John Deere 5200 5300 5400 Tractor Technical Manual TM1520

[Martin Welker]

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John Deere 5200 5300 5400 Tractor Technical Manual TM1520
Size: 28.59 MB
Format: PDF
Language: English
Brand: John Deere
Type of Machine: Tractor
Type of Manual: Technical Manual
Model: John Deere 5200 5300 5400 Tractor
Part Number: TM1520
Number of Pages: 820 Pages

Contents:
Section 10 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
Repair Specifications
Repair Specifications
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 Specifications
Storing Fuel
Do Not Use Galvanized Containers
Fill Fuel Tank
Diesel Engine Oil
Engine Coolant
Liquid Coolant Conditioner
Anti-Chatter Transmission/Hydraulic Oil
Mfwd Gear Oil
Extreme Pressure Or Multipurpose Grease
Alternative 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
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
Section 20 Engine Repair
Engine
John Deere Engine Repair—Use Ctm8
Remove Engine
Install Engine
Cooling System
Engine Water Pump Repair—Use Ctm8
Remove And Inspect Radiator
Install Radiator
Replace Thermostat
Section 30 Fuel And Air Repair
Fuel System
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
Turbocharger Repair—Use Ctm8
Remove, Inspect And Install Air Cleaner Elements
Remove Turbocharger
Install Turbocharger
Speed Control Linkage
Inspect And Repair Speed Control Linkage
Section 40 Electrical Repair
Battery, Starter And Alternator
Starter Repair—Use Ctm11
Remove And Install Battery
Remove And Install Starter
Replace Alternator/Regulator
Electrical System Components
Replace Air Filter Restriction Switch
Replace Coolant Temperature Sender
Replace Engine Speed Sensor
Replace Fuel Shut-Off Solenoid
Replace Engine Oil Pressure Switch
Replace Manifold Heater
Replace Manifold Heater Relay
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
Replace Connector Body—Blade Terminals
Replace Weather Pack™ Connector
Install Weather Pack Contact
Replace Front Wiring Harness
Replace Rear Wiring Harness
Section 50 Power Train Repair
Clutch Housing
Service Parts Kits
Separate Engine From Clutch Housing
Install Engine To Clutch Housing
Replace Clutch Housing Seal
Inspect And Repair Clutch Pedal And Linkage
Dual Clutch Assembly
Service Parts Kits
Remove And Install Dual Clutch Assembly
Disassemble And Inspect Dual Clutch Assembly
Assemble Dual Clutch Assembly
Traction Clutch Finger Adjustment
Pto Clutch Finger Adjustment
Remove And Inspect Clutch Release Mechanism And Shafts
Install Clutch Release Mechanism And Shafts
Collar Shift Transmission
Separate Clutch Housing From Transmission
Install Clutch Housing To Transmission
Inspect And Repair Gear Shift Lever
Inspect And Repair Range Shift Lever
Remove Transmission
Disassemble And Inspect Transmission
Assemble Transmission
Install Transmission
Disassemble, Inspect And Assemble Gear 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 Install Reverse Idler Shaft
Rear Pto Drive Shaft
Inspect And Repair Rear Pto Lever And Linkage
Remove And Install Rear Pto Drive Shaft Assembly
Disassemble, Inspect And Assemble Rear Pto Drive Shaft Assembly
Differential
Special Or Essential Tools
Service Parts Kits
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
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
Special Or Essential Tools
Inspect And Repair Mfwd Lever And Linkage
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, 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
Swivel Pin Bearing Clearance Adjustment
Differential Cone Point Adjustment
Differential Drive Shaft Pinion Bearing Preload Adjustment
Differential Driveshaft Pinion-To-Ring Gear Backlash Adjustment
Differential Side Bearing Preload Adjustment
Creeper Assembly
Remove And Install Creeper Assembly
Disassemble, Inspect And Assemble Creeper Assembly
Section 60 Steering And Brake Repair
Steering Repair
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
Brake Repair
Remove And Install Brake Valve And Pedals
Disassemble And Inspect Brake Valve
Brake Valve Cross Section
Assemble Brake Valve
Remove And Inspect Brakes
Install Brakes
Inspect And Replace Brake Hydraulic Lines
Section 70 Hydraulic Repair
Hydraulic Pump And Filter
Service Parts Kits
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 Filter/Manifold
Inspect And Replace Hydraulic Supply/Return Lines
Rockshaft
Service Parts Kits
Inspect And Repair Rockshaft Control Lever Assembly
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
Remove And Install Rockshaft Case
Remove, Inspect And Install Rockshaft Lift Arms
Remove, Inspect And Install Rockshaft Piston And Cylinder
Dual Selective Control Valve
Service Parts Kits
Inspect And Repair Joystick And Linkage
Remove And Install Dual Selective Control Valve (Scv)
Disassemble, Inspect And Assemble Dual Selective Control Valve (Scv)
Inspect And Replace Hydraulic Hoses—Dual Selective Control Valve (Scv)
Single (Third) Selective Control Valve
Service Parts Kits
Inspect And Repair Lever And Linkage
Remove And Install Single Selective Control Valve (Scv)
Disassemble, Inspect And Assemble Single (Third) Selective Control Valve (Scv)
Inspect And Replace Hydraulic Hoses—Single (Third) Selective Control Valve (Scv)
Section 80 Miscellaneous Repair
Front Axle¯2wd
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
Inspect And Replace Front Wheel Bearings
3-Point Hitch
Inspect And Repair Draft Links
Inspect And Repair Lift Link
Inspect And Repair Adjustable Lift Link
Inspect And Repair Center Link
Section 90 Operator Station Repair
Seat And Support
Remove And Install Seat And Support
Roll-Gard
Remove And Install Roll-Gard®
Section 210 Test And Adjustment Specifications/Operational Checkout Procedures
Test And Adjustment Specifications
Test And Adjustment Specifications
Operational Checkout Procedures
Operational Checkout Procedures
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 Lamp Tests
Engine Start Test
Transmission Neutral Start Check
Pto Neutral Start Check
Engine Fast And Slow Idle Operation
Power Steering Check
Differential Lock Test
Pto Engagement Check
Clutch Check
Transmission Shift Check
Range Lever Shift Check
Mfwd Drive Check
Brake Check
Rockshaft Check
Selective Control Valve Check
Miscellaneous Checks
Section 220 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 Lubrication System Operation—Continued
Engine Cooling System Operation
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 Low Power
Engine Low Power—Continued
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
Injection Pump Timing Adjustment—New Front Plate Installed
Valve Clearance Adjustment
Fan/Alternator Drive Belt Adjustment
Turbocharger Boost Pressure Test
Bleed Fuel System
Section 230 Fuel/Air Operation, Tests And Adjustments
Component Location
Component Location Information
Fuel System Components
Air Intake System Components—5200 And 5300
Air Intake System Components—5400
Theory Of Operation
Theory Of Operation Information
Fuel System Operation
Fuel Filter/Priming Pump Operation
Fuel Injection Pump Operation
Fuel Injection Nozzle Operation
Air Intake System Operation—5200 And 5300
Air Intake System Operation—5400
Turbocharger Operation
Diagnosis, Tests And Adjustments
Diagnostic Information
Fuel/Air Diagnosis, Tests And Adjustments
Section 240 Electrical System Operation, Tests And Adjustments
Component Location
Component Location Information
Engine Electrical Components
Dash Electrical Components
Machine Electrical Components
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
Lighting System Operation—Warning Lights
Lighting System Operation—Tail Light
Lighting System Operation—Headlights And Instrument Lights
Instrument Panel System Operation—Tachometer
Instrument Panel System Operation—Fuel Gauge
Instrument Panel System Operation—Temperature Gauge
Instrument Panel System Operation—Hourmeter
Pto Warning System Operation
Air Filter Restriction Indicator Operation
Optional Work Light Operation
Optional Dual Horn Operation
Optional Accessory Relay And Trailer Connector Operation
Diagnosis, Tests And Adjustments
Diagnostic Information
Wire Color Chart
Starting System Test Points —Normal Operation
Starting System Test Points —Normal Operation—Continued
Starting System Test Points —Normal Operation—Continued
Starting System Test Points —Bypass Attempt
Starting System Test Points —Bypass Attempt—Continued
Manifold Heater Test Points
Manifold Heater Test Points —Continued
Charging System Test Points
Charging System Test Points —Continued
Charging System Test Points—Continued
Lighting System Test Points —Turn Signals
Lighting System Test Points —Turn Signals—Continued
Lighting System Test Points —Turn Signals—Continued
Lighting System Test Points —Warning Lights
Lighting System Test Points —Warning Lights—Continued
Lighting System Test Points —Tail Light
Lighting System Test Points —Tail Light—Continued
Lighting System Test Points —Headlights And Instrument Lights
Lighting System Test Points —Headlights And Instrument Lights —Continued
Lighting System Test Points —Headlights And Instrument Lights —Continued
Lighting System Test Points —Headlights And Instrument Lights —Continued
Instrument Panel System Test Points —Tachometer
Instrument Panel System Test Points —Tachometer—Continued
Instrument Panel System Test Points —Fuel Gauge
Instrument Panel System Test Points —Fuel Gauge—Continued
Instrument Panel System Test Points —Temperature Gauge
Instrument Panel System Test Points —Temperature Gauge—Continued
Instrument Panel System Test Points —Hourmeter
Instrument Panel System Test Points —Hourmeter—Continued
Instrument Panel System Test Points —Oil Pressure
Instrument Panel System Points —Oil Pressure—Continued
Pto Warning System Test Points
Pto Warning System Test Points —Continued
Pto Warning System Test Points —Continued
Air Filter Restriction Test Points
Air Filter Restriction Test Points—Continued
Optional Work Light Test Points
Optional Work Light Test Points—Continued
Optional Dual Horn Test Points
Optional Dual Horn Test Points—Continued
Optional Accessory Relay And Trailer Connector Test Points
Optional Accessory Relay And Trailer Connector Test Points —Continued
Battery Voltage & 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
Seat Switch Test
Light Switch Test
Turn Signal Controller Test
Fuel Shut-Off Solenoid Test
Wiring Schematics
Schematic Information
Legend For 5200, 5300, 5400 Electrical Schematic
Legend For 5200, 5300, 5400 Electrical Schematic—Optional Equipment
Section 250 Power Train Operation, Tests And Adjustments
Component Location
Component Location Information
Power Train Components
Dual Stage Clutch Components
Transmission Components
Final Drive Components
Rear Pto Components
Theory Of Operation
Theory Of Operation Information
Dual Stage Clutch Operation
Dual Stage Clutch Operation—Continued
Dual Stage Clutch Operation—Continued
Transmission Lubrication System
Transmission Power Flow—Gear Shift
Transmission Power Flow—Range Shift
Rear Pto Operation
Differential Power Flow
Differential Lock Operation
Final Drive Operation
Mechanical Front Wheel Drive (Mfwd) Operation
Diagnosis, Tests And Adjustments
Diagnostic Information
Isolate The Problem Area
Isolate The Problem Area—Continued
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, Shift 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
Pto Clutch Lever Adjustment
Section 260 Steering And Brake Operation, Tests And Adjustments
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
Brake Valve Operation
Brake Valve Operation—Continued
Diagnosis, Tests And Adjustments
Diagnostic Information
Isolate The Problem—Steering System
Steering Sluggish Or Loss Of Steering
Isolate The Problem—Brakes
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 Check And Adjustment—Standard Axle
Toe-In Check And Adjustment—Mfwd
Mfwd Steering Stop Adjustment
Bleed Brake System
Section 270 Hydraulic System Operation, Tests And Adjustments
Component Location
Component Location Information
Hydraulic System Components
Selective Control Valve Components
Theory Of Operation
Theory Of Operation Information
Hydraulic System Operation
Hydraulic Filter Operation
Hydraulic Pump Operation
Rockshaft Control Valve Operation—Flow Regulator Valve
Rockshaft Control Valve Operation—Neutral Position
Rockshaft Control Valve Operation—Raise Position
Rockshaft Control Valve Operation—Lowering Position
Surge Relief Valve Operation
Main 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
Selective Control Valve Operation—Bucket Spool Regenerative Position
Double-Acting Sleeve 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—Single (Third) Scv
Scv Joystick Does Not Return To Neutral Position—Dual Scv
Scv Joystick Does Not Remain In Detent Position—Dual Scv
Remote Cylinder Does Not Extend Or Retract
Remote Cylinder Settles Under Load
Remote Cylinder Operates Too Fast Or Too Slow
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¯All
Rockshaft Leakage Test
Rockshaft Lift Cycle Test
Adjustments
Rockshaft Control Lever Friction Adjustment
Rockshaft Position-Sensing Feedback Linkage Adjustment
Rockshaft Draft-Sensing Feedback Linkage Adjustment
Main Relief Valve Adjustment
Hydraulic Schematics
Legend For Hydraulic Schematic—Without Selective Control Valve
Legend For Hydraulic Schematic—With Selective Control Valve
Section 299 Dealer Fabricated Tools
Dealer Fabricated Tools
Dflv1a Pto Clutch Finger Height Gauge
Dflv2a Traction Clutch Finger Height Gauge
Dflv3a Traction Clutch Finger Height Adjustment Tool
Dflv4a Final Drive Turning Tool
Index