Day: December 2, 2024

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INSTANT DOWNLOAD

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Complete service repair manual for John Deere Excavators 490D, 590D, with service information to maintain, repair, and rebuild like professional mechanics.

John Deere Excavators 490D, 590D 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.

TM1390 – John Deere 490D and 590D Excavator Technical Manual – Repair.pdf

Total Pages: 711 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable)
Language: English

MAIN SECTIONS
Foreword
General Information
Safety
General Specifications
Torque Values
Fuels And Lubricants
Tracks
Track System
Axles And Suspension Systems (Propel)
Axle Shaft, Bearings, And Reduction Gears
Hydraulic System
Engine
Removal And Installation
Engine Auxiliary Systems
Cold Weather Starting Aids
Cooling System
Speed Controls
Intake System
External Fuel Supply Systems
Dampener Drive (Flex Coupling)
Elements
Electrical System
Batteries, Support, And Cables
Alternator, Regulator And Charging System Wiring
Wiring Harness And Switches
Motors And Actuators
Frame Or Supporting Structure
Frame Installation
Chassis Weights
Operator’s Station
Removal And Installation
Operator Enclosure
Seat And Seat Belt
Heating And Air Conditioning
Sheet Metal And Styling
Hood Or Engine Enclosure
Excavator
Buckets
Frames
Hydraulic Systems
Swing Or Pivoting System
Mechanical Drive Elements
Hydraulic System
Dealer Fabricated Tools

TABLE OF CONTENTS
Section I: General Information…14
Group I: Safety…14
Follow Safe Procedures…18
Prepare for Emergencies…19
Prevent Acid Burns…20
Handle Chemical Products Safely…22
Handle Fluids Safely-Avoid Fires…23
Avoid High-Pressure Fluids…24
Warn Others of Service Work…25
Support Machine Properly…26
Operate Only from Operator's Seat…27
Park Machine Safely…28
Stay Clear of Moving Parts…29
Avoid Power Lines…30
Use Handholds and Steps…31
Keep Riders Off Machine…32
Move and Operate Machine Safely…33
Wear Protective Clothing…34
Protect Against Flying Debris…35
Protect Against Noise…36
Illuminate Work Area Safely…37
Service Machines Safely…38
Remove Paint Before Welding or Heating…39
Avoid Heating Near Pressurized Fluid Lines…40
Beware of Exhaust Fumes…41
Use Proper Lifting Equipment…42
Service Cooling System Safely…43
Dispose of Waste Properly…44
Work in a Clean Area…45
Use Tools Properly…46
Replace Safety Signs…47
Live With Safety…48
Group II: General Specifications…666
490D Specifications…666
490D Working Ranges…53
490D Drain And Refill Capacities…55
490D…56
490D Bucket Selection Chart-2.5 M (98 In.) Arm…58
490D Bucket Selection Chart-3.0 M (118 In.) Arm…59
490D Bucket Specifications…666
490D with 2.5 m (8 ft 2 in.) Arm Lift Capacity-Kg (Lb)…61
490D with 3.0 m (9 ft 10 in.) Arm Lift Capacity-Kg (Lb)…62
590D Specifications…666
590D Working Ranges…66
590D Operating Specifications…666
590D Drain And Refill Capacities…68
590D Engine and Hydraulic Specifications…666
590D Bucket Selection Chart-2.6 M (8 Ft 6 In.) Arm…71
590D Bucket Selection Chart-3.1 M (10 Ft. 2 In.) Arm…72
590D Bucket Specifications…666
590D Lift Capacity-Kg (Lb)…74
590D Lift Capacity-Kg (Lb)-Continued…76
Group III: Torque Values…15
Hardware Torque Specifications…666
Check Track Shoe Torque…79
Inch Cap Screw Torque Values…80
Metric Cap Screw Torque Values…82
Additional Metric Cap Screw Torque Values…84
Service Recommendations for O-Ring Boss Fittings…86
Service Recommendations For Flat Face O-Ring Seal Fittings…88
Service Recommendations For Flared Connections-Straight or Tapered Threads…90
SAE Four Bolt Flange Fitting Service Recommendations…92
Group IV: Fuels And Lubricants…15
Fuel Specifications…666
Fuel Storage…96
Engine Oil…97
Hydraulic Oil…98
Swing Gearbox, Propel Gearbox And Pump Gearbox Oils…99
Track Rollers And Idlers Oil…100
Swing Gear Grease…102
Grease…102
Lubricant Storage…103
Alternative Lubricants…104
Section 01: Tracks…105
Group 0130: Track System…105
Service Equipment And Tools…664
Other Material…665
Specifications…666
Measure Lower Track Roller Wear…110
Remove And Install Lower Track Roller…111
Disassemble And Assemble Lower Track Roller…113
Inspect Metal Face Seals…221
Measure Upper Track Roller Wear…122
Remove And Install Upper Track Roller…123
Assemble Upper Track Roller…126
Measure Track Shoe Grouser Wear…128
Remove And Install Track Shoe…129
Measure Track Link Wear…130
Measure Track Bushing Wear…131
Measure Track Pitch…132
Remove Track Chain…133
Install Track Chain…135
Disassemble And Assemble Track Chain…137
Adjust Track Sag…138
Measure Sprocket Wear…140
Remove And Install Sprocket…141
Measure Front Idler Wear…143
Remove And Install Front Idler…144
Disassemble Front Idler…145
Assemble Front Idler…148
Remove And Install Track Adjuster…151
Disassemble Track Adjuster…154
Assemble Track Adjuster…161
Section 02: Axles And Suspension Systems (Propel)…166
Group 0250: Axle Shaft, Bearings, And Reduction Gears…166
Service Equipment And Tools…664
Other Material…665
Specifications…666
Towing The Excavator-490D…171
Towing The Excavator-590D…174
Remove And Install Propel Gearbox-490D…178
Disassemble Propel Gearbox-490D…181
Assemble Propel Gearbox-490D…191
Remove And Install Propel Gearbox-590D…201
Disassemble Propel Gearbox-590D…205
Assemble Propel Gearbox-590D…214
Inspect Metal Face Seals…221
Group 0260: Hydraulic System…166
Essential Tools…495
Service Equipment And Tools…664
Other Material…665
Specifications…666
Remove And Install Propel Motor-490D…228
Disassemble Propel Motor-490D…233
Inspect Propel Motor-490D…243
Assemble Propel Motor-490D…247
Remove And Install Propel Motor-590D…257
Disassemble Propel Motor-590D…260
Assemble Propel Motor-590D…269
Remove And Install Propel Hydraulic Lines…276
Remove And Install Rotary Manifold…278
Disassemble And Assemble Rotary Manifold…281
Rotary Manifold Air Test…283
Section 04: Engine…284
Group 0400: Removal And Installation…284
4276 John Deere Engine Repair-Use CTM-4…286
Essential Tools…495
Other Material…665
Specifications…666
Remove And Install Engine-490D…292
Remove And Install Engine-590D…297
Remove And Install Oil Pan…301
Remove Fuel Injection Pump…302
Install Fuel Injection Pump…304
Remove And Install Fuel Injection Nozzles…306
Bleed Fuel System…309
Remove And Install Water Pump…311
Remove And Install Turbocharger-590D…313
Section 05: Engine Auxiliary Systems…315
Group 0505: Cold Weather Starting Aids…315
Other Material…665
Specifications…666
Remove And Install Starting Aid Solenoid And Nozzle…319
Remove And Install Engine Coolant Heater…321
Group 0510: Cooling System…315
Service Equipment And Tools…664
Specifications…666
Remove And Install Fan…326
Remove And Install Fan Belt…327
Fan Belt Tension Adjustment…328
Remove And Install Radiator…329
Group 0515: Speed Controls…315
Other Material…665
Specifications…666
Remove And Install Speed Control Assembly…333
Engine Speed Adjustment…334
Speed Control Linkage Adjustment…337
Speed Control Lever Tension Adjustment…340
Group 0520: Intake System…315
Service Equipment And Tools…664
Specifications…666
Remove And Install Air Cleaner-490D…344
Remove And Install Air Cleaner-590D…345
Air Intake System Leakage Test…346
Group 0560: External Fuel Supply Systems…315
Specifications…666
Remove And Install Fuel Tank…350
Remove And Install Fuel Filter…352
Section 07: Dampener Drive (Flex Coupling)…354
Group 0752: Elements…354
Other Material…665
Specifications…666
Disassemble And Assemble Flex Coupling-490D…358
Disassemble And Assemble Flex Coupling-590D…361
Section 16: Electrical System…363
Group 1671: Batteries, Support, And Cables…363
Specifications…666
Handle Batteries Safely…366
Test Batteries Using Coolant And Battery Tester…367
Test Batteries Using High Rate Discharge Test…368
Prevent Fire Hazards When Using Booster Batteries…369
Charge Battery…370
Remove And Install Batteries…371
Group 1672: Alternator, Regulator And Charging System Wiring…363
John Deere Engine Accessories-Alternator Repair-Use CTM-11…373
Service Equipment And Tools…664
Specifications…666
Remove And Install…376
Group 1674: Wiring Harness And Switches…363
Remove And Install Dome Light Switch…379
Remove And Install Control Panel Switches…380
Remove And Install Relay Starter Solenoid…381
Remove And Install Engine Hourmeter Switch…382
Remove And Install Engine Overheat Alarm Switch…383
Remove And Install Air Cleaner Restriction Indicator…384
Remove And Install Battery Relay…386
Remove And Install Battery Relay…386
Remove And Install Buzzer Stop Switch…387
Remove And Install Travel Alarm-590D…388
Changing Travel Alarm Volume…389
Group 1677: Motors And Actuators…363
John Deere Starting Motor Repair Use CTM-11…391
Service Equipment And Tools…664
Specifications…666
Remove And Install Starting Motor…394
Section 17: Frame Or Supporting Structure…395
Group 1740: Frame Installation…395
Welding Repair Of Major Structure…397
Group 1749: Chassis Weights…395
Essential Tools…495
Specifications…666
Remove And Install Counterweight…401
Section 18: Operator’s Station…402
Group 1800: Removal And Installation…402
Other Material…665
Specifications…666
Remove And Install Cab And Cab Floor…406
Remove And Install Cab (Without Floor)…413
Group 1810: Operator Enclosure…402
Service Equipment And Tools…664
Other Material…665
Remove And Install Windowpane And Two Piece Molding…418
Remove And Install Windowpane And One Piece Molding…420
Remove And Install Sliding Windows…421
Windowpane Dimensions…423
Remove And Install Cab Door…424
Remove And Install Door Latch…425
Remove And Install Inside Assist Handle…426
Remove, Disassemble, Assemble, And Install Windshield Wiper…427
Remove And Install Defroster Fan…428
Disassemble And Assemble Defroster Fan…429
Group 1821: Seat And Seat Belt…402
Disassemble And Assemble Seat…431
Group 1830: Heating And Air Conditioning…402
Disassemble And Assemble Blower Motor…433
Remove And Install 13,500 BTU Heater…434
Remove And Install 13,500 BTU Cab Heater Lines And Controls…436
Remove And Install 19,000 BTU Heater…438
Remove And Install 19,000 BTU Cab Heater Lines And Controls…439
Remove And Install 40,000 BTU Heater…441
Remove And Install 40,000 BTU Cab Heater Lines And Controls…442
Section 19: Sheet Metal And Styling…444
Group 1910: Hood Or Engine Enclosure…444
Specifications…666
Remove And Install Hood…447
Adjust Hood Latch Catch…448
Remove And Install Service Doors…449
Remove And Install Top Cover…450
Section 33: Excavator…451
Group 3302: Buckets…451
Service Equipment And Tools…664
Specifications…666
Remove And Install Bucket And Linkage…458
Remove And Install Bushings…492
Inspect Bucket Linkage Pins And Bushings…465
Adjust Bucket Pivot End Play…466
Disassemble And Assemble Bucket…467
Remove And Install Tooth Tip…468
Remove Tooth Shank…469
Install Tooth Shank…470
Group 3340: Frames…451
Service Equipment And Tools…664
Other Material…665
Specifications…666
Remove Arm…477
Install Arm…481
Remove Boom…484
Install Boom…488
Inspect Arm And Boom Pins And Bushings…491
Remove And Install Bushings…492
Group 3360: Hydraulic Systems…451
Essential Tools…495
Service Equipment And Tools…664
Other Material…665
Specifications…666
Hydraulic Cylinder Bleed Procedure…583
Release Pressure In Hydraulic System…502
Remove And Install Hydraulic Pump…504
Hydraulic Pump Start-Up Procedure…506
Disassemble Hydraulic Pump…507
Assemble Hydraulic Pump…511
Remove And Install Hydraulic Pump Regulator…514
Disassemble Pump Regulator…515
Assemble Pump Regulator…520
Remove And Install Pilot Pump…524
Disassemble And Assemble Pilot Pump…525
Remove And Install Solenoid Valve And Pilot Pressure Regulating Valve…527
Disassemble And Assemble Solenoid Valve And Pilot Pressure Regulating Valve…530
Remove And Install Engine Speed Mode Selection Cylinders…533
Disassemble And Assemble Engine Speed Mode Selection Cylinders…534
Remove And Install Hydraulic Control Valve…535
Disassemble Hydraulic Control Valve…542
Assemble Hydraulic Control Valve…553
Remove And Install Reservoir…564
Remove And Install Return Filter And Suction Filter…569
Remove And Install Oil Cooler Restriction Valve…572
Disassemble And Assemble Oil Cooler Restriction Valve…573
Remove And Install Oil Cooler Bypass Valve…574
Disassemble And Assemble Oil Cooler Bypass Valve…575
Remove And Install Oil Cooler…576
Remove And Install Bucket Cylinder…577
Remove And Install Arm Cylinder…579
Remove And Install Boom Cylinder…581
Hydraulic Cylinder Bleed Procedure…583
Disassemble Bucket, Arm And Boom Cylinders…584
Inspection Of Cylinder Rod…589
Assemble Bucket, Arm, And Boom Cylinders…590
Inspection Of Cylinder Pins And Bushings…596
Remove And Install Auxiliary Shut-Off Valve…597
Disassemble And Assemble Auxiliary Shut-Off Valve…599
Remove And Install Propel Function Ler Valve…601
Disassemble Propel Function Pilot Controller Valve…603
Assemble Propel Function Pilot Controller Valve…606
Remove And Install Dig Function Pilot Controller Valve…609
Disassemble Dig Function Pilot Controller Valve…612
Assemble Dig Function Pilot Controller Valve…615
Remove And Install Pilot Shut-Off Valve…618
Pilot Shut-Off Valve Linkage Adjustment…620
Disassemble And Assemble Pilot Shut-Off Valve…621
Disassemble And Assemble Pilot Filter…623
Inspect Pilot Filter Relief Valve…624
Remove And Install Flow Control Valve…625
Disassemble And Assemble Flow Control Valve…627
Remove And Install Check Valve Block…629
Disassemble And Assemble Check Valve Block…631
Section 43: Swing Or Pivoting System…632
Group 4350: Mechanical Drive Elements…632
Service Equipment And Tools…664
Other Material…665
Specifications…666
Remove And Install Swing Gearbox…637
Disassemble And Assemble Swing Gearbox…639
Remove And Install Swing Bearing…648
Disassemble And Assemble Swing Bearing…657
Install Swing Bearing Seals…662
Group 4360: Hydraulic System…632
Service Equipment And Tools…664
Other Material…665
Specifications…666
Remove And Install Swing Motor…667
Disassemble Swing Motor…669
Assemble Swing Motor…676
Disassemble And Assemble Crossover Relief Valves…682
Remove And Install Make-Up Valves…686
Disassemble And Assemble Swing Brake Release Valve…687
Section 99: Dealer Fabricated Tools…691
Group 9900: Dealer Fabricated Tools…691
DF1036 Propel Gearbox Nut Wrench-490D…693
DFT1070 Propel Gearbox Nut Wrench-590D…694
DF1038 Torque Adapter…695
Rotary Manifold Lifting Tool…696
ST4920 Track Recoil Spring Disassembly And Assembly Tool…697
DFT1087 Track Recoil Spring Disassembly And Assembly Guard Tool…701

John Deere 490D and 590D Excavator Repair Technical Manual (TM1390)

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INSTANT DOWNLOAD

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INSTANT DOWNLOAD

---

Complete Diagnostics, Operation and Test manual with electrical wiring diagrams for John Deere Excavators 490D, 590D, with workshop information to maintain, diagnose, service, and rebuild like professional mechanics.

John Deere Excavators 490D, 590D workshop Operation and 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.

TM1389 English – John Deere 490D and 590D Excavator Technical Manual – Operation and Test.PDF
ctm104 English – 4.5L AND 6.8L DIESEL ENGINES (BASE ENGINE) -: (WORLDWIDE EDITION) CTM.pdf

Total Pages: 652 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable)
Language: English

MAIN SECTIONS
Foreword
General Information
Safety
General Specifications
Torque Values
Fuels And Lubricants
Operational Checkout Procedure
Operational Checkout Procedure
Engine
Theory Of Operation
System Operational Checks
Diagnostic Information
Adjustments
Tests
Electrical System
Electrical System Operation And Test
Powertrain
Theory Of Operation
System Operational Checks
Diagnostic Information
Adjustments
Tests
Hydraulic System
Theory Of Operation
System Operational Checks
Diagnostic Information
Adjustments
Tests

TABLE OF CONTENTS
Section I: General Information…12
Group I: Safety…12
Follow Safe Procedures…16
Prepare for Emergencies…17
Prevent Acid Burns…18
Handle Chemical Products Safely…20
Handle Fluids Safely-Avoid Fires…21
Avoid High-Pressure Fluids…22
Warn Others of Service Work…23
Support Machine Properly…24
Operate Only from Operator's Seat…25
Park Machine Safely…26
Stay Clear of Moving Parts…27
Avoid Power Lines…28
Use Handholds and Steps…29
Keep Riders Off Machine…30
Move and Operate Machine Safely…31
Wear Protective Clothing…32
Protect Against Flying Debris…33
Protect Against Noise…34
Illuminate Work Area Safely…35
Service Machines Safely…36
Remove Paint Before Welding or Heating…37
Avoid Heating Near Pressurized Fluid Lines…38
Beware of Exhaust Fumes…39
Use Proper Lifting Equipment…40
Service Cooling System Safely…41
Dispose of Waste Properly…42
Work in a Clean Area…43
Use Tools Properly…44
Replace Safety Signs…45
Live With Safety…46
Group II: General Specifications…13
490D Specifications…49
490D Working Ranges…51
490D Drain And Refill Capacities…53
490D…54
490D Bucket Selection Chart-2.5 M (98 In.) Arm…56
490D Bucket Selection Chart-3.0 M (118 In.) Arm…57
490D Bucket Specifications…58
490D with 2.5 m (8 ft 2 in.) Arm Lift Capacity-Kg (Lb)…59
490D with 3.0 m (9 ft 10 in.) Arm Lift Capacity-Kg (Lb)…60
590D Specifications…62
590D Working Ranges…64
590D Operating Specifications…65
590D Drain And Refill Capacities…66
590D Engine and Hydraulic Specifications…67
590D Bucket Selection Chart-2.6 M (8 Ft 6 In.) Arm…69
590D Bucket Selection Chart-3.1 M (10 Ft. 2 In.) Arm…70
590D Bucket Specifications…71
590D Lift Capacity-Kg (Lb)…72
590D Lift Capacity-Kg (Lb)-Continued…74
Group III: Torque Values…13
Hardware Torque Specifications…77
Check Track Shoe Torque…78
Metric Bolt And Cap Screw Torque Values…79
Unified Inch Bolt And Cap Screw Torque Values…80
Check Oil Lines And Fittings…81
Service Recommendations For 37° Flare And 30° Cone Seat Connectors…82
Service Recommendations for O-Ring Boss Fittings…83
Service Recommendations For Flat Face O-Ring Seal Fittings…85
Service Recommendations For Metric Series Four Bolt Flange Fitting…87
Service Recommendations For Inch Series Four Bolt Flange Fittings…89
Group IV: Fuels And Lubricants…13
Fuel Specifications…92
Fuel Storage…93
Engine Oil…94
Hydraulic Oil…95
Swing Gearbox, Propel Gearbox And Pump Gearbox Oils…96
Track Rollers And Idlers Oil…97
Swing Gear Grease…99
Grease…99
Lubricant Storage…100
Alternative Lubricants…101
Synthetic Lubricants…102
Engine Coolant…103
Section 9005: Operational Checkout Procedure…104
Group 10: Operational Checkout Procedure…104
Operational Checkout Record Sheet-490D, 590D…108
Complete Machine Operational Checkout…111
Section 9010: Engine…153
Group 05: Theory Of Operation…153
Cooling System Operation-490D…156
Cooling System Operation-590D…157
Radiator Cap Operation…158
Air Cleaner Operation…159
Engine Lubrication Operation…160
Oil Cooler Operation…162
Fuel System Operation…164
Fuel Supply Pump Operation…165
Fuel Filter Operation…166
Fuel Injection Pump Operation…167
Fuel Injection Nozzle Operation…168
Turbocharger Operation-590D…170
Cold Weather Starting Aid Operation…172
Engine Speed Control System Operation…173
Group 10: System Operational Checks…153
Engine Operational Checks…190
Group 15: Diagnostic Information…153
Diagnose Engine Malfunctions…215
Coolant Requirements…224
General Recommendations…227
Group 20: Adjustments…153
Fan Belt Tension Adjustment…230
Engine Speed Adjustment…232
Engine Speed Control Linkage Adjustment…234
Speed Control Lever Tension Adjustment…236
Engine Valve Clearance Adjustment…237
Injection Pump Static Timing Adjustment…241
Group 25: Tests…153
JT39000 Tachometer Reader Installation Procedure…244
D01084AA Tachometer Reader Installation Procedure…245
JT05801 Clamp-On Electronic Tachometer Installation…611
Compression Pressure Test…247
Engine Oil Pressure Test…249
Engine Performance Test…250
Valve Lift Test…252
Fuel Supply Pump Pressure Test…254
Air Filter Restriction Indicator Switch Test…256
Air Intake System Leakage Test…258
Turbocharger Shaft Axial End Play Test-590D…260
Turbocharger Shaft Radial Movement Test-590D…261
Engine Power Test Using Turbocharger Boost Pressure-590D…262
Radiator Air Flow Test…264
Fuel Line Leakage Test…267
Section 9015: Electrical System…268
Group 00: Electrical System Operation And Test…268
Safety Precautions…273
Battery Operation…276
Using Booster Batteries…277
Procedure For Testing Batteries…278
Diagnose Battery Malfunctions…279
Fuse Specifications…280
Engine Coolant Level Indicator Light…281
Hydraulic Reservoir Level Indicator Light…282
Engine Coolant Temperature Gauge…283
Engine Coolant Temperature Indicator Light…284
Fuel Gauge…285
Fuel Level Indicator Light…286
Battery Charge Indicator Light…287
Engine Oil Pressure Warning Light…288
Engine Oil Filter Restriction Indicator Light…289
Air Cleaner Restriction Indicator Light…290
Visually Inspect Electrical System…291
Testing The Electrical System…292
Common Circuit Test…293
Electrical Operational Checks…294
Wiring Diagram Information…296
Power Circuit Diagnose Malfunctions…298
Power Circuit Operation…303
Power Circuit Wiring Diagram…304
Power Circuit Test…305
Starting Circuit Diagnose Malfunctions…307
Start Circuit Operation…312
Starter Operation…313
Start Circuit Wiring Diagram…316
Start Circuit Test…317
Charging Circuit Diagnose Malfunctions…319
Charging Circuit Operation…324
Alternator Operation-65 Amp Motorola…325
Charging Circuit Wiring Diagram…327
Charging Circuit Test…328
Diagnose Accessory Circuit Malfunctions…330
Accessory Circuit Operation…341
Accessory Circuit Wiring Diagram…345
Accessory Circuit Test…346
Engine Speed And Pump Displacement Control Circuit Diagnose Malfunctions…349
Engine Speed And Pump Displacement Control Operation…353
Engine Speed And Pump Displacement Control Circuit Operational Charts…354
Engine Speed And Pump Displacement Control System Operation…356
Engine Speed And Pump Displacement Control Circuit Wiring Diagram…357
Engine Speed And Pump Displacement Control Circuit Test…358
Monitor Circuit Diagnose Malfunctions…360
Monitor Circuit Operation…375
Monitor Circuit Test…377
Section 9020: Powertrain…379
Group 05: Theory Of Operation…379
Track Adjuster Operation…382
Propel Gearbox Operation-490D…383
Propel Gearbox Operation-590D…385
Propel Circuit Operation…387
Rotary Manifold Operation…390
Propel Motor Operation-490D…391
Propel Motor Operation-590D…393
Counterbalance Valve Neutral Operation-490D…394
Counterbalance Valve Neutral Operation-590D…395
Counterbalance Valve Propel Operation-490D…396
Counterbalance Valve Propel Operation-590D…397
Counterbalance Valve Braking Operation-490D…398
Counterbalance Valve Dynamic Braking Operation-590D…399
Propel Motor Relief Valve Operation-490D…400
Propel Motor Relief Valve Operation-590D…401
Propel Brake Operation-490D…402
Propel Motor Brake Operation-590D…403
Group 10: System Operational Checks…379
Power Train Operational Checks…416
Group 15: Diagnostic Information…379
Diagnose Undercarriage Components Malfunctions…430
Diagnose Propel System Malfunctions…432
Measure Track Bushing Wear…435
Measure Track Chain Pitch…436
Measure Track Link Wear…437
Measure Track Shoe Grouser Wear…438
Measure Track Roller Wear…439
Group 20: Adjustments…379
Adjust Track Sag…443
Group 25: Tests…380
Propel Speed Cycle Time…447
JT39000 Tachometer/Temperature Reader Installation…607
D01084AA Tachometer/Temperature Reader Installation…609
JT05801 Clamp-On Electronic Tachometer Installation…611
JT05800 Digital Thermometer Installation…612
Propel System Relief Valve Adjustment…455
Propel Motor Crossover Relief Valve Test And Adjustment…459
Propel Motor Operating Leakage Test…463
Propel Motor Start-Up Procedure…465
Swing Bearing Wobble Test…466
Section 9025: Hydraulic System…472
Group 05: Theory Of Operation…467
Hydraulic System…472
Pilot System Operation…474
Pilot Pump Operation…476
Pilot Filter Operation…477
Solenoid Valve And Pilot Pressure Regulating Valve Operation…478
Solenoid Valve Operation-Energized…480
Engine Speed Control Operation…482
Check Block Operation…483
Main Hydraulic Pump Displacement Operation…484
Shut-Off Valve Operation…486
Pilot Controller Operation-Neutral…488
Pilot Controller Operation-Metering…489
Pilot Controller Operation-Full Stroke…490
Propel Pilot Controller Operation-Neutral…491
Pilot Operation Of Main Control Valve…492
Flow Regulator Operation…493
Warm-Up Circuit Operation…494
Pump Inlet And Delivery Circuits Operation…496
Return Circuit Operation…497
Drain Circuit Operation…498
Return Filter Operation…499
Main Control Valve Operation…500
System Relief Valve Circuit Operation…502
System Relief Valve Operation…504
Circuit Relief Valve Operation…505
Flow Combiner And Swing Brake Release Valve Circuit Operation…506
Bucket And Auxiliary Work Circuits Operation…507
Boom Raise Work Circuit Operation…509
Boom Lower Work Circuit Operation…511
Arm In Work Circuit Operation…513
Arm Out Work Circuit Operation…515
Swing Work Circuit Operation…517
Combined Functions Operation…519
Swing Motor Operation…521
Swing Cross-Over Relief Valves And Make-Up Valves Operation…523
Brake Release Circuit Operation…524
Swing Gearbox Operation…525
Cylinder Operation…527
Main Hydraulic Pump Operation…529
Regulator Components Operation…530
High-Low Maximum Displacement Operation…532
Fuel Saving System Operation…534
Constant Horsepower System Operation…536
Group 10: System Operational Checks…468
Hydraulic Operational Checks…556
Group 15: Diagnostic Information…468
Diagnose Hydraulic System Malfunctions…576
Diagnose Pilot Circuit Malfunctions…578
Diagnose Dig Circuit Malfunctions…579
Diagnose Swing Circuit Malfunctions…581
Hydraulic Circuit Symbols…584
Pressure And Return Circuits…585
Boom, Arm, Bucket And Swing Circuits…586
Pilot Circuit-Controllers To Flow Regulator…587
Pilot Circuit-Flow Regulator To Main Control Valve Assembly…588
Pilot Circuit-Swing Motor, Engine Speed, And Pump Displacement Controls…589
Pilot Control Lever Pattern Information…590
Group 20: Adjustments…468
Pilot Shut-Off Valve Linkage Adjustment…595
Main Hydraulic Pump Displacement Adjustment…597
Group 25: Tests…468
Cycle Time Test…603
JT39000 Tachometer/Temperature Reader Installation…607
D01084AA Tachometer/Temperature Reader Installation…609
JT05801 Clamp-On Electronic Tachometer Installation…611
JT05800 Digital Thermometer Installation…612
Hydraulic Pump Start-Up Procedure…613
Pilot System Regulating Valve Test And Adjustment…614
Pilot Controller Test…616
System Relief Valve Test And Adjustment…619
Circuit Relief Valve Test And Adjustment…624
Swing Motor Crossover Relief Valve Test And Adjustment…628
Flow Sensing Valve Test And Adjustment…630
Hydraulic Pump Regulator Test And Adjustment (Engine Pulldown)-490D…634
Hydraulic Pump Regulator Test And Adjustment (Engine Pulldown)-590D…640
Hydraulic Pump Flow Test…647
Pilot Pump Flow Test…652
Boom, Arm And Bucket Cylinder Drift Test…654
Swing Motor Leakage Test…656
Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy…658
Hydraulic Schematic…660
Electrical Schematic-490D/590D…661

John Deere Excavators 490D, 590D Operation & Test Service Manual (TM1389)

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INSTANT DOWNLOAD

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INSTANT DOWNLOAD

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Complete repair manual for John Deere 4WD Loader 304H, with all the technical information to maintain, repair, and service like professional mechanics.

John Deere 4WD Loader 304H 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.

TM1864 English – John Deere 304H 4WD Loader Technical Manual – Repair.pdf
sp458vol2 English – Test and Service Specifications Manual

MAIN SECTIONS
Foreword
Help!! Help!! Help!! Help!!
General Information
Safety Information
General Specifications
Torque Values
Fuels and Lubricants
Wheels
Wheels and Fasteners
Axles and Suspension System
Removal and Installation
Axle Shafts and U-Joints
Axle Shaft, Bearings, and Rear Axle Reduction Gears
Hydrostatic Transmission
Hydrostatic Components Removal and Installation
Hydrostatic Components Repair
Engine
Removal and Installation
Fuel Injection System
Engine Auxiliary Systems
Cold Weather Starting Aids
Cooling System
Speed Controls
Intake System
External Exhaust System
External Fuel Supply Systems
Dampener Drive
Removal and Installation
Steering System
Power Steering
Hydraulic System
Service Brakes
Active Elements
Hydraulic System
Park Brake
Active Elements
Hydraulic System
Electrical Systems
Batteries, Support and Cables
Alternator, Regulator and Charging System Wiring
Lighting System
Wiring Harness and Switches
System Controls
Motors and Actuators
Sensors
Frame or Supporting Structure
Frame Installation
Counterweights
Operator`s Station
Removal and Installation
Operator Enclosure
Seat and Seat Belts
Heating and Air Conditioning
Sheet Metal and Styling
Hood or Engine Enclosure
Miscellaneous Shields
Safety and Convenience
Mirrors
Horn and Warning Devices
Main Hydraulic System
Hydraulic System
Loader
Bucket
Attachment Coupler
Frames
Hydraulic System
Dealer Fabricated Tools

Total Pages: 722 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

TABLE OF CONTENTS
Section 00: General Information….15
Group 0001: Safety Information….15
Handle Fluids Safely-Avoid Fires….18
Prevent Battery Explosions….19
Prepare for Emergencies….20
Prevent Acid Burns….21
Handle Chemical Products Safely….23
Avoid High-Pressure Fluids….24
Park Machine Safely….25
Support Machine Properly….26
Wear Protective Clothing….27
Work in Clean Area….28
Service Machines Safely….29
Work In Ventilated Area….30
Illuminate Work Area Safely….31
Replace Safety Signs….32
Use Proper Lifting Equipment….33
Remove Paint Before Welding or Heating….34
Avoid Heating Near Pressurized Fluid Lines….35
Keep ROPS Installed Properly….36
Service Tires Safely….37
Avoid Harmful Asbestos Dust….38
Practice Safe Maintenance….39
Use Proper Tools….40
Dispose of Waste Properly….41
Live With Safety….42
Group 0002: General Specifications….716
304H Loader Specifications….716
Drain and Refill Capacities….47
Group 0003: Torque Values….15
Hardware Torque Specifications….716
ROPS Torque Specifications….716
Metric Bolt and Cap Screw Torque Values….51
Additional Metric Cap Screw Torque Values….52
Service Recommendations For Metric 24° O-Ring Seal DIN 20078….54
Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings….56
Service Recommendations For O-Ring Boss Fittings With Shoulder….59
Service Recommendations for Metric Series Four Bolt Flange Fitting….62
Service Recommendations For Inch Series Four Bolt Flange Fittings….64
Group 0004: Fuels and Lubricants….16
Diesel Fuel….67
Lubricity of Diesel Fuel….68
Low Sulfur Diesel Fuel Conditioner….69
Diesel Fuel Storage….70
Fuel Tank….71
Do Not Use Galvanized Containers….72
Diesel Engine Coolant….73
Diesel Engine Oil….74
Hydraulic System, Park Brake, and Differential Oil….75
Service Brake Oil….76
Grease….77
Alternative and Synthetic Lubricants….78
Lubricant Storage….79
Mixing of Lubricants….80
Section 01: Wheels….81
Group 0110: Wheels and Fasteners….81
Service Equipment and Tools….706
Specifications….716
Remove and Install Wheel….85
Remove and Install Tire….86
Section 02: Axles and Suspension System….88
Group 0200: Removal and Installation….88
Service Equipment and Tools….706
Other Material….715
Specifications….716
Remove and Install Front Axle….93
Remove and Install Rear Axle….96
Group 0225: Axle Shafts and U-Joints….88
Specifications….716
Remove and Install Drive Shaft Assembly….109
Remove and Install Drive Shaft Carrier Bearing….111
Group 0250: Axle Shaft, Bearings, and Rear Axle Reduction Gears….88
Essential Tools….714
Service Equipment and Tools….706
Other Material….715
Specifications….716
Disassemble and Assemble Front Axle Planetary Drive….119
Remove and Install Front Axle Differential….130
Disassemble and Assemble Front and Rear Axle Differential….145
Disassemble Rear Axle Wheel Hub with Planetary Drive and Knuckle Housing….152
Disassemble and Assemble Rear Axle Constant Velocity Joint and Axle Shaft….158
Rear Axle Wheel Hub with Planetary Drive and Knuckle Housing Exploded View….160
Assemble Rear Axle Wheel Hub with Planetary Drive and Knuckle Housing….162
Remove and Install Rear Axle Reduction Gear Housing….171
Remove and Install Rear Axle Differential….176
Section 03: Hydrostatic Transmission….192
Group 0300: Hydrostatic Components Removal and Installation….192
Essential Tools….714
Service Equipment and Tools….706
Other Material….715
Specifications….716
Remove and Install Hydrostatic Pump Valves….198
Remove and Install Directional Control Valve….203
Remove and Install Charge Pump….205
Remove Hydrostatic Pump….213
Install Hydrostatic Pump….217
Remove and Install Hydrostatic Motor….221
Remove and Install Inching Valve….227
Hydrostatic Start-Up Procedure….229
Hydraulic Oil Clean-Up Procedure Using Portable Filter Caddy….680
Group 0360: Hydrostatic Components Repair….192
Essential Tools….714
Service Equipment and Tools….706
Other Material….715
Specifications….716
Disassemble and Assemble Directional Control Valve….238
Disassemble Hydrostatic Pump….240
Assemble Hydrostatic Pump….257
Hydrostatic Motor Components….274
Replace Hydrostatic Motor Control Valve Assembly O-Rings and Seals….275
Replace Hydrostatic Motor Flushing Valve Assembly O-Rings and Servo Piston Seals….277
Replace Hydrostatic Motor Shaft Seal….280
Disassemble Hydrostatic Motor….282
Inspect and Recondition Hydrostatic Motor Rotating Group….284
Assemble Hydrostatic Motor….288
Section 04: Engine….290
Group 0400: Removal and Installation….290
Service Equipment and Tools….706
Other Material….715
Specifications….716
POWERTECHPOWERTECH is a registered trademark of Deere & Company Yanmar (4TNE98) Engine-Use CTM119….290
Remove Engine….296
Install Engine….305
Group 0413: Fuel Injection System….290
Specifications….716
Remove and Install Fuel injection Pump….314
Section 05: Engine Auxiliary Systems….319
Group 0505: Cold Weather Starting Aids….319
Remove and Install Engine Intake Air Pre-Heater….321
Group 0510: Cooling System….319
Service Equipment and Tools….706
Other Material….715
Specifications….716
Remove and Install Alternator and A/C Compressor Belts….326
Remove and Install Hydraulic Cooling Fan Pump….329
Disassemble and Assemble Hydraulic Cooling Fan Pump….331
Remove and Install Cooling Fan and Cooling Fan Motor….334
Disassemble and Assemble Cooling Fan Motor….337
Remove and Install Radiator/Oil Cooler….341
Group 0515: Speed Controls….319
POWERTECH® Yanmar (4TNE98) Engine-Use CTM119….348
JT05801 Clamp-On Electronic Tachometer Installation….349
Remove and Install Speed Control Linkage….350
Speed Control Linkage Adjustment….354
Slow and Fast Idle Adjustment….355
Group 0520: Intake System….319
Service Equipment and Tools….706
Specifications….716
Remove and Install Air Cleaner Assembly….360
Air Intake System Leakage Test….362
Group 0530: External Exhaust System….319
Remove and Install Exhaust System….364
Group 0560: External Fuel Supply Systems….319
Specifications….716
Remove and Install Fuel Tank….367
Remove and Install Primary Fuel Filter (Water Separator)….369
Bleed Fuel System….371
Section 07: Dampener Drive….372
Group 0700: Removal and Installation….372
Other Material….715
Specifications….716
Remove and Install Dampener Drive….376
Section 09: Steering System….378
Group 0920: Power Steering….378
Specifications….716
Remove and Install Steering Link Assembly….381
Replace Tie Rod Ends….383
Adjust Steering Alignment….385
Group 0960: Hydraulic System….378
Essential Tools….714
Service Equipment and Tools….706
Other Material….715
Specifications….716
Remove and Install Steering Valve….395
Disassemble Steering Valve….404
Cross Section of Steering Valve….409
Assemble Steering Valve….411
Remove and Install Steering Column….417
Remove and Install Steering Cylinder….418
Disassemble and Assemble Steering Cylinder….422
Remove and Install Steering Cylinder Bushings….426
Section 10: Service Brakes….427
Group 1011: Active Elements….427
Service Equipment and Tools….706
Other Material….715
Specifications….716
Remove and Install Service Brake Pads….432
Remove and Install Service Brake Calipers and Disks….435
Disassemble and Assemble Service Brake Caliper….441
Group 1060: Hydraulic System….427
Remove and Install Brake Valve….448
Disassemble and Assemble Brake Valve….452
Remove and Install Service Brake Reservoir….455
Bleed Service Brakes….457
Section 11: Park Brake….460
Group 1111: Active Elements….460
Other Material….715
Specifications….716
Remove and Install Park Brake Caliper and Pads….464
Disassemble and Assemble Park Brake Caliper….467
Remove and Install Park Brake Actuator….469
Group 1160: Hydraulic System….460
Remove and Install Park Brake Solenoid Valve….473
Section 16: Electrical Systems….474
Group 1671: Batteries, Support and Cables….474
Service Equipment and Tools….706
Specifications….716
Service Batteries Carefully….479
Charge Battery….481
Remove and Install Batteries….482
Remove and Install Battery Disconnect Switch….484
Group 1672: Alternator, Regulator and Charging System Wiring….474
Alternators And Starting Motors-Use CTM119….518
Remove and Install Alternator….487
Group 1673: Lighting System….474
Remove and Install Brake, Turn, and Tail Lights….491
Group 1674: Wiring Harness and Switches….474
Essential Tools….714
Specifications….716
Replace DEUTSCHDEUTSCH is a trademark of the Deutsch Co. Connectors….474
Replace DEUTSCHDEUTSCH is a trademark of Deutsch Co. Rectangular or Triangular Connectors….474
Install DEUTSCHDEUTSCH is a trademark of Deutsch Co. Contact….474
Replace CINCHCINCH is a trademark of the Cinch Co. Connectors….474
Install CINCHCINCH is a trademark of the Cinch Co. Contact….474
Remove Connector Body From Blade Terminals….507
Group 1675: System Controls….474
Other Material….715
Remove and Install Display Monitor….510
Remove and Install FNR and Combination Switch….513
Group 1677: Motors and Actuators….474
Specifications….716
Alternators And Starting Motors-Use CTM119….518
Remove and Install Starting Motor….519
Remove and Install Front Windshield Wiper Motor….521
Group 1678: Sensors….475
Other Material….715
Specifications….716
Remove and Install Speed Sensor….527
Section 17: Frame or Supporting Structure….528
Group 1740: Frame Installation….528
Service Equipment and Tools….706
Specifications….716
Separate Loader and Rear Frames….532
Remove and Install Rotational Torque Spring….551
Remove and Install Upper Pivot Bushing Assembly….552
Remove and Install Lower Pivot Bushing Assembly….554
Group 1749: Counterweights….528
Specifications….716
Remove and Install Counterweight….557
Section 18: Operator's Station….561
Group 1800: Removal and Installation….561
Service Equipment and Tools….706
Specifications….716
Remove and Install Cab-with Platform….566
Remove and Install Cab-without Platform….578
Group 1810: Operator Enclosure….561
Service Equipment and Tools….706
Other Material….715
Remove and Install Front, Rear, and Side Windshields….586
Remove and Install Lower Door Windowpanes….589
Remove and Install Upper Door Windowpanes….590
Adjust Front Windshield Wiper….592
Group 1821: Seat and Seat Belts….561
Disassemble and Assemble Seat and Seat Belts….595
Group 1830: Heating and Air Conditioning….561
Essential Tools….714
Service Equipment and Tools….706
Other Material….715
Specifications….716
R134a Refrigerant Cautions….602
Proper Refrigerant Handling….603
R134a Compressor Oil Charge Check….604
R134a Compressor Oil Removal….605
R134a Component Oil Charge….606
Leak Testing….607
Refrigerant Hoses and Tubing Inspection….608
R134a Refrigerant Recovery, Recycling and Charging Station Installation Procedure….609
Recover R134a System….611
Evacuate R134a System….613
Charge R134a System….615
Air Conditioning System Cleaning Procedures….617
Purge Air Conditioning System….618
Flush Air Conditioning System….619
Air Conditioning System Exploded View….622
Remove and Install Heater Control Valve….624
Remove and Install Heater Core….625
Remove and Install Heater Control Cable….626
Remove and Install Blower Assembly….629
Remove and Install Air Conditioning Compressor….630
Remove and Install Receiver-Dryer and Condenser….632
Remove and Install Evaporator Coil….634
Remove and Install Expansion Valve….637
Expansion Valve Bench Test and Adjustment….640
Remove and Install Freeze Control Switch….642
Remove and Install Low/High Pressure Switch….644
Section 19: Sheet Metal and Styling….645
Group 1910: Hood or Engine Enclosure….645
Specifications….716
Remove and Install Engine Hood….648
Group 1913: Miscellaneous Shields….645
Specifications….716
Remove and Install Rear Fenders….652
Adjust Front Fenders….654
Section 20: Safety and Convenience….655
Group 2002: Mirrors….655
Remove and Install Mirrors and Sun Visor….657
Group 2004: Horn and Warning Devices….655
Remove and Install Horn….659
Remove and Install Backup Alarm….660
Section 21: Main Hydraulic System….662
Group 2160: Hydraulic System….662
Service Equipment and Tools….706
Other Material….715
Specifications….716
Remove and Install Main Hydraulic Pump/Priority Valve….667
Disassemble and Assemble Main Hydraulic Pump/Priority Valve….669
Remove and Install Return/Suction Filter Assembly….673
Disassemble and Assemble Return/Suction Filter Assembly….674
Remove and Install Hydraulic Reservoir….675
Remove and Install Hydraulic Oil Cooler….679
Hydraulic Oil Clean-Up Procedure Using Portable Filter Caddy….680
Section 31: Loader….682
Group 3102: Bucket….682
Remove and Install Bucket Teeth….685
Remove and Install Welded-On Bucket Cutting Edges….686
Remove and Install Bolt-On Cutting Edges….688
Repair Cracked Cutting Edge….689
Group 3104: Attachment Coupler….682
Other Material….715
Specifications….716
Remove and Install Quick Attach Lock-Out Valve….693
Disassemble and Assemble Quick Attach Lock-Out Valve….694
Disassemble and Assemble Quick Attach Hitch….695
Group 3140: Frames….682
Service Equipment and Tools….706
Other Material….715
Specifications….716
Remove and Install Loader Bucket Tilt Linkage….709
Remove and Install Bucket Linkage Bushings….711
Remove and Install Loader Boom Bushings….712
Group 3160: Hydraulic System….682
Essential Tools….714
Other Material….715
Specifications….716
Remove and Install Loader Control Valve….717
Disassemble and Assemble Loader Control Valve….720
Disassemble and Assemble Auxiliary, Fourth Function, or Bucket Valve Section….721
Disassemble and Assemble Boom Valve Section….723
Disassemble and Assemble System or Circuit Relief Valve….725
Remove and Install Boom Cylinder….727
Remove and Install Bucket Cylinder….729
Disassemble and Assemble Boom and Bucket Cylinders….731
Remove and Install Boom and Bucket Cylinder Bushings….736
Remove and Install Pilot Control Valve….737
Disassemble and Assemble Pilot Control Valve….740
Remove and Install Quick Attach/Auxiliary Pilot Control Valve….745
Disassemble and Assemble Quick Attach/Auxiliary Pilot Control Valve….747
Remove and Install Pilot Lockout and Park Brake Solenoid Valves….749
Remove and Install Pilot Accumulator….752
Section 99: Dealer Fabricated Tools….754
Group 9900: Dealer Fabricated Tools….754
DF1002 Rolling Drag Torque Bar….757
DFT1213 Service Brake Caliper Removal and Installation Tool….759
DFT1214 Hydrostatic Pump Servo Piston Snap Ring Removal and Installation Tool….760

John Deere 4WD Loader 304H Repair Service Manual (TM1864)

---

INSTANT DOWNLOAD

---

---

INSTANT DOWNLOAD

---

Complete Operation and Test manual with Electrical Wiring Diagrams for John Deere 4WD Loader 304H, with technical information to maintain, diagnose, and service like professional mechanics.

John Deere 4WD Loader 304H Diagnostic 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.

TM1863 English – John Deere 304H 4WD Loader Technical Manual (Operation and Test).PDF
tm10198 French – Chargeuse 304H Fonctionnement et tests.pdf
ctm119 – POWERTECH 0.9, 1.1, 1.2, 1.3, 1.5, 1.6 &2.0 L and Yanmar 4TNE98 Diesel Engines
ctm3 English – John Deere Series 220 Diesel Engines CTM
ctm55 Italian – Motori Diesel Yanmar Serie 3TN e 4TN CTM

Total Pages: 789 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

MAIN SECTIONS
Foreword
General Information
Safety Information
General Specifications
Torque Values
Fuels and Lubricants
Operational Checkout Procedure
Operational Checkout Procedure
Engine
Theory of Operation
Diagnostic Information
Adjustments
Tests
Electrical System
System Information
System Diagrams
Sub-System Diagnostics
References
Adjustments
Power Train
Theory Of Operation
Diagnostic Information
Adjustments
Tests
Hydraulic System
Theory Of Operation
Diagnostic Information
Adjustments
Test
Heating and Air Conditioning
Theory of Operation
Diagnostic Information
Adjustments
Tests

TABLE OF CONTENTS
Section 9000: General Information…14
Group 01: Safety Information…14
Handle Fluids Safely—Avoid Fires…17
Prevent Battery Explosions…18
Prepare for Emergencies…19
Prevent Acid Burns…20
Handle Chemical Products Safely…22
Avoid High-Pressure Fluids…23
Park Machine Safely…24
Support Machine Properly…25
Wear Protective Clothing…26
Work in Clean Area…27
Service Machines Safely…28
Work In Ventilated Area…29
Illuminate Work Area Safely…30
Replace Safety Signs…31
Use Proper Lifting Equipment…32
Remove Paint Before Welding or Heating…33
Avoid Heating Near Pressurized Fluid Lines…34
Keep ROPS Installed Properly…49
Service Tires Safely…36
Practice Safe Maintenance…37
Use Proper Tools…39
Decommissioning — Proper Recycling and Disposal of Fluids and Components…40
Live With Safety…41
Group 02: General Specifications…742
304H Loader Specifications…742
Drain and Refill Capacities…46
Group 03: Torque Values…14
Hardware Torque Specifications…742
Keep ROPS Installed Properly…49
Metric Bolt and Screw Torque Values…50
Additional Metric Cap Screw Torque Values…52
Service Recommendations For Metric 24° O-Ring Seal DIN 20078…54
Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings…56
Service Recommendations For O-Ring Boss Fittings With Shoulder…59
Service Recommendations for Metric Series Four Bolt Flange Fitting…62
Service Recommendations For Inch Series Four Bolt Flange Fittings…64
Group 04: Fuels and Lubricants…15
Diesel Fuel…68
Lubricity of Diesel Fuel…70
Low Sulfur Diesel Fuel Conditioner…71
Diesel Fuel Storage…72
Fuel Tank…73
Diesel Engine Oil — Non-Emissions Certified and Certified Tier 1 and Stage I…74
Hydraulic System, Park Brake, and Differential Oil…76
Service Brake Oil…77
Grease…78
Alternative and Synthetic Lubricants…79
Lubricant Storage…80
Mixing of Lubricants…81
Section 9005: Operational Checkout Procedure…82
Group 10: Operational Checkout Procedure…82
Operational Checkout Record Sheet—304H…86
Complete Machine Operational Checkout…89
Section 9010: Engine…142
Group 05: Theory of Operation…142
Yanmar 3.3 L (4TNE98) Engine—Use CTM119…180
Engine—Sectional View…145
General Engine Description…147
Group 15: Diagnostic Information…142
Yanmar 3.3 L (4TNE98) Engine—Use CTM119…180
Make Visual Inspection of Engine and Supporting Systems…150
Diagnose Engine Malfunctions…152
Group 20: Adjustments…142
Yanmar 3.3 L (4TNE98) Engine—Use CTM119…180
JT05801 Clamp-On Electronic Tachometer Installation…677
Alternator and A/C Compressor Belts Tension Adjustment…168
Slow and Fast Idle Adjustment…172
Speed Control Linkage Adjustment…174
Injection Pump Static Timing Adjustment…175
Group 25: Tests…142
Yanmar 3.3 L (4TNE98) Engine—Use CTM119…180
JT05801 Clamp-On Electronic Tachometer Installation…677
JT05800 Digital Thermometer Installation…678
Air Intake System Leakage Test…183
Fuel Line Leakage Test…184
Engine Power Test Using Engine Pulldown…185
Section 9015: Electrical System…188
Group 05: System Information…188
Electrical System Visual Inspection…193
Electrical Circuit Malfunctions…194
High Resistance Circuit…196
Open Circuit…198
Grounded Circuit…200
Shorted Circuit…202
Sensor Circuit Shorted to Power…204
Sensor Circuit Shorted to Itself…206
Sensor Circuit Shorted to Ground…208
Multimeter…210
Seven Step Electrical Test Procedure…211
Schematic, Wiring Diagram, and Component Location Information…213
Reading a System Functional Schematic…214
Reading a Wiring Diagram…216
Reading a Component Location Diagram…218
Reading a Connector End View Diagram…220
Electrical Schematic Symbols…221
Component Identification Table…223
Fuse (Blade-Type) Color Codes…225
Group 10: System Diagrams…188
Fuse Specifications…742
Main System Functional Schematics and Component Location Legend…230
Main System Functional Schematic Section Legend…236
Main System Functional Schematic…237
Power And Battery Cables (W1) Component Location…240
Loader/Rear Frame Harness (W2) Component Location…241
Loader/Rear Frame Harness (W2) Connectors, Wire, And Pin Locations…242
Cab Main Harness (W3) Component Location…244
Cab Main Harness (W3) Connectors, Wire, And Pin Locations…246
Front Console Harness (W4) Component Location…248
Front Console Harness (W4) Connectors, Wire, And Pin Locations…249
Side Console Harness (W5) Component Location…251
Cab Rear Harness (W6) Component Location…252
Cab Work Light Harness (W7) Component Location…253
Cab Work Light Harness (W7) Connectors, Wire, And Pin Locations…254
Optional Hydraulic Fourth Function Harness (W16) Component Location…255
Blower And A/C Harness (Door Mounted) (W17) Component Location…256
A/C Harness (Roof Mounted) (W18) Component Location…258
Group 15: Sub-System Diagnostics…189
Power Circuit Operational Information…260
Power Circuit Theory Of Operation…261
Power Circuit Functional Schematic…263
Power Circuit Diagnostic Procedures…264
Monitor Power, Alarm, And Mode Switch Circuits Operational Information…269
Monitor Power, Alarm, And Mode Switch Circuits Theory Of Operation…270
Monitor Power, Alarm, And Mode Switch Circuits Functional Schematic…271
Monitor Power, Alarm, And Mode Switch Circuits Diagnostic Procedures…272
Neutral Start Circuit Operational Information…276
Neutral Start Circuit Theory Of Operation…277
Neutral Start Circuit Functional Schematic…278
Neutral Start Circuit Diagnostic Procedures…279
Preheat And Start Release Circuits Operational Information…290
Preheat And Start Release Circuits Theory Of Operation…291
Preheat And Start Release Circuits Functional Schematic…292
Preheat And Start Release Circuits Diagnostic Procedures…293
Fuel Shut-Off Circuit Theory of Operation…299
Fuel Shut-Off Circuit Functional Schematic…300
Fuel Shut-Off Circuit Diagnostic Procedures…301
Charging Circuit Operational Information…308
Charging Circuit Theory Of Operation…309
Charging Circuit Functional Schematic…310
Charging Circuit Diagnostic Procedures…311
Hydrostatic Transmission Control, Park Brake Release, And Backup Alarm Circuits Specifications…742
Hydrostatic Transmission Control, Park Brake Release, And Backup Alarm Circuits Operational Information…315
Hydrostatic Transmission Control, Park Brake Release, And Backup Alarm Circuits Theory Of Operation…316
Hydrostatic Transmission Control, Park Brake Release, And Backup Alarm Circuits Functional Schematic…319
Hydrostatic Transmission Control, Park Brake Release, And Backup Alarm Circuits Diagnostic Procedures…320
Pilot, Boom Height Kickout, And Return-To-Dig Circuit Operational Information…362
Pilot, Boom Height Kickout, And Return-To-Dig Circuit Theory Of Operation…363
Pilot, Boom Height Kickout, And Return-To-Dig Circuit Functional Schematic…365
Pilot, Boom Height Kickout, And Return-To-Dig Diagnostic Procedures…366
Cooling Fan Drive Low/High Speed Circuit Operational Information…388
Cooling Fan Drive Low/High Speed Circuit Theory Of Operation…389
Cooling Fan Drive Low/High Speed Circuit Functional Schematic…390
Fan Drive Low/High Speed Circuit Diagnostic Procedures…391
Turn Lights And Flasher Circuit Operational Information…395
Turn Lights And Flasher Circuit Theory Of Operation…396
Turn Lights And Flasher Circuit Functional Schematic…397
Turn Lights And Flasher Circuit Diagnostic Procedures…398
Brake Lights Circuit Operational Information…411
Brake Lights Circuit Theory Of Operation…412
Brake Lights Circuit Functional Schematic…413
Brake Lights Circuit Diagnostic Procedures…414
Drive Lights, Marker Lights, And Tail Lights Circuits Operational Information…417
Drive Lights, Marker Lights, And Tail Lights Circuits Theory Of Operation…418
Drive Lights, Marker Lights, And Tail Lights Circuits Functional Schematic…419
Drive Lights, Marker Lights, And Tail Lights Circuit Diagnostic Procedures…420
Cab Work, Dome, And Beacon Lights Circuits Theory Of Operation…426
Cab Work, Dome, And Beacon Lights Circuit Functional Schematic…427
Cab Work, Dome, And Beacon Lights Circuits Diagnostic Procedures…428
Radio And Accessories Circuit Theory Of Operation…433
Radio And Accessories Circuit Functional Schematic…434
Front Windshield Wiper And Horn Circuit Theory Of Operation…435
Front Windshield Wiper And Horn Circuit Functional Schematic…436
Front Windshield Wiper And Horn Circuit Diagnostic Procedures…437
Rear Windshield Wiper Circuit Theory Of Operation…440
Rear Windshield Wiper Circuit Functional Schematic…441
Rear Windshield Wiper Circuit Diagnostic Procedures…442
Heater Blower And Air Conditioning Circuit Operational Information…445
Heater Blower And Air Conditioning Circuit Theory Of Operation…446
Heater Blower And Air Conditioning Circuit Functional Schematic…448
Heater Blower And Air Conditioning Circuit Diagnostic Procedures…449
Hydraulic Fourth Function Circuit Operational Information…455
Hydraulic Fourth Function Circuit Theory Of Operation…456
Hydraulic Fourth Function Circuit Functional Schematic…457
Hydraulic Fourth Function Circuit Diagnostic Procedures…458
Group 20: References…191
Alternators And Starting Motors—Use CTM119…462
Battery Specifications…742
Battery Operation…464
Diagnose Battery Malfunctions…465
Check Battery Electrolyte Level And Terminals…466
Procedure For Testing Batteries…469
Using Booster Batteries—12 Volt System…470
Change Monitor Speed Display—Metric/English…472
Monitor Service Codes…474
Group 25: Adjustments…191
Speed Sensor Adjustment…478
Adjust Boom Height Kickout…479
Adjust Return-To-Dig…481
Section 9020: Power Train…483
Group 05: Theory Of Operation…483
Power Train Description…487
Drive Dampener…489
Hydrostatic Transmission Operation—Neutral…491
Hydrostatic Transmission—Forward (Low Speed)…494
Hydrostatic Transmission—Forward (High Speed)…497
Hydrostatic Transmission—Reverse (Low Speed)…500
Hydrostatic Pump Operation…503
Hydrostatic Pump Swashplate Operation…505
Hydrostatic Pump Control Operation—Reverse (Engine Speed At Less Than Fast Idle)…507
Hydrostatic Pump Control Operation—Forward (Engine Speed At Fast Idle)…510
High Pressure Relief Valve Operation…513
Hydrostatic Motor Operation—Neutral…515
Hydrostatic Motor—Reverse (Low Speed)…517
Hydrostatic Motor—Forward (High Speed)…519
Inching Valve Operation…521
Service And Park Brake Description…522
Park Brake Release Solenoid Valve Operation…524
Park Brake Operation…527
Front And Rear Axle Differential Operation…529
Final Drive Operation…530
Gear Case Operation…532
Group 15: Diagnostic Information…483
Diagnose Hydrostatic Transmission Malfunctions…539
Diagnose Differential And Axle Malfunctions…544
Diagnose Driveline Malfunctions…546
Diagnose Park Brake Malfunctions…547
Diagnose Service Brake Malfunctions…549
Hydraulic Circuit Symbols…664
Power Train Component Location…551
Service And Park Brake System Component Location…553
Hydrostatic Transmission Schematic…555
Service And Park Brake System Schematic…557
Group 20: Adjustments…484
JT05801 Clamp-On Electronic Tachometer Installation…677
JT05800 Digital Thermometer Installation…678
Hydrostatic Transmission Oil Warm-Up Procedure…581
Hydrostatic Pump Servo Piston Neutral Adjustment…563
Hydrostatic Motor Minimum Displacement Adjustment…565
Brake/Inching Pedal Linkage Adjustment…567
Park Brake Adjustment…572
Hydrostatic Start-Up Procedure…574
Hydraulic Oil Clean-Up Procedure Using Portable Filter Caddy…674
Group 25: Tests…484
JT05801 Clamp-On Electronic Tachometer Installation…677
JT05800 Digital Thermometer Installation…678
Hydrostatic Transmission Oil Warm-Up Procedure…581
Before Performing Hydrostatic Transmission Tests…582
Neutral Charge Relief Valve Pressure Test And Adjustment…583
Hydrostatic Motor Begin Regulation Of Displacement Control Valve Test And Adjustment…586
Hydrostatic Pump Begin Regulation Test And Adjustment…590
Hydrostatic Pump Performance (Timing) Test And Adjustment…593
High Pressure Relief Valve Test And Adjustment…598
Hydrostatic Pump Pressure Override (POR) Valve Pressure Test And Adjustment…602
Hydrostatic Pump Isolation Procedure…606
Directional Control Valve Spool Leakage Test…611
Hydrostatic Adjusting Screws (With Tamper-Proof Caps)…614
Park Brake Release Pressure Test…616
Section 9025: Hydraulic System…618
Group 05: Theory Of Operation…618
Main Hydraulic System…623
Main Hydraulic Pump…626
Priority Valve…627
Steering Circuit…630
Steering Valve…632
Steering Valve, Cylinder Relief Valve…634
Loader Control Valve…635
System And Circuit Relief Valves (With Anti-Cavitation)…637
Pilot Control Valve…639
Pilot Lockout Solenoid Valve Operation…641
Cooling Fan Pump And Motor Circuit…644
Group 15: Diagnostic Information…618
Diagnose Hydraulic System Malfunctions…655
Hydraulic Circuit Symbols…664
Loader, Fan Drive and Fourth Function System Component Location…665
Steering System Component Location…666
Loader, Fan Drive, and Fourth Function System Schematic…668
Steering System Schematic…670
Group 20: Adjustments…618
Hydraulic Oil Clean-Up Procedure Using Portable Filter Caddy…674
Group 25: Test…618
JT05801 Clamp-On Electronic Tachometer Installation…677
JT05800 Digital Thermometer Installation…678
Hydraulic Oil Warm-Up Procedure…679
Boom Lock Installation…680
Main Hydraulic Pump Flow Test…681
Steering System Maximum Pressure Test…684
Steering Valve Leakage Test…687
Steering Cylinder Leakage Test…690
Loader System Relief Valve Pressure Test…692
Loader Circuit Relief Valve Pressure Test…695
Loader Cylinder Drift Test…699
Boom and Bucket Cylinder Leakage Test…701
Pilot Control Valve Pressure Test…703
Cooling Fan Motor RPM Test…708
Cooling Fan System Pressure and Pump Flow Test…710
Cycle Time Test…714
Section 9031: Heating and Air Conditioning…715
Group 05: Theory of Operation…715
Proper Refrigerant Handling…763
R134a Refrigerant Cautions…764
Refrigerant Theory of Operation…720
Compressor Operation…722
Condenser Operation…723
Receiver-Dryer Operation…724
Expansion Valve Operation…725
Freeze Control Switch Operation…727
Evaporator Coil Operation…728
Heat Exchanger Operation…729
Temperature Control, Blower Switch, and Air Conditioning Switch Operation (Door Mounted)…730
Low/High Pressure Switch (Door Mounted)…732
Group 15: Diagnostic Information…715
Diagnose Air Conditioning System Malfunctions…735
Diagnose Heater System Malfunctions…737
Group 20: Adjustments…715
Essential Tools…739
Service Equipment and Tools…740
Other Material…741
Specifications…742
R134a Refrigerant Cautions…764
R134a Compressor Oil Charge Check…744
R134a Compressor Oil Removal…745
R134a Component Oil Charge…746
Leak Testing…777
Refrigerant Hoses and Tubing Inspection…765
R134a Refrigerant Recovery, Recycling and Charging Station Installation Procedure…749
Recover R134a System…751
Evacuate R134a System…753
Charge R134a System…755
Air Conditioner System Cleaning Procedures…757
Purge Air Conditioner System…758
Flush Air Conditioner System…759
Group 25: Tests…716
Proper Refrigerant Handling…763
R134a Refrigerant Cautions…764
Refrigerant Hoses and Tubing Inspection…765
R134a Air Conditioning System Test…766
Operating Pressure Diagnostic Chart…769
Low/High Pressure Switch Test…773
Freeze Control Switch Test…776
Leak Testing…777

John Deere 4WD Loader 304H Diagnostics Technical Manual (TM1863)

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Complete Operator’s Manual for John Deere 304H loader, with all the technical information to maintain and operate.

omt184550 English – 304H loader Operator’s Manual.pdf
omt184551 Spanish – Cargadora 304H
omt184552 French – Chargeur 304H

Total Pages: 502 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)

TABLE OF CONTENTS
Section 05: Safety….14
304H Loader….16
Recognize Safety Information….17
Understand Signal Words….18
Follow Safety Instructions….19
Avoid Injury from Rollover Accidents ——————————– Wear Your Seat Belt ——————————– Do Not Attempt to Jump Clear of Tipping Machine-Serious or Fatal Crushing Injuries Will Result ——————————– Machine Will Tip Over Faster Than You Can Jump Free….20
Avoid Injury from Backover Accidents ———————————— Before Moving Machine, Be Sure All Persons Are Clear of Area ———————————— Always Be Alert for Bystanders Moving into the Work Area. Use Horn or Other Signal to Warn Bystanders Before Moving Machine ———————————— When Using a Signal Person, Keep Person in View at all Times. Be Sure Signal Person is Clear Before Backing Up….22
Avoid Injury from Rollaway Accidents ———————————— To Prevent Rollaway, Always Make Sure Machine Is Properly Secured Before Leaving Operator's Seat ———————————— Death or Serious Injury May Result if You Attempt to Mount or Stop a Moving Machine ————————————….23
Inspect Machine….24
Use Handholds and Steps….25
Prevent Machine Runaway….26
Use Seat Belt Properly….27
Maintain Seat Belt….28
Travel Safely….29
Drive Machine Safely….30
Operate Machine with Caution….31
Operating on Slopes….32
Carrying Loads….33
Avoid Power Lines….34
Beware of Exhaust Fumes….35
Keep Riders off Machine….36
Handle Fuel Safely-Avoid Fires….37
Prepare for Emergencies….38
Clean Trash from Machine….39
Protect Against Flying Debris….40
Wear Protective Clothing….41
Protect Against Noise….42
Handle Chemical Products Safely….43
Use Safety Lights and Devices….44
Keep ROPS Installed Properly….319
Warn Others of Service Work….46
Practice Safe Maintenance….47
Support Machine Properly….48
Remove Paint Before Welding or Heating….49
Avoid Heating Near Pressurized Fluid Lines….50
Avoid High-Pressure Fluids….51
Clean the Machine Regularly….52
Service Cooling System Safely….53
Store Attachments Safely….54
Dispose of Waste Properly….55
Section 06: Safety Signs….57
Safety Signs….57
Section 10: Operator's Station….65
Monitor Gauges, Indicators and Dash Switches….67
Side Console Switches….69
Warning Alarm….70
Battery Voltage Indicator….71
Low Engine Oil Pressure Indicator….72
Forward Direction Indicator….73
Reverse Direction Indicator….74
Hydraulic Oil Temperature Indicator….75
Park Brake Indicator….76
Clock, Hour Meter, and Speedometer….77
Monitor Messages….78
High Speed Indicator….79
Low Speed Indicator….80
Pilot Disable Indicator….81
Engine Air Filter Restriction Indicator….82
Engine Coolant Temperature Indicator….83
Seat Belt Indicator….84
High Beams ON Indicator….85
Turn Signal Indicator….86
Engine Preheat….87
Fuel Gauge….88
Engine Coolant Temperature Gauge….89
Boom and Bucket Control Lever….142
Quick Disconnect and Auxiliary Hydraulic Lever….91
FNR Lever and Speed Selector….92
Neutral Lock Latch….135
Turn Signal Lever….94
Pedals….95
Horn Button….96
Operating Front Windshield Wiper and Washer….97
Operating Rear Windshield Wiper and Washer….98
Adjusting Steering Column Tilt….99
Setting the Clock….100
Opening and Securing Side Door….101
Secondary Exit….103
Drive Lights….104
Work Lights-If Equipped….106
Heater Operation….108
Air Conditioner-If Equipped….110
Air Conditioner-If Equipped….110
Air Flow Control….111
Adjusting Seat….112
Cab Removal and Installation….114
4th Function Auxiliary Hydraulics-If Equipped….115
Section 20: Pre-Start Inspection….117
Inspect Machine Daily Before Starting….118
Section 25: Operating the Engine….390
Check Instruments Before Starting….121
Cold Weather Start-Up….122
Starting the Engine….390
Using Booster Batteries-12 Volt System….125
Check Instruments After Starting….128
Warm-Up….129
Cold Weather Warm-Up….130
Stopping the Engine….390
Section 30: Driving the Machine….132
Driving on Public Roads….133
General Driving Precautions….134
Neutral Lock Latch….135
Shifting the Machine….136
Slowing and Stopping the Machine….137
Park Brake Switch….138
Parking the Machine….139
Lock All Compartments….140
Section 35: Operating the Machine….141
Boom and Bucket Control Lever….142
Operating Quick Disconnect….144
Pilot Enable/Boom Down Switch….147
Brake/Inching Pedal….148
Boom Height Kickout Adjustment….149
Return-to-Dig Adjustment….151
Operating 4th Function Auxiliary Hydraulics-If Equipped….153
General Operating Tips….155
Turning the Machine….156
Excavating Banks or Stockpiles….157
Using the Loader Bucket….159
Backdragging….161
Backfilling….162
Truck Loading….163
Fork Attachment….164
Material Handler Arm Attachment….167
Section 40: Transporting….169
Transporting Precautions….170
Loading Machine on a Trailer….171
Towing Procedure….173
Lifting the Machine….177
Section 45: Fuels and Lubricants….178
Diesel Fuel….179
Lubricity of Diesel Fuel….180
Low Sulfur Diesel Fuel Conditioner….181
Diesel Fuel Storage….182
Fuel Tank….183
Diesel Engine Oil….184
Differentials and Final Drives Oil….185
Hydraulic System Oil….186
Service Brake Oil….187
Grease….188
Alternative and Synthetic Lubricants….189
Lubricant Storage….190
Mixing of Lubricants….191
Section 50: Periodic Maintenance….192
Service Your Machine at Specified Intervals….193
Drain Hose Storage….194
Check the Hour Meter Regularly….195
Use Correct Fuels and Lubricants….197
Prepare Machine for Maintenance….198
Locking Machine Frame….200
Boom Lock….201
Opening Hood….202
Check Windshield Washer Fluid Level….203
Maintenance and Repair Record Keeping System….204
OILSCAN Plus, OILSCAN Plus is a registered trademark of Deere & Company CoolScan PlusCoolScan Plus is a registered trademark of Deere & Company and 3-Way Coolant Test Kit….192
Service Intervals….445
Section 55: Maintenance-As Required….209
Inspect and Replace V-Belt(s)….210
Drain Fuel Filter Sediment….214
Clean Air Cleaner Elements….215
Inspect Element….217
Clean Dusty Primary Element….218
Lubricate Cab Door Hinges….219
Check Tire Pressure….220
Tire Pressures….222
Tighten Wheel Lug Nuts….223
Section 60: Maintenance-Every 10 Hours or Daily….224
Check Coolant Level….225
Check Engine Oil Level….226
Clean Air Cleaner Dust Unloader Valve….228
Check Hydraulic Oil Level….229
Section 65: Maintenance-Every 50 Hours….230
Lubricate Loader Linkage and Cylinder Pivots….231
Lubricate Gear Case to Front Axle Shaft….233
Lubricate Front and Rear Steering Cylinder Pivots….235
Lubricate Rear Steering Axle Pivots….236
Lubricate Oscillating Rear Axle….237
Lubricate Frame Hinge Pivot….238
Section 75: Maintenance-Every 250 Hours….239
Clean Cab Air Filter….240
Change Engine Oil and Replace Filter….242
Check Brake Oil Level….245
Section 80: Maintenance-Every 500 Hours….246
Check Coolant Conditioner….247
Check and Clean Hydraulic Oil Cooler and Radiator….248
Replace Primary Fuel Filter….249
Replace Final Fuel Filter….250
Bleeding the Fuel System….251
Check Air Intake Hose….252
Replace Hydraulic Oil Return Suction Filter….253
Check Battery Electrolyte Level and Terminals….255
Check Rear Differential and Gear Case Oil Level….259
Check Front Differential Oil Level….260
Check Front and Rear Final Drives Oil Level….261
Check Brake/Inching Pedal Linkage Adjustment….320
Section 85: Maintenance-Every 1000 Hours….263
Check Park Brake and Service Brake Pads….264
Replace Cab Air Filter….265
Speed Control Linkage Adjustment….266
Change Rear Differential and Gear Case Oil….267
Check and Adjust Engine Valve Lash….268
Clean Engine Crankcase Vent Tube….271
Replace Air Cleaner Elements….272
Replace Air Cleaner Dust Unloader Valve….274
Replace Hydraulic Tank Breather….275
Change Rear Final Drive Oil….276
Change Front Differential and Front Final Drives Oil….277
Section 86: Maintenance-Every 2000 Hours….279
Clean Hydraulic Oil Fill Strainer….280
Change Hydraulic System Oil….282
Section 88: Maintenance-Every 3000 Hours….284
Draining the Cooling System….285
Diesel Engine Coolant….288
Filling the Cooling System….289
Replace Seat Belt….291
Section 90: Maintenance….292
Test the Coolant Freeze-Protection Level….294
Precautions for Alternator and Regulator….295
Service Batteries Carefully….296
Checking Electrolyte Specific Gravity….298
Using Battery Charger….300
Replacing Batteries….301
Removing Batteries….302
Replacing Fuses….304
Fuse (Blade-Type) Color Codes….306
Engine Speeds….307
Checking Neutral Start System….308
Service Pilot Accumulator….309
Adding Attachments/Accessories to Rollover Protective Structure (ROPS)….310
Welding on Machine….311
Park Brake Adjustment….312
Service Brake Adjustment….314
Replace Marker Light and Drive Light Bulbs….315
Do Not Service Control Valves, Cylinders, Pumps or Motors….318
Keep ROPS Installed Properly….319
Brake/Inching Pedal Linkage Adjustment….320
Check Receiver/Dryer Moisture Indicator-If Equipped….323
Check Receiver-Dryer Moisture Indicator-If Equipped….324
Hardware Torque Specifications….325
Metric Bolt and Cap Screw Torque Values….326
Additional Metric Cap Screw Torque Values….328
Unified Inch Bolt and Cap Screw Torque Values….330
Check Oil Lines and Fittings….332
Service Recommendations For Metric 24° O-Ring Seal DIN 20078….333
Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings….335
Service Recommendations For O-Ring Boss Fittings With Shoulder….338
Service Recommendations for Metric Series Four Bolt Flange Fitting….341
Service Recommendations For Inch Series Four Bolt Flange Fittings….343
Section 95: Operational Checkout….346
Operational Checkout….346
Section 100: Troubleshooting….386
Using Troubleshooting Charts….387
Monitor Service Codes….388
Engine….390
Hydrostatic System….400
Differential and Axle….404
Service Brake….405
Driveline….406
Park Brake….407
Hydraulic System….408
Steering….412
Hydraulic Fan Motor and Pump….415
Heater System….416
Air Conditioning-If Equipped….417
Section 105: Storage….419
Prepare Machine for Storage….420
Monthly Storage Procedure….422
Section 110: Machine Numbers….424
Record Product Identification Number (PIN)….425
Record Engine Serial Number….426
Record Gear Case Serial Number….427
Record Hydrostatic Pump Serial Number….428
Record Front Axle Serial Number….429
Record Rear Axle Serial Number….430
Record Hydrostatic Motor Serial Number….431
Section 115: Specifications….432
304H Loader Specifications….433
Drain and Refill Capacities….435
Section 120: Crime Prevention Tips….436
Help Prevent Crime….437
Record Identification Numbers….438
Keep Proof of Ownership….439
Park Indoors Out of Sight….440
When Parking Outdoors….441
Reduce Vandalism….442
Report Thefts Immediately….443
Section CLIS: Checklists….444
Service Intervals….445

John Deere 304H Loader Operator’s Manual (OMT184550)

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