John Deere Tractors 5200, 5300, 5400 & 5500 Diagnostic and Repair Service Manual (TM1520)

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John Deere Tractors 5200, 5300, 5400 & 5500 Diagnostic and Repair Service Manual (TM1520)

tm1520 - 5200, 5300, 5400 and 5500 tractors diagnostic and repair Technical Manual.pdf

Complete Technical Manual with electrical wiring diagrams for John Deere Tractors 5200, 5300, 5400 and 5500, with all the shop information to maintain, diagnostic, repair, service like professional mechanics (Diagnosis, Operation, Tests, Repair, Service, Troubleshooting).

John Deere 5200, 5300, 5400 and 5500 Tractors workshop technical manual (All Inclusive) 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: 1,763 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

MAIN SECTIONS
Foreword
   John Deere Dealers
   General Information
      Safety
      General Specifications
      Fuel and Lubricants
      Serial Number Locations
      Features and Accessories
   Engine Repair
      Engine
      Cooling System
   Fuel and Air Repair
      Fuel System
      Air Intake System
      Speed Control Linkage
   Electrical Repair
      Battery, Starter and Alternator
      Electrical System Components
      Wiring Harness
   Power Train Repair
      Clutch Housing-Collar Shift/TSS Transmission
      Clutch Housing-Hydraulic Reverser Transmission
      Clutch Assembly-Collar Shift/TSS Transmission
      Clutch Assembly-Hydraulic Reverser Transmission
      Hydraulic Reverser
      Collar Shift/TSS Transmission
      Hydraulic Reverser Transmission
      Rear PTO Drive Shaft-Collar Shift/TSS Transmission
      Rear PTO Drive Shaft-Hydraulic Reverser Transmission
      Differential
      Final Drives
      Mechanical Front Wheel Drive
      Creeper Assembly
   Steering and Brake Repair
      Steering Repair
      Brake Repair
   Hydraulic Repair
      Hydraulic Pump and Filter
      Hydraulic Oil Cooler
      Rockshaft
      Dual Selective Control Valve
      Single (Third) Selective Control Valve
      Hydraulic Mid Mount Coupler
      Hydraulic Power Beyond
   Miscellaneous Repair
      Front Axle-2WD
      Wheels
      3-Point Hitch
   Operator Station Repair
      Seat and Support
      ROLL-GARD™
      Cab Components
      Air Conditioning System
      Heating System
   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, Tests and Adjustments
      Component Location
      Theory of Operation
      Diagnosis, Tests and Adjustments
      Wiring Schematics
   Power Train Operation, Tests and Adjustments
      Component Location-Collar Shift/TSS Transmission
      Component Location-Hydraulic Reverser Transmission
      Theory of Operation-Collar Shift/TSS Transmission
      Theory of Operation-Hydraulic Reverser Transmission
      Diagnosis, Tests and Adjustments-Collar Shift/TSS Transmission
      Diagnosis, Tests and Adjustments-Hydraulic Reverser
   Steering and Brake Operation, Tests and Adjustments
      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

tm1520 - 5200, 5300, 5400 and 5500 tractors diagnostic and repair technical manual

Table of Contents

Foreword

John Deere Dealers

Section 10: General Information

Group 05: Safety

Recognize Safety Information

Understand Signal Words

Follow Safety Instructions

Handle Fluids Safely-Avoid Fires

Prevent Battery Explosions

Prepare for Emergencies

Prevent Acid Burns

Service Cooling System Safely

Handle Chemical Products Safely

Avoid High-Pressure Fluids

Park Machine Safely

Support Machine Properly

Wear Protective Clothing

Work in Clean Area

Service Machines Safely

Work in Ventilated Area

Illuminate Work Area Safely

Replace Safety Signs

Use Proper Lifting Equipment

Keep ROPS Installed Properly

Service Tires Safely

Avoid Harmful Asbestos Dust

Avoid Heating Near Pressurized Fluid Lines

Remove Paint Before Welding or Heating

Use Proper Tools

Dispose of Waste Properly

Live With Safety

Group 10: General Specifications

Machine Specifications-5200 and 5300

Travel Speeds-5200 and 5300

Machine Specifications-5400 and 5500

Travel Speeds-5400 and 5500

Service Recommendations for O-Ring Boss Fittings

Service Recommendations for Flat Face O-Ring Seal Fittings

Metric Cap Screw Torque Values-Grade 7

Metric Bolt and Cap Screw Torque Values

Unified Inch Bolt and Cap Screw Torque Values

Group 20: Fuel and Lubricants

Diesel Fuel Specifications

Storing Fuel

Do Not Use Galvanized Containers

Fill Fuel Tank

Diesel Engine Oil

Diesel Engine Coolant

Liquid Coolant Conditioner

Transmission and Hydraulic Oil

MFWD Gear Oil

Grease (Specific Application)

Grease

Alternative and Synthetic Lubricants

Lubricant Storage

Group 25: Serial Number Locations

Serial Numbers

Product Identification Number Location

Engine Serial Number Location

Fuel Injection Pump Serial Number Location

Alternator Serial Number Location

Power Steering Valve Serial Number Location

Starter Serial Number Location

Transmission Serial Number Location

Front Axle (2WD) Serial Number Location

Mechanical Front Wheel Drive (MFWD) Serial Number Location

Air Conditioning Compressor Serial Number Location

Group 30: Features and Accessories

Features and Accessories

Standard Features-5200, 5300 and 5400

Standard Features-5500

Factory Installed Optional Equipment

Field Installed Optional Kits and Accessories

Section 20: Engine Repair

Group 05: Engine

Service Equipment and Tools

Specifications

Deere Repair-Use CTM8

Remove Engine-Tractors without Cab

Install Engine-Tractors without Cab

Remove Engine-Tractors with Cab

Install Engine-Tractors with Cab

Group 10: Cooling System

Specifications

Engine Water Pump Repair-Use CTM8

Remove and Inspect Radiator-5200 through 5400

Install Radiator-5200 through 5400

Remove and Inspect Radiator-5500 Models

Install Radiator-5500 Models

Replace Thermostat-Early Models

Replace Thermostat-Later Models

Section 30: Fuel and Air Repair

Group 05: Fuel System

Specifications

Injection Pump, Nozzle and Governor Repair-Use CTM8

Remove, Inspect and Install Fuel Tank-Without Cab

Remove, Inspect and Install Fuel Tank With Cab

Replace Fuel Filter-5200, 5300 and 5400

Remove and Install Fuel Filter/Primer Pump Assembly-5200, 5300 and 5400

Replace Fuel Filter-5500

Remove and Install Fuel Filter/Primer Pump Assembly-5500

Group 10: Air Intake System

Other Material

Specifications

Turbocharger Repair-Use CTM8

Remove, Inspect, and Install Air Cleaner Elements-Early Model Tractors

Remove, Inspect, and Install Air Cleaner Elements-Later Model Tractors

Remove Turbocharger-5400

Install Turbocharger-5400

Remove Turbocharger-5500

Install Turbocharger-5500

Turbocharger Break-In

Group 15: Speed Control Linkage

Inspect and Repair Speed Control Linkage

Section 40: Electrical Repair

Group 05: Battery, Starter and Alternator

Starter Repair-Use CTM77

Remove and Install Battery-Without Cab

Remove and Install Battery-With Cab

Remove and Install Starter-Early Models

Remove and Install Starter-Later Models

Replace Alternator/Regulator-40 Amp Without Cab

Replace Alternator/Regulator-60 Amp Without Cab

Group 10: Electrical System Components

Service Equipment and Tools

Other Material

Replace Air Filter Restriction Switch

Replace Coolant Temperature Sender

Replace Engine Speed Sensor

Replace Fuel Shut-Off Solenoid

Replace Engine Oil Pressure Sender

Replace Air Intake Heater

Replace Air Intake Heater Relay

Replace Key Switch

Replace Tractor Light Switch

Replace Radio (Optional Equipment)

Replace Speakers (Optional Equipment)

Replace Antenna (Optional Equipment)

Replace Turn Signal Controller

Replace Instrument Panel-Collar Shift/TSS Transmission

Replace Instrument Panel-Hydraulic Reverser Transmission

Replace Rear PTO Switch-Tractors Without Cab

Replace Rear PTO Switch-Tractors With Cab

Replace Neutral Start Switch

Replace Seat Switch

Replace Fuel Level Sender-Tractors Without Cab

Replace Fuel Level Sender-Tractors With Cab

Replace Wiper Control Switch

Replace Wiper Motor

Replace Blower Control Switch

Replace Air Conditioning Temperature Control Switch

Replace Dome Light

Replace Dome Light Switch

Group 15: Wiring Harness

Service Equipment and Tools

Service Parts Kits

Replace Connector Body-Blade Terminals

Replace WEATHER PACK WEATHER PACK is a trademark of Packard Electric Connector

Install Weather PackWEATHER PACK WEATHER PACK is a trademark of Packard Electric Contact

Replace Front Wiring Harness

Replace Rear Wiring Harness: 5200-5400 With Fuse Block Located in Engine Compartment

Replace Rear Wiring Harness: 5200-5400 With Fuse Block Located Under Steering Column

Replace Rear Wiring Harness-Cab Models

Replace Cab Wiring Harness-Lights

Replace Cab Wiring Harness-Radio/Antenna

Replace Cab Wiring Harness-Main

Section 50: Power Train Repair

Group 05: Clutch Housing-Collar Shift/TSS Transmission

Service Parts Kits

Specifications

Separate Engine from Clutch Housing-Tractors Without Cab

Install Engine to Clutch Housing-Tractors Without Cab

Separate Engine from Clutch Housing-Tractors With Cab

Install Engine to Clutch Housing-Tractors With Cab

Replace Clutch Housing Seal

Inspect and Repair Clutch Pedal and Linkage

Group 06: Clutch Housing-Hydraulic Reverser Transmission

Specifications

Separate Engine from Clutch Housing-Tractors Without Cab

Install Engine to Clutch Housing-(HYD REV) Tractors without Cab

Separate Engine from Clutch Housing-Tractors With Cab

Install Engine to Clutch Housing-Tractors With Cab

Inspect and Repair Clutch Pedal and Linkage

Group 10: Clutch Assembly-Collar Shift/TSS Transmission

Special or Essential Tools

Other Material

Service Parts Kits

Specifications

Remove and Install Clutch Assembly

Disassemble and Inspect Clutch Assembly

Assemble Clutch Assembly

Traction Clutch Finger Adjustment

PTO Clutch Finger Adjustment

Remove and Inspect Clutch Release Mechanism and Shafts

Install Clutch Release Mechanism and Shafts

Group 11: Clutch Assembly-Hydraulic Reverser Transmission

Special or Essential Tools

Other Material

Service Parts Kits

Specifications

Remove and Install Clutch Assembly

Disassemble and Inspect Clutch Assembly

Assemble Clutch Assembly

PTO Clutch Finger Adjustment

Remove and Inspect Clutch Release Mechanism and Shafts

Install Clutch Release Mechanism and Shafts

Remove, Inspect and Repair Transmission Pump

Group 12: Hydraulic Reverser

Specifications

Remove and Install Hydraulic Reverser Control Valve

Disassemble, Inspect and Repair Hydraulic Reverser Control Valve

Remove and Install Hydraulic Reverser

Disassemble, Inspect and Repair Reverse Idle Gear

Disassemble, Inspect and Repair Clutch Gear

Disassemble, Inspect and Repair Driven Shaft

Disassemble, Inspect and Repair Hydraulic Reverser

Group 15: Collar Shift/TSS Transmission

Specifications

Separate Clutch Housing from Transmission

Install Clutch Housing to Transmission

Inspect and Repair Gear Shift Lever

Inspect and Repair Range Shift Lever

Remove Transmission

Disassemble and Inspect Transmission

Assemble Transmission

Install Transmission

Disassemble, Inspect and Assemble Gear Shift Shaft Assemblies

Disassemble, Inspect and Assemble Transmission Top Shaft-Collar Shift Transmission

Disassemble, Inspect and Assemble Transmission Top Shaft-Top Shaft Synchronized (TSS) Transmission

Disassemble, Inspect and Assemble Range Reduction Shaft

Disassemble, Inspect and Assemble Driven Shaft

Remove, Inspect and Install MFWD and Range Gears

Remove, Inspect and Install Reverse Idler Shaft

Group 16: Hydraulic Reverser Transmission

Service Equipment and Tools

Specifications

Separate Clutch Housing from Transmission

Install Clutch Housing to Transmission

Inspect and Repair Gear Shift Lever

Inspect and Repair Range Shift Lever

Remove Transmission

Disassemble and Inspect Transmission

Assemble Transmission

Install Transmission

Disassemble, Inspect and Assemble Gear Shift Shaft Assemblies

Disassemble, Inspect and Assemble Transmission Bottom Shaft

Disassemble, Inspect and Assemble Range Reduction Shaft

Disassemble, Inspect and Assemble Top Shaft

Remove, Inspect and Install MFWD and Range Gears

Remove, Inspect and Replace Hydraulic Reverser Control Lever

Group 20: Rear PTO Drive Shaft-Collar Shift/TSS Transmission

Specifications

Inspect and Repair Rear PTO Lever and Linkage

Remove and Install Rear PTO Drive Shaft Assembly

Disassemble, Inspect and Assemble Rear PTO Drive Shaft Assembly

Group 21: Rear PTO Drive Shaft-Hydraulic Reverser Transmission

Specifications

Inspect and Repair Rear PTO Lever and Linkage

Remove and Install Rear PTO Drive Shaft Assembly

Disassemble, Inspect and Assemble Rear PTO Drive Shaft Assembly

Group 25: Differential

Essential Tools

Other Material

Service Parts Kits

Specifications

Remove and Install Differential Assembly

Disassemble, Inspect and Assemble Differential Assembly

Remove and Inspect Differential Drive Shaft

Install Differential Drive Shaft

Differential Cone Point Adjustment

Differential Backlash Adjustment

Remove, Inspect and Install Differential Lock Assembly

Group 30: Final Drives

Service Equipment and Tools

Other Material

Specifications

Remove and Install Final Drive Assembly

Remove and Inspect Planetary Drive Assembly

Install Planetary Drive Assembly

Remove, Inspect and Install Axle Shaft Assembly

Group 35: Mechanical Front Wheel Drive

Special or Essential Tools

Other Material

Specifications

Inspect and Repair MFWD Lever and Linkage

Remove and Install MFWD Drop Gearbox

Disassemble and Inspect MFWD Drop Gearbox

MFWD Drop Gearbox Cross Section

Assemble MFWD Drop Gearbox

Remove, Inspect and Install MFWD Drive Shaft

Remove and Install MFWD Axle Housing Assembly

Remove, Inspect and Install MFWD Axle Supports

Disassemble and Inspect MFWD Outer Drive

Assemble MFWD Outer Drive

Remove, Inspect and Install MFWD Swivel Housing

Remove, Inspect and Install MFWD Axle Shaft

Remove and Install MFWD Differential Carrier Assembly

Disassemble and Inspect MFWD Differential Carrier Assembly

Assemble MFWD Differential Carrier Assembly

Adjust Swivel Pin Bearing Preload-Early Models Only

Group 40: Creeper Assembly

Other Material

Specifications

Remove and Install Creeper Assembly

Disassemble, Inspect and Assemble Creeper Assembly (Early Models)

Disassemble, Inspect and Assemble Creeper Assembly (Later Models)

Section 60: Steering and Brake Repair

Group 05: Steering Repair

Service Equipment and Tools

Other Material

Specifications

Service Parts Kits

Remove and Install Steering Column and Valve

Disassemble and Inspect Steering Valve

Assemble Steering Valve

Remove and Install Steering Cylinder-2WD Axle

Disassemble, Inspect and Assemble Steering Cylinder-2WD Axle

Remove and Install Steering Cylinder-MFWD Axle

Disassemble, Inspect and Assemble Steering Cylinder-MFWD Axle

Remove, Inspect and Install Tie Rod Assembly-2WD Axle

Remove, Inspect and Install Tie Rod Assembly-MFWD Axle

Inspect and Replace Steering Hydraulic Lines-Without Oil Cooler

Inspect and Replace Steering Hydraulic Lines-With Oil Cooler

Group 10: Brake Repair

Other Material

Specifications

Remove and Install Brake Valve and Pedals

Disassemble and Inspect Brake Valve

Brake Valve Cross Section

Assemble Brake Valve

Remove and Inspect Brakes (Early Model Tractors)

Install Brakes (Early Model Tractors)

Remove and Inspect Brakes (Later Model Tractors)

Install Brakes (Later Model Tractors)

Inspect and Replace Brake Hydraulic Lines

Section 70: Hydraulic Repair

Group 05: Hydraulic Pump and Filter

Specifications

Remove Inspect and Install Hydraulic Oil Pick-Up Screen

Remove and Install Hydraulic Pump-5200, 5300 and 5400

Remove Hydraulic Pump External Components-5200, 5300 and 5400

Disassemble and Inspect Hydraulic Pump-5200, 5300 and 5400

Assemble Hydraulic Pump-5200, 5300 and 5400

Install Hydraulic Pump External Components-5200, 5300 and 5400

Remove and Install Hydraulic Pump-5500

Remove Hydraulic Pump External Components-5500

Disassemble and Inspect Hydraulic Pump-5500

Assemble Hydraulic Pump-5500

Install Hydraulic Pump External Components-5500

Remove and Install Hydraulic Filter/Manifold-Early Model

Remove and Install Hydraulic Filter/Manifold-Later Model

Inspect and Replace Hydraulic Supply/Return Lines

Group 06: Hydraulic Oil Cooler

Remove, Inspect and Install Hydraulic Oil Cooler

Group 10: Rockshaft

Other Material

Specifications

Service Parts Kits

Inspect and Repair Rockshaft Control Lever Assembly

Inspect and Repair Rockshaft Control Linkage

Inspect and Repair Draft Sensing Support Assembly

Replace Main Relief Valve

Replace Rockshaft Surge Relief Valve

Remove, Inspect and Install Rate-of-Drop Valve

Replace Rockshaft Control Valve

Remove and Install Rockshaft Case

Remove, Inspect and Install Rockshaft Lift Arms

Remove, Inspect and Install Rockshaft Piston and Cylinder

Group 15: Dual Selective Control Valve

Other Material

Specifications

Service Parts Kits

Inspect and Repair Joystick and Linkage-Early Model

Inspect and Repair Joystick and Linkage-Later Models

Inspect and Repair Joystick and Linkage-Tractors With Cab

Remove and Install Dual Selective Control Valve (SCV)

Disassemble, Inspect and Assemble Dual Selective Control Valve (SCV)

Inspect and Replace Hydraulic Hoses-Dual Selective Control Valve (SCV)

Group 16: Single (Third) Selective Control Valve

Other Material

Specifications

Service Parts Kits

Inspect and Repair Lever and Linkage

Remove and Install Single/Third Selective Control Valve (SCV)

Disassemble, Inspect and Assemble Single (Third) Selective Control Valve (SCV)

Inspect and Replace Hydraulic Hoses-Single (Third) Selective Control Valve

Group 20: Hydraulic Mid Mount Coupler

Inspect and Replace Hydraulic Hoses-Mid Mount Coupler Without Cab

Inspect and Replace Hydraulic Hoses-Mid Mount Coupler With Cab

Group 25: Hydraulic Power Beyond

Inspect and Replace Power Beyond Hydraulic Lines and Fittings

Inspect Power Beyond Motor Control Lines and Fittings

Section 80: Miscellaneous Repair

Group 05: Front Axle-2WD

Specifications

Remove and Install Front Axle-2WD

Inspect and Replace Pivot Pin and Bushings-2WD Axle

Remove and Install Spindle Assembly-2WD Axle

Inspect and Replace Spindle Shaft Bushings-2WD Axle

Group 10: Wheels

Specifications

Inspect and Replace Front Wheel Bearings

Group 15: 3-Point Hitch

Specifications

Inspect and Repair Fixed Draft Links

Inspect and Repair Telescoping Draft Links

Inspect and Repair Lift Link

Inspect and Repair Adjustable Lift Link

Inspect and Repair Center Link

Remove and Install Draw Bar and Support

Section 90: Operator Station Repair

Group 05: Seat and Support

Specifications

Remove and Install Seat and Support-Tractors Without Cab

Remove and Install Seat, Support and Base Plate-Tractors With Cab

Group 10: ROLL-GARDROLL-GARD is a trademark of Deere & Company.

Specifications

Remove and Install ROLL-GARD ROLL-GARD is a trademark of Deere & Company.

Group 15: Cab Components

Essential Tools

Specifications

Remove, Inspect and Install Cab Interior Recirculating Air Filter

Remove, Inspect and Install Exterior Cab Intake Air Filter

Remove and Install Front Headliner

Remove and Install Rear Headliner

Remove and Install Lower Front Windows

Remove and Install Windowpanes

Remove and Install Rear Window

Remove and Install Cab Doors

Remove and Install Cab Roof

Remove and Install Control Console and Support Plate

Remove Cab and Floor Plates

Install Cab and Floor Plates

Group 20: Air Conditioning System

Service Equipment and Tools

Specifications

Service Parts Kits

Hose and Tubing O-Ring Connection Torques

Recover/Recycle Air Conditioning Refrigerant

Replace Air Conditioning Receiver-Dryer

Remove, Inspect and Install Air Conditioning Condenser

Remove, Inspect and Install Air Conditioning Compressor

Test Volumetric Efficiency of Compressor

Test Compressor Shaft Seal Leakage

Disassemble and Assemble Compressor Clutch

Disassemble, Inspect, and Assemble Compressor

Check Compressor Clutch Hub Clearance

Inspect Compressor Manifold

Remove and Install Compressor Relief Valve

Remove Evaporator/Heater Core Housing

Install Evaporator/Heater Core Housing

Remove Blower Motors

Remove Evaporator/Heater Core

Leak Test Evaporator/Heater Core

Install Evaporator/Heater Core

Service Expansion Valve

Expansion Valve Bench Test-Diagram

Expansion Valve Bench Test

Refrigerant Oil Information

Check Compressor Oil Charge

Determine Correct Refrigerant Oil Charge

Add Refrigerant Oil to System

System Information

Flush Air Conditioning System

Evacuate Air Conditioning System

Charge Air Conditioning System

Group 25: Heating System

Replace Heater Temperature Control and Cable

Remove, Test and Install Heater Control Valve

Leak Test Heater Control Valve

Install Heater Control Valve

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

Fan and Belt Check

Compressor Belt Check

Fuel System Check

Air Intake System Check

Electrical System Check

Hydraulic System Check

MFWD Oil Check

Indicator Lamps Check

Cab Blower Motor Check

A/C Compressor Clutch Check

Engine Start Check

Transmission Neutral Start Check

PTO Neutral Start Check

Engine Fast and Slow Idle Operation

Power Steering Check

Differential Lock Check

PTO Engagement Check

Clutch Check

Transmission Shift Check

Range Lever Shift Check

MFWD Drive Check

Brake Check

Rockshaft Check

Selective Control Valve Check

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

Engine External Components-Left-Hand Side

Engine External Components-Right-Hand Side

Group 10: Theory of Operation

Theory of Operation Information

Engine Lubrication System Operation

Engine Cooling System Operation

Group 15: Diagnosis, Tests and Adjustments

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 Grey

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

Slow Idle Adjustment

Fast Idle Adjustment

Injection Pump Timing Adjustment

Injection Pump Timing Adjustment-New Front Plate Installed

Valve Clearance Adjustment

Fan/Alternator Drive Belt Adjustment

Compressor Drive Belt Adjustment

Turbocharger Boost Pressure Test-5400 and 5500

Bleed Fuel System-3-Cylinder Engine

Bleed Fuel System-4-Cylinder Engine

Section 230: Fuel/Air Operation, Tests and Adjustments

Group 05: Component Location

Component Location Information

Fuel System Components

Air Intake System Components-5200 and 5300

Air Intake System Components-5400 and 5500

Group 10: Theory of Operation

Theory of Operation Information

Fuel System Operation

Fuel Filter/Priming Pump Operation

Fuel Injection Pump Operation

Fuel Injection Nozzle Operation

Air Intake System Operation-5200 and 5300

Air Intake System Operation-5400 and 5500

Turbocharger Operation-5400 and 5500

Group 15: Diagnosis, Tests and Adjustments

Diagnostic Information

Fuel/Air Diagnosis, Tests and Adjustments

Section 240: Electrical System Operation, Tests and Adjustments

Group 05: Component Location

Component Location Information

Engine Electrical Components

Dash Electrical Components

Machine Electrical Components-5200-5400 Without Cab

Machine Electrical Components-5500 Without Cab

Machine Electrical Components-5200-5500 With Cab

Cab Control Panel and Electrical Components

Group 10: Theory of Operation

Theory of Operation Information

Fuse Block and Fuses-Early Models

Fuse Block and Fuses-Later Models

Fuse Block and Fuses-Cab Tractors

Cab Fuse Block and Fuses

Relays

Starting System Operation-Normal

Starting System Operation-Bypass Attempt

Manifold Heater System Operation

Charging System Operation

Lighting System Operation-Turn Signals

Lighting System Operation-Warning Lights

Lighting System Operation-Tail Light

Lighting System Operation-Headlights and Instrument Lights

Instrument Panel System Operation-Tachometer

Instrument Panel System Operation-Fuel Gauge

Instrument Panel System Operation-Temperature Gauge

Instrument Panel System Operation-Hourmeter

PTO Warning System Operation

Air Filter Restriction Indicator Operation

Rear Work Light Operation-Tractors Without Cab

Optional Horn Operation

Optional Accessory Relay and Trailer Connector Operation

Flood Light Operation-Tractors With Cab

Blower Motor Operation-Tractors With Cab

A/C Compressor Operation-Cab Tractors Only

Front Wiper/Washer Operation-Cab Tractors Only

Rear Wiper/Washer Operation-Cab Tractors Only

Dome Light Operation-Cab Tractors Only

Group 15: Diagnosis, Tests and Adjustments

Diagnostic Information

Wire Color Chart

Starting System Test Points-Normal Operation

Starting System Test Points-Bypass Attempt

Manifold Heater Test Points

Charging System Test Points

Lighting System Test Points-Turn Signals (Tractors Without Cab)

Lighting System Test Points-Turn Signals (Tractors With Cab)

Lighting System Test Points-Warning Lights (All Tractors)

Lighting System Test Points-Rear Work Light (Tractors Without Cab)

Lighting System Test Points-Flood Lights (Tractors With Cab)

Lighting System Test Points-Tail Light (Tractors Without Cab)

Lighting System Test Points-Tail Lights (Tractors With Cab)

Lighting System Test Points-Headlights and Instrument Lights

Lighting System Test Points-Dome Light (Tractors With Cab)

Instrument Panel System Test Points-Tachometer

Instrument Panel System Test Points-Fuel Gauge

Instrument Panel System Test Points-Temperature Gauge

Instrument Panel System Test Points-Hourmeter

Instrument Panel System Test Points-Oil Pressure

PTO Warning System Test Points

Air Filter Restriction Test Points

Optional Horn Test Points

Optional Accessory Relay and Trailer Connector Test Points

Blower Motor Test Points (Tractors With Cab)

A/C Compressor Clutch Coil Test Points (Tractors With Cab)

Front Wiper/Washer Test Points (Tractors With Cab)

Rear Wiper/Washer Test Points (Tractors With Cab)

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

Turn Signal Controller Test

Fuel Shut-Off Solenoid Test

Blower Switch Test

Blower Motor Resistors Test

A/C Thermostatic 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

Electrical Schematic-Early 5200-5400 Models (Without Cab)

Electrical Schematic (Optional Equipment)-Early 5200-5400 Models (Without Cab)

Electrical Schematic-Later 5200-5400 and All 5500 Models (Without Cab)

Electrical Schematic (Optional Equipment)-Later 5200-5400 and All 5500 Models (Without Cab)

Electrical Schematic-Later 5200-5400 Models and All 5500 (With Cab)

Electrical Schematic-Later 5200-5400 Models and All 5500 (With Cab)

Section 250: Power Train Operation, Tests and Adjustments

Group 05: Component Location-Collar Shift/TSS Transmission

Component Location Information

Power Train Components

Clutch Components

Transmission Components-Collar Shift

Transmission Components-Top Shaft Synchronized (TSS)

Final Drive Components

Rear PTO Components

Group 06: Component Location-Hydraulic Reverser Transmission

Component Location Information

Power Train Components-Hydraulic Reverser Transmission

Clutch Components-Hydraulic Reverser Transmission

Hydraulic Reverser Components

Transmission Components-Hydraulic Reverser Transmission

Final Drive Components

Rear PTO Components

Group 10: Theory of Operation-Collar Shift/TSS Transmission

Theory of Operation Information

Clutch Operation

Transmission Lubrication System

Transmission Power Flow-Gear Shift (Collar)

Transmission Power Flow-Gear Shift (TSS)

TSS Transmission Synchronizer Operation-Reverse and 2nd Gear (Disk-and-Plate- Type Synchronizer)

TSS Transmission Synchronizer Operation-1st and 3rd Gear (Cone-Type Synchronizer)

Transmission Power Flow-Range Shift

Rear PTO Operation

Differential Power Flow

Differential Lock Operation

Final Drive Operation

Mechanical Front Wheel Drive (MFWD) Operation

Group 11: Theory of Operation-Hydraulic Reverser Transmission

Theory of Operation Information

Clutch Operation-PTO Clutch Engaged (Hydraulic Reverser Transmission)

Clutch Operation-PTO Clutch Disengaged (Hydraulic Reverser Transmission)

Hydraulic Reverser General Information

Hydraulic Reverser Operation in Forward

Hydraulic Reverser Operation in Reverse

Hydraulic Reverser Power Flow

Hydraulic Reverser Control Valve Operation-Initial Engine Start-Up, Clutch Pedal Up

Hydraulic Reverser Control Valve Operation-F-N-R Lever in Neutral, Clutch Pedal Down

Hydraulic Control Valve Operation-F-N-R Lever in Neutral, Clutch Pedal Up

Hydraulic Control Valve Operation-F-N-R Lever in Forward, Clutch Pedal Up

Hydraulic Control Valve Operation-F-N-R Lever in Reverse, Clutch Pedal Up

Transmission Power Flow-Gear Shift

Gear Shift Synchronizer Operation

Transmission Power Flow-Range Shift

Transmission Lubrication System

Rear PTO Operation

Final Drive Operation

Differential Operation

MFWD Operation

Group 15: Diagnosis, Tests and Adjustments-Collar Shift/TSS 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

Clutch Pedal Free Play Adjustment

PTO Clutch Lever Adjustment

Group 16: Diagnosis, Tests and Adjustments-Hydraulic Reverser

Diagnostic Information

Isolate the Problem Area

Low Transmission Oil Level (Excessive Oil Leakage)

Clutch Pedal Does Not Return

Tractor Does Not Move in Forward or Reverse

Hydraulic Reverser Engages Too Quickly or Too Slowly

Hydraulic Reverser 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

Axle Troubleshooting

MFWD Troubleshooting

Hydraulic Control Valve Tests

Transmission Pump Flow Test

Adjust Forward-Neutral-Reverse Cable

Clutch Pedal Linkage Adjustment

Park Brake Cable Adjustment

Section 260: Steering and Brake Operation, Tests and Adjustments

Group 05: Component Location

Component Location Information

Steering System Components-5200, 5300 and 5400 Without Cab

Steering System Components-5500 and All Cab Units

Brake System Components-Early Models

Brake System Components-Later Models

Group 10: Theory of Operation

Theory of Operation Information

Steering System Components-5500 and All Cab Units

Steering System Operation-5200, 5300 and 5400 Without Cab

Steering System Operation-5500 and All Cab Units

Steering Valve Operation-Neutral and Manual Turning

Steering Valve Operation-Power Turning

Brake System Operation-Early Models

Brake System Operation-Later Models

Brake Valve Operation

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

Adjust Brake Drag

Bleed Brake System

Section 270: Hydraulic System Operation, Tests and Adjustments

Group 05: Component Location

Component Location Information

Hydraulic System Components

Selective Control Valve Components

Group 10: Theory of Operation

Theory of Operation Information

Hydraulic System Operation

Hydraulic Filter Operation-Early Model

Hydraulic Filter Operation-Later Model

Hydraulic Pump Operation

Rockshaft Control Valve Operation (Early Models)-Flow Regulator Valve

Rockshaft Control Valve Operation (Early Models)-Neutral Position

Rockshaft Control Valve Operation (Early Models)-Raise Position

Rockshaft Control Valve Operation (Early Models)-Lowering Position

Rockshaft Control Valve Operation (Later Models)-Two Flow Regulator Valves

Rockshaft Control Valve Operation (Later Models)-Neutral Position

Rockshaft Control Valve Operation (Later Models)-Raise Position

Rockshaft Control Valve Operation (Later Models)-Lower Position

Surge Relief Valve Operation

Main Relief Valve Operation

Rate-of-Drop Valve Operation-Full Open

Rate-of-Drop Valve Operation-Full Closed

Rockshaft Draft-Sensing Operation

Selective Control Valve Operation-Neutral Position

Selective Control Valve Operation-Extend and Retract Positions

Selective Control Valve Operation-Boom Spool Float Position

Selective Control Valve Operation-Bucket Spool Regenerative Position

Double-Acting Sleeve Coupler Operation

Group 15: Diagnosis

Diagnostic Information

Preliminary Hydraulic System Inspection

Hydraulic Oil Warm-Up Procedure

Hydraulic System Components

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

SCV Control Lever Does Not Return to Neutral Position-Single (Third) SCV

SCV Joystick Does Not Return to Neutral Position-Dual SCV

SCV Joystick Does Not Remain In Detent Position-Dual 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

Pump Flow Test-Without SCV

Main Relief Valve Test-Without SCV

Group 17: Hydraulic Tests-With SCV

Hydraulic System Tests-With SCV

Pump Flow Test-With SCV

Main Relief Valve Test-With SCV

SCV Leakage Test

Group 18: Hydraulic Tests-All

Rockshaft Leakage Test

Rockshaft Lift Cycle Test

Group 19: Adjustments

Rockshaft Control Lever Friction Adjustment

Rockshaft Position-Sensing Feedback Linkage Adjustment

Rockshaft Draft-Sensing Feedback Linkage Adjustment

Main Relief Valve Adjustment

Group 20: Hydraulic Schematics

Hydraulic Circuit Symbols

Hydraulic Schematic-Without Selective Control Valve

Hydraulic Schematic-With Selective Control Valve

Section 290: Operator Station

Group 05: Component Location

Air Conditioning System Components

Group 10: Theory of Operation

Refrigerant R134a

Air Conditioning System Air Flow

Air Conditioning System Cycle

Air Conditioning System Cycle

Compressor

Condenser

Receiver-Dryer

Expansion Valve

A/C Temperature Control Switch

Evaporator

Heater Temperature Control Knob

High and Low Pressure Switches

Group 15: Diagnosis, Tests and Adjustments

Special or Essential Tools

Service Equipment and Tools

Other Material

Specifications

Adjust Heater Temperature Control Cable

Section 299: Dealer Fabricated Tools

Group 00: Dealer Fabricated Tools

JDG826-PTO Clutch Finger Height Gauge

JDG827-Traction Clutch Finger Height Gauge

JDG828-Traction Clutch Finger Height Adjustment Tool

JDG919-PTO Clutch Finger Height Gauge-Hydraulic Reverser

DFLV1A Final Drive Turning Tool

DFRW83-Nozzle Assembly

DFRW20-Compressor Holding Fixture

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