John Deere 744J and 824J Loader Repair Technical Manual TM2084 PDF

Description

John Deere 744J and 824J Loader Repair Technical Manual TM2084 –  PDF DOWNLOAD

FILE DETAILS:

John Deere 744J and 824J Loader Repair Technical Manual TM2084 –  PDF DOWNLOAD

Language : English
Pages : 648
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

John Deere 744J and 824J Loader Repair Technical Manual TM2084 –  PDF DOWNLOAD

Contents 5
General Information 9
Safety Information 11
Recognize Safety Information 11
Follow Safety Instructions 11
Operate Only If Qualified 12
Wear Protective Equipment 12
Avoid Unauthorized Machine Modifications 12
Add Cab Guarding For Special Uses 13
Inspect Machine 13
Stay Clear of Moving Parts 13
Avoid High-Pressure Oils 14
Beware of Exhaust Fumes 14
Prevent Fires 15
Prevent Battery Explosions 15
Handle Chemical Products Safely 16
Dispose of Waste Properly 16
Prepare for Emergencies 16
Use Steps and Handholds Correctly 17
Start Only From Operator’s Seat 17
Use and Maintain Seat Belt 17
Prevent Unintended Machine Movement 18
Avoid Work Site Hazards 18
Use Special Care When Operating Loader 19
Keep Riders Off Machine 19
Avoid Backover Accidents 20
Avoid Machine Tip Over 20
Operating on Slopes 21
Operating or Traveling On Public Roads 21
Inspect and Maintain ROPS 22
Add And Operate Attachments Safely 22
Park And Prepare For Service Safely 23
Service Cooling System Safely 23
Remove Paint Before Welding or Heating 24
Make Welding Repairs Safely 24
Drive Metal Pins Safely 25
Wheels 27
Powered Wheels and Fasteners 29
Wheel Remove and Install 29
Tire Remove and Install 30
Axles and Suspension Systems 33
Removal and Installation 35
TEAMMATE™ Axles 35
Front Axle and Differential Remove and Install 36
Rear Axle and Differential Remove and Install 40
Input Drive Shafts And U-Joints 45
Drive Shaft Repair 45
Axle Shaft, Bearings, And Reduction Gears 47
TEAMMATE™ Axles 47
Hydraulic System 49
Differential Lock Solenoid Valve Remove and Install 49
Pin Disconnect and Axle Disconnect Valve Remove and Install 50
Pin Disconnect and Axle Disconnect Valve Disassemble and Assemble 51
Transmission 53
Transmission, Remove and Install 55
Transmission Remove and Install 55
Gears, Shafts, Bearings and Power Shift Clutch Packs 61
Torque Converter Remove and Install—744J (SN —586280) 61
Torque Converter Housing Disassemble and Assemble—744J (SN —586280) 64
Torque Converter Remove and Install—744J (SN 586280—) and 824J 78
Torque Converter Housing Disassemble and Assemble—744J (SN 586280—) and 824J 81
Transmission Power Take-Off Remove and Install 96
Transmission Power Take-Off Disassemble and Assemble103
Final Drive Disassemble and Assemble—744J (SN —586280)107
Final Drive Disassemble and Assemble—744J (SN 586280— ) and 824J134
Clutch Packs Remove and Install—744J (SN —586280)161
Clutch Packs Remove and Install—744J (SN 586280— ) and 824J168
High Range Forward Clutch (K4) and Third Speed Clutch (K3) Disassemble and Assemble—744J (SN —586280)171
High Range Forward Clutch (K4) and Third Speed Clutch (K3) Disassemble and Assemble—744J (SN 586280—) and 824J197
Reverse Clutch (KR) and Second Speed Clutch (K2) Disassemble and Assemble 744J (SN —586280)216
Reverse Clutch (KR) and Second Speed Clutch (K2) Disassemble and Assemble 744J (SN 586280—) and 824J240
Low Range Forward Clutch (KV) and First Speed Clutch (K1) Disassemble and Assemble 744J (SN —586280)259
Low Range Forward Clutch (KV) and First Speed Clutch (K1) Disassemble and Assemble 744J (SN 586280—) and 824J285
Adjust Transmission Speed Sensor306
Hydraulic System309
Transmission Oil Pump Remove and Install309
Transmission Oil Pump Disassemble and Assemble311
Transmission Control Valve Remove and Install—744J (SN —586280)317
Transmission Control Valve Remove and Install—744J (SN 586280—) and 824J323
Transmission Control Valve Disassemble and Assemble330
Transmission Filter Install343
Engine345
Removal and Installation347
POWERTECH® 125 L (6125) John Deere Engines347
Engine Remove and Install347
Oil Pan Remove and Install355
Engine Auxiliary Systems357
Cold Weather Starting Aids359
Start Aid Nozzle Remove and Install359
Cooling Systems361
Serpentine Belts Remove and Install361
Check and Adjust Air Conditioning Compressor Belt Tension—If Equipped362
Belt Tensioner Spring Check363
Fan and Fan Drive Remove and Install364
Radiator Remove and Install366
Oil Cooler Remove and Install368
Speed Controls371
Speed Control Linkage Remove and Install (SN —590067)371
Intake System373
Remove and Install Charge Air Cooler373
External Exhaust System377
Muffler Remove and Install377
External Fuel Supply Systems379
Remove and Install Fuel Tank379
Flex Plate Drive383
Elements385
Flex Plate Remove and Install385
Steering System387
Hydraulic System389
Steering Valve Remove and Install389
Steering Column Remove and Install392
Steering Cylinders Remove and Install (SN —612699)393
Steering Cylinder Bushings Remove and Install (SN —612699)395
Steering Cylinders Remove and Install (SN 612700— )395
Steering Cylinder Bushings Remove and Install (SN 612700— )397
Priority Valve Remove and Install397
Priority Valve Disassemble and Assemble398
Service Brakes399
Active Elements401
TEAMMATE™ Axles401
Inspect Service Brake Pads401
Brake Assembly Remove and Install403
Brake Linkage Adjustment406
Hydraulic System407
Brake Valve Remove and Install407
Brake Accumulator Remove and Install410
Park Brake413
Active Elements415
Park Brake Remove and Install415
Park Brake Disassemble and Assemble418
Hydraulic System427
Park Brake Release Solenoid Valve Remove and Install427
Park Brake Pressure Switch Remove and Install429
Frame or Supporting Structure431
Frame Installation433
Welding Repair of Major Structure433
Separate Engine and Loader Frame434
Upper Pivot Bearing and Seals Remove and Install438
Lower Pivot Bearing and Seals Remove and Install440
Frame Bottom Guards443
Fuel Tank Guard Remove and Install443
Front Axle Guard Remove and Install444
Transmission Bottom Guard Remove and Install444
Transmission Side Guards Remove and Install445
Chassis Weights447
Counterweights Remove and Install447
Operator’s Station449
Removal and Installation451
Cab Remove and Install451
Operator Enclosure457
Windowpanes Remove and Install457
Windshield Washer Remove and Install458
Front and Rear Windshield Wiper Motor Remove and Install459
Front Windshield Wiper Adjustment461
Wrist Support Remove and Install (SN —590067)462
Wrist Support Remove and Install (SN 590068—)464
Seat and Seat Belts467
Seat Belt Disassemble and Assemble467
Seat Disassemble and Assemble468
Heating and Air Conditioning469
Air Conditioning System Fittings Reference Chart469
R134a Refrigerant Cautions471
R134a Compressor Oil Charge Check471
R134a Compressor Oil Removal472
R134a Component Oil Charge473
Leak Testing474
Refrigerant Hoses and Tubing Inspection474
R134a Refrigerant, Recovery, Recycling and Charging Station Installation Procedure475
Recover R134a System476
Evacuate R134a System477
Charge R134a System479
Air Conditioner System Cleaning Procedures480
Air Conditioner System Purge481
Air Conditioner System Flush482
Air Conditioning Module With Heater/Evaporator Core484
Heater/Evaporator Core Remove and Install486
Expansion Valve Remove and Install488
Freeze Control Switch Remove and Install488
Freeze Control Switch Bench Test489
Heater Control Valve Remove and Install490
Heater Control Valve Leak Check491
Main Blower Assembly Remove and Install492
Pressurizer Motor Assembly Remove and Install493
Receiver-Dryer and Condenser Remove and Install493
High and Low Pressure Switches Remove and Install496
Recirculating Air Filter Remove and Install497
Fresh Air Filter Remove and Install497
Compressor Remove and Install500
Compressor Inspect501
Belt Tensioner Spring Check502
Sheet Metal and Styling503
Hood or Engine Enclosure506
Hood Remove and Install506
Engine Side Shields Remove and Install508
Grille and Grille Housing511
Grill Housing Remove and Install511
Loader521
Bucket523
Bucket Remove and Install523
Welded Bucket Cutting Edges Remove and Install526
Wear Plate Bucket Cutting Edges Remove and Install527
Cracked Cutting Edge Repair528
Frames529
NeverGrease™ Pin Joints529
Bucket Tilt Linkage Remove and Install532
Bucket Linkage Seals and Bushings Remove and Install536
Boom Remove and Install540
Boom Bushings, Seals and Shims Remove and Install543
Hydraulic System547
Hydraulic Oil Clean-Up Procedure Using Portable Filter Caddy547
Loader Hydraulic Pump Remove and Install548
Loader Hydraulic Pump Disassemble and Assemble552
Hydraulic Pump Control Valve Remove and Install574
Hydraulic Pump Control Valve Disassemble and Assemble576
Loader Control Valve Remove and Install577
Loader Control Valve Disassemble and Assemble579
Auxiliary Valve Section and Bucket Valve Section Disassemble and Assemble580
Boom Valve Section Disassemble and Assemble581
System Relief Valve Disassemble and Assemble582
Boom Circuit Relief Valve Disassemble and Assemble582
Service Bucket and Boom Section Pilot Orifice Check Valve583
Boom Cylinder—185 Series Remove and Install584
Bucket Cylinder—185 Series Remove and Install587
Boom or Bucket Cylinder Bushings and Seals Remove and Install589
Loader Start-Up Procedure590
Hydraulic Oil Reservoir Remove and Install591
Pilot Controller Remove and Install—Single Lever Controller (SN —590067)593
Pilot Controller Disassemble and Assemble—Single Lever Controller (SN —590067)595
Pilot Controller Remove and Install—Two Lever Controller (SN —590067)612
Pilot Controller Disassemble and Assemble—Two Lever Controller (SN —590067)613
Pilot Control Valve Remove and Install (SN 590068— )615
Pilot Control Valve Disassemble and Assemble (SN 590068— )616
Pressure Reducing Valve (PRV) Remove and Install (SN —590067)621
Boom Down Solenoid Valve Remove and Install (SN —590067)623
Boom Down Accumulator Remove and Install (SN 590068— )626
Pressure Reducing Valve Manifold Remove and Install (SN 590068— )627
Pressure Reducing Valve Manifold Disassemble and Assemble (SN 590068— )629
Ride Control Remove and Install631
Ride Control Valve Disassemble and Assemble634
Dealer Fabricated Tools637
Dealer Fabricated Tools639
DFT1091 Cylinder Stand Shim639
DF1044 Air Deflector Bushing640

DESCRIPTION:

John Deere 744J and 824J Loader Repair Technical Manual TM2084 –  PDF DOWNLOAD

• Foreword:
• This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use.
• Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.
• This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury.
• Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components. Operation and tests sections help you identify the majority of routine failures quickly.
• Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values.
• Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair.
• Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.

G.B 06/01/25