Complete all inclusive technical manual with electrical wiring diagrams for John Deere Compact Utility Tractors 2520 Series, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

John Deere Compact Utility Tractors 2520 Series workshop diagnosis operation test service repair 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.

tm2288 - Compact Utility Tractor 2520 Series Technical Manual.pdf
tm2288 - Compact Utility Tractor 2520 Series Technical Manual.epub

Total Pages: 1,312 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality) & EPUB/MOBI/AZW for Kindle/iPad/iPhone/Android.
Language: English

MAIN SECTIONS
Foreword
   Safety
      Safety
   Specifications and Information
      General Specifications
      Fuel and Lubricants
      Serial Number Locations
   Engine
      Specifications
      Theory of Operation
      Component Location
      Diagnostics
      Tests and Adjustments
      Repair
   Electrical
      General Information
      Specifications
      Component Location
      System Schematics
      Operation and Diagnostics
      Tests and Adjustments
   Export Electrical
      Specifications
      Component Location
      Schematics & Harnesses
      Operation & Diagnostics
   Power Train - Hydrostatic
      Specifications
      Component Location
      Diagnostics
      Theory of Operation
      Tests and Adjustments
      Repair
   Hydraulics
      Specifications
      Component Locations
      Schematics
      Operation and Diagnostics
      Troubleshooting
      Theory of Operation
      Tests and Adjustments
      Repair
   Steering
      Specifications
      Component Location
      Theory of Operation
      Diagnostics
      Tests and Adjustments
      Repair
   Brakes
      Specifications
      Component Location
      Theory of Operation
      Diagnostics
      Tests and Adjustments
      Repair
   Miscellaneous
      Specifications
      Repair

tm2288 - Compact Utility Tractor 2520 Series

Table of Contents

Foreword

Section 10: Safety

Group 05: Safety

Recognize Safety Information

Understand Signal Words

Replace Safety Signs

Handle Fluids Safely—Avoid Fires

Prepare for Emergencies

Prevent Battery Explosions

Prevent Acid Burns

Wear Protective Clothing

Avoid High-Pressure Fluids

Avoid Heating Near Pressurized Fluid Lines

Service Machines Safely

Use Proper Tools

Park Machine Safely

Support Machine Properly

Use Proper Lifting Equipment

Work in Clean Area

Protect Against High Pressure Spray

Illuminate Work Area Safely

Work In Ventilated Area

Remove Paint Before Welding or Heating

Avoid Harmful Asbestos Dust

Service Tires Safely

Stay Clear of Rotating Drivelines

Service Cooling System Safely

Dispose of Waste Properly

Handle Chemical Products Safely

Live With Safety

Section 20: Specifications and Information

Group 05: General Specifications

Metric Bolt and Screw Torque Values

Unified Inch Bolt and Screw Torque Values

Metric Cap Screw Torque Values—Grade 7

Gasket Sealant Application

Service Recommendations For Flat Face O-Ring Seal Fittings

Service Recommendations for O-Ring Boss Fittings

Group 10: Fuel and Lubricants

Diesel Fuel

Handling and Storing Diesel Fuel

Diesel Engine Oil

Diesel Engine Break-In Oil

Alternative and Synthetic Lubricants

Lubricant Storage

Mixing of Lubricants

Grease

Transmission and Hydraulic Oil

Heavy Duty Diesel Engine Coolant

Group 15: Serial Number Locations

Serial Numbers

Machine Product Identification Number

Engine Serial Number

Section 30: Engine

Group 05: Specifications

General Specifications

Repair Specifications

Tests and Adjustment Specifications

Operational Tests

Torque Values, Non-Standard Fasteners

Service Equipment and Tools

Other Materials

Group 10: Theory of Operation

Cooling System Operation

Lubrication System Operation

Group 15: Component Location

Fuel System Component Location

Diesel Engine Component Location (S.N. —040000)

Diesel Engine Component Location (S.N. 040001— )

Group 20: Diagnostics

Starting Problems

Low Engine Output

Exhaust Abnormal Under Load

Engine Runs Rough

Excessive Fuel Consumption

Lubricating Oil

Temperature Problems

Low Compression

Diagnostic Table

Group 25: Tests and Adjustments

Throttle Cable Adjustment

Cylinder Compression Test

Slow Idle Adjustment

Valve Clearance Adjustment

Valve Lift Check

Fuel Injection Nozzle Test

Injection Pump Timing

Thermostat Test

Water Pump/Alternator Drive Belt Adjustment

Radiator Bubble Test

Cooling System Pressure Test

Radiator Pressure Cap Test

Engine Oil Pressure Test

Fuel Supply Pump Pressure Test

Fuel System Leakage Test

Bleed Fuel System

Group 30: Repair

Glow Plug Removal and Installation

Rocker Cover Removal and Installation

Rocker Arm Assembly

Engine Removal and Installation

Engine Removal From Tunnel (Front Subframe Removed)

Engine and Subframe Removal From Tunnel Section (Front Split)

Cylinder Head Removal and Installation (Engine In Place)

Cylinder Head and Valves Removal and Installation (Engine Out)

Cylinder Head and Valves Disassembly and Assembly

Valve Seats

Grind Valve Seats

Lap Valves

Valve Recession

Valve Guides

Valve Springs

Exhaust Manifold

Intake Manifold

Measure Piston-To-Cylinder Head Clearance

Piston and Connecting Rod

Piston Inspection

Cylinder Bore

Crankshaft Rear Oil Seal

Crankshaft Front Oil Seal

Crankshaft End Play Check

Crankshaft and Main Bearings

Crankshaft Main Bearing Clearance Check

Connecting Rod Side Play Check

Connecting Rod Bearing Clearance Check

Camshaft End Play Check

Camshaft

Camshaft Followers

Timing Gear Cover (3TNV82A-MJK, -MJKE)

Timing Gear Cover (3TNV82A-BMJK)

Timing Gear Backlash Check

Idler Gear

Timing Gear Cover Mounting Plate

Oil Pan and Strainer

Oil Pump (3TNV82A-MJK, -MJKE)

Oil Pump (3TNV82A-BMJK)

Thermostat and Water Pump

Fuel Filter/Water Separator

Secondary Fuel Filter

Fuel Injection Pump

Fuel Injection Nozzles

Starting Motor Removal and Installation

Starting Motor Disassembly and Assembly

Starting Motor Inspection/Test

Starting Motor Gear Train

Starting Motor Solenoid

20 Amp Alternator

High Capacity Alternator

Section 40: Electrical

Group 05: General Information

Reading Electrical Schematics

Theory Of Operation Information

Diagnostic Information

Wire Color Abbreviation Chart

Common Circuit Tests

Conductors For 12 Volt Circuits

Group 10: Specifications

System Specifications

Service Equipment and Tools

Other Materials

Group 15: Component Location

Electrical Components (SN —406000)

Electrical Component Location (SN 406001— )

Group 20: System Schematics

Schematic and Wiring Harness Legend (SN —406000)

Schematic and Wiring Harness Legend (SN 406001— )

Electrical Schematic (SN —406000)

Electrical Schematic (SN 406001— )

W1 Main Wiring Harness (SN —406000)

W1 Main Wiring Harness (SN 406001— )

W2 Power Supply Wiring Harness (SN —406000)

W2 Power Supply Wiring Harness (SN 406001— )

W3 Battery Cable Wiring Harness

W4 Engine Wiring Harness

Y2 Fuel Shutoff Solenoid

W1 Main Wiring Harness Color Codes (SN —406000)

W1 Main Wiring Harness Color Codes (SN 406001— )

W2 Power Supply Wiring Harness Color Codes

W3 Battery Cable Wiring Harness Color Codes

Group 25: Operation and Diagnostics

Power Circuit Operation (SN —406000)

Power Circuit Electrical Schematic (SN —406000)

Power Circuit Diagnosis (SN —406000)

Power Circuit Operation (SN 406001— )

Power Circuit Electrical Schematic (SN 406001— )

Power Circuit Diagnosis (SN 406001— )

Cranking Circuit Operation (SN —406000)

Cranking Circuit Electrical Schematic (SN —406000)

Cranking Circuit Diagnosis (SN —406000)

Cranking Circuit Operation (SN 406001— )

Cranking Circuit Electrical Schematic (SN 406001— )

Cranking Circuit Diagnosis (SN 406001— )

Engine Preheater Circuit Operation (SN —406000)

Engine Preheater Circuit Electrical Schematic (SN —406000)

Engine Preheater Circuit Diagnosis (SN —406000)

Engine Glow Plug Circuit Operation (SN 406001— )

Engine Glow Plug Circuit Electrical Schematic (SN 406001— )

Engine Glow Plug Circuit Diagnosis (SN 406001— )

Fuel Supply Operation (SN —406000)

Fuel Supply Electrical Schematic (SN —406000)

Fuel Supply Diagnosis (SN —406000)

Fuel Supply Operation (SN 406001— )

Fuel Supply Electrical Schematic (Pull In - On Seat, PTO On) (SN 406001— )

Fuel Supply Electrical Schematic (Hold In - Off Seat, PTO Off) (SN 406001— )

Fuel Supply Diagnosis (SN 460001— )

Engine Shutoff Circuit Operation (SN —406000)

Engine Shutoff Circuit Operation (SN 406001— )

Engine Shutoff Electrical Schematic (SN —406000)

Engine Shutoff Electrical Schematic (SN 406001— )

Engine Shutoff Circuit Diagnosis All Models

Charging Circuit Operation (SN —406000)

Charging Circuit Electrical Schematic (SN —406000)

Charging Circuit Diagnosis (SN —406000)

Charging Circuit Operation (SN 406001— )

Charging Circuit Electrical Schematic (SN 406001— )

Charging Circuit Diagnosis (SN 406001— )

PTO Circuit Operation (SN —406000)

PTO Circuit Electrical Schematic (SN —406000)

PTO Circuit Diagnosis (SN —406000)

PTO Circuit Operation (SN 406001— )

PTO Circuit Electrical Schematic (SN 406001— )

PTO Circuit Diagnosis (SN 406001— )

Control Panel Circuit Operation (SN —406000)

Control Panel Circuit Electrical Schematic (SN —406000)

Control Panel Circuit Diagnosis (SN —406000)

Control Panel Circuit Operation (SN 406001— )

Control Panel Circuit Electrical Schematic (SN 406001— )

Control Panel Circuit Diagnosis (SN 406001— )

Light Switch Circuit Operation (SN —406000)

Light Switch Circuit Electrical Schematic (SN —406000)

Light Switch Circuit Diagnosis (SN —406000)

Light Switch Circuit Operation (SN 406001— )

Light Switch Circuit Electrical Schematic (SN 406001— )

Light Switch Circuit Diagnosis (SN 406001— )

Turn Signal Circuit Operation

Turn Signal Circuit Electrical Schematic (SN —406000)

Turn Signal Circuit Diagnosis (SN —406000)

Turn Signal Circuit Electrical Schematic (SN 406001— )

Turn Signal Circuit Diagnosis (SN 406001— )

Group 30: Tests and Adjustments

Ground Circuit Test

Battery Voltage and Specific Gravity Test

Battery—Charge

Battery—Load Test

Unregulated Voltage Output Test (SN —406000)

Stator Resistance Test (SN —406000)

Unregulated Amperage Test—55 Amp

Regulated Amperage and Voltage Test

Regulator/Rectifier Test (SN —406000)

Starting Motor Solenoid Test

No-Load Amperage Draw and RPM Test

Starting Motor Amperage Draw Test

Engine Coolant Temperature Sensor Test

Engine Oil Pressure Switch Test

Manifold Heater Test

Glow Plug Test

Diode Test

Fuse Test

Control Panel Light Test

Light Switch Test

Fuel Pull-In Relay Test

Relay Test (SN —406000)

Relay Test (SN 406001— )

Engine Preheater/Glow Plug Relay Test

Key Switch Test

Seat Switch Test

Transmission Neutral Switch Test

Turn Signal Switch Test

Position Lights Switch Test

Hazard Lights Switch Test

Rear PTO Switch Test

PTO Switch Test

Fuel Shutoff Solenoid Test

Fuel Gauge Sensor Test

PTO Solenoid Test

Parking Brake Switch Test and Adjustment

Brake Switch Test

Section 45: Export Electrical

Group 05: Specifications

System Specifications

Service Equipment and Tools

Other Materials

Group 10: Component Location

Electrical Components

Group 15: Schematics & Harnesses

Schematic and Wiring Harness Legend

Electrical Schematic (SN —486000)

W1 Main Wiring Harness (SN —486000)

W1 Main Wiring Harness Color Codes (SN —486000)

Electrical Schematic (SN 486001— )

W1 Main Wiring Harness (SN 486001— )

W1 Main Wiring Harness Color Codes (SN 486001— )

W2 Power Supply Wiring Harness

W2 Power Supply Wiring Harness Color Codes

W3 Battery Cable Wiring Harness

W3 Battery Cable Wiring Harness Color Codes

W4 Engine Wiring Harness

Y2 Fuel Shutoff Solenoid

Group 20: Operation & Diagnostics

Power Circuit Operation

Power Circuit Electrical Schematic

Power Circuit Diagnosis

Cranking Circuit Operation

Cranking Circuit Electrical Schematic

Cranking Circuit Diagnosis

Engine Preheater Circuit Operation

Engine Preheater Circuit Electrical Schematic

Engine Preheater Circuit Diagnosis

Fuel Supply Operation

Fuel Supply Electrical Schematic

Fuel Supply Diagnosis

Engine Shutoff Circuit Operation

Engine Shutoff Electrical Schematic

Engine Shutoff Circuit Diagnosis

Charging Circuit Operation

Charging Circuit Electrical Schematic

Charging Circuit Diagnosis

PTO Circuit Operation

PTO Circuit Electrical Schematic

PTO Circuit Diagnosis

Control Panel Circuit Operation

Control Panel Circuit Electrical Schematic

Control Panel Circuit Diagnosis

Marker, Head, and Brake Light Circuit Operation

Marker, Headlight, and Brake Light Circuit Electrical Schematic

Marker, Head, and Brake Light Circuit Diagnosis

Hazard Lights and Turn Signal Lights Circuit Operation

Hazard Lights and Turn Signal Lights Circuit Electrical Schematic

Hazard Lights and Turn Signal Lights Circuit Diagnosis

Section 50: Power Train - Hydrostatic

Group 05: Specifications

General Specifications

Torque Specification

Service Equipment and Tools

Other Materials

Group 10: Component Location

Hydrostatic Drive

Charge Pump Component Location

Hydrostatic Motor Component Location

Hydrostatic Pump Component Location

Center Case Component Location

Swash Plate Component Location

Valve Plate Component Location

Center Case Gears Component Location

Pinion Drive Component Location

Mid PTO Component Location

Differential Case Component Location

Reduction Shafts Component Location

Differential Carrier Component Location

PTO Clutch Shaft Component Location

Rear PTO Component Location

Differential Component Location - MFWD

Final Drive Component Location - MFWD

Group 15: Diagnostics

Hydrostatic Transmission

PTO System

Transaxle

Group 20: Theory of Operation

Transmission

Component Location - Hydrostatic Transmission

Hydrostatic Schematic

Charge Pump Theory of Operation

Valve Block Theory of Operation

PTO Clutch and Brake Control Valves Theory of Operation

PTO Clutch and Brake Theory of Operation

Power Transmission - Traction Drive

Power Transmission - Mid and Rear PTO

Group 25: Tests and Adjustments

Hydraulic Warm Up Procedure

Charge Pump/Steering System Relief Pressure Test

PTO Clutch Pressure Test

PTO Lubrication Pressure Test

PTO Brake Test

Transmission Neutral Adjustment

MFWD-to-Frame Clearance Adjustment

Group 30: Repair

Hydrostatic Transmission Removal

Charge Pump Removal

Charge Pump Disassembly and Inspection

Charge Pump Assembly and Installation

Hydro Motor Removal, Disassembly, and Inspection

Hydrostatic Motor Assembly and Installation

Hydrostatic Pump Removal and Installation

Valve Block Disassembly and Inspection

Valve Block Assembly

Cover Plate Removal and Installation

Cover Plate Disassembly and Inspection

Valve Plate Removal and Disassembly

Valve Plate Assembly and Installation

Differential Carrier Removal and Installation

Differential Carrier Disassembly and Inspection

Rear PTO Removal

Rear PTO Installation

Transmission Disassembly

Transmission Assembly

Mechanical Front Wheel Drive (MFWD) Removal

Final Drive Cover Disassembly and Inspection - MFWD

Final Drive Cover Assembly - MFWD

Final Drive Housing Disassembly and Inspection - MFWD

Final Drive Housing Assembly- MFWD

Spindle Housing Disassembly and Inspection

Spindle Housing Assembly

Differential Input Housing Disassembly - MFWD

Differential Input Housing Assembly - MFWD

Differential Disassembly and Inspection - MFWD

Differential Assembly - MFWD

Section 60: Hydraulics

Group 05: Specifications

General Hydraulic Specifications

Test and Adjustment Specifications

Repair Specifications

Torque Specifications

Service Equipment and Tools

Group 10: Component Locations

Hydraulic System

Rockshaft

Rockshaft Control Valve Component Location

Hydraulic Pump

Selective Control Valve Linkage Component Location

Selective Control Valve Component Location

Group 15: Schematics

Hydraulic Schematic

Steering Schematic

Rockshaft Hydraulic Schematic

Group 20: Operation and Diagnostics

Hydraulic System

Hydraulics—SCV Operation

Group 25: Troubleshooting

Hydraulic System

Group 30: Theory of Operation

Hydraulics (Rockshaft)

Draft Linkage

System Pressure Relief

Speed Control Valve—Neutral

Rockshaft Control Valve—Raise

Rockshaft Control Valve—Lower

Rockshaft Control Valve—Neutral

Group 35: Tests and Adjustments

Hydraulic Warm Up Procedure

Rockshaft Sensitivity Adjustment

Lift Arm Adjustment

Implement Pressure Relief Adjustment

Charge Pump/Steering System Relief Pressure Test

PTO Clutch Pressure Test

Pump Flow Test

Rockshaft Lift Cycle Test

Rockshaft Leakage Test

Group 40: Repair

Hydraulic Pump Removal and Installation

Hydraulic Pump Disassembly and Inspection

Hydraulic Pump Assembly

Screen Filter Removal and Replacement

Selective Control Valve (SCV)

Rockshaft Assembly Removal

Lift Arms Removal and Installation

Rockshaft Disassembly and Inspection

Rockshaft Removal

Rockshaft Control Valve Removal and Installation

Rockshaft Control Valve Disassembly, Inspection, and Assembly

Section 70: Steering

Group 05: Specifications

Steering Specifications

Torque Specifications

Service Equipment and Tools

Group 10: Component Location

Steering System Component Location

Steering System Schematic

Group 15: Theory of Operation

Steering Operation

Group 20: Diagnostics

System: Steering Checks

Symptom: Steering Problems

Symptom: Steering Noisy or Vibrates

Group 25: Tests and Adjustments

Steering System Test

Group 30: Repair

Tie Rod Removal and Installation

Steering Cylinder Removal and Installation

Steering Wheel Removal and Installation

Steering Control Unit (SCU) Removal and Installation

Section 80: Brakes

Group 05: Specifications

Brake Specifications

Torque Specifications

Service Equipment and Tools

Group 10: Component Location

Brake Pedals and Linkage

Brake Pedals and Linkage—Explode

Brake Pedals and Linkage—Explode (Export)

Park Brake Component Location

Park Brake Component Location (Export)

Brake Housing Component Location

Group 15: Theory of Operation

Brakes

Group 20: Diagnostics

System: Brake Checks

Symptom: Brake Problems

Symptom: Cruise Control Problems

Group 25: Tests and Adjustments

Brake Pedal Adjustment

Park Brake Adjustment - Export

Group 30: Repair

Brake Disassembly and Inspection

Brake Assembly

Brake Pedal and Linkage Removal and Installation

Park Brake Linkage

Park Brake Linkage - Export

Cruise Control Linkage

Section 90: Miscellaneous

Group 05: Specifications

General Specifications

Torque Specifications

Group 10: Repair

Seat and Seat Frame Removal and Installation

Roll Over Protection System Removal and Installation

Rear Fenders Removal and Installation

Fender/ROPS Support Removal and Installation

Foot Deck Removal and Installation

Front Wheel Removal and Installation

Rear Wheel Removal and Installation

Battery Removal and Installation

Hood Removal and Installation

Muffler and Exhaust Pipe Removal and Installation

Steering Wheel Removal and Installation

Control Panel Removal and Installation

Control Panel Lower Shroud Removal and Installation

Fuel Tank Removal and Installation

Three-Point Hitch Removal and Installation

John Deere Compact Utility Tractors 2520 Series Repair, Test & Adjustments Technical Service Manual (TM2288)