PDF Repair Technical Manual John Deere 450H 550H 650H Crawler Dozer - 3 MB
This technical manual (TM1744) provides in-depth repair and service information for John Deere 450H, 550H, and 650H crawler dozers.
It contains diagnostic procedures, disassembly and assembly instructions, and system specifications.
Professional technicians rely on this manual to perform accurate and efficient repairs on all major systems.
This is the ultimate guide for servicing your H-Series crawler.
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--- Page 1 ---
450H, 550H, 650H
Crawler Dozer
Repair
TECHNICAL MANUAL
H-Series Crawler Dozer
TM1744 24APR19 (ENGLISH)
Sean Wright
15161 N Goodwill Rd
Titusville
PA
16354
United States (US)
[email protected]
https://therepairmanual.com
Worldwide Construction
And Forestry Division
PRINTED IN U.S.A.
--- Page 3 ---
Safety
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.
T133509 —UN—15APR13
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.
T133840 —UN—20SEP00
TX03679,00016D3 -19-07SEP06-1/1
Beware of Exhaust Fumes
Prevent asphyxiation. Engine exhaust fumes can cause
sickness or death.
T133546 —UN—24AUG00
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.
TX03679,00016D4 -19-23JUN08-1/1
TM1744 (24APR19) 00-01-3 H-Series Crawler Dozer
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--- Page 4 ---
Safety
Q—Hour Meter: Use to determine when your machine displayed in the gauge window (1). The speed range is
needs periodic maintenance. displayed as a two digit value. The values can range from
SP1.0 to SP3.0. When the transmission speed control
R—Under-Seat Heater ON/OFF Switch: Push upper button (located on FNR lever) is pressed and held in the
half of switch to turn heater on. Push lower half to turn “Up” position, the range SP value can reach a maximum
heater off. value of SP3.0. When the speed control button is held in
the “Down” position, the value will decrease to a minimum
S—Transmission Speed Setting Gauge Display—If of SP1.0.
Equipped: When the machine is started, the transmission
gauge speed setting default range of SP1.6 will be
HG31779,00000AB -19-11JUL02-2/2
Instrument Panel (Later Machines)
T157845B —UN—22JUL02
1— Select Button 8— Engine Air Filter Restriction 12— Transmission Oil 17— Transmission Oil Pressure
2— Display Window Indicator (Yellow) Temperature Indicator Gauge
3— Engine Coolant Temperature 9— Hydraulic Oil Filter Indicator (Yellow) 18— Under-Seat Heater ON/OFF
Gauge (Yellow) 13— Check Service Code Switch
4— Engine Oil Pressure Gauge 10— Hydraulic Oil Temperature Indicator (Yellow) 19— Key Switch
5— Fuel Level Gauge (Yellow) 14— Stop Indicator (Red)
6— Seat Belt/Park Brake Indicator 11— Transmission Oil Filter 15— Start Aid Button
(Red) Indicator (Yellow) 16— Front and Rear Work Lights
7— Engine Alternator Voltage Switch
Indicator (Yellow)
IMPORTANT: When the STOP-engine indicator Each display indicator light is color-coded to indicate the
is activated, stop engine immediately and severity of the situation. Red is a high-level warning, yellow
investigate cause of problem. DO NOT start is a low-level warning and clear indicates a condition.
engine until problem has been corrected.
When a red indicator lights, an audible alarm will sound.
Stop the engine immediately and investigate the cause
of the problem.
HG31779,0000091 -19-04JUN02-1/1
TM1744 (24APR19) 00-01-13 H-Series Crawler Dozer
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--- Page 5 ---
Group 02
General Specifications
450H and 450H-LT Crawler Dozer Dimensions
T118300 —UN—11NOV98
NOTE: Specifications and design subject to change are based on a unit with roll-over protective
without notice. Whenever applicable, specifications structure, full fuel tank, 80 kg (175 lb) operator,
are in accordance with ICED and SAE standards. and standard equipment.
Except where otherwise noted, these specifications
Item Measurement Specification
A—Overall Height—ROPS or Cab Height 2590 mm (8 ft 6 in.)
B—Blade Height 826 mm (2 ft 8.6 in.)
C—Blade Lift Height 773 mm (2 ft 6 in.)
D—Digging Depth 528 mm (1 ft 9 in.)
E—Blade Tilt
90 inch Blade (Right Side) Distance 313 mm (1 ft)
97 inch Blade (Right Side) Distance 337 mm (1 ft 1.3 in.)
115 inch Blade (Right Side) Distance 400 mm (1 ft 4 in.)
(450H-LT)
F—Blade Tilt
90 inch Blade (Left Side) Distance 313 mm (1 ft)
97 inch Blade (Left Side) Distance 337 mm (1 ft 1.3 in.)
115 inch Blade (Left Side) Distance 400 mm (1 ft 4 in.)
(450H-LT)
G—450H Overall (Without Winch) Length 3937 mm (12 ft 11 in.)
G—450H Overall (With Winch) Length 4496 mm (14 ft 9 in.)
Continued on next page CED,OUO1032,1142 -19-07NOV98-1/2
TM1744 (24APR19) 00-02-1 H-Series Crawler Dozer
042419
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--- Page 6 ---
General Specifications
550H Crawler Dozer Weights
Item Measurement Specification
SAE Operating Weight Weight 7620 kg (16,800 lb)
Optional Equipment
Rock Guards (4) Weight 131 kg (288 lb)
Deluxe Seat (add) Weight 9 kg (20 lb)
Cab with Heater (add) Weight 268 kg (590 lb)
Cab with Air Conditioning (add) Weight 306 kg (675 lb)
ROPS Heater Weight 12 kg (26 lb)
High Intensity Lights Weight 4 kg (9 lb)
Retrieval Hitch Weight 23 kg (50 lb)
Extended Draw Bar Weight 33 kg (72 lb)
4000S Winch Weight 653 kg (1437 lb)
Winch Fairlead, Four Roller Weight 85 kg (187 lb)
Radial Ripper Weight 335 kg (738 lb)
Parallelogram Ripper Weight 592 kg (1306 lb)
CED,OUO1032,1380 -19-25MAR99-1/1
TM1744 (24APR19) 00-02-11 H-Series Crawler Dozer
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--- Page 7 ---
General Specifications
650H-LGP Crawler Dozer Weights
Item Measurement Specification
SAE Operating Weight Weight 8664 kg (19,100 lb)
Optional Equipment
Rock Guards (4) Weight 131 kg (288 lb)
Swamp Shoe Weight 72 kg (158 lb)
Deluxe Seat (add) Weight 9 kg (20 lb)
Cab with Heater (add) Weight 268 kg (590 lb)
Cab with Air Conditioning (add) Weight 306 kg (675 lb)
ROPS Heater Weight 12 kg (26 lb)
High Intensity Lights Weight 4 kg (9 lb)
Front Tow Hook Weight 15 kg (33 lb)
Retrieval Hitch Weight 23 kg (50 lb)
Extended Draw Bar Weight 33 kg (72 lb)
4000S Winch Weight 653 kg (1437 lb)
Winch Fairlead, Four Roller Weight 85 kg (187 lb)
Radial Ripper Weight 335 kg (738 lb)
Parallelogram Ripper Weight 592 kg (1306 lb)
CED,OUO1032,1381 -19-25MAR99-1/1
650H and 650H-LGP Other Information optimum control; hydrostatic steering eliminates
steering clutches and brakes.
• Lubrication: Pressure system with full-flow spin-on • Brakes: Hydrostatic (dynamic) braking stops the
filter and oil-to-water cooler. machine whenever the direction-control lever is moved
• Air Cleaner: Dual stage dry-type with safety element, to neutral, whenever the decelerator is depressed to the
pre-cleaner, and dash mounted restriction indicator. end of travel, or whenever the brake pedal is depressed.
• Cooling Fan: Blower-type. • Automatic Park Brake: Exclusive safety feature
• Transmission: Dual-path, electronic-controlled, engages wet, multiple-disk brakes automatically
hydrostatic drive; load-sensing feature automatically whenever the engine stops, whenever the operator
adjusts speed and power to match changing load applies the brake pedal, or whenever the neutral start
conditions; each individual track is powered by a lever lock is in stop position; machine cannot be driven
variable-displacement piston pump and two-speed with brake applied, reducing wear out or need for
fixed-displacement motor combination; decelerator adjustment.
controls speed from holding to 8.0 km/h (5.0 mph).
• Final Drives: Heavy-duty triple-reduction final drives • Undercarriage: John Deere Dura-Trax™ features
large deep-heat treated components; pins and bushings
attach directly to the main frame and are isolated from are sealed for life; rollers and idlers are permanently
track frame and dozer frame loads. sealed and lubricated; full-length track frame covers
• Steering: Single-lever steering and direction control; reduce material build up and ease cleaning.
full power turns, counter rotation, and infinitely variable
track speeds provide unlimited maneuverability and
CED,OUO1032,1388 -19-25MAR99-1/1
TM1744 (24APR19) 00-02-21 H-Series Crawler Dozer
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--- Page 8 ---
Torque Values
Service Recommendations for Metric Series Four Bolt Flange Fitting
T6890BB —UN—15APR13
Metric Series Four Bolt Flange Fitting
A—Sealing Surface C—Pinched O-Ring
B—Split Flange D—Single Piece Flange
1. Clean sealing surfaces (A). Inspect. Scratches cause
DO NOT use air wrenches. DO NOT tighten one cap
leaks. Roughness causes seal wear. Out-of-flat
screw fully before tightening the others. DO NOT over
causes seal extrusion. If defects cannot be polished
tighten.
out, replace component.
TORQUE CHARTa
2. Install the correct O-ring (and backup washer if Thread b
N·m lb·ft
required) into groove using petroleum jelly to hold it
M6 12 9
in place.
M8 30 22
3. Split flange: Loosely assemble split flange (B) halves. M10 57 42
Make sure split is centrally located and perpendicular M12 95 70
to the port. Hand tighten cap screws to hold parts in
M14 157 116
place. Do not pinch O-ring (C).
M16 217 160
4. Single piece flange (D): Place hydraulic line in center M18 334 246
of flange and install four cap screws. Flange must be M20 421 318
centrally located on port. Hand tighten cap screws to a
Tolerance ± 10%. The torques given are enough for the given size
hold flange in place. Do not pinch O-ring. connection with the recommended working pressure. Increasing
cap screw torque beyond these amounts will result in flange and
5. After components are properly positioned and cap cap screw bending and connection failures.
screws are hand tightened, tighten one cap screw, b
Metric standard thread.
then tighten the diagonally opposite cap screw.
Tighten two remaining cap screws. Tighten all cap
screws as specified in the chart below.
04T,90,K175 -19-29SEP99-1/1
TM1744 (24APR19) 00-03-9 H-Series Crawler Dozer
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--- Page 9 ---
Section 01
Tracks
Contents
Page
Page
Group 0130—Track System
Essential Tools........................................... 01-0130-1 Hydraulic Track Tension Adjuster
Service Equipment and Tools .................... 01-0130-1 Remove and Disassemble ..................01-0130-52
Other Material............................................ 01-0130-3 Assemble and Install ...........................01-0130-54
Specifications ............................................ 01-0130-4 Track Idler Recoil Spring
Rock Guards and Chain Guides Remove and Install .............................01-0130-55
Remove and Install ...............................01-0130-8 Disassemble and Assemble................01-0130-56
Carrier Roller Sprocket
Measure Wear.......................................01-0130-9 Remove and Install .............................01-0130-60
Remove and Install ...............................01-0130-9 Track Frame
Disassemble and Assemble................01-0130-10 Remove and Install .............................01-0130-60
Inspect Metal Face Seals....................01-0130-13 Frame Wear Strips
Check Oil Level ...................................01-0130-14 Remove and Install .............................01-0130-61
Track Roller
Measure Wear.....................................01-0130-15 Group 0199—Dealer Fabricated Tools
Remove and Install .............................01-0130-15 DF1041 Track Nut Removal Tool .............. 01-0199-1
Disassemble and Assemble................01-0130-16 DFT1087 Track Recoil Spring
Check Oil Level ...................................01-0130-17 Disassembly and Assembly
Test for Leakage..................................01-0130-17 Guard Tool ............................................. 01-0199-2
Test for Leakage..................................01-0130-17 ST4920 Track Recoil Spring
Inspect Metal Face Seals....................01-0130-18 Disassembly and Assembly
Track Shoe Tool ........................................................ 01-0199-3
Measure Grouser Wear.......................01-0130-19
Remove and Install .............................01-0130-20
Link
Measure Height...................................01-0130-21
Track Bushing Outer Diameter
Measure ..............................................01-0130-22
Track Pitch
Measure ..............................................01-0130-23
Track Sag
Check ..................................................01-0130-24
Adjust ..................................................01-0130-25
Sealed Track Chain
Remove...............................................01-0130-26
Turn Pins and Bushings ......................01-0130-31
Disassemble and Assemble Using Track
Press .......................................................01-0130-31
Install...................................................01-0130-31
Lubricated Track Chain
Remove and Install (Saw Tooth) .........01-0130-33
Disassemble to Turn Bushings and Lubricate
Chain .......................................................01-0130-35
Assemble to Turn Bushings and Lubricate
Chain .......................................................01-0130-36
Disassemble and Assemble to Turn Pins and Not
Lubricate..................................................01-0130-43
Front Idler
Measure Wear.....................................01-0130-47
Remove and Install .............................01-0130-47
Disassemble, Inspect, and Assemble ...................... 01-
0130-48
Adjustment Procedure.........................01-0130-50
Check Oil Level ...................................01-0130-51
TM1744 (24APR19) 01-1 H-Series Crawler Dozer
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--- Page 10 ---
Track System
1. Use a chain and hoist when removing rock guards.
3. Tighten chain guide cap screws.
Inspect parts, replace if necessary.
Chain Guides—Specification
2. Tighten rock guard cap screws. Chain Guides-to-
Rock Guard—Specification Track Frame Cap
Rock Guard-to-Track Screws—Torque......................................................... 203 N·m (150 lb-ft)
Frame Cap Chain Guide-to-Spacer-
Screws—Torque......................................................... 203 N·m (150 lb-ft) to-Rock Guard Cap
Rock Guard-to-Spacer- Screws—Torque......................................................... 278 N·m (205 lb-ft)
to-Rock Guard Cap
Screws—Torque......................................................... 278 N·m (205 lb-ft)
CED,OUTX547,66 -19-10JUN02-2/2
Measure Carrier Roller Wear
NOTE: See Undercarriage Appraisal Manual SP326
for additional information.
1. Use calipers to measure most worn area of roller
T5819AC —UN—01NOV88
running surface.
2. Measure caliper tip spread to the nearest 0.5 mm
(0.002 in.) using the scale.
3. Flat spots on roller thread indicates roller is not free
to turn.
Carrier Roller—Specification
450H and 550H Carrier
Roller Wear—Outside
Diameter...................................................................... 152.4 mm (6.0 in.)
100% Worn................................................................. 139.7 mm (5.5 in.)
650H Carrier Roller
Wear—Outside
Diameter...................................................................... 160.0 mm (6.3 in.)
100% Worn................................................................. 147.0 mm (5.8 in.)
CED,TX03399,5059 -19-16MAR99-1/1
Remove and Install Carrier Roller Assembly
Carrier Roller—Specification
Bracket-to-Frame Cap
Screw—Torque........................................................... 620 N·m (460 lb-ft)
T118482B —UN—16NOV98
1— Cap Screw (2 used)
CED,TX03399,5060 -19-28OCT98-1/1
TM1744 (24APR19) 01-0130-9 H-Series Crawler Dozer
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--- Page 11 ---
Track System
Measure Track Shoe Grouser Wear
Measure grouser height of several track shoes to find
an average using a depth gauge such as the JT05521
200 mm Ruler, JT05534 Right Angle Attachment and
D05231ST 300 mm Ruler from JT05518 or JT05523
Undercarriage Inspection Service Tool Kit.
T93612 —UN—23FEB89
NOTE: See Undercarriage Appraisal Manual SP326
for additional information.
Item Measurement Specification
Track Shoe
450H and 550H Single Bar Grouser Height 48.0 mm (1.89 in.)
New Shoe
450H and 550H Single Bar Grouser Height 20.0 mm (0.8 in.)
100% Worn
Track Shoe
650H Single Bar Grouser New Height 50.0 mm (1.97 in.)
Shoe
650H Single Bar Grouser 100% Height 23.0 mm (0.91 in.)
Worn
CED,OUTX547,77 -19-16MAR99-1/1
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--- Page 12 ---
Track System
9. Pull track chain apart. Remove spacers (B) and
washers (A) from between left and right track links.
10. Operate crawler and rotate track in the reverse
direction. Slowly, unwrap track off drive sprocket.
11. Place a jack under both crossbars and raise crawler to
T93558 —UN—01NOV88
provide clearance. Block crawler up securely.
A—Washer (4 used) B—Spacer (2 used)
Continued on next page CED,OUTX547,83 -19-08APR99-5/6
TM1744 (24APR19) 01-0130-29 H-Series Crawler Dozer
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--- Page 13 ---
Track System
12. Install a thrust ring on each end of pin.
13. Move completed split link assembly to rear seat of
saddle.
T96278 —UN—27OCT88
CED,OUTX547,89 -19-16MAR99-7/14
14. Apply LOCTITE® plastic gasket to link bore. The
sealant prevents loss of vacuum or lubricant leakage
through pin to link joint.
T96279 —UN—27OCT88
LOCTITE is a registered trademark of Loctite Corp.
Continued on next page CED,OUTX547,89 -19-16MAR99-8/14
TM1744 (24APR19) 01-0130-39 H-Series Crawler Dozer
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--- Page 14 ---
Track System
1— Idler Assembly 6— Metal Face Seal (2 used) 10— Guide (2 used) 14— Washer (4 used)
2— Shaft 7— Bushing (2 used) 11— Washer (8 used) 15— Cap Screw (4 used)
3— Bracket (2 used) 8— Pipe Plug 12— Cap Screw (8 used)
4— O-Ring (2 used) 9— Shim (as required) 13— Wear Plate (2 used)
5— Spring Pin (4 used)
1. Remove cap screws and washers to remove wear 6. Apply clean hydraulic oil to bushings (7).
strips and shims.
7. Inspect metal face seals. See Inspect Metal Face
2. Drive pins (5) out. Seals in this group.
IMPORTANT: Keep metal face seals (6) lubricated and 8. Install new metal face seals, if necessary.
together at all times while disassembled.
9. Install shaft (2), O-rings (4), and brackets (3).
3. Remove brackets (3), O-rings (4) and metal face seals 10. Drive in spring pins (5).
(6).
11. Install guides, wear plates and shims. See Idler
4. Remove shaft (2) and inspect bushings (7). Replace if Adjustment Procedure in this group.
necessary.
12. Fill idler with oil. See Check Idler Oil Level in this group.
5. Install new bushings. Drive in bushings until bottomed.
IMPORTANT: Lubricate idler bushings with oil
before installing shaft.
CED,OUTX547,93 -19-08APR99-2/2
TM1744 (24APR19) 01-0130-49 H-Series Crawler Dozer
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--- Page 15 ---
Track System
14. Install 10-ton jack on bottom of compression tool.
15. Put caps, tube and recoil spring (D) in compression
tool so spring is centered.
16. Install DFT1087 1 Recoil Spring Guard Tool (F). (See
Group 0199 for instructions to make tool.)
17. Install plate (A) and nuts (B) to secure spring.
18. Operate jack to compress spring.
19. Apply John Deere NEVER-SEEZ ® Lubricant to
threads of special cap screw (C). Install special cap
screw through hole (E). Be sure cap screw threads
fully engage end cap.
20. Slowly release jack and remove nuts and plate.
21. Install spring assembly. (See procedure in this group.)
A—Plate D—Recoil Spring
B—Nut (4 used) E—Hole in Plate
C—Cap Screw Head F— DFT1087 Recoil Spring