624h loader and tc62h tool carrier repair

624H Loader and TC62HTool Carrier Repair

TECHNICAL MANUAL624H Loader TC62H Tool Carrier

Repair

TM1640 15JAN04 (ENGLISH)

For complete service information also see:

624H Loader and TC62H Operation andTest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM16394.5 L & 6.8 L 4045 and 6068 DieselEngines Repair . . . . . . . . . . . . . . . . . . . . . . . CTM104Alternators and Starting Motors . . . . . . . . . . CTM77TeamMate III Axles . . . . . . . . . . . . . . . . . . . CTM150

Worldwide ConstructionAnd Forestry Division

LITHO IN U.S.A.

Introduction

DX,TMIFC –19–29SEP98–1/1

Foreword

This manual is written for an experienced technician.Essential tools required in performing certain servicework are identified in this manual and arerecommended for use.

Live with safety: Read the safety messages in theintroduction of this manual and the cautions presentedthroughout the text of the manual.

This is the safety-alert symbol. When you see thissymbol on the machine or in this manual, be alert tothe potential for personal injury.

Technical manuals are divided in two parts: repair andoperation and tests. Repair sections tell how to repairthe components. Operation and tests sections help youidentify the majority of routine failures quickly.

Information is organized in groups for the variouscomponents requiring service instruction. At thebeginning of each group are summary listings of allapplicable 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 specificmachines. They are on-the-job guides containing onlythe vital information needed for diagnosis, analysis,testing, and repair.

Fundamental service information is available fromother sources covering basic theory of operation,fundamentals of troubleshooting, general maintenance,and basic type of failures and their causes.

TM1640 (15JAN04) 624H Loader and TC62H Tool Carrier011504

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Introduction

TX,TM,FAX –19–03JUL01–1/1

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Introduction


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Contents00

SECTION 00—General Information SECTION 11—Park BrakeGroup 1111—Active ElementsGroup 0001—Safety Information

Group 0002—General Specifications Group 1160—Hydraulic SystemGroup 0003—Torque Values

SECTION 16—Electrical SystemGroup 0004—Fuels and Lubricants01Group 1671—Batteries, Support and Cables

Group 1672—Alternator, Regulator and ChargingSECTION 01—WheelsSystem WiringGroup 0110—Powered Wheels and Fasteners

Group 1673—Lighting SystemGroup 1674—Wiring Harness and Switches

SECTION 02—Axles and Suspension Systems Group 1675—System ControlsGroup 0200—Removal and Installation Group 1677—Motors and ActuatorsGroup 0225—Axle Shafts and U-JointsGroup 0250—Axle Shaft, Bearings, Reduction SECTION 17—Frame or Supporting Structure

Gears Group 1740—Frame InstallationGroup 0260—Hydraulic System Group 1746—Frame Bottom Guards

02

Group 1749—Chassis WeightsSECTION 03—Transmission

Group 0300—Removal and Installation SECTION 18—Operator’s StationGroup 1800—Removal and InstallationGroup 0350—Gears, Shafts, Bearings and PowerGroup 1810—Operator EnclosureShift ClutchGroup 1821—Seat and Seat BeltsGroup 0360—Hydraulic SystemGroup 1822—Steps and HandholdsGroup 0399—Dealer Fabricated ToolsGroup 1830—Heating and Air ConditioningGroup 1899—Dealer Fabricated ToolsSECTION 04—Engine

Group 0400—Removal and InstallationSECTION 19—Sheet Metal and Styling

03

Group 1910—Hood or Engine EnclosureSECTION 05—Engine Auxiliary Systems Group 1913—Miscellaneous Shields

Group 0505—Cold Weather Starting Aids Group 1921—Grille and Grille HousingGroup 0510—Cooling System Group 1927—Miscellaneous ShieldsGroup 0515—Speed ControlsGroup 0520—Intake System SECTION 20—Safety and ConvenienceGroup 0530—External Exhaust System Group 2002—MirrorGroup 0560—External Fuel Supply Systems Group 2003—Fire Extinguisher

Group 2004—Horn and Warning DevicesSECTION 07—Dampener Drive

SECTION 31—LoaderGroup 0752—Elements

04

Group 3102—BucketGroup 3140—FramesSECTION 09—Steering SystemGroup 3160—Hydraulic SystemGroup 0960—Hydraulic System

SECTION 10—Service BrakesGroup 1011—Active ElementsGroup 1060—Hydraulic System

All information, illustrations and specifications in this manual are based onthe latest information available at the time of publication. The right isreserved to make changes at any time without notice.

05

COPYRIGHT 2004DEERE & COMPANY

Moline, IllinoisAll rights reserved

A John Deere ILLUSTRUCTION ManualPrevious Editions

Copyright 1998, 1999, 2000, 2001, 2003

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TM1640 (15JAN04) i 624H Loader and TC62H Tool Carrier011504

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TM1640 (15JAN04) ii 624H Loader and TC62H Tool Carrier011504

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Section 00General Information

Contents

PagePage

Group 0001—Safety Information Service Recommendations For Flat FaceO-Ring Seal Fittings. . . . . . . . . . . . . . . . . .00-0003-9Handle Fluids Safely—Avoid Fires . . . . . . . .00-0001-1

Service Recommendations for MetricPrevent Battery Explosions . . . . . . . . . . . . . .00-0001-1Series Four Bolt Flange Fitting . . . . . . . .00-0003-10Prepare for Emergencies. . . . . . . . . . . . . . . .00-0001-1

Service Recommendations For InchPrevent Acid Burns . . . . . . . . . . . . . . . . . . . .00-0001-2Series Four Bolt Flange Fittings. . . . . . . .00-0003-11Handle Chemical Products Safely . . . . . . . . .00-0001-3

Avoid High-Pressure Fluids . . . . . . . . . . . . . .00-0001-3Group 0004—Fuels and LubricantsPark Machine Safely . . . . . . . . . . . . . . . . . . .00-0001-4Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-1Support Machine Properly . . . . . . . . . . . . . . .00-0001-4Lubricity of Diesel Fuel . . . . . . . . . . . . . . . . .00-0004-1Wear Protective Clothing. . . . . . . . . . . . . . . .00-0001-4Low Sulfur Diesel Fuel Conditioner . . . . . . . .00-0004-2Work in Clean Area. . . . . . . . . . . . . . . . . . . .00-0001-5Diesel Fuel Storage. . . . . . . . . . . . . . . . . . . .00-0004-2Service Machines Safely . . . . . . . . . . . . . . . .00-0001-5Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-3Work In Ventilated Area . . . . . . . . . . . . . . . .00-0001-5Diesel Engine Oil . . . . . . . . . . . . . . . . . . . . .00-0004-3Illuminate Work Area Safely . . . . . . . . . . . . .00-0001-5Transmission, Hydraulic System, ParkReplace Safety Signs . . . . . . . . . . . . . . . . . .00-0001-6

Brake, and Differential Oil . . . . . . . . . . . . .00-0004-4Use Proper Lifting Equipment . . . . . . . . . . . .00-0001-6Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-5Remove Paint Before Welding or Heating . . .00-0001-7Alternative and Synthetic Lubricants . . . . . . .00-0004-6Avoid Heating Near Pressurized FluidLubricant Storage . . . . . . . . . . . . . . . . . . . . .00-0004-6Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-7Mixing of Lubricants . . . . . . . . . . . . . . . . . . .00-0004-7Keep ROPS Installed Properly . . . . . . . . . . .00-0001-8

Service Tires Safely . . . . . . . . . . . . . . . . . . .00-0001-8Avoid Harmful Asbestos Dust . . . . . . . . . . . .00-0001-9Practice Safe Maintenance . . . . . . . . . . . . .00-0001-10Use Proper Tools . . . . . . . . . . . . . . . . . . . .00-0001-10Dispose of Waste Properly . . . . . . . . . . . . .00-0001-11Live With Safety . . . . . . . . . . . . . . . . . . . . .00-0001-11

Group 0002—General Specifications624H Specifications. . . . . . . . . . . . . . . . . . . .00-0002-1Drain and Refill Capacities—624H/TC62H . .00-0002-4TC62H Specifications . . . . . . . . . . . . . . . . . .00-0002-5Drain and Refill Capacities—TC62H . . . . . . .00-0002-8

Group 0003—Torque ValuesHardware Torque Specifications . . . . . . . . . .00-0003-1ROPS Torque Specifications . . . . . . . . . . . . .00-0003-1Metric Bolt and Cap Screw Torque

Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-2Additional Metric Cap Screw Torque

Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-3Unified Inch Bolt and Cap Screw Torque

Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-5Check Oil Lines And Fittings . . . . . . . . . . . . .00-0003-6Service Recommendations for O-Ring

Boss Fittings . . . . . . . . . . . . . . . . . . . . . . .00-0003-7

TM1640 (15JAN04) 00-1 624H Loader and TC62H Tool Carrier011504

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Contents

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TM1640 (15JAN04) 00-2 624H Loader and TC62H Tool Carrier011504

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Group 0001Safety Information

0000011

DX,FLAME –19–29SEP98–1/1

Handle Fluids Safely—Avoid Fires

TS

227

–UN

–23A

UG

88

When you work around fuel, do not smoke or work nearheaters or other fire hazards.

Store flammable fluids away from fire hazards. Do notincinerate or puncture pressurized containers.

Make sure machine is clean of trash, grease, and debris.

Do not store oily rags; they can ignite and burnspontaneously.

DX,SPARKS –19–03MAR93–1/1

Prevent Battery Explosions

TS

204

–UN

–23A

UG

88

Keep sparks, lighted matches, and open flame away fromthe top of battery. Battery gas can explode.

Never check battery charge by placing a metal objectacross the posts. Use a volt-meter or hydrometer.

Do not charge a frozen battery; it may explode. Warmbattery to 16°C (60°F).

DX,FIRE2 –19–03MAR93–1/1

Prepare for Emergencies

TS

291

–UN

–23A

UG

88

Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service,hospital, and fire department near your telephone.

TM1640 (15JAN04) 00-0001-1 624H Loader and TC62H Tool Carrier011504

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Safety Information

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DX,POISON –19–21APR93–1/1

Prevent Acid Burns

TS

203

–UN

–23A

UG

88

Sulfuric acid in battery electrolyte is poisonous. It is strongenough to burn skin, eat holes in clothing, and causeblindness if splashed into eyes.

Avoid the hazard by:

1. Filling batteries in a well-ventilated area.2. Wearing eye protection and rubber gloves.3. Avoiding breathing fumes when electrolyte is added.4. Avoiding spilling or dripping electrolyte.5. Use proper jump start procedure.

If you spill acid on yourself:

1. Flush your skin with water.2. Apply baking soda or lime to help neutralize the acid.3. Flush your eyes with water for 15—30 minutes. Get

medical attention immediately.

If acid is swallowed:

1. Do not induce vomiting.2. Drink large amounts of water or milk, but do not

exceed 2 L (2 quarts).3. Get medical attention immediately.


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Safety Information

0000013

DX,MSDS,NA –19–03MAR93–1/1

Handle Chemical Products Safely

TS

1132

–UN

–26N

OV

90

Direct exposure to hazardous chemicals can causeserious injury. Potentially hazardous chemicals used withJohn Deere equipment include such items as lubricants,coolants, paints, and adhesives.

A Material Safety Data Sheet (MSDS) provides specificdetails on chemical products: physical and health hazards,safety procedures, and emergency response techniques.

Check the MSDS before you start any job using ahazardous chemical. That way you will know exactly whatthe risks are and how to do the job safely. Then followprocedures and recommended equipment.

(See your John Deere dealer for MSDS’s on chemicalproducts used with John Deere equipment.)

DX,FLUID –19–03MAR93–1/1

Avoid High-Pressure Fluids

X98

11–U

N–2

3AU

G88

Escaping fluid under pressure can penetrate the skincausing serious injury.

Avoid the hazard by relieving pressure beforedisconnecting hydraulic or other lines. Tighten allconnections before applying pressure.

Search for leaks with a piece of cardboard. Protect handsand body from high pressure fluids.

If an accident occurs, see a doctor immediately. Any fluidinjected into the skin must be surgically removed within afew hours or gangrene may result. Doctors unfamiliar withthis type of injury should reference a knowledgeablemedical source. Such information is available from Deere& Company Medical Department in Moline, Illinois, U.S.A.


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Safety Information

000001

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DX,PARK –19–04JUN90–1/1

Park Machine Safely

TS

230

–UN

–24M

AY

89

Before working on the machine:

• Lower all equipment to the ground.• Stop the engine and remove the key.• Disconnect the battery ground strap.• Hang a "DO NOT OPERATE" tag in operator station.

DX,LOWER –19–24FEB00–1/1

Support Machine Properly

TS

229

–UN

–23A

UG

88

Always lower the attachment or implement to the groundbefore you work on the machine. If the work requires thatthe machine or attachment be lifted, provide securesupport for them. If left in a raised position, hydraulicallysupported devices can settle or leak down.

Do not support the machine on cinder blocks, hollow tiles,or props that may crumble under continuous load. Do notwork under a machine that is supported solely by a jack.Follow recommended procedures in this manual.

When implements or attachments are used with amachine, always follow safety precautions listed in theimplement or attachment operator’s manual.

DX,WEAR2 –19–03MAR93–1/1

Wear Protective Clothing

TS

206

–UN

–23A

UG

88Wear close fitting clothing and safety equipmentappropriate to the job.

Operating equipment safely requires the full attention ofthe operator. Do not wear radio or music headphoneswhile operating machine.


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Safety Information

0000015

DX,CLEAN –19–04JUN90–1/1

Work in Clean Area

T66

42E

J–U

N–1

8OC

T88

Before starting a job:

• Clean work area and machine.• Make sure you have all necessary tools to do your job.• Have the right parts on hand.• Read all instructions thoroughly; do not attempt

shortcuts.

DX,LOOSE –19–04JUN90–1/1

Service Machines Safely

TS

228

–UN

–23A

UG

88

Tie long hair behind your head. Do not wear a necktie,scarf, loose clothing, or necklace when you work nearmachine tools or moving parts. If these items were to getcaught, severe injury could result.

Remove rings and other jewelry to prevent electricalshorts and entanglement in moving parts.

DX,AIR –19–17FEB99–1/1

Work In Ventilated Area

TS

220

–UN

–23A

UG

88

Engine exhaust fumes can cause sickness or death. If it isnecessary to run an engine in an enclosed area, removethe exhaust fumes from the area with an exhaust pipeextension.

If you do not have an exhaust pipe extension, open thedoors and get outside air into the area

DX,LIGHT –19–04JUN90–1/1

Illuminate Work Area Safely

TS

223

–UN

–23A

UG

88

Illuminate your work area adequately but safely. Use aportable safety light for working inside or under themachine. Make sure the bulb is enclosed by a wire cage.The hot filament of an accidentally broken bulb can ignitespilled fuel or oil.


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Safety Information

000001

6

DX,SIGNS1 –19–04JUN90–1/1

Replace Safety Signs

TS

201

–UN

–23A

UG

88

Replace missing or damaged safety signs. See themachine operator’s manual for correct safety signplacement.

DX,LIFT –19–04JUN90–1/1

Use Proper Lifting Equipment

TS

226

–UN

–23A

UG

88

Lifting heavy components incorrectly can cause severeinjury or machine damage.

Follow recommended procedure for removal andinstallation of components in the manual.


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Safety Information

0000017

DX,PAINT –19–24JUL02–1/1

Remove Paint Before Welding or Heating

TS

220

–UN

–23A

UG

88

Avoid potentially toxic fumes and dust.

Hazardous fumes can be generated when paint is heatedby welding, soldering, or using a torch.

Remove paint before heating:

• Remove paint a minimum of 100 mm (4 in.) from areato be affected by heating. If paint cannot be removed,wear an approved respirator before heating or welding.

• If you sand or grind paint, avoid breathing the dust.Wear an approved respirator.

• If you use solvent or paint stripper, remove stripper withsoap and water before welding. Remove solvent orpaint stripper containers and other flammable materialfrom area. Allow fumes to disperse at least 15 minutesbefore welding or heating.

Do not use a chlorinated solvent in areas where weldingwill take place.

Do all work in an area that is well ventilated to carry toxicfumes and dust away.

Dispose of paint and solvent properly.

DX,TORCH –19–03MAR93–1/1

Avoid Heating Near Pressurized Fluid Lines

TS

953

–UN

–15M

AY

90

Flammable spray can be generated by heating nearpressurized fluid lines, resulting in severe burns toyourself and bystanders. Do not heat by welding,soldering, or using a torch near pressurized fluid lines orother flammable materials. Pressurized lines can beaccidentally cut when heat goes beyond the immediateflame area.


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Safety Information

000001

8

DX,ROPS3 –19–03MAR93–1/1

Keep ROPS Installed Properly

TS

212

–UN

–23A

UG

88

Make certain all parts are reinstalled correctly if theroll-over protective structure (ROPS) is loosened orremoved for any reason. Tighten mounting bolts to propertorque.

The protection offered by ROPS will be impaired if ROPSis subjected to structural damage, is involved in anoverturn incident, or is in any way altered by welding,bending, drilling, or cutting. A damaged ROPS should bereplaced, not reused.

DX,RIM –19–24AUG90–1/1

Service Tires Safely

TS

211

–UN

–23A

UG

88

Explosive separation of a tire and rim parts can causeserious injury or death.

Do not attempt to mount a tire unless you have the properequipment and experience to perform the job.

Always maintain the correct tire pressure. Do not inflatethe tires above the recommended pressure. Never weld orheat a wheel and tire assembly. The heat can cause anincrease in air pressure resulting in a tire explosion.Welding can structurally weaken or deform the wheel.

When inflating tires, use a clip-on chuck and extensionhose long enough to allow you to stand to one side andNOT in front of or over the tire assembly. Use a safetycage if available.

Check wheels for low pressure, cuts, bubbles, damagedrims or missing lug bolts and nuts.


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Safety Information

0000019

DX,DUST –19–15MAR91–1/1

Avoid Harmful Asbestos Dust

TS

220

–UN

–23A

UG

88

Avoid breathing dust that may be generated whenhandling components containing asbestos fibers. Inhaledasbestos fibers may cause lung cancer.

Components in products that may contain asbestos fibersare brake pads, brake band and lining assemblies, clutchplates, and some gaskets. The asbestos used in thesecomponents is usually found in a resin or sealed in someway. Normal handling is not hazardous as long asairborne dust containing asbestos is not generated.

Avoid creating dust. Never use compressed air forcleaning. Avoid brushing or grinding material containingasbestos. When servicing, wear an approved respirator. Aspecial vacuum cleaner is recommended to cleanasbestos. If not available, apply a mist of oil or water onthe material containing asbestos.

Keep bystanders away from the area.


PN=17

Safety Information

000001

10

DX,SERV –19–17FEB99–1/1

Practice Safe Maintenance

TS

218

–UN

–23A

UG

88

Understand service procedure before doing work. Keeparea clean and dry.

Never lubricate, service, or adjust machine while it ismoving. Keep hands, feet , and clothing frompower-driven parts. Disengage all power and operatecontrols to relieve pressure. Lower equipment to theground. Stop the engine. Remove the key. Allow machineto cool.

Securely support any machine elements that must beraised for service work.

Keep all parts in good condition and properly installed. Fixdamage immediately. Replace worn or broken parts.Remove any buildup of grease, oil, or debris.

On self-propelled equipment, disconnect battery groundcable (-) before making adjustments on electrical systemsor welding on machine.

On towed implements, disconnect wiring harnesses fromtractor before servicing electrical system components orwelding on machine.

DX,REPAIR –19–17FEB99–1/1

Use Proper Tools

TS

779

–UN

–08N

OV

89Use tools appropriate to the work. Makeshift tools andprocedures can create safety hazards.

Use power tools only to loosen threaded parts andfasteners.

For loosening and tightening hardware, use the correctsize tools. DO NOT use U.S. measurement tools onmetric fasteners. Avoid bodily injury caused by slippingwrenches.

Use only service parts meeting John Deere specifications.


PN=18

Safety Information

00000111

DX,DRAIN –19–03MAR93–1/1

Dispose of Waste Properly

TS

1133

–UN

–26N

OV

90

Improperly disposing of waste can threaten theenvironment and ecology. Potentially harmful waste usedwith John Deere equipment include such items as oil, fuel,coolant, brake fluid, filters, and batteries.

Use leakproof containers when draining fluids. Do not usefood or beverage containers that may mislead someoneinto drinking from them.

Do not pour waste onto the ground, down a drain, or intoany water source.

Air conditioning refrigerants escaping into the air candamage the Earth’s atmosphere. Government regulationsmay require a certified air conditioning service center torecover and recycle used air conditioning refrigerants.

Inquire on the proper way to recycle or dispose of wastefrom your local environmental or recycling center, or fromyour John Deere dealer.

DX,LIVE –19–25SEP92–1/1

Live With Safety

TS

231

–19–

07O

CT

88

Before returning machine to customer, make suremachine is functioning properly, especially the safetysystems. Install all guards and shields.


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Safety Information

000001

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624h loader and tc62h tool carrier repair

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