Complete Repair manual for John Deere 824K 4WD Loader with Engines 6135HDW01 (T3), 6135HDW03 (S2) (SN.before 641969), with all the service information to maintain, repair, and rebuild like professional mechanics.

John Deere 4WD Loaders 824K workshop 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.

TM10699 - John Deere 4WD Loaders 824K Technical Manual (Repair).pdf
TM10699 - John Deere 4WD Loaders 824K 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
   Technical Information Feedback Form
   General Information
      Safety Information
   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 Systems
      Cold Weather Starting Aids
      Cooling System
      Intake System
      External Exhaust System
      External Fuel Supply Systems
   Dampener 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

tm10699 - 824K 4WD Loader

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 Oils

Avoid High-Pressure Fluids

Beware of Exhaust Fumes

Prevent Fires

Clean Debris from Machine

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

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™ II 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 and 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

PowerTech Plus™ 13.5 L (6135) John Deere Engines

Engine Remove and Install

Crankshaft Dampener Remove and Install

Serpentine Belt Remove and Install

Section 05: Engine Auxiliary Systems

Group 0505: Cold Weather Starting Aids

Start Aid Nozzle Remove and Install

Start Aid Solenoid Remove and Install

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

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 System

Muffler Remove and Install

Group 0560: External Fuel Supply Systems

Fuel Tank Remove and Install

Fuel Filter (Water Separator) Remove and Install

Fast Fill Fuel System Disassemble and Assemble—If Equipped

Section 07: Dampener Drive

Group 0752: Elements

Output Dampener 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—If Equipped

Secondary Steering Valve Remove and Install

Joystick Steering Valve Remove and Install—If Equipped

Joystick Steering Valve Disassemble and Assemble—If Equipped

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—If Equipped

Joystick Steering Controller Assembly Remove and Install—If Equipped

Steering Joystick Disassemble and Assemble—If Equipped

Joystick Steering Armrest Disassemble and Assemble—If Equipped

Joystick Steering Armrest Tilt Pivot Disassemble and Assemble—If Equipped

Joystick Steering Armrest Rear Pivot Adjustment—If Equipped

Group 1830: Heating and Air Conditioning

Proper Refrigerant Handling

R134a Refrigerant Cautions

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

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

Group 1921: Grille and Grille Housing

Grille and Grille Housing Remove and Install

Section 31: Loader

Group 3102: Bucket

Bucket Remove and Install

Welded Bucket Cutting Edges Remove and Install

Bucket Teeth Remove and Install

Bolt-On Cutting Edges 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

Hi-Vis Coupler Disassemble and Assemble

Group 3160: Hydraulic System

General Oil Cleanup Procedure

Hydraulic Component Failure Cleanup Procedure

Follow-Up Oil Cleanup Procedure

Loader Hydraulic Pump Remove and Install

Main Hydraulic Pump Disassemble and Assemble

Steering/Loader Hydraulic Pump Remove and Install

Loader Control Valve Remove and Install

Loader Control Valve Disassemble and Assemble

Boom Section Disassemble and Assemble

Bucket Section Disassemble and Assemble

Auxiliary Section Disassemble and Assemble

Main Relief Valve Disassemble and Assemble

Circuit Relief With Anticavitation Valve Disassemble and Assemble

Anticavitation Valve Disassemble and Assemble

Auxiliary, Bucket, and Boom Section Pilot Orifice Check Valve

Boom Cylinder Remove and Install

Bucket Cylinder Remove and Install

Boom and Bucket Cylinder Disassemble and Assemble

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

Auxiliary Function Pilot Control Valve Remove and Install

Auxiliary Function Pilot Control Valve Disassemble and Assemble

Pilot Accumulator Remove and Install

Hydraulic Pump Manifold Remove and Install

Hydraulic Pump Manifold Disassemble and Assemble

Ride Control Valve Remove and Install—If Equipped

Ride Control Valve Disassemble and Assemble

Ride Control Accumulator Remove and Install

Pin Disconnect Valve Remove and Install

Pin Disconnect Valve Disassemble and Assemble

Hydraulic Fan Motor Remove and Install

Hydraulic Fan Pump Remove and Install

Hydraulic Fan Proportional/Relief Solenoid Valve Remove and Install

Hydraulic Fan Proportional/Relief Solenoid Valve Disassemble and Assemble

Reversing Fan Valve Remove and Install—If Equipped

Reversing Fan Valve Disassemble and Assemble—If Equipped

Section 99: Dealer Fabricated Tools

Group 9900: Dealer Fabricated Tools

DFT1044 Air Deflector Bushing

John Deere 4WD Loaders 824K Repair Service Manual (TM10699)