John Deere 204K 304K Repair Manual [Loader]

Factory Service Repair Manual TM12988 For John Deere 204K, 304K Loaders. Tons of illustrations, instructions, diagrams for step by step remove and install, assembly and disassembly, service, maintenance, inspection, repair, troubleshooting, tune-ups.

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Models

John Deere
204K
304K

Contents

Foreword
Manual Identification
– General Information
– Safety
Add and Operate Attachments Safely
Add Cab Guarding for Special Uses
Avoid Backover Accidents
Avoid High-Pressure Fluids
Avoid High-Pressure Oils
Avoid Machine Tip Over
Avoid Unauthorized Machine Modifications
Avoid Worksite Hazards
Clean Debris from Machine
Dispose of Waste Properly
Drive Metal Pins Safely
Follow Safety Instructions
Inspect and Maintain ROPS
Inspect Machine
Keep Riders Off Machine
Make Welding Repairs Safely
Operate Only If Qualified
Operating on Slopes
Operating or Traveling On Public Roads
Park and Prepare for Service Safely
Prepare for Emergencies
Prevent Battery Explosions
Prevent Fires
Prevent Unintended Machine Movement
Recognize Safety Information
Remove Paint Before Welding or Heating
Service Cooling System Safely
Service Tires Safely
Start Only From Operator’s Seat
Stay Clear of Moving Parts
Use and Maintain Seat Belt
Use Special Care When Operating Loader
Use Steps and Handholds Correctly
Wear Protective Equipment
Work In Ventilated Area
– General Information – Torque Values
Additional Metric Cap Screw Torque Values
Inch Series Four Bolt Flange Fitting For High Pressure Service Recommendations
Metric ° O-Ring Seal DIN Service Recommendations
Metric Bolt and Cap Screw Torque Values
Service Recommendations For Inch Series Four Bolt Flange Fittings
Service Recommendations for Metric Series Four Bolt Flange Fitting
Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings
Service Recommendations For O-Ring Boss Fittings With Shoulder
Unified Inch Bolt and Cap Screw Torque Values
– Wheels
Tire Remove and Install
Wheel Remove and Install
– Axles and Suspension Systems
Drive Shaft Remove and Install
Front and Rear Axle Disassemble and Assemble
Front Axle Remove and Install
Rear Axle Reduction Gear Case Disassemble and Assemble
Rear Axle Reduction Gear Case Remove and Install
Rear Axle Remove and Install
– Transmission
Charge Pump Remove and Install
Creep Control Valve Remove and Install
Directional Control Valve Remove and Install
Hydrostatic Motor Disassemble and Assemble
Hydrostatic Motor Remove and Install
Hydrostatic Pump Disassemble and Assemble
Hydrostatic Pump Remove and Install
Hydrostatic Pump Valves Remove and Install
Hydrostatic Start-Up Procedure
– Engine
Engine Remove and Install
John Deere Engine
Starter Motor Remove and Install
– Engine Auxiliary Systems
Air Intake System Remove and Install
Cooling Package Remove and Install
Fan Remove and Install
Fuel Tank Remove and Install
Muffler Remove and Install
– Dampener Drive
Damper Plate Remove and Install
– Steering System
Cab Steering Column Remove and Install
Canopy Steering Column Remove and Install
Orbital Steering Valve Assemble
Orbital Steering Valve Disassemble and Inspect
Orbital Steering Valve Remove and Install
Steering Cylinder Disassemble and Assemble
Steering Cylinder Remove and Install
– Service Brakes
Brake _ Inching Valve Assembly Remove and Install
Drum Brake Bleed
Drum Brake Remove and Install
Service Brakes (Wet Disc) Remove and Install
– Park Brake
Park Brake Valve Remove and Install
– Frames, Chassis, or Supporting Structure
Counterweight Remove and Install
Loader and Rear Frames Separation
Lower Pivot Bushing Assembly Remove and Install
Rear Link and Bushing Assembly Remove and Install
Upper Pivot Bushing Assembly Remove and Install
Welding Repair of Major Structures
– Operator’s Station
Air Conditioner Compressor Remove and Install
Air Conditioner Freeze Control Switch Remove and Install
Air Conditioner High _ Low Pressure Switch Remove and Install
Air Conditioner _ Heater Module Remove and Install
Blower Motor Remove and Install
Cab Remove and Install
Canopy Remove and Install
Charge Ra System
Condenser Remove and Install
Evacuate Ra System
Evaporator Coil Remove and Install
Expansion Valve Remove and Install
Flush and Purge Air Conditioner System
Heater Control Valve Remove and Install
Heater Core Remove and Install
Ra Refrigerant Oil Information
Ra Refrigerant Recovery _ Recycling and Charging Station Installation Procedure
Rear Wiper Motor Remove and Install
Receiver-Dryer Remove and Install
Recover Ra Refrigerant
Refrigerant Cautions and Proper Handling
Seat Remove and Install
Windowpanes Remove and Install
Windshield Wiper Motor Remove and Install
– Sheet Metal and Styling
Hood Remove and Install
Rear Fenders Remove and Install
– Main Hydraulic System
General Hydraulic Oil Cleanup Procedure
Hydraulic Component Failure Cleanup Procedure
Hydraulic Oil Reservoir Remove and Install
Hydraulic Pump _ Priority Valve Disassemble and Assemble
Hydraulic Pump _ Priority Valve Remove and Install
Hydraulic Start-Up Procedure
– Loader
Bolt-On Cutting Edge Remove and Install
Boom and Bucket Cylinders Disassemble and Assemble
Boom and Bucket Linkage Remove and Install
Boom Cylinder Remove and Install
Bucket Cylinder Remove and Install
Bucket Linkage Bushings Remove and Install
Cracked Cutting Edge Repair
Loader Boom Bushings Remove and Install
Loader Control Valve Remove and Install
Quik-Tatch™ Actuator Remove and Install
Quik-Tatch™ Coupler Remove and Install
Welded-On Bucket Cutting Edge Remove and Install