John Deere 824K Series II 4WD Loader Workshop Repair & Service Manual PDF (TM13227X19) - 824K-II, SN C664100/D664100 - TM13227X19 - John Deere 4WD Loaders 824K Series II Technical Manual (Repair).PDF
This is the full factory service and repair guide for the John Deere 824K-II 4WD Loader (SN: beginning at C664100, D664100) (PIN: 1DW824K***C664100—; 1DW824K***D664100—), containing every piece of service data needed to service, fix, and overhaul the machine the way a professional technician would.
The workshop repair manual for John Deere 824K Series II 4WD Loaders 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.
TM13227X19 - John Deere 4WD Loaders 824K Series II Technical Manual (Repair).PDF
TM13227X19 - John Deere 4WD Loaders 824K Series II Technical Manual (Repair).EPUB
Total Pages: 721 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!
Technical Information Feedback Form
General Information
Safety
Torque Values
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
Equipment Attaching
Hitches and Hitch Pins
Electrical System
Removal and Installation
Frame or Supporting Structure
Frame Installation
Frame Bottom Guards
Chassis Weights
Operator`s Station
Removal and Installation
Operator Enclosure
Seat and Seat Belt
Heating and Air Conditioning
Sheet Metal and Styling
Hood or Engine Enclosure
Loader
Bucket
Frames
Hydraulic System
Dealer Fabricated Tools
tm13227x19 - 824K Series II 4WD Loader
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
Avoid Static Electricity Risk When Refueling
Clean Debris from Machine
Prevent Battery Explosions
Handle Chemical Products Safely
Decommissioning — Proper Recycling and Disposal of Fluids and Components
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
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
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™ 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
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
Radiator Remove and Install
Hydraulic Oil Cooler Remove and Install
Transmission Oil Cooler Remove and Install
Axle Oil Cooler Remove and Install
Cooling Package Plenum Remove and Install
Group 0520: Intake System
Air Cleaner Remove and Install
Group 0530: External Exhaust Systems
Muffler Remove and Install
Group 0560: External Fuel Supply Systems
Fuel Tank Remove and Install
Auxiliary Fuel Filter and Water Separator Remove and Install
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—If Equipped
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
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
Section 15: Equipment Attaching
Group 1520: Hitches and Hitch Pins
Rear Hitch Remove and Install
Section 16: Electrical System
Group 1600: Removal and Installation
Installation of Repair Wire Assembly (RWA)
Boom Height Kickout/Return-to-Carry (BHKO/RTC) Position Sensor Remove and Install
Boom Height Kickout/Return-to-Carry (BHKO/RTC) Position Sensor Disassemble and Assemble
Freeze Control Switch Remove and Install
Air Conditioning High-Low Pressure Switch Remove and Install
Pressure Switches and Sensors Remove and Install
Replace Metri-Pack® (Push Type) Connectors
Replace Metri-Pack® Connectors
Replace DEUTSCH® Circular Connectors
Replace DEUTSCH® Rectangular or Triangular Connectors
Install DEUTSCH® Contact
Replace WEATHER PACK® Connector
Install WEATHER PACK® Contact
Replace CINCH™ Connectors
Install CINCH™ Contact
Repair 32 and 48 Way CINCH™ Connectors
Remove Connector Body from Blade Terminals
TPM—Tire Pressure Sensor Remove and Install
Section 17: Frame or Supporting Structure
Group 1740: Frame Installation
Welding on Machine
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
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 Belt
Seat Remove and Install
Seat Belt Remove and Install
Steering Joystick Disassemble and Assemble
Joystick Steering Armrest Disassemble and Assemble
Joystick Steering Armrest Rear Pivot Adjustment
Group 1830: Heating and Air Conditioning
R134a Refrigerant Cautions and Proper Handling
R134a Refrigerant Oil Information
R134a Refrigerant Recovery, Recycling, and Charging Station Installation Procedure
Recover R134a Refrigerant
Flush and Purge Air Conditioning System
Evacuate R134a System
Charge R134a System
Heater/Evaporator Coil Remove and Install
Expansion Valve Remove and Install
Receiver-Dryer Remove and Install
Condenser Remove and Install
Compressor Remove and Install
Section 19: Sheet Metal and Styling
Group 1910: Hood or Engine Enclosure
Hood Remove and Install
Engine Side Shields Remove and Install
Cooling Package Access Doors Remove and Install
Section 31: Loader
Group 3102: Bucket
Bucket Remove and Install
Welded Bucket Cutting Edges Remove and Install
Bucket Teeth and Shank Remove and Install
Bolt-On Cutting Edges Remove and Install
Cracked Cutting Edge Repair
Group 3140: Frames
Loader Bucket Tilt Linkage Remove and Install
Bucket Linkage Seals and Bushings Remove and Install
Loader Boom Bushings and Seals Remove and Install
Boom Remove and Install