John Deere 5220 5320 5420 5520 Tractor Diagnostic & Tests Service Manual TM2049 PDF - MJODTM2049.zip

Full Diagnosis & Tests service manual, complete with electrical wiring schematics, covering John Deere Tractors models 5220, 5320, 5420, and 5520 — packed with every technical detail needed to service, troubleshoot, and overhaul these machines to professional-shop standards.

The workshop Diagnosis & Tests technical manual for John Deere Tractors 5220, 5320, 5420 & 5520 contains:

* 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.

tm2049 - 5220, 5320, 5420, and 5520 Tractors Diagnostics Technical Manual.pdf

tm2049 - 5220, 5320, 5420, and 5520 Tractors Diagnostics Technical Manual.epub

PRODUCT DETAILS:

Total Pages: 1,416 pages

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

Language: English

MAIN SECTIONS

Foreword

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 & Adjust

Component Location

Theory of Operation

Diagnosis, Test and Adjust

Wiring Schematics

Power Train Operation, Tests and Adjustments

Component Location-CollarShift/SyncShuttle™ Transmission

Component Location-PowrReverser™ Transmission

Theory of Operation-CollarShift/SyncShuttle™ Transmission

Theory of Operation-PowrReverser™ Transmission

Diagnosis, Tests, and Adjustments-CS/SS Transmission

Diagnosis, Tests, and Adjustments-PowrReverser™

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-Without SCV

Hydraulic Tests-With SCV

Hydraulic Tests-All

Adjustments

Hydraulic Schematics

Operator Station

Component Location

Theory of Operation

Diagnosis, Tests, and Adjustments

Dealer Fabricated Tools

Dealer Fabricated Tools

tm2049 - 5220, 5320, 5420, and 5520 Tractors Diagnostic Technical Manual

Table of Contents

Foreword

Section 210: Operational Checkout Procedures

Group 10: Operational Checkout Procedures

Specifications

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 (S.N. —420000)

Fuel System Check (S.N. 420001— )

Air Intake System Check

Electrical System Check (S.N. —420000)

Electrical System Check (S.N. 420001— )

Hydraulic System Check (S.N. —420000)

Hydraulic System Check (S.N. 420001— )

MFWD Oil Check

MFWD Differential Oil Check

Indicator Lamps Check (S.N. —420000)

Indicator Lamps Check (S.N. 420001— )

Cab Blower Motor Check (S.N. —420000)

Cab Blower Motor Check (S.N. 420001— )

A/C Compressor Clutch Check

Engine Start Check—Straddle Mount Tractors

Engine Start Check—Isolated Open Operator Station and Cab Tractors

Transmission Neutral Start Check—Straddle Mount Tractors

Transmission Neutral Start Check—Isolated Open Operator Station and Cab Tractors

PTO Neutral Start Check

Engine Fast and Slow Idle Operation

Foot Throttle Pedal Check—Isolated Open Operator Station and Cab Tractors

Power Steering Check

Differential Lock Check

PTO Engagement Check

Clutch Check

Transmission Shift Check

Range Lever Shift Check

MFWD Drive Check

Brake Check

Park Brake Check—CollarShift and SyncShuttle SYNCSHUTTLE is a trademark of Deere & Company Transmissions

Park Brake Check—PowrReverser POWRREVERSER is a trademark of Deere & Company Transmission

Rockshaft Check—Straddle Mount Tractors

Rockshaft Check—Isolated Open Operator Station and Cab Tractors

Selective Control Valve Check—Straddle Mount Tractors

Selective Control Valve Check—Isolated Open Operator Station and Cab Tractors

Front End Loader Joystick Control Check (Optional)

A/C System 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 Lubrication System Operation—Continued

Engine Cooling System Operation—3-Cylinder

Engine Cooling System Operation—4-Cylinder

Group 15: Diagnosis, Tests, and Adjustments

Service Equipment and Tools

Specifications

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 Gray

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—Straddle Mount Tractors

Throttle Lever Adjustment—Isolated Open Operator Station and Cab Tractors

Slow Idle Adjustment

Fast Idle Adjustment

Foot Throttle Pedal Stop Adjustment—Isolated Open Operator Station and Cab Tractors

Injection Pump Timing Adjustment

Check and Adjust Valve Clearance

Fan/Alternator V-Belt Adjustment—5220 and 5320 Tractors

Compressor Drive Belt Adjustment—3-Cylinder

Turbocharger Boost Pressure Test—5320 and 5520 Tractors

Bleed Fuel System

Section 230: Fuel/Air Operation, Tests, and Adjustments

Group 05: Component Location

Component Location Information

Fuel System Components—Straddle Mount

Fuel System Components—Isolated Open Operator Station and Cab Tractors (S.N. —420000)

Fuel System Components—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )

Air Intake System Components—Without Turbocharger

Air Intake System Components—With Turbocharger

Group 10: Theory of Operation

Theory of Operation Information

Fuel System Operation—Straddle Mount

Fuel System Operation—Isolated Open Operator Station and Cab Tractors (S.N. —420000)

Fuel System Operation—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )

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—Without Turbocharger

Air Intake System Operation—With Turbocharger

Air Intake System Operation—With Turbocharger

Turbocharger Operation—5320 and 5520

Group 15: Diagnosis, Tests and Adjustments

Diagnostic Information

Fuel/Air Diagnosis, Tests and Adjustments

Section 240: Electrical System Operation, Test & Adjust

Group 05: Component Location

Component Location Information

Engine Electrical Components

Dash Electrical Components—Straddle Mount (S.N. —420000)

Dash Electrical Components—Straddle Mount (S.N. 420001— )

Dash Electrical Components—Isolated Open Operator Station and Cab Tractors (S.N. —420000)

Dash Electrical Components—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )

Machine Electrical Components—Straddle Mount (S.N. —420000)

Machine Electrical Components—Straddle Mount (S.N. 420001— )

Machine Electrical Components—Isolated Open Operator Station (S.N. —420000)

Machine Electrical Components—Isolated Open Operator Station (S.N. 420001— )

Machine Electrical Components—Cab Tractors (S.N. —420000)

Machine Electrical Components—Cab Tractors (S.N. 420001— )

Cab Control Panel and Electrical Components

Group 10: Theory of Operation

Theory of Operation Information

Fuse/Relay Block Assembly—Straddle Mount (S.N. —420000)

Fuse/Relay Block Assembly—Straddle Mount (S.N. 420001— )

Fuse/Relay Block Assembly—Early Model Cab Tractors (S.N. —420000)

Fuse/Relay Block Assembly—Isolated Open Operator Station and Late Model Cab Tractors (S.N. —420000)

Fuse/Relay Block Assembly—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )

Electrical Load Center—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )

HVAC/Wiper Relay Block Assembly—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )

Starting System Operation—Normal (S.N. —420000)

Starting System Operation—Normal (S.N. 420001— )

Starting System Operation—Bypass Attempt (S.N. —420000)

Starting System Operation—Bypass Attempt (S.N. 420001— )

Air Intake Heater System Operation (S.N. —420000) (Optional)

Air Intake Heater System Operation (S.N. 420001— ) (Optional)

Charging System Operation (S.N. —420000)

Charging System Operation (S.N. 420001— )

Lighting System Operation—Turn Signals and Enhanced Tail Lights—Straddle Mount (S.N. —420000)

Lighting System Operation—Turn Signals—Isolated Open Operator Station (S.N. —420000)

Lighting System Operation—Turn Signals—Straddle Mount and Isolated Open Operator Station (S.N. 420001— )

Lighting System Operation—Turn Signals—Early Model Cab Tractors (S.N. —420000)

Lighting System Operation—Turn Signals—Late Model Cab Tractors (S.N. —420000)

Lighting System Operation—Turn Signals—Cab Tractors (S.N. 420001— )

Lighting System Operation—Warning Lights—Straddle Mount (S.N. —420000)

Lighting System Operation—Warning Lights—Isolated Open Operator Station (S.N. —420000)

Lighting System Operation—Warning Lights—Straddle Mount and Isolated Open Operator Station (S.N. 420001— )

Lighting System Operation—Warning Lights—Early Model Cab Tractors (S.N. —420000)

Lighting System Operation—Warning Lights—Late Model Cab Tractors (S.N. —420000)

Lighting System Operation—Warning Lights—Cab Tractors (S.N. 420001— )

Lighting System Operation—Tail Lights—All Tractors (S.N. —420000)

Lighting System Operation—Tail Lights—All Tractors (S.N. 420001— )

Lighting System Operation—Headlights and Instrument Lights—Straddle Mount (S.N. —420000)

Lighting System Operation—Headlights and Instrument Lights—Straddle Mount (S.N. 420001— )

Lighting System Operation—Headlights and Instrument Lights—Early Model Cab Tractors (S.N. —420000)

Lighting System Operation—Headlights and Instrument Lights—Isolated Open Operator Station and Late Model Cab Tractors (S.N. —420000)

Lighting System Operation—Headlights and Instrument Lights—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )

Flood Light Operation—Straddle Mount (S.N. —420000)

Flood Light Operation—Isolated Open Operator Station (S.N. —420000)

Flood Light Operation—Cab Tractors (S.N. —420000)

Work Light Operation—Straddle Mount and Isolated Open Operator Station (S.N. 420001— )

Work Light and Beacon Operation—Cab Tractors (S.N. 420001— )

Instrument Panel System Operation—Tachometer/Hour Meter—All Tractors (S.N. —420000)

Instrument Cluster Operation—Tachometer/Hour Meter—All Tractors (S.N. 420001— )

Instrument Panel System Operation—Fuel Gauge—All Tractors (S.N. —420000)

Instrument Cluster Operation—Fuel Gauge—All Tractors (S.N. 420001— )

Instrument Panel System Operation—Coolant Temperature Gauge—All Tractors (S.N. —420000)

Instrument Cluster Operation—Coolant Temperature Gauge—All Tractors (S.N. 420001— )

PTO Warning System Operation—Straddle Mount (S.N. —420000)

PTO Warning System Operation—Early Model Cab Tractors (S.N. —420000)

PTO Warning System Operation—Isolated Open Operator Station and Late Model Cab Tractors (S.N. —420000)

PTO Warning System Operation—All Tractors (S.N. 420001— )

Air Filter Restriction Indicator Operation—All Tractors (S.N. —420000)

Air Filter Restriction Indicator Operation—All Tractors (S.N. 420001— )

Optional Horn Operation—All Tractors (S.N. —420000)—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )

Optional Horn Operation—Straddle Mount Tractors (S.N. 420001— )

Accessory Relay and Electrical Outlet Operation—All Tractors (S.N. —420000)

Accessory Relay and Electrical Outlet Operation—Straddle Mount Tractors (S.N. 420001— )

Accessory Relay and Electrical Outlet Operation—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )

Blower Motor Operation—Cab Tractors (S.N. —420000)

Blower Motor Operation—Cab Tractors (S.N. 420001— )

A/C Compressor Operation—Cab Tractors (S.N. —420000)

A/C Compressor Operation—Cab Tractors (S.N. 420001— )

Front Wiper/Washer Operation—Cab Tractors (S.N. —420000)

Front Wiper/Washer Operation—Cab Tractors (S.N. 420001— )

Rear Wiper/Washer Operation—Cab Tractors (S.N. —420000) (Optional)

Rear Wiper/Washer Operation—Cab Tractors (S.N. 420001— ) (Optional)

Dome Light Operation—Cab Tractors (S.N. —420000)

Dome Light Operation—Cab Tractors (S.N. 420001— )

Convenience Outlet Operation—Cab Tractors (S.N. —420000)

Convenience Outlet Operation—Cab Tractors (S.N. 420001— )

Group 15: Diagnosis, Test and Adjust

Diagnostic Information

Wire Color Chart

Starting System Test Points—Normal Operation—Straddle Mount (S.N. —420000)

Starting System Test Points—Normal Operation—Straddle Mount (S.N. 420001— )

Starting System Test Points—Normal Operation (Isolated Open Operator Station and Cab Tractors) (S.N. —420000)

Starting System Test Points—Normal Operation (Isolated Open Operator Station and Cab Tractors) (S.N. 420001— )

Starting System Test Points—Bypass Attempt—Straddle Mount (S.N. —420000)

Starting System Test Points—Bypass Attempt—Straddle Mount (S.N. 420001— )

Starting System Test Points—Bypass Attempt (Isolated Open Operator Station and Cab Tractors) (S.N. —420000)

Starting System Test Points—Bypass Attempt (Isolated Open Operator Station and Cab Tractors) (S.N. 420001— )

Air Intake Heater Test Points—Straddle Mount (S.N. —420000)

Air Intake Heater Test Points—Straddle Mount (S.N. 420001— )

Air Intake Heater Test Points—Isolated Open Operator Station and Cab Tractors (S.N. —420000)

Air Intake Heater Test Points—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )

Charging System Test Points—Straddle Mount (S.N. —420000)

Charging System Test Points—Straddle Mount (S.N. 420001— )

Charging System Test Points—Isolated Open Operator Station and Cab Tractors (S.N. —420000)

Charging System Test Points—Isolated Open Operator Station and Cab Tractors (S.N. 420001— )

Lighting System Test Points—Turn Signals and Enhanced Tail Lights—Straddle Mount (S.N. —420000)

Lighting System Test Points—Turn Signals and Enhanced Tail Lights—Straddle Mount (S.N. 420001— )

Lighting System Test Points—Turn Signal Switch Power (Isolated Open Operator Station and Cab Tractors) (S.N. —420000)

Lighting System Test points—Turn Signal Operation (Isolated Open Operator Station) (S.N. —420000)

Lighting System Test points—Turn Signals—Isolated Open Operator Station (S.N. 420001— )

Lighting System Test points—Turn Signals—Early Model Cab Tractors (S.N. —420000)

Lighting System Test points—Turn Signals—Isolated Open Operator Station and Late Model Cab Tractors (S.N. —420000)

Lighting System Test points—Turn Signals—Cab Tractors (S.N. 420001— )

Lighting System Test Points—Warning Lights—Straddle Mount (S.N. —420000)

Lighting System Test Points—Warning Lights—Straddle Mount (S.N. 420001— )

Lighting System Test Points—Warning Lights (Isolated Open Operator Station) (S.N. —420000)

Lighting System Test Points—Warning Lights (Isolated Open Operator Station) (S.N. 420001— )

Lighting System Test Points—Warning Lights—Early Model Cab Tractors (S.N. —420000)

Lighting System Test points—Warning Lights—Late Model Cab Tractors (S.N. —420000)