Complete service repair manual for John Deere 4WD Loader 624H & Tool Carrier Loader TC62H, with all the shop information to maintain, repair, and rebuild like professional mechanics.

John Deere 4WD Loader 624H & Tool Carrier Loader TC62H 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.

TM1640 - John Deere 624H 4WD Loader and TC62H Tool Carrier Loader Technical Manual - Repair.PDF
TM1640 - John Deere 624H 4WD Loader and TC62H Tool Carrier Loader Technical Manual - Repair.epub

Total Pages: 812 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
      General Specifications
      Torque Values
      Fuels and Lubricants
   Wheels
      Powered Wheels and Fasteners
   Axles and Suspension Systems
      Removal and Installation
      Axle Shafts and U-Joints
      Axle Shaft, Bearings, Reduction Gears
      Hydraulic System
   Transmission
      Removal and Installation
      Gears, Shafts, Bearings and Power Shift Clutch
      Hydraulic System
      Dealer Fabricated Tools
   Engine
      Removal and Installation
   Engine Auxiliary Systems
      Cold Weather Starting Aids
      Cooling System
      Speed Controls
      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
   Electrical System
      Batteries, Support and Cables
      Alternator, Regulator and Charging System Wiring
      Lighting System
      Wiring Harness and Switches
      System Controls
      Motors and Actuators
   Frame or Supporting Structure
      Frame Installation
      Frame Bottom Guards
      Chassis Weights
   Operator’s Station
      Removal and Installation
      Operator Enclosure
      Seat and Seat Belts
      Steps and Handholds
      Heating and Air Conditioning
      Dealer Fabricated Tools
   Sheet Metal and Styling
      Hood or Engine Enclosure
      Miscellaneous Shields
      Grille and Grille Housing
      Miscellaneous Shields
   Safety and Convenience
      Mirror
      Fire Extinguisher
      Horn and Warning Devices
   Loader
      Bucket
      Frames
      Hydraulic System

tm1640 - 624H Loader TC62H Tool Carrier

Table of Contents

Foreword

Technical Information Feedback Form

Section 00: General Information

Group 0001: Safety Information

Handle Fluids Safely—Avoid Fires

Prevent Battery Explosions

Prepare for Emergencies

Prevent Acid Burns

Handle Chemical Products Safely

Avoid High-Pressure Fluids

Park Machine Safely

Support Machine Properly

Wear Protective Clothing

Work in Clean Area

Service Machines Safely

Work In Ventilated Area

Illuminate Work Area Safely

Replace Safety Signs

Use Proper Lifting Equipment

Remove Paint Before Welding or Heating

Avoid Heating Near Pressurized Fluid Lines

Keep ROPS Installed Properly

Service Tires Safely

Avoid Harmful Asbestos Dust

Practice Safe Maintenance

Use Proper Tools

Decommissioning — Proper Recycling and Disposal of Fluids and Components

Live With Safety

Group 0002: General Specifications

624H Specifications

Drain and Refill Capacities—624H/TC62H

TC62H Specifications

Drain and Refill Capacities—TC62H

Group 0003: Torque Values

Hardware Torque Specifications

ROPS Torque Specifications

Metric Bolt and Screw Torque Values

Additional Metric Cap Screw Torque Values

Unified Inch Bolt and Screw Torque Values

Check Oil Lines And Fittings

Service Recommendations for O-Ring Boss Fittings

Service Recommendations For Flat Face O-Ring Seal Fittings

Service Recommendations for Metric Series Four Bolt Flange Fitting

Service Recommendations For Inch Series Four Bolt Flange Fittings

Group 0004: Fuels and Lubricants

Diesel Fuel

Lubricity of Diesel Fuel

Low Sulfur Diesel Fuel Conditioner

Diesel Fuel Storage

Fuel Tank

Diesel Engine Oil

Transmission, Hydraulic System, Park Brake, and Differential Oil

Grease

Alternative and Synthetic Lubricants

Lubricant Storage

Mixing of Lubricants

Section 01: Wheels

Group 0110: Powered Wheels and Fasteners

Service Equipment and Tools

Specifications

Remove and Install Wheel

Remove Tire

Install Tire

Section 02: Axles and Suspension Systems

Group 0200: Removal and Installation

Service Equipment and Tools

Specifications

Remove and Install Front Axle and Differential

Remove Rear Axle and Differential

Install Rear Axle and Differential

Disassemble and Assemble Axle Oscillating Supports

Group 0225: Axle Shafts and U-Joints

Specifications

Remove and Install Universal Joint and Drive Shaft

Disassemble, Inspect and Assemble Universal Joint and Drive Shaft

Group 0250: Axle Shaft, Bearings, Reduction Gears

John Deere TeamMate TeamMate is a trademark of Deere & Company. III Axles—Use CTM150

Essential Tools

Service Equipment and Tools

Other Material

Specifications

Axle Disconnect Input Shaft, Cross-Sectional View

Remove and Install Axle Disconnect Input Shaft

Disassemble, Inspect, and Assemble Axle Disconnect Input Shaft

Group 0260: Hydraulic System

Specifications

Remove and Install Differential Lock Solenoid Valve

Axle Recirculation System

Axle Recirculation System With Optional Oil Coolers

Axle Oil Coolers—Exploded View

Remove and Install Front Axle Oil Cooler

Disassemble and Assemble Front Axle Oil Cooler

Remove and Install Rear Axle Oil Cooler

Section 03: Transmission

Group 0300: Removal and Installation

Essential Tools

Specifications

Remove and Install Transmission

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

Essential Tools

Service Equipment and Tools

Other Material

Specifications

Remove Torque Converter and Housing

Install Torque Converter and Housing

Remove Clutches, Input and Output Shafts

Install Clutches, Input and Output Shafts

Disassemble Clutch Pack KV and KR

Assemble Clutch Pack KV and KR

Disassemble Clutch Pack K1, K2, and K3

Assemble Clutch Pack K1, K2, and K3

Disassemble Clutch Pack K4

Assemble Clutch Pack K4

Disassemble Input Shaft

Assemble Input Shaft

Group 0360: Hydraulic System

Specifications

Remove Transmission Pump

Remove and Install Converter Minimum Pressure Regulator Valve

Install Transmission Pump

Remove Transmission Hydraulic Control Valve

Install Transmission Hydraulic Control Valve

Transmission Hydraulic Control Valve Cross Section View

Disassemble Transmission Control Valve

Assemble Transmission Control Valve

Remove, Disassemble and Install Converter Relief Valve

Transmission Internal Oil Pipes and Tubes Remove and Install

Group 0399: Dealer Fabricated Tools

DFT1148 Pre-Load Clutch Pack Compression Ring Tool

DFT1149 Pre-Load Clutch Pack Compression Ring Tool

Section 04: Engine

Group 0400: Removal and Installation

PowerTech PowerTech is a trademark of Deere & Company. 4.5 L (4045) and 6.8 L (6068) John Deere Engines—Use CTM104

Service Equipment and Tools

Specifications

Remove and Install Engine

Section 05: Engine Auxiliary Systems

Group 0505: Cold Weather Starting Aids

Other Material

Specifications

Remove and Install Fluid Starting Aid Assembly

Remove and Install Engine Coolant Heater

Group 0510: Cooling System

Other Material

Specifications

Remove and Install Serpentine Belt

Remove and Install Fan and Fan Drive

Remove and Install Radiator and Oil Cooler

Disassemble and Assemble Radiator, Oil Cooler and Air-to-Air Aftercooler

Group 0515: Speed Controls

Specifications

Remove and Install Speed Control Linkage

Remove and Install Fuel Shut-Off Solenoid

Check and Adjust Fast and Slow Idle

Speed Control Linkage Adjustment

Adjust Fuel Shut-Off Solenoid

Group 0520: Intake System

Essential Tools

Service Equipment and Tools

Specifications

Remove and Install Air Cleaner

Remove and Install Air Filter Elements

Clean Dusty Primary Element

Clean Oily or Sooty Primary Element

Inspect Element

Air Intake System Leakage Test

Group 0530: External Exhaust System

Specifications

Remove and Install Muffler

Group 0560: External Fuel Supply Systems

Specifications

Remove and Install Fuel Tank

Drain and Clean Primary Fuel Filter (Water Separator)

Remove and Install Primary Fuel Filter (Water Separator)

Remove and Install Final Fuel Filter

Bleeding Fuel System

Section 07: Dampener Drive

Group 0752: Elements

Remove and Install Dampener

Section 09: Steering System

Group 0960: Hydraulic System

Service Equipment and Tools

Other Material

Specifications

Remove and Install Steering Valve

Steering Valve Disassemble and Assemble

Remove and Install Steering Column

Remove and Install Steering Cylinders

Loader Start-Up Procedure (Steering Cylinder)

Disassemble and Assemble Steering Cylinder

Remove and Install Steering Cylinder Bushings

Section 10: Service Brakes

Group 1011: Active Elements

Service Equipment and Tools

Specifications

Inspect External Service Brakes

Remove and Install Brake Assembly

Group 1060: Hydraulic System

Remove and Install Brake Valve

Remove and Install Brake Accumulator

Section 11: Park Brake

Group 1111: Active Elements

Other Material

Specifications

Remove and Install Park Brake

Disassemble and Assemble Park Brake

Group 1160: Hydraulic System

Specifications

Remove and Install Park Brake Release Solenoid Valve

Remove and Install Park Brake Pressure Switch

Section 16: Electrical System

Group 1671: Batteries, Support and Cables

Service Equipment and Tools

Specifications

Service Batteries Carefully

Check Battery Electrolyte Level and Terminals

Battery Charging Procedure

Using Booster Batteries—24 Volt System

Procedure for Testing Batteries

Remove and Install Batteries

Remove and Install Battery Disconnect Switch

Group 1672: Alternator, Regulator and Charging System Wiring

Bosch Alternator Repair—Use CTM77

Remove and Install Alternator

Remove and Install Regulator

Group 1673: Lighting System

Replace Halogen Bulbs

Remove and Install Work Lights

Remove and Install Front Turn Lights

Remove and Install Stop, Turn and Tail Light

Remove and Install Drive Lights and Guard

Remove and Install Dome Light and Door Light Switch

Group 1674: Wiring Harness and Switches

Essential Tools

Other Material

Specifications

Replace METRI-PACK Metri-Pack is a trademark of Packard Electrical. Connectors

Install DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Contact

Replace DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Connectors

Replace WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Connector

Install WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Contact

Remove and Install Transmission Control Valve Connector Body

Install Transmission Control Valve Connector Contact

Amp Crimper Tool for Transmission Controller Unit Connector—Operation

Amp Crimper Tool for Transmission Controller Unit Connector—Remove and Install Die Set

Amp Crimper Tool for Transmission Controller Unit Connector—Contact Support Adjustment

Amp Crimper Tool for Transmission Controller Unit Connector—Crimping Procedure

Amp Crimper Tool for Transmission Controller Unit Connector—Crimp Height Inspection

Amp Crimper Tool for Transmission Controller Unit Connector—Crimp Height Adjustment

Replace Transmission Controller Unit Connector Terminals

Replace Chassis Computer Unit Connector Terminals

Install CINCH CINCH is a trademark of the Cinch Co. Contact

Remove Connector Body from Blade Terminals

Remove Blade Terminals From Fuse Block

Boom Height Kickout Adjustment

Return-to-Carry Kickout Adjustment

Return-to-Dig Adjustment

Group 1675: System Controls

Remove and Install Transmission Control Unit (TCU)

Remove and Install Chassis Computer Unit (CCU)

Remove and Install Monitor Display Unit

Group 1677: Motors and Actuators

John Deere Starting Motor Repair—Use CTM77

Specifications

Remove and Install Starting Motor

Section 17: Frame or Supporting Structure

Group 1740: Frame Installation

Service Equipment and Tools

Specifications

Welding Major Structure

Separate Engine and Loader Frame

Remove and Install Upper Pivot Bearing and Seals

Remove and Install Lower Pivot Bearing and Seals

Group 1746: Frame Bottom Guards

Specifications

Remove and Install Fuel Tank Guard

Remove and Install Front Axle Guard

Remove and Install Transmission Bottom Guard

Remove and Install Transmission Side Guards

Group 1749: Chassis Weights

Specifications

Remove and Install Counterweights

Section 18: Operator’s Station

Group 1800: Removal and Installation

Essential Tools

Specifications

Remove and Install Cab or Canopy

Group 1810: Operator Enclosure

Other Material

Specifications

Remove and Install Windowpanes

Remove and Install Windshield Washer

Remove and Install Front and Rear Windshield Wiper Motor

Adjust Front Windshield Wiper

Remove and Install Wrist Support

Group 1821: Seat and Seat Belts

Disassemble and Assemble Seat Belt

Disassemble and Assemble Seat

Group 1822: Steps and Handholds

Remove and Install Access Platform and Steps

Remove and Install Engine Compartment Step

Remove and Install Mounted Step

Group 1830: Heating and Air Conditioning

Essential Tools

Service Equipment and Tools

Air Conditioning System Fittings Reference Chart

Other Material

Specifications

Refrigerant Theory of Operation

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

Recover R134a System

Evacuate R134a System

Charge R134a System

Air Conditioner System Cleaning Procedures

Purge Air Conditioner System

Flush Air Conditioner System

Blower/Air Conditioner Harness (W20) Component Location

Connectors for Blower/Air Conditioner Harness (W20)

Air Conditioning Module With Heater/Evaporator Coil

Remove and Install Heater/Evaporator Coil

Expansion Valve Remove and Install

Remove and Install Freeze Control Switch

Bench Test Freeze Control Switch

Remove and Install Heater Control Valve

Heater Control Valve Leak Check

Remove and Install Main Blower Assembly

Remove and Install Pressurizer Motor Assembly

Remove and Install Receiver-Dryer and Condenser

Remove and Install High and Low Pressure Switches

Remove and Install Fresh Air Filter

Remove and Install Recirculating Air Filter

Remove and Install Compressor

Disassemble and Assemble Compressor Clutch—R134a

Check Clutch Hub Clearance—R134a

Inspect Compressor Manifold—R134a

Disassemble, Inspect and Assemble Compressor—R134a

Group 1899: Dealer Fabricated Tools

DFRW20 Compressor Holding Fixture

Section 19: Sheet Metal and Styling

Group 1910: Hood or Engine Enclosure

Specifications

Remove and Install Hood

Remove and Install Engine Side Shields

Group 1913: Miscellaneous Shields

Remove and Install Transmission Shields

Remove and Install Battery Covers

Group 1921: Grille and Grille Housing

Service Equipment and Tools

Specifications

Remove and Install Grille and Grille Housing

Group 1927: Miscellaneous Shields

Remove and Install Front Fenders

Remove and Install Rear Fenders

Section 20: Safety and Convenience

Group 2002: Mirror

Remove and Install Rear View Mirror

Remove and Install Outside Mirror for Cab or Canopy

Group 2003: Fire Extinguisher

Remove and Install Fire Extinguisher and Bracket

Group 2004: Horn and Warning Devices

Remove and Install Horn

Remove and Install Reverse Warning Alarm

Change Volume Reverse Warning Alarm

Section 31: Loader

Group 3102: Bucket

Specifications

Ride Control Accumulator Safety

Remove and Install Bucket Tooth Shanks and Tips

Remove and Install Bucket

Remove and Install Welded Bucket Cutting Edges

Remove and Install Bolt-On Cutting Edges and Wear Plates

Repair Cracked Cutting Edge

Group 3140: Frames

Service Equipment and Tools

Other Material

Specifications

Remove and Install Loader Bucket Tilt Linkage

Remove and Install Bucket Linkage Seals and Bushings

Disassemble and Assemble Tool Carrier Upper Tilt Linkage

Disassemble and Assemble Tool Carrier Lower Tilt Linkage

Disassemble and Assemble Tool Carrier

Remove and Install Loader Boom Bushings and Seals

Remove and Install Tool Carrier Boom Bushings and Seals

Group 3160: Hydraulic System

Essential Tools

Service Equipment and Tools

Other Material

Specifications

Remove and Install Loader Hydraulic Pump

Hydraulic Pump (PVG 65) and (PVG 75) Cross Section

Disassemble, Inspect and Assemble Hydraulic Pump

Remove and Install Hydraulic Pump Control Valve

Disassemble and Assemble Hydraulic Pump Control Valve

Remove and Install Loader Control Valve

Disassemble and Assemble Loader Control Valve

Disassemble and Assemble Auxiliary Valve Section and Bucket Section

Disassemble and Assemble Bucket Valve Section—Tool Carrier

Disassemble and Assemble Boom Valve Section

Disassemble and Assemble Relief Valve

Disassemble and Assemble Bucket Circuit Relief Valve

Disassemble and Assemble Load Sense Relief Valve

Disassemble and Assemble Boom Circuit Relief Valve

Remove and Install Boom Cylinder

Loader Start-Up Procedure (Boom Cylinder)

Remove and Install 624H Bucket Cylinder—185 Series

Loader Start-Up Procedure (Bucket Cylinder)

624H Bucket Cylinder—185 Series, Cross Section

Disassemble 624H Bucket Cylinder—185 Series

Assemble 624H Bucket Cylinder—185 Series

Boom Cylinder Piston Wear Ring Configuration

Boom Cylinder 624H and TC62H and TC62H Tilt Cylinder—125 Series, Cross Section

Disassemble and Assemble 624H and TC62H Boom Cylinder and TC62H Tilt Cylinder—125 Series

Remove and Install Boom, Bucket or Tilt Cylinder Bushings and Seals

Remove and Install Hydraulic Reservoir

Hydraulic Oil Clean-Up Procedure Using Portable Filter Caddy

Pilot Controller Valve Remove and Install (Single Lever Controller)

Cross Section Pilot Controller Valve (Single Lever Controller)

Pilot Controller Valve Disassemble and Assemble (Single Lever Controller)

Pilot Controller Repair (Two Lever Controller) (S.N. —585560)

Pilot Controller Repair (Two Lever Controller) (S.N. 585561—)

Remove and Install Pressure Reducing Valve Manifold

Remove and Install Pressure Reducing Valve

Disassemble and Assemble Pressure Reducing Valve

Remove and Install Boom Down Solenoid Valve

Remove and Install Differential Lock Solenoid Valve

Remove and Install Pilot Enable Solenoid Valve

Ride Control Valve Remove and Install

Ride Control Valve Disassemble and Assemble

Ride Control Accumulator Remove and Install

Ride Control Accumulator Disassemble and Assemble

Remove and Install Pin Disconnect/Axle Disconnect Valve

Disassemble and Assemble Pin Disconnect Valve

Disassemble and Assemble Axle Disconnect Valve

John Deere 4WD Loader 624H & Tool Carrier Loader TC62H Repair Service Manual (TM1640)