John Deere 204K and 304K Loader Service Manual (Operation & Test) - TM12985
John Deere 204K and 304K Loader Service Manual (Operation & Test) - TM12985
TM12985 - John Deere 204K and 304K Loader Technical Manual (Operation & Test).PDF
Complete official service manual with Electrica Wiring Diagrams for John Deere 204K and 304K Loader, with all the shop information to maintain, diagnose, service, rebuild like professional mechanics.
John Deere 204K and 304K Loaders workshop diagnosis & test 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.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* 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: 564 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English
Covered models:
204K (PIN: 1LU204K***B030899-)
304K (PIN: 1LU304K***B030847-)
MAIN SECTIONS
Foreword
Manual Identification—READ THIS FIRST!
General Information
Safety Information
Diagnostic Trouble Codes (DTC)
Engine Control Unit (ECU) Diagnostic Trouble Codes
Monitor Display Diagnostic Trouble Codes
Operational Checkout Procedure
Operational Checkout Procedure
Engine
Theory of Operation
Diagnostic Information
Tests
Electrical System
System Information
System Diagrams
Sub-System Diagnostics
References
Power Train
Theory Of Operation
Diagnostic Information
Adjustments
Tests
Hydraulic System
Theory of Operation
Diagnostic Information
Test
Heating and Air Conditioning
Theory of Operation
Diagnostic Information
Tests
TABLE OF CONTENTS (Expanded View)
9000 - 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
Decommissioning — Proper Recycling and Disposal of Fluids and Components
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
9001 - DIAGNOSTIC TROUBLE CODES (DTC)
10 - Engine Control Unit (ECU) Diagnostic Trouble Codes
000091.03 — Primary Throttle Signal Out of Range High
000091.04 — Primary Throttle Signal Out of Range Low
001079.03 — Sensor Supply #1 Voltage Out of Range High
001079.04 — Sensor Supply #1 Voltage Out of Range Low
522241.03 — Fuel Injection Pump Rack Actuator Relay Out of Range High
522241.04 — Fuel Injection Pump Rack Actuator Relay Out of Range Low
522242.03 — Cold Start Aid Relay Driver Circuit Out of Range High
522242.04 — Cold Start Aid Relay Driver Circuit Out of Range Low
522243.03 — Air Heater Relay Driver Circuit Out of Range High
522243.04 — Air Heater Relay Driver Circuit Out of Range Low
Engine Control Unit (ECU) Diagnostic Trouble Codes
20 - Monitor Display Diagnostic Trouble Codes
Monitor Display Diagnostic Trouble Codes
9005 - OPERATIONAL CHECKOUT PROCEDURE
10 - Operational Checkout Procedure
Operational Checkout
9010 - ENGINE
05 - Theory of Operation
John Deere Engine
15 - Diagnostic Information
Engine Cooling System Component Location
Engine Fuel System Component Location
Engine Intake and Exhaust Component Location
John Deere Engine
25 - Tests
Engine Idle Speeds Check
John Deere Engine
9015 - ELECTRICAL SYSTEM
05 - System Information
Electrical Diagram Information
Electrical Schematic Symbols
10 - System Diagrams
Air Conditioner Harness (W10) Component Location
Air Conditioner Harness (W10) Wiring Diagram
Cab Harness (W8) Component Location
Cab Harness (W8) Wiring Diagram
Canopy Harness (W9) Component Location
Canopy Harness (W9) Wiring Diagram
Engine Harness (W6) Component Location
Engine Harness (W6) Wiring Diagram
Fuse and Relay Specifications
Loader_Rear Frame Harness (W7) Component Location
Loader_Rear Frame Harness (W7) Wiring Diagram
Quik-Tatch™ Extension Harness (W13) Component Location
Quik-Tatch™ Extension Harness (W13) Wiring Diagram
Quik-Tatch™ Harness (W12) Component Location
Quik-Tatch™ Harness (W12) Wiring Diagram
Service ADVISOR™ Harness (W11) Component Location
Service ADVISOR™ Harness (W11) Wiring Diagram
System Functional Schematic and Section Legend
System Functional Schematic, Component Location, and Wiring Diagram Master Legend
15 - Sub-System Diagnostics
Air Conditioner Circuit Theory of Operation
Cold Start Aid Preheat Circuit Theory of Operation
Controller Area Network (CAN) Theory of Operation
Engine Control Unit (ECU) Circuits Theory of Operation
Forward, Reverse, LO_HI Travel Speed, and Backup Alarm Circuits Theory of Operation
Hazard and Turn Lights Circuits Theory of Operation
Headlights, Marker Lights, and Horn Circuits Theory of Operation—Cab
Headlights, Marker Lights, and Horn Circuits Theory of Operation—Canopy
Hydraulic Enable and Third Function Detent Enable Circuits Theory of Operation
Monitor Display Circuits Theory of Operation
Park Brake Release Circuit Theory of Operation
Power Circuit Theory of Operation
Quik-Tatch™ Circuit Theory of Operation
Start and Charge Circuits Theory of Operation
20 - References
Alternator Test
CAN Circuit Test
Connector Terminal Test
Electrical Component Specifications
Engine Control Unit (ECU) Remove and Install
Engine Control Unit (ECU) Replacement Calibration
Engine Speed Control Pedal Sensor Test
Fuel Pump Replacement Calibration
Install CINCH™ Contact
Install DEUTSCH® Contact
Install WEATHER PACK® Contact
Intermittent Diagnostic Trouble Code (DTC) Diagnostics
Monitor Display Remove and Install
Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application
Remove Connector Body from Blade Terminals
Repair 32 and 48 Way CINCH™ Connectors
Replace CINCH™ Connectors
Replace DEUTSCH® Circular Connectors
Replace DEUTSCH® Rectangular or Triangular Connectors
Replace Metri-Pack® Connectors
Replace Metri-Pack® (Push Type) Connectors
Replace WEATHER PACK® Connector
Return-to-Dig Adjustment
Sensor Circuit Check
Service ADVISOR™ Connection Procedure
Service ADVISOR™ Diagnostic Application
Wire Harness Test
Yanmar Display Calibration Values Test
9020 - POWER TRAIN
05 - Theory of Operation
Brake Valve Operation
Creep Control Valve Operation
Differential Limited Slip Operation
High-Pressure Relief Valve Operation
Hydrostatic Motor Operation—Forward (High Speed)
Hydrostatic Motor Operation—Neutral
Hydrostatic Motor Operation—Reverse (Low Speed)
Hydrostatic Pump Control Operation—Forward (Engine Speed at Fast Idle)
Hydrostatic Pump Control Operation—Reverse (Engine Speed at Less Than Fast Idle)
Hydrostatic Pump Operation
Hydrostatic Pump Swash Plate Operation
Hydrostatic Transmission Operation—Forward (High Speed)
Hydrostatic Transmission Operation—Forward (Low Speed)
Hydrostatic Transmission Operation—Neutral
Hydrostatic Transmission Operation—Reverse (Low Speed)
Inching Valve Operation
Park Brake Release Solenoid Valve Operation
Power Train Description
Service and Park Brake Operation
15 - Diagnostic Information
Axle Overheats
Cannot Find or Hold Neutral
Differential Low on Oil
Excessive Differential and_or Axle Noise
Excessive Driveline Vibration or Noise
Foaming Oil
Hydraulic Oil Overheats (Machine Shifts to Low Speed Automatically)
Hydrostatic Transmission Schematic
Lack of Power or Sluggish
Machine Does Not Move at Low Idle
Machine Does Not Move
Machine Drives Erratically
Machine Moves in One Direction Only
Machine Moves in Wrong Direction
Machine Vibrates
Oil Seeping From Outer Axle Seal
Park Brake Indicator in Monitor Does Not Come ON When Park Brake Applied
Park Brake Overheats
Park Brake Will Not Apply
Park Brake Will Not Hold
Park Brake Will Not Release
Poor or No Service Brakes
Power Train Component Location
Service and Park Brake System Component Location
Service Brake and Park Brake System Schematic
Service Brakes Aggressive
Service Brakes Chatter
Service Brakes Dragging
Slow Acceleration—Fast Deceleration
20 - Adjustments
Brake_Inching Pedal Linkage Adjustment
Drum Brake Inspection
Hydrostatic Motor Minimum Displacement Adjustment
Hydrostatic Pump Servo Piston Neutral Adjustment
Service Brakes (Wet Disc) Inspection
25 - Tests
Before Performing Hydrostatic Transmission Tests
Directional Control Valve Spool Leakage Test
High-Pressure Relief Valve Test and Adjustment
Hydrostatic Adjusting Screws (With Tamper-Proof Caps)
Hydrostatic Motor Begin Regulation of Displacement Control Valve Test and Adjustment
Hydrostatic Pump Begin Regulation Test and Adjustment
Hydrostatic Pump Isolation Procedure
Hydrostatic Pump Performance (Timing) Test and Adjustment
Hydrostatic Pump Pressure Override (POR) Valve Pressure Test and Adjustment
Neutral Charge Relief Valve Pressure Test and Adjustment
Park Brake Release Pressure Test
9025 - HYDRAULIC SYSTEM
05 - Theory of Operation
Hydraulic Enable Solenoid Operation
Hydraulic Pump Operation
Hydraulic System Operation
Loader Control Valve Circuit Relief Valve With Anticavitation Operation
Loader Control Valve Operation—Auxiliary Section
Loader Control Valve Operation—Boom Section
Loader Control Valve Operation—Bucket Section
Loader Control Valve Operation
Loader System Relief Valve Operation
Orbital Steering Circuit Operation
Orbital Steering Valve Operation
Priority Valve Operation
Steering Cylinder Relief Valve Operation
15 - Diagnostic Information
Abrupt Steering Wheel Oscillation
Boom Down Does Not Work (Engine Off)
Boom Float Function Does Not Work
Constant Steering to Maintain Straight Travel
Erratic Steering
Free Play at Steering Wheel
Function Drifts Down
Function Drops Before Rising When Valve Is Activated
Hydraulic Oil Foams
Hydraulic System Schematic
Loader Hydraulic System Component Location
Low Hydraulic Power
Machine Turns in Opposite Direction
Machine Turns When Orbital Steering Valve Is in Neutral
No Hydraulic Functions
Noisy Hydraulic Pumps
No Steering Function During Slow Steering Wheel Movement
No Steering Functions
Oil Overheats
One Hydraulic Function Does Not Work
Orbital Steering System Component Location
Orbital Steering System Schematic
Orbital Steering Valve Locks Up
Slow Hydraulic Functions
Spongy or Soft Steering
Steering Wheel Does Not Immediately Return to Neutral When Released
Steering Wheel Turns by Itself
Steering Wheel Turns With No Resistance and Causes No Frame Movement
25 - Tests
Boom and Bucket Cylinder Leakage Test
Hydraulic Oil Warm-Up Procedure
Hydraulic Pump Flow Test
Hydraulic System Pressure Discharge Procedure
JT02156A Digital Pressure and Temperature Analyzer Kit Installation
Loader Circuit Relief Valve Pressure Test
Loader Cylinder Drift Test
Loader System Relief Valve Pressure Test
Orbital Steering System Relief Valve Pressure Test
Steering Cylinder Leakage Test
9031 - HEATING AND AIR CONDITIONING
05 - Theory of Operation
Air Conditioning System Cycle of Operation
15 - Diagnostic Information
Air Conditioner and Heater Component Location
Air Conditioner Does Not Cool Interior of Cab
Air Conditioner Runs Constantly, Too Cold
Air Conditioning System Does Not Operate
Heater Does Not Warm Interior of Cab
Heater System Does Not Operate
Interior Windows Continue to Fog
25 - Tests
Air Conditioner Compressor Clutch Test
Air Conditioner High_Low Pressure Switch Test
Operating Pressure Diagnostic Chart
R134a Refrigerant Cautions
Refrigerant Cautions and Proper Handling
Refrigerant Leak Test
