John Deere 204K & 304K Loader Workshop Service Repair Manual PDF (TM12988) - TM12988 - John Deere 204K and 304K Loader Repair Manual.PDF
TM12988 - John Deere 204K and 304K Loader Repair Manual.PDF
This is a full repair and service guide for the John Deere 204K and 304K Loader, packed with the shop-level detail needed to maintain, fix, and service the machine the way a professional technician would.
John Deere 204K and 304K Loaders workshop service repair manual includes:
* 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.
Total Pages: 438 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
Foreword
Manual Identification-READ THIS FIRST!
General Information
Safety Information
Torque Values
Wheels
Wheels and Fasteners
Axles and Suspension Systems
Removal and Installation
Axle Shafts and U-Joints
Axle Shaft, Bearings, and Rear Axle Reduction Gears
Transmission
Hydrostatic Components Removal and Installation
Hydrostatic Components Repair
Engine
Removal and Installation
Engine Auxiliary Systems
Cooling System
Intake System
External Exhaust System
External Fuel Supply Systems
Damper Drive
Removal and Installation
Steering System
Hydraulic System
Service Brakes
Active Elements
Hydraulic System
Park Brake
Hydraulic System
Frame or Supporting Structure
Frame Installation
Chassis Weights
Operator`s Station
Removal and Installation
Operator Enclosure
Seat and Seat Belt
Heating and Air Conditioning System
Sheet Metal and Styling
Hood or Engine Enclosure
Miscellaneous Shields
Main Hydraulic System
Hydraulic System
Loader
Bucket
Attachment Coupler
Frames
Hydraulic System
Related Manuals (sold separately)
TM12985, 204K & 304K Loader Service Manual (Operation & Test)
CTM10075X19, Rear Axle Reduction Gear Case Repair Manual,
CTM10076X19, Service Brake Discs Inspection,
CTM10077X10, Front and Rear Axle Repair Manual,
CTM10078X19, Hydrostatic Pump Repair Manual
CTM10079X19, Hydrostatic Motor Repair Manual
Covered models:
204K (PIN: 1LU204K***B030899-)
304K (PIN: 1LU304K***B030847-)
Table of Contents (Exploded View)
00 - General Information
01 - Safety
Add and Operate Attachments Safely
Add Cab Guarding for Special Uses
Avoid Backover Accidents
Avoid High-Pressure Fluids
Avoid High-Pressure Oils
Avoid Machine Tip Over
Avoid Unauthorized Machine Modifications
Avoid Worksite Hazards
Clean Debris from Machine
Dispose of Waste Properly
Drive Metal Pins Safely
Follow Safety Instructions
Handle Chemical Products Safely
Inspect and Maintain ROPS
Inspect Machine
Keep Riders Off Machine
Make Welding Repairs Safely
Operate Only If Qualified
Operating on Slopes
Operating or Traveling On Public Roads
Park and Prepare for Service Safely
Prepare for Emergencies
Prevent Battery Explosions
Prevent Fires
Prevent Unintended Machine Movement
Recognize Safety Information
Remove Paint Before Welding or Heating
Service Cooling System Safely
Service Tires Safely
Start Only From Operator's Seat
Stay Clear of Moving Parts
Use and Maintain Seat Belt
Use Special Care When Operating Loader
Use Steps and Handholds Correctly
Wear Protective Equipment
Work In Ventilated Area
03 - Torque Values
Additional Metric Cap Screw Torque Values
Inch Series Four Bolt Flange Fitting For High Pressure Service Recommendations
Metric 24° O-Ring Seal DIN 20078 Service Recommendations
Metric Bolt and Cap Screw Torque Values
Service Recommendations For Inch Series Four Bolt Flange Fittings
Service Recommendations for Metric Series Four Bolt Flange Fitting
Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings
Service Recommendations For O-Ring Boss Fittings With Shoulder
Unified Inch Bolt and Cap Screw Torque Values
01 - Wheels or Tracks
Tire Remove and Install
Wheel Remove and Install
02 - Axles and Suspension Systems
00 - Removal & Installation
Front Axle Remove and Install
Rear Axle Remove and Install
25 - Axle Shafts & U-Joints
Drive Shaft Remove and Install
50 - Axle Shaft, Bearings, & Rear Axle Reduction Gears
Front and Rear Axle Disassemble and Assemble
Rear Axle Reduction Gear Case Disassemble and Assemble
Rear Axle Reduction Gear Case Remove and Install
03 - Transmission
00 - Hydrostatic Components Removal & Installation
Charge Pump Remove and Install
Creep Control Valve Remove and Install
Directional Control Valve Remove and Install
Hydrostatic Motor Remove and Install
Hydrostatic Pump Remove and Install
Hydrostatic Pump Valves Remove and Install
Hydrostatic Start-Up Procedure
60 - Hydrostatic Components Repair
Hydrostatic Motor Disassemble and Assemble
Hydrostatic Pump Disassemble and Assemble
04 - Engine
00 - Removal & Installation
Engine Remove and Install
John Deere Engine
Starter Motor Remove and Install
05 - Engine Auxiliary Systems
10 - Cooling System
Cooling Package Remove and Install
Fan Remove and Install
20 - Intake System
Air Intake System Remove and Install
30 - External Exhaust System
Muffler Remove and Install
60 - External Fuel Supply Systems
Fuel Tank Remove and Install
07 - Dampener Drive
Damper Plate Remove and Install
09 - Steering System
60 - Hydraulic System
Cab Steering Column Remove and Install
Canopy Steering Column Remove and Install
Orbital Steering Valve Assemble
Orbital Steering Valve Disassemble and Inspect
Orbital Steering Valve Remove and Install
Steering Cylinder Disassemble and Assemble
Steering Cylinder Remove and Install
10 - Service Brakes
11 - Active Elements
Drum Brake Remove and Install
Service Brakes (Wet Disc) Remove and Install
60 - Hydraulic System
Brake_Inching Valve Assembly Remove and Install
Drum Brake Bleed
11 - Park Brake
60 - Hydraulic System
Park Brake Valve Remove and Install
17 - Frames, Chassis, or Supporting Structure
40 - Frame Installation
Loader and Rear Frames Separation
Lower Pivot Bushing Assembly Remove and Install
Rear Link and Bushing Assembly Remove and Install
Upper Pivot Bushing Assembly Remove and Install
Welding Repair of Major Structures
49 - Counterweights
Counterweight Remove and Install
18 - Operator's Station
00 - Removal & Installation
Cab Remove and Install
Canopy Remove and Install
10 - Operator Enclosure
Rear Wiper Motor Remove and Install
Windowpanes Remove and Install
Windshield Wiper Motor Remove and Install
21 - Seat & Seat Belts
Seat Remove and Install
30 - Heating & Air Conditioning
Air Conditioner Compressor Remove and Install
Air Conditioner Freeze Control Switch Remove and Install
Air Conditioner_Heater Module Remove and Install
Air Conditioner High_Low Pressure Switch Remove and Install
Blower Motor Remove and Install
Charge R134a System
Condenser Remove and Install
Evacuate R134a System
Evaporator Coil Remove and Install
Expansion Valve Remove and Install
Flush and Purge Air Conditioner System
Heater Control Valve Remove and Install
Heater Core Remove and Install
R134a Refrigerant Oil Information
R134a Refrigerant Recovery_Recycling and Charging Station Installation Procedure
Receiver-Dryer Remove and Install
Recover R134a Refrigerant
Refrigerant Cautions and Proper Handling
19 - Sheet Metal and Styling
10 - Hood or Engine Enclosure
Hood Remove and Install
13 - Miscellaneous Shields
Rear Fenders Remove and Install
21 - Main Hydraulic System
60 - Hydraulic System
General Hydraulic Oil Cleanup Procedure
Hydraulic Component Failure Cleanup Procedure
Hydraulic Oil Reservoir Remove and Install
Hydraulic Pump_Priority Valve Disassemble and Assemble
Hydraulic Pump_Priority Valve Remove and Install
Hydraulic Start-Up Procedure
31 - Loader
02 - Bucket
Bolt-On Cutting Edge Remove and Install
Cracked Cutting Edge Repair
Welded-On Bucket Cutting Edge Remove and Install
04 - Attachment Coupler
Quik-Tatch™ Actuator Remove and Install
Quik-Tatch™ Coupler Remove and Install
40 - Frames
Boom and Bucket Linkage Remove and Install
Bucket Linkage Bushings Remove and Install
Loader Boom Bushings Remove and Install
60 - Hydraulic System
Boom and Bucket Cylinders Disassemble and Assemble
Boom Cylinder Remove and Install
Bucket Cylinder Remove and Install
Loader Control Valve Remove and Install