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)