Diagnostics and Repair Technical Manual with electrical wiring diagrams for John Deere Tractors 5103, 5103S, 5203, with workshop information to maintain, diagnose, repair, and rebuild like professional mechanics.

John Deere Tractors 5103, 5103S, 5203 series Diagnosis Tests Service 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.

TM2041 - John Deere Tractors 5103, 5103S & 5203 Diagnostics and Repair Technical Manual.PDF

Total Pages: 1,432 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable)
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 Exhuast System
      Speed Control Linkage
   Electrical Repair
      Battery, Starter and Alternator
      Electrical System Components
      Wiring Harness
   Power Train Repair
      Clutch Housing
      Clutch Assembly
      'AA' Transmission
      'AA+' Transmission
      Rear PTO Dual Clutch
      Rear PTO Single Clutch
      Differential
      Final Drives
   Steering and Brake Repair
      Steering Repair
      Brake Repair
   Hydraulic Repair
      Hydraulic Pump and Filter
      JD Rockshaft
      MITA Rockshaft
   Miscellaneous Repair
      Front Axle
      Wheels
      3-Point Hitch
      Front Bumper (For 5103E)
   Operator Station Repair
      Seat and Support
      Operator Platform
      Fenders
   Operational Checkout Procedures
      Operational Checkout Procedures
   Engine Operation, Tests and Adjustments
      Component Location
      Component Location (For 5103E)
      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 & Adjustments (5038D, 5103, 5103S, 5203, 5104 and 5204)
      Component Location
      Theory of Operation
      Wiring Schematics
      Diagnosis, Test and Adjust
   Electrical System Operation, Tests & Adjustments (For 5103E)
      Component Location
      Theory of Operation
      Wiring Schematics
      Diagnosis, Test and Adjust
   Power Train Operation, Tests & Adjustments
      Component Location- 'AA' Power Train
      Component Location- 'AA+' Pattern Power Train
      Theory of Operation- 'AA' Transmission
      Theory of Operation- 'AA+' Pattern Transmission
      Diagnosis, Tests and Adjustments-Power Train
   Steering and Brake Operation, Tests & Adjustments
      Component Location
      Theory of Operation
      Diagnosis, Tests and Adjustments
   Hydraulic System Operation, Tests & Adjustments
      Component Location
      Theory of Operation
      Diagnosis
      Hydraulic Tests
      Adjustments - MITA Rockshaft
      Adjustments - JD Rockshaft
      Hydraulic Schematics

TABLE OF CONTENTS
Section 10: General Information................28
  Group 05: Safety................28
    Recognize Safety Information................31
    Understand Signal Words................32
    Follow Safety Instructions................33
    Handle Fluids Safely—Avoid Fires................34
    Prevent Battery Explosions................35
    Prepare for Emergencies................36
    Prevent Acid Burns................37
    Service Cooling System Safely................39
    Avoid High-Pressure Fluids................40
    Park Machine Safely................41
    Support Machine Properly................42
    Wear Protective Clothing................43
    Work in Clean Area................44
    Service Machines Safely................45
    Work In Ventilated Area................46
    Illuminate Work Area Safely................47
    Replace Safety Signs................48
    Use Proper Lifting Equipment................49
    Service Tires Safely................50
    Avoid Harmful Asbestos Dust................51
    Avoid Heating Near Pressurized Fluid Lines................52
    Remove Paint Before Welding or Heating................53
    Use Proper Tools................54
    Dispose of Waste Properly................55
    Live With Safety................56
  Group 10: General Specifications................1365
    John Deere 5103E Tractor................59
    John Deere 5103 Tractor................61
    John Deere 5038D Tractor................63
    John Deere 5103S Tractor................65
    John Deere 5203 Tractor................67
    John Deere 5104 Tractor................69
    John Deere 5204 Tractor................71
    Ground Speed Estimates................73
    Service Recommendations for O-Ring Boss Fittings................76
    Service Recommendations for Flat Face O-Ring Seal Fittings................78
    Metric Bolt and Cap Screw Torque Values................80
    Unified Inch Bolt and Cap Screw Torque Values................81
  Group 15: Fuel and Lubricants................29
    Diesel Fuel................85
    Fuel Storage................87
    Do Not Use Galvanized Containers................88
    Fill Fuel Tank................89
    Diesel Engine Oil................91
    Diesel Engine Coolant................92
    Transmission and Hydraulic Oil................94
    Grease (Specific Application)................95
    Grease................96
    Alternative and Synthetic Lubricants................97
    Lubricant Storage................98
  Group 20: Serial Number Locations................29
    Serial Numbers................100
    Product Identification Number Location................101
    Engine Serial Number Location................102
    Fuel Injection Pump Serial Number Location................103
    Alternator Serial Number Location................104
    Power Steering Valve Serial Number Location................105
    Starter Serial Number Location................106
    Transmission Serial Number Location................107
    Front Axle Serial Number Location................108
  Group 25: Features and Accessories................111
    Features and Accessories................111
    Standard Features................113
    Field Installed Optional Kits and Accessories................115
Section 20: Engine Repair................116
  Group 05: Engine................116
    Service Equipment and Tools................623
    Specifications................1365
    John Deere Engine Repair—Use CTM8................125
    Remove Engine................133
    Remove Engine................133
    Install Engine................140
  Group 10: Cylinder Head and Valves................116
    Special or Essential Tools................937
    Specifications................1365
    Torques for Hardware................337
    Cylinder Head - Exploded View................195
    Check Valve Lift................157
    Remove cylinder head................158
    Clean Injection Nozzle Bores................160
    Valve Actuating Parts................161
    Remove Valves and Valve Springs................162
    Checking Cylinder Head Flatness................163
    Clean Valve Guides................164
    Measure Valve Guides................165
    Clean and Inspect Valve Seats................167
    Lapping Valve Seats................168
    Check Valve Recess................169
    Remove Valve Seat Inserts................170
    Valve Seat Insert Installation................173
    Grind Valves................174
    Check Valve Spring Tension................175
    Inspect Valve Rotators................176
    Install Valves................177
    Install Cylinder Head................179
    Torque Turn Tightening Method................181
    Checking Rocker Arm Shaft................182
    Install Rocker Arm Assembly................184
    Valve Clearance................185
    Valve Adjustment Sequence................186
    Install Rocker Arm Cover................187
    Final Work................188
  Group 15: Cyl. Block, Liners, Pistons & Rods................117
    Special or Essential Tools................937
    Specifications................1365
    Torques for Hardware................337
    Exploded View................195
    Connecting Rods - General Information................196
    Remove Pistons and Connecting Rods................198
    Measure Cylinder Liner Bore................200
    Remove Cylinder Liners................201
    Cylinder Liner Deglazing................202
    Cylinder Block Cleaning................203
    Check Piston Cooling Jets................204
    Cam Follower Bore Measure................205
    Measure Camshaft Bore................206
    Remove Camshaft Bushing................207
    Install Camshaft Bushing................208
    Measure Crankshaft Bore................209
    Replace Crankshaft Bearing Caps................210
    Cylinder Block Top Desk Flatness................211
    Measure Cylinder Liner Protrusion................212
    Liner Packing Installation................214
    Liner O-Ring Installation................215
    Install Cylinder Liners................216
    Measure Connecting Rod Bearing................217
    Rod Bearing Clearance................219
    Measure Connecting Rod Bushing................220
    Replace Connecting Rod Bushing................221
    Measure Piston Pin................222
    Clean and Inspect Pistons................223
    Measure Piston Pin Bore................224
    Piston Top Ring Groove................225
    Second and Third Piston Ring Grooves................226
    Piston Head and Skirt Checking................227
    Install Piston Rings................228
    Piston Rings Staggering................230
    Piston/Liner Set Information................231
    Assemble Piston and Connecting Rod................232
    Install Piston and Connecting Rod................234
    Measure Piston Protrusion................237
    Complete Final Assembly................238
  Group 20: Crankshaft, Main Bearings and Flywheel................118
    Special or Essential Tools................937
    Specifications................1365
    Torques For Hardware................370
    Remove Crankshaft Pulley................245
    Install Crankshaft Pulley................246
    Flywheel Removal................247
    Flywheel Ring Gear Replacement................248
    Install Ball Bearing................249
    Install Flywheel................250
    Remove Crankshaft Rear Oil Seal................251
    Flywheel Housing Replacement................253
    Install Oil Seal/Wear Sleeve................255
    Crankshaft End Play Measure................256
    Remove Crankshaft................258
    Crankshaft Inspection................259
    Check Crankshaft Journal Diameter................260
    Determine Crankshaft Main Bearing Clearance Using PLASTIGAGE PLASTIGAGE is a trademark of DANA Corp.................118
    Regrind Crankshaft................263
    Crankshaft Regrinding Guidelines................264
    Micro-Finishing Specifications................1365
    Replace Crankshaft Gear................266
    Install Main Bearing Inserts................268
    Install 2-Piece Thrust Bearing................269
    Crankshaft Installation................270
  Group 25: Camshaft and Timing Gear Train................119
    Special or Essential Tools................937
    Specifications................1365
    Torques for Hardware................337
    Remove Crankshaft Front Oil Seal................277
    Remove Timing Gear Cover................278
    Measure Timing Gear Backlash................279
    Camshaft End Play Measure................280
    Remove Camshaft................281
    Measure Camshaft Journal................282
    Measure Height of Cam Lobe................283
    Replace Camshaft Gear................284
    Install Camshaft................285
    Check Cam Follower................286
    Idler Gear End Play Measure................287
    Remove Front Plate................288
    Idler Gear Bushing and Shaft Measure................290
    Idler Gear Bushing Replacement................292
    Remove Idler Shaft................293
    Install Idler Shaft Spring Pin................294
    Install Idler Shafts................295
    Install Front Plate................296
    Install Upper Timing Gear Train................298
    Install Lower Timing Gear Train................301
    Install Lower Timing Gear Train................301
    Install Oil Deflector................302
    Timing Gear Cover Identification................303
    Install Timing Gear Cover................304
    Install Crankshaft Front Oil Seal................306
    Install Wear Ring................307
    Install Auxiliary Equipment................308
  Group 30: Lubrication System................120
    Special or Essential Tools................937
    Specifications................1365
    Torques for Hardware................337
    Oil Cooler Identification................313
    Remove Oil Cooler................314
    Replace Oil Cooler Nipple................315
    Install Oil Cooler on Standard Engine................316
    Replace Oil Cooler/Filter Bracket on Engine with Auxiliary Drive................317
    Remove Oil Pressure Regulating Valve................319
    Replace Oil Pressure Regulating Valve Seat................320
    Install Oil Pressure Regulating Valve................321
    Replace Oil Dipstick Guide................322
    Replace Oil By-Pass Valve................323
    Replace Oil Pump Strainer................324
    Remove Oil Pump................325
    Oil Pump Gear Axial Clearance................326
    Oil Pump Gear Radial Clearance................327
    Oil Pump Specifications................1365
    Oil Pump Installation................329
    Install Oil Pan................332
  Group 35: Cooling System................120
    Special or Essential Tools................937
    Specifications................1365
    Torques for Hardware................337
    Remove and Inspect Radiator................342
    Remove and Inspect Radiator................342
    Water Pump — Exploded View................346
    Remove Water Pump................347
    Disassemble Water Pump................348
    Assemble Water Pump................350
    Install Water Pump................353
    Cooling System Deaeration................354
    Install Fan................355
    Install Radiator................357
    Replace Thermostat................360
Section 30: Fuel and Air Repair................363
  Group 05: Fuel System................363
    Special or Essential Tools................937
    Self-Manufactured Tool Template For Front Plate Replacement................368
    Specifications................1365
    Torques For Hardware................370
    Injection Pump, Nozzle and Governor Repair................371
    Remove, Inspect and Install Fuel Tank................372
    Replace Fuel Filter Inserts................374
    Remove and Install Fuel Filter Assembly................375
    Replace Fuel Level Indicator (For 5103E)................377
  Group 10: Air Intake and Exhuast System................363
    Remove, Inspect, and Install Air Cleaner Elements................381
    Check Air inlet Pipe................383
    Exhaust Manifold Inspection................384
  Group 15: Speed Control Linkage................363
    Inspect and Repair Speed Control Linkage................387
Section 40: Electrical Repair................389
  Group 05: Battery, Starter and Alternator................389
    Starter Repair—Use CTM77................391
    Remove and Install Battery................392
    Remove and Install Starter................394
    Replace Alternator/Regulator................396
    Replace Alternator/Regulator (For 5103E)................398
  Group 10: Electrical System Components................389
    Service Equipment and Tools................623
    Other Material................783
    Replace Air Filter Restriction Sensor................403
    Replace Air Filter Restriction Sensor (For 5103E)................404
    Replace Coolant Temperature Sender................405
    Replace Engine Speed Sensor................406
    Replace Engine Oil Pressure Sensor................407
    Replace Key Switch................408
    Replace Light Switch................409
    Replace Turn Signal Controller................411
    Replace Instrument Panel................412
    Replace Neutral Start Switch................415
    Replace Fuel Level Sender................416
    Replace 7 Pin Connector................418
  Group 15: Wiring Harness................389
    Special or Essential Tools................937
    Service Parts Kits................732
    Remove Connector Body from Blade Terminals................422
    Replace WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Connector................389
    Install WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Contact................389
    Replace Tractor Wiring Harness for 5103 E................427
    Replace Tractor Wiring Harness for 5038D, 5103, 5103S, 5203, 5104 And 5204 Tractors................430
Section 50: Power Train Repair................433
  Group 05: Clutch Housing................433
    Specifications................1365
    Separate Engine from Transmission Housing................438
    Install Engine to Transmission Housing................442
    Inspect and Repair Clutch Pedal and Linkage................445
  Group 10: Clutch Assembly................433
    Other Material................783
    Essential Tools................937
    Specifications................1365
    Remove and Install Dual Clutch Assembly................451
    Disassemble and Inspect Dual Clutch Assembly................455
    Assemble Dual Clutch Assembly................463
    Traction Clutch Finger Adjustment................469
    PTO Clutch Finger Adjustment................471
    Remove and Inspect Dual Clutch Release Mechanism and Shafts................473
    Install Dual Clutch Release Mechanism and Shafts................477
    Remove and Install Single Clutch Assembly (Ceramic)................480
    Remove and Install Single Clutch Assembly (Organic)................483
    Remove and Inspect Single Clutch Release Mechanism and Shaft................486
    Install Single Clutch Release Mechanism and Shaft................490
  Group 15: 'AA' Transmission................433
    Other Material................783
    Specifications................1365
    Remove, Inspect and Repair Gear Shift Lever And Cover................538
    Remove, Inspect and Install Range and Reverse Shift Lever................540
    Remove Transmission................543
    Disassemble and Inspect Transmission................545
    Assemble Transmission................551
    Install Transmission................557
    Disassemble, Inspect and Assemble Shift Shaft Assemblies................559
    Disassemble, Inspect, and Assemble Transmission Top Driven Shaft................520
    Disassemble, Inspect and Assemble Range Reduction Shaft................563
    Disassemble, Inspect and Assemble Driven Shaft................565
    Disassemble, Inspect and Assemble Traction Clutch Driven Shaft (Light Duty-Dual Clutch)................527
    Disassemble, Inspect and Assemble Traction Clutch Driven Shaft (Light Duty-Single Clutch)................529
    Disassemble, Inspect and Assemble Traction Clutch Driven Shaft (Heavy Duty-Dual Clutch)................531
    Disassemble, Inspect and Assemble Traction Clutch Driven Shaft (Heavy Duty-Single Clutch)................533
  Group 20: 'AA+' Transmission................434
    Other Material................783
    Specifications................1365
    Remove, Inspect and Repair Gear Shift Lever And Cover................538
    Remove, Inspect and Install Range and Reverse Shift Lever................540
    Remove Transmission................543
    Disassemble and Inspect Transmission................545
    Assemble Transmission................551
    Install Transmission................557
    Disassemble, Inspect and Assemble Shift Shaft Assemblies................559
    Disassemble, Inspect, and Assemble Transmission Main Shaft................561
    Disassemble, Inspect and Assemble Range Reduction Shaft................563
    Disassemble, Inspect and Assemble Driven Shaft................565
    Disassemble, Inspect and Assemble Traction Clutch Driven Shaft (Dual Clutch)................567
    Disassemble, Inspect and Assemble Traction Clutch Driven Shaft (Single Clutch)................569
  Group 25: Rear PTO Dual Clutch................434
    Other Material................783
    Specifications................1365
    Remove, Inspect and Install Rear PTO Lever and Linkage................588
    Remove and Install Rear PTO Drive Shaft Assembly................589
    Disassemble, Inspect and Assemble Rear PTO Drive Shaft Assembly................582
    Disassemble, Inspect and Assemble Rear PTO Drive Shaft Assembly................582
  Group 30: Rear PTO Single Clutch................434
    Other Material................783
    Specifications................1365
    Remove, Inspect and Install Rear PTO Lever and Linkage................588
    Remove and Install Rear PTO Drive Shaft Assembly................589
    Disassemble, Inspect and Assemble Rear PTO Drive Shaft Disassemble, Inspect and Assemble Rear PTO Drive Shaft & Shifter assembly{pgNO}435 Shifter assembly................591
  Group 35: Differential................435
    Essential Tools................937
    Other Material................783
    Specifications................1365
    Remove and Install Differential Assembly................598
    Disassemble, Inspect and Assemble 2 Pinion Differential Assembly................600
    Disassemble, Inspect and Assemble 4 Pinion Differential Assembly................602
    Remove and Inspect Differential Drive Shaft................604
    Install Differential Drive Shaft................608
    Remove, Inspect and Install Differential Lock Assembly................613
    Differential Cone Point Adjustment- For 2 Pinion Differential................615
    Differential Cone Point Adjustment - For 4 Pinion Differential................617
    Differential Backlash Adjustment................619
  Group 40: Final Drives................435
    Essential Tools................937
    Service Equipment and Tools................623
    Other Material................783
    Specifications................1365
    Remove and Install Final Drive Assembly................626
    Remove and Inspect Planetary Drive Assembly................628
    Assemble Planetary Carrier Assembly................631
    Install Planetary Drive Assembly for Oiled Rear Axle................633
    Install Planetary Drive Assembly for Greased Rear Axle................636
    Remove, Inspect, and Install Early Greased Axle Shaft Assembly................639
    Remove, Inspect, and Install Oiled Axle Shaft Assembly................643
    Remove, Inspect, and Install Late Greased Axle Shaft Assembly................652
Section 60: Steering and Brake Repair................656
  Group 05: Steering Repair................656
    Other Material................783
    Specifications................1365
    Service Parts Kits................732
    Remove and Install Steering Column and Valve................661
    Disassemble and Inspect Steering Valve................663
    Assemble Steering Valve................667
    Remove and Install Steering Cylinder................672
    Disassemble, Inspect and Assemble Steering Cylinder................674
    Remove, Inspect and Install Tie Rod Assembly................676
    Inspect and Replace Steering Hydraulic Lines................678
    Specifications-Mechanical Steering................680
    Remove Mechanical Steering Assembly................681
    Disassemble Steering Gearbox................685
    Inspect Steering Gearbox Parts................693
    Assemble Steering Gearbox................698
    Install Mechanical Steering Assembly................710
  Group 10: Brake Repair................656
    Other Material................783
    Specifications................1365
    Remove and Install Brake Pedals and Linkage................718
    Remove and Install Park Brake Lever and Linkage................720
    Remove and Inspect Brakes................721
    Install Brakes................723
Section 70: Hydraulic Repair................727
  Group 05: Hydraulic Pump and Filter................727
    Essential Tools................937
    Specifications................1365
    Service Parts Kits................732
    Remove, Inspect, and Install Hydraulic Oil Pick-Up Screen................733
    Remove and Install Hydraulic Pump................734
    Remove Hydraulic Pump External Components................736
    Disassemble and Inspect Hydraulic Pump................737
    Assemble Hydraulic Pump................740
    Install Hydraulic Pump External Components................742
    Remove and Install Hydraulic Oil Filter/Manifold................744
    Inspect and Replace Hydraulic Supply and Suction/Return Lines................746
  Group 10: JD Rockshaft................727
    Other Material................783
    Specifications................1365
    Inspect and Repair Rockshaft Control Linkage................751
    Inspect and Rockshaft Control Levers Assembly................755
    Inspect and Repair Draft Sensing Support Assembly................760
    Replace Main Relief Valve................763
    Replace Rockshaft Surge Relief Valve................765
    Remove, Inspect, and Install Rate-of-Drop Valve................766
    Replace Rockshaft Control Valve................769
    Remove and Install Rockshaft Case................818
    Remove, Inspect, and Install Rockshaft Lift Arms................777
    Remove, Inspect, and Install Rockshaft Piston and Cylinder................779
  Group 10: MITA Rockshaft................727
    Other Material................783
    Specifications................1365
    Remove, Inspect, and Install Rockshaft Control Lever Assembly................785
    Remove, Inspect, and Install Rockshaft Control Lever Support Assembly................788
    Remove, Inspect and Install Rockshaft Control Linkage................798
    Replace Main Relief valve................809
    Remove, Inspect and Install Rate-of-Drop valve................811
    Replace Rockshaft Control valve................814
    Remove and Install Rockshaft Case................818
    Remove, Inspect and Install Rockshaft Lift Arms................820
    Remove, Inspect and Install Rockshaft Piston and Cylinder................824
Section 80: Miscellaneous Repair................826
  Group 05: Front Axle................826
    Specifications................1365
    Remove and Install Front Axle................829
    Inspect and Replace Pivot Pin and Bushings................832
    Remove and Install Spindle Assembly................833
    Inspect and Replace Spindle Shaft Bushings................835
  Group 10: Wheels................826
    Specifications................1365
    Inspect and Replace Front Wheel Bearings For CARRARO Front Axle................838
    Inspect and Replace Front Wheel Bearings For DANA Front Axle................840
    Tighten Bolts—Rear Axle (M-14 Bolts)................842
    Tighten Bolts—Rear Axle (M-20 Stud)................843
    Replace SMV Emblem................844
  Group 15: 3-Point Hitch................826
    Specifications................1365
    Inspect and Repair Fixed Draft Links................847
    Inspect and Repair Standard Lift Link................849
    Inspect and Repair Adjustable Lift Link................851
    Inspect and Repair Center Link................853
    Inspect and Repair Fixed Draft Links (For 5103E)................854
    Inspect and Repair Standard Lift Link (For 5103E)................856
    Inspect and Repair Adjustable Lift Link (For 5103E)................857
    Remove and Install Wagon Hitch and Support................858
  Group 20: Front Bumper (For 5103E)................826
    Replace Front Bumper (For 5103E)................863
Section 90: Operator Station Repair................866
  Group 05: Seat and Support................866
    Specifications................1365
    Remove and Install Deluxe Seat and Support................869
    Remove and Install Standard Seat and Support................870
  Group 10: Operator Platform................866
    Specifications................1365
    Remove and Install Right-Side Platform................874
    Remove and Install Left-Side Platform and Step................877
  Group 15: Fenders................866
    Remove and Install Fenders - Old................880
    Remove and Install Fenders - New................881
Section 100: Operational Checkout Procedures................883
  Group 05: Operational Checkout Procedures................883
    Operational Checkout Procedure Information................885
    Engine Oil Level and Condition Check................886
    Coolant Level and Condition Check................887
    Transmission and Hydraulic Oil Check................888
    Fan and Belt Check................890
    Fuel System Check................891
    Air Intake System Check................893
    Electrical System Check................894
    Hydraulic System Check................896
    Indicator Lamps Check for 5038D, 5103, 5103S, 5203, 5104 Indicator Lamps Check for 5038D, 5103, 5103S, 5203, 5104 & 5204 Tractors{pgNO}883 5204 Tractors................897
    Indicator Lamps Check for 5103 E Tractors................898
    Engine Start Check................899
    Transmission Neutral Start Check................900
    Engine Fast and Slow Idle Operation................902
    Power Steering Check................903
    Differential Lock Check................904
    Clutch Check................905
    Speed Lever Shift Check................906
    Range Lever Shift Check................907
    Brake Check................909
    Rockshaft Check................910
    Miscellaneous Checks................912
Section 110: Engine Operation, Tests and Adjustments................913
  Group 05: Component Location................913
    Component Location Information................1385
    Engine External Components—Left-Hand Side................923
    Engine External Components—Right-Hand Side................925
  Group 10: Component Location (For 5103E)................913
    Component Location Information................1385
    Engine External Components—Left-Hand Side................923
    Engine External Components—Right-Hand Side................925
  Group 15: Theory of Operation................913
    Theory of Operation Information................1389
    Engine Lubrication System Operation................929
    Engine Cooling System Operation................933
  Group 20: Diagnosis, Tests and Adjustments................913
    Specifications................1365
    Essential Tools................937
    Diagnostic Information................1428
    Engine Turns Over But Will Not Start or Starts Hard................939
    Engine Runs Irregularly or Stalls Frequently................940
    Engine Runs Rough................941
    Engine Low Power................942
    Engine Smokes—Black or Grey................944
    Engine Smokes Excessively—White................945
    Engine Uses Excess Fuel................946
    Engine Has Excess Oil Consumption................947
    Engine Has Excess Noise or Vibration................948
    Engine Uses Excess Oil or Smokes Blue................949
    Engine Has Low Oil Pressure................950
    Engine Coolant Operating Temperature Incorrect................951
    Oil In Coolant or Coolant in Oil................952
    Radiator Bubble Test................953
    Cooling System Test................956
    Radiator Cap Pressure Test................957
    Engine Oil Pressure Test................958
    Cylinder Compression Pressure Test................960
    Throttle Lever Adjustment................962
    Fuel Injection Pump Setting................963
    Idle Speed Adjustment................968
    Valve Clearance Adjustment................969
    Fan/Alternator Drive Belt Adjustment................972
    Bleeding Fuel System................974
    Bleed Fuel System At Fuel Injection Nozzles................975
Section 120: Fuel/Air Operation, Tests and Adjustments................976
  Group 05: Component Location................976
    Component Location Information................1385
    Fuel System Components................979
    Air Intake System Components................982
  Group 10: Theory of Operation................976
    Theory of Operation Information................1389
    Fuel System Operation................985
    Fuel Filter Pump Operation................987
    Fuel Injection Nozzle Operation................988
    Fuel Transfer (Feed) Pump Operation................991
    In-Line Fuel Injection Pump Operation................993
    Governor Operation (In-Line Pump)................995
    Air Intake System Operation................997
  Group 15: Diagnosis, Tests and Adjustments................976
    Diagnostic Information................1428
    Fuel/Air Diagnosis, Tests and Adjustments................1001
Section 130: Electrical System Operation, Tests Section 130: Electrical System Operation, Tests & Adjustments (5038D, 5103, 5103S, 5203, 5104 and 5204){pgNO}1002 Adjustments (5038D, 5103, 5103S, 5203, 5104 and 5204)................1002
  Group 05: Component Location................1002
    Component Location Information................1385
    Engine Electrical Components—Right Hand Side................1130
    Engine Electrical Components—Left Hand Side................1131
    Dash And Center Control Console Electrical Components................1132
  Group 10: Theory of Operation................1002
    Theory of Operation Information................1389
    Fuse Block and Fuses................1136
    Relays................1138
    Starting System Operation................1139
    Charging System Operation................1141
    Lighting System Operation—Turn Signals................1143
    Lighting System Operation—Hazard Warning Lights................1145
    Lighting System Operation—Tail Lights................1147
    Lighting System Operation—Headlights and Instrument Lights................1149
    Instrument Panel System Operation—Tachometer/Hour Meter................1151
    Instrument Panel System Operation—Fuel Gauge................1029
    Instrument Panel System Operation—Temperature Gauge................1153
    Air Filter Restriction Indicator Operation................1033
    7-Pin Trailer Outlet Connector Operation................1035
    Horn Operation................1157
    Flood Light................1039
  Group 15: Wiring Schematics................1002
    Schematic Information................1161
    Component Identification Table................1162
    Electrical Schematic................1164
    Electrical Circuits................1166
  Group 20: Diagnosis, Test and Adjust................1002
    Diagnostic Information................1428
    Starting System Test Points—Normal Operation................1176
    Charging System Test Points................1182
    Lighting System Test Points—Turn Signals and Warning Lights................1061
    Lighting System Test Points—Rear Flood Light................1195
    Lighting System Test Points—Headlights and Instrument Lights................1199
    Instrument Panel System Test Points—Tachometer/Hourmeter................1207
    Instrument Panel System Test Points—Fuel Gauge................1083
    Instrument Panel System Test Points—Temperature Gauge................1210
    Instrument Panel System Test Points—Oil Pressure................1215
    Air Filter Restriction Test Points................1097
    Horn Test Points................1220
    Battery Voltage and Specific Gravity Tests................1105
    Charge Battery................1107
    Battery Load Test................1109
    Starter AMP Draw/RPM Test................1111
    Starter No-Load AMP Draw/RPM Test................1113
    Alternator/Regulator Test................1115
    Starter Solenoid Test................1117
    Starter Relay Test................1118
    Plug-In Relay Test................1119
    Diode Pack Test................1121
    Fuse Test................1123
    Neutral Start Switch Test................1124
    Turn Signal Controller (Flasher) Test................1125
Section 140: Electrical System Operation, Tests Section 140: Electrical System Operation, Tests & Adjustments (For 5103E){pgNO}1126 Adjustments (For 5103E)................1126
  Group 05: Component Location................1126
    Component Location Information................1385
    Engine Electrical Components—Right Hand Side................1130
    Engine Electrical Components—Left Hand Side................1131
    Dash And Center Control Console Electrical Components................1132
  Group 10: Theory of Operation................1126
    Theory of Operation Information................1389
    Fuse Block and Fuses................1136
    Relays................1138
    Starting System Operation................1139
    Charging System Operation................1141
    Lighting System Operation—Turn Signals................1143
    Lighting System Operation—Hazard Warning Lights................1145
    Lighting System Operation—Tail Lights................1147
    Lighting System Operation—Headlights and Instrument Lights................1149
    Instrument Panel System Operation—Tachometer/Hour Meter................1151
    Instrument Panel System Operation—Temperature Gauge................1153
    7-Pin Connector Operation................1155
    Horn Operation................1157
    Flood Light Operation................1159
  Group 15: Wiring Schematics................1126
    Schematic Information................1161
    Component Identification Table................1162
    Electrical Schematic................1164
    Electrical Circuits................1166
  Group 20: Diagnosis, Test and Adjust................1126
    Diagnostic Information................1428
    Starting System Test Points—Normal Operation................1176
    Starting System Test Points—Normal Operation................1176
    Charging System Test Points................1182
    Lighting System Test Points—Turn Signals and Tail Lights................1187
    Lighting System Test Points—Rear Flood Light................1195
    Lighting System Test Points—Headlights and Instrument Lights................1199
    Instrument Panel System Test Points—Tachometer/Hourmeter................1207
    Instrument Panel System Test Points—Temperature Gauge................1210
    Instrument Panel System Test Points—Oil Pressure................1215
    Horn Test Points................1220
Section 150: Power Train Operation, Tests Section 150: Power Train Operation, Tests & Adjustments{pgNO}1224 Adjustments................1224
  Group 05: Component Location— 'AA' Power Train................1224
    Component Location Information................1385
    Power Train Components................1243
    Dual Clutch Components................1244
    Single Clutch Components................1246
    Transmission Components ( Dual Clutch Tractor)................1247
    Transmission Components ( Single Clutch Tractor)................1236
    Final Drive Components................1251
    Rear PTO Components (Dual Clutch Tractor)................1252
    Rear PTO Components (Single Clutch Tractor)................1253
  Group 10: Component Location— 'AA+' Pattern Power Train................1224
    Component Location Information................1385
    Power Train Components................1243
    Dual Clutch Components................1244
    Single Clutch Components................1246
    Transmission Components ( Dual Clutch Tractor)................1247
    Transmission Components (Single Clutch Tractor)................1249
    Final Drive Components................1251
    Rear PTO Components (Dual Clutch Tractor)................1252
    Rear PTO Components (Single Clutch Tractor)................1253
  Group 15: Theory of Operation— 'AA' Transmission................1224
    Theory of Operation Information................1389
    Dual Clutch Operation................1283
    Single Clutch Operation................1288
    Transmission Lubrication System (Hydrostatic Steering Tractor)................1290
    Transmission Lubrication System ( Manual Steering Tractor)................1292
    Transmission Power Flow—Gear Shift................1294
    Transmission Power Flow—Range Shift and Reverse Drive................1296
    Rear PTO Operation ( Dual Clutch Tractor)................1298
    Rear PTO Operation ( Single Clutch Tractor)................1300
    Differential Power Flow................1302
    Differential Lock Operation................1304
    Final Drive Operation................1306
  Group 20: Theory of Operation— 'AA+' Pattern Transmission................1225
    Theory of Operation Information................1389
    Dual Clutch Operation................1283
    Single Clutch Operation................1288
    Transmission Lubrication System (Hydrostatic Steering Tractor)................1290
    Transmission Lubrication System ( Manual Steering Tractor)................1292
    Transmission Power Flow—Gear Shift................1294
    Transmission Power Flow—Range Shift and Reverse Drive................1296
    Rear PTO Operation ( Dual Clutch Tractor)................1298
    Rear PTO Operation ( Single Clutch Tractor)................1300
    Differential Power Flow................1302
    Differential Lock Operation................1304
    Final Drive Operation................1306
  Group 25: Diagnosis, Tests and Adjustments—Power Train................1225
    Diagnostic Information................1428
    Isolate the Problem Area................1310
    Traction Clutch Slips................1312
    Traction Clutch Dragging................1313
    Traction Clutch Does Not Engage................1314
    Traction Clutch Grabs................1315
    Traction Clutch Squeaks................1316
    Traction Clutch Does Not Release................1317
    Traction Clutch Chatters................1318
    Traction Clutch Rattles................1319
    Traction Clutch Engagement Is Noisy................1320
    Excessive Vibration in Traction Clutch................1321
    Clutch Pedal Does Not Return................1322
    Clutch Pedal Loose................1323
    Clutch Pedal Pulsates................1324
    Jerky or Rough Transmission of Power................1325
    Low Transmission Oil Level (Excessive Oil Leakage)................1326
    Gears Clash, Shifts Hard, or Will Not Engage................1327
    Two Speeds Engage Together................1328
    Transmission Will Not Stay in Gear................1329
    Transmission Noisy................1330
    PTO Noisy................1331
    PTO Hard to Engage................1332
    PTO Will Not Operate................1333
    PTO Will Not Stay Engaged................1334
    PTO Clutch Slips................1335
    PTO Clutch Dragging................1336
    PTO Clutch Does Not Engage................1337
    Excessive Differential Noise................1338
    Differential Does Not Work................1339
    Differential Chatters................1340
    Axle Noise................1341
    Axle Shaft Will Not Turn................1342
    Clutch Pedal Free Play Adjustment................1343
    PTO Clutch Lever Adjustment................1345
Section 160: Steering and Brake Operation, Tests Section 160: Steering and Brake Operation, Tests & Adjustments{pgNO}1347 Adjustments................1347
  Group 05: Component Location................1347
    Component Location Information................1385
    Steering System Components................1350
    Brake System Components................1352
  Group 10: Theory of Operation................1347
    Theory of Operation Information................1389
    Steering System Operation................1356
    Steering Valve Operation—Neutral and Manual Turning................1358
    Steering Valve Operation—Power Turning................1360
    Brake System Operation................1362
  Group 15: Diagnosis, Tests and Adjustments................1347
    Specifications................1365
    Diagnostic Information................1428
    Isolate the Problem—Steering System................1367
    Steering Sluggish or Loss of Steering................1368
    Isolate the Problem—Brakes................1369
    Steering Pump Flow Test................1441
    Steering Valve Relief Test................1372
    Steering Cylinder Leakage Test................1373
    Steering Valve Leakage Test................1374
    Steering Wheel Free Play - Adjustment................1376
    Toe-In Check and Adjustment—Standard Axle................1377
    Brake Pedal Adjustment................1380
Section 170: Hydraulic System Operation, Tests Section 170: Hydraulic System Operation, Tests & Adjustments{pgNO}1382 Adjustments................1382
  Group 05: Component Location................1382
    Component Location Information................1385
    Hydraulic System Components................1386
  Group 10: Theory of Operation................1382
    Theory of Operation Information................1389
    Hydraulic System Operation................1390
    Hydraulic Filter Operation................1393
    Hydraulic Pump Operation................1395
    MITA Rockshaft Control Valve Operation—Park Position................1397
    MITA Rockshaft Control Valve Operation—Raise Position................1399
    MITA Rockshaft Control Valve Operation—Lower Position................1401
    MITA Rockshaft Flow Control Valve Operation (FCV) —Neutral Position................1403
    MITA Rockshaft Flow Control Valve Operation (FCV) —Delivery Position................1405
    MITA Rockshaft Flow Control Valve Operation (FCV) —Discharge Position................1407
    MITA Rockshaft Rate-of-Drop Valve (Implement Lock) Operation................1409
    MITA Surge (Safety) Relief Valve Operation................1411
    JD Rockshaft Control Valve Operation—Neutral Phase................1413
    JD Rockshaft Control Valve Operation—Delivery Phase................1415
    JD Rockshaft Control Valve Operation—Discharge Phase................1417
    JD Rockshaft Rate-of-Drop Valve (Implement Lock) Operation................1419
    JD Rockshaft Draft-Sensing Operation................1421
    JD Rockshaft Surge Relief Valve Operation................1423
    JD Rockshaft Main Relief Valve Operation................1425
  Group 15: Diagnosis................1382
    Diagnostic Information................1428
    Preliminary Hydraulic System Inspection................1429
    Entire Hydraulic System Fails to Function/No Hydraulic Pump Output................1430
    Insufficient Pump Delivery................1431
    Hydraulic Functions Too Slow................1432
    Excessive Pump Pressure................1433
    Slow Hydraulic Pump Response................1434
    Excessive Pump Noise During Operation................1435
    Rockshaft Does Not Lift or Lifts Slowly................1436
    Rockshaft Does Not Lower or Lowers Slowly................1437
    Neutral Position Unstable, Rockshaft Drops after Engine Shut Down................1438
  Group 20: Hydraulic Tests................1383
    Hydraulic System Tests................1440
    Pump Flow Test................1441
    Main Relief Valve Test................1443
    Rockshaft Leakage Test................1445
    Rockshaft Lift Cycle Test................1447
  Group 25: Adjustments - MITA Rockshaft................1383
    Rockshaft Sensing Lever Friction Adjustment................1450
    Rockshaft Position-Sensing Lever Adjustment................1451
    Rockshaft Draft-Sensing Lever Adjustment................1453
  Group 40: Adjustments - JD Rockshaft................1383
    Rockshaft Lever Friction Adjustment................1456
    Rockshaft Position-Sensing Feedback Linkage Adjustment................1457
    Rockshaft Draft-Sensing Feedback Linkage Adjustment................1461
  Group 30: Hydraulic Schematics................1383
    Hydraulic Circuit Symbols................1465

John Deere Tractors 5103, 5103S, 5203 Diagnosis & Repair Service Manual (TM2041)