JOHN DEERE 450J CRAWLER DOZER TM2258 TECHNICAL PDF MANUAL

450J, 550J, 650J Crawler Dozer (S.N. -141666) Repair

REPAIR TECHNICAL MANUAL Dozer models 450J, 550J, 650J TM2258 18 AUG 15 (ENGLISH)

For complete service information also see: 450J, 550J, 650J Crawler Dozer (S.N. —141666) DiagnosticTM2257 Alternators and Starting MotorsCTM77 PowerTech 4.5L & 6.8L Diesel Engines Level 12 Electronic Fuel System Stanadyne DE10 Pump

WithCTM331

Super Caddy Oil Cleanup ProcedureCTM310 4000S WinchesCTM166 PowerTech 4.5L & 6.8L Diesel Engines Tier 1/Stage I, Tier 2/Stage II, Tier 3/Stage IIIA, Tier 3/Stage IIA Tier 3/Stage III, (BaseCTM104 Engine)

John Deere Construction and Forestry

TM2258-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.1

Table of contents FOREWORD HELP!! HELP!! HELP!! HELP!!

Section 00 - GENERAL INFORMATION Group 01 - Safety Group 03 - Torque Values Section 01 - TRACKS Group 0130 - Track System Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0201 - Drive Axle Housing and Support Group 0250 - Axle Shaft, Bearings, and Reduction Gear Section 03 - TRANSMISSION Group 0300 - Removal and Installation Group 0315 - Controls Linkage Group 0360 - Hydrostatic System Section 04 - ENGINE Group 0400 - Removal and Installation Section 05 - ENGINE AUXILIARY SYSTEMS Group 0505 - Cold Weather Starting Aids Group 0510 - Radiator and Fan Shroud Group 0515 - Engine Speed Control Group 0520 - Intake System Group 0530 - External Exhaust System Group 0540 - Mounting Frame Group 0560 - External Fuel Supply System Section 07 - DAMPENER DRIVE Group 0752 - Elements Section 11 - PARK BRAKE Group 1100 - Removal and Installation Group 1115 - Control Linkage Group 1160 - Hydraulic System Section 18 - OPERATOR′S STATION Group 1800 - Removal and Installation Group 1810 - Operator′s Enclosure Group 1821 - Seat and Seat Belt Group 1830 - Heating and Air Conditioning Section 19 - SHEET METAL AND STYLING Group 1910 - Hood and Engine Enclosure Group 1921 - Grille and Grille Housing Section 21 - MAIN HYDRAULIC SYSTEM Group 2160 - Hydraulic System Section 32 - BULLDOZER Group 3201 - Blades Group 3215 - Control Linkage Group 3240 - Frames Group 3260 - Hydraulic System Section 9900 - DEALER FABRICATED TOOLS Group 0999 - Dealer Fabricated Tools

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TM2258-REPAIR TECHNICAL MANUAL

For the full PDF version of this manual, Please click on the above download PDF button.

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TM2258-REPAIR TECHNICAL MANUAL

TM2258-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.1

Foreword 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.

CAUTION: This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury.

Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components.

Operation and tests sections help you 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.

Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair.

Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.

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TM2258-REPAIR TECHNICAL MANUAL

TM2258-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.1

HELP!! HELP!! HELP!! HELP!!

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TM2258-REPAIR TECHNICAL MANUAL

TM2258-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.1

Section 00 - GENERAL INFORMATION Table of contents Group 01 - Safety ..................................................................................................................................... 1 Recognize Safety Information ............................................................................................................... 1 Follow Safety Instructions ..................................................................................................................... 1 Operate Only If Qualified ...................................................................................................................... 2 Wear Protective Equipment .................................................................................................................. 3 Avoid Unauthorized Machine Modifications .......................................................................................... 3 Inspect Machine ................................................................................................................................... 3 Stay Clear of Moving Parts ................................................................................................................... 4 Avoid High-Pressure Fluids ................................................................................................................... 4 Beware of Exhaust Fumes .................................................................................................................... 5 Prevent Fires ........................................................................................................................................ 5 Prevent Battery Explosions ................................................................................................................... 6 Handle Chemical Products Safely ......................................................................................................... 7 Dispose of Waste Properly .................................................................................................................... 7 Prepare for Emergencies ...................................................................................................................... 7 Add Cab Guarding For Special Uses ..................................................................................................... 8 Start Only From Operator′s Seat ........................................................................................................... 8 Prevent Unintended Machine Movement .............................................................................................. 9 Avoid Work Site Hazards ...................................................................................................................... 9 Keep Riders Off Machine .................................................................................................................... 10 Avoid Backover Accidents .................................................................................................................. 11 Avoid Machine Tip Over ...................................................................................................................... 11 Park And Prepare For Service Safely .................................................................................................. 12 Service Cooling System Safely ........................................................................................................... 13 Remove Paint Before Welding or Heating ........................................................................................... 14 Make Welding Repairs Safely ............................................................................................................. 15 Drive Metal Pins Safely ....................................................................................................................... 15 Group 03 - Torque Values ..................................................................................................................... 16 Metric Bolt and Cap Screw Torque Values .......................................................................................... 16 Additional Metric Cap Screw Torque Values ....................................................................................... 17 Unified Inch Bolt and Cap Screw Torque Values ................................................................................. 19 Service Recommendations for 37° Flare and 30° Cone Seat Connectors ........................................... 20 Service Recommendations for O-Ring Boss Fittings ........................................................................... 21 O-Ring Boss Fittings In Aluminum Housing Service Recommendations—Excavators ......................... 23 Service Recommendations For Flared Connections—Straight or Tapered Threads ............................ 25 Service Recommendations For Flat Face O-Ring Seal Fittings ............................................................ 27 O-Ring Face Seal Fittings With SAE Inch Hex Nut And Stud End For High Pressure Service Recommendations ....................................................................................................................... 28 O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For Standard Pressure Service Recommendations ....................................................................................................................... 30 O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For High Pressure Service Recommendations ....................................................................................................................... 32 Service Recommendations for Metric Series Four Bolt Flange Fitting ................................................. 34 Service Recommendations For Inch Series Four Bolt Flange Fittings ................................................. 35 Inch Series Four Bolt Flange Fitting For High Pressure Service Recommendations ............................ 36 Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings ........................................ 38 Service Recommendations For O-Ring Boss Fittings With Shoulder ................................................... 40 Metric 24° O-Ring Seal DIN 20078 Service Recommendations ........................................................... 43

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TM2258-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 01: Safety

Group 01 - Safety Recognize Safety Information

Safety alert Symbols

Safety Alert Symbols This is the safety alert symbol. When you see this symbol on your machine or in this manual, be alert for the potential of personal injury.

Follow the precautions and safe operating practices highlighted by this symbol.

A signal word — DANGER, WARNING, or CAUTION — is used with the safety alert symbol. DANGER identifies the most serious hazards.

On your machine, DANGER signs are red in color, WARNING signs are orange, and CAUTION signs are yellow. DANGER and WARNING signs are located near specific hazards. General precautions are on CAUTION labels.

Follow Safety Instructions

Follow Safety Instructions Read the safety messages in this manual and on the machine. Follow these warnings and instructions carefully. Review them frequently. Keep safety signs in good condition. Replace missing or damaged safety signs. Be sure new equipment components <- Go to Section TOC

Section 00 page 1

TM2258-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 01: Safety

and repair parts include the current safety signs. Replacement safety signs are available from your John Deere dealer.

Be sure all operators of this machine understand every safety message. Replace operator′s manual and safety labels immediately if missing or damaged.

Operate Only If Qualified Do not operate this machine unless the operator′s manual has been read carefully, and you have been qualified by supervised training and instruction.

Operator should be familiar with the job site and surroundings before operating. Try all controls and machine functions with the machine in an open area before starting to work.

Know and observe all safety rules that may apply to every work situation and work site.

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Section 00 page 2

TM2258-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 01: Safety

Wear Protective Equipment

Protective Equipment Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses.

Wear close fitting clothing and safety equipment appropriate to the job.

Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear suitable hearing protection such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.

Avoid Unauthorized Machine Modifications Modifications of this machine, or addition of unapproved products or attachments, may affect machine stability or reliability, and may create a hazard for the operator or others near the machine. The installer of any modification which may affect the electronic controls of this machine is responsible for establishing that the modification does not adversely affect the machine or its performance.

Always contact an authorized dealer before making machine modifications that change the intended use, weight or balance of the machine, or that alter machine controls, performance or reliability.

Inspect Machine

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Section 00 page 3

TM2258-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 01: Safety

Inspect Machine Inspect machine carefully each day by walking around it before starting.

Keep all guards and shields in good condition and properly installed. Fix damage and replace worn or broken parts immediately. Pay special attention to hydraulic hoses and electrical wiring.

Stay Clear of Moving Parts

Stay Clear of Moving Parts Entanglements in moving parts can cause serious injury.

Stop engine before examining, adjusting or maintaining any part of machine with moving parts.

Keep guards and shields in place. Replace any guard or shield that has been removed for access as soon as service or repair is complete.

Avoid High-Pressure Fluids

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Section 00 page 4

TM2258-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 01: Safety

Avoid High Pressure Fluids

Avoid High-Pressure Fluids This machine uses a high-pressure hydraulic system. Escaping fluid under pressure can penetrate the skin causing serious injury.

Never search for leaks with your hands. Protect hands. Use a piece of cardboard to find location of escaping fluid. Stop engine and relieve pressure before disconnecting lines or working on hydraulic system.

If hydraulic fluid penetrates your skin, see a doctor immediately. Injected fluid must be removed surgically within hours or gangrene may result. Contact a knowledgeable medical source or the Deere & Company Medical Department in Moline, Illinois, U.S.A.

Beware of Exhaust Fumes

Beware of Exhaust Fumes Prevent asphyxiation. Engine exhaust fumes can cause sickness or death.

If you must operate in an enclosed space, provide adequate ventilation. Use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring outside air into the area.

Prevent Fires

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Section 00 page 5

TM2258-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 01: Safety

Handle Fuel Safely

Clean Machine Regularly

Carry A Fire Extinguisher Handle Fuel Safely: Store flammable fluids away from fire hazards. Never refuel machine while smoking or when near sparks or flame.

Clean Machine Regularly: Keep trash, debris, grease and oil from accumulating in engine compartment, around fuel lines, hydraulic lines, exhaust components and electrical wiring. Never store oily rags or flammable materials inside a machine compartment.

Maintain Hoses and Wiring: Replace hydraulic hoses immediately if they begin to leak, and clean up any oil spills. Examine electrical wiring and connectors frequently for damage.

Keep A Fire Extinguisher Available: Always keep a multi-purpose fire extinguisher on or near the machine. Know how to use extinguisher properly.

Prevent Battery Explosions

Battery Explosions Battery gas can explode. Keep sparks, lighted matches, and open flame away from the top of battery.

Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. <- Go to Section TOC

Section 00 page 6

TM2258-REPAIR TECHNICAL MANUAL

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