John Deere 5220 5320 5420 5520 Tractors TM2048 Repair Technical Manual PDF - MJODTM2048.zip

Full Service Guide for John Deere 5220, 5320, 5420, and 5520 Tractors — containing every detail needed to service, fix, and overhaul these machines the way expert technicians do.

This John Deere 5220, 5320, 5420, 5520 workshop service manual covers:

* 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.

* 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.

tm2048 - 5220, 5320, 5420, and 5520 Tractors Repair Technical Manual.pdf

tm2048 - 5220, 5320, 5420, and 5520 Tractors Repair Technical Manual.epub

PRODUCT DETAILS:

Total Pages: 1,345 pages

File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)

Language: English

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-CollarShift/SyncShuttle™ Transmissions

Clutch Assembly-PowrReverser™ Transmission

PowrReverser™

CollarShift/SyncShuttle™ Transmission

PowrReverser™ Transmission

Rear PTO Drive Shaft

Differential

Final Drives

Hi-Crop 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

Hydraulic Mid Mount Control Valve

Miscellaneous Repair

Front Axle-2WD

Wheels

3-Point Hitch

Fenders

Operator Station Repair

Seat and Support

Control Console and Panel

ROLL-GARD™

Cab Components

Isolated Open Operator Station Components

Air Conditioning System

Heating System

tm2048 - 5220, 5320, 5420, and 5520 Tractors 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 5220 and 5320

Machine Specifications 5420 and 5520

Collar Shift and SyncShuttle™ Transmission Ground Speed Estimates

Collar Shift and SyncShuttle™ Creeper Transmissions Ground Speed Estimates

PowrReverser™ Transmission Ground Speed Estimates

PowrReverser™ Creeper Transmissions Ground Speed Estimates

Correction Factors for Other Tire Sizes

Machine Dimensions (Straddle Mount)

Machine Dimensions (5520 Series Hi-Crop Straddle Mount)

Machine Dimensions (Isolated Open Operator Station)

Machine Dimensions (Cab)

Repair Specifications

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

Abbreviations

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 (Specific Application)

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—Straddle Mount and Isolated Open Operator Station Tractors

Standard Features—Cab Tractor

Standard Features—5520 Hi-Crop Straddle Mount Tractors

Standard Features—5220 through 5520

Factory Installed Optional Equipment (5220—5520)

Field Installed Optional Kits and Accessories—5220 through 5520

Section 20: Engine Repair

Group 05: Engine

Service Equipment and Tools

Specifications

John Deere Engine Repair—Use CTM104 or CTM125

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—Models 5420 and 5520

Section 30: Fuel and Air Repair

Group 05: Fuel System

Specifications

Injection Pump, Nozzle and Governor Repair—Use CTM104 or CTM125

Remove, Inspect and Install Fuel Tank—Straddle Mount Tractors

Remove, Inspect, and Install Fuel Tank—Isolated Open Operator Station and Cab Tractors (S.N. —420000)

Remove, Inspect, and Install Fuel Tank—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )

Replace Fuel Filter

Remove and Install Fuel Filter/Primer Pump Assembly

Group 10: Air Intake System

Turbocharger Repair—Use CTM104 or CTM125

Other Material

Specifications

Remove, Inspect, and Install Air Cleaner Elements—5220 and 5320 Tractors

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

Remove Turbocharger—5320 Tractors

Install Turbocharger—5320 Tractors

Remove Turbocharger—5520 Tractors

Install Turbocharger—5520 Tractors

Turbocharger Break-In

Group 15: Speed Control Linkage

Inspect and Repair Speed Control Linkage—Without 540/540E PTO—Straddle Mount Tractors

Inspect and Repair Speed Control Linkage—With 540/540E PTO—Straddle Mount Tractors

Inspect and Repair Speed Control Linkage—Without 540/540E PTO—Isolated Open Operator Station and Cab Tractors

Inspect and Repair Speed Control Linkage—With 540/540E PTO—Isolated Open Operator Station and Cab Tractors

Section 40: Electrical Repair

Group 05: Battery, Starter and Alternator

Starter Repair—Use CTM77

Remove and Install Battery—Straddle Mount and Isolated Open Operator Station

Remove and Install Battery—Cab Tractors

Remove and Install Starter—5220 and 5320 Tractors

Remove and Install Starter—5420 and 5520 Tractors

Replace Alternator/Regulator—3-Cylinder Engines

Replace Alternator/Regulator—4-Cylinder Engines

Group 10: Electrical System Components

Replace Air Filter Restriction Switch—5220 and 5320 Tractors

Replace Air Filter Restriction Switch—5420 and 5520 Tractors

Replace Cold Start Advance Switch

Replace Coolant Temperature Sender—5220 and 5320 Tractors

Replace Coolant Temperature Sender—5420 and 5520 Tractors

Replace Engine Speed Sensor

Replace Engine Oil Pressure Switch

Replace Air Intake Heater (Optional)

Replace Air Intake Heater Relay (Optional)

Replace Key Switch

Replace Tractor Light Switch (S.N. —420000)

Replace Light Switch (S.N. 420001— )

Replace Speakers (S.N. —420000)

Replace Speakers (S.N. 420001— )

Replace Antenna (S.N. —420000)

Replace Antenna (S.N. 420001— )

Replace Turn Signal Controller—Straddle Mount

Replace Turn Signal Switch—Isolated Open Operator Station and Cab Tractors

Replace Instrument Panel—Straddle Mount (S.N. —420000)

Replace Instrument Panel—Straddle Mount (S.N. 420001— )

Replace Instrument Panel—Isolated Open Operator Station and Cab Tractors (S.N. —420000)

Replace Instrument Panel—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )

Replace Rear PTO Switch—Straddle Mount

Replace Rear PTO Switch—Isolated Open Operator Station and Cab Tractors

Replace Neutral Start Switch—Straddle Mount

Replace Neutral Start Switch—Isolated Open Operator Station and Cab Tractors

Replace Fuel Level Sender—Straddle Mount

Replace Fuel Level Sender—Isolated Open Operator Station and Cab Tractors

Replace Wiper Control Switch

Replace Wiper Motor

Replace Blower Control Switch

Replace Air Conditioning ON/OFF Switch

Replace A/C Temperature Control Switch (S.N. —420000)

Replace A/C Temperature Control Switch (S.N. 420001— )

Replace Dome Light (S.N. —420000)

Replace Dome Light (S.N. 420001— )

Replace Door Switch (S.N. —420000)

Replace Door Switch (S.N. 420001— )

Group 15: Wiring Harness

Service Equipment and Tools

Service Parts Kits

Replace Connector Body—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 Electrical Harness—Straddle Mount

Replace Rear Electrical Harness—Isolated Open Operator Station (S.N. —420000)

Replace Rear Electrical Harness—Isolated Open Operator Station (S.N. 420001— )

Replace Rear Electrical Harness—Cab Tractors (S.N. —420000)

Replace Rear Electrical Harness—Cab Tractors (S.N. 420001— )

Replace Cab Roof Electrical Harness (S.N. —420000)

Replace Cab Roof Electrical Harness (S.N. 420001— )

Section 50: Power Train Repair

Group 05: Clutch Housing

Service Equipment and Tools

Other Material

Specifications

Separate Engine from Clutch Housing—Straddle Mount

Install Engine to Clutch Housing—Straddle Mount

Separate Engine from Clutch Housing—Isolated Open Operator Station and Cab Tractors

Install Engine to Clutch Housing—Isolated Open Operator Station and Cab Tractors

Replace Clutch Housing Seal

Inspect and Repair Clutch Pedal and Linkage—Straddle Mount (CollarShift, SyncShuttle™ and PowrReverser™ Transmissions)

Inspect and Repair Clutch Pedal and Linkage—Isolated Open Operator Station and Cab Tractors (CollarShift and SyncShuttle™ Transmissions)

Inspect and Repair Clutch Pedal and Linkage—Isolated Open Operator Station and Cab Tractors (PowrReverser™ Transmissions)

Group 10: Clutch Assembly—CollarShift/SyncShuttle™ Transmissions

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

Group 11: Clutch Assembly—PowrReverser™ Transmission

Essential Tools

Service Equipment and Tools

Other Material

Specifications

Service Parts Kits

Remove and Install Clutch Assembly

Disassemble and Inspect Clutch Assembly

Assemble Clutch Assembly

PTO Clutch Finger Adjustment

Remove and Inspect Clutch Release Mechanism and Shafts

Install Clutch Release Mechanism and Shafts

Remove, Inspect, and Repair Transmission Pump

Group 12: PowrReverser™

Essential Tools

Service Equipment and Tools

Other Material