JOHN DEERE 5525N TRACTOR TM2198 - PDF MANUAL

John Deere Agriculture

5325N, 5425N and 5525N Tractors Diagnostic Technical Manual

DIAGNOSIS AND TESTS SERVICE MANUAL 5325N, 5425N, 5525N

TM2198, July 2010

TM2198-DIAGNOSIS AND TESTS SERVICE MANUAL

(g) by Belgreen

Table of contents FOREWORD Section 210 - GENERAL Group 05 - Safety Group 10 - General Specifications Group 15 - General References Section 211 - DIAGNOSTIC TROUBLE CODES Group CCU - CCU Code Diagnostics Group HCU - HCU Code Diagnostics Group PTR - PTR Code Diagnostics Section 212 - OBSERVABLE SYMPTOMS Group 20 - Engines Group 30 - Fuel and Air Group 40 - Electrical Group 45 - Control Units Group 55 - POWRREVERSER Transmissions Group 56 - Drive Systems Group 60 - Steering and Brakes Group 70 - Hydraulics Group 90 - Operator Station Section 213 - SYSTEM DIAGNOSIS Group 40 - Starting, Charging and Start Aid Group 55 - POWRREVERSER Transmission Group 56A - Differential Lock Group 56B - MFWD Group 56C - Rear PTO Group 60A - Steering Group 60B - Rear Brakes Group 70A - Rear SCV System Diagnosis Group 70B - Mid-Mount Control Valve System Diagnosis Group 70C - Rear Hitch System Diagnosis Group 90 - Air Conditioning Section 220 - ENGINES Group 05 - General Information Group 15 - Tests and Adjustments Group 20 - Engine System Theory of Operation Section 230 - FUEL AND AIR Group 05 - General Information Group 20 - Fuel and Air Theory of Operation Section 240 - ELECTRICAL Group 05 - Load Center Fuses and Relays Group 15 - Tests and Adjustments Group 20 - Theory of Operation Group 25 - Functional Schematics Group 30 - Connector Information Section 245 - CONTROL UNITS Group 05 - General References Group 15 - Tests and Adjustments Group CCU - CCU

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TM2198-DIAGNOSIS AND TESTS SERVICE MANUAL

TM2198-DIAGNOSIS AND TESTS SERVICE MANUAL

(g) by Belgreen

Group HCU - HCU Group PTR - PTR Section 255 - POWRREVERSERPOWRREVERSER IS A TRADEMARK OF DEERE & COMPANY TRANSMISSION Group 05 - General Information Group 10 - Preliminary and Operational Checks Group 15 - Tests and Adjustments Group 20 - Theory of Operation Group 25 - Schematics and Diagrams Section 256 - DRIVE SYSTEMS Group 05 - General Information Group 10 - Preliminary and Operational Checks Group 15 - Tests and Adjustments Group 20 - Theory of Operation Group 25 - Schematics and Diagrams Section 260 - STEERING AND BRAKES Group 05 - General Information Group 10 - Preliminary And Operational Checks Group 15 - Test And Adjustments Group 20 - Theory Of Operation Section 270 - HYDRAULICS Group 05 - General Information Group 10 - Operational and Preliminary Checks Group 15 - Tests and Adjustments Group 20 - Theory of Operation Group 25 - Schematics and Diagrams Section 290 - OPERATOR STATION Group 05 - General information Group 10 - Preliminary and Operational Checks Group 15 - Tests and Adjustments Group 20 - Theory of Operation Section 299 - SERVICE TOOLS Group 05 - Dealer Fabricated Tools Group 10 - Service Tools and Kits

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TM2198-DIAGNOSIS AND TESTS SERVICE MANUAL

For the full PDF version of this manual, Please click on the above download PDF button.

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TM2198-DIAGNOSIS AND TESTS SERVICE MANUAL

GENERAL

(g) by Belgreen

Foreword This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use.

Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.

CAUTION: This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury.

Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components. Operation and tests sections help you identify the majority of routine failures quickly.

Information is organized in groups for the various components requiring service instruction.

At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values.

Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair.

Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.

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TM2198-DIAGNOSIS AND TESTS SERVICE MANUAL

TM2198-DIAGNOSIS AND TESTS SERVICE MANUAL

(g) by Belgreen

Section 210 - GENERAL Table of contents Group 05 - Safety ...................................................................................................................... 1 Recognize Safety Information ................................................................................................ 1 Understand Signal Words ....................................................................................................... 1 Follow Safety Instructions ...................................................................................................... 2 Handle Fluids Safely—Avoid Fires .......................................................................................... 2 Prevent Battery Explosions .................................................................................................... 3 Prepare for Emergencies ........................................................................................................ 4 Prevent Acid Burns ................................................................................................................. 5 Service and Operate Chemical Sprayers Safely ..................................................................... 7 Handle Chemical Products Safely ........................................................................................... 8 Avoid High-Pressure Fluids ..................................................................................................... 9 Park Machine Safely ............................................................................................................... 9 Support Machine Properly .................................................................................................... 10 Wear Protective Clothing ..................................................................................................... 10 Work in Clean Area .............................................................................................................. 11 Service Machines Safely ....................................................................................................... 12 Work In Ventilated Area ....................................................................................................... 12 Illuminate Work Area Safely ................................................................................................. 13 Replace Safety Signs ............................................................................................................ 13 Use Proper Lifting Equipment ............................................................................................... 14 Remove Paint Before Welding or Heating ............................................................................ 14 Avoid Heating Near Pressurized Fluid Lines ......................................................................... 15 Keep ROPS Installed Properly ............................................................................................... 16 Service Tires Safely .............................................................................................................. 17 Avoid Harmful Asbestos Dust ............................................................................................... 18 Practice Safe Maintenance ................................................................................................... 18 Use Proper Tools .................................................................................................................. 20 Dispose of Waste Properly ................................................................................................... 20 Prevent Machine Runaway ................................................................................................... 21 Handle Starting Fluid Safely ................................................................................................. 21 Service Cooling System Safely ............................................................................................. 22 Stay Clear of Rotating Drivelines ......................................................................................... 23 Protect Against High Pressure Spray .................................................................................... 23 Construct Dealer-Made Tools Safely .................................................................................... 24 Clean Vehicle of Hazardous Pesticides ................................................................................. 24 Live With Safety ................................................................................................................... 25 Group 10 - General Specifications ........................................................................................ 26 Reference 210-10-001, General Specifications .................................................................... 26 Reference 210-10-002, General Reference List ................................................................... 27 Group 15 - General References ............................................................................................. 29 Reference 210-15-002, Bolt and Cap Screw Torque Values ................................................. 29 Reference 210-15-003, Glossary of Terms ........................................................................... 31 Reference 210-15-004, JIC Hydraulic Symbols ..................................................................... 34 Reference 210-15-005, Wiring Diagram and Schematic Information ................................... 37 Reference 210-15-006, Electrical Schematic Symbols ......................................................... 37 Reference 210-15-007, Reading Wiring Schematics and Diagrams ..................................... 41

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TM2198-DIAGNOSIS AND TESTS SERVICE MANUAL

TM2198-DIAGNOSIS AND TESTS SERVICE MANUAL

(g) by Belgreen

Reference 210-15-008, Visually Inspect Electrical System ................................................... 46 Reference 210-15-009, Seven-Step Electrical Procedure ..................................................... 47 Reference 210-15-010, Using a Probe Light ......................................................................... 49 Reference 210-15-011, Circuit Types ................................................................................... 51 Reference 210-15-012, Circuit Malfunctions ........................................................................ 53 Reference 210-15-013, Troubleshooting Circuit Malfunctions .............................................. 57 Reference 210-15-014, Understanding Electrical vs. Electronic Circuits .............................. 62 Reference 210-15-015, Intermittent Electronic Problems .................................................... 65 Reference 210-15-016, Relay Circuit Types ......................................................................... 69 Reference 210-15-017, Using a Digital Multimeter .............................................................. 82 Reference 210-15-101, Troubleshooting Unresolved Problems ........................................... 84

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TM2198-DIAGNOSIS AND TESTS SERVICE MANUAL

Section 210 - GENERAL

Group 05: Safety

Group 05 - Safety Recognize Safety Information

This is a safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury.

Follow recommended precautions and safe operating practices.

Understand Signal Words

A signal word—DANGER, WARNING, or CAUTION—is used with the safety-alert symbol.

DANGER identifies the most serious hazards.

DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs. CAUTION also calls attention to safety messages in this <- Go to Section TOC

Section 210 page 1

TM2198-DIAGNOSIS AND TESTS SERVICE MANUAL

Section 210 - GENERAL

Group 05: Safety

manual.

Follow Safety Instructions

Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in good condition. Replace missing or damaged safety signs. Be sure new equipment components and repair parts include the current safety signs. Replacement safety signs are available from your John Deere dealer.

There can be additional safety information contained on parts and components sourced from suppliers that is not reproduced in this operator′s manual.

Learn how to operate the machine and how to use controls properly. Do not let anyone operate without instruction.

Keep your machine in proper working condition. Unauthorized modifications to the machine may impair the function and/or safety and affect machine life.

If you do not understand any part of this manual and need assistance, contact your John Deere dealer.

Handle Fluids Safely—Avoid Fires

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Section 210 page 2

TM2198-DIAGNOSIS AND TESTS SERVICE MANUAL

Section 210 - GENERAL

Group 05: Safety

When you work around fuel, do not smoke or work near heaters or other fire hazards.

Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers.

Make sure machine is clean of trash, grease, and debris.

Do not store oily rags; they can ignite and burn spontaneously.

Prevent Battery Explosions

Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode.

Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer. <- Go to Section TOC

Section 210 page 3

TM2198-DIAGNOSIS AND TESTS SERVICE MANUAL

Section 210 - GENERAL

Group 05: Safety

Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).

Prepare for Emergencies

Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.

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Section 210 page 4

TM2198-DIAGNOSIS AND TESTS SERVICE MANUAL

Section 210 - GENERAL

Group 05: Safety

Prevent Acid Burns

Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.

Avoid the hazard by: 1.Filling batteries in a well-ventilated area.

2.Wearing eye protection and rubber gloves.

3.Avoiding breathing fumes when electrolyte is added.

4.Avoiding spilling or dripping electrolyte.

5.Use proper jump start procedure.

If you spill acid on yourself: <- Go to Section TOC

Section 210 page 5

TM2198-DIAGNOSIS AND TESTS SERVICE MANUAL

Section 210 - GENERAL

Group 05: Safety

1.Flush your skin with water.

2.Apply baking soda or lime to help neutralize the acid.

3.Flush your eyes with water for 15—30 minutes. Get medical attention immediately.

If acid is swallowed: 1.Do not induce vomiting.

2.Drink large amounts of water or milk, but do not exceed 2 L (2 quarts).

3.Get medical attention immediately.

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Section 210 page 6

TM2198-DIAGNOSIS AND TESTS SERVICE MANUAL

Section 210 - GENERAL

Group 05: Safety

Service and Operate Chemical Sprayers Safely

Chemicals used in agricultural sprayers can be harmful to your health or the environment if not used carefully.

Always follow all label directions for effective, safe, and legal use of agricultural chemicals.

Reduce risk of exposure and injury: Wear appropriate personal protective equipment as recommended by the manufacturer. (See ‘Handle agricultural chemicals safely’ found in the Safety Section.)

Fill, flush, calibrate, and decontaminate sprayer in an area where runoff will not reach ponds, lakes or streams, livestock areas, or gardens, or near other people.

Keep children away from the chemicals, chemical solutions, and rinsates.

If spray or chemical concentrate contacts skin, hands, or face, wash immediately with soap and water.If spray or chemical concentrate gets into eyes, flush immediately with water. <- Go to Section TOC

Section 210 page 7

TM2198-DIAGNOSIS AND TESTS SERVICE MANUAL

Section 210 - GENERAL

Group 05: Safety

If nozzle clogs or system malfunctions, stop engine and relieve spray pressure from system.

Do not place nozzle tips or other components to the mouth to clear obstructions. Keep spare tips on hand for replacement.

Minimize risk of spray drift.

Use large nozzle tips operated at lower pressures Do not operate solution delivery system at pressures exceeding 345kPa (3.5 bar) (50 psi).

Do not spray when winds exceed 16 km/h (10 mph).

Do not spray when wind is blowing towards a nearby sensitive crop, garden, or populated area.

Properly dispose of unused chemicals, flushing solution, and empty chemical containers.

Decontaminate equipment used in mixing, transferring, and applying chemicals after use.

Handle Chemical Products Safely

Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere equipment include such items as lubricants, coolants, paints, and adhesives.

A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques.

Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and recommended equipment.

(See your John Deere dealer for MSDS’s on chemical products used with John Deere equipment.) <- Go to Section TOC

Section 210 page 8

TM2198-DIAGNOSIS AND TESTS SERVICE MANUAL

For the full PDF version of this manual, Please click on the above download PDF button.