Worldwide Construction And Forestry Division 700J User manual
700J
Crawler Dozer
Repair
(Serial No. 139436- )
TECHNICAL MANUAL
700J Crawler Dozer Repair (S.N.
139436— )
TM10269 10OCT07 (ENGLISH)
For complete service information also see:
700J Crawler Dozer Operation and Test
(S.N. 139436— ) ....................... TM10268
700J Crawler Dozer Operator’s Manual (S.N.
139436— ) ...........................OMT227267
Alternators and Starting Motors .......... CTM77
POWERTECH4.5 L and 6.8 L Diesel
Engines—Base Engine ................. CTM104
POWERTECH E4.5 L and 6.8 L Diesel
Engines—Level 16 Electronic Fuel System
with Denso HPCR ..................... CTM502
4000S Winches ....................... CTM166
Super Caddy Oil Cleanup Procedure ...... CTM310
120 Series Hydraulic Cylinders .......... TM-H120A
Undercarriage Appraisal Manual ......... SP326
Worldwide Construction
And Forestry Division
U.S.A.
Introduction
DX,TMIFC –19–29SEP98–1/1
Foreword
This manual is written for an experienced technician.
Essential tools required in performing certain service
work are identified in this manual and are
recommended for use.
Live with safety: Read the safety messages in the
introduction of this manual and the cautions presented
throughout the text of the manual.
This is the safety-alert symbol. When you see this
symbol on the machine or in this manual, be alert to
the potential for personal injury.
Technical manuals are divided in two parts: repair and
operation and tests. Repair sections tell how to repair
the components. Operation and tests sections help you
identify the majority of routine failures quickly.
Information is organized in groups for the various
components requiring service instruction. At the
beginning of each group are summary listings of all
applicable essential tools, service equipment and tools,
other materials needed to do the job, service parts kits,
specifications, wear tolerances, and torque values.
Technical Manuals are concise guides for specific
machines. They are on-the-job guides containing only
the vital information needed for diagnosis, analysis,
testing, and repair.
Fundamental service information is available from
other sources covering basic theory of operation,
fundamentals of troubleshooting, general maintenance,
and basic type of failures and their causes.
TM10269 (10OCT07) 700J Crawler Dozer (S.N. 139436— )
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Introduction
TX,TM,FAX –19–03JUL01–1/1
Technical Information Feedback Form
We need your help to continually improve our technical
publications. Please copy this page and FAX or mail your
comments, ideas and improvements.
SEND TO: John Deere Dubuque Works
P.O. Box 538
Attn: Publications Supervisor, Dept. 303
Dubuque, IA 52004-0538
FAX NUMBER: 563-589-5800
Ideas, Comments (Please State Page Number):
OVERALL, how would you rate the quality of this publication? (Check one)
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Company Name:
Technician Name:
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THANK YOU!
TM10269 (10OCT07) 700J Crawler Dozer (S.N. 139436— )
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Contents
00
SECTION 00—General Information SECTION 18—Operator’s Station
Group 1800—Removal and InstallationGroup 01—Safety
Group 03—Torque Values Group 1810—Operator’s Enclosure
Group 1821—Seat and Seat Belt
Group 1830—Heating and Air Conditioning
SECTION 01—Tracks
01
Group 0130—Track System
SECTION 19—Sheet Metal and Styling
Group 1910—Hood and Engine Enclosure
SECTION 02—Axles and Suspension Systems
Group 1921—Grille and Grille Housing
Group 0201—Drive Axle Housing and Support
Group 0250—Axle Shaft, Bearings, and Reduction
SECTION 21—Main Hydraulic System
Gear
Group 2160—Hydraulic System
SECTION 03—Transmission
SECTION 32—Bulldozer
Group 0300—Removal and Installation
Group 3201—Blades
Group 0315—Controls Linkage
Group 3215—Control Linkage
Group 0360—Hydrostatic System
02
Group 3240—Frames
Group 3260—Hydraulic System
SECTION 04—Engine
Group 0400—Removal and Installation
SECTION 99—Dealer Fabricated Tools
Group 9900—Dealer Fabricated Tools
SECTION 05—Engine Auxiliary Systems
Group 0505—Cold Weather Starting Aids
Group 0510—Radiator and Fan Shroud
Group 0520—Intake System
Group 0530—External Exhaust System
Group 0540—Mounting Frame
03
Group 0560—External Fuel Supply System
SECTION 07—Dampener Drive
Group 0752—Elements
SECTION 11—Park Brake
Group 1100—Removal and Installation
Group 1115—Control Linkage
Group 1160—Hydraulic System
SECTION 15—Equipment Attaching
04
Group 1511—Drawbar
Group 1540—Ripper
SECTION 17—Frames, Chassis, or Supporting
Structure
Group 1740—Frame Installation
Group 1749—Chassis Weights
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.
05
COPYRIGHT
2007
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION
Manual
07
11
15
17
TM10269 (10OCT07) i700J Crawler Dozer (S.N. 139436— )
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00
Section 00
General Information
Contents
Page
Group 01—Safety ......................00-01-1
Group 03—Torque Values
Torque Value
Metric Bolt and Cap Screw ..............00-03-1
Additional Metric Cap Screw Torque Values . . .00-03-2
Torque Value
Unified Inch Bolt and Cap Screw ..........00-03-4
Service Recommendations for 37°Flare
and 30°Cone Seat Connectors ...........00-03-5
Service Recommendations for O-Ring
Boss Fittings .........................00-03-6
Service Recommendation
O-Ring Boss Fittings In Aluminum
Housing—Excavators .................00-03-8
Service Recommendations For Flared
Connections—Straight or Tapered
Threads ............................00-03-10
Service Recommendations For Flat Face
O-Ring Seal Fittings...................00-03-11
Service Recommendation
O-Ring Face Seal Fittings with SAE
Inch Hex Nut and Stud End for High
Pressure..........................00-03-12
O-Ring Face Seal Fittings with Metric
Hex Nut and Stud End for Standard
Pressure..........................00-03-14
O-Ring Face Seal Fittings with Metric
Hex Nut and Stud End for High
Pressure..........................00-03-16
Service Recommendations for Metric
Series Four Bolt Flange Fitting ..........00-03-18
Service Recommendations For Inch
Series Four Bolt Flange Fittings..........00-03-19
Service Recommendation
Inch Series Four Bolt Flange For High
Pressure..........................00-03-20
Service Recommendations For
Non-Restricted Banjo (Adjustable)
Fittings.............................00-03-21
Service Recommendations For O-Ring
Boss Fittings With Shoulder.............00-03-23
Service Recommendation
Metric 24°O-Ring Seal DIN 20078 .......00-03-26
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Group 01
Safety
00
01
1
TX03679,00016CC –19–05OCT07–1/1
Recognize Safety Information
T133555 –UN–28AUG00T133588 –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.
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.
TX03679,00016F9 –19–05OCT07–1/1
Follow Safety Instructions
T133556 –UN–24AUG00
Read the safety messages in this manual and on the
machine. Follow these warnings and instructions carefully.
Review them frequently. Keep safety signs in good
condition. Replace missing or damaged safety signs. Be
sure new equipment components and repair parts include
the current safety signs. Replacement safety signs are
available from your John Deere dealer.
Be sure all operators of this machine understand every
safety message. Replace operator’s manual and safety
labels immediately if missing or damaged.
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Safety
00
01
2
TX03679,00016FA –19–05OCT07–1/1
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.
Operator should be familiar with the job site and
surroundings before operating. Try all controls and
machine functions with the machine in an open area
before starting to work.
Know and observe all safety rules that may apply to
every work situation and work site.
TX03679,00016D0 –19–05OCT07–1/1
Wear Protective Equipment
TS206 –UN–23AUG88
Guard against injury from flying pieces of metal or debris;
wear goggles or safety glasses.
Wear close fitting clothing and safety equipment
appropriate to the job.
Prolonged exposure to loud noise can cause impairment
or loss of hearing. Wear suitable hearing protection such
as earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.
AM40430,0000089 –19–05OCT07–1/1
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.
Always contact an authorized dealer before making
machine modifications that change the intended use,
weight or balance of the machine, or that alter
machine controls, performance or reliability.
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Safety
00
01
3
TX03679,0001734 –19–05OCT07–1/1
Inspect Machine
T6607AQ –UN–18OCT88
Inspect machine carefully each day by walking around it
before starting.
Keep all guards and shields in good condition and
properly installed. Fix damage and replace worn or broken
parts immediately. Pay special attention to hydraulic
hoses and electrical wiring.
TX03679,00016D2 –19–05OCT07–1/1
Stay Clear of Moving Parts
T133592 –UN–12SEP01
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.
DX,FLUID –19–03MAR93–1/1
Avoid High-Pressure Fluids
X9811 –UN–23AUG88
Escaping fluid under pressure can penetrate the skin
causing serious injury.
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.
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Safety
00
01
4
VD76477,000107C –19–22SEP06–1/1
Avoid High-Pressure Oil
T133509 –UN–17MAR06
T133840 –UN–20SEP00
This machine uses a high-pressure hydraulic system.
Escaping oil under pressure can penetrate the skin
causing serious injury.
Never search for leaks with your hands. Protect hands.
Use a piece of cardboard to find location of escaping oil.
Stop engine and relieve pressure before disconnecting
lines or working on hydraulic system.
If hydraulic oil penetrates your skin, see a doctor
immediately. Injected oil must be removed surgically
within hours or gangrene may result. Contact a
knowledgeable medical source or the Deere & Company
Medical Department in Moline, Illinois, U.S.A.
TX03679,00016D4 –19–05OCT07–1/1
Beware of Exhaust Fumes
T133546 –UN–24AUG00
Prevent asphyxiation. Engine exhaust fumes can cause
sickness or death.
If you must operate in a building, provide adequate
ventilation. Use an exhaust pipe extension to remove the
exhaust fumes or open doors and windows to bring
outside air into the area.
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Safety
00
01
5
TX03679,00016F5 –19–05OCT07–1/1
Prevent Fires
T133552 –UN–14SEP00T133553 –UN–07SEP00T133554 –UN–07SEP00
Handle Fuel Safely: Store flammable fluids away from
fire hazards. Never refuel machine while smoking or when
near sparks or flame.
Clean Machine Regularly: Keep trash, debris, grease
and oil from accumulating in engine compartment, around
fuel lines, hydraulic lines and electrical wiring. Never store
oily rags or flammable materials inside a machine
compartment.
Maintain Hoses and Wiring: Replace hydraulic hoses
immediately if they begin to leak, and clean up any oil
spills. Examine electrical wiring and connectors frequently
for damage.
Keep A Fire Extinguisher Available: Always keep a
multi-purpose fire extinguisher on or near the machine.
Know how to use extinguisher properly.
TX03679,000174A –19–05OCT07–1/1
Prevent Battery Explosions
TS204 –UN–23AUG88
Battery gas can explode. Keep sparks, lighted matches,
and open flame away from the top of battery.
Never check battery charge by placing a metal object
across the posts. Use a voltmeter or hydrometer.
Do not charge a frozen battery; it may explode. Warm
battery to 16°C (60°F).
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Safety
00
01
6
TX03679,00016D7 –19–05OCT07–1/1
Handle Chemical Products Safely
T133580 –UN–25AUG00
Exposure to hazardous chemicals can cause serious
injury. Under certain conditions, lubricants, coolants,
paints and adhesives used with this machine may be
hazardous.
If uncertain about safe handling or use of these chemical
products, contact your authorized dealer for a Material
Safety Data Sheet (MSDS) or go to internet website
http://www.jdmsds.com. The MSDS describes physical
and health hazards, safe use procedures, and emergency
response techniques for chemical substances. Follow
MSDS recommendations to handle chemical products
safely.
TX03679,0001733 –19–05OCT07–1/1
Dispose of Waste Properly
T133567 –UN–25AUG00
Improper disposal of waste can threaten the environment.
Fuel, oils, coolants, filters and batteries used with this
machine may be harmful if not disposed of properly.
Never pour waste onto the ground, down a drain, or into
any water source.
Air conditioning refrigerants can damage the atmosphere.
Government regulations may require using a certified
service center to recover and recycle used refrigerants.
If uncertain about the safe disposal of waste, contact your
local environmental or recycling center or your authorized
dealer for more information.
TX03679,000174B –19–05OCT07–1/1
Prepare for Emergencies
TS291 –UN–23AUG88
Be prepared if an emergency occurs or a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service,
hospital, and fire department near your telephone.
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Safety
00
01
7
TX03768,0000B77 –19–05OCT07–1/1
Add Cab Guarding For Special Uses
T139005 –UN–05MAR01
Special work situations or machine attachments may
expose the operator to intruding or flying objects. Using
this machine in a forestry application or woods
environment, or with attachments such as a winch,
requires added guarding to protect the operator.
Forestry protection packages or special screens should be
installed when working in areas where logs or branches
may strike the operator. A rear screen should always be
used with a winch to protect against a snapping cable.
Contact your authorized dealer for information on
protective guarding before operating in any hazardous
environment.
TX03768,0000B71 –19–14FEB07–1/1
Start Only From Operator’s Seat
T133715 –UN–07SEP00
Avoid unexpected machine movement. Before starting
engine, sit in operator’s seat. Ensure park lock lever is in
“lock” position.
Never attempt to start engine from the ground or tracks.
Do not attempt to start engine by shorting across the
starter solenoid terminals.
TX03768,0000B72 –19–01MAY01–1/1
Prevent Unintended Machine Movement
(LOCKED)
UP POSITION
(UNLOCKED)
DOWN POSITION
T159027 –19–30AUG02
Always move the park lock lever to the “lock”
position before leaving the operator’s seat for any
reason.
Be careful not to accidentally actuate controls when
co-workers 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.
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Safety
00
01
8
VD76477,000107A –19–10JAN07–1/1
Avoid Work Site Hazards
T139002 –UN–05MAR01T139003 –UN–05MAR01
Avoid contact with gas lines, buried cables and water
lines. Call utility line location services to identify all
underground utilities before starting work.
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.
Keep bystanders clear at all times. 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.
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.
TX03768,0000B73 –19–04DEC06–1/1
Keep Riders Off Machine
T137580 –UN–22FEB01
Only allow operator on machine.
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 his ability to
operate machine safely.
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Safety
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TX03768,0000B69 –19–04DEC06–1/1
Avoid Backover Accidents
T138441 –UN–22FEB01
Before moving machine, be sure all persons are clear
of the machine path. Turn around and look directly for
best visibility. Use mirror to assist in checking behind the
machine. Keep windows and mirror clean and in good
repair.
Be certain backup 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.
TX03768,0000B6B –19–29JAN01–1/1
Avoid Machine Tip Over
T133716 –19–14SEP00T138416 –UN–22FEB01T138415 –UN–22FEB01
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.
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.
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Safety
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01
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TX03768,0000B6A –19–29JAN01–1/1
Park And Prepare For Service Safely
T133332 –19–14DEC01
TS229 –UN–23AUG88
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/bucket
and attachments to the ground.
•Place park lock lever in “lock” position. Stop engine and
remove key.
•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/bucket 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.
Understand service procedures before beginning repairs.
Keep service area clean and dry. Use two people
whenever the engine must be running for service work.
VD76477,00012BF –19–10JAN07–1/1
Service Cooling System Safely
TS281 –UN–23AUG88
Explosive release of fluids from pressurized cooling
system can cause serious burns.
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.
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