John Deere Tractors 5220, 5320, 5420 & 5520 Diagnosis and Tests Service Technical Manual (TM2049)
Catalog:
Model:
Complete Diagnosis & Tests Technical Manual with electrical wiring diagrams for John Deere Tractors 5220, 5320, 5420, 5520, with all the technical information to maintain, diagnose, rebuild like professional mechanics.
John Deere Tractors 5220, 5320, 5420, 5520 workshop Diagnosis & Tests technical manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
tm2049 English - 5220, 5320, 5420, and 5520 Tractors Diagnostic Technical Manual - (388313-,420001-,-388312,-420000,-420001,388313-,420001-,-388312,-420000,-420001,388313-,420001-,-388312,-420000,-420001,388313-,420001-,-388312,-420000,-420001) Diagnosis and Tests
tm9110 French - Manuel technique de diagnostic des tracteurs 5220, 5320, 5420 et 5520 - (388313-,420001-,-388312,-420000,-420001,388313-,420001-,-388312,-420000,-420001,388313-,420001-,-388312,-420000,-420001,388313-,420001-,-388312,-420000,-420001)
PRODUCT DETAILS:
Total Pages: 1,666 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English French
MAIN SECTIONS
Foreword
Operational Checkout Procedures
Operational Checkout Procedures
Engine Operation, Tests, and Adjustments
Component Location
Theory of Operation
Diagnosis, Tests, and Adjustments
Fuel/Air Operation, Tests, and Adjustments
Component Location
Theory of Operation
Diagnosis, Tests and Adjustments
Electrical System Operation, Test & Adjust
Component Location
Theory of Operation
Diagnosis, Test and Adjust
Wiring Schematics
Power Train Operation, Tests and Adjustments
Component Location-CollarShift/SyncShuttle™ Transmission
Component Location-PowrReverser™ Transmission
Theory of Operation-CollarShift/SyncShuttle™ Transmission
Theory of Operation-PowrReverser™ Transmission
Diagnosis, Tests, and Adjustments-CS/SS Transmission
Diagnosis, Tests, and Adjustments-PowrReverser™
Steering and Brake Operation, Test & Adjust
Component Location
Theory of Operation
Diagnosis, Tests and Adjustments
Hydraulic System Operation, Tests, and Adjustments
Component Location
Theory of Operation
Diagnosis
Hydraulic Tests-Without SCV
Hydraulic Tests-With SCV
Hydraulic Tests-All
Adjustments
Hydraulic Schematics
Operator Station
Component Location
Theory of Operation
Diagnosis, Tests, and Adjustments
Dealer Fabricated Tools
TABLE OF CONTENTS
Section 210: Operational Checkout Procedures................23
Group 10: Operational Checkout Procedures................23
Specifications................127
Operational Checkout Procedure Information................27
Engine Oil Level and Condition Check................28
Coolant Level and Condition Check................29
Transmission and Hydraulic Oil Check................31
3-Cylinder Fan and V-Belt Check................33
4-Cylinder Fan and Serpentine Belt Check................34
Compressor Belt Check................35
Fuel System Check (S.N. —420000)................37
Fuel System Check (S.N. 420001— )................39
Air Intake System Check................41
Electrical System Check (S.N. —420000)................43
Electrical System Check (S.N. 420001— )................45
Hydraulic System Check (S.N. —420000)................48
Hydraulic System Check (S.N. 420001— )................49
MFWD Oil Check................51
MFWD Differential Oil Check................52
Indicator Lamps Check (S.N. —420000)................53
Indicator Lamps Check (S.N. 420001— )................54
Cab Blower Motor Check (S.N. —420000)................55
Cab Blower Motor Check (S.N. 420001— )................56
A/C Compressor Clutch Check................76
Engine Start Check—Straddle Mount Tractors................58
Engine Start Check—Isolated Open Operator Station and Cab Tractors................60
Transmission Neutral Start Check—Straddle Mount Tractors................62
Transmission Neutral Start Check—Isolated Open Operator Station and Cab Tractors................64
PTO Neutral Start Check................66
Engine Fast and Slow Idle Operation................68
Foot Throttle Pedal Check—Isolated Open Operator Station and Cab Tractors................70
Power Steering Check................72
Differential Lock Check................73
PTO Engagement Check................74
Clutch Check................76
Transmission Shift Check................77
Range Lever Shift Check................79
MFWD Drive Check................81
Brake Check................82
Park Brake Check—CollarShift and SyncShuttle SYNCSHUTTLE is a trademark of Deere & Company Transmissions................24
Park Brake Check—PowrReverser POWRREVERSER is a trademark of Deere & Company Transmission................24
Rockshaft Check—Straddle Mount Tractors................87
Rockshaft Check—Isolated Open Operator Station and Cab Tractors................89
Selective Control Valve Check—Straddle Mount Tractors................91
Selective Control Valve Check—Isolated Open Operator Station and Cab Tractors................93
Front End Loader Joystick Control Check (Optional)................95
A/C System Operational Check................97
Cab Heater Valve Check................98
Miscellaneous Checks................99
Section 220: Engine Operation, Tests, and Adjustments................100
Group 05: Component Location................100
Component Location Information................1152
3-Cylinder Engine External Components—Left-Hand Side................104
3-Cylinder Engine External Components—Right-Hand Side................106
4-Cylinder Engine External Components—Left-Hand Side................108
4-Cylinder Engine External Components—Right-Hand Side................110
Group 10: Theory of Operation................100
Theory of Operation Information................1174
Engine Lubrication System Operation................114
Engine Lubrication System Operation—Continued................117
Engine Cooling System Operation—3-Cylinder................119
Engine Cooling System Operation—4-Cylinder................121
Group 15: Diagnosis, Tests, and Adjustments................1396
Service Equipment and Tools................125
Specifications................127
Diagnostic Information................1245
Engine Turns Over but Will Not Start or Starts Hard................129
Engine Runs Irregularly or Stalls Frequently................130
Engine Runs Rough................131
Engine Has Low Power................132
Engine Smokes—Black or Gray................134
Engine Smokes Excessively—White................135
Engine Uses Excess Fuel................136
Engine Has Excess Noise or Vibration................137
Engine Uses Excess Oil or Smokes Blue................138
Engine Has Low Oil Pressure................139
Engine Coolant Operating Temperature Incorrect................140
Oil In Coolant or Coolant in Oil................142
Radiator Bubble Test................143
Cooling System Test................145
Radiator Cap Pressure Test................146
Engine Oil Pressure Test................147
Cylinder Compression Pressure Test................149
Fuel Shut-Off Solenoid Check................151
Throttle Lever Adjustment—Straddle Mount Tractors................152
Throttle Lever Adjustment—Isolated Open Operator Station and Cab Tractors................153
Slow Idle Adjustment................155
Fast Idle Adjustment................157
Foot Throttle Pedal Stop Adjustment—Isolated Open Operator Station and Cab Tractors................159
Injection Pump Timing Adjustment................160
Check and Adjust Valve Clearance................162
Fan/Alternator V-Belt Adjustment—5220 and 5320 Tractors................166
Compressor Drive Belt Adjustment—3-Cylinder................168
Turbocharger Boost Pressure Test—5320 and 5520 Tractors................170
Bleed Fuel System................172
Section 230: Fuel/Air Operation, Tests, and Adjustments................175
Group 05: Component Location................175
Component Location Information................1152
Fuel System Components—Straddle Mount................178
Fuel System Components—Isolated Open Operator Station and Cab Tractors (S.N. —420000)................180
Fuel System Components—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )................182
Air Intake System Components—Without Turbocharger................184
Air Intake System Components—With Turbocharger................186
Group 10: Theory of Operation................175
Theory of Operation Information................1174
Fuel System Operation—Straddle Mount................190
Fuel System Operation—Isolated Open Operator Station and Cab Tractors (S.N. —420000)................192
Fuel System Operation—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )................194
Fuel Filter/Priming Pump Operation................197
Fuel Filter/Priming Pump Operation................197
Fuel Injection Nozzle Operation................200
Fuel Injection Nozzle Operation................200
Air Intake System Operation—Without Turbocharger................202
Air Intake System Operation—Without Turbocharger................202
Air Intake System Operation—With Turbocharger................204
Air Intake System Operation—With Turbocharger................204
Turbocharger Operation—5320 and 5520................205
Group 15: Diagnosis, Tests and Adjustments................175
Diagnostic Information................1245
Fuel/Air Diagnosis, Tests and Adjustments................209
Section 240: Electrical System Operation, Test Section 240: Electrical System Operation, Test & Adjust{pgNO}210 Adjust................210
Group 05: Component Location................210
Component Location Information................1152
Engine Electrical Components................220
Dash Electrical Components—Straddle Mount (S.N. —420000)................222
Dash Electrical Components—Straddle Mount (S.N. 420001— )................224
Dash Electrical Components—Isolated Open Operator Station and Cab Tractors (S.N. —420000)................226
Dash Electrical Components—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )................229
Machine Electrical Components—Straddle Mount (S.N. —420000)................231
Machine Electrical Components—Straddle Mount (S.N. 420001— )................233
Machine Electrical Components—Isolated Open Operator Station (S.N. —420000)................235
Machine Electrical Components—Isolated Open Operator Station (S.N. 420001— )................237
Machine Electrical Components—Cab Tractors (S.N. —420000)................239
Machine Electrical Components—Cab Tractors (S.N. 420001— )................241
Cab Control Panel and Electrical Components................243
Group 10: Theory of Operation................210
Theory of Operation Information................1174
Fuse/Relay Block Assembly—Straddle Mount (S.N. —420000)................246
Fuse/Relay Block Assembly—Straddle Mount (S.N. 420001— )................248
Fuse/Relay Block Assembly—Early Model Cab Tractors (S.N. —420000)................250
Fuse/Relay Block Assembly—Isolated Open Operator Station and Late Model Cab Tractors (S.N. —420000)................253
Fuse/Relay Block Assembly—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )................256
Electrical Load Center—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )................258
HVAC/Wiper Relay Block Assembly—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )................260
Starting System Operation—Normal (S.N. —420000)................262
Starting System Operation—Normal (S.N. 420001— )................265
Starting System Operation—Bypass Attempt (S.N. —420000)................268
Starting System Operation—Bypass Attempt (S.N. 420001— )................271
Air Intake Heater System Operation (S.N. —420000) (Optional)................274
Air Intake Heater System Operation (S.N. 420001— ) (Optional)................276
Charging System Operation (S.N. —420000)................278
Charging System Operation (S.N. 420001— )................280
Lighting System Operation—Turn Signals and Enhanced Tail Lights—Straddle Mount (S.N. —420000)................283
Lighting System Operation—Turn Signals—Isolated Open Operator Station (S.N. —420000)................286
Lighting System Operation—Turn Signals—Straddle Mount and Isolated Open Operator Station (S.N. 420001— )................289
Lighting System Operation—Turn Signals—Early Model Cab Tractors (S.N. —420000)................292
Lighting System Operation—Turn Signals—Late Model Cab Tractors (S.N. —420000)................295
Lighting System Operation—Turn Signals—Cab Tractors (S.N. 420001— )................298
Lighting System Operation—Warning Lights—Straddle Mount (S.N. —420000)................301
Lighting System Operation—Warning Lights—Isolated Open Operator Station (S.N. —420000)................303
Lighting System Operation—Warning Lights—Straddle Mount and Isolated Open Operator Station (S.N. 420001— )................305
Lighting System Operation—Warning Lights—Early Model Cab Tractors (S.N. —420000)................307
Lighting System Operation—Warning Lights—Late Model Cab Tractors (S.N. —420000)................310
Lighting System Operation—Warning Lights—Cab Tractors (S.N. 420001— )................313
Lighting System Operation—Tail Lights—All Tractors (S.N. —420000)................316
Lighting System Operation—Tail Lights—All Tractors (S.N. 420001— )................318
Lighting System Operation—Headlights and Instrument Lights—Straddle Mount (S.N. —420000)................320
Lighting System Operation—Headlights and Instrument Lights—Straddle Mount (S.N. 420001— )................322
Lighting System Operation—Headlights and Instrument Lights—Early Model Cab Tractors (S.N. —420000)................324
Lighting System Operation—Headlights and Instrument Lights—Isolated Open Operator Station and Late Model Cab Tractors (S.N. —420000)................327
Lighting System Operation—Headlights and Instrument Lights—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )................330
Flood Light Operation—Straddle Mount (S.N. —420000)................333
Flood Light Operation—Isolated Open Operator Station (S.N. —420000)................335
Flood Light Operation—Cab Tractors (S.N. —420000)................337
Work Light Operation—Straddle Mount and Isolated Open Operator Station (S.N. 420001— )................339
Work Light and Beacon Operation—Cab Tractors (S.N. 420001— )................341
Instrument Panel System Operation—Tachometer/Hour Meter—All Tractors (S.N. —420000)................344
Instrument Cluster Operation—Tachometer/Hour Meter—All Tractors (S.N. 420001— )................346
Instrument Panel System Operation—Fuel Gauge—All Tractors (S.N. —420000)................348
Instrument Cluster Operation—Fuel Gauge—All Tractors (S.N. 420001— )................350
Instrument Panel System Operation—Coolant Temperature Gauge—All Tractors (S.N. —420000)................352
Instrument Cluster Operation—Coolant Temperature Gauge—All Tractors (S.N. 420001— )................354
PTO Warning System Operation—Straddle Mount (S.N. —420000)................356
PTO Warning System Operation—Early Model Cab Tractors (S.N. —420000)................358
PTO Warning System Operation—Isolated Open Operator Station and Late Model Cab Tractors (S.N. —420000)................361
PTO Warning System Operation—All Tractors (S.N. 420001— )................364
Air Filter Restriction Indicator Operation—All Tractors (S.N. —420000)................366
Air Filter Restriction Indicator Operation—All Tractors (S.N. 420001— )................368
Optional Horn Operation—All Tractors (S.N. —420000)—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )................370
Optional Horn Operation—Straddle Mount Tractors (S.N. 420001— )................372
Accessory Relay and Electrical Outlet Operation—All Tractors (S.N. —420000)................374
Accessory Relay and Electrical Outlet Operation—Straddle Mount Tractors (S.N. 420001— )................376
Accessory Relay and Electrical Outlet Operation—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )................378
Blower Motor Operation—Cab Tractors (S.N. —420000)................381
Blower Motor Operation—Cab Tractors (S.N. 420001— )................384
A/C Compressor Operation—Cab Tractors (S.N. —420000)................387
A/C Compressor Operation—Cab Tractors (S.N. 420001— )................390
Front Wiper/Washer Operation—Cab Tractors (S.N. —420000)................392
Front Wiper/Washer Operation—Cab Tractors (S.N. 420001— )................395
Rear Wiper/Washer Operation—Cab Tractors (S.N. —420000) (Optional)................398
Rear Wiper/Washer Operation—Cab Tractors (S.N. 420001— ) (Optional)................400
Dome Light Operation—Cab Tractors (S.N. —420000)................402
Dome Light Operation—Cab Tractors (S.N. 420001— )................404
Convenience Outlet Operation—Cab Tractors (S.N. —420000)................406
Convenience Outlet Operation—Cab Tractors (S.N. 420001— )................408
Group 15: Diagnosis, Test and Adjust................212
Diagnostic Information................1245
Wire Color Chart................412
Starting System Test Points—Normal Operation—Straddle Mount (S.N. —420000)................414
Starting System Test Points—Normal Operation—Straddle Mount (S.N. 420001— )................418
Starting System Test Points—Normal Operation (Isolated Open Operator Station and Cab Tractors) (S.N. —420000)................422
Starting System Test Points—Normal Operation (Isolated Open Operator Station and Cab Tractors) (S.N. 420001— )................426
Starting System Test Points—Bypass Attempt—Straddle Mount (S.N. —420000)................431
Starting System Test Points—Bypass Attempt—Straddle Mount (S.N. 420001— )................434
Starting System Test Points—Bypass Attempt (Isolated Open Operator Station and Cab Tractors) (S.N. —420000)................437
Starting System Test Points—Bypass Attempt (Isolated Open Operator Station and Cab Tractors) (S.N. 420001— )................440
Air Intake Heater Test Points—Straddle Mount (S.N. —420000)................443
Air Intake Heater Test Points—Straddle Mount (S.N. 420001— )................446
Air Intake Heater Test Points—Isolated Open Operator Station and Cab Tractors (S.N. —420000)................449
Air Intake Heater Test Points—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )................452
Charging System Test Points—Straddle Mount (S.N. —420000)................455
Charging System Test Points—Straddle Mount (S.N. 420001— )................458
Charging System Test Points—Isolated Open Operator Station and Cab Tractors (S.N. —420000)................461
Charging System Test Points—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )................464
Lighting System Test Points—Turn Signals and Enhanced Tail Lights—Straddle Mount (S.N. —420000)................468
Lighting System Test Points—Turn Signals and Enhanced Tail Lights—Straddle Mount (S.N. 420001— )................475
Lighting System Test Points—Turn Signal Switch Power (Isolated Open Operator Station and Cab Tractors) (S.N. —420000)................485
Lighting System Test points—Turn Signal Operation (Isolated Open Operator Station) (S.N. —420000)................487
Lighting System Test points—Turn Signals—Isolated Open Operator Station (S.N. 420001— )................493
Lighting System Test points—Turn Signals—Early Model Cab Tractors (S.N. —420000)................500
Lighting System Test points—Turn Signals—Isolated Open Operator Station and Late Model Cab Tractors (S.N. —420000)................507
Lighting System Test points—Turn Signals—Cab Tractors (S.N. 420001— )................514
Lighting System Test Points—Warning Lights—Straddle Mount (S.N. —420000)................521
Lighting System Test Points—Warning Lights—Straddle Mount (S.N. 420001— )................524
Lighting System Test Points—Warning Lights (Isolated Open Operator Station) (S.N. —420000)................529
Lighting System Test Points—Warning Lights (Isolated Open Operator Station) (S.N. 420001— )................534
Lighting System Test Points—Warning Lights—Early Model Cab Tractors (S.N. —420000)................540
Lighting System Test points—Warning Lights—Late Model Cab Tractors (S.N. —420000)................546
Lighting System Test points—Warning Lights—Cab Tractors (S.N. 420001— )................552
Lighting System Test Points—Flood Light(s)—Straddle Mount (S.N. —420000)................558
Lighting System Test Points—Work Lights—Straddle Mount (S.N. 420001— )................561
Lighting System Test Points—Flood Lights (Isolated Open Operator Station) (S.N. —420000)................565
Lighting System Test Points—Work Lights—Isolated Open Operator Station (S.N. 420001— )................569
Lighting System Test Points—Flood Lights (Cab Tractors) (S.N. —420000)................573
Lighting System Test Points—Work Lights—Cab Tractors (S.N. 420001— )................577
Lighting System Test Points—Tail Lights—Straddle Mount (S.N. —420000)................581
Lighting System Test Points—Tail Lights—Straddle Mount (S.N. 420001— )................584
Lighting System Test Points—Tail Lights (Isolated Open Operator Station and Cab Tractors) (S.N. —420000)................587
Lighting System Test Points—Tail Lights—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )................590
Lighting System Test Points—Headlights and Instrument Lights—Straddle Mount (S.N. —420000)................593
Lighting System Test Points—Headlights and Instrument Lights—Straddle Mount (S.N. 420001— )................597
Lighting System Test Points—Headlights and Instrument Lights—Early Model Cab Tractors (S.N. —420000)................600
Lighting System Test points—Headlights and Instrument Lights—Isolated Open Operator Station and Late Model Cab Tractors (S.N. —420000)................605
Lighting System Test points—Headlights and Instrument Lights—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )................610
Lighting System Test Points—Dome Light (Cab Tractors) (S.N. —420000)................615
Lighting System Test Points—Dome Light—Cab Tractors (S.N. 420001— )................618
Instrument Panel System Test Points—Tachometer/Hour Meter—Straddle Mount (S.N. —420000)................621
Instrument Cluster System Test Points—Tachometer/Hour Meter—Straddle Mount (S.N. 420001— )................624
Instrument Panel System Test Points—Tachometer/Hour Meter (Isolated Open Operator Station and Cab Tractors) (S.N. —420000)................627
Instrument Cluster Test Points—Tachometer/Hour Meter—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )................630
Instrument Panel System Test Points—Fuel Gauge—Straddle Mount (S.N. —420000)................633
Instrument Cluster System Test Points—Fuel Gauge—Straddle Mount (S.N. 420001— )................636
Instrument Panel System Test Points—Fuel Gauge (Isolated Open Operator Station and Cab Tractors) (S.N. —420000)................639
Instrument Cluster Test Points—Fuel Gauge (Isolated Open Operator Station and Cab Tractors) (S.N. 420001— )................642
Instrument Panel System Test Points—Temperature Gauge—Straddle Mount (S.N. —420000)................645
Instrument Cluster System Test Points—Temperature Gauge—Straddle Mount (S.N. 420001— )................648
Instrument Panel System Test Points—Temperature Gauge (Isolated Open Operator Station and Cab Tractors) (S.N. —420000)................651
Instrument Cluster Test Points—Temperature Gauge (Isolated Open Operator Station and Cab Tractors) (S.N. 420001— )................654
Instrument Cluster System Test Points—Oil Pressure—Straddle Mount (S.N. —420000)................657
Instrument Cluster System Test Points—Oil Pressure—Straddle Mount (S.N. 420001— )................660
Instrument Panel System Test Points—Oil Pressure (Isolated Open Operator Station and Cab Tractors) (S.N. —420000)................663
Instrument Cluster Test Points—Oil Pressure (Isolated Open Operator Station and Cab Tractors) (S.N. 420001— )................666
PTO Warning System Test Points—Straddle Mount (S.N. —420000)................669
PTO Warning System Test Points—Straddle Mount (S.N. 420001— )................672
PTO Warning System Test Points—Early Model Cab Tractors (S.N. —420000)................675
PTO Warning System Test Points—Isolated Open Operator Station and Late Model Cab Tractors (S.N. —420000)................679
PTO Warning System Test Points—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )................683
Air Filter Restriction Test Points—Straddle Mount (S.N. —420000)................686
Air Filter Restriction Test Points—Straddle Mount (S.N. 420001— )................689
Air Filter Restriction Test Points—Isolated Open Operator Station and Cab Tractors (S.N. —420000)................692
Air Filter Restriction Test Points—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )................695
Optional Horn Test Points—Straddle Mount (S.N. —420000)................698
Optional Horn Test Points—Straddle Mount (S.N. 420001— )................700
Optional Horn Test Points—Cab Tractors and Isolated Open Operator Station (S.N. —420000)................703
Optional Horn Test Points—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )................705
Accessory Relay and Electrical Outlet Test Points—Straddle Mount (S.N. —420000)................707
Accessory Relay and Electrical Outlet Test Points—Straddle Mount (S.N. 420001— )................711
Accessory Relay and Electrical Outlet Test Points—Early Model Cab Tractors (S.N. —420000)................715
Accessory Relay and Electrical Outlet Test Points—Isolated Open Operator Station and Late Model Cab Tractors (S.N. —420000)................720
Accessory Relay and Electrical Outlet Test Points—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )................725
Blower Motor Test Points—Cab Tractors (S.N. —420000)................728
Blower Motor Test Points—Cab Tractors (S.N. 420001— )................734
A/C Compressor Clutch Coil Test Points—Cab Tractors (S.N. —420000)................739
A/C Compressor Clutch Coil Test Points—Cab Tractors (S.N. 420001— )................742
Front Wiper/Washer Test Points—Cab Tractors (S.N. —420000)................744
Front Wiper/Washer Test Points—Cab Tractors (S.N. 420001— )................748
Rear Wiper/Washer Test Points—Cab Tractors (S.N. —420000)................752
Rear Wiper/Washer Test Points—Cab Tractors (S.N. 420001— )................755
Convenience Outlet Test Points—Cab Tractors (S.N. —420000)................759
Convenience Outlet Test Points—Cab Tractors (S.N. 420001— )................762
Battery Voltage and Specific Gravity Tests................765
Charge Battery................767
Battery Load Test................769
Starter Amp Draw/RPM Test................771
Starter No-Load Amp Draw/RPM Test................773
Alternator/Regulator Test................775
Starter Solenoid Test................777
Starter Relay Test................778
Key Switch Test................780
Plug-In Relay Test................782
Diode Pack Test................784
Fuse Test................786
Neutral Start Switch Test................787
PTO Switch Test................788
PTO Seat Switch Test................790
Light Switch Test................792
Flasher Module Test—Isolated Open Operator Station and Cab Tractors................794
Turn Signal Controller Test—Straddle Mount (S.N. —420000)................795
Turn Signal Switch Test—All Tractors (S.N. 420001— )................796
Fuel Shut-Off Solenoid Test................798
Blower Switch Test................799
Start Resistor Test................801
Blower Motor Resistors................802
A/C Temperature Control Switch Test................803
Front Wiper/Washer Switch Test................804
Rear Wiper/Washer Switch Test................806
Door Switch Test................807
Dome Light Switch Test................808
Group 20: Wiring Schematics................217
Schematic Information................811
Component Identification Table................812
5220—5520 Straddle Mount Electrical Schematic (S.N. —420000)................814
5220—5520 Straddle Mount Electrical Schematic (S.N. 420001— )................821
5220—5520 Early Model Cab Tractors Electrical Schematic (S.N. —420000)................830
5220—5520 Isolated Open Operator Station and Late Model Cab Tractors Electrical Schematic (S.N. —420000)................844
5220—5520 Isolated Open Operator Station and Cab Tractors Electrical Schematic (S.N. 420001— )................860
Section 250: Power Train Operation, Tests and Adjustments................884
Group 05: Component Location—CollarShift/SyncShuttle™ Transmission................884
Component Location Information................1152
Power Train Components—Straddle Mount (CollarShift and SyncShuttle™)................890
Power Train Components—Isolated Open Operator Station and Cab Tractors (CollarShift and SyncShuttle™)................892
Clutch Components—CollarShift and SyncShuttle™ Transmissions................894
Transmission Components—CollarShift................896
Transmission Components—SyncShuttle™................898
Final Drive Components................917
Hi-Crop Final Drive Axle Components................901
Rear PTO Components................918
Rear 540/540E PTO Components (SyncShuttle™ Transmission Only)................904
Group 06: Component Location—PowrReverser™ Transmission................884
Component Location Information................1152
Power Train Components—Straddle Mount (PowrReverser™ Transmission)................907
Power Train Components—Isolated Open Operator Station and Cab Tractors (PowrReverser™ Transmission)................909
Clutch Components—PowrReverser™ Transmission................911
PowrReverser™ Components................913
Transmission Components—PowrReverser™ Transmission................915
Final Drive Components................917
Rear PTO Components................918
Group 10: Theory of Operation—CollarShift/SyncShuttle™ Transmission................884
Theory of Operation Information................1174
Clutch Operation—CollarShift and SyncShuttle™ Transmissions................921
Transmission Lubrication System................929
CollarShift Transmission—Gear Shift Power Flow................931
SyncShuttle™ Transmission—Gear Shift Power Flow................933
SyncShuttle™ Transmission Synchronizer Operation—Reverse and 2nd Gear (Disk-and-Plate Type Synchronizer)................935
SyncShuttle™ Transmission Synchronizer Operation—1st and 3rd Gear (Cone-Type Synchronizer)................937
CollarShift Transmission—Range Shift Power Flow................939
Rear PTO Operation................990
Rear PTO Operation................990
Rear 540/540E PTO Operation (SyncShuttle™ and PowrReverser™ Transmissions)................945
Rear 540/540E PTO Operation (SyncShuttle™ and PowrReverser™ Transmissions)................945
Differential Power Flow................947
Differential Power Flow................947
Hi-Crop Axle Differential Power Flow................950
Hi-Crop Axle Differential Power Flow................950
Differential Lock Operation................952
Differential Lock Operation................952
Final Drive Operation................991
Mechanical Front Wheel Drive (MFWD) Drop Gearbox Operation................956
Mechanical Front Wheel Drive (MFWD) Drop Gearbox Operation................956
Group 11: Theory of Operation—PowrReverser™ Transmission................885
Theory of Operation Information................1174
Clutch Operation—PTO Clutch Disengaged (PowrReverser™ Transmission)................959
Clutch Operation—PTO Clutch Engaged (PowrReverser™ Transmission)................961
PowrReverser™ General Information................963
PowrReverser™ Operation in Forward................964
PowrReverser™ Operation in Reverse................966
PowrReverser™ Power Flow................968
PowrReverser™ Control Valve Operation—Initial Engine Start-Up, Clutch Pedal Up................970
PowrReverser™ Control Valve Operation—F-N-R Lever in Neutral, Clutch Pedal Down................972
PowrReverser™ Control Valve Operation—F-N-R Lever in Neutral, Clutch Pedal Up................974
PowrReverser™ Control Valve Operation—F-N-R Lever in Forward, Clutch Pedal Up................976
PowrReverser™ Control Valve Operation—F-N-R Lever in Reverse, Clutch Pedal Up................979
PowrReverser™ Transmission—Gear Shift Power Flow................981
Gear Shift Synchronizer Operation................983
PowrReverser™ Transmission—Range Shift Power Flow................985
PowrReverser™ Transmission Lubrication System................988
Rear PTO Operation................990
Final Drive Operation................991
Differential Operation................992
MFWD Operation................993
Group 15: Diagnosis, Tests, and Adjustments—CS/SS Transmission................886
Diagnostic Information................1245
Isolate the Problem Area................996
Traction Clutch Slips................998
Traction Clutch Dragging................999
Traction Clutch Does Not Engage................1000
Traction Clutch Grabs................1001
Traction Clutch Squeaks................1002
Traction Clutch Does Not Release................1003
Traction Clutch Chatters................1004
Traction Clutch Rattles................1005
Traction Clutch Engagement Is Noisy................1006
Excessive Vibration in Traction Clutch................1007
Clutch Pedal Does Not Return................1043
Clutch Pedal Loose................1009
Clutch Pedal Pulsates................1010
Jerky or Rough Transmission of Power................1011
Low Transmission Oil Level (Excessive Oil Leakage)................1042
Gears Clash, Shift Hard, or Will Not Engage................1047
Two Speeds Engage Together................1048
Transmission Will Not Stay in Gear................1049
Transmission Noisy................1050
PTO Noisy................1017
PTO Hard to Engage................1018
PTO Will Not Operate................1019
PTO Will Not Stay Engaged................1020
Excessive Differential Noise................1021
Differential Does Not Work................1022
No Differential Lock................1023
Differential Chatters................1024
Axle Noise................1025
Axle Shaft Will Not Turn................1026
MFWD Lever Is Hard to Engage................1027
MFWD Lever Will Not Stay in ON Position................1028
Noisy Front Wheel Drive Operation................1029
Check and Adjust Clutch Pedal Free Play—CollarShift and SyncShuttle™ Transmissions (Straddle Mount)................1030
Check and Adjust Clutch Pedal Free Play—CollarShift and SyncShuttle™ Transmissions (Isolated Open Operator Station and Cab Tractors)................1032
Adjusting PTO Clutch Lever Linkage—Straddle Mount................1034
Adjusting PTO Clutch Lever Linkage—Isolated Open Operator Station and Cab Tractors................1036
Group 16: Diagnosis, Tests, and Adjustments—PowrReverser™................887
Diagnostic Information—PowrReverser™ Transmission................1039
Isolate the Problem Area—PowrReverser™ Transmission................1040
Low Transmission Oil Level (Excessive Oil Leakage)................1042
Clutch Pedal Does Not Return................1043
Tractor Does Not Move in Forward or Reverse................1044
PowrReverser™ Engages Too Quickly or Too Slowly................1045
PowrReverser™ Does Not Disengage................1046
Gears Clash, Shift Hard, or Will Not Engage................1047
Two Speeds Engage Together................1048
Transmission Will Not Stay in Gear................1049
Transmission Noisy................1050
PTO Troubleshooting................1051
Differential Troubleshooting................1052
Final Drive Axle Troubleshooting................1053
MFWD Troubleshooting................1054
PowrReverser™ Control Valve Tests................1055
Transmission Pump Flow Test................1061
Adjust Forward-Neutral-Reverse Cable................1063
Clutch Pedal Linkage Adjustment................1070
Park Brake Cable Adjustment................1072
PTO 540/540E Lever and Linkage Adjustment................1077
Section 260: Steering and Brake Operation, Test Section 260: Steering and Brake Operation, Test & Adjust{pgNO}1079 Adjust................1079
Group 05: Component Location................1079
Component Location Information................1152
Steering System Components—5220—5320 Straddle Mount................1083
Steering System Components—5420—5520 Straddle Mount................1085
Steering System Components—5220—5320 Isolated Open Operator Station................1087
Steering System Components—5420—5520 Isolated Open Operator Station and All Cab Tractors................1089
Brake System Components................1091
Group 10: Theory of Operation................1079
Theory of Operation Information................1174
Steering System Operation—5220—5320 Straddle Mount................1095
Steering System Operation—5420—5520 Straddle Mount................1097
Steering System Operation—5220—5320 Isolated Open Operator Station................1099
Steering System Operation—5420—5520 Isolated Open Operator Station and All Cab Tractors................1101
Steering Valve Operation—Neutral and Manual Turning................1103
Steering Valve Operation—Power Turning................1105
Brake System Operation................1107
Brake Valve Operation (S.N. —420000)................1109
Brake Valve Operation (S.N. 420001— )................1113
Group 15: Diagnosis, Tests and Adjustments................1079
Diagnostic Information................1245
Isolate the Problem—Steering System................1119
Steering Sluggish or Loss of Steering................1120
Isolate the Problem—Brakes................1121
Excessive Brake Pedal Leak-Down................1122
Excessive Brake Chatter................1123
Steering Pump Flow Test................1124
Steering Valve Relief Test................1126
Steering Cylinder Leakage Test................1127
Steering Valve Leakage Test................1128
Toe-In Check and Adjustment—Standard Axle................1130
Toe-In Check and Adjustment—MFWD................1132
MFWD Steering Stop Adjustment................1134
Brake Pedal Adjustment (S.N. —420000)................1136
Brake Pedal Adjustment (S.N. 420001— )................1138
Bleed Brake System................1140
Adjust Brake (S.N. 388313— )................1141
Adjust Brake (S.N. —388312)................1143
Section 270: Hydraulic System Operation, Tests, and Adjustments................1147
Group 05: Component Location................1147
Component Location Information................1152
Hydraulic System Components—Straddle Mount Tractors (Without Oil Cooler)................1153
Hydraulic System Components—Isolated Open Operator Station and Cab Tractors (Without Oil Cooler)................1155
Hydraulic System Components—Straddle Mount Tractors (With Oil Cooler)................1157
Hydraulic System Components—Isolated Open Operator Station and Cab Tractors (With Oil Cooler)................1159
Selective Control Valve Components—Straddle Mount Tractors without Mid-Mount SCV (S.N. —420000)................1161
Selective Control Valve Components—Straddle Mount Tractors without Mid-Mount SCV (S.N. 420001— )................1163
Selective Control Valve Components—Isolated Open Operator Station and Cab Tractors without Mid-Mount SCV................1165
Selective Control Valve Components—Cab Tractors with Mid-Mount SCV................1167
Selective Control Valve Components—Isolated Open Operator Station Tractors with Mid-Mount SCV................1169
Selective Control Valve Components—Straddle Mount Tractors with Mid-Mount SCV (S.N. 420001— )................1171
Group 10: Theory of Operation................1147
Theory of Operation Information................1174
Hydraulic System Operation—Straddle Mount Tractors (S.N. —420000)................1175
Hydraulic System Operation—Straddle Mount Tractors (S.N. 420001— )................1178
Hydraulic System Operation—Isolated Open Operator Station and Cab Tractors................1181
Hydraulic Filter Operation................1184
Hydraulic Pump Operation................1186
Rockshaft Control Valve Operation—Two Flow Regulator Valves (Early Model Straddle Mount)................1188
Rockshaft Control Valve Operation—Neutral Position (Early Model Straddle Mount)................1190
Rockshaft Control Valve Operation—Raise Position (Early Model Straddle Mount)................1192
Rockshaft Control Valve Operation—Lower Position (Early Model Straddle Mount)................1194
Rockshaft Control Valve Operation—Neutral Position (Isolated Open Operator Station, Cab Tractors and Late Model Straddle Mount)................1196
Rockshaft Control Valve Operation—Raise Position (Isolated Open Operator Station, Cab Tractors and Late Model Straddle Mount)................1198
Rockshaft Control Valve Operation—Flow Control Operation (Isolated Open Operator Station, Cab Tractors and Late Model Cab Tractors)................1200
Rockshaft Control Valve Operation—Lower Position (Isolated Open Operator Station, Cab Tractors and Late Model Straddle Mount)................1202
Surge Relief Valve Operation................1204
Main Relief Valve Operation—Straddle Mount Tractors................1206
Main Relief Valve Operation—Isolated Open Operator Station and Cab Tractors................1208
Rate-of-Drop Valve Operation—Full Open (Straddle Mount)................1210
Rate-of-Drop Valve Operation—Full Open (Isolated Open Operator Station And Cab Tractors)................1212
Rate-of-Drop Valve Operation—Partially Open (Straddle Mount)................1214
Rate-of-Drop Valve Operation—Partially Open (Isolated Open Operator Station and Cab Tractors)................1216
Rate-of-Drop Valve Operation—Full Closed (Straddle Mount)................1218
Rate-of-Drop Valve Operation—Full Closed (Isolated Open Operator Station And Cab Tractors)................1220
Rockshaft Draft-Sensing Operation................1222
SCV Operation—Straddle Mount Tractors (Neutral Position)................1224
SCV Operation—Straddle Mount Tractors (Extend and Retract Positions)................1226
Float SCV Operation—Straddle Mount Tractors (Float Position)................1228
Regenerative SCV Operation—Straddle Mount Tractors (Regenerative Position)................1230
SCV Operation—Isolated Open Operator Station and Cab Tractors (Neutral Position)................1232
SCV Operation—Isolated Open Operator Station and Cab Tractors (Extend and Retract Positions)................1234
Float SCV Operation—Isolated Open Operator Station and Cab Tractors (Float Position)................1236
Regenerative SCV Operation—Isolated Open Operator Station and Cab Tractors (Regenerative Position)................1238
Quick Disconnect Coupler Operation (Straddle Mount)................1240
Quick Disconnect Coupler Operation (Cab and IOOS)................1242
Group 15: Diagnosis................1148
Diagnostic Information................1245
Preliminary Hydraulic System Inspection................1246
Hydraulic Oil Warm-Up Procedure................1247
Entire Hydraulic System Fails to Function/No Hydraulic Pump Output................1248
Insufficient Pump Delivery................1249
Hydraulic Functions Too Slow................1250
Excessive Pump Pressure................1251
Slow Hydraulic Pump Response................1252
Excessive Pump Noise During Operation................1253
Rockshaft Does Not Lift or Lifts Slowly................1254
Rockshaft Does Not Lower or Lowers Slowly................1255
Neutral Position Unstable, Rockshaft Drops after Engine Shut Down................1256
Mid-Mount Joystick Does Not Return to Neutral Position—Mid-Mount SCV................1257
Mid-Mount Joystick Does Not Remain in Detent Position—Mid-Mount SCV................1258
Remote Cylinder Does Not Extend or Retract................1259
Remote Cylinder Settles Under Load................1260
Remote Cylinder Operates Too Fast or Too Slow................1261
Group 16: Hydraulic Tests—Without SCV................1149
Hydraulic System Tests—Without SCV (Straddle Mount Tractors)................1264
Hydraulic System Tests—Without SCV (Isolated Open Operator Station and Cab Tractors)................1266
Pump Flow Test—Without SCV................1268
Main Relief Valve Test—Without SCV (Straddle Mount Tractors)................1270
Main Relief Valve Test—Without SCV (Isolated Open Operator Station and Cab Tractors)................1272
Group 17: Hydraulic Tests—With SCV................1149
Hydraulic System Tests—With SCV (Straddle Mount Tractors) (S.N. —420000)................1276
Hydraulic System Tests—With SCV (Straddle Mount Tractors) (S.N. 420001— )................1278
Hydraulic System Tests—With SCV (Isolated Open Operator Station and Cab Tractors)................1280
Pump Flow Test—With SCV................1282
Main Relief Valve Test—With SCV................1285
SCV Leakage Test................1287
Group 18: Hydraulic Tests—All................1149
Rockshaft Leakage Test—Straddle Mount................1291
Rockshaft Leakage Test—Isolated Open Operator Station and Cab Tractors................1293
Rockshaft Lift Cycle Test................1295
Group 19: Adjustments................1149
Selective Control Valve (SCV) Cable Adjustment—Isolated Open Operator Station and Cab Tractors................1302
Rockshaft Draft-Sensing and Position Control Lever Cable Adjustment—Isolated Open Operator Station and Cab Tractors................1307
Rockshaft Lever Friction Adjustment................1308
Rockshaft Position-Sensing Feedback Linkage Adjustment................1309
Rockshaft Draft-Sensing Feedback Linkage Adjustment................1313
Main Relief Valve Adjustment—Straddle Mount Tractors................1315
Main Relief Valve Adjustment—Isolated Open Operator Station and Cab Tractors................1316
Group 20: Hydraulic Schematics................1150
Hydraulic Circuit Symbols................1319
Hydraulic Schematic—Straddle Mount Tractors (Without SCV) (S.N. —420000)................1321
Hydraulic Schematic—Straddle Mount Tractors (With SCV) (S.N. —420000)................1323
Hydraulic Schematic—Straddle Mount Tractors (With Mid-Mount Valve) (S.N. —420000)................1325
Hydraulic Schematic—Isolated Open Operator Station and Cab Tractors (Without SCV) (S.N. —420000)................1327
Hydraulic Schematic—Isolated Open Operator Station and Cab Tractors (With SCV) (S.N. —420000)................1329
Hydraulic Schematic—Isolated Open Operator Station and Cab Tractors (With Mid-Mount Valve) (S.N. —420000)................1331
Hydraulic Schematic—Straddle Mount Tractors (Without SCV) (S.N. 420001— )................1333
Hydraulic Schematic—Straddle Mount Tractors (With SCV) (S.N. 420001— )................1335
Hydraulic Schematic—Straddle Mount Tractors (With Mid-Mount Valve) (S.N. 420001— )................1337
Hydraulic Schematic—Isolated Open Operator Station and Cab Tractors (Without SCV) (S.N. 420001— )................1339
Hydraulic Schematic—Isolated Open Operator Station and Cab Tractors (With SCV and Mid Mount) (S.N.420001— )................1341
Hydraulic Schematic—Isolated Open Operator Station and Cab Tractors (With Mid-Mount Valve) (S.N. 420001— )................1343
Hydraulic Schematic—Isolated Open Operator Station and Cab Tractors (With Triple Rear SCV, Mid Mount, Power Beyond Coupler and Power Beyond Flow Control)................1345
Section 290: Operator Station................1347
Group 05: Component Location................1347
Air Conditioning System Components (S.N. —420000)................1350
Air Conditioning System Components (S.N. 420001— )................1352
Group 10: Theory of Operation................1347
Refrigerant R134a................1355
Air Conditioning System Air Flow................1356
Air Conditioning System Cycle................1358
Compressor................1360
Condenser................1361
Receiver-Dryer................1362
Expansion Valve................1363
A/C Temperature Control Switch................1364
Evaporator................1365
A/C ON/OFF Switch and Temperature Control Knob................1366
Heater Temperature Control Knob................1367
High and Low Pressure Switches (S.N. —420000)................1368
High/Low Pressure Switch (S.N. 420001— )................1369
Group 15: Diagnosis, Tests, and Adjustments................1396
Diagnosis, Tests, and Adjustments................1396
Adjust Heater Temperature Control Cable................1422
Adjust A/C Temperature Control Switch................1424
Section 299: Dealer Fabricated Tools................1426
Group 00: Dealer Fabricated Tools................1426
DFLV1A Final Drive Turning Tool................1428
DFRW20—Compressor Holding Fixture................1429
John Deere Tractors 5220, 5320, 5420 & 5520 Diagnosis and Tests Service Technical Manual (TM2049)
