John Deere 304H 4WD Loader Repair Technical Manual TM1864

[Martin Welker]

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John Deere 304H 4WD Loader Repair Technical Manual TM1864
Size: 17.16 MB
Format: PDF
Language: English
Brand: John Deere
Type of Machine: Loader
Type of Manual: Repair Technical Manual
Model: John Deere 304H 4WD Loader
Part Number: TM1864
Publication Date: 2005
Number of Pages: 609 Pages

Contents:
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
Dispose of Waste Properly
Live With Safety
Group 0002 - General Specifications
304H Loader Specifications
Drain and Refill Capacities
Group 0003 - Torque Values
Hardware Torque Specifications
ROPS Torque Specifications
Metric Bolt and Cap Screw Torque Values
Additional Metric Cap Screw Torque Values
Service Recommendations For Metric 24° O-Ring Seal DIN 20078
Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings
Service Recommendations For O-Ring Boss Fittings With Shoulder
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
Do Not Use Galvanized Containers
Diesel Engine Coolant
Diesel Engine Oil
Hydraulic System, Park Brake, and Differential Oil
Service Brake Oil
Grease
Alternative and Synthetic Lubricants
Lubricant Storage
Mixing of Lubricants
Section 01 - WHEELS
Group 0110 - Wheels and Fasteners
Service Equipment and Tools
Specifications
Remove and Install Wheel
Remove and Install Tire
Section 02 - AXLES AND SUSPENSION SYSTEM
Group 0200 - Removal and Installation
Service Equipment and Tools
Other Material
Specifications
Remove and Install Front Axle
Remove and Install Rear Axle
Group 0225 - Axle Shafts and U-Joints
Specifications
Remove and Install Drive Shaft Assembly
Remove and Install Drive Shaft Carrier Bearing
Group 0250 - Axle Shaft, Bearings, and Rear Axle Reduction Gears
Essential Tools
Service Equipment and Tools
Other Material
Specifications
Disassemble and Assemble Front Axle Planetary Drive
Remove and Install Front Axle Differential
Disassemble and Assemble Front and Rear Axle Differential
Disassemble Rear Axle Wheel Hub with Planetary Drive and Knuckle Housing
Disassemble and Assemble Rear Axle Constant Velocity Joint and Axle Shaft
Rear Axle Wheel Hub with Planetary Drive and Knuckle Housing Exploded View
Assemble Rear Axle Wheel Hub with Planetary Drive and Knuckle Housing
Remove and Install Rear Axle Reduction Gear Housing
Remove and Install Rear Axle Differential
Section 03 - HYDROSTATIC TRANSMISSION
Group 0300 - Hydrostatic Components Removal and Installation
Essential Tools
Service Equipment and Tools
Other Material
Specifications
Remove and Install Hydrostatic Pump Valves
Remove and Install Directional Control Valve
Remove and Install Charge Pump
Remove Hydrostatic Pump
Install Hydrostatic Pump
Remove and Install Hydrostatic Motor
Remove and Install Inching Valve
Hydrostatic Start-Up Procedure
Hydraulic Oil Clean-Up Procedure Using Portable Filter Caddy
Group 0360 - Hydrostatic Components Repair
Essential Tools
Service Equipment and Tools
Other Material
Specifications
Disassemble and Assemble Directional Control Valve
Disassemble Hydrostatic Pump
Assemble Hydrostatic Pump
Hydrostatic Motor Components
Replace Hydrostatic Motor Control Valve Assembly O-Rings and Seals
Replace Hydrostatic Motor Flushing Valve Assembly O-Rings and Servo Piston Seals
Replace Hydrostatic Motor Shaft Seal
Disassemble Hydrostatic Motor
Inspect and Recondition Hydrostatic Motor Rotating Group
Assemble Hydrostatic Motor
Section 04 - ENGINE
Group 0400 - Removal and Installation
Service Equipment and Tools
Other Material
Specifications
POWERTECHPOWERTECH is a registered trademark of Deere & Company Yanmar (4TNE98) Engine-Use CTM119
Remove Engine
Install Engine
Group 0413 - Fuel Injection System
Specifications
Remove and Install Fuel injection Pump
Section 05 - ENGINE AUXILIARY SYSTEMS
Group 0505 - Cold Weather Starting Aids
Remove and Install Engine Intake Air Pre-Heater
Group 0510 - Cooling System
Service Equipment and Tools
Other Material
Specifications
Remove and Install Alternator and A/C Compressor Belts
Remove and Install Hydraulic Cooling Fan Pump
Disassemble and Assemble Hydraulic Cooling Fan Pump
Remove and Install Cooling Fan and Cooling Fan Motor
Disassemble and Assemble Cooling Fan Motor
Remove and Install Radiator/Oil Cooler
Group 0515 - Speed Controls
POWERTECH® Yanmar (4TNE98) Engine-Use CTM119
JT05801 Clamp-On Electronic Tachometer Installation
Remove and Install Speed Control Linkage
Speed Control Linkage Adjustment
Slow and Fast Idle Adjustment
Group 0520 - Intake System
Service Equipment and Tools
Specifications
Remove and Install Air Cleaner Assembly
Air Intake System Leakage Test
Group 0530 - External Exhaust System
Remove and Install Exhaust System
Group 0560 - External Fuel Supply Systems
Specifications
Remove and Install Fuel Tank
Remove and Install Primary Fuel Filter (Water Separator)
Bleed Fuel System
Section 07 - DAMPENER DRIVE
Group 0700 - Removal and Installation
Other Material
Specifications
Remove and Install Dampener Drive
Section 09 - STEERING SYSTEM
Group 0920 - Power Steering
Specifications
Remove and Install Steering Link Assembly
Replace Tie Rod Ends
Adjust Steering Alignment
Group 0960 - Hydraulic System
Essential Tools
Service Equipment and Tools
Other Material
Specifications
Remove and Install Steering Valve
Disassemble Steering Valve
Cross Section of Steering Valve
Assemble Steering Valve
Remove and Install Steering Column
Remove and Install 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
Other Material
Specifications
Remove and Install Service Brake Pads
Remove and Install Service Brake Calipers and Disks
Disassemble and Assemble Service Brake Caliper
Group 1060 - Hydraulic System
Remove and Install Brake Valve
Disassemble and Assemble Brake Valve
Remove and Install Service Brake Reservoir
Bleed Service Brakes
Section 11 - PARK BRAKE
Group 1111 - Active Elements
Other Material
Specifications
Remove and Install Park Brake Caliper and Pads
Disassemble and Assemble Park Brake Caliper
Remove and Install Park Brake Actuator
Group 1160 - Hydraulic System
Remove and Install Park Brake Solenoid Valve
Section 16 - ELECTRICAL SYSTEMS
Group 1671 - Batteries, Support and Cables
Service Equipment and Tools
Specifications
Service Batteries Carefully
Charge Battery
Remove and Install Batteries
Remove and Install Battery Disconnect Switch
Group 1672 - Alternator, Regulator and Charging System Wiring
Alternators And Starting Motors-Use CTM119
Remove and Install Alternator
Group 1673 - Lighting System
Remove and Install Brake, Turn, and Tail Lights
Group 1674 - Wiring Harness and Switches
Essential Tools
Specifications
Replace DEUTSCHDEUTSCH is a trademark of the Deutsch Co. Connectors
Replace DEUTSCHDEUTSCH is a trademark of Deutsch Co. Rectangular or Triangular Connectors
Install DEUTSCHDEUTSCH is a trademark of Deutsch Co. Contact
Replace CINCHCINCH is a trademark of the Cinch Co. Connectors
Install CINCHCINCH is a trademark of the Cinch Co. Contact
Remove Connector Body From Blade Terminals
Group 1675 - System Controls
Other Material
Remove and Install Display Monitor
Remove and Install FNR and Combination Switch
Group 1677 - Motors and Actuators
Specifications
Alternators And Starting Motors-Use CTM119
Remove and Install Starting Motor
Remove and Install Front Windshield Wiper Motor
Group 1678 - Sensors
Other Material
Specifications
Remove and Install Speed Sensor
Section 17 - FRAME OR SUPPORTING STRUCTURE
Group 1740 - Frame Installation
Service Equipment and Tools
Specifications
Separate Loader and Rear Frames
Remove and Install Rotational Torque Spring
Remove and Install Upper Pivot Bushing Assembly
Remove and Install Lower Pivot Bushing Assembly
Group 1749 - Counterweights
Specifications
Remove and Install Counterweight
Section 18 - OPERATOR′S STATION
Group 1800 - Removal and Installation
Service Equipment and Tools
Specifications
Remove and Install Cab-with Platform
Remove and Install Cab-without Platform
Group 1810 - Operator Enclosure
Service Equipment and Tools
Other Material
Remove and Install Front, Rear, and Side Windshields
Remove and Install Lower Door Windowpanes
Remove and Install Upper Door Windowpanes
Adjust Front Windshield Wiper
Group 1821 - Seat and Seat Belts
Disassemble and Assemble Seat and Seat Belts
Group 1830 - Heating and Air Conditioning
Essential Tools
Service Equipment and Tools
Other Material
Specifications
R134a Refrigerant Cautions
Proper Refrigerant Handling
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 Conditioning System Cleaning Procedures
Purge Air Conditioning System
Flush Air Conditioning System
Air Conditioning System Exploded View
Remove and Install Heater Control Valve
Remove and Install Heater Core
Remove and Install Heater Control Cable
Remove and Install Blower Assembly
Remove and Install Air Conditioning Compressor
Remove and Install Receiver-Dryer and Condenser
Remove and Install Evaporator Coil
Remove and Install Expansion Valve
Expansion Valve Bench Test and Adjustment
Remove and Install Freeze Control Switch
Remove and Install Low/High Pressure Switch
Section 19 - SHEET METAL AND STYLING
Group 1910 - Hood or Engine Enclosure
Specifications
Remove and Install Engine Hood
Group 1913 - Miscellaneous Shields
Specifications
Remove and Install Rear Fenders
Adjust Front Fenders
Section 20 - SAFETY AND CONVENIENCE
Group 2002 - Mirrors
Remove and Install Mirrors and Sun Visor
Group 2004 - Horn and Warning Devices
Remove and Install Horn
Remove and Install Backup Alarm
Section 21 - MAIN HYDRAULIC SYSTEM
Group 2160 - Hydraulic System
Service Equipment and Tools
Other Material
Specifications
Remove and Install Main Hydraulic Pump/Priority Valve
Disassemble and Assemble Main Hydraulic Pump/Priority Valve
Remove and Install Return/Suction Filter Assembly
Disassemble and Assemble Return/Suction Filter Assembly
Remove and Install Hydraulic Reservoir
Remove and Install Hydraulic Oil Cooler
Hydraulic Oil Clean-Up Procedure Using Portable Filter Caddy
Section 31 - LOADER
Group 3102 - Bucket
Remove and Install Bucket Teeth
Remove and Install Welded-On Bucket Cutting Edges
Remove and Install Bolt-On Cutting Edges
Repair Cracked Cutting Edge
Group 3104 - Attachment Coupler
Other Material
Specifications
Remove and Install Quick Attach Lock-Out Valve
Disassemble and Assemble Quick Attach Lock-Out Valve
Disassemble and Assemble Quick Attach Hitch
Group 3140 - Frames
Service Equipment and Tools
Other Material
Specifications
Remove and Install Loader Bucket Tilt Linkage
Remove and Install Bucket Linkage Bushings
Remove and Install Loader Boom Bushings
Group 3160 - Hydraulic System
Essential Tools
Other Material
Specifications
Remove and Install Loader Control Valve
Disassemble and Assemble Loader Control Valve
Disassemble and Assemble Auxiliary, Fourth Function, or Bucket Valve Section
Disassemble and Assemble Boom Valve Section
Disassemble and Assemble System or Circuit Relief Valve
Remove and Install Boom Cylinder
Remove and Install Bucket Cylinder
Disassemble and Assemble Boom and Bucket Cylinders
Remove and Install Boom and Bucket Cylinder Bushings
Remove and Install Pilot Control Valve
Disassemble and Assemble Pilot Control Valve
Remove and Install Quick Attach/Auxiliary Pilot Control Valve
Disassemble and Assemble Quick Attach/Auxiliary Pilot Control Valve
Remove and Install Pilot Lockout and Park Brake Solenoid Valves
Remove and Install Pilot Accumulator
Section 99 - DEALER FABRICATED TOOLS
Group 9900 - Dealer Fabricated Tools
DF1002 Rolling Drag Torque Bar
DFT1213 Service Brake Caliper Removal and Installation Tool
DFT1214 Hydrostatic Pump Servo Piston Snap Ring Removal and Installation Tool