Complete Diagnosis & Tests Technical Manual with electrical wiring diagrams for John Deere Tractors 5220, 5320, 5420, 5520, with all the technical information to maintain, diagnose, and rebuild like professional mechanics.

John Deere Tractors 5220, 5320, 5420 & 5520 workshop Diagnosis & Tests technical 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.

tm2049 - 5220, 5320, 5420, and 5520 Tractors Diagnostics Technical Manual.pdf
tm2049 - 5220, 5320, 5420, and 5520 Tractors Diagnostics Technical Manual.epub

PRODUCT DETAILS:
Total Pages: 1,416 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English

MAIN SECTIONS
 Foreword
   Operational Checkout Procedures
      Operational Checkout Procedures
   Engine Operation, Tests, and Adjustments
      Component Location
      Theory of Operation
      Diagnosis, Tests, and Adjustments
   Fuel/Air Operation, Tests, and Adjustments
      Component Location
      Theory of Operation
      Diagnosis, Tests and Adjustments
   Electrical System Operation, Test & Adjust
      Component Location
      Theory of Operation
      Diagnosis, Test and Adjust
      Wiring Schematics
   Power Train Operation, Tests and Adjustments
      Component Location-CollarShift/SyncShuttle™ Transmission
      Component Location-PowrReverser™ Transmission
      Theory of Operation-CollarShift/SyncShuttle™ Transmission
      Theory of Operation-PowrReverser™ Transmission
      Diagnosis, Tests, and Adjustments-CS/SS Transmission
      Diagnosis, Tests, and Adjustments-PowrReverser™
   Steering and Brake Operation, Test & Adjust
      Component Location
      Theory of Operation
      Diagnosis, Tests and Adjustments
   Hydraulic System Operation, Tests, and Adjustments
      Component Location
      Theory of Operation
      Diagnosis
      Hydraulic Tests-Without SCV
      Hydraulic Tests-With SCV
      Hydraulic Tests-All
      Adjustments
      Hydraulic Schematics
   Operator Station
      Component Location
      Theory of Operation
      Diagnosis, Tests, and Adjustments
   Dealer Fabricated Tools
      Dealer Fabricated Tools
 

tm2049 - 5220, 5320, 5420, and 5520 Tractors Diagnostic Technical Manual

Table of Contents

Foreword

Section 210: Operational Checkout Procedures

Group 10: Operational Checkout Procedures

Specifications

Operational Checkout Procedure Information

Engine Oil Level and Condition Check

Coolant Level and Condition Check

Transmission and Hydraulic Oil Check

3-Cylinder Fan and V-Belt Check

4-Cylinder Fan and Serpentine Belt Check

Compressor Belt Check

Fuel System Check (S.N. —420000)

Fuel System Check (S.N. 420001— )

Air Intake System Check

Electrical System Check (S.N. —420000)

Electrical System Check (S.N. 420001— )

Hydraulic System Check (S.N. —420000)

Hydraulic System Check (S.N. 420001— )

MFWD Oil Check

MFWD Differential Oil Check

Indicator Lamps Check (S.N. —420000)

Indicator Lamps Check (S.N. 420001— )

Cab Blower Motor Check (S.N. —420000)

Cab Blower Motor Check (S.N. 420001— )

A/C Compressor Clutch Check

Engine Start Check—Straddle Mount Tractors

Engine Start Check—Isolated Open Operator Station and Cab Tractors

Transmission Neutral Start Check—Straddle Mount Tractors

Transmission Neutral Start Check—Isolated Open Operator Station and Cab Tractors

PTO Neutral Start Check

Engine Fast and Slow Idle Operation

Foot Throttle Pedal Check—Isolated Open Operator Station and Cab Tractors

Power Steering Check

Differential Lock Check

PTO Engagement Check

Clutch Check

Transmission Shift Check

Range Lever Shift Check

MFWD Drive Check

Brake Check

Park Brake Check—CollarShift and SyncShuttle SYNCSHUTTLE is a trademark of Deere & Company Transmissions

Park Brake Check—PowrReverser POWRREVERSER is a trademark of Deere & Company Transmission

Rockshaft Check—Straddle Mount Tractors

Rockshaft Check—Isolated Open Operator Station and Cab Tractors

Selective Control Valve Check—Straddle Mount Tractors

Selective Control Valve Check—Isolated Open Operator Station and Cab Tractors

Front End Loader Joystick Control Check (Optional)

A/C System Operational Check

Cab Heater Valve Check

Miscellaneous Checks

Section 220: Engine Operation, Tests, and Adjustments

Group 05: Component Location

Component Location Information

3-Cylinder Engine External Components—Left-Hand Side

3-Cylinder Engine External Components—Right-Hand Side

4-Cylinder Engine External Components—Left-Hand Side

4-Cylinder Engine External Components—Right-Hand Side

Group 10: Theory of Operation

Theory of Operation Information

Engine Lubrication System Operation

Engine Lubrication System Operation—Continued

Engine Cooling System Operation—3-Cylinder

Engine Cooling System Operation—4-Cylinder

Group 15: Diagnosis, Tests, and Adjustments

Service Equipment and Tools

Specifications

Diagnostic Information

Engine Turns Over but Will Not Start or Starts Hard

Engine Runs Irregularly or Stalls Frequently

Engine Runs Rough

Engine Has Low Power

Engine Smokes—Black or Gray

Engine Smokes Excessively—White

Engine Uses Excess Fuel

Engine Has Excess Noise or Vibration

Engine Uses Excess Oil or Smokes Blue

Engine Has Low Oil Pressure

Engine Coolant Operating Temperature Incorrect

Oil In Coolant or Coolant in Oil

Radiator Bubble Test

Cooling System Test

Radiator Cap Pressure Test

Engine Oil Pressure Test

Cylinder Compression Pressure Test

Fuel Shut-Off Solenoid Check

Throttle Lever Adjustment—Straddle Mount Tractors

Throttle Lever Adjustment—Isolated Open Operator Station and Cab Tractors

Slow Idle Adjustment

Fast Idle Adjustment

Foot Throttle Pedal Stop Adjustment—Isolated Open Operator Station and Cab Tractors

Injection Pump Timing Adjustment

Check and Adjust Valve Clearance

Fan/Alternator V-Belt Adjustment—5220 and 5320 Tractors

Compressor Drive Belt Adjustment—3-Cylinder

Turbocharger Boost Pressure Test—5320 and 5520 Tractors

Bleed Fuel System

Section 230: Fuel/Air Operation, Tests, and Adjustments

Group 05: Component Location

Component Location Information

Fuel System Components—Straddle Mount

Fuel System Components—Isolated Open Operator Station and Cab Tractors (S.N. —420000)

Fuel System Components—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )

Air Intake System Components—Without Turbocharger

Air Intake System Components—With Turbocharger

Group 10: Theory of Operation

Theory of Operation Information

Fuel System Operation—Straddle Mount

Fuel System Operation—Isolated Open Operator Station and Cab Tractors (S.N. —420000)

Fuel System Operation—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )

Fuel Filter/Priming Pump Operation

Fuel Filter/Priming Pump Operation

Fuel Injection Nozzle Operation

Fuel Injection Nozzle Operation

Air Intake System Operation—Without Turbocharger

Air Intake System Operation—Without Turbocharger

Air Intake System Operation—With Turbocharger

Air Intake System Operation—With Turbocharger

Turbocharger Operation—5320 and 5520

Group 15: Diagnosis, Tests and Adjustments

Diagnostic Information

Fuel/Air Diagnosis, Tests and Adjustments

Section 240: Electrical System Operation, Test & Adjust

Group 05: Component Location

Component Location Information

Engine Electrical Components

Dash Electrical Components—Straddle Mount (S.N. —420000)

Dash Electrical Components—Straddle Mount (S.N. 420001— )

Dash Electrical Components—Isolated Open Operator Station and Cab Tractors (S.N. —420000)

Dash Electrical Components—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )

Machine Electrical Components—Straddle Mount (S.N. —420000)

Machine Electrical Components—Straddle Mount (S.N. 420001— )

Machine Electrical Components—Isolated Open Operator Station (S.N. —420000)

Machine Electrical Components—Isolated Open Operator Station (S.N. 420001— )

Machine Electrical Components—Cab Tractors (S.N. —420000)

Machine Electrical Components—Cab Tractors (S.N. 420001— )

Cab Control Panel and Electrical Components

Group 10: Theory of Operation

Theory of Operation Information

Fuse/Relay Block Assembly—Straddle Mount (S.N. —420000)

Fuse/Relay Block Assembly—Straddle Mount (S.N. 420001— )

Fuse/Relay Block Assembly—Early Model Cab Tractors (S.N. —420000)

Fuse/Relay Block Assembly—Isolated Open Operator Station and Late Model Cab Tractors (S.N. —420000)

Fuse/Relay Block Assembly—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )

Electrical Load Center—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )

HVAC/Wiper Relay Block Assembly—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )

Starting System Operation—Normal (S.N. —420000)

Starting System Operation—Normal (S.N. 420001— )

Starting System Operation—Bypass Attempt (S.N. —420000)

Starting System Operation—Bypass Attempt (S.N. 420001— )

Air Intake Heater System Operation (S.N. —420000) (Optional)

Air Intake Heater System Operation (S.N. 420001— ) (Optional)

Charging System Operation (S.N. —420000)

Charging System Operation (S.N. 420001— )

Lighting System Operation—Turn Signals and Enhanced Tail Lights—Straddle Mount (S.N. —420000)

Lighting System Operation—Turn Signals—Isolated Open Operator Station (S.N. —420000)

Lighting System Operation—Turn Signals—Straddle Mount and Isolated Open Operator Station (S.N. 420001— )

Lighting System Operation—Turn Signals—Early Model Cab Tractors (S.N. —420000)

Lighting System Operation—Turn Signals—Late Model Cab Tractors (S.N. —420000)

Lighting System Operation—Turn Signals—Cab Tractors (S.N. 420001— )

Lighting System Operation—Warning Lights—Straddle Mount (S.N. —420000)

Lighting System Operation—Warning Lights—Isolated Open Operator Station (S.N. —420000)

Lighting System Operation—Warning Lights—Straddle Mount and Isolated Open Operator Station (S.N. 420001— )

Lighting System Operation—Warning Lights—Early Model Cab Tractors (S.N. —420000)

Lighting System Operation—Warning Lights—Late Model Cab Tractors (S.N. —420000)

Lighting System Operation—Warning Lights—Cab Tractors (S.N. 420001— )

Lighting System Operation—Tail Lights—All Tractors (S.N. —420000)

Lighting System Operation—Tail Lights—All Tractors (S.N. 420001— )

Lighting System Operation—Headlights and Instrument Lights—Straddle Mount (S.N. —420000)

Lighting System Operation—Headlights and Instrument Lights—Straddle Mount (S.N. 420001— )

Lighting System Operation—Headlights and Instrument Lights—Early Model Cab Tractors (S.N. —420000)

Lighting System Operation—Headlights and Instrument Lights—Isolated Open Operator Station and Late Model Cab Tractors (S.N. —420000)

Lighting System Operation—Headlights and Instrument Lights—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )

Flood Light Operation—Straddle Mount (S.N. —420000)

Flood Light Operation—Isolated Open Operator Station (S.N. —420000)

Flood Light Operation—Cab Tractors (S.N. —420000)

Work Light Operation—Straddle Mount and Isolated Open Operator Station (S.N. 420001— )

Work Light and Beacon Operation—Cab Tractors (S.N. 420001— )

Instrument Panel System Operation—Tachometer/Hour Meter—All Tractors (S.N. —420000)

Instrument Cluster Operation—Tachometer/Hour Meter—All Tractors (S.N. 420001— )

Instrument Panel System Operation—Fuel Gauge—All Tractors (S.N. —420000)

Instrument Cluster Operation—Fuel Gauge—All Tractors (S.N. 420001— )

Instrument Panel System Operation—Coolant Temperature Gauge—All Tractors (S.N. —420000)

Instrument Cluster Operation—Coolant Temperature Gauge—All Tractors (S.N. 420001— )

PTO Warning System Operation—Straddle Mount (S.N. —420000)

PTO Warning System Operation—Early Model Cab Tractors (S.N. —420000)

PTO Warning System Operation—Isolated Open Operator Station and Late Model Cab Tractors (S.N. —420000)

PTO Warning System Operation—All Tractors (S.N. 420001— )

Air Filter Restriction Indicator Operation—All Tractors (S.N. —420000)

Air Filter Restriction Indicator Operation—All Tractors (S.N. 420001— )

Optional Horn Operation—All Tractors (S.N. —420000)—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )

Optional Horn Operation—Straddle Mount Tractors (S.N. 420001— )

Accessory Relay and Electrical Outlet Operation—All Tractors (S.N. —420000)

Accessory Relay and Electrical Outlet Operation—Straddle Mount Tractors (S.N. 420001— )

Accessory Relay and Electrical Outlet Operation—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )

Blower Motor Operation—Cab Tractors (S.N. —420000)

Blower Motor Operation—Cab Tractors (S.N. 420001— )

A/C Compressor Operation—Cab Tractors (S.N. —420000)

A/C Compressor Operation—Cab Tractors (S.N. 420001— )

Front Wiper/Washer Operation—Cab Tractors (S.N. —420000)

Front Wiper/Washer Operation—Cab Tractors (S.N. 420001— )

Rear Wiper/Washer Operation—Cab Tractors (S.N. —420000) (Optional)

Rear Wiper/Washer Operation—Cab Tractors (S.N. 420001— ) (Optional)

Dome Light Operation—Cab Tractors (S.N. —420000)

Dome Light Operation—Cab Tractors (S.N. 420001— )

Convenience Outlet Operation—Cab Tractors (S.N. —420000)

Convenience Outlet Operation—Cab Tractors (S.N. 420001— )

Group 15: Diagnosis, Test and Adjust

Diagnostic Information

Wire Color Chart

Starting System Test Points—Normal Operation—Straddle Mount (S.N. —420000)

Starting System Test Points—Normal Operation—Straddle Mount (S.N. 420001— )

Starting System Test Points—Normal Operation (Isolated Open Operator Station and Cab Tractors) (S.N. —420000)

Starting System Test Points—Normal Operation (Isolated Open Operator Station and Cab Tractors) (S.N. 420001— )

Starting System Test Points—Bypass Attempt—Straddle Mount (S.N. —420000)

Starting System Test Points—Bypass Attempt—Straddle Mount (S.N. 420001— )

Starting System Test Points—Bypass Attempt (Isolated Open Operator Station and Cab Tractors) (S.N. —420000)

Starting System Test Points—Bypass Attempt (Isolated Open Operator Station and Cab Tractors) (S.N. 420001— )

Air Intake Heater Test Points—Straddle Mount (S.N. —420000)

Air Intake Heater Test Points—Straddle Mount (S.N. 420001— )

Air Intake Heater Test Points—Isolated Open Operator Station and Cab Tractors (S.N. —420000)

Air Intake Heater Test Points—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )

Charging System Test Points—Straddle Mount (S.N. —420000)

Charging System Test Points—Straddle Mount (S.N. 420001— )

Charging System Test Points—Isolated Open Operator Station and Cab Tractors (S.N. —420000)

Charging System Test Points—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )

Lighting System Test Points—Turn Signals and Enhanced Tail Lights—Straddle Mount (S.N. —420000)

Lighting System Test Points—Turn Signals and Enhanced Tail Lights—Straddle Mount (S.N. 420001— )

Lighting System Test Points—Turn Signal Switch Power (Isolated Open Operator Station and Cab Tractors) (S.N. —420000)

Lighting System Test points—Turn Signal Operation (Isolated Open Operator Station) (S.N. —420000)

Lighting System Test points—Turn Signals—Isolated Open Operator Station (S.N. 420001— )

Lighting System Test points—Turn Signals—Early Model Cab Tractors (S.N. —420000)

Lighting System Test points—Turn Signals—Isolated Open Operator Station and Late Model Cab Tractors (S.N. —420000)

Lighting System Test points—Turn Signals—Cab Tractors (S.N. 420001— )

Lighting System Test Points—Warning Lights—Straddle Mount (S.N. —420000)

Lighting System Test Points—Warning Lights—Straddle Mount (S.N. 420001— )

Lighting System Test Points—Warning Lights (Isolated Open Operator Station) (S.N. —420000)

Lighting System Test Points—Warning Lights (Isolated Open Operator Station) (S.N. 420001— )

Lighting System Test Points—Warning Lights—Early Model Cab Tractors (S.N. —420000)

Lighting System Test points—Warning Lights—Late Model Cab Tractors (S.N. —420000)

Lighting System Test points—Warning Lights—Cab Tractors (S.N. 420001— )

Lighting System Test Points—Flood Light(s)—Straddle Mount (S.N. —420000)

Lighting System Test Points—Work Lights—Straddle Mount (S.N. 420001— )

Lighting System Test Points—Flood Lights (Isolated Open Operator Station) (S.N. —420000)

Lighting System Test Points—Work Lights—Isolated Open Operator Station (S.N. 420001— )

Lighting System Test Points—Flood Lights (Cab Tractors) (S.N. —420000)

Lighting System Test Points—Work Lights—Cab Tractors (S.N. 420001— )

Lighting System Test Points—Tail Lights—Straddle Mount (S.N. —420000)

Lighting System Test Points—Tail Lights—Straddle Mount (S.N. 420001— )

Lighting System Test Points—Tail Lights (Isolated Open Operator Station and Cab Tractors) (S.N. —420000)

Lighting System Test Points—Tail Lights—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )

Lighting System Test Points—Headlights and Instrument Lights—Straddle Mount (S.N. —420000)

Lighting System Test Points—Headlights and Instrument Lights—Straddle Mount (S.N. 420001— )

Lighting System Test Points—Headlights and Instrument Lights—Early Model Cab Tractors (S.N. —420000)

Lighting System Test points—Headlights and Instrument Lights—Isolated Open Operator Station and Late Model Cab Tractors (S.N. —420000)

Lighting System Test points—Headlights and Instrument Lights—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )

Lighting System Test Points—Dome Light (Cab Tractors) (S.N. —420000)

Lighting System Test Points—Dome Light—Cab Tractors (S.N. 420001— )

Instrument Panel System Test Points—Tachometer/Hour Meter—Straddle Mount (S.N. —420000)

Instrument Cluster System Test Points—Tachometer/Hour Meter—Straddle Mount (S.N. 420001— )

Instrument Panel System Test Points—Tachometer/Hour Meter (Isolated Open Operator Station and Cab Tractors) (S.N. —420000)

Instrument Cluster Test Points—Tachometer/Hour Meter—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )

Instrument Panel System Test Points—Fuel Gauge—Straddle Mount (S.N. —420000)

Instrument Cluster System Test Points—Fuel Gauge—Straddle Mount (S.N. 420001— )

Instrument Panel System Test Points—Fuel Gauge (Isolated Open Operator Station and Cab Tractors) (S.N. —420000)

Instrument Cluster Test Points—Fuel Gauge (Isolated Open Operator Station and Cab Tractors) (S.N. 420001— )

Instrument Panel System Test Points—Temperature Gauge—Straddle Mount (S.N. —420000)

Instrument Cluster System Test Points—Temperature Gauge—Straddle Mount (S.N. 420001— )

Instrument Panel System Test Points—Temperature Gauge (Isolated Open Operator Station and Cab Tractors) (S.N. —420000)

Instrument Cluster Test Points—Temperature Gauge (Isolated Open Operator Station and Cab Tractors) (S.N. 420001— )

Instrument Cluster System Test Points—Oil Pressure—Straddle Mount (S.N. —420000)

Instrument Cluster System Test Points—Oil Pressure—Straddle Mount (S.N. 420001— )

Instrument Panel System Test Points—Oil Pressure (Isolated Open Operator Station and Cab Tractors) (S.N. —420000)

Instrument Cluster Test Points—Oil Pressure (Isolated Open Operator Station and Cab Tractors) (S.N. 420001— )

PTO Warning System Test Points—Straddle Mount (S.N. —420000)

PTO Warning System Test Points—Straddle Mount (S.N. 420001— )

PTO Warning System Test Points—Early Model Cab Tractors (S.N. —420000)

PTO Warning System Test Points—Isolated Open Operator Station and Late Model Cab Tractors (S.N. —420000)

PTO Warning System Test Points—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )

Air Filter Restriction Test Points—Straddle Mount (S.N. —420000)

Air Filter Restriction Test Points—Straddle Mount (S.N. 420001— )

Air Filter Restriction Test Points—Isolated Open Operator Station and Cab Tractors (S.N. —420000)

Air Filter Restriction Test Points—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )

Optional Horn Test Points—Straddle Mount (S.N. —420000)

Optional Horn Test Points—Straddle Mount (S.N. 420001— )

Optional Horn Test Points—Cab Tractors and Isolated Open Operator Station (S.N. —420000)

Optional Horn Test Points—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )

Accessory Relay and Electrical Outlet Test Points—Straddle Mount (S.N. —420000)

Accessory Relay and Electrical Outlet Test Points—Straddle Mount (S.N. 420001— )

Accessory Relay and Electrical Outlet Test Points—Early Model Cab Tractors (S.N. —420000)

Accessory Relay and Electrical Outlet Test Points—Isolated Open Operator Station and Late Model Cab Tractors (S.N. —420000)

Accessory Relay and Electrical Outlet Test Points—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )

Blower Motor Test Points—Cab Tractors (S.N. —420000)

Blower Motor Test Points—Cab Tractors (S.N. 420001— )

A/C Compressor Clutch Coil Test Points—Cab Tractors (S.N. —420000)

A/C Compressor Clutch Coil Test Points—Cab Tractors (S.N. 420001— )

Front Wiper/Washer Test Points—Cab Tractors (S.N. —420000)

Front Wiper/Washer Test Points—Cab Tractors (S.N. 420001— )

Rear Wiper/Washer Test Points—Cab Tractors (S.N. —420000)

Rear Wiper/Washer Test Points—Cab Tractors (S.N. 420001— )

Convenience Outlet Test Points—Cab Tractors (S.N. —420000)

Convenience Outlet Test Points—Cab Tractors (S.N. 420001— )

Battery Voltage and Specific Gravity Tests

Charge Battery

Battery Load Test

Starter Amp Draw/RPM Test

Starter No-Load Amp Draw/RPM Test

Alternator/Regulator Test

Starter Solenoid Test

Starter Relay Test

Key Switch Test

Plug-In Relay Test

Diode Pack Test

Fuse Test

Neutral Start Switch Test

PTO Switch Test

PTO Seat Switch Test

Light Switch Test

Flasher Module Test—Isolated Open Operator Station and Cab Tractors

Turn Signal Controller Test—Straddle Mount (S.N. —420000)

Turn Signal Switch Test—All Tractors (S.N. 420001— )

Fuel Shut-Off Solenoid Test

Blower Switch Test

Start Resistor Test

Blower Motor Resistors

A/C Temperature Control Switch Test

Front Wiper/Washer Switch Test

Rear Wiper/Washer Switch Test

Door Switch Test

Dome Light Switch Test

Group 20: Wiring Schematics

Schematic Information

Component Identification Table

5220—5520 Straddle Mount Electrical Schematic (S.N. —420000)

5220—5520 Straddle Mount Electrical Schematic (S.N. 420001— )

5220—5520 Early Model Cab Tractors Electrical Schematic (S.N. —420000)

5220—5520 Isolated Open Operator Station and Late Model Cab Tractors Electrical Schematic (S.N. —420000)

5220—5520 Isolated Open Operator Station and Cab Tractors Electrical Schematic (S.N. 420001— )

Section 250: Power Train Operation, Tests and Adjustments

Group 05: Component Location—CollarShift/SyncShuttle™ Transmission

Component Location Information

Power Train Components—Straddle Mount (CollarShift and SyncShuttle™)

Power Train Components—Isolated Open Operator Station and Cab Tractors (CollarShift and SyncShuttle™)

Clutch Components—CollarShift and SyncShuttle™ Transmissions

Transmission Components—CollarShift

Transmission Components—SyncShuttle™

Final Drive Components

Hi-Crop Final Drive Axle Components

Rear PTO Components

Rear 540/540E PTO Components (SyncShuttle™ Transmission Only)

Group 06: Component Location—PowrReverser™ Transmission

Component Location Information

Power Train Components—Straddle Mount (PowrReverser™ Transmission)

Power Train Components—Isolated Open Operator Station and Cab Tractors (PowrReverser™ Transmission)

Clutch Components—PowrReverser™ Transmission

PowrReverser™ Components

Transmission Components—PowrReverser™ Transmission

Final Drive Components

Rear PTO Components

Group 10: Theory of Operation—CollarShift/SyncShuttle™ Transmission

Theory of Operation Information

Clutch Operation—CollarShift and SyncShuttle™ Transmissions

Transmission Lubrication System

CollarShift Transmission—Gear Shift Power Flow

SyncShuttle™ Transmission—Gear Shift Power Flow

SyncShuttle™ Transmission Synchronizer Operation—Reverse and 2nd Gear (Disk-and-Plate Type Synchronizer)

SyncShuttle™ Transmission Synchronizer Operation—1st and 3rd Gear (Cone-Type Synchronizer)

CollarShift Transmission—Range Shift Power Flow

Rear PTO Operation

Rear PTO Operation

Rear 540/540E PTO Operation (SyncShuttle™ and PowrReverser™ Transmissions)

Rear 540/540E PTO Operation (SyncShuttle™ and PowrReverser™ Transmissions)

Differential Power Flow

Differential Power Flow

Hi-Crop Axle Differential Power Flow

Hi-Crop Axle Differential Power Flow

Differential Lock Operation

Differential Lock Operation

Final Drive Operation

Mechanical Front Wheel Drive (MFWD) Drop Gearbox Operation

Mechanical Front Wheel Drive (MFWD) Drop Gearbox Operation

Group 11: Theory of Operation—PowrReverser™ Transmission

Theory of Operation Information

Clutch Operation—PTO Clutch Disengaged (PowrReverser™ Transmission)

Clutch Operation—PTO Clutch Engaged (PowrReverser™ Transmission)

PowrReverser™ General Information

PowrReverser™ Operation in Forward

PowrReverser™ Operation in Reverse

PowrReverser™ Power Flow

PowrReverser™ Control Valve Operation—Initial Engine Start-Up, Clutch Pedal Up

PowrReverser™ Control Valve Operation—F-N-R Lever in Neutral, Clutch Pedal Down

PowrReverser™ Control Valve Operation—F-N-R Lever in Neutral, Clutch Pedal Up

PowrReverser™ Control Valve Operation—F-N-R Lever in Forward, Clutch Pedal Up

PowrReverser™ Control Valve Operation—F-N-R Lever in Reverse, Clutch Pedal Up

PowrReverser™ Transmission—Gear Shift Power Flow

Gear Shift Synchronizer Operation

PowrReverser™ Transmission—Range Shift Power Flow

PowrReverser™ Transmission Lubrication System

Rear PTO Operation

Final Drive Operation

Differential Operation

MFWD Operation

Group 15: Diagnosis, Tests, and Adjustments—CS/SS Transmission

Diagnostic Information

Isolate the Problem Area

Traction Clutch Slips

Traction Clutch Dragging

Traction Clutch Does Not Engage

Traction Clutch Grabs

Traction Clutch Squeaks

Traction Clutch Does Not Release

Traction Clutch Chatters

Traction Clutch Rattles

Traction Clutch Engagement Is Noisy

Excessive Vibration in Traction Clutch

Clutch Pedal Does Not Return

Clutch Pedal Loose

Clutch Pedal Pulsates

Jerky or Rough Transmission of Power

Low Transmission Oil Level (Excessive Oil Leakage)

Gears Clash, Shift Hard, or Will Not Engage

Two Speeds Engage Together

Transmission Will Not Stay in Gear

Transmission Noisy

PTO Noisy

PTO Hard to Engage

PTO Will Not Operate

PTO Will Not Stay Engaged

Excessive Differential Noise

Differential Does Not Work

No Differential Lock

Differential Chatters

Axle Noise

Axle Shaft Will Not Turn

MFWD Lever Is Hard to Engage

MFWD Lever Will Not Stay in ON Position

Noisy Front Wheel Drive Operation

Check and Adjust Clutch Pedal Free Play—CollarShift and SyncShuttle™ Transmissions (Straddle Mount)

Check and Adjust Clutch Pedal Free Play—CollarShift and SyncShuttle™ Transmissions (Isolated Open Operator Station and Cab Tractors)

Adjusting PTO Clutch Lever Linkage—Straddle Mount

Adjusting PTO Clutch Lever Linkage—Isolated Open Operator Station and Cab Tractors

Group 16: Diagnosis, Tests, and Adjustments—PowrReverser™

Diagnostic Information—PowrReverser™ Transmission

Isolate the Problem Area—PowrReverser™ Transmission

Low Transmission Oil Level (Excessive Oil Leakage)

Clutch Pedal Does Not Return

Tractor Does Not Move in Forward or Reverse

PowrReverser™ Engages Too Quickly or Too Slowly

PowrReverser™ Does Not Disengage

Gears Clash, Shift Hard, or Will Not Engage

Two Speeds Engage Together

Transmission Will Not Stay in Gear

Transmission Noisy

PTO Troubleshooting

Differential Troubleshooting

Final Drive Axle Troubleshooting

MFWD Troubleshooting

PowrReverser™ Control Valve Tests

Transmission Pump Flow Test

Adjust Forward-Neutral-Reverse Cable

Clutch Pedal Linkage Adjustment

Park Brake Cable Adjustment

PTO 540/540E Lever and Linkage Adjustment

Section 260: Steering and Brake Operation, Test & Adjust

Group 05: Component Location

Component Location Information

Steering System Components—5220—5320 Straddle Mount

Steering System Components—5420—5520 Straddle Mount

Steering System Components—5220—5320 Isolated Open Operator Station

Steering System Components—5420—5520 Isolated Open Operator Station and All Cab Tractors

Brake System Components

Group 10: Theory of Operation

Theory of Operation Information

Steering System Operation—5220—5320 Straddle Mount

Steering System Operation—5420—5520 Straddle Mount

Steering System Operation—5220—5320 Isolated Open Operator Station

Steering System Operation—5420—5520 Isolated Open Operator Station and All Cab Tractors

Steering Valve Operation—Neutral and Manual Turning

Steering Valve Operation—Power Turning

Brake System Operation

Brake Valve Operation (S.N. —420000)

Brake Valve Operation (S.N. 420001— )

Group 15: Diagnosis, Tests and Adjustments

Diagnostic Information

Isolate the Problem—Steering System

Steering Sluggish or Loss of Steering

Isolate the Problem—Brakes

Excessive Brake Pedal Leak-Down

Excessive Brake Chatter

Steering Pump Flow Test

Steering Valve Relief Test

Steering Cylinder Leakage Test

Steering Valve Leakage Test

Toe-In Check and Adjustment—Standard Axle

Toe-In Check and Adjustment—MFWD

MFWD Steering Stop Adjustment

Brake Pedal Adjustment (S.N. —420000)

Brake Pedal Adjustment (S.N. 420001— )

Bleed Brake System

Adjust Brake (S.N. 388313— )

Adjust Brake (S.N. —388312)

Section 270: Hydraulic System Operation, Tests, and Adjustments

Group 05: Component Location

Component Location Information

Hydraulic System Components—Straddle Mount Tractors (Without Oil Cooler)

Hydraulic System Components—Isolated Open Operator Station and Cab Tractors (Without Oil Cooler)

Hydraulic System Components—Straddle Mount Tractors (With Oil Cooler)

Hydraulic System Components—Isolated Open Operator Station and Cab Tractors (With Oil Cooler)

Selective Control Valve Components—Straddle Mount Tractors without Mid-Mount SCV (S.N. —420000)

Selective Control Valve Components—Straddle Mount Tractors without Mid-Mount SCV (S.N. 420001— )

Selective Control Valve Components—Isolated Open Operator Station and Cab Tractors without Mid-Mount SCV

Selective Control Valve Components—Cab Tractors with Mid-Mount SCV

Selective Control Valve Components—Isolated Open Operator Station Tractors with Mid-Mount SCV

Selective Control Valve Components—Straddle Mount Tractors with Mid-Mount SCV (S.N. 420001— )

Group 10: Theory of Operation

Theory of Operation Information

Hydraulic System Operation—Straddle Mount Tractors (S.N. —420000)

Hydraulic System Operation—Straddle Mount Tractors (S.N. 420001— )

Hydraulic System Operation—Isolated Open Operator Station and Cab Tractors

Hydraulic Filter Operation

Hydraulic Pump Operation

Rockshaft Control Valve Operation—Two Flow Regulator Valves (Early Model Straddle Mount)

Rockshaft Control Valve Operation—Neutral Position (Early Model Straddle Mount)

Rockshaft Control Valve Operation—Raise Position (Early Model Straddle Mount)

Rockshaft Control Valve Operation—Lower Position (Early Model Straddle Mount)

Rockshaft Control Valve Operation—Neutral Position (Isolated Open Operator Station, Cab Tractors and Late Model Straddle Mount)

Rockshaft Control Valve Operation—Raise Position (Isolated Open Operator Station, Cab Tractors and Late Model Straddle Mount)

Rockshaft Control Valve Operation—Flow Control Operation (Isolated Open Operator Station, Cab Tractors and Late Model Cab Tractors)

Rockshaft Control Valve Operation—Lower Position (Isolated Open Operator Station, Cab Tractors and Late Model Straddle Mount)

Surge Relief Valve Operation

Main Relief Valve Operation—Straddle Mount Tractors

Main Relief Valve Operation—Isolated Open Operator Station and Cab Tractors

Rate-of-Drop Valve Operation—Full Open (Straddle Mount)

Rate-of-Drop Valve Operation—Full Open (Isolated Open Operator Station And Cab Tractors)

Rate-of-Drop Valve Operation—Partially Open (Straddle Mount)

Rate-of-Drop Valve Operation—Partially Open (Isolated Open Operator Station and Cab Tractors)

Rate-of-Drop Valve Operation—Full Closed (Straddle Mount)

Rate-of-Drop Valve Operation—Full Closed (Isolated Open Operator Station And Cab Tractors)

Rockshaft Draft-Sensing Operation

SCV Operation—Straddle Mount Tractors (Neutral Position)

SCV Operation—Straddle Mount Tractors (Extend and Retract Positions)

Float SCV Operation—Straddle Mount Tractors (Float Position)

Regenerative SCV Operation—Straddle Mount Tractors (Regenerative Position)

SCV Operation—Isolated Open Operator Station and Cab Tractors (Neutral Position)

SCV Operation—Isolated Open Operator Station and Cab Tractors (Extend and Retract Positions)

Float SCV Operation—Isolated Open Operator Station and Cab Tractors (Float Position)

Regenerative SCV Operation—Isolated Open Operator Station and Cab Tractors (Regenerative Position)

Quick Disconnect Coupler Operation (Straddle Mount)

Quick Disconnect Coupler Operation (Cab and IOOS)

Group 15: Diagnosis

Diagnostic Information

Preliminary Hydraulic System Inspection

Hydraulic Oil Warm-Up Procedure

Entire Hydraulic System Fails to Function/No Hydraulic Pump Output

Insufficient Pump Delivery

Hydraulic Functions Too Slow

Excessive Pump Pressure

Slow Hydraulic Pump Response

Excessive Pump Noise During Operation

Rockshaft Does Not Lift or Lifts Slowly

Rockshaft Does Not Lower or Lowers Slowly

Neutral Position Unstable, Rockshaft Drops after Engine Shut Down

Mid-Mount Joystick Does Not Return to Neutral Position—Mid-Mount SCV

Mid-Mount Joystick Does Not Remain in Detent Position—Mid-Mount SCV

Remote Cylinder Does Not Extend or Retract

Remote Cylinder Settles Under Load

Remote Cylinder Operates Too Fast or Too Slow

Group 16: Hydraulic Tests—Without SCV

Hydraulic System Tests—Without SCV (Straddle Mount Tractors)

Hydraulic System Tests—Without SCV (Isolated Open Operator Station and Cab Tractors)

Pump Flow Test—Without SCV

Main Relief Valve Test—Without SCV (Straddle Mount Tractors)

Main Relief Valve Test—Without SCV (Isolated Open Operator Station and Cab Tractors)

Group 17: Hydraulic Tests—With SCV

Hydraulic System Tests—With SCV (Straddle Mount Tractors) (S.N. —420000)

Hydraulic System Tests—With SCV (Straddle Mount Tractors) (S.N. 420001— )

Hydraulic System Tests—With SCV (Isolated Open Operator Station and Cab Tractors)

Pump Flow Test—With SCV

Main Relief Valve Test—With SCV

SCV Leakage Test

Group 18: Hydraulic Tests—All

Rockshaft Leakage Test—Straddle Mount

Rockshaft Leakage Test—Isolated Open Operator Station and Cab Tractors

Rockshaft Lift Cycle Test

Group 19: Adjustments

Selective Control Valve (SCV) Cable Adjustment—Isolated Open Operator Station and Cab Tractors

Rockshaft Draft-Sensing and Position Control Lever Cable Adjustment—Isolated Open Operator Station and Cab Tractors

Rockshaft Lever Friction Adjustment

Rockshaft Position-Sensing Feedback Linkage Adjustment

Rockshaft Draft-Sensing Feedback Linkage Adjustment

Main Relief Valve Adjustment—Straddle Mount Tractors

Main Relief Valve Adjustment—Isolated Open Operator Station and Cab Tractors

Group 20: Hydraulic Schematics

Hydraulic Circuit Symbols

Hydraulic Schematic—Straddle Mount Tractors (Without SCV) (S.N. —420000)

Hydraulic Schematic—Straddle Mount Tractors (With SCV) (S.N. —420000)

Hydraulic Schematic—Straddle Mount Tractors (With Mid-Mount Valve) (S.N. —420000)

Hydraulic Schematic—Isolated Open Operator Station and Cab Tractors (Without SCV) (S.N. —420000)

Hydraulic Schematic—Isolated Open Operator Station and Cab Tractors (With SCV) (S.N. —420000)

Hydraulic Schematic—Isolated Open Operator Station and Cab Tractors (With Mid-Mount Valve) (S.N. —420000)

Hydraulic Schematic—Straddle Mount Tractors (Without SCV) (S.N. 420001— )

Hydraulic Schematic—Straddle Mount Tractors (With SCV) (S.N. 420001— )

Hydraulic Schematic—Straddle Mount Tractors (With Mid-Mount Valve) (S.N. 420001— )

Hydraulic Schematic—Isolated Open Operator Station and Cab Tractors (Without SCV) (S.N. 420001— )

Hydraulic Schematic—Isolated Open Operator Station and Cab Tractors (With SCV and Mid Mount) (S.N.420001— )

Hydraulic Schematic—Isolated Open Operator Station and Cab Tractors (With Mid-Mount Valve) (S.N. 420001— )

Hydraulic Schematic—Isolated Open Operator Station and Cab Tractors (With Triple Rear SCV, Mid Mount, Power Beyond Coupler and Power Beyond Flow Control)

Section 290: Operator Station

Group 05: Component Location

Air Conditioning System Components (S.N. —420000)

Air Conditioning System Components (S.N. 420001— )

Group 10: Theory of Operation

Refrigerant R134a

Air Conditioning System Air Flow

Air Conditioning System Cycle

Compressor

Condenser

Receiver-Dryer

Expansion Valve

A/C Temperature Control Switch

Evaporator

A/C ON/OFF Switch and Temperature Control Knob

Heater Temperature Control Knob

High and Low Pressure Switches (S.N. —420000)

High/Low Pressure Switch (S.N. 420001— )

Group 15: Diagnosis, Tests, and Adjustments

Diagnosis, Tests, and Adjustments

Adjust Heater Temperature Control Cable

Adjust A/C Temperature Control Switch

Section 299: Dealer Fabricated Tools

Group 00: Dealer Fabricated Tools

DFLV1A Final Drive Turning Tool

DFRW20—Compressor Holding Fixture

John Deere Tractors 5220, 5320, 5420 & 5520 Diagnosis and Tests Service Technical Manual (TM2049)