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450K, 550K, and 650K Crawler Dozer Repair (PIN: 1T0450KX_ _F304771— ) (PIN: 1T0550KK_ _F305398— ) (PIN: 1T0650KK_ _F305399— )

REPAIR TECHNICAL MANUAL 450K, 550K, and 650K Crawler Dozer TM14163X19 15FEB18

Worldwide Construction And Forestry Division PRINTED IN U.S.A.

(ENGLISH)

Introduction 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.

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.

This is the safety-alert symbol. When this symbol is seen on the machine or in this manual, be alert for the potential of personal injury.

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.

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.

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. MM16284,0001A38 -19-01DEC15-1/1

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Introduction

Manual Identification—READ THIS FIRST!

TX1187692 —UN—11MAR15

IMPORTANT: Use only supporting manuals designated for the specific machine. If incorrect manual is chosen, improper service may occur. Verify product identification number (PIN) when choosing the correct manual. Choosing the Correct Supporting Manuals John Deere crawlers are available in different machine configurations based on the various markets into which they are sold. Different supporting manuals exist for different machine configurations. When necessary, product identification numbers are listed on the front covers of crawler manuals. These numbers are used to identify the correct supporting manual for the machine.

The product identification number (PIN) plate (1) is located on the left side of the machine above the center of the tracks. Each machine has a 17-character PIN (2) shown on PIN plate.

JOHN DEERE Product Identification Number *1T0650KXCEF123456*

CRAWLER DOZER 650K MADE IN USA DEERE & COMPANY, MOLINE, ILLINOIS, USA

TX1175561 —UN—28OCT14

Product Identification Number

PIN Plate Location

Example of PIN Plate 1— PIN Plate

Continued on next page

TM14163X19 (15FEB18)

2— 17-Character PIN

PN36905,00099B7 -19-20JAN17-1/2

450K, 550K, and 650K Crawler Dozer

021518

PN=3

Introduction

The following is an example for a machine that meets Final Tier 4 and Stage IV emission levels:

The PIN identifies the producing factory, machine model number, machine option, year of manufacture, engine emission level, and machine serial number.

17-Character PIN Examples 1

• (1—3) World Code: Identifies location where machine is manufactured.

1T0 .................. World Code (manufacturing location) 1DW ............. Davenport Works 1T8 ............... Thibodaux Works 1T0 ............... Dubuque Works 1FF ............... Deere—Hitachi (Kernersville, NC, USA) 1F9 ............... Deere—Hitachi (Indaiatuba, São Paulo, Brazil)

• (4—8) Machine Model and Series Identifier: Identifies model number and series.

450KX .............. Machine Model and Series Identifier

9 _

10 _

_ ..................... Manufacturing Year Code (variable) D .................. 2013 E .................. 2014 F .................. 2015 G ................. 2016 H ................. 2017

• (11) Engine Emission Code: Represents engine emission certification. F ..................... Engine Emission Code C ................. Tier 2 and Stage II D ................. Tier 3 and Stage III A

550KK .............. Machine Model and Series Identifier

E .................. Interim Tier 4 and Stage III B

650KK .............. Machine Model and Series Identifier

F .................. Final Tier 4 and Stage IV

• (9) Check Letter: This is a random character assigned

G ................. Interim Tier 4 and Stage III A (19-56 kW)

by the factory. This is not used in machine identification. _ ..................... Check Letter (variable)

• (10) Manufacturing Year Code: Identifies year of machine manufacture.

H .................. Final Tier 4 and Stage III A (19-37 kW) J ................... Final Tier 4 and Stage III B (37-56 kW) K .................. Final Tier 4 (8-19 kW)

• (12—17) Machine Serial Number: Identifies machine serial number. This character will change from one machine to another.

123456 ............. Machine Serial Number PN36905,00099B7 -19-20JAN17-2/2

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Contents Section 00—General Information

Group 1821—Seat and Seat Belt Group 1830—Heating and Air Conditioning

Group 0001—Safety Group 0003—Torque Values

Section 19—Sheet Metal and Styling

Section 01—Tracks

Group 1910—Hood or Engine Enclosure Group 1913—Miscellaneous Shields Group 1921—Grille and Grille Housing

Group 0130—Track System

Section 02—Axles and Suspension Systems Group 0201—Drive Axle Housing and Support Group 0250—Axle Shaft, Bearings, and Reduction Gears

Section 20—Safety, Convenience, and Miscellaneous Group 2004—Horn and Warning Devices

Section 03—Transmission

Section 21—Main Hydraulic System

Group 0300—Removal and Installation Group 0315—Controls Linkage Group 0325—Input Drive Shafts and U-Joints Group 0360—Hydrostatic System

Group 2160—Hydraulic System

Section 32—Bulldozer Group 3201—Blades Group 3215—Control Linkage Group 3240—Frames Group 3260—Hydraulic System

Section 04—Engine Group 0400—Removal and Installation

Section 05—Engine Auxiliary System

Section 42—Ground Conditioning Tool

Group 0505—Cold Weather Starting Aids Group 0510—Cooling Systems Group 0520—Intake System Group 0530—External Exhaust Systems Group 0560—External Fuel Supply Systems

Group 4200—Ripper Group 4201—Blades, Teeth, and Shanks Group 4260—Hydraulic System

Section 99—Dealer Fabricated Tools Group 9900—Dealer Fabricated Tools

Section 11—Park Brake Group 1100—Removal and Installation Group 1115—Controls Linkage Group 1160—Hydraulic System

Section 15—Equipment Attaching Group 1511—Drawbar

Section 16—Electrical System Group 1600—Removal and Installation

Section 17—Frame, Chassis, or Supporting Structure Group 1740—Frame Installation Group 1746—Frame Bottom Guards Group 1749—Chassis Weights

Section 18—Operator's Station Group 1800—Removal and Installation Group 1810—Operator Enclosure

Original Instructions. All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice. COPYRIGHT © 2018 DEERE & COMPANY Moline, Illinois All rights reserved. A John Deere ILLUSTRUCTION ™ Manual Previous Editions Copyright © 2017

TM14163X19 (15FEB18)

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Contents

TM14163X19 (15FEB18)

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Contents

Section 00 General Information

Page Page

Group 0001—Safety Information for European Union Directives and Eurasian Economic Union Technical Regulations Compliance........................ 00-0001-1 Recognize Safety Information ................... 00-0001-2 Follow Safety Instructions.......................... 00-0001-3 Operate Only If Qualified ........................... 00-0001-3 Wear Protective Equipment....................... 00-0001-3 Avoid Unauthorized Machine Modifications.......................................... 00-0001-4 Inspect Machine ........................................ 00-0001-4 Stay Clear of Moving Parts........................ 00-0001-4 Avoid High-Pressure Fluids ....................... 00-0001-5 Avoid High-Pressure Oils .......................... 00-0001-5 Work In Ventilated Area............................. 00-0001-5 Avoid Static Electricity Risk When Refueling ............................................... 00-0001-6 High Debris Applications ........................... 00-0001-6 Prevent Fires ............................................. 00-0001-7 In Case of Machine Fire ............................ 00-0001-7 Prevent Battery Explosions ....................... 00-0001-8 Handle Chemical Products Safely.............. 00-0001-8 Handle Starting Fluid Safely ...................... 00-0001-8 Decommissioning — Proper Recycling and Disposal of Fluids and Components ................................... 00-0001-9 Exhaust Filter Ash Handling and Disposal................................................. 00-0001-9 Prepare for Emergencies........................... 00-0001-9 Clean Debris from Machine ..................... 00-0001-10 Add Cab Guarding for Special Uses .................................................... 00-0001-10 Use Steps and Handholds Correctly .............................................. 00-0001-10 Start Only From Operator's Seat ............. 00-0001-10 Use and Maintain Seat Belt ..................... 00-0001-11 Prevent Unintended Machine Movement............................................ 00-0001-11 Avoid Work Site Hazards......................... 00-0001-12 Keep Riders Off Machine ........................ 00-0001-12 Avoid Backover Accidents ....................... 00-0001-13 Avoid Machine Tip Over and Machine Damage ................................ 00-0001-14 Use Special Care When Operating............................................. 00-0001-14 Inspect and Maintain ROPS .................... 00-0001-15 Travel Safely............................................ 00-0001-15 Prevent Acid Burns.................................. 00-0001-16 Add and Operate Attachments Safely................................................... 00-0001-16 Park and Prepare for Service Safely................................................... 00-0001-17 Service Machines Safely ......................... 00-0001-17 TM14163X19 (15FEB18)

Service Cooling System Safely ............... 00-0001-17 Remove Paint Before Welding or Heating ................................................ 00-0001-18 Make Welding Repairs Safely ................. 00-0001-18 Drive Metal Pins Safely ........................... 00-0001-18 Use Proper Lifting Equipment.................. 00-0001-19 Clean Exhaust Filter Safely ..................... 00-0001-20 Group 0003—Torque Values Torque Value Metric Bolt and Cap Screw....................00-0003-1 Additional Metric Cap Screw Torque Values ........................................ 00-0003-2 Unified Inch Bolt and Cap Screw ..........00-0003-3 Service Recommendations for 37° Flare and 30° Cone Seat Connectors ............................................ 00-0003-4 Service Recommendations for O-Ring Boss Fittings.............................. 00-0003-4 Service Recommendation O-Ring Boss Fittings In Aluminum HousingExcavators.............................................................00-0003-6 Service Recommendations for Flared Connections—Straight or Tapered Threads ................................... 00-0003-7 Service Recommendations for Flat Face O-Ring Seal Fittings ..................... 00-0003-8 O-Ring Face Seal Fittings with SAE Inch Hex Nut and Stud End for High Pressure.......................00-0003-9 O-Ring Face Seal Fittings with Metric Hex Nut and Stud End for Standard Pressure..............00-0003-11 O-Ring Face Seal Fittings with Metric Hex Nut and Stud End for High Pressure.....................00-0003-13 Service Recommendations for Metric Series Four Bolt Flange Fitting................................................... 00-0003-15 Service Recommendations For Inch Series Four Bolt Flange Fittings ................................................. 00-0003-16 Inch Series Four Bolt Flange For High Pressure ..................................................00-0003-17 Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings............................. 00-0003-18 Service Recommendations For O-Ring Boss Fittings With Shoulder .............................................. 00-0003-19 Metric 24 O-Ring Seal DIN 20078.......00-0003-21

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Contents

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Group 0001

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

1 2 3 4

TX1066144 —UN—19OCT09

TX1229153 —UN—23NOV16

Model Year Engine Power

Typical Mass

Crawler

CE Mark

JOHN DEERE

DEERE & COMPANY MOLINE, ILLINOIS Made in USA

TX1175987 —UN—03NOV14

TX1066156 —UN—15OCT09

Product Identification Number MM / YYYY

PIN Plate

EAC Marking

To the Customer

TX1066630 —UN—21OCT09

Effective June, 2006, all machines sold in the European Union must comply with the machinery directive 2006/42/EC and any amendments. Each machine meeting these requirements must bear the conformity mark CE. In addition, each machine must be accompanied with a Declaration of Conformity by the machine manufacturer. This declaration must be kept with the machine at all times and does not declare conformity to national road regulations. Effective February 15, 2013, all machines sold in the Eurasian Economic Union must comply with the Technical Regulations of the Eurasian Economic Union TR TS 010/2011 “On Safety of machinery and Equipment.” Each machine meeting these requirements must bear the EAC Marking. NOTE: This machine may need country approval for travel on public roads in Europe as some European countries require special equipment and approvals. Product Identification Number (PIN), CE Mark, EAC Marking, and EU Flex Label Locations

EU Flex Label 1— PIN Plate 2— CE Mark (if required)

The machine is identified by the PIN that is stamped on a serial number plate. The PIN plate (1), CE Mark or EAC Marking, and if required, EU flex label are located on the machine as indicated in the machine image.

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TM14163X19 (15FEB18)

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00-0001-1

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Safety

If this machine was certified (homologated) to the requirements of the Eurasian Economic Union, there will be a EAC marking (3) affixed in the indicated area.

NOTE: If this machine was certified (homologated) to the requirements of the European Union, there will be a CE mark affixed in indicated area (2). If required this machine will also be affixed with an EU Flex label (4) beside the CE mark in the indicated area. Sound and Vibration Specifications Model

450K

550K

650K

Operator sound pressure and exterior sound power levels are: Cab NOTE: Factors affecting listed values include operator performance, machine age, seat condition, the use of accessories, environment, and any machine movement. (*) Data acquisition system precision values with a 2% technical uncertainty. Sound levels were obtained using the test method specified per ISO 6396:2008 and ISO 6395:2008, respectively. Eurasian Economic Union Operator vibration levels are for properly maintained machines operating on a flat dirt area free of large objects such as trees and rocks. Whole body vibration levels were obtained using the test method specified per GOST 31191.1:2004. Whole Body Hand Arm

0.5 m/s2 or less

2.5 m/s2or less

2.5 m/s or less

NOTE: Factors affecting listed values include operator performance, machine age, the condition of window and door seals, the use of accessories, environment, and any machine movement. European Union Operator vibration levels are for properly maintained machines operating on a flat dirt area free of large objects such as trees and rocks. Vibration levels were obtained using the test method specified per ISO 2631-1:1997 or ISO TR 25398 where applicable. Whole Body Hand Arm

0.6 m/s2 or less

2.5 m/s2 or less

2.5 m/s or less

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.

T133588 —19—28AUG00

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.

T133555 —UN—15APR13

Recognize Safety Information

TX,RECOGNIZE -19-28JUN10-1/1

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Safety

Follow Safety Instructions

TS201 —UN—15APR13

Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in good condition. Replace missing or damaged safety signs. Use this operator’s manual for correct safety sign placement. Be sure that new equipment components and repair parts include the current safety signs. Replacement safety signs are available from your John Deere dealer. There can be additional safety information contained on parts and components sourced from suppliers that is not reproduced in this operator's manual. Learn how to operate the machine and how to use controls properly. Do not let anyone operate without instruction. Keep your machine in proper working condition. Unauthorized modifications to the machine could impair the function or safety and affect machine life.

If you do not understand any part of this manual and need assistance, contact your John Deere dealer. TX,FOLLOW -19-20JAN11-1/1

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.

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.

Operator should be familiar with the job site and surroundings before operating. Try all controls and TX,QUALIFIED -19-18JAN11-1/1

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

Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine. 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. Radio or music headphones are not suitable to use for hearing protection.

TS206 —UN—15APR13

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

TX,WEAR,PE -19-22SEP10-1/1

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Safety

Avoid Unauthorized Machine Modifications John Deere recommends using only genuine John Deere replacement parts to ensure machine performance. Never substitute genuine John Deere parts with alternate parts not intended for the application as these can create hazardous situations or hazardous performance. Non-John Deere Parts, or any damage or failures resulting from their use, are not covered by any John Deere warranty. 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 John Deere dealer before making machine modifications that change the intended use, weight, or balance of the machine, or that alter machine controls, performance, or reliability. AM40430,00000A9 -19-02JUN15-1/1

Inspect Machine

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.

T6607AQ —UN—15APR13

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

TX,INSPECT -19-08SEP10-1/1

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.

T133592 —UN—15APR13

Stay Clear of Moving Parts

TX,MOVING,PARTS -19-20JAN11-1/1

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Safety

Avoid High-Pressure Fluids

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A.

X9811 —UN—23AUG88

Escaping fluid under pressure can penetrate the skin causing serious injury.

DX,FLUID -19-06OCT16-1/1

Avoid High-Pressure Oils

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

T133840 —UN—20SEP00

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

T133509 —UN—15APR13

This machine uses a high-pressure hydraulic system. Escaping oil under pressure can penetrate the skin causing serious injury.

TX,HPOILS -19-20JAN11-1/1

Work In Ventilated Area

If you do not have an exhaust pipe extension, open the doors and get outside air into the area.

TS220 —UN—15APR13

Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension.

DX,AIR -19-17FEB99-1/1

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Safety

Avoid Static Electricity Risk When Refueling The removal of sulfur and other compounds in Ultra-Low Sulfur Diesel (ULSD) fuel decreases its conductivity and increases its ability to store a static charge. RG22142 —UN—17MAR14

Refineries may have treated the fuel with a static dissipating additive. However, there are many factors that can reduce the effectiveness of the additive over time. Static charges can build up in ULSD fuel while it is flowing through fuel delivery systems. Static electricity discharge when combustible vapors are present could result in a fire or explosion.

RG21992 —UN—21AUG13

Therefore, it is important to ensure that the entire system used to refuel your machine (fuel supply tank, transfer pump, transfer hose, nozzle, and others) is properly grounded and bonded. Consult with your fuel or fuel system supplier to ensure that the delivery system is in compliance with fueling standards for proper grounding and bonding practices.

DX,FUEL,STATIC,ELEC -19-12JUL13-1/1

T133552 —UN—15APR13

High Debris Applications Many operations create flammable debris such as mulching, shredding, recycling, and agricultural applications. Operating in such environments may require frequent cleaning of the machine and attachments. Frequency of cleaning will vary depending on a number of factors, including operating conditions and weather. Flammable Debris MB60223,0005003 -19-29JUN16-1/1

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Safety

T133552 —UN—15APR13

Prevent Fires Handle Fluids Safely: All fuels, most lubricants, and some coolant mixtures are flammable. Store flammable fluids away from fire hazards. Never refuel machine while smoking or when near sparks or flame. Clean Machine Regularly: Keep flammable debris (trash, leaves, twigs, straw, etc.), 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.

Handle Fuel Safely T133553 —UN—07SEP00

Maintain Hoses, Tubes, and Wiring: Replace hydraulic hoses and tubes 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 multipurpose fire extinguisher on or near the machine. Know how to use extinguisher properly.

Clean Machine Regularly T133554 —UN—07SEP00

Be Aware of the Operating Environment: Airborne debris may contain sparks or embers. Do not operate near any flame.

Carry A Fire Extinguisher MB60223,0005002 -19-29SEP16-1/1

In Case of Machine Fire CAUTION: Avoid personal injury from exposed flames. Maintain safe distance.

TS227 —UN—15APR13

• Turn the engine off. • Turn the battery disconnect switch to the OFF position, if equipped.

• If possible, fight the fire using the portable fire

extinguisher or other fire suppression equipment, if equipped. • Ensure that the fire does not spread to the surrounding area. Do not risk injury. If a fire is too far advanced, do not try to extinguish fire. • Call for help.

In Case of Machine Fire

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Safety

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

TS204 —UN—15APR13

Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F). Keep battery electrolyte levels properly maintained.

Battery Explosions KR46761,00010B4 -19-26JAN16-1/1

Handle Chemical Products Safely

A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques. Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and recommended equipment.

TS1132 —UN—15APR13

Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere equipment include such items as lubricants, coolants, paints, and adhesives.

(See your John Deere dealer for MSDS’s on chemical products used with John Deere equipment.) DX,MSDS,NA -19-03MAR93-1/1

Handle Starting Fluid Safely Starting fluid is highly flammable.

To prevent accidental discharge when storing the pressurized can, keep the cap on the container, and store in a cool, protected location. Do not incinerate or puncture a starting fluid container. Do not use starting fluid on an engine equipped with glow plugs or an air intake heater.

TS1356 —UN—18MAR92

Keep all sparks and flame away when using it. Keep starting fluid away from batteries and cables.

DX,FIRE3 -19-14MAR14-1/1

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Safety

Decommissioning — Proper Recycling and Disposal of Fluids and Components

TS1133 —UN—15APR13

Safety and environmental stewardship measures must be taken into account when decommissioning a machine and/or component. These measures include the following:

• Use appropriate tools and personal protective

equipment such as clothing, gloves, face shields or glasses, during the removal or handling of objects and materials. • Follow instructions for specialized components. • Release stored energy by lowering suspended machine elements, relaxing springs, disconnecting the battery or other electrical power, and releasing pressure in hydraulic components, accumulators, and other similar systems. • Minimize exposure to components which may have residue from agricultural chemicals, such as fertilizers and pesticides. Handle and dispose of these components appropriately. • Carefully drain engines, fuel tanks, radiators, hydraulic cylinders, reservoirs, and lines before recycling components. Use leak-proof containers when draining fluids. Do not use food or beverage containers. • Do not pour waste fluids onto the ground, down a drain, or into any water source. • Observe all national, state, and local laws, regulations, or ordinances governing the handling or disposal of waste fluids (example: oil, fuel, coolant, brake fluid);

filters; batteries; and, other substances or parts. Burning of flammable fluids or components in other than specially designed incinerators may be prohibited by law and could result in exposure to harmful fumes or ashes. • Service and dispose of air conditioning systems appropriately. Government regulations may require a certified service center to recover and recycle air conditioning refrigerants which could damage the atmosphere if allowed to escape. • Evaluate recycling options for tires, metal, plastic, glass, rubber, and electronic components which may be recyclable, in part or completely. • Contact your local environmental or recycling center, or your John Deere dealer for information on the proper way to recycle or dispose of waste. DX,DRAIN -19-01JUN15-1/1

Exhaust Filter Ash Handling and Disposal CAUTION: Under federal, state, and local laws or regulations, exhaust filter ash can be classified as a hazardous waste. Hazardous waste must be disposed of in accordance with all applicable federal, state, and local laws or regulations

governing hazardous waste disposal. Only a qualified service provider should remove ash from the exhaust filter. Personal protective equipment and clothing, maintained in a sanitary and reliable condition, should be used when handling and cleaning exhaust filter. See your authorized dealer for exhaust filter ash handling and disposal. TX,ASH,DISP -19-20JAN11-1/1

Prepare for Emergencies Be prepared if a fire starts.

Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.

TS291 —UN—15APR13

Keep a first aid kit and fire extinguisher handy.

DX,FIRE2 -19-03MAR93-1/1

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Safety

Clean Debris from Machine Keep engine compartment, radiator, batteries, hydraulic lines, exhaust components, fuel tank, and operator's station clean and free of debris. T6669AG —UN—15APR13

Clean any oil spills or fuel spills on machine surfaces. Temperature in engine compartment could go up immediately after engine is stopped. BE ON GUARD FOR FIRES DURING THIS PERIOD. Open access door(s) to cool the engine faster, and clean engine compartment.

TX,DEBRIS -19-20JAN11-1/1

Add Cab Guarding for Special Uses Special work situations or machine attachments could create an environment with falling or flying objects. Working near an overhead bank, demolition work, using a hydraulic hammer or winch, working in a forestry application or wooded area, or working in a waste management application, for example, could require added guarding to protect the operator.

Additional level II FOPS (falling object protective structure), forestry protection packages, and special screens or guarding should be installed when falling or flying objects could enter or damage the machine. A rear screen should always be used with a winch to protect against a snapping cable. Before operating in any special work environments, follow the operator protection recommendations of the manufacturer of any specialized attachment or equipment. Contact your authorized John Deere dealer for information on protective guarding. TX,CABGUARD -19-12FEB13-1/1

Prevent falls by facing the machine when you get on and off. Maintain 3-point contact with steps and handrails. Never use machine controls as handholds. Use extra care when mud, snow, or moisture present slippery conditions. Keep steps clean and free of grease or oil. Never jump when exiting machine. Never mount or dismount a moving machine.

T133468 —UN—15APR13

Use Steps and Handholds Correctly

TX,STEPS -19-09FEB11-1/1

Avoid unexpected machine movement. Start engine only while sitting in operator's seat. Ensure that all controls and working tools are in proper position for a parked machine. Never attempt to start engine from the ground. Do not attempt to start engine by shorting across the starter solenoid terminals.

T133715 —UN—15APR13

Start Only From Operator's Seat

TX,SOFOS -19-20JAN11-1/1

TM14163X19 (15FEB18)

00-0001-10

450K, 550K, and 650K Crawler Dozer 021518 PN=18

Safety

Use and Maintain Seat Belt T133716 —19—17APR13

Use seat belt when operating machine. Remember to fasten seat belt when loading and unloading from trucks and during other uses. Examine seat belt frequently. Be sure that webbing is not cut or torn. Replace seat belt immediately if any part is damaged or does not function properly. The complete seat belt assembly should be replaced every three years, regardless of appearance.

TX,SEAT,BELT -19-20JAN11-1/1

Always move the park lock levers to the up (locked) position before leaving the operator's seat for any reason. Be careful not to accidentally actuate controls when coworkers are present. Engage park lock and lower work equipment to the ground during work interruptions. Stop the engine before allowing anyone to approach the machine. Follow these same precautions before standing up, leaving the operator's seat, or exiting the machine.

(LOCKED) UP POSITION

(UNLOCKED) DOWN POSITION

T207688 —19—31JAN05

Prevent Unintended Machine Movement

ER79617,0000CF9 -19-30NOV10-1/1

TM14163X19 (15FEB18)

00-0001-11

450K, 550K, and 650K Crawler Dozer 021518 PN=19

Safety

Avoid Work Site Hazards Avoid contact with gas lines, buried cables, and water lines. Call utility line location services to identify all underground utilities before starting work. T139002 —UN—05MAR01

Prepare work site properly. Avoid operating near structures or objects that could fall onto the machine. Clear away debris that could move unexpectedly if run over. Avoid boom or attachment contact with overhead obstacles or overhead electrical lines. Never move machine closer than 3 m (10 ft) plus twice the line insulator length to overhead wires. Contact With Gas Line

T139003 —UN—05MAR01

Keep bystanders clear at all times. Keep bystanders away from raised booms, attachments, and unsupported loads. Avoid swinging or raising booms, attachments, or loads over or near personnel. Use barricades or a signal person to keep vehicles and pedestrians away. Use a signal person if moving machine in congested areas or where visibility is restricted. Always keep signal person in view. Coordinate hand signals before starting machine. Operate only on solid footing with strength sufficient to support machine. Be especially alert working near embankments or excavations. Avoid working under over-hanging embankments or stockpiles that could collapse under or on machine.

Only on Solid Footing

Reduce machine speed when operating with tool on or near ground when obstacles may be hidden (e.g., during snow removal or clearing mud, dirt, etc.). At high speeds,

hitting obstacles (rocks, uneven concrete, or manholes) can cause a sudden stop. Always wear your seat belt. VD76477,000135C -19-07AUG15-1/1

Keep Riders Off Machine Only allow operator on machine.

T137580 —UN—22FEB01

Riders are subject to injury. They may fall from machine, be caught between machine parts, or be struck by foreign objects. Riders may obstruct operator’s view or impair the operator’s ability to operate machine safely.

Keep Riders Off Machine TX03768,0000B73 -19-03JUN15-1/1

TM14163X19 (15FEB18)

00-0001-12

450K, 550K, and 650K Crawler Dozer 021518 PN=20

Safety

Before moving machine, be sure that all persons are clear of machine path. Turn around and look directly for best visibility. Use mirrors to assist in checking all around machine. Keep windows and mirrors clean, adjusted, and in good repair. Be certain reverse warning alarm is working properly. Use a signal person when backing if view is obstructed or when in close quarters. Keep signal person in view at all times. Use prearranged hand signals to communicate.

PC10857XW —UN—15APR13

Avoid Backover Accidents

Do not rely on the rear camera and radar object detection systems, if equipped, to determine if personnel are behind the machine. The system has limitations due to maintenance practices, environmental conditions, and operating range. TX,AVOID,BACKOVER -19-04MAR16-1/1

TM14163X19 (15FEB18)

00-0001-13

450K, 550K, and 650K Crawler Dozer 021518 PN=21

Safety

Avoid Machine Tip Over and Machine Damage TX1165594 —19—23JUL14

Use seat belt at all times. Do not jump if the machine tips. You will be unlikely to jump clear and the machine may crush you. Load and unload from trucks or trailers carefully. Be sure truck is wide enough and secured on a firm level surface. Use loading ramps and attach them properly to truck bed. Avoid trucks with steel beds because tracks slip more easily on steel.

Use Seat Belt

T138416 —UN—22FEB01

Be careful on slopes. Use extra care on soft, rocky, or frozen ground because machine may slip sideways in these conditions. When traveling up or down steep slopes, keep the bucket or blade on uphill side and just above ground level. Ensure solid footing. Use extra care when operating on stockpile materials, or near banks or excavations that may cave-in and cause machine to tip or fall. Do Not Jump if Machine Tips

T138415 —UN—22FEB01

Avoid machine damage on slopes. Use extra care to operate machine.

TX1165684 —UN—17JUL14

Load and Unload From Trucks or Trailers Carefully

Be Careful on Slopes CN93077,0000342 -19-03JUN15-1/1

Use Special Care When Operating Never use the attachment to lift people. Do not allow anyone to ride on attachment or use it as a work platform.

Be careful when lifting loads. Never attempt to lift loads too heavy for machine. Ensure machine stability and hydraulic capability with a test lift before attempting other maneuvers. Keep bystanders away from raised loads.

Operate carefully with raised loads. Raising the load reduces machine stability, especially on side slopes or an unstable surface. Drive and turn slowly with a raised load. DB84312,00000CA -19-21JAN16-1/1

TM14163X19 (15FEB18)

00-0001-14

450K, 550K, and 650K Crawler Dozer 021518 PN=22

Safety

Inspect and Maintain ROPS

To maintain the ROPS:

A damaged rollover protective structure (ROPS) should be replaced, not reused.

• Replace missing hardware using correct grade

The protection offered by ROPS could be impaired if ROPS is subjected to structural damage, is involved in an overturn incident, or is in any way altered by welding, bending, drilling, or cutting.

• Check hardware torque. • Check isolation mounts for damage, looseness, or

hardware.

wear; replace them if necessary.

• Check ROPS for cracks or physical damage.

If ROPS was loosened or removed for any reason, inspect it carefully before operating the machine again. TX,ROPS -19-20JAN11-1/1

Travel Safely When working on steep slopes, travel as straight up and down as possible to prevent roll-over. T6964AD —UN—20DEC88

DO NOT PARK ON A HILLSIDE OR AN INCLINE. Always park the machine on level ground. Know the location of bystanders before moving the machine. Always keep the reverse/travel warning alarm in working condition. The alarm warns bystanders when the machine starts to move in reverse.

Travel Safely

Use a signal person when moving the machine in congested areas. Coordinate hand signals before starting the machine. KR46761,00010AB -19-27MAR17-1/1

TM14163X19 (15FEB18)

00-0001-15

450K, 550K, and 650K Crawler Dozer 021518 PN=23

Safety

Prevent Acid Burns Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. Avoid the hazard by: 1. 2. 3. 4. 5.

Filling batteries in a well-ventilated area. Wearing eye protection and rubber gloves. Avoiding breathing fumes when electrolyte is added. Avoiding spilling or dripping electrolyte. Use proper jump start procedure.

If you spill acid on yourself: 1. Flush your skin with water. 2. Apply baking soda or lime to help neutralize the acid. 3. Flush your eyes with water for 15—30 minutes. Get medical attention immediately. If acid is swallowed: TS203 —UN—23AUG88

1. Do not induce vomiting. 2. Drink large amounts of water or milk, but do not exceed 2 L (2 quarts). 3. Get medical attention immediately.

DX,POISON -19-21APR93-1/1

Add and Operate Attachments Safely Always verify compatibility of attachments by contacting your authorized dealer. Adding unapproved attachments could affect machine stability or reliability and could create a hazard for others near the machine. Ensure that a qualified person is involved in attachment installation. Add guards to machine if operator protection

is required or recommended. Verify that all connections are secure and attachment responds properly to controls. Carefully read attachment manual and follow all instructions and warnings. In an area free of bystanders and obstructions, carefully operate attachment to learn its characteristics and range of motion. TX,ATTACH -19-20JAN11-1/1

TM14163X19 (15FEB18)

00-0001-16

450K, 550K, and 650K Crawler Dozer 021518 PN=24

Safety

Park and Prepare for Service Safely Warn others of service work. Always park and prepare your machine for service or repair properly.

• Park machine on a level surface and lower blade and T133332 —19—17APR13

attachments to the ground.

• Place park lock lever(s) in “up” (locked) position. Stop engine.

• Attach a “Do Not Operate” tag in an obvious place in the operator's station.

Securely support machine or attachment before working under it.

• Do not support machine with blade or attachments. • Do not support machine with cinder blocks or wooden pieces that may crumble or crush.

• Do not support machine with a single jack or other devices that may slip out of place.

TS229 —UN—23AUG88

Understand service procedures before beginning repairs. Keep service area clean and dry. Use two people whenever the engine must be running for service work.

TX,PARK,CRW -19-30JAN12-1/1

Service Machines Safely

TS228 —UN—23AUG88

Tie long hair behind head. Do not wear a necktie, scarf, loose clothing, or necklace when working near machine tools or moving parts. If these items were to get caught, severe injury could result. Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.

Service Machines Safely KR46761,00011BA -19-28JUN16-1/1

Service Cooling System Safely

Do not service radiator through the radiator cap. Only fill through the surge tank filler cap. Shut off engine. Only remove surge tank filler cap when cool enough to touch with bare hands. Slowly loosen cap to relieve pressure before removing completely.

TS281 —UN—15APR13

Explosive release of fluids from pressurized cooling system can cause serious burns.

TX,SURGE -19-19JAN11-1/1

TM14163X19 (15FEB18)

00-0001-17

450K, 550K, and 650K Crawler Dozer 021518 PN=25

Safety

Remove Paint Before Welding or Heating Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. TS220 —UN—15APR13

Remove paint before heating:

• Remove paint a minimum of 100 mm (4 in.) from area

to be affected by heating. If paint cannot be removed, wear an approved respirator before heating or welding. • If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. • If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

Do not use a chlorinated solvent in areas where welding will take place.

Do all work in an area that is well ventilated to carry toxic fumes and dust away. Dispose of paint and solvent properly. DX,PAINT -19-24JUL02-1/1

Make Welding Repairs Safely T133547 —UN—15APR13

IMPORTANT: Disable electrical power before welding. Turn off main battery switch and disconnect positive (+) and negative (-) battery cables. Do not weld or apply heat on any part of a reservoir or tank that has contained oil or fuel. Heat from welding and cutting can cause oil, fuel, or cleaning solution to create gases which are explosive, flammable, or toxic. Heating Near Pressurized Fluid Lines

Avoid welding or heating near pressurized fluid lines. Flammable spray may result and cause severe burns if pressurized lines malfunction as a result of heating. Do not let heat go beyond work area to nearby pressurized lines.

Make sure there is good ventilation. Wear eye protection and protective equipment when welding.

Remove paint properly. Do not inhale paint dust or fumes. Use a qualified welding technician for structural repairs. KR46761,00010AD -19-22JAN16-1/1

Always wear protective goggles or safety glasses and other protective equipment before striking hardened parts. Hammering hardened metal parts such as pins and bucket teeth could dislodge chips at high velocity. Use a soft hammer or a brass bar between hammer and object to prevent chipping.

T133738 —UN—15APR13

Drive Metal Pins Safely

TX,PINS -19-20JAN11-1/1

TM14163X19 (15FEB18)

00-0001-18

450K, 550K, and 650K Crawler Dozer 021518 PN=26

Safety

Use Proper Lifting Equipment Lifting heavy components or attachments incorrectly can cause injury or machine damage.

TS226 —UN—23AUG88

Follow recommended procedure for removal and installation of components or attachments.

Proper Lifting Equipment KR46761,00011BB -19-28JUN16-1/1

TM14163X19 (15FEB18)

00-0001-19

450K, 550K, and 650K Crawler Dozer 021518 PN=27

Safety

During exhaust filter cleaning operations, the engine may run at elevated idle and hot temperatures for an extended period of time. Exhaust gases and exhaust filter components reach temperatures hot enough to burn people, or ignite or melt common materials. Keep machine away from people, animals, or structures which may be susceptible to harm or damage from hot exhaust gases or components. Avoid potential fire or explosion hazards from flammable materials and vapors near the exhaust. Keep exhaust outlet away from people and anything that can melt, burn, or explode.

TS227 —UN—15APR13

Clean Exhaust Filter Safely

Closely monitor machine and surrounding area for smoldering debris during and after exhaust filter cleaning.

Always make sure that engine is stopped while hauling machine on a truck or trailer. Contact with exhaust components while still hot can result in serious personal injury. Avoid contact with these components until cooled to safe temperatures.

TS271 —UN—23AUG88

Adding fuel while an engine is running can create a fire or explosion hazard. Always stop engine before refueling machine and clean up any spilled fuel.

If service procedure requires engine to be running:

• Only engage power-driven parts required by service procedure

and machine

Keep hands, feet, and clothing away from power-driven parts. Always disable movement (neutral), set the parking brake or mechanism and disconnect power to attachments or tools before leaving the operator’s station.

TS1693 —UN—09DEC09

• Ensure that other people are clear of operator station

TS1695 —UN—07DEC09

Shut off engine and remove key (if equipped) before leaving the machine unattended.

DX,EXHAUST,FILTER -19-12JAN11-1/1

TM14163X19 (15FEB18)

00-0001-20

450K, 550K, and 650K Crawler Dozer 021518 PN=28

Group 0003

Torque Values Metric Bolt and Cap Screw Torque Values

TORQ2 —UN—15APR13

METRIC BOLT AND CAP SCREW TORQUE VALUES—Tolerance is ±10% unless otherwise specified

Top—Property Class and Head Markings; Bottom—Property Class and Nut Markings Class 4.8

Class 8.8 or 9.8

Class 10.9

Class 12.9

Thread Size

Lubricateda

Dryb

Lubricateda

Dryb

Lubricateda

Dryb

Lubricateda

Dryb

N·m (lb·in)

4.7 (42)

6 (53)

9 (79)

11.5 (102)

13 (114)

16.5 (146)

15.5 (138)

19.5 (174)

N·m (lb·ft)

32 (23.5)

40 (29.5)

37 (27.5)

47 (35)

63 (46)

80 (59)

75 (55)

95 (70)

M8 M10

11.5 (102) 23 (204)

14.5 (128)

22 (192)

28 (246)

N·m (lb·ft)

29 (21)

43 (32)

55 (40)

N·m (lb·ft) M12

40 (29.5)

50 (37)

75 (55)

95 (70)

110 (80)

140 (105)

130 (95)

165 (120)

M14

63 (46)

80 (59)

120 (88)

150 (110)

175 (130)

220 (165)

205 (150)

260 (190)

M16

100 (74)

125 (92)

190 (140)

240 (175)

275 (200)

350 (255)

320 (235)

400 (300)

M18

135 (100)

170 (125)

265 (195)

330 (245)

375 (275)

475 (350)

440 (325)

560 (410)

M20

190 (140)

245 (180)

375 (275)

475 (350)

530 (390)

675 (500)

625 (460)

790 (580)

M22

265 (195)

330 (245)

510 (375)

650 (480)

725 (535)

920 (680)

850 (625)

1080 (800)

M24

330 (245)

425 (315)

650 (480)

820 (600)

920 (680)

1150 (850)

1080 (800)

1350 (1000)

M27

490 (360)

625 (460)

950 (700)

1200 (885)

1350 (1000)

1700 (1250)

1580 (1160)

2000 (1475)

M30

660 (490)

850 (625)

1290 (950)

1630 (1200)

1850 (1350)

2300 (1700)

2140 (1580)

2700 (2000)

M33

900 (665)

1150 (850)

1750 (1300)

2200 (1625)

2500 (1850)

3150 (2325)

2900 (2150)

3700 (2730)

M36

1150 (850)

1450 (1075)

2250 (1650)

2850 (2100)

3200 (2350)

4050 (3000)

3750 (2770)

4750 (3500)

“Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or M20 and larger fasteners with JDM F13C, F13F, or F13J zinc flake coating.

“Dry” means plain or zinc plated without any lubrication, or M6 to M18 fasteners with JDM F13B, F13E, or F13H zinc flake coating.

CAUTION: Use only metric tools on metric hardware. Other tools may not fit properly. Tool may slip and cause injury.

Fasteners should be replaced with the same or higher property class. If higher property class fasteners are used, these should only be tightened to the strength of the original.

Make sure fastener threads are clean and that the thread engagement is properly started. This will prevent fasteners from failing when tightening. DO NOT use these values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for Tighten plastic insert or crimped steel-type lock nuts to approximately general use only. Check tightness of fasteners periodically. 50 percent of the dry torque shown in the chart, applied to the nut, not to the bolt head. Tighten toothed or serrated-type lock nuts to the full Shear bolts are designed to fail under predetermined loads. Always torque value. replace shear bolts with identical property class. OUT3035,TORQUE2 -19-08MAR17-1/1

TM14163X19 (15FEB18)

00-0003-1

450K, 550K, and 650K Crawler Dozer 021518 PN=29

Torque Values

T6873AA —UN—15APR13

Additional Metric Cap Screw Torque Values CAUTION: Use only metric tools on metric hardware. Other tools may not fit properly. They may slip and cause injury. Check tightness of cap screws periodically. Torque values listed are for general use only. Do not use these values if a different torque value or tightening procedure is listed for a specific application.

T-Bolt

T6873AB —UN—18OCT88

Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade. Fasteners should be replaced with the same or higher grade. If higher grade fasteners are used, these should only be tightened to the strength of the original. Make sure fastener threads are clean and that the thread engagement is properly started. This will prevent fasteners from failing when tightening.

H-Bolt

T6873AC —UN—18OCT88

Tighten cap screws having lock nuts to approximately 50 percent of amount shown in chart. METRIC CAP SCREW TORQUE VALUESa T-Bolt

H-Bolt

M-Bolt

Nominal Diameter

N·m

lb·ft

N·m

lb·ft

N·m

108

176

130

137

101

265

195

206

152

392

289

294

217

118

539

398

392

289

167

125

735

542

539

398

216

159

931

687

686

506

274

202

1372

1012

1029

759

392

289

1911

1410

1421

1049

539

398

2548

1890

1911

1410

735

542

3136

2314

2401

1772

931

687

lb·ft M-Bolt

Torque tolerance is ±10%. TX,TORQ_METRIC2 -19-13APR16-1/1

TM14163X19 (15FEB18)

00-0003-2

450K, 550K, and 650K Crawler Dozer 021518 PN=30

Torque Values

Unified Inch Bolt and Cap Screw Torque Values

TORQ1A —UN—15APR13

UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUES—Tolerance is ±10% unless otherwise specified.

Top—SAE Grade and Head Markings; Bottom—SAE Grade and Nut Markings Grade 2a (No Mark)

Grade 1 (No Mark)

Grade 8 or 8.2

Lubricated

Dry

Lubricatedb

Dryc

Lubricatedb

Dryc

Lubricatedb

Dryc

N·m (lb·in)

1/4

3.8 (33)

4.7 (42)

6 (53)

7.5 (66)

9.5 (84)

12 (108)

13.5 (120)

17 (150)

N·m (lb·ft)

28 (20.5)

35 (26)

3/8 7/16

7.7 (68) 13.5 (120) 22 (192)

Grade 5, 5.1, or 5.2

Thread Size

5/16

9.8 (86)

12 (108)

15.5 (138)

17.5 (156)

22 (192)

27.5 (240)

N·m (lb·ft)

28 (20.5)

35 (26)

44 (32.5)

19.5 (174)

25 (222)

N·m (lb·ft)

35 (26)

44 (32.5)

49 (36)

63 (46)

56 (41)

70 (52)

80 (59)

100 (74)

N·m (lb·ft) 1/2

34 (25)

42 (31)

53 (39)

67 (49)

85 (63)

110 (80)

120 (88)

155 (115)

9/16

48 (35.5)

60 (45)

76 (56)

95 (70)

125 (92)

155 (115)

175 (130)

220 (165) 305 (225)

5/8

67 (49)

85 (63)

105 (77)

135 (100)

170 (125)

215 (160)

240 (175)

3/4

120 (88)

150 (110)

190 (140)

240 (175)

300 (220)

380 (280)

425 (315)

540 (400)

7/8

190 (140)

240 (175)

190 (140)

240 (175)

490 (360)

615 (455)

690 (510)

870 (640)

285 (210)

360 (265)

285 (210)

360 (265)

730 (540)

920 (680)

1030 (760)

1300 (960)

1-1/8

400 (300)

510 (375)

400 (300)

510 (375)

910 (670)

1150 (850)

1450 (1075)

1850 (1350)

1-1/4

570 (420)

725 (535)

570 (420)

725 (535)

1280 (945)

1630 (1200)

2050 (1500)

2600 (1920)

1-3/8

750 (550)

950 (700)

750 (550)

950 (700)

1700 (1250)

2140 (1580)

2700 (2000)

3400 (2500)

1-1/2

990 (730)

1250 (930)

990 (730)

1250 (930)

2250 (1650)

2850 (2100)

3600 (2650)

4550 (3350)

Grade 2 applies for hex cap screws (not hex bolts) up to 6 in (152 mm) long. Grade 1 applies for hex cap screws over 6 in (152 mm) long, and for all other types of bolts and screws of any length.

b "Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings, or 7/8 in and larger fasteners with JDM F13C, F13F, or F13J zinc flake coating. c

"Dry" means plain or zinc plated without any lubrication, or 1/4 to 3/4 in fasteners with JDM F13B, F13E, or F13H zinc flake coating.

DO NOT use these values if a different torque value or tightening Make sure fastener threads are clean and that the thread engagement is procedure is given for a specific application. Torque values listed are for properly started. This will prevent fasteners from failing when tightening. general use only. Check tightness of fasteners periodically. Tighten plastic insert or crimped steel-type lock nuts to approximately Shear bolts are designed to fail under predetermined loads. Always 50 percent of the dry torque shown in the chart, applied to the nut, not replace shear bolts with identical grade. to the bolt head. Tighten toothed or serrated-type lock nuts to the full torque value. Fasteners should be replaced with the same or higher grade. If higher grade fasteners are used, these should only be tightened to the strength of the original. OUT3035,TORQUE1 -19-08MAR17-1/1

TM14163X19 (15FEB18)

00-0003-3

450K, 550K, and 650K Crawler Dozer 021518 PN=31

Torque Values

Service Recommendations for 37° Flare and 30° Cone Seat Connectors 1. Inspect flare and flare seat. They must be free of dirt or obvious defects. T6234AC —UN—15APR13

2. Defects in tube flare cannot be repaired. Overtightening a defective flared fitting will not stop leaks. 3. Align tube with fitting before attempting to start nut. 4. Lubricate male threads with hydraulic fluid or petroleum jelly. Cone Seat Connector

5. Index angle fittings and tighten by hand. 6. Tighten fitting or nut to torque value shown on torque chart. Do not allow hoses to twist when tightening fittings.

STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART Thread Size

N·m

3/8 - 24 UNF

lb·ft 6

7/16 - 20 UNF

1/2 - 20 UNF

9/16 - 18 UNF

3/4 - 16 UNF

7/8 - 14 UNF

1-1/16 - 12 UN

102

1-3/16 - 12 UN

122

1-5/16 - 12 UN

142

105

1-5/8 - 12

190

140

1-7/8 - 12 UN

217

160

NOTE: Torque tolerance is ± 10%. TX,TORQ_FLARE1 -19-13APR16-1/1

Service Recommendations for O-Ring Boss Fittings Straight Fitting T6243AE —UN—15APR13

1. Inspect O-ring boss seat for dirt or defects. 2. Lubricate O-ring with petroleum jelly. Place electrical tape over threads to protect O-ring. Slide O-ring over tape and into O-ring groove of fitting. Remove tape. 3. Tighten fitting to torque value shown on chart. Straight Fitting Continued on next page

TM14163X19 (15FEB18)

00-0003-4

TX,TORQ_ORB1 -19-13APR16-1/2

450K, 550K, and 650K Crawler Dozer 021518 PN=32

Torque Values Angle Fitting 1. Back off lock nut (A) and backup washer (B) completely to head end (C) of fitting. T6520AB —UN—15APR13

2. Turn fitting into threaded boss until backup washer contacts face of boss. 3. Turn fitting head end counterclockwise to proper index (maximum of one turn). NOTE: Do not allow hoses to twist when tightening fittings. 4. Hold fitting head end with a wrench and tighten locknut and backup washer to proper torque value.

Angle Fitting

STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART N·m

lb·ft

3/8-24 UNF

Thread Size

7/16-20 UNF

1/2-20 UNF

9/16-18 UNF

3/4-16 UNF

7/8-14 UNF

1-1/16-12 UN

102

1-3/16-12 UN

122

1-5/16-12 UN

142

105

1-5/8-12 UN

190

140

1-7/8-12 UN

217

160

A—Lock Nut B—Backup Washer

C—Head End

NOTE: Torque tolerance is ± 10%. TX,TORQ_ORB1 -19-13APR16-2/2

TM14163X19 (15FEB18)

00-0003-5

450K, 550K, and 650K Crawler Dozer 021518 PN=33

Torque Values

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

T196315 —UN—17NOV03

O-RING BOSS STRAIGHT OR ADJUSTABLE FITTING STUD END NUT WITH METRIC THREAD IN ALUMINUM HOUSING TORQUE VALUES—Tolerance is ± 10% unless otherwise specified.

O-Ring Boss Straight and Adjustable Fittings 1— Straight Fitting 2— O-Ring

5— Hex Nut 6— Backup Washer

3— Stud End 4— Adjustable Fitting

Thread Size mm

Hex Nut Size mm

N·m (lb·ft)

M12 x 1.5

39 (29)

M14 x 1.5

39 (29)

M16 x 1.5

55 (41)

M22 x 1.5

75 (55)

M27 x 2

110 (81)

M30 x 2

141 (104)

M33 x 2

165 (122)

M38 x 2

165 (122)

M42 x 2

275 (203)

O-RING BOSS STRAIGHT OR ADJUSTABLE FITTING STUD END NUT WITH INCH THREAD IN ALUMINUM HOUSING TORQUE VALUES—Tolerance is ± 10% unless otherwise specified.

O-RING BOSS PLUG STUD END WITH INCH THREAD IN ALUMINUM HOUSING TORQUE VALUES—Tolerance is ± 10% unless otherwise specified.

Thread Size in

N·m (lb·ft)

Thread Size in

1/8

—

1/8

7.8 (5.80)

1/4

28 (20)

1/4

11.8 (8.70)

3/8

39 (29)

3/8

23 (17)

1/2

75 (55)

1/2

39 (29)

3/4

126 (93)

3/4

55 (41)

165 (122)

86 (64)

1-1/8

—

1-1/4

126 (93)

1-1/4

259 (191)

1-1/2

157 (116)

1-3/8

—

204 (150)

1-1/2

330 (243)

1-3/4

—

N·m (lb·ft)

1. Inspect fitting and O-ring boss sealing surfaces and the O-ring. They must be free of dirt, scratches, nicks, or burrs. O-ring must be free of dirt, cuts, cracks, swelling, or flatten condition. 2. Back the stud end hex nut (5) off as far as possible. Push backup washer (6) towards the nut to fully expose the turn down section of stud end. Washer must fit turned down section and not be too loose.

Continued on next page

TM14163X19 (15FEB18)

00-0003-6

OUT3035,0000353 -19-04MAR16-1/2

450K, 550K, and 650K Crawler Dozer 021518 PN=34

Torque Values

3. Wrap electrical tape over threads to protect O-ring. Slide O-ring over the tape into turned down section. Remove tape. Apply hydraulic oil to the threads of stud end, turned down section, and O-ring. 4. Turn fitting into the boss by hand until face of nut or backup washer squeezes O-ring into the seat and

contacts face of boss. Loosen an adjustable fitting no more than one turn for alignment. 5. Tighten straight fitting or hex nut to the torque value given. Hold body of adjustable fitting using a second wrench when tightening hex nut. OUT3035,0000353 -19-04MAR16-2/2

Service Recommendations for Flared Connections—Straight or Tapered Threads 1. Inspect flare and flare seat. They must be free of dirt or obvious defects. T6873AE —UN—15APR13

2. Defects in the tube flare cannot be repaired. Overtightening a defective flared fitting will not stop leaks. 3. Align the tube with the fitting before attempting to start the nut. 4. Lubricate the male threads with hydraulic fluid or petroleum jelly.

Straight Thread

5. Index angle fittings and tighten by hand. 6. Tighten fitting or nut to torque value shown on the chart. Do not allow hoses to twist when tightening fittings. Straight Thread b

Tapered Thread

Thread Size

N·m

lb·ft

N·m

lb·ft

1/8

1/4

3/8

1/2

3/4

176

130

157

116

343

253

1-1/2

196

145

539

398

255

188

588

434

T6873AD —UN—15APR13

TORQUE CHARTa

Tapered Thread

Torque tolerance is ±10%. b With seat face.

NOTE: If female thread is cast iron (control valves, brake valves motors, etc.), torque must be reduced approximately 10%. TX,TORQ_FLARE2 -19-13APR16-1/1

TM14163X19 (15FEB18)

00-0003-7

450K, 550K, and 650K Crawler Dozer 021518 PN=35

Torque Values

Service Recommendations for Flat Face O-Ring Seal Fittings

4. Tighten fitting or nut to torque value shown on the chart. Do not allow hoses to twist when tightening fittings, use backup wrench on straight hose couplings.

1. Inspect the fitting sealing surfaces and O-ring. They must be free of dirt or defects.

IMPORTANT: Tighten fittings to 150% of listed torque value if indexing is necessary or if fitting is attached to an actuating devise.

2. Lubricate O-rings and install into grove using petroleum jelly to hold in place.

Tighten fittings to 50% of listed torque value if used in aluminum housing.

3. Index angle fittings and tighten by hand pressing joint together to ensure O-ring remains in place.

FLAT FACE O-RING SEAL FITTING TORQUE* Nominal Tube OD mm in

Thread Size

Bulkhead Nut

Swivel Nut

N·m

lb·ft

N·m

lb·ft

6.35

0.250

9/16-18

9.52

0.375

11/16-16

12.70

0.500

13/16-16

15.88

0.625

1-14

19.05

0.750

1-3/16-12

102

22.22

0.875

1-3/16-12

102

25.40

1.000

1-7/16-12

142

105

142

105

31.75

1.250

1-11/16-12

190

140

190

140

38.10

1.500

2-12

217

160

217

160

*Torque tolerance is +15 -20% unless otherwise specified. Stud End O-ring Seal Torque for Straight and Adjustable Fittings* Thread Size

Straight Hex Size

Locknut Hex Size

Straight Fitting or Locknut Toque N·m

3/8-24

5/8

9/16

7/16-20

5/8

1/2-20

3/4

11/16

9/16-18

3/4

25 55

lb·ft

3/4-16

7/8

15/16

7/8-14

1-1/16

104

1-1/16-12

1-1/4

1-3/8

176

130

1-3/16-12

1-3/8

1-1/2

230

170

1-5/16-12

1-1/2

1-5/8

285

210

*Torque tolerance is +15 -20% unless otherwise specified. OUO6092,00010A4 -19-04MAR16-1/1

TM14163X19 (15FEB18)

00-0003-8

450K, 550K, and 650K Crawler Dozer 021518 PN=36

Torque Values

O-Ring Face Seal Fittings With SAE Inch Hex Nut and Stud End for High-Pressure Service Recommendations O-RING FACE SEAL FITTINGS WITH SAE INCH HEX NUT AND STUD END FOR HIGH-PRESSURE, ABOVE 27 600 kPa (276 bar) (4000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified.

H70406 —UN—15APR13

G E F

H F E

O-Ring Face Seal Fittings A—90° Swivel Elbow and Tube Nut B—90° Adjustable Stud Elbow

C—Stud Straight and Tube Nut D—Bulkhead Union and Nut

Nominal Tube OD or Hose ID

E—Stud End F— Tube Nut G—Swivel Nut H—Hex Nut Bulkhead Nut

O-Ring Face Seal Hose or Tube Swivel Nut

Inch Tube OD or Hose ID

Thread Size

Hex Size

Torque

Hex Size

Torque

in —

N·m (lb·ft) —

in —

N·m (lb·ft) —

9/16-18 —

11/16 —

24 (18) —

13/16 —

32 (24) —

Metric Tube OD mm

Dash Size

mm (in)

-3

4.78 (0.188)

-4

6.35 (0.250)

-5

7.92 (0.312)

-6

9.53 (0.375)

11/16-16

13/16

37 (27)

42 (31)

-8

12.70 (0.500)

13/16-16

15/16

75 (55)

1-1/8

93 (69)

-10

15.88 (0.625)

1-14

1-1/8

103 (76)

1-5/16

118 (87)

-12

19.05 (0.750)

1-3/16-12

152 (112)

-14

22.23 (0.875)

1-3/16-12

152 (112)

1-1/2 —

175 (129)

1-3/8 —

-16

25.40 (1.000)

1-7/16-12

1-5/8

214 (158)

1-3/4

247 (182)

-20

31.75 (1.250)

1-11/16-12

1-7/8

286 (211)

328 (242)

-24

38.10 (1.500)

2-12

2-1/4

326 (240)

2-3/8

374 (276)

175 (129)

O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH SAE INCH STUD END FOR HIGH PRESSURE, ABOVE 27 600 kPa (276 bar) (4000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified. Thread Size

Straight Hex Sizea

Adjustable Nut Hex Size

Steel or Gray Iron Torque

N·m (lb·ft)

3/8-24

5/8

9/16

18 (13)

7/16-20

5/8

24 (18)

1/2-20

3/4

11/16

30 (22)

9/16-18

3/4

37 (27)

3/4-16

7/8

15/16

75 (55)

7/8-14

1-1/16

103 (76)

1-1/16-12

1-1/4

1-3/8

177 (131)

1-3/16-12

1-3/8

1-1/2

231 (170)

1-5/16-12

1-1/2

1-5/8

270 (199)

1-5/8-12

1-3/4

1-7/8

286 (211)

1-7/8-12

2-1/8

326 (240)

Straight hex size applies to fittings only and may not be the same as the corresponding plug of the same thread size.

1. Inspect fitting and connector sealing surfaces and the O-rings. They must be free of dirt, scratches, nicks,

and burrs. O-ring must be free of dirt, cuts, cracks, swelling, or flatten condition.

Continued on next page

TM14163X19 (15FEB18)

00-0003-9

OUT3035,0000420 -19-04MAR16-1/2

450K, 550K, and 650K Crawler Dozer 021518 PN=37

Torque Values

2. Back the stud end hex nut off as far as possible. Push backup washer towards the nut to fully expose the turn down section. Washer must fit turned down section and not be too loose.

4. Turn fitting into the boss by hand until face of nut or washer squeezes the O-ring into the seat and contacts face of boss. Loosen adjustable fittings no more than one turn for alignment.

3. Lubricate O-rings using a thin film of clean hydraulic oil or as needed, petroleum jelly to hold O-ring in place.

Hold connections together while tightening nut to ensure O-ring remains in place.

Install O-ring into groove making sure it is seated at the bottom. Excess petroleum jelly will prevent seating of O-ring and cause it to pop out.

5. Tighten fitting or nut to torque value shown. Use a second wrench to hold the fitting in position or to keep hose from twisting while tightening nut.

To protect an O-ring from threads, wrap electrical tape over the threads. Slide O-ring over the tape into the turned down section. Remove the tape. OUT3035,0000420 -19-04MAR16-2/2

TM14163X19 (15FEB18)

00-0003-10

450K, 550K, and 650K Crawler Dozer 021518 PN=38

Torque Values

O-Ring Face Seal Fittings With Metric Hex Nut and Stud End for Standard Pressure Service Recommendations O-RING FACE SEAL AND FITTINGS WITH METRIC HEX NUT AND STUD END FOR STANDARD PRESSURE, BELOW 27 600 kPa (275.8 bar) (4000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified.

T196337 —UN—15APR13

T196337

O-Ring Face Seal Fittings 1— 90° Swivel Elbow 2— 90° Adjustable Stud Elbow 3— Stud Straight

4— Bulkhead Union and Nut 5— External Hex Stud End Plug

Nominal Tube OD or Hose ID Metric Tube OD mm

Inch Tube OD or Hose ID

6— Tube Nut 7— Swivel Nut 8— Stud End 9— Hex Nut 10— O-Ring

11— Identification Groove

Bulkhead Nut

O-Ring Face Seal Hose or Tube Swivel Nut Thread Size

Hex Size

Torque

Hex Size

Torque

N·m (lb·ft) —

—

N·m (lb·ft) —

-2

3.18 (0.125)

in —

-3

4.78 (0.188)

—

-4

6.35 (0.250)

-5

7.92 (0.312)

9/16-18 —

17 —

16 (12) —

22 —

32 (24) —

-6

9.53 (0.375)

11/16-16

24 (18)

42 (31)

-8

12.70 (0.500)

13/16-16

50 (37)

93 (69)

-10

15.88 (0.625

1-14

69 (51)

118 (87)

-12

19.05 (0.750)

1-3/16-12

102 (75)

175 (129)

-14

22.23 (0.875)

1-3/16-12

102 (75)

175 (129)

25 28

-16 —

25.40 (1.000) —

1-7/16-12 —

41 —

142 (105) —

46 —

247 (182) —

-20

31.75 (1.250)

1-11/16-12

190 (140)

328 (242)

-24

38.10 (1.500)

-32

50.80 (2.000)

2-12 —

60 —

217 (160) —

60 —

374 (276) —

Dash Size

mm (in)

O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH METRIC STUD END FOR STANDARD PRESSURE, BELOW 27 600 kPa (275.8 bar) (4000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified. Thread Sizea mm

Straight Hex Sizeb mm

Adjustable Nut Hex Size mm

Steel or Gray Iron Torque

Aluminum or Brass Torque

N·m (lb·ft)

M8 x 1

8 (6)

5 (4)

M10 x 1

15 (11)

10 (7)

M12 x 1.5

25 (18)

17 (12)

M14 x 1.5

40 (30)

27 (20)

M16 x 1.5

45 (33)

30 (22)

M18 x 1.5

50 (37)

33 (25)

M22 x 1.5

69 (51)

46 (34)

M27 x 2

100 (74)

67 (49)

M30 x 2

130 (96)

87 (64)

M33 x 2

160 (118)

107 (79)

Continued on next page

TM14163X19 (15FEB18)

00-0003-11

OUT3035,0000366 -19-04MAR16-1/2

450K, 550K, and 650K Crawler Dozer 021518 PN=39

Torque Values O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH METRIC STUD END FOR STANDARD PRESSURE, BELOW 27 600 kPa (275.8 bar) (4000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified. Thread Sizea mm

Straight Hex Sizeb mm

Adjustable Nut Hex Size mm

Steel or Gray Iron Torque

Aluminum or Brass Torque

N·m (lb·ft)

M38 x 2

176 (130)

117 (87)

M42 x 2

210 (155)

140 (103)

M48 x 2

260 (192)

173 (128)

M60 x 2

315 (232)

210 (155)

Stud end threads are identified as metric by an identification groove in the hex nut next to the O-ring.

Straight hex size applies to fittings only and may not be the same as the corresponding plug of the same thread size.

1. Inspect fitting and connector sealing surfaces and the O-rings. They must be free of dirt, scratches, nicks, and burrs. O-ring must be free of dirt, cuts, cracks, swelling, or flatten condition. 2. Back the stud end hex nut off as far as possible. Push backup washer towards the nut to fully expose the turn down section. Washer must fit turned down section and not be too loose.

To protect an O-ring from threads, wrap electrical tape over the threads. Slide O-ring over the tape into the turned down section. Remove the tape. 4. Turn fitting into the boss by hand until face of nut or washer squeezes the O-ring into the seat and contacts face of boss. Loosen adjustable fittings no more than one turn for alignment. Hold connections together while tightening nut to ensure O-ring remains in place.

3. Lubricate O-rings using a thin film of clean hydraulic oil or as needed, petroleum jelly to hold O-ring in place. Install O-ring into groove making sure it is seated at the bottom. Excess petroleum jelly will prevent seating of O-ring and cause it to pop out.

5. Tighten fitting or nut to torque value shown. Use a second wrench to hold the fitting in position or to keep hose from twisting while tightening nut. OUT3035,0000366 -19-04MAR16-2/2

TM14163X19 (15FEB18)

00-0003-12

450K, 550K, and 650K Crawler Dozer 021518 PN=40

Torque Values

O-Ring Face Seal Fittings With Metric Hex Nut and Stud End for High-Pressure Service Recommendations O-RING FACE SEAL FITTINGS WITH METRIC HEX NUT AND STUD END FOR HIGH-PRESSURE, ABOVE 27 600 kPa (275.8 bar) (4000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified.

T196337 —UN—15APR13

10 T196337

O-Ring Face Seal Fittings 1— 90° Swivel Elbow 2— 90° Adjustable Stud Elbow 3— Stud Straight

4— Bulkhead Union and Nut 5— External Hex Stud End Plug

Nominal Tube OD or Hose ID

6— Tube Nut 7— Swivel Nut 8— Stud End 9— Hex Nut 10— O-Ring

11— Identification Groove

Bulkhead Nut

O-Ring Face Seal Hose or Tube Swivel Nut

Inch Tube OD or Hose ID

Thread Size

Torque

Hex Size mm

Torque

Metric Tube OD mm

Hex Size mm

Dash Size

mm (in)

-2

3.18 (0.125)

in —

—

N·m (lb·ft) —

—

N·m (lb·ft) —

—

17 —

24 (18) —

22 —

32 (24) —

-3

4.78 (0.188)

—

-4

6.35 (0.250)

-5

7.92 (0.312)

9/16-18 —

-6

9.53 (0.375)

11/16-16

37 (27)

42 (31)

-8

12.70 (0.500)

13/16-16

75 (55)

93 (69)

-10

15.88 (0.625)

1-14

103 (76)

118 (87)

-12

19.05 (0.750)

1-3/16-12

152 (112)

175 (129)

-14

22.23 (0.875)

1-3/16-12

152 (112)

175 (129)

25 28

-16 —

25.40 (1.000) —

1-7/16-12 —

41 —

214 (158) —

46 —

247 (182) —

-20

31.75 (1.250)

1-11/16-12

—

286 (211)

328 (242)

-24

38.10 (1.500)

2-12

—

326 (240)

374 (276)

O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH METRIC STUD END FOR HIGH PRESSURE, ABOVE 27 600 kPa (275.8 bar) (4000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified. Thread Sizea mm

Straight Hex Sizeb mm

Adjustable Nut Hex Size mm

M8 x 1

8 (6)

M10 x 1

15 (11)

M12 x 1.5

35 (26)

M14 x 1.5

45 (33)

M16 x 1.5

55 (41)

M18 x 1.5

70 (52)

M22 x 1.5

100 (74)

M27 x 2

170 (125)

M30 x 2

215 159)

M33 x 2

260 (192)

M38 x 2

320 (236)

M42 x 2

360 (266)

Continued on next page

TM14163X19 (15FEB18)

00-0003-13

Steel or Gray Iron Torque N·m (lb·ft)

OUT3035,0000421 -19-04MAR16-1/2

450K, 550K, and 650K Crawler Dozer 021518 PN=41

Torque Values O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH METRIC STUD END FOR HIGH PRESSURE, ABOVE 27 600 kPa (275.8 bar) (4000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified. Thread Sizea mm

Straight Hex Sizeb mm

Adjustable Nut Hex Size mm

Steel or Gray Iron Torque

M48 x 2

420 (310)

N·m (lb·ft)

Stud end threads are identified as metric by an identification groove in the hex nut next to the O-ring.

Straight hex size applies to fittings only and may not be the same as the corresponding plug of the same thread size.

5. Tighten fitting or nut to torque value shown. Use a second wrench to hold the fitting in position or to keep hose from twisting while tightening nut. OUT3035,0000421 -19-04MAR16-2/2

TM14163X19 (15FEB18)

00-0003-14

450K, 550K, and 650K Crawler Dozer 021518 PN=42

Torque Values

T6890BB —UN—15APR13

Service Recommendations for Metric Series Four Bolt Flange Fitting

Metric Series Four Bolt Flange Fitting A—Sealing Surface B—Split Flange

C—Pinched O-Ring D—Single Piece Flange

1. Clean sealing surfaces (A). Inspect. Scratches cause leaks. Roughness causes seal wear. Out-of-flat causes seal extrusion. If defects cannot be polished out, replace component.

DO NOT use air wrenches. DO NOT tighten one cap screw fully before tightening the others. DO NOT over tighten. TORQUE CHARTa

2. Install the correct O-ring (and backup washer if required) into groove using petroleum jelly to hold it in place.

3. Split flange: Loosely assemble split flange (B) halves. Make sure split is centrally located and perpendicular to the port. Hand tighten cap screws to hold parts in place. Do not pinch O-ring (C). 4. Single piece flange (D): Place hydraulic line in center of flange and install four cap screws. Flange must be centrally located on port. Hand tighten cap screws to hold flange in place. Do not pinch O-ring. 5. After components are properly positioned and cap screws are hand tightened, tighten one cap screw, then tighten the diagonally opposite cap screw. Tighten two remaining cap screws. Tighten all cap screws as specified in the chart below.

Thread

N·m

lb·ft 9

M10

M12

M14

157

116

M16

217

160

M18

334

246

M20

421

318

Tolerance ± 10%. The torques given are enough for the given size connection with the recommended working pressure. Increasing cap screw torque beyond these amounts will result in flange and cap screw bending and connection failures. b Metric standard thread.

TX,TORQ_FLANGE1 -19-13APR16-1/1

TM14163X19 (15FEB18)

00-0003-15

450K, 550K, and 650K Crawler Dozer 021518 PN=43

Torque Values

T6890BB —UN—15APR13

Service Recommendations For Inch Series Four Bolt Flange Fittings

Flange Fittings A—Sealing Surface B—Split Flange

C—Pinched O-Ring D—Single Piece Flange

1. Clean sealing surfaces (A). Inspect. Scratches cause leaks. Roughness causes seal wear. Out-of-flat causes seal extrusion. If defects cannot be polished out, replace component.

TORQUE CHART N·m

lb·ft

Nominal Flange Size

Cap Screw Size Min

Max

Min

Max

1/2

5/16-18 UNC

3/4

3/8-16 UNC

1-1/4

7/16-14 UNC

1-1/2

1/2-13 UNC

131

1/2-13 UNC

131

4. Single piece flange (D): Place hydraulic line in center of flange and install cap screws. Flange must be centrally located on port. Hand tighten cap screws to hold flange in place. Do not pinch O-ring.

2-1/2

1/2-13 UNC

107

131

5/8-11 UNC

158

264

117

195

3-1/2

5/8-11 UNC

158

264

117

195

5/8-11 UNC

158

264

117

195

5. Tighten one cap screw, then tighten the diagonally opposite cap screw. Tighten two remaining cap screws. Tighten all cap screws as specified in the chart below.

5/8-11 UNC

158

264

117

195

2. Install O-ring (and backup washer if required) into groove using petroleum jelly to hold it in place. 3. Split flange: Loosely assemble split flange (B) halves. Make sure split is centrally located and perpendicular to port. Hand tighten cap screws to hold parts in place. Do not pinch O-ring (C).

DO NOT use air wrenches. DO NOT tighten one cap screw fully before tightening the others. DO NOT over tighten. TX,TORQ_FLANGE2 -19-13APR16-1/1

TM14163X19 (15FEB18)

00-0003-16

450K, 550K, and 650K Crawler Dozer 021518 PN=44

Torque Values

T6890BB —UN—15APR13

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

Four Bolt Flange Fittings A—Sealing Surface B—Split Flange

C—Pinched O-Ring D—Single Piece Flange

If imperfection cannot be polished out, replace component.

INCH SERIES FOUR BOLT FLANGE FITTING FOR 41 400 kPa (414 bar) (6000 psi) PRESSURE SERIES TORQUE VALUES—Tolerance is ± 10% unless otherwise specified. Nominal Flange Size

Cap Screw Sizea

Min—Max Torque

N·m (lb·ft)b

1/2

5/16-18 UNC

20—31 (15—23)

3/4

3/8-16 UNC

34—54 (25—40)

7/16-14 UNC

57—85 (42—63)

1-1/4

1/2-13 UNC

85—131 (63—97)

1-1/2

5/8-11 UNC

159—264 (117—195)

3/4-10 UNC

271—468 (200—345)

JDM A17D, SAE Grade 5 or better cap screws with plated hardware. Lock washers are permissible but not recommended.

2. Install the O-ring (and backup ring, if used) into groove. Use petroleum jelly to hold it in place. IMPORTANT: DO NOT use air wrenches. DO NOT tighten one cap screw fully before tightening the others. DO NOT over tighten. 3. Split flange: Loosely assemble split flange (B) halves. Make sure split is centrally located and perpendicular to port. Hand tighten cap screws to hold flange halves and line in place. Do not pinch O-ring (C). Single piece flange (D): Make sure flange is centrally located on port and line is centered in flange. Install the cap screws. Hand tighten cap screws to hold flange and line in place. Do not pinch O-ring.

Minimum torques given are enough for the given size connection with the recommended working pressure. Torques can be increased to the maximum shown for each cap screw size if desired. Increasing cap screw torque beyond the maximum will result in flange and cap screw bending and connection failures.

1. Clean sealing surfaces (A). Inspect. Scratches, nicks, and burrs cause leaks. Roughness causes O-ring wear. Out-of-flat causes O-ring extrusion.

4. Tighten one cap screw and then the diagonally opposite cap screw. Tighten the two remaining cap screws. Tighten cap screws within the specified torque values. OUT3035,0000422 -19-04MAR16-1/1

TM14163X19 (15FEB18)

00-0003-17

450K, 550K, and 650K Crawler Dozer 021518 PN=45

Torque Values

Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings 1. Inspect all fitting sealing surfaces. They must be free of dirt and defects. 2. Inspect O-ring (A). It must be free of damage or defects. 3. Inspect sealing ring (B) for damage or defects. 4. Hold body in desired position while tightening stud by hand. 5. Tighten stud (C) to torque value shown on the chart. Do not allow body to twist when tightening stud. T113948 —UN—06MAR98

NOTE: The L in the Tube Fitting OD Size column indicates “light” designed fitting and the S indicates “heavy” designed fitting. Torque Value Tube Fitting O.D. Size

Metric Thread

N·m

lb·ft

6 L

M10 x 1

8 L

M12 x 1.5

10 L

M14 x 1.5

12 L

M16 x 1.5

100

15 L

M18 x 1.5

130

18 L

M22 x 1.5

22 L

M26 x 1.5

28 L

Non-Restricted Banjo Fitting Torque Value Inch Size

N·m

lb·ft

Tube Fitting O.D. Size

160

118

6 L

1/8

250

184

8 L

1/4

M33 x 2

400

295

10 L

1/4

35 L

M42 x 2

600

443

12 L

3/8

42 L

M48 x 2

800

590

15 L

1/2

130

6 S

M12 x 1.5

18 L

1/2

150

111

8 S

M14 x 1.5

22 L

3/4

250

184

400

295

10 S

M16 x 1.5

100

28 L

12 S

M18 x 1.5

130

35 L

1-1/4

600

443

118

42 L

1-1/2

800

590

118

6 S

1/4

184

8 S

1/4

3/8

100

14 S

1/2

130

16 S

1/2

150

111

20 S

3/4

250

184

25 S

400

295

30 S

1-1/4

600

443

38 S

1-1/2

800

590

14 S 16 S 20 S

M20 x 1.5 M22 x 1.5 M27 x 2

160 160 250

25 S

M33 x 2

400

295

10 S

30 S

M42 x 2

600

443

12 S

38 S

M48 x 2

800

590

TX,TORQ_BANJO -19-13APR16-1/1

TM14163X19 (15FEB18)

00-0003-18

450K, 550K, and 650K Crawler Dozer 021518 PN=46

Torque Values

Service Recommendations For O-Ring Boss Fittings With Shoulder 1. Inspect component seal boss seat for dirt or defects. T113957 —UN—06MAR98

2. Inspect EOlastic seal (A) for damage. Replace seal or fitting as necessary. To replace seal, put electrical tape over threads to protect seal. Slide seal over tape and into seal groove of fitting. Remove tape. 3. Tighten fitting to torque value shown on chart. IMPORTANT: Do not allow hoses to twist when tightening fittings. NOTE: The L in the Tube Fitting OD Size column indicates “light” designed fitting and the S indicates “heavy” designed fitting.

O-Ring Boss Fitting With Shoulder Torque Value Tube Fitting O.D. Size

Inch Size

N·m

lb·ft

6 L

1/8

Torque Value

8 L

1/4

N·m

10 L

1/4

12 L

3/8

59 103

Tube Fitting O.D. Size

Metric Thread

6 L

M10 x 1

15 L

1/2

140

1/2

100

74 133

lb·ft

8 L

M12 x 1.5

18 L

10 L

M14 x 1.5

22 L

3/4

180

12 L

M16 x 1.5

28 L

300

221

15 L

M18 x 1.5

35 L

1-1/4

600

443

18 L

M22 x 1.5

130

42 L

1-1/2

800

590

22 L

M26 x 1.5

190

140

6 S

1/4

28 L

M33 x 2

300

221

8 S

1/4

35 L

M42 x 2

600

443

10 S

3/8

42 L

M48 x 2

800

590

12 S

3/8

6 S

M12 x 1.5

14 S

1/2

160

118

8 S

M14 x 1.5

16 S

1/2

140

103

10 S

M16 x 1.5

20 S

3/4

250

184

12 S

M18 x 1.5

110

25 S

400

295

14 S

M20 x 1.5

140

103

30 S

1-1/4

650

479

16 S

M22 x 1.5

170

125

38 S

1-1/2

800

590

20 S

M27 x 2

250

184

25 S

M33 x 2

450

332

30 S

M42 x 2

600

443

38 S

M48 x 2

800

590

Continued on next page

TM14163X19 (15FEB18)

00-0003-19

TX,TORQ_ORB2 -19-13APR16-1/2

450K, 550K, and 650K Crawler Dozer 021518 PN=47

Torque Values Hex Socket Head Plugs Only Torque Value Thread Size

N·m

M10 x 1

M12 x 1.5

M14 x 1.5

M16 x 1.5

M18 x 1.5

M20 x 1.5

M22 x 1.5

100

M26 x 1.5

120

M27 x 2

150

111

M33 x 2

250

184

M42 x 2

400

295

M48 x 2

500

369

1/8

1/4

3/8

1/2

lb·ft

3/4

150

111

220

162

1-1/4

600

443

1-1/2

800

590 TX,TORQ_ORB2 -19-13APR16-2/2

TM14163X19 (15FEB18)

00-0003-20

450K, 550K, and 650K Crawler Dozer 021518 PN=48

Torque Values

Metric 24° O-Ring Seal DIN 20078 Service Recommendations METRIC 24° O-RING SEAL DIN 20078 TORQUE VALUES Fitting Tube OD Size mm

Heavy Fitting Size mm

Light Fitting Size mm

—

M12 x 1.5

M16 x 1.5

M14 x 1.5

M18 x 1.5

M16 x 1.5

M20 x 1.5

M22 x 1.5 —

M18 x 1.5 —

15 16 18 20 22 25 28 30

M24 x 1.5 — M30 x 2 — M36 x 2 —

M42 x 2 —

M52 x 2

M22 x 1.5 — M26 x 1.5 —

Torque Turns

Hand tighten so O-ring contacts seat plus an additional 1/4—1/3 turn using a wrench

M30 x 2 — M36 x 2 — M45 x 2 —

NOTE: These fittings are also referred to as EO and EO-2 Bite Type or Ermeto style fittings. T113889 —UN—15APR13

IMPORTANT: In this style of fittings, there are “heavy” and “light” designs. Usually “heavy” is used for pressure lines and “light” for return lines. Some “heavy” and “light” sizes can be threaded together but do not seal properly. Be sure not to mix “heavy” and “light” fittings. 1. Inspect the fitting sealing surfaces. They must be free of dirt scratches, nicks, and burrs.

Connection

2. Inspect the O-ring. It must be free dirt, cuts, cracks, swelling or flatten condition. 3. Lubricate O-rings using a thin film of clean hydraulic oil. 4. Align an adjustable fitting with the tube.

Hold connections together while tightening nut to ensure proper seal. 5. Tighten nut (A) hand tight so O-ring contacts seat and then an additional 1/4—1/3 turn using a wrench. TX,TORQ_ORS -19-13APR16-1/1

TM14163X19 (15FEB18)

00-0003-21

450K, 550K, and 650K Crawler Dozer 021518 PN=49

Torque Values

TM14163X19 (15FEB18)

00-0003-22

450K, 550K, and 650K Crawler Dozer 021518 PN=50

Contents

Section 01 Tracks

Page

Group 0130—Track System Welding On Machine ................................. 01-0130-1 Track Guides and Rock Guards Remove and Install................................ 01-0130-1 Carrier Roller Wear Inspection .................. 01-0130-4 Carrier Roller Remove and Install.............. 01-0130-4 Carrier Roller Disassemble and Assemble............................................... 01-0130-6 Metal Face Seals Inspection ..................... 01-0130-8 Carrier Roller Leakage Test..................... 01-0130-10 Track Roller Wear Inspection .................. 01-0130-11 Track Roller Remove and Install ............. 01-0130-12 Track Roller Disassemble and Assemble............................................. 01-0130-13 Track Roller Leakage Test....................... 01-0130-22 Track Shoe Grouser Wear Inspection ............................................ 01-0130-23 Track Shoe Remove and Install .............. 01-0130-24 Track Link Height Inspection ................... 01-0130-25 Bushing Outside Diameter for Lubricated Track Chain Inspection ............................................ 01-0130-26 Track Pitch for Lubricated Track Chain Inspection.................................. 01-0130-27 Lubricated Track Chain Remove and Install ............................................ 01-0130-28 Lubricated Track Chain to Turn Bushings and Lubricate Chain Disassemble and Assemble ................ 01-0130-32 Lubricated Track Chain to Turn Pins and Bushings and Not Lubricate Disassemble and Assemble ................ 01-0130-41 Track Sag Adjustment ............................. 01-0130-46 Front Idler Wear Inspection ..................... 01-0130-48 Front Idler Remove and Install ................ 01-0130-49 Front Idler Disassemble and Assemble............................................. 01-0130-50 Front Idler Adjustment ............................. 01-0130-57 Front Idler Oil Level Check ...................... 01-0130-58 Track Tension Adjuster Repair ................ 01-0130-59 Track Idler Recoil Spring Remove and Install ............................................ 01-0130-62 Track Idler Recoil Spring Disassemble and Assemble ................ 01-0130-63 Track Frame Remove and Install ............ 01-0130-67 Frame Wear Strips Remove and Install ................................................... 01-0130-68 Sprocket Remove and Install................... 01-0130-69

TM14163X19 (15FEB18)

01-1

450K, 550K, and 650K Crawler Dozer

021518

PN=1

Contents

TM14163X19 (15FEB18)

01-2

450K, 550K, and 650K Crawler Dozer

021518

PN=2

Group 0130

Track System Welding On Machine IMPORTANT: Disconnect battery ground strap or turn battery disconnect switch to OFF (if applicable). Disconnect both negative and positive battery cables and microprocessor unit (if applicable). IMPORTANT: Have only a qualified welder do this job. Connect welder ground clamp close to each weld area so electrical current does not pass through any bearings.

WELD METAL SPECIFICATIONS Item

Specification

Tensile Strength

482.6 MPa (70 000 psi)

Yield Strength

413.7 MPa (60 000 psi)

Elongation

22%

Use one of the following weld processes: • AWS-E-7018 covered electrode with shielded metal arc welding (SMAW) process. • AWS-ER-70S-3f wire electrode with gas metal arc welding (GMAW) process. • AWS-E70T-1 or E71T-1 wire electrode with flux core arc welding (FCAW) process.

Remove or protect all parts that can be damaged by heat or weld splatter.

TX,WELD,II -19-07OCT14-1/1

Track Guides and Rock Guards Remove and Install 530 N·m 390 lb·ft

Track Guide-to-Track Frame Cap Screw Torque

275 N·m 200 lb·ft

T133509 —UN—15APR13

SPECIFICATIONS Sprocket Guard-to-Track Frame Cap Screw Torque

Rock Guard Weight (approximate) 26 kg 57 lb Rock Guard-to-Track Frame Cap Screw Torque

275 N·m 200 lb·ft

Rock Guard Cap Screw Nut Torque 530 N·m 390 lb·ft

High-Pressure Fluid

SERVICE EQUIPMENT AND TOOLS

1. Release track tension. See Track Sag Adjustment. (Group 0130.)

D01182AA 20-Ton Floor Stands (4 used) OTHER MATERIAL

CAUTION: Prevent possible injury from unexpected track movement. Raise the machine off the ground and support with 20-ton floor stands. Tracks MUST be free to rotate in either direction.

Loctite® 271™ Threadlocker (high strength)

Track Guides Remove and Install CAUTION: High-pressure release of oil from pressurized system can cause serious burns or penetrating injury. DO NOT remove grease fitting to increase track sag. DO NOT tamper with relief valve. It is fitted with a cover. Slowly loosen check valve fitting to release grease from track tension adjuster.

2. Raise machine off the ground and support with D01182AA 20-Ton Floor Stands. Lower blade to ground. Tracks must be free to rotate in either direction.

Loctite and its related brand marks are trademarks of Henkel Corporation Continued on next page

TM14163X19 (15FEB18)

01-0130-1

BS40810,0000225 -19-09FEB17-1/4

450K, 550K, and 650K Crawler Dozer 021518 PN=53

Track System

1 2

6 7

3 9

9 10 TX1111444

TX1111444 —UN—05APR12

8 5

Rear Track Guide and Guard 1— Cap Screw (4 used) 2— Washer (4 used) 3— Cap Screw (4 used) 4— Washer (8 used)

5— Nut (4 used) 8— Cap Screw (12 used) 6— Sprocket Guard (left, 2 used) 9— Washer (16 used) 7— Sprocket Guard (right, 2 used) 10— Nut (4 used) 11— Rock Guard (right, 2 used)

3. Remove track frame covers to access sprocket guards (6 and 7). 4. Remove cap screws (1 and 8), and washers (2 and 9), and sprocket guards (6 and 7).

5. Remove cap screws (3 and 8), washers (4 and 9), and nut (5) to remove rear rock guards (11 and 13). When removing rock guards, spacer (12) will be taken out when cap screw (3) is removed.

Continued on next page

TM14163X19 (15FEB18)

12— Spacer (4 used) 13— Rock Guard (left, 2 used)

01-0130-2

BS40810,0000225 -19-09FEB17-2/4

450K, 550K, and 650K Crawler Dozer 021518 PN=54

Track System

6. Remove cap screws (8) and washers (9). Remove center track guides (14).

8. Apply Loctite® 271™ Threadlocker (high strength) to cap screws.

9. Install sprocket guards, washers, and cap screws (1). Tighten cap screws to specification.

TX1112123 —UN—11APR12

7. Inspect track guides and sprocket guards for wear and damage. Repair or replace as necessary.

Specification Sprocket Guard-toTrack Frame Cap Screw—Torque............................................................................530 N·m 390 lb·ft

Center Track Guide 8— Cap Screw (8 used) 9— Washer (8 used)

10. Install track guides, washers, and cap screws (8). Tighten cap screws to specification. Specification Track Guide-to-Track Frame Cap Screw—Torque............................................................................275 N·m 200 lb·ft

14— Center Track Guide (2 used)

11. Adjust track sag. See Track Sag Adjustment. (Group 0130.)

Loctite and its related brand marks are trademarks of Henkel Corporation BS40810,0000225 -19-09FEB17-3/4

Rock Guards Remove and Install

REMOVAL

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

T209074 —UN—03MAR05

10 4

1. Attach appropriate lifting device to rock guards (1 and 2).

Specification

Rock Guard—Weight (approximate).................................................................................. 26 kg 57 lb

Rock Guards

2. Remove components (1, 2, 4—6, and 8—10). 3. Inspect rock guards (1 and 2) for wear or damage. Repair or replace parts as necessary.

1— Rock Guard (2 used) 2— Rock Guard (2 used) 4— Cap Screw (standard track, 10 used; long track, 12 used) 5— Spacer (standard track, 10 used; long track, 12 used)

INSTALLATION Installation is reverse of removal procedure.

• Apply Loctite® 271™ Threadlocker (high strength) to

6— Nut (standard track, 10 used; long track, 12 used) 8— Cap Screw (standard track, 12 used; long track, 14 used) 9— Washer (standard track, 16 used; long track, 18 used) 10— Cap Screw (4 used)

cap screws (4, 8, and 10).

• Install cap screws (8 and 10). Tighten to specification.

• Install cap screws (4) and nuts (6). Tighten nuts to specification.

Specification Rock Guard-to-Track Frame Cap Screw—Torque............................................................................275 N·m 200 lb·ft

Specification Rock Guard Cap Screw Nut—Torque................................................................................530 N·m 390 lb·ft

Loctite and its related brand marks are trademarks of Henkel Corporation BS40810,0000225 -19-09FEB17-4/4

TM14163X19 (15FEB18)

01-0130-3

450K, 550K, and 650K Crawler Dozer 021518 PN=55

Track System

Carrier Roller Wear Inspection 149 mm 5.87 in

Carrier Roller OD (100% worn)

136 mm 5.35 in

T5819AC —UN—01NOV88

SPECIFICATIONS Carrier Roller OD (new)

1. Position an outside caliper over the most worn area of roller running surface, and close until caliper tips just touch tread surface. 2. Measure caliper tip spread using the scale to the nearest 0.5 mm (0.02 in). Measure Carrier Roller Wear

Specification Carrier Roller—OD (new)........................................................................................... 149 mm 5.87 in Carrier Roller—OD (100% worn) ............................................................................... 136 mm 5.35 in

For additional information:

• See 450J, 450K, 550J, 550K Carrier Roller Tread Diameter. (SP326.)

• See 605C, 605K, 650J, 650K Carrier Roller Tread Diameter. (SP326.)

3. Check for flat spots on carrier roller tread, which indicate roller is not free to turn.

BS40810,0000226 -19-08FEB17-1/1

Carrier Roller Remove and Install REMOVAL

TX1111572A —UN—04APR12

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. DO NOT remove grease fitting to increase sag. DO NOT tamper with relief valve. It is fitted with a cover. Slowly loosen check valve fitting to release grease from track tension adjuster. 1. Slowly turn check valve fitting (2) counterclockwise 1 turn to release track tension. See Track Sag Adjustment. (Group 0130.) 2. Raise and support track chain using a chain and hoist. 1— Grease Fitting 2— Check Valve Fitting

3— Plug

Continued on next page

TM14163X19 (15FEB18)

Track Adjuster Check Valve

01-0130-4

BS40810,0000227 -19-08FEB17-1/2

450K, 550K, and 650K Crawler Dozer 021518 PN=56

Track System

3. Loosen cap screws (4) and remove front or rear carrier rollers.

TX1233843A —UN—08FEB17

4. Clean and inspect parts. Repair or replace parts as necessary. See Carrier Roller Disassemble and Assemble. (Group 0130.) INSTALLATION Installation is reverse of removal procedure.

• Check for proper alignment of carrier rollers. • If carrier roller is out of alignment, loosen cap screws (4) and adjust outward.

• Adjust track sag. See Track Sag Adjustment. (Group

Carrier Roller Cap Screws

0130.)

4— Cap Screw (2 used) BS40810,0000227 -19-08FEB17-2/2

TM14163X19 (15FEB18)

01-0130-5

450K, 550K, and 650K Crawler Dozer 021518 PN=57

Track System

Carrier Roller Disassemble and Assemble

SPECIFICATIONS -18°C 0°F

Inner Bearing Cone Temperature

121°C 250°F

Outer Bearing Cone Temperature

121°C 250°F

10 8 11

Retainer Plate Cap Screws Torque 47 N·m 35 lb.-ft. Carrier Roller Oil Quantity

320 ml 10.8 oz.

ESSENTIAL TOOLS JDG205 Seal Installation Tool

6 9

T209436 —UN—10MAR05

Bearing Cups Temperature

OTHER MATERIAL

271 Loctite® Thread Lock and Sealer (high strength)

592 Loctite® Pipe Sealant

1. Remove snap ring (1).

Carrier Roller Assembly

2. Remove cover (3) using slide hammer. 3. Drain oil from housing.

1— Snap Ring 2— Pipe Plug 3— Cover 4— O-Ring 5— Cap Screw (2 used) 6— Retainer Plate

4. Remove retainer plate cap screws (5) and retainer plate (6). 5. Press outer bearing cone (7) and shaft (12) out of roller shell (9) using a press. 6. Press inner bearing cone (7) from shaft using a press.

protect lapped surfaces. See Metal Face Seals Inspection. (Group 0130.)

7. Press shaft (12) out of seal retainer (11) using a press. IMPORTANT: Metal face seals can be reused if they are not worn or damaged. A used seal must be kept together as a set because of wear patterns on seal ring face.

7— Bearing Cone (2 used) 8— Bearing Cup (2 used) 9— Roller Shell 10— Metal Face Seal 11— Seal Retainer 12— Shaft

9. Remove bearing cups (8) from roller shell. Inspect roller shell for grooved, burred or galled condition. 10. Replace parts as necessary.

8. Remove metal face seals (10). Keep seal rings together as a matched set with faces together to Loctite is a trademark of Henkel Corporation Continued on next page

TM14163X19 (15FEB18)

01-0130-6

AB06447,0000C0C -19-04MAY15-1/3

450K, 550K, and 650K Crawler Dozer 021518 PN=58

Track System

11. Cool bearing cups (8) to specification and press into roller shell.

Specification Bearing Cups—Temperature.................................................................................................. -18°C 0°F

10 8

12. Heat inner bearing cone (7) to specification and install tight against shoulder on shaft.

Specification

13. Install shaft (12) in roller shell.

6 9

T209436 —UN—10MAR05

Inner Bearing Cone—Temperature....................................................................... 121°C 250°F

14. Heat outer bearing cone (7) to specification and install on shaft so bearing is even with end of shaft.

Specification

Outer Bearing Cone—Temperature....................................................................... 121°C 250°F

1 Carrier Roller Assembly

15. Install retainer plate (6) and cap screws (5). Tighten cap screws to specification.

1— Snap Ring 2— Pipe Plug 3— Cover 4— O-Ring 5— Cap Screw (2 used) 6— Retainer Plate

Specification Retainer Plate Cap Screws—Torque............................................................................47 N·m 35 lb.-ft.

IMPORTANT: O-ring and seat surfaces must be clean, dry and oil free so O-rings do not slip when roller is turning.

7— Bearing Cone (2 used) 8— Bearing Cup (2 used) 9— Roller Shell 10— Metal Face Seal 11— Seal Retainer 12— Shaft

16. Thoroughly clean O-rings and seat surfaces in roller, cover, and seal rings using a volatile, non-petroleum base solvent and lint-free tissues. Continued on next page

TM14163X19 (15FEB18)

01-0130-7

AB06447,0000C0C -19-04MAY15-2/3

450K, 550K, and 650K Crawler Dozer 021518 PN=59

Track System

17. Install one half of metal face seal using JDG205 Seal Installation tool (13) into seal retainer (11). Install other half of seal (10) into roller shell.

T209590A —UN—16MAR05

18. Apply equal pressure with the fingers at four equally spaced points on seal ring face. O-ring and seal ring should seat squarely in bore. NOTE: A volatile, non-petroleum base solvent or talcum powder may be used as a lubricant. 19. Wipe both metal seal ring faces dry with a lint-free tissue. 20. Apply a thin film of oil, as used in the roller, to the shiny sealing area on both metal seal rings.

Metal Face Seal Installation Tool 10— Metal Face Seal 11— Seal Retainer

21. Apply PM37479 Thread Lock and Sealer (high strength) to shoulder area of shaft to bond seal retainer.

13— JDG205 Installation Tool

22. Install seal retainer (11) on shaft. Cover is a press fit. 23. Fill roller with clean oil. See Track Rollers, Front Idler, Carrier Roller and Track Frame Pivot Oil. (Operator's Manual.)

25. Install cover (3) with O-ring (4) into carrier roller (9). 26. Install snap ring (1). 27. Perform Carrier Roller Leakage Test. (Group 0130.)

Specification Carrier Roller Oil—Quantity................................................................................. 320 ml 10.8 oz.

28. Apply PM37397 Pipe Sealant to carrier roller oil fill pipe plug. Install plug.

24. Apply PM37617 Anti-Seize Lubricant or an equivalent to outside diameter of cover (3) and snap ring (1). AB06447,0000C0C -19-04MAY15-3/3

Metal Face Seals Inspection 1. Inspect for the following conditions to determine if seals can be reused:

• The narrow, highly polished sealing area (E) must be in the outer half of seal ring face (D).

• Sealing area must be uniform and concentric with the ID and OD of seal ring (A).

• Sealing area must not be chipped, nicked, or scratched.

D—Outer Half of Seal Ring Face E—Sealing Area (dark line)

T85079 —UN—24AUG93

A—Seal Ring B—Worn Area (shaded area) C—Seal Ring Face

Metal Face Seals Continued on next page

TM14163X19 (15FEB18)

01-0130-8

T47,0130,5939HQ -19-09APR15-1/3

450K, 550K, and 650K Crawler Dozer 021518 PN=60

Track System

2. Illustration shows examples of worn seal rings (A). I—Sealing area (D) is in inner half of seal ring face (C).

A—Seal Ring B—Worn Area (shaded area)

T85080 —UN—05DEC96

II—Sealing area (D) not concentric with ID and OD of seal ring. C—Inner Half of Seal Ring Face D—Sealing Area (dark line)

Cross Section of a Metal Face Seal T47,0130,5939HQ -19-09APR15-2/3

3. Clean reusable seals by removing all foreign material from seal rings, except seal face (A), using a scraper or a stiff bristled fiber brush.

T82840 —UN—23FEB89

4. Wash seal rings and O-rings using a volatile, non-petroleum base solvent to remove all oil. Thoroughly dry parts using a lint-free tissue. Apply a thin film of oil to seal ring face. Put face of seal rings together and hold using tape.

Seal Face T47,0130,5939HQ -19-09APR15-3/3

TM14163X19 (15FEB18)

01-0130-9

450K, 550K, and 650K Crawler Dozer 021518 PN=61

Track System

Carrier Roller Leakage Test SPECIFICATIONS Carrier Roller Leakage Test Air Pressure

107—127 kPa 0.8—1.2 bar 14—20 psi

1. Turn roller several times to seat metal face seals. 2. Remove plug and install parts (1—6). 3. Pressurize roller to specification using air pressure. Specification Carrier Roller Leakage Test—Air Pressure............................................................ 107—127 kPa 0.8—1.2 bar 14—20 psi

4. Close valve and wait for two minutes. Make sure roller maintains air pressure and oil does not leak past O-ring or metal face seals. T211091A —UN—11MAY05

5. If roller leaks oil or does not maintain pressure, check O-ring or seals. Repair as necessary and recheck for leaks. 6. Install and tighten plug. 1— Pressure Gauge 0—689 kPa (0—6.89 bar) (0—100 psi) 2— T80937 Adapter (-6 M 9/16-18UNF-2A ORFS x 1/8-27 NPTF) 3— JT03456 O-Ring Face Seal (2 used) (17/16 -20 M JIC x 11/16-16 F ORFS)

4— Shut-Off Valve 5— Regulator 6— 38H1030 Tee (-6 F ORFS x -6 M ORFS x -6 M ORFS) Parker No. (6R6LOS)

Carrier Roller Leakage Test

BS40810,0000124 -19-04MAY15-1/1

TM14163X19 (15FEB18)

01-0130-10

450K, 550K, and 650K Crawler Dozer 021518 PN=62

Track System

Track Roller Wear Inspection SPECIFICATIONS Track Roller OD (new)

182 mm 7.17 in

Track Roller OD (100% worn)

164 mm 6.46 in T6813AM —UN—29JAN98

SERVICE EQUIPMENT AND TOOLS D01182AA 20-Ton Floor Stand (4 used) JT05518A Undercarriage Inspection Kit JT07193 Special Roller Caliper

CAUTION: Prevent possible injury from unexpected track movement. Raise the machine off the ground and support with 20-ton floor stands. 1. Raise machine off the ground and support with D01182AA 20-Ton Floor Stands. Lower blade to ground. Tracks must be free to rotate in either direction. CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. DO NOT remove grease fitting to increase track sag. DO NOT tamper with relief valve. It is fitted with a cover. Slowly loosen check valve fitting to release grease from track tension adjuster.

Track Roller Tread Diameter

Specification Track Roller—OD (new).............................................................. 182 mm 7.17 in Track Roller—OD (100% worn)........................................................................................... 164 mm 6.46 in

2. Release track tension. See Track Sag Adjustment. (Group 0130.) NOTE: The maximum allowable wear for rebuilding roller tread is 100% worn.

Under some conditions roller wear can be uneven. If wear is uneven, the single flange rollers may be interchanged with other single flange rollers to even out wear. Double flange rollers may be interchanged with other double flange rollers. For additional information:

• See 450J, 450K, 550J, 550K Track Roller Tread Diameter. (SP326.)

• See 605C, 605K, 650J, 650K Track Roller Tread Diameter. (SP326.)

3. Measure roller tread diameter using a caliper such as JT07193 Special Roller Caliper from JT05518A Undercarriage Inspection Kit. BS40810,0000228 -19-08FEB17-1/1

TM14163X19 (15FEB18)

01-0130-11

450K, 550K, and 650K Crawler Dozer 021518 PN=63

Track System

Track Roller Remove and Install SPECIFICATIONS Track Roller Weight (approximate) 35 kg 77 lb 203 N·m 150 lb·ft

T133509 —UN—15APR13

Track Roller-to-Track Frame Cap Screw Torque

SERVICE EQUIPMENT AND TOOLS D01182AA 20-Ton Floor Stand (4 used)

REMOVAL CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Do not remove grease fitting to increase track sag. Do not tamper with relief valve. It is fitted with a cover. Slowly loosen check valve fitting to release grease from track tension adjuster. 1. Release track tension. See Track Sag Adjustment. (Group 0130.) CAUTION: Prevent possible injury from unexpected track movement. Raise the machine

High-Pressure Fluid

off the ground and support with 20-ton floor stands and floor stand kit. 2. Raise machine off the ground and support with D01182AA 20-Ton Floor Stands. Lower blade to ground. Tracks must be free to rotate in either direction. 3. If equipped remove center track guide or inner and outer rock guards. See Track Guides and Rock Guards Remove and Install. (Group 0130.) BS40810,0000229 -19-20JAN17-1/2

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 4. Attach appropriate lifting device to track roller (2). T209622A —UN—17MAR05

Specification Track Roller—Weight (approximate).................................................................................. 35 kg 77 lb

5. Remove cap screws (1) and track roller. 6. Clean and inspect parts. Repair or replace as necessary. See Track Roller Disassemble and Assemble. (Group 0130.) INSTALLATION

Track Roller Cap Screws 1— Cap Screw (2 used)

2— Track Roller

Installation is reverse of removal procedure.

• Position track roller (2) on track chain with oil fill plug

toward outside of unit. • Carefully lower crawler until roller cap screws can be installed. Tighten cap screws (1) to specification.

• Adjust track sag. See Track Sag Adjustment. (Group 0130.)

Specification Track Roller-to-Track Frame Cap Screw—Torque............................................................................203 N·m 150 lb·ft BS40810,0000229 -19-20JAN17-2/2

TM14163X19 (15FEB18)

01-0130-12

450K, 550K, and 650K Crawler Dozer 021518 PN=64

Track System

Track Roller Disassemble and Assemble Track Roller Disassemble

18 12

4 5

2 3

11 14

16 1 T210108 —UN—05APR05

T210108 Track Roller 1— Cap Screw (4 used) 2— Inner Bracket 3— O-Ring (4 used) 4— Metal Face Seal (4 used) 5— Bushing Case (2 used)

6— O-Ring (2 used) 7— Dowel Pin (2 used) 8— Bushing (2 used) 9— Snap Ring (2 used) 10— Roller Shaft

11— O-Ring (2 used) 12— Roller Shell 13— Outer Bracket 14— Plug (Rubber) 15— Plug (Plastic) 16— Lock Washer (4 used) Continued on next page

TM14163X19 (15FEB18)

01-0130-13

17— Cap Screw (12 used) 18— Lock Washer (12 used)

AB06447,0000C0B -19-04MAY15-1/16

450K, 550K, and 650K Crawler Dozer 021518 PN=65

Track System

NOTE: Single and double flange rollers are of the same design. Disassembly procedures are the same for both types of rollers.

T80426 —UN—26OCT88

1. Compress the metal face seals slightly using a 1 3/8 inch diameter disk (1) from D01045AA Bushing, Bearing, and Seal Driver Set and a press. Remove the snap ring (2) from both sides of roller shaft (3).

Roller Assembly in Press AB06447,0000C0B -19-04MAY15-2/16

2. Remove outer and inner brackets (1). NOTE: Metal face seals are a matched set. Seals are not interchangeable with other seals.

T80427 —UN—26OCT88

3. Remove metal face seal from inner and outer brackets.

Outer and Inner Brackets Continued on next page

TM14163X19 (15FEB18)

01-0130-14

AB06447,0000C0B -19-04MAY15-3/16

450K, 550K, and 650K Crawler Dozer 021518 PN=66

Track System

4. Remove and inspect metal face seals. See Metal Face Seals Inspection. (Group 0130.) 5. Remove O-rings (2) from both ends of shaft. T6018BC —UN—26OCT88

6. Remove cap screws (1) from bushing case at both ends of roller.

O-Rings AB06447,0000C0B -19-04MAY15-4/16

7. Remove roller shaft (1) and bushing case (2) using 2 3/8 inch diameter disk (3) and press. 8. Remove roller shaft from bushing case. 9. Turn roller over. Use 4 inch diameter disk to remove bushing case from roller housing. 10. Remove O-rings from bushing cases. 11. Inspect bushing in bushing case for excessive wear, pitting or scoring. Replace, if necessary.

T80432 —UN—26OCT88

12. Remove plastic and rubber plugs from shaft using twist drill. Flush oil passages in shaft with part cleaner solvent.

Roller Shaft Continued on next page

TM14163X19 (15FEB18)

01-0130-15

AB06447,0000C0B -19-04MAY15-5/16

450K, 550K, and 650K Crawler Dozer 021518 PN=67

Track System Track Roller Assemble 9— Lock Washer (12 used) 12— Dowel Pin (2 used) 13— Bushing (2 used) 14— O-Ring (2 used) 15— Roller Shell 16— Bushing Case (2 used) 17— Shaft 18— Bracket (2 used)

T209988 —UN—31MAR05

1— O-Ring (2 used) 2— Plug (Rubber) 3— Washer (4 used) 4— Cap Screw (4 used) 5— Snap Ring (2 used) 6— Plug (Plastic) 7— Metal Face Seal (2 used) 8— Cap Screw (12 used)

Double Flange Track Roller Shown Continued on next page

TM14163X19 (15FEB18)

01-0130-16

AB06447,0000C0B -19-04MAY15-6/16

450K, 550K, and 650K Crawler Dozer 021518 PN=68

Track System

NOTE: Assembly of single and double flange roller is the same. Single flange shown. 1. Cool bushing (1) and heat bushing case (3) to specification. Specification Bushing—Temperature.................................................................... -18°C 0°F Specification Bushing Case—Temperature............................................................................................... 121°C 250°F

2. Using a straight edge, mark bushing (1) from center line of dowel pin hole to center line of dowel pin (2). Align mark on bushing with dowel pin in bushing case. 3. Press bushing into case using 4 inch diameter disk from D01045AA Bushing, Bearing, and Seal Driver Set and a press.

1— Bushing 2— Dowel Pin 3— Bushing Case

T210063A —UN—31MAR05

4. When bushing case cools, install O-ring (5) on bushing case. 4— Disk (4 inch diameter) 5— O-Ring 6— Alignment Mark

Bushing Case Continued on next page

TM14163X19 (15FEB18)

01-0130-17

AB06447,0000C0B -19-04MAY15-7/16

450K, 550K, and 650K Crawler Dozer 021518 PN=69

Track System

5. Install bushing case (1) using aligning studs (2), 89 mm (3 1/2 inch) diameter x 6.3 mm (1/4 inch) wall pipe (5), 3 9/16 inch diameter disk (4), and a press. 6. Remove aligning studs. Install cap screws and lock washers. Tighten cap screws. 7. Turn roller (3) over and carefully install roller shaft. 8. Install bushing case (1) using aligning studs (2), 89 mm (3 1/2 inch) diameter x 6.3 mm (1/4) inch wall pipe (5), 3 9/16 inch diameter disk (4), and a press. 9. Remove studs. Install cap screws and lock washers. Tighten cap screws. 4— Disk (3 9/16 inch diameter) 5— Pipe

T80440 —UN—26OCT88

1— Bushing Case 2— Stud 3— Roller

Bushing Case AB06447,0000C0B -19-04MAY15-8/16

10. Install new O-ring in shaft groove (1).

T6018BA —UN—26OCT88

11. Degrease seal bore in bushing case, inner collar, and outer collar using a volatile, non-petroleum base type solvent. Make sure seal bores are clean and dry.

O-Rings Continued on next page

TM14163X19 (15FEB18)

01-0130-18

AB06447,0000C0B -19-04MAY15-9/16

450K, 550K, and 650K Crawler Dozer 021518 PN=70

Track System

T80574 —UN—26OCT88

IMPORTANT: The metal face seal must be extremely clean during assembly. Use a volatile, non-petroleum base type solvent to clean the metal seal ring (2) and rubber seal (1). DO NOT keep the rubber seal in a volatile, non-petroleum base type solvent for more than one minute. Wipe the seals dry with lint-free tissue to remove finger prints and foreign material. 12. Install rubber seal (1) on the metal seal ring (2). Make sure the rubber seal sits evenly on metal seal ring. Rubber Seal

AB06447,0000C0B -19-04MAY15-10/16

NOTE: A volatile, non-petroleum base solvent or talcum powder may be used as a lubricant. Solvent MUST NOT damage the O-rings or leave an oil residue.

1— Seal Ring Flange 2— JDG205 Seal Installation Tool

T6077AV —UN—26OCT88

13. Install seal assembly in the JDG205 Seal Installation Tool (2) so tool lip is between seal ring flange (1) and O-ring (3). 3— O-Ring

Seal Installation Tool AB06447,0000C0B -19-04MAY15-11/16

14. Push seal ring and O-ring into bore using tool (1). After O-ring (2) is pushed past retainer lip, turn tool clockwise and counterclockwise to seat O-ring uniformly. Install seal rings and O-rings in the outer and inner brackets using the same procedure.

1— JDG205 Seal Installation Tool

T80577 —UN—26OCT88

15. Check to make sure seal ring is sitting squarely in bore. Make sure rubber seal is seated uniformly in seal bore below the retainer lip. 2— O-Ring

Bore Tool Continued on next page

TM14163X19 (15FEB18)

01-0130-19

AB06447,0000C0B -19-04MAY15-12/16

450K, 550K, and 650K Crawler Dozer 021518 PN=71

Track System

16. Wipe metal seal rings dry with a lint free tissue. 17. Apply a thin film of oil, as used in the roller, to the shiny sealing area on metal seal rings.

T80578 —UN—26OCT88

18. Be sure the rubber seals are free of oil.

Metal Seal Rings AB06447,0000C0B -19-04MAY15-13/16

19. Install outer bracket. 20. Compress metal face seals slightly using a 1 3/8 inch diameter disk (1) and press. 21. Install snap ring (2) on shaft (3). 22. Remove roller from press. Install inner bracket and snap ring using same procedure. 3— Shaft

T80426 —UN—26OCT88

1— Disk (1 3/8 inch diameter) 2— Snap Ring

Installing Outer Bracket on Press Continued on next page

TM14163X19 (15FEB18)

01-0130-20

AB06447,0000C0B -19-04MAY15-14/16

450K, 550K, and 650K Crawler Dozer 021518 PN=72

Track System

23. Thoroughly clean nozzle (1), from JD313A Front Idler Lube Nozzle Kit, and around the plug end of track roller shaft.

T6090AI —UN—26OCT88

24. Insert nozzle in roller shaft with flat side up, as far as possible. 25. Slowly pump recommended oil into shaft using adapter (2) and grease gun (3) until oil without air bubbles is seen leaking past the flat on nozzle. See Track Rollers, Front Idler, Carrier Roller and Track Frame Pivot Oil. (Operator's Manual.) NOTE: Perform Track Roller Leakage Test BEFORE installing plugs. 26. Perform Track Roller Leakage Test. (Group 0130.)

JDG313A 1— JD313-1 Lube Nozzle 2— JD313-2 Adapter

3— Grease Gun

AB06447,0000C0B -19-04MAY15-15/16

27. Install new plastic plug (15) into rubber plug (14). Install plug assembly into shaft to specified depth (19).

Specification

15 T210171 —UN—07APR05

Track Roller Oil Plug—Depth.................................................................................. 10 mm 0.39 in.

28. Install track roller. See Track Roller Remove and Install . (Group 0130.) 14— Plug (rubber) 15— Plug (plastic)

19— Track Roller Oil Plug Depth Plug Assembly Depth

AB06447,0000C0B -19-04MAY15-16/16

TM14163X19 (15FEB18)

01-0130-21

450K, 550K, and 650K Crawler Dozer 021518 PN=73

Track System

Track Roller Leakage Test 1. Remove plug from track roller. 2. Fill track roller with recommended oil. See Track Rollers, Front Idler, Carrier Roller and Track Frame Pivot Oil. (Operator's Manual.) 3. Turn roller several times to seal metal face seals. 4. Assemble parts (1—5) as shown. 5. Pressurize roller with compressed air to specification and close valve (4). Specification Track Roller Leakage Test—Air Pressure............................................................ 107—127 kPa 0.8—1.2 bar 14—20 psi

1— Pressure Gauge 207 kPa (2.07 bar) (0—30 psi) 2— T149247 Rubber Plug 3— Male Barb-to-Male pipe Fitting (1/8-27 NPTF) Park No. (125HBL-4-2)

T211097A —UN—11MAY05

6. Track roller must maintain air pressure for two minutes. Oil must not leak past metal seals or rubber plug. If oil leaks past seals, repair as necessary. 4— Shut-Off Valve 5— Regulator

Track Roller Leakage Test BS40810,0000128 -19-04MAY15-1/2

7. Install new plastic plug (15) into rubber plug (14). Install plug assembly into shaft to specified depth (19).

Specification

14— Plug (rubber) 15— Plug (plastic)

15 T210171 —UN—07APR05

Track Roller Oil Plug—Depth.................................................................................. 10 mm 0.39 in. 19— Track Roller Oil Plug Depth

Plug Assembly Depth BS40810,0000128 -19-04MAY15-2/2

TM14163X19 (15FEB18)

01-0130-22

450K, 550K, and 650K Crawler Dozer 021518 PN=74

Track System

Track Shoe Grouser Wear Inspection 48 mm 1.89 in

450K/550K Track Shoe Grouser Height (100% worn)

20 mm 0.79 in

650K Track Shoe Grouser Height (new)

47 mm 1.85 in

650K Track Shoe Grouser Height (100% worn)

18 mm 0.71 in

T6789AE —UN—23FEB89

SPECIFICATIONS 450K/550K Track Shoe Grouser Height (new)

SERVICE EQUIPMENT AND TOOLS JT05518A Undercarriage Inspection Kit

Measuring Grouser Height

The maximum allowable wear for rebuilding grouser bars with weld is 100% worn. 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 JT05518A Undercarriage Inspection Kit. Specification 450K/550K Track Shoe Grouser—Height (new)................................................................. 48 mm 1.89 in 450K/550K Track Shoe Grouser—Height (100% worn)............................................................................................. 20 mm 0.79 in

650K Track Shoe Grouser—Height (new)................................................................. 47 mm 1.85 in 650K Track Shoe Grouser—Height (100% worn)............................................................................................. 18 mm 0.71 in

For additional information:

• See 450J, 450K, 550J, 550K Single Bar Grouser Height. (SP326.)

• See 650J, 650K Single Bar Grouser Height. (SP326.)

BS40810,000022A -19-08FEB17-1/1

TM14163X19 (15FEB18)

01-0130-23

450K, 550K, and 650K Crawler Dozer 021518 PN=75

Track System

Track Shoe Remove and Install SPECIFICATIONS 450K/550K 450K/550K Track Shoe Cap Screw 88 N·m + 1/3 Turn (120°) (9/16 in) Torque Turn 65 lb·ft + 1/3 Turn (120°)

450K/550K Track Shoe Cap Screw 50—100 Hour Check Torque (minimum)

T96291 —UN—23FEB89

450K/550K Split Master Link Shoe 88 N·m + 1/2 Turn (180°) Cap Screw (9/16 in) Torque Turn 65 lb·ft + 1/2 Turn (180°) 305 N·m 225 lb·ft

650K 650K Track Shoe Cap Screw (5/8 in) Torque Turn

163 N·m + 1/3 Turn (120°) 120 lb·ft + 1/3 Turn (120°)

650K Split Master Link Shoe Cap Screw (5/8 in) Torque Turn

163 N·m + 1/2 Turn (180°) 120 lb·ft + 1/2 Turn (180°)

650K Track Shoe Cap Screw 50—100 Hour Check Torque (minimum)

380 N·m 280 lb·ft

Cap Screws and Nuts

T96292 —UN—23FEB89

SERVICE EQUIPMENT AND TOOLS DF1041 Track Nut Removal Tool OTHER MATERIAL NEVER-SEEZ® Anti-Seize Lubricant

NOTE: Cap screws hold the master shoe and split master link together. Link side of master shoe has machined surfaces.

Nuts

1. Remove nuts and cap screws using DF1041 Track Nut Removal Tool. For instructions to make tool, see DF1041 Track Nut Removal Tool. (Group 9900.) T6352AH —UN—23FEB89

2. Before installing shoes, clean paint, dirt, and debris from mounting surfaces of shoes and links. 3. For all cap screws except those for split master links and shoe, apply oil (SAE 30) to threads and bearing surface under head. For split master link and shoe cap screws, apply NEVER-SEEZ® Anti-Seize Lubricant or an equivalent to threads and bearing surface under head. IMPORTANT: Never use an impact wrench to start cap screws in split master link. Start cap screws by hand to avoid cross-threading.

Crisscross Tightening Sequence A—Rounded Edges

B—Chamfered Edges

4. Install new cap screws. Install new nuts using DF1041 Track Nut Removal Tool with rounded edges (A) against link and chamfered edges (B) away from link. See DF1041 Track Nut Removal Tool. (Group 9900.)

450K/550K Split Master Link Shoe Cap Screw (9/16 in)—Torque Turn..................................... 88 N·m + 1/2 Turn (180°) 65 lb·ft + 1/2 Turn (180°)

5. Tighten cap screws to the initial torque using a crisscross sequence. Then repeat sequence for the additional turn.

650K—Specification 650K Track Shoe Cap Screw (5/8 in)—Torque Turn................................................................ 163 N·m + 1/3 Turn (120°) 120 lb·ft + 1/3 Turn (120°) 650K Split Master Link Shoe Cap Screw (5/8 in)—Torque Turn............................................. 163 N·m + 1/2 Turn (180°) 120 lb·ft + 1/2 Turn (180°)

450K/550K—Specification 450K/550K Track Shoe Cap Screw (9/16 in)—Torque Turn............................................... 88 N·m + 1/3 Turn (120°) 65 lb·ft + 1/3 Turn (120°)

Continued on next page

TM14163X19 (15FEB18)

01-0130-24

BS40810,000022B -19-20JAN17-1/2

450K, 550K, and 650K Crawler Dozer 021518 PN=76

Track System

6. Check torque after 50—100 hours of operation to make sure cap screws are tightened to minimum torque. 450K/550K—Specification 450K/550K Track Shoe Cap Screw 50—100 Hour Check—Torque (minimum)...................................................................................305 N·m 225 lb·ft

650K—Specification 650K Track Shoe Cap Screw 50—100 Hour Check—Torque (minimum)...................................................................................380 N·m 280 lb·ft

NEVER-SEEZ is a trademark of Emhart Chemical Group BS40810,000022B -19-20JAN17-2/2

Track Link Height Inspection SPECIFICATIONS 450K/550K Track Link Height (new)

96 mm 3.78 in

650K Track Link Height (new)

100 mm 3.94 in

650K Track Link Height (100% worn)

90 mm 3.54 in

T5802AD —UN—02NOV88

450/550K Track Link Height (100% 86.7 mm 3.41 in worn)

SERVICE EQUIPMENT AND TOOLS JT05518A Undercarriage Inspection Kit

Measuring Track Link Height

1. Using depth gauge from JT05518A Undercarriage Inspection Kit, measure outer side of track link against pin boss as shown. 2. Measure two track links to nearest 0.5 mm (0.02 in). Specification 450K/550K Track Link—Height (new)........................................................................ 96 mm 3.78 in 450/550K Track Link—Height (100% worn).......................................................................................... 86.7 mm 3.41 in

650K Track Link—Height (new)........................................................................................... 100 mm 3.94 in 650K Track Link—Height (100% worn).................................................................................. 90 mm 3.54 in

For additional information:

• See 450J, 450K, 550J, 550K Link Height. (SP326.) • See 605C, 605K, 650J, 650K Link Height. (SP326.) BS40810,000022C -19-08FEB17-1/1

TM14163X19 (15FEB18)

01-0130-25

450K, 550K, and 650K Crawler Dozer 021518 PN=77

Track System

Bushing Outside Diameter for Lubricated Track Chain Inspection SPECIFICATIONS 450K/550K Bushing (standard) OD (new)

53.8 mm 2.12 in

450K/550K Bushing (standard) OD (100% worn, high impact applications)

48.2 mm 1.90 in

450K/550K Bushing (standard) OD (100% worn, normal impact applications)

45.8 mm 1.80 in

T5802AB —UN—26OCT88

450K/550K

650K

Measuring Bushing Outside Diameter

650K Bushing (standard) OD (new)

56.8 mm 2.24 in

650K Bushing (standard) OD (100% worn, high impact applications)

50.8 mm 2.00 in

650K Bushing (standard) OD (100% worn, normal impact applications)

48.2 mm 1.90 in

450K/550K/650K Bushing (SC-2™ Maximum Life) OD (new)

56.8 mm 2.24 in

Bushing (SC-2™ Maximum Life) OD (100% worn, high impact applications)

50.8 mm 2.00 in

Bushing (SC-2™ Maximum Life) OD (100% worn, normal impact applications)

48.2 mm 1.90 in

SERVICE EQUIPMENT AND TOOLS JT05518A Undercarriage Inspection Service Tool Kit

1. Clean surfaces to be measured of two adjacent bushings and underside of track shoe in the area between bushings. NOTE: Lubricated track chain bushings are measured for vertical wear only using calipers. Bushing vertical wear can be measured using the depth gauge method only after bushing turn procedure is used. Reference Undercarriage Appraisal Manual, SP326. 2. For caliper method, put caliper from JT05518A Undercarriage Inspection Service Tool Kit around bushing at area of vertical wear as shown. Measure several different bushings to nearest 0.5 mm (0.020 in). Specification 450K/550K Bushing (standard)—OD (new)................................................................ 53.8 mm 2.12 in 450K/550K Bushing (standard)—OD (100% worn, high impact applications)............................................................................... 48.2 mm 1.90 in 450K/550K Bushing (standard)—OD (100% worn, normal impact applications)............................................................................... 45.8 mm 1.80 in

650K Bushing (standard)—OD (new)................................................................ 56.8 mm 2.24 in 650K Bushing (standard)—OD (100% worn, high impact applications)............................................................................... 50.8 mm 2.00 in 650K Bushing (standard)—OD (100% worn, normal impact applications)............................................................................... 48.2 mm 1.90 in Bushing (SC-2™ Maximum Life)—OD (new).......................................................................................... 56.8 mm 2.24 in Bushing (SC-2™ Maximum Life)—OD (100% worn, high impact applications)............................................................................... 50.8 mm 2.00 in Bushing (SC-2™ Maximum Life)—OD (100% worn, normal impact applications).................................................................... 48.2 mm 1.90 in

For additional information: 450K/550K

• See 450J, 450K, 550J, 550K Step Bushing Outer Diameter—Normal Impact Applications. (SP326.)

• See 450J, 450K, 550J, 550K Step Bushing Outer Diameter—High Impact Applications. (SP326.)

• See 450J, 450K, 550J, 550K Step Bushing Outer

Diameter (Depth Gauge)—Normal Impact Applications. (SP326.) • See 450J, 450K, 550J, 550K Step Bushing Outer Diameter (Depth Gauge)—High Impact Applications. (SP326.) • See 450J, 450K, 550J, 550K SC-2™ Maximum Life Step Bushing Outer Diameter—Normal Impact Applications. (SP326.)

Continued on next page

TM14163X19 (15FEB18)

01-0130-26

BS40810,000022D -19-08FEB17-1/2

450K, 550K, and 650K Crawler Dozer 021518 PN=78

Track System

• See 450J, 450K, 550J, 550K SC-2™ Maximum

Life Step Bushing Outer Diameter—High Impact Applications. (SP326.) • See 450J, 450K, 550J, 550K SC-2™ Maximum Life Step Bushing Outer Diameter (Depth Gauge)—Normal Impact Applications. (SP326.) • See 450J, 450K, 550J, 550K SC-2™ Maximum Life Step Bushing Outer Diameter (Depth Gauge)—High Impact Applications. (SP326.) 650K

• See 605C, 605K, 650J, 650K Step Bushing Outer Diameter—Normal Impact Applications. (SP326.)

• See 605C, 605K, 650J, 650K Step Bushing Outer Diameter—High Impact Applications. (SP326.)

• See 605C, 605K, 650J, 650K Step Bushing Outer

Diameter (Depth Gauge)—High Impact Applications. (SP326.) • See 605C, 605K, 650J, 650K SC-2™ Extended Life and Maximum Life Step Bushing Outer Diameter—Normal Impact Applications. (SP326.) • See 605C, 605K, 650J, 650K SC-2™ Extended Life and Maximum Life Step Bushing Outer Diameter—High Impact Applications. (SP326.) • See 605C, 605K, 650J, 650K SC-2™ Extended Life and Maximum Life Step Bushing Outer Diameter (Depth Gauge)—Normal Impact Applications. (SP326.) • See 605C, 605K, 650J, 650K SC-2™ Extended Life and Maximum Life Step Bushing Outer Diameter (Depth Gauge)—High Impact Applications. (SP326.)

• See 605C, 605K, 650J, 650K Step Bushing Outer

Diameter (Depth Gauge)—Normal Impact Applications. (SP326.) BS40810,000022D -19-08FEB17-2/2

Track Pitch for Lubricated Track Chain Inspection 685.2 mm 26.98 in

Track Pitch Length (100% worn)

697.9 mm 27.48 in

T6813AL —UN—29JAN98

SPECIFICATIONS Track Pitch Length (new)

NOTE: Track pitch does not extend unless there is lubrication leakage, which causes a dry joint. Measure pitch only when there is lubrication leakage or a visible extension of a joint. Measuring Track Pitch

IMPORTANT: Track pin may be operated with a dry joint until it reaches wear limit specified. Then it must be repaired. A dry joint will not hold lubrication until it is repaired. Track pin may break if joint is not repaired after it reaches wear limit.

Track Pitch—Length (100% worn)............................................................................. 697.9 mm 27.48 in

1. Place a pin or block between sprocket and chain. Then move unit in reverse until chain is tight.

• See 450J, 450K, 550J, 550K Chain Pitch. (SP326.) • See 605C, 605K, 650J, 650K Chain Pitch. (SP326.)

For additional information:

2. Measure from left side of pin in dry joint across four links to left side of pin (as shown). Specification Track Pitch—Length (new)........................................................................................ 685.2 mm 26.98 in BS40810,000022E -19-20JAN17-1/1

TM14163X19 (15FEB18)

01-0130-27

450K, 550K, and 650K Crawler Dozer 021518 PN=79

Track System

Lubricated Track Chain Remove and Install SPECIFICATIONS 450K/550K Split Link Cap Screw (9/16 in) Torque Turn

88 N·m + 1/2 Turn (180°) 65 lb·ft + 1/2 Turn (180°)

450K/550K Track Shoe Cap Screw 50—100 Hour Check Torque (minimum)

305 N·m 225 lb·ft

650K Track Shoe Cap Screw 50—100 Hour Check Torque (minimum)

380 N·m 280 lb·ft

T133509 —UN—15APR13

650K Split Link Cap Screw (5/8 in) 163 N·m + 1/2 Turn (180°) Torque Turn 120 lb·ft. + 1/2 Turn (180°)

High-Pressure Fluid

SERVICE EQUIPMENT AND TOOLS D01182AA 20-Ton Floor Stand (4 used) OTHER MATERIAL

TX1098968A —UN—10OCT11

NEVER-SEEZ® Anti-Seize Lubricant

CAUTION: Prevent possible injury from unexpected track movement. Raise the machine off the ground and support with 20-ton floor stands and floor stand kit. Tracks must be free to rotate in either direction. 1. Raise machine off the ground and support with D01182AA 20-Ton Floor Stands. Lower blade to ground. Tracks must be free to rotate in either direction. CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Do not remove grease fitting to increase track sag. Do not tamper with relief valve. It is fitted with a cover. Slowly loosen check valve fitting to release grease from track tension adjuster.

Track Adjuster Check Valve 3— Check Valve Fitting 4— Grease Fitting

5— Relief Valve

between the sprocket and the track chain and rotate track to retract the adjusting cylinder if required. See Track Sag Adjustment. (Group 0130.)

2. Slowly turn check valve fitting (3) counterclockwise 1 turn to release track tension. Put a piece of pipe NEVER-SEEZ is a trademark of Emhart Chemical Group Continued on next page

TM14163X19 (15FEB18)

01-0130-28

BS40810,000022F -19-08FEB17-1/5

450K, 550K, and 650K Crawler Dozer 021518 PN=80

Track System

3. Rotate track until split link (9) is positioned in front of idler. 4. To prevent track from falling, block track as shown. 5. Remove four cap screws (1) to remove track shoe (2) and disassemble split link. 6. Attach chain (10) to track and support track chain with hoist to avoid damage to split link. 7. Start machine and slowly rotate drive sprocket in reverse direction to move track off drive sprocket.

T211292A —UN—11MAY05

IMPORTANT: Track chain must be installed under track frame with wide end of links toward rear of machine or accelerated wear to track chain will occur. 8. Install track chain by putting chain under track frame with the wide end of links toward rear of machine. 9. Block track shoes so split link is positioned directly over idler. Track Shoe 9— Split Link 10— Chain

TX1098970A —UN—30SEP11

1— Cap Screw (4 used) 2— Track Shoe

Split Chain Link Continued on next page

TM14163X19 (15FEB18)

01-0130-29

BS40810,000022F -19-08FEB17-2/5

450K, 550K, and 650K Crawler Dozer 021518 PN=81

Track System

10. Attach chain (10) and hoist near end of track chain for support.

TX1098969A —UN—30SEP11

11. Guide track over sprocket while operator drives machine slowly forward guiding track chain over carrier rollers and front idler. 12. Stop machine when ends of split links meet. 13. Remove any foreign material from split link tooth racks and ramp surfaces (6). Clean surface with wire brush if necessary. 14. Check for burrs, especially at tip of split link ramp (7). Remove all burrs so ramp surfaces are flat.

Track Chain Installation

15. Check cap screw holes (8) in each split link. Cap screw holes must be clean and free of foreign material.

TX1098970A —UN—30SEP11

IMPORTANT: To prevent damage to threads, do not use a pry bar in holes to align split link. 16. Carefully align split links together and align cap screw holes. 6— Ramp Surface (4 used) 7— Tip of Split Link Ramp 8— Cap Screw Hole (4 used)

9— Split Link 10— Chain

Align Split Link BS40810,000022F -19-08FEB17-3/5

17. Remove any foreign material from shoe and link mounting surfaces. 18. Install track shoe (2) on links and start cap screws by hand to avoid cross-threading. 19. Apply NEVER-SEEZ® Anti-Seize Lubricant or an equivalent to cap screw threads and bearing surface under head. 20. Install track cap screws by hand to check alignment. IMPORTANT: To avoid cross-threading, do not use impact wrench to start the track shoe cap screws. 2— Track Shoe

T211292A —UN—11MAY05

1— Cap Screw (4 used)

Track Shoe NEVER-SEEZ is a trademark of Emhart Chemical Group Continued on next page

TM14163X19 (15FEB18)

01-0130-30

BS40810,000022F -19-08FEB17-4/5

450K, 550K, and 650K Crawler Dozer 021518 PN=82

Track System

Specification 450K/550K Split Link Cap Screw (9/16 in)—Torque Turn.................................................................. 88 N·m + 1/2 Turn (180°) 65 lb·ft + 1/2 Turn (180°) 650K Split Link Cap Screw (5/8 in)—Torque Turn................................................................ 163 N·m + 1/2 Turn (180°) 120 lb·ft. + 1/2 Turn (180°)

Crisscross Tightening Sequence

22. Remove floor stands and lower machine to ground. 23. Adjust track sag. See Track Sag Adjustment. (Group 0130.) 24. Check torque after 50—100 hours of operation to make sure cap screws are tightened to the minimum torque specification. Specification 450K/550K Track Shoe Cap Screw 50—100 Hour Check—Torque (minimum)...................................................................................305 N·m 225 lb·ft

T210112 —UN—01APR05

21. Tighten cap screws to initial torque using tightening sequence as shown. Then turn each cap screw an additional half turn (180°).

1— Cap Screw (4 used)

650K Track Shoe Cap Screw 50—100 Hour Check—Torque (minimum)...................................................................................380 N·m 280 lb·ft

BS40810,000022F -19-08FEB17-5/5

TM14163X19 (15FEB18)

01-0130-31

450K, 550K, and 650K Crawler Dozer 021518 PN=83

Track System

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

NOTE: Tooling listed below is purchased through WTC Machinery Corporation (800) 248-8405.

SPECIFICATIONS Track Press Relief Valve Settings Force (maximum)

444 800 N 100 000 lb.-force

Bushing Projection Height

1.75—2.25 mm 0.069—0.089 in.

Lubricated Track Chain Seal Test Vacuum

68—102 kPa 20—30 in. Hg

Lubricated Track Chain Oil Pressure

140—205 kPa 1.4—2.05 bar 20—30 psi

3. Use the appropriate track press tool set.

“91” Series Adjustable Tooling 910025—Jaw 910114—Side Plate (2 used) 910214—Side Plate (2 used) 910314—Shims (4 used) 912003—Adjustable Tool Holder (2 used) 912004—Stationary Tool Holder (2 used) 913013—Pin Disassembly Tool (2 used) 914015—Bushing Disassembly Tool (2 used) 915175—Pin Assembly Tool (2 used) 916240—Bushing Assembly Tool (2 used) 917060—Shim Group

ESSENTIAL TOOLS JDG190 Plug Installer

“C” Style (Spring Loaded) Tooling SERVICE EQUIPMENT AND TOOLS

(A2656-303)

61119 Seal Tester and Lubricator for S.A.L.T. Crawler Equipment

IMPORTANT: Track press disassembly tools must be in proper alignment with links to prevent broaching of pin and bushing. Damaged link bores cannot be reused.

OTHER MATERIAL PM1525607 U.S. Aviation Gasket Sealant

NOTE: The following procedure is for disassembly of track chain to inspect, clean, replace damaged or worn parts, turn bushings, and lubricate chain.

4. Start disassembly at pin-end half of split link. Check for proper alignment of tools with pin and bushing.

If track chain is disassembled only to turn pins and bushings and no parts will be replaced, see Lubricated Track Chain to Turn Pins and Bushings and Not Lubricate Disassemble and Assemble. (Group 0130.)

5. Make an index mark on bushings to aid in reassembly, when turning bushings 1/2 turn (180°) to expose a new wear surface.

1. Remove track shoes and track chain. See Track Shoe Remove and Install and see Lubricated Track Chain Remove and Install. (Group 0130.)

CAUTION: Always wear safety glasses when operating the press. Parts may break or chip, which could create a risk of personal injury.

NOTE: A clean track is necessary for proper disassembly.

6. Extend right ram (C) to push pin (G) and bushing (E) from the right link (D). The right link is forced against the side of saddle (B) as pin and bushing are pushed out.

2. Wash chain with high-pressure water. It will not be necessary to wash links before reassembly if chain is thoroughly cleaned.

7. Retract right ram. The right link, with seals and thrust ring, will stay on the ram tools.

Continued on next page

TM14163X19 (15FEB18)

01-0130-32

BS40810,000012C -19-04MAY15-1/18

450K, 550K, and 650K Crawler Dozer 021518 PN=84

Track System E—Bushing F— Left Link G—Pin

T96266 —UN—27OCT88

A—Left Ram B—Saddle C—Right Ram D—Right Link

Track Press Disassembly Tool BS40810,000012C -19-04MAY15-2/18

8. Extend left ram (A) to push the pin (C) and bushing (F) from left link (G). The left link is forced against the side of saddle (B) as pin and bushing are pushed out.

T96267 —UN—27OCT88

9. Retract left ram. The left link, with seal and thrust ring, will remain on the ram tools. 10. Remove links, bushing, and thrust rings from press. A—Left Ram B—Saddle C—Pin D—Right Ram

E—Right Link F— Bushing G—Left Link

Track Press Disassembly Tool BS40810,000012C -19-04MAY15-3/18

11. Inspect parts as they are disassembled to determine which ones can be reused.

T6682AJ —UN—01NOV88

If there is internal wear at any joint, replace seal ring, pin, bushing, thrust ring, and load ring. These parts must be replaced to successfully lubricate chain. 12. If pin and bushing contains oil when disassembled, new pins, seals, bushings, or thrust rings are not necessary. Do not remove usable seals from link counterbore. Do not remove any dirt from around seals. 13. Repeat steps 4—12 to disassemble rest of chain. Track Press Disassembly Tool

14. Remove rubber plug (F) from pins using a drill. A—Bushing B—Seal Ring C—Load Ring Continued on next page

TM14163X19 (15FEB18)

01-0130-33

D—Thrust Ring E—Pin F— Rubber Plug BS40810,000012C -19-04MAY15-4/18

450K, 550K, and 650K Crawler Dozer 021518 PN=85

Track System

15. Inspect pin ends. If the chamfer is missing due to wear, grind a 3 mm (0.12 in.) x 15° chamfer on pin. If chamfer is missing in plug hole, add new 4 mm (0.16 in.) x 30° chamfer.

A—4 mm (0.16 in.) B—30°

T96269 —UN—27OCT88

16. Clean pins, bushings, and thrust rings in solvent. C—15° D—3 mm (0.12 in.)

Pin Ends BS40810,000012C -19-04MAY15-5/18

CAUTION: Make sure all control levers of press are in the neutral position. 17. Assemble track using the following track press tool sets. T96272 —UN—27OCT88

NOTE: Tooling listed below is purchased through WTC Machinery Corporation (800) 248-8405. “91” Series (Adjustable Camlock) Tooling 910025—Jaw 910114—Side Plate (2 used) 910214—Side Plate (2 used) 910314—Shims (4 used) 912003—Adjustable Tool Holder (2 used) 912004—Stationary Tool Holder (2 used) 913013—Pin Disassembly Tool (2 used) 914015—Bushing Disassembly Tool (2 used) 915175—Pin Assembly Tool (2 used) 916240—Bushing Assembly Tool (2 used) 917060—Shim Group

Rubber Plug A—Rubber Plug

B—JDG190 Plug Installer

18. Apply a mixture of 50% alcohol and 50% water to rubber plug (A) and install using JDG190 Plug Installer (B).

“C” Style (Spring Loaded) Tooling (A2656-303)

BS40810,000012C -19-04MAY15-6/18

NOTE: The pin-end halves of master split link must be temporarily assembled to bushing end halves of link for proper positioning on plungers. Pin-end halves will later have to be separated for installation at end of chain. T96273 —UN—27OCT88

19. Assemble master split link halves using master shoe bolts and washers (as required). Tighten bolts just enough to hold links together. Split links are a matched set and must be assembled as a set. 20. Install assembled split links on ram plungers. 21. Install bushing (A) in front seat of saddle (B) so the mark is 180° opposite original location to expose a new wear surface.

Bushing A—Bushing Continued on next page

TM14163X19 (15FEB18)

01-0130-34

B—Saddle BS40810,000012C -19-04MAY15-7/18

450K, 550K, and 650K Crawler Dozer 021518 PN=86

Track System

22. Adjust track press pressure relief valve setting. Specification Track Press Relief Valve Settings—Force (maximum)...............................................................................444 800 N 100 000 lb.-force

T96274 —UN—27OCT88

23. Advance left ram until left split link contacts the saddle. Advance right ram until it stops to press split link and bushing assembly together.

Adjusting Track Press Pressure Relief Valve BS40810,000012C -19-04MAY15-8/18

24. Measure bushing projection from shoulder of link using a depth micrometer. Bushing projection determines clearance between overlapping links and proper spacing of link bolt holes.

T96275 —UN—27OCT88

Specification Bushing Projection—Height......................................................................1.75—2.25 mm 0.069—0.089 in.

25. If bushing projection does not meet specification, check pressure setting or adjust shim packs behind plungers. Only the first two joints must be checked for proper bushing projection. Bushing Projection Continued on next page

TM14163X19 (15FEB18)

01-0130-35

BS40810,000012C -19-04MAY15-9/18

450K, 550K, and 650K Crawler Dozer 021518 PN=87

Track System

T96276 —UN—27OCT88

26. Apply track chain lubricant to bushing ends before next set of links are installed.

Track Chain Lubricant BS40810,000012C -19-04MAY15-10/18

IMPORTANT: Pins must be installed so cross-drilled hole is toward link wear surface or they may break when chain is used. To make assembly easier, install all pins so holes in the end are toward the same side of chain.

A—End Hole

T96277 —UN—27OCT88

27. Install pin in bushing so cross-drilled hole (B) is toward link wear surface. Install all pins so end hole (A) is toward the same side of chain, either left or right. B—Cross-Drilled Hole

Cross-Drilled Hole BS40810,000012C -19-04MAY15-11/18

28. Install a thrust ring on each end of pin.

T96278 —UN—27OCT88

29. Move completed split link assembly to rear seat of saddle.

Thrust Ring Continued on next page

TM14163X19 (15FEB18)

01-0130-36

BS40810,000012C -19-04MAY15-12/18

450K, 550K, and 650K Crawler Dozer 021518 PN=88

Track System

T96279 —UN—27OCT88

30. Apply PM1525607 Aviation Gasket Sealant or an equivalent to the link bore. The sealant prevents loss of vacuum or lubricant leakage through the pin to link joint.

Aviation Sealant BS40810,000012C -19-04MAY15-13/18

31. Install bushing (F) in front saddle seat. Install left link (B) and right link on ram plungers. Assemble the load ring (C) and seal ring (D). Install the assembly into link (B) counterbore so pointed lip of seal ring is toward bushing (F). D—Seal Ring F— Bushing

T96280 —UN—27OCT88

B—Link C—Load Ring

Bushing in Front Saddle Continued on next page

TM14163X19 (15FEB18)

01-0130-37

BS40810,000012C -19-04MAY15-14/18

450K, 550K, and 650K Crawler Dozer 021518 PN=89

Track System

32. Advance left ram until left link contacts the saddle. Advance right ram until it stops (plungers in both rams against shim pack). F— Right Link G—Bushing H—Shim (as needed) I— Left Link

T96282 —UN—27OCT88

A—Left Ram B—Saddle C—Pin D—Plunger (2 used) E—Right Ram

T96283 —UN—27OCT88

Saddle

Diagram Saddle BS40810,000012C -19-04MAY15-15/18

NOTE: To ensure zero end play in joint, special spacers must be fabricated using a section of bushing. 33. Retract left ram. Install special spacer (A) between the joint in rear seat of saddle and ram. T96284 —UN—27OCT88

IMPORTANT: Too much pressure to thrust ring may cause it to crush. Use only minimum force to push joint tight. 34. Advance left ram using only minimum force required to push joint tight. Pressure must be approximately one half the relief valve setting. Remove spacer. Special Spacer A—Special Spacer Continued on next page

TM14163X19 (15FEB18)

01-0130-38

BS40810,000012C -19-04MAY15-16/18

450K, 550K, and 650K Crawler Dozer 021518 PN=90

Track System

35. After one complete joint has been assembled, check end play of track links to make sure bushing, thrust rings, and link counterbore faces are pressed solid against each other. Position base of dial indicator on one link assembly and pointer against the other link assembly. 36. Pry link assemblies in one direction then in opposite direction to measure the amount of end play. End play must be zero.

T96285 —UN—27OCT88

37. As track chain is being further assembled, end play may be checked by manually prying upward on each link. If link rotates downward increase press force and re-press.

Measuring End Play Continued on next page

TM14163X19 (15FEB18)

01-0130-39

BS40810,000012C -19-04MAY15-17/18

450K, 550K, and 650K Crawler Dozer 021518 PN=91

Track System

38. As chain is being assembled, check to make sure there is some clearance between the overlapping face of links, using a feeler gauge. If links contact each other, check bushing projection.

39. Add oil (SAE 80W 90) using a No. 61119 Seal Tester and Lubricator for S.A.L.T. Crawler Equipment. Push nozzle through plug all the way into pin. Depress control lever on the handle enough to draw specified vacuum as indicated on the gauge.

T96286 —UN—27OCT88

Specification Bushing Projection—Height......................................................................1.75—2.25 mm 0.069—0.089 in.

Bushing Projection

Specification Lubricated Track Chain Seal Test—Vacuum............................................................. 68—102 kPa 20—30 in. Hg

T96287 —UN—01NOV88

40. Release lever. If there is no decrease in vacuum for a minimum of 5 seconds, the joints are sealed. If there is a vacuum decrease, seals are not sealing and the joint must be taken apart and repaired. 41. Add oil by depressing the second lever. Oil pressure (read on the same gauge) must be to specification after both levers are released. Specification Lubricated Track Chain Oil—Pressure.................................................................... 140—205 kPa 1.4—2.05 bar 20—30 psi

Seal Tester

T6465AY —UN—01NOV88

42. For pins using rubber plug and plastic plug, immediately install plug using JDG190 Plug Installer after adding oil. For pins using self-sealing plug, slowly pull nozzle (C) out to allow any compressed air to escape through nozzle from first hole (A) to second hole (B). Add oil to each joint after assembling so only one joint would have to be disassembled if a vacuum leak occurs.

Pin Using Self-Sealing Plug

43. Repeat step 10—26 for all joints. 44. Install assembled split links on ram plungers, and advance rams to press split links together.

A—First Hole B—Second Hole

T96288 —UN—27OCT88

45. Install track shoes and track chain. See Track Shoe Remove and Install and see Lubricated Track Chain Remove and Install. (Group 0130.) C—Nozzle

Assembled Split Links BS40810,000012C -19-04MAY15-18/18

TM14163X19 (15FEB18)

01-0130-40

450K, 550K, and 650K Crawler Dozer 021518 PN=92

Track System

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

Track Press Relief Valve Force (maximum)

444 800 N 100 000 lb. force

Bushing Projection Height

1.75—2.25 mm 0.069—0.089 in.

T96266 —UN—27OCT88

Lubricated Track Pin End Chamfer 3 mm x 15° 0.12 in. x 15°

ESSENTIAL TOOLS 23058 Track Shoe Gauge

Track Press Disassembly Tool

NOTE: The following procedure is for disassembly of track chain only to turn pins and bushings. (Chain is not lubricated after assembly.)

A—Left Ram B—Saddle C—Right Ram D—Right Link

If this procedure does not apply to the repair job, see Lubricated Track Chain to Turn Bushings and Lubricate Chain Disassemble and Assemble. (Group 0130.) 1. Remove track shoes and track chain. See Track Shoe Remove and Install and see Lubricated Track Chain Remove and Install. (Group 0130.)

4. Make an index mark on bushings and pins to aid in reassembly, when turning bushings 1/2 turn (180°) to expose a new wear surface. CAUTION: Always wear safety glasses when operating the press. Parts may break or chip, which could create a risk of personal injury.

2. Use the appropriate track press tool set. NOTE: Tooling listed below is purchased through WTC Machinery Corporation (800) 248-8405. “91” Series Adjustable Tooling 910025—Jaw 910114—Side Plate (2 used) 910214—Side Plate (2 used) 910314—Shims (4 used) 912003—Adjustable Tool Holder (2 used) 912004—Stationary Tool Holder (2 used) 913013—Pin Disassembly Tool (2 used) 914015—Bushing Disassembly Tool (2 used) 915175—Pin Assembly Tool (2 used) 916240—Bushing Assembly Tool (2 used) 917060—Shim Group

E—Bushing F— Left Link G—Pin

5. Extend right ram (C) to push pin (G) and bushing (E) from the right link (D). The right link is forced against the side of saddle (B) as the pin and bushing are pushed out. 6. Retract right ram. The right link, with seals and thrust ring, will stay on the ram tools.

“C” Style (Spring Loaded) Tooling (A2656-303)

IMPORTANT: Track press disassembly tools must be in proper alignment with links to prevent broaching of pin and bushing. Damaged links cannot be reused. 3. Check for proper alignment of tools with pin and bushing. Continued on next page

TM14163X19 (15FEB18)

01-0130-41

BS40810,000012D -19-04MAY15-1/10

450K, 550K, and 650K Crawler Dozer 021518 PN=93

Track System

7. Extend left ram (A) to push the pin (C) and bushing (F) from the left link (G). The left link is forced against the side of saddle (B) as pin and bushing are pushed out.

T96267 —UN—27OCT88

8. Retract left ram. The left link, with seal and thrust ring, will remain on the ram tools. 9. Remove links and bushing from press. 10. Repeat steps 4—9 to disassemble rest of chain. IMPORTANT: Pins must be installed so cross-drilled hole is toward link wear surface or they may break when chain is used. 11. All pins, bushings, seals, and thrust rings are used for assembly, because chain is not lubricated. Do not remove rubber plug and plastic plug from pins. Do not remove seals from track links. Turn pin end-for-end to get a new wear surface, then install it into bushing so cross-drilled hole is toward link wear surface. Install all pins so hole in end of pin is toward the same side of chain, either left or right side.

Track Press Disassembly Tool A—Left Ram B—Saddle C—Pin D—Right Ram

E—Right Link F— Bushing G—Left Link

BS40810,000012D -19-04MAY15-2/10

12. Inspect pin ends for wear. If there is no chamfer (A and B), grind a new chamfer to specification.

A—15°

T5798AJ —UN—26OCT88

Specification Lubricated Track Pin End—Chamfer........................................................................ 3 mm x 15° 0.12 in. x 15° B—3 mm (0.12 in.)

Pin Ends BS40810,000012D -19-04MAY15-3/10

13. Smooth area of track link wear (A) using a grinder, if necessary.

T96289 —UN—27OCT88

A—Track Link

Track Link Wear Continued on next page

TM14163X19 (15FEB18)

01-0130-42

BS40810,000012D -19-04MAY15-4/10

450K, 550K, and 650K Crawler Dozer 021518 PN=94

Track System

14. Assemble track links using the following track press tool sets. “91” Series Adjustable Tooling

T96273 —UN—27OCT88

913013—Pin Disassembly Tool (2 used) 914015—Bushing Disassembly Tool (2 used) 915175—Pin Assembly Tool (2 used) 916240—Bushing Assembly Tool (2 used) “C” Style (Spring Loaded) Tooling (A2656-303)

NOTE: The pin end halves of master split link must be temporarily assembled to bushing end halves of link for proper positioning of plungers. Pin end halves will later have to be separated for installation at end of chain.

Bushing in Front Saddle A—Bushing

15. Assemble master split link halves using master shoe bolts and washers (as required). Tighten bolts just enough to hold link together.

B—Saddle

17. Install bushing (A) in front seat of saddle (B) so the mark is 180° opposite original location to expose a new wear surface.

16. Install assembled split links on ram plungers.

BS40810,000012D -19-04MAY15-5/10

18. Adjust track press pressure relief valve setting. Specification Track Press Relief Valve —Force (maximum)..................................................................444 800 N 100 000 lb. force

T96274 —UN—27OCT88

19. Advance rams to press split links together until the correct bolt spacing is obtained for the master shoe.

Adjusting Track Pressure Valve Continued on next page

TM14163X19 (15FEB18)

01-0130-43

BS40810,000012D -19-04MAY15-6/10

450K, 550K, and 650K Crawler Dozer 021518 PN=95

Track System

IMPORTANT: Pins must be installed so cross-drilled hole is toward link wear surface or they may break when chain is used.

A—Pin End Hole

T96277 —UN—27OCT88

20. Turn pin end-for-end to get a new wear surface, then install it into bushing so cross-drilled hole (B) is toward link wear surface. Install all pins so hole (A) in end of pin is toward the same side of chain, either left or right side. B—Cross-Drilled Hole

Bushing Cross-Drilled Holes BS40810,000012D -19-04MAY15-7/10

21. Install a thrust ring on each side of pin.

T96278 —UN—27OCT88

22. Move completed link assembly to rear seat of saddle.

Installation Thrust Ring Continued on next page

TM14163X19 (15FEB18)

01-0130-44

BS40810,000012D -19-04MAY15-8/10

450K, 550K, and 650K Crawler Dozer 021518 PN=96

Track System

23. Install bushing (G) in front saddle seat. Install right and left links (F and I) on ram plungers (D).

A—Left Ram B—Saddle C—Pin D—Plunger (2 used) E—Right Ram

T96283 —UN—27OCT88

24. Advance left ram (A) until left link contacts the saddle (B). Advance right ram until link is pressed together and bolts can be installed through 23058 Track Shoe Gauge (J). F— Right Link G—Bushing H—Plunger Shims I— Left Link J— 23058 Track Shoe Gauge

T96290 —UN—27OCT88

Track Press Disassembly Tool

Track Shoe Gauge BS40810,000012D -19-04MAY15-9/10

25. As chain is being assembled, check to make sure there is some clearance between the overlapping face of links using a feeler gauge. If links contact each other, check bushing projection.

T96286 —UN—27OCT88

Specification Bushing Projection—Height......................................................................1.75—2.25 mm 0.069—0.089 in.

26. Repeat steps 14—25 to assemble rest of chain. 27. The last link assembled is the split link pin ends. Assemble a set of extra "slave" split link bushing ends to pin ends using bolts and washers used in step 15. Tighten bolts just enough to hold together link. 28. Install assembled split links on ram plungers and advance rams to press split links together.

Check Bushing Projection

29. Install track shoes and track chain. See Track Shoe Remove and Install and see Lubricated Track Chain Remove and Install. (Group 0130.) BS40810,000012D -19-04MAY15-10/10

TM14163X19 (15FEB18)

01-0130-45

450K, 550K, and 650K Crawler Dozer 021518 PN=97

Track System

Track Sag Adjustment SPECIFICATIONS Track Sag Distance

45—57 mm 1.75—2.25 in.

Check Track Sag 1. Allow machine to slowly roll forward so track pin (1) is centered over carrier roller (2). 2. Measure track sag either between carrier roller (2) and front idler if equipped with one carrier roller or between longest span location. The longest span location is from the top of the track grouser (3) and straight edge (4). Specification Track Sag—Distance..............................................................45—57 mm 1.75—2.25 in. 3— Track Sag 4— Straightedge

TX1113942 —UN—16MAY12

1— Track Pin 2— Carrier Rollers

TX1113940A —UN—16MAY12

Track Sag

Check Track Sag Continued on next page

TM14163X19 (15FEB18)

01-0130-46

BS40810,000012E -19-17FEB15-1/2

450K, 550K, and 650K Crawler Dozer 021518 PN=98

Track System Decrease Track Sag:

TX1111572A —UN—04APR12

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. DO NOT remove grease fitting to increase track sag. DO NOT tamper with relief valve. It is fitted with a cover. Slowly loosen check valve fitting to release grease from track tension adjuster. 1. Tighten check valve fitting (2) securely. 2. Apply grease to grease fitting (1) using a 55 200 kPa (552 bar) (8000 psi) capacity grease gun. 3. Drive machine slowly in forward and reverse directions to allow track adjuster cylinder to fully adjust. 4. Check track sag again.

Track Adjuster Check Valve 1— Grease Fitting 2— Check Valve Fitting

Increase Track Sag: 1. Loosen check valve fitting (2), NOT the lubrication fitting, one to three turns counterclockwise to release grease through vent hole.

3— Plug

4. Check track sag again.

2. Tighten check valve fitting. 3. Drive machine slowly in forward and reverse directions to allow track adjuster cylinder to fully adjust. BS40810,000012E -19-17FEB15-2/2

TM14163X19 (15FEB18)

01-0130-47

450K, 550K, and 650K Crawler Dozer 021518 PN=99

Track System

Front Idler Wear Inspection 17 mm 0.67 in

Front Idler Flange (standard bushings) Height (100% worn)

22.5 mm 0.89 in

Front Idler Flange (SC-2™ Maximum Life bushings) Height (new)

17 mm 0.67 in

Front Idler Flange (SC-2™ Maximum Life bushings) Height (100% worn)

25 mm 0.96 in

T96419 —UN—27OCT88

SPECIFICATIONS Front Idler Flange (standard bushings) Height (new)

Measuring Front Idler Wear

SERVICE EQUIPMENT AND TOOLS JT05518A Undercarriage Inspection Kit

NOTE: The maximum allowable height of flange for rebuilding wear surface is 100% worn. Measure height of flange using a depth gauge such as the JT05521 200 mm Ruler, JT05534 Right Angle Attachment, and D05231ST 300 mm Ruler from JT05518A Undercarriage Inspection Kit. Specification Front Idler Flange (standard bushings)—Height (new)............................................................................................. 17 mm 0.67 in Front Idler Flange (standard bushings)—Height (100% worn)............................................................................... 22.5 mm 0.89 in

Front Idler Flange (SC-2™ Maximum Life bushings)—Height (new)............................................................................................. 17 mm 0.67 in Front Idler Flange (SC-2™ Maximum Life bushings)—Height (100% worn).................................................................................. 25 mm 0.96 in

For additional information:

• See 450J, 450K, 550J, 550K Front Idler Flange Height. (SP326.)

• See 605C, 605K, 650J, 650K Front Idler Flange Height. (SP326.)

SC-2 is a trademark of Deere & Company BS40810,0000230 -19-09FEB17-1/1

TM14163X19 (15FEB18)

01-0130-48

450K, 550K, and 650K Crawler Dozer 021518 PN=100

Track System

Front Idler Remove and Install 94 kg 207 lb

650K Front Idler Weight (approximate)

121 kg 267 lb

T118526B —UN—17NOV98

SPECIFICATIONS 450K/550K Front Idler Weight (approximate)

Front Idler Yoke Cap Screw Torque 140 N·m 103 lb·ft

REMOVAL 1. Disconnect track chain. See Lubricated Track Chain Remove and Install. (Group 0130.)

Front Idler

2. Remove cap screws (1) from both sides. 1— Cap Screw (4 used)

2— Track Adjuster Check Valve

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 3. Attach appropriate lifting device and slide front idler forward off track frame. Specification 450K/550K Front Idler—Weight (approximate).................................................................................. 94 kg 207 lb 650K Front Idler—Weight (approximate)................................................................................ 121 kg 267 lb

INSTALLATION Installation is reverse of removal procedure.

• Install idler on track frame. Tighten cap screws to specification.

Specification Front Idler Yoke Cap Screw—Torque............................................................................140 N·m 103 lb·ft

• Adjust idler. See Front Idler Adjustment. (Group 0130.)

4. Clean and inspect parts. Repair or replace parts as necessary. See Front Idler Disassemble and Assemble. (Group 0130.) BS40810,0000243 -19-08FEB17-1/1

TM14163X19 (15FEB18)

01-0130-49

450K, 550K, and 650K Crawler Dozer 021518 PN=101

Track System ESSENTIAL TOOLS

Front Idler Disassemble and Assemble

JDG205 Seal Installation Tool

SPECIFICATIONS Bushing Temperature

SERVICE EQUIPMENT AND TOOLS

-18°C 0°F 121°C 250°F

Front Idler Bushing Case Cap Screw Torque

40.2—47 N·m 30—35 lb-ft

Front Idler Shaft Lock Nut Torque

140—180 N·m 103—133 lb.-ft.

Front Idler Capacity

330 ml 11.2 oz

Front Idler Oil Plug Torque

39 N·m 29 lb.-ft.

Front Idler Lower Wear Strip Cap Screw Torque

90—110 N·m 66—81 lb.-ft.

Front Idler Disassembly

T210217 —UN—07APR05

Bushing Case Temperature

D01045AA Bushing, Bearing and Seal Driver Set

T210217 Front Idler Exploded View 1— Idler 2— Shaft 3— O-ring (2 used) 4— O-ring (2 used) 5— O-ring 6— Plug 7— Bracket (left) 8— Bushing Cover (2 used) 9— Bushing (2 used) 10— Dowel Pin (2 used)

11— Lock Washer (12 used) 12— Cap Screw (12 used) 13— Metal Face Seal (2 used) 14— Bracket (right) 15— Wear Strip (lower) (2 used) 16— Shim (as required)

17— Lock (2 used) 18— Nut (2 used) 19— Washer (2 used) 20— Cap Screw (2 used) 21— Washer (20 used) 22— Cap Screw (6 used) 23— Bushing (rubber) (4 used)

24— Washer (4 used) 25— Wear Strip (upper) (2 used) 26— Plate (2 used) 27— Bolt (6 used) 28— Wear Strip (middle) (2 used)

1. Remove wear plates (28), bushings (23), and washers (24).

3. Loosen nut (18). Strike head of nut to dislodge lock (17).

2. Remove cap screws (22) and washers (21).

4. Remove nut (9) and push lock (17) down to remove lock and washer (19). Continued on next page

TM14163X19 (15FEB18)

01-0130-50

AB06447,0000C0A -19-04MAY15-1/12

450K, 550K, and 650K Crawler Dozer 021518 PN=102

Track System

5. Remove cap screws (20), washers (21), shims (16), and plate (15). AB06447,0000C0A -19-04MAY15-2/12

6. Remove bracket (7 or 14) using puller.

T211338A —UN—19MAY05

7. Remove cap screws (12) and washers (11).

Front Idler Bracket Removal Continued on next page

TM14163X19 (15FEB18)

01-0130-51

AB06447,0000C0A -19-04MAY15-3/12

450K, 550K, and 650K Crawler Dozer 021518 PN=103

Track System

8. Remove shaft (2) and bushing cover (8) from idler using a 2 inch disk from D01045AA Bushing, Bearing, and Seal Driver Set and a press. 9. Remove shaft from bushing case. Remove O-rings from shaft and bushing case. NOTE: Tape metal face seals together to keep them in matched sets. 10. Remove metal face seals (13) and tape together. 11. Lift second bracket off idler.

T211339A —UN—19MAY05

12. Remove cap screws (12) and washers (11) from second bushing case. 13. Turn idler over. Use a 4 inch disk to remove second bushing case from idler. Remove O-ring from bushing case. NOTE: Tape metal face seals together to keep them in matched sets. 14. Remove metal face seals (13) and tape together.

Front Idler Shaft Removal

15. Inspect all parts for excessive wear or damage. Replace if necessary. Continued on next page

TM14163X19 (15FEB18)

01-0130-52

AB06447,0000C0A -19-04MAY15-4/12

450K, 550K, and 650K Crawler Dozer 021518 PN=104

Track System

T210217 —UN—07APR05

Front Idler Assembly

11— Lock Washer (12 used) 12— Cap Screw (12 used) 13— Metal Face Seal (2 used) 14— Bracket (right) 15— Wear Strip (lower) (2 used) 16— Shim (as required)

17— Lock (2 used) 18— Nut (2 used) 19— Washer (2 used) 20— Cap Screw (2 used) 21— Washer (20 used) 22— Cap Screw (6 used) 23— Bushing (rubber) (4 used)

Continued on next page

TM14163X19 (15FEB18)

01-0130-53

24— Washer (4 used) 25— Wear Strip (upper) (2 used) 26— Plate (2 used) 27— Bolt (6 used) 28— Wear Strip (middle) (2 used)

AB06447,0000C0A -19-04MAY15-5/12

450K, 550K, and 650K Crawler Dozer 021518 PN=105

Track System

NOTE: Track roller and front idler procedures are similar. Track roller shown where noted. 1. Cool bushing (1) and heat bushing case (3) to specification. Specification Bushing—Temperature.................................................................... -18°C 0°F Specification Bushing Case—Temperature............................................................................................... 121°C 250°F

1— Bushing 2— Dowel Pin 3— Bushing Case

T210063A —UN—31MAR05

4. When bushing case cools, install O-ring (5) on bushing case. 4— Disk (4 inch diameter) 5— O-Ring 6— Alignment Mark

Bushing Case AB06447,0000C0A -19-04MAY15-6/12

5. Install bushing case (1) using aligning studs (2), 4 inch diameter disk (4), and a press. 6. Remove aligning studs. Install cap screws and lock washers. Tighten cap screws to specification. Specification Front Idler Bushing Case Cap Screw —Torque.......................................................... 40.2—47 N·m 30—35 lb.-ft.

7. Turn idler over and carefully install shaft.

T211330A —UN—19MAY05

8. Install bushing case (1) using aligning studs (2), 101.6 mm (4 inch) diameter x 6.3 mm (1/4 inch) wall pipe, 4 inch diameter disk (4), and a press. 9. Remove studs. Install cap screws and lock washers. Tighten cap screws to specification. Specification Front Idler Bushing Case Cap Scre—Torque.............................................................. 40.2—47 N·m 30—35 lb.-ft. Bushing Case 1— Bushing Case 2— Stud

3— Front Idler 4— Disk (3 9/16 inch diameter) Continued on next page

TM14163X19 (15FEB18)

01-0130-54

AB06447,0000C0A -19-04MAY15-7/12

450K, 550K, and 650K Crawler Dozer 021518 PN=106

Track System

10. Install new O-ring in shaft groove (1).

T6018BA —UN—26OCT88

11. Degrease seal bore in bushing case, inner collar, and outer collar using a volatile, non-petroleum base type solvent. Make sure seal bores are clean and dry.

O-Ring (Track Roller Shown) AB06447,0000C0A -19-04MAY15-8/12

T80574 —UN—26OCT88

AB06447,0000C0A -19-04MAY15-9/12

NOTE: A volatile, non-petroleum base solvent or talcum powder may be used as a lubricant. Solvent MUST NOT damage the O-rings or leave an oil residue.

1— Seal Ring Flange 2— JDG205 Seal Installation Tool

T6077AV —UN—26OCT88

13. Install seal assembly in the JDG205 Seal Installation Tool (2) so tool lip is between seal ring flange (1) and O-ring (3). 3— O-Ring

Seal Installation Tool Continued on next page

TM14163X19 (15FEB18)

01-0130-55

AB06447,0000C0A -19-04MAY15-10/12

450K, 550K, and 650K Crawler Dozer 021518 PN=107

Track System

1— JDG205 Seal Installation Tool

T80577 —UN—26OCT88

15. Check to make sure seal ring is sitting squarely in bore. Make sure rubber seal is seated uniformly in seal bore below the retainer lip. 2— O-Ring

Seal Installation (Track Roller Shown) AB06447,0000C0A -19-04MAY15-11/12

16. Wipe metal seal rings dry with a lint free tissue. 17. Apply a thin film of oil, as used in the idler, to the shiny sealing area on metal seal rings. 18. Be sure the rubber seals are free of oil. T80578 —UN—26OCT88

19. Install bracket. 20. Install dowel pin (17), washer (19), and nut (18). Tighten nut to specification. Specification Front Idler Shaft Lock Nut —Torque............................................................................ 140—180 N·m 103—133 lb.-ft.

21. Turn idler over and install new O-ring, metal face seals, bracket, dowel pin, washer, and nut. 22. Slowly pump recommended oil into shaft. See Track Rollers, Front Idler, Carrier Roller and Track Frame Pivot Oil. (Operator's Manual.) Specification Front Idler —Capacity................................................................... 330 ml 11.2 oz

23. Install plug. Tighten to specification. Specification Front Idler Oil Plug —Torque........................................................................................39 N·m 29 lb.-ft.

Metal Seal Rings (Track Roller Shown)

24. Install shims (16), lower wear strip (15) , washers (21), and cap screws (20). Tighten cap screws to specification. Specification Front Idler Lower Wear Strip Cap Screw —Torque.............................................................................. 90—110 N·m 66—81 lb.-ft.

25. Install washers (12 and 24), rubber bushings (23), upper wear strips (25), and cap screws (22). Do not tighten cap screws. 26. Install idler assembly. See Front Idler Remove and Install. (Group 0130.) AB06447,0000C0A -19-04MAY15-12/12

TM14163X19 (15FEB18)

01-0130-56

450K, 550K, and 650K Crawler Dozer 021518 PN=108

Track System

Front Idler Adjustment SPECIFICATIONS 0.8 mm or less 0.030 in. or less

Idler Bracket-to-Wear Strip Cap Screws Torque

163 Nm 120 lb-ft

Guide Plate Shimming Clearance

0.8 mm 0.030 in.

Guide Plate-to-Idler Bracket Cap Screws Torque

163 Nm 120 lb-ft

A—Cap Screw (8 used) B—Shim (as required)

C—Shim (as required) D—Cap Screw (4 used)

T118123 —UN—02NOV98

Bottom Wear Strip Shimming Clearance

Front Idler Shim Adjustment E—Idler F— Track Frame G—Wear Strip (2 used)

NOTE: Removal of front idler is necessary only when shimming bottom wear strips.

Front Idler—Specification Idler Bracket-toWear Strip Cap Screws—Torque...........................................................................163 Nm 120 lb-ft

1. Remove front idler. See Front Idler Remove and Install. (Group 0130.). 2. Install bottom wear strip (G). Add or remove shims (C) under wear strip to obtain 0.8 mm (0.030 in.) or less clearance.

4. Install front idler. See Front Idler Remove and Install. (Group 0130.)

Front Idler—Specification Bottom Wear Strip Shimming—Clearance......................................................0.8 mm or less 0.030 in. or less

3. Tighten cap screws (A).

5. Check guide plate (H) clearance. Add or remove shims (B) to obtain 0.8 mm (0.030 in.) clearance. Front Idler—Specification Guide Plate Shimming—Clearance................................................................. 0.8 mm 0.030 in.

Continued on next page

TM14163X19 (15FEB18)

H—Guide Plate (2 used)

01-0130-57

PM10405,00007D9 -19-26APR12-1/2

450K, 550K, and 650K Crawler Dozer 021518 PN=109

Track System

Front Idler—Specification Guide Plate-to-Idler Bracket Cap Screws—Torque.......................................................................... 163 Nm 120 lb-ft

6. Tighten cap screws (D).

PM10405,00007D9 -19-26APR12-2/2

Front Idler Oil Level Check SPECIFICATIONS Front Idler 39 N·m 29 lb.-ft.

T118598B —UN—23NOV98

Oil Level Plug Torque

NOTE: Idlers and rollers are typically sealed for life and the plug in the side is used by the factory to fill the oil cavity initially. Opening this plug to check the oil level introduces the potential to allow contamination entry or leakage from the plug. The plug should only be removed after a seal repair. Idler Oil Fill Plug

Removing the idler oil level plug (1) does not always indicate oil level. Possible vacuum in the oil cavity can keep oil from flowing out. Idlers that appear low or out of oil may have sufficient oil. Applying a small amount of low volume forced air into the idler will overcome the vacuum and allow a small amount of oil to flow from idler.

1— Idler Oil Fill Plug

slight amount of pressure inside the idler will relieve any vacuum and allow oil to flow from fill hole.

NOTE: The oil fill hole should be on outside of idler on the right side of machine. The oil fill hole should be on the inside of idler on the left hand side of the machine.

3. Add proper oil slowly using oil can.

1. Rotate plug opening to a 45° angle.

5. Apply pipe sealant or TEFLON® tape to new plug. Install and tighten oil level plug.

2. Remove the oil level fill plug (1). If oil flows out, oil level is correct. If oil does not flow, insert the nozzle of a plastic bottle into the hole and squeeze air pressure into idler. A

4. Add oil until oil flows from oil level hole.

Front Idler—Specification Oil Level Plug—Torque..................................................................39 N·m 29 lb.-ft.

TEFLON is a registered trademark of Du Pont Co. BS40810,0000132 -19-17FEB15-1/1

TM14163X19 (15FEB18)

01-0130-58

450K, 550K, and 650K Crawler Dozer 021518 PN=110

Track System SERVICE EQUIPMENT AND TOOLS

Track Tension Adjuster Repair SPECIFICATIONS 155 Nm 115 lb.-ft.

T118556 —UN—23NOV98

Adjusting Cylinder Yoke-to-Idler Bracket Cap Screws Torque

Bearing, Bushing and Seal Driver Set

Continued on next page

TM14163X19 (15FEB18)

01-0130-59

BS40810,0000133 -19-17MAR15-1/4

450K, 550K, and 650K Crawler Dozer 021518 PN=111

Track System

Track Adjuster 1— Cap 2— Tube 3— Compression Spring 4— Cap (front end)

5— Track Adjusting Piston 6— Yoke 7— Washer (4 used)

8— Cap Screw (4 used) 9— Check Valve 10— Grease Fitting

12— Yoke Seal 13— Scrapper Seal 14— Plug

2. Remove adjuster assembly from track frame.

CAUTION: Grease for track adjuster cylinder is under high pressure. Never remove special grease fitting to release the grease. If grease does not escape immediately from vent hole with relief valve open, slowly drive machine in forward and reverse until grease escapes. DO NOT disassemble parts unless you follow the correct procedure and have correct tools.

IMPORTANT: Do not pull piston from track adjusting yoke unless seal and piston seal are to be replaced or seals will be damaged. 3. To aid disassembly, remove grease fitting (10) to prevent suction.

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury may call the Deere & Company Medical Department in Moline, Illinois, or other knowledgeable medical source.

4. Pull track adjusting piston (5) from yoke (6). 5. Remove and discard scraper seal (13) and yoke seal (12). 6. Inspect and clean all parts.

1. Remove front idler. See Front Idler Remove and Install. (Group 0130.) Continued on next page

TM14163X19 (15FEB18)

01-0130-60

BS40810,0000133 -19-17MAR15-2/4

450K, 550K, and 650K Crawler Dozer 021518 PN=112

Track System

1. Fold seal (B) as shown and install into yoke (A) with seal lip into bore first. 2. Install scraper seal (C) using 57 mm and 73 mm disks.

A—Track Adjuster Yoke B—Yoke Seal

T7247BP —UN—09APR90

3. Install piston. C—Scraper Seal

T118646 —UN—30NOV98

Seal Folded

T118647 —UN—30NOV98

Track Adjuster Yoke Seal

Track Adjuster Seal and Scraper Seal BS40810,0000133 -19-17MAR15-3/4

4. Install track adjuster in track frame. 5. Install grease fitting and plug (2). 6. Install idler and tighten cap screws (1).

1— Cap Screw (4 used)

T118526B —UN—17NOV98

Hydraulic Track Tension Adjuster—Specification Adjusting Cylinder Yoke-to-Idler Bracket Cap Screws—Torque...................................................................155 Nm 115 lb.-ft. 2— Track Adjuster Check Valve Idler-to-Yoke Cap Screws

BS40810,0000133 -19-17MAR15-4/4

TM14163X19 (15FEB18)

01-0130-61

450K, 550K, and 650K Crawler Dozer 021518 PN=113

Track System

Track Idler Recoil Spring Remove and Install 51 mm 2.0 in.

Spring Length

404 mm 15.9 in.

T6555DH —UN—01JUN89

SPECIFICATIONS Spacer Width

ESSENTIAL TOOLS T16678 Special Bolt (1-8 UNC-2A x 15-1/2 JDM A17D) OTHER MATERIAL PM37617 Anti-Seeize Lubricant Idler Recoil Spring

IMPORTANT: Avoid damage to track adjuster seals. When sliding idler assemble forward, do not pull track adjusting piston from yoke as scraper seal may damage piston seal.

CAUTION: Spring or rod may break if dropped while handling, transporting or disassembling. Nicks or weld craters in spring and rod assembly can cause stress concentration resulting in structural damage, creating a risk of personal injury. Put a heavy protective covering around spring assembly when handling, transporting or disassembling.

1. Slide front idler with hydraulic track tension adjuster assembly forward. 2. Remove cover. 3. Thoroughly clean threads of rear cap. CAUTION: Avoid injury from unexpected recoil spring movement. Always use the special bolt to prevent accidental release of idler recoil spring. 4. Apply anti-seeize lubricant and insert a T16678 Special Bolt and a 51 mm (2.0 in.) spacer through track spring retainer plate and into rear cap. Track Recoil Spring—Specification Spacer—Width.............................................................................. 51 mm 2.0 in.

Tighten bolt until spring compresses to 404 mm (15.9 in.) between outer end of front cap and rear cap.

A compression tool must be used for disassembly and assembly because of the extreme preload on spring. 5. Remove spring. 6. Release compression on track spring immediately after removal. See Track Idler Recoil Spring Disassemble and Assemble. (Group 0130.) 7. Install spring and cover. 8. Slide front idler with hydraulic track tension adjuster back, aligning spring nut with piston.

Track Recoil Spring 550K-650K—Specification Spring—Length........................................................................... 404 mm 15.9 in. SH03936,000590D -19-16MAY12-1/1

TM14163X19 (15FEB18)

01-0130-62

450K, 550K, and 650K Crawler Dozer 021518 PN=114

Track System

Track Idler Recoil Spring Disassemble and Assemble SPECIFICATIONS Track Recoil Spring 450K/550K Recoil Spring Free Length (approximate)

454 mm 18 in

450K/550K Test Length at 54 535—64 019 N (12 260—14 392 lbf)

376 mm 14.8 in

650K Recoil Spring Free Length (approximate)

433 mm 17 in

650K Test Length at 68 058—83 982 N (15 300—18 880 lbf)

376 mm 14.8 in

SERVICE EQUIPMENT AND TOOLS DFT1087a Recoil Spring Guard Tool ST4920a Recoil Spring Tool a

Dealer Fabricated Tool. See Group 9900 for instructions to make tool. OTHER MATERIAL T6557DY —UN—25OCT88

NEVER-SEEZ® Anti-Seize Lubricant

CAUTION: Spring or rod may break if dropped while handling, transporting, or disassembling. Nicks or weld craters in spring and rod assembly can cause stress concentration resulting in structural damage, creating a risk of personal injury. Put a heavy protective covering around spring assembly when handling, transporting, or disassembling.

Compression Tool A—ST4920 Compression Tool B—Nut (4 used)

A compression tool must be used for disassembly and assembly because of the extreme preload on spring. 1. Put a 10-ton jack on bottom of ST4920 Compression Tool (A). For instructions on making this tool, see ST4920 Track Recoil Spring Disassembly and Assembly Tool. (Group 9900.) Remove nuts (B) and top plate (C). 2. Put recoil spring in compression tool. Track Recoil Spring—Specification 450K/550K Recoil Spring—Free Length (approximate).............................................................................. 454 mm 18 in

C—Top Plate

450K/550K—Test Length at 54 535—64 019 N (12 260—14 392 lbf).......................................................................... 376 mm 14.8 in 650K Recoil Spring—Free Length (approximate).............................................................................. 433 mm 17 in 650K—Test Length at 68 058—83 982 N (15 300—18 880 lbf).......................................................................... 376 mm 14.8 in

NEVER-SEEZ is a trademark of Emhart Chemical Group Continued on next page

TM14163X19 (15FEB18)

01-0130-63

BS40810,0000231 -19-10FEB17-1/4

450K, 550K, and 650K Crawler Dozer 021518 PN=115

Track System

3. Install DFT1087 Recoil Spring Guard Tool (F). For instructions on making this tool, see DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool. (Group 9900.) 4. Install plate (A) and nuts (B) from ST4920 Recoil Spring Tool to secure spring. 5. Be sure cap screw head (C) fits through hole in plate (E). IMPORTANT: Cap screw head MUST be centered through hole in plate for proper operation of tool. 6. Compress spring until cap screw head (C) fully extends through hole in plate. 7. Remove cap screw head (C). 8. Slowly release jack pressure. 9. Remove nuts and plate.

A—Plate B—Nut (4 used) C—Cap Screw Head

T7126AA —UN—15SEP89

10. Remove spring. D—Recoil Spring E—Hole in Plate F— DFT1087 Recoil Spring Guard Tool

T7247BN —UN—09APR90

Recoil Spring Guard Tool

Plate, Spring, Screw Head, and Nuts Continued on next page

TM14163X19 (15FEB18)

01-0130-64

BS40810,0000231 -19-10FEB17-2/4

450K, 550K, and 650K Crawler Dozer 021518 PN=116

T7247BO —UN—09APR90

Track System

Rear/Front End Caps, Spring, and Stop Tube A—Rear End Cap

B—Spring C—Stop Tube

11. Disassemble and assemble parts as shown.

D—Front End Cap

12. Check spring for nicks or weld craters. Replace as necessary. Continued on next page

TM14163X19 (15FEB18)

01-0130-65

BS40810,0000231 -19-10FEB17-3/4

450K, 550K, and 650K Crawler Dozer 021518 PN=117

Track System

13. Install 10-ton jack on bottom of compression tool. 14. Put caps, tube, and recoil spring (D) in compression tool so spring is centered. 15. Install DFT1087 Recoil Spring Guard Tool (F). For instructions on making this tool, see DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool. (Group 9900.) 16. Install plate (A) and nuts (B) to secure spring. 17. Operate jack to compress spring. 18. Apply NEVER-SEEZ® Anti-Seize Lubricant to threads of special cap screw head (C). Install special cap screw through hole in plate (E). Be sure cap screw threads fully engage end cap. 19. Slowly release jack and remove nuts and plate.

A—Plate B—Nut (4 used) C—Cap Screw Head

T7126AA —UN—15SEP89

20. Install spring assembly. See Track Idler Recoil Spring Remove and Install. (Group 0130.) D—Recoil Spring E—Hole in Plate F— DFT1087 Recoil Spring Guard Tool

T7247BN —UN—09APR90

Recoil Spring Guard Tool

Plate, Spring, Screw Head, and Nuts NEVER-SEEZ is a trademark of Emhart Chemical Group BS40810,0000231 -19-10FEB17-4/4

TM14163X19 (15FEB18)

01-0130-66

450K, 550K, and 650K Crawler Dozer 021518 PN=118

Track System

Track Frame Remove and Install SPECIFICATIONS Track Frame Assembly Weight (approximate)

939 kg 2070 lb. T118665B —UN—30NOV98

Frame-to-Track-Frame Cap Screw 620 N·m 460 lb.-ft. Torque

REMOVAL 1. Remove track chain. See Lubricated Track Chain Remove and Install. (Group 0130.) 2. Remove rear cover (1) and spring cover (2). Track Frame

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

1— Rear Cover 2— Spring Cover

3— Cap Screw (10 used)

3. Attach appropriate lifting device to track frame. Specification Track Frame Assembly—Weight (approximate)................................................................................ 939 kg 2070 lb.

INSTALLATION Installation is reverse of removal procedure.

• With appropriate lifting device, install track frame and cap screws, but do not tighten.

4. Remove cap screws (3) and track frame. 5. Clean and inspect parts. Repair or replace as necessary.

BS40810,0000136 -19-06APR15-1/2

• Align sprocket (1) with center of rear track roller (2), as shown. - Tighten cap screws to specification.

1— Sprocket

TX1068734A —UN—05JAN10

Specification Frame-to-Track-Frame Cap Screw—Torque....................................................................620 N·m 460 lb.-ft. 2— Rear Track Roller

Sprocket-to-Rear Track Roller Alignment (top view) BS40810,0000136 -19-06APR15-2/2

TM14163X19 (15FEB18)

01-0130-67

450K, 550K, and 650K Crawler Dozer 021518 PN=119

Track System

T8058AH —UN—13SEP93

Frame Wear Strips Remove and Install

A—Track Frame B—Wear Strip (2 used)

C—6 ± 1.5 mm (0.23 ± 0.06 in.)

D—30.8 mm (1.21 in.) E—Welded Areas

1. Remove front idler. See Front Idler Remove and Install. (Group 0130.)

Before welding, clean all dirt and paint from the weld areas and turn battery disconnect switch to OFF. Connect the welder ground clamp close to each weld area so electrical current does not pass through any bearings.

2. Remove wear strips (B). 3. Grind track frame (A) wear strip surfaces smooth. Area must be free of any weld spatter. IMPORTANT: Good welds are important. Have only a qualified welder do the procedure. Use E7018 electrodes.

4. If track frame is still on machine, make sure the battery disconnect switch is turned to the OFF position. Continued on next page

TM14163X19 (15FEB18)

01-0130-68

MH66O88,0000958 -19-25MAR08-1/2

450K, 550K, and 650K Crawler Dozer 021518 PN=120

Track System

5. Clamp wear strip in position, using dimensions (C and D). 6. Weld each wear strip in eight places as indicated using E7018 electrodes.

7. Install and adjust front idler. See Front Idler Remove and Install and see Front Idler Adjustment. (Group 0130.) MH66O88,0000958 -19-25MAR08-2/2

Sprocket Remove and Install 69 kg 152 lb.

Drive Sprocket-to-Axle Shaft Cap Screw Torque (lubricated)

420 N·m 310 lb.-ft.

T118653B —UN—30NOV98

SPECIFICATIONS Sprocket Weight (approximate)

Sprocket Guard Upper Cap Screw 624 N·m 460 lb.-ft. Torque Sprocket Guard Lower Cap Screw 203 N·m 150 lb.-ft. Torque

NOTE: Sealed sprocket shown. Sprocket (sealed sprocket shown)

1. Disconnect track chain. See Lubricated Track Chain Remove and Install. (Group 0130.) 2. Raise rear of machine using a 10-ton floor jack and support with blocks.

1— Guard 2— Guard

3— Cap Screw (12 used)

3. Remove guards (1 and 2). CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 4. Attach appropriate lifting device to sprocket. Specification Sprocket—Weight (approximate).................................................................................. 69 kg 152 lb.

5. Remove cap screws (3) and lift sprocket from final drive. 6. Sprocket is not repairable. If excessively worn or damaged, replace. 7. Install sprocket. Tighten cap screws to specification.

Specification Drive Sprocket-toAxle Shaft Cap Screw—Torque (lubricated)..................................................................................420 N·m 310 lb.-ft.

8. Install sprocket guards. Tighten cap screws to specification. Specification Sprocket Guard Upper Cap Screw—Torque....................................................................624 N·m 460 lb.-ft. Sprocket Guard Lower Cap Screw—Torque....................................................................203 N·m 150 lb.-ft.

9. Install track chain. See Lubricated Track Chain Remove and Install. (Group 0130.) BS40810,0000138 -19-26MAR15-1/1

TM14163X19 (15FEB18)

01-0130-69

450K, 550K, and 650K Crawler Dozer 021518 PN=121

Track System

TM14163X19 (15FEB18)

01-0130-70

450K, 550K, and 650K Crawler Dozer 021518 PN=122

Section 02 Axles and Suspension Systems Contents Page

Group 0201—Drive Axle Housing and Support Final Drive Remove and Install.................. 02-0201-1 Group 0250—Axle Shaft, Bearings, and Reduction Gears Final Drive Disassemble and Assemble............................................... 02-0250-1

TM14163X19 (15FEB18)

02-1

450K, 550K, and 650K Crawler Dozer

021518

PN=1

Contents

TM14163X19 (15FEB18)

02-2

450K, 550K, and 650K Crawler Dozer

021518

PN=2

Group 0201

Drive Axle Housing and Support Final Drive Remove and Install SPECIFICATIONS 450K/550K Sprocket Weight (approximate)

55 kg 121 lb

650K Sprocket Weight (approximate)

69 kg 152 lb

TX1113153A —UN—30APR12

450K Final Drive Assembly Weight 413 kg (approximate) 911 lb 550K Final Drive Assembly Weight 406 kg (approximate) 895 lb 650K Final Drive Assembly Weight 392 kg (approximate) 864 lb Final Drive Mounting Cap Screw (10) Torque

320 N·m 236 lb·ft

Final Drive Mounting Cap Screw (8) Torque

320 N·m 236 lb·ft Guards (650K shown)

SERVICE EQUIPMENT AND TOOLS DF1063 Lift Bracket

1— Cover 2— Outer Guard

DFT1166 Final Drive Lifting Bracket Adapter

3— Cap Screw (12 used) 4— Inner Guard

DFT1167 Final Drive Lifting Bracket Adapter Spacer OTHER MATERIAL

Specification 450K/550K Sprocket—Weight (approximate).................................................................................. 55 kg 121 lb 650K Sprocket—Weight (approximate).................................................................................. 69 kg 152 lb

Loctite® 277™ Threadlocker (high strength)

REMOVAL 1. Disconnect track chain. See Lubricated Track Chain Remove and Install. (Group 0130.) 2. Remove hydrostatic motor. See Hydrostatic Motor Remove and Install. (Group 0300.) CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 3. Remove cover (1), outer guard (2), inner guard (4), cap screws (3), and sprocket. See Sprocket Remove and Install. (Group 0130.) Loctite and its related brand marks are trademarks of Henkel Corporation

BS40810,0000232 -19-03MAR17-1/4

4. Install DF1063 Lift Bracket (5), DFT1166 Final Drive Lifting Bracket Adapter (6), and DFT1167 Final Drive Lifting Bracket Adapter Spacer (7) on final drive. TX1233083A —UN—27JAN17

• See DF1063 Lift Bracket. (Group 9900.) • See DFT1166 Final Drive Lifting Bracket Adapter. (Group 9900.)

• See DFT1167 Final Drive Lifting Bracket Adapter Spacer. (Group 9900.)

5— Lift Bracket 6— Final Drive Lifting Bracket Adapter

7— Final Drive Lifting Bracket Adapter Spacer Lifting Bracket (650K shown) Continued on next page

TM14163X19 (15FEB18)

02-0201-1

BS40810,0000232 -19-03MAR17-2/4

450K, 550K, and 650K Crawler Dozer 021518 PN=125

Drive Axle Housing and Support

Remove cap screws (8).

TX1233084A —UN—27JAN17

8— Cap Screw (5 used)

Frame-to-Final Drive Cap Screws BS40810,0000232 -19-03MAR17-3/4

Disconnect park brake hose (9).

TX1233085A —UN—27JAN17

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 7. Attach appropriate lifting device to final drive assembly. Specification 450K Final Drive Assembly—Weight (approximate)................................................................................ 413 kg 911 lb 550K Final Drive Assembly—Weight (approximate)................................................................................ 406 kg 895 lb 650K Final Drive Assembly—Weight (approximate)................................................................................ 392 kg 864 lb

8. Remove cap screws (10) and final drive assembly. 9. Clean and inspect all parts. Repair or replace as necessary. See Final Drive Disassemble and Assemble. (Group 0250.) INSTALLATION Installation is reverse of removal procedure.

• Clean all mating surfaces of final drive. • Apply Loctite® 277™ Threadlocker (high strength) to

Final Drive 9— Park Brake Hose

10— Cap Screw (11 used)

• Tighten cap screws (10) to specification. Specification Final Drive Mounting Cap Screw (10)—Torque....................................................................320 N·m 236 lb·ft

• Tighten cap screws (8) to specification. Specification Final Drive Mounting Cap Screw (8)—Torque......................................................................320 N·m 236 lb·ft

surface of final drive and attaching hardware.

Loctite and its related brand marks are trademarks of Henkel Corporation BS40810,0000232 -19-03MAR17-4/4

TM14163X19 (15FEB18)

02-0201-2

450K, 550K, and 650K Crawler Dozer 021518 PN=126

Group 0250

Axle Shaft, Bearings, and Reduction Gears Final Drive Disassemble and Assemble NOTE: 450J shown unless otherwise indicated.

T199297A —UN—10MAY04

NOTE: The approximate capacity of each final drive is 8.5 L (9 qt). 1. Drain oil from final drive. CAUTION: Final drive assembly weighs approximately 340 kg (750 lbs). Use proper lifting equipment and safety precautions. Failure to do so may cause personal injury. Park Brake Assembly

2. Block and support final drive on heavy-duty bench. Specification Final Drive Assembly—Weight................................................... 340 kg Approximate 750 lb Approximate

3. Remove park brake assembly. See Park Brake Remove and Install. (Group 1100.) TE14778,0000024 -19-04MAY15-1/25

4. Remove axle shaft cover (1) and second idler pinion gear cover (2). 2— Second Idler Pinion Gear Cover T199777A —UN—10MAY04

1— Axle Shaft Cover

Covers TE14778,0000024 -19-04MAY15-2/25

Remove cap screws (3), retaining plate (1) and shims (2). 3— Cap Screws (3 used) T199779A —UN—10MAY04

1— Retaining Plate 2— Shims

Axle Shaft Shims and Retaining Plate Continued on next page

TM14163X19 (15FEB18)

02-0250-1

TE14778,0000024 -19-04MAY15-3/25

450K, 550K, and 650K Crawler Dozer 021518 PN=127

Axle Shaft, Bearings, and Reduction Gears

6. Remove housing cap screws (1). 7. Remove housing alignment dowel pins (2).

T199780A —UN—10MAY04

NOTE: The axle shaft inner bearing cone is pressed into the housing. Jack screws are needed to pull housing with bearing cone from shaft. Turn jack screws equally while separating housing halves. 8. Separate housing halves by installing jack screws (3). 9. Remove O-ring (4). 1— Cap Screws (24 used) 2— Dowel Pins (2 used)

3— Jack Screws (4 used) 4— O-Ring

Jack Screw TE14778,0000024 -19-04MAY15-4/25

10. Remove snap ring (1) from axle shaft.

T118848B —UN—11DEC98

1— Snap Ring

Snap Ring TE14778,0000024 -19-04MAY15-5/25

11. Remove first idler cluster gear (1) with bearing.

T118849B —UN—23DEC98

1— First Idler Cluster Gear

First Idler Cluster Gear Continued on next page

TM14163X19 (15FEB18)

02-0250-2

TE14778,0000024 -19-04MAY15-6/25

450K, 550K, and 650K Crawler Dozer 021518 PN=128

Axle Shaft, Bearings, and Reduction Gears

NOTE: Remove second idler ring and pinion gear assembly with final drive gear partially pulled up axle shaft.

T118850B —UN—11DEC98

12. Remove final drive gear (3) with bearing (1) and spacer (2). 13. Remove final drive gear spacer from axle shaft. 14. Lift housing half (4) off of axle shaft. 1— Bearing 2— Spacer

3— Gear 4— Housing Half

T119800B —UN—22JAN99

Final Drive Gear

Second Idler Pinion Gear Assembly TE14778,0000024 -19-04MAY15-7/25

15. Remove bearing (1) from axle shaft. 16. Remove and discard seal assembly (2). 17. Clean and inspect housing and parts. 2— Seal

T118852B —UN—11DEC98

1— Bearing

Axle Shaft Bearing and Seal Continued on next page

TM14163X19 (15FEB18)

02-0250-3

TE14778,0000024 -19-04MAY15-8/25

450K, 550K, and 650K Crawler Dozer 021518 PN=129

Axle Shaft, Bearings, and Reduction Gears

18. Remove parts (2—6) as shown. 19. Inspect final drive input gear (4) and bearing cones (3 and 5). Replace as necessary.

T118987 —UN—14DEC98

20. Install bearing cup (2) into brake housing. 21. Install bearing cup (6) into housing half (7). 22. Install bearing cones (3 and 5) onto final drive input gear (4). 1— Brake Housing 2— Bearing Cup 3— Bearing Cone 4— Final Drive Input Gear

5— Bearing Cone 6— Bearing Cup 7— Housing

Final Drive Input Gear

TE14778,0000024 -19-04MAY15-9/25

23. Remove parts (1—4) as shown. 24. Inspect second idler pinion gear (3) and bearing cones (1 and 4). Replace as necessary.

1— Bearing Cone 2— Second Idler Ring Gear

T118988 —UN—14DEC98

25. Install bearing cones (1 and 4) onto second idler pinion gear (3). 3— Second Idler Pinion Gear 4— Bearing Cone

Second Idler Pinion Gear TE14778,0000024 -19-04MAY15-10/25

NOTE: A snap ring, located in the center of the cluster gear bore, is used to provide proper spacing for bearing cups in assembly.

T118989 —UN—14DEC98

26. Remove bearing cups (1 and 4) from first idler cluster gear (3). 27. Install bearing cups (1 and 4) into the first idler cluster gear (3). Seat bearing cups on snap ring. 1— Bearing Cup 2— Snap Ring

3— First Idler Cluster Gear 4— Bearing Cup First Idler Cluster Gear Continued on next page

TM14163X19 (15FEB18)

02-0250-4

TE14778,0000024 -19-04MAY15-11/25

450K, 550K, and 650K Crawler Dozer 021518 PN=130

Axle Shaft, Bearings, and Reduction Gears

28. Remove final drive axle bearing cup (2) and second pinion outer bearing cup (3) from final drive housing (1).

1— Housing 2— Final Drive Axle Bearing Cup

T118990 —UN—14DEC98

29. Install final drive axle bearing cup (2) and second pinion outer bearing cup (3) into final drive housing (1). Fully seat bearing cups in bottom of bores. 3— Second Pinion Outer Bearing Cup

Seat Bearings in Housing TE14778,0000024 -19-04MAY15-12/25

30. Clean seal rubber rings and all surfaces that contact rubber rings with a non-petroleum based solvent. Thoroughly dry parts and surfaces using a lint-free tissue. T118986 —UN—14DEC98

31. Install seal assembly (2) onto axle shaft (3). 32. Install bearing cone (1) onto axle shaft (3), tight against shoulder. 1— Bearing Cone 2— Seal

3— Axle Shaft

Seal Assembly TE14778,0000024 -19-04MAY15-13/25

IMPORTANT: Special tool JDG1266 Final Drive Seal Protector centers axle in housing during installation. Failure to use the tool will result in a torn or damaged seal assembly. T118867B —UN—23DEC98

33. Install special tool (1) JDG1266 in bore of housing. 34. Place axle shaft assembly (2) on level surface. 35. Lower housing (3) onto axle shaft assembly (2). NOTE: Axle shaft and housing must be square and level for assembly. 36. With the weight of the housing on the axle flange, block and support housing using a level.

Special Tool, 450J Final Drive 1— JDG1266 Final Drive Seal Protector 2— Axle Shaft Assembly

37. Disconnect hoist and remove special tool (1).

Continued on next page

TM14163X19 (15FEB18)

02-0250-5

3— Housing

TE14778,0000024 -19-04MAY15-14/25

450K, 550K, and 650K Crawler Dozer 021518 PN=131

Axle Shaft, Bearings, and Reduction Gears

38. Install final drive gear spacer (1) onto axle shaft.

T118854B —UN—11DEC98

1— Final Drive Gear Spacer

Final Drive Gear Spacer TE14778,0000024 -19-04MAY15-15/25

NOTE: Install second idler pinion gear assembly (2) after final drive gear (1) is lowered halfway into position. 39. Install final drive gear (1). 2— Second Idler Pinion Gear Assembly

T118855B —UN—11DEC98

1— Final Drive Gear

Final Drive Gear and Pinion Gear Assembly Continued on next page

TM14163X19 (15FEB18)

02-0250-6

TE14778,0000024 -19-04MAY15-16/25

450K, 550K, and 650K Crawler Dozer 021518 PN=132

Axle Shaft, Bearings, and Reduction Gears

T81191 —UN—23FEB89

CAUTION: DO NOT heat oil over 182°C (360°F). Oil fumes or oil can ignite above 193°C (380°F). Use a thermometer. DO NOT allow flame or heater element to come in direct contact with the oil. Heat oil in a well ventilated area. 40. Install spacer (1) onto axle shaft with chamfer side toward gear. 41. Heat bearing cone (2) and install onto axle shaft above spacer (1). 1— Spacer

2— Bearing Cone

T118856B —UN—11DEC98

Heat Oil

Bearing Cone TE14778,0000024 -19-04MAY15-17/25

42. Install first idler cluster gear (1). 43. Heat bearing cone (2) and install onto axle shaft. 44. Install snap ring (3) onto axle shaft. T118857B —UN—11DEC98

Select the appropriate snap ring (3) by checking end play on first idler cluster gear and compare to following specifications. Final Drive—Specification Final Drive First Idler Cluster Gear—End Play......................................................0—0.228 mm 0—0.009 in. 1— First Idler Cluster Gear 2— Bearing Cone

Bearing and Snap Ring

3— Snap Ring

Continued on next page

TM14163X19 (15FEB18)

02-0250-7

TE14778,0000024 -19-04MAY15-18/25

450K, 550K, and 650K Crawler Dozer 021518 PN=133

Axle Shaft, Bearings, and Reduction Gears

45. Install housing alignment dowel pins (1) in housing half.

T119802B —UN—25JAN99

46. Apply PM37509 Cure Primer and PM38656 Thread Lock and Sealer (high strength) to housing sealing surface. 47. Join housing halves. 48. Install cap screws and tighten evenly to specifications. Final Drive—Specification Final Drive Housing Cap Screws—Initial Torque.................................................................135 N·m 100 lb-ft Final Torque................................................................................320 N·m 235 lb-ft

Final Drive Housing 1— Dowel Pins (2 used) TE14778,0000024 -19-04MAY15-19/25

49. Seat bearing cup (1) onto bearing cone.

T199786A —UN—11MAY04

1— Bearing Cup

Second Pinion Gear Bearing Cup Continued on next page

TM14163X19 (15FEB18)

02-0250-8

TE14778,0000024 -19-04MAY15-20/25

450K, 550K, and 650K Crawler Dozer 021518 PN=134

Axle Shaft, Bearings, and Reduction Gears

50. Measure distance between housing and bearing cone. Add shims (1) to achieve specified preload-end play.

T199781A —UN—10MAY04

Final Drive—Specification Final Drive Pinion Shaft—Preload-End Play........................................... 0.025 mm preload—0.152 mm end play 0.001 in. preload—0.005 in. end play

51. Install O-ring (2). 52. Install cover with three cap screws (4) and tighten to specifications. Final Drive—Specification Final Drive Pinion Shaft Cover Cap Screws—Torque............................................................................80 N·m 60 lb-ft 3— Cover 4— Cap Screw (3 used)

T199782A —UN—10MAY04

1— Shims 2— O-Ring

Second Idler Pinion Gear Shaft End Play Measurement

Retaining Plate Continued on next page

TM14163X19 (15FEB18)

02-0250-9

TE14778,0000024 -19-04MAY15-21/25

450K, 550K, and 650K Crawler Dozer 021518 PN=135

Axle Shaft, Bearings, and Reduction Gears

T81191 —UN—23FEB89

CAUTION: DO NOT heat oil over 182°C (360°F). Oil fumes or oil can ignite above 193°C (380°F). Use a thermometer. DO NOT allow flame or heater element to come in direct contact with the oil. Heat oil in a well ventilated area. NOTE: Housing and axle shaft flange must be level, with weight of housing on axle flange. 53. Heat bearing and install onto axle shaft. 54. Install shims (2) removed initially, and add an additional 0.508 mm (0.020 in.) shims to provide an end play on axle shaft.

Heat Oil

55. Install retaining plate (1). 56. Tighten retaining plate cap screws to specification (3).

T199779A —UN—10MAY04

Final Drive—Specification Retaining Plate Cap Screws—Torque..........................................................................156 N·m 115 lb-ft

57. Attach final drive housing to a hoist. 58. Lift final drive and rotate axle and tap on retaining cap with hammer and punch. Torque cap screws again to specification. Repeat this step until cap screws do not turn when tightened after tapping retainer plate. 1— Retaining Plate 2— Shims

Axle Shaft Shims and Retaining Plate

3— Cap Screws (3 used)

TE14778,0000024 -19-04MAY15-22/25

59. Place dial indicator at the exact center of retaining cap as shown and adjust to zero.

TX1054194A —UN—14JAN09

60. Lower final drive assembly until axle shaft flange is on a level surface with weight of final drive housing on axle flange and bearing. Loosen hoist chains, balance and rotate find drive housing by hand. Record indicator maximum reading. 61. The maximum dial indicator reading will be the axle shaft bearing end play. 62. Remove retaining plate and adjust shims as required to obtain specified axle shaft preload. Final Drive—Specification Final Drive Axle Shaft Preload—Preload....................................................0.05 mm—0.155 mm 0.002—0.006 in.

63. Apply PM37509 Cure Primer and PM38656 Thread Lock and Sealer (high strength) to retaining plate cap screws and tighten to specifications.

Axle Preload Adjustment

Final Drive—Specification Final Drive Axle Shaft Retaining Plate Cap Screws—Torque..........................................................................156 N·m 115 lb-ft

Continued on next page

TM14163X19 (15FEB18)

02-0250-10

TE14778,0000024 -19-04MAY15-23/25

450K, 550K, and 650K Crawler Dozer 021518 PN=136

Axle Shaft, Bearings, and Reduction Gears

64. Apply PM37509 Cure Primer and PM38656 Thread Lock and Sealer (high strength) to axle shaft cover plate (1). Install cover and tighten cap screws to specifications.

1— Cover Plate

T199784A —UN—10MAY04

Final Drive—Specification Final Drive Axle Shaft Cover Plate Cap Screws—Torque............................................................................80 N·m 60 lb-ft

2— Cap Screws (4 used) Axle Shaft Cover

TE14778,0000024 -19-04MAY15-24/25

65. Install park brake assembly. See Park Brake Remove and Install. (Group 1100.)

T199297A —UN—10MAY04

CAUTION: Use only regulated, compressed air of 34.5 kPa (0.345 bar) (5 psi) maximum to check seal on final drive housing. If high pressure compressed air is used, premature case seal failure can occur. Wear proper face and body protection when using compressed air. 66. Install a 0—15 psi gauge and shut-off valve in the housing oil fill hole.

Park Brake Assembly

67. Using a regulated air source, apply a maximum of 34.5 kPa (0.345 bar) (5 psi) to case and close shut-off valve. 68. Observe pressure gauge for five minutes. If any pressure drop occurs, the housing must be checked for leaks and resealed. TE14778,0000024 -19-04MAY15-25/25

TM14163X19 (15FEB18)

02-0250-11

450K, 550K, and 650K Crawler Dozer 021518 PN=137

Axle Shaft, Bearings, and Reduction Gears

TM14163X19 (15FEB18)

02-0250-12

450K, 550K, and 650K Crawler Dozer 021518 PN=138

Contents

Section 03 Transmission

Page

Group 0300—Removal and Installation Hydrostatic Pump and Motor Initial Start-Up Procedure................................ 03-0300-1 Hydrostatic Pump Remove and Install ..................................................... 03-0300-2 Hydrostatic Motor Remove and Install ..................................................... 03-0300-6 Group 0315—Controls Linkage Transmission Control Lever (TCL) Remove and Install................................ 03-0315-1 Transmission Control Lever (TCL) Disassemble and Assemble .................. 03-0315-2 Decelerator/Brake Pedal Remove and Install ............................................ 03-0315-19 Decelerator/Brake Pedal Disassemble and Assemble ................ 03-0315-20 Group 0325—Input Drive Shafts and U-Joints Damper Drive Remove and Install.............. 03-0325-1 Group 0360—Hydrostatic System Hydrostatic Pump Disassemble................. 03-0360-1 Charge Pump Disassemble and Assemble............................................... 03-0360-9 Pump Displacement Control Valve (PDCV) Disassemble and Assemble............................................. 03-0360-13 Multi-Function Valve Remove and Install ................................................... 03-0360-15 Multi-Function Valve Disassemble and Assemble...................................... 03-0360-15 Hydrostatic Pump Assemble ................... 03-0360-17 Neutral Charge Relief Valve Disassemble and Assemble ................ 03-0360-24 Hydrostatic Motor Disassemble............... 03-0360-25 Hydrostatic Motor Assemble.................... 03-0360-37 Hydrostatic Thermal Bypass Valve Remove and Install.............................. 03-0360-52 Hydrostatic Charge Oil Filter Assembly Remove and Install ............. 03-0360-53 Hydrostatic Charge Oil Filter Assembly Disassemble and Assemble............................................. 03-0360-54 Hydrostatic and Hydraulic Oil Reservoir Cleanout Cover Remove and Install.............................. 03-0360-55 Hydraulic Oil Reservoir Remove and Install ............................................ 03-0360-55

TM14163X19 (15FEB18)

03-1

450K, 550K, and 650K Crawler Dozer

021518

PN=1

Contents

TM14163X19 (15FEB18)

03-2

450K, 550K, and 650K Crawler Dozer

021518

PN=2

Group 0300

Removal and Installation Hydrostatic Pump and Motor Initial Start-Up Procedure 345 kPa 3.45 bar 50 psi

Engine Speed

Slow Idle

Engine Speed

Fast Idle

TX1232810A —UN—24JAN17

SPECIFICATIONS Transmission Charge Pressure

SERVICE EQUIPMENT AND TOOLS D01182AA 20-Ton Floor Stand (4 used)

This procedure is used to bleed air from the hydrostatic circuit after a major component repair. CAUTION: Prevent possible injury from unexpected track movement. Raise the machine off the ground and support with appropriate stands. Tracks MUST be clear of tools and objects before rotating. 1. Raise machine off the ground and support with D01182AA 20-Ton Floor Stands. Lower blade to ground. Tracks must be free to rotate in either direction. 2. Fill reservoir with specified oil. See Hydraulic and Hydrostatic Oil. (Operator's Manual.)

Fuse Panel F31— Engine Control Unit (ECU) Unswitched Power 25 A Fuse 1

F64— Fuse Box 2

8. Crank engine in 30 second intervals until transmission charge pressure reaches specification. Specification Transmission Charge—Pressure....................................................................... 345 kPa 3.45 bar 50 psi

3. Check oil level. See Check Hydraulic/Hydrostatic System Oil Level. (Operator’s Manual.)

9. Turn battery disconnect switch to OFF position.

4. Turn battery disconnect switch to OFF position.

11. Turn battery disconnect to ON position.

5. Remove engine control unit (ECU) unswitched power 25 A fuse 1 (F31) from fuse box 2 (F64).

12. Start engine and run at specification for 1 minute.

6. Turn battery disconnect to ON position.

Specification Engine—Speed..........................................................................Slow Idle

7. Display transmission charge pressure on standard display unit (SDM). See Diagnostics—Machine Information, SDM. (Group 9015-16.) IMPORTANT: Overheating, caused by excessive operation, will severely damage starting motor. Never operate starting motor more than 30 seconds. Allow at least 2 minutes for cooling and battery recovery before operating again.

10. Install ECU unswitched power 25 A fuse 1.

13. Set engine speed to specification. Specification Engine—Speed.......................................................................... Fast Idle

14. Operate machine at low speed in forward, reverse, and counter-rotation for several minutes. This process flushes the displacement control valve areas. 15. Check oil level in hydraulic oil reservoir. BS40810,0000233 -19-27JAN17-1/1

TM14163X19 (15FEB18)

03-0300-1

450K, 550K, and 650K Crawler Dozer 021518 PN=141

Removal and Installation

Hydrostatic Pump Remove and Install

2. Turn battery disconnect switch to OFF position.

SPECIFICATIONS Hydrostatic Pump Assembly Weight (approximate)

120 kg 265 lb

Damper Hub Set Screw Torque

86 N·m 63 lb·ft

Hydrostatic Pump-to-Flywheel Housing Cap Screw Torque

112 N·m 83 lb·ft

Hydraulic Pump Mounting Cap Screw Torque

112 N·m 83 lb·ft

3. Drain hydraulic and hydrostatic oil reservoirs. See Drain and Refill Hydraulic/Hydrostatic System Oil and Replace Filters. (Operator’s Manual.) REMOVAL NOTE: Hydrostatic pumps can be removed through the operator’s station floor access plate or by removing the operator’s station.

SERVICE EQUIPMENT AND TOOLS

1. If removing operator’s station, see Operator’s Station Remove and Install. (Group 1800.)

D01182AA 20-Ton Floor Stand (4 used) DFT1119 Pump Lifting Bracket

If not removing operator’s station, remove under seat heater. See Under Seat Heater Remove and Install (Group 1830.)

DFT1130 Adapter OTHER MATERIAL Loctite® 7649™ Primer N™ Cure Primer

Loctite® 242® Threadlocker (medium strength)

Install identification tags to all electrical connectors, hydraulic hoses, and lines to aid in assembly. Clean component and adjacent areas before starting work. Close all openings using caps and plugs.

NOTE: Other models are similar to graphic shown.

MACHINE PREPARATION 2. Disconnect lines (1, 2, 6, 7, and 9—11). CAUTION: Prevent possible injury from unexpected track movement. Raise the machine off the ground and support with 20-ton floor stands. Tracks MUST be free to rotate in either direction.

3. Disconnect hydrostatic oil temperature sensor (8) connector. 4. Remove cap screws (4) from hydraulic pump and remove pump. Set pump aside.

1. Raise machine off the ground and support with D01182AA 20-Ton Floor Stands. Lower blade to ground. Tracks must be free to rotate in either direction.

Continued on next page

TM14163X19 (15FEB18)

03-0300-2

BS40810,0000234 -19-28FEB17-1/6

450K, 550K, and 650K Crawler Dozer 021518 PN=142

Removal and Installation 8— Hydrostatic Oil Temperature Sensor 9— Line (park brake) 10— Line (oil filter to charge pump) 11— Line (charge pump to oil filter)

TX1113233A —UN—03MAY12

1— Line (front pump tee fitting to cooler bypass valve) 2— Line (front pump to rear pump) 4— Hydraulic Pump Mounting Cap Screw (4 used) 6— Line (oil cooler bypass valve to reservoir) 7— Line (left motor tee fitting to oil cooler bypass valve)

Hydrostatic Pumps Loctite and its related brand marks are trademarks of Henkel Corporation BS40810,0000234 -19-28FEB17-2/6

NOTE: Other models are similar to graphic shown. NOTE: For ease of removal and installation of pumps, lines can be tied together and pulled up and out of the way. 5. Disconnect lines (16—19 and 21). 6. Disconnect rear and front pump pressure control pilot (PCP) (22 and 23) wiring connectors.

15— Hydrostatic Pump-to-Rear Mount Bracket Cap Screw (2 used) 16— Line (front charge pump to rear charge pump tee fitting) 17— Line (front pump reverse outlet port to R.H. motor port) 18— Line (front pump forward outlet port to R.H. motor port) 19— Line (rear pump forward outlet port to L.H. motor port)

TX1232841A —UN—26JAN17

7. Remove cap screws (15 and 20) and rear pump mounting bracket. 20— Rear Pump Mount Bracket-to-Frame Cap Screw (4 used) 21— Line (rear pump reverse outlet port to L.H. motor port) 22— Rear Pump Pressure Control Pilot (PCP) 23— Front Pump Pressure Control Pilot (PCP)

Hydrostatic Pumps

Continued on next page

TM14163X19 (15FEB18)

03-0300-3

BS40810,0000234 -19-28FEB17-3/6

450K, 550K, and 650K Crawler Dozer 021518 PN=143

Removal and Installation

8. Drill and tap two plugs to accommodate a 1/2-in eyebolt. 9. Remove pump fittings and install eyebolts as shown. T118456A —UN—10DEC98

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 10. Connect hydrostatic pumps to hoist using chains, DFT1119 Pump Support, and DFT1130 Adapter. See DFT1119 Pump Support and see DFT1130 Adapter. (Group 9900.) Specification Hydrostatic Pump Assembly—Weight (approximate)................................................................................ 120 kg 265 lb

11. Remove hydrostatic pump mounting cap screws and pull pumps back far enough for damper hub to clear flywheel housing cover. 12. Place a wood block under rear pump and lower pumps to rest on frame.

Pump Lift Eyebolts

14. Carefully remove pumps from left side of machine, damper drive first. The best clearance is achieved close to the floor, passing through the recess in console frame. 15. Mark orientation of fittings to aid in assembly. Remove hydraulic lines and fittings from pumps.

13. Disconnect rear chain. Shorten and reconnect to lift out pumps at approximate 45° angle. BS40810,0000234 -19-28FEB17-4/6

TX1232845A —UN—26JAN17

16. Remove the cap screws (24) joining the two pumps and then separate pumps. 24— Cap Screw (4 used)

Double Pump Assembly Cap Screws Continued on next page

TM14163X19 (15FEB18)

03-0300-4

BS40810,0000234 -19-28FEB17-5/6

450K, 550K, and 650K Crawler Dozer 021518 PN=144

Removal and Installation

TX1232846 —UN—26JAN17

TX1232846 Damper Assembly 25— Flywheel Housing Plate

27— Damper Hub

26— Set Screw

17. Remove set screw (26) and damper hub (27) from pump drive shaft. 18. Clean and inspect parts. Repair or replace parts as necessary. See Hydrostatic Pump Disassemble. (Group 0360.)

Specification Hydrostatic Pump-toFlywheel Housing Cap Screw—Torque............................................................................ 112 N·m 83 lb·ft

NOTE: Ensure that flange side is down and serial plate is on the right side on hydraulic pump without winch.

INSTALLATION Installation is reverse of removal procedure.

• Install damper hub until internal snap ring contacts end of pump shaft.

• Apply Loctite® 7649™ Primer N™ Cure Primer and Loctite® 242® Threadlocker (medium strength) to threads of set screws. Tighten set screw (26) to specification.

• Tighten cap screws (4) to specification. Specification Hydraulic Pump Mounting Cap Screw—Torque.................................................................... 112 N·m 83 lb·ft

• Calibrate transmission control unit (TCU). See

Specification Damper Hub Set Screw—Torque..............................................................................86 N·m 63 lb·ft

Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

• Clean threads and apply clean hydraulic oil to

hydrostatic pump-to-flywheel housing cap screws. Tighten to specification.

Loctite and its related brand marks are trademarks of Henkel Corporation BS40810,0000234 -19-28FEB17-6/6

TM14163X19 (15FEB18)

03-0300-5

450K, 550K, and 650K Crawler Dozer 021518 PN=145

Removal and Installation

Hydrostatic Motor Remove and Install SPECIFICATIONS Hydrostatic Motor Weight (approximate)

35 kg 77 lb

Hydrostatic Motor Mounting Cap Screw Torque

130 N·m 96 lb·ft

ESSENTIAL TOOLS DFT1132 Hydrostatic Motor/Hydraulic Pump Tool TX1187897A —UN—16MAR15

DFT1137 Hydrostatic Motor Removal and Installation Tool OTHER MATERIAL Loctite® 7649™ Primer N™ Cure Primer Loctite® 277™ Threadlocker (high strength)

REMOVAL 1. Lower all equipment to ground.

Hydrostatic Motor (left side shown)

2. Stop engine. Operate all hydraulic controls to release pressure in hydraulic system. See Hydraulic System Pressure Release. (Operator’s Manual.)

1— Case Drain Hose 2— Forward Direction Hose 3— Reverse Direction Hose 4— Park Brake Hose

3. Turn battery disconnect switch to OFF. 4. Drain reservoir or apply a vacuum to reservoir. See Drain and Refill Hydraulic/Hydrostatic System Oil and Replace Filters. (Operator’s Manual.) 5. Remove rear access cover or rear mounted optional equipment from rear of machine.

B6—Left Hydrostatic Pressure Sensor B12— Left Motor Speed Sensor Y1— Left Motor Shift Solenoid

8. Disconnect case drain hose (1) and park brake hose (4). 9. Disconnect forward and reverse hoses (2 and 3).

6. Remove left or right floor access plate.

10. Close all openings using caps and plugs. 11. Disconnect wire connectors from left motor shift solenoid (Y1), left hydrostatic pressure sensor (B6), and left motor speed sensor (B12).

CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 7. Tag and mark hose locations to aid in assembly. Loctite and its related brand marks are trademarks of Henkel Corporation

Continued on next page

TM14163X19 (15FEB18)

03-0300-6

BS40810,0000236 -19-10MAR17-1/2

450K, 550K, and 650K Crawler Dozer 021518 PN=146

Removal and Installation

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

13. Attach DFT1137 Hydrostatic Motor Removal and Installation Tools (A and C) to motor. See DFT1137 Hydrostatic Motor Removal and Installation Tool. (Group 9900.)

C Hydrostatic Motor Removal

14. Attach DFT1132 Hydrostatic Motor/Hydraulic Pump Tool to eyebolt in DFT1137 Hydrostatic Motor Removal and Installation Tool.

A—DFT1137 Hydrostatic Motor Removal and Installation Tool (top piece) B—DFT1132 Hydrostatic Motor/Hydraulic Pump Tool

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 15. Remove nuts and washers from motor-to-mounting flange. Specification Hydrostatic Motor—Weight (approximate).................................................................................. 35 kg 77 lb

TX1074259 —UN—05APR10

12. Attach DFT1132 Hydrostatic Motor/Hydraulic Pump Tool (B) to hoist with sling. See DFT1132 Hydrostatic Motor/Hydraulic Pump Tool. (Group 9900.)

C—DFT1137 Hydrostatic Motor Removal and Installation Tool (bottom piece)

Specification Hydrostatic Motor Mounting Cap Screw—Torque............................................................................130 N·m 96 lb·ft

16. Carefully pry motor away from mounting flange.

5. Remove hydrostatic motor removal and installation tools.

17. Remove motor through hole in rear of machine.

6. Connect hydrostatic lines and wiring connector.

18. Clean threads of mounting holes and cap screws.

7. Fill reservoir if drained. See Drain and Refill Hydraulic/Hydrostatic System Oil and Replace Filters. (Operator’s Manual.)

19. Repair or replace motor. See Hydrostatic Motor Disassemble and see Hydrostatic Motor Assemble. (Group 0360.) INSTALLATION 1. Apply petroleum jelly to new O-ring and install on transmission motor flange.

8. Turn battery disconnect switch to ON. 9. Calibrate transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

2. Guide hydrostatic motor through frame opening.

10. Install rear access plate or rear mounted optional equipment.

3. Position motor on studs, align splines in coupler, and slide motor into position.

11. Replace bottom access plates if removed.

4. Apply Loctite® 7649™ Primer N™ Cure Primer and Loctite® 277™ Threadlocker (high strength) to threads of cap screws and tighten to specification. Loctite and its related brand marks are trademarks of Henkel Corporation BS40810,0000236 -19-10MAR17-2/2

TM14163X19 (15FEB18)

03-0300-7

450K, 550K, and 650K Crawler Dozer 021518 PN=147

Removal and Installation

TM14163X19 (15FEB18)

03-0300-8

450K, 550K, and 650K Crawler Dozer 021518 PN=148

Group 0315

Controls Linkage Transmission Control Lever (TCL) Remove and Install SPECIFICATIONS 37 N·m 27 lb.-ft.

Cap Screw Torque

OTHER MATERIAL Loctite® 7649™ Primer N™ Cure Primer Loctite® 242® Threadlocker (medium strength)

1. Turn battery disconnect switch to the OFF position.

T199276A —UN—16APR04

2. Remove cap screws (1) and transmission control lever (TCL) assembly. 1— Cap Screw (4 used)

Transmission Control Lever (TCL) Loctite and its related brand marks are trademarks of Henkel Corporation DA93471,00000C2 -19-02MAR15-1/2

3. Install identification tags and disconnect sensors (B2 and B3), switch (S12), and TCL (A10). 4. Clean and inspect all parts. Replace if necessary. See Transmission Control Lever (TCL) Disassemble and Assemble. (Group 0315.) 5. Connect sensors, switch, and TCL.

TX1182375 —UN—13JAN15

6. Apply Loctite® 7649™ Primer N™ Cure Primer and Loctite® 242® Threadlocker (medium strength) to threads of cap screws. Install transmission control lever (TCL) assembly using cap screws (1). Tighten to specification. Specification Cap Screw—Torque......................................................................37 N·m 27 lb.-ft.

7. Turn battery disconnect switch to the ON position. 8. Adjust transmission control lever (TCL). See Transmission Control Lever (TCL) Adjustment. (Group 9015-20.) 9. Calibrate transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

Transmission Control Lever (TCL) A10— Transmission Control Lever (TCL) B2—Forward, Neutral, and Reverse (FNR) Sensor

B3—Steer Sensor S12— Neutral Start Switch

Loctite is a trademark of Henkel Corporation DA93471,00000C2 -19-02MAR15-2/2

TM14163X19 (15FEB18)

03-0315-1

450K, 550K, and 650K Crawler Dozer 021518 PN=149

Controls Linkage

Transmission Control Lever (TCL) Disassemble and Assemble SPECIFICATIONS FNR Linkage Nut Torque

19 N·m 168 lb.-in.

Steer Rod Ball Joint Nut Torque

9 N·m 80 lb.-in.

Steer Sensor Cap Screw Torque

5 N·m 44 lb.-in.

FNR Sensor Cap Screw Torque

5 N·m 44 lb.-in.

Neutral Start Switch Torque

14 N·m 124 lb.-in.

Neutral Start Switch Cover Cap Screw Torque

5 N·m 44 lb.-in.

Lever Cap Screw and Nut Torque

19 N·m 168 lb.-in.

Detent Spring Retaining Plate Cap 5 N·m 44 lb.-in. Screw Torque Spring End Lock Nut Torque

8 N·m 71 lb.-in.

Steer Shaft Assembly Mounting Cap Screw Torque

34 N·m 25 lb.-ft.

TCL Top Plate Socket Head Cap Screw Torque

9 N·m 80 lb.-in.

ESSENTIAL TOOLS JDG1303 Bearing Driver Kit OTHER MATERIAL Loctite® 7649™ Primer N™ Cure Primer Loctite® 242® Threadlocker (medium strength)

Continued on next page

TM14163X19 (15FEB18)

03-0315-2

DA93471,00000C3 -19-06MAY15-1/38

450K, 550K, and 650K Crawler Dozer 021518 PN=150

TX1181019 —UN—19JAN15

Controls Linkage

Transmission Control Lever (TCL)

Continued on next page

TM14163X19 (15FEB18)

03-0315-3

DA93471,00000C3 -19-06MAY15-2/38

450K, 550K, and 650K Crawler Dozer 021518 PN=151

Controls Linkage 1— Cam Shaft 2— Bearing (3 used) 3— Bearing 4— Seal (2 used) 5— Bearing Block 6— Universal Driveshaft 7— TCL Harness and Switch 8— Seal (2 used) 9— Bearing (2 used) 10— Spring Pin 11— Universal Driveshaft 12— Plug (2 used) 13— Cam 14— Spring Pin (2 used) 15— Washer (2 used) 16— Plate 17— FNR Linkage 18— Nut

19— Nut 20— Cover 21— Socket Head Cap Screw (6 used) 22— Bushing 23— Washer 24— Socket Head Cap Screw 25— Spacer 26— Nut (2 used) 27— Retaining Plate 28— Switch Cover 29— Washer (2 used) 30— Spacer (2 used) 31— Spring 32— Spring 33— Spring 34— Spring 35— Spring End Lock Nut (2 used) 36— Rod End Lock Nut

37— Needle Roller 38— O-Ring (2 used) 39— Socket Head Cap Screw 40— Detent Spring 41— Socket Head Cap Screw (2 used) 42— Steer Rod Ball Joint 43— Post 44— Post (3 used) 45— Label 46— Clip Kit 47— O-Ring 48— O-Ring (2 used) 49— Socket Head Cap Screw (4 used) 50— Socket Head Cap Screw (4 used) 51— Boot 52— Tie Band (2 used)

53— Washer (3 used) 54— Clamp 55— Socket Head Cap Screw (4 used) 56— Bushing 57— Bushing 58— Spring Guide (2 used) 59— Detent Lever 60— Steer Shaft A10— Transmission Control Lever (TCL) B2—Forward, Neutral, and Reverse (FNR) Sensor B3—Steer Sensor S12— Neutral Start Switch

Loctite and its related brand marks are trademarks of Henkel Corporation DA93471,00000C3 -19-06MAY15-3/38

T199273A —UN—16APR04

1. Remove transmission control lever (TCL) from side console. See Transmission Control Lever (TCL) Remove and Install. (Group 0315.)

Transmission Control Lever (TCL) Continued on next page

TM14163X19 (15FEB18)

03-0315-4

DA93471,00000C3 -19-06MAY15-4/38

450K, 550K, and 650K Crawler Dozer 021518 PN=152

Controls Linkage

2. Separate boot from plate using a screwdriver. 3. Remove tie bands (1). 4. Put identification marks (2) on both sides of wire lead to aid in assembly. 5. Remove clamp (3) from wire lead. 3— Clamp

T124638B —UN—17SEP99

1— Tie Band (2 used) 2— Identification Mark (2 used)

Transmission Control Lever (TCL) DA93471,00000C3 -19-06MAY15-5/38

6. Remove screws (1—3) and boot from TCL. 3— Screw With Nut (2 used)

T124645B —UN—17SEP99

1— Screw (2 used) 2— Screw

TCL Grip Assembly Continued on next page

TM14163X19 (15FEB18)

03-0315-5

DA93471,00000C3 -19-06MAY15-6/38

450K, 550K, and 650K Crawler Dozer 021518 PN=153

Controls Linkage

7. Split grip halves (1) to remove switch (2). Boot (3) on switch can be replaced, if necessary. 3— Boot

T124646B —UN—17SEP99

1— Grip 2— Switch

Grip Assembly DA93471,00000C3 -19-06MAY15-7/38

8. Loosen lock nut (1). 9. Remove steer shaft (2) from ball joint (3). 10. Remove socket head cap screws (4) and remove steer shaft assembly from body. 3— Ball Joint 4— Socket Head Cap Screw (2 used) T119639B —UN—19JAN99

1— Lock Nut 2— Steer Shaft

Steer Shaft Removal Continued on next page

TM14163X19 (15FEB18)

03-0315-6

DA93471,00000C3 -19-06MAY15-8/38

450K, 550K, and 650K Crawler Dozer 021518 PN=154

Controls Linkage

11. Remove rod end lock nut (8). NOTE: Used two wrenches to loosen spring end lock nuts (1). T119641B —UN—19JAN99

NOTE: Springs are color coded to aid in assembly. 12. Remove one spring end lock nut (1), spring guide (2), spacer (3), spring (4) or (7) and spring seat (5) from one side of steering plate (6). 13. Place steer shaft (9) in soft jaw vise and remove spring end lock nut (1), spring guide (2), spacer (3), spring (4) or (7) and spring seat (5) from other side of steering plate. 6— Steering Plate 7— Spring (gold) 8— Rod End Lock Nut 9— Steer Shaft T119642B —UN—19JAN99

1— Spring End Lock Nut (2 used) 2— Spring Guide (2 used) 3— Spacer (2 used) 4— Spring (chrome) 5— Spring Seat (2 used)

Steer Shaft Assembly

Steer Shaft Disassemble DA93471,00000C3 -19-06MAY15-9/38

14. Remove socket head cap screws (1), retaining plate (2) and detent spring (3). 15. Remove nut (4), socket head cap screw (8), spacer (5), washer (7), and detent lever (9). 16. Remove bushing (6) from detent lever. 6— Bushing 7— Washer 8— Socket Head Cap Screw 9— Dentent Lever

T119643B —UN—19JAN99

1— Socket Head Cap Screw (2 used) 2— Retaining Plate 3— Detent Spring 4— Nut 5— Spacer

Plate and Lever Assembly Continued on next page

TM14163X19 (15FEB18)

03-0315-7

DA93471,00000C3 -19-06MAY15-10/38

450K, 550K, and 650K Crawler Dozer 021518 PN=155

Controls Linkage

17. Remove socket head cap screws from steer sensor (1) and forward, neutral, and reverse (FNR) sensor (2). Remove sensors and O-rings. 2— Forward, Neutral, and Reverse (FNR) Sensor

T119644B —UN—19JAN99

1— Steer Sensor

Operation Sensors DA93471,00000C3 -19-06MAY15-11/38

18. Remove cover (3) and neutral start switch (4). 4— Neutral Start Switch

T119645B —UN—19JAN99

3— Cover

Neutral Start Switch DA93471,00000C3 -19-06MAY15-12/38

19. Disconnect FNR linkage (1) and remove steer rod ball joint (2) from bracket assembly (3). 3— Bracket Assembly T119646B —UN—19JAN99

1— FNR Linkage 2— Steer Rod Ball Joint

Linkage Continued on next page

TM14163X19 (15FEB18)

03-0315-8

DA93471,00000C3 -19-06MAY15-13/38

450K, 550K, and 650K Crawler Dozer 021518 PN=156

Controls Linkage

NOTE: Care should be taken to avoid damaging bearing block, bearings, and seals.

T119649B —UN—19JAN99

20. Remove two seal plugs and using a 1/4 in. punch with rounded edges, drive universal driveshaft (1) from bracket assembly. Remove bracket. 1— Universal Driveshaft

Universal Driveshaft DA93471,00000C3 -19-06MAY15-14/38

21. Remove universal driveshaft (2) and bearing block (1). 2— Universal Driveshaft

T119650B —UN—19JAN99

1— Bearing Block

Universal Driveshaft and Bearing Block DA93471,00000C3 -19-06MAY15-15/38

NOTE: When driving pin out of plate, support assembly to prevent damage to bearings and seals. 22. With the plate (2) placed at the furthest reverse position, drive spring pin (1) out until plate (2) can be rotated around cam shaft (3).

T119651B —UN—18JAN99

23. Remove cam shaft (3) by pulling on cam (5). Be sure to catch plate (2) with rod end assembly and two spacers (4) when removing cam shaft. 24. Remove FNR linkage assembly from plate, if replacement is required. 25. Remove cam (5) from cam shaft (3) by driving out spring pin, if replacement is required. 26. Remove spring pin (1) from plate (2). 1— Spring Pin 2— Plate 3— Cam Shaft

Plate and Cam Assembly

4— Spacer (2 used) 5— Cam

Continued on next page

TM14163X19 (15FEB18)

03-0315-9

DA93471,00000C3 -19-06MAY15-16/38

450K, 550K, and 650K Crawler Dozer 021518 PN=157

Controls Linkage

27. Remove seals (1 and 3) using a pick. 2— Bearing (2 used)

T121377B —UN—11MAY99

1— Seal (2 used)

Seals and Bearings DA93471,00000C3 -19-06MAY15-17/38

28. Remove bearings (2) using JDG1303 Bearing Driver Kit. 4— Bearing (2 used) T121378B —UN—11MAY99

3— Seal (2 used)

Seals and Bearings DA93471,00000C3 -19-06MAY15-18/38

29. Remove bearings (4 and 5) using bearing driver kit. 30. Clean and inspect parts.

T121379B —UN—11MAY99

5— Bearing (2 used)

Bearings Continued on next page

TM14163X19 (15FEB18)

03-0315-10

DA93471,00000C3 -19-06MAY15-19/38

450K, 550K, and 650K Crawler Dozer 021518 PN=158

Controls Linkage

IMPORTANT: Drive bearing from lettered side of bearing only.

T121380B —UN—11MAY99

31. Install bearing (3) using JDG1303-4 Driver Disk and JDG1303-5 Driver Rod. Drive bearing until driver disk is fully seated on bracket, this will set bearing to proper depth. 32. Repeat step 31 for installing other bearing. IMPORTANT: Lip side of seal must face away from bearing. 33. Apply petroleum jelly to seal and install seal (5) on JDG1303-7 Driver Disk (4) with lip of seal facing toward driver disk. 1— JDG1305-5 Driver Rod 2— JDG1303-4 Driver Disk

Bearing Installation

3— Bearing (2 used)

DA93471,00000C3 -19-06MAY15-20/38

34. Place seal and driver disk square on bracket. Insert JDG1303-5 Driver Rod and drive seal until driver disk is fully seated on bracket. 35. Repeat steps 33 and 34 for installing other seals. 5— Seal (2 used) T121381B —UN—11MAY99

1— JDG1305-5 Driver Rod 4— JDG1303-7 Driver Disk

Seal Installation DA93471,00000C3 -19-06MAY15-21/38

IMPORTANT: Drive bearing from lettered side of bearing only.

1— JDG1303-1 Bearing Driver 2— JDG1303-3 Sleeve

T121382B —UN—11MAY99

36. Install bearing (3) using JDG1303-1 Bearing Driver (1) and JDG1303-3 Sleeve (2). Drive bearing until driver is fully seated, this will set bearing to proper depth. 3— Bearing

Bearing Installation Continued on next page

TM14163X19 (15FEB18)

03-0315-11

DA93471,00000C3 -19-06MAY15-22/38

450K, 550K, and 650K Crawler Dozer 021518 PN=159

Controls Linkage

37. Install bearing (4) using bearing driver (1). Drive bearing until driver is fully seated, this will set bearing to proper depth. 4— Bearing

T121383B —UN—11MAY99

1— JDG1303-1 Bearing Driver

Bearing Installation DA93471,00000C3 -19-06MAY15-23/38

IMPORTANT: Lip side of seal must face away from bearing. 38. Apply petroleum jelly to seals and install seal (5) on JDG1303-6 Driver Disk with lip of seal facing toward driver disk. T121384B —UN—11MAY99

39. Place seal and driver disk square in opening and firmly press with finger pressure to install seal. Press disk driver until fully seated. 40. Repeat steps to install other seal. 5— Seal (2 used) Seal Installation

DA93471,00000C3 -19-06MAY15-24/38

IMPORTANT: Drive bearing from lettered side of bearing only.

1— JDG1303-1 Bearing Driver 2— JDG1303-2 Sleeve

T121385B —UN—11MAY99

41. Install bearing (3) from the stepped recess side (yellow) opening. Using JDG1303-1 Bearing Driver (1) and JDG1303-2 Sleeve (2), drive bearing through until bearing driver is fully seated. This will set bearing to proper depth. 3— Bearing

Bearing Installation Continued on next page

TM14163X19 (15FEB18)

03-0315-12

DA93471,00000C3 -19-06MAY15-25/38

450K, 550K, and 650K Crawler Dozer 021518 PN=160

Controls Linkage

42. Install bearing (4) using bearing driver (1). Drive bearing until bearing driver is fully seated, this will set bearing to proper depth. 4— Bearing

T121386B —UN—11MAY99

1— JDG1303-1 Bearing Driver

Bearing Installation DA93471,00000C3 -19-06MAY15-26/38

43. Install FNR linkage on plate, if removed. Tighten nut to specification. Specification FNR Linkage Nut—Torque..................................................................................19 N·m 168 lb.-in.

44. Install cam (5) on cam shaft and install spring pin (1). T119651B —UN—18JAN99

NOTE: When driving pin in plate, support assembly to prevent damage to bearings and seals. 45. While holding plate (2) and spacers (4) in place, install cam shaft (3) as shown with spring pin holes for plate and cam in line. Install spring pin (1) in plate (2). 1— Spring Pin 2— Plate 3— Cam Shaft

4— Spacer (2 used) 5— Cam

Plate and Shaft

DA93471,00000C3 -19-06MAY15-27/38

NOTE: Align pin bore in bearing block and universal driveshaft. 46. Install bearing block (1) and universal driveshaft (2). 2— Universal Driveshaft

T119650B —UN—19JAN99

1— Bearing Block

Universal Driveshaft and Spacer Continued on next page

TM14163X19 (15FEB18)

03-0315-13

DA93471,00000C3 -19-06MAY15-28/38

450K, 550K, and 650K Crawler Dozer 021518 PN=161

Controls Linkage

NOTE: Care should be taken to avoid damaging bearing block, bearings, and seals.

T119649B —UN—19JAN99

47. Install lever assembly, and using a 1/4 in. punch with rounded edges, drive universal driveshaft (1) into bracket assembly. Pin should protrude equally on both ends. 48. Install seal plugs. 1— Universal Driveshaft

Universal Driveshaft DA93471,00000C3 -19-06MAY15-29/38

T119646B —UN—19JAN99

49. Apply Loctite® 7649™ Primer N™ Cure Primer and Loctite® 242® Threadlocker (medium strength) to threads of FNR linkage and steer rod ball joint ends. Connect FNR linkage (1) and install steer rod ball joint (2) on bracket assembly (3). Tighten FNR linkage and steer rod ball joint nuts to specifications. Specification FNR Linkage Nut—Torque..................................................................................19 N·m 168 lb.-in. Steer Rod Ball Joint Nut—Torque....................................................................................9 N·m 80 lb.-in.

FNR Linkage and Steer Rod Ball Joint 1— FNR Linkage 2— Steer Rod Ball Joint

3— Bracket Assembly

Loctite and its related brand marks are trademarks of Henkel Corporation DA93471,00000C3 -19-06MAY15-30/38

NOTE: Steer sensor and FNR sensors are interchangeable.

T119644B —UN—19JAN99

50. Install sensors (1 and 2) and O-rings. Tighten cap screws to specification. Specification Steer Sensor Cap Screw—Torque................................................................................5 N·m 44 lb.-in. FNR Sensor Cap Screw—Torque................................................................................5 N·m 44 lb.-in. Steer and FNR Sensors 1— Steer Sensor

2— Forward, Neutral, and Reverse Sensor Continued on next page

TM14163X19 (15FEB18)

03-0315-14

DA93471,00000C3 -19-06MAY15-31/38

450K, 550K, and 650K Crawler Dozer 021518 PN=162

Controls Linkage

51. Install neutral start switch (4) and tighten to specification.

T119645B —UN—19JAN99

Specification Neutral Start Switch—Torque.............................................................................14 N·m 124 lb.-in.

52. Install cover (3) and tighten cap screws to specification. Specification Neutral Start Switch Cover Cap Screw—Torque................................................................................5 N·m 44 lb.-in. 3— Cover

Neutral Start Switch and Cover

4— Neutral Start Switch DA93471,00000C3 -19-06MAY15-32/38

53. Install bushing (6), washer (7), spacer (5), socket head cap screw (8), and nut (4). Tighten cap screw first and then nut, to specification. Specification Detent Lever Cap Screw and Nut—Torque...........................................................................19 N·m 168 lb.-in.

54. Install detent spring (3), retaining plate (2), and socket head cap screws (1). Tighten cap screws to specification.

1— Socket Head Cap Screw (2 used) 2— Retaining Plate 3— Detent Spring 4— Nut 5— Spacer

6— Bushing 7— Washer 8— Socket Head Cap Screw 9— Detent Lever Plate and Lever Assembly

Continued on next page

TM14163X19 (15FEB18)

T119643B —UN—19JAN99

Specification Detent Spring Retaining Plate Cap Screw—Torque................................................................................5 N·m 44 lb.-in.

03-0315-15

DA93471,00000C3 -19-06MAY15-33/38

450K, 550K, and 650K Crawler Dozer 021518 PN=163

Controls Linkage

NOTE: Steering plate (6) must be installed so that the flat side faces chrome spring (4).

T119641B —UN—19JAN99

55. Place steering shaft in soft jaw vise. Install steering plate (6), spring seat (5), spring (4) or (7), spacer (3) spring guide (2) and spring end lock nut (1). Repeat steps for opposite end, then tighten spring end lock nuts (1) to specification. Specification Spring End Lock Nut—Torque....................................................................................8 N·m 71 lb.-in. Steer Shaft Assemble

56. Install rod end lock nut (8). 6— Steering Plate 7— Spring (gold) 8— Rod End Lcok Nut 9— Steer Shaft

T119642B —UN—19JAN99

1— Spring End Lock Nut (2 used) 2— Spring Guide (2 used) 3— Spacer (2 used) 4— Spring (chrome) 5— Spring Seat (2 used)

Steer Shaft Disassemble DA93471,00000C3 -19-06MAY15-34/38

57. Install steer shaft assembly and socket head cap screws (4). Tighten cap screws to specification.

T119639B —UN—19JAN99

Specification Steer Shaft Assembly Mounting Cap Screw—Torque..............................................................................34 N·m 25 lb.-ft.

58. Screw steer shaft into ball joint (3) and tighten rod end lock nut (1). 1— Rod End Lock Nut 2— Steer Shaft

3— Ball Joint 4— Socket Head Cap Screw (2 used) Steer Shaft Install Continued on next page

TM14163X19 (15FEB18)

03-0315-16

DA93471,00000C3 -19-06MAY15-35/38

450K, 550K, and 650K Crawler Dozer 021518 PN=164

Controls Linkage

59. If removed, install boot (3) and switch (2) in grip (1). 3— Boot

T124646B —UN—17SEP99

1— Grip 2— Switch

Grip Assembly DA93471,00000C3 -19-06MAY15-36/38

60. Install and tighten screws (1—3). 3— Screw With Nut (2 used)

T124645B —UN—17SEP99

1— Screw (2 used) 2— Screw

TCL Assembly Continued on next page

TM14163X19 (15FEB18)

03-0315-17

DA93471,00000C3 -19-06MAY15-37/38

450K, 550K, and 650K Crawler Dozer 021518 PN=165

Controls Linkage

IMPORTANT: Tie bands MUST be installed and wire lead MUST be positioned in clamp between assembly marks to provide a loop in wiring harness for steering. 61. Install tie bands (1) on wire harness. 62. Install clamp (3). 3— Clamp

T124638B —UN—17SEP99

1— Tie Band (2 used) 2— Identification Mark (2 used)

Transmission Control Lever (TCL) DA93471,00000C3 -19-06MAY15-38/38

63. Install socket head cap screws (1) and tighten to specification. Specification TCL Top Plate Socket Head Cap Screw—Torque................................................................................9 N·m 80 lb.-in.

64. Install boot (2). 65. Install transmission control lever (TCL) assembly inside console. See Transmission Control Lever (TCL) Remove and Install. (Group 0315.) T199277A —UN—16APR04

66. Adjust single lever control. See Transmission Control Lever (TCL) Adjustment. (Group 9015-20.) 67. Recalibrate transmission controller. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) 1— Socket Head Cap Screw (4 used)

2— Boot

Transmission Control Lever (TCL) Assembled DA93471,00000C3 -19-06MAY15-39/38

TM14163X19 (15FEB18)

03-0315-18

450K, 550K, and 650K Crawler Dozer 021518 PN=166

Controls Linkage

Decelerator/Brake Pedal Remove and Install B1

SPECIFICATIONS

73 N·m 54 lb.-ft.

TX1180931 —UN—13JAN15

Nut Torque

1. Disconnect decelerator sensor (B1). 2. Remove nuts (1) and assembly. 3. Inspect and replace parts as necessary. NOTE: When installing assembly, verify that the round dust seal is in place on rear of support. Decelerator/Brake Pedal

4. Install assembly and tighten nuts (1) to specification. Specification Nut—Torque..................................................................................73 N·m 54 lb.-ft.

1— Nut (4 used)

B1—Decelerator Sensor

5. Connect decelerator sensor (B1). DA93471,00000C4 -19-10FEB15-1/1

TM14163X19 (15FEB18)

03-0315-19

450K, 550K, and 650K Crawler Dozer 021518 PN=167

Controls Linkage

Decelerator/Brake Pedal Disassemble and Assemble SPECIFICATIONS Bearing Placement Distance from inside surface

0—1.0 mm 0—0.039 in.

Pin Placement Distance from surface

0—1.0 mm 0—0.039 in.

Nut (6) Torque

73 N·m 54 lb.-ft.

Stop Plate Cap Screw Torque

37 N·m 27 lb.-ft.

Sensor Hex Socket Head Cap Screws Torque

6 N·m 53 lb.-in.

8 15

6 11

B1 13 17

2 4

5 11

16 12

1 TX1180955 —UN—13JAN15

10 4 7 7

TX1180955

Decelerator/Brake Pedal (exploded view) 1— Pedal 2— Shaft 3— Support 4— Spring Pin (7 used) 5— Torsion Spring 6— Nut (3 used)

7— Cap Screw (3 used) 8— Cap Screw (2 used) 9— Hex Socket Head Cap Screw (2 used) 10— Nut (4 used)

1. Remove assembly from machine. See Decelerator/Brake Pedal Remove and Install. (Group 0315.)

11— Washer (3 used) 12— Snap Ring 13— Needle Bearing (2 used) 14— Spring 15— Stop Plate

16— Pin Fastener 17— O-Ring B1—Decelerator Sensor

3. Remove decelerator sensor (B1), and O-ring (17).

2. Remove hex socket head cap screws (9) securing decelerator sensor. Continued on next page

TM14163X19 (15FEB18)

03-0315-20

DA93471,00000C5 -19-11FEB15-1/12

450K, 550K, and 650K Crawler Dozer 021518 PN=168

Controls Linkage

TX1180967A —UN—13JAN15

CAUTION: Decelerator pedal is under spring pressure. Removing stop plate without relieving spring pressure can cause bodily injury. Relieve spring pressure by slowly loosening cap screws and holding pressure against pedal. 4. Loosen cap screws (8) securing stop plate (15). 5. Remove cap screws (8), relieving tension in torsion spring (5). 4— Pin 5— Torsion Spring

8— Cap Screw (2 used) 15— Stop Plate Stop Plate

DA93471,00000C5 -19-11FEB15-2/12

6. Remove spring pins (4) retaining pedal on shaft.

T200195A —UN—19MAY04

4— Spring Pin (2 used)

Spring Pins DA93471,00000C5 -19-11FEB15-3/12

7. Remove shaft (2), torsion spring (5), and washer (11). 11— Washer

T200196A —UN—19MAY04

2— Shaft 5— Torsion Spring

Shaft Removal Continued on next page

TM14163X19 (15FEB18)

03-0315-21

DA93471,00000C5 -19-11FEB15-4/12

450K, 550K, and 650K Crawler Dozer 021518 PN=169

Controls Linkage

8. Loosen nuts (6). 9. Remove cap screws (7).

6— Nut (2 used) 7— Cap Screw (2 used) 11— Washer

TX1180969A —UN—13JAN15

10. Apply pressure to washer (11) to compress spring (14) enough to remove snap ring (12). 12— Snap Ring 14— Spring 16— Pin Fastener

Stop Cap Screws DA93471,00000C5 -19-11FEB15-5/12

11. Remove pin fastener (16) and washer (11). 12. Disassemble remaining parts as necessary. Press out needle bearings (13) if necessary.

11— Washer

TX1180971A —UN—13JAN15

13. Clean and inspect all parts. Replace if necessary. 16— Pin Fastener

Pin Fastener DA93471,00000C5 -19-11FEB15-6/12

14. Press bearings (13) into support (3) to specification.

T200199A —UN—19MAY04

Specification Bearing Placement—Distance from inside surface..........................................................................................0—1.0 mm 0—0.039 in.

15. Apply petroleum jelly to bearings rollers. 16. Install pins (4) into support (3) to specification. Specification Pin Placement—Distance from surface............................................................................0—1.0 mm 0—0.039 in. 3— Support 4— Spring Pin (4 used)

13— Needle Bearing (2 used)

Continued on next page

TM14163X19 (15FEB18)

Pins and Bearings

03-0315-22

DA93471,00000C5 -19-11FEB15-7/12

450K, 550K, and 650K Crawler Dozer 021518 PN=170

Controls Linkage

17. Install pin fastener (16) through washer (11) into back of support (3). 16— Pin Fastener TX1180971A —UN—13JAN15

11— Washer

Pin Fastener DA93471,00000C5 -19-11FEB15-8/12

18. Install spring (14) and washer (11) onto shaft and compress to install snap ring (12).

TX1180969A —UN—13JAN15

19. Install cap screws (7) with nuts (6). Tighten nuts to specification. Specification Nut (6)—Torque.............................................................................73 N·m 54 lb.-ft. 6— Nut (2 used) 7— Cap Screw (2 used) 11— Washer

12— Snap Ring 14— Spring 16— Pin Fastener Brake Stop

DA93471,00000C5 -19-11FEB15-9/12

20. Assemble torsion spring (5) onto pedal then rotate spring until spring is stopped by pin.

2— Shaft 5— Torsion Spring

T200196A —UN—19MAY04

21. Place pedal with spring and washer (11) into support and install shaft (2) through assembly. 11— Washer

Shaft and Pedal Continued on next page

TM14163X19 (15FEB18)

03-0315-23

DA93471,00000C5 -19-11FEB15-10/12

450K, 550K, and 650K Crawler Dozer 021518 PN=171

Controls Linkage

22. Verify torsion spring is installed correctly then install pin (4) into the outer hole on shaft, between washer and pedal. Verify pin has equal length on each side of shaft.

T200195A —UN—19MAY04

23. Rotate pedal to align the hole in the pedal and shaft. Install pin (4) into hole. 4— Spring Pin (2 used)

Spring Pins DA93471,00000C5 -19-11FEB15-11/12

24. Secure pedal assembly and press pedal downwards. Install stop plate (15) and secure with cap screws (8). Tighten cap screws to specification. TX1180967A —UN—13JAN15

Specification Stop Plate Cap Screw—Torque..............................................................................37 N·m 27 lb.-ft.

25. Install decelerator sensor (B1) with O-ring (17) onto shaft (2). 26. Slowly rotate sensor into position and install hex socket head cap screws (9). Tighten to specifications. Specification Sensor Hex Socket Head Cap Screws—Torque......................................................................6 N·m 53 lb.-in.

Stop Plate 4— Pin 5— Torsion Spring

8— Cap Screw (2 used) 15— Stop Plate

27. Install assembly on machine. See Decelerator/Brake Pedal Remove and Install. (Group 0315.) 28. Adjust brake pedal. See Decelerator/Brake Pedal Adjustment. (Group 9015-20.) DA93471,00000C5 -19-11FEB15-12/12

TM14163X19 (15FEB18)

03-0315-24

450K, 550K, and 650K Crawler Dozer 021518 PN=172

Group 0325

Input Drive Shafts and U-Joints OTHER MATERIAL

Damper Drive Remove and Install

Loctite® 7649™ Primer N™ Cure Primer

SPECIFICATIONS 86 N·m 63 lb·ft

Cap Screw Torque

40 N·m 30 lb·ft

1— Set Screw 2— Damper Hub

3— Cap Screw (8 used) 4— Washer (8 used)

Loctite® 242® Threadlocker (medium strength)

TX1016199 —UN—05DEC06

Set Screw Torque

Damper Components 5— Damper Plate 6— Snap Ring

REMOVAL

• Tighten set screw to specification.

1. Remove hydrostatic pumps. See Hydrostatic Pump Remove and Install. (Group 0300.)

Specification Set Screw—Torque.......................................................................86 N·m 63 lb·ft

2. Remove set screw (1) and damper hub (2). 3. Remove cap screws (3), washers (4), and damper plate (5). 4. Clean and inspect parts. Repair or replace as necessary.

• Use Loctite® 7649™ Primer N™ Cure Primer to

prepare cap screw threads and allow 2 minutes to cure. Apply Loctite® 242® Threadlocker (medium strength) to threads of cap screws. • Tighten cap screws to specification. Specification Cap Screw—Torque......................................................................40 N·m 30 lb·ft

INSTALLATION Installation is reverse of removal procedure.

• Install damper hub until internal snap ring (6) contacts end of pump shaft.

Loctite and its related brand marks are trademarks of Henkel Corporation JL05046,000027C -19-27FEB17-1/1

TM14163X19 (15FEB18)

03-0325-1

450K, 550K, and 650K Crawler Dozer 021518 PN=173

Input Drive Shafts and U-Joints

TM14163X19 (15FEB18)

03-0325-2

450K, 550K, and 650K Crawler Dozer 021518 PN=174

Group 0360

Hydrostatic System Hydrostatic Pump Disassemble 60 kg 133 lb

End Cap Journal Bearing Depth

Flush to 0.50 mm Flush to 0.020 in

RW25727 —UN—09JUN97

SPECIFICATIONS Hydrostatic Pump Weight (approximate)

88.2 mm Swash Plate Leveling Outer Springs Free Length (approximate) 3.5 in Swash Plate Leveling Outer Springs Test Length

83.3 mm at 160 N 3.3 in at 36 lbf

81 mm Swash Plate Leveling Inner Springs Free Length (approximate) 3.2 in Swash Plate Leveling Inner Springs Test Length

76.2 mm at 78 N 3.0 in at 17.5 lbf

Swash Plate Hold-Down Spring Free Length (approximate)

21.6 mm 0.85 in

Swash Plate Hold-Down Spring Test Length

19.8 mm at 613 N 0.78 in at 138 lbf

Swash Plate Leveler-to-Side Cover Lock Nuts Torque

23 N·m 204 lb·in

Swash Plate Servo Arm Cap Screw Torque

32 N·m 24 lb·ft

Swash Plate Feedback Link Cap Screw Torque

32 N·m 24 lb·ft

Seal Carrier, Retaining Screws, and Plate A—Socket Head Cap Screw (3 used) B—Retaining Plate

C—Seal Carrier D—Shaft

Specification Hydrostatic Pump—Weight (approximate).................................................................................. 60 kg 133 lb

ESSENTIAL TOOLS

2. Remove displacement control valve assembly. See Pump Displacement Control Valve (PDCV) Disassemble and Assemble. (Group 0360.)

JDG1072 Journal Bearing Sizing Tool SERVICE EQUIPMENT AND TOOLS D01006AA Bench-Mounted Holding Fixture D01061AA Blind-Hole Puller

CAUTION: The weight of the hydrostatic pump is approximately 60 kg (133 lb). Use proper lifting equipment and safety precautions. Failure to do so may cause personal injury. IMPORTANT: Absolute cleanliness is essential when working on hydraulic components. NOTE: Orientate double boss of pump housing on holding fixture as shown. 1. Mount the hydrostatic pump on a D01006AA Bench-Mounted Holding Fixture. Continued on next page

TM14163X19 (15FEB18)

03-0360-1

DA93471,0000102 -19-03MAR17-1/19

450K, 550K, and 650K Crawler Dozer 021518 PN=175

Hydrostatic System

3. Remove socket head cap screws (A) and retaining plate (B). NOTE: The bearings on shaft (D) are slip fit in the housing bore.

A—Socket Head Cap Screw (3 used) B—Retaining Plate

RW25727 —UN—09JUN97

4. Remove seal carrier (C) and shaft (D) with bearings. Lightly tap on opposite end of shaft to aid in removal. C—Seal Carrier D—Shaft

Retaining Plate DA93471,0000102 -19-03MAR17-2/19

5. Inspect bearing assembly (B). 6. Remove retaining ring (A) and remove outer bearing assembly (B) from inner bearing race.

RW25728 —UN—11JUN97

7. Remove inner bearing race from shaft using a press. 8. Install new inner bearing race onto shaft using a press. 9. Install new outer bearing assembly (B) and retaining ring (A) onto shaft. IMPORTANT: Cover shaft splines with shim stock to protect lip seal. Bearing, Retaining Ring, and O-Ring

10. Wrap the spline or key end of shaft with thin plastic (shim stock) to prevent damage to the shaft seal lip during installation. Lubricate the inside diameter of the new seal with petroleum jelly. Install new shaft lip seal (C) in seal carrier with spring side of seal toward pump housing.

A—Retaining Ring B—Bearing Assembly

C—Lip Seal D—O-Ring

12. Rotate pump 180°.

11. Install O-ring (D) on seal carrier.

DA93471,0000102 -19-03MAR17-3/19

13. Remove the two small socket head cap screws (3 and 4) and socket head cap screws with washers (2). NOTE: Leveler spring shims may dislodge during end cap removal.

1— Adapter Plate 2— Socket Head Cap Screw With Washer (4 used)

T119614B —UN—15JAN99

14. Remove adapter plate and O-ring from end cap. Remove end cap and gasket from pump housing. 3— Socket Head Cap Screw With Lift Bracket 4— Socket Head Cap Screw

Pump End Cap Continued on next page

TM14163X19 (15FEB18)

03-0360-2

DA93471,0000102 -19-03MAR17-4/19

450K, 550K, and 650K Crawler Dozer 021518 PN=176

Hydrostatic System

IMPORTANT: Do not damage the end cap surface when removing or installing bearing (A). 15. Inspect journal bearing (A).

T118279 —UN—17NOV98

16. Carefully remove the bearing using D01061AA Blind-Hole Puller (B). 17. Lightly lubricate the new journal bearing and install into end cap using a press. Specification End Cap Journal Bearing—Depth............................................................ Flush to 0.50 mm Flush to 0.020 in Bearing Puller A—Journal Bearing

B—Blind Hole Puller DA93471,0000102 -19-03MAR17-5/19

IMPORTANT: New journal bearing MUST be sized using a JDG1072 Journal Bearing Sizing Tool. DO NOT use the pump shaft. This will cause inadequate lubrication and shortened bearing life. 18. Size the journal bearing using a JDG1072 Journal Bearing Sizing Tool (C).

RW25782 —UN—21JUN97

C—Journal Bearing Sizing Tool

Using JDG1072 Journal Bearing Sizing Tool Continued on next page

TM14163X19 (15FEB18)

03-0360-3

DA93471,0000102 -19-03MAR17-6/19

450K, 550K, and 650K Crawler Dozer 021518 PN=177

Hydrostatic System

NOTE: Shims for springs (1) may stay with the end cap during end cap removal.

Specification Swash Plate Leveling Outer Springs—Free Length (approximate)................................................................. 88.2 mm 3.5 in Test Length ..................................................................83.3 mm at 160 N 3.3 in at 36 lbf Swash Plate Leveling Inner Springs—Free Length (approximate).................................................................... 81 mm 3.2 in Test Length ....................................................................76.2 mm at 78 N 3.0 in at 17.5 lbf Swash Plate Hold-Down Spring—Free Length (approximate)............................................................................. 21.6 mm 0.85 in Test Length ..................................................................19.8 mm at 613 N 0.78 in at 138 lbf

T156798B —UN—27JUN02

19. Remove and inspect springs (1 and 4) and shims.

Swash Plate 1— Spring (2 used) 2— Alignment Pin (2 used)

3— Valve Plate 4— Hold Down Spring

20. Remove valve plate (3). 21. Remove alignment pins (2).

IMPORTANT: Note the direction of arrows stamped on valve plate and mark housing accordingly. DA93471,0000102 -19-03MAR17-7/19

22. Put alignment marks (2) on the side cover and pump housing. 23. Remove and discard the six cap screws (1). 2— Alignment Marks T118259B —UN—08JAN99

1— Cap Screw (6 used)

Mark Side Cover Continued on next page

TM14163X19 (15FEB18)

03-0360-4

DA93471,0000102 -19-03MAR17-8/19

450K, 550K, and 650K Crawler Dozer 021518 PN=178

Hydrostatic System

24. Remove leveler assembly (A) by removing two lock nuts on outside of cover. 25. Discard O-ring (B). B—O-Ring

T118277 —UN—22APR99

A—Leveler Assembly

Side Cover Disassembly DA93471,0000102 -19-03MAR17-9/19

26. Inspect parts (A—D). Replace as required. 27. Assemble side cover using new lock nuts (E). Tighten nuts to specifications. Specification Swash Plate Leveler-to-Side Cover Lock Nuts—Torque........................................................................23 N·m 204 lb·in

28. Install O-ring on side cover (A). D—Cap Screw (2 used) E— Lock Nut (2 used)

T118278 —UN—22APR99

A—Side Cover B—Leveler C—Insert (2 used)

Side Cover Assembly Continued on next page

TM14163X19 (15FEB18)

03-0360-5

DA93471,0000102 -19-03MAR17-10/19

450K, 550K, and 650K Crawler Dozer 021518 PN=179

Hydrostatic System

IMPORTANT: Wear patterns develop between servo pistons and servo cylinders. Servo cylinders must be installed in original positions.

RW25735 —UN—20JUN97

29. Tag or identify servo cylinders (A) for assembly into the bore from which the cylinders were removed. 30. Remove capscrews and remove cylinders (A) using a slide hammer and 8 mm screw in threaded hole (B). IMPORTANT: Wear patterns develop between cylinder block bores and pistons. Pistons must be installed in original cylinder block bores. Servo Cylinders and Cylinder Block Assembly

31. Tag or identify pistons and cylinder block bores to aid in proper assembly.

A—Servo Cylinder (2 used) B—Threaded Hole

32. Remove cylinder block assembly (C).

C—Cylinder Block Assembly

DA93471,0000102 -19-03MAR17-11/19

33. Compress the cylinder block spring using a press and remove the spiral retaining ring. 34. Remove retainer.

T8492AA —UN—14JUN95

35. Remove spring and spring seats. 36. Clean cylinder block and components. 37. Assemble cylinder block.

Cylinder Block Spring Removal DA93471,0000102 -19-03MAR17-12/19

38. Remove bearing cage link pin (A) and locator link (B). B—Locator Link

RW25736 —UN—09JUN97

A—Cage Link Pin

Bearing Cage Link Pin and Locator Link Continued on next page

TM14163X19 (15FEB18)

03-0360-6

DA93471,0000102 -19-03MAR17-13/19

450K, 550K, and 650K Crawler Dozer 021518 PN=180

Hydrostatic System

39. Remove the swash plate and piston assembly (A) through the housing side cover opening.

40. Tag or identify servo piston orientation to aid in proper assembly. 41. Remove the servo piston (C) and slider block (B). A—Swash Plate and Piston Assembly B—Slider Block

C—Servo Piston Piston Assembly

RW25738 —UN—09JUN97

RW25737 —UN—20JUN97

IMPORTANT: Wear patterns develop between servo pistons and servo cylinders. Servo piston must be installed with original orientation.

Servo Piston and Slider Block DA93471,0000102 -19-03MAR17-14/19

NOTE: Do not stretch seal rings (B) any more than necessary when installing.

A—O-Ring

RW25739 —UN—09JUN97

43. Install seal ring (B) over O-ring on each end of piston. B—Seal Ring

Expander O-Ring

RW25740 —UN—09JUN97

42. Replace expander O-ring (A) on each end of servo piston.

Seal Ring DA93471,0000102 -19-03MAR17-15/19

IMPORTANT: Bearing cage wears patterns in bearing race and swash plate. Components must be installed in proper position with original orientation. RW25741 —UN—20JUN97

44. Tag or identify swash plate bearing cage positions to aid in proper assembly. 45. Remove and inspect swash plate bearing cage (A). Replace as required. 46. Tag or identify bearing race positions to aid in proper assembly. 47. Remove and inspect the two bearing races (B). Replace as required.

Swash Plate Bearing Cage and Bearing Races A—Bearing Cage (2 used) Continued on next page

TM14163X19 (15FEB18)

03-0360-7

B—Bearing Race (2 used) DA93471,0000102 -19-03MAR17-16/19

450K, 550K, and 650K Crawler Dozer 021518 PN=181

Hydrostatic System

IMPORTANT: Parts have critical, high tolerance surfaces which require careful handling to prevent damage. 48. Disassemble and inspect parts (A—E) discarding cap screws (F). D—Slipper Guide Bearing (2 used) E—Spacer (4 used) F— Cap Screw (4 used)

T121170 —UN—17APR99

A—Swash Plate B—Piston Assembly (9 used) C—Slipper Guide

Disassemble Swash Plate and Piston Assembly DA93471,0000102 -19-03MAR17-17/19

IMPORTANT: Servo arm alignment is critical. Do not remove servo arm (A) from swash plate unless replacing.

RW25742 —UN—11JUN97

49. Remove feedback link (C) by removing socket head cap screw (D). 50. Inspect swash plate guide (B). 51. Remove cap screw (E) only if replacement of servo arm is needed. NOTE: Servo arm is a press fit. 52. Install new servo arm carefully aligning the slot and threaded holes in swash plate. Arm must be pressed completely into swash plate slot.

Servo Arm, Feedback Link, and Swash Plate Guide A—Servo Arm B—Swash Plate Guide C—Feedback Link

53. Install servo arm cap screw (E) and tighten to specifications. Specification Swash Plate Servo Arm Cap Screw—Torque......................................................................32 N·m 24 lb·ft

54. Install feedback link (C) and swash plate guide (B). Tighten socket head cap screw (D) to specifications.

Specification Swash Plate Feedback Link Cap Screw—Torque..............................................................................32 N·m 24 lb·ft

Continued on next page

TM14163X19 (15FEB18)

D—Socket Head Cap Screw E—Cap Screw

03-0360-8

DA93471,0000102 -19-03MAR17-18/19

450K, 550K, and 650K Crawler Dozer 021518 PN=182

Hydrostatic System

RW25729 —UN—16JUN97

55. Clean the threaded holes in the swash plate (A) and pump housing side cover opening (B) using the correct tap. IMPORTANT: Pump housing must be clear of any contamination before assembling pump. 56. Clean inside of pump housing eliminating any excess thread locking compound or other contamination. A—M6 Threaded Holes in Swash Plate

Swash Plate

B—M8 Threaded Holes in Housing

RW25744 —UN—16JUN97

IMPORTANT: Threaded holes in swash plate and pump housing side cover opening must be cleaned of old locking compound prior to reassembly.

Pump Housing Side Cover Opening

DA93471,0000102 -19-03MAR17-19/19

Charge Pump Disassemble and Assemble SPECIFICATIONS Charge Pump Retaining Plate Cap 16 N·m 142 lb·in Screw Torque 298 N·m 220 lb·ft

T199994A —UN—17MAY04

Flange Adapter Socket Head Screw Torque

IMPORTANT: Absolute cleanliness is essential when working on hydrostatic components. 1. Remove cap screws (1), flange adapter (2) and O-ring. 1— Socket Head Screw (4 used)

2— Flange Adapter

Remove Flange Adapter DA93471,0000140 -19-06MAR17-1/10

2. Remove cap screws (3) and retaining plate (4). 4— Retaining Plate

T199995A —UN—17MAY04

3— Cap Screw (6 used)

Pump Retaining Screws Continued on next page

TM14163X19 (15FEB18)

03-0360-9

DA93471,0000140 -19-06MAR17-2/10

450K, 550K, and 650K Crawler Dozer 021518 PN=183

Hydrostatic System

IMPORTANT: Wear patterns develop between pump gerotor assembly (5) and eccentric ring (6). Components must be installed in proper position with original orientation. T199996A —UN—17MAY04

3. Tag or identify visible side of pump gerotor assembly (5) and eccentric ring (6) to aid in proper assembly. 4. Remove and inspect parts (1—8) and replace as required. 5. Remove bushing from charge pump cover (1). 6. Clean all parts and lightly apply clean hydraulic oil. Charge Pump Cover-to-Port Layout 1— Charge Pump Cover 2— Auxiliary Drive Coupling 3— Charge Pump Shaft 4— Key

5— Charge Pump Gerotor 1 Assembly 1 6— Eccentric Ring 7— Alignment Pin 8— Port Plate

Serviced as an assembly DA93471,0000140 -19-06MAR17-3/10

IMPORTANT: Charge pump rotation is determined by the orientation of eccentric ring in the gerotor assembly, and the location of the alignment pin (1). Incorrect assembly will not provide charge oil to the pump and will result in damage to the pump.

T199997A —UN—17MAY04

NOTE: One of the large cap screws and four washers must be installed in the end cap, as illustrated, before assembling the charge pump. 7. Install charge pump alignment pin (1) in the right rotation hole as illustrated. 8. Install port plate (2). 1— Alignment Pin

2— Port Plate Install Alignment Pin Continued on next page

TM14163X19 (15FEB18)

03-0360-10

DA93471,0000140 -19-06MAR17-4/10

450K, 550K, and 650K Crawler Dozer 021518 PN=184

Hydrostatic System

IMPORTANT: Wear patterns develop between pump gerotor gears (3) and eccentric ring (1). Components must be installed in proper position with original orientation. 9. Install the eccentric ring (1) making sure alignment pin (2) is correctly installed. 10. Install the gerotor gears (3). 3— Gerotor Gears

T119171B —UN—07JAN99

1— Eccentric Ring 2— Alignment Pin

Eccentric Ring Alignment Pin and Gears DA93471,0000140 -19-06MAR17-5/10

11. Install charge pump shaft (1) with key (2) aligning with slot in gerotor gear. 2— Key T199993A —UN—17MAY04

1— Pump Shaft

Charge Pump Shaft and Key DA93471,0000140 -19-06MAR17-6/10

12. Install auxiliary drive coupling (1).

T119593B —UN—15JAN99

1— Auxiliary Drive Coupling

Auxiliary Drive Coupling Continued on next page

TM14163X19 (15FEB18)

03-0360-11

DA93471,0000140 -19-06MAR17-7/10

450K, 550K, and 650K Crawler Dozer 021518 PN=185

Hydrostatic System

13. Install bushing in charge pump cover. 14. Install charge pump cover (2) making sure hole (1) in cover aligns correctly with alignment pin (3). 3— Alignment Pin

T119172B —UN—07JAN99

1— Hole in Cover 2— Charge Pump Cover

Charge Pump Cover, Hole and Alignment Pin DA93471,0000140 -19-06MAR17-8/10

15. Install retaining plate (1) and cap screws (2). Tighten to specification.

T119594B —UN—22JAN99

Specification Charge Pump Retaining Plate Cap Screw—Torque..............................................................................16 N·m 142 lb·in

16. Lubricate O-ring (4) with petroleum jelly and install. 17. Remove cap screw and washers (3). 1— Retaining Plate 2— Cap Screw (6 used)

3— Cap Screw and Washers 4— O-Ring

Retaining Plate DA93471,0000140 -19-06MAR17-9/10

18. Install flange adapter (2). 19. Install socket head screws and washers (1). Tighten to specification. T199994A —UN—17MAY04

Specification Flange Adapter Socket Head Screw—Torque..................................................................298 N·m 220 lb·ft

20. Install pumps and calibrate transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) 1— Socket Head Screw and Washer (4 used)

2— Flange Adapter

Pump Flange Adapter

DA93471,0000140 -19-06MAR17-10/10

TM14163X19 (15FEB18)

03-0360-12

450K, 550K, and 650K Crawler Dozer 021518 PN=186

Hydrostatic System

Pump Displacement Control Valve (PDCV) Disassemble and Assemble SPECIFICATIONS 11 N·m 96 lb·in

Electronic Displacement Control-to-Control Valve Cap Screws Torque

5 N·m 44 lb·in

Displacement Control Valve-to-Hydrostatic Pump Cap Screws Torque

16 N·m 142 lb·in

1— Control Valve Housing 2— Cap Screw (4 used) 3— Pressure Control Pilot (PCP)

4— O-Ring (3 used) 5— O-Ring (1 used) 6— Cap 7— Spring 8— Valve Spool 9— Feedback Link

T199990A —UN—17MAY04

EDC Valve Spool Caps Torque

Control Valve Disassembled 10— Link Arm 14— Valve Spool 11— Override Linkage Assembly 15— Cap 12— Cap Screw (2 used) 16— Adjustment Screw 13— Spring

2. Remove cap (15) and valve spool (14). Replace O-ring.

IMPORTANT: Hydrostatic pump displacement control valve (PDCV) is serviced as an assembly. Replace if damaged. Disassemble for cleaning purposes only.

3. Remove cap (6), spring (7), and valve spool (8). Replace O-ring.

Absolute cleanliness is essential when working on hydraulic components. 1. Remove the socket head cap screws and pump displacement control valve (PDCV) from the pump housing. NOTE: The pressure control pilot (PCP) (3) is serviced as an assembly. DO NOT disassemble.

4. Loosen adjusting screw (16) to release tension on spring (13). 5. Remove caps screws (12). 6. Lift linkage assembly (9, 10 and 11) with spring from housing.

Continued on next page

TM14163X19 (15FEB18)

03-0360-13

DA93471,000012C -19-06MAR17-1/3

450K, 550K, and 650K Crawler Dozer 021518 PN=187

Hydrostatic System

NOTE: Override linkage assembly (11) is not repairable. Do not disassemble.

10. Install new O-rings and Pressure Control Pilot (PCP). Tighten cap screws (2) to specifications.

7. Clean and inspect parts.

Hydrostatic Pump—Specification Electronic Displacement Control-to-Control Valve Cap Screws—Torque......................................................................5 N·m 44 lb·in

8. Assemble parts (9—13). 9. Install valve spools, spring, O-rings and caps. Tighten caps to specifications. Hydrostatic Pump—Specification EDC Valve Spool Caps—Torque............................................................................... 11 N·m 96 lb·in

DA93471,000012C -19-06MAR17-2/3

IMPORTANT: If system has been contaminated with debris, the screen filter (E) must be removed for cleaning of associated parts. Screen filters are not reusable, replace after removal, see parts catalog for replacement parts. 11. Inspect and clean screen filters (E) before installing displacement control valve (B). 12. Install gasket (A). IMPORTANT: Linkage pin (C) must be installed correctly into link (D) or swash plate will not move. 13. Install displacement control valve (B) to pump making sure neutral feedback linkage pin (C) installs correctly into feedback link (D). TX1012687A —UN—28SEP06

14. Install and tighten the six cap screws to specifications. Hydrostatic Pump—Specification Displacement Control Valve-to-Hydrostatic Pump Cap Screws—Torque............................................................................16 N·m 142 lb·in

CAUTION: After the displacement control valve has been disassembled, the tracks could rotate when park lock lever is lowered until null adjustment is performed. 15. Perform pump displacement control valve neutral adjustment. See Pump Displacement Control Valve (PDCV) Neutral (Null) Adjustment. (Group 9026-25.)

Control Valve, Pin and Feedback Link A—Gasket B—Displacement Control Valve C—Feedback Linkage Pin

D—Feedback Link E—Screen Filter (3 used)

16. Calibrate transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) DA93471,000012C -19-06MAR17-3/3

TM14163X19 (15FEB18)

03-0360-14

450K, 550K, and 650K Crawler Dozer 021518 PN=188

Hydrostatic System

Multi-Function Valve Remove and Install SPECIFICATIONS Multi-Function Valve Torque

89 N·m 66 lb·ft

1. Remove multi-function valve from hydrostatic pump housing. 2. Inspect valve for wear or damage. 3. Install and tighten valve to specification.

TX1174810A —UN—20OCT14

Specification Multi-Function Valve—Torque...............................................................................89 N·m 66 lb·ft

4. If valve was disassembled or a new valve is installed, perform Multi-Function Relief Valve Test. (Group 9026-25.) 1— Forward Multi-Function Valve

2— Reverse Multi-Function Valve Multi-Function Valves

DA93471,00000CA -19-06MAR17-1/1

Multi-Function Valve Disassemble and Assemble SPECIFICATIONS Multi-Function Valve Lock Nut Torque

16 N·m 144 lb·in

Multi-Function Valves Torque

79 N·m 58 lb·ft

T118409B —UN—17NOV98

CAUTION: Multi-function valves contain springs under compression. Release spring tension by turning adjusting screw counter clockwise. 1. Use a small screw driver to separate multi-function valve body from poppet assembly.

Multi-Function Valve Continued on next page

TM14163X19 (15FEB18)

03-0360-15

DA93471,000012A -19-06MAR17-1/2

450K, 550K, and 650K Crawler Dozer 021518 PN=189

Hydrostatic System

2. Carefully loosen cap (2) to release pressure on springs (7 and 12). Disassemble valve as shown. 3. Clean valve components and check for any contamination. NOTE: Other than O-rings, multi-function valve components are not serviceable.

T119706B —UN—20JAN99

4. If any valve components are damaged, replace the entire valve. 5. Lubricate valve components with clean hydraulic oil. 6. Assemble multi-function valve. Use a vise to carefully press poppet assembly onto valve body. Tighten lock nut (1) to specification. Specification Multi-Function Valve Lock Nut—Torque..................................................................................16 N·m 144 lb·in

7. Check valve poppet movement in end of the multi-function valves. 8. Install and tighten multi-function valves to specifications. Specification Multi-Function Valves—Torque.............................................................................79 N·m 58 lb·ft

9. Perform multi-function relief valve test. See Multi-Function Relief Valve Test. (Group 9026-25.)

Exploded View Multi-function Valve 1— Lock Nut 2— Cap 3— Bypass Piston 4— O-Ring 5— Valve Housing 6— O-Ring 7— Spring 8— Spring Guide

9— Pressure Limiter Poppet 10— Guide 11— Washer 12— Spring 13— High Pressure Relief Valve Poppet 14— Check Valve Poppet 15— O-Ring

10. Calibrate transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) DA93471,000012A -19-06MAR17-2/2

TM14163X19 (15FEB18)

03-0360-16

450K, 550K, and 650K Crawler Dozer 021518 PN=190

Hydrostatic System

Hydrostatic Pump Assemble SPECIFICATIONS 14 N·m 124 lb·in

Cap Screw Torque

Side Cover-to-Pump Housing Blind Hole Cap Screws Torque

33 N·m 24 lb·ft

Side Cover-to-Pump Housing Through (Top Two) Hole Cap Screws Torque

33 N·m 24 lb·ft

End Cap/Adapter-to-Pump Cap Screws (Large) Torque

298 N·m 220 lb·ft

End Cap-to-Pump Cap Screws (Small) Torque

33 N·m 24 lb·ft

Input Shaft Seal Carrier Retaining Cap Screw Torque

16 N·m 142 lb·in

RW25758 —UN—16JUN97

Servo Cylinder Cap Screws Torque 33 N·m 24 lb·ft

Installing Bearing Races A—Bearing Race (2 used)

ESSENTIAL TOOLS

2. Lubricate and install bearing cage on the bearing races.

JDG1094 Leveling Plate OTHER MATERIAL Loctite® 242® Threadlocker (medium strength)

NOTE: Apply clean hydrostatic oil to all internal parts before assembly. IMPORTANT: Components must be installed in proper position with original orientation to prevent premature pump failure. Bearing races must be completely seated in housing. Inspect bearing cage wear patterns in bearing race and swash plate to determine remaining service life. 1. Install bearing races (A) in housing. DA93471,00000FE -19-07MAR17-1/17

T8464BL —UN—14JUN95

IMPORTANT: Damage to polished surfaces can cause premature pump failure. Be careful when handling parts with polished surfaces to prevent nicks or scratches. NOTE: Either side of slipper guide can be installed against slippers. Flip slipper guide if excessive wear is on top bearing surface. 3. Inspect slipper guide surface, install smoothest side away from slippers. Clean slipper guide bearing screw holes on swash plate surface using M8 tap. NOTE: Apply clean hydrostatic oil to all internal parts before assembly.

Piston Assemblies

4. Install the piston assemblies into the slipper guide. 5. Apply clean hydrostatic oil on slippers. Center the pistons and guide on the swash plate. Continued on next page

TM14163X19 (15FEB18)

03-0360-17

DA93471,00000FE -19-07MAR17-2/17

450K, 550K, and 650K Crawler Dozer 021518 PN=191

Hydrostatic System

IMPORTANT: For correct assembly and to prevent premature wear, slipper guide bearing must be installed as shown. The split between the slipper guide bearing plates must be located in line with the swash plate arm. The TEFLON® surface side of slipper guide bearing must be installed against the slipper guide. 6. Install first slipper guide bearing plate (C) with TEFLON® surface against the slipper guide (A) as shown.

T121169 —UN—17APR99

IMPORTANT: To prevent premature pump failure, new slipper guide bearing plate cap screws must be installed. Install new cap screws whenever slipper guide bearing plates are removed. 7. Apply Loctite® 242® Threadlocker (medium strength) on cap screw threads. Install new cap screws (D) through the slipper guide bearing and spacers (B) as shown. Finger tighten the cap screws into the swash plate. A—Slipper Guide B—Spacer (4 used)

C—Slipper Guide Bearing (2 used) D—Cap Screw (4 used)

Slipper Guide Bearings, Spacers & Screws

TEFLON is a trademark of Du Pont Co. Loctite and its related brand marks are trademarks of Henkel Corporation DA93471,00000FE -19-07MAR17-3/17

8. Tighten slipper guide bearing cap screws to specification. T8464BQ —UN—14JUN95

Check movement of the assembly by hand. The slipper guide and piston slippers must slide freely on the swash plate. Hydrostatic Pump Swash Plate-to-Slipper Guide Bearing—Specification Cap Screw—Torque......................................................................14 N·m 124 lb·in

9. Lubricate the pistons and cylinder block bores in clean hydraulic oil. Continued on next page

TM14163X19 (15FEB18)

03-0360-18

Slipper Guide Assembly

DA93471,00000FE -19-07MAR17-4/17

450K, 550K, and 650K Crawler Dozer 021518 PN=192

Hydrostatic System

IMPORTANT: Wear patterns develop between cylinder block bores and pistons. Pistons must be installed in original cylinder block bores. 10. Align pistons with original cylinder block bores and install assembly (A) in cylinder block (B). B—Cylinder Block

RW25746 —UN—12JUN97

A—Swash Plate and Piston Assembly

Swash Plate/Piston Assemblies and Cylinder Block DA93471,00000FE -19-07MAR17-5/17

IMPORTANT: Wear patterns develop between servo pistons and servo cylinders. Servo piston must be installed with original orientation.

A—Servo Piston

RW25747 —UN—11JUN97

12. Install bronze slider block (B) onto servo arm of swash plate assembly. B—Slider Block

Servo Piston Continued on next page

TM14163X19 (15FEB18)

03-0360-19

RW25748 —UN—11JUN97

11. Install servo piston (A) into pump housing.

Bronze Slider Block DA93471,00000FE -19-07MAR17-6/17

450K, 550K, and 650K Crawler Dozer 021518 PN=193

Hydrostatic System

NOTE: A second person will be needed to help align the slider block into the servo piston during swash plate installation. A cap screw approximately 229 mm (9 in) long, two flat washers 63 mm (2.5) OD and nut should be used to assist in lowering cylinder block into housing. 13. Lower swash plate and piston assembly partially into the pump housing. T118276 —UN—20NOV98

14. Hold the assembly above the cradle bearings to correctly position the feedback link (C) in the control opening. 15. Align slider block (D) into the servo piston and continue to lower swash plate assembly into position on the bearings. 16. Remove the cap screw and washer used for cylinder block installation.

Cap Screw Assembly Tool

17. Check for clearance between the servo arm and slider block (D). If no clearance exists, recheck the assembly of the bearing cage and races.

19. Lubricate each of the internal bores of the servo cylinder with clean hydraulic oil. 20. Install O-rings on servo cylinder. A—Piston Assembly B—Assembled Cap Screw Tool

C—Feedback Link D—Bronze Slider Block Feedback Link

RW25755 —UN—12JUN97

RW25754 —UN—12JUN97

18. Check to make sure swash plate assembly and servo piston slide freely.

Slider Block DA93471,00000FE -19-07MAR17-7/17

IMPORTANT: Wear patterns develop between servo pistons and servo cylinders. Servo cylinders must be installed in original positions.

22. Tighten the servo cylinder cap screws to specifications. Hydrostatic Pump—Specification Servo Cylinder Cap Screws—Torque............................................................................33 N·m 24 lb·ft

23. Move the swash plate to align the spring pin in the swash plate with the slot in the swash plate bearing cage and the pin hole in the housing. 24. Install cage locator link (B) and locator link pin (C).

Servo Cylinder

A—Servo Cylinder B—Locator Link Continued on next page

TM14163X19 (15FEB18)

03-0360-20

RW25757 —UN—12JUN97

RW25756 —UN—12JUN97

21. Hold the servo piston in position and install the servo cylinders (A) into original bores.

Cage Locator Link and Locator Link Pin

C—Locator Link Pin

DA93471,00000FE -19-07MAR17-8/17

450K, 550K, and 650K Crawler Dozer 021518 PN=194

Hydrostatic System

IMPORTANT: T-Bar must be positioned on top of swash plate. 25. Install O-ring on side cover. 26. Install side cover (A) to pump housing making sure O-ring is not damaged during installation. 27. Align side cover and pump housing with mark (B).

T156777B —UN—27JUN02

28. Install two new cap screws (C) as illustrated to hold cover. Do not fully tighten the cap screws. 29. Install leveling springs (D) and swash plate hold-down spring (E). A—Side Cover B—Alignment Mark C—Cap Screw (2 used)

D—Swash Plate Leveling Spring (2 used) E—Swash Plate Hold-Down Spring Side Cover Alignment Marks

DA93471,00000FE -19-07MAR17-9/17

30. Install JDG1094 Leveling Plate (A) to pump housing making sure spring pockets (B) are correctly aligned with springs (C).

C—Leveling Spring (3 used) D—Cap Screw (2 used)

RW25760 —UN—16JUN97

A—JDG1094 Leveling Plate B—Spring Pocket (3 used)

Leveling Plate, Spring Pockets & Springs Continued on next page

TM14163X19 (15FEB18)

03-0360-21

RW25761 —UN—16JUN97

31. Install and tighten cap screws (D).

JDG1094 Leveling Plate and Cap Screws DA93471,00000FE -19-07MAR17-10/17

450K, 550K, and 650K Crawler Dozer 021518 PN=195

Hydrostatic System

IMPORTANT: The base of the depth micrometer must be positioned on top of the JDG1094 Leveling Plate when measuring zero angle position of the swash plate. RW25762 —UN—16JUN97

The rod must be located on the swash plate and NOT on the piston retainer plate. NOTE: Depth gauge must have capability of measuring approximately 100—127 mm (4—5 in). 32. Measure the zero angle position of the swash plate using a depth micrometer as illustrated making sure the end of the micrometer rod (A) is contacting the swash plate flat surface (B).

Measure Depth

33. Measure the other side of swash plate at (C).

A—Depth Micrometer B—Swash Plate Flat Surface

IMPORTANT: Measurements must not vary more than 0.025 mm (0.001 in) on either side of the swash plate.

C—Opposite Measuring Location

34. Take a second measurement on each side. DA93471,00000FE -19-07MAR17-11/17

35. Rotate the side cover at location (D) as necessary to obtain zero angle position of swash plate. 36. Once zero angle position has been established. Tighten the two side cover screws (E) to specifications. T118274 —UN—17NOV98

Hydrostatic Pump—Specification Side Cover-to-Pump Housing Blind Hole Cap Screws—Torque............................................................................33 N·m 24 lb·ft

37. Install the remaining new four side cover cap screws to specifications. Hydrostatic Pump—Specification Side Cover-to-Pump Housing Through (Top Two) Hole Cap Screws—Torque............................................................................33 N·m 24 lb·ft

38. Recheck zero angle position to verify side cover did not move while torquing the four side cover cap screws (E).

Move Side Cover for Zero Angle D—Side Cover Rotation

39. Remove leveling plate.

Continued on next page

TM14163X19 (15FEB18)

E—Cap Screw (4 used)

03-0360-22

DA93471,00000FE -19-07MAR17-12/17

450K, 550K, and 650K Crawler Dozer 021518 PN=196

Hydrostatic System

40. Install two alignment pins (A). 41. Lubricate the running surface of the cylinder block.

T156793B —UN—27JUN02

NOTE: Make sure valve plate (B) and gasket (D) do not get caught on alignment pins (A) during installation. NOTE: The arrow cut-outs in the valve plate must point in the direction of pump rotation when viewed from the shaft end. 42. Install valve plate (B) making sure the direction arrows (C) stamped in the valve plate are correctly positioned. 43. Install gasket (D). A—Alignment Pin (2 used) B—Valve Plate

Direction of Arrows C—Directional Arrow (2 used) D—Gasket DA93471,00000FE -19-07MAR17-13/17

IMPORTANT: Use hardened swash plate leveler spring shims only. Using other materials for shims may result in damage to pump.

RW25765 —UN—20JUN97

44. Install the leveler spring shims (A) in the end cap pockets using petroleum jelly to hold shims. 45. Lubricate the end cap journal bearing (B) with clean hydraulic oil. A—Leveler Spring Shim (2 used)

B—End Cap Journal Bearing

Installing Leveler Spring Shims DA93471,00000FE -19-07MAR17-14/17

46. Install the end cap to the pump housing making sure springs align with the end cap pockets. 47. Install O-ring, new adapter plate (1), and socket head cap screws (2). Tighten cap screws to specifications.

T119614B —UN—15JAN99

Hydrostatic Pump—Specification End Cap/Adapter-toPump Cap Screws (Large)—Torque..........................................................................298 N·m 220 lb·ft

48. Install socket head cap screw (3) with spacer and lifting bracket and cap screw (4). Tighten to specifications. Hydrostatic Pump—Specification End Cap-to-Pump Cap Screws (Small)—Torque................................................................33 N·m 24 lb·ft

Washers and Hex Screws 1— Adapter Plate 2— Socket Head Cap Screws (4 used)

Continued on next page

TM14163X19 (15FEB18)

03-0360-23

3— Socket Head Cap Screw with Spacer and Lift Bracket 4— Socket Head Cap Screw DA93471,00000FE -19-07MAR17-15/17

450K, 550K, and 650K Crawler Dozer 021518 PN=197

Hydrostatic System

49. Turn the pump 180° to install the shaft. 50. Install the shaft and bearing assembly.

RW25767 —UN—20JUN97

51. Rotate the shaft to insure the rotating assembly turns freely.

Installing Shaft and Bearing Assembly DA93471,00000FE -19-07MAR17-16/17

52. Carefully install seal carrier (A) with lip seal. 53. Install retaining plate (B) and socket head cap screws (C). Tighten to specifications. RW25768 —UN—20JUN97

Hydrostatic Pump—Specification Input Shaft Seal Carrier Retaining Cap Screw—Torque..............................................................................16 N·m 142 lb·in

54. Install displacement control valve assembly. See Pump Displacement Control Valve (PDCV) Disassemble and Assemble. (Group 0360.) Seal Carrier, Retaining Plate and Screws A—Seal Carrier B—Retaining Plate

C—Socket Head Cap Screw (3 used) DA93471,00000FE -19-07MAR17-17/17

Neutral Charge Relief Valve Disassemble and Assemble

T119677B —UN—19JAN99

1. Disconnect lines and remove relief valve from bottom of front hydrostatic pump. Note orientation of valve to aid in assembly. 2. Remove parts (2—8). Clean and inspect all parts for wear or damage. 3. Install new O-rings and assemble valve. 4. Perform Neutral Charge Relief and Operating Charge Relief Pressure Test. (Group 9026-25.) Charge Relief Valve 1— Valve Housing 2— Poppet 3— Spring 4— Adjusting Screw

5— O-Ring 6— Lock Nut 7— Lock Nut 8— O-Ring DA93471,000012B -19-25MAR15-1/1

TM14163X19 (15FEB18)

03-0360-24

450K, 550K, and 650K Crawler Dozer 021518 PN=198

Hydrostatic System

Hydrostatic Motor Disassemble SERVICE EQUIPMENT AND TOOLS D01173AA 17-1/2-Ton Puller Set Continued on next page

TM14163X19 (15FEB18)

03-0360-25

DA93471,0000119 -19-11MAY15-1/16

450K, 550K, and 650K Crawler Dozer 021518 PN=199

Hydrostatic System

TM14163X19 (15FEB18)

03-0360-26

450K, 550K, and 650K Crawler Dozer 021518 PN=200

TM14163X19 (15FEB18)

TX1191950

TX1191950 —UN—29APR15

03-0360-27

Continued on next page

Hydrostatic System

12 11

021518

PN=201

550K/650K Hydrostatic Motor (exploded view shown)

450K, 550K, and 650K Crawler Dozer

DA93471,0000119 -19-11MAY15-2/16

55 B12

Hydrostatic System

TM14163X19 (15FEB18)

03-0360-28

450K, 550K, and 650K Crawler Dozer 021518 PN=202

Hydrostatic System

1— Cap Screw (4 used) 2— Cover 3— O-Ring 4— Cap Screw 5— Seal 6— Ring 7— Bushing 8— Set Pin 9— Retaining Cap Screw 10— Valve Segment 11— O-Ring (3 used) 12— Plug (3 used) 13— Flushing Valve Spool 14— O-Ring (2 used) 15— Plug (2 used) 16— Spring (2 used) 17— Cap Screw (8 used)

18— Piston 19— Pin 20— Set Screw 21— Spring 22— Spring Seat 23— O-Ring 24— Operating Charge Relief Valve 25— O-Ring 26— End Cap Housing 27— Gasket 28— Servo Cover 29— O-Ring (3 used) 30— Plug (3 used) 31— Plug 32— O-Ring 33— Spool Valve 34— Motor Shift Solenoid Spool Valve

NOTE: Procedure shown is for left hydrostatic motor. Procedure for right side is same.

35— Cap Screw (4 used) 36— O-Ring 37— Cap Screw (3 used) 38— Cap Screw (2 used) 39— Guard 40— Bearing Plate 41— Cylinder Block 42— Synchronizer Shaft 43— Shaft Assembly 44— Gasket 45— Dowel Pin (2 used) 46— Minimum Displacement Stop Screw 47— Plug (2 used) 48— O-Ring (2 used)

49— Dowel Pin 50— O-Ring 51— Rotating Group Housing 52— Seal 53— Snap Ring 54— O-Ring 55— Cap Screw 56— Synchronizing Shaft Support Pin (2 used) B6—Left Hydrostatic Pressure Sensor B12— Left Motor Speed Sensor Y1— Left Motor Shift Solenoid

1. Remove guard (39) and left motor shift solenoid (Y1). DA93471,0000119 -19-11MAY15-3/16

2. Remove motor shift solenoid spool valve (34) and remove servo cover (28). 35— Cap Screw (4 used) 46— Minimum Displacement Stop Screw

TX1183202A —UN—27JAN15

28— Servo Cover 34— Motor Shift Solenoid Spool Valve

Motor Shift Solenoid Spool Valve Continued on next page

TM14163X19 (15FEB18)

03-0360-29

DA93471,0000119 -19-11MAY15-4/16

450K, 550K, and 650K Crawler Dozer 021518 PN=203

Hydrostatic System

3. Remove gasket (27), spring (21), and spring seat (22) from servo cover. 28— Servo Cover 30— Plug 31— Plug

TX1187206A —UN—06MAR15

21— Spring 22— Spring Seat 27— Gasket

Spring Assembly and Gasket DA93471,0000119 -19-11MAY15-5/16

4. Remove spool valve components (13—16). 5. Remove cap screws (17) and end cap housing (26). 16— Spring 17— Cap Screw (8 used) 26— End Cap Housing

TX1187207A —UN—06MAR15

13— Flushing Valve Spool 14— O-Ring (2 used) 15— Plug (2 used)

Flushing Valve Spool (550K/650K hydrostatic motor shown) Continued on next page

TM14163X19 (15FEB18)

03-0360-30

DA93471,0000119 -19-11MAY15-6/16

450K, 550K, and 650K Crawler Dozer 021518 PN=204

Hydrostatic System

6. Remove operating charge relief valve (24) with O-ring (23) from end cap housing (26). 24— Operating Charge Relief Valve

TX1183208A —UN—27JAN15

23— O-Ring

Operating Charge Relief Valve DA93471,0000119 -19-11MAY15-7/16

7. Remove gasket (44), shaft assembly (43), and remove bearing plate (40). 44— Gasket 45— Dowel Pin (2 used)

TX1183209A —UN—27JAN15

40— Bearing Plate 43— Shaft Assembly

Rotating Group Housing Continued on next page

TM14163X19 (15FEB18)

03-0360-31

DA93471,0000119 -19-11MAY15-8/16

450K, 550K, and 650K Crawler Dozer 021518 PN=205

Hydrostatic System

NOTE: Make a mark for orientation of valve segment (10) and retaining cap screw (9) to aid in assembly. 8. Remove retaining cap screw (9) and valve segment (10). 18— Piston 26— End Cap Housing

TX1183210A —UN—27JAN15

8— Set Pin 9— Retaining Cap Screw 10— Valve Segment

TX1183211A —UN—04FEB15

Valve Segment

Valve Segment (removed) Continued on next page

TM14163X19 (15FEB18)

03-0360-32

DA93471,0000119 -19-11MAY15-9/16

450K, 550K, and 650K Crawler Dozer 021518 PN=206

Hydrostatic System

9. Remove set screw (20) and pin (19) from piston (18). With pin (19) removed set pin (8) can be removed from piston. 19— Pin 20— Set Screw

TX1183212A —UN—28JAN15

8— Set Pin 18— Piston

Piston Assembly (disassembled) DA93471,0000119 -19-11MAY15-10/16

10. Remove cap screw (4) and bushing (7). Clean and inspect parts. Replace as needed. 7— Bushing 26— End Cap Housing

TX1183214A —UN—30JAN15

4— Cap Screw 5— Seal 6— Ring

Bushing Continued on next page

TM14163X19 (15FEB18)

03-0360-33

DA93471,0000119 -19-11MAY15-11/16

450K, 550K, and 650K Crawler Dozer 021518 PN=207

Hydrostatic System

NOTE: Make a mark for orientation of synchronizer shaft (42) to aid in assembly. 11. Remove cylinder block (41) from shaft assembly (43), and synchronizing shaft support pins (56). 43— Shaft Assembly

TX1183219A —UN—28JAN15

41— Cylinder Block 42— Synchronizer Shaft

TX1183216A —UN—03FEB15

Shaft Assembly

Cylinder Block Continued on next page

TM14163X19 (15FEB18)

03-0360-34

DA93471,0000119 -19-11MAY15-12/16

450K, 550K, and 650K Crawler Dozer 021518 PN=208

Hydrostatic System

12. Remove left motor speed sensor (B12) with O-ring (54). B12— Left Motor Speed Sensor

TX1183222A —UN—28JAN15

47— Plug (2 used) 55— Cap Screw

Left Motor Speed Sensor (550K/650K hydrostatic motor shown) DA93471,0000119 -19-11MAY15-13/16

13. Remove dowel pin (49) with O-ring (50). 50— O-Ring 51— Rotating Group Housing

TX1183217A —UN—04FEB15

47— Plug (2 used) 49— Dowel Pin

Dowel Pin (550K/650K hydrostatic motor shown) Continued on next page

TM14163X19 (15FEB18)

03-0360-35

DA93471,0000119 -19-11MAY15-14/16

450K, 550K, and 650K Crawler Dozer 021518 PN=209

Hydrostatic System

14. Use D01173AA 17-1/2-Ton Puller Set to remove shaft assembly (43) from rotating group housing. 59— Two-Jaw Puller

TX1190010A —UN—07APR15

43— Shaft Assembly 51— Rotating Group Housing

Shaft Removal (850K/1050K hydrostatic motor shown) DA93471,0000119 -19-11MAY15-15/16

15. Remove snap ring (53) and seal (52). 16. Clean and inspect components. Replace as needed. 53— Snap Ring

TX1190872A —UN—20APR15

51— Rotating Group Housing 52— Seal

Snap Ring (550K/650K hydrostatic motor shown) DA93471,0000119 -19-11MAY15-16/16

TM14163X19 (15FEB18)

03-0360-36

450K, 550K, and 650K Crawler Dozer 021518 PN=210

Hydrostatic System

Hydrostatic Motor Assemble SPECIFICATIONS Dowel Pin Torque

8 N·m 71 lb·in

Cap Screw (55) Torque

8 N·m 71 lb·in

Set Screw Torque

34 N·m 25 lb·ft

Retaining Cap Screw Torque

8 N·m 71 lb·in

Cap Screw (17) Torque

78 N·m 58 lb·ft

Bushing Cap Screw Torque

66 N·m 49 lb·ft

Cap Screw (1) Torque

115 N·m 85 lb·ft

Left Hydrostatic Pressure Sensor Torque

42 N·m 31 lb·ft

Operating Charge Relief Valve Torque

67 N·m 49 lb·ft

Cap Screw (35) Torque

37 N·m 27 lb·ft

Plug (15) Torque

67 N·m 49 lb·ft

Cap Screw (37) Torque

6 N·m 53 lb·in Continued on next page

TM14163X19 (15FEB18)

03-0360-37

DA93471,00000F4 -19-08MAR17-1/17

450K, 550K, and 650K Crawler Dozer 021518 PN=211

Hydrostatic System

TM14163X19 (15FEB18)

03-0360-38

450K, 550K, and 650K Crawler Dozer 021518 PN=212

TM14163X19 (15FEB18)

TX1191950

TX1191950 —UN—29APR15

03-0360-39

Continued on next page

Hydrostatic System

12 11

021518

PN=213

550K/650K Hydrostatic Motor (exploded view shown)

450K, 550K, and 650K Crawler Dozer

DA93471,00000F4 -19-08MAR17-2/17

55 B12

Hydrostatic System

TM14163X19 (15FEB18)

03-0360-40

450K, 550K, and 650K Crawler Dozer

021518

PN=214

Hydrostatic System

Continued on next page

TM14163X19 (15FEB18)

03-0360-41

DA93471,00000F4 -19-08MAR17-3/17

450K, 550K, and 650K Crawler Dozer 021518 PN=215

Hydrostatic System

IMPORTANT: Prevent possible damage to shaft assembly (43). Place metal press spacer (58) in the middle of shaft assembly. Ensure not to damage the piston shaft retaining seats (57). 1. Press shaft assembly (43) into rotating group housing (51) until shaft assembly is fully seated. 57— Piston Shaft Retaining Seat 58— Metal Press Spacer

TX1192854A —UN—08MAY15

43— Shaft Assembly 51— Rotating Group Housing

TX1189632A —UN—01APR15

Metal Press Spacer Placement

Pressing Shaft Assembly Continued on next page

TM14163X19 (15FEB18)

03-0360-42

DA93471,00000F4 -19-08MAR17-4/17

450K, 550K, and 650K Crawler Dozer 021518 PN=216

Hydrostatic System

NOTE: Shaft assembly (43) is serviced as an assembly. 2. Install synchronizer shaft (42) with synchronizing shaft support pins (56) into shaft assembly. Apply petroleum jelly to shaft key and shaft key centering pins to hold assembly together.

41— Cylinder Block 42— Synchronizer Shaft

TX1183219A —UN—28JAN15

3. Use cylinder block and shaft assembly alignment marks from disassembly to install cylinder block (41). Install two pistons into cylinder block and insert remaining pistons into cylinder block, rotating cylinder block in a clockwise rotation until all pistons are in place. Ensure that synchronizing shaft rollers are all in place inside cylinder block and shaft assembly. 43— Shaft Assembly

TX1183216A —UN—03FEB15

Shaft Assembly

Cylinder Block Continued on next page

TM14163X19 (15FEB18)

03-0360-43

DA93471,00000F4 -19-08MAR17-5/17

450K, 550K, and 650K Crawler Dozer 021518 PN=217

Hydrostatic System

IMPORTANT: To prevent damage to shaft assembly bearing. Ensure dowel pin (49) is seated above bearing race. 4. With shaft assembly properly seated, install dowel pin (49) with O-ring (50) into rotating group housing. Tighten dowel pin to specification. Specification Dowel Pin—Torque..........................................................................8 N·m 71 lb·in 50— O-Ring 51— Rotating Group Housing TX1183217A —UN—04FEB15

47— Plug (2 used) 49— Dowel Pin

Dowel Pin (550K/650K hydrostatic motor shown) DA93471,00000F4 -19-08MAR17-6/17

5. Install left motor speed sensor (B12) with new O-ring (54). Tighten cap screw (55) to specification. Specification Cap Screw (55)—Torque...................................................................................8 N·m 71 lb·in B12— Left Motor Speed Sensor

TX1183222A —UN—28JAN15

47— Plug (2 used) 55— Cap Screw

Motor Speed Sensor (550K/650K hydrostatic motor shown) Continued on next page

TM14163X19 (15FEB18)

03-0360-44

DA93471,00000F4 -19-08MAR17-7/17

450K, 550K, and 650K Crawler Dozer 021518 PN=218

Hydrostatic System

6. Install piston (18) into end cap housing (26). Install set pin (8) into piston, insert pin (19), and insert set screw (20) and tighten to specification. Specification Set Screw—Torque.......................................................................34 N·m 25 lb·ft 19— Pin 20— Set Screw

TX1183212A —UN—28JAN15

8— Set Pin 18— Piston

Piston Assembly Disassembled Continued on next page

TM14163X19 (15FEB18)

03-0360-45

DA93471,00000F4 -19-08MAR17-8/17

450K, 550K, and 650K Crawler Dozer 021518 PN=219

Hydrostatic System

7. Using alignment marks from disassembly, install valve segment (10) on top of set pin (8). Install retaining cap screw (9) and tighten to specification. Specification Retaining Cap Screw—Torque................................................................................8 N·m 71 lb·in 18— Piston 26— End Cap Housing

TX1183211A —UN—04FEB15

8— Set Pin 9— Retaining Cap Screw 10— Valve Segment

TX1183210A —UN—27JAN15

Valve Segment (removed)

Valve Segment Continued on next page

TM14163X19 (15FEB18)

03-0360-46

DA93471,00000F4 -19-08MAR17-9/17

450K, 550K, and 650K Crawler Dozer 021518 PN=220

Hydrostatic System

8. Install bearing plate (40) on cylinder block (41). NOTE: Apply clean hydrostatic oil to all internal parts prior to assembly. 9. Install new gasket (44). IMPORTANT: To prevent damage to the hydrostatic motor, DO NOT force the end cap into position on the housing. Apply clean hydrostatic oil to all parts while assembling.

TX1183209A —UN—27JAN15

10. Apply clean hydrostatic oil to valve segment (10) and bearing plate (40) mating surfaces. IMPORTANT: To prevent damage to the hydrostatic motor, DO NOT allow the pistons or synchronizing shaft rollers to fall out of position. Apply clean hydrostatic oil to all parts while assembling. NOTE: The valve segment (10) must engage bearing in cylinder block (41) for proper assembly. 11. Using orientation marks from disassembly, install end cap housing (26) onto rotating group housing (51) using dowel pins (45) for assembly alignment.

Rotating Group Housing 40— Bearing Plate 43— Shaft Assembly Continued on next page

TM14163X19 (15FEB18)

03-0360-47

44— Gasket 45— Dowel Pin (2 used) DA93471,00000F4 -19-08MAR17-10/17

450K, 550K, and 650K Crawler Dozer 021518 PN=221

Hydrostatic System

12. Install cap screws (17) and tighten by hand in sequence shown (1—8) while rotating motor shaft to ensure proper positioning of shaft key rollers. 13. Tighten cap screws (17) using sequence shown to approximately 1/2 final torque value. Repeat sequence and tighten to final torque specification. Specification Cap Screw (17)—Torque.................................................................................78 N·m 58 lb·ft

TX1184350 —UN—04FEB15

17— Cap Screw (8 used)

T8506AQ —UN—10JUL95

End Cap and Rotating Group Housing

Screw Torque Sequence Continued on next page

TM14163X19 (15FEB18)

03-0360-48

DA93471,00000F4 -19-08MAR17-11/17

450K, 550K, and 650K Crawler Dozer 021518 PN=222

Hydrostatic System

NOTE: Apply clean hydrostatic oil to seal (5) and ring (6) prior to assembly. 14. Install bushing (7) with new ring (6) and seal (5) into end cap housing. Tighten bushing cap screw (4) to specification. Specification Bushing Cap Screw—Torque..............................................................................66 N·m 49 lb·ft

TX1183214A —UN—30JAN15

15. Install O-ring (3), cover (2) and tighten cap screws (1) to specification. Specification Cap Screw (1)—Torque............................................................... 115 N·m 85 lb·ft

16. Install left hydrostatic pressure sensor (B6) with O-ring (25) into port M5 of end cap housing (26). Tighten to specification. Specification Left Hydrostatic Pressure Sensor—Torque............................................................................42 N·m 31 lb·ft

Bushing 4— Cap Screw 5— Seal 6— Ring

7— Bushing 26— End Cap Housing

DA93471,00000F4 -19-08MAR17-12/17

17. Install operating charge relief valve (24) and new O-ring (23). Tighten to specification. Specification Operating Charge Relief Valve—Torque...............................................................................67 N·m 49 lb·ft 24— Operating Charge Relief Valve

TX1183208A —UN—27JAN15

23— O-Ring

Operating Charge Relief Valve Continued on next page

TM14163X19 (15FEB18)

03-0360-49

DA93471,00000F4 -19-08MAR17-13/17

450K, 550K, and 650K Crawler Dozer 021518 PN=223

Hydrostatic System

18. Install spring (21), spring seat (22), gasket (27), servo cover (28), and cap screws (35) into end cap housing. Tighten cap screws to specification. Specification Cap Screw (35)—Torque.................................................................................37 N·m 27 lb·ft 28— Servo Cover 30— Plug 31— Plug

TX1187206A —UN—06MAR15

21— Spring 22— Spring Seat 27— Gasket

Spring Assembly and Gasket DA93471,00000F4 -19-08MAR17-14/17

19. Install components (13—16) as shown. Tighten plug (15) to specification. Specification Plug (15)—Torque.........................................................................67 N·m 49 lb·ft 16— Spring (2 used) 17— Cap Screw (8 used) 26— End Cap Housing

TX1187207A —UN—06MAR15

13— Flushing Valve Spool 14— O-Ring (2 used) 15— Plug (2 used)

Flushing Valve Spool (550K/650K hydrostatic motor shown) Continued on next page

TM14163X19 (15FEB18)

03-0360-50

DA93471,00000F4 -19-08MAR17-15/17

450K, 550K, and 650K Crawler Dozer 021518 PN=224

Hydrostatic System

20. Install motor shift solenoid spool valve (34). 21. Install O-ring (36) and left motor shift solenoid (Y1) with cap screws (37). Tighten to specification. Specification Cap Screw (37)—Torque...................................................................................6 N·m 53 lb·in

22. Install Guard (39) with cap screws (38). 23. Rotate shaft 360° to check final assembly. 35— Cap Screw (4 used) 46— Minimum Displacement Stop Screw

TX1183202A —UN—27JAN15

28— Servo Cover 34— Motor Shift Solenoid Spool Valve

Motor Shift Solenoid Spool Valve DA93471,00000F4 -19-08MAR17-16/17

24. Install seal (52) into rotating group housing (51). 25. Install snap ring (53). 52— Seal 53— Snap Ring

TX1183201A —UN—24JAN15

43— Shaft Assembly 51— Rotating Group Housing

Seal and Snap Ring (550K/650K hydrostatic motor shown) DA93471,00000F4 -19-08MAR17-17/17

TM14163X19 (15FEB18)

03-0360-51

450K, 550K, and 650K Crawler Dozer 021518 PN=225

Hydrostatic System

Hydrostatic Thermal Bypass Valve Remove and Install SPECIFICATIONS

T199914A —UN—14MAY04

Hydrostatic Thermal Bypass Valve 80 N·m Mounting Cap Screw Torque 60 lb.-ft.

NOTE: Hoses removed for clarity. 1. Drain or apply a vacuum to hydrostatic oil reservoir. 2. Disconnect hydrostatic oil temperature sensor (3) connector. Hydrostatic Thermal Bypass Valve

3. Disconnect hoses (1, 5, 6, 9, and 11). 4. Remove cap screws (8) and nuts (2). 5. Remove oil cooler thermal bypass valve (7). Replace parts as needed. 6. Install oil cooler thermal bypass valve (7) using cap screws (8) and nuts (2). Tighten cap screws to specification. Specification Hydrostatic Thermal Bypass Valve Mounting Cap Screw—Torque......................................................................80 N·m 60 lb.-ft.

1— Hydrostatic Motors-toHydrostatic Thermal Bypass Valve Case Drain Line 2— Nut (2 used) 3— Hydrostatic Oil Temperature Sensor 4— Tee Fitting 5— Hydrostatic Pumps-toHydrostatic Thermal Bypass Valve Case Drain Line 6— Hydrostatic Thermal Bypass Valve-toHydrostatic Oil Cooler Line

7— Hydrostatic Thermal Bypass Valve 8— Cap Screws (2 used) 9— Hydrostatic Oil Cooler-to-Hydrostatic Oil Reservoir 10— Tee Fitting 11— Hydrostatic Thermal Bypass Valve-toHydrostatic Oil Reservoir Line 12— Rear Hydrostatic Pump (port M3/X11)-to-Park Brake Solenoid Valve

7. Install hoses (1, 5, 6, 9, and 11). 8. Install hydrostatic oil temperature sensor (3) connector. 9. Fill hydrostatic oil reservoir if drained. See Drain and Refill Hydraulic/Hydrostatic System Oil and Replace Filters. (Operator’s Manual.) AB06447,0000D45 -19-10MAR17-1/1

TM14163X19 (15FEB18)

03-0360-52

450K, 550K, and 650K Crawler Dozer 021518 PN=226

Hydrostatic System

Hydrostatic Charge Oil Filter Assembly Remove and Install SPECIFICATIONS Cap Screw Torque

50 N·m 37 lb·ft

MACHINE PREPARATION 1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.)

TX1235162A —UN—01MAR17

Hydrostatic Charge Oil Filter Assembly

REMOVAL 1. Disconnect hydrostatic oil filter restriction switch (B15) wire lead.

1— Cap Screw 2— Cap Screw (3 used) 3— Hydrostatic Charge Oil Filter Assembly

2. Remove cap screw (1) and hydrostatic oil filter ground (W6). IMPORTANT: Prevent hydraulic system contamination. Absolute cleanliness is essential when working on hydraulic components. Clean component and adjacent areas before starting work. Close all openings using caps and plugs. 3. Install identification tags and disconnect hydraulic hoses (4). Close all openings using caps and plugs.

4— Hydraulic Hose (2 used) B15— Hydrostatic Oil Filter Restriction Switch W6—Hydrostatic Oil Filter Ground

INSTALLATION Installation is reverse of removal procedure.

• Tighten cap screws (1 and 2) to specification. Specification Cap Screw—Torque......................................................................50 N·m 37 lb·ft

4. Remove cap screws (2) and hydrostatic charge oil filter assembly (3). BS40810,000024C -19-10MAR17-1/1

TM14163X19 (15FEB18)

03-0360-53

450K, 550K, and 650K Crawler Dozer 021518 PN=227

Hydrostatic System

Hydrostatic Charge Oil Filter Assembly Disassemble and Assemble 2 4 12 3 9 B15

4 5

10 11

TX1187751 —UN—11MAR15

TX1187751 Hydrostatic Charge Oil Filter Assembly 1— Hydrostatic Filter 2— Elbow Fitting 3— O-Ring 4— O-Ring (2 used)

5— Elbow Fitting 6— O-Ring 7— Hydrostatic Oil Sample Port 8— O-Ring

DISASSEMBLE Disassemble parts as shown. Inspect parts. Replace if necessary. ASSEMBLE Assemble parts as shown. Torque Specifications

9— O-Ring 10— Nut (2 used) 11— Washer 12— Hydrostatic Filter Manifold

B15— Hydrostatic Oil Filter Restriction Switch

Specification Hydrostatic Oil Sample Port—Torque................................................................................. 11 N·m 97 lb·in Hydrostatic Oil Filter Restriction Switch—Torque................................................................... 1.4—6.8 N·m 12—60 lb·in DA93471,000012D -19-08MAR17-1/1

TM14163X19 (15FEB18)

03-0360-54

450K, 550K, and 650K Crawler Dozer 021518 PN=228

Hydrostatic System

Hydrostatic and Hydraulic Oil Reservoir Cleanout Cover Remove and Install SPECIFICATIONS Cleanout Cover Nut Torque

31 N·m 23 lb·ft

MACHINE PREPARATION 1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.)

TX1232872A —UN—30JAN17

2. Drain hydraulic and hydrostatic oil reservoir. See Drain and Refill Hydraulic/Hydrostatic System Oil and Replace Filters. (Operator’s Manual.) REMOVAL 1. Remove operator’s station floor plate. See Remove Operator’s Station Floor Plate. (Operator’s Manual.) IMPORTANT: Prevent fluid contamination. Remove paint and debris from sealing edge of cleanout cover and from stud threads prior to removal.

Hydrostatic and Hydraulic Oil Reservoir Cleanout Cover

2. Remove paint from sealing edge of hydraulic oil reservoir cleanout cover (1) and from stud threads.

1— Cleanout Cover 2— Gasket

3— Nut (6 used) 4— Hydraulic Oil Reservoir

3. Remove nuts (3), cleanout cover, and gasket (2). 4. Clean reservoir as required. Specification Cleanout Cover Nut—Torque..................................................................................31 N·m 23 lb·ft

INSTALLATION Installation is reverse of removal procedure.

• Tighten nuts (3) to specification.

• Paint affected areas as required. BS40810,0000244 -19-10MAR17-1/1

Hydraulic Oil Reservoir Remove and Install 159 kg 351 lb

Cap Screw (12) Torque

320 N·m 236 lb·ft

Cap Screw (10) Torque

130 N·m 96 lb·ft

TX1234290A —UN—20FEB17

SPECIFICATIONS Hydraulic Oil Reservoir Weight (approximate)

MACHINE PREPARATION 1. Remove operator’s station. See Operator’s Station Remove and Install. (Group 1800.)

Fender (left side shown)

2. Drain hydraulic oil reservoir. See Drain and Refill Hydraulic/Hydrostatic System Oil and Replace Filters. (Operator’s Manual.)

1— Left Side Fender 2— Battery (2 used)

3— Cap Screw (7 used)

REMOVAL 1. Remove rear sheet metal. See Rear Sheet Metal Remove and Install. (Group 1913.)

3. Remove batteries (2). See Replacing and Removing Batteries. (Operator’s Manual.)

2. Remove cap screws (3) and left side fender (1). Continued on next page

TM14163X19 (15FEB18)

03-0360-55

BS40810,0000245 -19-10MAR17-1/3

450K, 550K, and 650K Crawler Dozer 021518 PN=229

TX1234291A —UN—01MAR17

Hydrostatic System

Hydraulic Oil Reservoir (top view) 4— Clamp (8 used) 5— Diesel Exhaust Fluid (DEF) Tank Coolant Valve 6— Cap Screw (2 used)

7— Hydraulic Line (650K, 8 used; 450K/550K, 7 used) 8— Hydraulic Line 9— Hydraulic Oil Filter Assembly

10— Cap Screw (5 used) 11— Filter Plate 12— Cap Screw (3 used) 13— Hydraulic Oil Reservoir

15— Fill Neck Line B18— Hydraulic Oil Temperature Sensor

4. Disconnect hydraulic oil temperature sensor (B18).

6. Remove hydraulic oil filter assembly (9) and set aside.

IMPORTANT: Prevent hydraulic system contamination. Absolute cleanliness is essential when working on hydraulic components. Clean component and adjacent areas before starting work. Close all openings using caps and plugs.

7. Remove cap screws (10) and set filter plate (11) aside. 8. Remove clamps (4). 9. Remove cap screws (6) and set diesel exhaust fluid (DEF) tank coolant valve (5) aside.

5. Install identification tags and disconnect hydraulic line (8). Close all openings using caps and plugs. Continued on next page

TM14163X19 (15FEB18)

03-0360-56

BS40810,0000245 -19-10MAR17-2/3

450K, 550K, and 650K Crawler Dozer 021518 PN=230

Hydrostatic System

10. Install identification tags and disconnect hydraulic lines (7) and fill neck line (15) from hydraulic oil reservoir (13). Close all openings using caps and plugs. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 11. Attach appropriate lifting device to hydraulic oil reservoir.

TX1234292A —UN—28FEB17

Specification Hydraulic Oil Reservoir—Weight (approximate)................................................................................ 159 kg 351 lb

12. Remove cap screws (12) and hydraulic oil reservoir. 13. Clean and inspect parts. Repair or replace as necessary. INSTALLATION Installation is reverse of removal procedure.

Hydraulic Oil Reservoir (bottom view)

• Tighten cap screws (12) to specification. Specification Cap Screw (12)—Torque...............................................................................320 N·m 236 lb·ft

7— Hydraulic Line (650K, 8 used; 450K/550K, 7 used)

• Tighten cap screws (10) to specification. Specification Cap Screw (10)—Torque...............................................................................130 N·m 96 lb·ft BS40810,0000245 -19-10MAR17-3/3

TM14163X19 (15FEB18)

03-0360-57

450K, 550K, and 650K Crawler Dozer 021518 PN=231

Hydrostatic System

TM14163X19 (15FEB18)

03-0360-58

450K, 550K, and 650K Crawler Dozer 021518 PN=232

Section 04 Engine Contents Page

Group 0400—Removal and Installation John Deere Engine.................................... 04-0400-1 Engine Remove and Install........................ 04-0400-1 Engine Mounts Remove and Install ..................................................... 04-0400-6

TM14163X19 (15FEB18)

04-1

450K, 550K, and 650K Crawler Dozer

021518

PN=1

Contents

TM14163X19 (15FEB18)

04-2

450K, 550K, and 650K Crawler Dozer

021518

PN=2

Group 0400

Removal and Installation • See Electric Low-Pressure Fuel System Operation

John Deere Engine

For theory of operation on John Deere 4045 PowerTech™ 4.5 L diesel engine not contained in this group, see the following:

or see High-Pressure Fuel System Operation. (CTM120119.) • See Air Intake and Exhaust System Operation. (CTM120119.) • See Cold Start Aid Operation. (CTM120119.) • See Aftertreatment System Operation. (CTM120119.)

• See General Engine Operation. (CTM120119.) • See Cooling System Operation. (CTM120119.) • See Lubrication System Operation. (CTM120119.)

For additional information, see PowerTech™ 4.5 L OEM Diesel Engines—Final Tier 4/Stage IV Platform. (CTM120119.)

This machine uses a John Deere 4045 PowerTech™ 4.5 L diesel engine.

PowerTech is a trademark of Deere & Company AB51738,00006FD -19-08JAN15-1/1

Engine Remove and Install SPECIFICATIONS Engine Weight (approximate)

595 kg 1312 lb

Engine Cradle Cap Screw Torque

130 N·m 96 lb·ft

Flywheel Cover Cap Screw Torque 73 N·m 54 lb·ft TX1188114A —UN—23MAR15

SERVICE EQUIPMENT AND TOOLS JT07184 Pump Support Bracket

Install identification tags to all electrical connectors, hoses, and lines to aid in assembly. Clean component and adjacent areas before starting work. Close all openings using caps and plugs. MACHINE PREPARATION Engine (650K, left side shown)

1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.)

1— Cap Screw (6 used) 2— Rear Hood Support 3— Positive Connection

2. Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch. (Operator’s Manual.)

4— Ground Connection 5— Fuel Return Line

REMOVAL 1. Remove cooling package. See Cooling Package Remove and Install. (Group 0510.)

4. Remove positive and ground connections (3 and 4) from starter motor.

2. Remove cap screws (1) and rear hood support (2).

5. Disconnect fuel return line (5).

3. Remove air conditioner compressor and set to the side, leaving lines attached. See Compressor Remove and Install. (Group 1830.) Continued on next page

TM14163X19 (15FEB18)

04-0400-1

BS40810,0000235 -19-10MAR17-1/6

450K, 550K, and 650K Crawler Dozer 021518 PN=235

Removal and Installation

6. Remove crankcase ventilation filter assembly (6). 7. Disconnect final fuel filter-to-low-pressure fuel manifold hose (7). 8. Disconnect under seat heater return line (8) and under seat heater supply line (9). 9. Disconnect diesel exhaust fluid (DEF) dosing unit coolant line (10). TX1234131A —UN—21FEB17

10. Remove the quick service ports as necessary. 11. For 650K Machines: Remove hydraulic fan pump (210) and set to the side, leaving lines attached. See Hydraulic Fan Pump Remove and Install. (Group 2160.) 6— Crankcase Ventilation Filter Assembly 7— Final Fuel Filter-to-LowPressure Fuel Manifold Hose 8— Under Seat Heater Return Line

9— Under Seat Heater Supply Line 10— Diesel Exhaust Fluid (DEF) Dosing Unit Coolant Line 210— Hydraulic Fan Pump

Engine (650K, right side shown)

BS40810,0000235 -19-10MAR17-2/6

12. Disconnect engine control unit (ECU) connector 1 and 2 (X5501 and X5502). 13. Disconnect vehicle harness-to-engine harness 31-pin connector (X5048). 14. Disconnect start relay (K1) and engine auxiliary harness-to-load center harness 12-pin connector (X45). TX1188323A —UN—23MAR15

15. Remove floor mat and floor plate. See Remove Operator’s Station Floor Plate. (Operator’s Manual.) 16. Disconnect engine harness (W32) and engine auxiliary harness (W9) from left frame rail. See Engine Harness (W32) Component Location and see Engine Auxiliary Harness (W9) Component Location. (Group 9015-10.) 17. Remove middle bottom guard. See Bottom Guards Remove and Install. (Group 1746.) Operator's Station Left Access Panel K1—Start Relay X45— Engine Auxiliary Harness-to-Load Center Harness 12-Pin Connector X5048—Vehicle Harness-toEngine Harness 31-Pin Connector

X5501—Engine Control Unit (ECU) Connector 1 X5502—Engine Control Unit (ECU) Connector 2

Continued on next page

TM14163X19 (15FEB18)

04-0400-2

BS40810,0000235 -19-10MAR17-3/6

450K, 550K, and 650K Crawler Dozer 021518 PN=236

Removal and Installation

18. Remove flywheel cap screws (12) from flywheel cover to engine. 30— Front Hydrostatic Pump (right track)

TX1188646A —UN—27MAR15

12— Flywheel Cap Screw (12 used)

Flywheel Cover BS40810,0000235 -19-10MAR17-4/6

19. Support hydrostatic pump using JT07184 Pump Support Bracket (15) and a ratchet lifting device (16). CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

TX1113255A —UN—14MAY12

NOTE: Certain lifting brackets may require a spacer to be placed between the lifting bracket and engine to keep lifting brackets parallel. 20. Install appropriate lifting brackets (17) to engine. Attach lifting brackets to load leveler (18) and appropriate lifting device. Specification Engine—Weight (approximate) ............................................................................... 595 kg 1312 lb

Support Bracket and Lifting Brackets 15— JT07184 Pump Support Bracket 16— Ratchet Lifting Device

Continued on next page

TM14163X19 (15FEB18)

04-0400-3

17— Lifting Bracket (2 used) 18— Load Leveler

BS40810,0000235 -19-10MAR17-5/6

450K, 550K, and 650K Crawler Dozer 021518 PN=237

Removal and Installation

21. Remove engine cradle cap screws (19). See Engine Mounts Remove and Install. (Group 0400.) 22. Remove engine. 23. Clean and inspect parts. Repair or replace parts as necessary. INSTALLATION Installation is reverse of removal procedure.

Specification Engine Cradle Cap Screw—Torque............................................................................130 N·m 96 lb·ft

• Tighten flywheel cap screws to specification.

Specification Flywheel Cover Cap Screw—Torque..............................................................................73 N·m 54 lb·ft

• Prime fuel system and bleed air. See Bleed Fuel

TX1234132 —UN—17FEB17

• Tighten engine cradle cap screws to specification.

Engine Cradle Cap Screws

System. (Operator’s Manual.)

19— Engine Cradle Cap Screw (14 used) BS40810,0000235 -19-10MAR17-6/6

TM14163X19 (15FEB18)

04-0400-4

450K, 550K, and 650K Crawler Dozer 021518 PN=238

Removal and Installation

TM14163X19 (15FEB18)

04-0400-5

450K, 550K, and 650K Crawler Dozer 021518 PN=239

Removal and Installation

Engine Mounts Remove and Install

1 2

2 7

9 3

2 2 10

2 4

4 5

6 7

1 2

8 3

2 4

TX1111407 —UN—05JUN12

TX1111407 Engine Mounts

Continued on next page

TM14163X19 (15FEB18)

04-0400-6

AB51738,0000AB6 -19-04MAR15-1/2

450K, 550K, and 650K Crawler Dozer 021518 PN=240

Removal and Installation 1— Engine Mount Cap Screw (4 used) 2— Washer (4 used) 3— Isolator (4 used)

4— Plate (4 used) 5— Nut (4 used) 6— Washer (8 used) 7— Cap Screw (8 used)

11— Right Rail Assembly

8— Washer (6 used) 9— Cap Screw (6 used) 10— Left Rail Assembly

Item

Measurement

Specification

Engine

Weight (approximate)

595 kg 1310 lb.

Item

Measurement

Specification

Engine Cradle

Weight (approximate)

52 kg 113 lb.

Item

Measurement

Specification

Engine Mount Cap Screws

Torque

346 N·m 255 lb.-ft. AB51738,0000AB6 -19-04MAR15-2/2

TM14163X19 (15FEB18)

04-0400-7

450K, 550K, and 650K Crawler Dozer 021518 PN=241

Removal and Installation

TM14163X19 (15FEB18)

04-0400-8

450K, 550K, and 650K Crawler Dozer 021518 PN=242

Section 05 Engine Auxiliary System Contents Page Page

Group 0505—Cold Weather Starting Aids Engine Coolant Heater Remove and Install .............................................. 05-0505-1

Group 0560—External Fuel Supply Systems Primary Fuel Filter and Water Separator Remove and Install ............... 05-0560-1 Final Fuel Filter Remove and Install ..................................................... 05-0560-2 Auxiliary Fuel Filter and Water Separator Remove and Install—If Equipped ............................... 05-0560-2 Fuel Tank Remove and Install ................... 05-0560-3

Group 0510—Cooling Systems Fan Blade Remove and Install .................. 05-0510-1 Cooling Package Remove and Install ..................................................... 05-0510-4 Charge Air Cooler Remove and Install ..................................................... 05-0510-9 Radiator Remove and Install ..................... 05-0510-9 Hydrostatic Oil Cooler Remove and Install ................................................... 05-0510-10 Group 0520—Intake System Air Cleaner Remove and Install................. 05-0520-1 Precleaner Remove and Install—If Equipped ............................................... 05-0520-1 Group 0530—External Exhaust Systems Exhaust Tube Remove and Install.............. 05-0530-1 JDG11340 Bellows Alignment Fixture.................................................... 05-0530-2 Exhaust Bellows Alignment Procedure .............................................. 05-0530-6 Diesel Oxidation Catalyst (DOC) Remove and Install.............................. 05-0530-11 Diesel Particulate Filter (DPF) Remove and Install.............................. 05-0530-12 Exhaust Filter Remove and Install............ 05-0530-13 Aftertreatment Assembly Remove and Install ............................................ 05-0530-14 Service Filter Cleaning ............................ 05-0530-16 Selective Catalyst Reduction (SCR) Remove and Install................... 05-0530-17 Diesel Exhaust Fluid (DEF) Tank Remove and Install.............................. 05-0530-18 Diesel Exhaust Fluid (DEF) Tank Header Remove and Install ................. 05-0530-19 Diesel Exhaust Fluid (DEF) Tank Header Disassemble and Assemble............................................. 05-0530-20 Diesel Exhaust Fluid (DEF) Tank Cleaning Procedure............................. 05-0530-21 Diesel Exhaust Fluid (DEF) Dosing Unit Remove and Install ...................... 05-0530-22 Diesel Exhaust Fluid (DEF) Dosing Injector Remove and Install ................. 05-0530-23 Diesel Exhaust Fluid (DEF) Decomposition Tube Remove and Install ............................................ 05-0530-23

TM14163X19 (15FEB18)

05-1

450K, 550K, and 650K Crawler Dozer

021518

PN=1

Contents

TM14163X19 (15FEB18)

05-2

450K, 550K, and 650K Crawler Dozer

021518

PN=2

Group 0505

Cold Weather Starting Aids Engine Coolant Heater Remove and Install SPECIFICATIONS

T6642EK —UN—01NOV88

Engine Coolant Heater Nut Torque 34 N·m 25 lb.-ft.

CAUTION: Prevent possible injury. Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off engine. Remove filler cap when cool to touch. Slowly loosen filler cap to relieve the pressure, then remove. Coolant May Be Hot

1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.)

2. Drain cooling system into appropriate container for storage or disposal. See Drain and Refill Engine Cooling System. (Operator’s Manual.)

Use a heavy-duty grounded cord to connect coolant heater to electrical power.

Engine Coolant Heater

3. Loosen lock nut (2) and remove power cord (1). Loosen nut (3) and remove heater element (4) from block.

4. Inspect and replace parts as necessary. 5. Install heater into cylinder block. 6. Hold assembly, using a wrench. Tighten nut (3) to specification.

TX1111571 —UN—05APR12

CAUTION: Prevent possible injury, keep electrical connectors clean to prevent arcing. Only plug coolant heater into electrical power if heater element is immersed in coolant. Sheath could burst and result in personal injury.

NOTE: The heater element (4) cannot be repaired. Replace if defective.

3— Nut 4— Element

1— Power Cord 2— Lock nut (2 used)

Specification Engine Coolant Heater Nut—Torque..................................................................................34 N·m 25 lb.-ft.

7. Install power cord (1). 8. Refill cooling system. See Drain and Refill Engine Cooling System. (Operator’s Manual.) AB51738,0000A90 -19-17FEB15-1/1

TM14163X19 (15FEB18)

05-0505-1

450K, 550K, and 650K Crawler Dozer 021518 PN=245

Cold Weather Starting Aids

TM14163X19 (15FEB18)

05-0505-2

450K, 550K, and 650K Crawler Dozer 021518 PN=246

Group 0510

Cooling Systems Fan Blade Remove and Install 450K and 550K SPECIFICATIONS Fan Blade Cap Screw Torque

73 N·m 54 lb·ft

Tensioner Cap Screw Torque

50 N·m 37 lb·ft

MACHINE PREPARATION 1. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.) 2. Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch. (Operator’s Manual.) REMOVAL TX1232059A —UN—17JAN17

1. Remove engine side shields. See Engine Side Shields Remove and Install. (Group 1910.) 2. Remove serpentine belt (1) and tensioner (4). See Inspect or Replace Belt and Check Automatic Belt Tensioner. (Operator’s Manual.) 3. Remove fan guard (3). 1— Serpentine Belt 2— Cap Screw (3 used) 3— Fan Guard

4— Tensioner 5— Fan Blade

Fan Guard

Continued on next page

TM14163X19 (15FEB18)

05-0510-1

JL48493,0000361 -19-08FEB17-1/5

450K, 550K, and 650K Crawler Dozer 021518 PN=247

Cooling Systems

4. Remove fan blade (5). INSTALLATION Installation is reverse of removal procedure.

• Tighten fan blade cap screws (6) to specification.

TX1232065A —UN—17JAN17

Specification Fan Blade Cap Screw—Torque..............................................................................73 N·m 54 lb·ft

• Tighten tensioner cap screw to specification. Specification Tensioner Cap Screw—Torque..............................................................................50 N·m 37 lb·ft

650K Fan Blade

SPECIFICATIONS Fan Blade Cap Screw Torque

37 N·m 27 lb·ft

Fan Blade Bracket Torque

130 N·m 96 lb·ft

5— Fan Blade

6— Cap Screw (4 used)

MACHINE PREPARATION

2. Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch. (Operator’s Manual.)

1. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.)

REMOVAL JL48493,0000361 -19-08FEB17-2/5

1. Remove lower front grille (9). 2. Remove C-clamp (10) to disconnect cable. 3. Remove front grille (7) from frame and set aside. 9— Lower Front Grille 10— C-Clamp

TX1232038A —UN—23JAN17

6— Cap Screw (8 used) 7— Front Grille 8— Cap Screw (6 used)

Front Grille Continued on next page

TM14163X19 (15FEB18)

05-0510-2

JL48493,0000361 -19-08FEB17-3/5

450K, 550K, and 650K Crawler Dozer 021518 PN=248

Cooling Systems

4. Install identification tags and disconnect fan drive pressure sensor (B54), hydraulic fan proportional relief solenoid (Y11), and hydraulic fan reversing solenoid (Y12). For non-reversing hydraulic fan connections, see Standard Fan Harness (W12) Component Location. (Group 9015-10.) 5. Remove hydraulic fan blade assembly (12) from frame and set aside. Y11— Hydraulic Fan Proportional Relief Solenoid Y12— Hydraulic Fan Reversing Solenoid

TX1232043A —UN—23JAN17

11— Cap Screw (6 used) 12— Hydraulic Fan Blade Assembly B54— Fan Drive Pressure Sensor

Hydraulic Fan Blade Assembly (reversing option shown) JL48493,0000361 -19-08FEB17-4/5

6. Remove fan blade (14). INSTALLATION Installation is reverse of removal procedure.

• Tighten fan blade cap screws (13) to specification.

TX1232046A —UN—23JAN17

Specification Fan Blade Cap Screw—Torque..............................................................................37 N·m 27 lb·ft

• Tighten fan blade bracket to specification. Specification Fan Blade Bracket—Torque..........................................................................130 N·m 96 lb·ft 13— Cap Screw (6 used)

14— Fan Blade

Fan Blade JL48493,0000361 -19-08FEB17-5/5

TM14163X19 (15FEB18)

05-0510-3

450K, 550K, and 650K Crawler Dozer 021518 PN=249

Cooling Systems

Cooling Package Remove and Install 450K and 550K SPECIFICATIONS Standard Front Grille Weight (approximate)

36 kg 79 lb

Heavy-Duty Front Grille Weight (approximate)

40 kg 88 lb

Cooling Package Weight (approximate)

61 kg 135 lb

MACHINE PREPARATION TX1232197A —UN—18JAN17

1. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.) 2. Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch. (Operator’s Manual.) 3. Drain cooling system. See Drain and Refill Engine Cooling System. (Operator's Manual.) 4. Apply vacuum or drain hydraulic oil reservoir. See Drain and Refill Hydraulic/Hydrostatic System Oil and Replace Filters. (Operator’s Manual.)

Front Grille 1— Cap Screw (6 used) 2— Front Grille 3— Lower Front Grille

REMOVAL 1. Remove hood. See Hood Remove and Install. (Group 1910.) 2. Remove fan blade. See Fan Blade Remove and Install. (Group 0510.) 3. Remove aftertreatment assembly. See Aftertreatment Assembly Remove and Install. (Group 0530.) 4. Remove lower front grille (3). 5. Remove C-clamp (4) to disconnect cable. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

4— C-Clamp 5— Cap Screw (4 used)

Specification Standard Front Grille—Weight (approximate).................................................................................. 36 kg 79 lb Heavy-Duty Front Grille—Weight (approximate).................................................................................. 40 kg 88 lb

6. Install appropriate lifting device and disconnect front grille (2) from frame. Set grille aside. Continued on next page

TM14163X19 (15FEB18)

05-0510-4

JL48493,0000362 -19-10MAR17-1/7

450K, 550K, and 650K Crawler Dozer 021518 PN=250

Cooling Systems

7. Disconnect cooling package harness (W10). See Cooling Package Harness (W10) Component Location or see Cooling Package (IGC Controls) Harness (W11) Component Location. (Group 9015-10.) 8. Remove cap screws (6) to disconnect lines and hoses from fan shroud and frame. 9. Disconnect hoses (9, 10, and 14) from surge tank. Close all openings using caps and plugs. TX1232325A —UN—15FEB17

10. Disconnect upper hose and line connections (12 and 15—17) from cooling package. Close all openings using caps and plugs. 11. Remove fan shroud (8). 12. Remove bracket (13). 13— Bracket 14— Surge Tank-to-Thermostat Housing Hose 15— Upper Hydraulic Cooler Line 16— Radiator-to-Surge Tank Hose 17— Upper Radiator Hose W10—Cooling Package Harness

Cooling Package

TX1232328A —UN—18JAN17

6— Cap Screw (4 used) 7— Cap Screw (4 used) 8— Fan Shroud 9— Surge Tank Hose 10— Surge Tank Overflow Hose 11— Cap Screw (5 used) 12— Upper Charge Air Cooler Hose

TX1234084A —UN—15FEB17

Upper Cooling Package Connections

Bracket Cap Screws Continued on next page

TM14163X19 (15FEB18)

05-0510-5

JL48493,0000362 -19-10MAR17-2/7

450K, 550K, and 650K Crawler Dozer 021518 PN=251

Cooling Systems

13. Disconnect lower hose and line connections (18—20) from cooling package. Close all openings using caps and plugs. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 14. Install appropriate lifting device and remove cooling package. TX1232330A —UN—18JAN17

Specification Cooling Package—Weight (approximate).............................................................................................. 61 kg 135 lb

INSTALLATION Installation is reverse of removal procedure. Lower Cooling Package Connections

• Fill hydraulic oil reservoir if drained. See Drain and

Refill Hydraulic/Hydrostatic System Oil and Replace Filters. (Operator’s Manual.) • Fill cooling system. See Drain and Refill Engine Cooling System. (Operator's Manual.)

6— Cap Screw (4 used) 18— Lower Charge Air Cooler Hose

19— Lower Hydraulic Cooler Line 20— Lower Radiator Hose

650K 4. Apply vacuum or drain hydraulic oil reservoir. See Drain and Refill Hydraulic/Hydrostatic System Oil and Replace Filters. (Operator’s Manual.)

SPECIFICATIONS Cooling Package Weight (approximate)

61 kg 135 lb

REMOVAL

MACHINE PREPARATION 1. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.)

1. Remove hood and engine side shields. See Hood Remove and Install and see Engine Side Shields Remove and Install. (Group 1910.)

2. Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch. (Operator’s Manual.)

2. Disconnect fan blade assembly from frame. See Fan Blade Remove and Install. (Group 0510.)

3. Drain cooling system. See Drain and Refill Engine Cooling System. (Operator's Manual.)

3. Remove aftertreatment assembly. See Aftertreatment Assembly Remove and Install. (Group 0530.) Continued on next page

TM14163X19 (15FEB18)

05-0510-6

JL48493,0000362 -19-10MAR17-3/7

450K, 550K, and 650K Crawler Dozer 021518 PN=252

Cooling Systems

4. Disconnect fan shroud (8) from cooling package. 21— Cap Screw (4 used)

TX1232141A —UN—18JAN17

8— Fan Shroud

Fan Shroud JL48493,0000362 -19-10MAR17-4/7

5. Remove bracket (13). 22— Cap Screw (6 used)

TX1232144A —UN—18JAN17

13— Bracket

Cooling Package Bracket Continued on next page

TM14163X19 (15FEB18)

05-0510-7

JL48493,0000362 -19-10MAR17-5/7

450K, 550K, and 650K Crawler Dozer 021518 PN=253

Cooling Systems

6. Disconnect upper hose and line connections (12 and 15—17) from cooling package. Close all openings using caps and plugs. 7. Disconnect hoses (9, 10, and 14) from surge tank. Close all openings using caps and plugs. 8. Remove cap screws (23) and tuck back hoses (9 and 10) out of the way. 15— Upper Hydraulic Cooler Line 16— Radiator-to-Surge Tank Hose 17— Upper Radiator Hose 23— Cap Screw (2 used)

TX1232146A —UN—18JAN17

9— Surge Tank Hose 10— Surge Tank Overflow Hose 12— Upper Charge Air Cooler Hose 14— Surge Tank-to-Thermostat Housing Hose

Upper Cooling Package Connections JL48493,0000362 -19-10MAR17-6/7

9. Disconnect lower hose and line connections (18—20) from cooling package. Close all openings using caps and plugs. 10. Remove cap screw (24). CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

TX1232185A —UN—18JAN17

11. Install appropriate lifting device and remove cooling package. Specification Cooling Package—Weight (approximate).............................................................................................. 61 kg 135 lb

12. Remove fan shroud if necessary. Lower Cooling Package Connections

INSTALLATION Installation is reverse of removal procedure.

• Fill hydraulic oil reservoir if drained. See Drain and Refill Hydraulic/Hydrostatic System Oil and Replace Filters. (Operator’s Manual.) • Fill cooling system. See Drain and Refill Engine Cooling System. (Operator's Manual.)

18— Lower Charge Air Cooler Hose 19— Lower Hydraulic Cooler Line

20— Lower Radiator Hose 24— Cap Screw

JL48493,0000362 -19-10MAR17-7/7

TM14163X19 (15FEB18)

05-0510-8

450K, 550K, and 650K Crawler Dozer 021518 PN=254

Cooling Systems

Charge Air Cooler Remove and Install REMOVAL 1. Remove cooling package. See Cooling Package Remove and Install. (Group 0510.) 2. Remove cap screws (2) and disconnect charge air cooler (1) from hydrostatic oil cooler (3). 3. Repair or replace charge air cooler as required. INSTALLATION

1— Charge Air Cooler 2— Cap Screw (4 used) 3— Hydrostatic Oil Cooler

TX1232337A —UN—23JAN17

Installation is reverse of removal procedure. 4— Cap Screw (4 used) 5— Radiator

Cooling Package JL48493,0000363 -19-10MAR17-1/1

Radiator Remove and Install REMOVAL 1. Remove cooling package. See Cooling Package Remove and Install. (Group 0510.) 2. Remove cap screws (4) and disconnect radiator (5) from hydrostatic oil cooler (3). 3. Repair or replace radiator as required. INSTALLATION

1— Charge Air Cooler 2— Cap Screw (4 used) 3— Hydrostatic Oil Cooler

TX1232337A —UN—23JAN17

Installation is reverse of removal procedure. 4— Cap Screw (4 used) 5— Radiator

Cooling Package JL48493,0000364 -19-10MAR17-1/1

TM14163X19 (15FEB18)

05-0510-9

450K, 550K, and 650K Crawler Dozer 021518 PN=255

Cooling Systems

Hydrostatic Oil Cooler Remove and Install REMOVAL 1. Remove cooling package. See Cooling Package Remove and Install. (Group 0510.) 2. Remove cap screws (2) and disconnect charge air cooler (1) from hydrostatic oil cooler (3). 3. Remove cap screws (4) and disconnect radiator (5) from hydrostatic oil cooler. 4. Repair or replace hydrostatic oil cooler as required. TX1232337A —UN—23JAN17

INSTALLATION Installation is reverse of removal procedure. 1— Charge Air Cooler 2— Cap Screw (4 used) 3— Hydrostatic Oil Cooler

4— Cap Screw (4 used) 5— Radiator

Cooling Package JL48493,0000365 -19-17JAN17-1/1

TM14163X19 (15FEB18)

05-0510-10

450K, 550K, and 650K Crawler Dozer 021518 PN=256

Group 0520

Intake System Air Cleaner Remove and Install REMOVAL

1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) 2. Turn battery disconnect switch to the OFF position. 3. Remove engine side shields as required. See Engine Side Shields Remove and Install. (Group 1910.) 4. Remove hood. See Hood Remove and Install. (Group 1910.)

4 3 1 TX1187649 —UN—13MAR15

5. Loosen clamp (1) at the air cleaner outlet. 6. Remove cap screws (3) from bottom of air cleaner mount (4). 7. Remove air cleaner (2). Inspect and replace parts as necessary. INSTALLATION

Air Cleaner

Installation is reverse of removal procedure. 1— Clamp 2— Air Cleaner

3— Cap Screw (4 used) 4— Air Cleaner Mount AB51738,0000A86 -19-20APR15-1/1

Precleaner Remove and Install—If Equipped 1. Turn battery disconnect switch to the OFF position. 2. Remove clamp (1).

3. Remove precleaner (2). 4. Service or replace precleaner as required. 5. Install precleaner. 6. Install clamp. 7. Turn battery disconnect switch to the ON position. 2— Precleaner

TX1187666 —UN—13MAR15

1— Clamp

Intake Air Precleaner AB51738,0000ABC -19-11MAR15-1/1

TM14163X19 (15FEB18)

05-0520-1

450K, 550K, and 650K Crawler Dozer 021518 PN=257

Intake System

TM14163X19 (15FEB18)

05-0520-2

450K, 550K, and 650K Crawler Dozer 021518 PN=258

Group 0530

External Exhaust Systems Exhaust Tube Remove and Install Torque Specifications Specification Clamp—Torque.............................................................................20 N·m 177 lb·in

Machine Preparation

• Install JDG11340 Bellows Alignment Fixture to exhaust

TX1188779A —UN—07APR15

bellows (1). See JDG11340 Bellows Alignment Fixture. (Group 0530.)

Additional Information CAUTION: Prevent possible burn injuries. Allow exhaust components sufficient time to cool before performing service. IMPORTANT: Prevent possible damage to exhaust tube. Use a straight edge on flexible part of exhaust tube during installation.

Exhaust Tube 1— Exhaust Bellows 2— Clamp (2 used)

3— Gasket (2 used) 4— Exhaust Tube

• Prior to removal, apply alignment mark on exhaust tube (4) on turbocharger housing to aid in installation.

• After installing exhaust tube, perform bellows alignment procedure. See Exhaust Bellows Alignment Procedure. (Group 0530.)

BS40810,0000238 -19-19JAN17-1/1

TM14163X19 (15FEB18)

05-0530-1

450K, 550K, and 650K Crawler Dozer 021518 PN=259

External Exhaust Systems

JDG11340 Bellows Alignment Fixture The table below lists the model and series of machine with the required configurations of JDG11340 Bellows Alignment Fixture. Backhoes Model/Series

Configuration

210L (PIN: 1T8210LX_ _F892615— )

310L (PIN: 1T0310LX _ _F273920—F303523)

310SL (PIN: 1T0310SL_ _F273920—F303523)

315SL (PIN: 1T0315SL_ _F273920—F303523)

310SL HL (PIN: 1T0310HL_ _F273920—F303523)

410L (PIN: 1T0410LX_ _F273920—F303523)

710L (PIN: 1T0710LX_ _F294269— )

B Crawlers

Model/Series

Configuration

450K (PIN: 1T0450KX_ _F304771— )

550K (PIN: 1T0550KX_ _F275977—F305397)

550K (PIN: 1T0550KK_ _F305398— )

650K (PIN: 1T0650KX_ _F275978—F305397)

650K (PIN: 1T0650KK_ _F305399— )

700K (PIN:1T0700KX_ _F275598— )

C Excavators

Model/Series

Configuration

160GLC (PIN: 1FF160GX_ _E055001— ) (iT4/S3B)

180GLC (PIN: 1FF180GX_ _E020001— ) (iT4/S3B)

210GLC (PIN: 1FF210GX_ _E520001— ) (iT4/S3B)

210G (PIN: 1FF210GX_ _E520001— ) (iT4/S3B)

130G (PIN: 1FF130GX_ _E040001— ) (iT4/S3B)

Knuckleboom Loaders Model/Series

Configuration

337E (PIN: 1T0337E_ _ _F291461— ) (FT4)

437E (PIN: 1T0437E_ _ _F291461— ) (FT4)

Continued on next page

TM14163X19 (15FEB18)

05-0530-2

VD76477,000059F -19-15FEB17-1/4

450K, 550K, and 650K Crawler Dozer 021518 PN=260

External Exhaust Systems

7 15 14 4

2 8 5

3 TX1190356 —UN—16APR15

TX1190356 JDG11340 Bellows Alignment Fixture Components 1— JDG11340 Insert (2 used) 2— JDG11340 Collar 3— JDG11340 Collar 4— JDG11340 Collar

5— JDG11340 Collar 6— JDG11340 Bar (2 used) 7— Cap Screw (8 used) 8— Cap Screw (6 used)

9— Latch (2 used) 10— Cap Screw (12 used) 14— JDG15039 Insert (2 used) 15— JDG11335P3P1 Bar (2 used) (not included with JDG11340) Configuration B

NOTE: All tool parts are common except the inserts and bars. Refer to the tables below for configurations and part numbers for the inserts and bars. Using the table below, construct tool with proper configuration.

Insert

JDG15039

Bar 278.1 mm (10.90 in)

JDG11335P3P1

Center of Groove-to-Center of Groove Measurement

251.0 mm 9.88 in

Configuration C

Configuration A Insert

JDG11340

Bar 238.1 mm (9.38 in)

JDG11340

Center of Groove-to-Center of Groove Measurement

210.0 mm 8.27 in

Insert

JDG15039

Bar 238.1 mm (9.38 in)

JDG11340

Center of Groove-to-Center of Groove Measurement

210.0 mm 8.27 in

Continued on next page

TM14163X19 (15FEB18)

05-0530-3

VD76477,000059F -19-15FEB17-2/4

450K, 550K, and 650K Crawler Dozer 021518 PN=261

External Exhaust Systems

For assembly, install insert with groove (11) closest to the bar. 12— Cap Screw (3 used) 16— JDG15039 Insert (4 used)

TX1111863 —UN—05APR12

1— JDG11340 Insert (4 used) 11— Groove

12 11

JDG11340 Insert Installation

TX1190437 —UN—13APR15

JDG15039 Insert Installation Continued on next page

TM14163X19 (15FEB18)

05-0530-4

VD76477,000059F -19-15FEB17-3/4

450K, 550K, and 650K Crawler Dozer 021518 PN=262

External Exhaust Systems

TX1111864 —UN—09APR12

TX1111864 Center of Groove-to-Center of Groove Measurement 13— Center of Groove-to-Center of Groove Measurement

To verify the tool is built correctly, measure center of groove-to-center of groove (13) for the required configuration. NOTE: The JDG11335P3P1 Bars in configuration B are not included with JDG11340 Bellows Alignment Fixture.

Configuration B Insert

JDG15039

Bar 278.1 mm (10.90 in)

JDG11335P3P1

Center of Groove-to-Center of Groove Measurement

251.0 mm 9.88 in

Configuration C

Configuration A Insert

JDG11340

Bar 238.1 mm (9.38 in)

JDG11340

Center of Groove-to-Center of Groove Measurement

210.0 mm 8.27 in

Insert

JDG15039

Bar 238.1 mm (9.38 in)

JDG11340

Center of Groove-to-Center of Groove Measurement

210.0 mm 8.27 in VD76477,000059F -19-15FEB17-4/4

TM14163X19 (15FEB18)

05-0530-5

450K, 550K, and 650K Crawler Dozer 021518 PN=263

External Exhaust Systems

Exhaust Bellows Alignment Procedure

may risk the release of unfiltered exhaust into the atmosphere.

IMPORTANT: The life of the exhaust bellows is dependent on being properly aligned. If not aligned correctly, the life of the exhaust bellows will significantly decrease and

TX1080155 —UN—26JUL10

NOTE: Graphic is for reference only.

TX1080155 Axial, Angular, and Lateral Specifications 24— Axial

25— Angular

26— Lateral

This procedure is to be performed whenever the exhaust tube or exhaust bellows is disconnected. The JDG11340 Bellows Alignment Fixture is used to hold the exhaust bellows at nominal alignment. While the exhaust bellows is held at nominal alignment, the technician is able to see and measure to verify that the exhaust bellows is in alignment with the exhaust filter. The life of the bellows depends on how well the exhaust bellows is aligned axially (24), angularly (25), and laterally (26). Axial tolerance is ±6.4 mm (±0.252 in), angular tolerance is 2°, and lateral tolerance is ±8.5 mm (±0.335 in). Use the adjustable frame with the adjustment points to align the exhaust bellows with the exhaust filter inlet.

• JDG11340 Bellows Alignment Fixture

-Use to hold exhaust bellows at nominal alignment for adjustment of exhaust superstructure. See JDG11340 Bellows Alignment Fixture. (Group 0530.)

Torque Specifications Specification Clamp—Torque.............................................................................20 N·m 177 lb·in Cap Screw (7)—Torque...............................................................130 N·m 96 lb·ft

Tools Continued on next page

TM14163X19 (15FEB18)

05-0530-6

BS40810,000023A -19-27FEB17-1/6

450K, 550K, and 650K Crawler Dozer 021518 PN=264

External Exhaust Systems Exhaust Bellows Alignment Procedure 1. Install aftertreatment assembly. See Aftertreatment Assembly Remove and Install. (Group 0530.) TX1190133A —UN—09APR15

2. Assemble JDG11340 Bellows Alignment Fixture (6) and install on exhaust bellows (5). See JDG11340 Bellows Alignment Fixture. (Group 0530.) IMPORTANT: Prevent misalignment of exhaust bellows. Rotation of exhaust tube on turbocharger outlet is essential for alignment of bellows. NOTE: Clamp (3) must be tight enough to hold exhaust tube on turbocharger outlet, but loose enough to allow exhaust tube to be turned manually on turbocharger outlet.

JDG11340 Bellows Alignment Fixture

3. Install gasket (1), exhaust tube (4), and clamp (3) to turbocharger housing (2) using alignment mark. See Exhaust Tube Remove and Install. (Group 0530.) 4— Exhaust Tube 5— Exhaust Bellows 6— JDG11340 Bellows Alignment Fixture

TX1233706A —UN—13FEB17

1— Gasket 2— Turbocharger Housing 3— Clamp

Exhaust Tube Continued on next page

TM14163X19 (15FEB18)

05-0530-7

BS40810,000023A -19-27FEB17-2/6

450K, 550K, and 650K Crawler Dozer 021518 PN=265

External Exhaust Systems

NOTE: The gap (8) between the exhaust filter and the exhaust bellows has to remain consistent throughout the circumference of the joint. 4. Verify gap. If gap is consistent, proceed to step 7. 9— Diesel Oxidation Catalyst (DOC) Inlet

TX1190135A —UN—09APR15

4— Exhaust Tube 8— Gap

TX1190136A —UN—09APR15

Gap (consistent)

Gap (needs adjustment) Continued on next page

TM14163X19 (15FEB18)

05-0530-8

BS40810,000023A -19-27FEB17-3/6

450K, 550K, and 650K Crawler Dozer 021518 PN=266

External Exhaust Systems

5. Horizontally adjust exhaust filter if needed. a. Loosen horizontal adjustment cap screws (7). TX1233705A —UN—13FEB17

b. Adjust aftertreatment assembly and turn exhaust tube on turbocharger outlet if necessary. c. Verify gap. 6. Tighten cap screws (7) to specification. Specification Cap Screw (7)—Torque...............................................................130 N·m 96 lb·ft

IMPORTANT: Prevent misalignment of exhaust bellows. Check alignment after tightening adjustment cap screws. Readjustment may be needed.

Horizontal Adjustment 7— Horizontal Adjustment Cap Screw (4 used)

7. Verify gap. BS40810,000023A -19-27FEB17-4/6

8. Install exhaust tube-to-diesel oxidation catalyst (DOC) inlet clamp (10). 9. Tighten clamps (3 and 10) to specification. TX1233707A —UN—13FEB17

Specification Clamp—Torque.............................................................................20 N·m 177 lb·in

10. Tap the circumference of each clamp with a dead blow hammer and tighten clamp to specification. Specification Clamp—Torque.............................................................................20 N·m 177 lb·in

Exhaust Tube

11. Remove bellows alignment fixture. 10— Exhaust Tube-to-Diesel Oxidation Catalyst (DOC) Inlet Clamp Continued on next page

TM14163X19 (15FEB18)

05-0530-9

BS40810,000023A -19-27FEB17-5/6

450K, 550K, and 650K Crawler Dozer 021518 PN=267

External Exhaust Systems

TX1230098 —UN—08DEC16

251 mm (9-7/8 in)

TX1230098 Exhaust Bellows Length

12. Verify length of exhaust bellows.

Specification Exhaust Bellows—Length............................................................................... 251 mm 9-7/8 in BS40810,000023A -19-27FEB17-6/6

TM14163X19 (15FEB18)

05-0530-10

450K, 550K, and 650K Crawler Dozer 021518 PN=268

External Exhaust Systems

Diesel Oxidation Catalyst (DOC) Remove and Install SPECIFICATIONS 17 N·m 150 lb·in

TX1233416A —UN—03FEB17

Clamp Torque

REMOVAL 1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) CAUTION: Prevent possible burn injuries. Allow exhaust components sufficient time to cool before performing service. 2. Remove exhaust filter. See Exhaust Filter Remove and Install. (Group 0530.) 3. Scribe alignment marks (2) on components to aid in installation. 4. Remove clamp (3) and diesel oxidation catalyst (DOC) (1). 5. Clean and inspect parts. Repair or replace as necessary. See Exhaust Filter — Tear Down and Inspection. (CTM120019.)

Diesel Oxidation Catalyst (DOC) 1— Diesel Oxidation Catalyst (DOC) 2— Alignment Mark (2 used)

3— Clamp 4— Diesel Particulate Filter (DPF)

• Tighten clamp (3) to specification. Specification Clamp—Torque.............................................................................17 N·m 150 lb·in

• Perform exhaust bellows alignment procedure. See

Exhaust Bellows Alignment Procedure. (Group 0530.)

INSTALLATION Installation is reverse of removal procedure. BS40810,000024A -19-21FEB17-1/1

TM14163X19 (15FEB18)

05-0530-11

450K, 550K, and 650K Crawler Dozer 021518 PN=269

External Exhaust Systems

Diesel Particulate Filter (DPF) Remove and Install SPECIFICATIONS 17 N·m 150 lb·in

TX1233415A —UN—03FEB17

Clamp Torque

Diesel Particulate Filter (DPF) 1— Diesel Oxidation Catalyst (DOC) 2— Alignment Mark (4 used) 3— Clamp

4— Diesel Particulate Filter (DPF) 5— Clamp 6— Outlet Cone

3. Scribe alignment marks (2) on components to aid in installation. 4. Remove clamp (5). Set outlet cone (6) aside.

• Tighten clamps (3 and 5) to specification.

5. Remove clamp (3) and diesel particulate filter (DPF) (4).

Specification Clamp—Torque.............................................................................17 N·m 150 lb·in

6. Clean and inspect parts. Repair or replace as necessary. See Diesel Particulate Filter Maintenance and Service. (CTM120019.)

• Perform exhaust bellows alignment procedure. See

Exhaust Bellows Alignment Procedure. (Group 0530.)

INSTALLATION Installation is reverse of removal procedure. BS40810,000023B -19-21FEB17-1/1

TM14163X19 (15FEB18)

05-0530-12

450K, 550K, and 650K Crawler Dozer 021518 PN=270

External Exhaust Systems

Exhaust Filter Remove and Install SPECIFICATIONS 42 N·m 31 lb·ft TX1233417A —UN—06FEB17

Nut Torque

REMOVAL 1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) CAUTION: Prevent possible burn injuries. Allow exhaust components sufficient time to cool before performing service. 2. Remove aftertreatment assembly. See Aftertreatment Assembly Remove and Install. (Group 0530.) 3. Install identification tags and disconnect hoses (3). Close all openings using caps and plugs.

Aftertreatment Assembly (left side shown) 1— Nut (4 used) 2— Mounting Band (2 used) 3— Hose (2 used) 4— Exhaust Filter

4. Install identification tags and disconnect electrical sensors (B5201, B5202, and B5502).

5— Aftertreatment Assembly B5201—Diesel Oxidation Catalyst (DOC) Inlet Temperature Sensor B5202—Diesel Oxidation Catalyst (DOC) Outlet Temperature Sensor B5502—Aftertreatment Inlet NOx Sensor

5. Remove nuts (1) and mounting bands (2) from aftertreatment assembly (5). 6. Remove exhaust filter (4).

• Tighten nuts (1) to specification.

7. Clean and inspect parts. Repair or replace parts as necessary.

Specification Nut—Torque..................................................................................42 N·m 31 lb·ft

INSTALLATION Installation is reverse of removal procedure. BS40810,000024B -19-27FEB17-1/1

TM14163X19 (15FEB18)

05-0530-13

450K, 550K, and 650K Crawler Dozer 021518 PN=271

External Exhaust Systems

Aftertreatment Assembly Remove and Install SPECIFICATIONS Aftertreatment Assembly Weight (approximate)

82 kg 181 lb

Mounting Cap Screw Torque

130 N·m 96 lb·ft

MACHINE PREPARATION 1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) TX1233626A —UN—09FEB17

IMPORTANT: Do not turn battery disconnect switch to OFF position for at least 4 minutes after engine stops. The selective catalytic reduction (SCR) system automatically purges itself of diesel exhaust fluid (DEF) immediately after the engine is stopped. If adequate time is not allowed for lines to be purged, residual DEF can freeze and possibly damage components of the SCR system during cold-weather exposure. Air Cleaner

2. Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch. (Operator’s Manual.) 1— Air Cleaner Tube 2— Exhaust Tube

REMOVAL 1. Remove engine side shields and hood. See Hood Remove and Install. (Group 1910.) CAUTION: Prevent possible burning injuries. Allow exhaust components sufficient time to cool before performing service.

B5500—Intake Air Sensor

NOTE: A bellows alignment procedure will need to be performed if the exhaust tube is removed. 3. Remove exhaust tube (2). See Exhaust Tube Remove and Install. (Group 0530.)

2. Install identification tags and disconnect intake air sensor (B5500) and remove air cleaner tube (1). Continued on next page

TM14163X19 (15FEB18)

05-0530-14

BS40810,000023C -19-27FEB17-1/3

450K, 550K, and 650K Crawler Dozer 021518 PN=272

External Exhaust Systems

IMPORTANT: Prevent DEF system contamination. Absolute cleanliness is essential when working on DEF components. Clean component and adjacent areas before starting work. Close all openings using caps and plugs. 4. Install identification tags and disconnect coolant hoses (5) and DEF dosing injector line (4). Close all openings using caps and plugs.

TX1233627A —UN—09FEB17

5. Install identification tags and disconnect electrical connectors (B5212, B5502, and Y5020). See Aftertreatment Harness (W8) Component Location. (Group 9015-10.) 6. Remove clamps (3). 3— Clamp (2 used) 4— DEF Dosing Injector Line 5— Coolant Hose (2 used)

B5212—Selective Catalyst Reduction (SCR) Temperature Module B5502—Aftertreatment Inlet NOx Sensor Y5020—Diesel Fluid Injector (DEF) Dosing Injector

Diesel Exhaust Fluid (DEF) Dosing Injector Continued on next page

TM14163X19 (15FEB18)

05-0530-15

BS40810,000023C -19-27FEB17-2/3

450K, 550K, and 650K Crawler Dozer 021518 PN=273

External Exhaust Systems

7. Scribe alignment marks (6) on mounting bracket to aid in installation. 8. Install identification tags and disconnect electrical sensors (B5109 and B5503). 9. Remove mounting cap screws (7). CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 10. Attach appropriate lifting device to the lifting brackets (8). Remove aftertreatment assembly. TX1233628A —UN—09FEB17

Specification Aftertreatment Assembly—Weight (approximate).................................................................................. 82 kg 181 lb

INSTALLATION Installation is reverse of removal procedure.

• Install aftertreatment assembly and mounting cap

Mounting Bracket

screws, but do not tighten.

• Perform exhaust bellows alignment procedure. See

Exhaust Bellows Alignment Procedure. (Group 0530.)

• Tighten mounting cap screws to specification.

6— Alignment Mark (4 used) 7— Mounting Cap Screw (4 used) 8— Lifting Bracket (3 used)

TX1233629A —UN—09FEB17

Specification Mounting Cap Screw—Torque............................................................................130 N·m 96 lb·ft B5109—Diesel Particulate Filter (DPF) Differential Pressure Sensor B5503—Aftertreatment Outlet NOx Sensor

Aftertreatment Assembly BS40810,000023C -19-27FEB17-3/3

Service Filter Cleaning For more information on service filter cleaning, see Service Filter Cleaning. (Group 9010-20.) AB51738,0000A7B -19-17FEB15-1/1

TM14163X19 (15FEB18)

05-0530-16

450K, 550K, and 650K Crawler Dozer 021518 PN=274

External Exhaust Systems

Selective Catalyst Reduction (SCR) Remove and Install SPECIFICATIONS Exhaust Mounting Band Nut Torque

42 N·m 31 lb·ft

Aftertreatment Outlet NOx Sensor 50 N·m 37 lb·ft Torque Selective Catalyst Reduction (SCR) Inlet Temperature Sensor Torque

45 N·m 33 lb·ft

Exhaust Clamp Nut Torque

20 N·m 177 lb·in TX1233344A —UN—02FEB17

OTHER MATERIAL Loctite® 41205 Anti-Seize Lubricant (heavy duty)

MACHINE PREPARATION 1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) IMPORTANT: Do not turn battery disconnect switch to OFF position for at least 4 minutes after engine stops. The selective catalytic reduction (SCR) system automatically purges itself of diesel exhaust fluid (DEF) immediately after the engine is stopped. If adequate time is not allowed for lines to be purged, residual DEF can freeze and possibly damage components of the SCR system during cold-weather exposure.

Decomposition Tube

2. Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch. (Operator’s Manual.) REMOVAL TX1233345A —UN—03FEB17

1. Remove hood and engine side shields. See Hood Remove and Install. (Group 1910.) CAUTION: Prevent possible burn injuries. Allow exhaust components sufficient time to cool before performing service. 2. Remove exhaust clamp (1). 3. Install identification tags and remove sensors (B60 and B5503).

Selective Catalyst Reduction (SCR)

4. Remove jam nuts (3). 5. Remove exhaust mounting band nuts (2) and exhaust mounting bands (4). 6. Remove selective catalyst reduction (SCR) (5).

1— Exhaust Clamp 2— Exhaust Mounting Band Nut (4 used) 3— Jam Nut (2 used) 4— Exhaust Mounting Band (2 used)

5— Selective Catalyst Reduction (SCR) B60— Selective Catalyst Reduction (SCR) Inlet Temperature Sensor B5503—Aftertreatment Outlet NOx Sensor

7. Clean and inspect parts. Repair or replace as necessary. INSTALLATION Installation is reverse of removal procedure.

• Tighten exhaust mounting band nuts to specification.

Specification Exhaust Mounting Band Nut—Torque..................................................................................42 N·m 31 lb·ft

• Apply Loctite® 41205 Anti-Seize Lubricant (heavy duty) to threads of exhaust sensor.

Continued on next page

TM14163X19 (15FEB18)

05-0530-17

NM95233,0000B8D -19-10APR17-1/2

450K, 550K, and 650K Crawler Dozer 021518 PN=275

External Exhaust Systems

• Tighten exhaust sensors to specification.

• Tighten exhaust clamp to specification.

Specification Aftertreatment Outlet NOx Sensor—Torque....................................................................50 N·m 37 lb·ft Selective Catalyst Reduction (SCR) Inlet Temperature Sensor—Torque............................................................................45 N·m 33 lb·ft

Specification Exhaust Clamp Nut—Torque..................................................................................20 N·m 177 lb·in

Loctite and its related brand marks are trademarks of Henkel Corporation NM95233,0000B8D -19-10APR17-2/2

Diesel Exhaust Fluid (DEF) Tank Remove and Install SPECIFICATIONS Diesel Exhaust Fluid (DEF) Tank Capacity

11.8 L 3.1 gal

MACHINE PREPARATION 1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.)

TX1233245A —UN—01FEB17

IMPORTANT: Do not remove battery leads for at least 4 minutes after engine stops. The selective catalytic reduction (SCR) system automatically purges itself of diesel exhaust fluid (DEF) immediately after the engine is stopped. If adequate time is not allowed for lines to be purged, residual DEF can freeze and possibly damage components of the SCR system during cold-weather exposure. 2. Disconnect negative (-) battery lead.

Diesel Exhaust Fluid (DEF) Tank

3. Remove left side sheet metal. See Rear Sheet Metal Remove and Install. (Group 1913.) 4. Drain or siphon diesel exhaust fluid (DEF) tank. See Disposal of Diesel Exhaust Fluid (DEF). (Operator’s Manual.) REMOVAL IMPORTANT: Prevent DEF system contamination. Absolute cleanliness is essential when working on DEF components. Clean components and adjacent areas before starting work. Close all openings using caps and plugs. 1. Install identification tags and disconnect lines (1). Close all openings using caps and plugs. 2. Disconnect electrical connector (2). 3. Remove nut (5), strap (4), and diesel exhaust fluid (DEF) tank (3).

1— Line (5 used) 2— Electrical Connector 3— Diesel Exhaust Fluid (DEF) Tank

4— Strap 5— Nut

4. Clean and inspect parts. Repair or replace as necessary. INSTALLATION Installation is reverse of removal procedure.

• Refill DEF tank. See Refilling Diesel Exhaust Fluid (DEF) Tank. (Operator’s Manual.)

Specification Diesel Exhaust Fluid (DEF) Tank—Capacity.................................................................... 11.8 L 3.1 gal BS40810,000023E -19-02MAR17-1/1

TM14163X19 (15FEB18)

05-0530-18

450K, 550K, and 650K Crawler Dozer 021518 PN=276

External Exhaust Systems

Diesel Exhaust Fluid (DEF) Tank Header Remove and Install MACHINE PREPARATION 1. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.)

TX1227612A —UN—03NOV16

2. Remove diesel exhaust fluid (DEF) tank (1). See Diesel Exhaust Fluid (DEF) Tank Remove and Install. (Group 0530.) IMPORTANT: Prevent damage to diesel exhaust fluid (DEF) system hoses. DEF system hoses are fragile and can easily be damaged if proper care is not used. Avoid bending, twisting, or kinking DEF system hoses. IMPORTANT: Prevent leaks from diesel exhaust fluid (DEF) tank. Rubber gasket between DEF tank header (2) and DEF tank needs to be installed correctly. Install gasket with top side facing up. REMOVAL AND INSTALLATION 1. Remove cap screws (3) and DEF tank header.

Diesel Exhaust Fluid (DEF) Tank Header 1— Diesel Exhaust Fluid (DEF) Tank 2— Diesel Exhaust Fluid (DEF) Tank Header

3— Cap Screw (6 used)

2. Repair or replace parts as necessary. BS40810,0000248 -19-10MAR17-1/2

3. Align DEF tank header recess (4), gasket alignment tab (5), and DEF tank alignment mark (6). Install DEF tank header and cap screws. 4. Install DEF tank. See Diesel Exhaust Fluid (DEF) Tank Remove and Install. (Group 0530.) 6— Diesel Exhaust Fluid (DEF) Tank Alignment Mark TX1227613A —UN—03NOV16

4— Diesel Exhaust Fluid (DEF) Tank Header Recess 5— Gasket Alignment Tab

Diesel Exhaust Fluid (DEF) Tank Header and Gasket Alignment BS40810,0000248 -19-10MAR17-2/2

TM14163X19 (15FEB18)

05-0530-19

450K, 550K, and 650K Crawler Dozer 021518 PN=277

External Exhaust Systems

Diesel Exhaust Fluid (DEF) Tank Header Disassemble and Assemble SPECIFICATIONS Cap Screw Torque

3 N·m 27 lb·in

TX1227375A —UN—31OCT16

IMPORTANT: Prevent machine damage and inaccurate readings from diesel exhaust fluid (DEF) tank concentration sensor. Oils on skin may cause inaccurate readings and set false diagnostic trouble codes (DTCs). Avoid contacting DEF tank concentration sensor with hands or fingers. Diesel Exhaust Fluid (DEF) Baffle Remove and Install 1. Remove cap screws (4) and DEF baffle (3). 2. Install new DEF baffle and cap screws. Tighten to specification. Specification Cap Screw—Torque........................................................................3 N·m 27 lb·in

DEF Baffle 3— Diesel Exhaust Fluid (DEF) Baffle

4— Cap Screw (2 used)

TW62213,0000445 -19-19SEP17-1/2

Diesel Exhaust Fluid (DEF) Tank Header Suction Filter Remove and Install 1. Remove DEF baffle. See Diesel Exhaust Fluid (DEF) Tank Header Disassemble and Assemble—Diesel Exhaust Fluid (DEF) Baffle Remove and Install. 2. Remove retaining clip (2) and suction filter (1). 3. Repair or replace parts as necessary. 4. Install suction filter and retaining clip. 2— Retaining Clip TX1226670A —UN—24OCT16

1— Suction Filter

DEF Suction Filter TW62213,0000445 -19-19SEP17-2/2

TM14163X19 (15FEB18)

05-0530-20

450K, 550K, and 650K Crawler Dozer 021518 PN=278

External Exhaust Systems

Diesel Exhaust Fluid (DEF) Tank Cleaning Procedure

12. Fill DEF tank. See Refilling Diesel Exhaust Fluid (DEF) Tank. (Operator’s Manual.)

Cleaning Procedure—DEF Tank Removed

13. Operate machine and check for leaks.

IMPORTANT: Diesel exhaust fluid (DEF) tank must be fully flushed to prevent machine damage from contaminants. Perform flushing procedure 3 or more times.

Cleaning Procedure—DEF Tank Installed

1. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.) 2. Remove DEF tank. See Diesel Exhaust Fluid (DEF) Tank Remove and Install. (Group 0530.) 3. Remove DEF header. See Diesel Exhaust Fluid (DEF) Tank Header Remove and Install. (Group 0530.)

1. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.) 2. Remove DEF header. See Diesel Exhaust Fluid (DEF) Tank Header Remove and Install. (Group 0530.) 3. Drain DEF tank. See Disposal of Diesel Exhaust Fluid (DEF). (Operator’s Manual.) 4. Using a garden hose with a twist type spray nozzle, rinse top and sides of DEF tank for approximately 30 seconds.

IMPORTANT: If DEF tank is flushed with a fluid other than distilled water or clean DEF, a final rinse with clean DEF must be performed before installing DEF tank or components.

7. Install DEF tank drain plug.

NOTE: If distilled water is not available, clean DEF can be used.

8. Add approximately 3.8 L (1 gal) of clean, unused DEF to DEF tank to dilute and absorb any residual water.

4. Partially fill DEF tank with clean distilled water.

9. Using a vacuum with a clean length of bulk hose attached, vacuum DEF from DEF tank. Be sure to remove DEF from all corners and low spots.

5. Agitate liquid inside of DEF tank to remove built-up contaminants from bottom of tank. 6. Drain DEF tank through filler neck. See Disposal of Diesel Exhaust Fluid (DEF). (Operator’s Manual.) 7. Repeat steps 4—6 a total of 3 times.

5. Allow tank to drain completely. 6. Repeat steps 4 and 5 a total of 3 times.

10. Replace DEF header suction screen. See Diesel Exhaust Fluid (DEF) Tank Header Disassemble and Assemble. (Group 0530.) 11. Install DEF header. See Diesel Exhaust Fluid (DEF) Tank Header Remove and Install. (Group 0530.)

8. Thoroughly dry inside of DEF tank. 9. Using distilled water or clean DEF, rinse DEF header assembly and thoroughly dry. 10. Install DEF header. See Diesel Exhaust Fluid (DEF) Tank Header Remove and Install. (Group 0530.) 11. Install DEF tank. See Diesel Exhaust Fluid (DEF) Tank Remove and Install. (Group 0530.) NOTE: For DEF tank capacity, see 450K LT and 450K LGP Crawler Dozer Drain and Refill Capacities, see 550K XLT and 550K LGP Crawler Dozer Drain and Refill Capacities, or see 650K XLT and 650K LGP Crawler Dozer Drain and Refill Capacities. (Operator’s Manual.)

NOTE: For DEF tank capacity, see 450K LT and 450K LGP Crawler Dozer Drain and Refill Capacities, see 550K XLT and 550K LGP Crawler Dozer Drain and Refill Capacities, or see 650K XLT and 650K LGP Crawler Dozer Drain and Refill Capacities. (Operator’s Manual.) 12. Fill DEF tank. See Refilling Diesel Exhaust Fluid (DEF) Tank. (Operator’s Manual.) 13. Operate machine and check for leaks.

TW62213,0000468 -19-26SEP17-1/1

TM14163X19 (15FEB18)

05-0530-21

450K, 550K, and 650K Crawler Dozer 021518 PN=279

External Exhaust Systems

Diesel Exhaust Fluid (DEF) Dosing Unit Remove and Install MACHINE PREPARATION 1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.)

TX1233187A —UN—01FEB17

REMOVAL IMPORTANT: Prevent DEF system contamination. Absolute cleanliness is essential when working on DEF components. Clean components and adjacent areas before starting work. Close all openings using caps and plugs.

1— Dosing Line (3 used) 2— Nut (2 used) 3— Electrical Connector

4— Cap Screw B5501—Diesel Exhaust Fluid (DEF) Dosing Unit

1. Install identification tags and disconnect dosing lines (1). Close all openings using caps and plugs.

INSTALLATION

2. Disconnect electrical connector (3).

• Check for active diagnostic trouble codes (DTCs) using

3. Remove nuts (2), cap screw (4), and diesel exhaust fluid (DEF) dosing unit (B5501). 4. Clean and inspect parts. Repair or replace as necessary.

Installation is reverse of removal procedure. Service ADVISOR™. See Diagnostics—Codes, SDM. (Operator’s Manual.) See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-15.)

Service ADVISOR is a trademark of Deere & Company BS40810,0000240 -19-27FEB17-1/1

TM14163X19 (15FEB18)

05-0530-22

450K, 550K, and 650K Crawler Dozer 021518 PN=280

External Exhaust Systems

Diesel Exhaust Fluid (DEF) Dosing Injector Remove and Install

TS281 —UN—15APR13

CAUTION: Prevent possible injury from hot spraying fluids. Shut off engine. Remove filler cap only when cool enough to touch with bare hands. Slowly loosen cap to relieve pressure before removing completely. CAUTION: Prevent possible burning injuries. Allow exhaust component sufficient time to cool before performing service. Pressurized Fluids

2. Disconnect negative battery lead. 3. Remove right engine side shield. See Engine Side Shields Remove and Install. (Group 1910.) Additional Information

• See DEF Dosing Injector — Removal. (CTM120119.) • See DEF Dosing Injector — Installation. (CTM120119.)

Machine Preparation 1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) AB51738,0000A81 -19-30MAR15-1/1

Diesel Exhaust Fluid (DEF) Decomposition Tube Remove and Install CAUTION: Prevent possible burning injuries. Allow exhaust components sufficient time to cool before performing service. Machine Preparation

2. Remove right engine side shield. See Engine Side Shields Remove and Install. (Group 1910.) Additional Information • See DEF Decomposition Tube — Removal. (CTM120119.) • See DEF Decomposition Tube — Installation. (CTM120119.)

1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) AB51738,0000A82 -19-30MAR15-1/1

TM14163X19 (15FEB18)

05-0530-23

450K, 550K, and 650K Crawler Dozer 021518 PN=281

External Exhaust Systems

TM14163X19 (15FEB18)

05-0530-24

450K, 550K, and 650K Crawler Dozer 021518 PN=282

Group 0560

External Fuel Supply Systems Primary Fuel Filter and Water Separator Remove and Install REMOVAL 1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) 2. Open right rear service door. 3. Install identification tags and disconnect fuel lines (1). Close all openings using caps and plugs. 4. Install identification tags and disconnect electrical connectors (2). 5. Remove cap screws (3) and primary fuel filter and water separator (4).

TX1234139A —UN—20FEB17

6. Clean and inspect parts. Repair or replace as necessary. INSTALLATION Installation is reverse of removal procedure. IMPORTANT: Do not prefill fuel filters. Debris in unfiltered fuel will damage fuel system components.

• Prime fuel system and bleed air. See Replace Primary and Final Fuel Filters and see Bleed Fuel System. (Operator’s Manual.)

Primary Fuel Filter and Water Separator 1— Fuel Line (2 used) 2— Electrical Connector (2 used)

3— Cap Screw (2 used) 4— Primary Fuel Filter and Water Separator

JL05046,0000281 -19-21FEB17-1/1

TM14163X19 (15FEB18)

05-0560-1

450K, 550K, and 650K Crawler Dozer 021518 PN=283

External Fuel Supply Systems

Final Fuel Filter Remove and Install REMOVAL 1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) 2. Open right rear service door.

TX1188231A —UN—23MAR15

3. Install identification tags and disconnect fuel lines (1). Close all openings using caps and plugs. 4. Remove cap screws (2) and final fuel filter (3). 5. Clean and inspect parts. Repair or replace as necessary. INSTALLATION Installation is reverse of removal procedure. IMPORTANT: Do not prefill fuel filters. Debris in unfiltered fuel will damage fuel system components.

Final Fuel Filter 1— Fuel Line (2 used) 2— Cap Screw (2 used)

• Prime fuel system and bleed air. See Replace Primary

3— Final Fuel Filter

and Final Fuel Filters and see Bleed Fuel System. (Operator’s Manual.)

JL05046,0000282 -19-13FEB17-1/1

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

1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) 2. Open right rear service door.

3. Open air vent (1) and drain (2) to remove fuel. Drain fuel into a suitable container and dispose of fuel waste properly.

4. Install identification tags and disconnect fuel lines (3). Close all openings using caps and plugs.

TX1188320 —UN—19MAR15

4 R6

5. Disconnect fuel filter heater (R6) connector.

6. Remove cap screws (6). Auxiliary Fuel Filter

7. Remove auxiliary fuel filter and water separator (7). INSTALLATION

1— Air Vent 2— Drain 3— Fuel Line (2 used) 4— Primary Fuel Filter and Water Separator

Installation is reverse of removal procedure.

• Fill fuel filter by opening air vent and pushing priming hand pump (8).

IMPORTANT: Do not prefill fuel filter. Debris in unfiltered fuel will damage fuel system components.

6— Cap Screw (2 used) 7— Auxiliary Fuel Filter and Water Separator 8— Priming Hand Pump R6—Fuel Filter Heater

• Prime fuel system and bleed air. See Replace Auxiliary Fuel Filter—If Equipped and see Bleed Fuel System. (Operator's Manual.)

AB51738,0000A73 -19-22APR15-1/1

TM14163X19 (15FEB18)

05-0560-2

450K, 550K, and 650K Crawler Dozer 021518 PN=284

External Fuel Supply Systems

Fuel Tank Remove and Install SPECIFICATIONS Mounting Cap Screw Torque

320 N·m 236 lb·ft

MACHINE PREPARATION 1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) 2. Turn battery disconnect switch to the OFF position.

TX1233012A —UN—27JAN17

3. Drain fuel. See Drain Fuel From Fuel Tank. (Operator’s Manual.) REMOVAL 1. Remove rear bottom guard. See Bottom Guards Remove and Install. (Group 1746.) 2. Remove cap screw (1) and fuel tank ground (W4). 3. Remove rear sheet metal. See Rear Sheet Metal Remove and Install. (Group 1913.) 1— Cap Screw

Fuel Neck

W4—Fuel Tank Ground Continued on next page

TM14163X19 (15FEB18)

05-0560-3

BS40810,0000246 -19-10MAR17-1/2

450K, 550K, and 650K Crawler Dozer 021518 PN=285

External Fuel Supply Systems

4. Disconnect fuel level sensor (B19). See Vehicle Harness (W16) Component Location. (Group 9015-10.) 5. Install identification tags and disconnect fuel tank-to-low-pressure fuel pump hose (6) and fuel tank-to-high-pressure fuel pump hose (5). Close all openings using caps and plugs. 6. Remove mounting cap screws (3) and nuts (2). Remove fuel tank (4). 7. Clean and inspect parts. Repair or replace as necessary. TX1233013A —UN—27JAN17

INSTALLATION Installation is reverse of removal procedure.

• Tighten mounting cap screws to specification. Specification Mounting Cap Screw—Torque............................................................................320 N·m 236 lb·ft

Fuel Tank

• Prime fuel system and bleed air. See Bleed Fuel System. (Operator’s Manual.) • Fill fuel tank. For more information: - See 450K LT and 450K LGP Crawler Dozer Drain and Refill Capacities. (Operator’s Manual.) - See 550K XLT and 550K LGP Crawler Dozer Drain and Refill Capacities. (Operator’s Manual.) - See 650K XLT and 650K LGP Crawler Dozer Drain and Refill Capacities. (Operator’s Manual.) 5— Fuel Tank-to-High-Pressure Fuel Pump Hose 6— Fuel Tank-to-Low-Pressure Fuel Pump Hose B19— Fuel Level Sensor

TX1233014A —UN—27JAN17

2— Nut (4 used) 3— Mounting Cap Screw (4 used) 4— Fuel Tank

Fuel Hoses BS40810,0000246 -19-10MAR17-2/2

TM14163X19 (15FEB18)

05-0560-4

450K, 550K, and 650K Crawler Dozer 021518 PN=286

Contents

Section 11 Park Brake

Page

Group 1100—Removal and Installation Park Brake Remove and Install ..................11-1100-1 Park Brake Valve Remove and Install ......................................................11-1100-3 Group 1115—Controls Linkage Park Lock Linkage Remove and Install ...................................................... 11-1115-1 Park Lock Linkage Disassemble and Assemble......................................... 11-1115-3 Group 1160—Hydraulic System Park Brake Disassemble and Assemble................................................11-1160-1 Park Brake Valve Disassemble and Assemble................................................11-1160-5

TM14163X19 (15FEB18)

11-1

450K, 550K, and 650K Crawler Dozer

021518

PN=1

Contents

TM14163X19 (15FEB18)

11-2

450K, 550K, and 650K Crawler Dozer

021518

PN=2

Group 1100

Removal and Installation Park Brake Remove and Install SPECIFICATIONS 73 N·m 54 lb·ft T199199A —UN—16APR04

Park Brake Mounting Cap Screw Torque

SERVICE EQUIPMENT AND TOOLS DFT1132 Hydrostatic Motor/Hydraulic Pump Tool DFT1211 Final Drive Lifting Bracket Adapter JT01748 Lifting Bracket

1. Lower all equipment to the ground. 2. Stop engine. Operate all hydraulic controls to release pressure in the hydraulic system.

Park Brake Remove and Install

3. Turn battery disconnect switch to OFF.

1— Park Brake Hose

2— Cap Screw (6 used)

4. Remove hydrostatic motor. See Hydrostatic Motor Remove and Install. (Group 0300.) 6. Remove cap screw (2).

5. Disconnect park brake hose (1).

BS40810,000024E -19-03MAR17-1/6

7. Attach DFT1132 Hydrostatic Motor/Hydraulic Pump Tool (1) to hoist with sling. See DFT1132 Hydrostatic Motor/Hydraulic Pump Tool. (Group 9900.)

T199200A —UN—16APR04

Attach DFT1211 Final Drive Lifting Bracket Adapter (2) to JT01748 Lifting Bracket (3) with cap screw. See DFT1211 Final Drive Lifting Bracket Adapter. (Group 9900.) Attach JT01748 Lifting Bracket and DFT1132 Hydrostatic Motor/Hydraulic Pump Tool to park brake with cap screw. 1— DFT1132 Hydrostatic Motor/Hydraulic Pump Tool 2— DFT1211 Final Drive Lifting Bracket Adapter

3— JT01748 Lifting Bracket

Dealer Fabricated Tools

BS40810,000024E -19-03MAR17-2/6

NOTE: Make sure coupler from final drive to park brake remains fully engaged in final drive.

T199201A —UN—16APR04

8. Install slide hammer in threaded hole using adapter. Pull park brake assembly using slide hammer while keeping coupler in final drive. 9. Remove through frame opening in rear of machine. 1— Slide Hammer

2— Threaded Adapter

Slide Hammer Continued on next page

TM14163X19 (15FEB18)

11-1100-1

BS40810,000024E -19-03MAR17-3/6

450K, 550K, and 650K Crawler Dozer 021518 PN=289

Removal and Installation

10. Remove O-ring (1) from park brake flange. 11. Repair or replace park brake. See Park Brake Disassemble and Assemble. (Group 1160.) T199203A —UN—16APR04

12. Clean and inspect parts. 13. Apply petroleum jelly to new O-ring and install on park brake flange. 1— O-Ring

O-Ring BS40810,000024E -19-03MAR17-4/6

14. Install guide screws (1) in final drive. Guide park brake through frame opening and position on guide screws. T199206A —UN—16APR04

1— Guide Screw (2 used)

Guide Screws BS40810,000024E -19-03MAR17-5/6

15. Install park brake into final drive. If necessary, move track using bottle jack under track shoe to help align final drive coupler to park brake.

T199205A —UN—16APR04

16. Install two cap screws to secure park brake to final drive. Remove guide screws and install remaining cap screws. Tighten cap screws to specification. Specification Park Brake Mounting Cap Screw—Torque..............................................................................73 N·m 54 lb·ft

17. Install park brake hose. 18. Install hydrostatic motor. See Hydrostatic Motor Remove and Install. (Group 0300.)

Bottle Jack

19. Turn battery disconnect switch to ON. BS40810,000024E -19-03MAR17-6/6

TM14163X19 (15FEB18)

11-1100-2

450K, 550K, and 650K Crawler Dozer 021518 PN=290

Removal and Installation

Park Brake Valve Remove and Install 1. Lower all equipment to ground and stop engine. 2. Place park lock lever in UP (locked) position. 3. Turn battery disconnect switch OFF. 4. Disconnect hoses (1—4). 5. Disconnect harness connectors (B8, B9, and Y3). 6. Remove cap screws (5) and park brake valve manifold (57). TX1187476A —UN—16MAR15

7. Install park brake valve manifold and tighten cap screws to specification. Specification Park Brake Valve Mounting Cap Screw—Torque..............................................................................37 N·m 27 lb.-ft.

8. Connect harness connectors. Park Brake Valve

9. Connect hoses. 10. Turn battery disconnect switch to ON.

1— Right Park Brake Hose 2— Left Park Brake Hose 3— Hydrostatic Reservoir Hose 4— Charge Pump-to-Park Brake Valve Hose 5— Cap Screw (2 used)

57— Park Brake Valve Manifold B8—Hydrostatic Charge Pressure Sensor B9—Brake Pressure Sensor Y3— Park Brake Solenoid

DA93471,0000131 -19-09MAR15-1/1

TM14163X19 (15FEB18)

11-1100-3

450K, 550K, and 650K Crawler Dozer 021518 PN=291

Removal and Installation

TM14163X19 (15FEB18)

11-1100-4

450K, 550K, and 650K Crawler Dozer 021518 PN=292

Group 1115

Controls Linkage Park Lock Linkage Remove and Install MACHINE PREPARATION 1. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.) 2. Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch. (Operator’s Manual.) TX1232805A —UN—26JAN17

REMOVAL 1. Disconnect the necessary park lock lever switch (S2 or S14). For more information, see Operator’s Station Harness (W20) Component Location or if equipped with SmartGrade™, see Operator’s Station (SmartGrade™ and IGC Controls) Harness (W21) Component Location. (Group 9015-10.) S2— Left Park Lock Lever Switch

S14— Right Park Lock Lever Switch

Park Lock Lever Switches

SmartGrade is a trademark of Deere & Company JL48493,0000369 -19-25JUL17-1/4

2. Remove the necessary park lock lever knob (1). 3. To remove the left park lock lever assembly, remove the transmission control lever assembly (3) from the console and tie back out of the way. To remove the right park lock lever assembly, remove the blade control lever assembly (5) from the console and tie back out of the way. Disconnect electrical connections if necessary. TX1232814A —UN—26JAN17

• For electrical connector locations, see Operator’s

Station Harness (W20) Component Location or if equipped with SmartGrade™, see Operator’s Station (SmartGrade™ and IGC Controls) Harness (W21) Component Location. (Group 9015-10.) • For mechanical blade control disconnection information, see Blade Control Lever Linkage Remove and Install. (Group 3215.) • For mechanical auxiliary control disconnection information, see Auxiliary Control Lever Linkage Remove and Install. (Group 3215.) 4— Cap Screw (5 used) 5— Blade Control Lever Assembly

TX1232815A —UN—26JAN17

1— Park Lock Lever Knob (2 used) 2— Cap Screw (4 used) 3— Transmission Control Lever Assembly

Transmission Control Lever Assembly

Blade Control Lever Assembly (integrated grade control [IGC] option shown) SmartGrade is a trademark of Deere & Company Continued on next page

TM14163X19 (15FEB18)

11-1115-1

JL48493,0000369 -19-25JUL17-2/4

450K, 550K, and 650K Crawler Dozer 021518 PN=293

Controls Linkage

4. Remove the necessary armrest (6) and side pad (9). 5. Remove the necessary console cover (7 or 10). 9— Side Pad (2 used) 10— Right Console Cover 11— Screw (5 used)

TX1232834A —UN—26JAN17

6— Armrest (2 used) 7— Left Console Cover 8— Screw (5 used)

Console Covers (450K only) JL48493,0000369 -19-25JUL17-3/4

TX1232836A —UN—26JAN17

6. To remove the left park lock lever assembly, remove cap screws (13) and maneuver the assembly through the transmission control lever opening. To remove the right park lock lever assembly, remove cap screws (12) and maneuver the assembly through the blade control lever opening. INSTALLATION Installation is reverse of removal procedure. 12— Cap Screw (2 used)

13— Cap Screw (2 used) Park Lock Lever Linkage

JL48493,0000369 -19-25JUL17-4/4

TM14163X19 (15FEB18)

11-1115-2

450K, 550K, and 650K Crawler Dozer 021518 PN=294

Controls Linkage

Park Lock Linkage Disassemble and Assemble SPECIFICATIONS Tighten lock nut until solid then loosen 1/2 turn.

Lock Nut (23) Torque

Tighten lock nut until solid then loosen 1/2—2 turns.

Hex Socket Head Cap Screw Torque

10 N·m 89 lb·in

T199655 —UN—07MAY04

Lock Nut (9) Torque

T199655 Park Lock Lever (exploded assembly, left side shown) 1— Cotter Pin 2— Nut 3— Pin Fastener 4— Pin Fastener 5— Washer 6— Spring 7— Hex Socket Head Cap Screw (2 used)

8— Flanged Head Cap Screw (2 used) 9— Lock Nut 10— Washer 11— Washer (2 used) 12— Washer 13— Washer 14— Control Lever

1. Lower all equipment to ground and stop engine. 2. Turn battery disconnect switch to OFF position. 3. Remove park lock assembly. See Park Lock Linkage Remove and Install. (Group 1115.)

15— Stud 16— Switch 17— Bracket 18— Threaded Stud 19— Threaded Stud 20— Spring Washer (5 used) 21— Knob 22— Washer (2 used)

23— Lock Nut 24— Plate (2 used) 25— Compression Spring 26— Plate

5. Remove lock nut (23), spring washers (20), plates (24), and washers (22). 6. Loosen lock nut (9) several turns. Do not remove.

4. Remove plate (26), compression spring (25), and washer (10). Continued on next page

TM14163X19 (15FEB18)

11-1115-3

DA93471,00000D4 -19-18JAN17-1/3

450K, 550K, and 650K Crawler Dozer 021518 PN=295

Controls Linkage

CAUTION: Park lock control lever is under spring pressure. Removing control lever without relieving spring pressure can cause bodily injury. Relieve spring pressure by SLOWLY removing control lever over stops and rotating lever over center. 7. Using pry bar, lift control lever (14) and pin fastener (3) until control lever is higher than stops (27 and 28). Prying control lever allows lever to rotate further and relieve spring tension.

T199670A —UN—04MAY04

8. Remove control lever (14), pin fastener (4), spring (6), and washer (5). 9. Disassemble remaining parts. 10. Assemble pin fastener (4) onto control lever stud (15) using washers (11) and cotter pin (1). 11. Assemble pin fastener (3) onto threaded stud (19) using washers (12 and 13), and lock nut (9). Do not tighten lock nut.

Park Lock Lever Assembly (left side shown)

12. Assemble plate (24) and washer (22) onto threaded stud (18).

3— Pin Fastener 9— Lock Nut 14— Control Lever

13. Assemble washer (5) and compress spring (6) onto pin fastener (3). 14. With pin fastener (4) slid into spring (6), assemble control lever onto threaded stud (18). 15. Rotate control lever until lever fits over stops (27 and 28). Push into place.

23— Lock Nut 27— Stop 28— Stop

Specification Lock Nut (9)—Torque...................................................... Tighten lock nut until solid then loosen 1/2 turn.

17. Assemble washer (22) and plate (24) onto threaded stud (18).

16. Tighten lock nut (9) to specification.

DA93471,00000D4 -19-18JAN17-2/3

18. Assemble spring washers (20) as shown. Assemble lock nut (23) and tighten to specification.

T199665 —UN—04MAY04

Specification Lock Nut (23)—Torque............................................ Tighten lock nut until solid then loosen 1/2—2 turns.

19. Assemble switch (16) onto bracket using hex socket head cap screws (7). Tighten to specification. Specification Hex Socket Head Cap Screw—Torque..............................................................................10 N·m 89 lb·in

20. Assemble washer (10) and compression spring (25) onto control lever (14). 21. Assemble plate (26) onto control lever (14) with chamfer pointing away from spring.

20 23 Park Lock Lever Spring Washers Cross Section (left side shown) 20— Spring Washer (5 used)

23— Lock Nut

22. Install park lock assembly. See Park Lock Linkage Remove and Install. (Group 1115.) DA93471,00000D4 -19-18JAN17-3/3

TM14163X19 (15FEB18)

11-1115-4

450K, 550K, and 650K Crawler Dozer 021518 PN=296

Group 1160

Hydraulic System Park Brake Disassemble and Assemble SPECIFICATIONS Park Brake Park Brake Assembly Socket Head Cap Screw Torque

37 N·m 27 lb·ft

1. Remove park brake. See Park Brake Remove and Install. (Group 1100.) 2. Scribe a line between cover and housing to aid assembly.

T198544A —UN—22APR04

3. Remove four socket head cap screws and washers (1) and separate cover from housing. 4. Remove O-ring from cover. 1— Socket Head Cap Screw and Washer (4 used)

Brake Assembly WS68074,0001B7E -19-20JAN17-1/8

Remove spring retainer plate (1).

T198545A —UN—19MAR04

1— Spring Retainer Plate

Spring Retainer Plate Continued on next page

TM14163X19 (15FEB18)

11-1160-1

WS68074,0001B7E -19-20JAN17-2/8

450K, 550K, and 650K Crawler Dozer 021518 PN=297

Hydraulic System

Remove springs (1 and 2). 2— Springs (12 used)

T198546A —UN—19MAR04

1— Springs (12 used)

Springs WS68074,0001B7E -19-20JAN17-3/8

7. Remove piston (1).

T198548A —UN—19MAR04

1— Piston

Piston WS68074,0001B7E -19-20JAN17-4/8

Remove O-rings (1 and 2) from piston. 2— O-Ring

T198550A —UN—19MAR04

1— O-Ring

Piston O-Rings Continued on next page

TM14163X19 (15FEB18)

11-1160-2

WS68074,0001B7E -19-20JAN17-5/8

450K, 550K, and 650K Crawler Dozer 021518 PN=298

Hydraulic System

9. Remove splined coupling (1). 10. Scribe a line between quill and housing to aid assembly. T198549A —UN—19MAR04

1— Splined Coupling

Splined Coupling WS68074,0001B7E -19-20JAN17-6/8

11. Insert two screws (1) through housing (2) into quill. Tap screws with plastic hammer to separate quill from housing. 3— Quill T198551A —UN—19MAR04

1— Screw (2 used) 2— Housing

Separate Housings Continued on next page

TM14163X19 (15FEB18)

11-1160-3

WS68074,0001B7E -19-20JAN17-7/8

450K, 550K, and 650K Crawler Dozer 021518 PN=299

Hydraulic System

12. Remove friction disks (1) and separator plates (2) from housing. Remove O-ring (3). T198552A —UN—19MAR04

13. Clean and inspect parts. 14. Install splined coupling in quill. 15. Install a separator plate, then a friction disk, and continue alternating plates and disks until all are installed in quill. 16. Install O-ring on quill. 17. Apply clean hydraulic oil to O-ring, quill, and housing.

Disks and Separator Plates

18. Install housing onto quill. 1— Friction Disk (7 used) 2— Separator Plate (8 used)

19. Install O-rings on piston. 20. Apply clean hydraulic oil to piston, O-rings, and housing. 21. Install piston in housing. 22. Install double springs into piston.

3— O-Ring

27. Install cap screws and washers. Tighten cap screws to specification. Park Brake—Specification Park Brake Assembly Socket Head Cap Screw—Torque..............................................................................37 N·m 27 lb·ft

23. Install spring retainer onto springs. 24. Install O-ring on cover. 25. Apply clean hydraulic oil to cover, O-ring, and housing. 26. Install cover in housing.

WS68074,0001B7E -19-20JAN17-8/8

TM14163X19 (15FEB18)

11-1160-4

450K, 550K, and 650K Crawler Dozer 021518 PN=300

Hydraulic System OTHER MATERIAL

Park Brake Valve Disassemble and Assemble

Loctite® 7649™ Primer N™ Cure Primer

SPECIFICATIONS Socket Head Cap Screw Torque

3—4 N·m 27—35 lb·in

Pressure Sensor (B8 and B9) Torque

20 N·m 177 lb·in

Loctite® 242® Threadlocker (medium strength)

7 5

1 8

57 4 Y3

3 B9

9 TX1186070 —UN—16MAR15

2 2

TX1186070

Park Brake Valve 1— O-Ring (3 used) 2— Cap Screw (2 used) 3— Tee Fitting 4— O-Ring (2 used)

5— Adapter Fitting 6— O-Ring 7— O-Ring 8— Adapter Fitting 9— Socket Head Cap Screw (2 used)

57— Park Brake Valve Manifold B8—Hydrostatic Charge Pressure Sensor B9—Brake Pressure Sensor

1. Mark position of hydraulic tee fitting (3) to aid in assembly and remove.

Y3— Park Brake Solenoid

3. Remove adapter fittings (5 and 8).

2. Remove pressure sensors (B8 and B9). Loctite and its related brand marks are trademarks of Henkel Corporation Continued on next page

TM14163X19 (15FEB18)

11-1160-5

JL48493,000036A -19-08FEB17-1/2

450K, 550K, and 650K Crawler Dozer 021518 PN=301

Hydraulic System

4. Remove socket head cap screws (9) and park brake solenoid (Y3) from park brake valve manifold (57). 5. Remove O-rings (13—16). TX1186089A —UN—18MAR15

6. Clean and inspect parts. Replace as needed. 7. Lubricate parts with clean hydraulic oil. 8. Install O-rings (13—16) on solenoid valve. 9. Install park brake solenoid (Y3) in park brake valve manifold (57). 10. Clean threads of socket head cap screws (9). Apply Loctite® 7649™ Primer N™ Cure Primer and Loctite® 242® Threadlocker (medium strength) to threads of socket head cap screws (9) and tighten to specification.

Park Brake Valve 9— Socket Head Cap Screw (2 used) 13— O-Ring 14— O-Ring 15— O-Ring

Specification Socket Head Cap Screw—Torque......................................................................... 3—4 N·m 27—35 lb·in

16— O-Ring 57— Park Brake Valve Manifold Y3— Park Brake Solenoid

13. Install tee fitting (3) in position as marked during removal.

11. Install adapter fittings (5 and 8). 12. Install pressure sensors (B8 and B9) and tighten to specification. Specification Pressure Sensor (B8 and B9)—Torque..................................................................................20 N·m 177 lb·in Loctite and its related brand marks are trademarks of Henkel Corporation

JL48493,000036A -19-08FEB17-2/2

TM14163X19 (15FEB18)

11-1160-6

450K, 550K, and 650K Crawler Dozer 021518 PN=302

Section 15 Equipment Attaching Contents Page

Group 1511—Drawbar Drawbar Remove and Install ..................... 15-1511-1 Extended Drawbar Remove and Install ..................................................... 15-1511-2

TM14163X19 (15FEB18)

15-1

450K, 550K, and 650K Crawler Dozer

021518

PN=1

Contents

TM14163X19 (15FEB18)

15-2

450K, 550K, and 650K Crawler Dozer

021518

PN=2

Group 1511

Drawbar Drawbar Remove and Install SPECIFICATIONS Drawbar Weight (approximate)

23 kg 51 lb

Drawbar-to-Main Frame Cap Screw Torque

675 N·m 498 lb·ft

REMOVAL 1. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Operator’s Manual.) TX1232352A —UN—23JAN17

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 2. Attach appropriate lifting device to drawbar (2). Remove cap screws (1) and drawbar from rear of machine. Specification Drawbar—Weight (approximate).................................................................................. 23 kg 51 lb

INSTALLATION

Drawbar 1— Cap Screw (4 used)

2— Drawbar

Installation is reverse of removal procedure.

• Tighten cap screws (1) to specification. Specification Drawbar-to-Main Frame Cap Screw—Torque....................................................................675 N·m 498 lb·ft JL48493,0000366 -19-08FEB17-1/1

TM14163X19 (15FEB18)

15-1511-1

450K, 550K, and 650K Crawler Dozer 021518 PN=305

Drawbar

Extended Drawbar Remove and Install SPECIFICATIONS Extended Drawbar Weight (approximate)

32 kg 71 lb

Extended Drawbar-to-Main Frame 675 N·m Cap Screw Torque 498 lb·ft

REMOVAL 1. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Operator’s Manual.) TX1232367A —UN—23JAN17

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 2. Attach appropriate lifting device to extended drawbar (2). Remove cap screws (1) and extended drawbar from rear of machine. Specification Extended Drawbar—Weight (approximate).................................................................................. 32 kg 71 lb

INSTALLATION

Extended Drawbar 1— Cap Screw (4 used)

2— Extended Drawbar

Installation is reverse of removal procedure.

• Tighten cap screws (1) to specification. Specification Extended Drawbarto-Main Frame Cap Screw—Torque............................................................................675 N·m 498 lb·ft JL48493,0000367 -19-08FEB17-1/1

TM14163X19 (15FEB18)

15-1511-2

450K, 550K, and 650K Crawler Dozer 021518 PN=306

Section 16 Electrical System Contents Page

Group 1600—Removal and Installation Integrated Grade Control (IGC) Lever Remove and Install...................... 16-1600-1 Integrated Grade Control (IGC) Lever Disassemble and Assemble............................................... 16-1600-2 Auxiliary Joystick Remove and Install—IGC ........................................... 16-1600-3 Exhaust Filter Sensor Installation .............. 16-1600-4 Rotary Sensor Remove and Install ..................................................... 16-1600-4 Air Conditioner Freeze Control Switch Remove and Install .................... 16-1600-5 Controller Remove and Install ................... 16-1600-7 Replace (Pull-Type) Metri-Pack® Connectors ............................................ 16-1600-7 Replace (Push-Type) Metri-Pack® Connectors ............................................ 16-1600-8 Replace Metri-Pack® Connectors.............. 16-1600-8 Replace Weather Pack™ Connector .............................................. 16-1600-9 Install Weather Pack™ Contact............... 16-1600-10 Replace DEUTSCH® Rectangular or Triangular Connectors ..................... 16-1600-11 Replace DEUTSCH® Circular Connectors .......................................... 16-1600-13 Replace DEUTSCH® Connectors .......................................... 16-1600-14 Install DEUTSCH® Contact..................... 16-1600-15 Replace Cinch™ Connectors .................. 16-1600-16 Install Cinch™ Contact ............................ 16-1600-18 Repair 32 and 48-Way Cinch™ Connectors .......................................... 16-1600-19 Remove Connector Body From Blade Terminals ................................... 16-1600-21 Repair Molex Connectors ........................ 16-1600-22 Replace TYCO™ Connectors ................. 16-1600-23

TM14163X19 (15FEB18)

16-1

450K, 550K, and 650K Crawler Dozer

021518

PN=1

Contents

TM14163X19 (15FEB18)

16-2

450K, 550K, and 650K Crawler Dozer

021518

PN=2

Group 1600

Removal and Installation Integrated Grade Control (IGC) Lever Remove and Install 1. Turn battery disconnect switch to OFF position. 2. Remove cap screws (1). 3. Lift plate (2) to expose electrical connectors (3 and 4). 2— Plate

TX1187312A —UN—11MAR15

1— Cap Screw (5 used)

Integrated Grade Control (IGC) Lever JL05046,0000158 -19-11MAR15-1/2

4. Disconnect electrical connectors. 5. Remove complete lever assembly from machine.

TX1091280A —UN—25APR11

6. Remove nuts (5) from bottom of IGC lever (6) and remove IGC lever from plate. 7. Repair or replace parts as required. 8. Install IGC lever in plate using nuts. 9. Connect electrical connections. 10. Install IGC lever assembly using cap screws. 11. Turn battery disconnect switch to ON position.

Integrated Grade Control (IGC) Lever (bottom view)

12. Operate machine and verify all functions work correctly. 3— Electrical Connector 4— Electrical Connector

5— Nut (4 used) 6— IGC Lever JL05046,0000158 -19-11MAR15-2/2

TM14163X19 (15FEB18)

16-1600-1

450K, 550K, and 650K Crawler Dozer 021518 PN=309

Removal and Installation

Integrated Grade Control (IGC) Lever Disassemble and Assemble

21 12

14 3 8

5 19

7 TX1188326 —UN—26MAR15

7 4 1

TX1188326 Integrated Grade Control (IGC) Lever Assembly (joystick)

Continued on next page

TM14163X19 (15FEB18)

16-1600-2

JL05046,0000159 -19-14APR15-1/2

450K, 550K, and 650K Crawler Dozer 021518 PN=310

Removal and Installation 1— Nut (8 used) 2— Cap Screw (5 used) 3— Cap Screw (8 used) 4— Washer (16 used)

5— Gasket (2 used) 7— Nut (4 used) 8— Plate (2 used) 9— Boot 12— Electrical Connector

13— Cover (2 used) 14— Mulit-Function Controller 19— Plate 20— Screw (3 used)

21— Screw 22— Nut (2 used) 23— Cap Screw (2 used)

Disassemble and assemble parts as shown. JL05046,0000159 -19-14APR15-2/2

Auxiliary Joystick Remove and Install—IGC 1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) 2. Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch. (Operator’s Manual.) 3. Open right rear service door. 4. Disconnect electrical connector (3) from auxiliary joystick (1). 5. Remove screws (2) and remove auxiliary joystick. TX1187345A —UN—11MAR15

NOTE: Auxiliary joystick is not serviceable and must be replaced as an assembly. 6. Replace auxiliary joystick as needed. 7. Install auxiliary joystick and screws. 8. Connect electrical connector. 9. Close right rear service door. Auxiliary Joystick

10. Turn battery disconnect switch to the ON position. See Battery Disconnect Switch. (Operator’s Manual.) 11. Start engine and verify operation of ripper. 3— Electrical Connector

TX1187341A —UN—11MAR15

1— Auxiliary Joystick 2— Screw (4 used)

Auxiliary Joystick (bottom view) JL05046,0000152 -19-11MAR15-1/1

TM14163X19 (15FEB18)

16-1600-3

450K, 550K, and 650K Crawler Dozer 021518 PN=311

Removal and Installation

Exhaust Filter Sensor Installation

• Diesel Oxidation Catalyst (DOC) Inlet Temperature

When installing sensors, apply Loctite® 41205 to the following sensor threads prior to installation:

• Diesel Oxidation Catalyst (DOC) Outlet Temperature

• Diesel Particulate Filter (DPF) Differential Pressure

• Select Catalytic Reduction (SCR) Inlet Temperature

Sensor (B5201)

Sensor (B5109)

Sensor (B5202)

Sensor (B60)

Loctite and its related brand marks are trademarks of Henkel Corporation JL05046,000015B -19-31MAR15-1/1

Rotary Sensor Remove and Install SPECIFICATIONS Rotary Sensor Mounting Cap Screws Torque

5 N·m 48 lb·in

1. To ease removal and installation, remove the transmission control lever (TCL) or decelerator assembly. See Transmission Control Lever (TCL) Remove and Install or see Decelerator/Brake Pedal Remove and Install. (Group 0315.) 2. Remove the cap screws (4) and sensor (2). 3. Install new O-ring (3) if needed. 4. Install sensor on keyed shaft (1). 5. Twist sensor to line up with mounting holes.

Specification Rotary Sensor Mounting Cap Screws—Torque......................................................................5 N·m 48 lb·in

7. Install the TCL or decelerator assembly. 1— Shaft 2— Sensor

TX1099633 —UN—28OCT11

6. Install cap screws and tighten to specification.

3— O-Ring 4— Cap Screw (2 used)

Rotary Sensor (forward, neutral, reverse [FNR] sensor shown) JR05199,0000687 -19-17JAN17-1/1

TM14163X19 (15FEB18)

16-1600-4

450K, 550K, and 650K Crawler Dozer 021518 PN=312

Removal and Installation

Air Conditioner Freeze Control Switch Remove and Install MACHINE PREPARATION 1. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.) 2. Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch. (Operator’s Manual.) TX1232951A —UN—30JAN17

REMOVAL 1. Remove filter cover (6) and filter. 2. Remove cap screws (5) to disconnect heating and air conditioning system unit from cab frame. 3. Remove cap screws (2) and lower condenser housing cover (1). Heating and Air Conditioning System Covers

4. Remove side covers (4).

1— Condenser Housing Cover 2— Cap Screw (10 used) 3— Cap Screw (4 used)

4— Side Cover (2 used) 5— Cap Screw (6 used) 6— Filter Cover JL48493,000036B -19-01MAR17-1/4

5. Remove cap screws (7). 6. Remove heating and air conditioning system unit cover (9). 7. Install identification tags and disconnect heater and air conditioner harness connector (X35). See Heater and Air Conditioner Harness (W27) Component Location. (Group 9015-10.) 9— Heating and Air Conditioning System Unit Cover X35— Heater and Air Conditioner Harness Connector

TX1232851A —UN—30JAN17

7— Cap Screw (2 used) 8— Cap Screw (8 used)

Heating and Air Conditioning System Unit Continued on next page

TM14163X19 (15FEB18)

16-1600-5

JL48493,000036B -19-01MAR17-2/4

450K, 550K, and 650K Crawler Dozer 021518 PN=313

Removal and Installation

8. Disconnect drain hoses (10). 9. Install identification tags and disconnect heater core lines (11). Close all openings using caps and plugs. 11— Heater Core Line (2 used)

TX1232960A —UN—27JAN17

10— Drain Hose (2 used)

Heater Core Lines JL48493,000036B -19-01MAR17-3/4

10. Disconnect air conditioner freeze control switch (B31) and remove cap screw (12).

TX1232963A —UN—27JAN17

11. Slide the heating and air conditioning system unit out. Disconnect the sensor probe (14) at the top. 12. Remove the air conditioner freeze control switch. INSTALLATION Installation is reverse of removal procedure.

• Verify operation of air conditioning system. See Air Conditioner Check. (Group 9005-10.)

14— Sensor Probe B31— Air Conditioner Freeze Control Switch

Air Conditioner Freeze Control Switch

TX1232965A —UN—27JAN17

12— Cap Screw 13— Electrical Connector (2 used)

Sensor Probe JL48493,000036B -19-01MAR17-4/4

TM14163X19 (15FEB18)

16-1600-6

450K, 550K, and 650K Crawler Dozer 021518 PN=314

Removal and Installation

Controller Remove and Install When a machine controller is replaced, the new controller must be programmed according to the machine's serial number. This will ensure the correct software and options are installed on the controller for that particular machine. The machine may run and operate without programming

the new controller, but some features and options may not be available. NOTE: Transmission calibration must be performed after replacing and programming vehicle control unit (VCU). See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) BS40810,0000119 -19-20JAN15-1/1

Replace (Pull-Type) Metri-Pack® Connectors 1. Disconnect the Metri-Pack® connector (1). Remove tie bands and tape. TX1222231A —UN—31AUG16

NOTE: JDG777 Terminal Extraction Tool or a T-pin can be used to remove terminals. JDG777 Terminal Extraction Tool is included in JT07195B Electrical Repair Kit. 2. Insert a T-pin (2) 6.4 mm (0.25 in) into connector body socket (3). 3. Angle T-pin so pin tip slides close to the plastic socket edge pushing terminal locking tab (4) inward.

Metri-Pack® Pull-Type Connector

4. Remove T-pin and push terminal (5) out of socket.

TX1222232A —UN—31AUG16

5. Remove terminal. Cut, strip, and crimp wire through connector. 6. Check to make sure that locking tab on new terminal is in outward position, then pull on wire until terminal locks in connector body socket. Terminal seats only one way. If terminal does not pull into the connector body socket, make sure that terminal is aligned correctly. 4— Locking Tab 5— Push Terminal

Metri-Pack® Pull-Type Socket

TX1222229A —UN—31AUG16

1— Connector 2— T-Pin 3— Body Socket

Metri-Pack® Pull-Type Terminals Metri-Pack is a trademark of Delphi Connection Systems TX,METRIPACK_PULL -19-31AUG16-1/1

TM14163X19 (15FEB18)

16-1600-7

450K, 550K, and 650K Crawler Dozer 021518 PN=315

Removal and Installation

Replace (Push-Type) Metri-Pack® Connectors TX1222230A —UN—31AUG16

1. Disconnect the Metri-Pack® connector. Remove the tie bands and tape. 2. Remove the connector lock (1), and mark wire colors for identification. 3. Identify wire color locations with connector terminal letters. NOTE: JDG776 Extraction Tool can be used with 56, 280, and 630-series Metri-Pack® terminals. JDG777 Extraction Tool can be used with 150-series Metri-Pack® terminals.

Metri-Pack® Push-Type Connector

4. Insert JDG776 or JDG777 Terminal Extraction Tool (2) into connector body socket (3) pushing the terminal locking tab inward. JDG776 and JDG777 Terminal Extraction Tools are included in JT07195B Electrical Repair Kit. 5. Remove extraction tool and pull terminal (4) out of the socket.

1— Connector Lock 2— JDG777 Extraction Tool 3— Connector Body Socket

4— Terminal 5— Locking Tab

7. Push terminal into connector body socket until terminal locks.

6. Replace terminal. Make sure locking tab (5) on the new terminal is in the outward position. Metri-Pack is a trademark of Delphi Connection Systems TX,METRIPACK_PUSH -19-31AUG16-1/1

Replace Metri-Pack® Connectors ESSENTIAL TOOLS

TX1222213A —UN—30AUG16

JDG939 Metri-Pack® Extractor Tool

1. A small locking tab (1) is located inside the Metri-Pack® connector. Use a small screwdriver (2) to move tab outward to the first detent position; the tab clicks. 1— Tab

2— Screwdriver

Metri-Pack® Connector Metri-Pack is a trademark of Delphi Connection Systems Continued on next page

TM14163X19 (15FEB18)

16-1600-8

TX,METRIPACK -19-30AUG16-1/3

450K, 550K, and 650K Crawler Dozer 021518 PN=316

Removal and Installation

2. Slide JDG939 Metri-Pack® Extractor Tool (4) into connector body until it is positioned over terminal contact. TX1222214A —UN—30AUG16

3. Pull wire out of connector body. 4. Install contact in proper location using correct size grommet. 5. Push contact straight into connector body until positive stop is felt. 6. Pull on wire slightly to be certain contact is locked in place. JDG939 Metri-Pack® Extractor Tool

7. Transfer remaining wires to correct terminal in new connector. 3— Wire

4— JDG939 Metri-Pack® Extractor Tool TX,METRIPACK -19-30AUG16-2/3

8. Use a small screwdriver (2) to move tab (1) inward to the first detent position. The tab clicks and locks the wires in the connector body. 1— Tab

TX1222213A —UN—30AUG16

2— Screwdriver

Metri-Pack® Connector TX,METRIPACK -19-30AUG16-3/3

Replace Weather Pack™ Connector ESSENTIAL TOOLS JDG364 Extraction Tool TS0128 —UN—23AUG88

1. Identify wire color locations with connector terminal letters. 2. Open connector body. 3. Insert JDG364 Extraction Tool over terminal contact in connector body. 4. Hold extractor tool fully seated and pull wire from connector body.

Weather Pack™ Terminal Contact

If terminal cannot be removed, insert wire or nail through extractor tool handle and push terminal contact from connector. Weather Pack is a trademark of Delphi-Packard Continued on next page

TM14163X19 (15FEB18)

16-1600-9

TX,WEATHER_REP -19-15AUG16-1/2

450K, 550K, and 650K Crawler Dozer 021518 PN=317

Removal and Installation

NOTE: Connector bodies are "keyed" for proper contact mating. Be sure that contacts are in proper alignment.

TS0130 —UN—23AUG88

5. Carefully spread contact lances to ensure good seating on connector body. Push contact into new connector body until fully seated. 6. Pull on wire slightly to be certain contact is locked in place. 7. Transfer remaining wires to correct terminal in new connector. Weather Pack™ Connector Body

8. Close connector body.

TX,WEATHER_REP -19-15AUG16-2/2

Install Weather Pack™ Contact ESSENTIAL TOOLS JDG783 Terminal Applicator TS0136 —UN—23AUG88

NOTE: Cable seals are color coded for three sizes of wire:

• Green—18 to 20 gauge wire • Gray—14 to 16 gauge wire • Blue—10 to 12 gauge wire 1. Slip correct size cable seal on wire. 2. Strip insulation from wire to expose 6 mm (0.25 in) and align cable seal with edge of insulation.

Correct Size Cable

NOTE: Contacts have numbered identification for two sizes of wire:

TS1623 —UN—02NOV94

• #15 for 14 to 16 gauge wire • #19 for 18 to 20 gauge wire 3. Put proper size contact on wire and crimp in place with a W-type crimp, using JDG783 Terminal Applicator.

Strip Insulation Continued on next page

TM14163X19 (15FEB18)

16-1600-10

TX,WEATH_INST -19-31AUG16-1/2

450K, 550K, and 650K Crawler Dozer 021518 PN=318

Removal and Installation

4. Secure cable seal to contact as shown, using JDG783 Terminal Applicator.

TX1222329A —UN—31AUG16

Proper contact installation for sleeve (1) and pin (2) is shown. 2— Pin

1— Sleeve

Weather Pack™ Contact Installation Weather Pack is a trademark of Delphi-Packard TX,WEATH_INST -19-31AUG16-2/2

Replace DEUTSCH® Rectangular or Triangular Connectors SERVICE EQUIPMENT AND TOOLS

T130688B —UN—01MAY00

JDG1383 Terminal Tool

NOTE: Connector shown is the female half or a 4-pin square connector. Other similar styles of DEUTSCH® connectors can be serviced using the same procedure. 1. Pull connector (1) apart. Inspect and clean connector seal and contacts. Removing Locking Wedge

2. Remove locking wedge (2) from connector using hook on JDG1383 Terminal Tool. 1— Connector

2— Locking Wedge

DEUTSCH is a trademark of TE Connectivity Ltd. Continued on next page

TM14163X19 (15FEB18)

16-1600-11

TX,DEUTSCH1 -19-15AUG16-1/2

450K, 550K, and 650K Crawler Dozer 021518 PN=319

Removal and Installation

3. Release primary locking latch (3) next to the pin to be removed using screwdriver on JDG1383 Terminal Tool. 4. Gently pull wire out from back of connector. T130689B —UN—01MAY00

5. Replace connector contact as necessary. 6. Install wire terminal back into connector until terminal clicks into place. NOTE: Locking wedge in 2-pin connector is not symmetrical. For these connectors, latch shoulder should be positioned next to terminals. 7. Install locking wedge until it snaps into place.

Releasing Primary Latch

T130690B —UN—01MAY00

3— Primary Locking Latch (4 used for 4-pin connector)

Removing Wire TX,DEUTSCH1 -19-15AUG16-2/2

TM14163X19 (15FEB18)

16-1600-12

450K, 550K, and 650K Crawler Dozer 021518 PN=320

Removal and Installation

Replace DEUTSCH® Circular Connectors

TX1222336A —UN—31AUG16

NOTE: JDG361 Extractor Tool, JDG362 Extractor Tool, and JDG363 Extractor Tool are available in JDG359 DEUTSCH Electrical Repair Tool Kit. 1. Select correct size extractor tool for size of wire to be removed:

• JDG361 Extractor Tool for 12 to 14 gauge wire • JDG362 Extractor Tool for 16 to 18 gauge wire • JDG363 Extractor Tool for 20 gauge wire 2. Start correct size extractor tool (1) over wire at handle. Extractor Tool

3. Slide extractor tool along wire until tool tip snaps onto wire.

TS120 —UN—23AUG88

IMPORTANT: Avoid damage to wire and terminal contact. Do not twist extractor tool when inserting in connector. Slide extractor tool along wire into connector body. 4. Slide extractor tool along wire into DEUTSCH® connector body until it is positioned over terminal contact. 5. Using extractor tool (1), pull wire out of connector body. Slide Extractor Tool

6. Install contact in proper connector location using correct size grommet. 1— Extractor Tool DEUTSCH is a trademark of TE Connectivity Ltd.

TX,DEUTSCH2 -19-31AUG16-1/2

7. Push contact straight into connector body until positive stop is felt.

TS122 —UN—23AUG88

8. Pull on wire and verify that contact is locked in place.

Push Contact TX,DEUTSCH2 -19-31AUG16-2/2

TM14163X19 (15FEB18)

16-1600-13

450K, 550K, and 650K Crawler Dozer 021518 PN=321

Removal and Installation

Replace DEUTSCH® Connectors

TX1222336A —UN—31AUG16

3. Slide extractor tool rearward along wire until tool tip snaps onto wire.

TS120 —UN—23AUG88

IMPORTANT: Avoid damage to wire and terminal contact. Do not twist extractor tool when inserting in connector. Slide extractor tool along wire into connector body. 4. Slide extractor tool along wire into connector body until it is positioned over terminal contact. 5. Using extractor tool, pull wire out of connector body. 6. Install contact in proper location using correct size grommet.

Slide Extractor Tool 1— Extractor Tool TX,DEUTSCH3 -19-31AUG16-1/2

7. Push contact straight into connector body until positive stop is felt. 8. Pull on wire slightly to be certain contact is locked in place. TS122 —UN—23AUG88

9. Transfer remaining wires to correct terminal in new connector.

Push Contact TX,DEUTSCH3 -19-31AUG16-2/2

TM14163X19 (15FEB18)

16-1600-14

450K, 550K, and 650K Crawler Dozer 021518 PN=322

Removal and Installation

Install DEUTSCH® Contact 1. Strip 6 mm (0.25 in) insulation from wire. TX1222337A —UN—31AUG16

2. Adjust selector (1) on JDG360 Crimper for correct wire size. 3. Loosen lock nut (2) and turn in adjusting screw (3) until it stops. 1— Selector 2— Lock Nut

3— Adjusting Screw

JDG360 Crimper TX,DEUTSCH4 -19-31AUG16-1/4

IMPORTANT: Select proper size contact sleeve or pin to fit connector body.

TX1222343A —UN—31AUG16

4. Insert contact (4) and turn adjusting screw (3) until contact is flush with cover (5). 5. Tighten lock nut (2). 2— Lock Nut 3— Adjusting Screw

4— Contact 5— Cover

Adjusting Screw TX,DEUTSCH4 -19-31AUG16-2/4

6. Insert wire in contact and crimp until handle touches stop. Contact must remain centered between indenters while crimping. TS118 —UN—23AUG88

7. Release handle and remove contact.

Crimp Continued on next page

TM14163X19 (15FEB18)

16-1600-15

TX,DEUTSCH4 -19-31AUG16-3/4

450K, 550K, and 650K Crawler Dozer 021518 PN=323

Removal and Installation

8. Inspect contact to be certain all wires are in crimped barrel.

TS0135 —UN—23AUG88

If all wire strands are not crimped into contact, cut off wire at contact and repeat contact installation procedures. 9. Readjust crimping tool for each crimping procedure.

Inspect Contact TX,DEUTSCH4 -19-31AUG16-4/4

Replace Cinch™ Connectors 1. Remove extraction tool (1) from the loading side of connector. 2. Insert blade of extraction tool into locking tabs (2) of secondary lock (3). Rotate tool away from the Cinch™ connector to pry one side of the secondary lock out of the locked position. Repeat this step for the other locking tab. 3— Secondary Lock

T132105B —UN—29JUN00

1— Extraction Tool 2— Secondary Lock Locking Tab (2 used)

Unlock Secondary Lock Cinch is a trademark of Cinch Inc. TX,CINCH_REPLACE -19-11AUG16-1/3

3. After unlocking one side of the secondary lock, use a screwdriver or similar device to hold in the unlocked position while unlocking the second locking tab.

T132301B —UN—29JUN00

Remove secondary lock (3). 3— Secondary Lock

Remove Secondary Lock Continued on next page

TM14163X19 (15FEB18)

16-1600-16

TX,CINCH_REPLACE -19-11AUG16-2/3

450K, 550K, and 650K Crawler Dozer 021518 PN=324

Removal and Installation

4. Insert pointed side of extraction tool (1) into the contact cavity so that the flat side of tool faces secondary lock cavity (4). This releases the primary contact locking tab. T132107B —UN—29JUN00

5. Pull wire out of the connector. 6. Replace terminals as necessary. See Install Cinch™ Contact. (Group 1600.) 7. Insert contact and wire into connector until it clicks. 8. Install secondary lock. 1— Extraction Tool

4— Cavity

Removing Terminals TX,CINCH_REPLACE -19-11AUG16-3/3

TM14163X19 (15FEB18)

16-1600-17

450K, 550K, and 650K Crawler Dozer 021518 PN=325

Removal and Installation

Install Cinch™ Contact ESSENTIAL TOOLS

T138057 —UN—14FEB01

JDG708 AMP® Crimper

Tool Position for Insertion A—Top of Tool B—Contact Support C—Locator

D—Wire E—Micro Timer Slot F— Junior Timer Slot

G—Contact I— Wire Tab J— Insulation Tab

1. Hold JDG708 AMP® Crimper so that the tool is positioned as shown (left side of graphic). Squeeze crimper handles together and allow them to open fully. IMPORTANT: Avoid damage to electrical connector and contacts. Do not attempt to crimp an improperly positioned contact. Make sure that both sides of the insulation barrel are started evenly into the crimping section. 2. Position the Cinch™ contact so that the mating end of the contact (G) is on the locator (C) side of the tool. Wire and insulation tabs (I and J) point to top of tool (A). Push wire tab (I) against the movable locator.

3. Hold the contact in position and squeeze crimper handles together until ratchet engages sufficiently to hold the contact in position. Do not deform wire and insulation tabs (I and J). 4. Insert stripped wire into contact insulation and wire tabs until it is against locator (C). 5. Hold the wire in place. Squeeze crimper handles together until ratchet releases. Allow crimper handles to open and remove crimped contact. 6. Install contact into connector. See Replace Cinch™ Connectors. (Group 1600.)

AMP is a trademark of Tyco Electronics Cinch is a trademark of Cinch Inc. TX,CINCH_INSTALL -19-11AUG16-1/1

TM14163X19 (15FEB18)

16-1600-18

450K, 550K, and 650K Crawler Dozer 021518 PN=326

Removal and Installation

Repair 32 and 48-Way Cinch™ Connectors ESSENTIAL TOOLS

RXA0070459 —UN—10SEP03

JDG1725 Terminal Extractor Tool (included in JDG1744 Flexbox Terminal Repair Kit) JDG1727 Terminal Crimping Tool (included in JDG1744 Flexbox Terminal Repair Kit)

1. Push tab (A) and rotate locking cam (B) 90° to disconnect connector from controller. 2. Move cover locks (C) slightly outward with a small screwdriver. 3. Remove cover (D) away from wires. C—Cover Lock (2 used) D—Cover

RXA0070462 —UN—10SEP03

A—Tab B—Locking Cam

Cinch™ Connector

RXA0070463 —UN—10SEP03

Cinch™ Cover Lock Tabs

Cinch™ Cover TX,CINCH_32,48WAY -19-11AUG16-1/4

4. Pull terminal lock (A) out until it stops. Do not force terminal lock removal.

RXA0070464 —UN—10SEP03

A—Terminal Lock

Terminal Lock Continued on next page

TM14163X19 (15FEB18)

16-1600-19

TX,CINCH_32,48WAY -19-11AUG16-2/4

450K, 550K, and 650K Crawler Dozer 021518 PN=327

Removal and Installation

RXA0070456 —UN—09SEP03

NOTE: JDG1725 Terminal Extractor Tool is included in JDG1744 Flexbox Terminal Repair Kit. JDG1725 Terminal Extractor Tool has two different sizes of pins: 0.6 for smaller 20 gauge holes (A) and 1.5 for larger 16 and 18 gauge holes (B). 5. Insert JDG1725 Terminal Extractor Tool into holes (C) next to terminal hole (D) to unlock terminal. 6. Pull wire and terminal (E) from connector body. D—Terminal Hole E—Terminal

RXA0070471 —UN—10SEP03

A—20 Gauge Hole (24 used) B—16 and 18 Gauge Hole (16 used) C—Hole (40 used)

JDG1727 Terminal Crimping Tool and JDG1725 Terminal Extractor Tool

RXA0070472 —UN—10SEP03

Connector Holes

RXA0070473 —UN—10SEP03

Cinch™ Connector Terminal Holes

JDG1725 Terminal Extractor Tool Continued on next page

TM14163X19 (15FEB18)

16-1600-20

TX,CINCH_32,48WAY -19-11AUG16-3/4

450K, 550K, and 650K Crawler Dozer 021518 PN=328

Removal and Installation

7. Remove old terminal and strip 4.85 mm (0.191 in) of insulation from wire.

RXA0070479 —UN—10SEP03

NOTE: JDG1727 Terminal Crimping Tool is included in JDG1744 Flexbox Terminal Repair Kit. 8. Firmly grip JDG1727 Terminal Crimping Tool (A). Squeeze ratcheting mechanism until it bottoms out, then allow it to open completely. 9. With tool in ready position (open handle), open terminal receptacle (B). 10. Insert terminal (C) into correct wire gauge window so crimp wings are facing up.

Crimp Terminal

11. Close terminal receptacle (B). 12. Squeeze handle until two clicks are heard. RXA0070480 —UN—10SEP03

13. Insert stripped wire (D) into terminal. 14. Hold wire stationary and squeeze tool together until ratchet releases. 15. Remove terminated wire from tool. 16. Push terminal into connector body until fully seated. Pull on wire slightly to ensure that terminal is locked in position. JDG1727 Terminal Crimping Tool

17. Push terminal lock closed. 18. Install cover.

A—JDG1727 Terminal Crimping Tool B—Terminal Receptacle

RXA0070481 —UN—10SEP03

19. Install connector to controller and close connector body locking cam. C—Terminal D—Wire

JDG1727 Terminal Crimping Tool TX,CINCH_32,48WAY -19-11AUG16-4/4

Remove Connector Body From Blade Terminals 1. Using a small screw driver, depress locking tang (A) on terminal. Slide connector body off.

A—Locking Tang

RW4218 —UN—23AUG88

2. Before installing connector body, bend locking tang back to its original position (B). B—Original Position

Blade Terminals TX,BLADE_REM -19-16AUG16-1/1

TM14163X19 (15FEB18)

16-1600-21

450K, 550K, and 650K Crawler Dozer 021518 PN=329

Removal and Installation

Repair Molex Connectors ESSENTIAL TOOLS JDG10146 Terminal Extraction Tool

1— Cover

TX1139722A —UN—09JUL13

1. Remove cover (1) from connector (2). 2— Connector

Connector and Cover TX,MOLEX -19-25AUG16-1/4

2. Remove tie band (3).

TX1139723A —UN—09JUL13

3— Tie Band

Tie Band TX,MOLEX -19-25AUG16-2/4

3. Insert JDG10146 terminal extraction tool (4) into terminal service hole (5). 5— Terminal Service Hole

TX1139726A —UN—09JUL13

4— JDG10146 Terminal Extraction Tool

Terminal Service Hole Continued on next page

TM14163X19 (15FEB18)

16-1600-22

TX,MOLEX -19-25AUG16-3/4

450K, 550K, and 650K Crawler Dozer 021518 PN=330

Removal and Installation

4. Once terminal lock is released, slowly remove extraction tool and wire (6). 5. Repair or replace as necessary. IMPORTANT: Prevent terminal damage during insertion. Ensure proper orientation of terminals. 6. Insert wire into proper terminal until secured by the terminal lock. TX1139725A —UN—09JUL13

7. Secure wires to connector with new tie band. 8. Install cover. 6— Wire

Wire Extraction TX,MOLEX -19-25AUG16-4/4

Replace TYCO™ Connectors ESSENTIAL TOOLS JDG1725 Terminal Extractor Tool

1. Move secondary lock slightly outward to secondary lock open position (2) on TYCO™ connector. 2— Secondary Lock Open Position

TX1191078A —UN—24APR15

1— Secondary Lock Closed Position

Secondary Lock Positions TYCO is a trademark of TE Connectivity Ltd. Continued on next page

TM14163X19 (15FEB18)

16-1600-23

TX,TYCO -19-25AUG16-1/3

450K, 550K, and 650K Crawler Dozer 021518 PN=331

Removal and Installation

2. Remove wire cover (3).

TX1191080A —UN—24APR15

3— Wire Cover

Wire Cover TX,TYCO -19-25AUG16-2/3

3. Insert JDG1725 Terminal Extractor Tool to unlock terminal. 4. Pull wire and terminal from connector body. 5. Inspect and replace terminals as needed. 6. Push terminal into connector body until fully seated. Pull on wire slightly to ensure terminal is locked in position.

TX1191081A —UN—24APR15

7. Push secondary lock to secondary lock closed position (1).

JDG1725 Terminal Extractor Tool TX,TYCO -19-25AUG16-3/3

TM14163X19 (15FEB18)

16-1600-24

450K, 550K, and 650K Crawler Dozer 021518 PN=332

Section 17 Frame, Chassis, or Supporting Structure Contents Page

Group 1740—Frame Installation Welding Repair of Major Structures .............................................. 17-1740-1 Group 1746—Frame Bottom Guards Bottom Guards Remove and Install ..................................................... 17-1746-1 Group 1749—Chassis Weights Front Counterweight Remove and Install ..................................................... 17-1749-1 Rear Counterweight Remove and Install ..................................................... 17-1749-2

TM14163X19 (15FEB18)

17-1

450K, 550K, and 650K Crawler Dozer

021518

PN=1

Contents

TM14163X19 (15FEB18)

17-2

450K, 550K, and 650K Crawler Dozer

021518

PN=2

Group 1740

Frame Installation Welding Repair of Major Structures IMPORTANT: Disconnect battery ground strap or turn battery disconnect switch to OFF (if applicable).

2. Use one of the following weld processes:

• AWS-E-7018 covered electrode with shielded metal arc welding (SMAW) process.

Disconnect both negative and positive battery cables and microprocessor unit (if applicable).

• AWS-ER-70S-3 wire electrode with gas metal arc welding (GMAW) process.

IMPORTANT: Have only a qualified welder do this job. Connect welder ground clamp close to each weld area so electrical current does not pass through any bearings. Remove or protect all parts that can be damaged by heat or weld splatter. CAUTION: Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. Do all work outside or in a well ventilated area. Dispose of paint and solvent properly. If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

• AWS-E70T-1 or E71T-1 wire electrode with flux core arc welding (FCAW) process.

Welding Repair of Major Structure—Specification Weld Metal—Tensile Strength...................................................................................482.6 MPa 70,000 psi Yield Strength .........................................................................413.7 MPa 60,000 psi Elongation......................................................................................... 22%

IMPORTANT: Area to be repaired must be preheated to allow better weld penetration. 3. To repair weld metal failure, remove failed weld metal using arc or grinding equipment. Thoroughly clean area to be welded. Preheat structural assemblies to a minimum of 38°C (100°F). Preheat ground engaging tools (cutting edges, skid shoes, and teeth shanks) to 177°C (350°F). To repair base metal failure remove enough material to allow weld to penetrate to the bottom of crack. Preheat structural assemblies to a minimum of 38°C (100°F). Preheat ground engaging tools (cutting edges, skid shoes, and teeth shanks) to 177°C (350°F).

1. Remove paint before welding or heating. IMPORTANT: Electrical current traveling from the welder through the machine electrical system may damage the machine electrical system, including battery, machine information center, and pump and valve controller. Disconnect battery ground cable, machine information center, and pump and valve controller electrical connectors before welding on the machine. Have only a qualified welder do this job. Connect welder ground clamp close to each weld area so electrical current does not pass through any bearings. Remove or protect all parts that can be damaged by heat or weld splatter.

Welding Repair of Major Structure—Specification Structural Assemblies—Preheat Temperature..................................................................................... 38°C 100°F Ground Engaging Tools—Preheat Temperature................................................................................... 177°C 350°F

BS40810,000010A -19-19DEC14-1/1

TM14163X19 (15FEB18)

17-1740-1

450K, 550K, and 650K Crawler Dozer 021518 PN=335

Frame Installation

TM14163X19 (15FEB18)

17-1740-2

450K, 550K, and 650K Crawler Dozer 021518 PN=336

Group 1746

Frame Bottom Guards Bottom Guards Remove and Install REMOVAL

CAUTION: Avoid possible injury from heavy component. Use appropriate lifting device. Weight may increase significantly due to buildup of mud or debris.

TX1233315A —UN—10FEB17

1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.)

2. Remove bottom guards (1—3) as required. 3. Clean machine of dirt and debris. Repair or replace parts as necessary. INSTALLATION

Bottom Guards 1— Front Bottom Guard (2 used) 2— Middle Bottom Guard

3— Rear Bottom Guard

Installation is reverse of removal procedure. JL05046,000027B -19-13FEB17-1/1

TM14163X19 (15FEB18)

17-1746-1

450K, 550K, and 650K Crawler Dozer 021518 PN=337

Frame Bottom Guards

TM14163X19 (15FEB18)

17-1746-2

450K, 550K, and 650K Crawler Dozer 021518 PN=338

Group 1749

Chassis Weights Front Counterweight Remove and Install SPECIFICATIONS Front Counterweight Weight (approximate)

86 kg 190 lb

REMOVAL 1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.)

TX1233244 —UN—03FEB17

CAUTION: Prevent possible crushing injury from heavy component. Use an appropriate lifting device. 2. Attach appropriate lifting device to front counterweight (1). Specification Front Counterweight—Weight (approximate)............................................................................................... 86 kg 190 lb

3. Remove cap screws (3), washers (2), and front counterweight.

2 3

Front Counterweight 1— Front Counterweight 2— Washer (4 used)

3— Cap Screw (4 used)

4. Clean and inspect parts. Repair or replace as necessary. INSTALLATION Installation is reverse of removal procedure. JL05046,000027A -19-27FEB17-1/1

TM14163X19 (15FEB18)

17-1749-1

450K, 550K, and 650K Crawler Dozer 021518 PN=339

Chassis Weights

Rear Counterweight Remove and Install SPECIFICATIONS Rear Counterweight Weight (approximate)

159 kg 351 lb

REMOVAL 1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.)

2. Remove drawbar (if equipped). See Drawbar Remove and Install or see Extended Drawbar Remove and Install. (Group 1511.)

2 TX1233227A —UN—01FEB17

3 CAUTION: Prevent possible crushing injury from heavy component. Use an appropriate lifting device. 3. Attach appropriate lifting device to rear counterweight (1).

Specification Rear Counterweight

Rear Counterweight—Weight (approximate)............................................................................................. 159 kg 351 lb

1— Rear Counterweight 2— Washer (6 used)

3— Cap Screw (6 used)

4. Remove cap screws (3), washers (2), and rear counterweight. 5. Clean and inspect parts. Repair or replace as necessary.

INSTALLATION Installation is reverse of removal procedure. JL05046,0000279 -19-03FEB17-1/1

TM14163X19 (15FEB18)

17-1749-2

450K, 550K, and 650K Crawler Dozer 021518 PN=340

Contents

Section 18 Operator's Station

Page

Group 1800—Removal and Installation Operator’s Station Remove and Install ..................................................... 18-1800-1 Group 1810—Operator Enclosure Windowpanes Remove and Install ..................................................... 18-1810-1 Window Wiper Motor Remove and Install ..................................................... 18-1810-4 Window Washer Pumps Remove and Install ............................................ 18-1810-10 Group 1821—Seat and Seat Belt Air Suspension Seat Remove and Install ...............................18-1821-1 Replacing Seat Belt ................................... 18-1821-1 Group 1830—Heating and Air Conditioning R134a Refrigerant Cautions and Proper Handling..................................... 18-1830-1 R134a Refrigerant Oil Information.............. 18-1830-2 R134a Refrigerant Recovery, Recycling, and Charging Station Installation Procedure............................ 18-1830-3 Recover R134a Refrigerant....................... 18-1830-3 Flush and Purge Air Conditioning System................................................... 18-1830-4 Evacuate R134a System ........................... 18-1830-5 Charge R134a System .............................. 18-1830-6 Evaporator or Heater Core Remove and Install .............................................. 18-1830-7 Expansion Valve Remove and Install ................................................... 18-1830-11 Blower Motor and Blower Motor Speed Resistor Remove and Install ................................................... 18-1830-12 Heater Disassemble and Assemble............................................. 18-1830-13 Under Seat Heater Remove and Install ................................................... 18-1830-14 Under Seat Heater Disassemble and Assemble...................................... 18-1830-15 Receiver-Dryer Remove and Install ................................................... 18-1830-16 Condenser Remove and Install ............... 18-1830-17 Compressor Remove and Install ............. 18-1830-18

TM14163X19 (15FEB18)

18-1

450K, 550K, and 650K Crawler Dozer

021518

PN=1

Contents

TM14163X19 (15FEB18)

18-2

450K, 550K, and 650K Crawler Dozer

021518

PN=2

Group 1800

Removal and Installation Operator’s Station Remove and Install 816 kg 1799 lb

Canopy Weight (approximate)

520 kg 1146 lb

Cab Mount Cap Screw Torque

620 N·m 457 lb·ft

TX1234208A —UN—21FEB17

SPECIFICATIONS Cab Weight (approximate)

SERVICE EQUIPMENT AND TOOLS JT05552 Lifting Eyebolts

MACHINE PREPARATION

Load Center Connections

1. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.)

X38— Load Center (IGC controls) Harness-to-Operator's Station Harness 31-Pin Connector X57— Load Center Harness-to-Operator's Station Harness 35-Pin Connector

2. Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch. (Operator’s Manual.) 3. Drain cooling system. See Drain and Refill Engine Cooling System. (Operator’s Manual.) CAUTION: Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves, and protective clothing.

X62— Load Center Harness-to-Operator's Station Harness 23-Pin Connector

Harness (W20) Component Location. (Group 9015-10.)

NOTE: Any time air conditioning system is discharged, a new receiver-dryer must be installed.

• For Integrated Grade Control (IGC) Machines

4. For Cab Machines Only: Recover refrigerant from air conditioning system. See Recover R134a Refrigerant. (Group 1830.)

With SmartGrade™: Disconnect electrical connector (X38). See Operator’s Station (SmartGrade™ and IGC Controls) Harness (W21) Component Location. (Group 9015-10.)

REMOVAL NOTE: This procedure applies to both cab and canopy configurations. 1. Install identification tags and disconnect electrical connectors (X57 and X62). See Operator’s Station SmartGrade is a trademark of Deere & Company JL48493,000037B -19-12DEC17-1/7

2. For Cab Machines Only: Disconnect washer fluid lines (1) at washer fluid reservoir and secure lines to operator’s station. TX1234215A —UN—21FEB17

1— Washer Fluid Line (2 used)

Washer Fluid Reservoir Continued on next page

TM14163X19 (15FEB18)

18-1800-1

JL48493,000037B -19-12DEC17-2/7

450K, 550K, and 650K Crawler Dozer 021518 PN=343

Removal and Installation

3. Disconnect hydraulic control connections: a. For IGC Control Machines:

• Install identification tags and disconnect winch

pressure light (H4), auxiliary electrical connector (2), and IGC lever electrical connectors (3). See Operator’s Station (SmartGrade™ and IGC Controls) Harness (W21) Component Location. (Group 9015-10.) TX1234244A —UN—21FEB17

b. For Mechanical Hydraulic Control Machines:

• Remove blade control lever handle (4) and auxiliary control lever handle (5).

• Remove cap screws (6) and cover plate (7). c. For Winch-Equipped Machines:

• Remove control knob (8). • Remove cap screws (9) and winch control guide

IGC Hydraulic Connections

plate (10).

7— Cover Plate 8— Control Knob 9— Cap Screw (4 used) 10— Winch Control Guide Plate H4—Winch Pressure Light

TX1114118A —UN—22MAY12

2— Auxiliary Electrical Connector 3— IGC Lever Electrical Connector (2 used) 4— Blade Control Lever Handle 5— Auxiliary Control Lever Handle 6— Cap Screw (5 used)

TX1114120A —UN—22MAY12

Hydraulic Control Handles

Control Linkage Continued on next page

TM14163X19 (15FEB18)

18-1800-2

JL48493,000037B -19-12DEC17-3/7

450K, 550K, and 650K Crawler Dozer 021518 PN=344

Removal and Installation

4. Remove floor plate from machine. See Remove Operator’s Station Floor Plate. (Operator’s Manual.) 5. Disconnect ground strap (11) from frame. 6. Install identification tags and disconnect heater hoses (12). Close all openings using caps and plugs. 12— Heater Hose (2 used) TX1234248A —UN—21FEB17

11— Ground Strap

Heater Hoses (under floor plate) JL48493,000037B -19-12DEC17-4/7

7. For Cab Machines Only:

• Remove left engine side shield. See Engine Side Shields Remove and Install. (Group 1910.)

• Install identification tags and disconnect air

TX1234250A —UN—21FEB17

conditioner lines (13). Close all openings using caps and plugs.

13— Air Conditioner Line (2 used)

Air Conditioner Lines Continued on next page

TM14163X19 (15FEB18)

18-1800-3

JL48493,000037B -19-12DEC17-5/7

450K, 550K, and 650K Crawler Dozer 021518 PN=345

Removal and Installation

8. Remove lower cab mounts (14) on both sides. 9. Remove panels covering upper cab mounts (15) inside the operator’s station. Remove upper cab mounts. 15— Upper Cab Mount (2 used)

TX1114173A —UN—22MAY12

14— Lower Cab Mount (2 used)

TX1115150A —UN—05JUN12

Mounting Cap Screw Location

Upper Cab Mount Continued on next page

TM14163X19 (15FEB18)

18-1800-4

JL48493,000037B -19-12DEC17-6/7

450K, 550K, and 650K Crawler Dozer 021518 PN=346

Removal and Installation

10. Install JT05552 Lifting Eyebolts (16) in top of operator’s station. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 11. Attach appropriate lifting device and remove operator’s station.

TX1114237A —UN—22MAY12

Specification Cab—Weight (approximate)................................................................................ 816 kg 1799 lb Canopy—Weight (approximate)................................................................................ 520 kg 1146 lb

INSTALLATION Installation is reverse of removal procedure.

• Tighten cab mount cap screws to specification. Specification Cab Mount Cap Screw—Torque............................................................................620 N·m 457 lb·ft

JT05552 Lifting Eyebolts 16— JT05552 Lifting Eyebolt (4 used)

• For Cab Machines:

- Install new receiver-dryer. See Receiver-Dryer Remove and Install. (Group 1830.) - Add oil. See R134a Refrigerant Oil Information. (Group 1830.) - Evacuate and charge the air conditioning system. See Evacuate R134a System and see Charge R134a System. (Group 1830.)

- Verify operation of air conditioning system. See Air Conditioner Check—If Equipped. (Group 9005-10.) • Fill cooling system. See Drain and Refill Engine Cooling System. (Operator’s Manual.) JL48493,000037B -19-12DEC17-7/7

TM14163X19 (15FEB18)

18-1800-5

450K, 550K, and 650K Crawler Dozer 021518 PN=347

Removal and Installation

TM14163X19 (15FEB18)

18-1800-6

450K, 550K, and 650K Crawler Dozer 021518 PN=348

Windowpanes Remove and Install

TM14163X19 (15FEB18)

TX1234662

TX1234662 —UN—28FEB17

18-1810-1

Continued on next page

10 11

Group 1810

021518

PN=349

450K, 550K, and 650K Crawler Dozer

Windowpane Assembly

Operator Enclosure

3 4

17 18

JL48493,000037C -19-13MAR17-1/2

Operator Enclosure

TM14163X19 (15FEB18)

18-1810-2

450K, 550K, and 650K Crawler Dozer 021518 PN=350

Operator Enclosure 1— Front Window 2— Rear Window 3— Heater Lines Cover 4— Cap Screw (4 used) 5— Air Conditioner Lines Cover

6— Screw (2 used) 7— Cover 8— Cap Screw (3 used) 9— Door Windowpane 10— Spacer 11— Door Handle 12— Spacer

13— Screw (2 used) 14— Latch 15— Sliding Windowpane 16— Seal 17— Nut (2 used) 18— Stationary Windowpane

Fixed Windowpanes: NOTE: Use this procedure to replace all rear/front windowpanes and door windowpanes. REMOVAL 1. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.) 2. Purchase urethane adhesive and appropriate primers from a local auto glass dealer. 3. If window frame is removable, remove frame from cab. 4. Fixed Cab Windowpanes:

19— Seal 20— Filler Vinyl Seal 21— Filler Vinyl Seal 22— Screw (2 used)

If an auto glass dealer is not installing the windowpanes, use the following procedure: IMPORTANT: Windowpanes must have an ultraviolet barrier around the edge of the glass since ultraviolet rays deteriorate the adhesive. Windowpanes ordered through John Deere Parts have the ultraviolet barrier. If the windowpane is purchased through a glass dealer, the dealer must put an ultraviolet barrier on the glass. DO NOT apply paint to the border of the glass. 1. Apply primers according to adhesive manufacturer's recommendations.

a. Remove front window wiper arms and rear window wiper motor (if equipped). See Window Wiper Motor Remove and Install. (Group 1810.)

2. Apply a 12.5 mm (1/2 in) bead of adhesive on top of the existing adhesive. Bead must be high enough to fill gap between frame and installed window.

b. Remove heater lines cover (3) and air conditioner lines cover (5).

3. Put the new windowpane into position. Use light hand pressure to force down windowpane around the edges until even with metal frame. DO NOT over press adhesive.

c. Remove front window (1) and rear window (2). 5. Door Windowpanes: a. Remove window wiper motors from doors. See Window Wiper Motor Remove and Install. (Group 1810.) b. Remove cover (7). c. Remove cap screws (8). Disconnect and remove door handle (11). d. Support and remove door windowpane (9).

4. If windowpane is installed directly on cab, use tape to hold it in place while adhesive cures. Allow adhesive to cure for 24 hours before operating machine. 5. Install cab and door hardware as shown. 6. Install window wiper motors. See Window Wiper Motor Remove and Install. (Group 1810.) Sliding Windowpanes: REMOVAL

6. Scrape broken glass off existing adhesive. DO NOT remove adhesive from window frame or cab.

1. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.)

7. Trim existing adhesive so it has a smooth surface.

2. Remove screws (22) and filler vinyl seals (20 and 21).

8. Inspect and clean both replacement glass and window frame. Use water with a mild detergent and allow to dry.

3. Remove seal (19) and stationary windowpane (18). 4. Remove screws (13) and latch (14).

INSTALLATION Use a urethane auto glass adhesive sealant to hold windowpanes in place. Also, use the primers that are recommended for the adhesive formulation, which has been selected. DO NOT use any other type of adhesive other than a urethane. It is also recommended that an auto glass dealer install the windowpanes.

5. Remove seal (16) and sliding windowpane (15). 6. Replace windowpanes as necessary. INSTALLATION Installation is reverse of removal procedure. JL48493,000037C -19-13MAR17-2/2

TM14163X19 (15FEB18)

18-1810-3

450K, 550K, and 650K Crawler Dozer 021518 PN=351

Operator Enclosure

Window Wiper Motor Remove and Install Door-Mounted Window Wiper Motor Remove and Install SPECIFICATIONS Shoulder Screw Nut (11) Torque

8 N·m 71 lb·in

Wiper Motor Nut (9) Torque

10 N·m 89 lb·in

Wiper Arm Nut (4) Torque

18 N·m 159 lb·in

TX1091120A —UN—25APR11

MACHINE PREPARATION NOTE: This procedure can be used for door-mounted window wiper motors and rear window wiper motor removal and installation. 1. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.) 2. Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch. (Operator’s Manual.)

Wiper Motor Cover

REMOVAL 1. Gently remove cover (1). 2. Disconnect washer hose (2) and electrical connector (3). 3— Electrical Connector

TX1091121A —UN—25APR11

1— Cover 2— Washer Hose

Wiper Motor Continued on next page

TM14163X19 (15FEB18)

18-1810-4

JL48493,0000375 -19-01MAR17-1/6

450K, 550K, and 650K Crawler Dozer 021518 PN=352

Operator Enclosure

NOTE: For ease of installation, note location of wiper arm (5) to wiper motor shaft. 3. Mark location of wiper arm to wiper motor and remove nut (4). 4. Gently remove wiper arm (5) from wiper motor.

4— Nut 5— Wiper Arm 6— Cover

TX1091122A —UN—25APR11

5. Remove cover (6). 7— Shoulder Screw With Nozzle 8— Shoulder Screw

Wiper Arm Continued on next page

TM14163X19 (15FEB18)

18-1810-5

JL48493,0000375 -19-01MAR17-2/6

450K, 550K, and 650K Crawler Dozer 021518 PN=353

Operator Enclosure

6. Remove nut (9) and retaining washer (10). 7. Support wiper motor. Remove nuts (11) and shoulder screws (7 and 8). Remove wiper motor. TX1091123A —UN—25APR11

INSTALLATION Installation is reverse of removal procedure.

• Tighten nuts to specification. Specification Shoulder Screw Nut (11)—Torque....................................................................................8 N·m 71 lb·in Wiper Motor Nut (9)—Torque...................................................................................10 N·m 89 lb·in Wiper Arm Nut (4)—Torque...................................................................................18 N·m 159 lb·in

Wiper Motor

• Verify operation of wiper motor. See Left and Right

Door Wiper Check or see Rear Wiper Check. (Group 9005-10.)

Front Window Wiper Motor Remove and Install 4 N·m 35 lb·in

Wiper Motor Nut (19) Torque

8 N·m 71 lb·in

TX1091124A —UN—25APR11

SPECIFICATIONS Wiper Motor Nut (14) Torque

Wiper Motor Shaft Nut (16) Torque 22 N·m 195 lb·in Wiper Arm (18) Torque

30 N·m 22 lb·ft

MACHINE PREPARATION Wiper Motor

1. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.) 9— Nut 10— Retaining Washer

2. Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch. (Operator’s Manual.)

11— Nut (2 used)

REMOVAL Continued on next page

TM14163X19 (15FEB18)

18-1810-6

JL48493,0000375 -19-01MAR17-3/6

450K, 550K, and 650K Crawler Dozer 021518 PN=354

Operator Enclosure

1. Remove rear view mirror (2). 2. Remove air conditioner cover (4).

1— Cap Screw (2 used) 2— Mirror 3— Cap Screw (2 used)

TX1091213A —UN—26APR11

3. Remove headliner bracket (6). 4— Air Conditioner Cover 5— Cap Screw (2 used) 6— Headliner Bracket

TX1233440A —UN—07FEB17

Mirror Removal

TX1091214A —UN—25APR11

Air Conditioner Cover

Headliner Bracket Continued on next page

TM14163X19 (15FEB18)

18-1810-7

JL48493,0000375 -19-01MAR17-4/6

450K, 550K, and 650K Crawler Dozer 021518 PN=355

Operator Enclosure

4. Remove screws (7) and headliner console (8). 5. Remove heater vents (10) to gain access to cap screws (12). 6. Remove cap screws (12), securing headliner (11) to cab roof. Lower headliner. 7. Disconnect front wiper motor (M2) electrical connection. 11— Headliner 12— Cap Screw (6 used) M2—Front Wiper Motor

TX1233441A —UN—07FEB17

7— Screw (4 used) 8— Headliner Console 9— Screw (12 used) 10— Heater Vent (6 used)

TX1091216A —UN—25APR11

Headliner Console

TX1233443A —UN—07FEB17

Headliner Cap Screws

Front Wiper Motor Continued on next page

TM14163X19 (15FEB18)

18-1810-8

JL48493,0000375 -19-01MAR17-5/6

450K, 550K, and 650K Crawler Dozer 021518 PN=356

Operator Enclosure

8. Disconnect washer hose (13) from cab. NOTE: For ease of installation, mark location of wiper arm (17) to wiper motor shaft before removal. 9. Mark location of wiper arm for installation. Remove nut (16) and gently remove wiper arm (17). 10. Remove cap (15) from wiper motor shaft. 11. Remove nut (14). 12. Disconnect wiper arm (18).

TX1233444A —UN—07FEB17

13. Remove nut (19) and remove front wiper motor. INSTALLATION Installation is reverse of removal procedure.

• Tighten nuts to specification.

Wiper Arm Removal

TX1233445A —UN—07FEB17

Specification Wiper Motor Nut (14)—Torque...................................................................................4 N·m 35 lb·in Wiper Motor Nut (19)—Torque...................................................................................8 N·m 71 lb·in Wiper Motor Shaft Nut (16)—Torque.................................................................................22 N·m 195 lb·in

• Tighten wiper arm (18) to specification. Specification Wiper Arm (18)—Torque................................................................30 N·m 22 lb·ft

• Verify operation of front window wiper. See Front Wiper Check. (Group 9005-10.)

Wiper Motor Removal 13— Washer Hose 14— Nut 15— Cap 16— Nut

17— Wiper Arm 18— Wiper Arm 19— Nut

JL48493,0000375 -19-01MAR17-6/6

TM14163X19 (15FEB18)

18-1810-9

450K, 550K, and 650K Crawler Dozer 021518 PN=357

Operator Enclosure

Window Washer Pumps Remove and Install 1. Drain window washer reservoir (5).

T208116A —UN—03MAY05

2. Disconnect window washer pump inlet (1) and outlet hose (2). 3. Disconnect window washer pump harness (6). 4. Remove window washer pump (3). 5. Install window washer pump. 6. Connect window washer pump inlet and outlet hoses. 7. Connect window washer pump harness.

Window Washer Pump Remove and Install

8. Fill window washer reservoir (5). 1— Hose (Window Washer Reservoir to Front/Rear Window Washer Pump Inlet) 2— Hose (Washer Pump Outlet-to-Front/Rear Windows 3— Front/Rear Window Washer Pump 4— Front/Rear Window Washer Pump Harness 5— Window Washer Reservoir

6— Left/Right Door Window Washer Pump Harness 7— Left/Right Door Window Washer Pump 8— Hose (Washer Pump Outlet-to-Right/Left Door Windows) 9— Hose (Window Washer Reservoir to Left/Right Door Window Washer Pump Inlet)

BS40810,000014C -19-17FEB15-1/1

TM14163X19 (15FEB18)

18-1810-10

450K, 550K, and 650K Crawler Dozer 021518 PN=358

Group 1821

Seat and Seat Belt Seat Remove and Install SPECIFICATIONS Seat Weight (approximate)

54 kg 120 lb

1. Remove cap screws (4) and armrests (1).

TX1180403A —UN—15DEC14

2. Disconnect electrical connector from air seat motor (M13). See Operator’s Station Harness (W20) Component Location. (Group 9015-10.) 3. Remove cap screws (3) from seat (2). CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 4. Attach appropriate lifting device to seat. Remove seat. Specification Seat—Weight (approximate).................................................................................. 54 kg 120 lb

Seat 1— Armrest (2 used) 2— Seat

5. Clean and inspect parts. Repair or replace as necessary. 6. Install seat and cap screws (3).

3— Cap Screw (4 used) 4— Cap Screw (4 used)

8. Install armrests and cap screws (4).

7. Connect electrical connector. BS40810,000014D -19-20JAN17-1/1

Replacing Seat Belt For information, see Replacing Seat Belt. (Operator’s Manual.) JL48493,0000378 -19-07FEB17-1/1

TM14163X19 (15FEB18)

18-1821-1

450K, 550K, and 650K Crawler Dozer 021518 PN=359

Seat and Seat Belt

TM14163X19 (15FEB18)

18-1821-2

450K, 550K, and 650K Crawler Dozer 021518 PN=360

Group 1830

Heating and Air Conditioning R134a Refrigerant Cautions and Proper Handling

If skin freezes to container, pour COOL water over container to free the skin. Go to a physician or hospital immediately for treatment.

SERVICE EQUIPMENT AND TOOLS Refrigerant Identifier

CAUTION: DO NOT allow liquid refrigerant to contact eyes or skin. Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves, and protective clothing. If liquid refrigerant contacts eyes or skin, DO NOT rub the area. Splash large amounts of COOL water on affected area. Go to a physician or hospital immediately for treatment.

IMPORTANT: To meet government standards relating to the use of refrigerants, R134a is used in the air conditioning system. Because it does not contain chlorine, R134a is not detrimental to the ozone in the atmosphere. However, it is illegal to discharge any refrigerant into the atmosphere. It must be recovered using the appropriate recovery stations. Use correct refrigerant recovery, recycling, and charging stations. Do not mix refrigerants, hoses, fittings, components, or refrigerant oils.

DO NOT allow refrigerant to contact open flames or very hot surfaces such as electric welding arc, electric heating element, and lighted smoking materials.

Use only John Deere approved R134a refrigerant products. Mixing of products not compatible will cause system damage and contaminate recovery, recycling, and charging station equipment. Care must be taken to identify and use equipment, refrigerant oil, and refrigerant designed only for R134a refrigerant systems. Refrigerant should be tested for type and purity before recovery, recycling, or charging of system. Refrigerant identifier should be used before any testing or repair to system is performed.

DO NOT heat refrigerant over 52°C (125°F) in a closed container. Heated refrigerant will develop high pressure which can burst the container. Keep refrigerant containers away from heat sources. Store refrigerant in a cool place. DO NOT handle damp refrigerant container with bare hands. Skin may freeze to container. Wear gloves.

AB06447,0000CB9 -19-20OCT16-1/2

Refrigerant Identifier

Used to safely and correctly identify type and check purity of refrigerant prior to recovery, recycling, and charging of air conditioning systems. AB06447,0000CB9 -19-20OCT16-2/2

TM14163X19 (15FEB18)

18-1830-1

450K, 550K, and 650K Crawler Dozer 021518 PN=361

Heating and Air Conditioning

R134a Refrigerant Oil Information

b. Remove and discard receiver-dryer. See Receiver-Dryer Remove and Install. (Group 1830.)

SPECIFICATIONS Compressor Oil Volume

160 mL 5.41 fl oz

System Oil Volume

264.9 mL 8.95 fl oz

c. Remove, clean, but do not disassemble expansion valve. See Expansion Valve Remove and Install. (Group 1830.) d. Flush complete system, if needed. See Flush and Purge Air Conditioning System. (Group 1830.)

OTHER MATERIAL TY22101 R134a Compressor Oil

e. If compressor is serviceable, pour flushing solvent in manifold ports and internally wash out old oil.

If installing a new compressor, make sure oil level is visible through suction port. Oil level is normally below drive shaft.

f. Install expansion valve. See Expansion Valve Remove and Install. (Group 1830.)

Normal operating oil level of compressor removed from operation cannot be seen through suction port of compressor. Compressors can be divided into three categories when determining correct oil charge for system:

• New compressor • Used compressor removed from operation • Compressor internally washed with flushing solvent

g. Install new receiver-dryer. See Receiver-Dryer Remove and Install. (Group 1830.) 7. Install compressor. See Compressor Remove and Install. (Group 1830.) IMPORTANT: Prevent possible air conditioning system damage. Do not add any more oil than required or maximum cooling will be reduced. Do not leave system or R134a compressor oil containers open. Refrigerant oil easily absorbs moisture. Do not spill R134a compressor oil on acrylic or ABS plastic. This oil will deteriorate these materials rapidly. Identify R134a oil containers and measures to eliminate accidental mixing of different oils.

CAUTION: Avoid possible injury. All new compressors are charged with a mixture of nitrogen, R134a refrigerant, and R134a refrigerant oil. Wear safety goggles and discharge compressor slowly. 1. Handle refrigerant carefully. See R134a Refrigerant Cautions and Proper Handling. (Group 1830.) 2. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.) 3. Remove and repair or replace compressor. See Compressor Remove and Install. (Group 1830.) 4. Drain oil into graduated container while rotating compressor shaft if a new compressor is required. 5. Record measured oil and discard oil properly. 6. If oil drained from a compressor removed from operation is very black or amount of oil is less than specification, perform the following: Specification Compressor Oil—Volume................................................................................. 160 mL 5.41 fl oz

8. Add required amount of R134a compressor oil. If any section of hose is removed and flushed or replaced, measure length of hose and use formula 3 mL per 30 cm (0.1 fl oz per ft) to determine correct amount of oil to be added. Specification Compressor Oil—Volume................................................................................. 160 mL 5.41 fl oz System Oil—Volume................................................................. 264.9 mL 8.95 fl oz

9. Connect all components. 10. Evacuate air conditioning system. See Evacuate R134a System. (Group 1830.) 11. Charge R134a air conditioning system. See Charge R134a System. (Group 1830.)

a. Determine if R134a leakage was detected. See R134a Refrigerant Leak Test. (Group 9031-25.) JL48493,000036C -19-10MAR17-1/1

TM14163X19 (15FEB18)

18-1830-2

450K, 550K, and 650K Crawler Dozer 021518 PN=362

Heating and Air Conditioning

R134a Refrigerant Recovery, Recycling, and Charging Station Installation Procedure

CAUTION: Avoid possible injury. Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves, and protective clothing. 1. Handle refrigerant carefully. See R134a Refrigerant Cautions and Proper Handling. (Group 1830.) 2. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.) CAUTION: Avoid possible injury. Do not remove high-pressure relief valve. Air conditioning system will discharge.

TX1153908 —UN—18FEB14

IMPORTANT: Prevent possible air conditioning system contamination. Use correct refrigerant recovery, recycling, and charging station. Do not mix refrigerant, hoses, fittings, components, or refrigerant oils.

Refrigerant Recovery, Recycling, and Charging Station

3. Close both high and low-pressure valves on refrigerant recovery, recycling, and charging station (5).

1— Cap (2 used) 2— Low Side Pressure (blue) Hose 3— High Side Pressure (red) Hose

4. Remove caps (1) from test ports. 5. Connect low side pressure (blue) hose (2) from refrigerant recovery, recycling, and charging station to low-pressure test port on compressor.

4— Air Conditioner Compressor 5— Refrigerant Recovery, Recycling, and Charging Station

7. Follow manufacturer’s instructions when using refrigerant recovery, recycling, and charging station.

6. Connect high side pressure (red) hose (3) to high-pressure test port on compressor.

JL48493,000036D -19-10MAR17-1/1

Recover R134a Refrigerant

high-pressure relief valve. Air conditioning system will discharge rapidly.

CAUTION: Prevent possible injury. Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves, and protective clothing. 1. Handle refrigerant carefully. See R134a Refrigerant Cautions and Proper Handling. (Group 1830.) 2. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.) 3. Run air conditioning system for 3 minutes to help in recovery process. 4. Turn air conditioning system off before proceeding with recovery steps.

IMPORTANT: Prevent possible air conditioning system damage. Use correct refrigerant recovery, recycling, and charging stations. Do not mix refrigerant, hoses, fittings, components, or refrigerant oils. 5. With engine OFF, connect refrigerant recovery, recycling, and charging station. See R134a Refrigerant Recovery, Recycling, and Charging Station Installation Procedure. (Group 1830.) 6. Follow manufacturer’s instructions when using refrigerant recovery, recycling, and charging station.

CAUTION: Avoid possible injury from air conditioning system refrigerant. Do not remove AS79221,0000598 -19-08DEC16-1/1

TM14163X19 (15FEB18)

18-1830-3

450K, 550K, and 650K Crawler Dozer 021518 PN=363

Heating and Air Conditioning

Flush and Purge Air Conditioning System SPECIFICATIONS Air Pressure Minimum Pressure (for flushing and purging)

NOTE: Purging condenser circuit takes 10—12 minutes to thoroughly remove solvent.

620 kPa 6.2 bar 90 psi

Additional flushing cycles are required if system is heavily contaminated with burned oil or metal particles.

ESSENTIAL TOOLS TY25601 Cooling System Cleaner JT02075 Air Conditioner Flusher

4. Disconnect hose from aeration nozzle to check circuit for cooling system cleaner. Hold hose close to piece of cardboard; continue purging until cardboard is dry.

Procedure Set-Up CAUTION: Prevent possible injury. Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves, and protective clothing. 1. Handle refrigerant carefully. See R134a Refrigerant Cautions and Proper Handling. (Group 1830.) 2. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.) 3. Recover refrigerant from system. See Recover R134a Refrigerant. (Group 1830.) IMPORTANT: Do not attempt to flush through compressor or receiver-dryer. Flushing solution may not be completely removed from components and could cause system malfunction.

5. Dispose of cooling system cleaner properly. Evaporator and Expansion Valve Flush and Purge 1. Add TY25601 Cooling System Cleaner and connect JT02075 Air Conditioner Flusher outlet hose to receiver-dryer outlet hose using appropriate adapter. 2. Attach hose and aerator nozzle to compressor inlet line using appropriate adapter. Put nozzle in container to collect cooling system cleaner. 3. Open air valve to force cooling system cleaner into condenser circuit. Air pressure must be at least to specification for flushing and purging.

4. Remove compressor. See Compressor Remove and Install. (Group 1830.)

Specification Air Pressure—Minimum Pressure (for flushing and purging)....................................................................................... 620 kPa 6.2 bar 90 psi

NOTE: Any time air conditioning system is discharged, a new receiver-dryer must be installed.

NOTE: Purging condenser circuit takes 10—12 minutes to thoroughly remove solvent.

5. Remove and discard receiver-dryer. See Receiver-Dryer Remove and Install. (Group 1830.)

Additional flushing cycles are required if system is heavily contaminated with burned oil or metal particles.

Condenser Flush and Purge 1. Add TY25601 Cooling System Cleaner and connect JT02075 Air Conditioner Flusher outlet hose to inlet end of compressor discharge line using appropriate adapter. 2. Attach return hose and aerator nozzle to end of receiver-dryer inlet hose using appropriate adapter. Put nozzle in container to collect cooling system cleaner. 3. Open air valve to force cooling system cleaner into condenser circuit. Air pressure must be at least to specification for flushing and purging. Specification Air Pressure—Minimum Pressure (for flushing and purging)....................................................................................... 620 kPa 6.2 bar 90 psi

4. Disconnect hose from aeration nozzle to check circuit for cooling system cleaner. Hold hose close to piece of cardboard; continue purging until cardboard is dry. 5. Dispose of cooling system cleaner properly. Procedure Wrap-Up 1. Install new receiver-dryer. See Receiver-Dryer Remove and Install. (Group 1830.) 2. Add required oil. See R134a Refrigerant Oil Information. (Group 1830.) 3. Install compressor. See Compressor Remove and Install. (Group 1830.) 4. Charge system. See Charge R134a System. (Group 1830.)

JL48493,000036E -19-10MAR17-1/1

TM14163X19 (15FEB18)

18-1830-4

450K, 550K, and 650K Crawler Dozer 021518 PN=364

Heating and Air Conditioning

Evacuate R134a System

from 98 kPa (980 mbar) (29 in Hg) for each 300 m (1000 ft) elevation above sea level.

SPECIFICATIONS Vacuum Pressure at Sea Level

98 kPa 980 mbar 29 in Hg

Vacuum Pressure Above Sea Level

Subtract 3.4 kPa from 98 kPa for each 300 m elevation Subtract 34 mbar from 980 mbar for each 300 m elevation Subtract 1 in Hg from 29 in Hg for each 1000 ft elevation

6. Evacuate system until low-pressure gauge registers specified vacuum. If specified vacuum cannot be obtained in 15 minutes, a leak may be present. Locate and repair leak. See R134a Refrigerant Leak Test. (Group 9031-25.)

1. Handle refrigerant carefully. See R134a Refrigerant Cautions and Proper Handling. (Group 1830.)

Specification Vacuum—Pressure at Sea Level...................................................................................... 98 kPa 980 mbar 29 in Hg Pressure Above Sea Level ..................................................................... Subtract 3.4 kPa from 98 kPa for each 300 m elevation Subtract 34 mbar from 980 mbar for each 300 m elevation Subtract 1 in Hg from 29 in Hg for each 1000 ft elevation

2. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.)

7. When vacuum reaches specified level, close low side and high side valves. Turn vacuum pump off.

CAUTION: Avoid possible injury from air conditioning system refrigerant. Do not remove high-pressure relief valve. Air conditioning system will discharge rapidly.

8. If vacuum decreases more than specified amount in 5 minutes, there is a leak in system.

Leak Present Decrease in Vacuum 3.4 kPa 34 mbar 1 in Hg

CAUTION: Prevent possible injury. Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves, and protective clothing.

IMPORTANT: Prevent possible air conditioning system damage. Use correct refrigerant recovery, recycling, and charging stations. Do not mix refrigerant, hoses, fittings, components, or refrigerant oils. 3. Connect refrigerant recovery, recycling, and charging station. See R134a Refrigerant Recovery, Recycling, and Charging Station Installation Procedure. (Group 1830.) 4. Open low and high-pressure valves on refrigerant recovery, recycling, and charging station.

Specification Leak Present—Decrease in Vacuum..................................................................................... 3.4 kPa 34 mbar 1 in Hg

9. Locate and repair leak. See R134a Refrigerant Leak Test. (Group 9031-25.) 10. Start evacuation. Open low side and high side valves. 11. Evacuate system for 30 minutes after initial specified vacuum is reached. 12. Stop evacuation. Close low side and high side valves. 13. Charge system. See Charge R134a System. (Group 1830.)

5. Follow manufacturer’s instructions and evacuate system. NOTE: Vacuum specifications listed are for sea level conditions. Subtract 3.4 kPa (34 mbar) (1 in Hg) AS79221,000059A -19-07NOV17-1/1

TM14163X19 (15FEB18)

18-1830-5

450K, 550K, and 650K Crawler Dozer 021518 PN=365

Heating and Air Conditioning

Charge R134a System

and Charging Station Installation Procedure. (Group 1830.)

SPECIFICATIONS Evacuate System Vacuum

Air Conditioning System Refrigerant Charge Weight

Subtract 3.4 kPa from 98 kPa for each 300 m elevation above sea level Subtract 34 mbar from 980 mbar for each 300 m elevation above sea level Subtract 1 in Hg from 29 in Hg for each 1000 ft elevation above sea level 1.72 kg 3.8 lb

CAUTION: Prevent possible injury. Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves, and protective clothing. 1. Handle refrigerant carefully. See R134a Refrigerant Cautions and Proper Handling. (Group 1830.) 2. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.) CAUTION: Avoid possible injury from air conditioning system refrigerant. Do not remove high-pressure relief valve. Air conditioning system will discharge rapidly. IMPORTANT: Use correct refrigerant recovery, recycling, and charging stations. Do not mix refrigerant, hoses, fittings, components, or refrigerant oils.

4. Evacuate system. See Evacuate R134a System. (Group 1830.) NOTE: Before beginning to charge air conditioning system, the following conditions must exist: Engine STOPPED, the pump must be capable of pulling at least 28.6 in Hg vacuum (sea level). Subtract 3.4 kPa (34 mbar) (1 in Hg) from 98 kPa (980 mbar) (29 in Hg) for each 300 m (1000 ft) elevation above sea level. Specification Evacuate System—Vacuum........................ Subtract 3.4 kPa from 98 kPa for each 300 m elevation above sea level Subtract 34 mbar from 980 mbar for each 300 m elevation above sea level Subtract 1 in Hg from 29 in Hg for each 1000 ft elevation above sea level

5. Follow manufacturer’s instructions and charge system. 6. Add refrigerant until system is charged to specification. Specification Air Conditioning System Refrigerant—Charge Weight.......................................................................................... 1.72 kg 3.8 lb

7. Perform air conditioning check. See Operational Checkout. (Group 9005-10.)

3. Connect refrigerant recovery, recycling, and charging station. See R134a Refrigerant Recovery, Recycling, JL48493,000036F -19-10MAR17-1/1

TM14163X19 (15FEB18)

18-1830-6

450K, 550K, and 650K Crawler Dozer 021518 PN=366

Heating and Air Conditioning

Evaporator or Heater Core Remove and Install 26 kg 57 lb

Expansion Valve Cap Screw (7) Torque

5.5 N·m 49 lb·in

Expansion Valve Cap Screw (16) Torque

4.5—5.1 N·m 40—45 lb·in TX1232951A —UN—30JAN17

SPECIFICATIONS Heating and Air Conditioning Unit Weight (approximate)

Heating and Air Conditioning System Covers 1— Condenser Housing Cover 2— Cap Screw (10 used) 3— Cap Screw (4 used)

3. Recover air conditioning system. See Recover R134a Refrigerant. (Group 1830.)

4— Side Cover (2 used) 5— Cap Screw (6 used) 6— Filter Cover

REMOVAL 1. Remove filter cover (6) and filter.

4. Remove side covers (4).

2. Remove cap screws (5) to disconnect heating and air conditioning unit from cab frame. 3. Remove cap screws (2) and lower condenser housing cover (1). Continued on next page

TM14163X19 (15FEB18)

18-1830-7

JL48493,0000372 -19-02MAR17-1/4

450K, 550K, and 650K Crawler Dozer 021518 PN=367

Heating and Air Conditioning

5. Remove adapter plate (8). Install identification tags and disconnect evaporator core lines (9). Close all openings using caps and plugs. 6. Install identification tags and disconnect air conditioner high/low-pressure switch (B32). 7. Disconnect drain hoses (10). 8. Install identification tags and disconnect heater core lines (11). Close all openings using caps and plugs.

7— Cap Screw 8— Adapter Plate 9— Evaporator Core Line (2 used) 10— Drain Hose (2 used)

TX1233228A —UN—08FEB17

9. Remove cap screws (12) to disconnect the heating and air conditioning unit brackets. 11— Heater Core Line (2 used) 12— Cap Screw (2 used) B32— Air Conditioner High/Low-Pressure Switch

TX1233240A —UN—07FEB17

Evaporator Core Lines

Heater Core Lines Continued on next page

TM14163X19 (15FEB18)

18-1830-8

JL48493,0000372 -19-02MAR17-2/4

450K, 550K, and 650K Crawler Dozer 021518 PN=368

Heating and Air Conditioning

TX1233250A —UN—07FEB17

10. Install identification tags and disconnect the heater and air conditioner harness connector (X35) and condenser harness connector (X65). See Heater and Air Conditioner Harness (W27) Component Location. (Group 9015-10.) CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 11. Attach appropriate lifting device and remove the heating and air conditioning unit from the machine. Specification Heating and Air Conditioning Unit—Weight (approximate).................................................................................. 26 kg 57 lb

Heater and Air Conditioner Connections X35— Heater and Air Conditioner Harness Connector

Continued on next page

TM14163X19 (15FEB18)

18-1830-9

X65— Condenser Harness Connector

JL48493,0000372 -19-02MAR17-3/4

450K, 550K, and 650K Crawler Dozer 021518 PN=369

Heating and Air Conditioning

12. Disconnect sensor probe (15) and remove top cover (14). 13. Remove cap screws (16), expansion valve (17), and adapter plate (18). 14. Remove heater core (19) or evaporator core (20). INSTALLATION

TX1233275A —UN—08FEB17

Installation is reverse of removal procedure.

• Tighten expansion valve cap screws (7 and 16) to specification.

Specification Expansion Valve Cap Screw (7)—Torque.......................................................................5.5 N·m 49 lb·in Expansion Valve Cap Screw (16)—Torque............................................................ 4.5—5.1 N·m 40—45 lb·in

Heating and Air Conditioning Unit

• Install new receiver-dryer. See Receiver-Dryer Remove and Install. (Group 1830.)

• Add oil. See R134a Refrigerant Oil Information. (Group 1830.)

• Evacuate and charge the air conditioning system.

13— Cap Screw (17 used) 14— Top Cover 15— Sensor Probe 16— Cap Screw (2 used)

TX1233282A —UN—08FEB17

See Evacuate R134a System and see Charge R134a System. (Group 1830.) • Verify operation of air conditioning system. See Air Conditioner Check—If Equipped. (Group 9005-10.) 17— Expansion Valve 18— Adapter Plate 19— Heater Core 20— Evaporator Core

Evaporator and Heater Core JL48493,0000372 -19-02MAR17-4/4

TM14163X19 (15FEB18)

18-1830-10

450K, 550K, and 650K Crawler Dozer 021518 PN=370

Heating and Air Conditioning

Expansion Valve Remove and Install 5.5 N·m 49 lb·in

Expansion Valve Cap Screw (8) Torque

4.5—5.1 N·m 40—45 lb·in

TX1233319A —UN—07FEB17

SPECIFICATIONS Expansion Valve Cap Screw (3) Torque

Expansion Valve Cover 1— Cap Screw (2 used)

2— Cover

REMOVAL NOTE: Any time air conditioning system is discharged, a new receiver-dryer must be installed. 1. Remove cover (2). JL48493,0000373 -19-02MAR17-1/2

2. Remove adapter plate (4). Install identification tags and disconnect evaporator core lines (5). Close all openings using caps and plugs. 3. Remove cap screws (8) and disconnect expansion valve (7) from adapter plate (6) and evaporator core. INSTALLATION Installation is reverse of removal procedure. TX1233320A —UN—07FEB17

• Tighten expansion valve cap screws (3 and 8) to specification.

Specification Expansion Valve Cap Screw (3)—Torque.......................................................................5.5 N·m 49 lb·in Expansion Valve Cap Screw (8)—Torque.............................................................. 4.5—5.1 N·m 40—45 lb·in

Expansion Valve

3— Cap Screw 4— Adapter Plate 5— Evaporator Core Line (2 used)

TX1233321A —UN—07FEB17

• Install new receiver-dryer. See Receiver-Dryer Remove and Install. (Group 1830.) • Add oil. See R134a Refrigerant Oil Information. (Group 1830.) • Evacuate and charge the air conditioning system. See Evacuate R134a System and see Charge R134a System. (Group 1830.) • Verify operation of air conditioning system. See Air Conditioner Check—If Equipped. (Group 9005-10.) 6— Adapter Plate 7— Expansion Valve 8— Cap Screw (2 used) Expansion Valve

JL48493,0000373 -19-02MAR17-2/2

TM14163X19 (15FEB18)

18-1830-11

450K, 550K, and 650K Crawler Dozer 021518 PN=371

Heating and Air Conditioning

Blower Motor and Blower Motor Speed Resistor Remove and Install MACHINE PREPARATION TX1178556A —UN—26NOV14

Condenser Housing Cover

2. Remove blower motor cover (4). 3— Cap Screw (8 used) 4— Blower Motor Cover TX1233030A —UN—31JAN17

1— Cap Screw (10 used) 2— Condenser Housing Cover

Blower Motor Cover JL48493,0000370 -19-01MAR17-1/2

3. Install identification tags and disconnect electrical connectors (5) from blower motor (M12) and blower motor speed resistor (R5). TX1233031A —UN—31JAN17

4. Remove bracket (7), blower motor speed resistor, and blower motor. 5. From back side of blower motor, remove cap screws (8) and blower motor speed resistor. INSTALLATION Installation is reverse of removal procedure.

• Verify operation of blower motor. See Heater Blower Motor Check. (Group 9005-10.)

8— Cap Screw (2 used) M12— Blower Motor R5—Blower Motor Speed Resistor TX1233037A —UN—31JAN17

5— Electrical Connector (4 used) 6— Cap Screw (3 used) 7— Bracket

Blower Motor

Blower Motor JL48493,0000370 -19-01MAR17-2/2

TM14163X19 (15FEB18)

18-1830-12

450K, 550K, and 650K Crawler Dozer 021518 PN=372

Heating and Air Conditioning

Heater Disassemble and Assemble DISASSEMBLE

6 5

4 3

7 8

2 1

4 12 9

15 16

27 25

26 17 24

18 20 TX1233574 —UN—08FEB17

TX1233574 Heating and Air Conditioning Unit Continued on next page

TM14163X19 (15FEB18)

18-1830-13

JL48493,0000376 -19-01MAR17-1/2

450K, 550K, and 650K Crawler Dozer 021518 PN=373

Heating and Air Conditioning 1— Cap Screw (8 used) 2— Blower Motor Cover 3— Top Cover 4— Cap Screw (7 used) 5— Isolator 6— Foam Seal 7— Cap Screw (6 used) 8— Heater Core

9— Evaporator Core 10— Adapter Plate 11— O-Ring 12— O-Ring 13— Expansion Valve 14— Cap Screw (2 used) 15— Cap Screw (6 used) 16— Drain Pan

1. Remove heating and air conditioning unit. See Evaporator or Heater Core Remove and Install. (Group 1830.) 2. Disassemble components as shown.

17— Recirculation Filter 18— Isolator 19— Bottom Cover 20— Air Filter 21— Cap Screw (4 used) 22— Blower Motor Panel 23— Blower Motor

24— Cap Screw (3 used) 25— Bracket 26— Cap Screw 27— Freeze Control Switch 28— Grommet 29— Resistor

ASSEMBLE Assemble components as shown.

• Install heating and air conditioning unit. See Evaporator or Heater Core Remove and Install. (Group 1830.)

JL48493,0000376 -19-01MAR17-2/2

Under Seat Heater Remove and Install MACHINE PREPARATION TX1233630A —UN—10FEB17

1. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.) 2. Turn battery disconnect switch to OFF position. See Battery Disconnect Switch. (Operator’s Manual.) 3. Drain engine coolant. See Drain and Refill Engine Cooling System. (Operator's Manual.) REMOVAL 1. Remove operator’s station floor plate. See Remove Operator’s Station Floor Plate. (Operator’s Manual.)

Under Seat Heater Harness Connector

2. Remove seat. See Seat Remove and Install. (Group 1821.) TX1233631A —UN—10FEB17

3. Install identification tags and disconnect under seat heater harness connector (X54). See Operator’s Station Harness (W20) Component Location or see Under Seat Heater Harness (W29) Component Location. (Group 9015-10.) 4. Remove seat pan (2). 5. Install identification tags and disconnect under seat heater hoses (3). Close all openings using caps and plugs.

Seat Pan

6. Remove under seat heater unit from cab. INSTALLATION TX1233632A —UN—10FEB17

Installation is reverse of removal procedure.

• Fill engine coolant. See Drain and Refill Engine Cooling System. (Operator's Manual.)

• Verify operation of under seat heater. See Under Seat Heater Check. (Group 9005-10.)

1— Cap Screw (6 used) 2— Seat Pan

3— Under Seat Heater Hose (2 used) X54— Under Seat Heater Harness Connector

Under Seat Heater Hoses

JL48493,0000379 -19-07FEB17-1/1

TM14163X19 (15FEB18)

18-1830-14

450K, 550K, and 650K Crawler Dozer 021518 PN=374

Heating and Air Conditioning

Under Seat Heater Disassemble and Assemble DISASSEMBLE

3 3 2 4 5

1 12

13 12 3

11 10 9

TX1233594 —UN—08FEB17

8 6

TX1233594

Under Seat Heater 1— Heater Core 2— Bracket 3— Gasket Kit 4— Cap Screw (4 used)

5— Blower Motor 6— Cap Screw (2 used) 7— Backing Plate 8— Heater Tray

9— Cap Screw (4 used) 10— Resistor 11— Cap Screw (2 used) 12— Grommet (2 used)

13— Under Seat Heater Harness

1. Remove under seat heater unit from cab. See Under Seat Heater Remove and Install. (Group 1830.)

ASSEMBLE

2. Disassemble components as shown.

Assemble components as shown.

3. Clean and inspect parts. Repair or replace as necessary.

• Install under seat heater unit. See Under Seat Heater Remove and Install. (Group 1830.)

JL48493,0000377 -19-01MAR17-1/1

TM14163X19 (15FEB18)

18-1830-15

450K, 550K, and 650K Crawler Dozer 021518 PN=375

Heating and Air Conditioning

Receiver-Dryer Remove and Install NOTE: Any time air conditioning system is discharged, a new receiver-dryer must be installed. TX1233319A —UN—07FEB17

Receiver-Dryer Cover

REMOVAL 1— Cap Screw (2 used)

2— Cover

1. Remove cover (2). JL48493,0000374 -19-06MAR17-1/2

2. Install identification tags and disconnect refrigerant hoses (3 and 4). Close all openings using caps and plugs. 3. Remove clamps (6) and remove receiver-dryer (5). INSTALLATION Installation is reverse of removal procedure.

• Add oil. See R134a Refrigerant Oil Information. (Group 1830.)

• Evacuate and charge the air conditioning system.

See Evacuate R134a System and see Charge R134a System. (Group 1830.) • Verify operation of air conditioning system. See Air Conditioner Check—If Equipped. (Group 9005-10.) 6— Clamp (2 used) 7— Cap Screw (2 used) TX1233355A —UN—07FEB17

3— Receiver-Dryer-toCondenser Hose 4— Evaporator-to-ReceiverDryer Hose 5— Receiver-Dryer

Receiver-Dryer JL48493,0000374 -19-06MAR17-2/2

TM14163X19 (15FEB18)

18-1830-16

450K, 550K, and 650K Crawler Dozer 021518 PN=376

Heating and Air Conditioning

Condenser Remove and Install REMOVAL TX1178556A —UN—26NOV14

NOTE: Any time air conditioning system is discharged, a new receiver-dryer must be installed. 1. Recover the air conditioning system. See Recover R134a Refrigerant. (Group 1830.) 2. Remove cap screws (1) and lower condenser housing cover (2). 1— Cap Screw (10 used)

2— Condenser Housing Cover

Condenser Housing Cover JL48493,0000371 -19-01MAR17-1/2

3. Install identification tags and disconnect condenser lines (3) and condenser harness connector (X65). Close all openings using caps and plugs. See Heater and Air Conditioner Harness (W27) Component Location. (Group 9015-10.) 4. Remove condenser (4). INSTALLATION TX1233175A —UN—02FEB17

Installation is reverse of removal procedure.

• Install new receiver-dryer. See Receiver-Dryer Remove and Install. (Group 1830.)

• Add compressor oil. See R134a Refrigerant Oil Information. (Group 1830.)

• Evacuate and charge the air conditioning system.

See Evacuate R134a System and see Charge R134a System. (Group 1830.) Condenser

3— Condenser Line (2 used) 4— Condenser

5— Cap Screw (6 used) X65— Condenser Harness Connector JL48493,0000371 -19-01MAR17-2/2

TM14163X19 (15FEB18)

18-1830-17

450K, 550K, and 650K Crawler Dozer 021518 PN=377

Heating and Air Conditioning

Compressor Remove and Install SPECIFICATIONS Refrigerant Line Torque

10 N·m 89 lb·in

MACHINE PREPARATION TX1113499A —UN—05JUN12

1. Park and prepare machine for service safely. See Park and Prepare for Service Safely. (Group 0001.) 2. Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch. (Operator’s Manual.) CAUTION: Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves, and protective clothing. Air Conditioner Compressor Mounting

3. Recover refrigerant from air conditioning system. See Recover R134a Refrigerant. (Group 1830.) REMOVAL

1— Belt 3— Refrigerant Line (2 used) 4— Cap Screw (3 used)

NOTE: Any time air conditioning system is discharged, a new receiver-dryer must be installed. 1. Remove engine side shield. See Engine Side Shields Remove and Install. (Group 1910.) 2. Remove serpentine belt. See Inspect or Replace Belt and Check Automatic Belt Tensioner. (Operator’s Manual.) 3. Disconnect air conditioner compressor clutch solenoid (Y14) electrical connector. See Engine Auxiliary Harness (W9) Component Location. (Group 9015-10.) 4. Install identification tags and disconnect refrigerant lines (3). Close all openings using caps and plugs. 5. Remove cap screws (4) and remove air conditioner compressor (5). 6. Replace air conditioner compressor as needed. INSTALLATION Installation is reverse of removal procedure.

5— Air Conditioner Compressor Y14— Air Conditioner Compressor Clutch Solenoid

IMPORTANT: Prevent possible damage to compressor. Damaged or used O-rings and seals will leak. Always use new O-rings and seals.

• Using new O-rings, tighten refrigerant lines to specification.

Specification Refrigerant Line—Torque.................................................................................10 N·m 89 lb·in

• Install new receiver-dryer. See Receiver-Dryer Remove and Install. (Group 1830.)

• Evacuate and charge the air conditioning system.

See Evacuate R134a System and see Charge R134a System. (Group 1830.) • Verify operation of the air conditioning system. See Air Conditioner Check—If Equipped. (Group 9005-10.) JL48493,000037A -19-01MAR17-1/1

TM14163X19 (15FEB18)

18-1830-18

450K, 550K, and 650K Crawler Dozer 021518 PN=378

Section 19 Sheet Metal and Styling Contents Page

Group 1910—Hood or Engine Enclosure Hood Remove and Install .......................... 19-1910-1 Engine Side Shields Remove and Install ..................................................... 19-1910-2 Group 1913—Miscellaneous Shields Rear Sheet Metal Remove and Install ..................................................... 19-1913-1 Group 1921—Grille and Grille Housing Grille Remove and Install .......................... 19-1921-1

TM14163X19 (15FEB18)

19-1

450K, 550K, and 650K Crawler Dozer

021518

PN=1

Contents

TM14163X19 (15FEB18)

19-2

450K, 550K, and 650K Crawler Dozer

021518

PN=2

Group 1910

Hood or Engine Enclosure Hood Remove and Install SPECIFICATIONS Hood Weight (approximate)

39 kg 86 lb

REMOVAL 1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) TX1232016A —UN—11JAN17

2. Remove engine side shields. See Engine Side Shields Remove and Install. (Group 1910.) 3. Open access door (3). 4. Install identification tags and disconnect electrical connectors from left front drive light (E2) and right front drive light (E3). 5. Remove cap screws (2) from hood (1).

Hood

CAUTION: Prevent possible crushing injury from heavy component. Use an appropriate lifting device.

1— Hood 2— Cap Screw (8 used) 3— Access Door

E2— Left Front Drive Light E3— Right Front Drive Light

6. Attach appropriate lifting device and remove hood. Specification Hood—Weight (approximate).................................................................................. 39 kg 86 lb

INSTALLATION Installation is reverse of removal procedure.

7. Clean and inspect parts. Repair or replace as necessary. JL05046,000026B -19-12JAN17-1/1

TM14163X19 (15FEB18)

19-1910-1

450K, 550K, and 650K Crawler Dozer 021518 PN=381

Hood or Engine Enclosure

Engine Side Shields Remove and Install REMOVAL 1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Operator’s Manual.) 2. Remove cap screws (2) and engine side shields (1). 3. Clean and inspect parts. Repair or replace as necessary. INSTALLATION Installation is reverse of removal procedure. 2— Cap Screw (23 used)

TX1232272A —UN—19JAN17

1— Engine Side Shield (3 used)

TX1232271A —UN—19JAN17

Engine Side Shields (right side shown)

Engine Side Shield (left side shown) JL05046,000026E -19-08FEB17-1/1

TM14163X19 (15FEB18)

19-1910-2

450K, 550K, and 650K Crawler Dozer 021518 PN=382

Group 1913

Miscellaneous Shields Rear Sheet Metal Remove and Install SPECIFICATIONS Right Rear Sheet Metal Weight (approximate)

29 kg 64 lb

Left Rear Sheet Metal Weight (approximate)

28 kg 62 lb

Rear Sheet Metal Weight (approximate)

36 kg 79 lb

MACHINE PREPARATION 1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) 2. Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch. (Operator’s Manual.) REMOVAL TX1234571A —UN—22FEB17

Right Rear Sheet Metal 1. Open right rear service door. 2. Remove cap screws (1) and set washer fluid reservoir (2) aside. 1— Cap Screw (3 used)

2— Washer Fluid Reservoir Washer Fluid Reservoir

JL05046,0000285 -19-23FEB17-1/4

CAUTION: Prevent possible injury from heavy component. Use appropriate lifting device. 3. Attach appropriate lifting device to right rear sheet metal (4). Specification Right Rear Sheet Metal—Weight (approximate).................................................................................. 29 kg 64 lb

4. Remove cap screws (3) and right rear sheet metal.

3— Cap Screw (7 used)

TX1234572A —UN—22FEB17

5. Clean and inspect parts. Repair or replace as necessary. 4— Right Rear Sheet Metal

Right Rear Sheet Metal Continued on next page

TM14163X19 (15FEB18)

19-1913-1

JL05046,0000285 -19-23FEB17-2/4

450K, 550K, and 650K Crawler Dozer 021518 PN=383

Miscellaneous Shields Left Rear Sheet Metal CAUTION: Prevent possible injury from heavy component. Use appropriate lifting device. 1. Attach appropriate lifting device to left rear sheet metal (6). Specification Left Rear Sheet Metal—Weight (approximate).................................................................................. 28 kg 62 lb TX1234573A —UN—22FEB17

2. Remove cap screws (5) and left rear sheet metal. 3. Clean and inspect parts. Repair or replace as necessary. 5— Cap Screw (7 used)

6— Left Rear Sheet Metal

Left Rear Sheet Metal JL05046,0000285 -19-23FEB17-3/4

Rear Sheet Metal 1. Remove right and left rear sheet metal. 2. Remove cap screws (7) and plate (8). CAUTION: Prevent possible injury from heavy component. Use appropriate lifting device.

TX1234574A —UN—22FEB17

3. Attach appropriate lifting device to rear sheet metal (10). Specification Rear Sheet Metal—Weight (approximate).................................................................................. 36 kg 79 lb

4. Loosen cap screws (9). 5. Remove cap screws (11) and rear sheet metal. 6. Clean and inspect parts. Repair or replace as necessary. INSTALLATION

Rear Sheet Metal 7— Cap Screw (2 used) 8— Plate 9— Cap Screw (2 used)

10— Rear Sheet Metal 11— Cap Screw (6 used)

Installation is reverse of removal procedure. JL05046,0000285 -19-23FEB17-4/4

TM14163X19 (15FEB18)

19-1913-2

450K, 550K, and 650K Crawler Dozer 021518 PN=384

Group 1921

Grille and Grille Housing Grille Remove and Install SPECIFICATIONS 450K/550K Standard Grille Weight 36 kg 79 lb (approximate) 450K/550K Extreme Duty Grille Weight (approximate)

39 kg 86 lb

650K Standard Grille Weight (approximate)

30 kg 66 lb

650K Extreme Duty Grille Weight (approximate)

40 kg 88 lb

REMOVAL 1. Stop engine and relieve hydraulic system pressure. See Hydraulic System Pressure Release. (Operator’s Manual.) 2. Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch. (Operator’s Manual.) 3. Remove cap screws (2) and lower front grille (1). Grille (550K shown)

4. Remove cable clamp (5) and set cable (7) aside. 5. Install identification tags and disconnect hydraulic lines (6). Close all openings using caps and plugs. CAUTION: Prevent possible injury from heavy component. Use appropriate lifting device. 6. Attach appropriate lifting device to grille (3).

7. Remove cap screws (4) and grille.

TX1232853A —UN—30JAN17

Specification 450K/550K Standard Grille—Weight (approximate).................................................................................. 36 kg 79 lb 450K/550K Extreme Duty Grille—Weight (approximate).................................................................................. 39 kg 86 lb 650K Standard Grille—Weight (approximate).................................................................................. 30 kg 66 lb 650K Extreme Duty Grille—Weight (approximate).................................................................................. 40 kg 88 lb

Hydraulic Lines (550K shown) 1— Lower Front Grille 2— Cap Screw (450K/550K, 4 used; 650K, 6 used) 3— Grille 4— Cap Screw (450K/550K, 6 used; 650K, 8 used)

5— Cable Clamp 6— Hydraulic Line (4 used) 7— Cable

INSTALLATION

8. Clean and inspect parts. Repair or replace as necessary.

Installation is reverse of removal procedure. JL05046,000026C -19-13FEB17-1/1

TM14163X19 (15FEB18)

19-1921-1

450K, 550K, and 650K Crawler Dozer 021518 PN=385

Grille and Grille Housing

TM14163X19 (15FEB18)

19-1921-2

450K, 550K, and 650K Crawler Dozer 021518 PN=386

Section 20 Safety, Convenience, and Miscellaneous Contents Page

Group 2004—Horn and Warning Devices Backup Alarm Remove and Install.............. 20-2004-1 Backup Alarm Volume Adjustment............................................. 20-2004-1

TM14163X19 (15FEB18)

20-1

450K, 550K, and 650K Crawler Dozer

021518

PN=1

Contents

TM14163X19 (15FEB18)

20-2

450K, 550K, and 650K Crawler Dozer

021518

PN=2

Group 2004

Horn and Warning Devices Backup Alarm Remove and Install REMOVAL TX1231986A —UN—17JAN17

1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) 2. Open right rear service door. 3. Install identification tags and disconnect wiring leads (2) from backup alarm (H2). 4. Remove cap screws (1) and backup alarm. 5. Clean and inspect parts. Repair or replace as necessary. INSTALLATION

Backup Alarm 1— Cap Screw (2 used) 2— Wiring Lead (2 used)

Installation is reverse of removal procedure.

H2—Backup Alarm

JL05046,000026A -19-19JAN17-1/1

Backup Alarm Volume Adjustment 1. To change alarm to high volume, remove nuts from terminals (2 and 3). 2. Attach shorting bar (1) to terminals (2 and 3). 3— Terminal TX1090264A —UN—01APR11

1— Shorting Bar 2— Terminal

Backup Alarm BS40810,00000F0 -19-08DEC14-1/1

TM14163X19 (15FEB18)

20-2004-1

450K, 550K, and 650K Crawler Dozer 021518 PN=389

Horn and Warning Devices

TM14163X19 (15FEB18)

20-2004-2

450K, 550K, and 650K Crawler Dozer 021518 PN=390

Section 21 Main Hydraulic System Contents Page

Group 2160—Hydraulic System General Oil Cleanup Procedure ................ 21-2160-1 Hydraulic Component Failure Cleanup Procedure................................ 21-2160-2 Hydraulic Pump Remove and Install ..................................................... 21-2160-3 Hydraulic Pump (With Winch Option) Disassemble and Assemble............................................... 21-2160-4 Hydraulic Pump (Without Winch Option) Disassemble and Assemble............................................... 21-2160-8 Hydraulic Fan Pump Remove and Install ................................................... 21-2160-10 Hydraulic Fan Motor Remove and Install ................................................... 21-2160-11

TM14163X19 (15FEB18)

21-1

450K, 550K, and 650K Crawler Dozer

021518

PN=1

Contents

TM14163X19 (15FEB18)

21-2

450K, 550K, and 650K Crawler Dozer

021518

PN=2

Group 2160

Hydraulic System General Oil Cleanup Procedure

Avoid entanglement and possible electrocution from filter caddy power cord. Do not operate machine while filter caddy is connected to machine.

SERVICE EQUIPMENT AND TOOLS JDG10712 Super Caddy

This procedure is to be used on machines that have had hydraulic system repair without a catastrophic component failure. Filter caddy procedure must be done prior to starting machine after a component has been repaired or replaced. IMPORTANT: Intermixing of oils can cause premature hydraulic component damage and oil contamination. Oil types and filters must not be intermixed. Use filter element in same type oil to avoid intermixing of oils. Oil contamination could result if filter caddy is used in dusty or wet conditions. Clean work practices and cleanliness of filter caddy and attachments are critical when filtering oil. NOTE: Filter oil should be at 27°C (80°F) or above for best Super Caddy™ performance. Reduce flow rate to filter oil below 27°C (80°F). Super Caddy requires a 20-amp electric circuit. Use of electrical extension cord is not recommended. NOTE: Park machine in an area that will allow all hydraulic functions to be operated. 1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) 2. Clean exterior of oil fill cap and surrounding area to prevent contamination. 3. Remove hydraulic oil reservoir cap. NOTE: When installing suction and discharge wands into the hydraulic oil reservoir, locate the submerged ends of the wands as far away from each other as possible to ensure maximum oil movement during cleanup procedure. 4. Install suction and discharge wands from JDG10712 Super Caddy into the hydraulic oil reservoir through the oil fill tube. 5. Seal suction and discharge wands to oil fill tube to secure wands to hydraulic oil reservoir and prevent contamination.

6. Use JDG10712 Super Caddy to remove oil contaminants. Refer to the Super Caddy operator's manual or see Super Caddy in Service ADVISOR™ for operating procedure. 7. When cleaning process is done, disconnect Super Caddy from machine. 8. Fill hydraulic oil reservoir to operating level. See Drain and Refill Hydraulic/Hydrostatic System Oil and Replace Filters. (Operator's Manual.) 9. Run machine at slow idle. Operate each circuit a minimum of 2 minutes in each direction to flush any remaining contaminants back through hydraulic system filters. 10. Stop engine. Install Super Caddy to machine as before. 11. Repeat Super Caddy operation procedure until contaminant value is at specifications per Super Caddy operator's manual or see Super Caddy in Service ADVISOR for operating procedure. 12. When oil reaches an acceptable level of cleanliness, disconnect Super Caddy from machine. 13. Install new hydraulic oil filter. See Drain and Refill Hydraulic/Hydrostatic System Oil and Replace Filters. (Operator’s Manual.) NOTE: Instrument cleanliness and clean work practices are critical when taking oil samples. Dust, wind, and moisture, as well as contaminated sample pumps, bottles, and tubing, can affect results. 14. Obtain oil sample for fluid analysis. Oil sample must be taken from system before oil passes through the filter when oil is warm. See Take Fluid Samples. (Operator's Manual.) 15. Fill hydraulic oil reservoir to proper operating level. See Drain and Refill Hydraulic/Hydrostatic System Oil and Replace Filters. (Operator's Manual.) 16. Return machine to service.

CAUTION: Prevent possible personal injury from unexpected machine movement. Clear all persons from area before operating machine. Super Caddy is a trademark of Deere & Company Service ADVISOR is a trademark of Deere & Company JL05046,0000284 -19-15FEB17-1/1

TM14163X19 (15FEB18)

21-2160-1

450K, 550K, and 650K Crawler Dozer 021518 PN=393

Hydraulic System

Hydraulic Component Failure Cleanup Procedure IMPORTANT: Oil types and filters must not be intermixed. To avoid intermixing of oils, use filter element in same type oil.

14. Fill reservoir to operating level. See Check Hydraulic/Hydrostatic System Oil Level. (Operator’s Manual.)

Avoid operating Super Caddy™ in dusty or wet conditions. Oil contamination will result.

CAUTION: Avoid entanglement and possible electrocution from Super Caddy™ power cord. Do not operate machine while Super Caddy™ is connected to machine.

NOTE: Instrument cleanliness and clean work practices are critical when filtering oil or taking oil samples. Dust, wind, and moisture, as well as contaminated sample pumps, bottles, and tubing affect results.

Prevent possible personal injury from unexpected machine movement. Clear all persons from area before operating machine.

1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.)

15. Make sure that area is clear and large enough to operate all functions of machine.

2. Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch. (Operator’s Manual.) 3. Clean all machine components and surrounding areas.

16. Turn battery disconnect switch to ON position. IMPORTANT: Prevent possible machine damage due to trapped air. Do not operate hydraulic functions over relief.

4. Remove and clean fill cap and strainer. In sealed plastic bag, store fill cap and strainer. 5. Cover fill tube with plastic bag or all-purpose tape.

17. To prevent component damage during start-up, perform Hydrostatic Pump and Motor Initial Start-Up Procedure. (Group 9026-25.)

6. To remove oil contaminants before reservoir is drained, use Super Caddy™. See General Oil Cleanup Procedure. (Group 2160.)

18. Ensure reservoir is still at operating level. See Check Hydraulic/Hydrostatic System Oil Level. (Operator’s Manual.)

7. Drain reservoir. See Drain and Refill Hydraulic/Hydrostatic System Oil and Replace Filters. (Operator’s Manual.) 8. Remove, disassemble, clean, and inspect system components. 9. Repair or replace damaged components. Install all components. IMPORTANT: Oil cooler and accumulators cannot be cleaned of contamination and must be replaced. System manifolds cannot always be cleaned of contamination and must be replaced.

IMPORTANT: Trapped air suddenly compressed in a cylinder makes enough heat to ignite the oil used for assembly causing cap seal and ring damage. Start with cylinder rod retracted and the rod end filled with clean oil. Operate function to extend rod. Procedure eliminates most of the air and reduces the possibility of damage. 19. Run machine at slow idle. To move air and contaminants back through machine’s oil filter, operate each circuit a minimum of 2 minutes in each direction.

10. Replace oil cooler and system accumulators. Some manifolds cannot be cleaned. Replace manifolds as required.

20. Cycle cylinders an additional 10 times to be sure that air is eliminated from circuit.

11. Replace hydraulic filter. See Drain and Refill Hydraulic/Hydrostatic System Oil and Replace Filters. (Operator’s Manual.)

22. Filter oil until Super Caddy™ shuts off and contaminant value is to specification. Refer to operator's manual included with Super Caddy™ or see Super Caddy™ in Service ADVISOR™ for operating procedure.

21. Operate all functions for 3—5 minutes in each direction.

IMPORTANT: Ultra Clean process must have all tee-fittings disconnected. Lines or hoses with tee-fittings must be cleaned individually. 12. Locate and disconnect all circuit hoses and lines from pumps, motors, valves, manifolds, and tee-fittings. To minimize contamination, close all openings of lines and components with caps and plugs. 13. Clean all lines and hoses using Ultra Clean hose kit. Install all removed lines and hoses.

23. Replace hydraulic filter. See Drain and Refill Hydraulic/Hydrostatic System Oil and Replace Filters. (Operator’s Manual.) NOTE: Instrument cleanliness and clean work practices are critical when filtering oil or taking oil samples. Dust, wind, and moisture, as well as contaminated sample pumps, bottles, and tubing affect results.

Continued on next page

TM14163X19 (15FEB18)

21-2160-2

JL05046,000026D -19-08FEB17-1/2

450K, 550K, and 650K Crawler Dozer 021518 PN=394

Hydraulic System 24. Obtain oil sample for fluid analysis. Oil sample must be taken from system before oil passes through the return filter when oil is warm. 25. Ensure reservoir is still at operating level. See Check Hydraulic/Hydrostatic System Oil Level. (Operator’s Manual.)

26. Return machine to service. 27. After 100 hours of service, obtain oil sample for fluid analysis. Confirm oil is within specification.

Super Caddy is a trademark of Deere & Company Service ADVISOR is a trademark of Deere & Company JL05046,000026D -19-08FEB17-2/2

Hydraulic Pump Remove and Install SPECIFICATIONS Hydraulic Pump (standard) Weight 19 kg 42 lb (approximate) Hydraulic Pump (with drive through 29 kg 64 lb shaft) Weight (approximate) 112 N·m 83 lb·ft

Cap Screw Torque

TX1234239A —UN—20FEB17

REMOVAL CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 1. Stop engine and relieve hydraulic system pressure. See Hydraulic System Pressure Release. (Operator’s Manual.)

Hydraulic Pump 1— Hydraulic Line (2 used) 2— Cap Screw (4 used)

2. Remove under seat heater. See Under Seat Heater Remove and Install. (Group 1830.) 3. Drain hydraulic oil reservoir. See Drain and Refill Hydraulic/Hydrostatic System Oil and Replace Filters. (Operator’s Manual.) IMPORTANT: Prevent possible system contamination. Absolute cleanliness is essential when working on hydraulic components. Clean component and adjacent areas before starting work. 4. Install identification tags and disconnect hydraulic lines (1). Close all openings using caps and plugs. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 5. Use appropriate lifting device to support hydraulic pump (3). Specification Hydraulic Pump (standard)—Weight (approximate).................................................................................. 19 kg 42 lb

3— Hydraulic Pump

Hydraulic Pump (with drive through shaft)—Weight (approximate).................................................................................. 29 kg 64 lb

6. Remove cap screws (2) and hydraulic pump. 7. Clean and inspect parts. Repair or replace as necessary. See Hydraulic Pump (With Winch Option) Disassemble and Assemble or see Hydraulic Pump (Without Winch Option) Disassemble and Assemble. (Group 2160.) INSTALLATION Installation is reverse of removal procedure.

• Tighten cap screws to specification. Specification Cap Screw—Torque.................................................................... 112 N·m 83 lb·ft JL05046,000027D -19-20FEB17-1/1

TM14163X19 (15FEB18)

21-2160-3

450K, 550K, and 650K Crawler Dozer 021518 PN=395

Hydraulic System

Hydraulic Pump (With Winch Option) Disassemble and Assemble SPECIFICATIONS Hydraulic Pump Hydraulic Pump Housing Cap Screw and Nut Torque

271 N·m 200 lb.-ft.

Hydraulic Pump Stub Shaft Retainer Nut Torque

22 N·m 200 lb.-in.

1. Remove retainer ring (2) and seal retainer (1). NOTE: For replacement of input shaft seals (4—5) perform steps 1—4 only. T156546 —UN—02JUL02

2. Remove seals (4 and 5). 3. Install seal (4) flush with face of recess in housing with lip toward gear. 4. Install seal (5) flush with counterbore seal in seal retainer (1) with lip away from gear. 5. Install O-ring (3) on seal retainer and apply petroleum jelly to lip of seals and O-ring. Install seal retainer and retainer ring.

Pump Seal Assembly 1— Seal Retainer 2— Retainer Ring 3— O-Ring

Continued on next page

TM14163X19 (15FEB18)

21-2160-4

4— Seal 5— Seal

SK32938,0000925 -19-08APR15-1/4

450K, 550K, and 650K Crawler Dozer 021518 PN=396

T157005 —UN—09JUL02

Hydraulic System

Pump With Winch 1— Seal Retainer 2— Retainer Ring 3— O-Ring 4— Vent 5— Square Seal (2 used) 6— Gear Shaft Set

7— Thrust Plate (2 used) 8— Channel Seal (2 used) 9— O-Ring 10— Seal 11— Stub Shaft Assembly

6. Put a mark across housings (14, 16, and 17) to aid in assembly. IMPORTANT: The assembly of gear shaft set, thrust plates, and channel seals are important. For correct reassembly identify location of parts.

12— Threaded Seal Retainer 13— Cap Screw 14— Stub Shaft Housing 15— Alignment Pin (4 used)

7. Remove cap screws, nuts, and washers and separate housings. Remove gear shaft set (6) and thrust plates (7). NOTE: Gear shaft set, and pump housings are not serviceable. If any of these parts are worn or damaged, replace pump. Continued on next page

TM14163X19 (15FEB18)

16— Gear Housing 17— Front Housing 18— Seal 19— Seal

21-2160-5

SK32938,0000925 -19-08APR15-2/4

450K, 550K, and 650K Crawler Dozer 021518 PN=397

Hydraulic System

8. Remove set screws (1) from stub shaft housing (4). 9. Remove stub shaft retainer (3) from stub shaft housing (4). T118260B —UN—07JAN99

10. Remove stub shaft assembly (2) from stub shaft housing (4) using a spanner wrench. NOTE: Stub shaft assembly is not serviceable. If worn or damaged, replace. 11. Inspect parts for wear or damage. Replace parts as necessary. 12. Replace seal (5) and O-ring (6) on stub shaft retainer (3). 4— Stub Shaft Housing 5— Seal 6— O-Ring

T119315B —UN—07JAN99

1— Set Screws (2 used) 2— Stub Shaft Assembly 3— Stub Shaft Retainer

Stub Shaft Assembly

Stub Shaft Seals Continued on next page

TM14163X19 (15FEB18)

21-2160-6

SK32938,0000925 -19-08APR15-3/4

450K, 550K, and 650K Crawler Dozer 021518 PN=398

T156547 —UN—02JUL02

Hydraulic System

Hydraulic Pump With Winch 1— Matched Gear Set 3— Stub Shaft Housing 4— Stud (3 used) 5— Nut (5 used) 6— Stub Shaft Retainer

7— Stub Shaft Assembly 8— Set Screw (2 used) 9— Cap Screw 10— Backing Seal (2 used) 11— Channel Seal (2 used)

13. Apply clean hydraulic oil on all internal parts. 14. Install stub shaft assembly (7) in stub shaft housing (3), seating the bearing in the bottom of housing. 15. Install stub shaft retainer (6) in housing and tighten so there is no end play on stub shaft assembly (7). 16. Install and tighten set screws (8). 17. Install matched gear set (1) in center housing (13). 18. Install channel seals (11) in thrust plates (12). Install backing seals (10) into step of channel seals (11). 19. Install thrust plate and seal assemblies on the matched gear set with the seals facing away from the gear and sealing toward the pressure side of the pump as shown above.

12— Thrust Plate (2 used) 13— Center Gear Housing 14— Alignment Pin (4 used) 15— Lower Gear Housing

16— Seal 17— Seal 18— Seal Retainer 19— O-Ring 20— Retainer Ring 21— Vent

21. Assemble stub shaft housing (3) to center and lower gear housings. 22. Install studs (4) with nuts (5) and cap screw (9). Tighten cap screw and nuts to specifications. Hydraulic Pump—Specification Hydraulic Pump Housing Cap Screw and Nut—Torque................................................................................271 N·m 200 lb.-ft. Hydraulic Pump Stub Shaft Retainer Nut—Torque..................................................................................22 N·m 200 lb.-in.

20. Assemble center gear housing (13) and lower gear housing (15). SK32938,0000925 -19-08APR15-4/4

TM14163X19 (15FEB18)

21-2160-7

450K, 550K, and 650K Crawler Dozer 021518 PN=399

Hydraulic System

Hydraulic Pump (Without Winch Option) Disassemble and Assemble 1. Remove retaining ring (2) and seal retainer (1). 2. Remove seals (4 and 5). 3. Install seal (4) flush with face of recess in housing with lip toward gear. 4. Install seal (5) flush with counterbore seal in retainer (1) with lip away from gear.

1— Seal Retainer 2— Retaining Ring 3— O-Ring

T156546 —UN—02JUL02

5. Install O-ring (3) on seal retainer and apply petroleum jelly to lip of seals and O-ring. Install seal retainer (1) and retaining ring (2). 4— Seal 5— Seal

Pump Seal Assembly Continued on next page

TM14163X19 (15FEB18)

21-2160-8

WS68074,0001B78 -19-29JUL09-1/2

450K, 550K, and 650K Crawler Dozer 021518 PN=400

T156550 —UN—02JUL02

Hydraulic System

Hydraulic Pump Assembly 1— Matched Gear Set 2— Center Gear Housing 3— Gasket Seal (2 used) 4— Upper Gear Housing

5— Cap Screw (4 used) 6— Backing Seal (2 used) 7— Channel Seal (2 used) 8— Thrust Plate (2 used)

6. Put a mark across housings (2, 4 and 10) to aid in assembly. 7. Remove cap screws and washers. Separate housings. 8. Remove matched gear set (1) and thrust plates (8) with seals (6 and 7). NOTE: Pump parts (1, 2, 4, 8 and 10) are not serviceable. If any of these parts are worn or damaged, replace pump.

9— Alignment Pin (4 used) 10— Lower Gear Housing 11— Seal 12— Seal 13— Seal Retainer

14— O-ring 15— Retainer Ring

13. Install thrust plate (8) and seal assemblies on the matched gear set (1) with the seals facing away from the gear and sealing toward the pressure side of the pump as shown above. 14. Assemble center gear housing (2) and lower gear housing (10). 15. Install upper gear housing and cap screws. Tighten cap screws to specifications.

9. Inspect parts for wear or damage. Replace parts as necessary. 10. Apply clean hydraulic oil on all internal parts.

Hydraulic Pump—Specification Hydraulic Pump Housing Cap Screws (Without Winch Option)—Torque...............................................................271 N·m 200 lb-ft

11. Install matched gear set (1) in center gear housing (2). 12. Install channel seals (7) in thrust plates (8). Install backing seals (6) into step of channel seals. WS68074,0001B78 -19-29JUL09-2/2

TM14163X19 (15FEB18)

21-2160-9

450K, 550K, and 650K Crawler Dozer 021518 PN=401

Hydraulic System

Hydraulic Fan Pump Remove and Install This procedure applies to 650K machines only. REMOVAL

TX1232326A —UN—20JAN17

CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 1. Stop engine and relieve hydraulic system pressure. See Hydraulic System Pressure Release. (Operator’s Manual.) 2. Apply vacuum or drain hydraulic oil reservoir. See Drain and Refill Hydraulic/Hydrostatic System Oil and Replace Filters. (Operator’s Manual.) 3. Remove engine side shields on right side of machine. See Engine Side Shields Remove and Install. (Group 1910.)

Hydraulic Fan Pump 1— Hydraulic Line (2 used) 2— Cap Screw (2 used)

3— Hydraulic Fan Pump

4. Install identification tags and disconnect hydraulic lines (1). Close all openings using caps and plugs. 5. Remove cap screws (2) and hydraulic fan pump (3). 6. Clean and inspect parts. Repair or replace as necessary.

INSTALLATION Installation is reverse of removal procedure. JL05046,000026F -19-08FEB17-1/1

TM14163X19 (15FEB18)

21-2160-10

450K, 550K, and 650K Crawler Dozer 021518 PN=402

Hydraulic System

Hydraulic Fan Motor Remove and Install SPECIFICATIONS 100 N·m 74 lb·ft

Nut (3) Torque

SERVICE EQUIPMENT AND TOOLS D01207AA 2 and 3-Way Puller OTHER MATERIAL TX1232357A —UN—20JAN17

Loctite® 242® Threadlocker (medium strength)

This procedure applies to 650K machines only. REMOVAL CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 1. Stop engine and relieve hydraulic system pressure. See Hydraulic System Pressure Release. (Operator’s Manual.) 2. Apply vacuum or drain hydraulic oil reservoir. See Drain and Refill Hydraulic/Hydrostatic System Oil and Replace Filters. (Operator’s Manual.) 3. Remove fan blade. See Fan Blade Remove and Install. (Group 0510.)

Hydraulic Fan Motor 1— Hydraulic Line (3 used) 2— Nut (2 used) 3— Nut

4— Hydraulic Fan Motor Hub 5— Hydraulic Fan Motor

8. Clean and inspect parts. Repair or replace as necessary. INSTALLATION Installation is reverse of removal procedure.

4. Install identification tags and disconnect hydraulic lines (1). Close all openings using caps and plugs.

• Apply Loctite® 242® Threadlocker (medium strength)

5. Remove nut (3).

Specification Nut (3)—Torque...........................................................................100 N·m 74 lb·ft

6. Attach D01207AA 2 and 3-Way Puller to hydraulic fan motor hub (4) and remove hub.

to the threads of nut (3) and tighten to specification.

7. Remove nuts (2) and hydraulic fan motor (5). Loctite and its related brand marks are trademarks of Henkel Corporation JL05046,0000270 -19-08FEB17-1/1

TM14163X19 (15FEB18)

21-2160-11

450K, 550K, and 650K Crawler Dozer 021518 PN=403

Hydraulic System

TM14163X19 (15FEB18)

21-2160-12

450K, 550K, and 650K Crawler Dozer 021518 PN=404

Contents

Section 32 Bulldozer

Page

Group 3201—Blades Cutting Edges and End Bits Remove and Install................................ 32-3201-1 Blade Remove and Install.......................... 32-3201-2 Group 3215—Control Linkage Blade Control Lever Linkage Remove and Install................................ 32-3215-1 Auxiliary Control Linkage Remove and Install ...............................32-3215-4 Group 3240—Frames C-Frame Remove and Install..................... 32-3240-1 Group 3260—Hydraulic System Hydraulic Control Valve Remove and Install .............................................. 32-3260-1 Hydraulic Control Valve Remove and Install—IGC .................................... 32-3260-2 Hydraulic Control Valve Disassemble and Assemble..................32-3260-4 Wiper Seals and Lip Seals, Replace.....32-3260-5 Disassemble and Assemble Auxiliary Section ......... 323260-11 Disassemble and Assemble Angle Section.............. 323260-12 Disassemble and Assemble Tilt Section .................. 323260-14 Disassemble and Assemble Lift Section .................. 323260-15 Disassemble and Assemble System Relief Valve........................................................32-3260-16 Hydraulic Control Valve Disassemble and Assemble—IGC................................... 32-3260-18 Lift Cylinder Remove and Install.............. 32-3260-19 Tilt Cylinder Remove and Install.............. 32-3260-20 Angle Cylinder Remove and Install ................................................... 32-3260-20 Hydraulic Cylinder Repair........................ 32-3260-21

TM14163X19 (15FEB18)

32-1

450K, 550K, and 650K Crawler Dozer

021518

PN=1

Contents

TM14163X19 (15FEB18)

32-2

450K, 550K, and 650K Crawler Dozer

021518

PN=2

Group 3201

Blades Cutting Edges and End Bits Remove and Install SPECIFICATIONS 70 kg 154 lb

Cutting Edge Weight (approximate)

TX1234591 —UN—02MAR17

4 1

TX1234591

Cutting Edge and End Bits 1— Cap Screw (15 used) 2— Washer (15 used)

3— Nut (15 used) 4— End Bit

5— Cutting Edge 6— End Bit

REMOVAL

3. Remove nuts (3), cutting edge, and end bits (4 and 6).

1. Block blade frame securely with cutting edge (5) above ground level. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

4. Clean and inspect parts. Repair or replace parts as necessary. INSTALLATION Installation is reverse of removal procedure.

2. Attach appropriate lifting device to cutting edge. Specification Cutting Edge—Weight (approximate).................................................................................. 70 kg 154 lb BS40810,000024D -19-02MAR17-1/1

TM14163X19 (15FEB18)

32-3201-1

450K, 550K, and 650K Crawler Dozer 021518 PN=407

Blades

Blade Remove and Install SPECIFICATIONS Blade Weight (approximate)

709 kg 1563 lb

Cap Screw (10) Torque

490 N·m 361 lb·ft

SERVICE EQUIPMENT AND TOOLS DFT1278 30 mm Wrench With 3/4-in Drive

MACHINE PREPARATION

TX1242400A —UN—28JUL17

1. Park machine on a flat, level surface and lower front attachment to the ground. CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 2. Stop engine and relieve hydraulic system pressure. See Hydraulic System Pressure Release. (Operator’s Manual.)

Blade With SmartGrade™

REMOVAL 1. If equipped with SmartGrade™, remove cover (15) and disconnect SmartGrade™ grille harness-to-SmartGrade™ blade inertial measurement unit (IMU) harness connector (X129). W55—SmartGrade™ Blade Inertial Measurement Unit (IMU) Harness X129— SmartGrade™ Grille Harness-toSmartGrade™ Blade Inertial Measurement Unit (IMU) Harness Connector

TX1242401A —UN—28JUL17

15— Cover 16— Cap Screw (3 used) W54—SmartGrade™ Grille Harness

Blade With SmartGrade™ SmartGrade is a trademark of Deere & Company Continued on next page

TM14163X19 (15FEB18)

32-3201-2

JL05046,0000286 -19-03AUG17-1/3

450K, 550K, and 650K Crawler Dozer 021518 PN=408

Blades

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 2. Use appropriate lifting device to support blade (1). Specification Blade—Weight (approximate)................................................................................ 709 kg 1563 lb TX1234677A —UN—01MAR17

3. Remove cap screws (3), retainers (4), and pins (5) from cylinders (2). 4. Remove cap screw (6), retainer (7), and pin (8) from pitch linkage (9). 1— Blade 2— Cylinder (3 used) 3— Cap Screw (3 used) 4— Retainer (3 used) 5— Pin (3 used)

6— Cap Screw 7— Retainer 8— Pin 9— Pitch Linkage

Blade Continued on next page

TM14163X19 (15FEB18)

32-3201-3

JL05046,0000286 -19-03AUG17-2/3

450K, 550K, and 650K Crawler Dozer 021518 PN=409

Blades

5. Remove cap screws (10) and washers (11). See DFT1278 30 mm Wrench With 3/4-in Drive. (Group 9900.) TX1234682A —UN—27FEB17

6. Remove blade. 7. Clean and inspect parts. Repair or replace as necessary. INSTALLATION Installation is reverse of removal procedure. IMPORTANT: Avoid machine damage. Do not lubricate zinc-plated cap screws with oil or anti-seize. Always install dry. NOTE: When tightening cap screws (10), angle blade to maximum pitch on both sides.

Blade Retainer and Socket 10— Cap Screw (8 used) 11— Washer (8 used) 12— Blade Retainer

13— Shim (6 used) 14— Socket

• Install blade retainer (12) without shims (13) and tighten B ADAPTOR

A TORQUE WRENCH TX1064881 —UN—23SEP09

cap screws (10). Measure gap between socket (14) and blade retainer. Install shims to fill gap and add one shim. Tighten cap screws (10) to hold blade in place, but do not tighten to specification. • Adjust pitch linkage. See Blade Pitch Linkage Adjustment. (Group 9025-20.)

• Tighten cap screws (10) to specification using DFT1278 30 mm Wrench With 3/4-in Drive along with torque adaptor formula: S = (A x T)/(A + B).

Specification Cap Screw (10)—Torque...............................................................................490 N·m 361 lb·ft

Torque Wrench

• Grease all points as specified in operator’s manual. See • To check for binding, operate blade through full range of Lubricate Dozer Linkage and Blade Socket. (Operator's Manual.)

motion for all blade functions.

JL05046,0000286 -19-03AUG17-3/3

TM14163X19 (15FEB18)

32-3201-4

450K, 550K, and 650K Crawler Dozer 021518 PN=410

Group 3215

Control Linkage Blade Control Lever Linkage Remove and Install SPECIFICATIONS Blade Control Lever Linkage Blade Control Linkage Mount Cap 15 N·m 11 lb.-ft. Screw Torque 3/8 in. Lock Nut Torque

35 N·m 26 lb.-ft.

5/16 in. Lock Nut Torque

19 N·m 14 lb.-ft.

Continued on next page

TM14163X19 (15FEB18)

32-3215-1

SH03936,000594C -19-07JUN12-1/2

450K, 550K, and 650K Crawler Dozer 021518 PN=411

T141321 —UN—07AUG01

Control Linkage

Blade Control Linkage

SH03936,000594C -19-07JUN12-2/2

TM14163X19 (15FEB18)

32-3215-2

450K, 550K, and 650K Crawler Dozer 021518 PN=412

Control Linkage 1— Grommet (2 used) 2— Boot 3— Cap Screw (4 used) 4— Blade Control Handle 5— Nut 6— Control Shaft 7— Lock Nut (5 used) 8— Stud Link Ball Joint 9— Ball Joint (2 used)

10— Lock Nut (2 used) 11— Tilt Valve and Lift Section Link (2 used) 12— Ball Joint (2 used) 13— Nut (3 used) 14— Washer (4 used) 15— Cap Screw (4 used)

1. Open access door to control valve.

16— U-Joint Control Housing 17— U-Joint 18— Snap Ring 19— Washer 20— Bearing (2 used) 21— Cotter Pin 22— Pin 23— Rod-to-Angle Valve Section Link

24— Ball Joint 25— Cap Screw 26— Washer (4 used) 27— Bellcrank 28— Washer 29— Cap Screw (2 used) 30— Washer (4 used)

9. Tighten lock nuts (10) to specification.

2. Remove lock nuts (7) on tilt and lift valve ball joints (12). 3. Remove cotter pin (21) and pin (22) on angle valve rod. 4. Remove cap screw (25) and washer (26) from bellcrank (27). 5. Remove cap screws (15) and washers (14) from U-joint assembly. 6. Remove cap screws (3) and boot (2). Remove assembly.

Blade Control Valve Linkage—Specification 3/8 in. Lock Nut—Torque..................................................................................35 N·m 26 lb.-ft.

10. Tighten lock nuts (7) to specification. Blade Control Valve Linkage—Specification 5/16 in. Lock Nut—Torque..................................................................................19 N·m 14 lb.-ft.

11. Adjust blade control lever linkage. See Blade Control Lever Linkage Adjustment. (Group 9025-20.)

7. Disassemble and assemble parts as required. 8. Tighten cap screws to specification (15). Blade Control Valve Linkage—Specification Blade Linkage Mount Cap Screw—Torque......................................................................15 N·m 11 lb.-ft.

SH03936,000594C -19-07JUN12-3/2

TM14163X19 (15FEB18)

32-3215-3

450K, 550K, and 650K Crawler Dozer 021518 PN=413

Control Linkage

Auxiliary Control Lever Linkage Remove and Install SPECIFICATIONS Auxiliary Control Lever Linkage Lever-to-Bracket Cap Screw Torque

50 N·m 37 lb.-ft.

Continued on next page

TM14163X19 (15FEB18)

32-3215-4

SH03936,000594D -19-07JUN12-1/2

450K, 550K, and 650K Crawler Dozer 021518 PN=414

T198500 —UN—16MAR04

Control Linkage

Auxiliary Control Lever Linkage

SH03936,000594D -19-07JUN12-2/2

TM14163X19 (15FEB18)

32-3215-5

450K, 550K, and 650K Crawler Dozer 021518 PN=415

Control Linkage 1— Control Valve Linkage Assembly 2— Bracket 3— Washer

4— Lever 5— Ball Joint 6— Rod 7— Cap Screw 8— Lock Nut

9— Lock Nut 10— Nut 11— Cap Screw (2 used) 12— Pin

1. Open access cover to control valve.

13— Cotter Pin 14— Grip 16— Boot

Auxiliary Control Lever Linkage —Specification Lever-to-Bracket Cap Screw—Torque..............................................................................50 N·m 37 lb.-ft.

2. Remove pin (12). 3. Remove cap screw (7). 4. Remove boot (16).

8. Adjust auxiliary control lever linkage. See Auxiliary Hydraulic Control Lever Linkage Adjustment. (Group 9025-20.)

5. Remove auxiliary linkage assembly. 6. Disassemble and assemble parts as required. 7. Install cap screw (7), pin (12), and boot (16). Tighten cap screw (7) to specification.

SH03936,000594D -19-07JUN12-3/2

TM14163X19 (15FEB18)

32-3215-6

450K, 550K, and 650K Crawler Dozer 021518 PN=416

Group 3240

Frames C-Frame Remove and Install SPECIFICATIONS 450K/550K C-Frame Weight (approximate)

310 kg 683 lb

650K C-Frame Weight (approximate)

376 kg 829 lb

REMOVAL TX1234885A —UN—01MAR17

1. Remove blade. See Blade Remove and Install. (Group 3201.) CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 2. Use appropriate lifting device to support C-frame (1). Specification 450K/550K C-Frame—Weight (approximate) ............................................................................... 310 kg 683 lb 650K C-Frame—Weight (approximate) ............................................................................... 376 kg 829 lb

3. Remove cable clamp (5), cap screws (4), and bracket (2). 4. Install identification tags and disconnect hydraulic lines (3). Close all openings using caps and plugs.

C-Frame 1— C-Frame 2— Bracket 3— Hydraulic Line (2 used) 4— Cap Screw (3 used)

5— Cable Clamp 6— Angle Cylinder (2 used) 7— Tilt Cylinder

6. Remove angle cylinders (6). See Angle Cylinder Remove and Install. (Group 3260.)

5. Remove tilt cylinder (7). See Tilt Cylinder Remove and Install. (Group 3260.) JL05046,0000287 -19-06MAR17-1/2

7. Remove cap screws (8), retainers (9), and pins (10) from lift cylinders (14). 8. Remove nuts (12), cap screws (13), and pins (11). 9. Remove C-frame. 10. Clean and inspect parts. Repair or replace as necessary. INSTALLATION

1— C-Frame 8— Cap Screw (2 used) 9— Retainer (2 used) 10— Pin (2 used)

TX1234883 —UN—01MAR17

Installation is reverse of removal procedure. 11— Pin (2 used) 12— Nut (2 used) 13— Cap Screw (2 used) 14— Lift Cylinder (2 used)

C-Frame JL05046,0000287 -19-06MAR17-2/2

TM14163X19 (15FEB18)

32-3240-1

450K, 550K, and 650K Crawler Dozer 021518 PN=417

Frames

TM14163X19 (15FEB18)

32-3240-2

450K, 550K, and 650K Crawler Dozer 021518 PN=418

Group 3260

Hydraulic System Hydraulic Control Valve Remove and Install IMPORTANT: Prevent possible system contamination. Absolute cleanliness is essential when working on hydraulic components. Clean component and adjacent areas before starting work. REMOVAL

TX1232555A —UN—24JAN17

CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 1. Stop engine and relieve hydraulic system pressure. See Hydraulic System Pressure Release. (Operator’s Manual.) 2. Remove rear sheet metal on right side of machine. See Rear Sheet Metal Remove and Install. (Group 1913.) 3. Apply vacuum or drain hydraulic oil reservoir. See Drain and Refill Hydraulic/Hydrostatic System Oil and Replace Filters. (Operator’s Manual.) 4. Disconnect hydrostatic oil filter restriction switch (B15).

Hydrostatic Oil Filter 1— Cap Screw (4 used) 2— Hydrostatic Oil Filter

B15— Hydrostatic Oil Filter Restriction Switch

5. Remove cap screws (1) and set hydrostatic oil filter (2) aside. JL05046,0000271 -19-08FEB17-1/2

6. Disconnect linkage rods (3). NOTE: The number of hydraulic lines (6) on the control valve may vary depending on machine options. The 550K 4-spool hydraulic control valve is shown. 7. Install identification tags and disconnect hydraulic lines (6). Close all openings using caps and plugs. 8. Remove cap screws (5) and hydraulic control valve (4).

TX1232556A —UN—23JAN17

9. Clean and inspect parts. Repair and replace as necessary. See Hydraulic Control Valve Disassemble and Assemble. (Group 3260.) INSTALLATION Installation is reverse of removal procedure. 3— Linkage Rod (4 used) 4— Hydraulic Control Valve

5— Cap Screw (3 used) 6— Hydraulic Line (10 used)

Hydraulic Control Valve (550K shown) JL05046,0000271 -19-08FEB17-2/2

TM14163X19 (15FEB18)

32-3260-1

450K, 550K, and 650K Crawler Dozer 021518 PN=419

Hydraulic System

Hydraulic Control Valve Remove and Install—IGC SPECIFICATIONS 3-Spool Hydraulic Control Valve Weight (approximate)

31 kg 68 lb

4-Spool Hydraulic Control Valve Weight (approximate)

37 kg 82 lb

TX1232730A —UN—24JAN17

IMPORTANT: Prevent possible system contamination. Absolute cleanliness is essential when working on hydraulic components. Clean component and adjacent areas before starting work. Install identification tags to all electrical connectors and hydraulic lines to aid in assembly. Close all openings using caps and plugs. REMOVAL CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.

Hydrostatic Oil Filter 1— Clamp (2 used) 2— Cap Screw (4 used) 3— Hydrostatic Oil Filter 4— Bracket

1. Stop engine and relieve hydraulic system pressure. See Hydraulic System Pressure Release. (Operator’s Manual.) 2. Remove rear sheet metal on right side of machine. See Rear Sheet Metal Remove and Install. (Group 1913.) 3. Apply vacuum or drain hydraulic oil reservoir. See Drain and Refill Hydraulic/Hydrostatic System Oil and Replace Filters. (Operator’s Manual.)

B15— Hydrostatic Oil Filter Restriction Switch X43— Electrical Connector X44— Electrical Connector

5. Disconnect hydrostatic oil filter restriction switch (B15). 6. Remove cap screws (2) and set hydrostatic oil filter (3) aside. 7. Remove bracket (4).

4. Disconnect electrical connectors (X43 and X44) and remove clamps (1). Continued on next page

TM14163X19 (15FEB18)

32-3260-2

JL05046,0000272 -19-25JUL17-1/2

450K, 550K, and 650K Crawler Dozer 021518 PN=420

Hydraulic System

NOTE: The number of hydraulic lines (5) on the hydraulic control valve may vary depending on machine options. The 650K 4-spool hydraulic control valve (7) is shown. 8. Disconnect hydraulic lines (5) and hydraulic pump pressure sensor (B42).

TX1232731A —UN—24JAN17

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 9. Use appropriate lifting device to support hydraulic control valve (7). Specification 3-Spool Hydraulic Control Valve—Weight (approximate).................................................................................. 31 kg 68 lb 4-Spool Hydraulic Control Valve—Weight (approximate).................................................................................. 37 kg 82 lb

Hydraulic Control Valve (650K shown) 5— Hydraulic Line (13 used) 6— Cap Screw (3 used)

7— Hydraulic Control Valve B42— Hydraulic Pump Pressure Sensor

10. Remove cap screws (6) and hydraulic control valve. 11. Disconnect electrical connectors from solenoids (Y9 and Y21—Y28). If equipped with SmartGrade™, see Control Valve (SmartGrade™ and IGC Controls) Harness (W14) Component Location. (Group 9015-10.)

INSTALLATION Installation is reverse of removal procedure.

12. Clean and inspect parts. Repair and replace as necessary. See Hydraulic Control Valve Disassemble and Assemble—IGC. (Group 3260.) SmartGrade is a trademark of Deere & Company JL05046,0000272 -19-25JUL17-2/2

TM14163X19 (15FEB18)

32-3260-3

450K, 550K, and 650K Crawler Dozer 021518 PN=421

Hydraulic System

Hydraulic Control Valve Disassemble and Assemble 24.4 N·m 216 lb.-in.

Control Valve Tie Rod and Nut (3/8 in.) Torque

45.0 N·m 33 lb.-ft.

Control Valve Tie Rod and Nut (7/16 in.) Torque

65.0 N·m 48 lb.-ft.

Control Valve Tie Rod and Nut (1/2 in.) Torque

100.0 N·m 74 lb.-ft.

T118810 —UN—10DEC98

SPECIFICATIONS Control Valve Tie Rod and Nut (5/16 in.) Torque

IMPORTANT: Prevent damage to hydraulic components. Keep all components for each valve section together as a set.

Control Valve

1. To aid in assembly, identify each section with a mark. 2. Place valve in a vertical position with the inlet section down. Support with wood blocks. 3. Remove nuts (8) and tie rods (7). 4. Carefully remove sections (1—6). Do not lose or damage O-rings (11), load checks (10), and springs (9). Keep load checks and valve sections together as a set.

T119779 —UN—22JAN99

IMPORTANT: Prevent damage to mating surfaces of valve sections. Carefully remove and protect components during disassembly. 5. Inspect O-rings between each section for wear or damage. Replace as necessary. 6. Inspect springs and load checks for scoring, wear, or damage. Replace as necessary. 7. Apply clean hydraulic oil to all internal parts.

Control Valve Section

8. Install load check (10), spring (9), and O-ring (11) into each spool section.

1— Inlet Section 2— Auxiliary Section 3— Angle Section 4— Tilt Section 5— Lift Section 6— Outlet Section

IMPORTANT: Tighten tie rod and nuts evenly to prevent valve spool binding or leakage between sections. 9. Assemble sections (1—6) making sure load checks (10), springs (9), and O-rings (11) remain in position. 10. Tighten nuts to specification. Specification Control Valve Tie Rod and Nut (5/16 in.)—Torque................................................................24.4 N·m 216 lb.-in. Control Valve Tie Rod and Nut (3/8 in.)—Torque..................................................................45.0 N·m 33 lb.-ft.

7— Tie Rod (3 used) 8— Nut (6 used) 9— Spring (1 in each spool section) 10— Load Check (1 in each spool section) 11— O-Ring (1 between each section)

Control Valve Tie Rod and Nut (7/16 in.)—Torque................................................................65.0 N·m 48 lb.-ft. Control Valve Tie Rod and Nut (1/2 in.)—Torque................................................................100.0 N·m 74 lb.-ft.

SK32938,000093E -19-13MAY15-1/1

TM14163X19 (15FEB18)

32-3260-4

450K, 550K, and 650K Crawler Dozer 021518 PN=422

Hydraulic System

Wiper Seals and Lip Seals on Hydraulic Control Valve Remove and Install NOTE: Replace cap end seals first and tang end seals second. On cap ends, hold tang ends together by placing a screwdriver through tang ends linkage holes. 1. Remove screws (1) and retainer plate (2) from valve section. 2. Use an O-ring pick to remove wiper seal (3) and lip seal (4). 4— Lip Seal 5— Spool

T118812 —UN—10DEC98

1— Screw (2 used) 2— Retainer Plate 3— Wiper Seal

Wiper and Lip Seal Assembly Continued on next page

TM14163X19 (15FEB18)

32-3260-5

CED,TX03768,2528 -19-10JUL09-1/7

450K, 550K, and 650K Crawler Dozer 021518 PN=423

Hydraulic System

3. Remove socket head cap screws (10) and cap (9) from valve section. 4. Remove spool end screw (8), spring seats (6), centering spring (7) and retainer plate (2). 5. Use an O-ring pick to remove wiper seal (3) and lip seal (4). 7— Centering Spring 8— Spool End Screw 9— Cap 10— Socket Head Cap Screw (2 used)

TX1060104 —UN—04JUN09

2— Retainer Plate 3— Wiper Seal 4— Lip Seal 5— Spool 6— Spring Seat (2 used)

Wiper, Lip Seal and Spool Assembly Continued on next page

TM14163X19 (15FEB18)

32-3260-6

CED,TX03768,2528 -19-10JUL09-2/7

450K, 550K, and 650K Crawler Dozer 021518 PN=424

Hydraulic System

IMPORTANT: Avoid damage to OD or ID of new lip seal during installation. JDG10583 Seal Installation Tool MUST be used to install lip seal and wiper seal. NOTE: Tang (12) of JDG10583 Seal Installation Tool compresses the seal to prevent air from being trapped under it during installation. 6. Lube lip seal (4) and place lip seal into JDG10583 Seal Installation Tool (11) with open side of seal away from tool.

4— Lip Seal 11— JDG10583 Seal Installation Tool

TX1060098 —UN—04JUN09

7. Place seal installation tool over end of spool. 12— Tang

TX1060099A —UN—04JUN09

JDG10583 Seal Installation Tool

JDG10583 Seal Installation Tool Continued on next page

TM14163X19 (15FEB18)

32-3260-7

CED,TX03768,2528 -19-10JUL09-3/7

450K, 550K, and 650K Crawler Dozer 021518 PN=425

Hydraulic System

8. Push seal installation tool (11) to install lip seal into counterbore of valve housing. 9. Lube wiper seal and place wiper seal into seal installation tool with smaller OD of wiper seal into tool. 10. Place seal installation tool over end of spool.

TX1060101A —UN—04JUN09

11— JDG10583 Seal Installation Tool

JDG10583 Seal Installation Tool CED,TX03768,2528 -19-10JUL09-4/7

IMPORTANT: Avoid damage to the wiper seal during assembly. The wiper seal must sit flush just below the surface of the valve housing 11. Push seal installation tool to install wiper seal (3) into counterbore just below surface of valve housing. 9— Cap TX1060103A —UN—04JUN09

3— Wiper Seal 4— Lip Seal

Seal Installation Continued on next page

TM14163X19 (15FEB18)

32-3260-8

CED,TX03768,2528 -19-10JUL09-5/7

450K, 550K, and 650K Crawler Dozer 021518 PN=426

Hydraulic System

12. Install retainer plate (2), spring seats (6) and centering spring (7). 13. Clean threads of spool (5) and spool end screw (8). Apply PM37509 Cure Primer to threads. 14. Apply PM37421 Thread Lock and Sealer (high strength) to threads of spool end screw (8). Install and tighten spool end screw to specification. Hydraulic Control Valve—Specification Valve Spool End Screw—Torque.............................................................................9.5 N·m 84 lb.-in.

15. Install cap (9) and socket head cap screws (10). Tighten to specification. Hydraulic Control Valve—Specification Valve Spool Cap Socket Head Screws—Torque.................................................................9.5 N·m 84 lb.-in. 7— Centering Spring 8— Spool End Screw 9— Cap 10— Socket Head Cap Screw (2 used)

TX1060104 —UN—04JUN09

2— Retainer Plate 3— Wiper Seal 4— Lip Seal 5— Spool 6— Spring Seat (2 used)

Wiper, Lip Seal and Spool Assembly Continued on next page

TM14163X19 (15FEB18)

32-3260-9

CED,TX03768,2528 -19-10JUL09-6/7

450K, 550K, and 650K Crawler Dozer 021518 PN=427

Hydraulic System

16. Install retainer plate (2) and screws (1). Tighten to specification. Hydraulic Control Valve—Specification Valve Spool Retainer Plate Screws—Torque..................................................................5.5 N·m 48 lb.-in.

17. Check for correct installation of seals by pushing down on spool (5). Spool must return to neutral position. 4— Lip Seal 5— Spool

T118812 —UN—10DEC98

1— Screw (2 used) 2— Retainer Plate 3— Wiper Seal

Wiper and Lip Seal Assembly CED,TX03768,2528 -19-10JUL09-7/7

TM14163X19 (15FEB18)

32-3260-10

450K, 550K, and 650K Crawler Dozer 021518 PN=428

Hydraulic System

T118814 —UN—14DEC98

Auxiliary Control Valve Section Disassemble and Assemble

Control Valve Auxiliary Section 1— Valve Housing 2— Cap Screw (2 used) 3— Cap 4— Centering Spring

5— Spool End Screw 6— Spring Seat (2 used) 7— Retaining Plate (2 used)

IMPORTANT: Spool must be installed into the valve housing the same way it was removed for proper operation of the hydraulic function. 1. Remove parts (2, 3, 7, 10 and 11) from valve housing (1). 2. Using a protective cover or wooden blocks, put spool in vise. Remove spool end screw (5), centering spring (4) and spring seats (6). 3. Inspect parts for wear or damage. Replace all O-rings and seals. 4. Put clean hydraulic oil on spool and install spool into valve housing. Install lip seals (9) and wiper seals (8) using JDG10583 Seal Installation Tool. See Wiper Seals and Lip Seals on Hydraulic Control Valve Remove and Install. (Group 3260.) 5. Install parts (4—7) on spool. Clean threads of spool and spool end screw. Apply PM37509 Cure Primer to threads. Apply PM37421 Thread Lock and Sealer

8— Wiper Seal (2 used) 9— Lip Seal (2 used) 10— Screw (2 used) 11— Spool

12— Load Check and Spring 13— Shutoff Plug (2 used)

(high strength) on spool end screw. Install and tighten screw to specification. Hydraulic Control Valve—Specification Auxiliary Valve Spool End Screw—Torque.............................................................................9.5 N·m 84 lb.-in.

6. Apply grease on centering spring (4). 7. Assemble remaining parts. Tighten cap screws (2), screws (10) and shutoff plugs (13) to specifications. Hydraulic Control Valve—Specification Auxiliary Valve Spool Cap Socket Head Screws—Torque...........................................................................9.5 N·m 84 lb.-in. Auxiliary Valve Retainer Plate Screws—Torque..................................................................5.5 N·m 48 lb.-in. Auxiliary Valve Shutoff Plugs—Torque...............................................................................45 N·m 33 lb.-ft. CED,OUTX547,200 -19-29JUL09-1/1

TM14163X19 (15FEB18)

32-3260-11

450K, 550K, and 650K Crawler Dozer 021518 PN=429

Hydraulic System

Angle Control Valve Section Disassemble and Assemble

11 9

TX1060176 —UN—08JUN09

12 6

TX1060176 Control Valve Angle Section 1— Valve Housing 2— Cap Screw (2 used) 3— Spacer 4— Cap 5— Centering Spring

6— Spool End Screw 7— Spring Seat (2 used) 8— Retaining Plate (2 used) 9— Wiper Seal (2 used)

10— Lip Seal (2 used) 11— Screw (2 used) 12— Spool 13— Load Check and Spring

IMPORTANT: Spool must be installed into the valve housing the same way it was removed for proper operation of the hydraulic function. 1. Remove parts (2, 4, 8, and 11) and spool (12) from valve housing (1).

6. Install parts (3 and 5—8) on spool. Clean threads of spool and spool end screw. Apply PM37509 Cure Primer to threads. Apply PM37421 Thread Lock and Sealer (high strength) on spool end screw. Install and tighten spool end screw to specification. Hydraulic Control Valve—Specification Angle Valve Spool End Screw—Torque.............................................................................9.5 N·m 84 lb.-in.

IMPORTANT: To avoid changing adjustment, do not loosen adjustment screw on end of relief. 2. Remove work port relief valves (14).

7. Apply grease to centering spring (5).

3. Using a protective cover or wooden blocks, place spool in vise. Remove spool end screw (6), spacer (3), centering spring (5) and spring seats (7).

8. Assemble remaining parts. Tighten cap screws (2) and screws (11) to specifications.

4. Inspect parts for wear or damage. Replace all O-rings and seals. 5. Put clean hydraulic oil on spool and install spool into valve housing (1). Install lip seals (10) and wiper seals (9) using JDG10583 Seal Installation Tool. See Wiper Seals and Lip Seals on Hydraulic Control Valve Remove and Install. (Group 3260.)

Hydraulic Control Valve—Specification Angle Valve Spool Cap Socket Head Screws—Torque...........................................................................9.5 N·m 84 lb.-in. Angle Valve Retainer Plate Screws—Torque..................................................................5.5 N·m 48 lb.-in.

Continued on next page

TM14163X19 (15FEB18)

14— Work Port Relief Valve (2 used)

32-3260-12

CED,OUO1004,533 -19-14JUL09-1/2

450K, 550K, and 650K Crawler Dozer 021518 PN=430

Hydraulic System

IMPORTANT: Tightening work ports relief using jam nut on end of relief will cause damage to work ports relief. Do not tighten work ports relief using jam nut on end of relief.

Hydraulic Control Valve—Specification Angle Valve Circuit Relief—Torque....................................................................... 41—49 N·m 30—36 lb.-ft.

9. Assemble work ports reliefs (14) into housing (1). Tighten reliefs to specification. CED,OUO1004,533 -19-14JUL09-2/2

TM14163X19 (15FEB18)

32-3260-13

450K, 550K, and 650K Crawler Dozer 021518 PN=431

Hydraulic System

T118816 —UN—14DEC98

Tilt Control Valve Section Disassemble and Assemble

Control Valve Tilt Section 1— Valve Housing 2— Cap Screw (2 used) 3— Spacer 4— Cap 5— Centering Spring

6— Spool End Screw 7— Spring Seat (2 used) 8— Retaining Plate (2 used)

IMPORTANT: Spool must be installed into the valve housing the same way it was removed for proper operation of the hydraulic function. 1. Remove parts (2, 4, 8, 11 and 12) from valve housing (1). 2. Using a protective cover or wooden blocks, place spool in vise. Remove spool end screw (6), spacer (3), centering spring (5) and spring seats (7). 3. Inspect parts for wear or damage. Replace all O-rings and seals. 4. Put clean hydraulic oil on spool and install spool into valve housing. Install lip seals (10) and wiper seals (9) using JDG10583 Seal Installation Tool. See Wiper Seals and Lip Seals on Hydraulic Control Valve Remove and Install. (Group 3260.) 5. Install parts (3 and 5—8) on spool. Clean threads of spool and spool end screw. Apply PM37509 Cure Primer to threads. Apply PM37421 Thread Lock and

9— Wiper Seal (2 used) 10— Lip Seal (2 used) 11— Screw (2 used)

12— Spool 13— Load Check and Spring

Sealer (high strength) on spool end screw (6). Install and tighten tilt valve spool end screw to specification. Hydraulic Control Valve—Specification Tilt Valve Spool End Screw—Torque.............................................................................9.5 N·m 84 lb.-in.

6. Apply grease to centering spring (5). 7. Assemble remaining parts. Tighten cap screws (2) and screws (11) to specifications. Hydraulic Control Valve—Specification Tilt Valve Spool Cap Socket Head Screws—Torque...........................................................................9.5 N·m 84 lb.-in. Tilt Valve Retainer Plate Screws—Torque...........................................................................5.5 N·m 48 lb.-in.

CED,OUO1004,534 -19-29JUL09-1/1

TM14163X19 (15FEB18)

32-3260-14

450K, 550K, and 650K Crawler Dozer 021518 PN=432

Hydraulic System

T118817 —UN—14DEC98

Lift Control Valve Section Disassemble and Assemble

Control Valve Lift Section 1— Valve Housing 2— Cap Screw (2 used) 3— Centering Spring 4— Detent Spool End Screw 5— Cap 6— Detent Sleeve

7— Spacer 8— Small Detent Ball (4 used) 9— Retainer Ring 10— Large Detent Ball 11— Detent Spring

12— Spring Seat (2 used) 13— Cap Spacer 14— O-Ring 15— O-Ring 16— Lip Seal 17— Wiper Seal 18— Screw (2 used)

19— Spool 20— Retainer Plate 21— Check Valve and Spring

IMPORTANT: For proper valve disassembly, spool should be in center (neutral) position, not the detent position. Spool must be installed into the valve housing the same way it was removed for proper operation of the hydraulic function.

3. Remove parts (3, 4, 8 and 10—12). Remove detent balls (8 and 10) and detent spring (11) from detent spool end screw (4). Remove parts (13—15) from spool (19) and seals (16 and 17) from valve housing (1).

1. Remove retainer ring (9) with a screwdriver and spacer (7). Remove parts (2, 18, and 20). The spool (19) and whole end assembly (3—6, 8 and 10—15) can now be removed from the valve housing (1).

4. Inspect parts for wear or damage. Replace all O-rings and seals. 5.

NOTE: Use a catch pan under valve spool assembly for catching four small detent balls (8) during procedure. 2. Using a protective cover or wooden blocks, put spool in vise. Slide detent spool cap (5) and detent sleeve (6) off of detent spool end screw (4) until detent sleeve is stopped by detent balls (8). Push a 3.8 mm (0.125 in.) punch through detent sleeve into detent spool end screw (4) and depress large detent ball (10) against detent spring (11). This will retract the four small detent balls (8) to allow full removal of parts (5 and 6). Remove detent sleeve from cap (5).

Put clean hydraulic oil on spool (19) and install spool into valve housing (1). On the spool tang (handle) end, install lip seal (16) and wiper seal (17) using JDG10583 Seal Installation Tool. See Wiper Seals and Lip Seals on Hydraulic Control Valve Remove and Install. (Group 3260.)

NOTE: Lubricate O-ring (14) prior to installation to prevent O-ring damage. 6. On cap end, install cap spacer (13) and O-rings (14 and 15).

Continued on next page

TM14163X19 (15FEB18)

32-3260-15

CED,TX03768,2533 -19-14JUL09-1/2

450K, 550K, and 650K Crawler Dozer 021518 PN=433

Hydraulic System

7. Clean threads of spool and spool end screw. Apply PM37509 Cure Primer to threads. Apply PM37421 Thread Lock and Sealer (high strength) on threads and assemble spring seats (12), centering spring (3) and detent spool end screw end screw (4) onto end of spool. Tighten spool end screw to specification. Hydraulic Control Valve—Specification Lift Valve Spool End Screw—Torque.............................................................................9.5 N·m 84 lb.-in.

8. Apply grease to centering spring (3). 9. Install detent spring (11) and detent balls (8 and 10) into detent spool end screw (4). Hold small detent balls (8) in place with grease. 10. Slide cap (5) onto spool end. Slide detent sleeve (6) into cap (5), until it touches detent balls (8). Push a 3.18 mm (0.125 in.) punch through detent sleeve (6) into detent spool end screw (4) and depress large detent ball (10) against detent spring (11). This will

retract the four detent balls (8) to allow full installation of the detent sleeve (6) over the spool end and inside the cap. Check to make sure that all four detent balls (8) are in place. 11. Install spacer (7) and retainer ring (9). Install cap screws (2) and tighten to specification. Hydraulic Control Valve—Specification Lift Valve Cap Socket Head Cap Screws—Torque...........................................................................9.5 N·m 84 lb.-in.

12. Install retainer plate (20) and tighten screws (18) to specification. Hydraulic Control Valve—Specification Lift Valve Spool Retaining Plate Screws—Torque..................................................................5.5 N·m 48 lb.-in. CED,TX03768,2533 -19-14JUL09-2/2

System Relief Valve Disassemble and Assemble NOTE: Only O-rings and backup rings are serviceable as a kit. If other parts are damaged, replace relief valve assembly. 1. Disassemble and inspect parts for wear and damage. 2. Put clean hydraulic oil on all parts before assembly. 3. Adjust system relief valve. See Hydraulic System Relief Valve Test. (Group 9025-25.) J— Piston K—Poppet L— O-Ring M—O-Ring N—O-Ring O—Valve Body P—Spring Q—Valve Body Plug R—Nut T100630 —UN—05MAR97

A—Adjusting Screw B—O-Ring (2 used) C—O-Ring D—Pilot Poppet E—Spring F— Backup Ring G—Spring H—Backup Ring I— Poppet

System Relief Valve—Cross Section PM10405,0000815 -19-30APR12-1/1

TM14163X19 (15FEB18)

32-3260-16

450K, 550K, and 650K Crawler Dozer 021518 PN=434

Hydraulic System

TM14163X19 (15FEB18)

32-3260-17

450K, 550K, and 650K Crawler Dozer 021518 PN=435

Hydraulic System

TX1189171 —UN—23APR15

Hydraulic Control Valve Disassemble and Assemble—IGC

IGC Control Valve

Continued on next page

TM14163X19 (15FEB18)

32-3260-18

SK32938,0000977 -19-30APR15-1/2

450K, 550K, and 650K Crawler Dozer 021518 PN=436

Hydraulic System 1— Outlet Valve Section 2— Lift Valve Section 3— Tilt Valve Section 4— Angle Valve Section 5— Auxiliary Valve Section 6— Inlet Valve Section 7— Solenoid Valve 8— Solenoid Valve Coil 9— Nut 10— Hydraulic Pressure Valve

11— Solenoid Assembly (3-spool, 15— Screw (3-spool, 12 used; 6 used; 4-spool, 8 used) 4-spool, 16 used) 12— Screw (3-spool, 12 used; 16— Solenoid Housing (3-spool, 4-spool, 16 used) 3 used; 4-spool, 4 used) 13— Check Valve (3-spool, 3 17— Check Valve (3-spool, 2 used; 4-spool, 4 used) used; 4-spool, 3 used) 14— Fitting Plug (3-spool, 3 used; 18— Pilot Spring Housing 4-spool, 4 used) (3-spool, 3 used; 4-spool, 4 used)

DISASSEMBLE

19— Spring (3-spool, 3 used; 4-spool, 4 used) 20— Check Valve 21— O-Ring 22— Drain Plug 23— Pressure Relief Valve 24— Tie Rod (3 used) 25— Nut (3 used)

whenever a section or valve is removed for repair or replacement. Lubricate all internal parts, seals, and O-rings before assembling.

IMPORTANT: Prevent damage to mating surfaces of valve sections. Carefully remove and protect components during disassembly.

Apply clean hydraulic oil to all internal parts. Prevent valve spool binding and leakage between sections. Tighten nuts evenly.

Disassemble components as shown. ASSEMBLE IMPORTANT: Prevent damage to hydraulic components. Replace seals and O-rings

Assemble components as shown. SK32938,0000977 -19-30APR15-2/2

Lift Cylinder Remove and Install SPECIFICATIONS

TX1233145A —UN—02FEB17

Lift Cylinder Weight (approximate) 23 kg 51 lb

Lift Cylinder

1. Stop engine and relieve hydraulic system pressure. See Hydraulic System Pressure Release. (Operator’s Manual.) 2. Apply vacuum or drain hydraulic oil reservoir. See Drain and Refill Hydraulic/Hydrostatic System Oil and Replace Filters. (Operator’s Manual.) 3. Install identification tags and disconnect hydraulic lines (1). Close all openings using caps and plugs. CAUTION: Prevent possible crushing injury from heavy component. Use an appropriate lifting device.

1— Hydraulic Line (2 used) 2— Cap Screw (2 used) 3— Pin (2 used)

4— Retainer 5— Lift Cylinder

5. Remove cap screws (2) and retainer (4). 6. Remove pins (3) and lift cylinder. See Hydraulic Cylinder Repair. (Group 3260.) 7. Clean and inspect parts. Repair or replace as necessary. INSTALLATION

4. Attach appropriate lifting device to lift cylinder (5). Specification

Installation is reverse of removal procedure.

Lift Cylinder—Weight (approximate).................................................................................. 23 kg 51 lb JL05046,0000276 -19-10MAR17-1/1

TM14163X19 (15FEB18)

32-3260-19

450K, 550K, and 650K Crawler Dozer 021518 PN=437

Hydraulic System

Tilt Cylinder Remove and Install SPECIFICATIONS

TX1233158A —UN—02FEB17

Tilt Cylinder Weight (approximate) 24 kg 53 lb

Tilt Cylinder

1— Hydraulic Line (2 used) 2— Cap Screw (2 used) 3— Pin (2 used)

4— Retainer (2 used) 5— Tilt Cylinder

5. Remove cap screws (2) and retainer (4).

3. Install identification tags and disconnect hydraulic lines (1). Close all openings using caps and plugs.

6. Remove pins (3) and tilt cylinder. See Hydraulic Cylinder Repair. (Group 3260.)

CAUTION: Prevent possible crushing injury from heavy component. Use an appropriate lifting device.

7. Clean and inspect parts. Repair or replace as necessary. INSTALLATION

4. Attach appropriate lifting device to tilt cylinder (5).

Installation is reverse of removal procedure.

Specification Tilt Cylinder—Weight (approximate).................................................................................. 24 kg 53 lb

JL05046,0000278 -19-10MAR17-1/1

Angle Cylinder Remove and Install CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.

TX1233418A —UN—07FEB17

REMOVAL 1. Stop engine and relieve hydraulic system pressure. See Hydraulic System Pressure Release. (Operator’s Manual.) 2. Apply vacuum or drain hydraulic oil reservoir. See Drain and Refill Hydraulic/Hydrostatic System Oil and Replace Filters. (Operator’s Manual.) 3. Remove clamps (1), cap screw (2), and hose guard (3). 1— Clamp (2 used) 2— Cap Screw

3— Hose Guard 4— Angle Cylinder Continued on next page

TM14163X19 (15FEB18)

Angle Cylinder Hose Guard

32-3260-20

JL05046,0000277 -19-27FEB17-1/2

450K, 550K, and 650K Crawler Dozer 021518 PN=438

Hydraulic System

4. Install identification tags and disconnect hydraulic lines (5). Close all openings using caps and plugs. 5. Remove cap screws (6) and retainers (7). 6. Remove pins (8) and angle cylinder (4). 7. Clean and inspect parts. Repair or replace as necessary. See Hydraulic Cylinder Repair. (Group 3260.) TX1233419A —UN—06FEB17

INSTALLATION Installation is reverse of removal procedure. 4— Angle Cylinder 5— Hydraulic Line (2 used) 6— Cap Screw (2 used)

7— Retainer (2 used) 8— Pin (2 used)

Angle Cylinder JL05046,0000277 -19-27FEB17-2/2

Hydraulic Cylinder Repair Repair or replace parts as necessary. See Cylinder Disassembly. (CTM120519.) JL05046,0000273 -19-24JAN17-1/1

TM14163X19 (15FEB18)

32-3260-21

450K, 550K, and 650K Crawler Dozer 021518 PN=439

Hydraulic System

TM14163X19 (15FEB18)

32-3260-22

450K, 550K, and 650K Crawler Dozer 021518 PN=440

Section 42 Ground Conditioning Tool Contents Page

Group 4200—Ripper Ripper Remove and Install—If Equipped ............................................... 42-4200-1 Group 4201—Blades, Teeth, and Shanks Shank and Tooth Remove and Install ..................................................... 42-4201-1 Group 4260—Hydraulic System Ripper Cylinder Remove and Install ..................................................... 42-4260-1

TM14163X19 (15FEB18)

42-1

450K, 550K, and 650K Crawler Dozer

021518

PN=1

Contents

TM14163X19 (15FEB18)

42-2

450K, 550K, and 650K Crawler Dozer

021518

PN=2

Group 4200

Ripper Ripper Remove and Install—If Equipped SPECIFICATIONS Ripper Weight (approximate)

980 kg 2161 lb

Cap Screw Torque

675 N·m 498 lb·ft

REMOVAL TX1233025A —UN—30JAN17

Ripper

2. Apply vacuum or drain hydraulic oil reservoir. See Drain and Refill Hydraulic/Hydrostatic System Oil and Replace Filters. (Operator’s Manual.) 3. Remove shanks. See Shank and Tooth Remove and Install. (Group 4201.) 4. Install identification tags and disconnect hydraulic lines (1). Close all openings using caps and plugs.

1— Hydraulic Line (2 used) 2— Ripper

3— Cap Screw (14 used)

7. Clean and inspect parts. Repair or replace as necessary. INSTALLATION

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 5. Use appropriate lifting device to support ripper (2). Specification Ripper—Weight (approximate)................................................................................ 980 kg 2161 lb

Installation is reverse of removal procedure.

• Tighten cap screws to specification. Specification Cap Screw—Torque....................................................................675 N·m 498 lb·ft

6. Remove cap screws (3) and ripper. JL05046,0000275 -19-10MAR17-1/1

TM14163X19 (15FEB18)

42-4200-1

450K, 550K, and 650K Crawler Dozer 021518 PN=443

Ripper

TM14163X19 (15FEB18)

42-4200-2

450K, 550K, and 650K Crawler Dozer 021518 PN=444

Group 4201

Blades, Teeth, and Shanks Shank and Tooth Remove and Install SPECIFICATIONS Shank Weight (approximate)

43 kg 95 lb

REMOVAL 1. Park machine on a flat, level surface and lower front attachment to the ground. TX1232993A —UN—27JAN17

2. Raise and support ripper frame, allowing clearance for shank (3) removal. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 3. Attach appropriate lifting device to shank. Specification Shank—Weight (approximate).................................................................................. 43 kg 95 lb

4. Remove cotter pin (1), pin (2), and shank.

Shank and Tooth 1— Cotter Pin 2— Pin 3— Shank

4— Pin 5— Tooth

5. Remove pin (4) and tooth (5). 6. Clean and inspect parts. Repair or replace as necessary. INSTALLATION Installation is reverse of removal procedure. JL05046,0000274 -19-08FEB17-1/1

TM14163X19 (15FEB18)

42-4201-1

450K, 550K, and 650K Crawler Dozer 021518 PN=445

Blades, Teeth, and Shanks

TM14163X19 (15FEB18)

42-4201-2

450K, 550K, and 650K Crawler Dozer 021518 PN=446

Group 4260

Hydraulic System Ripper Cylinder Remove and Install SPECIFICATIONS Ripper Cylinder Weight (approximate)

66 kg 144 lb.

1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) 2. Operate all hydraulic controls to release pressure in hydraulic system. 3. Turn battery disconnect to the OFF position. See Battery Disconnect Switch. (Operator’s Manual.)

TX1113408 —UN—04MAY12

1 2

4. To reduce hydraulic oil loss, apply vacuum to hydraulic reservoir. CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.

Ripper Cylinder Hydraulic Hose 1— Cylinder Hydraulic Hose (rod end)

2— Cylinder Hydraulic Hose (head end)

5. Tag and disconnect hydraulic hoses (1 and 2) on ripper cylinder (7). Close all openings using caps and plugs. Continued on next page

TM14163X19 (15FEB18)

42-4260-1

AB51738,0000AC2 -19-26JAN17-1/2

450K, 550K, and 650K Crawler Dozer 021518 PN=447

Hydraulic System

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

7 5

6. Using an appropriate lifting device, support upper ripper frame (6). 7. Remove lock nut (5) and cap screw (4) from rod end and head end of cylinder.

8. Using an appropriate lifting device, support ripper cylinder (7).

TX1113580 —UN—08MAY12

Specification Ripper Cylinder—Weight (approximate).................................................................................. 66 kg 144 lb.

9. Remove pins (3) from ripper cylinder and remove cylinder. 10. Repair or replace ripper cylinder as needed. See Cylinder Identification. (CTM120519.) 11. Install ripper cylinder (7) and pins (3).

Ripper Cylinder Pin (rod end)

12. Install cap screws (4) and lock nuts (5). 13. Connect hydraulic hoses (1 and 2) to ripper cylinder (7). 14. Turn battery disconnect switch to the ON position. See Battery Disconnect Switch. (Operator’s Manual.) 15. Start engine and verify operation of ripper. 16. Check hydraulic oil level. See Check Hydraulic/Hydrostatic System Oil Level. (Operator’s Manual.) 3— Pin (2 used) 4— Cap Screw (2 used) 5— Lock Nut (2 used)

6— Upper Ripper Frame 7— Ripper Cylinder

5 3

TX1113581 —UN—08MAY12

Ripper Cylinder (head end) AB51738,0000AC2 -19-26JAN17-2/2

TM14163X19 (15FEB18)

42-4260-2

450K, 550K, and 650K Crawler Dozer 021518 PN=448

Contents

Section 99 Dealer Fabricated Tools

Page

Group 9900—Dealer Fabricated Tools DF1041 Track Nut Removal Tool .............. 99-9900-1 DF1063 Lift Bracket................................... 99-9900-2 DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool ............................................. 99-9900-3 DFT1119 Pump Support ............................ 99-9900-4 DFT1130 Adapter ...................................... 99-9900-5 DFT1132 Hydrostatic Motor/Hydraulic Pump Tool ................... 99-9900-6 DFT1137 Hydrostatic Motor Removal and Installation Tool................ 99-9900-7 DFT1166 Final Drive Lifting Bracket Adapter .................................................. 99-9900-8 DFT1167 Final Drive Lifting Bracket Adapter Spacer...................................... 99-9900-9 DFT1211 Final Drive Lifting Bracket Adapter ................................................ 99-9900-10 DFT1278 30 mm Wrench With 3/4-in Drive .......................................... 99-9900-10 ST4920 Track Recoil Spring Disassembly and Assembly Tool ...................................................... 99-9900-11

TM14163X19 (15FEB18)

99-1

450K, 550K, and 650K Crawler Dozer

021518

PN=1

Contents

TM14163X19 (15FEB18)

99-2

450K, 550K, and 650K Crawler Dozer

021518

PN=2

Group 9900

Dealer Fabricated Tools

TX1074246 —UN—22APR10

DF1041 Track Nut Removal Tool

DF1041 Track Nut Removal Tool 1— 3/8 in Drill and Tap 2— Weld Block; Grind Round

3— 2 Slots 9.5 mm x 19.0 mm (3/8 4— 3/8 in Drill and Tap; Locates in x 3.4 in) Nut with Cap Screw in Assembly

Use DF1041 Track Nut Removal Tool to remove and install track shoe nuts. TX,DF1041 -19-08JUN16-1/1

TM14163X19 (15FEB18)

99-9900-1

450K, 550K, and 650K Crawler Dozer 021518 PN=451

Dealer Fabricated Tools

DF1063 Lift Bracket 1 2 2 2 2 2 2 2 5

4 9

7 11 12

4 13 5

14 13 8

TX1072724

TX1072724 —UN—05MAR10

DF1063 Lift Bracket 1— 508.0 mm (20.0 in) 2— 50.8 mm (2.0 in) 3— 25.4 mm (1.0 in) 4— 38.1 mm (1.50 in) 5— 203.2 mm (8.0 in)

6— 63.5 mm (2.50 in) 7— 2286.0 mm (90.0 in) 8— 152.4 mm (6.0 in) 9— 3/4 in Drill Through Both Sides (8 holes)

Use DF1063 Lift Bracket to remove and install components. Material required:

10— 3/8 in Drill Through (4 holes) 14— 82.6 mm (3.25 in) 11— 44.5 mm (1.75 in) 15— 114.3 mm (4.50 in) 12— 76.2 mm (3.0 in) 13— 15.9 mm (0.625 in)

• 1.5 in x 3.0 in square tube • 1/2 in 1020 steel • 3/8 in x 1.5 in cap screw with nut (4 used) TX,DF1063 -19-27MAY16-1/1

TM14163X19 (15FEB18)

99-9900-2

450K, 550K, and 650K Crawler Dozer 021518 PN=452

Dealer Fabricated Tools

T7162AF —UN—17OCT89

DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool

DFT1087 Dimensions A—3/16 in 1020 CR Steel Plate B—9/16 in Hole (2 places)

C—1/2 in Nut (2 used) E—1/2 x 3 in Steel Round Stock D—1/2 x 2 in Cap Screw (2 used) (2 used)

Track Recoil Spring Disassembly and Assembly Guard Tool is used with ST4920 Track Recoil Spring Disassembly and Assembly Tool. See ST4920 Track Recoil Spring Disassembly and Assembly Tool. (Group 9900.) Material required:

• 3/16 in 1020 CR Steel Plate (A) • 9/16 in Hole (2 places) (B) • 1/2 in Nut (2 used) (C) • 1/2 x 2 in Cap Screw (D) (2 used) • 1/2 x 3 in Steel Round Stock (E) (2 used) TX,DFT1087 -19-08JUN16-1/2

Track Recoil Spring Guard Tool...........................DFT1087

Used with ST4920 Track Recoil Spring Disassembly and Assembly Tool. TX,DFT1087 -19-08JUN16-2/2

TM14163X19 (15FEB18)

99-9900-3

450K, 550K, and 650K Crawler Dozer 021518 PN=453

Dealer Fabricated Tools

DFT1119 Pump Support Ø38 mm (1.5 in.) 13 mm (0.5 in.) 76 mm (3 in.)

13 mm (0.5 in.) 76.2 x 76.2 x 6.35 mm 610 mm (3 x 3 x 0.250 in.) (24 in.) 9.5 mm 76 mm (0.375 in.) (3 in.) 9.5 mm (0.375 in.) Ø11 mm (0.438 in.)

19 mm (0.750 in.)

89 mm (3.5 in.) 102 mm (4 in.) 63.5 x 63.5 x 6.35 mm (2.5 x 2.5 x 0.250 in.)

Ø11 mm (0.438 in.) 12 PLACES

38 mm (1.5 in.) 76 mm (3 in.) 114 mm (4.5 in.)

457 mm (18 in.)

Ø12 mm (0.472 in.) 5 Places

38 mm (1.5 in.) 76 mm (3 in.) 152 mm (6 in.) 229 mm (9 in.) 305 mm (12 in.) 380 mm (15 in.) 457 mm (18 in.) 533 mm (21 in.) 610 mm (24 in.)

9.5 mm (0.375 in.)

1524 mm (60 in.)

104.8 mm (4.125 in.) 165 mm (6.5 in.) 376 mm (14.8 in.)

TX1022920 —UN—11JAN08

9.5 mm (0.375 in.)

88.9 x 88.9 x 6.35 mm (3.5 x 3.5 x 0.250 in.)

233 mm (9.2 in.) TX1022920

335 mm (13.2 in.) DFT1119 Pump Support

Use DFT1119 Pump Support with a hand hoist to support pump when engine is removed. Two end stands are needed.

• 76.2 mm x 76.2 mm x 6.35 mm (3.0 in x 3.0 in x 0.25 in) Square Steel Tubing

• 63.5 mm x 63.5 mm x 6.35 mm (2.5 in x 2.5 in x 0.25 in) Square Steel Tubing

Drill the holes through the square steel tubing so they are centered.

• 19 mm (3/4 in.) Flat Bar Stock • M10 x 89 mm or 3/8 in x 3-1/2 in Grade D (SAE Grade

Material required: • C3 x 5 Steel Channel • 88.9 mm x 88.9 mm x 6.35 mm (3.5 in x 3.5 in x 0.25 in) Square Steel Tubing

• M10 or 3/8 in Grade D (SAE Grade 5) Nut (2 used)

5) Cap Screw (2 used)

TX,DFT1119 -19-14SEP16-1/1

TM14163X19 (15FEB18)

99-9900-4

450K, 550K, and 650K Crawler Dozer 021518 PN=454

Dealer Fabricated Tools

T8319BN —UN—20SEP94

DFT1130 Adapter

DFT1130 Adapter Specifications A—Adapter Plate

B—Tube C—Stop Plate

Adapter is used with DF1063 Lift Bracket to remove and install travel motor. Material required:

• 38.1 mm x 38.1 mm x 4.8 mm (1-1/2 in x 1-1/2 in x 3/16 in) square tube (B)

• 6.4 mm (1/4 in) 1020 steel plate (C)

• 12.7 mm (1/2 in) 1020 steel plate (A) TX,DFT1130 -19-07JUN16-1/1

TM14163X19 (15FEB18)

99-9900-5

450K, 550K, and 650K Crawler Dozer 021518 PN=455

Dealer Fabricated Tools

T8366AC —UN—15APR13

DFT1132 Hydrostatic Motor/Hydraulic Pump Tool

DFT1132 Hydrostatic Motor/Hydraulic Pump Tool A—1 in Nut B—Pipe 2134 mm (84 in) long

C—Pipe 457 mm (18 in) long D—1 in ID Heavy Wall Steel Pipe

Use with DFT1137 Hydrostatic Motor Removal and Installation Tool to remove and install hydrostatic motors and hydraulic pump from machine.

E—Pipe F— Weld G—Pipe

• 25.4 mm (1 in) ID x 2591 mm (102 in) long heavy wall steel pipe

• Weld (E) to (G)

Material required: TX,DFT1132 -19-07JUN16-1/1

TM14163X19 (15FEB18)

99-9900-6

450K, 550K, and 650K Crawler Dozer 021518 PN=456

Dealer Fabricated Tools

TX1074242 —UN—22APR10

DFT1137 Hydrostatic Motor Removal and Installation Tool

DFT1137 Hydrostatic Motor Removal and Installation Tool 1— Top Piece

2— Bottom Piece

Use with DFT1132 to remove and install hydrostatic motors from rear of machine. Material required:

• 1-1/2 in x 3/4 in x 12 in long steel bars (2 used) • M12 x 1.75 eyebolt • 1/2 in x 9 in cap screw (2 used, 750J)

• 1/2 in x 10 in cap screw (2 used, 850J) Assembly: Install and tighten eyebolt in bracket. Trim any excess eyebolt material so it is even with bottom surface of bracket. TX,DFT1137 -19-07JUN16-1/1

TM14163X19 (15FEB18)

99-9900-7

450K, 550K, and 650K Crawler Dozer 021518 PN=457

Dealer Fabricated Tools

T118673 —UN—01DEC98

DFT1166 Final Drive Lifting Bracket Adapter

To be used with DFT1063 Final Drive Lifting Bracket and DFT1167 Final Drive Lifting Bracket Adapter Spacer.

Material: 1/2 in. 1020 Steel TX,DFT1166 -19-07JUN16-1/1

TM14163X19 (15FEB18)

99-9900-8

450K, 550K, and 650K Crawler Dozer 021518 PN=458

Dealer Fabricated Tools

T118674 —UN—01DEC98

DFT1167 Final Drive Lifting Bracket Adapter Spacer

To be used with DFT1166 Final Drive Lifting Bracket Adapter when installing DF1063 Final Drive lifting Bracket.

Material: 1/2 in. 1020 Steel Plate TX,DFT1167 -19-07JUN16-1/1

TM14163X19 (15FEB18)

99-9900-9

450K, 550K, and 650K Crawler Dozer 021518 PN=459

Dealer Fabricated Tools

TX1074262 —UN—05APR10

DFT1211 Final Drive Lifting Bracket Adapter

DFT1211 Lifting Bracket Adapter

DFT1211 Lifting Bracket Adapter used with JT01748 Lifting Bracket to remove and install final drive.

• 38.1 mm x 101.6 mm x 12.7 mm (1.5 in x 4 in x 0.5 in) 1020 steel plate

Material required: TX,DFT1211 -19-07JUN16-1/1

DFT1278 30 mm Wrench With 3/4-in Drive

Material required:

• 30 mm 12-point box end wrench • 3/4-in drive socket 1— 30 mm 12-Point Box End Wrench 2— 171 mm (6.75 in)

3— 3/4-in Drive Socket (weld on)

TX1008812A —UN—16JUN06

Used to remove hard to reach hydrostatic pump mounting nuts.

TX,DFT1278 -19-27MAY16-1/1

TM14163X19 (15FEB18)

99-9900-10

450K, 550K, and 650K Crawler Dozer 021518 PN=460

Dealer Fabricated Tools

ST4920 Track Recoil Spring Disassembly and Assembly Tool NOTE: It is recommended that DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool be used with track recoil spring disassembly and assembly tool. Dimensions given are metric. Tool is the same as used on other machines except the holder (C). For each track adjuster use the holder with the correct size hole for the nut on that track adjuster. Track Recoil Spring Disassembly and Assembly Tool (compression tool) is used with hydraulic jack to compress recoil spring in track adjuster repair. Material required:

• 1020 HR Steel for Holder (C), Supporting Plate (E), Base Plate (F), and Base (G).

T6585UY —UN—24MAR98

• "D" Grade (SAE Grade 5) for Eyebolts (D), Nuts (A), and Cap Screws (H).

• "F" Grade (SAE Grade 8) for Studs (B). Print Numbers:

• A—ST4050 Nut • B—ST4045 Bolt • C—ST4035 Holder (Plate)

- ST4036 Holder (Plate) - ST4037 Holder (Plate) • D—ST4047 Eyebolt • E—ST4040 Supporting Base • F—ST4042 Base Plate • G—ST4041 Base • H—ST4046 Cap Screw • I—ST4049 Lock Washer

A—Nut (12 used) B—Stud (4 used) C—Holder D—Eyebolt (2 used) E—Supporting Plate

Continued on next page

TM14163X19 (15FEB18)

99-9900-11

F— Base Plate G—Base (4 used) H—Cap Screw (8 used) I— Lock Washer (8 used)

TX,01,RB519 -19-19APR06-1/4

450K, 550K, and 650K Crawler Dozer 021518 PN=461

T7029CI —UN—06JUL89

Dealer Fabricated Tools

Continued on next page

TM14163X19 (15FEB18)

99-9900-12

TX,01,RB519 -19-19APR06-2/4

450K, 550K, and 650K Crawler Dozer 021518 PN=462

T7029CH —UN—06JUL89

Dealer Fabricated Tools

Continued on next page

TM14163X19 (15FEB18)

99-9900-13

TX,01,RB519 -19-19APR06-3/4

450K, 550K, and 650K Crawler Dozer 021518 PN=463

T7029CG —UN—06JUL89

Dealer Fabricated Tools

A—Nut (12 used) B—Stud (4 used) C—Holder

D—Eyebolt (2 used) E—Supporting Plate F— Base Plate

G—Base (4 used) H—Cap Screw (8 used) I— Lock Washer (8 used) TX,01,RB519 -19-19APR06-4/4

TM14163X19 (15FEB18)

99-9900-14

450K, 550K, and 650K Crawler Dozer 021518 PN=464

Index Page Page

A Adjust track sag ............................................... 01-0130-46 Adjuster Track tension, remove and disassemble ............................................... 01-0130-59 Adjustment Backup alarm volume .................................... 20-2004-1 Air cleaner Remove and install ........................................ 05-0520-1 Air conditioner freeze control switch Remove and install ........................................ 16-1600-5 Air conditioner system Flush and purge ............................................. 18-1830-4 Air conditioning Charge ........................................................... 18-1830-6 R134a refrigerant oil information.................... 18-1830-2 Refrigerant cautions and proper handling........................................................ 18-1830-1 Air conditioning compressor Remove and install ...................................... 18-1830-18 Air suspension seat Remove and install ........................................ 18-1821-1 Alignment procedure Exhaust bellows ............................................. 05-0530-6 Angle control valve section Disassemble and assemble ......................... 32-3260-12 Angle cylinder Assemble ..................................................... 32-3260-21 Disassemble ................................................ 32-3260-21 Remove and install ...................................... 32-3260-20 Assemble Hydrostatic motor......................................... 03-0360-37 Hydrostatic pump ......................................... 03-0360-17 Attachments Adding safely ............................................... 00-0001-16 Operating safely........................................... 00-0001-16 Auxiliary blade control linkage Remove and install ........................................ 32-3215-4 Auxiliary control valve section Disassemble and assemble ......................... 32-3260-11 Auxiliary fuel filter Remove and install ........................................ 05-0560-2 Auxiliary fuel filter and water separator Remove and install ........................................ 05-0560-2 Auxiliary joystick Remove and install ........................................ 16-1600-3 Avoid static electricity risk when fueling ............ 00-0001-6

B Backover Accidents ......................................... 00-0001-13 Backup alarm Remove and install ........................................ 20-2004-1 Backup alarm volume Adjustment ..................................................... 20-2004-1

Bellows alignment JDG11340 bellows alignment fixture.............. 05-0530-2 Bellows alignment procedure Exhaust .......................................................... 05-0530-6 Blade Remove and install ........................................ 32-3201-2 Blade control linkage Remove and install ........................................ 32-3215-1 Blade edges and end bits Remove and install ........................................ 32-3201-1 Blower motor Remove and install ...................................... 18-1830-12 Blower motor speed resistor Remove and install ...................................... 18-1830-12 Bottom guards Remove and install ........................................ 17-1746-1 Brake valve Remove and install .........................................11-1100-3 Brake, park Remove and install .........................................11-1100-1 Brakes, park Disassemble and assemble ............................11-1160-1 Bushing Bushing outside diameter for lubricated track chain inspection................................. 01-0130-26

C C-Frame Remove and install ........................................ 32-3240-1 Carrier roller Disassemble and assemble ........................... 01-0130-6 Leakage test ................................................ 01-0130-10 Remove and install ........................................ 01-0130-4 Wear Inspection ............................................. 01-0130-4 CE Mark Location ......................................................... 00-0001-1 Chain, lubricated track Remove and install ...................................... 01-0130-28 Charge air cooler Remove and install ........................................ 05-0510-9 Charge pump Disassemble and assemble ........................... 03-0360-9 Cinch™ connectors 32 and 48-way, repair .................................. 16-1600-19 Install contact ............................................... 16-1600-18 Replace........................................................ 16-1600-16 Cleaning Service filter ................................................. 05-0530-16 Cleaning procedure DEF tank ...................................................... 05-0530-21 Diesel exhaust fluid (DEF) tank ................... 05-0530-21 Cleanup procedure Hydraulic component failure .......................... 21-2160-2 Oil................................................................... 21-2160-1 Compressor Remove and install ...................................... 18-1830-18 Continued on next page

TM14163X19 (15FEB18)

Index-1

450K, 550K, and 650K Crawler Dozer 021518 PN=1

Index

Page

Condenser Remove and install ...................................... 18-1830-17 Connector repair Blade terminal, remove connector body ........................................................... 16-1600-21 Cinch™, 32 and 48-way............................... 16-1600-19 Cinch™, install contact ................................ 16-1600-18 Cinch™, replace .......................................... 16-1600-16 DEUTSCH® circular, replace....................... 16-1600-13 DEUTSCH® rectangular, replace ................ 16-1600-11 DEUTSCH® triangular, replace ................... 16-1600-11 DEUTSCH®, install contact ......................... 16-1600-15 DEUTSCH®, replace ................................... 16-1600-14 Metri-Pack...................................................... 16-1600-8 Metri-Pack® pull type, replace ....................... 16-1600-7 Metri-Pack® push type, replace..................... 16-1600-8 Molex ........................................................... 16-1600-22 Tyco™, replace ............................................ 16-1600-23 Weather Pack™, install contact ................... 16-1600-10 Weather Pack™, replace ............................... 16-1600-9 Control valve, IGC Disassemble and assemble ......................... 32-3260-18 Cooling package Remove and install ........................................ 05-0510-4 Cooling system Service safely............................................... 00-0001-17 Counterweight, front Remove and install ........................................ 17-1749-1 Counterweight, rear Remove and install ........................................ 17-1749-2 Cutting edges and end bits Remove and install ........................................ 32-3201-1 Cylinder Hydraulic, repair........................................... 32-3260-21 Cylinder, angle Assemble ..................................................... 32-3260-21 Disassemble ................................................ 32-3260-21 Cylinder, lift Assemble ..................................................... 32-3260-21 Disassemble ................................................ 32-3260-21 Cylinder, tilt Assemble ..................................................... 32-3260-21 Disassemble ................................................ 32-3260-21

DFT1132 hydrostatic motor/hydraulic pump tool ..................................................... 99-9900-6 DFT1137 hydrostatic motor removal.............. 99-9900-7 DFT1166 Final drive lifting bracket adapter ......................................................... 99-9900-8 DFT1167 Final drive lifting bracket adapter spacer .......................................................... 99-9900-9 DFT1211 final drive lifting bracket adapter ....................................................... 99-9900-10 DFT1278 30 mm wrench with 3/4-in drive ........................................................... 99-9900-10 Decelerator sensor Remove and install ........................................ 16-1600-4 Decelerator-Brake Pedal Disassemble and Assemble......................... 03-0315-20 Remove and Install ...................................... 03-0315-19 Decomposition tube Remove and install ...................................... 05-0530-23 DEF decomposition tube Remove and install ...................................... 05-0530-23 DEF dosing injector Remove and install ...................................... 05-0530-23 DEF dosing unit Remove and install ...................................... 05-0530-22 DEF tank Cleaning procedure...................................... 05-0530-21 Remove and install ...................................... 05-0530-18 DEF tank header Disassemble and assemble ......................... 05-0530-20 DEUTSCH® connectors Circular, replace ........................................... 16-1600-13 Install contact ............................................... 16-1600-15 Rectangular, replace .................................... 16-1600-11 Replace........................................................ 16-1600-14 Triangular, replace ....................................... 16-1600-11 DF1041 track nut removal tool .......................... 99-9900-1 DF1063 lift bracket ............................................ 99-9900-2 DFT1087 track recoil spring disassembly and assembly guard tool.................................. 99-9900-3 DFT1119 pump support ..................................... 99-9900-4 DFT1130 adapter............................................... 99-9900-5 DFT1132 hydrostatic motor/hydraulic pump tool ................................................................... 99-9900-6 DFT1137 hydrostatic motor removal ................. 99-9900-7 DFT1166 Final drive lifting bracket adapter............................................................. 99-9900-8 DFT1167 Final drive lifting bracket adapter spacer .............................................................. 99-9900-9 DFT1211 Final drive lifting bracket adapter........................................................... 99-9900-10 DFT1278 30 mm wrench with 3/4-in drive ............................................................... 99-9900-10 Diassemble and assemble Integrated grade control (IGC) lever .............. 16-1600-2 Diesel exhaust fluid (DEF) decomposition tube Remove and install ...................................... 05-0530-23

D Damper drive Remove and install ........................................ 03-0325-1 Dealer fabricated tool ST4920 track recoil spring disassembly and assembly tool ...................................... 99-9900-11 Dealer fabricated tools DF1041 track nut removal tool....................... 99-9900-1 DF1063 lift bracket......................................... 99-9900-2 DFT1087 track recoil spring disassembly and assembly guard tool .............................. 99-9900-3 DFT1119 pump support ................................. 99-9900-4 DFT1130 adapter ........................................... 99-9900-5

Continued on next page

TM14163X19 (15FEB18)

Index-2

450K, 550K, and 650K Crawler Dozer 021518 PN=2

Index

Page

Diesel exhaust fluid (DEF) dosing injector Remove and install ...................................... 05-0530-23 Diesel exhaust fluid (DEF) dosing unit Remove and install ...................................... 05-0530-22 Diesel exhaust fluid (DEF) tank Cleaning procedure...................................... 05-0530-21 Remove and install ...................................... 05-0530-18 Diesel exhaust fluid (DEF) tank header Disassemble and assemble ......................... 05-0530-20 Diesel exhaust fluid header Remove and install ...................................... 05-0530-19 diesel oxidation catalyst (DOC) Remove and install ...................................... 05-0530-11 Diesel particulate filter (DPF) Remove and install ...................................... 05-0530-12 Disassemble Hydrostatic motor......................................... 03-0360-25 Hydrostatic pump ........................................... 03-0360-1 Disassemble and assemble Charge pump ................................................. 03-0360-9 Control Valve, IGC ....................................... 32-3260-18 DEF tank header.......................................... 05-0530-20 Diesel exhaust fluid (DEF) tank header ........................................................ 05-0530-20 Heater .......................................................... 18-1830-13 IGC control valve ......................................... 32-3260-18 Under seat heater ........................................ 18-1830-15 Disassemble and Assemble Decelerator-Brake Pedal.............................. 03-0315-20 Park Lock Linkage .......................................... 11-1115-3 Transmission Control Lever (TCL) ................. 03-0315-2 Drawbar Remove and install ........................................ 15-1511-1

Eurasian Economic Union Technical Regulations...................................................... 00-0001-1 European Union Directives Compliance............ 00-0001-1 Evaporator Remove and install ........................................ 18-1830-7 Exhaust Bellows alignment procedure......................... 05-0530-6 Exhaust bellows Alignment procedure...................................... 05-0530-6 Exhaust filter...................................................... 00-0001-9 Remove and install ..................05-0530-13, 05-0530-14 Exhaust filter sensor Installation...................................................... 16-1600-4 Exhaust filter structure Remove and install ...................................... 05-0530-14 Exhaust Filter, Safety Safety, Exhaust Filter ................................... 00-0001-20 Exhaust tube Remove and Install ........................................ 05-0530-1 Expansion valve Remove and install ...................................... 18-1830-11 Extended drawbar Remove and install ........................................ 15-1511-2

E EAC Marking ..................................................... 00-0001-1 ECU Remove and install ........................................ 16-1600-7 Edges, cutting Remove and install ........................................ 32-3201-1 Electrical Welding procedure......................................... 17-1740-1 End bits Remove and install ........................................ 32-3201-1 Engine John deere ..................................................... 04-0400-1 Mounts, remove and install ............................ 04-0400-6 Remove and install ........................................ 04-0400-1 Theory of operation........................................ 04-0400-1 Engine control unit (ECU) Remove and install ........................................ 16-1600-7 Engine coolant heater Remove and install ........................................ 05-0505-1 Engine mounts Remove and install ........................................ 04-0400-6 Engine side shields Remove and install ........................................ 19-1910-2

F Fan blade Remove and install ........................................ 05-0510-1 Filter, hydrostatic Disassemble and assemble ......................... 03-0360-54 Remove and install ...................................... 03-0360-53 Final drive Disassemble and assemble ........................... 02-0250-1 Remove and install ........................................ 02-0201-1 Fire prevention................................................... 00-0001-7 FNR sensor Remove and install ........................................ 16-1600-4 Frame Track, remove and install............................. 01-0130-67 Frame wear strips Remove and install ...................................... 01-0130-68 Front idler Adjustment ................................................... 01-0130-57 Disassemble and assemble ......................... 01-0130-50 Oil level check.............................................. 01-0130-58 Remove and install ...................................... 01-0130-49 Fuel tank Remove and install ........................................ 05-0560-3

G Grille Remove and install ........................................ 19-1921-1 Grouser Track shoe, wear inspection ........................ 01-0130-23

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TM14163X19 (15FEB18)

Index-3

450K, 550K, and 650K Crawler Dozer 021518 PN=3

Index

Page

H Heater Disassemble and assemble ......................... 18-1830-13 Heater core Remove and install ........................................ 18-1830-7 Hood Remove and install ........................................ 19-1910-1 HVAC Charge ........................................................... 18-1830-6 Hydraulic Component failure cleanup procedure ..................................................... 21-2160-2 Fittings, 30° cone seat ................................... 00-0003-4 Fittings, 37° flare ............................................ 00-0003-4 Oil cleanup procedure.................................... 21-2160-1 Hydraulic control valve Disassemble and assemble ........................... 32-3260-4 Disassemble and assemble lift section........................................................ 32-3260-15 Disassemble and assemble tilt section........................................................ 32-3260-14 Remove and install ........................................ 32-3260-1 Wiper seals and lip seals, replace ................. 32-3260-5 Hydraulic control valve, IGC Remove and install ........................................ 32-3260-2 Hydraulic cylinder Repair .......................................................... 32-3260-21 Hydraulic fan motor Remove and install ...................................... 21-2160-11 Hydraulic fan pump Remove and install ...................................... 21-2160-10 Hydraulic fitting Flared connections......................................... 00-0003-7 Non-restricted banjo (adjustable)................. 00-0003-18 O-ring boss with shoulder ............................ 00-0003-19 Hydraulic pump Disassemble and assemble (with winch option) .......................................................... 21-2160-4 Disassemble and assemble (without winch option) ................................................ 21-2160-8 Remove and install ........................................ 21-2160-3 Hydraulic reservoir Remove and install ...................................... 03-0360-55 Hydrostatic and Hydraulic Reservoir Cleanout Cover Remove and Install ...................................... 03-0360-55 Hydrostatic filter Disassemble and assemble ......................... 03-0360-54 Remove and install ...................................... 03-0360-53 Hydrostatic motor Assemble ..................................................... 03-0360-37 Disassemble ................................................ 03-0360-25 Initial start-up procedure ................................ 03-0300-1 Remove and install ........................................ 03-0300-6 Hydrostatic oil cooler Remove and install ...................................... 05-0510-10

Hydrostatic pump Assemble ..................................................... 03-0360-17 Disassemble .................................................. 03-0360-1 Initial start-up procedure ................................ 03-0300-1 Multifunction valve, disassemble and assemble.................................................... 03-0360-15 Neutral charge relief valve, disassemble and assemble............................................. 03-0360-24 Pump displacement control valve (PDCV), disassemble and assemble........................ 03-0360-13 Remove and install ........................................ 03-0300-2 Hydrostatic system Hydrostatic pump and motor initial start-up procedure ..................................................... 03-0300-1

I Identification Manual ....................................................................... --3 Idler Front, adjustment ......................................... 01-0130-57 Front, oil level check .................................... 01-0130-58 Front, remove and install ............................. 01-0130-49 Idler, front Disassemble and assemble ......................... 01-0130-50 Measure wear .............................................. 01-0130-48 IGC auxiliary joystick Remove and install ........................................ 16-1600-3 IGC control valve Disassemble and assemble ......................... 32-3260-18 IGC valve Remove and install ........................................ 32-3260-2 Inch bolt and cap screw Torque value .................................................. 00-0003-3 Inch series four bolt flange fitting Service recommendation, torque value for high pressure ............................................. 00-0003-17 Inspection Bushing outside diameter for lubricated track chain.................................................. 01-0130-26 Carrier roller wear .......................................... 01-0130-4 Track link height........................................... 01-0130-25 Track shoe grouser wear ............................. 01-0130-23 Installation Exhaust filter sensor ...................................... 16-1600-4 Integrated grade control (IGC) Remove and install ........................................ 16-1600-1 Integrated grade control (IGC) lever Diassemble and assemble............................. 16-1600-2

J JDG11340 bellows alignment fixture ................. 05-0530-2 John deere Engine............................................................ 04-0400-1

Continued on next page

TM14163X19 (15FEB18)

Index-4

450K, 550K, and 650K Crawler Dozer 021518 PN=4

Index

Page

Leakage test Carrier roller ................................................. 01-0130-10 Left rear sheet metal Remove and install ........................................ 19-1913-1 Lift cylinder Assemble ..................................................... 32-3260-21 Disassemble ................................................ 32-3260-21 Remove and install ...................................... 32-3260-19 Linkage Auxiliary, remove and install .......................... 32-3215-4 Blade, remove and install............................... 32-3215-1 Lubricated track chain Assemble and not relubricate ...................... 01-0130-41 Disassemble and assemble ......................... 01-0130-41 Disassemble and not relubricate.................. 01-0130-41 Disassemble to lubricate.............................. 01-0130-32 Disassemble to turn bushing........................ 01-0130-32 Remove and install ...................................... 01-0130-28

O-ring boss fitting in aluminum housingexcavators Torque value, service recommendation ............................................................... 00-0003-6 O-ring boss fittings............................................. 00-0003-4 O-ring face seal fitting Inch hex nut and stud end for high pressure torque values................................. 00-0003-9 Metric hex nut and stud end for high pressure torque values............................... 00-0003-13 Metric hex nut and stud end for standard pressure torque values............................... 00-0003-11 O-ring seal, metric 24 Service recommendation ............................. 00-0003-21 Oil Cleanup procedure ........................................ 21-2160-1 Oil information R134a refrigerant ........................................... 18-1830-2 Operation qualification....................................... 00-0001-3 Operator's station Remove and install ........................................ 18-1800-1

M Machine modifications Avoid .............................................................. 00-0001-4 Machine,inspect................................................. 00-0001-4 Manual Identification............................................................... --3 Measure front idler wear.................................. 01-0130-48 Metal face seals Inspect ........................................................... 01-0130-8 Metri-Pack® connectors Pull type, replace ........................................... 16-1600-7 Push type, replace ......................................... 16-1600-8 Metric bolt and cap screw Torque value .................................................. 00-0003-1 Molex connectors Repair .......................................................... 16-1600-22 Motor Hydrostatic, initial start-up procedure ............ 03-0300-1 Mounts Engine, remove and install............................. 04-0400-6 Multi-Function Valve Remove and Install ...................................... 03-0360-15 Multi-function valve, disassemble and assemble ....................................................... 03-0360-15

N Neutral charge relief valve, disassemble and assemble ....................................................... 03-0360-24

P Park and Prepare for Service Safely Park and prepare for service safely ............. 00-0001-17 Park brake Disassemble and assemble ............................11-1160-1 Remove and Install .........................................11-1100-1 Park brake valve Disassemble and assemble ............................11-1160-5 Remove and install .........................................11-1100-3 Park lock linkage Remove and install ......................................... 11-1115-1 Park Lock Linkage Disassemble and Assemble............................ 11-1115-3 Parts, moving Stay clear ....................................................... 00-0001-4 Pins, metal Drive safely .................................................. 00-0001-18 Precleaner Remove and install ........................................ 05-0520-1 Primary fuel filter and water separator Remove and install ........................................ 05-0560-1 Product Identification Number Location ......................................................... 00-0001-1 Pump Hydrostatic, initial start-up procedure ............ 03-0300-1 Pump displacement control valve (PDCV), disassemble and assemble ........................... 03-0360-13

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TM14163X19 (15FEB18)

Index-5

450K, 550K, and 650K Crawler Dozer 021518 PN=5

Index

Page

R134a refrigerant Recover.......................................................... 18-1830-3 R134a system Charge ........................................................... 18-1830-6 Evacuate ........................................................ 18-1830-5 Radiator Remove and install ........................................ 05-0510-9 Rear sheet metal Remove and install ........................................ 19-1913-1 Receiver-dryer Remove and install ...................................... 18-1830-16 Recognize Safety, information ......................................... 00-0001-2 Recovery/charging station Installation procedure..................................... 18-1830-3 Refrigerant cautions and proper handling Air conditioning .............................................. 18-1830-1 Refrigerant oil information R134a ............................................................ 18-1830-2 Refueling, avoid static electricity risk................. 00-0001-6 Remove and install Air cleaner...................................................... 05-0520-1 Air conditioner freeze control switch .............. 16-1600-5 Angle cylinder .............................................. 32-3260-20 Auxiliary fuel filter........................................... 05-0560-2 Auxiliary fuel filter and water separator ...................................................... 05-0560-2 Backup alarm ................................................. 20-2004-1 Blade.............................................................. 32-3201-2 Blower motor................................................ 18-1830-12 Blower motor speed resistor ........................ 18-1830-12 Bottom guards................................................ 17-1746-1 C-Frame......................................................... 32-3240-1 Charge air cooler ........................................... 05-0510-9 Compressor ................................................. 18-1830-18 Condenser ................................................... 18-1830-17 Damper drive ................................................. 03-0325-1 Decomposition tube ..................................... 05-0530-23 DEF decomposition tube.............................. 05-0530-23 DEF dosing injector...................................... 05-0530-23 DEF dosing unit ........................................... 05-0530-22 DEF tank ...................................................... 05-0530-18 Diesel exhaust fluid (DEF) decomposition tube ............................................................ 05-0530-23 Diesel exhaust fluid (DEF) dosing injector........................................................ 05-0530-23 Diesel exhaust fluid (DEF) dosing unit......... 05-0530-22 Diesel exhaust fluid (DEF) tank ................... 05-0530-18 Diesel exhaust fluid header.......................... 05-0530-19 diesel oxidation catalyst (DOC).................... 05-0530-11 Diesel particulate filter (DPF) ....................... 05-0530-12 Drawbar ......................................................... 15-1511-1 Engine coolant heater .................................... 05-0505-1 Engine side shields ........................................ 19-1910-2 Evaporator ..................................................... 18-1830-7

Exhaust filter ............................05-0530-13, 05-0530-14 Exhaust filter structure ................................. 05-0530-14 Exhaust tube .................................................. 05-0530-1 Expansion valve........................................... 18-1830-11 Extended drawbar.......................................... 15-1511-2 Final drive ...................................................... 02-0201-1 Fuel tank ........................................................ 05-0560-3 Grille............................................................... 19-1921-1 Heater core .................................................... 18-1830-7 Hood .............................................................. 19-1910-1 Hydraulic control valve................................... 32-3260-1 Hydraulic fan motor...................................... 21-2160-11 Hydraulic fan pump ...................................... 21-2160-10 Hydraulic pump .............................................. 21-2160-3 Hydraulic reservoir ....................................... 03-0360-55 Hydrostatic motor........................................... 03-0300-6 Hydrostatic oil cooler.................................... 05-0510-10 Hydrostatic pump ........................................... 03-0300-2 Integrated grade control (IGC) ....................... 16-1600-1 Lift cylinder................................................... 32-3260-19 Operator's station........................................... 18-1800-1 Precleaner...................................................... 05-0520-1 Primary fuel filter and water separator ........... 05-0560-1 Radiator ......................................................... 05-0510-9 Rear sheet metal............................................ 19-1913-1 Receiver-dryer ............................................. 18-1830-16 Ripper ............................................................ 42-4200-1 SCR ............................................................. 05-0530-17 Seat belt......................................................... 18-1821-1 Secondary fuel filter ....................................... 05-0560-2 Selective catalytic reduction (SCR).............. 05-0530-17 Shank and tooth............................................. 42-4201-1 Tilt cylinder................................................... 32-3260-20 Track shoe ................................................... 01-0130-24 Under seat heater ........................................ 18-1830-14 Water separator ............................................. 05-0560-2 Remove and Install Decelerator-Brake Pedal.............................. 03-0315-19 Hydrostatic and Hydraulic Reservoir Cleanout Cover .......................................... 03-0360-55 Multi-Function Valve..................................... 03-0360-15 Transmission Control Lever (TCL) ................. 03-0315-1 Window Wiper Motor...................................... 18-1810-4 Windowpanes ................................................ 18-1810-1 Right rear sheet metal Remove and install ........................................ 19-1913-1 Ripper Remove and install ........................................ 42-4200-1 Ripper Cylinder Remove and Install ........................................ 42-4260-1 Rock guard Remove and install ........................................ 01-0130-1 Roller, carrier Disassemble and assemble ........................... 01-0130-6 Remove and install ........................................ 01-0130-4 Roller, track Disassemble and assemble ......................... 01-0130-13 Remove and install ...................................... 01-0130-12

Continued on next page

TM14163X19 (15FEB18)

Index-6

450K, 550K, and 650K Crawler Dozer 021518 PN=6

Index

Page

Test for oil leakage ....................................... 01-0130-22 Wear inspection ........................................... 01-0130-11 ROPS Inspect ......................................................... 00-0001-15 Maintain ....................................................... 00-0001-15

Specifications Sound............................................................. 00-0001-1 Vibration......................................................... 00-0001-1 Spring Track idler recoil, disassemble and assemble.................................................... 01-0130-63 Track idler recoil, remove and install ........... 01-0130-62 Sprocket Remove and Install ...................................... 01-0130-69 Sprocket guard Remove and install ........................................ 01-0130-1 SSM Remove and install ........................................ 16-1600-7 Standard display monitor Remove and install ........................................ 16-1600-7 Start-up procedure Hydrostatic pump and motor initial start-up ......................................................... 03-0300-1 Steer sensor Remove and install ........................................ 16-1600-4 Steps Use correctly Handholds ................................................ 00-0001-10 System relief valve Disassemble and assemble ......................... 32-3260-16

S Safety Add cab guarding for special uses..........................................00-0001-3, 00-0001-10 Avoid machine tip over................................. 00-0001-14 Clean debris from machine .......................... 00-0001-10 Fire................................................................. 00-0001-7 Keep riders off machine ............................... 00-0001-12 Lifting equipment.......................................... 00-0001-19 Operator's seat ............................................ 00-0001-10 Prevent unintended machine movement .................................................. 00-0001-11 Protective equipment ..................................... 00-0001-3 Service machine .......................................... 00-0001-17 Safety hazards Travel ........................................................... 00-0001-15 Safety, high-pressure fluids Avoid high-pressure fluids.............................. 00-0001-5 Safety, information Recognize ...................................................... 00-0001-2 SCR Remove and install ...................................... 05-0530-17 SDM Remove and install ........................................ 16-1600-7 Sealed switch module Remove and install ........................................ 16-1600-7 Seals, metal face Inspect ........................................................... 01-0130-8 Seat belt Remove and install ........................................ 18-1821-1 Secondary fuel filter Remove and install ........................................ 05-0560-2 Selective catalytic reduction (SCR) Remove and install ...................................... 05-0530-17 Service filter Cleaning....................................................... 05-0530-16 Service recommendation Inch series four bolt flange fitting for high pressure ..................................................... 00-0003-17 O-ring boss fitting in aluminum housing excavators.................................................... 00-0003-6 O-ring face seal fittings with inch hex nut and stud end for high pressure .................... 00-0003-9 O-ring face seal fittings with metric hex nut and stud end for high pressure ............ 00-0003-13 O-ring face seal fittings with metric hex nut and stud end for standard pressure ........... 00-0003-11 O-ring seal, metric 24................................... 00-0003-21 Shank and tooth Remove and install ........................................ 42-4201-1

T Theory of operation Engine............................................................ 04-0400-1 Thermal bypass valve Remove and install ...................................... 03-0360-52 Tilt cylinder Assemble ..................................................... 32-3260-21 Disassemble ................................................ 32-3260-21 Remove and install ...................................... 32-3260-20 Tool JDG11340 bellows alignment fixture.............. 05-0530-2 Tool, dealer fabricated ST4920 track recoil spring disassembly and assembly tool ...................................... 99-9900-11 Torque value 30° cone seat hydraulic fittings ...................... 00-0003-4 37° flare hydraulic fittings............................... 00-0003-4 Flared connections......................................... 00-0003-7 Flat face O-ring seal fitting ............................. 00-0003-8 Inch SAE four bolt flange fitting.................... 00-0003-16 Inch series four bolt flange fitting for high pressure ..................................................... 00-0003-17 Metric bolt and cap screw .............................. 00-0003-1 Metric cap screw ............................................ 00-0003-2 Metric four bolt flange fitting......................... 00-0003-15 Non-restricted banjo fittings ......................... 00-0003-18 O-Ring boss fitting ......................................... 00-0003-4 O-ring boss fitting in aluminum housingexcavators ....................................... 00-0003-6 O-ring boss fittings with shoulder................. 00-0003-19 Continued on next page

TM14163X19 (15FEB18)

Index-7

450K, 550K, and 650K Crawler Dozer 021518 PN=7

Index

Page

O-ring face seal fittings with inch hex nut and stud end for high pressure .................... 00-0003-9 O-ring face seal fittings with metric hex nut and stud end for high pressure ............ 00-0003-13 O-ring face seal fittings with metric hex nut and stud end for standard pressure ........... 00-0003-11 O-ring seal, metric 24................................... 00-0003-21 Unified inch bolt and cap screw ..................... 00-0003-3 Track chain bushing Bushing outside diameter for lubricated track chain inspection................................. 01-0130-26 Track chain, lubricated Remove and install ...................................... 01-0130-28 Track frame Remove and install ...................................... 01-0130-67 Track guide Remove and install ........................................ 01-0130-1 Track guides and rock guards Remove and install ........................................ 01-0130-1 Track idler recoil spring Disassemble and assemble ......................... 01-0130-63 Remove and install ...................................... 01-0130-62 Track link bushing Bushing outside diameter for lubricated track chain inspection................................. 01-0130-26 Track link height Inspection..................................................... 01-0130-25 Track roller Disassemble and Assemble......................... 01-0130-13 Remove and install ...................................... 01-0130-12 Test for oil leakage ....................................... 01-0130-22 Wear inspection ........................................... 01-0130-11 Track sag Adjust ........................................................... 01-0130-46 Track sag adjustment ...................................... 01-0130-46 Track shoe Remove and install ...................................... 01-0130-24 Track shoe grouser wear Inspection..................................................... 01-0130-23 Track tension adjuster Remove and disassemble............................ 01-0130-59 Transmission Control Lever (TCL) Disassemble and Assemble........................... 03-0315-2 Remove and Install ........................................ 03-0315-1

Tyco™ connectors Replace connector ....................................... 16-1600-23

TM14163X19 (15FEB18)

U Under seat heater Disassemble and assemble ......................... 18-1830-15 Remove and install ...................................... 18-1830-14

V Valve, hydraulic control Disassemble and assemble ........................... 32-3260-4 Valve, hydraulic control, IGC Remove and install ........................................ 32-3260-2 Valve, section auxiliary Disassemble and assemble ......................... 32-3260-11 Valve, system relief Disassemble and assemble ......................... 32-3260-16 VCU Remove and install ........................................ 16-1600-7 Vehicle control unit (VCU) Remove and install ........................................ 16-1600-7

W Washer pump, window Remove and install ...................................... 18-1810-10 Water separator Remove and install ........................................ 05-0560-2 Wear strips Frame, remove and install ........................... 01-0130-68 Weather Pack™ connectors Install contact ............................................... 16-1600-10 Replace.......................................................... 16-1600-9 Welding procedure ............................................ 17-1740-1 Welding repairs................................................ 00-0001-18 Window washer pump Remove and install ...................................... 18-1810-10 Window Wiper Motor Remove and Install ........................................ 18-1810-4 Windowpanes Remove and Install ........................................ 18-1810-1

Index-8

450K, 550K, and 650K Crawler Dozer 021518 PN=8

Index

TM14163X19 (15FEB18)

Index-9

450K, 550K, and 650K Crawler Dozer 021518 PN=9

Index

TM14163X19 (15FEB18)

Index-10

450K, 550K, and 650K Crawler Dozer 021518 PN=10