Motor Remove and Install........................................................................144 Controls Linkage................................................................................................147 Transmission Control Lever (TCL) Remove and Install.........................................................147 Transmission Control Lever (TCL) Disassemble and Assemble...................................................148 Decelerator/Brake Pedal Remove and Install..................................................................165 Decelerator/Brake Pedal Disassemble and Assemble............................................................166 Input Drive Shafts and U-Joints.................................................................................171 Damper Drive Remove and Install.............................................................................171 Hydrostatic System..............................................................................................173 Hydrostatic Pump Disassemble................................................................................173 Charge Pump Disassemble and Assemble........................................................................181 Pump Displacement Control Valve (PDCV) Disassemble and Assemble.............................................185 Multi-Function Valve Remove and Install.....................................................................187 Multi-Function Valve Disassemble and Assemble...............................................................187 Hydrostatic Pump Assemble...................................................................................189 Neutral Charge Relief Valve Disassemble and Assemble........................................................196 Hydrostatic Motor Disassemble...............................................................................197 Hydrostatic Motor Assemble..................................................................................209 Hydrostatic Thermal Bypass Valve Remove and Install.........................................................224 Hydrostatic Charge Oil Filter Assembly Remove and Install...................................................225 Hydrostatic Charge Oil Filter Assembly Disassemble and Assemble.............................................226 Hydrostatic and Hydraulic Oil Reservoir Cleanout Cover Remove and Install...................................227 Hydraulic Oil Reservoir Remove and Install..................................................................229 Engine..............................................................................................................233 Removal and Installation........................................................................................235 John Deere Engine...........................................................................................235 Engine Remove and Install...................................................................................235 Engine Mounts Remove and Install............................................................................240 Engine Auxiliary System.............................................................................................243 Cold Weather Starting Aids......................................................................................245 Engine Coolant Heater Remove and Install....................................................................245 Cooling Systems.................................................................................................247 Fan Blade and Shroud Remove and Install.....................................................................247 Cooling Package Remove and Install..........................................................................248 Charge Air Cooler Remove and Install........................................................................250 Radiator Remove and Install.................................................................................251 Hydrostatic Oil Cooler Remove and Install...................................................................253 Fuel Cooler Remove and Install..............................................................................254 Intake System...................................................................................................255 Air Cleaner Remove and Install..............................................................................255 Precleaner Remove and Install—If Equipped...................................................................255 External Exhaust Systems........................................................................................257 Exhaust Tube Remove and Install.............................................................................257 JDG11340 Bellows Alignment Fixture..........................................................................258 Exhaust Bellows Alignment Procedure.........................................................................262 Diesel Particulate Filter (DPF) Remove and Install..........................................................269 Aftertreatment Assembly Remove and Install..................................................................270 Service Filter Cleaning.....................................................................................271 Selective Catalyst Reduction (SCR) Remove and Install.......................................................272 Diesel Exhaust Fluid (DEF) Tank Remove and Install..........................................................273 Diesel Exhaust Fluid (DEF) Header Remove and Install........................................................273 Diesel Exhaust Fluid (DEF) Tank Header Suction Screen Remove and Install....................................274 Diesel Exhaust Fluid (DEF) Dosing Unit Remove and Install...................................................274 Diesel Exhaust Fluid (DEF) Dosing Injector Remove and Install...............................................275 Diesel Exhaust Fluid (DEF) Decomposition Tube Remove and Install............................................275 External Fuel Supply Systems....................................................................................277 Primary Fuel Filter and Water Separator Remove and Install..................................................277 Secondary Fuel Filter Remove and Install....................................................................277 Auxiliary Fuel Filter and Water Separator Remove and Install—If Equipped....................................278 Fuel Tank Remove and Install................................................................................279 Park Brake..........................................................................................................281 Removal and Installation........................................................................................283 Park Brake Remove and Install...............................................................................283 Park Brake Valve Remove and Install.........................................................................285 Controls Linkage................................................................................................287 Park Lock Linkage Remove and Install........................................................................287 Park Lock Linkage Disassemble and Assemble..................................................................289 Hydraulic System................................................................................................291 Park Brake Disassemble and Assemble.........................................................................291 Park Brake Valve Disassemble and Assemble...................................................................295 Equipment Attaching.................................................................................................297 Drawbar.........................................................................................................299 Drawbar Remove and Install..................................................................................299 Extended Drawbar Remove and Install.........................................................................300 Electrical System...................................................................................................301 Removal and Installation........................................................................................303 Integrated Grade Control (IGC) Lever Remove and Install.....................................................303 Integrated Grade Control (IGC) Lever Disassemble and Assemble...............................................304 Auxiliary Joystick Remove and Install—IGC...................................................................305 Exhaust Filter Sensor Installation..........................................................................306 Rotary Sensor Remove and Install............................................................................306 Air Conditioner Freeze Control Switch Remove and Install....................................................306 Controller Remove and Install...............................................................................307 Replace WEATHER PACKWEATHER PACK is a trademark of Packard Electric.™ Connector.............................307 Install WEATHER PACKWEATHER PACK is a trademark of Packard Electric.™ Contact...............................308 Replace DEUTSCHDEUTSCH is a trademark of the Deutsch Co.™ Connectors........................................309 Replace DEUTSCHDEUTSCH is a trademark of Deutsch Co.™ Rectangular or Triangular Connectors..................310 Install DEUTSCHDEUTSCH is a trademark of the Deutsch Co.™ Contact...........................................311 Replace CINCHCINCH is a trademark of the Cinch Co.™ Connectors..............................................312 Install CINCHCINCH is a trademark of the Cinch Co.™ Contact.................................................314 Repair 32 and 48 Way CINCHCINCH is a trademark of the Cinch Co.™ Connectors.................................315 Replace (Pull Type) Metri-Pack™ Connectors..................................................................318 Replace (Push Type) Metri-Pack™ Connectors..................................................................319 Frame, Chassis, or Supporting Structure.............................................................................321 Frame Installation..............................................................................................323 Welding Repair of Major Structures..........................................................................323 Frame Bottom Guards.............................................................................................325 Bottom Guards Remove and Install............................................................................325 Chassis Weights.................................................................................................327 Front Counterweight Remove and Install......................................................................327 Rear Counterweight Remove and Install.......................................................................328 Operator's Station..................................................................................................329 Removal and Installation........................................................................................331 Operator’s Station Remove and Install.......................................................................331 Operator Enclosure..............................................................................................335 Slide Glass Remove and Install..............................................................................335 Stationary Glass Remove and Install.........................................................................336 Windowpanes Remove and Install..............................................................................337 Window Wiper Motor Remove and Install.......................................................................340 Window Washer Pumps Remove and Install......................................................................346 Seat and Seat Belt..............................................................................................347 Seat Remove and Install.....................................................................................347 Seat Belt Remove and Install................................................................................347 Heating and Air Conditioning....................................................................................349 R134a Refrigerant Cautions and Proper Handling..............................................................349 R134a Refrigerant Oil Information...........................................................................350 R134a Refrigerant Recovery, Recycling, and Charging Station Installation Procedure..........................351 Recover R134a Refrigerant...................................................................................351 Flush and Purge Air Conditioning System.....................................................................352 Evacuate R134a System.......................................................................................354 Charge R134a System.........................................................................................355 Evaporator or Heater Core Remove and Install................................................................356 Expansion Valve Remove and Install..........................................................................358 Blower Motor and Blower Motor Speed Resistor Remove and Install.............................................359 Heater Disassemble and Assemble.............................................................................360 Under Seat Heater Disassemble and Assemble..................................................................362 Receiver-Dryer Remove and Install...........................................................................363 Condenser Remove and Install................................................................................364 Compressor Remove and Install...............................................................................365 Sheet Metal and Styling.............................................................................................367 Hood or Engine Enclosure........................................................................................369 Hood Remove and Install.....................................................................................369 Engine Side Shields Remove and Install......................................................................369 Rear Hood Support Remove and Install........................................................................369 Grille and Grille Housing.......................................................................................371 Grille Remove and Install...................................................................................371 Safety, Convenience, and Miscellaneous..............................................................................373 Horn and Warning Devices........................................................................................375 Backup Alarm Remove and Install.............................................................................375 Backup Alarm Volume Adjustment..............................................................................375 Main Hydraulic System...............................................................................................377 Hydraulic System................................................................................................379 General Oil Cleanup Procedure...............................................................................379 Hydraulic Component Failure Cleanup Procedure...............................................................381 Hydraulic Pump Remove and Install...........................................................................383 Hydraulic Pump (With Winch Option) Disassemble and Assemble.................................................385 Hydraulic Pump (Without Winch Option) Disassemble and Assemble..............................................389 Hydraulic Fan Pump Remove and Install.......................................................................391 Hydraulic Fan Motor Remove and Install......................................................................392 Hydraulic Fan Reversing Valve Remove and Install—If Equipped................................................393 Hydraulic Fan Reversing Valve Disassemble and Assemble......................................................394 Hydraulic Reservoir Cleanout Cover Remove and Install.......................................................394 Hydraulic Reservoir Remove and Install......................................................................394 Bulldozer...........................................................................................................395 Blades..........................................................................................................397 Cutting Edges and End Bits Remove and Install...............................................................397 Blade Remove and Install....................................................................................399 Blade Retainer Split Bearing Installation...................................................................402 Control Linkage.................................................................................................405 Blade Control Lever Linkage Remove and Install..............................................................405 Auxiliary Control Lever Linkage Remove and Install..........................................................408 Frames..........................................................................................................411 C-Frame Remove and Install..................................................................................411 Hydraulic System................................................................................................415 Hydraulic Control Valve Remove and Install..................................................................415 Hydraulic Control Valve Remove and Install—IGC..............................................................417 Hydraulic Control Valve Disassemble and Assemble............................................................419 Wiper Seals and Lip Seals on Hydraulic Control Valve Remove and Install.....................................420 Auxiliary Control Valve Section Disassemble and Assemble....................................................426 Angle Control Valve Section Disassemble and Assemble........................................................427 Tilt Control Valve Section Disassemble and Assemble.........................................................429 Lift Control Valve Section Disassemble and Assemble.........................................................430 System Relief Valve Disassemble and Assemble................................................................431 Hydraulic Control Valve Disassemble and Assemble—IGC........................................................432 Lift Cylinder Remove and Install............................................................................434 Tilt Cylinder Remove and Install............................................................................435 Angle Cylinder Remove and Install...........................................................................436 Hydraulic Cylinder Repair...................................................................................436 Ground Conditioning Tool............................................................................................437 Ripper..........................................................................................................439 Ripper Remove and Install—If Equipped.......................................................................439 Blades, Teeth, and Shanks.......................................................................................441 Shank and Tooth Remove and Install..........................................................................441 Hydraulic System................................................................................................443 Ripper Cylinder Remove and Install..........................................................................443 Dealer Fabricated Tools.............................................................................................445 Dealer Fabricated Tools.........................................................................................447 DF1041 Track Nut Removal Tool...............................................................................447 DF1063 Final Drive Lift Bracket.............................................................................448 DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool.............................................449 DFT1119 Pump Support........................................................................................450 DFT1130 Adapter.............................................................................................451 DFT1132 Hydrostatic Motor Removal and Installation Tool.....................................................452 DFT1137 Hydrostatic Motor Removal and Installation Tool.....................................................453 DFT1166 Final Drive Lifting Bracket Adapter.................................................................454 DFT1167 Final Drive Lifting Bracket Adapter Spacer..........................................................455 DFT1211 Final Drive Lifting Bracket Adapter.................................................................456 DFT1278 30 mm Wrench with 3/4 in. Drive.....................................................................456 ST4920 Track Recoil Spring Disassembly and Assembly Tool....................................................457 Page Number............................................................................................................. 3 Section 00.......................................................................................................... 5 Group 0001...................................................................................................... 7 Group 0003...................................................................................................... 21 Section 01.......................................................................................................... 43 Group 0130...................................................................................................... 45 Section 02..........................................................................................................117 Group 0201......................................................................................................119 Group 0250......................................................................................................123 Section 03..........................................................................................................135 Group 0300......................................................................................................137 Group 0315......................................................................................................147 Group 0325......................................................................................................171 Group 0360......................................................................................................173 Section 04..........................................................................................................233 Group 0400......................................................................................................235 Section 05..........................................................................................................243 Group 0505......................................................................................................245 Group 0510......................................................................................................247 Group 0520......................................................................................................255 Group 0530......................................................................................................257 Group 0560......................................................................................................277 Section 11..........................................................................................................281 Group 1100......................................................................................................283 Group 1115......................................................................................................287 Group 1160......................................................................................................291 Section 15..........................................................................................................297 Group 1511......................................................................................................299 Section 16..........................................................................................................301 Group 1600......................................................................................................303 Section 17..........................................................................................................321 Group 1740......................................................................................................323 Group 1746......................................................................................................325 Group 1749......................................................................................................327 Section 18..........................................................................................................329 Group 1800......................................................................................................331 Group 1810......................................................................................................335 Group 1821......................................................................................................347 Group 1830......................................................................................................349 Section 19..........................................................................................................367 Group 1910......................................................................................................369 Group 1921......................................................................................................371 Section 20..........................................................................................................373 Group 2004......................................................................................................375 Section 21..........................................................................................................377 Group 2160......................................................................................................379 Section 32..........................................................................................................395 Group 3201......................................................................................................397 Group 3215......................................................................................................405 Group 3240......................................................................................................411 Group 3260......................................................................................................415 Section 42..........................................................................................................437 Group 4200......................................................................................................439 Group 4201......................................................................................................441 Group 4260......................................................................................................443 Section 99..........................................................................................................445 Group 9900......................................................................................................447
S.S 22/02/2025
