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

John Deere 5200, 5300, 5400 and 5500 Tractors workshop technical manual (All Inclusive) includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

TM1520 English - 5200, 5300, 5400 and 5500 tractors diagnostic and repair Technical Manual.pdf

PRODUCT DETAILS:
Total Pages: 1,783 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable)
Language: English

MAIN SECTIONS
Foreword
   John Deere Dealers
   General Information
      Safety
      General Specifications
      Fuel and Lubricants
      Serial Number Locations
      Features and Accessories
   Engine Repair
      Engine
      Cooling System
   Fuel and Air Repair
      Fuel System
      Air Intake System
      Speed Control Linkage
   Electrical Repair
      Battery, Starter and Alternator
      Electrical System Components
      Wiring Harness
   Power Train Repair
      Clutch Housing-Collar Shift/TSS Transmission
      Clutch Housing-Hydraulic Reverser Transmission
      Clutch Assembly-Collar Shift/TSS Transmission
      Clutch Assembly-Hydraulic Reverser Transmission
      Hydraulic Reverser
      Collar Shift/TSS Transmission
      Hydraulic Reverser Transmission
      Rear PTO Drive Shaft-Collar Shift/TSS Transmission
      Rear PTO Drive Shaft-Hydraulic Reverser Transmission
      Differential
      Final Drives
      Mechanical Front Wheel Drive
      Creeper Assembly
   Steering and Brake Repair
      Steering Repair
      Brake Repair
   Hydraulic Repair
      Hydraulic Pump and Filter
      Hydraulic Oil Cooler
      Rockshaft
      Dual Selective Control Valve
      Single (Third) Selective Control Valve
      Hydraulic Mid Mount Coupler
      Hydraulic Power Beyond
   Miscellaneous Repair
      Front Axle-2WD
      Wheels
      3-Point Hitch
   Operator Station Repair
      Seat and Support
      ROLL-GARD™
      Cab Components
      Air Conditioning System
      Heating System
   Operational Checkout Procedures
      Operational Checkout Procedures
   Engine Operation, Tests and Adjustments
      Component Location
      Theory of Operation
      Diagnosis, Tests and Adjustments
   Fuel/Air Operation, Tests and Adjustments
      Component Location
      Theory of Operation
      Diagnosis, Tests and Adjustments
   Electrical System Operation, Tests and Adjustments
      Component Location
      Theory of Operation
      Diagnosis, Tests and Adjustments
      Wiring Schematics
   Power Train Operation, Tests and Adjustments
      Component Location-Collar Shift/TSS Transmission
      Component Location-Hydraulic Reverser Transmission
      Theory of Operation-Collar Shift/TSS Transmission
      Theory of Operation-Hydraulic Reverser Transmission
      Diagnosis, Tests and Adjustments-Collar Shift/TSS Transmission
      Diagnosis, Tests and Adjustments-Hydraulic Reverser
   Steering and Brake Operation, Tests and Adjustments
      Component Location
      Theory of Operation
      Diagnosis, Tests and Adjustments
   Hydraulic System Operation, Tests and Adjustments
      Component Location
      Theory of Operation
      Diagnosis
      Hydraulic Tests-Without SCV
      Hydraulic Tests-With SCV
      Hydraulic Tests-All
      Adjustments
      Hydraulic Schematics
   Operator Station
      Component Location
      Theory of Operation
      Diagnosis, Tests and Adjustments
   Dealer Fabricated Tools

TABLE OF CONTENTS
Section 10: General Information................32
  Group 05: Safety................32
    Recognize Safety Information................36
    Understand Signal Words................37
    Follow Safety Instructions................38
    Handle Fluids Safely-Avoid Fires................39
    Prevent Battery Explosions................40
    Prepare for Emergencies................41
    Prevent Acid Burns................42
    Service Cooling System Safely................44
    Handle Chemical Products Safely................45
    Avoid High-Pressure Fluids................46
    Park Machine Safely................47
    Support Machine Properly................48
    Wear Protective Clothing................49
    Work in Clean Area................50
    Service Machines Safely................51
    Work in Ventilated Area................52
    Illuminate Work Area Safely................53
    Replace Safety Signs................54
    Use Proper Lifting Equipment................55
    Keep ROPS Installed Properly................56
    Service Tires Safely................57
    Avoid Harmful Asbestos Dust................58
    Avoid Heating Near Pressurized Fluid Lines................59
    Remove Paint Before Welding or Heating................60
    Use Proper Tools................61
    Dispose of Waste Properly................62
    Live With Safety................63
  Group 10: General Specifications................1754
    Machine Specifications-5200 and 5300................67
    Travel Speeds-5200 and 5300................70
    Machine Specifications-5400 and 5500................72
    Travel Speeds-5400 and 5500................75
    Service Recommendations for O-Ring Boss Fittings................77
    Service Recommendations for Flat Face O-Ring Seal Fittings................79
    Metric Cap Screw Torque Values-Grade 7................81
    Metric Bolt and Cap Screw Torque Values................82
    Unified Inch Bolt and Cap Screw Torque Values................84
  Group 20: Fuel and Lubricants................33
    Diesel Fuel Specifications................1754
    Storing Fuel................90
    Do Not Use Galvanized Containers................91
    Fill Fuel Tank................92
    Diesel Engine Oil................94
    Diesel Engine Coolant................96
    Liquid Coolant Conditioner................98
    Transmission and Hydraulic Oil................99
    MFWD Gear Oil................100
    Grease (Specific Application)................101
    Grease................102
    Alternative and Synthetic Lubricants................103
    Lubricant Storage................104
  Group 25: Serial Number Locations................33
    Serial Numbers................106
    Product Identification Number Location................107
    Engine Serial Number Location................108
    Fuel Injection Pump Serial Number Location................109
    Alternator Serial Number Location................110
    Power Steering Valve Serial Number Location................111
    Starter Serial Number Location................112
    Transmission Serial Number Location................113
    Front Axle (2WD) Serial Number Location................114
    Mechanical Front Wheel Drive (MFWD) Serial Number Location................115
    Air Conditioning Compressor Serial Number Location................116
  Group 30: Features and Accessories................118
    Features and Accessories................118
    Standard Features-5200, 5300 and 5400................119
    Standard Features-5500................121
    Factory Installed Optional Equipment................123
    Field Installed Optional Kits and Accessories................125
Section 20: Engine Repair................126
  Group 05: Engine................126
    Service Equipment and Tools................1752
    Specifications................1754
    Deere Repair-Use CTM8................130
    Remove Engine-Tractors without Cab................131
    Install Engine-Tractors without Cab................137
    Remove Engine-Tractors with Cab................142
    Install Engine-Tractors with Cab................148
  Group 10: Cooling System................126
    Specifications................1754
    Engine Water Pump Repair-Use CTM8................155
    Remove and Inspect Radiator-5200 through 5400................156
    Install Radiator-5200 through 5400................160
    Remove and Inspect Radiator-5500 Models................163
    Install Radiator-5500 Models................167
    Replace Thermostat-Early Models................171
    Replace Thermostat-Later Models................173
Section 30: Fuel and Air Repair................175
  Group 05: Fuel System................175
    Specifications................1754
    Injection Pump, Nozzle and Governor Repair-Use CTM8................178
    Remove, Inspect and Install Fuel Tank-Without Cab................179
    Remove, Inspect and Install Fuel Tank With Cab................183
    Replace Fuel Filter-5200, 5300 and 5400................191
    Remove and Install Fuel Filter/Primer Pump Assembly-5200, 5300 and 5400................192
    Replace Fuel Filter-5500................193
    Remove and Install Fuel Filter/Primer Pump Assembly-5500................194
  Group 10: Air Intake System................175
    Other Material................1753
    Specifications................1754
    Turbocharger Repair-Use CTM8................198
    Remove, Inspect, and Install Air Cleaner Elements-Early Model Tractors................199
    Remove, Inspect, and Install Air Cleaner Elements-Later Model Tractors................201
    Remove Turbocharger-5400................204
    Install Turbocharger-5400................206
    Remove Turbocharger-5500................208
    Install Turbocharger-5500................211
    Turbocharger Break-In................214
  Group 15: Speed Control Linkage................175
    Inspect and Repair Speed Control Linkage................217
Section 40: Electrical Repair................219
  Group 05: Battery, Starter and Alternator................219
    Starter Repair-Use CTM77................222
    Remove and Install Battery-Without Cab................223
    Remove and Install Battery-With Cab................225
    Remove and Install Starter-Early Models................227
    Remove and Install Starter-Later Models................229
    Replace Alternator/Regulator-40 Amp Without Cab................231
    Replace Alternator/Regulator-60 Amp Without Cab................232
  Group 10: Electrical System Components................219
    Service Equipment and Tools................1752
    Other Material................1753
    Replace Air Filter Restriction Switch................237
    Replace Coolant Temperature Sender................238
    Replace Engine Speed Sensor................239
    Replace Fuel Shut-Off Solenoid................240
    Replace Engine Oil Pressure Sender................241
    Replace Air Intake Heater................242
    Replace Air Intake Heater Relay................243
    Replace Key Switch................245
    Replace Tractor Light Switch................246
    Replace Radio (Optional Equipment)................248
    Replace Speakers (Optional Equipment)................249
    Replace Antenna (Optional Equipment)................250
    Replace Turn Signal Controller................252
    Replace Instrument Panel-Collar Shift/TSS Transmission................253
    Replace Instrument Panel-Hydraulic Reverser Transmission................256
    Replace Rear PTO Switch-Tractors Without Cab................260
    Replace Rear PTO Switch-Tractors With Cab................261
    Replace Neutral Start Switch................262
    Replace Seat Switch................263
    Replace Fuel Level Sender-Tractors Without Cab................264
    Replace Fuel Level Sender-Tractors With Cab................265
    Replace Wiper Control Switch................267
    Replace Wiper Motor................269
    Replace Blower Control Switch................270
    Replace Air Conditioning Temperature Control Switch................272
    Replace Dome Light................275
    Replace Dome Light Switch................276
  Group 15: Wiring Harness................220
    Service Equipment and Tools................1752
    Service Parts Kits................947
    Replace Connector Body-Blade Terminals................281
    Replace WEATHER PACK WEATHER PACK is a trademark of Packard Electric Connector................220
    Install Weather PackWEATHER PACK WEATHER PACK is a trademark of Packard Electric Contact................220
    Replace Front Wiring Harness................286
    Replace Rear Wiring Harness: 5200-5400 With Fuse Block Located in Engine Compartment................288
    Replace Rear Wiring Harness: 5200-5400 With Fuse Block Located Under Steering Column................291
    Replace Rear Wiring Harness-Cab Models................293
    Replace Cab Wiring Harness-Lights................295
    Replace Cab Wiring Harness-Radio/Antenna................297
    Replace Cab Wiring Harness-Main................299
Section 50: Power Train Repair................302
  Group 05: Clutch Housing-Collar Shift/TSS Transmission................302
    Service Parts Kits................947
    Specifications................1754
    Separate Engine from Clutch Housing-Tractors Without Cab................332
    Install Engine to Clutch Housing-Tractors Without Cab................314
    Separate Engine from Clutch Housing-Tractors With Cab................340
    Install Engine to Clutch Housing-Tractors With Cab................344
    Replace Clutch Housing Seal................326
    Inspect and Repair Clutch Pedal and Linkage................348
  Group 06: Clutch Housing-Hydraulic Reverser Transmission................302
    Specifications................1754
    Separate Engine from Clutch Housing-Tractors Without Cab................332
    Install Engine to Clutch Housing-(HYD REV) Tractors without Cab................336
    Separate Engine from Clutch Housing-Tractors With Cab................340
    Install Engine to Clutch Housing-Tractors With Cab................344
    Inspect and Repair Clutch Pedal and Linkage................348
  Group 10: Clutch Assembly-Collar Shift/TSS Transmission................302
    Special or Essential Tools................1751
    Other Material................1753
    Service Parts Kits................947
    Specifications................1754
    Remove and Install Clutch Assembly................381
    Disassemble and Inspect Clutch Assembly................382
    Assemble Clutch Assembly................386
    Traction Clutch Finger Adjustment................365
    PTO Clutch Finger Adjustment................390
    Remove and Inspect Clutch Release Mechanism and Shafts................392
    Install Clutch Release Mechanism and Shafts................395
  Group 11: Clutch Assembly-Hydraulic Reverser Transmission................302
    Special or Essential Tools................1751
    Other Material................1753
    Service Parts Kits................947
    Specifications................1754
    Remove and Install Clutch Assembly................381
    Disassemble and Inspect Clutch Assembly................382
    Assemble Clutch Assembly................386
    PTO Clutch Finger Adjustment................390
    Remove and Inspect Clutch Release Mechanism and Shafts................392
    Install Clutch Release Mechanism and Shafts................395
    Remove, Inspect and Repair Transmission Pump................398
  Group 12: Hydraulic Reverser................303
    Specifications................1754
    Remove and Install Hydraulic Reverser Control Valve................402
    Disassemble, Inspect and Repair Hydraulic Reverser Control Valve................404
    Remove and Install Hydraulic Reverser................413
    Disassemble, Inspect and Repair Reverse Idle Gear................418
    Disassemble, Inspect and Repair Clutch Gear................420
    Disassemble, Inspect and Repair Driven Shaft................422
    Disassemble, Inspect and Repair Hydraulic Reverser................424
  Group 15: Collar Shift/TSS Transmission................303
    Specifications................1754
    Separate Clutch Housing from Transmission................502
    Install Clutch Housing to Transmission................507
    Inspect and Repair Gear Shift Lever................512
    Inspect and Repair Range Shift Lever................515
    Remove Transmission................517
    Disassemble and Inspect Transmission................525
    Assemble Transmission................531
    Install Transmission................537
    Disassemble, Inspect and Assemble Gear Shift Shaft Assemblies................556
    Disassemble, Inspect and Assemble Transmission Top Shaft-Collar Shift Transmission................486
    Disassemble, Inspect and Assemble Transmission Top Shaft-Top Shaft Synchronized (TSS) Transmission................488
    Disassemble, Inspect and Assemble Range Reduction Shaft................561
    Disassemble, Inspect and Assemble Driven Shaft................493
    Remove, Inspect and Install MFWD and Range Gears................565
    Remove, Inspect and Install Reverse Idler Shaft................497
  Group 16: Hydraulic Reverser Transmission................304
    Service Equipment and Tools................1752
    Specifications................1754
    Separate Clutch Housing from Transmission................502
    Install Clutch Housing to Transmission................507
    Inspect and Repair Gear Shift Lever................512
    Inspect and Repair Range Shift Lever................515
    Remove Transmission................517
    Disassemble and Inspect Transmission................525
    Assemble Transmission................531
    Install Transmission................537
    Disassemble, Inspect and Assemble Gear Shift Shaft Assemblies................556
    Disassemble, Inspect and Assemble Transmission Bottom Shaft................558
    Disassemble, Inspect and Assemble Range Reduction Shaft................561
    Disassemble, Inspect and Assemble Top Shaft................563
    Remove, Inspect and Install MFWD and Range Gears................565
    Remove, Inspect and Replace Hydraulic Reverser Control Lever................567
  Group 20: Rear PTO Drive Shaft-Collar Shift/TSS Transmission................304
    Specifications................1754
    Inspect and Repair Rear PTO Lever and Linkage................582
    Remove and Install Rear PTO Drive Shaft Assembly................584
    Disassemble, Inspect and Assemble Rear PTO Drive Shaft Assembly................585
  Group 21: Rear PTO Drive Shaft-Hydraulic Reverser Transmission................304
    Specifications................1754
    Inspect and Repair Rear PTO Lever and Linkage................582
    Remove and Install Rear PTO Drive Shaft Assembly................584
    Disassemble, Inspect and Assemble Rear PTO Drive Shaft Assembly................585
  Group 25: Differential................304
    Essential Tools................903
    Other Material................1753
    Service Parts Kits................947
    Specifications................1754
    Remove and Install Differential Assembly................591
    Disassemble, Inspect and Assemble Differential Assembly................593
    Remove and Inspect Differential Drive Shaft................595
    Install Differential Drive Shaft................598
    Differential Cone Point Adjustment................602
    Differential Backlash Adjustment................604
    Remove, Inspect and Install Differential Lock Assembly................606
  Group 30: Final Drives................305
    Service Equipment and Tools................1752
    Other Material................1753
    Specifications................1754
    Remove and Install Final Drive Assembly................612
    Remove and Inspect Planetary Drive Assembly................614
    Install Planetary Drive Assembly................617
    Remove, Inspect and Install Axle Shaft Assembly................620
  Group 35: Mechanical Front Wheel Drive................305
    Special or Essential Tools................1751
    Other Material................1753
    Specifications................1754
    Inspect and Repair MFWD Lever and Linkage................627
    Remove and Install MFWD Drop Gearbox................629
    Disassemble and Inspect MFWD Drop Gearbox................631
    MFWD Drop Gearbox Cross Section................634
    Assemble MFWD Drop Gearbox................636
    Remove, Inspect and Install MFWD Drive Shaft................641
    Remove and Install MFWD Axle Housing Assembly................643
    Remove, Inspect and Install MFWD Axle Supports................645
    Disassemble and Inspect MFWD Outer Drive................647
    Assemble MFWD Outer Drive................650
    Remove, Inspect and Install MFWD Swivel Housing................653
    Remove, Inspect and Install MFWD Axle Shaft................657
    Remove and Install MFWD Differential Carrier Assembly................659
    Disassemble and Inspect MFWD Differential Carrier Assembly................661
    Assemble MFWD Differential Carrier Assembly................666
    Adjust Swivel Pin Bearing Preload-Early Models Only................677
  Group 40: Creeper Assembly................306
    Other Material................1753
    Specifications................1754
    Remove and Install Creeper Assembly................682
    Disassemble, Inspect and Assemble Creeper Assembly (Early Models)................685
    Disassemble, Inspect and Assemble Creeper Assembly (Later Models)................687
Section 60: Steering and Brake Repair................689
  Group 05: Steering Repair................689
    Service Equipment and Tools................1752
    Other Material................1753
    Specifications................1754
    Service Parts Kits................947
    Remove and Install Steering Column and Valve................695
    Disassemble and Inspect Steering Valve................697
    Assemble Steering Valve................701
    Remove and Install Steering Cylinder-2WD Axle................706
    Disassemble, Inspect and Assemble Steering Cylinder-2WD Axle................707
    Remove and Install Steering Cylinder-MFWD Axle................709
    Disassemble, Inspect and Assemble Steering Cylinder-MFWD Axle................711
    Remove, Inspect and Install Tie Rod Assembly-2WD Axle................712
    Remove, Inspect and Install Tie Rod Assembly-MFWD Axle................714
    Inspect and Replace Steering Hydraulic Lines-Without Oil Cooler................716
    Inspect and Replace Steering Hydraulic Lines-With Oil Cooler................718
  Group 10: Brake Repair................689
    Other Material................1753
    Specifications................1754
    Remove and Install Brake Valve and Pedals................723
    Disassemble and Inspect Brake Valve................725
    Brake Valve Cross Section................728
    Assemble Brake Valve................730
    Remove and Inspect Brakes (Early Model Tractors)................733
    Install Brakes (Early Model Tractors)................735
    Remove and Inspect Brakes (Later Model Tractors)................737
    Install Brakes (Later Model Tractors)................740
    Inspect and Replace Brake Hydraulic Lines................743
Section 70: Hydraulic Repair................746
  Group 05: Hydraulic Pump and Filter................746
    Specifications................1754
    Remove Inspect and Install Hydraulic Oil Pick-Up Screen................750
    Remove and Install Hydraulic Pump-5200, 5300 and 5400................752
    Remove Hydraulic Pump External Components-5200, 5300 and 5400................754
    Disassemble and Inspect Hydraulic Pump-5200, 5300 and 5400................756
    Assemble Hydraulic Pump-5200, 5300 and 5400................759
    Install Hydraulic Pump External Components-5200, 5300 and 5400................761
    Remove and Install Hydraulic Pump-5500................763
    Remove Hydraulic Pump External Components-5500................765
    Disassemble and Inspect Hydraulic Pump-5500................767
    Assemble Hydraulic Pump-5500................770
    Install Hydraulic Pump External Components-5500................772
    Remove and Install Hydraulic Filter/Manifold-Early Model................774
    Remove and Install Hydraulic Filter/Manifold-Later Model................775
    Inspect and Replace Hydraulic Supply/Return Lines................776
  Group 06: Hydraulic Oil Cooler................746
    Remove, Inspect and Install Hydraulic Oil Cooler................779
  Group 10: Rockshaft................746
    Other Material................1753
    Specifications................1754
    Service Parts Kits................947
    Inspect and Repair Rockshaft Control Lever Assembly................784
    Inspect and Repair Rockshaft Control Linkage................789
    Inspect and Repair Draft Sensing Support Assembly................793
    Replace Main Relief Valve................795
    Replace Rockshaft Surge Relief Valve................797
    Remove, Inspect and Install Rate-of-Drop Valve................798
    Replace Rockshaft Control Valve................800
    Remove and Install Rockshaft Case................803
    Remove, Inspect and Install Rockshaft Lift Arms................805
    Remove, Inspect and Install Rockshaft Piston and Cylinder................807
  Group 15: Dual Selective Control Valve................747
    Other Material................1753
    Specifications................1754
    Service Parts Kits................947
    Inspect and Repair Joystick and Linkage-Early Model................813
    Inspect and Repair Joystick and Linkage-Later Models................817
    Inspect and Repair Joystick and Linkage-Tractors With Cab................820
    Remove and Install Dual Selective Control Valve (SCV)................824
    Disassemble, Inspect and Assemble Dual Selective Control Valve (SCV)................827
    Inspect and Replace Hydraulic Hoses-Dual Selective Control Valve (SCV)................831
  Group 16: Single (Third) Selective Control Valve................747
    Other Material................1753
    Specifications................1754
    Service Parts Kits................947
    Inspect and Repair Lever and Linkage................837
    Remove and Install Single/Third Selective Control Valve (SCV)................839
    Disassemble, Inspect and Assemble Single (Third) Selective Control Valve (SCV)................841
    Inspect and Replace Hydraulic Hoses-Single (Third) Selective Control Valve................843
  Group 20: Hydraulic Mid Mount Coupler................747
    Inspect and Replace Hydraulic Hoses-Mid Mount Coupler Without Cab................847
    Inspect and Replace Hydraulic Hoses-Mid Mount Coupler With Cab................849
  Group 25: Hydraulic Power Beyond................747
    Inspect and Replace Power Beyond Hydraulic Lines and Fittings................856
    Inspect Power Beyond Motor Control Lines and Fittings................861
Section 80: Miscellaneous Repair................862
  Group 05: Front Axle-2WD................862
    Specifications................1754
    Remove and Install Front Axle-2WD................865
    Inspect and Replace Pivot Pin and Bushings-2WD Axle................868
    Remove and Install Spindle Assembly-2WD Axle................869
    Inspect and Replace Spindle Shaft Bushings-2WD Axle................871
  Group 10: Wheels................862
    Specifications................1754
    Inspect and Replace Front Wheel Bearings................874
  Group 15: 3-Point Hitch................862
    Specifications................1754
    Inspect and Repair Fixed Draft Links................878
    Inspect and Repair Telescoping Draft Links................879
    Inspect and Repair Lift Link................881
    Inspect and Repair Adjustable Lift Link................883
    Inspect and Repair Center Link................885
    Remove and Install Draw Bar and Support................887
Section 90: Operator Station Repair................889
  Group 05: Seat and Support................889
    Specifications................1754
    Remove and Install Seat and Support-Tractors Without Cab................893
    Remove and Install Seat, Support and Base Plate-Tractors With Cab................894
  Group 10: ROLL-GARDROLL-GARD is a trademark of Deere & Company.................889
    Specifications................1754
    Remove and Install ROLL-GARD ROLL-GARD is a trademark of Deere & Company.................889
  Group 15: Cab Components................889
    Essential Tools................903
    Specifications................1754
    Remove, Inspect and Install Cab Interior Recirculating Air Filter................905
    Remove, Inspect and Install Exterior Cab Intake Air Filter................907
    Remove and Install Front Headliner................908
    Remove and Install Rear Headliner................910
    Remove and Install Lower Front Windows................912
    Remove and Install Windowpanes................915
    Remove and Install Rear Window................916
    Remove and Install Cab Doors................918
    Remove and Install Cab Roof................921
    Remove and Install Control Console and Support Plate................923
    Remove Cab and Floor Plates................926
    Install Cab and Floor Plates................936
  Group 20: Air Conditioning System................889
    Service Equipment and Tools................1752
    Specifications................1754
    Service Parts Kits................947
    Hose and Tubing O-Ring Connection Torques................948
    Recover/Recycle Air Conditioning Refrigerant................949
    Replace Air Conditioning Receiver-Dryer................1744
    Remove, Inspect and Install Air Conditioning Condenser................1743
    Remove, Inspect and Install Air Conditioning Compressor................1742
    Test Volumetric Efficiency of Compressor................1742
    Test Compressor Shaft Seal Leakage................962
    Disassemble and Assemble Compressor Clutch................964
    Disassemble, Inspect, and Assemble Compressor................1742
    Check Compressor Clutch Hub Clearance................969
    Inspect Compressor Manifold................970
    Remove and Install Compressor Relief Valve................971
    Remove Evaporator/Heater Core Housing................972
    Install Evaporator/Heater Core Housing................976
    Remove Blower Motors................980
    Remove Evaporator/Heater Core................982
    Leak Test Evaporator/Heater Core................984
    Install Evaporator/Heater Core................985
    Service Expansion Valve................1745
    Expansion Valve Bench Test-Diagram................988
    Expansion Valve Bench Test................990
    Refrigerant Oil Information................991
    Check Compressor Oil Charge................992
    Determine Correct Refrigerant Oil Charge................993
    Add Refrigerant Oil to System................995
    System Information................996
    Flush Air Conditioning System................997
    Evacuate Air Conditioning System................1000
    Charge Air Conditioning System................1002
  Group 25: Heating System................890
    Replace Heater Temperature Control and Cable................1010
    Remove, Test and Install Heater Control Valve................1019
    Leak Test Heater Control Valve................1018
    Install Heater Control Valve................1019
Section 210: Operational Checkout Procedures................1020
  Group 10: Operational Checkout Procedures................1020
    Specifications................1754
    Operational Checkout Procedure Information................1024
    Engine Oil Level and Condition Check................1025
    Coolant Level and Condition Check................1026
    Transmission and Hydraulic Oil Check................1027
    Fan and Belt Check................1028
    Compressor Belt Check................1029
    Fuel System Check................1030
    Air Intake System Check................1032
    Electrical System Check................1034
    Hydraulic System Check................1036
    MFWD Oil Check................1037
    Indicator Lamps Check................1038
    Cab Blower Motor Check................1039
    A/C Compressor Clutch Check................1048
    Engine Start Check................1041
    Transmission Neutral Start Check................1042
    PTO Neutral Start Check................1043
    Engine Fast and Slow Idle Operation................1044
    Power Steering Check................1045
    Differential Lock Check................1046
    PTO Engagement Check................1047
    Clutch Check................1048
    Transmission Shift Check................1049
    Range Lever Shift Check................1050
    MFWD Drive Check................1051
    Brake Check................1052
    Rockshaft Check................1053
    Selective Control Valve Check................1055
    A/C System Operational Check................1057
    Cab Heater Valve Check................1058
    Miscellaneous Checks................1059
Section 220: Engine Operation, Tests and Adjustments................1060
  Group 05: Component Location................1060
    Component Location Information................1619
    Engine External Components-Left-Hand Side................1064
    Engine External Components-Right-Hand Side................1066
  Group 10: Theory of Operation................1060
    Theory of Operation Information................1625
    Engine Lubrication System Operation................1070
    Engine Cooling System Operation................1074
  Group 15: Diagnosis, Tests and Adjustments................1060
    Diagnostic Information................1672
    Engine Turns Over but Will Not Start or Starts Hard................1078
    Engine Runs Irregularly or Stalls Frequently................1079
    Engine Runs Rough................1080
    Engine Has Low Power................1081
    Engine Smokes-Black or Grey................1083
    Engine Smokes Excessively-White................1084
    Engine Uses Excess Fuel................1085
    Engine Has Excess Noise or Vibration................1086
    Engine Uses Excess Oil or Smokes Blue................1087
    Engine Has Low Oil Pressure................1088
    Engine Coolant Operating Temperature Incorrect................1089
    Oil In Coolant or Coolant in Oil................1091
    Radiator Bubble Test................1092
    Cooling System Test................1094
    Radiator Cap Pressure Test................1095
    Engine Oil Pressure Test................1096
    Cylinder Compression Pressure Test................1098
    Fuel Shut-Off Solenoid Check................1100
    Throttle Lever Adjustment................1101
    Slow Idle Adjustment................1102
    Fast Idle Adjustment................1104
    Injection Pump Timing Adjustment................1106
    Injection Pump Timing Adjustment-New Front Plate Installed................1107
    Valve Clearance Adjustment................1110
    Fan/Alternator Drive Belt Adjustment................1114
    Compressor Drive Belt Adjustment................1116
    Turbocharger Boost Pressure Test-5400 and 5500................1118
    Bleed Fuel System-3-Cylinder Engine................1120
    Bleed Fuel System-4-Cylinder Engine................1122
Section 230: Fuel/Air Operation, Tests and Adjustments................1124
  Group 05: Component Location................1124
    Component Location Information................1619
    Fuel System Components................1127
    Air Intake System Components-5200 and 5300................1129
    Air Intake System Components-5400 and 5500................1130
  Group 10: Theory of Operation................1124
    Theory of Operation Information................1625
    Fuel System Operation................1133
    Fuel Filter/Priming Pump Operation................1135
    Fuel Injection Pump Operation................1137
    Fuel Injection Nozzle Operation................1140
    Air Intake System Operation-5200 and 5300................1142
    Air Intake System Operation-5400 and 5500................1144
    Turbocharger Operation-5400 and 5500................1146
  Group 15: Diagnosis, Tests and Adjustments................1124
    Diagnostic Information................1672
    Fuel/Air Diagnosis, Tests and Adjustments................1149
Section 240: Electrical System Operation, Tests and Adjustments................1150
  Group 05: Component Location................1150
    Component Location Information................1619
    Engine Electrical Components................1156
    Dash Electrical Components................1157
    Machine Electrical Components-5200-5400 Without Cab................1159
    Machine Electrical Components-5500 Without Cab................1161
    Machine Electrical Components-5200-5500 With Cab................1163
    Cab Control Panel and Electrical Components................1165
  Group 10: Theory of Operation................1150
    Theory of Operation Information................1625
    Fuse Block and Fuses-Early Models................1169
    Fuse Block and Fuses-Later Models................1171
    Fuse Block and Fuses-Cab Tractors................1173
    Cab Fuse Block and Fuses................1175
    Relays................1177
    Starting System Operation-Normal................1178
    Starting System Operation-Bypass Attempt................1180
    Manifold Heater System Operation................1182
    Charging System Operation................1184
    Lighting System Operation-Turn Signals................1186
    Lighting System Operation-Warning Lights................1188
    Lighting System Operation-Tail Light................1190
    Lighting System Operation-Headlights and Instrument Lights................1192
    Instrument Panel System Operation-Tachometer................1194
    Instrument Panel System Operation-Fuel Gauge................1196
    Instrument Panel System Operation-Temperature Gauge................1198
    Instrument Panel System Operation-Hourmeter................1200
    PTO Warning System Operation................1202
    Air Filter Restriction Indicator Operation................1204
    Rear Work Light Operation-Tractors Without Cab................1206
    Optional Horn Operation................1208
    Optional Accessory Relay and Trailer Connector Operation................1209
    Flood Light Operation-Tractors With Cab................1211
    Blower Motor Operation-Tractors With Cab................1213
    A/C Compressor Operation-Cab Tractors Only................1216
    Front Wiper/Washer Operation-Cab Tractors Only................1219
    Rear Wiper/Washer Operation-Cab Tractors Only................1221
    Dome Light Operation-Cab Tractors Only................1223
  Group 15: Diagnosis, Tests and Adjustments................1151
    Diagnostic Information................1672
    Wire Color Chart................1227
    Starting System Test Points-Normal Operation................1229
    Starting System Test Points-Bypass Attempt................1233
    Manifold Heater Test Points................1237
    Charging System Test Points................1240
    Lighting System Test Points-Turn Signals (Tractors Without Cab)................1244
    Lighting System Test Points-Turn Signals (Tractors With Cab)................1248
    Lighting System Test Points-Warning Lights (All Tractors)................1253
    Lighting System Test Points-Rear Work Light (Tractors Without Cab)................1256
    Lighting System Test Points-Flood Lights (Tractors With Cab)................1259
    Lighting System Test Points-Tail Light (Tractors Without Cab)................1264
    Lighting System Test Points-Tail Lights (Tractors With Cab)................1267
    Lighting System Test Points-Headlights and Instrument Lights................1270
    Lighting System Test Points-Dome Light (Tractors With Cab)................1275
    Instrument Panel System Test Points-Tachometer................1278
    Instrument Panel System Test Points-Fuel Gauge................1282
    Instrument Panel System Test Points-Temperature Gauge................1285
    Instrument Panel System Test Points-Hourmeter................1289
    Instrument Panel System Test Points-Oil Pressure................1293
    PTO Warning System Test Points................1297
    Air Filter Restriction Test Points................1301
    Optional Horn Test Points................1304
    Optional Accessory Relay and Trailer Connector Test Points................1307
    Blower Motor Test Points (Tractors With Cab)................1311
    A/C Compressor Clutch Coil Test Points (Tractors With Cab)................1316
    Front Wiper/Washer Test Points (Tractors With Cab)................1319
    Rear Wiper/Washer Test Points (Tractors With Cab)................1323
    Battery Voltage and Specific Gravity Tests................1326
    Charge Battery................1328
    Battery Load Test................1330
    Starter AMP Draw/RPM Test................1332
    Starter No-Load Amp Draw/RPM Test................1334
    Alternator/Regulator Test................1336
    Starter Solenoid Test................1338
    Starter Relay Test................1339
    Key Switch Test................1341
    Plug-In Relay Test................1343
    Diode Pack Test................1345
    Fuse Test................1347
    Neutral Start Switch Test................1348
    PTO Switch Test................1349
    PTO Seat Switch Test................1350
    Light Switch Test................1351
    Turn Signal Controller Test................1353
    Fuel Shut-Off Solenoid Test................1354
    Blower Switch Test................1355
    Blower Motor Resistors Test................1357
    A/C Thermostatic Control Switch Test................1359
    Front Wiper/Washer Switch Test................1360
    Rear Wiper/Washer Switch Test................1362
    Door Switch Test................1363
    Dome Light Switch Test................1364
  Group 20: Wiring Schematics................1152
    Schematic Information................1366
    Component Identification Table................1367
    Electrical Schematic-Early 5200-5400 Models (Without Cab)................1369
    Electrical Schematic (Optional Equipment)-Early 5200-5400 Models (Without Cab)................1371
    Electrical Schematic-Later 5200-5400 and All 5500 Models (Without Cab)................1373
    Electrical Schematic (Optional Equipment)-Later 5200-5400 and All 5500 Models (Without Cab)................1375
    Electrical Schematic-Later 5200-5400 Models and All 5500 (With Cab)................1381
    Electrical Schematic-Later 5200-5400 Models and All 5500 (With Cab)................1381
Section 250: Power Train Operation, Tests and Adjustments................1385
  Group 05: Component Location-Collar Shift/TSS Transmission................1385
    Component Location Information................1619
    Power Train Components................1391
    Clutch Components................1393
    Transmission Components-Collar Shift................1395
    Transmission Components-Top Shaft Synchronized (TSS)................1397
    Final Drive Components................1411
    Rear PTO Components................1412
  Group 06: Component Location-Hydraulic Reverser Transmission................1385
    Component Location Information................1619
    Power Train Components-Hydraulic Reverser Transmission................1403
    Clutch Components-Hydraulic Reverser Transmission................1405
    Hydraulic Reverser Components................1407
    Transmission Components-Hydraulic Reverser Transmission................1409
    Final Drive Components................1411
    Rear PTO Components................1412
  Group 10: Theory of Operation-Collar Shift/TSS Transmission................1385
    Theory of Operation Information................1625
    Clutch Operation................1415
    Transmission Lubrication System................1476
    Transmission Power Flow-Gear Shift (Collar)................1424
    Transmission Power Flow-Gear Shift (TSS)................1426
    TSS Transmission Synchronizer Operation-Reverse and 2nd Gear (Disk-and-Plate- Type Synchronizer)................1428
    TSS Transmission Synchronizer Operation-1st and 3rd Gear (Cone-Type Synchronizer)................1430
    Transmission Power Flow-Range Shift................1473
    Rear PTO Operation................1478
    Differential Power Flow................1437
    Differential Lock Operation................1439
    Final Drive Operation................1479
    Mechanical Front Wheel Drive (MFWD) Operation................1443
  Group 11: Theory of Operation-Hydraulic Reverser Transmission................1385
    Theory of Operation Information................1625
    Clutch Operation-PTO Clutch Engaged (Hydraulic Reverser Transmission)................1447
    Clutch Operation-PTO Clutch Disengaged (Hydraulic Reverser Transmission)................1449
    Hydraulic Reverser General Information................1451
    Hydraulic Reverser Operation in Forward................1452
    Hydraulic Reverser Operation in Reverse................1454
    Hydraulic Reverser Power Flow................1456
    Hydraulic Reverser Control Valve Operation-Initial Engine Start-Up, Clutch Pedal Up................1458
    Hydraulic Reverser Control Valve Operation-F-N-R Lever in Neutral, Clutch Pedal Down................1460
    Hydraulic Control Valve Operation-F-N-R Lever in Neutral, Clutch Pedal Up................1462
    Hydraulic Control Valve Operation-F-N-R Lever in Forward, Clutch Pedal Up................1464
    Hydraulic Control Valve Operation-F-N-R Lever in Reverse, Clutch Pedal Up................1467
    Transmission Power Flow-Gear Shift................1469
    Gear Shift Synchronizer Operation................1471
    Transmission Power Flow-Range Shift................1473
    Transmission Lubrication System................1476
    Rear PTO Operation................1478
    Final Drive Operation................1479
    Differential Operation................1480
    MFWD Operation................1481
  Group 15: Diagnosis, Tests and Adjustments-Collar Shift/TSS Transmission................1386
    Diagnostic Information................1672
    Isolate the Problem Area................1523
    Traction Clutch Slips................1486
    Traction Clutch Dragging................1487
    Traction Clutch Does Not Engage................1488
    Traction Clutch Grabs................1489
    Traction Clutch Squeaks................1490
    Traction Clutch Does Not Release................1491
    Traction Clutch Chatters................1492
    Traction Clutch Rattles................1493
    Traction Clutch Engagement is Noisy................1494
    Excessive Vibration in Traction Clutch................1495
    Clutch Pedal Does Not Return................1527
    Clutch Pedal Loose................1497
    Clutch Pedal Pulsates................1498
    Jerky or Rough Transmission of Power................1499
    Low Transmission Oil Level (Excessive Oil Leakage)................1526
    Gears Clash, Shift Hard, or Will Not Engage................1531
    Two Speeds Engage Together................1532
    Transmission Will Not Stay In Gear................1503
    Transmission Noisy................1534
    PTO Noisy................1505
    PTO Hard to Engage................1506
    PTO Will Not Operate................1507
    PTO Will Not Stay Engaged................1508
    Excessive Differential Noise................1509
    Differential Does Not Work................1510
    No Differential Lock................1511
    Differential Chatters................1512
    Axle Noise................1513
    Axle Shaft Will Not Turn................1514
    MFWD Lever is Hard to Engage................1515
    MFWD Lever Will Not Stay In “ON” Position................1516
    Noisy Front Wheel Drive Operation................1517
    Clutch Pedal Free Play Adjustment................1518
    PTO Clutch Lever Adjustment................1519
  Group 16: Diagnosis, Tests and Adjustments-Hydraulic Reverser................1387
    Diagnostic Information................1672
    Isolate the Problem Area................1523
    Low Transmission Oil Level (Excessive Oil Leakage)................1526
    Clutch Pedal Does Not Return................1527
    Tractor Does Not Move in Forward or Reverse................1528
    Hydraulic Reverser Engages Too Quickly or Too Slowly................1529
    Hydraulic Reverser Does Not Disengage................1530
    Gears Clash, Shift Hard, or Will Not Engage................1531
    Two Speeds Engage Together................1532
    Transmission Will Not Stay in Gear................1533
    Transmission Noisy................1534
    PTO Troubleshooting................1535
    Differential Troubleshooting................1536
    Axle Troubleshooting................1537
    MFWD Troubleshooting................1538
    Hydraulic Control Valve Tests................1539
    Transmission Pump Flow Test................1545
    Adjust Forward-Neutral-Reverse Cable................1547
    Clutch Pedal Linkage Adjustment................1554
    Park Brake Cable Adjustment................1556
Section 260: Steering and Brake Operation, Tests and Adjustments................1559
  Group 05: Component Location................1559
    Component Location Information................1619
    Steering System Components-5200, 5300 and 5400 Without Cab................1563
    Steering System Components-5500 and All Cab Units................1573
    Brake System Components-Early Models................1567
    Brake System Components-Later Models................1569
  Group 10: Theory of Operation................1559
    Theory of Operation Information................1625
    Steering System Components-5500 and All Cab Units................1573
    Steering System Operation-5200, 5300 and 5400 Without Cab................1575
    Steering System Operation-5500 and All Cab Units................1577
    Steering Valve Operation-Neutral and Manual Turning................1579
    Steering Valve Operation-Power Turning................1581
    Brake System Operation-Early Models................1583
    Brake System Operation-Later Models................1585
    Brake Valve Operation................1587
  Group 15: Diagnosis, Tests and Adjustments................1559
    Diagnostic Information................1672
    Isolate the Problem-Steering System................1593
    Steering Sluggish or Loss of Steering................1594
    Isolate the Problem-Brakes................1595
    Excessive Brake Pedal Leak-Down................1596
    Excessive Brake Chatter................1597
    Steering Pump Flow Test................1598
    Steering Valve Relief Test................1600
    Steering Cylinder Leakage Test................1602
    Steering Valve Leakage Test................1603
    Toe-In Check and Adjustment-Standard Axle................1605
    Toe-In Check and Adjustment-MFWD................1607
    MFWD Steering Stop Adjustment................1609
    Brake Pedal Adjustment................1610
    Adjust Brake Drag................1612
    Bleed Brake System................1614
Section 270: Hydraulic System Operation, Tests and Adjustments................1615
  Group 05: Component Location................1615
    Component Location Information................1619
    Hydraulic System Components................1675
    Selective Control Valve Components................1622
  Group 10: Theory of Operation................1615
    Theory of Operation Information................1625
    Hydraulic System Operation................1626
    Hydraulic Filter Operation-Early Model................1629
    Hydraulic Filter Operation-Later Model................1631
    Hydraulic Pump Operation................1633
    Rockshaft Control Valve Operation (Early Models)-Flow Regulator Valve................1635
    Rockshaft Control Valve Operation (Early Models)-Neutral Position................1637
    Rockshaft Control Valve Operation (Early Models)-Raise Position................1639
    Rockshaft Control Valve Operation (Early Models)-Lowering Position................1641
    Rockshaft Control Valve Operation (Later Models)-Two Flow Regulator Valves................1643
    Rockshaft Control Valve Operation (Later Models)-Neutral Position................1645
    Rockshaft Control Valve Operation (Later Models)-Raise Position................1647
    Rockshaft Control Valve Operation (Later Models)-Lower Position................1649
    Surge Relief Valve Operation................1651
    Main Relief Valve Operation................1653
    Rate-of-Drop Valve Operation-Full Open................1655
    Rate-of-Drop Valve Operation-Full Closed................1657
    Rockshaft Draft-Sensing Operation................1659
    Selective Control Valve Operation-Neutral Position................1661
    Selective Control Valve Operation-Extend and Retract Positions................1663
    Selective Control Valve Operation-Boom Spool Float Position................1665
    Selective Control Valve Operation-Bucket Spool Regenerative Position................1667
    Double-Acting Sleeve Coupler Operation................1669
  Group 15: Diagnosis................1615
    Diagnostic Information................1672
    Preliminary Hydraulic System Inspection................1673
    Hydraulic Oil Warm-Up Procedure................1674
    Hydraulic System Components................1675
    Entire Hydraulic System Fails to Function/No Hydraulic Pump Output................1677
    Insufficient Pump Delivery................1678
    Hydraulic Functions Too Slow................1679
    Excessive Pump Pressure................1680
    Slow Hydraulic Pump Response................1681
    Excessive Pump Noise During Operation................1682
    Rockshaft Does Not Lift or Lifts Slowly................1683
    Rockshaft Does Not Lower or Lowers Slowly................1684
    Neutral Position Unstable, Rockshaft Drops After Engine Shut-Down................1685
    SCV Control Lever Does Not Return to Neutral Position-Single (Third) SCV................1686
    SCV Joystick Does Not Return to Neutral Position-Dual SCV................1687
    SCV Joystick Does Not Remain In Detent Position-Dual SCV................1688
    Remote Cylinder Does Not Extend or Retract................1689
    Remote Cylinder Settles Under Load................1690
    Remote Cylinder Operates Too Fast or Too Slow................1691
  Group 16: Hydraulic Tests-Without SCV................1616
    Hydraulic System Tests-Without SCV................1694
    Pump Flow Test-Without SCV................1696
    Main Relief Valve Test-Without SCV................1698
  Group 17: Hydraulic Tests-With SCV................1616
    Hydraulic System Tests-With SCV................1702
    Pump Flow Test-With SCV................1704
    Main Relief Valve Test-With SCV................1706
    SCV Leakage Test................1707
  Group 18: Hydraulic Tests-All................1616
    Rockshaft Leakage Test................1711
    Rockshaft Lift Cycle Test................1713
  Group 19: Adjustments................1616
    Rockshaft Control Lever Friction Adjustment................1716
    Rockshaft Position-Sensing Feedback Linkage Adjustment................1717
    Rockshaft Draft-Sensing Feedback Linkage Adjustment................1721
    Main Relief Valve Adjustment................1723
  Group 20: Hydraulic Schematics................1617
    Hydraulic Circuit Symbols................1726
    Hydraulic Schematic-Without Selective Control Valve................1728
    Hydraulic Schematic-With Selective Control Valve................1730
Section 290: Operator Station................1732
  Group 05: Component Location................1732
    Air Conditioning System Components................1735
  Group 10: Theory of Operation................1732
    Refrigerant R134a................1738
    Air Conditioning System Air Flow................1739
    Air Conditioning System Cycle................1741
    Air Conditioning System Cycle................1741
    Compressor................1742
    Condenser................1743
    Receiver-Dryer................1744
    Expansion Valve................1745
    A/C Temperature Control Switch................1746
    Evaporator................1747
    Heater Temperature Control Knob................1748
    High and Low Pressure Switches................1749
  Group 15: Diagnosis, Tests and Adjustments................1732
    Special or Essential Tools................1751
    Service Equipment and Tools................1752
    Other Material................1753
    Specifications................1754
    Adjust Heater Temperature Control Cable................1782
Section 299: Dealer Fabricated Tools................1784
  Group 00: Dealer Fabricated Tools................1784
    JDG826-PTO Clutch Finger Height Gauge................1786
    JDG827-Traction Clutch Finger Height Gauge................1787
    JDG828-Traction Clutch Finger Height Adjustment Tool................1788
    JDG919-PTO Clutch Finger Height Gauge-Hydraulic Reverser................1789
    DFLV1A Final Drive Turning Tool................1790
    DFRW83-Nozzle Assembly................1791
    DFRW20-Compressor Holding Fixture................1793

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