Operation and T est
Download Operation Technical Manual
OPERA TION & TEST TECHNICAL MANUAL
624K 4WD Loader TM13210X19 20DEC18 (ENGLISH)
Introduction
Foreword
READ THIS MANUAL carefully learn how operate and service your machine correctly Failure could result personal injury equipment damage. This manual and safety signs your machine may also available other (See your John Deere dealer order
equipment described this The warranty explained the warranty certificate statement which you should have received from your dealer .
THIS MANUAL SHOULD CONSIDERED a permanent part your machine and should remain with the machine when you sell
MEASUREMENTS this manual are given both metric and customary unit Use only correct replacement parts and fasteners. Metric and inch fasteners may require a specific metric inch wrench.
This warranty provides you the assurance that John Deere will back its products where defects appear within the warranty some John Deere also provides field often without charge the customer , even the product out warranty . Should the equipment abused, modified change its performance beyond the original factory the warranty will become void and field improvements may Setting fuel delivery above specifications otherwise overpowering machines will result such action.
RIGHT - HAND AND LEFT - HAND sides are determined facing the direction forward
WRITE PRODUCT IDENTIFICA TION NUMBERS
.I.N.) the Machine Numbers section. Accurately record all the numbers help tracing the machine should Y our dealer also needs these numbers when you order File the identification numbers a secure place f the
W ARRANTY provided part John support program for customers who operate and maintain their
THE TIRE MANUF ACTURER'S warranty supplied with your machine may not apply outside the
you are not the original owner this machine, your interest contact your local John Deere dealer inform them this serial number This will help John Deere notify you any issues product
IMPORT ANT : Use only supporting manuals designated for your specific machine. incorrect manual chosen, improper service may occur . V erify product identification number (PIN) and engine model number when choosing the correct manual.
Choosing the Correct Supporting Manuals
John Deere four wheel drive (4WD) loaders are available dif ferent machine configurations based the various markets into which they are Dif ferent supporting manuals exist for dif ferent machine configurations.
When necessary , product identification numbers (PINs) are listed the front covers 4WD loader These numbers are used identify the correct supporting manual for your
Product Identification Number
The product identification number (PIN) plate (1) located left side machine frame under the cab door Each machine has a - character PIN (3) shown this
PIN Plate Location
Número de Identificação de Produto
PIN Plate (17 character)
PIN Plate Character PIN
The PIN identifies the producing factory , machine model number , machine year engine emission level, and machine serial number .
The following example for a 624K machine that meets T ier 2 and Stage emission levels: - Character PIN Example 1 2 3 4 5 6 7 8 9
• W orld Code: Identifies location where machine
1BZ W orld Code
1DW
1T8
Davenport W orks
Thibodaux W orks
1T0 Dubuque W orks
1FF USA)
1F9 .
São Brazil)
1BZ Brazil W orks São Brazil)
• Machine Model Identifier: Identifies model number .
624K Machine Model Identifier
Z Machine Option Code Z .
Manufacturing Y ear Code (variable)
2013
2014
2015
2016
• Engine Emission Code: Represents engine emission
Engine Emission Code
T ier 2 and Stage
T ier 3 and Stage III A
Interim T ier 4 and Stage III B
T ier 4
Interim T ier 4 and Stage III A (19 - kW)
Final T ier 4 and Stage III A (19 - kW)
Final T ier 4 and Stage III A (37 - kW)
High Lift Z - Bar
. Standard Z - Bar H
• (9)
Check Letter: This a random character assigned the factory This not used machine
Check Letter (variable)
• (10)
Manufacturing Y ear Code: Identifies year machine
Final T ier 4 - kW)
• Machine Serial Number: Identifies machine serial number . This character will change from one machine another 123456
Machine Serial Number
Section Information
Group
Section 9001—Diagnostics
Group Control Unit (ECU) Diagnostic
T rouble Codes
Group ransmission Control Unit (TCU) Diagnostic
T rouble Codes
Group ehicle Control Unit (VCU) Diagnostic
T rouble Codes
Group Switch Module (SSM) Diagnostic
T rouble Codes
Group Display Unit (ADU) Diagnostic
T rouble Codes
Group Object Detection (ROD) Diagnostic
T rouble Codes
Section Checkout Procedure
Group Checkout Procedure
Section
Group Operation
Group Information
Group ests
Section System
Group Information
Group Diagrams
Group - System Diagnostics
Group Operation
Group
Section 9020—Power T rain
Group Operation
Group Information
Group
Group ests
Section 9025—Hydraulic System
Group Operation
Group Information
Group
Group ests
Section and Air Conditioning
Group Operation
Group Information
Group ests
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9000 - - 7
Use Steps and Handholds Correctly 9000 - - 7
Start Only From Seat 9000 - - 8
Use and Maintain Seat Belt 9000 - - 8 Prevent Unintended Machine Movement
Use Special Care When Operating Loader 9000 -Keep Riders f Machine 9000 -A void Backover Accidents
A void Machine T Over
Recognize Safety Information
This the safety alert When you see this symbol your machine this manual, alert for the potential personal injury .
Follow the precautions and safe operating practices highlighted this symbol.
A signal word W CAUTION used with the safety alert DANGER identifies the most serious
your machine, DANGER signs are red color , W ARNING signs are and CAUTION signs are yellow DANGER and W ARNING signs are located near specific General precautions are CAUTION
Follow Safety Instructions
Carefully read all safety messages this manual and your machine safety signs. Keep safety signs good Replace missing damaged safety Use this operator ’ s manual for correct safety sign sure that new equipment components and repair parts include the current safety Replacement safety signs are available from your John Deere dealer
There can additional safety information contained parts and components sourced from suppliers that not reproduced this
Learn how operate the machine and how use controls properly . not let anyone operate without instruction.
Keep your machine proper working Unauthorized modifications the machine could impair the function safety and fect machine
Operate Only Qualified
not operate this machine unless the manual has been read carefully , and you have been qualified supervised training and
Operator should familiar with the job site and surroundings before T all controls and
you not understand any part this manual and need assistance, contact your John Deere dealer .
machine functions with the machine open area before starting
Know and observe all safety rules that may apply every work situation and work
W ear Protective Equipment
Guard against injury from flying pieces metal debris; wear goggles safety
W ear close fitting clothing and safety equipment appropriate the job.
Operating equipment safely requires the full attention the operator not wear radio music headphones while operating
Prolonged exposure loud noise can cause impairment loss hearing. W ear suitable hearing protection such earmuf earplugs protect against objectionable uncomfortable loud Radio music headphones are not suitable use for hearing
A void Unauthorized Machine Modifications
John Deere recommends using only genuine John Deere replacement parts ensure machine
Never substitute genuine John Deere parts with alternate parts not intended for the application these can create hazardous situations hazardous Non - John Deere any damage failures resulting from their are not covered any John Deere warranty
reliability , and may create a hazard for the operator others near the The installer any modification which may fect the electronic controls this machine responsible for establishing that the modification does not adversely fect the machine its
Always contact authorized John Deere dealer before making machine modifications that change the intended use, weight, balance the machine, that alter machine reliability
Modifications this addition unapproved products may fect machine stability
Inspect Machine
Inspect machine carefully each day walking around before
Keep all guards and shields good condition and properly Fix damage and replace worn broken parts immediately Pay special attention hydraulic hoses and electrical wiring.
Stay Clear Moving Parts
Entanglements moving parts can cause serious injury
Stop engine before examining, adjusting, maintaining any part machine with moving
Keep guards and shields
Replace any guard shield that has been removed for access soon service repair complete.
A void High-Pressure Fluids
Inspect hydraulic hoses periodically – least once per year – for exposed wire braid any other signs wear
Replace worn damaged hose assemblies immediately with John Deere approved replacement
Escaping fluid under pressure can penetrate the skin causing serious injury
A void the hazard relieving pressure before disconnecting hydraulic other T ighten all connections before applying
Search for leaks with a piece Protect hands and body from high - pressure fluids.
with this type injury should reference a knowledgeable medical Such information available English from Deere & Company Medical Department Moline, Illinois, U.S.A., calling 1 - 800 - 822 - 8262 309 - 748 -
accident see a doctor immediately Any fluid injected into the skin must surgically removed within a few hours gangrene may Doctors unfamiliar
A void High-Pressure Oils
This machine uses a high - pressure hydraulic Escaping oil under pressure can penetrate the skin causing serious injury
Never search for leaks with your hands. Protect hands. Use a piece cardboard find location escaping oil. Stop engine and relieve pressure before disconnecting lines working hydraulic
hydraulic oil penetrates your skin, see a doctor immediately . Injected oil must removed surgically within hours gangrene could Contact a knowledgeable medical source the Deere & Company Medical Department
W ork V entilated Area
Engine exhaust fumes can cause sickness necessary run engine enclosed remove the exhaust fumes from the area with exhaust pipe
you not have exhaust pipe extension, open the doors and get outside air into the
Prevent Fires
Handle Fluids Safely: All fuels, most lubricants, and some coolant mixtures are flammable. Store flammable fluids away from fire Never refuel machine while smoking when near sparks
Clean Machine Regularly: Keep flammable debris (trash, leaves, twigs, straw , and forth), grease and oil from accumulating engine compartment, around fuel hydraulic exhaust and electrical Never store oily rags flammable materials inside a machine
Maintain Hoses, T ubes, and W iring: Replace hoses and tubes immediately they begin leak, and clean any oil Examine electrical wiring and connectors frequently for
Keep A Fire Extinguisher A vailable: Always keep a multipurpose fire extinguisher near the machine. Know how use extinguisher properly .
A ware the Operating
Environment: Airborne debris may contain sparks not operate near any
T133552
T133553
T133554
A void Static Electricity Risk When Refueling
The removal sulfur and other compounds Ultra - Low Sulfur Diesel (ULSD) fuel decreases its conductivity and increases its ability store a static
Refineries may have treated the fuel with a static dissipating additive. However , there are many factors that can reduce the fectiveness the additive over
Static charges can build ULSD fuel while flowing through fuel delivery Static electricity discharge when combustible vapors are present could result a fire explosion.
important ensure that the entire system used refuel your machine (fuel supply transfer transfer and others) properly grounded and bonded. Consult with your fuel fuel system supplier ensure that the delivery system compliance with fueling standards for proper grounding and bonding
Clean Debris from Machine
Keep engine radiator , hydraulic lines, exhaust components, fuel tank, and station clean and free debris.
Clean any oil spills fuel spills machine
T emperature engine compartment could immediately after engine stopped. GUARD FOR FIRES DURING THIS
Open access door(s) cool the engine faster , and clean engine
Prevent Battery Explosions
Keep lighted and open flame away from the top battery Battery gas can
Never check battery charge placing a metal object across the Use a volt - meter hydrometer
not charge a frozen battery; may W arm battery 16°C (60°F).
Handle Chemical Products Safely
Direct exposure hazardous chemicals can cause serious injury Potentially hazardous chemicals used with John Deere equipment include such items and
A Material Safety Data Sheet (MSDS) provides specific details chemical products: physical and health safety and emergency response
Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how the job safely . Then follow procedures and recommended
(See your John Deere dealer for MSDS’ s chemical products used with John Deere
Decommissioning Proper Recycling and Disposal Fluids and Components
Safety and environmental stewardship measures must taken into account when decommissioning a machine and/or These measures include the following:
• Use appropriate tools and personal protective equipment such clothing, gloves, face shields glasses, during the removal handling objects and
• Follow instructions for specialized
• Release stored energy lowering suspended machine relaxing disconnecting the battery other electrical power , and releasing pressure hydraulic components, accumulators, and other similar
• Minimize exposure components which may have residue from agricultural such fertilizers and Handle and dispose these components appropriately
• Carefully drain engines, fuel tanks, radiators, hydraulic and lines before recycling Use leak - proof containers when draining not use food beverage
• not pour waste fluids onto the down a into any water
filters; batteries; other substances Burning flammable fluids components other than specially designed incinerators may prohibited law and could result exposure harmful fumes ashes.
• Service and dispose air conditioning systems appropriately Government regulations may require a certified service center recover and recycle air conditioning refrigerants which could damage the atmosphere allowed
• Evaluate recycling options for tires, metal, plastic, rubber , and electronic components which may part completely
• Observe all national, state, and local laws, regulations, ordinances governing the handling disposal waste fluids (example: brake fluid);
• Contact your local environmental recycling center , your John Deere dealer for information the proper way recycle dispose
Prepare for Emergencies
prepared a fire
Keep a first aid kit and fire extinguisher handy
Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.
Add Cab Guarding for Special Uses
Special work situations machine attachments could create environment with falling flying objects.
W orking near overhead demolition using a hydraulic hammer working a forestry application wooded working a waste management for could require added guarding protect the operator .
Not Use Starting Fluid
CAUTION: A void explosion fire. Machine equipped with electrical cold start assist not use starting fluid any type the machine.
engine damage will result from using starting fluids any type this machine.
Additional level FOPS (falling object protective forestry protection and special screens guarding should installed when falling flying objects could enter damage the machine. A rear screen should always used with a winch protect against a snapping Before operating any special work follow the operator protection recommendations the manufacturer any specialized attachment Contact your authorized John Deere dealer for information protective guarding.
Use Steps and Handholds Correctly
Prevent falls facing the machine when you get and Maintain 3 - point contact with steps and Never use machine controls
Use extra care when mud, snow , moisture present slippery Keep steps clean and free grease Never jump when exiting Never mount dismount a moving
Start Only From Seat
A void unexpected machine Start engine only while sitting Ensure that all controls and working tools are proper position for a parked
Never attempt start engine from the ground. not attempt start engine shorting across the starter solenoid
Use and Maintain Seat Belt
Use seat belt when operating machine Remember fasten seat belt when loading and unloading from trucks and during other uses.
Examine seat belt frequently sure that webbing not cut Replace seat belt immediately any part damaged does not function properly
The complete seat belt assembly should replaced every three regardless
Prevent Unintended Machine Movement
Lower all equipment the ground during work interruptions. Place transmission control neutral, press park brake switch (1) engage park press pilot enable/boom down switch (2) disable the and stop engine before allowing anyone approach the
Follow these same precautions before standing up, leaving the exiting the
Park Brake Switch Pilot Enable/Boom Down Switch
A void W ork Site Hazards
A void contact with gas buried and water lines. Call utility line location services identify all underground utilities before starting work.
Prepare work site properly . A void operating near structures objects that could fall onto the machine. Clear away debris that could move unexpectedly run over
A void boom attachment contact with overhead obstacles overhead electrical lines. Never move machine closer than 3 m (10 ft.) plus twice the line insulator length overhead wires.
Keep bystanders clear all times. Keep bystanders away from raised and unsupported
A void swinging raising loads over near personnel. Use barricades a signal person keep vehicles and pedestrians away . Use a signal person moving machine congested areas where visibility Always keep signal person view Coordinate hand signals before starting
Operate only solid footing with strength suf ficient support machine. especially alert working near embankments
A void working under overhanging embankments stockpiles that could collapse under
Reduce machine speed when operating with tool near ground when obstacles may hidden during snow removal clearing high speeds hitting obstacles uneven manholes) can cause a sudden Always wear your seat
Operate Only Solid Footing
Use Special Care When Operating Loader
Never use the loader lift not allow anyone ride the bucket use the bucket a work platform.
Operate carefully with raised loads. Raising the load reduces machine stability , especially side slopes unstable Drive and turn slowly with a raised Ensure that objects the bucket are secure. not attempt lift carry objects that are too big too long fit inside the bucket unless secured with adequate chain other device. Keep bystanders away from raised loads.
careful when lifting objects. Never attempt lift objects too heavy for your Assure machine stability and hydraulic capability with a test lift before attempting other maneuvers. Use adequate chain sling and proper rigging techniques attach and stabilize Never lift object above near another
Keep Riders Off Machine
Only allow operator
Riders are subject injury . They may fall from machine, caught between machine struck foreign
Riders may obstruct operator ’ s view impair his ability operate machine safely
A void Backover Accidents
Before moving machine, sure that all persons are clear machine T urn around and look directly for best visibility Use mirrors assist checking all around Keep windows and mirrors and good repair
certain reverse warning alarm working properly .
Use a signal person when backing view obstructed when close quarters. Keep signal person view all Use prearranged hand signals
not rely the rear camera and radar object detection determine personnel are behind the The system has limitations due maintenance environmental and operating
Keep Riders Off Machine
A void Machine T Over
Use seat belt all
not jump the machine tips. Y will unlikely jump clear and the machine may crush
Load and unload from trucks trailers carefully . sure truck wide enough and a firm level Use loading ramps and attach them properly truck
careful slopes. A void sharp Balance loads weight evenly distributed and load stable. Carry tools and loads close the ground aid visibility and lower center gravity Use extra care rocky , frozen
Know the capacity the machine. not careful with heavy loads. Using oversize buckets lifting heavy objects reduces machine stability .
Ensure solid footing. Use extra care soft ground conditions that may not uniformly support the especially when raising the not operate close banks open excavations that may cave and cause machine tip
Operating Slopes
A void side slope travel whenever Drive steep slope forward and down
Select low gear speed before starting down The grade the slope will limited ground condition and load being
Use service brakes control
Sudden brake application with a loaded bucket downhill side could cause machine tip
Operating T raveling Public Roads
Machines that work near vehicle traf fic travel slower than normal highway speeds must have proper lighting and markings assure they are visible other
Install additional lights, beacon lights, slow moving vehicle (SMV) emblems, other devices and use required make the machine visible and identify a work Check state and local regulations assure Keep these devices clean and working
Inspect and Maintain ROPS
A damaged rollover protective structure (ROPS) should not
T o maintain the ROPS:
• Replace missing hardware using correct grade
The protection fered ROPS could impaired ROPS subjected structural damage, involved overturn any way altered ROPS was loosened removed for any inspect carefully before operating the machine again.
• Check hardware
• Check isolation mounts for wear; replace them necessary
• Check ROPS for cracks physical damage.
Add and Operate Attachments Safely
required V erify that all connections are secure and attachment responds properly
Always verify compatibility attachments contacting your authorized dealer Adding unapproved attachments could fect machine stability reliability and could create a hazard for others near the machine.
Carefully read attachment manual and follow all instructions and area free bystanders and obstructions, carefully operate attachment learn its characteristics and range
Ensure that a qualified person involved attachment Add guards machine operator protection
Park and Prepare for Service Safely
W arn others service Always park and prepare your machine for service repair properly
• Park machine a level surface and lower equipment the ground.
• Engage park brake.
• Stop
• Install frame locking bar
• Attach a NOT OPERA tag obvious place the
Securely support machine attachment before working under
• not support machine with other hydraulically actuated
• not support machine with cinder blocks wooden pieces that can crumble crush.
• not support machine with a single jack other devices that could slip out
Understand service procedures before beginning Keep service area clean and dry . Use two people whenever the engine must running for service work.
Service Cooling System Safely
Explosive release fluids from pressurized cooling system can cause serious burns. not service radiator through the radiator Only fill through the surge tank filler Shut f Only remove surge tank filler cap when cool enough touch with bare Slowly loosen cap relieve pressure before removing completely .
Service T ires Safely
Explosive separation a tire and rim parts can cause serious injury
not attempt mount a tire unless you have the proper equipment and experience perform the job.
Always maintain the correct tire not inflate the tires above the recommended Never weld heat a wheel and tire assembly The heat can cause increase air pressure resulting a tire W elding can structurally weaken deform the wheel.
When inflating use a clip - chuck and extension hose long enough allow you stand one side and NOT front over the tire assembly Use a safety cage
Check wheels for low pressure, cuts, bubbles, damaged rims missing lug bolts and
Remove Paint Before W elding
A void potentially toxic fumes and
Heating
Hazardous fumes can generated when paint heated welding, soldering, using a torch.
Remove paint before heating:
• Remove paint a minimum 100 from area fected heating. paint cannot removed, wear approved respirator before heating welding.
• you sand grind avoid breathing the W ear approved respirator
• you use solvent paint stripper , remove stripper with soap and water before Remove solvent paint stripper containers and other flammable material from area. Allow fumes disperse least minutes before welding
not use a chlorinated solvent areas where welding will take
all work area that well ventilated carry toxic fumes and dust away
Dispose paint and solvent properly .