John Deere 624J Loader Repair Service Manual (TM10245)

TM10245 - John Deere 624J Loader (S.N. 611797— )  Technical Manual (Repair).pdf

Complete Repair Service Technical Manual for John Deere 624J Loader, with all the shop information to maintain, repair, service like professional mechanics.

John Deere 624J Loader workshop technical manual (repair) 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: 674 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

Table of Contents

Foreword

Technical Information Feedback Form

Section 00: General Information

Group 0001: Safety Information

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 Fluids

Avoid High-Pressure Oils

Beware of Exhaust Fumes

Prevent Fires

Prevent Battery Explosions

Handle Chemical Products Safely

Dispose of Waste Properly

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

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™ IV Axles

Front Axle and Differential Remove and Install

Rear Axle and Differential Remove

Rear Axle and Differential Install

Axle Oscillating Supports Disassemble and Assemble

Group 0225: Axle Shafts and U-Joints

Universal Joint and Drive Shaft Remove and Install

Group 0250: Axle Shaft, Bearings, Reduction Gears

TeamMate™ IV Axles

Group 0260: Hydraulic System

Differential Lock Solenoid Valve Remove and Install

Axle Circulation System

Axle Oil Coolers Disassemble and Assemble

Section 03: Transmission

Group 0300: Removal and Installation

Transmission Remove and Install

Group 0350: Gears, Shafts, Bearings and Power Shift Clutch

Torque Converter And Housing Remove

Torque Converter and Housing Install

Clutches, Input and Output Shafts Remove

Clutches, Input and Output Shafts Install

Clutch Pack KV and KR Disassemble

Clutch Pack KV and KR Assemble

Clutch Pack K1, K2, and K3 Disassemble

Clutch Pack K1, K2, and K3 Assemble

Clutch Pack K4 Disassemble

Clutch Pack K4 Assemble

Input Shaft Disassemble

Input Shaft Assemble

Output Shaft Disassemble

Output Shaft Assemble

Group 0360: Hydraulic System

Transmission Pump Remove and Install

Converter Minimum Pressure Regulator Valve Remove and Install

Transmission Pump Install

Transmission Hydraulic Control Valve Remove

Transmission Hydraulic Control Valve Install

Transmission Hydraulic Control Valve Cross Section View

Transmission Control Valve Disassemble

Transmission Control Valve Assemble

Torque Converter Relief Valve Remove, Disassemble and Install

Transmission Internal Oil Pipes and Tubes Remove and Install

Section 04: Engine

Group 0400: Removal and Installation

PowerTech Plus POWERTECH is a trademark of Deere & Company 4.5 L (4045) and 6.8 L (6068) John Deere Engines

Engine Remove and Install

Engine Crankshaft Dampener Remove and Install

Serpentine Belt Remove and Install

Section 05: Engine Auxiliary Systems

Group 0505: Cold Weather Starting Aids

Engine Coolant Heater Remove and Install

Group 0510: Cooling System

Intercooler Remove and Install

Radiator Remove and Install

Hydraulic Oil Cooler Remove and Install

Transmission Oil Cooler Remove and Install

Cooling Package Plenum Remove and Install

Group 0520: Intake System

Air Cleaner Remove and Install

Element Inspect

Group 0530: External Exhaust System

Muffler Remove and Install

Group 0560: External Fuel Supply Systems

Fuel Tank Remove and Install

Primary Fuel Filter (Water Separator) Remove and Install

Section 07: Dampener Drive

Group 0752: Elements

Output Dampener Remove and Install

Section 09: Steering System

Group 0960: Hydraulic System

Steering Valve Remove and Install

Steering Column Remove and Install

Steering Column Disassemble and Assemble

Steering Cylinders Remove and Install (S.N. —618132)

Steering Cylinders Remove and Install (S.N. 618133— )

Steering Cylinder Bushings Remove and Install (S.N. —618132)

Steering Cylinder Bushings Remove and Install (S.N 618133— )

Loader Start-Up Procedure (Steering Cylinder)

Section 10: Service Brakes

Group 1011: Active Elements

Service Brake Assembly Remove And Install

Brake Pedal and Linkage Disassemble and Assemble

Group 1060: Hydraulic System

Brake Valve Remove and Install

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

Remove and Install Upper Pivot Bearing and Seals

Remove and Install Lower Pivot Bearing and Seals

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

Rear Counterweight Remove and Install

Section 18: Operator’s Station

Group 1800: Removal and Installation

Cab Remove

Cab Install

Group 1810: Operator Enclosure

Windowpanes Remove and Install

Cab Door Hold-Open Release Adjust

Front and Rear Windshield Wiper Motor Remove and Install

Group 1830: Heating and Air Conditioning

Air Conditioning System Fittings Reference Chart

R134a Refrigerant Cautions

R134a Compressor Oil Charge Check

R134a Compressor Oil Removal

R134a Component Oil Charge

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

Main Blower Assembly Remove and Install

Pressurizer Motor Assembly Remove and Install

Receiver-Dryer and Condenser Remove and Install

A/C Binary Pressure Switch Remove and Install

Fresh Air Filter Remove and Install

Recirculating Air Filter Remove and Install

Compressor Remove and Install

Compressor Clutch—R134a Disassemble and Assemble

Clutch Hub Clearance—R134a Check

Section 19: Sheet Metal and Styling

Group 1910: Hood or Engine Enclosure

Hood Remove and Install

Engine Side Shields Remove and Install

Section 31: Loader

Group 3102: Bucket

Bucket Remove and Install

Powerllel Pin-On Bucket Remove and Install

Welded Bucket Cutting Edges Remove and Install

Bolt-On Cutting Edges and Wear Plates Remove and Install

Cracked Cutting Edge Repair

Group 3140: Frames

NeverGrease™ Pin Joints

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

Powerllel Leveling Link Disassemble and Assemble

Powerllel Bellcrank Remove and Install

Powerllel Bucket Cylinder Remove and Install

Powerllel Bucket Link Disassemble and Assemble

Powerllel Guide Links Remove and Install

Powerllel Coupler Disassemble and Assemble

Powerllel Loader Boom Disassemble and Assemble

Hi-Vis Coupler Disassemble and Assemble

Group 3160: Hydraulic System

Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy

Hydraulic Pump Start-Up Procedure

Hydraulic Pump Remove and Install

Hydraulic Pump Disassemble and Assemble

Loader Control Valve Remove and Install

Loader Control Valve Disassemble and Assemble

Auxiliary Valve Section and Bucket Section Disassemble and Assemble

Boom Valve Section Disassemble and Assemble

Inlet Valve Section Disassemble and Assemble

Relief Valve Disassemble and Assemble

Load Sense Relief Valve Disassemble and Assemble

Boom Anticavitation Valve Disassemble and Assemble

Boom Cylinder Remove and Install

Bucket Cylinder Remove and Install

Boom and Bucket Cylinder Repair

Boom or Bucket Cylinder Bushings and Seals Remove and Install

Loader Start-Up Procedure

Hydraulic Reservoir Remove and Install

Pilot Control Valve Remove and Install

Pilot Control Valve Disassemble and Assemble

Boom Down Accumulator Remove and Install

Pressure Reducing Valve Manifold Remove and Install

Pressure Reducing Valve Manifold Disassemble and Assemble

Ride Control Valve Remove and Install

Ride Control Valve Disassemble and Assemble

Ride Control Accumulator Remove and Install

Pin Disconnect Valve Remove and Install

Pin Disconnect Valve Disassemble and Assemble

Fan Drive and Axle Circulation Pump Remove and Install

Section 9900: Dealer Fabricated Tools

Group 0099: Dealer Fabricated Tools

DFT1132 Hydraulic Pump Removal and Installation Tool

DFT1149 Pre-Load Clutch Pack Compression Ring Tool

tm10245 - 624J Loader (611797- )

Table of Contents

Foreword

Technical Information Feedback Form

General Information

Safety Information

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 Fluids

Avoid High-Pressure Oils

Beware of Exhaust Fumes

Prevent Fires

Prevent Battery Explosions

Handle Chemical Products Safely

Dispose of Waste Properly

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

Remove Paint Before Welding or Heating

Make Welding Repairs Safely

Drive Metal Pins Safely

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

Wheels

Powered Wheels and Fasteners

Wheel Remove and Install

Tire Remove and Install

Axles and Suspension Systems

Removal and Installation

TeamMate™ IV Axles

Front Axle and Differential Remove and Install

Rear Axle and Differential Remove

Rear Axle and Differential Install

Axle Oscillating Supports Disassemble and Assemble

Axle Shafts and U-Joints

Universal Joint and Drive Shaft Remove and Install

Axle Shaft, Bearings, Reduction Gears

TeamMate™ IV Axles

Hydraulic System

Differential Lock Solenoid Valve Remove and Install

Axle Circulation System

Axle Oil Coolers Disassemble and Assemble

Transmission

Removal and Installation

Transmission Remove and Install

Gears, Shafts, Bearings and Power Shift Clutch

Torque Converter And Housing Remove

Torque Converter and Housing Install

Clutches, Input and Output Shafts Remove

Clutches, Input and Output Shafts Install

Clutch Pack KV and KR Disassemble

Clutch Pack KV and KR Assemble

Clutch Pack K1, K2, and K3 Disassemble

Clutch Pack K1, K2, and K3 Assemble

Clutch Pack K4 Disassemble

Clutch Pack K4 Assemble

Input Shaft Disassemble

Input Shaft Assemble

Output Shaft Disassemble

Output Shaft Assemble

Hydraulic System

Transmission Pump Remove and Install

Converter Minimum Pressure Regulator Valve Remove and Install

Transmission Pump Install

Transmission Hydraulic Control Valve Remove

Transmission Hydraulic Control Valve Install

Transmission Hydraulic Control Valve Cross Section View

Transmission Control Valve Disassemble

Transmission Control Valve Assemble

Torque Converter Relief Valve Remove, Disassemble and Install

Transmission Internal Oil Pipes and Tubes Remove and Install

Engine

Removal and Installation

PowerTech Plus POWERTECH is a trademark of Deere & Company 4.5 L (4045) and 6.8 L (6068) John Deere Engines

Engine Remove and Install

Engine Crankshaft Dampener Remove and Install

Serpentine Belt Remove and Install

Engine Auxiliary Systems

Cold Weather Starting Aids

Engine Coolant Heater Remove and Install

Cooling System

Intercooler Remove and Install

Radiator Remove and Install

Hydraulic Oil Cooler Remove and Install

Transmission Oil Cooler Remove and Install

Cooling Package Plenum Remove and Install

Intake System

Air Cleaner Remove and Install

Element Inspect

External Exhaust System

Muffler Remove and Install

External Fuel Supply Systems

Fuel Tank Remove and Install

Primary Fuel Filter (Water Separator) Remove and Install

Dampener Drive

Elements

Output Dampener Remove and Install

Steering System

Hydraulic System

Steering Valve Remove and Install

Steering Column Remove and Install

Steering Column Disassemble and Assemble

Steering Cylinders Remove and Install (S.N. —618132)

Steering Cylinders Remove and Install (S.N. 618133— )

Steering Cylinder Bushings Remove and Install (S.N. —618132)

Steering Cylinder Bushings Remove and Install (S.N 618133— )

Loader Start-Up Procedure (Steering Cylinder)

Service Brakes

Active Elements

Service Brake Assembly Remove And Install

Brake Pedal and Linkage Disassemble and Assemble

Hydraulic System

Brake Valve Remove and Install

Brake Accumulator Remove and Install

Park Brake

Active Elements

Park Brake Remove and Install

Park Brake Disassemble and Assemble

Hydraulic System

Park Brake Release Solenoid Valve Remove and Install

Frame or Supporting Structure

Frame Installation

Welding Major Structure

Engine and Loader Frame Separate

Remove and Install Upper Pivot Bearing and Seals

Remove and Install Lower Pivot Bearing and Seals

Frame Bottom Guards

Front Axle Guard Remove and Install

Transmission Bottom Guard Remove and Install

Chassis Weights

Counterweights Remove and Install

Rear Counterweight Remove and Install

Operator’s Station

Removal and Installation

Cab Remove

Cab Install

Operator Enclosure

Windowpanes Remove and Install

Cab Door Hold-Open Release Adjust

Front and Rear Windshield Wiper Motor Remove and Install

Heating and Air Conditioning

Air Conditioning System Fittings Reference Chart

R134a Refrigerant Cautions

R134a Compressor Oil Charge Check

R134a Compressor Oil Removal

R134a Component Oil Charge

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

Main Blower Assembly Remove and Install

Pressurizer Motor Assembly Remove and Install

Receiver-Dryer and Condenser Remove and Install

A/C Binary Pressure Switch Remove and Install

Fresh Air Filter Remove and Install

Recirculating Air Filter Remove and Install

Compressor Remove and Install

Compressor Clutch—R134a Disassemble and Assemble

Clutch Hub Clearance—R134a Check

Sheet Metal and Styling

Hood or Engine Enclosure

Hood Remove and Install

Engine Side Shields Remove and Install

Loader

Bucket

Bucket Remove and Install

Powerllel Pin-On Bucket Remove and Install

Welded Bucket Cutting Edges Remove and Install

Bolt-On Cutting Edges and Wear Plates Remove and Install

Cracked Cutting Edge Repair

Frames

NeverGrease™ Pin Joints

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

Powerllel Leveling Link Disassemble and Assemble

Powerllel Bellcrank Remove and Install

Powerllel Bucket Cylinder Remove and Install

Powerllel Bucket Link Disassemble and Assemble

Powerllel Guide Links Remove and Install

Powerllel Coupler Disassemble and Assemble

Powerllel Loader Boom Disassemble and Assemble

Hi-Vis Coupler Disassemble and Assemble

Hydraulic System

Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy

Hydraulic Pump Start-Up Procedure

Hydraulic Pump Remove and Install

Hydraulic Pump Disassemble and Assemble

Loader Control Valve Remove and Install

Loader Control Valve Disassemble and Assemble

Auxiliary Valve Section and Bucket Section Disassemble and Assemble

Boom Valve Section Disassemble and Assemble

Inlet Valve Section Disassemble and Assemble

Relief Valve Disassemble and Assemble

Load Sense Relief Valve Disassemble and Assemble

Boom Anticavitation Valve Disassemble and Assemble

Boom Cylinder Remove and Install

Bucket Cylinder Remove and Install

Boom and Bucket Cylinder Repair

Boom or Bucket Cylinder Bushings and Seals Remove and Install

Loader Start-Up Procedure

Hydraulic Reservoir Remove and Install

Pilot Control Valve Remove and Install

Pilot Control Valve Disassemble and Assemble

Boom Down Accumulator Remove and Install

Pressure Reducing Valve Manifold Remove and Install

Pressure Reducing Valve Manifold Disassemble and Assemble

Ride Control Valve Remove and Install

Ride Control Valve Disassemble and Assemble

Ride Control Accumulator Remove and Install

Pin Disconnect Valve Remove and Install

Pin Disconnect Valve Disassemble and Assemble

Fan Drive and Axle Circulation Pump Remove and Install

Dealer Fabricated Tools

Dealer Fabricated Tools

DFT1132 Hydraulic Pump Removal and Installation Tool

DFT1149 Pre-Load Clutch Pack Compression Ring Tool