John Deere 5220 Tractor operator’s manual by bhfy94m

5220,5320,5420,and 5520TractorOperation andTest

TECHNICALMANUAL

5220,5320,5420,and5520Tractor

OperationandTest

TM204918MAR02(ENGLISH)

Forcompleteserviceinformationalsosee:

5220,5320,5420,and5520Tractor

Repair ...............................

ComponentTechnicalManual4045

Engine

ComponentTechnicalManual4045

MechanicalFuelSystem ................

ComponentTechnicalManual3029

Engine ..............................

AlternatorsandStartingMotors ..........

TM2048

CTM104

CTM207

CTM125

CTM77

JohnDeereAugustaWorks LITHOINU.S.A.

Foreword

Thismanualiswrittenforanexperiencedtechnician. Essentialtoolsrequiredinperformingcertainservice workareidentifiedinthismanualandare recommendedforuse.

Livewithsafety:Readthesafetymessagesinthe introductionofthismanualandthecautionspresented throughoutthetextofthemanual.

Thisisthesafety-alertsymbol.Whenyouseethis symbolonthemachineorinthismanual,bealertto thepotentialforpersonalinjury.

Technicalmanualsaredividedintwoparts:repairand operationandtests.Repairsectionstellhowtorepair thecomponents.Operationandtestssectionshelpyou identifythemajorityofroutinefailuresquickly.

Informationisorganizedingroupsforthevarious componentsrequiringserviceinstruction.Atthe beginningofeachgrouparesummarylistingsofall applicableessentialtools,serviceequipmentandtools, othermaterialsneededtodothejob,servicepartskits, specifications,weartolerances,andtorquevalues.

TechnicalManualsareconciseguidesforspecific machines.Theyareon-the-jobguidescontainingonly thevitalinformationneededfordiagnosis,analysis, testing,andrepair.

Fundamentalserviceinformationisavailablefrom othersourcescoveringbasictheoryofoperation, fundamentalsoftroubleshooting,generalmaintenance, andbasictypeoffailuresandtheircauses.

Introduction DX,TMIFC–19–29SEP98–1/1

TM2049(18MAR02)5220,5320,5420,and5520Tractors 031802 PN=2

SECTION270—HydraulicSystemOperation,Tests,

Allinformation,illustrationsandspecificationsinthismanualarebasedon thelatestinformationavailableatthetimeofpublication.Therightis reservedtomakechangesatanytimewithoutnotice.

210

Group05—ComponentLocation Group10—OperationalCheckoutProcedures Group10—TheoryofOperation Group15—Diagnosis SECTION220—EngineOperation,Tests,and Group16—HydraulicTests—WithoutSCV Adjustments 220 Group17—HydraulicTests—WithSCV Group05—ComponentLocation Group18—HydraulicTests—All Group10—TheoryofOperation Group19—Adjustments Group15—Diagnosis,Tests,andAdjustments Group20—HydraulicSchematics

SECTION290—OperatorStation Adjustments Group05—ComponentLocation Group05—ComponentLocation Group10—TheoryofOperation Group10—TheoryofOperation Group15—Diagnosis,Tests,andAdjustments Group15—Diagnosis,TestsandAdjustments SECTION299—DealerFabricatedTools 230

Group00—DealerFabricatedTools

Group05—ComponentLocation Group10—TheoryofOperation Group15—Diagnosis,TestandAdjust Group20—WiringSchematics

andAdjustments Group05—ComponentLocation— CollarShift/SyncShuttle Transmission 240 Group06—ComponentLocation—PowrReverser Transmission Group10—TheoryofOperation— CollarShift/SyncShuttle Transmission Group11—TheoryofOperation—PowrReverser Transmission Group15—Diagnosis,Tests,andAdjustments— CS/SSTransmission Group16—Diagnosis,Tests,andAdjustments— PowrReverser 250

Group05—ComponentLocation Group10—TheoryofOperation

Contents

SECTION210—OperationalCheckoutProceduresandAdjustments

SECTION230—Fuel/AirOperation,Tests,and

SECTION240—ElectricalSystemOperation,Test&

Adjust

SECTION250—PowerTrainOperation,Tests

SECTION260—SteeringandBrakeOperation,Test &Adjust

Group15—Diagnosis,TestsandAdjustments

260 COPYRIGHT  2002 DEERE&COMPANY Moline,Illinois Allrightsreserved AJohnDeereILLUSTRUCTION Manual 270 290 299 INDX TM2049(18MAR02) i 5220,5320,5420,and5520Tractors 031802 PN=1

210 Section210

Contents PagePage Group10—OperationalCheckoutProcedures RockshaftCheck—IsolatedOpen Specifications 210-10-1 OperatorStationandCabTractors ...... 210-10-33 OperationalCheckoutProcedure SelectiveControlValveCheck—Straddle Information 210-10-1 MountTractors 210-10-34 EngineOilLevelandConditionCheck ...... 210-10-2 SelectiveControlValveCheck—Isolated CoolantLevelandConditionCheck ........ 210-10-3 OpenOperatorStationandCab TransmissionandHydraulicOilCheck 210-10-4 Tractors 210-10-35 3-CylinderFanandV-BeltCheck 210-10-5 FrontEndLoaderJoystickControlCheck 4-CylinderFanandSerpentineBeltCheck...210-10-6 (Optional) 210-10-36 CompressorBeltCheck 210-10-7 A/CSystemOperationalCheck 210-10-37 FuelSystemCheck 210-10-8 CabHeaterValveCheck ................ 210-10-38 AirIntakeSystemCheck 210-10-9 MiscellaneousChecks .................. 210-10-38 ElectricalSystemCheck 210-10-10 HydraulicSystemCheck 210-10-11 MFWDOilCheck ..................... 210-10-12 MFWDDifferentialOilCheck ............. 210-10-12 IndicatorLampsCheck 210-10-13 CabBlowerMotorCheck 210-10-14 A/CCompressorClutchCheck 210-10-15 EngineStartCheck—StraddleMount Tractors 210-10-16 EngineStartCheck—IsolatedOpen OperatorStationandCabTractors 210-10-17 TransmissionNeutralStartCheck—Straddle MountTractors 210-10-18 TransmissionNeutralStartCheck— IsolatedOpenOperatorStationandCab Tractors 210-10-19 PTONeutralStartCheck................ 210-10-20 EngineFastandSlowIdleOperation 210-10-21 FootThrottlePedalCheck—IsolatedOpen OperatorStationandCabTractors 210-10-22 PowerSteeringCheck.................. 210-10-23 DifferentialLockCheck 210-10-23 PTOEngagementCheck 210-10-24 ClutchCheck 210-10-25 TransmissionShiftCheck ............... 210-10-26 RangeLeverShiftCheck ............... 210-10-27 MFWDDriveCheck 210-10-28 BrakeCheck 210-10-29 ParkBrakeCheck—CollarShiftand SYNCSHUTTLE Transmissions ....... 210-10-30 ParkBrakeCheck—POWRREVERSER Transmission 210-10-31 RockshaftCheck—StraddleMount Tractors ........................... 210-10-32 TM2049(18MAR02) 210-1 5220,5320,5420,and5520Tractors 031802 PN=1

OperationalCheckoutProcedures

OperationalCheckoutProcedureInformation

Theprocedurescoveredinthisgroupareusedtogivea quickcheckoutofallthesystemsandcomponentsonthe unit.Thesecheckoutsshouldberuntoensureproper operationafteranyextendedstorage,whentheunit comesinforservice,andafterrepairshavebeenmade ontheunit.Theycanalsobehelpfulindeterminingthe valueoftheunitattrade-intime.Theunitshouldbe placedonalevelsurfacetorunthecheckouts.Allthe checkoutsshouldbedoneandallofthestepsofeach checkoutshouldbefollowed.

Eachcheckoutlists:

• Conditions—Howtheunitshouldbesetupforthe checkout.

• Procedure—Thespecificactiontobedone.

• Normal—Whatshouldhappenorbeheardorbeseen.

• IfNotNormal—Wheretogoifothertestsor adjustmentsareneeded.

Whenperformingthecheckout,besuretosetyour machineuptothetestconditionslistedandfollowthe sequencecarefully.The“Normal”paragraphgivesthe resultthatshouldhappenwhenperformingthecheckout. Iftheresultsarenotnormal,gototheSectionandGroup listedinthe“IfNotNormal”paragraphtodeterminethe causeandrepairthemalfunction.

Thephotographthataccompanieseachcheckout procedureisincludedtohelpconductthecheckout.

Group10 OperationalCheckoutProcedures 210 10 1 OUO1082,0000190–19–26MAR01–1/1 Specifications ItemMeasurementSpecification EngineSlowIdleSpeedRotation825 ± 25 EngineFastIdleSpeedRotation2625 ± 25 MX,21010HE,1A–19–12SEP00–1/1

TM2049(18MAR02) 210-10-1 5220,5320,5420,and5520Tractors 031802 PN=7

EngineOilLevelandConditionCheck

CONDITIONS:

• Machineparkedonflat,levelsurface.

• KeyswitchinOFFposition.

• Transmissioninparkposition.

• Enginenotrunforatleastfiveminutes.

PROCEDURE:

• Cleandirtfromareaarounddipstickopening.

• Removeandwipeoffdipstick.

• Installdipstickuntilseatedintube.

• Removedipstickandchecklevelandconditionofoil.

NORMAL:

• Oillevelbetweenfullandaddmarksofdipstick.

• Oilnotexcessivelythickorthin.

• Nofuelodorinoil.

• Novisibleforeignmaterialinoil.

IFNOTNORMAL:

• Addproperoiltofullmarkondipstick.(See TransmissionandHydraulicOilinTM2048Section10, Group20.)

• Replacecontaminatedoilandfilter.

• SeeSection220,Group15forDiagnosis,Tests,and Adjustments

OperationalCheckoutProcedures 210 10 2

OUO1082,0000140–19–13MAR01–1/1

M45603–UN–06AUG90

TM2049(18MAR02) 210-10-2 5220,5320,5420,and5520Tractors 031802 PN=8

CoolantLevelandConditionCheck

CONDITIONS:

• Machineparkedonflat,levelsurface.

• KeyswitchinOFFposition.

• Transmissioninparkposition.

PROCEDURE:

• Observelevelofcoolantinrecoverytank.

• Checkconditionofrecoverytankandtank-to-radiator hose.

NORMAL:

• Recoverytankandhoseingoodcondition,noholesor cracks.

• Coolantatfullmarkifengineatoperatingtemperature.

• Coolantclean;nooil,rust-likediscolorationorforeign materialinfluid.

IFNOTNORMAL:

• Replacerecoverytankorhose,addcoolant,and rechecklevelafteroperation.

• Addcoolanttopropermarkontank.

• Checkradiator-to-tankhoseandrecoverytankforholes orcracks.

• Changecoolantandflushcoolingsystem.

• SeeSection220,Group15forDiagnosis,Tests,and Adjustments.

OperationalCheckoutProcedures 210 10 3

OUO1082,0000141–19–13MAR01–1/1

LV4946–UN–09JUN00

LV4947–UN–09JUN00

3-CylinderEngine 4-CylinderEngine

TM2049(18MAR02) 210-10-3 5220,5320,5420,and5520Tractors 031802 PN=9

TransmissionandHydraulicOilCheck

CONDITIONS:

• Machineparkedonflat,levelsurface.

• KeyswitchinOFFposition.

• Transmissioninparkposition.

PROCEDURE:

• Straddlemounttractors:Cleandirtfromareaaround dipstickopening(A).

• Isolatedopenoperatorplatformandcabtractors:Clean dirtfromareaarounddipstickopening(B).

• Removeandwipeoffdipstick.

• Installdipstickuntilseatedintube.

• Removedipstickandchecklevelandconditionofoil.

NORMAL:

• Oillevelbetweenfullandaddmarksofdipstick.

• Oilnotexcessivelythickorthin.

• Novisibleforeignmaterialinoil.

IFNOTNORMAL:

• Addproperoiltofullmarkondipstick.

• Replacecontaminatedoilandfilter.

• SeeDiagnosis,Tests,andAdjustments—CS/SS Transmission(Section250,Group15),Diagnosis,Tests andAdjustments(Section260,Group15),orDiagnosis (Section270,Group15)fortransmissionandhydraulic systemdiagnosis,testsandadjustments.

OperationalCheckoutProcedures 210 10 4

OUO1082,0000126–19–08MAR02–1/1

LV6183–UN–15FEB01 LV6475–UN–14MAR01

A—Dipstick(StraddleMountTractor) B—Dipstick(IsolatedOpenOperatorStationor CabTractors)

TM2049(18MAR02) 210-10-4 5220,5320,5420,and5520Tractors 031802 PN=10

3-CylinderFanandV-BeltCheck

CONDITIONS:

• KeyswitchinOFFposition.

• Enginenotrunforatleast15minutes.

• Transmissioninparkposition.

PROCEDURE:

• InspectfanandV-beltfordamage.

• Checkbelttension.(SeeFan/AlternatorV-Belt Adjustment—5220and5320TractorsinSection220, Group15.)

NORMAL:

• Fanundamaged;nocracksorbentblades.

• Beltnotcracked,frayedorglazed.

• Beltdoesnot“squeal”duringoperation.

IFNOTNORMAL:

• Replacedamagedfanorbelt.

• Adjustbelttension.(SeeFan/AlternatorV-Belt Adjustment—5220and5320TractorsinSection220, Group15.)

OUO1082,0000142–19–13MAR01–1/1

OperationalCheckoutProcedures 210 10 5

LV6192–UN–15FEB01

TM2049(18MAR02) 210-10-5 5220,5320,5420,and5520Tractors 031802 PN=11

4-CylinderFanandSerpentineBeltCheck

CONDITIONS:

• KeyswitchinOFFposition.

• Enginenotrunforatleast15minutes.

• Transmissioninparkposition.

PROCEDURE:

• Inspectfanandserpentinebeltfordamage.

• Checkbelttensioner(A)springtension.(SeeInspect andReplaceBeltTensioner—Models5420and5520in TM2048Section20,Group10.)

NORMAL:

• Fanundamaged;nocracksorbentblades.

• Beltnotcracked,frayedorglazed.

• Beltdoesnot“squeal”duringoperation.

IFNOTNORMAL:

• Replacedamagedfanorserpentinebelt.

• Replacebelttensioner.(SeeInspectandReplaceBelt Tensioner—Models5420and5520inTM2048Section 20,Group10.)

OperationalCheckoutProcedures 210 10 6

OUO1082,0000146–19–28FEB02–1/1 LV6178–UN–15FEB01 A—BeltTensioner

TM2049(18MAR02) 210-10-6 5220,5320,5420,and5520Tractors 031802 PN=12

CompressorBeltCheck

NOTE:Three-cylinderengineshown.Someprocedures forthefour-cylinderengineareslightlydifferent. Seespecificsbelow.

NOTE:Airintaketuberemovedforclarityofphoto.

CONDITIONS:

• KeyswitchinOFFposition.

• Enginenotrunforatleast15minutes.

• Transmissioninparkposition.

PROCEDURE:

• Inspectbeltfordamage.

• 3-cylinderengines:Checkbelttension.(See Fan/AlternatorV-BeltAdjustment—5220and5320 TractorsandCompressorDriveBeltAdjustment— 3-CylinderinSection220,Group15.)

• 4-cylinderengines:Inspectbelttensionerandspring tension.(SeeInspectandReplaceBeltTensioner— Models5420and5520inTM2048Section20,Group 10.)

NORMAL:

• Beltnotcracked,frayedorglazed.

• Beltdoesnot“squeal”duringoperation.

IFNOTNORMAL:

• Replacedamagedcompressorbelt.

• 3-cylinderengines:Adjustbelttension.(See Fan/AlternatorV-BeltAdjustment—5220and5320 TractorsandCompressorDriveBeltAdjustment— 3-CylinderinSection220,Group15.)

• 4-cylinderengines:Replacebelttensioner.(SeeInspect andReplaceBeltTensioner—Models5420and5520in TM2048Section20,Group10.)

OperationalCheckoutProcedures 210 10 7

OUO1082,0000147–19–28FEB02–1/1

LV6184–UN–15FEB01

TM2049(18MAR02) 210-10-7 5220,5320,5420,and5520Tractors 031802 PN=13

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FuelSystemCheck

CONDITIONS:

• Machineparkedonflat,levelsurface.

• KeyswitchinOFFposition.

• Transmissioninparkposition.

• Straddlemounttractors:Fueldrainvalve(A)closed.

• Isolatedopenoperatorstationorcabtractors:Fuel drainvalve(B)closed.

• Fuelshut-offvalve(C)open.

PROCEDURE:

• Observefuellevelandcondition.

• Checkfueltankcapandsealcondition.

• Checkfuelfilter(D)condition.

• Checkfueltank,lines,andhosesforkinks,leaks,or damage.

NORMAL:

• FuellevelOK.

• Correcttypeandgradeofcleanfuel.

• Fueltankoverflowhoseandventvalveingood condition.(Nopressureorvacuumobservedinfueltank whencapisremoved.)

• Noleaksinsystem.

• Nowaterorsedimentinfuelfilterbowl.

IFNOTNORMAL:

• Addcorrecttypeandgradeofcleanfuel.(SeeSection 10,Group20inTM2048.)

• Cleancontaminatedfueltank,filter,orlines.

• Repairorreplacedamagedfueltank,cap,drainvalve, filter,orlines.(SeeSection30,Group05inTM2048.)

A—FuelDrainValve(StraddleMount)

B—FuelDrainValve(IsolatedOpenOperator StationorCabTractors)

C—FuelShut-OffValve

D—FuelFilter

OperationalCheckoutProcedures 210 10 8

OUO1082,0000125–19–08MAR02–1/1

LV6187–UN–15FEB01 LV6185–UN–15FEB01 LV6186–UN–15FEB01

TM2049(18MAR02) 210-10-8 5220,5320,5420,and5520Tractors 031802 PN=14

AirIntakeSystemCheck

CONDITIONS:

• KeyswitchinOFFposition.

• Transmissioninparkposition.

PROCEDURE:

• Observeconditionofprimaryandsecondaryairfilter elements.

• Checkconditionofairintakehose,tube,and turbocharger(ifequipped).

• Observeaircleanerrestrictionindicatorondash(engine running).

NORMAL:

• Airintakeandelementsfreeofdebris.

• Airintakehosesandtubeingoodcondition.Hose clampstight.Intaketubegasketintact.

• Aircleanerunloadervalvenotplugged.

• Aircleanerhousingsealed.

• Aircleanerrestrictionindicatorlightoff.

• Turbocharger(ifequipped)operateswithnogrindingor bearingnoise.

IFNOTNORMAL:

• Clean,repairorreplaceasrequired.

• 5320and5520tractors:Repairdamagedturbocharger, (ifequipped).

• SeeSection220,Group15fordiagnosis,tests,and adjustments.

• SeeSection30,Group10forinspectionandrepair.

OperationalCheckoutProcedures 210 10 9

OUO1082,0000143–19–28FEB02–1/1

LV6189–UN–15FEB01

LV6196–UN–15FEB01

AirFilter(5320Shown) Turbocharger(5320Shown)

TM2049(18MAR02) 210-10-9 5220,5320,5420,and5520Tractors 031802 PN=15