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

John Deere Tractors 5400N and 5500N workshop technical service repair 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.

TM1585 - John Deere 5400N and 5500N Tractors Diagnostic and Repair Technical Manual.pdf

Total Pages: 1,476 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Category: Technical Manual
Language: English
Published on 2007/11/15

MAIN SECTIONS
 Foreword
   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
      Clutch Assembly
      Synchronized Reverser
      Transmission
      Rear PTO Drive Shaft
      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
      Selective Control Valve (SCV)
   Miscellaneous Repair
      Front Axle-2WD
      Wheels
      Fenders
      3-Point Hitch
   Operator Station Repair
      Seat and Support
      ROLL-GARD™
      Rear Bar
      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, Test and Adjust
      Component Location
      Theory of Operation
      Diagnosis, Test and Adjust
      Wiring Schematics
   Power Train Operation, Tests & Adjustments
      Component Location
      Theory of Operation
      Diagnosis, Tests and Adjustments
   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
      Adjustments
      Hydraulic Schematics
   Operator Station
      Component Location
      Theory of Operation
      Diagnosis, Tests, and Adjustments
   Dealer Fabricated Tools
      Dealer Fabricated Tools

TABLE OF CONTENTS
Section 10: General Information................27
  Group 05: Safety................27
    Recognize Safety Information................31
    Handle Fluids Safely-Avoid Fires................35
    Understand Signal Words................33
    Follow Safety Instructions................34
    Handle Fluids Safely-Avoid Fires................35
    Prevent Battery Explosions................36
    Prepare for Emergencies................37
    Prevent Acid Burns................38
    Service Cooling System Safely................40
    Handle Chemical Products Safely................41
    Avoid High-Pressure Fluids................42
    Park Machine Safely................43
    Support Machine Properly................44
    Wear Protective Clothing................45
    Work in Clean Area................46
    Service Machines Safely................47
    Work In Ventilated Area................48
    Illuminate Work Area Safely................49
    Replace Safety Signs................50
    Use Proper Lifting Equipment................51
    Keep ROPS Installed Properly................52
    Service Tires Safely................53
    Avoid Harmful Asbestos Dust................54
    Avoid Heating Near Pressurized Fluid Lines................55
    Remove Paint Before Welding or Heating................56
    Use Proper Tools................57
    Dispose of Waste Properly................58
    Live With Safety................59
  Group 10: General Specifications................1474
    Machine Specifications................1474
    SyncReverser™ Transmission Ground Speed Estimates................70
    Creeper Transmission Ground Speed Estimates................71
    Correction Factors for Other Tire Sizes................72
    Service Recommendations for O-Ring Boss Fittings................73
    Service Recommendations for Flat Face O-Ring Seal Fittings................75
    Metric Cap Screw Torque Values-Grade 7................77
    Metric Bolt and Cap Screw Torque Values................78
    Unified Inch Bolt and Cap Screw Torque Values................80
  Group 20: Fuel and Lubricants................28
    Diesel Fuel Specifications................1474
    Storing Fuel................84
    Do Not Use Galvanized Containers................85
    Fill Fuel Tank................86
    Diesel Engine Oil................87
    Diesel Engine Coolant................88
    Liquid Coolant Conditioner................89
    Transmission and Hydraulic Oil................90
    MFWD Gear Oil................91
    Grease................92
    Alternative and Synthetic Lubricants................93
    Lubricant Storage................94
  Group 25: Serial Number Locations................28
    Serial Numbers................96
    Product Identification Number Location................97
    Engine Serial Number Location................98
    Fuel Injection Pump Serial Number Location................99
    Alternator Serial Number Location................100
    Power Steering Valve Serial Number Location................101
    Starter Serial Number Location................102
    Transmission Serial Number Location................103
    Front Axle (2WD) Serial Number Location................104
    Mechanical Front Wheel Drive (MFWD) Serial Number Location................105
    Air Conditioning Compressor Serial Number Location................106
  Group 30: Features and Accessories................108
    Features and Accessories................108
    Standard Features................109
    Factory Installed Optional Equipment................112
    Field Installed Optional Kits and Accessories................114
Section 20: Engine Repair................115
  Group 05: Engine................115
    Specifications................1474
    John Deere Engine Repair-Use CTM8................118
    Remove Engine-Tractors Without Cab................119
    Install Engine-Tractors Without Cab................125
    Remove Engine-Tractors With Cab................131
    Install Engine-Tractors With Cab................136
  Group 10: Cooling System................115
    Engine Water Pump Repair-Use CTM8................142
    Remove and Inspect Radiator-Tractors Without Cab................143
    Install Radiator-Tractors Without Cab................146
    Remove and Inspect Radiator-Tractors With Cab................149
    Install Radiator-Tractors With Cab................154
    Replace Thermostat-Early Models................158
    Replace Thermostat-Later Models................160
Section 30: Fuel and Air Repair................162
  Group 05: Fuel System................162
    Specifications................1474
    Injection Pump, Nozzle and Governor Repair-Use CTM8................165
    Remove, Inspect, and Install Fuel Tank-Tractors Without Cab................166
    Remove, Inspect, and Install Fuel Tank-Tractors With Cab................170
    Replace Fuel Filter................174
    Remove and Install Fuel Filter/Primer Pump Assembly................175
  Group 10: Air Intake System................162
    Specifications................1474
    Turbocharger Repair-Use CTM8................178
    Remove, Inspect, and Install Air Cleaner Elements-Early Models................179
    Remove, Inspect, and Install Air Cleaner Elements-Later Model Tractors................181
    Remove Turbocharger-5400N................184
    Install Turbocharger-5400N................186
    Remove Turbocharger-5500N................188
    Install Turbocharger-5500N................191
    Turbocharger Break-In................194
  Group 15: Speed Control Linkage................162
    Inspect and Repair Speed Control Linkage................197
Section 40: Electrical Repair................199
  Group 05: Battery, Starter, and Alternator................199
    Starter Repair-Use CTM77................202
    Remove and Install Battery-Tractor Without Cab................203
    Remove and Install Battery-Tractor With Cab................205
    Remove and Install Starter-Early Models................207
    Remove and Install Starter-Later Models................209
    Replace Alternator/Regulator-40 Amp Without Cab................211
    Replace Alternator/Regulator-60 Amp With Cab................212
  Group 10: Electrical System Components................199
    Other Material................1473
    Specifications................1474
    Service Equipment and Tools................1471
    Replace Air Filter Restriction Switch................218
    Replace Coolant Temperature Sender................219
    Replace Engine Speed Sensor................220
    Replace Fuel Shut-Off Solenoid................221
    Replace Engine Oil Pressure Switch................222
    Replace Manifold Heater................223
    Replace Manifold Heater Relay................224
    Replace Key Switch................225
    Replace Light Switch................226
    Replace Turn Signal Controller................228
    Replace Instrument Panel................229
    Replace Rear PTO Switch................234
    Replace PTO Seat Switch................235
    Replace Neutral Start Switch................236
    Replace Fuel Level Sender-Tractors Without Cab................237
    Replace Fuel Level Sender-Tractors With Cab................238
    Replace Park Brake Switch................240
    Replace Radio (Optional Equipment)................241
    Replace Speakers (Optional Equipment)................243
    Replace Antenna (Optional Equipment)................244
    Replace Blower Control Switch................246
    Replace Air Conditioning Temperature Control Switch................248
    Replace Front Wiper/Washer Control Switch................252
    Replace Dome Light................254
    Replace Dome Light Switch................256
    Replace Convenience Outlet................258
    Replace Cab Plug-In Relays................998
    Replace Front Wiper Motor-Cab................261
  Group 15: Wiring Harness................200
    Essential Tools................770
    Service Equipment and Tools................1471
    Service Parts Kits................775
    Replace Connector Body-Blade Terminals................272
    Replace WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Connector................200
    Install WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Contact................200
    Replace Front Wiring Harness-Tractors Without Cab................277
    Replace Front Wiring Harness-Tractors With Cab................279
    Replace Rear Wiring Harness-Tractors Without Cab................281
    Replace Rear Wiring Harness-Tractors With Cab................284
    Replace Cab Main Wiring Harness-Lights................287
    Replace Cab Controls Wiring Harness-Main................289
    Replace Cab Wiring Harness................291
Section 50: Power Train Repair................293
  Group 05: Clutch Housing................293
    Service Equipment and Tools................1471
    Other Material................1473
    Specifications................1474
    Separate Engine from Clutch Housing-Tractors Without Cab................301
    Install Engine to Clutch Housing-Tractors Without Cab................305
    Separate Engine from Clutch Housing-Tractors With Cab................309
    Install Engine to Clutch Housing-Tractors With Cab................314
    Inspect and Repair Clutch Pedal and Linkage................319
  Group 10: Clutch Assembly................293
    Essential Tools................770
    Service Equipment and Tools................1471
    Other Material................1473
    Specifications................1474
    Service Parts Kits................775
    Remove and Install Clutch Assembly................327
    Disassemble and Inspect Clutch Assembly................328
    Assemble Clutch Assembly................332
    Traction Clutch Finger Adjustment................337
    PTO Clutch Finger Adjustment................339
    Remove and Inspect Clutch Release Mechanism and Shafts................341
    Install Clutch Release Mechanism and Shafts................345
  Group 15: Synchronized Reverser................293
    Service Equipment and Tools................1471
    Specifications................1474
    Inspect and Repair F-N-R Selector Lever and Linkage-Tractors Without Cab................351
    Inspect and Repair F-N-R Selector Lever and Linkage-Tractors With Cab................353
    Inspect and Repair Synchronized Reverser................355
  Group 20: Transmission................293
    Service Equipment and Tools................1471
    Other Material................1473
    Specifications................1474
    Inspect and Repair Park Brake Lever................367
    Separate Clutch Housing from Transmission................369
    Install Clutch Housing to Transmission................374
    Remove, Inspect, and Repair Gear Shift Lever................379
    Remove, Inspect, and Repair Range Shift Lever................382
    Remove Transmission................385
    Disassemble and Inspect Transmission................391
    Assemble and Install Transmission................395
    Disassemble, Inspect and Assemble Shift Shaft Assemblies................404
    Disassemble, Inspect, and Assemble Transmission Top Shaft................406
    Disassemble, Inspect, and Assemble Range Reduction Shaft................409
    Disassemble, Inspect, and Assemble Driven Shaft................411
    Remove, Inspect, and Install MFWD and Range Gears................413
    Remove, Inspect, and Repair Park Brake................415
  Group 25: Rear PTO Drive Shaft................294
    Service Equipment and Tools................1471
    Other Material................1473
    Specifications................1474
    Inspect and Repair Rear PTO Lever and Linkage................421
    Inspect and Repair PTO 540/540E Lever and Linkage................423
    Remove and Install Rear PTO Drive Shaft Assembly................425
    Disassemble, Inspect and Assemble Rear PTO Drive Shaft Assembly................427
  Group 30: Differential................294
    Essential Tools................770
    Service Equipment and Tools................1471
    Other Material................1473
    Specifications................1474
    Service Parts Kit................436
    Remove and Install Differential Assembly................437
    Disassemble, Inspect, and Assemble Differential Assembly................439
    Remove and Inspect Differential Drive Shaft................441
    Install Differential Drive Shaft................445
    Differential Cone Point Adjustment................449
    Differential Backlash Adjustment................451
    Remove, Inspect, and Install Differential Lock Assembly................453
  Group 35: Final Drives................295
    Essential Tools................770
    Service Equipment and Tools................1471
    Other Material................1473
    Specifications................1474
    Remove and Install Final Drive Assembly................460
    Remove and Inspect Planetary Drive Assembly................462
    Install Planetary Drive Assembly................465
    Remove, Inspect, and Install Axle Shaft Assembly................468
  Group 40: Mechanical Front Wheel Drive................295
    Essential Tools................770
    Service Equipment and Tools................1471
    Other Material................1473
    Specifications................1474
    Inspect and Repair MFWD Lever and Linkage................476
    Remove and Install MFWD Drop Gearbox................478
    Disassemble and Inspect MFWD Drop Gearbox................480
    MFWD Drop Gearbox Cross Section................483
    Assemble MFWD Drop Gearbox................485
    Remove, Inspect, and Install MFWD Drive Shaft................491
    Remove and Install MFWD Axle................493
    Remove and Install MFWD Axle Pivot Pin and Pivot Bushings................496
    Disassemble and Inspect MFWD Outer Drive................498
    Assemble MFWD Outer Drive................502
    Remove, Inspect, and Install MFWD Swivel Housing................505
    Remove, Inspect, and Install MFWD Axle Shaft................510
    Remove and Install MFWD Differential Carrier Assembly................512
    Disassemble and Inspect MFWD Differential Carrier Assembly................514
    Assemble MFWD Differential Carrier Assembly................519
  Group 45: Creeper Assembly................295
    Other Material................1473
    Specifications................1474
    Remove and Install Creeper Assembly................531
    Disassemble, Inspect and Assemble Creeper Assembly................533
Section 60: Steering and Brake Repair................535
  Group 05: Steering Repair................535
    Other Material................1473
    Service Parts Kits................775
    Specifications................1474
    Remove and Install Steering Column and Valve................540
    Disassemble and Inspect Steering Valve................542
    Assemble Steering Valve................546
    Remove and Install Steering Cylinder-2WD Axle................551
    Disassemble, Inspect and Assemble Steering Cylinder-2WD Axle................553
    Disassemble, Inspect and Assemble Steering Cylinder-MFWD Axle................555
    Remove, Inspect and Install Tie Rod Assembly-2WD Axle................558
    Remove, Inspect and Install Tie Rod Assembly-MFWD Axle................560
    Inspect and Replace Steering Hydraulic Lines-Without Oil Cooler................562
    Inspect and Replace Steering Hydraulic Lines-With Oil Cooler................564
  Group 10: Brake Repair................535
    Service Equipment and Tools................1471
    Other Material................1473
    Specifications................1474
    Remove and Install Brake Valve................570
    Disassemble and Inspect Brake Pedals and Valve................572
    Brake Valve Cross Section................575
    Assemble Brake Valve................577
    Remove, Inspect and Install Brakes-Early Models................580
    Remove, Inspect and Install Brakes-Later Models................583
    Inspect and Replace Brake Hydraulic Lines................588
Section 70: Hydraulic Repair................591
  Group 05: Hydraulic Pump and Filter................591
    Service Equipment and Tools................1471
    Specifications................1474
    Service Parts Kits................775
    Remove, Inspect and Install Hydraulic Oil Pick-Up Screen................597
    Remove and Install Hydraulic Pump-5400N And 5500N................600
    Remove Hydraulic Pump External Components-5400N And 5500N................602
    Disassemble and Inspect Hydraulic Pump-5400N And 5500N................604
    Assemble Hydraulic Pump-5400N And 5500N................607
    Install Hydraulic Pump External Components-5400N And 5500N................609
    Remove and Install Large Capacity Hydraulic Pump-5500N (Optional)................611
    Remove Large Capacity Hydraulic Pump External Components-5500N (Optional)................613
    Disassemble and Inspect Large Capacity Hydraulic Pump-5500N (Optional)................615
    Assemble Large Capacity Hydraulic Pump-5500N (Optional)................618
    Install Large Capacity Hydraulic Pump External Components-5500N (Optional)................620
    Remove and Install Hydraulic Oil Filter and Manifold................622
    Inspect and Replace Hydraulic Supply and Return Lines................624
  Group 06: Hydraulic Oil Cooler................591
    Remove, Inspect, and Install Hydraulic Oil Cooler................628
  Group 10: Rockshaft................591
    Service Equipment and Tools................1471
    Other Material................1473
    Specifications................1474
    Service Parts Kits................775
    Inspect and Repair Rockshaft Control Lever Assembly-Early Models................635
    Inspect and Repair Rockshaft Control Lever Assembly-Later Models................640
    Inspect and Repair Rockshaft Control Linkage................646
    Inspect and Repair Draft Sensing Support Assembly................650
    Remove, Inspect and Install Secondary Relief Valve................652
    Replace Rockshaft Surge Relief Valve................654
    Remove, Inspect and Install Rate-of-Drop Valve................655
    Replace Rockshaft Control Valve................657
    Replace Rockshaft End Cover................660
    Remove and Install Rockshaft Case................663
    Remove, Inspect and Install Rockshaft Lift Arms................666
    Remove, Inspect, and Install Rockshaft Piston and Cylinder................668
  Group 15: Selective Control Valve (SCV)................592
    Other Material................1473
    Specifications................1474
    Service Parts Kits................775
    Remove and Install Selective Control Valve (SCV)................674
    Disassemble, Inspect, and Assemble Selective Control Valve (SCV)................676
    Inspect and Replace SCV Lines and Fittings................680
    Inspect and Replace Power Beyond Lines and Fittings................682
    Inspect and Replace Power Beyond Motor Control Lines and Fittings................683
Section 80: Miscellaneous Repair................684
  Group 05: Front Axle-2WD................684
    Service Equipment and Tools................1471
    Specifications................1474
    Remove and Install Front Axle-2WD................688
    Inspect and Replace Pivot Pin and Bushings-2WD Axle................692
    Remove and Install Spindle Assembly-2WD Axle................693
    Inspect and Replace Spindle Shaft Bushings-2WD Axle................695
  Group 10: Wheels................684
    Service Equipment and Tools................1471
    Specifications................1474
    Inspect and Replace Front Wheel Bearings-2WD Axle................699
  Group 15: Fenders................684
    Specifications................1474
    Remove and Install Fenders................703
  Group 20: 3-Point Hitch................684
    Specifications................1474
    Inspect and Repair Draft Links................709
    Inspect and Repair Adjustable Lift Links................710
    Inspect and Repair Center Link................712
    Remove and Install Drawbar and Support................714
Section 90: Operator Station Repair................716
  Group 05: Seat and Support................716
    Specifications................1474
    Remove and Install Seat and Support-Without Cab................720
    Remove and Install Seat and Support-With Cab................721
  Group 10: ROLL-GARDROLL-GARD is a trademark of Deere & Company.................716
    Specifications................1474
    Remove and Install ROLL-GARD ROLL-GARD is a trademark of Deere & Company.................716
  Group 15: Rear Bar................716
    Specifications................1474
    Remove and Install Rear Bar-Without Cab................727
    Remove and Install Rear Bar-With Cab................731
  Group 20: Cab Components................716
    Essential Tools................770
    Other Material................1473
    Specifications................1474
    Remove Cab and Floor Plates................738
    Install Cab and Floor Plates................745
    Remove and Install Cab Outer Roof................751
    Remove and Install Lower Front Windows and Support................752
    Remove and Install Rear Side Cab Windows................758
    Remove and Install Rear Cab Window................760
    Remove and Install Front Windshield................762
    Remove and Install Cab Doors................764
    Remove, Inspect, and Install Cab Recirculating/Fresh Air Filter................765
  Group 25: Air Conditioning System................716
    Essential Tools................770
    Service Equipment and Tools................1471
    Other Material................1473
    Service Parts Kits................775
    Specifications................1474
    Hose and Tubing O-Ring Connection Torques................778
    Recover/Recycle Air Conditioning Refrigerant................779
    Replace Air Conditioning Receiver-Dryer................1463
    Remove, Inspect, and Install Air Conditioning Condenser................1462
    Remove, Inspect, and Install Air Conditioning Compressor................1461
    Test Volumetric Efficiency of Compressor................1461
    Test Compressor Shaft Seal Leakage................793
    Disassemble and Assemble Compressor Clutch................795
    Disassemble, Inspect, and Assemble Compressor................1461
    Check Compressor Clutch Hub Clearance................801
    Inspect Compressor Manifold................802
    Remove and Install Compressor Relief Valve................803
    Remove Evaporator/Heater Core Housing................804
    Install Evaporator/Heater Core Housing................811
    Remove and Install Blower Motors................816
    Remove, Test and Install Evaporator/Heater Core................824
    Leak Test Evaporator/Heater Core................823
    Install Evaporator/Heater Core................824
    Service Expansion Valve................1464
    Expansion Valve Bench Test................827
    Refrigerant Oil Information................829
    Check Compressor Oil Charge................830
    Determine Correct Refrigerant Oil Charge................831
    Add Refrigerant Oil to System................833
    System Information................834
    Flush Air Conditioning System................835
    Evacuate Air Conditioning System................838
    Charge Air Conditioning System................840
  Group 30: Heating System................717
    Remove, Test and Install Heater Control Valve................847
    Leak Test Heater Control Valve................846
    Install Heater Control Valve................847
Section 210: Operational Checkout Procedures................849
  Group 10: Operational Checkout Procedures................849
    Operational Checkout Procedure Information................851
    Engine Oil Level and Condition Check................852
    Coolant Level and Condition Check................853
    Transmission and Hydraulic Oil Check................854
    Fan and Belt Check................855
    Compressor Belt Check................856
    Fuel System Check................857
    Air Intake System Check................858
    Electrical System Check................860
    Hydraulic System Check................862
    MFWD Oil Check................863
    Indicator Lamps Check................864
    Cab Blower Motor Check................865
    A/C Compressor Clutch Check................874
    Engine Start Check................867
    Transmission Neutral Start Check................868
    PTO Neutral Start Check................869
    Engine Fast and Slow Idle Operation................870
    Power Steering Check................871
    Differential Lock Check................872
    PTO Engagement Check................873
    Clutch Check................874
    Transmission Shift Check................875
    Range Lever Shift Check................876
    MFWD Drive Check................877
    Park Brake Check................878
    Rockshaft Check................879
    Selective Control Valve Check................881
    A/C System Operational Check................883
    Cab Heater Valve Check................884
    Miscellaneous Checks................885
Section 220: Engine Operation, Tests and Adjustments................886
  Group 05: Component Location................886
    Component Location Information................1357
    Engine External Components-Left Side................890
    Engine External Components-Right Side................892
  Group 10: Theory of Operation................886
    Theory of Operation Information................1363
    Engine Lubrication System Operation................896
    Engine Lubrication System Operation-Continued................899
    Engine Cooling System Operation................901
  Group 15: Diagnosis, Tests and Adjustments................886
    Service Equipment and Tools................1471
    Specifications................1474
    Diagnostic Information................1402
    Engine Turns Over But Will Not Start or Starts Hard................909
    Engine Runs Irregularly or Stalls Frequently................910
    Engine Runs Rough................911
    Engine Has Low Power................912
    Engine Low Power-Continued................913
    Engine Smokes-Black or Grey................914
    Engine Smokes Excessively-White................915
    Engine Uses Excess Fuel................916
    Engine Has Excess Noise or Vibration................917
    Engine Uses Excess Oil or Smokes Blue................918
    Engine Has Low Oil Pressure................919
    Engine Coolant Operating Temperature Incorrect................920
    Oil in Coolant or Coolant in Oil................922
    Radiator Bubble Test................923
    Cooling System Test................925
    Radiator Cap Pressure Test................926
    Engine Oil Pressure Test................927
    Cylinder Compression Pressure Test................929
    Fuel Shut-Off Solenoid Check................931
    Throttle Lever Adjustment................932
    Slow Idle Adjustment................933
    Fast Idle Adjustment................935
    Injection Pump Timing Adjustment................937
    Check and Adjust Valve Clearance................938
    Fan/Alternator Drive Belt Adjustment................942
    Compressor Drive Belt Adjustment................944
    Turbocharger Boost Pressure Test................946
    Bleed Fuel System................948
Section 230: Fuel/Air Operation, Tests and Adjustments................951
  Group 05: Component Location................951
    Component Location Information................1357
    Fuel System Components................954
    Air Intake System Components................956
  Group 10: Theory of Operation................951
    Theory of Operation Information................1363
    Fuel System Operation................959
    Fuel Filter/Priming Pump Operation................961
    Fuel Injection Pump Operation................963
    Fuel Injection Nozzle Operation................966
    Air Intake System Operation................968
    Turbocharger Operation................970
  Group 15: Diagnosis, Tests and Adjustments................951
    Diagnostic Information................1402
    Fuel/Air Diagnosis, Tests and Adjustments................973
Section 240: Electrical System Operation, Test and Adjust................974
  Group 05: Component Location................974
    Component Location Information................1357
    Engine Electrical Components................979
    Dash Electrical Components................980
    Machine Electrical Components-Tractor Without Cab................982
    Machine Electrical Components-Tractor With Cab................984
    Cab Control Panel and Electrical Components................986
  Group 10: Theory of Operation................974
    Theory of Operation Information................1363
    Fuse Block and Fuses-Early Tractors................990
    Fuse Block and Fuses-Later Tractors Without Cab................992
    Fuse Block and Fuses-Cab Tractors................994
    Cab Fuse Block and Fuses................996
    Relays................998
    Starting System Operation-Normal................999
    Starting System Operation-Bypass Attempt................1001
    Manifold Heater System Operation................1003
    Charging System Operation................1005
    Lighting System Operation-Turn Signals................1007
    Lighting System Operation-Warning Lights and Tail Light................1009
    Lighting System Operation-Headlights and Instrument Lights................1011
    Rear Flood Light Operation-Tractors Without Cab................1013
    Flood Light Operation-Tractor With Cab................1015
    Instrument Panel System Operation-Tachometer................1017
    Instrument Panel System Operation-Fuel Gauge................1019
    Instrument Panel System Operation-Temperature Gauge................1021
    Instrument Panel System Operation-Hour Meter................1023
    PTO Warning System Operation................1025
    Air Filter Restriction Indicator Operation................1027
    Optional Horn Operation................1029
    Accessory Relay and Optional Trailer Connection Operation................1031
    Blower Motor System Operation-Tractors With Cab................1033
    A/C Compressor System Operation-Tractors With Cab................1036
    Front Wiper/Washer System Operation-Tractors With Cab................1039
    Rear Wiper/Washer System Operation-Tractors With Cab................1041
    Dome Light Operation-Tractors With Cab................1043
  Group 15: Diagnosis, Test and Adjust................975
    Diagnostic Information................1402
    Wire Color Chart................1047
    Starting System Test Points-Normal Operation................1049
    Starting System Test Points-Bypass Attempt................1053
    Manifold Heater Test Points................1056
    Charging System Test Points................1059
    Lighting System Test Points Left Turn Signals-Tractors Without Cab................1062
    Lighting System Test Points Right Turn Signals-Tractors Without Cab................1066
    Lighting System Test Points Left Turn Signals-Tractors With Cab................1070
    Lighting System Test Points Right Turn Signals-Tractors With Cab................1074
    Lighting System Test Points-Warning Lights (All Tractors)................1078
    Lighting System Test Points-Rear Flood Light (Tractors Without Cab)................1081
    Lighting System Test Points-Flood Lights (Tractors With Cab)................1084
    Lighting System Test Points-Dome Light (Tractors With Cab)................1088
    Lighting System Test Points-Tail Light................1091
    Lighting System Test Points-Headlights and Instrument Lights................1094
    Instrument Panel System Test Points-Tachometer................1099
    Instrument Panel System Test Points-Fuel Gauge................1103
    Instrument Panel System Test Points-Temperature Gauge................1106
    Instrument Panel System Test Points-Hour Meter................1109
    Instrument Panel System Test Points-Engine Oil Pressure Indicator................1113
    PTO Warning System Test Points................1116
    Air Filter Restriction Indicator Test Points................1120
    Optional Horn Test Points................1123
    Accessory Relay and Trailer Connector Test Points................1126
    Blower Motor Test Points (Tractors With Cab)................1130
    A/C Compressor Clutch Coil Test Points (Tractors With Cab)................1135
    Front Wiper/Washer Test Points (Tractors With Cab)................1137
    Battery Voltage Battery Voltage & Specific Gravity Tests{pgNO}976 Specific Gravity Tests................1140
    Charge Battery................1142
    Battery Load Test................1144
    Starter Amp Draw/RPM Test................1146
    Starter No-Load Amp Draw/RPM Test................1148
    Alternator/Regulator Test................1150
    Starter Solenoid Test................1152
    Starter Relay Test................1153
    Key Switch Test................1155
    Plug-In Relay Test................1157
    Diode Pack Test................1159
    Fuse Test................1161
    Neutral Start Switch Test................1162
    PTO Switch Test................1163
    PTO Seat Switch Test................1165
    Light Switch Test................1166
    Turn Signal Controller Test................1167
    Fuel Shut-Off Solenoid Test................1168
    Blower Switch Test................1169
    Blower Motor Resistors................1171
    A/C Thermostatic Control Switch Test................1173
    Front Wiper/Washer Switch Test................1174
    Door Switch Test................1176
    Dome Light Switch Test................1177
  Group 20: Wiring Schematics................976
    Schematic Information................1179
    Component Identification Table................1180
    5400N and 5500N Electrical Schematic and Legend-Early Tractors Without Cab................1182
    5400N and 5500N Electrical Schematic and Legend-Later Tractors Without Cab................1188
    5400N and 5500N Electrical Schematic and Legend-Later Tractors With Cab................1194
Section 250: Power Train Operation, Tests Section 250: Power Train Operation, Tests & Adjustments{pgNO}1203 Adjustments................1203
  Group 05: Component Location................1203
    Component Location Information................1357
    Power Train Components................1208
    Clutch Components................1210
    Synchronized Reverser Components................1212
    Transmission Components................1213
    Park Brake Components................1215
    Final Drive Components................1217
    Rear PTO Components................1219
  Group 10: Theory of Operation................1203
    Theory of Operation Information................1363
    Clutch Operation................1222
    Synchronized Reverser Operation................1229
    Synchronized Reverser Power Flow................1231
    Transmission Lubrication System................1233
    Transmission Power Flow-Gear Shift................1235
    Transmission Gear Shift Synchronizer Operation................1237
    Transmission Power Flow-Range Shift................1239
    Park Brake Operation................1242
    Differential Power Flow................1244
    Differential Lock Operation................1246
    Final Drive Operation................1248
    Rear PTO Operation................1250
    Mechanical Front Wheel Drive (MFWD) Operation................1252
  Group 15: Diagnosis, Tests and Adjustments................1203
    Diagnostic Information................1402
    Isolate the Problem Area................1256
    Traction Clutch Slips................1258
    Traction Clutch Dragging................1259
    Traction Clutch Does Not Engage................1260
    Traction Clutch Grabs................1261
    Traction Clutch Squeaks................1262
    Traction Clutch Does Not Release................1263
    Traction Clutch Chatters................1264
    Traction Clutch Rattles................1265
    Traction Clutch Engagement Is Noisy................1266
    Excessive Vibration in Traction Clutch................1267
    Clutch Pedal Does Not Return................1268
    Clutch Pedal Loose................1269
    Clutch Pedal Pulsates................1270
    Jerky or Rough Transmission of Power................1271
    Low Transmission Oil Level (Excessive Oil Leakage)................1272
    Gears Clash, Shifts Hard, or Will Not Engage................1273
    Two Speeds Engage Together................1274
    Transmission Will Not Stay in Gear................1275
    Transmission Noisy................1276
    PTO Noisy................1277
    PTO Hard to Engage................1278
    PTO Will Not Operate................1279
    PTO Will Not Stay Engaged................1280
    Excessive Differential Noise................1281
    Differential Does Not Work................1282
    No Differential Lock................1283
    Differential Chatters................1284
    Axle Noise................1285
    Axle Shaft Will Not Turn................1286
    MFWD Lever is Hard to Engage................1287
    MFWD Lever Will Not Stay in “ON” Position................1288
    Noisy Front Wheel Drive Operation................1289
    Clutch Pedal Free Play Adjustment................1290
    PTO Clutch Lever Adjustment................1291
    Park Brake Band Adjustment................1293
    Park Brake Linkage Adjustment................1295
    PTO 540/540E Lever and Linkage Adjustment................1297
    Forward/Reverse Selector Lever Adjustment................1299
Section 260: Steering and Brake Operation, Tests, and Adjustments................1301
  Group 05: Component Location................1301
    Component Location Information................1357
    Steering System Components................1305
    Steering System Components-5500N and All Cab Tractors................1307
    Brake System Components-Early Models................1309
    Brake System Components-Late Models................1311
  Group 10: Theory of Operation................1301
    Theory of Operation Information................1363
    Steering System Operation-5400N Without Cab................1315
    Steering System Operation-5500N and All Cab Tractors................1317
    Steering Valve Operation-Neutral and Manual Turning................1319
    Steering Valve Operation-Power Turning................1321
    Brake System Operation-Early Models................1323
    Brake System Operation-Late Models................1325
    Brake Valve Operation................1327
  Group 15: Diagnosis, Tests, and Adjustments................1301
    Diagnostic Information................1402
    Isolate the Problem-Steering System................1333
    Steering Sluggish or Loss of Steering................1334
    Isolate the Problem-Brakes................1335
    Excessive Brake Pedal Leak-Down................1336
    Excessive Brake Chatter................1337
    Steering Pump Flow Test................1424
    Steering Valve Relief Test................1340
    Steering Cylinder Leakage Test................1342
    Steering Valve Leakage Test................1343
    Toe-In Check and Adjustment-Standard 2WD Axle................1345
    Toe-In Check and Adjustment-MFWD Axle................1347
    Steering Stop Adjustment-2WD Axle................1349
    Steering Stop Adjustment-MFWD Axle................1350
    Brake Pedal Adjustment................1351
    Bleed Brake System................1353
Section 270: Hydraulic System Operation, Tests, and Adjustments................1354
  Group 05: Component Location................1354
    Component Location Information................1357
    Hydraulic System Components................1405
    Selective Control Valve (SCV) Components................1360
  Group 10: Theory of Operation................1354
    Theory of Operation Information................1363
    Hydraulic System Operation................1364
    Hydraulic Filter Operation-5400N (Early Models)................1367
    Hydraulic Filter Operation-5400N and 5500N (Later Models)................1369
    Hydraulic Pump Operation................1371
    Rockshaft Control Valve Operation-Two Flow Regulator Valves................1373
    Rockshaft Control Valve Operation-Neutral Position................1375
    Rockshaft Control Valve Operation-Raise Position................1377
    Rockshaft Control Valve Operation-Lower Position................1379
    Surge Relief Valve Operation................1383
    Relief Valve Operation................1383
    Rate-of-Drop Valve Operation-Full Open................1385
    Rate-of-Drop Valve Operation-Partially Open................1387
    Rate-of-Drop Valve Operation-Full Closed................1389
    Rockshaft Draft-Sensing Operation................1391
    Selective Control Valve Operation-Neutral Position................1393
    Selective Control Valve Operation-Extend and Retract Positions................1395
    Selective Control Valve Operation-Boom Spool Float Position................1397
    Double-Acting Sleeve Coupler Operation................1399
  Group 15: Diagnosis................1354
    Diagnostic Information................1402
    Preliminary Hydraulic System Inspection................1403
    Hydraulic Oil Warm-Up Procedure................1404
    Hydraulic System Components................1405
    Entire Hydraulic System Fails to Function/No Hydraulic Pump Output................1407
    Insufficient Pump Delivery................1408
    Hydraulic Functions Too Slow................1409
    Excessive Pump Pressure................1410
    Slow Hydraulic Pump Response................1411
    Excessive Pump Noise During Operation................1412
    Rockshaft Does Not Lift or Lifts Slowly................1413
    Rockshaft Does Not Lower or Lowers Slowly................1414
    Neutral Position Unstable, Rockshaft Drops after Engine Shut Down................1415
    SCV Control Lever Does Not Return to Neutral Position................1416
    Remote Cylinder Does Not Extend or Retract................1417
    Remote Cylinder Settles Under Load................1418
    Remote Cylinder Operates Too Fast or Too Slow................1419
  Group 20: Hydraulic Tests................1355
    Hydraulic System Tests................1422
    Pump Flow Test................1424
    Relief Valve Test................1426
    Selective Control Valve (SCV) Leakage Test................1428
    Rockshaft Leakage Test................1430
    Rockshaft Lift Cycle Test................1432
  Group 25: Adjustments................1355
    Rockshaft Control Lever Friction Adjustment................1435
    Rockshaft Draft-Sensing and Position-Sensing Linkage Adjustment................1436
    Rockshaft Draft-Sensing Feedback Linkage Adjustment................1440
    Relief Valve Adjustment................1442
  Group 30: Hydraulic Schematics................1355
    Hydraulic Circuit Symbols................1445
    Legend for Hydraulic Schematic-Early Models................1447
    Legend for Hydraulic Schematic-Later Models................1449
Section 290: Operator Station................1451
  Group 05: Component Location................1451
    Air Conditioning System Components................1454
  Group 10: Theory of Operation................1451
    Refrigerant R134a................1457
    HVAC System Air Flow................1458
    Air Conditioning System Cycle................1459
    Compressor................1461
    Condenser................1462
    Receiver-Dryer................1463
    Expansion Valve................1464
    A/C Temperature Control Switch................1465
    Evaporator................1466
    Heater Temperature Control Knob................1467
    High and Low Pressure Switches................1468
  Group 15: Diagnosis, Tests, and Adjustments................1451
    Special or Essential Tools................1470
    Service Equipment and Tools................1471
    Other Material................1473
    Specifications................1474
Section 299: Dealer Fabricated Tools................1501
  Group 00: Dealer Fabricated Tools................1501
    DFLV1A-Final Drive Turning Tool................1503
    DFRW20-Compressor Holding Fixture................1504
    DFRW83-Nozzle Assembly................1505
    JDG826-PTO Clutch Finger Height Gauge................1507
    JDG827-Traction Clutch Finger Height Gauge................1508
    JDG828-Traction Clutch Finger Height Adjustment Tool................1509

John Deere Tractors 5400N & 5500N Diagnostics & Repair Service Manual (TM1585)