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John Deere 624J Troubleshooting
The
John Deere 624J wheel loader is powered by John Deere PowerTech 6068H
six-cylinder turbocharged diesel engine with a rated power of 165 hp (119 kW) at
2200 rpm. The John Deere 624J is equipped with a 4-speed powershift
transmission, power steering system, hydraulic wet multi-disc brakes, and
20.5R25 standard tires. The hydraulic system has a pump with fluid flow rate of
58 gpm (220 lpm). The hydraulic pressure is 3600 psi (248 bar). The wheel loader
has a rated operating capacity of 10925 lbs (4955 kg) and tipping load of 21850
lbs (9910 kg). The max lift height is 156.1" (3965 mm) to hinge pin, and
breakout force is 28480 lbs (12920 kg).
| Engine Troubleshooting |
Engine difficult to start or doesn't start
Air trapped in fuel system - Bleed air.
Clogged fuel filter - Service or replace the filter.
Fuel injection nozzles are damaged - Inspect nozzles and replace if necessary.
Dirt or water in fuel system - Drain water or flush dirt from the system.
Valve out of adjustment - Have it adjusted.
Fuel injection pump is damaged - Replace or repair injection pump.
Engine starts and immediately shuts off
Plugged air cleaner - Service or replace air cleaner.
Fuel filter element is dirty - Replace filter element.
Fuel injection pump has loose connections - Tighten the connections.
Damaged or clogged injectors - Clean fuel injectors or change it.
Damaged fuel injection pump - Change pump or rebuild it.
Engine stops unexpectedly during operation
Coolant temperature is low - Normalize the temperature by warming up the engine.
Clogged fuel filter - Change filter element.
Air in fuel tank - Bleed fuel tank.
Fuel injection nozzles are damaged or dirty - Check and replace nozzles if required.
Fuel injection pump timing is not adjusted - Use the correct fuel injection pump timing adjustment.
Engine stalls while idle
Improperly adjusted low idle speed - Adjust as required.
Fuel injection pump damage - Replacement or repair required.
Damaged or clogged injectors - Replace fuel injectors.
Valve clearance is not correct - Adjust valve clearance according to specifications.
Diesel power loss
Dirty air cleaner - Install new air cleaner element.
Defective injection nozzle - Change fuel injection nozzles.
Incorrect fuel injection pressure - Correct the pressure settings.
Valve clearance is wrong - Adjust valve clearance.
Incorrectly adjusted low idle speed - Correct low idle adjustment.
Fuel lines or hoses are dirty - Service fuel hoses and lines.
Cylinder head gasket defective - Change cylinder head gasket.
Worn or damaged piston rings - Piston rings replacement required.
Engine overheated
Engine coolant is insufficient - Fill radiator to proper level and check components for faults.
Engine oil level is low - Checking oil level and add if necessary.
Radiator core is clogged or radiator cap is leaking - Clean radiator or install new cap.
Damaged or worn fan belt - Belt replacement is recommended.
Diesel engine is overloaded - Reduce load on the engine.
Oil pressure too low
Oil level is insufficient - Add oil as required.
Dirty oil filter element - Change or clean engine oil filter element.
Oil grade or viscosity is incorrect - Fill up with the proper oil viscosity.
Excessive oil clearance of crankshaft bearing - Bearing needs to be changed.
Defective oil pump - Remove and inspect oil pump.
Abnormal engine noise or knocking
Insufficient engine oil - Add oil to the engine crankcase.
Engine is cold - Warm up the engine.
Improper setting of fuel injection pump timing - Use the correct fuel injection pump timing adjustment.
Low idle speed setting is incorrect - Test and adjust.
Fuel injectors are dirty or defective - Replace or clean fuel injectors.
Connecting rod is worn or not aligned - Connecting rod must be aligned or replaced.
Worn or broken pistons - Pistons need to be replaced.
| Transmission Troubleshooting |
Transmission oil pressure is low
Lack of transmission oil supply - Add oil to the transmission housing.
Transmission oil filter is dirty (if equipped) - Clean or replace the transmission filter.
Relief valve malfunction - Replace valve as required.
Transmission noises
Transmission oil insufficient - Fill up the transmission oil.
Transmission oil is dirty - Change the oil.
Defective gears or improper backlash - Adjust backlash correctly or replace the gears.
Bearings are damaged or worn - Change faulty bearings.
Shift forks are worn or bent - Shift forks need to be replaced.
Shaft splines are worn or stuck - Change the shaft.
Hard to shift gears
Worn or rusty gear shift linkage - Change or lubricate shift linkage.
Worn or bent gear shift forks - Change the shift forks.
Gearshift mechanism is damaged - Replace or repair the mechanism.
Malfunction or incorrect clutch adjustment - Adjust or change the clutch.
Transmission oil leakage
Transmission fluid level is high - Correct the fluid level.
Broken seals or gaskets - Change defective gaskets or seal.
| Hydraulics Troubleshooting |
Hydraulic system has overheating
Hydraulic pressure is not correct - Adjust it correctly.
Main relief valve is faulty or misadjusted - Adjust or change relief valve.
Dirty hydraulic oil - The oil must be changed.
Hydraulic fluid level is low - Add fluid to the hydraulic system.
Worn hydraulic oil pump - Repair or change pump if required.
Lift arm cannot be raised or lowered
Damaged lift controls - Inspect and repair if necessary.
Damaged hydraulic oil pump - Repair or install new hydraulic pump.
Hydraulic control valve malfunction - Install a new hydraulic valve or repair it.
Damaged hydraulic cylinder - Repair or install a new lift cylinder.
Hydraulic fluid is insufficient - Fill the system to proper hydraulic fluid level.
Bucket can't tilt
Bucket controls are faulty - Replace or repair.
Hydraulic pump is broken - Install new pump or repair it.
Faulty hydraulic control valve - Install a new valve or repair it.
Hydraulic bucket cylinder is defective - Repair or install a new cylinder.
Hydraulic oil level low - Check and refill the hydraulic oil.
Bucket or lift arm functions slowly
Hydraulic pump is worn - Test the pump flow rate and change pump if required.
Oil leaks from hydraulic cylinder - Change cylinder piston seals.
Low hydraulic oil level - Need to add oil.
Hydraulic control valve is unadjusted or worn - Repair or adjust properly.
Hydraulic pressure loss - Adjust it correctly.
Bucket or boom jerks when working
Air leaks in hydraulic system - Bleed air from hydraulic system.
Hydraulic oil filter clogging - Service or replace the hydraulic filter.
Contaminated hydraulic oil - Change hydraulic oil.
Scratched cylinder rod or tube - Replace damaged component.
Hydraulic pump is noisy
Hydraulic leaks or low oil level - Repair hydraulic leaks or add oil as required.
Plugged hydraulic filter - Service or change hydraulic filter.
Clogged suction line - Suction line must be serviced.
Air in hydraulic pump - Remove air from hydraulics.
Pump components are damaged - Install new hydraulic pump or rebuild it.
| Electrical Troubleshooting |
Battery is not charging
Corroded or loose electrical wire connections - Tighten or service cable connections.
Battery terminal connectors are faulty - Replace terminal connectors.
Battery faulty cell - Battery replacement required.
Defective or loose belt - Change belt or adjust belt tension.
Starter turns slowly
Low battery output - Recharge the battery.
Battery runs out quickly - Service charging system or install new battery.
Wires are disconnected or battery terminals are corroded - Connect cables correctly or replace terminals.
Starter is not cranking
Battery is drained or defective - Charge or change the battery.
Disconnected or incorrectly connected wires - Inspect battery wires and connect correctly.
Battery voltage is low - Low battery charging, charge as required.
Faulty starter motor - Repair or change starter.
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| WHEEL LOADERS SPECIFICATIONS |
Bobcat
Caterpillar
Case
Doosan
John Deere
Kubota