John Deere 5225 5325 5425 5525 5603 5625 Tractor Workshop Repair Service Manual (TM2187) PDF - MJODTM2187.zip

Full Repair and Service Workshop Manual covering John Deere Tractors models 5225, 5325, 5425, 5525, 5603, and 5625 — containing every piece of technical data needed to keep, fix, and service these machines the way expert technicians do.

The workshop technical repair manual for John Deere Tractors 5225, 5325, 5425, 5525, 5603, and 5625 features:

* 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.

tm2187 - 5225, 5325, 5425, 5525, 5625, and 5603 Tractors Repair Technical Manual.pdf

Total Pages: 1,514 pages

File Format: PDF (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-SYNCSHUTTLE™ Transmissions

Clutch Assembly-POWRREVERSERPOWRREVER™ Transmission

POWRREVERSERPOWRREVER™

SYNCSHUTTLE™ Transmission

POWRREVERSERPOWRREVER™ 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 (5225-5625, and 5E Limited)

Rockshaft (5603)

Selective Control Valve (5225-5625, and 5E Limited)

Selective Control Valve (5603)

Hydraulic Mid-Mount Control Valve

Miscellaneous Repair

Front Axle-2WD

Wheels

3-Point Hitch

Fenders

Hood

Operator Station Repair

Seat and Support

Control Console and Panel

ROLL-GARD™

Cab Components

Isolated Open Operator Station Components

Air Conditioning System

Heating System

Dealer Fabricated Tools

tm2187 - 5225, 5325, 5425, 5525, 5625, and 5603 Tractors Repair Technical Manual

Table of Contents

Foreword

Section 10: General Information

Group 05: Safety

Recognize Safety Information

Handle Fluids Safely—Avoid Fires

Prevent Battery Explosions

Prepare for Emergencies

Prevent Acid Burns

Service and Operate Chemical Sprayers 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

Remove Paint Before Welding or Heating

Avoid Heating Near Pressurized Fluid Lines

Keep ROPS Installed Properly

Service Tires Safely

Avoid Harmful Asbestos Dust

Practice Safe Maintenance

Use Proper Tools

Dispose of Waste Properly

Prevent Machine Runaway

Handle Starting Fluid Safely

Service Cooling System Safely

Stay Clear of Rotating Drivelines

Protect Against High Pressure Spray

Construct Dealer-Made Tools Safely

Clean Vehicle of Hazardous Pesticides

Live With Safety

Group 10: General Specifications

Machine Specifications 5225 and 5325

Machine Specifications 5425, 5525, 5625, 5603, 5083E Limited, 5093E Limited, and 5101E Limited

SYNCSHUTTLE SYNCSHUTTLE is a trademark of Deere & Company Transmission Ground Speed Estimates

SYNCSHUTTLE SYNCSHUTTLE is a trademark of Deere & Company Creeper Transmissions Ground Speed Estimates

POWRREVERSER POWRREVERSER is a trademark of Deere & Company Transmission Ground Speed Estimates

POWRREVERSER POWRREVERSER is a trademark of Deere & Company Creeper Transmissions Ground Speed Estimates

Correction Factors for Other Tire Sizes

Machine Dimensions (Straddle Mount)

Machine Dimensions (5525 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

Handling and Storing Diesel Fuel

Do Not Use Galvanized Containers

Lubricity of Diesel Fuel

Testing Diesel Fuel

BioDiesel Fuel

Filling Fuel Tank

Diesel Engine Break-In Oil (5425, 5525, 5625, 5603, 5083E Limited, 5093E Limited, and 5101E Limited)

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

Oil Filters

Diesel Engine Coolant (engine with wet sleeve cylinder liners)

Operating in Warm Temperature Climates

Additional Information About Diesel Engine Coolants and John Deere LIQUID COOLANT CONDITIONER

Testing Diesel Engine Coolant

Transmission and Hydraulic Oil

Use Correct Transmission/Hydraulic Filter Element

MFWD Axle Housing and Wheel Hub Oil

Grease

Grease (Specific Application)

Mixing of Lubricants

Alternative and Synthetic Lubricants

Lubricant Storage

Group 25: Serial Number Locations

Serial Numbers

Product Identification Number Location

Engine Serial Number Location—4-Cylinder

Engine Serial Number Location—5-Cylinder

Fuel Injection Pump Serial Number Location

Alternator Identification Number Location

Power Steering Valve Serial Number Location

Starter Serial Number Location—4-Cylinder

Starter Serial Number Location—5-Cylinder

Transmission Serial Number Location

Front Axle (2WD) Serial Number Location

Mechanical Front Wheel Drive (MFWD) Serial Number Location

Air Conditioning Compressor Serial Number Location

Cab 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—5525 Hi-Crop Straddle Mount Tractors

Factory Installed Optional Equipment

Field Installed Optional Kits and Accessories

Section 20: Engine Repair

Group 05: Engine

Service Equipment and Tools

Specifications

John Deere Engine Repair—Use CTM104 or CTM301

Remove Engine

Install Engine

Group 10: Cooling System

Specifications

Engine Coolant Pump Repair—Use CTM104 or CTM301

Remove and Install Coolant Recovery Tank

Remove and Inspect Radiator

Install Radiator

Remove and Install Thermostat—4-Cylinder Engine

Remove and Install Thermostat—5-Cylinder Engine

Inspect and Replace Belt Tensioner—4-Cylinder Engine

Inspect and Replace Belt Tensioner—5-Cylinder Engine

Section 30: Fuel and Air Repair

Group 05: Fuel System

Specifications

Injection Pump, Nozzle and Governor Repair—Use CTM104 or CTM301

Remove, Inspect and Install Fuel Tank—Straddle Mount

Remove, Inspect, and Install Fuel Tank—Isolated Open Operator Station and Cab Tractors—Early Model

Remove, Inspect, and Install Fuel Tank—5E Limited Tractors

Replace Fuel Filter/Water Separator—4-Cylinder Engines

Replace Fuel Filter/Water Separator—5-Cylinder Engines

Remove and Install Fuel Filter/Primer Pump Assembly

Replace Fuel Transfer Pump—5603, 5625, 5083E Limited, 5093E Limited and 5101E Limited

Group 10: Air Intake System

Turbocharger Repair—Use CTM104 or CTM301

Specifications

Other Material

Remove, Inspect, and Install Air Cleaner Elements

Remove Turbocharger—4-Cylinder Tractors

Install Turbocharger—4-Cylinder Tractors

Remove Turbocharger—5-Cylinder Tractors

Install Turbocharger—5-Cylinder Tractors

Turbocharger Break-In

Group 15: Speed Control Linkage

Inspect and Repair Speed Control Linkage—4-Cylinder Engine—Straddle Mount

Inspect and Repair Speed Control Linkage—5-Cylinder Engine—Straddle Mount

Inspect and Repair Speed Control Linkage—5425, 5525 and 5625—Isolated Open Operator Station and Cab Tractors

Inspect and Repair Speed Control Linkage—5603, 5083E Limited, 5093E Limited, and 5101E Limited—Cab Tractor

Inspect and Repair Speed Control Linkage—5-Cylinder Engine—Isolated Open Operator Station and Cab Tractors

Inspect and Repair Speed Control Linkage—540/1000 PTO

Section 40: Electrical Repair

Group 05: Battery, Starter and Alternator

Starter Repair—Use CTM77

Prevent Battery Explosions

Remove and Install Battery

Remove and Install Starter—5-Cylinder Engine

Remove and Install Starter—4-Cylinder Engine

Replace Alternator/Regulator—4-Cylinder Engine

Replace Alternator/Regulator—5-Cylinder Engine

Group 10: Electrical System Components

Essential Tools

Other Material

Specifications

Replace Air Filter Restriction Switch

Replace Cold Start Advance Switch

Replace Coolant Temperature Sender—5-Cylinder Tractors

Replace Coolant Temperature Sender—4-Cylinder Tractors

Replace Engine Speed Sensor

Replace Engine Oil Pressure Switch

Replace Key Switch—5225, 5325, 5425, 5525 and 5625 Tractors

Replace Key Switch—5603, 5083E Limited, 5093E Limited, and 5101E Limited

Replace Light Switch—5225, 5325, 5425, 5525 and 5625

Replace Light Switch—5603, 5083E Limited, 5093E Limited, and 5101E Limited

Replace Speakers

Replace Antenna

Replace Turn Signal Switch—5225, 5325, 5425, 5525 and 5625

Replace Turn Signal Switch—5603, 5083E Limited, 5093E Limited, and 5101E Limited

Replace Instrument Panel—Straddle Mount

Replace Instrument Panel—5225, 5325, 5425, 5525 and 5625 IOOS and Cab Tractors

Replace Instrument Panel—5603, 5083E Limited, 5093E Limited, and 5101E Limited Cab Tractors

Program Instrument Cluster

Replace Rear PTO Switch—Straddle Mount

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

Replace Rear PTO Switch—Electro-Hydraulic PTO

Replace Rockshaft Control Module—Electro-Hydraulic Hitch

Replace Load Depth Control—Electro-Hydraulic Hitch

Replace Neutral Start Switch—Straddle Mount—SYNCSHUTTLE SYNCSHUTTLE is a trademark of Deere & Company Transmission

Replace Neutral Start Switch—Isolated Open Operator Station and Cab Tractors—SYNCSHUTTLE SYNCSHUTTLE is a trademark of Deere & Company Transmissions

Replace Fuel Level Sender—Straddle Mount

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

Replace Wiper Control Switch—5225, 5325, 5425, 5525 and 5625

Replace Wiper Control Switch—5603, 5083E Limited, 5093E Limited, and 5101E Limited

Replace Wiper Motor

Replace Blower Control Switch

Replace A/C On/Off Switch

Replace A/C Temperature Control Switch

Replace Blower Motor Resistor

Replace Air Conditioning High/Low Pressure Switch

Replace Dome Light

Replace Door Switch

Replace Seat Switch—Isolated Open Operator Station and Cab Tractors

Replace Seat Switch—Straddle Mount Tractors

Replace VEC Load Center—Isolated Open Operator Station

Replace VEC Load Center—Cab Tractors

Replace VEC Load Center—Straddle Mount

Replace Electro-Hydraulic Controller—5225, 5325, 5425, 5525 and 5625 IOOS and Cab Tractors

Replace Electro-Hydraulic Controller—5603, 5083E Limited, 5093E Limited, and 5101E Limited

Replace Electro-Hydraulic Controller—Straddle Mount

Replace Start Relay

Replace Hitch Solenoids—Isolated Open Operator Station and Cab Tractors With EH Hitch

Replace Countershaft Speed Sensor—POWRREVERSER POWRREVERSER is a trademark of Deere & Company Tractors

Replace Wheel Speed Sensor

Replace Enable Pressure Sensor—POWRREVERSER POWRREVERSER is a trademark of Deere & Company Transmission

Replace Clutch Pedal Position Sensor—POWRREVERSER POWRREVERSER is a trademark of Deere & Company Transmission

Replace Clutch Disengage Switch—POWRREVERSER POWRREVERSER is a trademark of Deere & Company Transmission

Replace Rear PTO Sensor—POWRREVERSER POWRREVERSER is a trademark of Deere & Company Transmission—With Electro-Hydraulic PTO

Replace Hitch Draft Sensor—Electro-Hydraulic Hitch

Replace Hitch Position Sensor—Electro-Hydraulic Hitch

Replace Electro-Hydraulic Directional Reverser—POWRREVERSER POWRREVERSER is a trademark of Deere & Company Transmission

Replace Park Switch—POWRREVERSER POWRREVERSER is a trademark of Deere & Company Transmission

Replace Brake Pedal Switch—Electro-Hydraulic Tractors

Replace Hi/Lo Shifter Switch—POWRREVERSER POWRREVERSER is a trademark of Deere & Company Transmission

Replace Mid-Mount Solenoid Switch

Replace External Raise/Lower Switch—Isolated Open Operator Station and Cab Tractors

Replace Mid-Mount Solenoid

Replace Clutch Enable Solenoid—POWRREVERSER POWRREVERSER is a trademark of Deere & Company Transmission

Replace Trans Forward Solenoid—POWRREVERSER POWRREVERSER is a trademark of Deere & Company Transmission

Replace Trans Reverse Solenoid—POWRREVERSER POWRREVERSER is a trademark of Deere & Company Transmission

Replace High Solenoid—POWRREVERSER POWRREVERSER is a trademark of Deere & Company Transmission—With Electro-Hydraulic Hi/Lo

Replace Rear PTO Solenoid—Electro-Hydraulic PTO

Replace MFWD Solenoid

Replace MFWD Switch