Complete Operation & Test technical manual with Electrical Wiring Diagrams for John Deere 204K and 304K Loader, with all the shop information to maintain, diagnose, and rebuild like professional mechanics.

John Deere 204K and 304K Loaders workshop service 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.

TM12985 - John Deere 204K and 304K Loader Technical Manual (Operation & Test).pdf
tm12986 - John Deere Chargeurs compacts à transmission quatre roues motrices 204K et 304K.pdf

Total Pages: 625 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Category: Operation and Test
Language: English French
Category: Operation and Test
Language: English French
Published on 2020/02/02

Covered models:
  204K (PIN: 1LU204K***B030899-)
  304K (PIN: 1LU304K***B030847-)

MAIN SECTIONS
   Foreword
   Manual Identification—READ THIS FIRST!
   General Information
      Safety Information
   Diagnostic Trouble Codes (DTC)
      Engine Control Unit (ECU) Diagnostic Trouble Codes
      Monitor Display Diagnostic Trouble Codes
   Operational Checkout Procedure
      Operational Checkout Procedure
   Engine
      Theory of Operation
      Diagnostic Information
      Tests
   Electrical System
      System Information
      System Diagrams
      Sub-System Diagnostics
      References
   Power Train
      Theory Of Operation
      Diagnostic Information
      Adjustments
      Tests
   Hydraulic System
      Theory of Operation
      Diagnostic Information
      Test
   Heating and Air Conditioning
      Theory of Operation
      Diagnostic Information
      Tests

TABLE OF CONTENTS (Expanded View)
 9000 - GENERAL INFORMATION
    01 - 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
        Decommissioning — Proper Recycling and Disposal of Fluids and Components
        Drive Metal Pins Safely
        Follow Safety Instructions
        Handle Chemical Products Safely
        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
 9001 - DIAGNOSTIC TROUBLE CODES (DTC)
    10 - Engine Control Unit (ECU) Diagnostic Trouble Codes
       000091.03 — Primary Throttle Signal Out of Range High
       000091.04 — Primary Throttle Signal Out of Range Low
       001079.03 — Sensor Supply #1 Voltage Out of Range High
       001079.04 — Sensor Supply #1 Voltage Out of Range Low
       522241.03 — Fuel Injection Pump Rack Actuator Relay Out of Range High
       522241.04 — Fuel Injection Pump Rack Actuator Relay Out of Range Low
       522242.03 — Cold Start Aid Relay Driver Circuit Out of Range High
       522242.04 — Cold Start Aid Relay Driver Circuit Out of Range Low
       522243.03 — Air Heater Relay Driver Circuit Out of Range High
       522243.04 — Air Heater Relay Driver Circuit Out of Range Low
       Engine Control Unit (ECU) Diagnostic Trouble Codes
    20 - Monitor Display Diagnostic Trouble Codes
        Monitor Display Diagnostic Trouble Codes
 9005 - OPERATIONAL CHECKOUT PROCEDURE
    10 - Operational Checkout Procedure
        Operational Checkout
 9010 - ENGINE
    05 - Theory of Operation
       John Deere Engine
    15 - Diagnostic Information
       Engine Cooling System Component Location
       Engine Fuel System Component Location
       Engine Intake and Exhaust Component Location
       John Deere Engine
    25 - Tests
        Engine Idle Speeds Check
        John Deere Engine
 9015 - ELECTRICAL SYSTEM
    05 - System Information
       Electrical Diagram Information
       Electrical Schematic Symbols
    10 - System Diagrams
       Air Conditioner Harness (W10) Component Location
       Air Conditioner Harness (W10) Wiring Diagram
       Cab Harness (W8) Component Location
       Cab Harness (W8) Wiring Diagram
       Canopy Harness (W9) Component Location
       Canopy Harness (W9) Wiring Diagram
       Engine Harness (W6) Component Location
       Engine Harness (W6) Wiring Diagram
       Fuse and Relay Specifications
       Loader_Rear Frame Harness (W7) Component Location
       Loader_Rear Frame Harness (W7) Wiring Diagram
       Quik-Tatch™ Extension Harness (W13) Component Location
       Quik-Tatch™ Extension Harness (W13) Wiring Diagram
       Quik-Tatch™ Harness (W12) Component Location
       Quik-Tatch™ Harness (W12) Wiring Diagram
       Service ADVISOR™ Harness (W11) Component Location
       Service ADVISOR™ Harness (W11) Wiring Diagram
       System Functional Schematic and Section Legend
       System Functional Schematic, Component Location, and Wiring Diagram Master Legend
    15 - Sub-System Diagnostics
       Air Conditioner Circuit Theory of Operation
       Cold Start Aid Preheat Circuit Theory of Operation
       Controller Area Network (CAN) Theory of Operation
       Engine Control Unit (ECU) Circuits Theory of Operation
       Forward, Reverse, LO_HI Travel Speed, and Backup Alarm Circuits Theory of Operation
       Hazard and Turn Lights Circuits Theory of Operation
       Headlights, Marker Lights, and Horn Circuits Theory of Operation—Cab
       Headlights, Marker Lights, and Horn Circuits Theory of Operation—Canopy
       Hydraulic Enable and Third Function Detent Enable Circuits Theory of Operation
       Monitor Display Circuits Theory of Operation
       Park Brake Release Circuit Theory of Operation
       Power Circuit Theory of Operation
       Quik-Tatch™ Circuit Theory of Operation
       Start and Charge Circuits Theory of Operation
    20 - References
        Alternator Test
        CAN Circuit Test
        Connector Terminal Test
        Electrical Component Specifications
        Engine Control Unit (ECU) Remove and Install
        Engine Control Unit (ECU) Replacement Calibration
        Engine Speed Control Pedal Sensor Test
        Fuel Pump Replacement Calibration
        Install CINCH™ Contact
        Install DEUTSCH® Contact
        Install WEATHER PACK® Contact
        Intermittent Diagnostic Trouble Code (DTC) Diagnostics
        Monitor Display Remove and Install
        Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application
        Remove Connector Body from Blade Terminals
        Repair 32 and 48 Way CINCH™ Connectors
        Replace CINCH™ Connectors
        Replace DEUTSCH® Circular Connectors
        Replace DEUTSCH® Rectangular or Triangular Connectors
        Replace Metri-Pack® Connectors
        Replace Metri-Pack® (Push Type) Connectors
        Replace WEATHER PACK® Connector
        Return-to-Dig Adjustment
        Sensor Circuit Check
        Service ADVISOR™ Connection Procedure
        Service ADVISOR™ Diagnostic Application
        Wire Harness Test
        Yanmar Display Calibration Values Test
 9020 - POWER TRAIN
    05 - Theory of Operation
       Brake Valve Operation
       Creep Control Valve Operation
       Differential Limited Slip Operation
       High-Pressure Relief Valve Operation
       Hydrostatic Motor Operation—Forward (High Speed)
       Hydrostatic Motor Operation—Neutral
       Hydrostatic Motor Operation—Reverse (Low Speed)
       Hydrostatic Pump Control Operation—Forward (Engine Speed at Fast Idle)
       Hydrostatic Pump Control Operation—Reverse (Engine Speed at Less Than Fast Idle)
       Hydrostatic Pump Operation
       Hydrostatic Pump Swash Plate Operation
       Hydrostatic Transmission Operation—Forward (High Speed)
       Hydrostatic Transmission Operation—Forward (Low Speed)
       Hydrostatic Transmission Operation—Neutral
       Hydrostatic Transmission Operation—Reverse (Low Speed)
       Inching Valve Operation
       Park Brake Release Solenoid Valve Operation
       Power Train Description
       Service and Park Brake Operation
    15 - Diagnostic Information
       Axle Overheats
       Cannot Find or Hold Neutral
       Differential Low on Oil
       Excessive Differential and_or Axle Noise
       Excessive Driveline Vibration or Noise
       Foaming Oil
       Hydraulic Oil Overheats (Machine Shifts to Low Speed Automatically)
       Hydrostatic Transmission Schematic
       Lack of Power or Sluggish
       Machine Does Not Move at Low Idle
       Machine Does Not Move
       Machine Drives Erratically
       Machine Moves in One Direction Only
       Machine Moves in Wrong Direction
       Machine Vibrates
       Oil Seeping From Outer Axle Seal
       Park Brake Indicator in Monitor Does Not Come ON When Park Brake Applied
       Park Brake Overheats
       Park Brake Will Not Apply
       Park Brake Will Not Hold
       Park Brake Will Not Release
       Poor or No Service Brakes
       Power Train Component Location
       Service and Park Brake System Component Location
       Service Brake and Park Brake System Schematic
       Service Brakes Aggressive
       Service Brakes Chatter
       Service Brakes Dragging
       Slow Acceleration—Fast Deceleration
    20 - Adjustments
       Brake_Inching Pedal Linkage Adjustment
       Drum Brake Inspection
       Hydrostatic Motor Minimum Displacement Adjustment
       Hydrostatic Pump Servo Piston Neutral Adjustment
       Service Brakes (Wet Disc) Inspection
    25 - Tests
        Before Performing Hydrostatic Transmission Tests
        Directional Control Valve Spool Leakage Test
        High-Pressure Relief Valve Test and Adjustment
        Hydrostatic Adjusting Screws (With Tamper-Proof Caps)
        Hydrostatic Motor Begin Regulation of Displacement Control Valve Test and Adjustment
        Hydrostatic Pump Begin Regulation Test and Adjustment
        Hydrostatic Pump Isolation Procedure
        Hydrostatic Pump Performance (Timing) Test and Adjustment
        Hydrostatic Pump Pressure Override (POR) Valve Pressure Test and Adjustment
        Neutral Charge Relief Valve Pressure Test and Adjustment
        Park Brake Release Pressure Test
 9025 - HYDRAULIC SYSTEM
    05 - Theory of Operation
       Hydraulic Enable Solenoid Operation
       Hydraulic Pump Operation
       Hydraulic System Operation
       Loader Control Valve Circuit Relief Valve With Anticavitation Operation
       Loader Control Valve Operation—Auxiliary Section
       Loader Control Valve Operation—Boom Section
       Loader Control Valve Operation—Bucket Section
       Loader Control Valve Operation
       Loader System Relief Valve Operation
       Orbital Steering Circuit Operation
       Orbital Steering Valve Operation
       Priority Valve Operation
       Steering Cylinder Relief Valve Operation
    15 - Diagnostic Information
       Abrupt Steering Wheel Oscillation
       Boom Down Does Not Work (Engine Off)
       Boom Float Function Does Not Work
       Constant Steering to Maintain Straight Travel
       Erratic Steering
       Free Play at Steering Wheel
       Function Drifts Down
       Function Drops Before Rising When Valve Is Activated
       Hydraulic Oil Foams
       Hydraulic System Schematic
       Loader Hydraulic System Component Location
       Low Hydraulic Power
       Machine Turns in Opposite Direction
       Machine Turns When Orbital Steering Valve Is in Neutral
       No Hydraulic Functions
       Noisy Hydraulic Pumps
       No Steering Function During Slow Steering Wheel Movement
       No Steering Functions
       Oil Overheats
       One Hydraulic Function Does Not Work
       Orbital Steering System Component Location
       Orbital Steering System Schematic
       Orbital Steering Valve Locks Up
       Slow Hydraulic Functions
       Spongy or Soft Steering
       Steering Wheel Does Not Immediately Return to Neutral When Released
       Steering Wheel Turns by Itself
       Steering Wheel Turns With No Resistance and Causes No Frame Movement
    25 - Tests
        Boom and Bucket Cylinder Leakage Test
        Hydraulic Oil Warm-Up Procedure
        Hydraulic Pump Flow Test
        Hydraulic System Pressure Discharge Procedure
        JT02156A Digital Pressure and Temperature Analyzer Kit Installation
        Loader Circuit Relief Valve Pressure Test
        Loader Cylinder Drift Test
        Loader System Relief Valve Pressure Test
        Orbital Steering System Relief Valve Pressure Test
        Steering Cylinder Leakage Test
 9031 - HEATING AND AIR CONDITIONING
    05 - Theory of Operation
       Air Conditioning System Cycle of Operation
    15 - Diagnostic Information
       Air Conditioner and Heater Component Location
       Air Conditioner Does Not Cool Interior of Cab
       Air Conditioner Runs Constantly, Too Cold
       Air Conditioning System Does Not Operate
       Heater Does Not Warm Interior of Cab
       Heater System Does Not Operate
       Interior Windows Continue to Fog
    25 - Tests
        Air Conditioner Compressor Clutch Test
        Air Conditioner High_Low Pressure Switch Test
        Operating Pressure Diagnostic Chart
        R134a Refrigerant Cautions
        Refrigerant Cautions and Proper Handling
        Refrigerant Leak Test
        
John Deere 204K and 304K Loader Service Manual (Operation & Test) - TM12985