John Deere 5105 5205 Utility Tractors Repair Technical Manual TM1792

[Martin Welker]

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John Deere 5105 5205 Utility Tractors Repair Technical Manual TM1792
Size: 20.11 MB
Format: PDF
Language: English
Brand: John Deere
Type of Machine: Utility Tractors
Type of Manual: Repair Technical Manual
Model: John Deere 5105 5205 Utility Tractors
Part Number: TM1792
Number of Pages: 894 Pages

Contents:
General Information
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
General Specifications
Machine Specifications
Drain and Refill Capacities
Machine Dimensions
Ground Speed Estimates
Service Recommendations for O-Ring Boss Fittings
Service Recommendations for Flat Face O-Ring Seal Fittings
Metric Bolt and Cap Screw Torque Values
Unified Inch Bolt and Cap Screw Torque Values
Fuel and Lubricants
Diesel Fuel
Fuel Storage
Do Not Use Galvanized Containers
Fill Fuel Tank
Diesel Engine Oil
Engine Coolant
Liquid Coolant Conditioner
Transmission and Hydraulic Oil
MFWD Gear Oil
Grease (Specific Application)
Grease
Alternative and Synthetic Lubricants
Lubricant Storage
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
Features and Accessories
Features and Accessories
Standard Features
Factory Installed Optional Equipment
Field Installed Optional Kits and Accessories
Engine Repair
Engine
Service Equipment and Tools
Specifications
John Deere Engine Repair—Use CTM8
Remove Engine
Install Engine
Cooling System
Specifications
Engine Water Pump Repair—Use CTM8
Remove, Inspect and Install Radiator
Replace Thermostat
Fuel and Air Repair
Fuel System
Specifications
Injection Pump, Nozzle and Governor Repair—Use CTM8
Remove, Inspect and Install Fuel Tank
Replace Fuel Filter
Remove and Install Fuel Filter/Primer Pump Assembly
Air Intake System
Remove, Inspect, and Install Air Cleaner Elements
Speed Control Linkage
Inspect and Repair Speed Control Linkage
Electrical Repair
Battery, Starter and Alternator
Starter Repair—Use CTM77
Remove and Install Battery
Remove and Install Starter
Replace Alternator/Regulator
Electrical System Components
Service Equipment and Tools
Other Material
Replace Air Filter Restriction Sensor
Replace Coolant Temperature Sender
Replace Engine Speed Sensor
Replace Engine Oil Pressure Sensor
Replace Key Switch
Replace Light Switch
Replace Turn Signal Controller
Replace Instrument Panel
Replace Rear PTO Switch
Replace Neutral Start Switch
Replace Seat Switch
Replace Fuel Level Sender
Wiring Harness
Special or Essential Tools
Service Parts Kits
Remove Connector Body from Blade Terminals
Replace WEATHER PACK™ Connector
Install WEATHER PACK™ Contact
Replace Tractor Wiring Harness
Power Train Repair
Clutch Housing
Specifications
Separate Engine from Transmission Housing
Install Engine to Transmission Housing
Inspect and Repair Clutch Pedal and Linkage
Clutch Assembly
Other Material
Essential Tools
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
Transmission
Other Material
Specifications
Remove, Inspect and Repair Gear Shift Lever And Cover
Remove, Inspect and Install Range and Reverse Shift Lever
Remove Transmission
Disassemble and Inspect Transmission
Assemble Transmission
Install Transmission
Disassemble, Inspect and Assemble Shift Shaft Assemblies
Disassemble, Inspect, and Assemble Transmission Top Driven Shaft
Disassemble, Inspect and Assemble Range Reduction Shaft
Disassemble, Inspect and Assemble Driven Shaft
Disassemble, Inspect and Assemble Traction Clutch Driven Shaft
Disassemble, Inspect and Assemble Synchronizer
Rear PTO
Other Material
Specifications
Remove, Inspect and Install Rear PTO Lever and Linkage
Remove and Install Rear PTO Drive Shaft Assembly
Disassemble, Inspect and Assemble Rear PTO Drive Shaft Assembly
Differential
Essential Tools
Other Material
Specifications
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
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
Mechanical Front Wheel Drive
Essential Tools
Other Material
Specifications
Inspect and Repair MFWD Lever and Linkage
Remove and Install MFWD Drop Gearbox
Disassemble and Inspect MFWD Drop Gearbox
Remove, Inspect and Install MFWD Drive Shaft
Remove and Install MFWD Axle Housing Assembly
Remove, Inspect and Install MFWD Axle Supports
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
Steering and Brake Repair
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
Remove and Install Steering Cylinder—MFWD 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—Tractor With 2WD
Inspect and Replace Steering Hydraulic Lines—Tractor With MFWD
Brake Repair
Other Material
Specifications
Remove and Install Brake Pedals and Linkage
Remove and Install Park Brake Lever and Linkage
Remove and Inspect Brakes
Install Brakes
Hydraulic Repair
Hydraulic Pump and Filter
Specifications
Service Parts Kits
Remove, Inspect, and Install Hydraulic Oil Pick-Up Screen
Remove and Install Hydraulic Pump
Remove Hydraulic Pump External Components
Disassemble and Inspect Hydraulic Pump
Assemble Hydraulic Pump
Install Hydraulic Pump External Components
Remove and Install Hydraulic Oil Filter/Manifold
Inspect and Replace Hydraulic Supply and Suction/Return Lines
Rockshaft
Other Material
Specifications
Remove, Inspect, and Install Rockshaft Control Lever Assembly
Remove, Inspect, and Install Rockshaft Control Lever Support Assembly
Remove, Inspect and Install Rockshaft Control Linkage
Remove, Inspect, and Install Draft Sensing Support Assembly
Remove and Install Inlet Valve
Replace Main Relief Valve
Remove, Inspect and Install Rate-of-Drop Valve
Replace Rockshaft Control Valve
Remove and Install Rockshaft Case
Remove, Inspect and Install Rockshaft Lift Arms
Remove, Inspect and Install Rockshaft Piston and Cylinder
Selective Control Valve (SCV)
Other Material
Specifications
Remove and Install Regenerative Selective Control Valve (SCV)
Disassemble, Inspect and Assemble Regenerative Selective Control Valve (SCV)
Inspect and Replace Hydraulic Lines—Regenerative Selective Control Valve (SCV)
Remove and Install Float Selective Control Valve (SCV)
Disassemble, Inspect and Assemble Float Selective Control Valve (SCV)
Inspect and Replace Hydraulic Lines—Float Selective Control Valve (SCV)
Hydraulic Mid Mount Coupler
Other Material
Specifications
Remove and Install Mid Mount Control Valve
Disassemble, Inspect and Assemble Mid Mount Control Valve
Inspect and Replace Hydraulic Hoses—Mid Mount Coupler
Remove, Inspect and Install Joystick and Linkage—Mid Mount Coupler
Disassemble, Inspect, and Assemble Joystick—Mid Mount Coupler
Miscellaneous Repair
Front Axle—2WD
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
Wheels
Specifications
Inspect and Replace Front Wheel Bearings
3-Point Hitch
Specifications
Inspect and Repair Fixed Draft Links
Inspect and Repair Telescoping Draft Links
Inspect and Repair Standard Lift Link
Inspect and Repair Adjustable Lift Link
Inspect and Repair Center Link
Remove and Install Drawbar and Support
Operator Station Repair
Seat and Support
Specifications
Remove and Install Seat and Support
ROLL-GARD™
Specifications
Remove and Install ROLL-GARD™
Operator Platform
Specifications
Remove and Install Right-Side Platform
Remove and Install Left-Side Platform and Step
Fenders
Remove and Install Fenders
Operational Checkout Procedures
Operational Checkout Procedures
Operational Checkout Procedure Information
Engine Oil Level and Condition Check
Coolant Level and Condition Check
Transmission and Hydraulic Oil Check
Fan and Belt Check
Fuel System Check
Air Intake System Check
Electrical System Check
Hydraulic System Check
MFWD Oil Check
Indicator Lamps 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
Brake Check
Rockshaft Check
Selective Control Valve Check
Mid-Mount Coupler Control Valve Check—(Optional Equipment)
Miscellaneous Checks
Engine Operation, Tests and Adjustments
Component Location
Component Location Information
Engine External Components—Left-Hand Side
Engine External Components—Right-Hand Side
Theory of Operation
Theory of Operation Information
Engine Lubrication System Operation
Engine Cooling System Operation
Diagnosis, Tests and Adjustments
Specifications
Essential Tools
Diagnostic Information
Engine Turns Over But Will Not Start or Starts Hard
Engine Runs Irregularly or Stalls Frequently
Engine Runs Rough
Engine 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
Valve Clearance Adjustment
Fan/Alternator Drive Belt Adjustment
Bleed Fuel System
Fuel/Air Operation, Tests and Adjustments
Component Location
Component Location Information
Fuel System Components
Air Intake System Components
Theory of Operation
Theory of Operation Information
Fuel System Operation
Fuel Filter/Priming Pump Operation
Fuel Injection Nozzle Operation
Air Intake System Operation
Diagnosis, Tests and Adjustments
Diagnostic Information
Fuel/Air Diagnosis, Tests and Adjustments
Electrical System Operation, Tests & Adjust
Component Location
Component Location Information
Engine Electrical Components—Right Hand Side
Engine Electrical Components—Left Hand Side
Dash And Center Control Console Electrical Components
Tractor Electrical Components—5105-5205
Theory of Operation
Theory of Operation Information
Fuse Block and Fuses
Relays
Starting System Operation—Normal
Starting System Operation—Bypass Attempt
Manifold Heater System Operation
Charging System Operation
Lighting System Operation—Turn Signals And Enhanced Tail Lights
Lighting System Operation—Warning Lights
Lighting System Operation—Tail Lights
Lighting System Operation—Headlights and Instrument Lights
Instrument Panel System Operation—Tachometer/Hour Meter
Instrument Panel System Operation—Fuel Gauge
Instrument Panel System Operation—Temperature Gauge
PTO Warning System Operation
Air Filter Restriction Indicator Operation
7-Pin Trailer Outlet Connector Operation
Optional Horn Operation
Optional Rear Work Light
Diagnosis, Test and Adjust
Diagnostic Information
Wire Color Chart
Starting System Test Points—Normal Operation
Starting System Test Points—Bypass Attempt
Manifold Heater Test Points
Charging System Test Points
Lighting System Test Points—Turn Signals And Enhanced Tail Lights
Lighting System Test Points—Warning Lights
Lighting System Test Points—Rear Flood Light (Optional Equipment)
Lighting System Test Points—Headlights and Instrument Lights
Instrument Panel System Test Points—Tachometer/Hourmeter
Instrument Panel System Test Points—Fuel Gauge
Instrument Panel System Test Points—Temperature Gauge
Instrument Panel System Test Points—Oil Pressure
PTO Warning System Test Points
Air Filter Restriction Test Points
Optional Horn Test Points
Accessory Relay and Trailer Connector Test Points
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
Mini Plug-In Relay
Diode Pack Test
Fuse Test
Neutral Start Switch Test
PTO Switch Test
PTO Seat Switch Test
Light Switch Test
Turn Signal Controller Test
Fuel Shut-Off Solenoid Test
Wiring Schematics
Schematic Information
Component Identification Table
5105 and 5205 Electrical Schematic Legend
5105 and 5205 Electrical Schematic Legend
Power Train Operation, Tests & Adjustments
Component Location—Power Train
Component Location Information
Power Train Components
Clutch Components
Transmission Components
Final Drive Components
Rear PTO Components
Theory of Operation—Transmission
Theory of Operation Information
Clutch Operation
Transmission Lubrication System
Transmission Power Flow—Gear Shift
Transmission Power Flow—Range Shift and Reverse
Transmission Operation—Reverse and A Range Synchronizer
Rear PTO Operation
Differential Power Flow
Differential Lock Operation
Final Drive Operation
Mechanical Front Wheel Drive (MFWD) Operation
Diagnosis, Tests and Adjustments—Power Train
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
PTO Clutch Slips
PTO Clutch Dragging
PTO Clutch Does Not Engage
Excessive Differential Noise
Differential Does Not Work
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
PTO Clutch Lever Adjustment
Steering and Brake Operation, Test & Adjust
Component Location
Component Location Information
Steering System Components
Brake System Components
Theory of Operation
Theory of Operation Information
Steering System Operation
Steering Valve Operation—Neutral and Manual Turning
Steering Valve Operation—Power Turning
Brake System Operation
Diagnosis, Tests and Adjustments
Specifications
Diagnostic Information
Isolate the Problem—Steering System
Steering Sluggish or Loss of Steering
Isolate the Problem—Brakes
Steering Pump Flow Test
Steering Valve Relief Test
Steering Cylinder Leakage Test
Steering Valve Leakage Test
Toe-In Check and Adjustment—Standard Axle
Toe-In Check and Adjustment—MFWD
MFWD Steering Stop Adjustment
Brake Pedal Adjustment
Hydraulic System Operation, Test & Adjust
Component Location
Component Location Information
Hydraulic System Components
Selective Control Valve Components
Power Beyond Control Valve Components
Mid Mount Control Valve Components
Theory of Operation
Theory of Operation Information
Hydraulic System Operation
Hydraulic Filter Operation
Hydraulic Pump Operation
Rockshaft Control Valve Operation—Neutral Position
Rockshaft Control Valve Operation—Raise Position
Rockshaft Control Valve Operation—Lower Position
Surge 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
Float Selective Control Valve Operation—Neutral Position
Regenerative Selective Control Valve Operation—Neutral Position
Float Selective Control Valve Operation—Extend Position
Regenerative Selective Control Valve Operation—Extend Position
Float Selective Control Valve Operation—Retract Position
Regenerative Selective Control Valve Operation—Retract Position
Float Selective Control Valve Operation— Float Position
Regenerative Selective Control Valve Operation—Regenerative Position
Quick Disconnect Coupler Operation
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—Float SCV
SCV Lever Does Not Remain in Detent Position—Float SCV
SCV Lever Does Not Return to Neutral Position—Regenerative SCV
Remote Cylinder Does Not Extend or Retract
Remote Cylinder Settles Under Load
Remote Cylinder Operates Too Fast or Too Slow
Mid Mount Control Valve Joystick Lever Does Not Return to Neutral Position
Hydraulic Tests—Without SCV
Hydraulic System Tests—Without SCV
Pump Flow Test—Without SCV
Main Relief Valve Test—Without SCV
Hydraulic Tests—With SCV
Hydraulic System Tests—With SCV
Pump Flow Test—With SCV
Main Relief Valve Test—With SCV
SCV Leakage Test
Hydraulic Tests—With Mid Mount Control Valve
Hydraulic System Tests—With Mid Mount Control Valve
Pump Flow Test—With Mid Mount Control Valve
Main Relief Valve Test—With Mid Mount Control Valve
Mid Mount Control Valve Leakage Test
Hydraulic Tests—All
Rockshaft Leakage Test
Rockshaft Lift Cycle Test
Adjustments
Rockshaft Sensing Lever Friction Adjustment
Rockshaft Position-Sensing Lever Adjustment
Rockshaft Draft-Sensing Lever Adjustment
Mid Mount Control Valve Joystick Cable Adjustment
Hydraulic Schematics
Hydraulic Circuit Symbols
Hydraulic Schematic—With Selective Control Valve
Hydraulic Schematic—With Mid Mount Control Valve
Hydraulic Schematic—With Selective Control Valve and Power Beyond Valve
Dealer Fabricated Tools
Dealer Fabricated Tools
DFLV1A Final Drive Turning Tool
INDEX