John Deere Tractors 5203S, 5310, 5310S Diagnostic & Repair Service Manual (TM4898)

tm4898 - 5310 And 5203S Tractors Technical Manual.pdf

Complete All Inclusive Technical Manual with electrical wiring diagrams for John Deere India Tractors 5203S, 5310, 5310S, with all the shop information to maintain, diagnostic, repair, service like professional mechanics (Diagnosis, Operation, Tests, Repair, Service, Troubleshooting).

John Deere Tractors 5203S, 5310, 5310S technical diagnostics repair service manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

Total Pages: 1,363 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

MAIN SECTIONS
 Foreword
   General Information
      Safety
      General Specifications
      Fuel and Lubricants
      Serial Number Locations
      Features and Accessories
   Engine Repair
      Engine
      Cylinder Head and Valves
      Cyl. Block, Liners, Pistons & Rods
      Crankshaft, Main Bearings and Flywheel
      Camshaft and Timing Gear Train
      Lubrication System
      Cooling System
   Fuel and Air Repair
      Fuel System
      Air Intake and Exhaust System
      Speed Control Linkage
   Electrical Repair
      Battery, Starter and Alternator
      Electrical System Components
      Wiring Harness
   Power Train Repair
      Clutch Housing
      Clutch Assembly- CollarShift Transmissions
      Transmission
      Rear PTO Drive Shaft
      Differential
      Final Drives
   Steering and Brake Repair
      Steering Repair
      Brake Repair
   Hydraulic Repair
      Hydraulic Pump and Filter
      Rockshaft
      Selective Control Valve (SCV)
   Miscellaneous Repair
      Front Axle
      Wheels
      3-Point Hitch
   Operator Station Repair
      Seat and Support
      Operator Platform
      Fenders
   Operational Checkout Procedures
      Operational Checkout Procedures
   Engine Operation, Test and Adjustments
      Component Location
      Theory of Operation
      Diagnosis, Tests and Adjustments
   Fuel/Air Operation, Test and Adjustments
      Component Location
      Theory of Operation (5310 and 5203S)
      Theory of Operation (5310 S)
      Diagnosis, Tests and Adjustments
   Electrical Operation, Test and Adjustments (5310 S)
      Component Location
      Theory of Operation
      Wiring Schematics
      Diagnosis, Test and Adjustment
   Electrical Operation, Test and Adjustments (5310 and 5203S)
      Component Location
      Theory of Operation
      Wiring Schematics
      Diagnosis, Test and Adjustment
   Power Train Operation, Tests and Adjustments
      Component Location-CollarShift Transmission
      Theory of Operation-CollarShift Transmission
      Diagnosis, Tests, and Adjustments-CS Transmission
   Steering and Brake Operation, Test & Adjustments
      Component Location
      Theory of Operation
      Diagnosis, Tests and Adjustments
   Hydraulic System Operation, Test and Adjustments
      Component Location
      Theory of Operation
      Diagnosis
      Hydraulic Tests-With SCV
      Hydraulic Tests
      Adjustments
      Hydraulic Schematics

tm4898 - 5310 And 5203S Tractors

Table of Contents

Foreword

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

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

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

L&T-John Deere 5310 S Tractor

L&T-John Deere 5310 Tractor

L&T-John Deere 5203S Tractor

Ground Speed Estimates

Service Recommendations for O-Ring Boss Fittings

Service Recommendations for Flat Face O-Ring Seal Fittings

Metric Bolt and cap screw Torque Values

Unified Inch Bolt and cap screw Torque Values

Group 20: Fuel and Lubricants

Diesel Fuel

Fuel Storage

Do Not Use Galvanized Containers

Fill Fuel Tank

Diesel Engine Oil

Diesel Engine Coolant

Transmission and Hydraulic Oil

Grease (Specific Application)

Grease

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 Serial Number Location

Group 30: Features and Accessories

Features and Accessories

Standard Features

Field Installed Optional Kits and Accessories

Section 20: Engine Repair

Group 05: Engine

Service Equipment and Tools

Specifications

John Deere Engine Repair-Use CTM8

Remove Engine (5310 and 5203S)

Install Engine (5310 and 5203S)

Remove Engine (5310 S)

Install Engine (5310 S)

Engine Disassembly Sequence

Sealant Application Guidelines

Engine Re-Assembly Sequence

Engine break-in guidelines

Perform engine break-in

Diesel Engine Break-In Oil

Group 10: Cylinder Head and Valves

Special or Essential Tools

Specifications

Torques for Hardware

Cylinder Head - Exploded View

Check Valve Lift

Remove Cylinder Head

Clean Injection Nozzle Bores

Valve Actuating Parts

Remove Valves and Valve Springs

Checking Cylinder Head Flatness

Clean Valve Guides

Measure Valve Guides

Clean and Inspect valve Seats

Lapping Valve Seats

Check Valve Recess

Remove Valve Seat Inserts

Valve Seat Insert Installation

Grind Valves

Check Valve Spring Tension

Inspect Valve Rotators

Install Valves

Install Cylinder Head

Torque Turn Tightening Method

Checking Rocker Arm Shaft

Reassembling Rocker Arm Shaft

Install Rocker Arm Assembly

Valve Clearance

Valve Adjustment Sequence

Install Rocker Arm Cover

Final Work

Group 15: Cyl. Block, Liners, Pistons & Rods

Special or Essential Tools

Specifications

Torques for Hardware

Exploded View

Connecting Rods - General Information

Remove Pistons and Connecting Rods

Measure Cylinder Liner Bore

Remove Cylinder Liners

Cylinder Liner Deglazing

Cylinder Block Cleaning

Check Piston Cooling Jets

Cam Follower Bore Measure

Measure Camshaft Bore

Remove Camshaft Bushing

Install Camshaft Bushing

Measure Crankshaft Bore

Replace Crankshaft Bearing Caps

Cylinder Block Top Desk Flatness

Measure Cylinder Liner Protrusion

Liner Packing Installation

Liner O-Ring Installation

Install Cylinder Liners

Measure Connecting Rod Bearing

Rod Bearing Clearance

Measure Connecting Rod Bushing

Replace Connecting Rod Bushing (3029D)

Replace Connecting Rod Bushing (3029T)

Measure Piston Pin

Clean and Inspect Pistons

Measure Piston Pin Bore

Piston Top Ring Groove

Second and Third Piston Ring Grooves

Piston Head and Skirt Checking

Install Piston Rings

Piston Rings Staggering

Piston/Liner Set Information

Assemble Piston and Connecting Rod

Install Piston and Connecting Rod

Measure Piston Protrusion

Complete Final Assembly (5310 and 5203S)

Complete Final Assembly (5310 S)

Group 20: Crankshaft, Main Bearings and Flywheel

Special or Essential Tools

Specifications

Torques For Hardware

Remove Crankshaft Pulley

Install Crankshaft Pulley

Flywheel Removal

Flywheel Ring Gear Replacement

Install Ball Bearing

Install Flywheel

Remove Crankshaft Rear Oil Seal

Flywheel Housing Replacement

Install Oil Seal/Wear Sleeve

Crankshaft End Play Measure

Remove Crankshaft

Crankshaft Inspection

Check Crankshaft Journal Diameter

Determine Crankshaft Main Bearing Clearance Using PLASTIGAGEPLASTIGAGE is a trademark of DANA Corp.

Regrind Crankshaft

Crankshaft Regrinding Guidelines

Micro-Finishing Specifications

Replace Crankshaft Gear

Install Main Bearing Inserts

Install 2-Piece Thrust Bearing

Crankshaft Installation

Group 25: Camshaft and Timing Gear Train

Special or Essential Tools

Specifications

Torques for Hardware

Remove Crankshaft Front Oil Seal

Remove Timing Gear Cover

Measure Timing Gear Backlash

Camshaft End Play Measure

Remove Camshaft

Measure Camshaft Journal

Measure Height of Cam Lobe

Replace Camshaft Gear

Install Camshaft

Check Cam Follower

Idler Gear End Play Measure

Remove Front Plate

Idler Gear Bushing and Shaft Measure

Idler Gear Bushing Replacement

Remove Idler Shaft

Install Idler Shaft Spring Pin

Install Idler Shafts

Install Front Plate

Install Upper Timing Gear Train

Install Lower Timing Gear Train

Install Oil Deflector

Timing Gear Cover Identification

Install Timing Gear Cover

Install Crankshaft Front Oil Seal

Install Wear Ring

Install Auxiliary Equipment

Group 30: Lubrication System

Special or Essential Tools

Specifications

Torques for Hardware

Oil Cooler Identification

Remove Oil Cooler

Replace Oil Cooler Nipple

Install Oil Cooler

Replace Oil Cooler/Filter Bracket on Engine with Auxiliary Drive

Remove Oil Pressure Regulating Valve

Replace Oil Pressure Regulating Valve Seat

Install Oil Pressure Regulating Valve

Replace Oil Dipstick Guide

Replace Oil By-Pass Valve

Replace Oil Pump Strainer

Remove Oil Pump

Oil Pump Gear Axial Clearance

Oil Pump Gear Radial Clearance

Oil Pump Specifications

Oil Pump Installation

Install Oil Pan

Group 35: Cooling System

Special or Essential Tools

Specifications

Torques for Hardware

Remove and Inspect Radiator

Water Pump - Exploded View

Remove Water Pump

Disassemble Water Pump

Assemble Water Pump

Install Water Pump

Inspect Thermostat

Cooling System Deaeration

Check Fan/Alternator Belt Tension

Install Fan

Install Radiator

Replace Thermostat

Section 30: Fuel and Air Repair

Group 05: Fuel System

Special or Essential Tools

Self-Manufactured Tool Template For Front Plate Replacement

Specifications

Torques For Hardware

Injection Pump, Nozzle and Governor Repair-Use CTM8

Remove, Inspect and Install Fuel Tank

Replace Fuel Filter Inserts (5310 and 5203S)

Replace Fuel Filter (5310 S)

Remove and Install Fuel Filter Assembly (5310 and 5203S)

Remove and Install Fuel Filter/Primer Pump Assembly (5310 S)

Group 10: Air Intake and Exhaust System

Remove, Inspect, and Install Air Cleaner Elements

Check Air inlet Pipe (5310 and 5203S)

Check Air inlet Pipe (5310 S)

Exhaust Manifold Inspection

Turbocharger Cut-Away View (Borge Warner)

Check Radial Clearance

Check Axial Clearance

Repair Turbocharger

Prelube Turbocharger

Install Turbocharger

Turbocharger Break-In

Recommendations for Turbocharger Use

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

Remove and Install Starter

Replace Alternator/Regulator

Group 10: Electrical System Components

Service Equipment and Tools

Other Material

Replace Air Filter Restriction Sensor

Replace Coolant Temperature Sender

Replace Engine Speed Sensor

Replace Engine Oil Pressure Sensor

Replace Key Switch

Replace Light Switch

Replace Turn Signal Controller

Replace Instrument Panel

Replace Neutral Start Switch

Replace Fuel Level Sender

Replace 7 Pin Connector

Group 15: Wiring Harness

Special or Essential Tools

Service Parts Kits

Remove Connector Body from Blade Terminals

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

Install WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Contact

Replace Tractor Wiring Harness

Section 50: Power Train Repair

Group 05: Clutch Housing

Service Equipment and Tools

Other Material

Specifications

Separate Engine from Clutch Housing (5310 and 5203S)

Install Engine to Clutch Housing (5310 and 5203S)

Separate Engine from Clutch Housing (5310 S)

Install Engine to Clutch Housing (5310 S)

Replace Clutch Housing Seal

Inspect and Repair Clutch Pedal and Linkage

Group 10: Clutch Assembly- CollarShift Transmissions

Essential Tools

Service Equipment and Tools

Other Material

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 15: Transmission

Specifications

Separate Clutch Housing from Transmission

Install Clutch Housing to Transmission

Inspect and Repair Gear and Range Shift Levers

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-CollarShift Transmission

Disassemble, Inspect, and Assemble Range Reduction Shaft

Disassemble, Inspect and Assemble Driven Shaft

Remove, Inspect, and Install Range Gears

Remove, Inspect, and Install Reverse Idler Shaft

Group 20: Rear PTO Drive Shaft

Other Material

Specifications

Remove, Inspect and Install Rear PTO Lever and Linkage

Remove and Install Standard Rear PTO Drive Shaft Assembly

Disassemble, Inspect and Assemble Standard Rear PTO Drive Shaft Assembly

Remove, Inspect and Install 540/540E Shift Lever and Linkage (Optional)

Remove and Install 540/540E Rear PTO Drive Shaft Assembly (Optional)

Disassemble, Inspect and Assemble Rear 540/540E PTO Drive Shaft Assembly (Optional)

Group 25: Differential

Essential Tools

Service Equipment and Tools

Other Material

Specifications

Service Parts Kits

Remove and Install Differential Assembly

Disassemble, Inspect, and Assemble Differential Assembly

Remove and Inspect Differential Drive Shaft

Install Differential Drive Shaft

Remove, Inspect, and Install Differential Lock Assembly (Optional 5203S)

Differential Cone Point Adjustment

Differential Backlash Adjustment

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

Section 60: Steering and Brake Repair

Group 05: Steering Repair

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

Group 10: Brake Repair

Service Equipment and Tools

Other Material

Specifications

Remove and Install Brake valve and Pedals

Disassemble and Inspect Brake Pedals and valve

Brake valve Cross Section

Assemble Brake valve

Remove and Inspect Brakes

Install Brakes

Inspect and Replace Brake Hydraulic Lines

Section 70: Hydraulic Repair

Group 05: Hydraulic Pump and Filter

Essential Tools

Specifications

Service Parts Kits

Remove, Inspect, and Install Hydraulic Oil Pick-Up Screen

Remove and Install Hydraulic Pump

Remove Hydraulic Pump External Components

Disassemble and Inspect Hydraulic Pump

Assemble Hydraulic Pump

Install Hydraulic Pump External Components

Remove and Install Hydraulic Oil Filter/Manifold

Inspect and Replace Hydraulic Supply and Suction/Return Lines

Group 10: Rockshaft

Other Material

Specifications

Remove, Inspect, and Install Rockshaft Control Lever Assembly

Remove, Inspect, and Install Rockshaft Control Lever Support Assembly

Remove, Inspect and Install Rockshaft Control Linkage

Replace Main 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: Selective Control Valve (SCV)

Install Single Selective Control Valve (SCV)

Install Rear Coupler Bracket

Install Hydraulic Hoses

Install Second Selective Control Valve (SCV)

Assemble Rear Quick Coupler

Install Hydraulic Hoses

Section 80: Miscellaneous Repair

Group 05: Front Axle

Specifications

Remove and Install Front Axle (5310 and 5203S)

Remove and Install Front Axle (5310 S)

Inspect and Replace Pivot Pin and Bushings (5310 and 5203S)

Inspect and Replace Pivot Pin and Bushings (5310 S)

Remove and Install Spindle Assembly (5310 and 5203S)

Remove and Install Spindle Assembly (5310 S)

Inspect and Replace Spindle Shaft Bushings (5310 and 5203S)

Inspect and Replace Spindle Shaft Bushings (5310 S)

Group 10: Wheels

Specifications

Inspect and Replace Front Wheel Bearings

Tighten Bolts-Rear Axle (M-14 Bolts)

Tighten Bolts-Rear Axle (M-20 Stud) (5310 and 5203S)

Tighten Bolts-Rear Axle (M-20 Stud) (5310 S)

Group 15: 3-Point Hitch

Specifications

Inspect and Repair Fixed Draft Links

Inspect and Repair Lift Link (5310 and 5203S)

Inspect and Repair Lift Link (5310 S)

Inspect and Repair Adjustable Lift Link

Inspect and Repair Center Link

Remove and Install Wagon Hitch and Support

Section 90: Operator Station Repair

Group 05: Seat and Support

Specifications

Remove and Install Deluxe Seat and Support

Group 15: Operator Platform

Specifications

Remove and Install Right-Side Platform and Step - Old

Remove and Install Left-Side Platform and Step - Old

Remove and Install Right-Side Platform and Step - New

Remove and Install Left-Side Platform and Step - New

Group 20: Fenders

Remove and Install Fenders - Old

Remove and Install Fenders - New

Section 210: Operational Checkout Procedures

Group 10: Operational Checkout Procedures

Operational Checkout Procedure Information

Engine Oil Level and Condition Check

Coolant Level and Condition Check

Transmission and Hydraulic Oil Check

Fan and Belt Check

Fuel System Check (5310 and 5203S)

Fuel System Check (5310 S)

Air Intake System Check

Electrical System Check

Hydraulic System Check

Indicator Lamps Check

Engine Start Check

Transmission Neutral Start Check

Engine Fast and Slow Idle Operation

Power Steering Check

Differential Lock Check

Clutch Check

Transmission Shift Check

Range Lever Shift Check

Brake Check

Rockshaft Check

Selective Control Valve Check

Miscellaneous Checks

Section 220: Engine Operation, Test and Adjustments

Group 05: Component Location

Component Location Information

Engine External Components-Left-Hand Side (5310 and 5203S)

Engine External Components-Left-Hand Side (5310 S)

Engine External Components-Right-Hand Side (5310 and 5203S)

Engine External Components-Right-Hand Side (5310 S)

Group 10: Theory of Operation

Theory of Operation Information

Engine Lubrication System Operation (5310 and 5203S)

Engine Lubrication System Operation (5310 S)

Engine Cooling System Operation

Group 15: Diagnosis, Tests and Adjustments

Specifications

Essential Tools

Diagnostic Information

Engine Turns Over But Will Not Start or Starts Hard

Engine Runs Irregularly or Stalls Frequently

Engine Runs Rough

Engine 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 (5310 and 5203S)

Cylinder Compression Pressure Test (5310 S)

Fuel Shut-Off Solenoid Check (5310 S)

Throttle Lever Adjustment

Fuel Injection Pump Setting (5310 and 5203S)

Fuel Injection Pump Timing Adjustment (5310 S)

Idle Speed Adjustment (5310 and 5203S)

Slow Idle Adjustment (5310 S)

Fast Idle Adjustment (5310 S)

Valve Clearance Adjustment

Fan/Alternator Drive Belt Adjustment

Bleeding Fuel System (5310 and 5203S)

Bleed Fuel System At Fuel Injection Nozzles

Bleeding Fuel System (5310 S)

Section 230: Fuel/Air Operation, Test and Adjustments

Group 05: Component Location

Component Location Information

Fuel System Components (5310 and 5203S)

Fuel System Components (5310 S)

Air Intake System Components (5310 and 5203S)

Air Intake System Components (5310 S)

Group 10: Theory of Operation (5310 and 5203S)

Theory of Operation Information

Fuel System Operation

Fuel Filter Operation

Fuel Injection Nozzle Operation

Fuel Transfer (Feed) Pump Operation

In-Line Fuel Injection Pump Operation

Governor Operation (In-Line Pump)

Air Intake System Operation

Group 10: Theory of Operation (5310 S)

Theory of Operation Information

Fuel System Operation

Fuel Filter Pump Operation

Fuel Injection Pump Operation

Fuel Injection Nozzle Operation

Air Intake System Operation

Turbocharger Operation

Check Turbocharger Boost Pressure

Diagnosing Turbocharger Malfunctions

Group 15: Diagnosis, Tests and Adjustments

Diagnostic Information

Fuel/Air Diagnosis, Tests and Adjustments

Section 240: Electrical Operation, Test and Adjustments (5310 S)

Group 05: Component Location

Component Location Information

Engine Electrical Components-Right Hand Side

Engine Electrical Components-Left Hand Side

Dash And Center Control Console Electrical Components

Group 10: Theory of Operation

Theory of Operation Information

Fuse Block and Fuses

Relays

Starting System Operation-Normal

Starting System Operation-Bypass Attempt

Charging System Operation

Lighting System Operation-Turn Signals

Lighting System Operation-Warning Lights

Lighting System Operation-Tail Lights

Lighting System Operation-Headlights and Instrument Lights

Instrument Panel System Operation-Tachometer/Hour Meter

Instrument Panel System Operation-Fuel Gauge

Instrument Panel System Operation-Temperature Gauge

Air Filter Restriction Indicator Operation

7-Pin Trailer Outlet Connector Operation

Horn Operation

Flood Light

Group 20: Wiring Schematics

Schematic Information

Component Identification Table

Electrical Schematic

Group 15: Diagnosis, Test and Adjustment

Diagnostic Information

Starting System Test Points-Normal Operation

Charging System Test Points

Lighting System Test Points-Turn Signals and Warning Lights

Lighting System Test Points-Rear Flood Light

Lighting System Test Points-Headlights and Instrument Lights

Instrument Panel System Test Points-Tachometer/Hourmeter

Instrument Panel System Test Points-Fuel Gauge

Instrument Panel System Test Points-Temperature Gauge

Instrument Panel System Test Points-Oil Pressure

Air Filter Restriction Test Points

Horn Test Points

Section 250: Electrical Operation, Test and Adjustments (5310 and 5203S)

Group 05: Component Location

Component Location Information

Engine Electrical Components-Right Hand Side

Engine Electrical Components-Left Hand Side

Dash And Center Control Console Electrical Components

Group 10: Theory of Operation

Theory of Operation Information

Fuse Block and Fuses

Relays

Starting System Operation

Charging System Operation

Lighting System Operation-Turn Signals

Lighting System Operation-Hazard Warning Lights

Lighting System Operation-Tail Lights

Lighting System Operation-Headlights and Instrument Lights

Instrument Panel System Operation-Tachometer/Hour Meter

Instrument Panel System Operation-Fuel Gauge

Instrument Panel System Operation-Temperature Gauge

Air Filter Restriction Indicator Operation

7-Pin Trailer Outlet Connector Operation

Horn Operation

Flood Light

Group 20: Wiring Schematics

Schematic Information

Component Identification Table

Electrical Schematic

Group 15: Diagnosis, Test and Adjustment

Diagnostic Information

Starting System Test Points-Normal Operation

Charging System Test Points

Lighting System Test Points-Turn Signals and Warning Lights

Lighting System Test Points-Rear Flood Light

Lighting System Test Points-Headlights and Instrument Lights

Instrument Panel System Test Points-Tachometer/Hourmeter

Instrument Panel System Test Points-Fuel Gauge

Instrument Panel System Test Points-Temperature Gauge

Instrument Panel System Test Points-Oil Pressure

Air Filter Restriction Test Points

Horn Test Points

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

Plug-In Relay Test

Diode Pack Test

Fuse Test

Neutral Start Switch Test

Turn Signal Controller (Flasher) Test

Section 260: Power Train Operation, Tests and Adjustments

Group 05: Component Location-CollarShift Transmission

Component Location Information

Power Train Components-(CollarShift )

Clutch Components-Dual

Transmission Components-CollarShift

Final Drive Components

Rear PTO Components

Rear 540/540E PTO Components

Group 10: Theory of Operation-CollarShift Transmission

Theory of Operation Information

Clutch Operation-Dual Clutch

Transmission Lubrication System

CollarShift Transmission-Gear Shift Power Flow

CollarShift Transmission-Range Shift Power Flow

Rear PTO Operation

Rear PTO Operation

Rear 540/540E PTO Operation

Rear PTO Operation

Differential Power Flow

Differential Power Flow

Differential Lock Operation (Optional 5203S)

Final Drive Operation

Group 15: Diagnosis, Tests, and Adjustments-CS 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

Check and Adjust Clutch Pedal Free Play

PTO Clutch Lever Adjustment

Section 270: Steering and Brake Operation, Test & Adjustments

Group 05: Component Location

Component Location Information

Steering System Components

Brake System Components

Group 10: Theory of Operation

Theory of Operation Information

Steering System Operation

Steering valve Operation-Neutral and Manual Turning

Steering valve Operation-Power Turning

Brake System Operation

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

Adjusting Toe-In

Brake Pedal Adjustment

Bleed Brake System

Section 280: Hydraulic System Operation, Test and Adjustments

Group 05: Component Location

Component Location Information

Hydraulic System Components

Group 10: Theory of Operation

Theory of Operation Information

Hydraulic System Operation

Hydraulic Filter Operation

Hydraulic Pump Operation

Rockshaft Control Valve Operation-Neutral Position

Rockshaft Control Valve Operation-Raise Position

Rockshaft Control Valve Operation-Lower Position

Flow Control Valve Operation (FCV) -Neutral Position

Flow Control Valve Operation (FCV) -Delivery Position

Flow Control Valve Operation (FCV) -Discharge Position

Selective Control Valve-Neutral Position

Selective Control Valve-Retract Position

Selective Control Valve-Extend Position

Selective Control Valve-Float Position

Surge (Safety) Relief valve Operation

Rate-of-Drop valve (Implement Lock) Operation

Group 15: Diagnosis

Diagnostic Information

Preliminary Hydraulic System Inspection

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

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 16: Hydraulic Tests

Hydraulic System Tests

Pump Flow Test

Main Relief valve Test

Rockshaft Leakage Test

Rockshaft Lift Cycle Test

Group 20: Adjustments

Rockshaft Sensing Lever Friction Adjustment

Control of Assembly of Reaction Spring

Measurement Control of Push rod

Adjustment of Position Control Lever

Adjustment Of Draft Control Lever

Group 21: Hydraulic Schematics

Hydraulic Circuit Symbols