John Deere Tractors Models 500, 504, B550, B554 All Inclusive Service Technical Manual (TM701519)
Complete All Inclusive Technical Manual with electrical wiring diagrams for John Deere Tractors 500, 504, B550 and B554 (2WD or MFWD), with workshop information to maintain, diagnose, repair, and rebuild like professional mechanics (Diagnosis, Operation, Tests, Repair, Service, Troubleshooting).
John Deere Tractors Models 500, 504, B550 and B554 workshop technical 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.
PRODUCT DETAILS:
Total Pages: 1,021 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English
tm701519 - John Deere Tractors Models 500, 504, B550, B554 Technical Manual.epub
tm701519 - John Deere Tractors Models 500, 504, B550, B554 Technical Manual.pdf
MAIN SECTIONS
Foreword
General
Safety regulations
Technical specifications
Fuel and lubricating oil
Position of serial number plate
Discharge oil and water before servicing
Engine
Engine
Cooling system
Fuel system, air intake and exhaust
Speed control lever
Fuel system
Air intake and exhaust system
Electrical system
Battery and engine
Electrical system components
Wiring harness
Fuses and relays
Electrical schematic
Drive system
Rear PTO shaft
Clutch
Feeder house
Gearbox
Rear differential
Final drive
MFWD
2WD front axle
Steering and braking device
Steering system
Brake
Air brake (optional)
Hydraulic system
Hydraulic pump, oil tank and oil pipe assembly
Lifter
Trailer device
Miscellaneous
Engine hood and shield
Three-point suspension device
Wheel
Front counterweight tray
Cab
Remove and install components
Seat
Safety bracket
Special tools (made by dealers)
Special tools (made by dealers)
Work checking procedures
Work checking procedures
Engine operational principles, test and adjust
Component locations
Operational principles
Diagnose, test and adjust
Operational principles, test and adjustment of fuel/air intake system
Component locations
Operational principles
Diagnose, test and adjust
Operational principles, test and adjustment of electrical system
Component locations
Operational principles
Diagnose, test and adjust
Circuit diagram
Operational principles, test and adjustment of drive system
Component locations
Operational principles
Diagnose, test and adjust
Operational principles, test and adjustment of steering and braking devices
Component locations
Operational principles
Diagnose, test and adjust
Operational principles, test and adjustment of hydraulic system
Component locations
Operational principles
Diagnose, test and adjust
TABLE OF CONTENTS.......1
Section 10: General.......212
Group 05: Safety regulations.......19
Live With Safety.......24
Recognize Safety Information.......25
Understand Signal Words.......26
Follow Safety Instructions.......27
Prepare for Emergencies.......28
Wear Protective Clothing.......29
Protect Against Noise.......30
Handle Fuel Safely—Avoid Fires.......31
Handle Starting Fluid Safely.......32
Fire Prevention.......33
In Case of Fire.......34
Keep ROPS Installed Properly.......35
Use Foldable ROPS and Seat Belt Properly.......36
Stay Clear of Rotating Drivelines.......37
Use Steps and Handholds Correctly.......39
Read Operator Manuals for ISOBUS Implements.......40
Use Seat Belt Properly.......41
Operating the Tractor Safely.......42
Avoid Backover Accidents.......44
Limited Use in Forestry Operation.......45
Operating the Loader Tractor Safely.......46
Keep Riders Off Machine.......47
Instructional Seat.......48
Use Safety Lights and Devices.......49
Transport Towed Equipment at Safe Speeds.......50
Use Caution On Slopes and Uneven Terrain.......52
Freeing a Mired Machine.......53
Avoid Contact with Agricultural Chemicals.......54
Handle Agricultural Chemicals Safely.......55
Handling Batteries Safely.......57
Avoid Heating Near Pressurized Fluid Lines.......59
Remove Paint Before Welding or Heating.......60
Handle Electronic Components and Brackets Safely.......61
Practice Safe Maintenance.......62
Avoid Hot Exhaust.......63
Clean Exhaust Filter Safely.......64
Work In Ventilated Area.......67
Support Machine Properly.......68
Prevent Machine Runaway.......69
Park Machine Safely.......70
Transport Tractor Safely.......71
Service Cooling System Safely.......72
Service Accumulator Systems Safely.......73
Service Tires Safely.......74
Service Front-Wheel Drive Tractor Safely.......75
Tightening Wheel Retaining Bolts/Nuts.......76
Avoid High-Pressure Fluids.......77
Do Not Open High-Pressure Fuel System.......78
Store Attachments Safely.......79
Dispose of Waste Properly.......80
Use a Safety Chain.......81
Engine Coolant.......82
Produce dealer self-made tools safely.......83
Handle Global Positioning System (GPS) receiver safely.......84
Avoid tractor being out of control.......85
Use Proper Lifting Equipment.......86
Work in Clean Area.......87
Illuminate Work Area Safely.......88
Service Machines Safely.......89
Use Proper Tools.......90
Group 10: Technical specifications.......792
Technical specifications for 2WD model.......96
Technical specifications of mechanical front-wheel drive model.......101
Maximum control force.......106
Minimum turning radius.......107
PTO shaft properties.......108
Traction properties.......109
Properties of hydraulic suspension system.......110
Pouring capacity (L).......111
Metric bolt and screw torque values.......113
Imperial bolt and screw torque values.......115
Hydraulic system imperial connector torque.......118
Hydraulic system metric connector torque.......119
Clean air filter.......121
Check hose clamps.......122
Clear dust on engine cover and screen.......124
Clean radiator.......125
Check lifter, gearbox and front drive axle oil level.......126
Clean battery.......128
Check neutral start circuit.......129
Tractor operation check.......131
Group 15: Fuel and lubricating oil.......21
Handle fuel safely - Prevent fire.......133
Handle Fluids Safely—Avoid Fires.......134
Handling and Storing Diesel Fuel.......138
Cold Weather Operation.......136
Hot Weather Operation.......137
Diesel Fuel.......138
Lubricity of Diesel Fuel.......140
Testing Diesel Fuel.......141
Fill the fuel tank.......142
Alternative and Synthetic Lubricants.......144
Lubricant Storage.......145
Diesel engine break-in oil.......146
Diesel engine oil.......148
Oil Filters.......150
Heavy Duty Diesel Engine Coolant.......151
Use of Water as Coolant.......152
Liquid coolant conditioner.......153
Transmission and Hydraulic Oil.......154
Use Correct Transmission/Hydraulic Filter Element.......155
MFWD Front Axle Housing Oil.......156
MFWD Wheel Hub Oil.......157
Refuel gearbox.......158
Regularly check and service the gearbox.......159
Lubricating grease (specific applications).......160
Grease.......161
Group 20: Position of serial number plate.......22
Serial number.......163
Tractor serial number.......164
Tractor machine serial number - 13-digit PIN.......165
Engine serial number.......166
Group 25: Discharge oil and water before servicing.......22
MFWD model front axle oil discharge.......168
MFWD drive transfer case oil discharge.......169
Steering oil tank hydraulic oil discharge.......170
Gearbox oil discharge.......171
Lifter oil discharge.......172
Diesel tank discharge.......173
Coolant discharge.......174
Engine oil discharge.......176
Section 20: Engine.......177
Group 05: Engine.......177
Basic or recommended tools.......179
Technical specifications.......792
Engine maintenance.......181
Remove and install engine.......243
Group 10: Cooling system.......177
Technical specifications.......792
Maintenance of engine water pump.......188
Remove, install and adjust fan drive belt.......189
Remove, check and install radiator.......191
Replace thermostat.......196
Install thermostat.......198
Section 30: Fuel system, air intake and exhaust.......200
Group 05: Speed control lever.......200
Technical specifications.......792
Check and repair engine control mechanism assembly.......203
Adjust foot throttle cable and pedal force.......205
Adjust shut-off cable.......207
Adjust throttle handle.......208
Adjust synchronization of foot throttle pedal and throttle handle.......209
Group 10: Fuel system.......200
General.......212
Technical information.......213
Remove, check and install fuel tank.......214
Replace fuel transfer pump.......219
Replace sediment bowl.......220
Replace sediment bowl assembly.......221
Replace fuel filter and engine oil filter.......223
Bleed air from fuel system.......797
Group 15: Air intake and exhaust system.......200
Technical specifications.......792
Remove, check and install air filter.......228
Remove, check and install muffler.......231
Section 40: Electrical system.......234
Group 05: Battery and engine.......234
Avoid damaging electrical system.......237
Replace battery.......238
Charging battery.......927
Connect battery cables.......240
Remove and install battery.......241
Remove and install engine.......243
Group 10: Electrical system components.......234
Service equipment and tools.......246
Replace water temperature sensor.......247
Replace engine oil pressure sensor.......248
Replace engine speed sensor.......249
Replace fuel volume sensor.......250
Replace keyswitch.......252
Replace warning light switch.......254
Replace high/low beam switch / light switch / work light switch / turn signal light switch / horn switch.......256
Replace brake light switch.......258
Replace gearbox neutral start switch.......259
Replace PTO neutral start switch.......261
Replace horn.......262
Replace flasher.......263
Replace trailer socket (optional).......264
Replace air pressure alarm switch (optional).......265
Group 15: Wiring harness.......840
Cable repair pliers.......267
Remove and install electrical connectors.......268
Separate blade terminals from connectors.......269
Replace connector.......270
Install contact.......272
Replace tractor wiring harness.......273
Wiring harness.......840
Group 20: Fuses and relays.......235
Locations of fuses.......280
Fuse specifications and functions.......282
Replace start relays.......283
Group 25: Electrical schematic.......940
Cable color codes.......939
Electrical schematic.......940
Section 50: Drive system.......290
Group 10: Rear PTO shaft.......290
Exploded view of rear PTO control assembly.......294
Exploded view of output driving shaft module.......296
Exploded view of PTO shaft.......298
PTO shaft protection cover assembly.......300
Remove, check and assemble PTO control assembly.......301
Disassemble and check rear PTO shaft assembly.......304
Assemble rear PTO shaft assembly.......314
Group 15: Clutch.......290
Recommended tools.......327
Technical specifications.......792
Remove, check and install clutch assembly.......329
Adjustment of clutch.......331
Disassemble, check and assemble clutch assembly.......333
Adjustment of clutch assembly.......337
Group 20: Feeder house.......290
Technical specifications.......792
Remove and install feeder house.......341
Exploded view of feeder house (2WD).......344
Exploded view of feeder house (4WD).......347
Disassemble, check and assemble feeder house.......350
Group 25: Gearbox.......290
Exploded view of gearbox first shaft (MFWD).......360
Exploded view of gearbox second shaft.......362
Exploded view of gearbox second shaft (MFWD).......364
Exploded view of control lever assembly and shift fork shaft module.......366
Exploded view of gearbox cover assembly.......368
Remove and install gearbox.......370
Disassemble, check and assemble shift shaft.......373
Disassemble and check first shaft and second shaft.......376
Assemble first shaft and second shaft.......388
Group 30: Rear differential.......291
Technical specifications.......792
General repair procedures - rear differential.......409
Exploded view of rear differential assembly.......410
Remove and install differential assembly.......412
Disassemble, check and assemble differential assembly.......418
Group 35: Final drive.......291
Technical specifications.......792
Exploded view of final drive assembly.......432
Remove and install final drive assembly.......434
Disassemble and check final drive assembly.......439
Assemble final drive assembly.......442
Group 40: MFWD.......291
Technical specifications.......792
Exploded view of drive transfer case and drive shaft (4WD).......450
Remove, check and install drive transfer case and drive shaft (4WD).......452
Disassemble, check and assemble drive transfer case (4WD).......456
Exploded view of bracket and front central drive.......460
Exploded view of front central drive and half shaft housing.......462
Exploded view of front final drive.......464
Remove and check front wheel final drive assembly.......467
Assemble front wheel final drive assembly.......478
Disassemble and check front central drive assembly.......496
Assemble front central drive assembly.......506
Group 45: 2WD front axle.......291
Exploded view of front axle bracket.......523
Exploded view of knuckle and front wheel hub.......525
Exploded view of steering horizontal lever.......527
Remove, check and assemble front axle.......528
Section 60: Steering and braking device.......534
Group 05: Steering system.......534
Technical specifications.......792
Remove and install steering wheel.......537
Remove and install steering column.......538
Remove and install hydraulic steering oil tank.......539
Remove and install hydraulic steering system pipes.......542
Remove and install steering cylinder assembly.......552
Remove and install constant flow pump.......557
Remove and install full hydraulic steering gear.......560
Adjust toe-in (MFWD).......1035
Adjust front wheel toe-in and wheel tread (2WD model).......1037
Group 10: Brake.......534
Technical specifications.......792
Remove and install brake pedals.......569
Remove and install braking device.......574
Remove and install handbrake assembly.......581
Adjust brake stroke.......583
Group 10B: Air brake (optional).......534
Technical requirements.......587
Exploded view of air brake.......588
Exhaust air and discharge water from air reservoir.......590
Remove, check and install valve lever assembly.......591
Remove, check and install cut-off brake valve.......593
Remove, check and install air pipes.......595
Remove, check and install air reservoir.......601
Remove, check and install air reservoir bracket.......603
Repair of compressor.......604
Adjust cut-off brake valve.......605
Section 70: Hydraulic system.......606
Group 05: Hydraulic pump, oil tank and oil pipe assembly.......606
Remove and install gear pump.......610
Remove and install lifter oil tank.......613
Remove and install lifter oil pipes.......616
Group 10: Lifter.......606
Technical specifications.......792
Remove and install lifter assembly.......628
Remove and install lifter parts - lifter upper cover and filter assembly.......630
Remove and install lifter parts - shut-off valve transition plate assembly.......631
Remove and install lifter parts - outer lift arm and lift shaft.......632
Remove and install lifter parts - internal connecting parts.......634
Remove and install lifter parts - cylinder and distributor.......635
Remove and install lifter parts - distributor.......637
Remove and install lifter parts - safety valve and shut-off valve rod.......642
Remove and install lifter parts - lifter oil level gauge.......643
Group 15: Trailer device.......606
Technical specifications.......792
Remove and install trailer device.......646
Section 80: Miscellaneous.......648
Group 05: Engine hood and shield.......648
Remove engine hood.......652
Install engine hood.......655
Remove and install engine hood air spring strut.......658
Remove and install engine hood lock.......659
Remove and install PTO shaft shield.......660
Group 10: Three-point suspension device.......648
Adjust upper lever.......663
Remove and install upper lever assembly.......664
Adjust oblique lever.......666
Remove and install oblique lever.......667
Remove and install lower lever.......670
Adjust external stopper chain assembly.......672
Remove and install external stopper chain.......673
Group 15: Wheel.......648
Technical specifications.......792
Remove and install guide wheels.......679
Remove and install front drive wheels.......680
Remove and install drive wheels.......681
Remove and install rear wheel counterweight.......682
Group 20: Front counterweight tray.......648
Remove, check and install front counterweight tray.......688
Section 90: Cab.......693
Group 05: Remove and install components.......693
Remove and install gantry.......697
Remove and install instrument cover.......700
Remove and install fender and flooring welding assembly.......703
Remove and install boarding step.......706
Remove and install rear-view mirrors.......708
Remove and install cross-beam welding.......710
Group 10: Seat.......693
Remove and install seat.......716
Group 15: Safety bracket.......693
Remove and install safety bracket.......722
Section 99: Special tools (made by dealers).......724
Group 05: Special tools (made by dealers).......724
Q22-264 special tool for installing final drive housing shaft sleeve Ⅰ.......727
Q23-83 special tool for installing composite bushes at both ends of first shaft.......729
Q22-4 special shaft for installing clutch assembly.......731
Q23-5 special tool for installing bearing 305.......737
Q23-6 special tool for installing bushes.......739
Q22-56 special tool for installing oil seals.......741
Q22-57 special tool for installing bearings.......742
Q22-105 special tool for installing brake camshaft.......744
Q22-7 special tool for installing reverse gear composite bushes.......746
Q23-3 special tool for installing bearing 6207.......747
Q22-106 special tool for installing bearing 30211 inner ring.......749
Section 210: Work checking procedures.......751
Group 10: Work checking procedures.......751
Information of work checking procedures.......753
Engine oil level and status check.......754
Coolant level and status check.......756
Gearbox oil level check.......758
Lifter oil check.......760
Fan and belt check.......762
Fuel system check.......764
Air intake system check.......766
Electrical system check.......768
Hydraulic system check.......769
Indicator bulb check.......770
Engine start check.......772
Power steering check.......773
Clutch check.......774
Shift lever check.......775
Brake check.......777
Other checks.......779
Section 220: Engine operational principles, test and adjust.......780
Group 05: Component locations.......780
Information of component locations.......1041
Engine external components - left side.......783
Engine external components - right side.......785
Group 10: Operational principles.......780
Information of operational principles.......1044
Operational principles of engine cooling system.......789
Group 15: Diagnose, test and adjust.......780
Technical specifications.......792
Cooling system test.......793
Throttle adjustment.......794
Fan/Generator drive belt adjustment.......795
Bleed air from fuel system.......797
Air filter blockage.......799
Engine cannot start or is difficult to start.......801
Insufficient engine power.......803
Engine emits black smoke.......804
Engine emits blue smoke.......805
Engine emits white smoke.......806
Engine oil pressure is abnormal.......807
Engine oil level rises.......808
Abnormal sound.......809
Water temperature of engine is too high.......810
Engine oil consumption is too much.......811
Excessive vibration.......812
Starter motor failure.......813
Generator failure.......814
Section 230: Operational principles, test and adjustment of fuel/air intake system.......815
Group 05: Component locations.......815
Information of component locations.......1041
Fuel system components.......818
Air intake/exhaust system components.......820
Group 10: Operational principles.......815
Information of operational principles.......1044
Operational principles of fuel system.......823
Operational principles of air intake/exhaust system.......825
Group 15: Diagnose, test and adjust.......815
Diagnostic information.......1053
Fuel/air intake system diagnosis, test and adjustment.......829
Exhaust noise is abnormal.......830
Section 240: Operational principles, test and adjustment of electrical system.......832
Group 05: Component locations.......832
Information of component locations.......1041
Engine electrical components - right side.......836
Engine electrical components - left side.......837
Electrical components of dashboard and main control panel.......838
Wiring harness.......840
Group 10: Operational principles.......832
Information of operational principles.......1044
Fuses.......846
Relays.......848
Operational principles of starting system.......849
Operational principles of battery charging system.......851
Operational principles of lighting system - left/right turn signal light.......853
Operational principles of lighting system - High/Low beam.......855
Operational principles of lighting system - dashboard switch light.......857
Operational principles of lighting system - work lights.......859
Operational principles of lighting system - taillights, front screen lights and brake lights.......861
Operational principles of lighting system - hazard warning light.......864
Operational principles of dashboard system - oil pressure alarm indicator.......866
Operational principles of dashboard system - air brake indicator (optional).......868
Operational principles of dashboard system - tachometer.......870
Operational principles of dashboard system - fuel gauge.......872
Operational principles of dashboard system - water temperature gauge.......874
Operational principles of horn.......876
Group 15: Diagnose, test and adjust.......832
Diagnostic information.......1053
Cable color table.......882
Starting system test point.......883
Battery charging system test point.......886
Lighting system test points - left/right turn signal light.......888
Lighting system test points - high/low beam.......892
Lighting system test point - dashboard switch light.......896
Lighting system test points - work light.......900
Lighting system test points - taillight, front screen light and brake light.......903
Lighting system test points - hazard warning light.......907
Dashboard system test points - oil pressure alarm indicator.......911
Dashboard system test points - air brake indicator test point (optional).......914
Dashboard system test points - tachometer.......916
Dashboard system test points - fuel gauge.......918
Dashboard system test points - water temperature gauge.......921
Horn test point.......924
Battery voltage test.......926
Charging battery.......927
Keyswitch test.......928
Fuse test.......930
Neutral start switch test.......931
Hazard alarm switch test.......932
Front floodlight high/low beam switch test.......933
Light switch test.......934
Work light switch test.......935
Turn signal light switch test.......936
Horn switch test.......937
Group 20: Circuit diagram.......833
Cable color codes.......939
Electrical schematic.......940
Section 250: Operational principles, test and adjustment of drive system.......943
Group 05: Component locations.......943
Information of component locations.......1041
Drive system components.......946
Clutch components.......947
Gearbox components.......948
Front drive axle component.......961
Final drive components.......968
Group 10: Operational principles.......943
Information of operational principles.......1044
Operational principles of clutch.......972
Operational principles of gearbox.......974
Operational principles of final drive.......979
Operational principles of rear PTO shaft.......981
Operational principles of drive transfer case transmission.......983
Operational principles of MFWD.......985
Group 15: Diagnose, test and adjust.......943
Diagnostic information.......1053
Isolate defective components.......990
Clutch slippage.......992
Clutch cannot be disengaged completely.......993
Clutch engagement.......994
Clutch cannot be disengaged.......995
Clutch pedal does not return.......996
Power is transmitted unstably or unsteadily.......997
Gearbox oil level is low (serious oil leakage).......998
Gear bumps, shifting is difficult or fails to engage.......999
Gearbox fails to stay at required gear position.......1000
PTO shaft generates much noise.......1001
PTO shaft is difficult to engage.......1002
PTO shaft fails to stay at engaged status.......1003
Differential generates much noise.......1004
Section 260: Operational principles, test and adjustment of steering and braking devices.......1005
Group 05: Component locations.......1005
Information of component locations.......1041
Steering system components.......1008
Braking system components.......1011
Group 10: Operational principles.......1005
Information of operational principles.......1044
Operational principles of hydraulic steering system.......1017
Operational principles of braking system.......1020
Group 15: Diagnose, test and adjust.......1005
Diagnostic information.......1053
Isolate defective components - steering system.......1028
It is difficult or fails to steer.......1029
Steering cylinder leakage test.......1030
Isolate defective components - brake.......1031
Braking is not stable.......1032
Isolate defective components - air brake.......1033
Air pressure alarm switch light is lit.......1034
Adjust toe-in (MFWD).......1035
Adjust front wheel toe-in and wheel tread (2WD model).......1037
Section 270: Operational principles, test and adjustment of hydraulic system.......1039
Group 05: Component locations.......1039
Information of component locations.......1041
Lifter assembly.......1042
Group 10: Operational principles.......1039
Information of operational principles.......1044
Operational principles of hydraulic system.......1045
Group 15: Diagnose, test and adjust.......1039
Diagnostic information.......1053
Preliminary checks of hydraulic system.......1054
Entire hydraulic system is not working / hydraulic oil pump does not supply oil.......1055
Insufficient oil supply from oil pump.......1056
Oil pump pressure is too high.......1057
Too much noise is generated when oil pump works.......1058
Lifter does not lift or lifting speed is too slow.......1059
John Deere Tractors Models 500, 504, B550, B554 All Inclusive Service Technical Manual (TM701519)
