John Deere 824K 4WD Loader Workshop Service Repair Manual, Engine 6135HDW02 iT4, SN 641970-664578 (TM12115) PDF Download - TM12115 - John Deere 4WD Loaders 824K Technical Manual (Repair).PDF
Full workshop repair manual for the John Deere 824K 4WD Loader, powered by the 6135HDW02 (iT4) engine (SN.641970—664578)(PIN: DW824KZ**E641970—664578), containing every piece of service data needed to keep, fix, and overhaul the machine just as professional technicians do.
The John Deere 824K 4WD Loader workshop repair manual covers:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
TM12115 - John Deere 4WD Loaders 824K Technical Manual (Repair).PDF
TM12115 - John Deere 4WD Loaders 824K Technical Manual (Repair).EPUB
Total Pages: 754 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English
MAIN SECTIONS
Foreword
Manual Identification-READ THIS FIRST!
General Information
Safety
Wheels
Powered Wheels and Fasteners
Axles and Suspension Systems
Removal and Installation
Input Drive Shafts and U-Joints
Axle Shaft, Bearings, and Reduction Gears
Hydraulic System
Transmission
Removal and Installation
Gears, Shafts, Bearings and Power Shift Clutch
Hydraulic System
Engine
Removal and Installation
Engine Auxiliary System
Cold Start Aids
Cooling Systems
Intake System
External Exhaust Systems
External Fuel Supply Systems
Damper Drive
Elements
Steering System
Hydraulic System
Service Brakes
Active Elements
Hydraulic System
Park Brake
Active Elements
Hydraulic System
Frame or Supporting Structure
Frame Installation
Frame Bottom Guards
Chassis Weights
Operator`s Station
Removal and Installation
Operator Enclosure
Seat and Seat Belts
Heating and Air Conditioning
Sheet Metal and Styling
Hood or Engine Enclosure
Grille and Grille Housing
Loader
Bucket
Frames
Hydraulic System
Dealer Fabricated Tools
tm12115 - 824K 4WD Loader (S.N. 641970—664578)
Table of Contents
Foreword
Manual Identification—READ THIS FIRST!
Section 00: General Information
Group 0001: Safety
Recognize Safety Information
Follow Safety Instructions
Operate Only If Qualified
Wear Protective Equipment
Avoid Unauthorized Machine Modifications
Add Cab Guarding for Special Uses
Inspect Machine
Stay Clear of Moving Parts
Avoid High-Pressure Oils
Avoid High-Pressure Fluids
Work In Ventilated Area
Prevent Fires
Clean Debris from Machine
Prevent Battery Explosions
Handle Chemical Products Safely
Decommissioning — Proper Recycling and Disposal of Fluids and Components
Exhaust Filter Ash Handling and Disposal
Prepare for Emergencies
Use Steps and Handholds Correctly
Start Only From Operator's Seat
Use and Maintain Seat Belt
Prevent Unintended Machine Movement
Avoid Work Site Hazards
Use Special Care When Operating Loader
Keep Riders Off Machine
Avoid Backover Accidents
Avoid Machine Tip Over
Operating on Slopes
Operating or Traveling On Public Roads
Inspect and Maintain ROPS
Add and Operate Attachments Safely
Park and Prepare for Service Safely
Clean Exhaust Filter Safely
Service Cooling System Safely
Service Tires Safely
Remove Paint Before Welding or Heating
Make Welding Repairs Safely
Drive Metal Pins Safely
Group 0003: Torque Values
Metric Bolt and Cap Screw Torque Values
Additional Metric Cap Screw Torque Values
Unified Inch Bolt and Cap Screw Torque Values
Service Recommendations for 37° Flare and 30° Cone Seat Connectors
Service Recommendations for O-Ring Boss Fittings
O-Ring Boss Fittings in Aluminum Housing Service Recommendations—Excavators
Service Recommendations for Flared Connections—Straight or Tapered Threads
Service Recommendations for Flat Face O-Ring Seal Fittings
O-Ring Face Seal Fittings With SAE Inch Hex Nut and Stud End for High-Pressure Service Recommendations
O-Ring Face Seal Fittings With Metric Hex Nut and Stud End for Standard Pressure Service Recommendations
O-Ring Face Seal Fittings With Metric Hex Nut and Stud End for High-Pressure Service Recommendations
Service Recommendations for Metric Series Four Bolt Flange Fitting
Service Recommendations For Inch Series Four Bolt Flange Fittings
Inch Series Four Bolt Flange Fitting for High-Pressure Service Recommendations
Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings
Service Recommendations For O-Ring Boss Fittings With Shoulder
Metric 24° O-Ring Seal DIN 20078 Service Recommendations
Section 01: Wheels
Group 0110: Powered Wheels and Fasteners
Wheel Remove and Install
Tire Remove and Install
Section 02: Axles and Suspension Systems
Group 0200: Removal and Installation
TeamMate™ II Axles
Front Axle and Differential Remove and Install
Rear Axle and Differential Remove and Install
Axle Oscillating Supports Disassemble and Assemble
Group 0225: Input Drive Shafts and U-Joints
Universal Joint and Drive Shaft Remove and Install
Group 0250: Axle Shaft, Bearings, and Reduction Gears
TeamMate™ Axles
Group 0260: Hydraulic System
Differential Lock Solenoid Valve Remove and Install
Axle Circulation Pump Remove and Install
Section 03: Transmission
Group 0300: Removal and Installation
Transmission Remove and Install
Group 0350: Gears, Shafts, Bearings and Power Shift Clutch
Torque Converter Input Shaft Remove and Install
Torque Converter Housing Disassemble and Assemble
Transmission Input Shaft Remove and Install
Transmission Input Shaft Disassemble and Assemble
Transmission Drive Two Disassemble and Assemble
Transmission Drive Three Disassemble and Assemble
Output Shaft Drive Disassemble
Output Shaft Drive Assemble
Clutch Packs Remove and Install
Low Range Forward Clutch (KV) and First Speed Clutch (K1) Disassemble and Assemble
High Range Forward Clutch (K4) and Third Speed Clutch (K3) Disassemble and Assemble
Reverse Clutch (KR) and Second Speed Clutch (K2) Disassemble and Assemble
Low Range Forward Clutch (KV) and First Speed Clutch (K1) Bearing Preload Adjustment
High Range Forward Clutch (K4) and Third Speed Clutch (K3) Bearing Preload Adjustment
Reverse Clutch (KR) and Second Speed Clutch (K2) Bearing Preload Adjustment
Transmission Speed Sensors Remove and Install
Group 0360: Hydraulic System
Transmission Pump Remove and Install
Transmission Pump Disassemble and Assemble
Transmission Hydraulic Control Valve Remove and Install
Transmission Hydraulic Control Valve Disassemble and Assemble
Transmission Suction Screen Remove and Install
Section 04: Engine
Group 0400: Removal and Installation
John Deere Engine
Engine Remove and Install
Engine Crankshaft Damper Remove and Install
Serpentine Belt Remove and Install
Section 05: Engine Auxiliary System
Group 0505: Cold Start Aids
Cold Start Aid—Starting Fluid Nozzle Remove and Install
Cold Start Aid—Starting Fluid Solenoid Remove and Install
Cold Start Aid—Block Heater Remove and Install
Group 0510: Cooling Systems
Charge Air Cooler Remove and Install
Left Radiator Remove and Install
Right Radiator Remove and Install
Hydraulic Oil Cooler Remove and Install
Transmission Oil Cooler Remove and Install
Fuel Cooler Remove and Install
Front Axle Oil Cooler Remove and Install
Rear Axle Oil Cooler Remove and Install
Cooling Package Plenum Remove and Install
Group 0520: Intake System
Air Cleaner Remove and Install
Precleaner Remove and Install
Group 0530: External Exhaust Systems
Exhaust Tube Remove and Install
Exhaust Bellows Alignment Procedure
Diesel Particulate Filter (DPF) Remove and Install
Exhaust Filter Remove and Install
Service Filter Cleaning
Group 0560: External Fuel Supply Systems
Fuel Tank Remove and Install
Primary Fuel Filter (Water Separator) Remove and Install
Secondary Fuel Filter Remove and Install
Auxiliary Fuel Filter Remove and Install—If Equipped
Fast Fill Fuel System Disassemble and Assemble
Section 07: Damper Drive
Group 0752: Elements
Output Damper Remove and Install
Section 09: Steering System
Group 0960: Hydraulic System
NeverGrease™ Pin Joints
Orbital Steering Valve Remove and Install
Steering Column Remove and Install
Steering Column Disassemble and Assemble
Steering Cylinders Remove and Install
Steering Cylinder Bushings Remove and Install
Secondary Steering Pump Remove and Install
Secondary Steering Valve Remove and Install
Joystick Steering Valve Remove and Install
Joystick Steering Valve Disassemble and Assemble
Loader Start-Up Procedure (Steering Cylinder)
Section 10: Service Brakes
Group 1011: Active Elements
Service Brake Assembly Remove and Install
Service Brake Pedal and Linkage Disassemble and Assemble
Group 1060: Hydraulic System
Service Brake Valve Remove and Install
Service Brake Accumulator Remove and Install
Section 11: Park Brake
Group 1111: Active Elements
Park Brake Remove and Install
Park Brake Disassemble and Assemble
Group 1160: Hydraulic System
Park Brake Release Solenoid Valve Remove and Install
Section 17: Frame or Supporting Structure
Group 1740: Frame Installation
Welding Major Structure
Engine and Loader Frame Separate
Upper Pivot Bearing and Seals Remove and Install
Lower Pivot Bearing and Seals Remove and Install
Group 1746: Frame Bottom Guards
Fuel Tank Guard Remove and Install
Front Axle Guard Remove and Install
Transmission Bottom Guard Remove and Install
Group 1749: Chassis Weights
Counterweights Remove and Install
Section 18: Operator's Station
Group 1800: Removal and Installation
Cab Remove and Install
Group 1810: Operator Enclosure
Windowpanes Remove and Install
Cab Door Hold-Open Release Adjust
Cab Door Hold-Open Latch Pin Adjust
Front and Rear Windshield Wiper Motor Remove and Install
Group 1821: Seat and Seat Belts
Seat Remove and Install
Seat Belt Remove and Install
Joystick Steering Armrest and Wiring Harness Remove and Install
Joystick Steering Controller Assembly Remove and Install
Steering Joystick Disassemble and Assemble
Joystick Steering Armrest Disassemble and Assemble
Joystick Steering Armrest Tilt Pivot Disassemble and Assemble
Joystick Steering Armrest Rear Pivot Adjustment
Group 1830: Heating and Air Conditioning
Refrigerant Cautions and Proper Handling
R134a Compressor Oil Charge Check
R134a Compressor Oil Removal
R134a Component Oil Charge
Refrigerant Leak Testing
Refrigerant Hoses and Tubing Inspection
R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure
R134a System Recover
R134a System Evacuate
R134a System Charge
Air Conditioner System Cleaning Procedures
Air Conditioner System Purge
Air Conditioner System Flush
Air Conditioning Module With Heater/Evaporator Coil
Heater/Evaporator Coil Remove and Install
Expansion Valve Remove and Install
Freeze Control Switch Remove and Install
Freeze Control Switch Bench Test
Heater Control Valve Remove and Install
Heater Control Valve Leak Check
Blower Motor Assembly Remove and Install
Receiver-Dryer Remove and Install
Condenser Remove and Install
Air Conditioning High-Low Pressure Switch Remove and Install
Compressor Remove and Install
Compressor Clutch—R134a Disassemble and Assemble
Section 19: Sheet Metal and Styling
Group 1910: Hood or Engine Enclosure
Hood Remove and Install
Engine Side Shields Remove and Install
Group 1921: Grille and Grille Housing
Grille and Grille Housing Remove and Install
Section 31: Loader
Group 3102: Bucket
Bucket Remove and Install