Complete All Inclusive Technical Manual with electrical wiring diagrams for John Deere Tractors 5320N, 5420N, 5520N, with all the shop information to maintain, diagnose, repair, and service like professional mechanics (Diagnosis, Operation, Tests, Repair, Service, Troubleshooting).

John Deere USA Tractors 5320N, 5420N, 5520N workshop diagnosis repair service 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.

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Language: English
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PRODUCT DETAILS:
Total Pages: 2,212 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

MAIN SECTION
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)
      Hydraulic Power Beyond
   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, Tests & 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, Test & Adjust
      Component Location
      Theory of Operation
      Diagnosis, Tests and Adjustments
   Hydraulic System Operation, Tests, and Adjustments
      Component Location
      Theory of Operation
      Diagnosis
      Hydraulic Tests
      Adjustments
      Hydraulic Schematics
   Operator Station
      Component Location
      Theory of Operation
      Diagnosis, Tests, and Adjustments
   Dealer Fabricated Tools

tm1872 - 5320N, 5420N and 5520N Tractors Diagnostic and Repair Technical Manual

Table of Contents

Foreword

Section 10: General Information

Group 05: Safety

Recognize Safety Information

Understand Signal Words

Follow Safety Instructions

Handle Fluids Safely—Avoid Fires

Prevent Battery Explosions

Prepare for Emergencies

Prevent Acid Burns

Service Cooling System Safely

Handle Chemical Products Safely

Avoid High-Pressure Fluids

Park Machine Safely

Support Machine Properly

Wear Protective Clothing

Work in Clean Area

Service Machines Safely

Work In Ventilated Area

Illuminate Work Area Safely

Replace Safety Signs

Use Proper Lifting Equipment

Keep ROPS Installed Properly

Service Tires Safely

Avoid Harmful Asbestos Dust

Avoid Heating Near Pressurized Fluid Lines

Remove Paint Before Welding or Heating

Use Proper Tools

Dispose of Waste Properly

Live With Safety

Group 10: General Specifications

Machine Specifications

SyncReverser™ Transmission Ground Speed Estimates

Creeper Transmission Ground Speed Estimates

Correction Factors for Other Tire Sizes

Service Recommendations for O-Ring Boss Fittings

Service Recommendations For Flat Face O-Ring Seal Fittings

Metric Cap Screw Torque Values—Grade 7

Metric Bolt and Screw Torque Values

Unified Inch Bolt and Screw Torque Values

Group 20: Fuel and Lubricants

Diesel Fuel Specifications

Storing Fuel

Do Not Use Galvanized Containers

Fill Fuel Tank

Diesel Engine Oil — Non-Emissions Certified and Certified Tier 1 and Stage I

Diesel Engine Coolant (engine with wet sleeve cylinder liners)

Liquid Coolant Conditioner

Transmission and Hydraulic Oil

MFWD Gear Oil

Grease

Alternative and Synthetic Lubricants

Lubricant Storage

Group 25: Serial Number Locations

Serial Numbers

Product Identification Number Location

Engine Serial Number Location

Fuel Injection Pump Serial Number Location

Alternator Serial Number Location

Power Steering Valve Serial Number Location

Starter Serial Number Location

Transmission Serial Number Location

Front Axle (2WD) Serial Number Location

Mechanical Front Wheel Drive (MFWD) Serial Number Location

Air Conditioning Compressor Serial Number Location

Group 30: Features and Accessories

Features and Accessories

Standard Features

Factory Installed Optional Equipment

Field Installed Optional Kits and Accessories

Section 20: Engine Repair

Group 05: Engine

Specifications

Service Equipment and Tools

John Deere Engine Repair—Use CTM104, CTM125 or CTM207

Remove Engine—Tractors Without Cab

Install Engine—Tractors Without Cab

Remove Engine—Tractors With Cab

Install Engine—Tractors With Cab

Group 10: Cooling System

Specifications

Engine Water Pump Repair—Use CTM104 or CTM125

Remove and Inspect Radiator

Install Radiator

Replace Thermostat

Inspect and Replace Belt Tensioner

Section 30: Fuel and Air Repair

Group 05: Fuel System

Specifications

Injection Pump, Nozzle and Governor Repair—Use CTM207 or CTM125

Remove, Inspect, and Install Fuel Tank—Tractors Without Cab

Remove, Inspect, and Install Fuel Tanks—Tractors With Cab

Replace Fuel Filter

Remove and Install Fuel Filter/Primer Pump Assembly

Group 10: Air Intake System

Specifications

Turbocharger Repair—Use CTM104 or CTM125

Remove, Inspect, and Install Air Cleaner Elements—5320N

Remove, Inspect, and Install Air Cleaner Elements—5420N and 5520N

Remove Turbocharger—5320N

Install Turbocharger—5320N

Remove Turbocharger—5520N

Install Turbocharger—5520N

Turbocharger Break-In

Group 15: Speed Control Linkage

Inspect and Repair Speed Control Linkage—Tractors Without Cab

Inspect and Repair Speed Control Linkage—Tractors With Cab

Section 40: Electrical Repair

Group 05: Battery, Starter, and Alternator

Starter Repair—Use CTM77

Remove and Install Battery—Tractor Without Cab

Remove and Install Battery—Tractor With Cab

Remove and Install Starter—5320N

Remove and Install Starter—5420N and 5520N

Replace Alternator/Regulator—40 Amp Without Cab

Replace Alternator/Regulator—60 and 65 Amp With Cab

Group 10: Electrical System Components

Other Material

Replace Air Filter Restriction Switch—5320N

Replace Air Filter Restriction Switch—5420N and 5520N

Replace Coolant Temperature Sender—5320N

Replace Coolant Temperature Sender—5420N and 5520N

Replace Engine Speed Sensor

Replace Engine Oil Pressure Switch

Replace Air Intake Heater (Optional Equipment)

Replace Air Intake Heater Relay (Optional Equipment)

Replace Key Switch

Replace Light Switch (S.N. —438002)

Replace Light Switch (S.N. 438003— )

Replace Turn Signal Controller

Replace Instrument Panel (S.N. —438002)

Replace Instrument Panel (S.N. 438003— )

Replace Rear PTO Switch—Tractor Without Cab

Replace Rear PTO Switch—Tractor With Cab

Replace PTO Seat Switch—Tractor Without Cab

Replace Neutral Start Switch—Tractor Without Cab

Replace Neutral Start Switch—Tractor With Cab

Replace Fuel Level Sender—Tractors Without Cab

Replace Fuel Level Sender—Tractors With Cab

Replace Park Brake Switch—Tractor Without Cab

Replace Park Brake Switch—Tractor With Cab

Replace Radio (Optional Equipment)

Replace Speakers

Replace Antenna (Optional Equipment)

Replace Blower Control Switch

Replace Air Conditioning Temperature Control Switch

Replace Front Wiper/Washer Control Switch

Replace Dome Light

Replace Dome Light Switch

Replace Convenience Outlet

Replace Cab Plug-In Relays

Replace Front Wiper Motor—Tractor With Cab

Group 15: Wiring Harness

Special or Essential Tools

Service Parts Kits

Remove Connector Body from Blade Terminals

Replace WEATHER PACK WEATHER PACK is a trademark of Packard Electric Connector

Install WEATHER PACK WEATHER PACK is a trademark of Packard Electric Contact

Replace Front Wiring Harness—3-Cylinder

Replace Front Wiring Harness—4-Cylinder

Replace Rear Wiring Harness—Tractors Without Cab (S.N. —438002)

Replace Rear Wiring Harness—Tractors Without Cab (S.N. 438003— )

Replace Rear Wiring Harness—Tractors With Cab

Replace Cab Main Wiring Harness

Replace Cab Controls Wiring Harness

Section 50: Power Train Repair

Group 05: Clutch Housing

Service Equipment and Tools

Other Material

Specifications

Service Parts Kits

Separate Engine from Clutch Housing—Tractors Without Cab

Install Engine to Clutch Housing—Tractors Without Cab

Separate Engine from Clutch Housing—Tractors With Cab

Install Engine to Clutch Housing—Tractors With Cab

Inspect and Repair Clutch Pedal and Linkage—Tractors Without Cab

Inspect and Repair Clutch Pedal and Linkage—Tractors With Cab

Group 10: Clutch Assembly

Essential Tools

Service Equipment and Tools

Other Material

Specifications

Remove and Install Clutch Assembly

Disassemble and Inspect Clutch Assembly

Assemble Clutch Assembly

Traction Clutch Finger Adjustment

PTO Clutch Finger Adjustment

Remove and Inspect Clutch Release Mechanism and Shafts

Install Clutch Release Mechanism and Shafts

Install Clutch Release Mechanism and Shafts

Group 15: Synchronized Reverser

Service Equipment and Tools

Specifications

Inspect and Repair F-N-R Selector Lever and Linkage

Inspect and Repair Synchronized Reverser

Group 20: Transmission

Service Equipment and Tools

Other Material

Specifications

Inspect and Repair Park Brake Lever

Separate Clutch Housing from Transmission—Tractors Without Cab

Install Clutch Housing to Transmission—Tractors Without Cab

Separate Clutch Housing from Transmission—Tractors With Cab

Install Clutch Housing to Transmission—Tractors With Cab

Remove, Inspect, and Repair Gear Shift Lever—Tractors Without Cab

Remove, Inspect, and Repair Gear Shift Lever—Tractors With Cab

Remove, Inspect, and Repair Range Shift Lever—Tractors Without Cab

Remove, Inspect, and Repair Range Shift Lever—Tractors With Cab

Remove Transmission—Tractors Without Cab

Remove Transmission—Tractors With Cab

Disassemble and Inspect Transmission

Assemble and Install Transmission—Tractors Without Cab

Assemble and Install Transmission—Tractors With Cab

Disassemble, Inspect, and Assemble Shift Shaft Assemblies

Disassemble, Inspect, and Assemble Transmission Top Shaft

Disassemble, Inspect, and Assemble Range Reduction Shaft

Disassemble, Inspect, and Assemble Driven Shaft

Remove, Inspect, and Install MFWD and Range Gears

Remove, Inspect, and Repair Park Brake

Group 25: Rear PTO Drive Shaft

Service Equipment and Tools

Other Material

Specifications

Inspect and Repair Rear PTO Lever and Linkage-Tractors Without Cab

Inspect and Repair Rear PTO Lever and Linkage-Tractors Without Cab

Inspect and Repair Rear PTO Lever and Linkage—Tractors With Cab

Inspect and Repair Rear PTO Lever and Linkage (540/540E)—Tractors Without Cab

Inspect and Repair Rear PTO Lever and Linkage (540/540E)—Tractors Without Cab

Inspect and Repair Rear PTO Lever and Linkage (540/540E)—Tractors With Cab

Inspect and Repair Rear PTO Lever and Linkage (540/540E)—Tractors With Cab

Remove and Install Rear PTO Drive Shaft Assembly

Disassemble, Inspect, and Assemble Rear PTO Drive Shaft Assembly

Group 30: Differential

Essential Tools

Service Equipment and Tools

Other Material

Specifications

Service Parts Kit

Remove and Install Differential Assembly

Disassemble, Inspect, and Assemble Differential Assembly

Remove and Inspect Differential Drive Shaft

Install Differential Drive Shaft

Remove, Inspect, and Install Differential Lock Assembly

Differential Cone Point Adjustment

Differential Backlash Adjustment

Group 35: Final Drives

Essential Tools

Service Equipment and Tools

Other Material

Specifications

Remove and Install Final Drive Assembly

Remove and Inspect Planetary Drive Assembly

Install Planetary Drive Assembly

Remove, Inspect, and Install Axle Shaft Assembly

Group 40: Mechanical Front Wheel Drive

Essential Tools

Service Equipment and Tools

Other Material

Specifications

Inspect and Repair MFWD Lever and Linkage—Tractors Without Cab

Inspect and Repair MFWD Lever and Linkage—Tractors With Cab

Remove and Install MFWD Drop Gearbox

Disassemble and Inspect MFWD Drop Gearbox

MFWD Drop Gearbox Cross Section

Assemble MFWD Drop Gearbox

Remove, Inspect, and Install MFWD Drive Shaft

Remove and Install MFWD Axle

Remove and Install MFWD Axle Pivot Pin and Pivot Bushings

Disassemble and Inspect MFWD Outer Drive

Assemble MFWD Outer Drive

Remove, Inspect, and Install MFWD Swivel Housing

Remove, Inspect, and Install MFWD Axle Shaft

Remove and Install MFWD Differential Carrier Assembly

Disassemble and Inspect MFWD Differential Carrier Assembly

Assemble MFWD Differential Carrier Assembly

Group 45: Creeper Assembly

Other Material

Specifications

Remove and Install Creeper Assembly

Disassemble, Inspect, and Assemble Creeper Assembly

Section 60: Steering and Brake Repair

Group 05: Steering Repair

Other Material

Specifications

Service Parts Kits

Remove and Install Steering Column and Valve

Disassemble and Inspect Steering Valve

Assemble Steering Valve

Remove and Install Steering Cylinder—2WD Axle

Disassemble, Inspect, and Assemble Steering Cylinder—2WD Axle

Disassemble, Inspect and Assemble Steering Cylinder—MFWD Axle

Remove, Inspect and Install Tie Rod Assembly—2WD Axle

Remove, Inspect and Install Tie Rod Assembly—MFWD Axle

Inspect and Replace Steering Hydraulic Lines—3-Cylinder Tractors Without Cab

Inspect and Replace Steering Hydraulic Lines—4-Cylinder Tractors Without Cab

Inspect and Replace Steering Hydraulic Lines—3- And 4-Cylinder Tractors With Cab

Group 10: Brake Repair

Service Equipment and Tools

Other Material

Specifications

Remove and Install Brake Valve (S.N. —438002)

Disassemble and Inspect Brake Pedals and Valve (S.N. —438002)

Brake Valve Cross Section (S.N. —438002)

Assemble Brake Valve (S.N. —438002)

Remove and Install Brake Valve (S.N. 438003— )

Disassemble and Inspect Brake Pedals and Valve (S.N. 438003— )

Brake Valve Cross Section (S.N. 438003— )

Assemble Brake Valve (S.N. 438003— )

Remove and Inspect Brakes

Install Brakes

Inspect and Replace Brake Hydraulic Lines

Inspect and Replace Brake Hydraulic Lines

Section 70: Hydraulic Repair

Group 05: Hydraulic Pump and Filter

Service Equipment and Tools

Specifications

Service Parts Kits

Remove, Inspect, and Install Hydraulic Oil Pick-Up Screen

Remove and Install Hydraulic Pump—5320N

Remove Hydraulic Pump External Components—5320N

Disassemble and Inspect Hydraulic Pump—5320N

Assemble Hydraulic Pump—5320N

Install Hydraulic Pump External Components—5320N

Remove and Install Hydraulic Pump—5420N and 5520N

Remove Large Capacity Hydraulic Pump External Components—5420N and 5520N

Disassemble and Inspect Large Capacity Hydraulic Pump—5420N and 5520N

Assemble Large Capacity Hydraulic Pump—5420N and 5520N

Install Large Capacity Hydraulic Pump External Components—5420N and 5520N

Remove and Install Hydraulic Oil Filter/Manifold

Inspect and Replace Hydraulic Supply/Return Lines—Tractors Without Cab

Inspect and Replace Hydraulic Supply/Return Lines—Tractors With Cab

Group 06: Hydraulic Oil Cooler

Remove, Inspect, and Install Hydraulic Oil Cooler

Group 10: Rockshaft

Service Equipment and Tools

Other Material

Specifications

Service Parts Kits

Inspect and Repair Rockshaft Control Lever Assembly—Tractors Without Cab

Inspect and Repair Rockshaft Control Lever Assembly—Tractors With Cab

Inspect and Repair Rockshaft Control Linkage

Inspect and Repair Draft Sensing Support Assembly

Replace Main Relief Valve

Replace Rockshaft Surge Relief Valve

Remove, Inspect, and Install Rate-of-Drop Valve

Replace Rockshaft Control Valve

Replace Rockshaft End Cover

Remove and Install Rockshaft Case

Remove, Inspect, and Install Rockshaft Lift Arms

Remove, Inspect, and Install Rockshaft Piston and Cylinder

Group 15: Selective Control Valve (SCV)

Other Material

Specifications

Service Parts Kits

Remove and Install Selective Control Valve (SCV)—Tractors Without Cab

Remove and Install Selective Control Valve (SCV)—Tractors With Cab

Disassemble, Inspect, and Assemble Selective Control Valve (SCV)

Inspect and Replace SCV-to-Rear Coupler Hydraulic Lines—Tractors Without Cab

Inspect and Replace SCV-to-Rear Coupler Hydraulic Lines—Tractors With Cab

Group 20: Hydraulic Power Beyond

Specifications

Power Beyond—Early Model Tractors Without Cab

Power Beyond Quick Coupler—Later Model Tractor

Power Beyond Motor Control Hydraulic Line Routing—Later Model Tractor

Section 80: Miscellaneous Repair

Group 05: Front Axle—2WD

Service Equipment and Tools

Specifications

Remove and Install Front Axle—2WD

Inspect and Replace Pivot Pin and Bushings—2WD Axle

Remove and Install Spindle Assembly—2WD Axle

Inspect and Replace Spindle Shaft Bushings—2WD Axle

Group 10: Wheels

Service Equipment and Tools

Specifications

Inspect and Replace Front Wheel Bearings—2WD Axle

Group 15: Fenders

Specifications

Remove and Install Fenders—Tractors without Cab

Group 20: 3-Point Hitch

Specifications

Inspect and Repair Draft Links

Inspect and Repair Adjustable Lift Links

Inspect and Repair Center Link

Remove and Install Drawbar and Support

Section 90: Operator Station Repair

Group 05: Seat and Support

Specifications

Remove and Install Seat and Support—Without Cab

Remove and Install Seat and Support—With Cab

Group 10: ROLL-GARDROLL-GARD is a trademark of Deere & Company.

Specifications

Remove and Install ROLL-GARD ROLL-GARD is a trademark of Deere & Company.

Group 15: Rear Bar

Specifications

Remove and Install Rear Bar—Without Cab

Group 20: Cab Components

Other Material

Essential Tools

Specifications

Remove Cab

Install Cab

Remove and Install Cab Outer Roof

Remove and Install Lower Front Windows

Remove and Install Rear Side Cab Windows

Remove and Install Rear Cab Window

Remove and Install Front Windshield

Remove and Install Cab Doors

Remove, Inspect, and Install Cab Recirculating/Fresh Air Filter

Group 25: Air Conditioning System

Essential Tools

Service Equipment and Tools

Other Material

Service Parts Kits

Hose and Tubing O-Ring Connection Torques

Recover/Recycle Air Conditioning Refrigerant

Replace Air Conditioning Receiver-Dryer

Remove, Inspect, and Install Air Conditioning Condenser

Remove, Inspect, and Install Air Conditioning Compressor

Test Volumetric Efficiency of Compressor

Test Compressor Shaft Seal Leakage

Disassemble and Assemble Compressor Clutch

Disassemble, Inspect, and Assemble Compressor

Check Compressor Clutch Hub Clearance

Inspect Compressor Manifold

Remove and Install Compressor Relief Valve

Remove Evaporator/Heater Core Housing

Install Evaporator/Heater Core Housing

Remove and Install Blower Motors

Remove Evaporator/Heater Core

Leak Test Evaporator/Heater Core

Install Evaporator/Heater Core

Service Expansion Valve

Expansion Valve Bench Test

Refrigerant Oil Information

Check Compressor Oil Charge

Determine Correct Refrigerant Oil Charge

Add Refrigerant Oil to System

System Information

Flush Air Conditioning System

Evacuate Air Conditioning System

Charge Air Conditioning System

Group 30: Heating System

Remove Heater Control Valve

Leak Test Heater Control Valve

Install Heater Control Valve

Section 210: Operational Checkout Procedures

Group 10: Operational Checkout Procedures

Operational Checkout Procedure Information

Engine Oil Level and Condition Check

Coolant Level and Condition Check

Transmission and Hydraulic Oil Check

3—Cylinder Fan and V-Belt Check

4—Cylinder Fan and Serpentine Belt Check

Compressor Belt Check

Fuel System Check

Air Intake System Check

Electrical System Check

Hydraulic System Check

MFWD Oil Check

MFWD Differential Oil Check

Indicator Lamps Check

Cab Blower Motor Check

A/C Compressor Clutch Check

Engine Start Check

Transmission Neutral Start Check

PTO Neutral Start Check

Engine Fast and Slow Idle Operation

Power Steering Check

Differential Lock Check

PTO Engagement Check

Clutch Check

Transmission Shift Check

Range Lever Shift Check

MFWD Drive Check

Park Brake Check

Rockshaft Check—Tractors Without Cab

Rockshaft Check—Tractors With Cab

Selective Control Valve Check—Tractors Without Cab

Selective Control Valve Check—Tractors With Cab

A/C Operational Check

Cab Heater Valve Check

Miscellaneous Checks

Section 220: Engine Operation, Tests and Adjustments

Group 05: Component Location

Component Location Information

3-Cylinder Engine External Components—Left-Hand Side

3-Cylinder Engine External Components—Right-Hand Side

4-Cylinder Engine External Components—Left-Hand Side

4-Cylinder Engine External Components—Right-Hand Side

Group 10: Theory of Operation

Theory of Operation Information

Engine Lubrication System Operation

Engine Cooling System Operation—3-Cylinder

Engine Cooling System Operation—4-Cylinder

Group 15: Diagnosis, Tests and Adjustments

Diagnostic Information

Engine Turns Over but Will Not Start or Starts Hard

Engine Runs Irregularly or Stalls Frequently

Engine Runs Rough

Engine Has Low Power

Engine Smokes—Black or Grey

Engine Smokes Excessively—White

Engine Uses Excess Fuel

Engine Has Excess Noise or Vibration

Engine Uses Excess Oil or Smokes Blue

Engine Has Low Oil Pressure

Engine Coolant Operating Temperature Incorrect

Oil in Coolant or Coolant in Oil

Radiator Bubble Test

Cooling System Test

Radiator Cap Pressure Test

Engine Oil Pressure Test

Cylinder Compression Pressure Test

Fuel Shut-Off Solenoid Check

Throttle Lever Adjustment

Slow Idle Adjustment

Fast Idle Adjustment

Injection Pump Timing Adjustment

Check and Adjust Valve Clearance

Fan/Alternator Drive Belt Adjustment—3-Cylinder without Cab

Compressor Drive Belt Adjustment—3-Cylinder with Cab

Turbocharger Boost Pressure Test—5320N and 5520N

Bleed Fuel System

Section 230: Fuel/Air Operation, Tests and Adjustments

Group 05: Component Location

Component Location Information

Fuel System Components—Tractors Without Cab

Fuel System Components—Tractors With Cab

Air Intake System Components—Without Turbocharger

Air Intake System Components—With Turbocharger

Group 10: Theory of Operation

Theory of Operation Information

Fuel System Operation—Tractors Without Cab

Fuel System Operation—Tractors With Cab

Fuel Filter/Priming Pump Operation

Fuel Filter/Priming Pump Operation

Fuel Injection Nozzle Operation

Fuel Injection Nozzle Operation

Air Intake System Operation—Without Turbocharger

Air Intake System Operation—With Turbocharger

Air Intake System Operation—With Turbocharger

Turbocharger Operation

Group 15: Diagnosis, Tests and Adjustments

Diagnostic Information

Section 240: Electrical System Operation, Tests & Adjust

Group 05: Component Location

Component Location Information

Engine Electrical Components

Dash Electrical Components

Dash Electrical Components—Tractors Without Cab (S.N. 438003— )

Tractor Electrical Components—3-Cylinder Tractor Without Cab

Tractor Electrical Components—4-Cylinder Tractor Without Cab

Tractor Electrical Components—Tractor With Cab

Cab Control Panel and Electrical Components

Group 10: Theory of Operation

Theory of Operation Information

Fuse Block and Fuses—Tractors Without Cab

Fuse/Relay Block Assembly—Tractors Without Cab (S.N. 438003— )

Fuse Block and Fuses—Cab Tractors

Cab Fuse Block and Fuses

Relays

Starting System Operation—Normal

Starting System Operation—Bypass Attempt

Air Intake Heater System Operation

Air Intake Heater System Operation—Tractors Without Cab (S.N. 438003— ) (Optional)

Charging System Operation

Charging System Operation—Tractors Without Cab (S.N. 438003— )

Turn Signal System Operation—Tractors Without Cab

Turn Signal System Operation—Tractors Without Cab (S.N. 438003— )

Turn Signal System Operation—Tractors With Cab

Warning Lights and Tail Light System Operation—Tractors Without Cab

Warning Lights System Operation—Tractors Without Cab (S.N. 438003— )

Tail Light System Operation—Tractors Without Cab (S.N. 438003— )

Warning Lights and Tail Lights System Operation—Tractors With Cab

Headlights and Instrument Lights System Operation

Headlights and Instrument Lights System Operation—Tractors Without Cab (S.N. 438003— )

Rear Flood Light Operation—Tractors Without Cab

Rear Work Light Operation—Tractors Without Cab (S.N. 438003— )

Flood Light System Operation—Tractors With Cab

Tachometer and Hour Meter System Operation

Tachometer and Hour Meter System Operation—Tractors Without Cab (S.N. 438003— )

Fuel Gauge System Operation—Tractors Without Cab

Fuel Gauge System Operation—Tractors Without Cab (S.N. 438003— )

Fuel Gauge System Operation—Tractors With Cab

Temperature Gauge System Operation

Temperature Gauge System Operation—Tractors Without Cab (S.N. 438003— )

PTO Warning System Operation

PTO Warning System Operation—Tractors Without Cab (S.N. 438003— )

Air Filter Restriction Indicator Operation

Air Filter Restriction Indicator Operation—Tractors Without Cab (S.N. 438003— )

Optional Horn Operation

Optional Horn Operation—Tractors Without Cab (S.N. 438003— )

Accessory Relay and Trailer Connection Operation

Accessory Relay and Trailer Connection and Junction Block Operation (S.N. 438003— )

Blower Motor System Operation—Tractors With Cab

A/C Compressor System Operation—Tractors With Cab

Front Wiper/Washer System Operation—Tractors With Cab

Rear Wiper/Washer System Operation—Tractors With Cab

Dome Light Operation—Tractors With Cab

Group 15: Diagnosis, Test and Adjust

Diagnostic Information

Wire Color Chart

Starting System Test Points—Normal Operation

Starting System Test Points—Normal Operation—Tractors Without Cab (S.N. 438003— )

Starting System Test Points—Bypass Attempt

Starting System Test Points—Bypass Attempt—Tractors Without Cab (S.N. 438003— )

Air Intake Heater Test Points

Air Intake Heater Test Points—Tractors Without Cab (S.N. 438003— )

Charging System Test Points

Charging System Test Points—Tractors Without Cab (S.N. 438003— )

Lighting System Test Points—Left Turn Signals (Tractors Without Cab)

Lighting System Test Points—Right Turn Signals (Tractors Without Cab)

Lighting System Test Points—Turn Signals—Tractors Without Cab (S.N. 438003— )

Lighting System Test Points—Left Turn Signals (Tractors With Cab)

Lighting System Test Points—Right Turn Signals (Tractors With Cab)

Lighting System Test Points—Warning Lights

Lighting System Test Points—Warning Lights—Tractors Without Cab (S.N. 438003— )

Lighting System Test Points—Rear Flood Light—Tractors Without Cab (S.N. —438002)

Lighting System Test Points—Rear Work Light—Tractors Without Cab (S.N. 438003— )

Lighting System Test Points—Flood Lights (Tractors With Cab)

Lighting System Test Points—Dome Light (Tractors With Cab)

Lighting System Test Points—Tail Light—Tractors Without Cab (S.N. —438002)

Lighting System Test Points—Tail Light—Tractors Without Cab (S.N. 438003— )

Lighting System Test Points—Tail Light (Tractors With Cab)

Lighting System Test Points—Headlights and Instrument Lights

Lighting System Test Points—Headlights and Instrument Lights—Tractors Without Cab (S.N. 438003— )

Instrument Panel System Test Points—Hour Meter and Tachometer

Instrument Cluster Test Points—Hour Meter and Tachometer—Tractors Without Cab (S.N. 438003— )

Instrument Panel System Test Points—Fuel Gauge—Tractors Without Cab (S.N. —438002)

Instrument Cluster Test Points—Fuel Gauge—Tractors Without Cab (S.N. 438003— )

Instrument Panel System Test Points—Fuel Gauge (Tractors With Cab)

Instrument Panel System Test Points—Temperature Gauge

Instrument Cluster Test Points—Temperature Gauge—Tractors Without Cab (S.N. 438003— )

Instrument Panel System Test Points—Oil Pressure

Instrument Cluster Test Points—Oil Pressure—Tractors Without Cab (S.N. 438003— )

PTO Warning System Test Points

PTO Warning System Test Points—Tractors Without Cab (S.N. 438003— )

Air Filter Restriction Test Points

Air Filter Restriction Test Points—Tractors Without Cab (S.N. 438003— )

Optional Horn Test Points

Optional Horn Test Points—Tractors Without Cab (S.N. 438003— )

Accessory Relay and Trailer Connector Test Points

Accessory Relay and Trailer Connector and Junction Block Test Points—Tractors Without Cab (S.N. 438003— )

Blower Motor Test Points (Tractors With Cab)

A/C Compressor Clutch Coil Test Points (Tractors With Cab)

Front Wiper/Washer Test Points (Tractors With Cab)

Convenience Outlet Test Points (Tractors With Cab)

Battery Voltage and Specific Gravity Tests

Charge Battery

Battery Load Test

Starter Amp Draw/RPM Test

Starter No-Load Amp Draw/RPM Test

Alternator/Regulator Test

Starter Solenoid Test

Starter Relay Test

Key Switch Test

Plug-In Relay Test

Diode Pack Test

Fuse Test

Neutral Start Switch Test

PTO Switch Test

PTO Seat Switch Test

Light Switch Test

Turn Signal Controller Test

Turn Signal Switch Test (S.N. 438003— )

Fuel Shut-Off Solenoid Test

Blower Switch Test

Blower Motor Resistors

A/C Thermostatic Control Switch Test

Front Wiper/Washer Switch Test

Door Switch Test

Dome Light Switch Test

Group 20: Wiring Schematics

Schematic Information

Component Identification Table

Electrical Schematic—Without Cab (S.N. —438002)

Electrical Schematic—Without Cab (S.N. 438003— )

Electrical Schematic—With Cab

Section 250: Power Train Operation, Tests & Adjustments

Group 05: Component Location

Component Location Information

Power Train Components—Tractors Without Cab

Power Train Components—Tractors With Cab

Clutch Components

Synchronized Reverser Components

Transmission Components

Park Brake Components

Final Drive Components

Rear PTO Components

Group 10: Theory of Operation

Theory of Operation Information

Clutch Operation

Synchronized Reverser Operation

Synchronized Reverser Power Flow

Transmission Lubrication System

Transmission Power Flow—Gear Shift

Transmission Gear Shift Synchronizer Operation

Transmission Power Flow—Range Shift

Park Brake Operation

Differential Power Flow

Differential Lock Operation

Final Drive Operation

Rear PTO Operation

Rear PTO Operation

Mechanical Front Wheel Drive (MFWD) Operation

Group 15: Diagnosis, Tests and Adjustments

Diagnostic Information

Isolate the Problem Area

Traction Clutch Slips

Traction Clutch Dragging

Traction Clutch Does Not Engage

Traction Clutch Grabs

Traction Clutch Squeaks

Traction Clutch Does Not Release

Traction Clutch Chatters

Traction Clutch Rattles

Traction Clutch Engagement Is Noisy

Excessive Vibration in Traction Clutch

Clutch Pedal Does Not Return

Clutch Pedal Loose

Clutch Pedal Pulsates

Jerky or Rough Transmission of Power

Low Transmission Oil Level (Excessive Oil Leakage)

Gears Clash, Shifts Hard, or Will Not Engage

Two Speeds Engage Together

Transmission Will Not Stay in Gear

Transmission Noisy

PTO Noisy

PTO Hard to Engage

PTO Will Not Operate

PTO Will Not Stay Engaged

Excessive Differential Noise

Differential Does Not Work

No Differential Lock

Differential Chatters

Axle Noise

Axle Shaft Will Not Turn

MFWD Lever is Hard to Engage

MFWD Lever Will Not Stay in “ON” Position

Noisy Front Wheel Drive Operation

Clutch Pedal Free Play Adjustment—Tractors Without Cab

Clutch Pedal Free Play Adjustment—With Cab

PTO Clutch Lever Adjustment

Park Brake Band Adjustment

Park Brake Linkage Adjustment

PTO 540/540E Lever and Linkage Adjustment—Tractors Without Cab

PTO 540/540E Lever and Linkage Adjustment—Tractors With Cab

Forward/Reverse Selector Lever Adjustment

Section 260: Steering and Brake Operation, Test & Adjust

Group 05: Component Location

Component Location Information

Steering System Components—5320N Tractors Without Cab

Steering System Components—5420N, 5520N and Tractors With Cab

Brake System Components

Group 10: Theory of Operation

Theory of Operation Information

Steering System Operation—5320N Tractors Without Cab

Steering System Operation—5420N, 5520N and Tractors With Cab

Steering Valve Operation—Neutral and Manual Turning

Steering Valve Operation—Power Turning

Brake System Operation

Brake System Operation

Brake Valve Operation (S.N. —438002)

Brake Valve Operation (S.N. 438003— )

Group 15: Diagnosis, Tests and Adjustments

Specifications

Diagnostic Information

Isolate the Problem—Steering System

Steering Sluggish or Loss of Steering

Isolate the Problem—Brake System

Excessive Brake Pedal Leak-Down

Excessive Brake Chatter

Steering Pump Flow Test

Steering Valve Relief Test

Steering Cylinder Leakage Test

Steering Valve Leakage Test

Toe-In/Toe-Out Check and Adjustment—2WD Axle

Toe-In/Toe-Out Check and Adjustment—MFWD Axle

Steering Stop Adjustment—2WD Axle

Steering Stop Adjustment—MFWD Axle

Brake Pedal Adjustment (S.N. —438002)

Brake Pedal Adjustment (S.N. 438003— )

Bleed Brake System

Adjust Brake Drag

Section 270: Hydraulic System Operation, Tests, and Adjustments

Group 05: Component Location

Component Location Information

Hydraulic System Components—Without Oil Cooler

Hydraulic System Components—With Oil Cooler

Selective Control Valve (SCV) Components—Tractors Without Cab

Selective Control Valve (SCV) Components—Tractors With Cab

Group 10: Theory of Operation

Theory of Operation Information

Hydraulic System Operation—Tractors Without Cab

Hydraulic System Operation—Tractors With Cab

Hydraulic Filter Operation

Hydraulic Pump Operation

Rockshaft Control Valve Operation—Two Flow Regulator Valves

Rockshaft Control Valve Operation—Neutral Position

Rockshaft Control Valve Operation—Raise Position

Rockshaft Control Valve Operation—Lower Position

Surge Relief Valve Operation

Relief Valve Operation

Rate-of-Drop Valve Operation—Full Open

Rate-of-Drop Valve Operation—Partially Open

Rate-of-Drop Valve Operation—Full Closed

Rockshaft Draft-Sensing Operation

Selective Control Valve Operation—Neutral Position

Selective Control Valve Operation—Extend and Retract Positions

Selective Control Valve Operation—Boom Spool Float Position

Quick Disconnect Coupler Operation

Group 15: Diagnosis

Diagnostic Information

Preliminary Hydraulic System Inspection

Hydraulic Oil Warm-Up Procedure

Entire Hydraulic System Fails to Function/No Hydraulic Pump Output

Insufficient Pump Delivery

Hydraulic Functions Too Slow

Excessive Pump Pressure

Slow Hydraulic Pump Response

Excessive Pump Noise During Operation

Rockshaft Does Not Lift or Lifts Slowly

Rockshaft Does Not Lower or Lowers Slowly

Neutral Position Unstable, Rockshaft Drops after Engine Shut Down

SCV Control Lever Does Not Return to Neutral Position

Remote Cylinder Does Not Extend or Retract

Remote Cylinder Settles Under Load

Remote Cylinder Operates Too Fast or Too Slow

Group 20: Hydraulic Tests

Specifications

Hydraulic System Tests

Pump Flow Test

Relief Valve Test

Selective Control Valve (SCV) Leakage Test

Rockshaft Leakage Test

Rockshaft Lift Cycle Test

Group 25: Adjustments

Specifications

Rockshaft Control Lever Friction Adjustment

Rockshaft Draft-Sensing and Position-Sensing Linkage Adjustment

Rockshaft Draft-Sensing Feedback Linkage Adjustment—Tractors Without Cab

Rockshaft Draft-Sensing Feedback Linkage Adjustment—Tractors With Cab

Relief Valve Adjustment—Tractors Without Cab

Relief Valve Adjustment—Tractors With Cab

Group 30: Hydraulic Schematics

Hydraulic Circuit Symbols

Hydraulic Schematic (S.N. —438002)

Hydraulic Schematic (S.N. 438003—)

Power Beyond Hydraulic Schematic

Section 290: Operator Station

Group 05: Component Location

Air Conditioning System Components

Group 10: Theory of Operation

Refrigerant R134a

HVAC System Air Flow

Air Conditioning System Cycle

Compressor

Condenser

Receiver-Dryer

Expansion Valve

A/C Temperature Control Switch

Evaporator

Heater Temperature Control Knob

High and Low Pressure Switches

Group 15: Diagnosis, Tests, and Adjustments

Special or Essential Tools

Service Equipment and Tools

Other Material

Specifications

Section 299: Dealer Fabricated Tools

Group 00: Dealer Fabricated Tools

DFLV1A Final Drive Turning Tool

DFRW20—Compressor Holding Fixture

John Deere Tractors 5320N, 5420N, 5520N Diagnostics & Repair Service Manual (TM1872)