JOHN DEERE 5204 TRACTOR TECHNICAL MANUAL TM900019 - PDF

John Deere Agriculture

5103, 5203, 5303, 5403, 5045, 5055, 5065 And 5075 USA, Mexico and Australia Tractors; 5103, 5203, 5303 And 5403 Australia Tractors; 5303 And 5403 Latin America Tractors; 5204 And 5303 Mexico Tractors

TECHNICAL MANUAL Models 5303, 5103, 5203, 5204, 5403

TM900019, September 2013

TM900019-TECHNICAL MANUAL

(g) by Belgreen

Table of contents

FOREWORD Section 10 - GENERAL INFORMATION Group 05 - Safety Group 10 - General Specifications Group 15 - Fuel and Lubricants Group 20 - Serial Number Locations Group 25 - Features and Accessories Section 20 - ENGINE REPAIR Group 05 - Engine Group 10 - Cylinder Head and Valves Group 15 - Cyl. Block, Liners, Pistons & Rods Group 20 - Crankshaft, Main Bearings and Flywheel Group 25 - Camshaft and Timing Gear Train Group 30 - Lubrication System Group 35 - Cooling System Section 30 - FUEL AND AIR REPAIR Group 05 - Fuel System Group 10 - Air Intake and Exhaust System Group 15 - Speed Control Linkage Section 40 - ELECTRICAL REPAIR Group 05 - Battery, Starter and Alternator Group 10 - Electrical System Components Group 15 - Wiring Harness Section 50 - POWER TRAIN REPAIR Group 05 - Clutch Housing Group 10 - Clutch Assembly Group 15 - ′S′ Transmission Group 20 - ′AA′ Transmission Group 21 - Rear PTO (′S′ Transmission) Group 25 - Rear PTO (′AA′ Transmission) Group 26 - Differential Group 30 - Final Drives Group 35 - Mechanical Front Wheel Drive Section 60 - STEERING AND BRAKE REPAIR Group 05 - Steering Repair Group 10 - Brake Repair (′S′ Transmission) Group 15 - Brake Repair (′AA′ Transmission) Section 70 - HYDRAULIC REPAIR Group 05 - Hydraulic Pump and Filter Group 10 - MITA Rockshaft Group 15 - JD Rockshaft Group 20 - MITA Selective Control Valve (SCV) Group 25 - EATON Selective Control Valve (SCV) Group 30 - Mid Mount Selective Control Valve (SCV) Section 80 - MISCELLANEOUS REPAIR Group 05 - Front Axle - 2WD Group 10 - Wheels Group 15 - 3-Point Hitch Group 25 - Hood <- Go to Global Table of contents

TM900019-TECHNICAL MANUAL

TM900019-TECHNICAL MANUAL

(g) by Belgreen

Section 90 - OPERATOR STATION REPAIR Group 05 - Seat and Support Group 06 - Center Console Group 10 - Roll-GardRoll-Gard is a trademark of Deere & Company Group 15 - Operator Platform Group 20 - Fenders Group 25 - Canopy (If Equipped) Section 210 - OPERATIONAL CHECKOUT PROCEDURES Group 10 - Operational Checkout Procedures Section 220 - ENGINE OPERATION, TESTS AND ADJUSTMENTS Group 05 - Component Location Group 10 - Theory of Operation Group 15 - Diagnosis, Tests and Adjustments Section 230 - FUEL/AIR OPERATION, TEST AND ADJUSTMENTS Group 05 - Component Location Group 10 - Theory of Operation Group 15 - Diagnosis, Tests and Adjustments Section 240 - ELECTRICAL SYSTEM OPERATION, TESTS & ADJUST Group 05 - Component Location Group 10 - Theory of Operation—Latin America, Mexico, USA and Australia (5103, 5203, 5303, 5403) Tractors Group 15 - Theory of Operation—USA and Australia Tractors Group 20 - Diagnosis, Test and Adjust—Latin America, Mexico (5303), USA and Australia (5103, 5203, 5303, 5403) Tractors Group 25 - Diagnosis, Test and Adjust—USA and Australia Tractors Group 30 - Diagnosis, Test and Adjust (Mexico 5204 Tractors) Group 35 - Wiring Schematics—Latin America, Mexico (5303), USA and Australia (5103, 5203, 5303, 5403) Tractors Group 40 - Wiring Schematics—For USA and Australia Tractors Group 45 - Wiring Schematics (Mexico 5204 Tractors) Group 50 - Component Information—Connectors(For USA and Australia Tractors) Section 250 - POWER TRAIN OPERATION, TESTS AND ADJUSTMENTS Group 05 - Component Location—Transmission Group 10 - Theory of Operation—Transmission Group 15 - Diagnosis, Tests, and Adjustments-Transmission Section 260 - STEERING AND BRAKE OPERATION, TEST & ADJUSTMENTS Group 05 - Component Location Group 10 - Theory of Operation Group 15 - Diagnosis, Tests and Adjustments Section 270 - HYDRAULIC SYSTEM OPERATION, TEST AND ADJUSTMENTS Group 05 - Component Location Group 10 - Theory of Operation Group 15 - Diagnosis Group 20 - Hydraulic Tests - Without SCV Group 25 - Hydraulic Tests—With SCV Group 18 - Hydraulic Tests—With Mid Mount Control Valve Group 30 - Hydraulic Tests - All Group 40 - Adjustments Group 45 - Hydraulic Schematics

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TM900019-TECHNICAL MANUAL

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TM900019-TECHNICAL MANUAL

GENERAL INFORMATION

(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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TM900019-TECHNICAL MANUAL

(g) by Belgreen

Section 10 - GENERAL INFORMATION Table of contents Group 05 - Safety ...................................................................................................................... 2 Recognize Safety Information ................................................................................................ 2 Understand Signal Words ....................................................................................................... 2 Follow Safety Instructions ...................................................................................................... 3 Handle Fluids Safely—Avoid Fires .......................................................................................... 3 Prevent Battery Explosions .................................................................................................... 4 Prepare for Emergencies ........................................................................................................ 5 Prevent Acid Burns ................................................................................................................. 6 Service Cooling System Safely ............................................................................................... 7 Avoid High-Pressure Fluids ..................................................................................................... 7 Park Machine Safely ............................................................................................................... 8 Support Machine Properly ...................................................................................................... 9 Wear Protective Clothing ..................................................................................................... 10 Work in Clean Area .............................................................................................................. 11 Service Machines Safely ....................................................................................................... 11 Work In Ventilated Area ....................................................................................................... 12 Illuminate Work Area Safely ................................................................................................. 12 Replace Safety Signs ............................................................................................................ 13 Use Proper Lifting Equipment ............................................................................................... 13 Service Tires Safely .............................................................................................................. 14 Avoid Harmful Asbestos Dust ............................................................................................... 16 Avoid Heating Near Pressurized Fluid Lines ......................................................................... 16 Remove Paint Before Welding or Heating ............................................................................ 17 Use Proper Tools .................................................................................................................. 18 Dispose of Waste Properly ................................................................................................... 19 Live With Safety ................................................................................................................... 19 Group 10 - General Specifications ........................................................................................ 21 Machine Specifications (For USA and Australia Tractors) ..................................................... 21 Machine Specifications (For USA Tractors) ........................................................................... 24 Machine Specifications (For Latin America Tractors) ........................................................... 29 Machine Specifications (Mexico Tractors) ............................................................................ 31 Repair Specifications ............................................................................................................ 33 Ground Speed Estimates ...................................................................................................... 38 Service Recommendations for O-Ring Boss Fittings ............................................................. 42 Service Recommendations for Flat Face O-Ring Seal Fittings .............................................. 45 Metric Bolt and Cap Screw Torque Values ............................................................................ 47 Unified Inch Bolt and Cap Screw Torque Values ................................................................... 48 Group 15 - Fuel and Lubricants ............................................................................................. 49 Diesel Fuel ........................................................................................................................... 49 Biodiesel Fuel ....................................................................................................................... 51 Handling and Storing Diesel Fuel ......................................................................................... 53 Fuel Storage ......................................................................................................................... 54 Do Not Use Galvanized Containers ...................................................................................... 55 Fill Fuel Tank ........................................................................................................................ 56 Diesel Engine Oil .................................................................................................................. 58

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TM900019-TECHNICAL MANUAL

TM900019-TECHNICAL MANUAL

(g) by Belgreen

Heavy Duty Diesel Engine Coolant ....................................................................................... 60 Transmission and Hydraulic Oil ............................................................................................ 62 Grease (Specific Application) ............................................................................................... 63 Grease .................................................................................................................................. 63 Alternative and Synthetic Lubricants ................................................................................... 64 Lubricant Storage ................................................................................................................. 64 Group 20 - Serial Number Locations .................................................................................... 65 Serial Numbers ..................................................................................................................... 65 Product Identification Number Location ............................................................................... 65 Engine Serial Number Location ............................................................................................ 65 Fuel Injection Pump Serial Number Location ........................................................................ 66 Alternator Serial Number Location ....................................................................................... 67 Power Steering Valve Serial Number Location ..................................................................... 67 Starter Serial Number Location ............................................................................................ 68 Transmission Serial Number Location .................................................................................. 69 Front Axle Serial Number Location (2WD) ............................................................................ 70 Front Axle Serial Number Location (MFWD) ......................................................................... 70 Group 25 - Features and Accessories ................................................................................... 72 Features and Accessories ..................................................................................................... 72 Standard Features ................................................................................................................ 73 Factory Installed Optional Equipment .................................................................................. 79 Field Installed Optional Kits and Accessories ....................................................................... 79

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TM900019-TECHNICAL MANUAL

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

Section 10 - GENERAL INFORMATION

Group 05: Safety

Group 05 - Safety Recognize Safety Information

Safety-alert symbol 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

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TM900019-TECHNICAL MANUAL

Section 10 - GENERAL INFORMATION

Group 05: Safety

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 manual.

Follow Safety Instructions

Safety Messages 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.

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.

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Section 10 - GENERAL INFORMATION

Group 05: Safety

Handle Fluids Safely—Avoid Fires

Avoid Fires 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

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Section 10 - GENERAL INFORMATION

Group 05: Safety

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.

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

Prepare for Emergencies

First Aid Kit 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 10 - GENERAL INFORMATION

Group 05: Safety

Prevent Acid Burns

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. <- Go to Section TOC

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Section 10 - GENERAL INFORMATION

Group 05: Safety

4.Avoiding spilling or dripping electrolyte.

5.Use proper jump start procedure.

If you spill acid on yourself: 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.

Service Cooling System Safely

Cooling System Explosive release of fluids from pressurized cooling system can cause serious burns.

Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

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Section 10 - GENERAL INFORMATION

Group 05: Safety

Avoid High-Pressure Fluids

High-Pressure Fluids Escaping fluid under pressure can penetrate the skin causing serious injury.

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids.

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A.

Park Machine Safely

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Section 10 - GENERAL INFORMATION

Group 05: Safety

Remove the Key Before working on the machine: Lower all equipment to the ground.

Stop the engine and remove the key.

Disconnect the battery ground strap.

Hang a "DO NOT OPERATE" tag in operator station.

Support Machine Properly

Support Properly

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Section 10 - GENERAL INFORMATION

Group 05: Safety

Always lower the attachment or implement to the ground before you work on the machine. If the work requires that the machine or attachment be lifted, provide secure support for them.

If left in a raised position, hydraulically supported devices can settle or leak down.

Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. Follow recommended procedures in this manual.

When implements or attachments are used with a machine, always follow safety precautions listed in the implement or attachment operator′s manual.

Wear Protective Clothing

Protective Clothing Wear close fitting clothing and safety equipment appropriate to the job.

Prolonged exposure to loud noise can cause impairment or loss of hearing.

Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.

Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine.

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Section 10 - GENERAL INFORMATION

Group 05: Safety

Work in Clean Area

Clean Work Area Before starting a job: Clean work area and machine.

Make sure you have all necessary tools to do your job.

Have the right parts on hand.

Read all instructions thoroughly; do not attempt shortcuts.

Service Machines Safely

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Section 10 - GENERAL INFORMATION

Group 05: Safety

Moving Parts Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result.

Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.

Work In Ventilated Area

Engine exhaust fumes Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension.

If you do not have an exhaust pipe extension, open the doors and get outside air into the area.

Illuminate Work Area Safely

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Section 10 - GENERAL INFORMATION

Group 05: Safety

Work Area Safely Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.

Replace Safety Signs

Safety Signs Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement.

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Section 10 - GENERAL INFORMATION

Group 05: Safety

Use Proper Lifting Equipment

Proper Lifting Equipment Lifting heavy components incorrectly can cause severe injury or machine damage.

Follow recommended procedure for removal and installation of components in the manual.

Service Tires Safely

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Section 10 page 14

TM900019-TECHNICAL MANUAL

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