User Manual

ManualsBrandsJohn Deere ManualsGardening equipment318

316,

318 and 420

Lawn and Garden

Tractors

For complete service information also see:

Onan Engines (16,18,20,24 HP) . . . . . . . . . CTM2

John Deere Horicon Works

TM1590 (17MAY95)

LITHO IN U.S.A.

ENGLISH

Summary of content (440 pages)

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316, 318 and 420 Lawn and Garden Tractors For complete service information also see: Onan Engines (16,18,20,24 HP) . . . . . . . . . CTM2 John Deere Horicon Works TM1590 (17MAY95) LITHO IN U.S.A.
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Contents SECTION 10—GENERAL INFORMATION Group 05—Safety Group 10—General Specifications Group 15—Repair Specifications Group 20—Test and Adjustment Specifications Group 25—Fuels and Lubricants Group 30—Serial Number Locations SECTION 240—ELECTRICAL CHECKOUT, OPERATION AND DIAGNOSIS Group 05—Electrical System Checkout Group 10—Electrical Schematics Group 15—Component Location and Operation Group 20—Electrical System Diagnosis Group 25—Electrical System Component Tests and Adjustments SECTION 20—ENGINE REPA
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Contents 10 20 40 50 60 70 80 220 240 250 TM1590 (17MAY95) ii 316, 318 & 420 Lawn and Garden Tractors 020895
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Contents 260 270 299 INDX TM1590 (17MAY95) iii 316, 318 & 420 Lawn and Garden Tractors 020895
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Contents 260 270 299 INDX TM1590 (17MAY95) iv 316, 318 & 420 Lawn and Garden Tractors 020895
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Introduction 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. N 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.
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Dealer Presentation Sheet JOHN DEERE DEALERS IMPORTANT: Please remove this page and route through your service department. This is a complete revision for models 316, 318 and 420 found in TM1277 and TM1345. The complete revision of remaining machines (322, 330, 332 and 430) can be found in TM1591. AFTER recieving both TM1590 and TM1591, please discard old TM1277 dated December 1987, TM1345 dated June 1986 and TM1309 dated July 1985. NOTE: There are several “versions” of each model tractor.
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Dealer Presentation Sheet TM1590 (17MAY95) 316, 318 & 420 Lawn and Garden Tractors 020895
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Section 10 GENERAL INFORMATION 10 Contents Page Group 05—Safety . . . . . . . . . . . . . . . . 10-05-1 Group 10—General Specifications Machine Specifications . . . . . . . . . . . . . 10-10-1 Group 15—Repair Specifications Repair Specifications . . . . . . . . . . . . Metric Series Torque Chart . . . . . . . . Inch Series Torque Chart . . . . . . . . . Metric Torque Values—Grade 7 . . . . . Set Screw Torque Chart . . . . . . . . . . Service Recommendations O-Ring Boss Fittings . . . . . . . . . . .
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Contents 10 TM1590 (17MAY95) 10-2 316, 318 & 420 Lawn and Garden Tractors 020895
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Group 05 Safety RECOGNIZE SAFETY INFORMATION 10 05 1 -UN-07DEC88 This is the safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. T81389 Follow recommended precautions and safe operating practices. DX,ALERT -19-03MAR93 DX,SIGNAL -19-03MAR93 DX,READ -19-03MAR93 UNDERSTAND SIGNAL WORDS -19-30SEP88 A signal word—DANGER, WARNING, or CAUTION—is used with the safety-alert symbol. DANGER identifies the most serious hazards.
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Safety HANDLE FLUIDS SAFELY—AVOID FIRES -UN-23AUG88 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. TS227 Do not store oily rags; they can ignite and burn spontaneously.
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Safety PREVENT ACID BURNS 10 05 3 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: 1. Flush your skin with water. 2.
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Safety HANDLE CHEMICAL PRODUCTS SAFELY -UN-26NOV90 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. TS1132 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.
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Safety PREPARE MACHINE FOR REPAIR 10 05 5 1. Move hydrostatic control lever to STOP position. -UN-24APR89 2. Disengage PTO’s 3. Lower all equipment to the ground. M34228 4. Engage park brake. 5. Stop the engine and remove the key. 6. Operate all hydraulic control levers to release hydraulic pressure in the system. Before you leave the operator’s seat, wait for engine and attachment parts to stop moving.
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Safety WEAR PROTECTIVE CLOTHING -UN-23AUG88 Wear close fitting clothing and safety equipment appropriate to the job. Prolonged exposure to loud noise can cause impairment or loss of hearing. TS206 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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Safety WORK IN VENTILATED AREA 10 05 7 -UN-23AUG88 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. TS220 If you do not have an exhaust pipe extension, open the doors and get outside air into the area.
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Safety -UN-23AUG88 Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. TS220 Do all work outside or in a well ventilated area. Dispose of paint and solvent properly. Remove paint before welding or heating: • If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. • If you use solvent or paint stripper, remove stripper with soap and water before welding.
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Safety SERVICE TIRES SAFELY 10 05 9 -UN-12APR90 Explosive separation of a tire and rim parts can cause serious injury or death. Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job. TS952 Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a wheel and tire assembly. The heat can cause an increase in air pressure resulting in a tire explosion.
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Safety PRACTICE SAFE MAINTENANCE Understand service procedure before doing work. Keep area clean and dry. Never lubricate, service, or adjust machine while it is moving. Keep hands, feet , and clothing from power-driven parts. Disengage all power and operate controls to relieve pressure. Lower equipment to the ground. Stop the engine. Remove the key. Allow machine to cool. Securely support any machine elements that must be raised for service work. Keep all parts in good condition and properly installed.
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Safety DISPOSE OF WASTE PROPERLY 10 05 11 -UN-26NOV90 Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with John Deere equipment include such items as oil, fuel, coolant, brake fluid, filters, and batteries. TS1133 Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them. Do not pour waste onto the ground, down a drain, or into any water source.
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Safety 10 05 12 TM1590 (17MAY95) 10-05-12 316, 318 & 420 Lawn and Garden Tractors 020895
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Group 10 General Specifications MACHINE SPECIFICATIONS 316 318 ENGINE Manufacturer . . . . . . . . . . . . . Type . . . . . . . . . . . . . . . . . . Model Number Early . . . . . . . . . . . . . . . . . Later . . . . . . . . . . . . . . . . . Horsepower (SAEJ607) Early . . . . . . . . . . . . . . . . . Later . . . . . . . . . . . . . . . . . Torque . . . . . . . . . . . . . . . . . Engine Rated Speeds Fast Idle (No Load) . . . . . . . Low Idle (No Load) . . . . . . . Number of Cylinders . . . . . . . .
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General Specifications/Machine Specifications 316 10 10 2 ELECTRICAL SYSTEM, continued Battery Type . . . . . . . . . . . . . . Battery Voltage . . . . . . . . . . . . . Battery Reserve Capacity @ 25 amp . . . . . . . . . . . . . . . . Battery Cold Cranking amp @ 0˚F Headlights . . . . . . . . . . . . . . . . Rear Reflector/Tail Lights . . . . . . Dash Indicator Lights . . . . . . . Operator Presence System . . . . . Dash Instrumentation Hourmeter . . . . . . . . . . . . . . 318 420 . . BCI Group 22F .
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General Specifications/Machine Specifications 316 PTO Front . . . . . . . . . . Rear . . . . . . . . . . . Type . . . . . . . . . . . Control . . . . . . . . . PTO rpm (No Load) Front . . . . . . . . . Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318 Standard . . . . . . . . Optional . . . . . . . . . Electric Clutch . . . . . Elec. Switch on Dash . . . . . . . . 420 Standard . . . . . . . . Optional . . . . . . . . .
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General Specifications/Machine Specifications 10 10 4 TM1590 (17MAY95) 10-10-4 316, 318 & 420 Lawn and Garden Tractors 020895
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Group 15 Repair Specifications REPAIR SPECIFICATIONS Item ENGINE For all repair specifications—Use CTM2 Engine Mounting Cap Screw/Nut Torque 316 . . . . . . . . . . . . . . . . . . . . . . . . 318 and 420 . . . . . . . . . . . . . . . . . . Drive Shaft-to-Engine Cap Screw Torque PTO Belt Tension Spring Length (420) Horizontal Adjuster (Early) . . . . . . . . . Vertical Adjuster (Later) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 N·m (29 lb-ft) . . . . .
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Repair Specifications/Repair Specifications Item 10 15 2 Specifications STEERING AND BRAKES Steering—316 Gearbox Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . Steering Wheel-to-Shaft Nut Torque . . . . . . . . . . . . . . . . . . . Pitman Arm Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . Preload Adjuster Maximum End Clearance . . . . . . . . . . . . . . . Side Cover-to-Gearbox Housing Cap Screw Torque . . . . . . . . . Worm Bearing Preload Rolling Torque . . . . . . . .
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Repair Specifications/Repair Specifications Item MISCELLANEOUS Front Axle PTO Belt Tension Spring Length (420) Horizontal Adjuster (Early) . . . . . . . . . . . Vertical Adjuster (Later) . . . . . . . . . . . . Toe-In . . . . . . . . . . . . . . . . . . . . . . . . . . Mower Blade Spindles Driven Sheave-to-Spindle Lock Nut Torque . Blade-to-Spindle Cap Screw Torque . . . . . . Mower Blade Jack Sheave Jack Sheave-to-Spindle Lock Nut Torque . . . Blade-to-Spindle Cap Screw Torque . . . . . .
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Repair Specifications/Metric Series Torque Chart METRIC BOLT AND CAP SCREW TORQUE VALUES TS1163 -19-04MAR91 10 15 4 Class 4.8 Size Lubricateda Class 8.8 or 9.8 Drya Lubricateda Class 10.9 Drya Lubricateda Class 12.9 Drya Lubricateda Drya N·m lb-ft N·m lb-ft N·m lb-ft N·m lb-ft N·m lb-ft N·m lb-ft N·m lb-ft N·m lb-ft M6 M8 M10 4.8 12 23 3.5 8.5 17 6 15 29 4.5 11 21 9 22 43 6.5 16 32 11 28 55 8.5 20 40 13 32 63 9.5 24 47 17 40 80 12 30 60 15 37 75 11.
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Repair Specifications/Inch Series Torque Chart UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUES TS1162 -19-04MAR91 10 15 5 Grade 2b Grade 1 Size Lubricateda Drya Lubricateda Grade 5, 5.1, or 5.2 Drya Lubricateda Grade 8 or 8.2 Drya Lubricateda Drya N·m lb-ft N·m lb-ft N·m lb-ft N·m lb-ft N·m lb-ft N·m lb-ft N·m lb-ft N·m lb-ft 1/4 5/16 3/8 3.7 7.7 14 2.8 5.5 10 4.7 10 17 3.5 7 13 6 12 22 4.5 9 16 7.5 15 27 5.5 11 20 9.5 20 35 7 15 26 12 25 44 9 18 33 13.
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Repair Specifications/Set Screw Torque Chart NOTE: When bolting aluminum parts, tighten to 80% of torque specified in table. Size N·m (lb-ft) M6 M8 M10 M12 M14 M16 9.5 - 12.2 20.3 - 27.1 47.5 - 54.2 81.4 - 94.9 128.8 - 146.4 210.2 - 240 (7-9) (15-20) (35-40) (60-70) (95-108) (155-177) -19-15DEC94 MX,15901015,3 -19-01MAR95 M77900 10 15 6 METRIC CAP SCREW TORQUE VALUES—GRADE 7 NOTE: Allow a tolerance of plus or minus 10 per cent on all torques given in this chart.
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Repair Specifications/Service Recommendations SERVICE RECOMMENDATIONS FOR O-RING BOSS FITTINGS 10 15 7 -UN-18OCT88 STRAIGHT FITTING 1. Inspect O-ring boss seat for dirt or defects. T6243AE 2. Lubricate O-ring with petroleum jelly. Place electrical tape over threads to protect O-ring. Slide O-ring over tape and into O-ring groove of fitting. Remove tape. 3. Tighten fitting to torque value shown on chart. ANGLE FITTING -UN-18OCT88 1.
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Repair Specifications/Service Recommendations -UN-18OCT88 1. Inspect the fitting sealing surfaces. They must be free of dirt or defects. 2. Inspect the O-ring. It must be free of damage or defects. 3. Lubricate O-rings and install into groove using petroleum jelly to hold in place. T6243AD 10 15 8 SERVICE RECOMMENDATIONS FOR FLAT FACE O-RING SEAL FITTINGS 4. Push O-ring into the groove with plenty of petroleum jelly so O-ring is not displaced during assembly. 5.
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Repair Specifications/Service Recommendations TUBE AND HOSE FITTING, 37˚ FLARE AND 30˚ CONE SEAT CONNECTOR SERVICE RECOMMENDATIONS 10 15 9 1. Inspect the flare and the flare seat. They must be free of dirt and defects. If repeated leaks occur, inspect for defects with a magnifying glass. If burrs and raised nicks on the connector body cannot be removed with a slip stone, replace the connector. 2. Defects in the tube flare cannot be repaired. Replace the tube.
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Repair Specifications/Service Recommendations TUBE AND HOSE FITTING, 37˚ FLARE AND 30˚ CONE SEAT CONNECTOR TORQUE 10 15 10 Thread Size 3/8-24 UNF 7/16-20 UNF 1/2-20 UNF 9/16-18 UNF 3/4-16 UNF 7/8-14 UNF 1-1/16-12 UN 1-3/16-12 UN 1-5/16-12 UN 1-5/8-12 UN 1-7/8-12 UN 1. Tolerance of ± 10 percent.
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Group 20 Test and Adjustment Specifications TEST AND ADJUSTMENT SPECIFICATIONS Item ENGINE Spark Plug Gap . . . . . . . . . . . . . . . . . . . Slow Idle Speed . . . . . . . . . . . . . . . . . . . Fast Idle Speed . . . . . . . . . . . . . . . . . . . Dashpot-to-Governor Arm Bracket Clearance (B43E, B43G and B48G) . . . . . . . . . . . . . Fuel Pump Minimum Fuel Flow . . . . . . . . . . . . . . . Minimum Vacuum . . . . . . . . . . . . . . . . Minimum Fuel Pressure . . . . . . . . . . . .
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Test and Adjustment Specifications Item 10 20 2 ELECTRICAL SYSTEM, continued Starter (Solenoid Shift) 316 (S.N. 362984— ), 318 (S.N. 364138— Current Draw (Maximum) . . . . . . . . . . . . No-Load rpm (Minimum) . . . . . . . . . . . . . No-Load Amp Draw (Maximum) . . . . . . . . Alternator Regulated Current Output 316 (P218G), 318 and 420 . . . . . . . . . . 316 (B43E) . . . . . . . . . . . . . . . . . . . . Unregulated Output P218G and P220G Spec A . . . . . . . . . . . . . . . . . . . . . Spec B and C .
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Group 25 Fuels and Lubricants FUEL N 10 25 1 CAUTION: Handle fuel carefully. If the engine is hot or running, do not fill the fuel tank. Do not smoke while you fill the fuel tank or service the fuel system. Fill fuel tank only to bottom of filler neck. IMPORTANT: DO NOT mix oil with gasoline. 1. Unleaded fuel is recommended. Regular leaded gasoline with an anti-knock index of 87 or higher may be used. Avoid switching from unleaded to regular gasoline to prevent engine damage.
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Fuels and Lubricants/Engine Oil ENGINE OIL Use oil viscosity based on the expected air temperature range during the period between oil changes. The following oils are preferred: • John Deere TURF-GARD™ • John Deere PLUS-4® Other oils may be used if they meet one or more of the following: • API Service Classification SH • API Service Classification SG • CCMC Specification G5 -UN-07NOV94 Arctic oils (such as Military Specification MIL-L-46167B) may be used at temperature below -30˚C (-22˚F).
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Fuels and Lubricants/Transmission and Hydraulic Oil TRANSMISSION AND HYDRAULIC OIL 10 25 3 Use oil viscosity based on the expected air temperature range during the period between oil changes.
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Fuels and Lubricants/Mower Deck Gear Case Oil GREASE Use grease based on the expected air temperature range during the service interval.
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Fuels and Lubricants/Mixing of Lubricants ALTERNATIVE AND SYNTHETIC LUBRICANTS Conditions in certain geographical areas may require lubricant recommendations different from those printed in this manual. Some John Deere lubricants may not be available in your location. Consult your John Deere dealer to obtain information and recommendations. 10 25 5 Synthetic lubricants may be used if they meet the performance requirements listed in this manual.
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Fuels and Lubricants/Mixing of Lubricants 10 25 6 TM1590 (17MAY95) 10-25-6 316, 318 & 420 Lawn and Garden Tractors 020895
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Group 30 Serial Number Locations SERIAL NUMBERS 10 30 1 When working on machines or components that are covered by warranty, it is IMPORTANT that you include the tractor Product Identification Number and the component serial number on the warranty claim form. The location of component serial number plates are shown below. MX,M21,1030R,1 -19-22APR85 PRODUCT IDENTIFICATION NUMBER M34494 -UN-08NOV89 NOTE: All identification number plates are located on the pedestal.
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Serial Number Locations/Serial Numbers DIFFERENTIAL SERIAL NUMBER M38479 -UN-29AUG88 Serial number plate (A) location.
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Section 20 ENGINE REPAIR Contents Page 20 Group 05—Engine Repair—Use CTM2 . . . . . . . . . . . . . . . Remove and Install . . . . . . . . . . . . . . .
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Contents 20 TM1590 (17MAY95) 20-2 316, 318 & 420 Lawn and Garden Tractors 020895
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Group 05 Engine ONAN ENGINE REPAIR—USE CTM2 TS225 -UN-17JAN89 For complete repair information, the component technical manual (CTM) is also required. Use the component technical manual in conjunction with this machine manual. MX,15902005,1 -19-09DEC94 REMOVE AND INSTALL ENGINE 1. Disconnect battery negative (—) cable. 2. Disconnect headlight lead and headlight ground. 3. Remove grille, side panels, hood, hood support and air cleaner. 4. Disconnect items (A—C).
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Engine/Remove and Install 5. Disconnect items (A—F). 6. Disconnect drive shaft at engine. 7. Loosen PTO belt tension and remove belts from engine. 8. Remove engine mounting cap screws. 9. Attach load positioning sling to lift eyes and remove engine. 10. Make repairs as necessary. (See CTM2.) M49501 -UN-20DEC89 A—Positive Battery Cable B—Choke Cable C—Throttle Cable D—Battery Ground Cable at Engine E—Positive Battery Cable from Starter F—Starter Solenoid Lead MX,15902005,3 -19-24FEB95 11.
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Section 40 ELECTRICAL REPAIR Contents Page Group 05—Front PTO Clutch Remove . . . . . . . . . . . . . . . . . . . . . . . Disassemble, Inspect and Assemble . . . . Install . . . . . . . . . . . . . . . . . . . . . . . . .
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Contents 40 TM1590 (17MAY95) 40-2 316, 318 & 420 Lawn and Garden Tractors 020895
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Group 05 Front PTO Clutch REMOVE FRONT PTO CLUTCH 1. Remove grille and right-hand side panel. -UN-03AUG89 2. Loosen PTO belt tension and remove belts from PTO clutch sheaves. 3. Disconnect PTO clutch wire lead. M32108 NOTE: On some models, the brake plate may be assembled to the armature assembly. Early 420 Shown 4. On 316 and 318: 40 05 1 —Remove armature assembly from field coil. —Remove three springs. On 420: —Push idler back and remove brake plate. —Remove three springs.
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Front PTO Clutch/Disassemble, Inspect and Assemble DISASSEMBLE, INSPECT AND ASSEMBLE FRONT PTO CLUTCH -UN-03AUG89 1. Inspect armature for bent, weak or broken contact springs. Replace armature if damaged. M32117 2. Inspect rotor and armature face contacts for wear. Replace if worn or grooved. Clean face contacts of dirt or foreign material. MX,15904005,3 -19-12MAY95 NOTE: Bearing is press-fit in armature. Remove only if replacement is necessary. -UN-03AUG89 3.
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Front PTO Clutch/Disassemble, Inspect and Assemble -UN-03AUG89 IMPORTANT: Support the armature assembly on the spring rivets when installing bearing/hub assembly into armature assembly, or damage to armature and springs will occur. M32120 10. Support armature on spring rivets and install bearing/hub assembly into pulley hub with a press and a 2-15/16 in. driver disk. 11. Install snap ring. MX,15904005,6 -19-14DEC94 40 05 3 12. Inspect field coil for wear or damage. Replace if necessary. 13.
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Front PTO Clutch/Install INSTALL FRONT PTO CLUTCH -UN-03AUG89 IMPORTANT: Make sure clutch wire lead is in same position as when removed, to prevent shorting of wires. M32112 1. Install field coil and fasten with four cap screws and lock washers. Be sure coil assembly pilots, on backside of coil, are seated in engine face. Tighten cap screws. 2. Install rotor and key. Early 420 Shown 40 05 4 MX,15904005,8 -19-01MAR95 NOTE: Some models have a notch in the hub of the armature assembly.
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Front PTO Clutch/Install -UN-03AUG89 7. Put a 0.46 mm (0.018 in.) flat feeler gauge through slots in brake plate between rotor and armature. Turn lock nuts until space between rotor and armature is 0.46 mm (0.018 in.). Be sure all three nuts are adjusted so space between armature and rotor is adjusted to specification at each of three slots in brake plate. M32123 8. After adjusting, turn ignition switch ON. Move PTO switch ON and OFF several times to seat parts. Turn ignition switch OFF.
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Front PTO Clutch/Install 40 05 6 TM1590 (17MAY95) 40-05-6 316, 318 & 420 Lawn and Garden Tractors 020895
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Section 50 POWER TRAIN REPAIR Contents Page Page Group 05—Transmission Other Materials . . . . . . . . Service Parts Kits . . . . . . Charge Pump Remove and Install . . . . Disassemble and Inspect Assemble . . . . . . . . . . Remove and Install Charge Relief Valve . . . Implement Relief Valve . Remove Transmission . . . . Disassemble Transmission Cover . . . . Pump and Motor . . . . . . Pump and Motor Housing Assemble Pump and Motor Housing Pump and Motor . . . . . . Transmission Cover . . . .
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Contents 50 TM1590 (17MAY95) 50-2 316, 318 & 420 Lawn and Garden Tractors 020895
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Group 05 Transmission OTHER MATERIAL Number Name Use M79292 MPG-2® Multi-Purpose Polymer Grease Prevents parts from seizing. Apply to splines of transmission input shaft. ®MPG-2 is a registered trademark of DuBois USA.
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Transmission/Charge Pump REMOVE AND INSTALL CHARGE PUMP 1. Remove fender deck and fuel tank. CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. X9811 N -UN-23AUG88 2. Remove drive shaft. (See procedure in Group 25.) -UN-25JAN90 3. Remove two cap screws and charge pump.
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Transmission/Charge Pump NOTE: Transmission is removed for photographic purpose only. -UN-29AUG88 4. Remove pin (A). Inspect pin for straightness and rounded ends. Replace if necessary. 5. Inspect machined surface (B) of transmission for severe scoring. If scoring is noted replace transmission. M36084 6. Make repairs as necessary. (See Disassemble, Inspect and Assemble Charge Pump.) 7. Installation is done in the reverse order of removal.
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Transmission/Charge Pump 3. Inspect inner ring key way for damage or shear pin debris. -UN-29JAN90 4. Inspect rotor ring (A) for cracks or signs of scoring on the outer edge. M36086 5. Inspect gerotor set for wear or damage. If any component is worn or damaged, replace gerotor set as an assembly. MX,15905005,5 -19-23FEB95 6. Pry out seal using a screwdriver. -UN-29AUG88 7. Inspect bearing for wear or damage. Remove bearing using a driver set. M36087 8. Inspect housing for wear or damage.
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Transmission/Remove and Install 4. Install new O-ring (B). Apply petroleum jelly to seal and housing to hold O-ring in its groove. M36085 -UN-29AUG88 5. Install rotor ring (A) and inner ring. The gerotor set must spin freely in housing. MX,15905005,8 -19-23FEB95 REMOVE AND INSTALL CHARGE RELIEF VALVE -UN-25JAN90 1. Remove fender deck and fuel tank. 2. Remove charge relief valve plug from right side of transmission housing.
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Transmission/Remove Transmission REMOVE AND INSTALL IMPLEMENT RELIEF VALVE -UN-25JAN90 1. Remove fender deck and fuel tank. 2. Remove implement relief valve plug from top of transmission housing. M36539 IMPORTANT: If relief valve is being disassembled to be cleaned, the same number and thicknesses of shims must be installed when assembled. 420 Shown 3. Remove shims (A) if equipped, spring and valve. 4. Inspect valve and housing for wear or damage. Valve must slide freely in bore.
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Transmission/Remove Transmission -UN-25JAN90 NOTE: There are different versions of the swashplate control arm. Also, attaching swashplate control arm to the control shaft on transmission is different. Some machines use a safety wire and roll pin, others use a nut and cap screw. M36541 6. Remove safety wire and roll pin (A) or nut and cap screw to disconnect transmission control linkage. Early Model Shown 50 05 7 MX,15905005,13 -19-23FEB95 7. Disconnect two hoses (A and B). M36542 -UN-25JAN90 8.
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Transmission/Remove Transmission NOTE: Steps 9 through 11 are for 420 only. Go to Step 12 to continue removal procedures for all machines. -UN-19JAN95 9. Move 2-speed axle shift lever to fast (rabbit) position to aid in removal of linkage. M36543 10. Remove cotter pin (A), washer (B) and pin (G) to disconnect two-speed differential linkage (C). 11. Remove cotter pin (F) and pin (E) to disconnect differential lock linkage (D).
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Transmission/Remove Transmission 12. Use a floor jack to support transmission and place jack stands under tractor frame. -UN-24FEB95 NOTE: Early models have two bolts (A) attaching differential to frame support bracket (C). Later models have one shoulder bolt (A) or one bolt with a washer and spacer. 14. Disconnect suction hose (B) from transmission. Close all openings using caps and plugs. M77300 13. Remove two bolts or shoulder bolt (A) or bolt, washer and spacer.
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Transmission/Remove Transmission NOTE: Disconnect brakes on both sides of machine. 17. Disconnect spring (A). -UN-19JAN95 18. Remove nut (B), plate or washer (D) and spring (C). 19. Bend tabs (F) flat. Remove two cap screws (E) from each side of machine. M77903 20. Lower differential and transmission assembly and roll away from frame.
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Transmission/Disassemble DISASSEMBLE TRANSMISSION COVER 1. Thoroughly clean outside surface of transmission using a steam cleaner or cleaning solvent. 2. Install transmission on a bench fixture. 3. Remove charge pump (B). (See procedure in this group.) -UN-21FEB95 4. Remove implement relief valve (D). (See procedure in this group.) 5. Remove charge relief valve (C). (See procedure in this group.) M77333 6. Remove filter (A).
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Transmission/Disassemble 10. Remove O-ring, backup ring (B), and O-ring (A). -UN-29AUG88 NOTE: Originally equipped 420 Lawn and Garden Tractor transmissions do no have manually operated check valves. If check valves have been replaced; service replacements will have manually operated check valves. M36102 11. Internal valve (C) must move freely inside check valve. 5M3,5005K,Q -19-18DEC87 12. Remove four pipe plugs. M77334 -UN-21FEB95 50 05 12 MX,15905005,41 -19-14MAR95 13.
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Transmission/Disassemble IMPORTANT: Do not allow internal parts to fall when removing center section. M36523 -UN-25JAN90 16. Put transmission on work bench and remove cap screws, center section and gasket (A). 5M3,5005K,U -19-18DEC87 IMPORTANT: Do not nick or scratch lapped or machined surfaces of the center section, valve plates or cylinder blocks. 50 05 13 Keep pump and motor components separate, they are not interchangeable. 17. Remove valve plates (A and B).
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Transmission/Disassemble -UN-20DEC89 18. Inspect bearing plates. Bearing plates should be flat, free of all nicks, burrs, scratches and erosion around the ports. The bronze metal should show no scoring, smearing or be discolored. NOTE: Scoring is indicated by fine scratches or grooves cut into the plate. M49510 When these scratches can be detected by feel, finger nail or lead pencil, the plate should be replaced. -UN-20DEC89 Some models may have a narrow slot (A) rather then a wide slot (B).
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Transmission/Disassemble 2. Inspect cylinder block assemblies. -UN-29AUG88 IMPORTANT: Do not interchange pistons between motor and pump cylinder blocks. Pistons and cylinder blocks are matched. M36111 Lift piston retainer and pistons from cylinder block. Check for free movement of pistons in cylinder bores. M45,5005A,51 -19-11JAN85 3. Remove and inspect all pistons. -UN-29AUG88 Check barrel (B) for scoring, discoloration, or any signs of separation of slippers.
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Transmission/Disassemble 5. Inspect both cylinder blocks. Check ball guide area (A) for scoring, wear and damage. -UN-29AUG88 Check nine cylinder bores (B) for burrs and scoring. Check lapped surface (C) for wear and damage. M36114 Check spring assembly (D) for damage and free movement. -UN-29AUG88 If any part of the cylinder block is damaged, the cylinder block assembly must be replaced.
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Transmission/Disassemble -UN-25JAN90 IMPORTANT: Pump shaft and bearing assembly could restrict movement of swashplate. Full swashplate movement is approximately 25 mm (1 in.) in each direction. If necessary tap shaft with a soft faced hammer. M36525 2. Push top of swashplate (C) down until it contacts the stops in the housing. IMPORTANT: DO NOT drive pins after they bottom. Housing damage will result. 3. Drive pin (B) until it bottoms in housing. 4.
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Transmission/Disassemble 10. Inspect bearing, replace if necessary. -UN-29AUG88 IMPORTANT: Be sure to hold shaft while removing bearing. M36120 11. Remove bearing using a 1 in. driver disk (A), bearing puller attachment and a press. M45,5005A,59 -19-13MAR85 12. Remove three seals from housing. M36121 -UN-29AUG88 50 05 18 M45,5005A,60 -19-11JAN85 5M3,5005K,AA -19-18DEC87 M45,5005A,62 -19-13MAR85 NOTE: Some transmissions will have bearings, while others will have bushings. -UN-29AUG88 13.
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Transmission/Assemble 16. Inspect bearing, replace if necessary. -UN-29AUG88 IMPORTANT: Be sure to hold shaft while removing bearing. M36124 17. Remove bearing using a 1 in. driver disk (A), bearing puller attachment and a press. M45,5005A,63 -19-26APR85 ASSEMBLE PUMP AND MOTOR HOUSING -UN-29AUG88 IMPORTANT: Always use new seals and O-rings. Damaged or used parts will leak. NOTE: Lubricate all seals and O-rings with petroleum jelly during assembly. M36126 1.
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Transmission/Assemble M36130 -UN-29AUG88 6. Push pump shaft into bearing until it is on the shaft shoulder using a 1-in. driver disk (A) bearing puller attachment and a press. M45,5005A,69 -19-13MAR85 NOTE: Tape over splines to protect seals from possible damage when installing shafts, remove tape after installation. -UN-25JAN90 7. Install pump shaft. 8. Install swashplate (C), control shaft (E), and shaft (A). 9. Drive pin (B) into swashplate and shaft until pin is about 6 mm (1/4 in.
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Transmission/Assemble ASSEMBLE PUMP AND MOTOR -UN-29AUG88 IMPORTANT: Do not nick or scratch lapped surface of cylinder blocks. M36116 Piston-to-Bore relationship need not be maintained; keep pump and motor components separate, they are not interchangeable. 1. Put clean John Deere Low Viscosity HY-GARD® oil or an equivalent on all internal parts. 2. Install pump and motor thrust plates. 50 05 21 MX,15905005,27 -19-23FEB95 3. Install pistons and piston retainer.
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Transmission/Assemble ASSEMBLE TRANSMISSION COVER -UN-29AUG88 IMPORTANT: Do not nick or scratch lapped or machined surfaces of the center section, valve plates or cylinder block. Keep pump and motor components separate. They are not interchangeable. M36132 Always use new seals and O-rings. Damaged or used parts will leak. NOTE: Lubricate all seals and O-rings with petroleum jelly during assembly. MX,15905005,28 -19-23FEB95 2.
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Transmission/Assemble -UN-25JAN90 IMPORTANT: Use extreme care when assembling the center section, valve plates and cylinder block to avoid dropping, nicking or scratching lapped surfaces. 4. Install center section and gasket (A) on housing and install eight cap screws. Tighten cap screws evenly. M36523 NOTE: Center section will seem springy, this is because the springs inside the cylinder blocks are being compressed. 5M3,5005K,AG 50 05 23 -19-18DEC87 5. Install transmission in bench fixture.
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Transmission/Assemble M77334 -UN-21FEB95 8. Install and tighten four pipe plugs. MX,15905005,42 -19-14MAR95 9. Install O-ring (A), backup ring (B) and O-ring. Internal valve (C) must move freely. M36102 -UN-29AUG88 50 05 24 M45,5005A,82 -19-13MAR85 M36101 -UN-29AUG88 10. Install and tighten two check valves. M45,5005A,83 -19-14JAN85 5M3,5005K,AI -19-18DEC87 11. Install plugs and O-rings (A). M36100 -UN-29AUG88 12. Install suction line fitting.
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Transmission/Install Transmission 13. Install new filter (A). 14. Install charge relief valve (C), implement relief valve (D) and charge pump (B). (See procedures in this group.) MX,15905005,31 -19-14MAR95 M77333 -UN-21FEB95 A—Oil Filter B—Charge Pump C—Charge Relief Valve D—Implement Relief Valve INSTALL TRANSMISSION IMPORTANT: Always use new seals and O-rings. Damaged or used parts will leak. NOTE: Lubricate all seals and O-rings with petroleum jelly during assembly. 1. Install new O-ring (B). 2.
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Transmission/Install Transmission 4. Position differential assembly under tractor. -UN-25JAN90 5. On 420; Hold differential lock linkage away from differential using wire, tape, etc. M36578 6. Lift and position differential assembly. Put drive shaft on transmission input shaft. Turn pump shaft to align splines. 420 Shown 50 05 26 MX,15905005,33 -19-07MAR95 7. Position brake linkage and install install cap screws (E) on each side of machine. Tighten cap screws to 100 N·m (75 lb-ft).
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Transmission/Install Transmission 10. Lock brake pedals together (318 and 420) and apply park brake. -UN-25JAN90 11. Loosen lock nut (A). M36554 12. Turn nut until spring is 42 mm (1.650 in.) long. Tighten lock nut. MX,15905005,35 -19-23FEB95 M77300 Early Models -UN-24FEB95 IMPORTANT: It is recommended to replace the early model differential frame support bracket (C) with the later configuration (D). The early models attached the differential to the frame support bracket with two bolts (A).
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Transmission/Install Transmission NOTE: Steps 18 and 19 are for 420 only. Go to Step 20 to continue installation procedures for all machines. -UN-19JAN95 18. Connect differential lock linkage (D). Install pin (E) and cotter pin (F). M36543 19. Connect two-speed differential linkage (C). Install pin (G), washer (B) and cotter pin (A). A—Cotter Pin B—Washer C—Two-Speed Differential Linkage D—Differential Lock Linkage E—Pin F—Cotter Pin G—Pin 50 05 28 MX,15905005,37 -19-23FEB95 20.
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Transmission/Install Transmission -UN-25JAN90 NOTE: There are different versions of the swashplate control arm. Also, attaching swashplate control arm to the control shaft on transmission is different. Some machines use a safety wire and roll pin, others use a nut and cap screw. M36541 22. Attach swashplate control arm to control shaft with roll pin and safety wire or cap screw and nut. Tighten nut to 60 N·m (44 lb-ft). Early Models Shown 50 05 29 MX,15905005,39 -19-23FEB95 23.
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Transmission/Install Transmission 50 05 30 TM1590 (17MAY95) 50-05-30 316, 318 & 420 Lawn and Garden Tractors 020895
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Group 10 Transmission Control Linkage INSPECT AND REPAIR TRANSMISSION CONTROL LINKAGE—VERSION ONE (ALL MODELS) M77907 -UN-13FEB95 50 10 1 A—Knob B—Clip C—Speed Control Lever D—Torsion Spring E—Compression Spring F—Bracket G—Pin H—Shock Absorber I—Brake Plate (2 used) J—Friction Disc (2 used) K—Guide L—Speed Control Rod M—Turnbuckle N—Stud (Early Models) O—Spacer P—Swashplate Arm Q—Wire R—Spring Pin S—Eyebolt (Later Models) 1. Remove belly screen/pan, fender deck and fuel tank. 4.
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Transmission Control Linkage/Inspect and Repair Control Linkage INSPECT AND REPAIR TRANSMISSION CONTROL LINKAGE—VERSION TWO (316 AND 318) M77908 -UN-13MAR95 50 10 2 A—Knob B—Clip C—Speed Control Lever D—Shock Absorber E—Spacer F—Compression Spring G—Friction Disc (2 used) H—Speed Control Rod I—Spacer J—Turnbuckle K—Spacer L—Eyebolt M—Guide N—Weld Nut O—Swashplate Arm Assembly (Early Models) 1. Remove belly screen, fender deck and fuel tank.
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Transmission Control Linkage/Inspect and Repair Control Linkage INSPECT AND REPAIR TRANSMISSION CONTROL LINKAGE—VERSION TWO (420) M77909 -UN-13FEB95 50 10 3 A—Knob B—Clip C—Speed Control Lever D—Torsion Spring E—Compression Spring F—Bracket G—Pin H—Shock Absorber I—Brake Plate (2 used) J—Friction Disc (2 used) K—Guide L—Speed Control Rod M—Turnbuckle N—Eyebolt O—Spacer 1. Remove belly pan, fender deck and fuel tank.
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Transmission Control Linkage/Inspect and Repair Control Linkage INSPECT AND REPAIR TRANSMISSION CONTROL LINKAGE—VERSION THREE (ALL MODELS) M77910 -UN-13MAR95 50 10 4 A—Knob B—Clip C—Speed Control Lever D—Weld Nut E—Friction Disc (2 used) F—Pin G—Torsional Dampener H—Bracket I—Control Plate J—Angle Bracket K—Detent Arm (2 used) L—Compression Spring M—Pivot Pin N—Adjustable Eccentric Bearing O—Bracket P—Ball Bearing Q—Clamp-On Nut 1. Remove belly screen/pan, fender deck and fuel tank.
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Transmission Control Linkage/Inspect and Repair Control Linkage INSPECT AND REPAIR TRANSMISSION CONTROL LINKAGE—VERSION FOUR (ALL MODELS) M77911 -UN-13FEB95 50 10 5 A—Knob B—Clip C—Speed Control Lever D—Weld Nut E—Friction Disc (2 used) F—Bracket G—Control Plate H—Speed Control Link I—Angle Bracket J—Detent Arm (2 used) K—Compression Spring L—Pivot Pin M—Adjustable Eccentric Bearing N—Ball Bearing O—Clamp-On Nut P—Spring Washer Q—Nut (2 used) R—Bracket S—Swashplate Arm 1.
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Transmission Control Linkage/Differential Lock and Two-Speed Control Linkage (420) INSPECT AND REPAIR DIFFERENTIAL LOCK AND TWO-SPEED CONTROL LINKAGE (420) M77912 -UN-13FEB95 50 10 6 A—Pin B—Spring C—Two-Speed Control Rod D—Knob E—Stud Extension F—Front Angle Bracket G—Rear Angle Bracket H—Two-Speed Bracket I—Differential Lock Rod 1. Remove belly pan. J—Knob K—Clip (2 used) L—Pin 3. Adjust two-speed axle lever detent, if necessary. (See procedure in Section 250, Group 15.) 2.
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Group 15 Differential OTHER MATERIAL Number Name Use TY6305/TY9485/764 Clean and Cure Primer Cleans parts and speeds cure of sealant. T43512/TY9473/242 Thread Lock and Sealer (Medium Strength) Apply to threads of carrier cap screws. TY6304/TY9484/518 Flexible Sealant Apply to mating surfaces of differential cover and case halves. LOCTITE® PRODUCTS U.S./Canadian/LOCTITE No. ®LOCTITE is a registered trademark of the Loctite Corp.
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Differential/Disassemble and Inspect REMOVE AND INSTALL DIFFERENTIAL 1. Remove transmission (D). (See procedure in Group 05.) 2. Remove both axles (B). (See procedure in Group 20.) 3. Remove bracket (C) and fittings (A). 4. Installation is done in the reverse order of removal.
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Differential/Disassemble and Inspect NOTE: Early models have FLAT thrust washers. Later models have TABBED thrust washers. All service or replacement thrust washers will have the tabs. M36168 -UN-29AUG88 IMPORTANT: It is recommended to replace the early model (flat) thrust washers with the later model (tabbed) thrust washers. The early model washers may spin with their respective shafts, causing wear to the cover bearing surfaces. 3. Remove three thrust washers (A).
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Differential/Disassemble and Inspect 5. If equipped with differential lock; disassemble shift rod assembly by removing three E-Rings (A) washers (B), springs (C), fork (D), and snap ring (E). -UN-19JAN95 Inspect shaft for straightness or damage. Replace if necessary. M36230 A—E-Ring (3 used) B—Washer (3 used) C—Spring (2 used) D—Fork E—Snap Ring MX,15905015,5 -19-23FEB95 NOTE: Early model with differential lock shown. -UN-25AUG88 7. Disassemble and inspect pinion assembly.
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Differential/Disassemble and Inspect NOTE: Later models have oil grooves (E), an oil hole (D) and a thrust washer (F) in carriers. -UN-03AUG89 Machines without differential lock have one thrust washer in each carrier. Machines with differential lock have one thrust washer and one new style carrier on the non-differential lock side only. Bearings (C) are press-fit on carriers. Remove bearings only if replacement is necessary. M31971 All service or replacement carriers will have these features.
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Differential/Disassemble and Inspect 12. Remove and inspect countershaft assembly. -UN-29AUG88 Inspect spur gear (A) and bevel gear (B) for worn or damaged teeth. Inspect countershaft (C) for worn or damaged splines or bearing surfaces. M36175 13. Remove spacer (D), thrust washers (E) and thrust bearing (F). Inspect parts for wear or damage. Replace if necessary.
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Differential/Disassemble and Inspect M36234 -UN-22NOV89 M36233 -UN-22NOV89 14. Two-speed differential; remove set screw, spring, and detent ball.
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Differential/Disassemble and Inspect 15. Remove and inspect intermediate shaft assembly; if equipped with two-speed differential, remove shift rod assembly with intermediate shaft. -UN-29AUG88 Inspect intermediate gears (B and C) for worn or damaged teeth. NOTE: Early models have a FLAT thrust washer. Later models have a TABBED thrust washer. All service or replacement thrust washers will have the tabs.
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Differential/Disassemble and Inspect 18. Remove and inspect output shaft assembly. Inspect output gear (C) for worn or damaged teeth. -UN-29AUG88 Inspect output shaft (B) for wear on splined surfaces. IMPORTANT: It is recommended to replace the early model (flat) thrust washers with the later model (tabbed) thrust washers. The early model washers may spin with their respective shafts, causing wear to the case bearing surface. M36177 NOTE: Early models have a FLAT thrust washer.
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Differential/Disassemble and Inspect 20. Inspect differential case and cover for wear, cracks or damage. Replace case and/or cover if necessary. Inspect case and cover bearing surfaces of output shaft (A), intermediate shaft (B) and countershaft (C) for wear, cracks or damage. Inspect depth of oil grooves (D) in case and cover. If depth of grooves are less than 0.25 mm (0.010 in.), replace case and/or cover. Inspect reinforcement ribs (E). If ribs protrude above wear surface, file or grind flush.
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Differential/Disassemble and Inspect 22. Replace bearings if necessary. Removal or Installation Side Driven From Pilot Size Driver Size Output Pinion Bearing Remove Install Outside Inside 1-1/4 in. 1-1/4 in. 1-9/16 in. 1-9/16 in. Shifter Shaft Bearing Remove Install Outside Inside 1 in. 1-1/4 in. 1-1/4 in. Remove Install Outside Inside 1 in. 1-1/4 in. 1-1/4 in.
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Differential/Assemble ASSEMBLE DIFFERENTIAL NOTE: This assembly procedure is for the One-Speed Differential (316 and 318) and the Two-Speed Differential with Differential Lock (420). The differences are noted. Lubricate all seals with petroleum jelly during assembly. Early models have FLAT thrust washers. Later models have TABBED thrust washers. All service or replacement thrust washers will have the tabs. -UN-24FEB95 Always use new seals. Damaged or used parts will leak. 1.
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Differential/Assemble 5. Assemble gear (C) and shaft (B). M77336 -UN-21FEB95 6. Install output shaft assembly through tabbed thrust washer (A). M77337 -UN-21FEB95 One-Speed Differential Two-Speed Differential MX,15905015,19 -19-14MAR95 M36236 -UN-22NOV89 7. Two-speed differential; assemble shift rod by installing fork (B) and two E-rings (A).
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Differential/Assemble 8. Assemble gears (B and C) and shaft (D). -UN-29AUG88 9. Install intermediate shaft assembly through tabbed thrust washer (A); if equipped with two-speed, install shift rod assembly with intermediate shaft assembly. M36176 A—Thrust Washer B—Intermediate Gear C—Intermediate Gear D—Intermediate Shaft One-Speed Differential M36235 -UN-22NOV89 50 15 14 Two-Speed Differential MX,15905015,21 -19-23FEB95 M36233 -UN-22NOV89 M36234 -UN-22NOV89 10.
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Differential/Assemble 11. Assemble gears (A and B) and shaft (C). -UN-29AUG88 12. Install countershaft assembly through spacer (D), thrust bearing (F) and thrust washers (E).
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Differential/Assemble NOTE: Early model with differential lock shown. -UN-25AUG88 13. If removed, install collar (with differential lock) and bearings on carriers (F) using a driver set and a press. Install bearings flush with shaft surfaces. NOTE: Carriers on later models have oil grooves, an oil hole and a thrust washer in carriers. M31977 Machines without differential lock have one thrust washer in each carrier.
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Differential/Assemble M36170 -UN-22NOV89 19. Install differential; if equipped with differential lock, install shift rod assembly with differential.
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Differential/Assemble NOTE: Early models have FLAT thrust washers. Later models have TABBED thrust washers. All service or replacement thrust washers will have the tabs. IMPORTANT: It is recommended to replace the early model (flat) thrust washers with the later model (tabbed) thrust washers. The early model washers may spin with their respective shafts, causing wear to the cover bearing surfaces. 20.
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Differential/Assemble -UN-29AUG88 IMPORTANT: If replacement gasket is made of rubber coated laminated metal, clean mating surfaces of differential case and cover and install gasket. Do not apply sealant. It will cause oil to leak. M36181 If replacement gasket is made of paper, clean mating surfaces of differential case and cover, apply recommended sealant, then install gasket. 23. Clean the mating surfaces of differential case and cover using Clean and Cure Primer.
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Differential/Assemble 50 15 20 TM1590 (17MAY95) 50-15-20 316, 318 & 420 Lawn and Garden Tractors 020895
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Group 20 Rear Axles OTHER MATERIAL Number Name Use M79292 MPG-2® Multi-Purpose Polymer Grease Prevents parts from seizing. Apply to axle shafts. TY6305/TY9485/764 Clean and Cure Primer Cleans parts and speeds cure of sealant. T43512/TY9473/242 Thread Lock and Sealer (Medium Strength) Apply to threads of brake plate-to-axle cap screws. LOCTITE® PRODUCTS U.S./Canadian/LOCTITE No. ®MPG-2 is a registered trademark of DuBois USA. ®LOCTITE is a registered trademark of the Loctite Corp.
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Rear Axles/Remove 8. Disconnect spring (A). 9. Remove nut (B), plate or washer (D) and spring (C). M78048 -UN-13FEB95 A—Return Spring B—Nut C—Spring D—Plate (Early Models) —Washer (Later Models) Early Models M78049 -UN-13FEB95 50 20 2 Later Models MX,15905020,7 -19-23FEB95 10. Bend tabs (A) flat and remove two cap screws. M36562 -UN-25JAN90 11. Remove four cap screws and washers (B) to remove brake plate assembly (C). 5M3,5020K,E -19-18DEC87 M36563 -UN-25JAN90 12.
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Rear Axles/Remove 13. Inspect bearing (A), replace if necessary. -UN-25AUG88 IMPORTANT: Be sure to hold shaft while removing bearing. M31951 14. Remove bearing using a bearing puller (B) and a press. 5M3,5020K,G -19-18DEC87 15. Remove two cap screws (A) to disconnect axle from hitch plate (B). M36564 -UN-25JAN90 16. Remove six cap screws to remove axle housing. 5M3,5020K,H -19-18DEC87 5M3,5020K,I -19-18DEC87 5M3,5020K,J -19-18DEC87 M36565 -UN-25JAN90 17. Remove spacer.
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Rear Axles/Install INSTALL AXLE -UN-25JAN90 IMPORTANT: Always use new seals. Damaged or used parts will leak. NOTE: Lubricate all seals with petroleum jelly during assembly. M36567 1. Install new seal 3 mm (0.118 in.) below machined surface of differential using a 2-1/16 in. driver disk. MX,15905020,3 -19-23FEB95 2. Install spacer. M36565 -UN-25JAN90 50 20 4 M21,5020R,15 -19-14MAY85 3. Install axle housing and fasten with six cap screws. Tighten cap screws to 81 N·m (60 lb-ft).
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Rear Axles/Install M31952 -UN-25AUG88 5. Install bearing (A) on axle shaft using a bearing puller (B) and a press. Push bearing tight against axle shaft shoulder. M21,5020R,17 -19-14MAY85 M21,5020R,18 -19-14MAY85 6. Apply clean transmission fluid to the splined end of the axle shaft. -UN-25JAN90 7. Carefully install axle shaft into housing and through seal in differential. Align splines on shaft with splined gear inside differential. M36569 8.
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Rear Axles/Install 9. Clean the threads of all four brake plate cap screws and threaded axle housing using Clean and Cure Primer. -UN-25JAN90 10. Apply thread lock and sealer (medium strength) on threads of brake plate cap screws (A). 11. Install brake rod in brake arm hole. M36570 12. Install brake plate assembly (B) on axle. Install and tighten four cap screws (A) to specifications. 13. Install brake support (C), lock plate (D) and two cap screws. Tighten cap screws to specifications.
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Rear Axles/Install 16. Lock brake pedals together (318 and 420) and apply park brake. -UN-25JAN90 17. Loosen lock nut (A). M36554 18. Turn nut until spring is 42 mm (1.650 in.) long. Tighten lock nut. MX,15905020,5 -19-23FEB95 19. Apply MPG-2® Multi-Purpose Polymer Grease on axle shaft. -UN-25JAN90 20. Install key and brake drum. 21. Install washer and nut. Tighten nut to specifications. M36571 22. Bend one side of washer over nut to lock nut in place. 23. Install wheel.
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Rear Axles/Install 50 20 8 TM1590 (17MAY95) 50-20-8 316, 318 & 420 Lawn and Garden Tractors 020895
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Group 25 Drive Shaft OTHER MATERIAL Number Name Use M79292 MPG-2® Multi-Purpose Polymer Grease Prevents parts from seizing. Apply to splines of transmission input shaft. ®MPG-2 is a registered trademark of DuBois USA. MX,15905005,OTH-19-07MAR95 REMOVE AND INSTALL DRIVE SHAFT—316 1. Disconnect battery negative (—) cable. -UN-09DEC89 2. Remove right-hand engine side panel. 3. Remove belly screen. M55037 4. Hold drive shaft using a screwdriver.
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Drive Shaft/Remove and Install—318 and 420 REMOVE AND INSTALL DRIVE SHAFT—318 AND 420 -UN-12JAN90 1. Disconnect battery negative (—) cable. 2. Remove right-hand engine side panel. 3. Remove belly screen/pan. M43706 NOTE: Pedestal side removed for for photographic purpose only. 4. Hold drive shaft with screwdriver and remove four cap screws (A) holding drive shaft to crankcase pulley. 5. Loosen two lock nuts and cap screws, if equipped, on drive shaft at transmission pump shaft end. 50 25 2 6.
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Drive Shaft/Disassemble and Inspect CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. -UN-23AUG88 N X9811 NOTE: Fender deck and fuel tank removed for photographic purpose only. 7.
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Drive Shaft/Assemble M43748 -UN-12JAN90 2. Remove four snap rings (A). M21,5025K,8 -19-08SEP86 M21,5025K,9 -19-17SEP86 3. Remove cross and bearing assembly using soft metal rod. Push bearing down until it can be removed. -UN-12JAN90 4. Turn cross and bearing assembly over. Push down until bearing can be removed. M43739 5. Separate end yoke from splined yoke. 6. Remove cross and bearing assembly using a soft metal rod. Push bearing down until bottom bearing can be removed.
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Drive Shaft/Assemble 2. Install cross in splined yoke with grease fitting toward splined yoke (A). -UN-12JAN90 3. Install bearing with soft metal rod and press or soft-faced hammer. Push bearing down only until snap ring groove is inside splined yoke. M43753 4. Turn cross and bearing assembly over and install other bearing. 5. Install four snap rings.
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Drive Shaft/Assemble 50 25 6 TM1590 (17MAY95) 50-25-6 316, 318 & 420 Lawn and Garden Tractors 020895
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Section 60 STEERING AND BRAKE REPAIR Contents Page Group 05—Steering—316 Special or Essential Tools . Service Parts Kits . . . . . . Gearbox Remove and Install . . . . Disassemble and Inspect Assemble . . . . . . . . . . .......... .......... . . . . . . . . . . 60-05-2 . . . . . . . . . . 60-05-6 . . . . . . . . . . 60-05-12 Group 06—Steering—318 and 420 Other Materials . . . . . . . . . . . . . . Service Parts Kits . . . . . . . . . . . . Steering Valve Remove and Install . . . . . . . . . .
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Contents 60 TM1590 (17MAY95) 60-2 316, 318 & 420 Lawn and Garden Tractors 020895
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Group 05 Steering—316 SPECIAL OR ESSENTIAL TOOLS NOTE: Order tools according to information given in the U.S. SERVICE-GARD™ Catalog or in the European Microfiche Tool Catalog (MTC). DX,TOOLS -19-05JUN91 MX,JDG457 -19-01MAR95 Steering Gear Service Set....................JDG457 Used to service steering gearbox.
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Steering—316/Gearbox REMOVE AND INSTALL STEERING GEARBOX AND SHAFT -UN-23AUG88 1. Remove drive shaft. (See procedure in Section 50, Group 25.) 2. Remove engine side panels, battery and battery base. X9811 3. Remove fender deck. IMPORTANT: Do not pound on end of steering shaft or damage to steering shaft will occur. 4. Remove steering wheel. -UN-03OCT89 5. Disconnect lines (A, B and C) from hydraulic control valve. MX,15906005,1 -19-29MAR95 -UN-03OCT89 6. Remove nut and line clamp.
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Steering—316/Gearbox M33939 -UN-03OCT89 7. Remove bracket mounting cap screw. MX,15906005,3 -19-10MAR95 M33940 -UN-03OCT89 8. Remove clip and disconnect brake neutral return linkage. MX,15906005,4 -19-10MAR95 M33942 -UN-03OCT89 9. Remove pitman arm nut and washer. Remove pitman arm using a two-jaw puller. MX,15906005,5 -19-10MAR95 M33943 -UN-03OCT89 10. Remove cotter pin (A) and washer (B) to disconnect brake llinkage on left side of machine frame.
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Steering—316/Gearbox M33958 -UN-03OCT89 11. Remove safety wire and spring pin to remove brake arm (A), washer (B) and bushing (C). MX,15906005,7 -19-10MAR95 12. Remove left side of pedestal. -UN-03OCT89 13. Remove cotter pin (A) and draft pin (B). Turn rockshaft control valve linkage (C) to gain access for steering shaft removal. M33961 60 05 4 MX,15906005,8 -19-10MAR95 M34170 -UN-08NOV89 14. Remove cotter pins (A) and washers (B) to disconnect brake linkage on right side of machine frame.
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Steering—316/Gearbox M33963 -UN-03OCT89 16. Remove brake arm (A), washer (B) and bushing (C). MX,15906005,11 -19-10MAR95 17. Remove three cap screws (A) from gearbox mounting plate. MX,15906005,12 -19-10MAR95 M77339 -UN-14MAR95 60 05 5 18. Remove steering gearbox and shaft as an assembly, from bottom of machine. M33965 -UN-03OCT89 19. Make repairs as necessary. (See procedure in this group.
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Steering—316/Gearbox 20. Inspect steering shaft bushings for wear or damage. Replace if necessary. -UN-03OCT89 21. Remove bushings using a pilot bearing puller. 22. Installation is done in the reverse order of removal. M34018 • If removed, install steering shaft bushings using a driver set. • Apply multipurpose grease to I.D. of steering shaft bushings. TORQUE SPECIFICATIONS Gearbox Mounting Cap Screws . . . . . . . . . . . . . . . 95 N·m (70 lb-ft) Steering Wheel-to-Shaft Nut . . . . . . . . . . . . .
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Steering—316/Gearbox 6. Put gearbox in a vise. M33969 -UN-03OCT89 7. Remove three side cover cap screws. MX,15906005,17 -19-01MAR95 NOTE: If replacing side cover gasket only, it is not necessary to remove preload adjuster nut. M33970 -UN-03OCT89 8. Hold preload adjuster screw and remove adjuster nut. MX,15906005,18 -19-01MAR95 M33971 -UN-03OCT89 9. Remove pitman shaft, gasket and side cover as an assembly.
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Steering—316/Gearbox M33972 -UN-03OCT89 10. Remove preload adjuster and shim, if equipped, from side cover. MX,15906005,20 -19-01MAR95 -UN-03OCT89 11. Remove worm bearing adjuster lock nut using a punch and hammer. M33973 60 05 8 MX,15906005,21 -19-01MAR95 M33974 -UN-08NOV89 12. Remove worm bearing adjuster. MX,15906005,22 -19-01MAR95 IMPORTANT: Do not allow worm shaft to turn to the end of its travel or damage can occur to the ends of the ball guides. M33978 -UN-03OCT89 13.
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Steering—316/Gearbox 14. Pry out lower bearing retainer using a screwdriver. M33976 -UN-03OCT89 15. Remove lower worm bearing cone. MX,15906005,24 -19-01MAR95 NOTE: Bearing cup is press-fit in bearing adjuster. Remove bearing cup only if replacement is necessary. -UN-03OCT89 Bearing cups and cones are matched and must be replaced as complete assemblies. M33977 16. Inspect bearing cup in bearing adjuster for wear or damage. Replace if necessary. 17. Screw bearing adjuster (A) into gearbox housing.
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Steering—316/Gearbox M33980 -UN-03OCT89 19. Remove ball guide screw and clamp. MX,15906005,27 -19-01MAR95 20. Remove ball guides (A), balls (B) and ball nut (D) from worm shaft (C). -UN-03OCT89 NOTE: Ball nut and worm shaft are matched and must be replaced as a complete assembly. If any ball becomes lost or damaged, install new balls as a complete set. 21. Inspect all parts for wear or damage. Replace as necessary.
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Steering—316/Gearbox M34019 -UN-03OCT89 22. Remove pitman shaft and worm shaft seals from gearbox housing. M34020 -UN-03OCT89 Pitman Shaft Seal Worm Shaft Seal MX,15906005,29 -19-01MAR95 -UN-03OCT89 NOTE: Pitman shaft needle bearing and worm shaft bearing cup are press-fit in gearbox housing. Remove bearing or cup only if replacement is necessary. Lip (B) is part of gearbox housing, not part of bearing race. M33987 23.
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Steering—316/Gearbox NOTE: A steering gearlash adjustment shim is available through the parts catalog. M33989 -UN-03OCT89 27. Check preload adjuster (A) end clearance with a feeler gauge as shown. If clearance is greater than 0.05 mm (0.002 in.), order and install shim (B). MX,15906005,31 -19-10MAR95 ASSEMBLE STEERING GEARBOX AND SHAFT -UN-08NOV89 IMPORTANT: Always use new seals and gasket. Damaged or used parts will leak. NOTE: Apply clean multipurpose grease on all internal parts during assembly.
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Steering—316/Gearbox 3. Install new pitman shaft and worm shaft seals into gearbox housing using drivers from JDG457 Steering Gear Service Set. M34161 -UN-08NOV89 4. Apply multipurpose grease to lip of seals. M34158 -UN-08NOV89 Pitman Shaft Seal Worm Shaft Seal MX,15906005,33 -19-01MAR95 -UN-03OCT89 IMPORTANT: Install ball nut onto worm shaft as shown. An improperly installed ball nut could cause gear damage or steering lockup. M33988 5.
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Steering—316/Gearbox 6. Insert ball guide half into ball nut (C) as shown. 7. Fill circuit with 27 balls (A) and install other half of ball guide (B). -UN-03OCT89 8. Repeat procedures on other circuit with remaining balls and guides. M33992 60 05 14 MX,15906005,35 -19-01MAR95 M33980 -UN-03OCT89 9. Install ball guide clamp with screws and tighten securely. MX,15906005,36 -19-01MAR95 10. Pack upper worm bearing cone with multipurpose grease. M33979 -UN-03OCT89 11.
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Steering—316/Gearbox IMPORTANT: Tape splined end of worm shaft to prevent seal damage during shaft installation. -UN-03OCT89 12. Apply tape around splined end of worm shaft. M33978 13. Install ball nut (A) and worm shaft (B) with bearing cone, into gearbox housing. Remove tape. MX,15906005,38 -19-01MAR95 14. Install new bearing cup in worm bearing adjuster, if removed, using a driver set. -UN-03OCT89 15. Pack lower worm bearing cone with multipurpose grease. M33996 16.
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Steering—316/Gearbox 22. Assemble pitman shaft (A) with preload adjuster (B) and shim (C), if equipped. -UN-06MAR95 23. Install side cover (D) onto shaft with preload adjuster. 24. Turn preload adjuster screw counterclockwise until it bottoms. Then, back screw off one-half turn. M33999 A—Pitman Shaft B—Preload Adjuster C—Shim (if equipped) D—Side Cover MX,15906005,41 -19-01MAR95 25. Install new gasket on side cover. IMPORTANT: Tape end of pitman shaft to prevent seal damage during shaft installation.
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Steering—316/Gearbox M34003 -UN-03OCT89 • Carefully turn worm shaft all the way to end of travel, then turn back one-half turn. MX,15906005,44 -19-01MAR95 NOTE: Due to tolerances, some 11/16 in. sockets require a wrapping of card stock around the serrations on end of worm shaft. • Install 1-1/8 in. socket with ratchet on worm bearing adjuster and an 11/16 in. 12-point socket with torque wrench on end of worm shaft.
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Steering—316/Gearbox 31. Adjust over center preload: -UN-03OCT89 • Back off preload adjuster until it stops, then turn it in one full turn. • Center gear travel by rotating shaft. M34002 • Check torque required to turn worm shaft. Record reading. MX,15906005,47 -19-01MAR95 • Turn preload adjuster in, until rolling torque required to turn worm shaft is 0.50—1.20 N·m (4—10 lb-in.) more than first reading. -UN-03OCT89 • Install lock nut.
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Group 06 Steering—318 and 420 OTHER MATERIAL Number Name Use TY6305/TY9485/764 Clean and Cure Primer Cleans parts and speeds cure of sealant. TY9369/NA/222 Thread Lock and Sealer (Low Strength) Apply to threads of metering assembly screws. LOCTITE® PRODUCTS U.S./Canadian/LOCTITE No. ®LOCTITE is a registered trademark of the Loctite Corp.
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Steering—318 and 420/Steering Valve REMOVE AND INSTALL STEERING VALVE AND COLUMN -UN-23AUG88 NOTE: Removal and installation procedures for later models may vary slightly. 1. Remove fender deck. X9811 2. Remove engine side panels. 3. Remove battery and battery base. NOTE: On some machines, it may be necessary to remove hour meter, starter solenoid and circuit breaker to remove right-hand pedestal side. -UN-06MAR95 4. Remove right-hand pedestal side. 5. Remove drive shaft.
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Steering—318 and 420/Steering Valve 11. Remove steering unit from bottom of machine. 12. Make repairs as necessary. (See procedure in this group.) 13. Installation is done in the revese order of removal. -UN-28JUL89 • Install steering unit with marks made during removal or with alignment grooves in port manifold and cover, facing toward engine. • Tighten steering wheel-to-shaft nut to 15 N·m (133 lb-in.). M31840 • Bleed hydraulic system. (See procedure in Section 270, Group 20.
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Steering—318 and 420/Steering Valve M77338 -UN-21FEB95 4. Four-port and early five-port; Loosen plug one turn. MX,15906006,5 -19-14MAR95 -UN-08JAN90 IMPORTANT: Do not damage fittings during nut removal. Do not nick or scratch the machined surfaces of the steering valve. 60 06 4 M43841 5. Remove nuts to remove port cover assembly (four plates bonded together). Early Five-Port Shown MX,15906006,6 -19-10MAR95 M77303 -UN-06MAR95 6. Later five-port; Remove port cover and check ball (A).
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Steering—318 and 420/Steering Valve NOTE: Four-port not shown. Unit is similar to early five-port. -UN-29AUG88 7. Remove seal ring and O-rings (A). M36834 8. Inspect port cover for scratches on machined surfaces or damage to fittings. Replace cover if damaged. M78056 -UN-06MAR95 Early Five-Port Later Five-Port MX,15906006,8 -19-29MAR95 M43832 -UN-08JAN90 9. Four-port and early five-port; Remove plug (A), O-ring (B) and check ball (C).
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Steering—318 and 420/Steering Valve NOTE: Port manifold has three springs which may come loose during disassembly. -UN-29AUG88 10. Carefully remove port manifold (three plates bonded together). M36836 IMPORTANT: Do not interchange springs. The steering valve has two sets of springs. Keep springs with respective manifold. 11. Remove three springs (A). NOTE: If one or more springs are damaged, all six springs in valve must be replaced. 12. Inspect springs and pins (B) for distortion, wear, or damage.
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Steering—318 and 420/Steering Valve M36839 -UN-29AUG88 15. Remove valve plate. Inspect the slots and ground surfaces for nicks or wear. If the valve plate is scored or the edges are not sharp, the valve plate and valve ring both must be replaced. MX,15906006,13 -19-01MAR95 16. Remove and inspect hex drive assembly. Check sides and slot for wear, grooves, or scoring. Pin (A) should be tight and show no wear or damage. -UN-29AUG88 17. Remove three springs (B). M36840 18.
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Steering—318 and 420/Steering Valve M36843 -UN-29AUG88 21. Remove metering ring and upper and lower seals (A). If the bore (B) is scored, the metering ring must be replaced. MX,15906006,17 -19-01MAR95 IMPORTANT: Do not clamp metering assembly in a vise. -UN-29AUG88 22. Remove metering assembly. Put assembly on a clean surface. M36844 60 06 8 MX,15906006,18 -19-01MAR95 23. Remove commutator seal (A). -UN-29AUG88 24. Remove 11 screws to remove commutator cover.
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Steering—318 and 420/Steering Valve IMPORTANT: DO NOT use a screwdriver to remove commutator. Commutator can be damaged. -UN-29AUG88 27. Remove commutator and five pins (A) using a wood dowel or equivalent. M36848 NOTE: The commutator is made up of two plates bonded together. It is a permanent assembly and cannot be disassembled. 28. Check commutator machined surface, holes and edges for nicks. Edges must be sharp. MX,15906006,21 -19-01MAR95 29. Remove drive link spacer.
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Steering—318 and 420/Steering Valve 32. Lift the rotor and stator from the drive plate. -UN-29AUG88 33. Check the drive plate side of the rotor assembly for nicks, grooves, or scoring. A spiral pattern due to rotor movement is normal. The thrust bearing side of the plate should also show a normal wear pattern without grooves, flaking, or dents. M36851 The flat sides of the input shaft hole should not be grooved or worn.
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Steering—318 and 420/Steering Valve 36. Remove upper cover plate (four plates bonded together). M36854 -UN-29AUG88 37. Check plate surface for grooves, dents, or metal flakes. A polished pattern due to the action of the seal is normal. MX,15906006,26 -19-01MAR95 38. Remove steering shaft and snap ring (A). M36855 -UN-29AUG88 39. Inspect steering shaft serrations, threads, and flats for grooves, wear, or damage. MX,15906006,27 -19-01MAR95 40. Remove washer and steering tube (A).
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Steering—318 and 420/Steering Valve 43. Remove nuts holding the four bolts to the fixture, and remove the bolts. M36858 -UN-29AUG88 44. Inspect bolts for wear or damage. Replace if necessary. MX,15906006,30 -19-01MAR95 ASSEMBLE STEERING VALVE AND COLUMN -UN-29AUG88 IMPORTANT: Always use new seals and O-rings. Damaged or used parts will leak. NOTE: Lubricate all seals and O-rings with petroleum jelly during assembly. M36858 1. Apply clean John Deere Low Viscosity HY-GARD® oil on all internal parts.
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Steering—318 and 420/Steering Valve 6. Install steering tube (A) on bolts. Be sure the square holes in the steering tube are seated on the square shoulders of the bolts. -UN-29AUG88 7. Apply multipurpose grease on retainer plate (B) and washer. M36856 8. Install washer. MX,15906006,33 -19-01MAR95 9. Install snap ring (A) on steering shaft. M36855 -UN-29AUG88 10. Install steering shaft with threaded end down into steering tube.
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Steering—318 and 420/Steering Valve 12. Apply multipurpose grease on the face of the upper cover plate, steering shaft end and thrust bearing (B). -UN-29AUG88 NOTE: Wide shoulder of spacer (A) faces up, away from upper cover plate. 13. Install parts (A—E). M36853 A—Thrust Bearing Spacer B—Thrust Bearing C—Face Seal D—Backup-Ring (4-Port and Early 5-Port) E—Seal Spacer -UN-06MAR95 Four-Port and Early Five-Port M77305 60 06 14 Later Five-Port MX,15906006,36 -19-10MAR95 14.
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Steering—318 and 420/Steering Valve 19. Install commutator (A) on rotor, with long grooves (B) upward. -UN-29AUG88 IMPORTANT: Pins must be installed below the surface of the commutator to prevent commutator cover damage. M36862 20. Align commutator holes with rotor holes and install five pins. 21. Put a few drops of clean John Deere Low Viscosity HY-GARD® oil into each groove of the commutator. MX,15906006,39 -19-01MAR95 22.
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Steering—318 and 420/Steering Valve -UN-29AUG88 IMPORTANT: The following procedure must be used to minimize an out-of-round condition between commutator ring and drive plate. The commutator ring is self-centering when the drive plate is shimmed. Use DFMX2 Alignment Shims. M36864 26. Install metering assembly, with drive plate (A) up into metering ring (B). 27. Install two DFMX2 Alignment Shims (C) each between drive plate and metering ring 120˚ apart. (See Section 299 for instructions to make shims.
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Steering—318 and 420/Steering Valve 29. Remove Shims and metering assembly from metering ring. -UN-29AUG88 30. Install THICK end of drive link into the slot in the rotor. Hold the drive link and rotate the metering assembly by hand. The rotor should turn freely inside the stator. M36866 If the rotor binds or does not move, disassemble and inspect to find the cause. MX,15906006,43 -19-29MAR95 31. Apply petroleum jelly on seal ring. Install seal ring on metering ring end without pin holes.
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Steering—318 and 420/Steering Valve 35. Apply petroleum jelly on new commutator seal (A) and seal ring (B). -UN-29AUG88 36. Install new commutator seal with yellow mark (C) or narrow edge, down into commutator cover. 37. Install seal ring (B) and pins (D). M36869 A—Commutator Seal B—Seal Ring C—Yellow Mark or Narrow Edge D—Pin (2 used) MX,15906006,46 -19-01MAR95 IMPORTANT: Align grooves (A) in isolation manifold with groove (B) in upper cover plate. -UN-29AUG88 38.
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Steering—318 and 420/Steering Valve -UN-29AUG88 IMPORTANT: Valve plate must be installed with “PORT SIDE” (A) directly opposite (12 o’clock position) from alignment groves (B) for proper operation. Valve plate spring slots and springs must be aligned to prevent spring damage when installing port manifold. M36872 44. Install valve plate, with “PORT SIDE” up, on isolation manifold. Turn valve plate to make sure springs are centered in valve plate spring slots. 45.
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Steering—318 and 420/Steering Valve M43832 -UN-08JAN90 48. Four-port and early five-port; Install new O-ring (B) on plug (A). Install check ball (C). Be sure check ball is seated in bottom of hole. Install plug. Do not tighten. Five-Port Shown MX,15906006,52 -19-10MAR95 NOTE: Four-port not shown. Unit is similar to early five-port. -UN-08JAN90 49. Later five-port; Install check ball (E) in countersunk hole (hole closest to the center of the port manifold). 50.
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Steering—318 and 420/Steering Valve 53. Four-port and early five-port; Tighten plug (A) to 14 N·m (124 lb-in.). M43844 -UN-08JAN90 54. Remove steering valve from fixture.
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Steering—318 and 420/Steering Cylinder REMOVE AND INSTALL STEERING CYLINDER -UN-23AUG88 CAUTION: 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. X9811 N M31822 60 06 22 -UN-28JUL89 If an accident occurs, see a doctor immediately.
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Group 10 Brakes OTHER MATERIAL Number Name Use M79292 MPG-2® Multi-Purpose Polymer Grease Prevents parts from seizing. Apply to axle shafts. TY6305/TY9485/764 Clean and Cure Primer Cleans parts and speeds cure of sealant. T43512/TY9473/242 Thread Lock and Sealer (Medium Strength) Apply to threads of brake plate-to-axle cap screws. LOCTITE® PRODUCTS U.S./Canadian/LOCTITE No. ®MPG-2 is a registered trademark of DuBois USA. ®LOCTITE is a registered trademark of the Loctite Corp.
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Brakes/Brakes REMOVE BRAKES CAUTION: Avoid breathing dust that may be generated when handling components containing asbestos fibers. Inhaled asbestos fibers may cause lung cancer. Normal handling is not hazardous as long as airborne dust containing asbestos is not generated. -UN-23AUG88 N -UN-25JAN90 TS220 Avoid creating dust. Never use compressed air for cleaning. Avoid brushing or grinding material containing asbestos. When servicing, wear an approved respirator.
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Brakes/Brakes 7. Inspect lining on brake shoes (A) for wear or oil contamination. Replace shoes if worn. Inspect axle oil seal if shoes are oily. -UN-25JAN90 8. Inspect return spring (B) and hold-down springs (C) for wear or stretching. 9. Check adjuster assembly (D) for ease of movement. M36573 10. Remove brake return spring (B), hold-down springs (C), adjuster (D), and shoes (A). A—Brake Shoes B—Return Spring C—Hold-Down Springs D—Adjuster Assembly MX,15905010,20 -19-14FEB95 11.
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Brakes/Brakes 13. Bend lock plate tabs (A) flat. Remove two cap screws (B). 14. Remove four cap screws and washers to remove brake plate assembly. 15. Remove brake arm (C) and brake support (D).
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Brakes/Brakes INSTALL BRAKES 1. Install brake support (A) on brake arm (B). 2. Install brake arm in brake plate (C). 3 Clean the threads of all four brake plate cap screws and threaded axle housing using Clean and Cure Primer. 4 Apply thread lock and sealer (medium strength) on threads of brake plate cap screws. 5. Install brake rod (D) in brake arm hole. 6. Install brake plate assembly on axle. Install and tighten four cap screws to specificctions. -UN-25JAN90 7.
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Brakes/Brakes 8. Install spring (C), plate or washer (D) and nut (B). 9. Connect return spring (A). M78048 -UN-13FEB95 A—Return Spring B—Nut C—Spring D—Plate (Early Models) —Washer (Later Models) -UN-13FEB95 Early Models M78049 60 10 6 Later Models MX,15905010,24 -19-07MAR95 10. Lock brake pedals together (318 and 420) and apply park brake. -UN-25JAN90 11. Loosen lock nut (A). M36554 12. Turn nut until spring is 42 mm (1.650 in.) long. Tighten lock nut. MX,15905010,25 -19-14FEB95 13.
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Brakes/Brakes 14. Apply MPG-2® Multi-Purpose Polymer Grease to axle shaft. -UN-25JAN90 15. Install key and brake drum. 16. Install washer and nut. Tighten nut to specifications. M36571 17. Bend one side of washer over nut to lock nut in place. 18. Install wheel. Tighten cap screws to specifications. 19. Remove support stands. 20. Connect battery negative (—) cable. 21. Adjust brakes. (See procedure in this group.) TORQUE SPECIFICATIONS Brake Drum-to-Axle Nut . . . . . . . . . . . . . . . . . . . .
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Brakes/Brake Pedal(s) and Neutral Return Linkage 6. Lock brake pedals together (318 and 420) and apply parking brake. -UN-25JAN90 7. Check length of spring on both sides of machine. Spring should be approximately 42 mm (1.650 in.). 8. If necessary, adjust length of spring. M36554 9. Loosen lock nut (A). 10. Turn nut until spring is 42 mm (1.650 in.) long. Tighten lock nut. 11. Remove support stands. 12. Connect battery negative (—) cable.
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Brakes/Brake Pedal(s) and Neutral Return Linkage M77914 -UN-14MAR95 60 10 9 A—Neutral Return Cam Plate B—Spacer C—Left-Hand Brake Arm D—Bearing (4 used) E—Pedal Pad F—Brake Pedal G—Neutral Return Link H—Neutral Return Shaft (Later Models) I—Bracket J—Neutral Return Shaft (Early Models) K—Lock Wire and Spring Pin L—Neutral Return Arm M—Neutral Return Sliding Lever N—Eccentric Adjustment Nut Version One (316) NOTE: Brake pedal and neutral return linkage—Version One, is used on machines equipped with
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Brakes/Brake Pedal(s) and Neutral Return Linkage M77915 -UN-13FEB95 60 10 10 A—Strap (2 used) B—Spacer C—Bushing (2 used) D—Washer (2 used) E—Ball Bearings F—Safety Wire and Spring Pin G—Left-Hand Brake Arm H—Bearing (4 used) I—Pedal Pad J—Brake Pedal K—Neutral Return Shaft L—Bracket M—Neutral Return Link N—Neutral Return Arm O—Lock Wire and Spring Pin P—Neutral Return Cam Q—Clamp-On Nut R—Speed Control Arm (2 used) S—Bushings T—Eccentric Adjustment Nut Version Two (316) NOTE: Brake pedal and neutr
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Brakes/Brake Pedal(s) and Neutral Return Linkage M77916 -UN-13FEB95 60 10 11 A—Washer (2 used) B—Spring C—Bushings D—Ball Bearing E—Safety Wire and Spring Pin F—Left-Hand Brake Arm G—Bearing (4 used) H—Pedal Pad I—Brake Pedal J—Neutral Return Shaft K—Bracket L—Neutral Return Link M—Neutral Return Arm N—Lock Wire and Spring Pin O—Neutral Return Cam P—Clamp-On nut Q—Speed Control Arm (2 used) R—Bushings S—Eccentric Adjustment Nut Version Three (316) NOTE: Brake pedal and neutral return linkage—Versio
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Brakes/Brake Pedal(s) and Neutral Return Linkage 7. Install all parts. 8. Connect brake rods to brake pedal. -UN-13FEB95 9. Install spring (C), plate or washer (D) and nut (B). 10. Connect return spring (A). M78048 A—Return Spring B—Nut C—Spring D—Plate (Early Models) —Washer (Later Models) -UN-13FEB95 Early Models M78049 60 10 12 Later Models MX,15906010,5 -19-07MAR95 11. Apply parking brake. 12. Loosen lock nut (A). -UN-25JAN90 13. Turn nut until spring is 42 mm (1.650 in.) long.
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Brakes/Brake Pedal(s) and Neutral Return Linkage INSPECT AND REPAIR BRAKE PEDALS AND NEUTRAL RETURN LINKAGE—318 -UN-13FEB95 1. Remove belly screen and fender deck. NOTE: Disconnect brake rods from both sides of machine. M78048 2. Disconnect return spring (A). 3. Remove nut (B), plate or washer (D) and spring (C). Inspect springs for weak coils. Early Models 4. Disconnect brake rods from brake pedal.
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Brakes/Brake Pedal(s) and Neutral Return Linkage M77917 -UN-14MAR95 60 10 14 A—Neutral Return Cam Plate B—Spacer C—Eccentric Adjustment Nut D—J-Bolt E—Left Pedal Pad F—Plate G—Strap H—Support I—Right Pedal Pad J—Right Brake Pedal K—Left Brake Pedal L—Neutral Return Link M—Neutral Return Link N—Neutral Return Shaft O—Bearing (4 used) P—Lock Wire and Spring Pin Q—Left-Hand Brake Arm R—Lock Wire and Spring Pin S—Neutral Return Arm Version One (318) NOTE: Brake pedal and neutral return linkage—Version
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Brakes/Brake Pedal(s) and Neutral Return Linkage M77918 -UN-14MAR95 60 10 15 A—Neutral Return Cam Plate B—Spacer C—Neutral Return Sliding Lever D—Eccentric Adjustment Nut E—Lock Wire and Spring Pin F—Neutral Return Arm G—Left Pedal Pad H—Plate I—Strap J—Support K—Right Pedal Pad L—Right Brake Pedal M—Left Brake Pedal N—Neutral Return Link O—Neutral Return Link P—Neutral Return Shaft Q—Bearing (4 used) R—Lock Wire and Spring Pin S—Left-Hand Brake Arm Version Two (318) NOTE: Brake pedal and neutral r
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Brakes/Brake Pedal(s) and Neutral Return Linkage M77919 -UN-13FEB95 60 10 16 A—Strap (2 used) B—Spacer C—Bushing (2 used) D—Washer (2 used) E—Ball Bearings F—Neutral Return Cam G—Safety Wire and Spring Pin H—Neutral Return Arm I—Left Pedal Pad J—Plate K—Strap L—Support M—Right Pedal Pad N—Right Brake Pedal O—Left Brake Pedal P—Neutral Return Link Q—Neutral Return Link R—Neutral Return Shaft S—Bearing (4 used) T—Left-Hand Brake Arm U—Lock Wire and Spring Pin V—Clamp-On Nut W—Speed Control Arm (2 used)
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Brakes/Brake Pedal(s) and Neutral Return Linkage M78040 -UN-13JAN95 60 10 17 A—Washer (2 used) B—Spring C—Bushings D—Ball Bearing E—Neutral Return Cam F—Safety Wire and Spring Pin G—Neutral Return Arm H—Left Pedal Pad I—Plate J—Strap K—Support L—Right Pedal Pad M—Right Brake Pedal N—Left Brake Pedal O—Neutral Return Link P—Neutral Return Link Q—Neutral Return Shaft R—Bearing (4 used) S—Left-Hand Brake Arm T—Lock Wire and Spring Pin U—Clamp-On Nut V—Speed Control Arm (2 used) W—Bushings X—Eccentric Ad
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Brakes/Brake Pedal(s) and Neutral Return Linkage 7. Install all parts. 8. Connect brake rods to brake pedal. -UN-13FEB95 9. Install spring (C), plate or washer (D) and nut (B). 10. Connect return spring (A). M78048 A—Return Spring B—Nut C—Spring D—Plate (Early Models) —Washer (Later Models) -UN-13FEB95 Early Models M78049 60 10 18 Later Models MX,15906010,5 -19-07MAR95 11. Lock brake pedals together and apply parking brake. 12. Loosen lock nut (A). -UN-25JAN90 13.
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Brakes/Brake Pedal(s) and Neutral Return Linkage INSPECT AND REPAIR BRAKE PEDALS AND NEUTRAL RETURN LINKAGE—420 -UN-13FEB95 1. Remove belly pan and fender deck. NOTE: Disconnect brake rods from both sides of machine. M78048 2. Disconnect return spring (A). 3. Remove nut (B), plate or washer (D) and spring (C). Inspect springs for weak coils. Early Models 4. Disconnect brake rods from brake pedal.
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Brakes/Brake Pedal(s) and Neutral Return Linkage M78041 -UN-14MAR95 60 10 20 A—Neutral Return Cam Plate B—Spacer C—J-Bolt D—Left Pedal Pad E—Plate F—Strap G—Support H—Right Pedal Pad I—Right Brake Pedal J—Neutral Return Link K—Left Brake Pedal L—Neutral Return Link M—Neutral Return Shaft N—Bearing (4 used) O—Neutral Return Welded Shaft P—Lock Wire and Spring Pin Q—Left-Hand Brake Arm R—Eccentric Adjustment Nut Version One (420) NOTE: Brake pedal and neutral return linkage—Version One, is used on ma
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Brakes/Brake Pedal(s) and Neutral Return Linkage M78042 -UN-13MAR95 60 10 21 A—Strap (2 used) B—Spacer C—Bushing (2 used) D—Washer (2 used) E—Ball Bearings F—Left Pedal Pad G—Plate H—Strap I—Support J—Right Pedal Pad K—Right Brake Pedal L—Left Brake Pedal M—Neutral Return Link N—Neutral Return Link O—Neutral Return Shaft (Short) P—Bearing (4 used) Q—Neutral Return Shaft (Long) R—Neutral Return Cam S—Lock Wire and Spring Pin T—Left-Hand Brake Arm U—Clamp-On Nut V—Speed Control Arm (2 used) W—Bushings
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Brakes/Brake Pedal(s) and Neutral Return Linkage M78043 -UN-13MAR95 60 10 22 A—Washer (2 used) B—Spring C—Bushings D—Ball Bearing E—Left Pedal Pad F—Plate G—Strap H—Support I—Right Pedal Pad J—Right Brake Pedal K—Left Brake Pedal L—Neutral Return Link M—Neutral Return Link N—Neutral Return Shaft (Short) O—Bearing (4 used) P—Neutral Return Shaft (Long) Q—Neutral Return Cam R—Lock Wire and Spring Pin S—Left-Hand Brake Arm T—Clamp-On Nut U—Speed Control Arm (2 used) V—Bushings W—Eccentric Adjustment Nut
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Brakes/Brake Pedal(s) and Neutral Return Linkage 7. Install all parts. 8. Connect brake rods to brake pedal. -UN-13FEB95 9. Install spring (C), plate or washer (D) and nut (B). 10. Connect return spring (A). M78048 A—Return Spring B—Nut C—Spring D—Plate (Early Models) —Washer (Later Models) M78049 -UN-13FEB95 Early Models Later Models MX,15906010,5 -19-07MAR95 11. Lock brake pedals together and apply parking brake. 12. Loosen lock nut (A). -UN-25JAN90 13. Turn nut until spring is 42 mm (1.650 in.
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Brakes/Inspect and Repair Park Brake Lever INSPECT AND REPAIR PARK BRAKE LEVER 1. Remove belly screen/pan. 2. Inspect all parts for wear or damage. Replace as necessary.
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Section 70 HYDRAULIC REPAIR Contents Page Group 05—Hydraulic Control Valve Other Materials . . . . . . . . . . . . . . . Service Parts Kits . . . . . . . . . . . . . Remove and Install 316 and 318 . . . . . . . . . . . . . . . 420 . . . . . . . . . . . . . . . . . . . . . Disassemble, Inspect and Assemble Single-Spool . . . . . . . . . . . . . . . . Two-Spool . . . . . . . . . . . . . . . . . Three-Spool . . . . . . . . . . . . . . . . ... ... 70-05-1 70-05-1 ... ... 70-05-2 70-05-4 ... ... ...
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Contents 70 TM1590 (17MAY95) 70-2 316, 318 & 420 Lawn and Garden Tractors 020895
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Group 05 Hydraulic Control Valve OTHER MATERIAL Number Name Use M79292 MPG-2® Multi-Purpose Polymer Grease Prevents parts from seizing. Apply to spool springs and end cap cavities. TY6305/TY9485/764 Clean and Cure Primer Cleans parts and speeds cure of sealant. T43512/TY9473/242 Thread Lock and Sealer (Medium Strength) Apply to threads spool screws. LOCTITE® PRODUCTS U.S./Canadian/LOCTITE No. ®MPG-2 is a registered trademark of DuBois USA.
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Hydraulic Control Valve/Remove and Install REMOVE AND INSTALL HYDRAULIC CONTROL VALVE—316 AND 318 -UN-23AUG88 CAUTION: 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. X9811 N M31751 -UN-28JUL89 If an accident occurs, see a doctor immediately.
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Hydraulic Control Valve/Remove and Install M55071 -UN-09DEC89 7. Remove cotter pin(s) (A) from draft pin(s) (B). Disconnect control linkage. 316 Shown MX,15907005,3 -19-20APR95 8. Remove two mounting bolts (B) and control valve (A). 9. Installation is done in the reverse order of removal. -UN-03AUG89 • Fill transmission with the recommended amount of John Deere Low Viscosity HY-GARD® oil. M32046 • Bleed the hydraulic system. (See procedure in Section 270, Group 20.
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Hydraulic Control Valve/Remove and Install REMOVE AND INSTALL HYDRAULIC CONTROL VALVE—420 -UN-23AUG88 CAUTION: 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. X9811 N M31895 -UN-28JUL89 If an accident occurs, see a doctor immediately.
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Hydraulic Control Valve/Disassemble, Inspect and Assemble M78058 -UN-24MAR95 DISASSEMBLE, INSPECT AND ASSEMBLE HYDRAULIC CONTROL VALVE—SINGLE-SPOOL A—Spool B—Body C—O-Ring D—Washer E—Spring F—Spring Retainer G—Screw H—Cap I—Screw (2 used) J—Plug • Apply clean John Deere Low Viscosity HY-GARD® oil on all internal parts during assembly. IMPORTANT: Spool and body are matched and must be replaced as a unit. Always use new O-rings. Damaged or used parts will leak.
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Hydraulic Control Valve/Disassemble, Inspect and Assemble M78059 -UN-14APR95 DISASSEMBLE, INSPECT AND ASSEMBLE HYDRAULIC CONTROL VALVE—TWO-SPOOL A—Check Valve Plug (2 used) B—O-Ring (2 used) C—Spring (2 used) D—Poppet (2 used) E—Spool 70 05 6 F—Float Detent Spool G—Body H—O-Ring (2 used) I—Bushing (2 used) J—Washer (2 used) K—Spring L—Detent M—Spring N—Ball (2 used) O—Cap P—Plug Q—Cap R—Snap Ring S—Washer T—Spring U—Snap Ring V—Sleeve W—Washer (as required) Version One NOTE: There are five version
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M78840 -UN-14APR95 Hydraulic Control Valve/Disassemble, Inspect and Assemble A—Check Valve Plug (2 used) B—O-Ring (2 used) C—Spring (2 used) D—Poppet (2 used) E—Spool F—O-Ring (4 used) G—Float Detent Spool H—Body I—Bushing (2 used) J—Washer (2 used) K—Spring L—Detent M—Ball (3 used) N—Spring O—Cap P—Washer Q—Cap R—Cap S—Snap Ring T—Spacer U—Spring V—Washer Versions Two and Three IMPORTANT: Spools and body are matched and must be replaced as a unit.
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M78841 -UN-14APR95 Hydraulic Control Valve/Disassemble, Inspect and Assemble 70 05 8 A—Check Valve Plug (2 used) B—O-Ring (2 used) C—Spring (2 used) D—Poppet (2 used) E—Spools and Body F—O-Ring (4 used) G—Washers H—Spring I—Spacer J—Detent K—Cap L—Ball (2 used) M—Spring (2 used) N—Plug (2 used) O—Screw and Washer (4 used) P—Cap Q—Screw R—Spacer S—Spring T—Washer Versions Four and Five IMPORTANT: Spools and body are matched and must be replaced as a unit.
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Hydraulic Control Valve/Disassemble, Inspect and Assemble M78842 -UN-24APR95 DISASSEMBLE, INSPECT AND ASSEMBLE HYDRAULIC CONTROL VALVE—THREE-SPOOL A—Check Valve Plug (3 used) B—O-Ring (3 used) C—Spring (3 used) D—Poppet (3 used) E—Lock Nut (Version Three only) F—Cap G—Shim (as required) H—O-Ring I—Spring J—Poppet K—Spools and Body L—O-Ring (6 used) M—Bushing (3 used) N—Washer (2 used) O—Spacer (2 used) P—Spring (2 used) Q—Washer (2 used) R—Snap Ring (2 used) S—Cap (2 used) 70 05 9 T—Plug (2 used, Ve
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M78843 -UN-14APR95 Hydraulic Control Valve/Disassemble, Inspect and Assemble 70 05 10 A—Check Valve Plug (3 used) B—O-Ring (3 used) C—Spring (3 used) D—Poppet (3 used) E—Spools and Body F—O-Ring (6 used) G—Washer (4 used) H—Spring (2 used) I—Spacer (2 used) J—Screw (2 used) K—Cap (2 used) L—Screw and Washer (6 used) M—Plug (2 used) N—Spring (2 used) O—Ball (2 used) P—Cap Q—Detent R—Spacer S—Spring Version Four IMPORTANT: Spools and body are matched and must be replaced as a unit.
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Section 80 MISCELLANEOUS REPAIR Contents Page Group 05—Front Axle Special or Essential Tools . . . . . . . . Front Axle—316 and 318 Remove and Install . . . . . . . . . . . Inspect and Replace Pivot Bushings Front Axle—420 Remove . . . . . . . . . . . . . . . . . . Disassemble and Inspect Pivot Pin Assemble Pivot Pin . . . . . . . . . . . Install . . . . . . . . . . . . . . . . . . . . Spindles Remove and Install . . . . . . . . . . . Inspect and Replace Bushings . . .
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Contents 80 TM1590 (17MAY95) 80-2 316, 318 & 420 Lawn and Garden Tractors 020895
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Group 05 Front Axle SPECIAL OR ESSENTIAL TOOLS NOTE: Order tools according to information given in the U.S. SERVICE-GARD™ Catalog or in the European Microfiche Tool Catalog (MTC). DX,TOOLS -19-05JUN91 Installer Sleeve.............................JDM8-3 For 420 tractor; Used to install PTO shaft asssembly into pivot pin. MX,15908005,A -19-08MAR95 REMOVE AND INSTALL FRONT AXLE—316 AND 318 -UN-28JUL89 NOTE: The 316 has manual steering and is connected to the steering arm by a drag link.
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Front Axle/Front Axle—420 6. Place a floor jack under center of axle. 7. Remove cotter pin from pivot bolt. -UN-03AUG89 8. Remove pivot bolt nut and remove bolt through axle (towards rear). Remove axle. M32002 9. Inspect axle and pivot bushings for damage or wear. (See procedure in this group.) 10. Installation is done in the reverse order of removal. • Apply multipurpose grease to pivot bolt before installing. • Tighten pivot bolt nut until axle is snug, but still free to pivot.
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Front Axle/Front Axle—420 M31970 -UN-03AUG89 5. Loosen axle deflector adjustment bolts and turn in to allow maximum clearance. MX,15908005,6 -19-15FEB95 6. Remove front grille. M31991 -UN-03AUG89 7. Remove two nuts (A) and belt guard. MX,15908005,7 -19-07MAR95 8. Loosen belt adjuster (A), using a screwdriver or bar to keep the adjuster from cocking as it is loosened. M31992 -UN-17FEB95 9. Remove both belts from sheaves.
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Front Axle/Front Axle—420 10. Remove snap ring from drive pulley. M31994 -UN-03AUG89 11. Remove drive pulley from PTO shaft. MX,15908005,9 -19-15FEB95 M31996 -UN-03AUG89 12. Remove two pivot pin retaining nuts (A). MX,15908005,10 -19-15FEB95 13. Place a floor jack under center of axle. 15. Inspect pivot pin bore (B) and axle (C) for damage or excessive wear. Replace axle if necessary. M31998 16. Inspect pivot pin for damage or wear. (See procedure in this group.
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Front Axle/Front Axle—420 M36803 -UN-25JAN90 2. Push PTO shaft (A) and bearing (B) from pivot pin using a press. MX,15908005,13 -19-15FEB95 3. Inspect PTO shaft bearing (A) for wear or damage. Replace if necessary. -UN-29JAN90 4. If replacing bearing, remove snap ring (B). M36804 5. Push PTO shaft from bearing using a press and a knife-edge puller. MX,15908005,14 -19-15FEB95 6. Inspect caged needle bearing (A) for wear or damage. Replace if necessary. M36806 -UN-25JAN90 7.
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Front Axle/Front Axle—420 ASSEMBLE PIVOT PIN—420 M36808 -UN-25JAN90 1. Support pivot pin on a press. Put a driver disk (A) on bearing (B). Install bearing using a press until disk bottoms on pivot pin. MX,15908005,16 -19-15FEB95 2. Install snap ring (A) on PTO shaft. -UN-25JAN90 3. Support bearing on a knife-edge puller. Press PTO shaft (B) into bearing until it bottoms on snap ring.
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Front Axle/Front Axle—420 4. Support pivot pin on a press. Install PTO shaft assembly into pivot pin. 5. Put JDM8-3 Installation Sleeve (A) or a piece of pipe over PTO shaft. Put a suitable size driver disk (B) on Sleeve or pipe. M36810 -UN-25JAN90 6. Press shaft assembly into pivot pin until bearing bottoms in bore. MX,15908005,18 -19-07MAR95 M36802 -UN-29JAN90 7. Install snap ring (A). MX,15908005,19 -19-15FEB95 INSTALL FRONT AXLE—420 -UN-03AUG89 1.
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Front Axle/Front Axle—420 4. Slide drive pulley onto PTO shaft. 5. Install snap ring in PTO shaft groove. M31994 -UN-03AUG89 6. Install belts on lower drive sheave and work onto upper sheave. MX,15908005,21 -19-15FEB95 7. Tighten belt adjuster: -UN-20DEC89 When adjusting PTO belt tension on horizontal adjuster, tighten bolt until spring measures 41 mm (1.600 in.). M49503 When adjusting PTO belt tension on vertical adjuster, tighten nut until spring measures 35 mm (1.380 in.).
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Front Axle/Spindles 10. Connect steering cylinder to spindle. 11. Install bolt and nut through steering arm and cylinder. M31963 -UN-28JUL89 12. Install cotter pin, if equipped, in steering arm bolt. MX,15908005,24 -19-07MAR95 13. Adjust axle deflector bolts for smooth up and down operation of axle. -UN-03AUG89 14. Test for proper axle deflector adjustment, by pushing down on a wheel. The axle should move freely without sticking in one spot. Readjust if necessary. M31970 15.
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Front Axle/Spindles M32068 -UN-03AUG89 6. Disconnect both tie rod ends and remove tie rod. MX,15908005,27 -19-15FEB95 7. Put an alignment mark across top of steering arm and left spindle to aid in installation. M32069 -UN-03AUG89 8. Remove nut, washer (if equipped), bolt and steering arm from left spindle. MX,15908005,28 -19-15FEB95 9. Slide left spindle down out of axle to remove.
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Front Axle/Spindles 10. Remove snap ring from top of right spindle. 11. Slide right spindle down out of axle to remove. -UN-03AUG89 12. Inspect spindles for wear or damage. Replace if necessary. M32072 13. Inspect bushings for wear or damage. Replace if necessary. (See procedure in this group.) 14. Installation is done in the reverse order of removal. • On left-hand side; align marks made on steering arm and spindle shaft. • Apply multipurpose grease to lubrication fittings. • Adjust toe-in.
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Front Axle/Adjust Toe-in INSPECT AND REPLACE WHEEL BEARINGS 1. Remove front wheels. M32007 -UN-03AUG89 2. The front wheels are equipped with sealed roller bearings in both the front and rear of hub. Check the bearings for damage by spinning the inner race by hand. If the bearing binds or shows excessive wear, it must be replaced. 3. Tap the bearings out from the back side with a long drift and a hammer. 4. Install new bearings using a driver set. MX,15908005,32 -19-12MAY95 ADJUST TOE-IN M32064 2.
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Front Axle/Adjust Toe-in 4. Loosen jam nuts and adjust tie rod to lengthen or shorten distance. -UN-03AUG89 IMPORTANT: Make sure there is free movement of ball joints after tightening jam nuts. M32066 5. Make certain to securely tighten jam nuts after adjusting tie rod.
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Front Axle/Adjust Toe-in 80 05 14 TM1590 (17MAY95) 80-05-14 316, 318 & 420 Lawn and Garden Tractors 020895
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Group 10 Mower Spindle and Jack Sheave Repair SERVICE MOWER BLADE SPINDLES—38 (EARLY), 46 AND 50-INCH MOWER NOTE: On 50-Inch, Three-Point Hitch Mowers; some spindles may have a grease zerk in the top end of the spindle shaft. If, for any reason the spindle must be disassembled, be sure to lubricate and torque parts as required. -UN-21FEB95 When assembling bearings and spacer, fill cavities (J and M) 75 percent full of multipurpose grease.
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Mower Spindle and Jack Sheave Repair/Mower Blade Spindles SERVICE MOWER BLADE SPINDLES—EARLY 60-INCH AND 260 ROTARY MOWER If, for any reason the spindle must be disassembled, be sure to lubricate and torque parts as required. When assembling bearings and spacer, fill cavities (E and H) 75 percent full of multipurpose grease.
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Mower Spindle and Jack Sheave Repair/Mower Blade Spindles SERVICE MOWER BLADE SPINDLES—LATER 60-INCH AND 260 ROTARY MOWER If, for any reason the spindle must be disassembled, be sure to lubricate and torque parts as required. IMPORTANT: Bushing (F) must be installed with grease grooves on end of bushing facing bearing (R) or bearings won’t get any grease. -UN-21FEB95 Bearing (M) must be install with sealed surface side facing away from snap ring (N) to keep grease within grease cavity (P) and bearing.
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Mower Spindle and Jack Sheave Repair/Mower Blade Jack Sheaves SERVICE MOWER BLADE JACK SHEAVES—46 AND 50-INCH MOWER Mower blade jack sheaves normally require no lubrication or service. If, for any reason the jack sheave must be disassembled, be sure to lubricate and torque parts as required. When assembling bearings and spacer, fill cavities (K and N) 75 percent full of multipurpose grease. TORQUE SPECIFICATIONS Lock Nut (A) . . . . . . . . . . . . . . . . . . . . . . . . . .
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Group 15 Mower Gear Case Repair OTHER MATERIAL Number Name Use TY6305/TY9485/764 Clean and Cure Primer Cleans parts and speeds cure of sealant. TY15130/NA/395 Form-In-Place Gasket Sealant Early 60-Inch Mower and 260 Rotary Mower; Apply to mating surfaces of gear case and caps. LOCTITE® PRODUCTS U.S./Canadian/LOCTITE No. ®LOCTITE is a registered trademark of the Loctite Corp. MX,15908015,OTH-19-22FEB95 DISASSEMBLE AND INSPECT MOWER GEAR CASE—50-INCH MOWER M77316 -UN-24FEB95 1.
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Mower Gear Case Repair/50-Inch Mower 2. Remove four cap screws (A) and input shaft assembly. 3. Remove lock nut (B), washer (C) and bevel gear (E) and bearing from shaft. NOTE: Bearing cone is press-fit on bevel gear. Remove bearing only if replacement is necessary. Bearing cone, cup in pillow block and shim(s) are matched and must be replaced as complete assemblies. 4. Inspect bearing cone (D) for wear or damage. Replace if necessary. 5.
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Mower Gear Case Repair/50-Inch Mower 7. Press on threaded end of input shaft (C) to remove seal (A) and input shaft assembly from pillow block (I). NOTE: Bearing cone is press-fit on input shaft. Remove bearing only if replacement is necessary. Bearing cups are press-fit in pillow block. Remove cups only if replacement is necessary. Bearing cones and cups are matched and must be replaced as complete assemblies. 8. Inspect bearing cone (D) and cups (G and H) for wear or damage. Replace as necessary. 9.
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Mower Gear Case Repair/50-Inch Mower 12. Remove vent plug (A) and adapter (B) from gear case (C). 13. Remove four cap screws (D). Remove retainer (L) and output shaft assembly (M). 14. Remove output shaft assembly (M) from retainer (L). IMPORTANT: Remove and discard crush ring (I). A new crush ring must be installed during assembly to achieve proper output shaft end play. 15. Remove O-ring (G), shim (J), bearing cup (H) and crush ring (I). Discard crush ring. 16. Press out seal (K) from retainer (L).
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Mower Gear Case Repair/50-Inch Mower NOTE: Bearing cones are press-fit on output shaft. Remove bearings only if replacement is necessary. Bearing cones and cups are matched and must be replaced as complete assemblies. 20. Inspect bearing cones (A and D) for wear or damage. Replace if necessary. 21. Press output shaft (B) from bearing cone (A). Remove snap ring (C). 22. Remove bearing cone (D) from output shaft (B) using a knife-edge puller and a press. 23. Remove bevel gear (E), snap ring (F) and key (G).
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Mower Gear Case Repair/50-Inch Mower ASSEMBLE MOWER GEAR CASE—50-INCH MOWER IMPORTANT: Always use new seals and O-rings. Damaged or used parts will leak. NOTE: Lubricate all O-rings with petroleum jelly during assembly. Apply clean gear case oil on all internal parts during assembly. 1. Install snap ring (F), key (G) and bevel gear (E). Install bevel gear on output shaft, small O.D. first. 2. Press bearing cone (D) on output shaft (B) with small O.D. facing away from bevel gear (E).
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Mower Gear Case Repair/50-Inch Mower 5. Install new bearing cup (F), if removed, using a driver set. 6. Press plug (E) into gear case (C) with lip facing away from gear case. Install plug until recessed 1.59 mm (0.062 in.) below gear case surface. 7. Install adapter (B) and vent plug (A). 8. Press new seal (K) into retainer (L) until top of seal is recessed 2.54 mm (0.100 in.) below retainer surface. 9. Apply multipurpose grease to lip of seal.
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Mower Gear Case Repair/50-Inch Mower 16. Install snap ring (F). 17. Install new bearing cups (G and H), if removed, using a driver set. Press into pillow block (I) until seated against snap ring and housing. 18. Install snap ring (B) on input shaft (C). 19. Press bearing cone (D) on input shaft with small O.D. facing away from snap ring (B). Install bearing until it bottoms against snap ring. IMPORTANT: Tape end of input shaft to prevent seal damage during seal installation. 20.
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Mower Gear Case Repair/50-Inch Mower 25. Install shims (F) on bevel gear (E). 26. Press bearing cone (D) on bevel gear (E) with small O.D. facing away from bevel gear. Install bearing until it bottoms against shims. 27. Install key (G) into input shaft. 28. Install bevel gear assembly onto input shaft. IMPORTANT: DO NOT overtighten lock nut (B). Overtightening can damage bearing cone (D). 29. Install washer (C) and lock nut (B). Tighten lock nut until there is zero endplay in input shaft. 30.
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Mower Gear Case Repair/Early 60-Inch Mower (Curtis) DISASSEMBLE AND INSPECT MOWER GEAR CASE—EARLY 60-INCH MOWER (CURTIS) -UN-24FEB95 1. Remove drain plugs (A and B) and drain oil from gear case. M77328 2. Scribe an alignment mark across caps and gear case. Mark both caps in relation to the case side they are removed from to aid in assembly.
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Mower Gear Case Repair/Early 60-Inch Mower (Curtis) 3. Remove four cap screws and lock plates (A). 4. Remove cap (B) and input shaft assembly from gear case (C). 5. Remove shims (D) and input shaft assembly from cap (B). 6. Pry out seal (E). NOTE: Bearing cup is press-fit in cap. Remove bearing cup only if replacement is necessary. Bearing cone (K) is press-fit on input shaft. Bearing cones and cups (one in gear case housing) are matched and must be replaced as complete assemblies. -UN-24FEB95 7.
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Mower Gear Case Repair/Early 60-Inch Mower (Curtis) 13. Remove four cap screws and lock plates (A). 14. Remove cap (B) and output shaft assembly from gear case (C). 15. Remove shims (D) and output shaft assembly from cap (B). 16. Pry out seal (E). NOTE: Bearing cup is press-fit in cap. Remove bearing cup only if replacement is necessary. Bearing cone (K) is press-fit on input shaft. Bearing cones and cups (one in gear case housing) are matched and must be replaced as complete assemblies. -UN-24FEB95 17.
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Mower Gear Case Repair/Early 60-Inch Mower (Curtis) 23. Remove vent plug (A) and adapter (B). NOTE: Bearing cups are press-fit in gear case. Remove bearing cups only if replacement is necessary. Bearing cups and cones are matched and must be replaced as complete assemblies. 24. Inspect bearing cups (D and E) for wear or damage. Replace if necessary. -UN-24FEB95 IMPORTANT: Remove bearing cups using a slide hammer and inside puller, if possible. Using a punch and hammer can damage gear case.
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Mower Gear Case Repair/Early 60-Inch Mower (Curtis) ASSEMBLE MOWER GEAR CASE—EARLY 60-INCH MOWER (CURTIS) IMPORTANT: Always use new seals. Damaged or used seals will leak. NOTE: Apply clean gear case oil on all internal parts during assembly. 1. Install shims (F), if equipped, into gear case (C). -UN-24FEB95 2. Install new bearing cups (E and D), if removed, using a driver set. 3. Install adapter (B) and vent plug (A).
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Mower Gear Case Repair/Early 60-Inch Mower (Curtis) 4. Install key (L) and bevel gear (J), shoulder end first, onto shaft (H). 5. Align holes in bevel gear and shaft and install spring pin (I). 6. Press bearing cone (K) on shaft with small O.D. facing away from bevel gear (J). Install bearing cone until seated. 7. Slide bearing cone (G) onto other end of output shaft (H). IMPORTANT: Do not press seal in until seated or bottomed out. Seal will become damaged and will leak. -UN-24FEB95 8.
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Mower Gear Case Repair/Early 60-Inch Mower (Curtis) IMPORTANT: Tape end of output shaft to prevent seal damage during shaft installation. 11. Apply tape around end of output shaft. 12. Assemble output shaft assembly and cap (B). Remove tape. NOTE: Flat sides of cap must align with flat sides of gear case. Gear case mounting surface must be flat to install gear case on mower deck. 13. Install shims (D). Align marks made during disassembly and install output shaft assembly into gear case (C). 14.
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Mower Gear Case Repair/Early 60-Inch Mower (Curtis) 19. Install key (L) and bevel gear (J), shoulder end first, onto shaft (H). 20. Align holes in bevel gear and shaft and install spring pin (I). 21. Press bearing cone (K) on shaft with small O.D. facing away from bevel gear (J). Install bearing until seated. 22. Slide bearing cone (G) onto other end of input shaft (H). IMPORTANT: Do not press seal in until seated or bottomed out. Seal will become damaged and will leak. -UN-24FEB95 23.
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Mower Gear Case Repair/Early 60-Inch Mower (Curtis) IMPORTANT: Tape end of input shaft to prevent seal damage during shaft installation. 26. Apply tape around end of input shaft. 27. Assemble input shaft assembly and cap (B). Remove tape. NOTE: Flat sides of cap must align with flat sides of gear case. Gear case mounting surface must be flat to install gear case on mower deck. 28. Install shims (D). Align marks made during disassembly and install input shaft assembly into gear case (C). 29.
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Mower Gear Case Repair/Later 60-Inch Mower (Peerless) DISASSEMBLE AND INSPECT MOWER GEAR CASE—LATER 60-INCH MOWER (PEERLESS) M77311 -UN-24FEB95 1. Remove drain plugs (A and B) and drain oil from gear case. MX,15908015,19 -19-22FEB95 2. Remove four cap screws (A) and input shaft assembly. 3. Remove lock nut (B), washer (C) and bevel gear (E) and bearing from shaft. NOTE: Bearing cone is press-fit on bevel gear. Remove bearing cone only if replacement is necessary.
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Mower Gear Case Repair/Later 60-Inch Mower (Peerless) 7. Press on threaded end of input shaft (C) to remove seal (A) and input shaft assembly from pillow block (H). NOTE: Bearing cone is press-fit on input shaft. Remove bearing only if replacement is necessary. Bearing cups are press-fit in pillow block. Remove cups only if replacement is necessary. Bearing cones and cups are matched and must be replaced as complete assemblies. 8. Inspect bearing cone (D) and cups (F and G) for wear or damage.
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Mower Gear Case Repair/Later 60-Inch Mower (Peerless) 12. Remove vent plug (A) from retainer (G). 13. Remove four cap screws (B). Remove retainer (G) and output shaft assembly (K) by tapping on end of shaft with a rubber mallet. 14. Remove output shaft assembly (K) from retainer (G). 15. Remove O-ring (F) and shim (C) from retainer (G). IMPORTANT: Remove and discard crush ring (E). A new crush ring must be installed during assembly to achieve proper output shaft end play. 16.
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Mower Gear Case Repair/Later 60-Inch Mower (Peerless) NOTE: Bearing cones are press-fit on output shaft. Remove bearings only if replacement is necessary. Bearing cones and cups are matched and must be replaced as complete assemblies. 20. Inspect bearing cones (A and D) for wear or damage. Replace if necessary. 21. Press shaft (C) from bearing cone (A). Remove snap ring (B). 22. Remove bearing cone (D) from shaft (C) using a knife-edge puller and a press. 23.
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Mower Gear Case Repair/Later 60-Inch Mower (Peerless) ASSEMBLE MOWER GEAR CASE—LATER 60-INCH MOWER (PEERLESS) IMPORTANT: Always use new seals and O-rings. Damaged or used parts will leak. NOTE: Lubricate all O-rings with petroleum jelly during assembly. Apply clean gear case oil on all internal parts during assembly. 1. Install snap ring (G) in first groove under keyway for key (H). 2. Install key (H), bevel gear (F) and shims (E). Install bevel gear on shaft with shoulder facing away from snap ring (G).
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Mower Gear Case Repair/Later 60-Inch Mower (Peerless) 6. Install new bearing cup (I), if removed, into gear case (J) using a driver set. 7. Press new seal (H) into gear case (J) until top of seal is recessed 2.54 mm (0.100 in.) below gear case surface. 8. Apply multipurpose grease to lip of seal. 9. Install vent plug (A). IMPORTANT: A new crush ring must be installed during assembly. The ring collapses when retainer is tightened to gear case to achieve proper output shaft end play. 10.
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Mower Gear Case Repair/Later 60-Inch Mower (Peerless) 15. Install new bearing cups (F and G), if removed, using a driver set. Press into pillow block (H) until seated against housing. 16. Install snap ring (B) onto input shaft (C). 17. Press bearing cone (D) on input shaft with small O.D. facing away from snap ring (B). Install bearing until it bottoms againt snap ring. IMPORTANT: Tape end of input shaft to prevent seal damage during seal installation. 18. Apply tape around large end of input shaft. 19.
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Mower Gear Case Repair/Later 60-Inch Mower (Peerless) 23. Install shim (F) on bevel gear (E). 24. Press bearing cone (D) on bevel gear (E) with small O.D. facing away from bevel gear. Install bearing until it bottoms against shim. 25. Install key (G) into input shaft. 26. Install bevel gear assembly onto input shaft. IMPORTANT: DO NOT overtighten lock nut (B). Overtightening can damage bearing cone (D). 27. Install washer (C) and lock nut (B). Tighten lock nut until there is zero endplay in input shaft. 28.
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Mower Gear Case Repair/260 Rotary Mower DISASSEMBLE AND INSPECT MOWER GEAR CASE—260 ROTARY MOWER M77323 -UN-24FEB95 1. Remove drain plugs (A and B) and drain oil from gear case.
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Mower Gear Case Repair/260 Rotary Mower 2. Remove four cap screws (A). 3. Remove output shaft assembly and housing from gear case (B). 4. Remove shims (C). 5. Punch a hole in seal (D) and pry out of housing (L). 6. Bend out exterior locking tab on toothed washer (E) from lock nut (F). 7. Turn lock nut (F) counterclockwise using a hammer and punch. Remove lock nut. 8. Bend interior locking tab on toothed washer (E) away from groove in shaft (I). Remove toothed washer. -UN-24FEB95 9.
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Mower Gear Case Repair/260 Rotary Mower 13. Remove bearing cone (A) from shaft (B) using a knife-edge puller and a press. 14. Remove c-ring (C), locking collar (D), bevel gear (E) and key (F). 15. Inspect all parts for wear or damage. Replace as necessary.
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Mower Gear Case Repair/260 Rotary Mower 16. Remove four cap screws (A). 17. Remove input shaft assembly (B) from gear case (C). 18. Remove four cap screws (D), end cap (E) and shims (F). 19. Remove vent plug (H) and adapter (I). NOTE: Bearing cup is press-fit in end cap. Remove bearing cup only if replacement is necessary. Bearing cones and cups are matched and must be replaced as complete assemblies. 20. Inspect bearing cup (G) for wear or damage. Replace if necessary.
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Mower Gear Case Repair/260 Rotary Mower 22. Remove input shaft assembly from cap (A). 23. Remove shims (B). 24. Remove seal (C) using a punch and hammer. NOTE: Bearing cup is press-fit in cap. Remove bearing cup only if replacement is necessary. Bearing cups and cones are matched and must be replaced as complete assemblies. 25. Inspect bearing cup (D) for wear or damage. Replace if necessary. 26. Remove bearing cup using a brass drift or punch and hammer. -UN-24FEB95 27.
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Mower Gear Case Repair/260 Rotary Mower ASSEMBLE MOWER GEAR CASE—260 ROTARY MOWER IMPORTANT: Always use new seals. Damaged or used seals will leak. NOTE: Apply clean gear case oil on all internal parts during assembly. 1. Install key (I) into input shaft (E). 2. Press bevel gear (G), tapered end first, onto shaft (E) until started. 3. Press bearing cone (H) on shaft with small O.D. facing away from bevel gear (G). Install both bearing cone and bevel gear until bearing bottoms against shaft.
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Mower Gear Case Repair/260 Rotary Mower 11. Install new bearing cup (G), if removed, into end cap (E) using a driver set. 12. Install shims (F) onto end cap (E). 13. Clean mating surfaces of cap, shims and gear case using Clean and Cure Primer. Apply a bead of Form-In-Place Gasket, or an equivalant, between inside edge of top shim and flange on end cap (E). 14. Install end cap and four cap screws (D) onto gear case (C). Tighten cap screws to 30 N·m (22 lb-ft). 15.
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Mower Gear Case Repair/260 Rotary Mower 22. Install key (F) and bevel gear (E) on shaft (B). Install bevel gear with shoulder end toward threaded end of shaft. 23. Install locking collar (D) with groove facing away from bevel gear. Install c-ring (C). 24. Press bearing cone (A) on shaft with small O.D. facing away from bevel gear (E). Install bearing until it bottoms locking collar (D) against c-ring (C).
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Mower Gear Case Repair/260 Rotary Mower 25. Install new bearing cups (K and J), if removed, into housing (L) using a driver set. 26. Install output shaft assembly (I) into housing (L). 27. Slide bearing cone (H) on shaft with small O.D. facing toward housing (L). 28. Install tabbed washer (G) and toothed washer (E). Press internal tab on toothed washer (E) into slot on shaft using a screwdriver. 29. Install lock nut (F).
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Mower Gear Case Repair/260 Rotary Mower 40. AFTER installing gear case on mower deck, fill gear case to proper level with John Deere API GL-5 Gear Oil. M77323 -UN-24FEB95 41. Install plugs (A and B).
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Section 220 ENGINE, FUEL AND AIR SYSTEM CHECKOUT AND DIAGNOSIS Contents Page Group 05—Engine, Fuel and Air Checkout Before You Start . . . . . . . . . . . Engine Oil and Leak Check . . . . Fuel Leak Check . . . . . . . . . . . Throttle Lever Check . . . . . . . . Engine Start Check . . . . . . . . . Choke Lever Check . . . . . . . . . Engine Oil Pressure Check . . . . Engine Performance Check . . . . Operator Complaint Not Identified System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Contents 220 TM1590 (17MAY95) 220-2 316, 318 & 420 Lawn and Garden Tractors 020895
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Group 05 Engine, Fuel and Air System Checkout BEFORE YOU START Always begin with this group to identify a failure in the engine, fuel or air system. The step-by-step procedures will provide you with a quick check of the system. No special tools are required to perform these checks. If a failure is indicated, you will be referred to a more detailed check, adjustment, or test. This procedure is designed as a quick check of the system.
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Engine, Fuel and Air System Checkout/Engine Performance Check Å ENGINE START CHECK Operator on seat. Turn key switch to START position. Put hydrostatic control lever in N/STOP position. OK: GO TO Ö NOT OK: GO TO Starter must crank engine. Engine must start. ;, GROUP 10. Put PTO lever in OFF position. Pull choke knob all the way out. M55029 -UN-09DEC89 Depress brake pedal(s). MX,159022005,5 -19-16MAY95 Ö CHOKE LEVER CHECK Ò Run engine at half throttle.
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Engine, Fuel and Air System Checkout/Operator Complaint Not Identified 7a Engine Under No-Load 7b Start engine. OK: GO TO Move throttle lever from slow idle to fast idle. NOT OK: GO TO ;, GROUP 10. LISTEN: Engine must accelerate smoothly, without hesitation. LOOK: Exhaust must be clear. M55061 -UN-09DEC89 LISTEN: Governor must hold engine at a constant rpm and not surge. LISTEN: Engine must not make any abnormal sounds or backfire.
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Engine, Fuel and Air System Checkout/Operator Complaint Not Identified 220 05 4 TM1590 (17MAY95) 220-05-4 316, 318 & 420 Lawn and Garden Tractors 020895
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Group 10 Diagnosis, Tests and Adjustments ABOUT THIS GROUP Always perform the system checkout procedures in Group 05 BEFORE making any tests or adjustments in this group. The step-by-step procedures in this group provide you with the detailed diagnostic information you will need to isolate a malfunction. Basic diagnostic equipment is used. Always start with the first step and follow the sequence from left to right. Read each step completely before performing the test.
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Diagnosis, Tests and Adjustments/Troubleshooting Guide A ENGINE WILL NOT START OR STARTS HARD • Test spark plugs: GO TO ‘ • Test fuel filter: GO TO Ú • Adjust choke cable: GO TO Å • Adjust throttle cable: GO TO Æ • Adjust idle mixture screw: GO TO Ö • Test fuel transfer pump: GO TO Ü • Check for sheared flywheel key—P218G (316 and 318) and P220G (420): See Engine CTM2. • Adjust timing—B43E (316), B43G (318) and B48G (420): GO TO 1! • Check ignition system: See Section 240.
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Diagnosis, Tests and Adjustments/Troubleshooting Guide C ENGINE MISSES • Test spark plugs: GO TO ‘ • Test fuel filter: GO TO Ú • Adjust choke cable: GO TO Å • Adjust carburetor: GO TO Ö • Adjust timing—B43E (316), B43G (318) and B48G (420): GO TO 1! • Check ignition system: See Section 240. • Check and adjust valve clearance: See Engine CTM2.
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Diagnosis, Tests and Adjustments/Troubleshooting Guide E ENGINE DOES NOT DEVELOP FULL POWER • Adjust throttle cable: GO TO Æ • Adjust choke cable: GO TO Å • Adjust governor linkage: GO TO Ò • Adjust carburetor: GO TO Ö • Test spark plugs: GO TO ‘ • Check muffler for restriction or plugged condition. • Test fuel filter: GO TO Ú • Test fuel transfer pump: GO TO Ü • Adjust timing—B43E (316), B43G (318) and B48G (420): GO TO 1! • Check ignition system: See Section 240.
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Diagnosis, Tests and Adjustments/Troubleshooting Guide G ENGINE OVERHEATS • Check muffler for restriction or plugged condition. • Adjust carburetor: GO TO Ö • Adjust governor linkage: TO TO Ò • Check engine oil pressure: GO TO 1# • Check oil pump suction screen for plugged condition: See Engine CTM2. • Check oil pump for wear or damage: See Engine CTM2. • Check oil passages: See Engine CTM2. • Check internal bearing clearance: See Engine CTM2.
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Diagnosis, Tests and Adjustments/Throttle Cable Adjustment J ENGINE SMOKES EXCESSIVELY AND USES TOO MUCH OIL • Test crankcase vacuum: GO TO 1Ô • Inspect crankcase breather: See Engine CTM2. • Test compression pressure: GO TO 1@ • Check valve stem seals (if equipped): See Engine CTM2. • Check for correct engine oil dipstick being used. • Check for proper installation of oil passage plug: See Engine CTM2.
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Diagnosis, Tests and Adjustments/Idle Mixture and Speed Adjustment Å Remove air filter. CHOKE CABLE ADJUSTMENT MX,159022010,16-19-03MAY95 4a Early Models Pull choke knob out and then push knob in. If necessary, loosen screw (A) and push choke knob all the way in. LOOK: Choke plate must be completely closed, then completely open. Pull on choke lever to completely open choke plate. Tighten screw (A). Check for completely open and completely closed positions.
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Diagnosis, Tests and Adjustments/Idle Mixture and Speed Adjustment N M37098 -UN-29AUG88 CAUTION: ENGINE WILL BE HOT. BE CAREFUL NOT TO BURN HANDS. NOTE: Check engine speeds using JDM71 Vibration Tachometer. Turn low speed stop screw (A) counterclockwise until throttle stop screw controls engine speed. Put Tachometer (A) on air cleaner. Set Tachometer to read 1250 rpm. M37099 -UN-29AUG88 Turn throttle stop screw until engine speed is 1250 rpm.
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Diagnosis, Tests and Adjustments/Dashpot Adjustment (B43E, B43G and B48G) Ò GOVERNOR LINKAGE ADJUSTMENT NOTE: “B-Series” Engine Shown. Disconnect throttle rod (A) from governor arm (B). M37441 Push throttle rod and governor arm toward carburetor until they stop. Be sure dashpot spring (if equipped) is completely compressed. -UN-25JAN90 Install throttle rod into closest governor arm hole. If between holes, install in next hole away from carburetor. Check governor spring sensitivity.
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Diagnosis, Tests and Adjustments/Fuel Transfer Pump Test IMPORTANT: DO NOT hold dashpot using a pliers. Dashpot can be damaged. If adjustment is necessary, loosen lock nut (A). AFTER ADJUSTMENT: GO TO Ò and adjust governor linkage. Turn dashpot until clearance is obtained. Hold dashpot while tightening lock nut. M37457 Ú -UN-25JAN90 MX,159022010,21-19-27APR95 Disconnect fuel filter outlet hose. Hold fuel filter in a graduated container.
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Diagnosis, Tests and Adjustments/Timing Adjustment (B43E, B43G and B48G) 1Ô CRANKCASE VACUUM TEST Remove dipstick. Start engine and run at fast idle. Put plug (A) in dipstick hole. IMPORTANT: Do not hook up rest of Test Kit until engine is running or fluid in Manometer will be sucked into crankcase during cranking mode. Make test connections from JT05697 U-Tube Manometer Kit. Record crankcase vacuum reading.
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Diagnosis, Tests and Adjustments/Engine Oil Pressure Test 1@ COMPRESSION PRESSURE TEST Start and run engine approximately five minutes at fast idle, to bring it to normal operating temperature. Disconnect and ground spark plug wires away from spark plug holes. Remove spark plugs. Install JDM59 Compression Gauge. Make sure choke plate is in wide open position. Stop engine. Move throttle lever to fast idle position. Crank engine and record pressure reading.
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Diagnosis, Tests and Adjustments/Throttle Lever Adjustment NOT OK: GO TO 1$ MX,159022010,30-19-05MAY95 1$ OIL PRESSURE REGULATING VALVE CHECK Remove air cleaner base. Measure cap screw (A) thread length. Remove oil pressure regulating valve (B). Inspect spring (C) for weak or broken coils. Inspect valve and valve seat for stuck condition, metal particles, wear or damage. Move air cleaner bracket until oil pressure regulating valve cap screw can be removed.
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Diagnosis, Tests and Adjustments/Throttle Lever Adjustment 220 10 14 TM1590 (17MAY95) 220-10-14 316, 318 & 420 Lawn and Garden Tractors 020895
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Section 240 ELECTRICAL CHECKOUT, OPERATION AND DIAGNOSIS Contents Page Page Group 05—Electrical System Checkout Before You Start . . . . . . . . . . . . . . . . Dash Lamp Circuit Check . . . . . . . . . . Starting Circuit Check . . . . . . . . . . . . . Ignition Circuit (Spark) Check . . . . . . . . PTO Clutch and Lamp Check . . . . . . . Brake Neutral Start Check . . . . . . . . . . Transmission Neutral Start Check . . . . . PTO Neutral Start Check . . . . . . . . . . . Seat Switch Check for PTO . . . .
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Contents 240 TM1590 (17MAY95) 240-2 316, 318 & 420 Lawn and Garden Tractors 020895
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Group 05 Electrical System Checkout BEFORE YOU START Always begin with this group to identify a failure in the electrical system. The step-by-step procedures will provide you with a quick check of the system. No special tools are required to perform these checks. If a failure is indicated, you will be referred to a more detailed check, adjustment, or test located in Groups 20 and 25. location of system components, refer to Group 15 in this section.
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Electrical System Checkout/Ignition Circuit (Spark) Check 1a DASH LAMPS DO NOT OPERATE Key switch OFF. For machines: 316 (S.N. —475000) 318 (S.N. —475000) 420 (S.N. —595880), disconnect fuse holders and check 20-amp fuse (A) and 2-amp fuse (B). NOTE: A—20-Amp Fuse B—2-Amp Fuse C—20-Amp Fuse D—3-Amp Fuse M55140 -UN-13APR95 M77926 -UN-12APR95 For machines: 316 (S.N. 475001— ) 318 (S.N. 475001— ) 420 (S.N. 595881— ), remove and check 20-amp fuse (C) and 3-amp fuse (D). FUSE OK: GO TO ;, Group 20.
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Electrical System Checkout/Brake Neutral Start Check Å PTO CLUTCH AND LAMP CHECK Sit on seat. Move PTO switch to ON position. PTO switch OFF. OK: GO TO Ö NOT OK: GO TO 4a LISTEN: Clutch must “click” ON. Turn key switch to RUN position. LOOK: PTO lamp must come ON. M55019 -UN-09DEC89 M36492 -UN-29JAN90 MX,159024005,6 -19-16MAY95 4a PTO DOES NOT OPERATE PROPERLY Key switch OFF. For machines: 316 (S.N. —475000) 318 (S.N. —475000) 420 (S.N.
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Electrical System Checkout/Seat Switch Check for PTO Ò TRANSMISSION NEUTRAL START CHECK Õ PTO switch OFF. OK: GO TO Later Models; Depress brake pedal(s). NOT OK: GO TO Ò, Group 20. Pull hydrostatic lever away from N/STOP switch slot. M55018 -UN-09DEC89 Turn key switch to START position. LISTEN: Engine must NOT crank. MX,159024005,9 -19-16MAY95 Õ PTO NEUTRAL START CHECK PTO switch OFF. Move PTO switch to ON position. Hydrostatic lever in N/STOP position. Õ, Group 20.
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Electrical System Checkout/Lighting Check Ü SEAT SWITCH CHECK FOR IGNITION 1Ô PTO switch OFF. OK: GO TO Sit on seat. NOT OK: GO TO Ü, Group 20. Later Models; Depress brake pedal(s). Hydrostatic lever in N/STOP position. Start engine and operate at low idle. M55018 -UN-09DEC89 Move hydrostatic lever to SLOW FORWARD position. Raise off seat for 2—3 seconds. LISTEN: Engine must stop. Restart engine. Drive machine in SLOW FORWARD. Raise off seat and quickly sit back down before one second elapses.
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Electrical System Checkout/Operator Complaint Not Identified 1@ OPERATOR COMPLAINT NOT IDENTIFIED If you completed the checkout procedure and did not isolate a malfunction, the problem may be intermittent. PERFORM BATTERY TESTS AND GROUND TESTS AS INSTRUCTED IN GROUP 20 AND REPEAT THE CHECKOUT PROCEDURE IN THIS GROUP. IF A MALFUNCTION IS NOT IDENTIFIED AFTER REPEATING SYSTEM CHECKOUT PROCEDURE, FACTORY ASSISTANCE IS AVAILABLE THROUGH THE DEALER TECHNICAL ASSISTANCE CENTER (DTAC).
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Group 10 Electrical Schematics 240 10 1 TM1590 (17MAY95) 240-10-1 316, 318 & 420 Lawn and Garden Tractors 020895
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Electrical Schematics 316, 318 AND 420 ELECTRICAL SCHEMATIC—SINGLE PTO A1—TDC Module A2—Ignition Module (S.N. 420001— ) B1—Engine Oil Pressure Switch C1—Condenser (S.N. 420001— ) E1—Spark Plug E2—Spark Plug E3—Ignition (Breaker) Points (S.N. —420000) E4—Left Headlight E5—Middle Headlight E6—Right Headlight E7—Left Tail Light E8—Right Tail Light F1—20-Amp Fuse F2—2-Amp Fuse: 316 (S.N. —475000) 318 (S.N. —475000) 420 (S.N. —595880) 3-Amp Fuse: 316 (S.N. 475001— ) 318 (S.N. 475001— ) 420 (S.N.
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TM1590 (MAY-95) 316, 318, AND 420 ELECTRICAL SCHEMATIC 316, 318, AND 420 ELECTRICAL SCHEMATIC — SINGLE PTO 5/14/98 240-10-3
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TM1590 (MAY-95) 316, 318, AND 420 ELECTRICAL SCHEMATIC 316, 318, AND 420 ELECTRICAL SCHEMATIC — SINGLE PTO 5/14/98 240-10-3
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TM1590 (MAY-95) 316, 318, AND 420 ELECTRICAL SCHEMATIC 316, 318, AND 420 ELECTRICAL SCHEMATIC — SINGLE PTO 5/14/98 240-10-3
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316, 318, AND 420 ELECTRICAL SCHEMATIC TM1590 (MAY-95) 316, 318, AND 420 ELECTRICAL SCHEMATIC — DUAL PTO 240-10-4 5/14/98
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316, 318, AND 420 ELECTRICAL SCHEMATIC TM1590 (MAY-95) 316, 318, AND 420 ELECTRICAL SCHEMATIC — DUAL PTO 240-10-4 5/14/98
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316, 318, AND 420 ELECTRICAL SCHEMATIC TM1590 (MAY-95) 316, 318, AND 420 ELECTRICAL SCHEMATIC — DUAL PTO 240-10-4 5/14/98
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Electrical Schematics/Dual PTO 316, 318 AND 420 ELECTRICAL SCHEMATIC—DUAL PTO A1—TDC Module A2—Ignition Module (S.N. 420001— ) B1—Engine Oil Pressure Switch C1—Condenser (S.N. 420001— ) E1—Spark Plug E2—Spark Plug E3—Ignition (Breaker) Points (S.N. —420000) E4—Left Headlight E5—Middle Headlight E6—Right Headlight E7—Left Tail Light E8—Right Tail Light F1—20-Amp Fuse F2—2-Amp Fuse: 316 (S.N. —475000) 318 (S.N. —475000) 420 (S.N. —595880) 3-Amp Fuse: 316 (S.N. 475001— ) 318 (S.N. 475001— ) 420 (S.N.
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Electrical Schematics/Dual PTO 240 10 6 TM1590 (17MAY95) 240-10-6 316, 318 & 420 Lawn and Garden Tractors 020895
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Group 15 Component Location and Operation M31718 -UN-19JAN95 ELECTRICAL COMPONENT LOCATION 1—Tail Light (2 used) 2—Seat Switch 3—Rear Electric PTO Clutch (Optional) 4—Key Switch 5—TDC Module 6—Transmission Neutral Start Switch 7—Light Switch 8—PTO Switches 9—2-Amp and 20-Amp Fuse: (See Note) 316 (S.N. —475000) 318 (S.N. —475000) 420 (S.N. —595880) 10—Battery 11—Positive (+) Battery Cable 12—Negative (—) Battery Cable 13—Headlights 14—Front Electric PTO Clutch 15—Stator Alternator 16—Igntion Module (S.
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Component Location and Operation/Theory of Operation STARTING CIRCUIT OPERATION The function of the starting circuit is to crank the engine by energizing starter motor (M1). PTO switches (S2 and S3), transmission neutral switch (S5), and brake switch (S4) are used as interlock safety switches within the starter circuit. For the starter motor to energize, the following conditions must be met: • • • • brake is engaged.
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M77921 -19-04MAR95 Component Location and Operation/Theory of Operation A—Starter Solenoid Main Contact F1—20 Amp Fuse F3—25 Amp Circuit Breaker G1—Battery K2—Starter Solenoid M1—Starter Motor S1—Key Switch S2—Front PTO Switch S3—Rear PTO Switch (Optional) S4—Brake Switch: 316 (S.N. 596121— ) 318 (S.N. 600305— ) 420 (S.N.
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Component Location and Operation/Theory of Operation IGNITION CIRCUIT OPERATION The function of the ignition circuit is to produce spark across the gap of spark plugs (E1 and E2). The circuit is a battery ignition type that fires both spark plugs simultaniously, thus eliminating the need for a distributor. The ignition circuit automatically stops the engine anytime the operator rises off the seat for more than one second when tractor is in gear or if PTO is engaged.
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M77922 -19-04MAR95 Component Location and Operation/Theory of Operation A—TDC Ignition Relay Contacts B—TDC Ignition Relay Coil C—Switch Transistor D—Time Delay Switch Transistor E—Time Delay IC (Internal Circuit) A1—Time Delay Control (TDC) Module A2—Ignition Module (S.N. 420001— ) C1—Condenser (S.N. 420001— ) E1—Spark Plug E2—Spark Plug E3—Ignition Points (S.N. —420000) F1—20 Amp Fuse F2—2 Amp Fuse (Early Machines) 3 Amp Fuse (Later Machines) F3—25 Amp Circuit Breaker NOTE: 1. For machines 316 (S.N.
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Component Location and Operation/Theory of Operation PTO CIRCUIT OPERATION The function of the PTO circuit is to energize the PTO clutch(es) and turn on the PTO lamp(s). Also, the PTO circuit automatically disengages the PTO clutch(es) anytime the operator rises off the seat for more than one second. To engage the PTO clutch(es), the following conditions must be met: • Operator on seat. • Key Switch at RUN position. • PTO switches initially at OFF position, then moved to ON position.
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M77923 -19-04MAR95 Component Location and Operation/Theory of Operation A—Time Delay IC (Internal Circuit) B—Time Delay Switch Transistor C—Isolation Diode D—TDC PTO Relay Contacts E—Isolation Diode F—Isolation Diode G—TDC PTO Relay Coil A1—Time Delay Control (TDC) Module F1—20 Amp Fuse F2—2 Amp Fuse (Early Machines) 3 Amp Fuse (Later Machines) F3—25 Amp Circuit Breaker G1—Battery M1—Starter Motor P1—Front PTO Lamp P2—Rear PTO Lamp (Optional) S1—Key Switch S2—Front PTO Switch S3—Rear PTO Switch (Optiona
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Component Location and Operation/Theory of Operation CHARGING CIRUIT OPERATION The function of the charging circuit is to keep the battery properly charged by supplying approximately 13.6—14.7 VDC to the battery while the engine is operating. The charging system is a permanent magnet and stator type. The magnets are located in the flywheel, which rotates around the stationary stator (G2) windings. Current output is controlled by voltage regulator/rectifier (N1), mounted separately from the stator.
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M77924 -19-04MAR95 Component Location and Operation/Theory of Operation A—Battery Discharge Lamp Control A1—Time Delay Control (TDC) Module F1—20 Amp Fuse F2—2 Amp Fuse (Early Machines) 3 Amp Fuse (Later Machines) F3—25 Amp Circuit Breaker G1—Battery G2—Stator M1—Starter Motor N1—Voltage Regulator/Rectifier P4—Battery Discharge Lamp P5—Engine Oil Pressure Lamp S1—Key Switch W1—Engine Ground (See Note) X1—Key Switch 5-Pin Connector X2— Key Switch 1-Pin Connector X3—Front PTO Switch 2-Pin Connector 240
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Component Location and Operation/Theory of Operation M77925 -19-04MAR95 OIL PRESSURE LAMP CIRCUIT OPERATION B1—Engine Oil Pressure Switch F1—20 Amp Fuse F3—25 Amp Circuit Breaker G1—Battery M1—Starter Motor P5—Engine Oil Pressure Lamp S1—Key Switch X1—Key Switch 5-Pin Connector The purpose of the oil pressure lamp circuit is to warn the operator when engine oil pressure is too low for safe operation of the engine. 240 15 10 Oil pressure switch (B1) is a normally-closed switch.
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Group 20 Electrical System Diagnosis ABOUT THIS GROUP Always perform the system checkout procedures in Group 05 BEFORE doing any tests in this group. The step-by-step procedures in this group provide you with the detailed diagnostic information you will need to isolate a malfunction. Always start with the first step and follow the sequence from left to right. Read each step completely before performing the test. Basic diagnostic equipment is used.
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Electrical System Diagnosis/Battery Tests Check specific gravity of each cell with a hydrometer. SPECIFIC GRAVITY ALL CELLS LESS THAN 1.175: GO TO —@ ALL CELLS MORE THAN 1.225 WITH LESS THAN 50 (0.050) GRAVITY POINT VARIATION: GO TO —# ALL CELLS LESS THAN 1.225 WITH LESS THAN 50 (0.050) GRAVITY POINT VARIATION: GO TO —! CELLS VARY MORE THAN 50 POINTS: Replace Battery. M78971 —! -UN-09MAY95 Test Battery Voltage MX,159024025,3 -19-16MAY95 NOTE: Battery need not be disconnected from machine.
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Electrical System Diagnosis/Battery Tests —@ Charge Battery Connect a variable-rate type charger to battery. Start charger at a slow rate. Increase charge rate one setting at a time. Check ammeter (on charger) after 1 minute at each setting. Try to maintain a 10 amp charge rate. Use boost setting as necessary. BATTERY DID NOT REQUIRE WATER AT STEP B AND IS ACCEPTING A 10-AMP CHARGE: GO TO —$ BATTERY REQUIRED WATER AT STEP B OR ALL CELLS WERE BELOW 1.
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Electrical System Diagnosis/Dash Lamp Circuit Tests —% Connect JT05685 Tester to battery. Load Test Battery REPLACE BATTERY AS NEEDED. Follow instructions on back of meter for testing battery. M36665 -UN-29AUG88 MX,159024025,9 -19-16MAY95 ; DASH LAMP CIRCUIT TESTS Listed at right are symptoms that may occur in a malfunctioning dash lamp circuit. Locate the symptom that applies, then proceed to the appropriate test. LAMP CIRCUIT SYMPTOMS: —Fuses Blow When Any Of The Lamp Circuits Are Energized.
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Electrical System Diagnosis/Dash Lamp Circuit Tests 1b 20-Amp Power Circuit Test at TDC Module Turn key switch to RUN VOLTAGE: GO TO 1c position. NO VOLTAGE: Pink Check for voltage at wire between 20-amp terminal with pink and fuse and TDC 8-pin purple wires (A) at TDC connector is open. 8-pin connector. Repair or replace as necessary, then GO TO ;, Group 05. Remove battery base to access TDC 8-pin connector.
PAGE 318
Electrical System Diagnosis/Dash Lamp Circuit Tests 1e Power Circuit Test at Key Switch— Fuse Side Turn key switch to RUN position. Check for voltage at key switch terminal “A”, where red and pink wires (A) connect to key switch. M55141 VOLTAGE: For 20-amp power circuit, pink wire between fuse and key switch is open. For 2-amp or 3-amp power circuit, red wire between fuse and key switch is open. -UN-09DEC89 Repair or replace wire as necessary, then GO TO ; and Å, Group 05.
PAGE 319
Electrical System Diagnosis/Dash Lamp Circuit Tests 1h Check for voltage at battery cable terminal (B) at starter solenoid. Main Power Circuit Test at Starter Solenoid—For Early Models: 316 (SN —362983) 318 (SN —364137) 420 (SN —360009) NOTE: On Later Models; Starter solenoid is on starter. VOLTAGE AT SOLENOID: Replace wire to breaker. NO VOLTAGE: Replace battery cable. M37158 Make repairs as necessary, then GO TO ;, Group 05.
PAGE 320
Electrical System Diagnosis/Dash Lamp Circuit Tests 1k Engine Oil Pressure Lamp Power Circuit Test. Turn key switch to RUN position. Remove oil pressure NO VOLTAGE: GO TO lamp socket from panel. 1a Remove bulb. Check for voltage at terminal with double yellow wires (A). M37299 1l Engine Oil Pressure Lamp Short Circuit Test Turn key switch OFF. Battery Discharge Lamp Test MX,159024025,21-19-16MAY95 Disconnect engine harness connector.
PAGE 321
Electrical System Diagnosis/Dash Lamp Circuit Tests 1o Battery Discharge Lamp Ground Circuit Test Key switch OFF. Check for continuity of brown wire (A) between TDC 8-pin connector and bulb socket (C) of the battery discharge lamp socket. M37163 -UN-25JAN90 CONTINUITY: GO TO 1q NO CONTINUITY: Repair connector as necessary. NO CONTINUITY: Repair or replace brown wire between lamp socket and TDC 8-pin connector. CONTINUITY: Check for continuity between (A and B) at TDC 8-pin connector.
PAGE 322
Electrical System Diagnosis/Starting Circuit Tests ‘ STARTING CIRCUIT TESTS Listed at right are symptoms that may occur in a malfunctioning starting circuit. Locate the symptom that applies, then proceed to the appropriate test. IMPORTANT: Test battery and verify grounds before testing starting circuit. (See steps A and B at the beginning of this group.) STARTING CIRCUIT SYMPTOMS: —Starter Operates, But Doesn’t Crank Engine: REPAIR STARTER (See CTM2.
PAGE 323
Electrical System Diagnosis/Starting Circuit Tests 2c Starter Test— For Machines: 316 (SN 362984— ) 318 (SN 364138— ) 420 (SN 360010— ) PTO switch OFF. Connect one end of a jumper wire to terminal (A) on the starter solenoid, then briefly touch other end of jumper to battery cable terminal (B). Key switch OFF. Hydrostatic lever in N/STOP position. STARTER OPERATES: GO TO 2e STARTER DOESN’T OPERATE: GO TO 2d Park brake engaged. Disconnect spark plug wires from spark plugs and ground to engine block.
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Electrical System Diagnosis/Starting Circuit Tests 2f Starter Circuit Test at Brake Switch—For Machines: 316 (SN 596121— ) 318 (SN 600305— ) 420 (SN 595881— ) PTO switch OFF. Check for voltage at VOLTAGE: Replace purple wire terminal (A). switch, then GO TO ‘, Group 05. If there is voltage at (A), purple wire NO VOLTAGE: GO TO between key switch and 2g brake switch is open. Hydrostatic lever in N/STOP position. Park brake engaged. Turn key switch to RUN position.
PAGE 325
Electrical System Diagnosis/Starting Circuit Tests 2h Starter Circuit Test at Transmission Neutral Start Switch—Continued PTO switch OFF. Push switch arm (B) fully in and check for voltage at terminal with purple/white wire (A). Move hydrostatic lever to FORWARD position. VOLTAGE: With hydrostatic lever at N/STOP position, loosen adjusting nut (C) and slide switch toward hydrostatic lever until switch contacts just close, then tighten nut. Turn key switch to RUN position.
PAGE 326
Electrical System Diagnosis/Ignition Circuit Tests 2j Starter Circuit Test at PTO Switch Turn key switch to RUN position. Check for voltage at terminal (A) with yellow and purple wires, then at terminal with single purple wire. M55146 -UN-11DEC89 VOLTAGE ONE TERMINAL: Replace switch. VOLTAGE BOTH TERMINALS: Purple wire between jumper connector and PTO switch is open. NO VOLTAGE: GO TO 1e Repair or replace wire, then GO TO ‘, Group 05.
PAGE 327
Electrical System Diagnosis/Ignition Circuit Tests 3b Ignition Circuit Test—For Machines (S.N. —420000) Disconnect spark plug wires and remove spark plugs. Connect a jumper wire from positive (+) battery terminal to positive (+) coil terminal (A). Crank engine and check for spark. Connect a spark tester to each of the spark plug wires. SPARK: Wire between ignition coil positive (+) terminal and 3-pin engine connector is open or 3-pin engine connector is faulty.
PAGE 328
Electrical System Diagnosis/Ignition Circuit Tests 3e Ignition Coil Test: Secondary Windings— For Machines (S.N. —420000) Key switch OFF. Using a ohmmeter, measure resistance of secondary windings at spark plug wire terminals (A). Disconnect all wires from ignition coil. M77938 -UN-19JAN95 RESISTANCE NOT OK: Replace coil, then GO TO Æ, Group 05. Resistance should be 12.6—15.4 K-ohms when temperature of coil is approximately 20˚C (68˚F).
PAGE 329
Electrical System Diagnosis/Ignition Circuit Tests 3g Ignition Coil Test: Pimary Windings— For Machines (S.N. 420001— ) Key switch OFF. Disconnect all wires from ignition coil. M45244 -UN-12JAN90 Using a ohmmeter, RESISTANCE OK: GO measure resistance of TO 3h primary windings across terminals (A). RESISTANCE NOT OK: Replace coil, then Resistance should be GO TO Æ, Group 05. 3.7—4.6 ohms when temperature of coil is approximately 20˚C (68˚F).
PAGE 330
Electrical System Diagnosis/Ignition Circuit Tests 3i Ignition Control Module Test— For Machines (S.N. 420001— ) Connect coil wires. Ground spark plug wires. M45246 -UN-12JAN90 NOTE: Terminal (A) is larger in diameter of the two posts. VOLTAGE DOES NOT SWITCH: Replace ignition control module. Measure ignition module voltage. Connect voltmeter red lead to negative (—) coil terminal (A) and black lead to engine ground. IMPORTANT: Always replace ignition module and trigger ring as a set.
PAGE 331
Electrical System Diagnosis/Ignition Circuit Tests Remove blower housing to access gearcase cover timing marks (A) and flywheel timing mark (B). Connect one lead of an ohmmeter or continuity tester to the primary windings negative (—) terminal of the ignition coil. Connect the other tester lead to engine ground or negative (—) terminal of battery. Slowly turn flywheel clockwise until meter or tester shows no continuity. Turn flywheel 360 degrees until meter or tester again shows no continuity.
PAGE 332
Electrical System Diagnosis/Ignition Circuit Tests 3k Ignition Timing Check— For Machines (S.N. 420001— ) N NOTE: Ignition timing is not adjustable. If a misfire condition exists, the flywheel key may be partially sheared. This can be verified by checking the ignition timing. CAUTION: FAILURE TO REMOVE SPARK PLUGS BEFORE TURNING FLYWHEEL BY HAND MAY CAUSE ENGINE TO START RESULTING IN INJURY. Disconnect and ground spark plug wires. Remove spark plugs.
PAGE 333
Electrical System Diagnosis/PTO Clutch and Lamp Tests 3m Main Power Test for TDC Module Turn key switch to RUN position. At both sides of TDC 8-pin connector, check for voltage at terminal with pink and purple wires and terminal with single purple wire (A). M37173 -UN-25JAN90 VOLTAGE: Verify good ground at TDC 2-pin connector, then GO TO 3n VOLTAGE AT ONE TERMINAL: Repair connector, then GO TO Æ, Group 05.
PAGE 334
Electrical System Diagnosis/PTO Clutch and Lamp Tests 4a PTO Lamp Test Remove battery base to access instrument panel. If bulb is good, check for continuity between black wire at contact (A) and ground. Disconnect PTO lamp socket. Remove and check bulb. M36643 CONTINUITY: Replace blue wire between PTO switch and bulb socket. Repair or replace wire as necessary, then GO TO Å, Group 05. NO CONTINUITY: Repair or replace ground wire as necessary, then GO TO Å, Group 05.
PAGE 335
Electrical System Diagnosis/PTO Clutch and Lamp Tests 4d PTO Clutch Test Separate PTO clutch connector at right-hand side of engine. Connect a jumper wire to battery positive (+) terminal and jump to dark blue clutch lead (A). NOTE: Machines (S.N. —475000) shown. Later machines use a 2-pin connector. M36626 -UN-25JAN90 For machines (S.N. 475001— ), also connect a jumper wire from the black PTO clutch lead to ground. LISTEN: Clutch should “click” when engaged. CLUTCH ENGAGES: For machines (S.N.
PAGE 336
Electrical System Diagnosis/PTO Clutch and Lamp Tests 4i Power Circuit Voltage Test at 2-Amp or 3-Amp Fuse Turn key switch to RUN position. For machines: 316 (S.N. —475000) 318 (S.N. —475000) 420 (S.N. —595880), check for voltage at both ends of 2-amp, in-line fuse (B). VOLTAGE BOTH SIDES: Replace red wire to TDC 8-pin connector. VOLTAGE ONE SIDE: Check fuse contacts. NO VOLTAGE: GO TO M55140 -UN-13APR95 M77926 -UN-12APR95 1e For machines: 316 (S.N. 475001— ) 318 (S.N. 475001— ) 420 (S.N.
PAGE 337
Electrical System Diagnosis/Brake Neutral Start Safety Switch Test 4m 20-Amp Power Circuit Test at TDC Module Turn key switch to RUN position. Check for voltage at pink and purple leads and single purple lead (A) at TDC 8-pin connector. VOLTAGE ONE LEAD: Repair connector.
PAGE 338
Electrical System Diagnosis/Seat Switch Test For PTO Time Delay Ò TRANSMISSION NEUTRAL START SAFETY SWITCH TEST Key switch OFF. With switch arm (A) fully released, check for continuity across terminals (B). Put hydrostatic lever in REVERSE position. CONTINUITY: Replace and adjust switch. M45195 -UN-08JAN90 NO CONTINUITY: Replace and adjust switch. CONTINUITY: Adjust switch if necessary. IMPORTANT: After NO CONTINUITY: Push tightening nut (C), switch arm (A) fully in.
PAGE 339
Electrical System Diagnosis/Hour Meter Circuit Test Ü SEAT SWITCH TEST FOR IGNITION TIME DELAY Key switch OFF. Check the black leads (A) of the TDC 2-pin connector for good ground. M37289 GOOD GROUND: Replace TDC module, then GO TO ;, Group 05. POOR GROUND: Clean and tighten all ground connections then GO TO Ü, Group 05. -UN-25JAN90 MX,159024025,75-19-16MAY95 1Ô HOUR METER CIRCUIT TEST Check fuses. Check for continuity between terminal with two black wires (A) and ground.
PAGE 340
Electrical System Diagnosis/Lighting Test 1! LIGHTING TEST Check bulbs and 20-amp fuse. Check for voltage at connector terminal (A). NO VOLTAGE: Replace light switch. NOTE: If lights come on when key switch is in the RUN position, but light switch is in OFF position, replace light switch. NO VOLTAGE: GO TO VOLTAGE: GO TO Turn key switch to RUN position. 1c 1:a VOLTAGE: Check for voltage at other switch terminal.
PAGE 341
Group 25 Electrical System Component Tests and Adjustments BEFORE YOU START Always perform the system checkout procedures in Group 05 and the System Diagnosis in Group 20 BEFORE making any tests in this group. These procedures include any special tooling required to identify a failure. Make the repair and perform the System Checkout in Group 05 to be certain all failures are solved. MX,159024030,1 -19-16MAY95 ; KEY SWITCH TEST Remove key switch from machine.
PAGE 342
Electrical System Component Tests and Adjustments/Starter Tests Æ STARTER DRAW TEST Before performing starter draw test, test battery. (See Battery Tests B in Group 20 of this section.) Disconnect and ground spark plug wires. M37179 -UN-25JAN90 IMPORTANT: Before making any test connections, turn load knob (A) on meter fully counterclockwise. Connect JT05685 Battery Tester to machine battery. Red lead to positive (+) terminal, black lead to negative (—) terminal.
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Electrical System Component Tests and Adjustments/Starter Tests 3a Disconnect battery ground cable. Bendix Starter— No Load Running Test Remove starter and mount in a vise. STARTER DOESN’T RUN: Repair starter. (See CTM2.) STARTER RUNS: GO TO 3b Connect jumper cables from starter to machine battery or battery of similar capacity. Connect positive clamp to starter positive (+) terminal (A). Connect negative (—) battery cable (B) to starter body. Starter should run.
PAGE 344
Electrical System Component Tests and Adjustments/Starter Tests 3d Disconnect battery ground cable. Solenoid Shift Starter—No Load Running Test Remove starter and mount in a vise. Use jumper cables to connect starter to machine battery or battery of similar capacity. STARTER DOESN’T RUN: Repair starter. (See CTM2.) STARTER ENGAGES AND RUNS: GO TO 3e Connect positive clamp (A) to positive (+) battery cable terminal on starter solenoid. Connect negative (—) battery cable (B) to starter body.
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Electrical System Component Tests and Adjustments/Alternator and Regulator/Rectifier Tests 3f Mount starter in a vise and connect to a battery as instructed in step 3d Solenoid Shift Starter—No Load Amp Draw Test With starter running, check amperage with JT05712 Current Gun (A). Starter should draw 53 amps or less at 7000 rpm.
PAGE 346
Electrical System Component Tests and Adjustments/Alternator and Regulator/Rectifier Tests 4a NOTE: The specifications listed in the table below are the approximate maximum VAC output of unregulated stators used on the “P” series and “B” series engines. Alternator Test For Unregulated Output Disconnect stator leads (A) from regulator. Start engine and run at full throttle (approx. 3450 rpm). Connect voltmeter to stator leads (A).
PAGE 347
Electrical System Component Tests and Adjustments/PTO Clutch Adjustment Check 4b Stator Resistance Test Key switch OFF. Stator leads disconnected from regulator. NOTE: Because of the small amount of resistance in the stator windings, use a digital multimeter or an analog meter with a high sensitivity rating to measure resistance of stator windings. If an analog meter is to be used, make sure it is at the lowest scale setting and is zeroed. Connect ohmmeter to stator leads (A).
PAGE 348
Electrical System Component Tests and Adjustments/System Short Circuit Tests Ò NOTE: For machines: 316 (S.N. —475000) 318 (S.N. —475000) 420 (S.N. —595880), A—20-Amp Fuse B—2-Amp Fuse SYSTEM SHORT CIRCUIT TESTS FOR 20-AMP FUSE THE 20-AMP FUSE PROVIDES CURRENT TO: —Neutral Start (Interlock) Circuit —Lighting Circuit M55140 M77926 -UN-13APR95 1. With the PTO switch in the ON position, turn key switch to RUN position. FUSE BLOWS: Short is in the 20-amp fuse power circuit. 2.
PAGE 349
Electrical System Component Tests and Adjustments/System Short Circuit Tests Õ NOTE: For machines: 316 (S.N. —475000) 318 (S.N. —475000) 420 (S.N.
PAGE 350
Electrical System Component Tests and Adjustments/System Short Circuit Tests 240 25 10 TM1590 (17MAY95) 240-25-10 316, 318 & 420 Lawn and Garden Tractors 020895
PAGE 351
Section 250 POWER TRAIN CHECKOUT, OPERATION AND DIAGNOSIS Contents Page Page Group 05—Power Train Checkout Before You Start . . . . . . . . . . . . . Transmission Oil Leak Check . . . . . Hydrostatic Lever Friction Check . . . Transmission Neutral Check . . . . . Neutral Return Check . . . . . . . . . . Transmission Drive Check . . . . . . . Speed Reduction Check . . . . . . . . Two-Speed Axle Lever Check (420) Differential Lock Check (420) . . . . . Operator Complaint Not Identified . . . . . . . . . .
PAGE 352
Contents 250 TM1590 (17MAY95) 250-2 316, 318 & 420 Lawn and Garden Tractors 020895
PAGE 353
Group 05 Power Train Checkout BEFORE YOU START Always begin with this group to identify a failure in the power train. The step-by-step procedures will provide you with a quick check of the system. No tools are required to perform these checks. If a failure is indicated, you will be referred to a more detailed check, adjustment, or test. This procedure is designed as a quick check of the system.
PAGE 354
Power Train Checkout/Speed Reduction Check Å NEUTRAL RETURN CHECK 318 and 420; Lock pedals together. Move hydrostatic lever to full forward or reverse position. OK: GO TO Ö NOT OK: GO TO 1Ô, GROUP 15. Depress brake pedal(s). M36667 -UN-25JAN90 M36668 -UN-25JAN90 LOOK: Hydrostatic lever must move to “STOP” position from forward or reverse. MX,159025005,5 -19-20APR95 Ö TRANSMISSION DRIVE CHECK Start and run engine at fast idle. Operate machine under no load and then under load conditions.
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Power Train Checkout/Operator Complaint Not Identified Move hydrostatic lever to full forward position. Depress left brake pedal. OK: GO TO Õ NOT OK: GO TO LOOK: Hydrostatic lever must move to slow forward position. Left wheel must stop; right wheel must continue to turn. M36671 Õ TWO-SPEED AXLE LEVER CHECK (420) Ü, GROUP 15. -UN-25JAN90 MX,159025005,8 -19-25APR95 Start and run engine at half throttle. Move two-speed axle lever to slow speed position.
PAGE 356
Power Train Checkout/Operator Complaint Not Identified 250 05 4 TM1590 (17MAY95) 250-05-4 316, 318 & 420 Lawn and Garden Tractors 020895
PAGE 357
Group 10 Theory of Operation 250 10 1 TM1590 (17MAY95) 250-10-1 316, 318 & 420 Lawn and Garden Tractors 020895
PAGE 358
Theory of Operation/Hydrostatic Transmission Operation HYDROSTATIC TRANSMISSION OPERATION Function: Transfers power from the input (pump) shaft to the gear drive components of the transmission. It also provides infinitely variable speed and torque within a range in forward and reverse directions. the pistons follow the contour of the swashplate they move outward, drawing oil into their bores.
PAGE 359
M78856 -UN-03APR95 Theory of Operation/Hydrostatic Transmission Operation A—Input (Pump) Shaft B—Variable Hydrostatic Pump C—Charge Pump D—Filter E—Forward Check (Freewheel) Valve F—Reservoir G—Charge Relief Valve H—Hydrostatic Transmission Housing I—Hydrostatic Drive Motor J—Output (Motor) Shaft K—Transmission Case Drain L—Implement Relief Valve M—Reverse Check (Freewheel) Valve MX,159025010,2 -19-20APR95 250 10 3 TM1590 (17MAY95) 250-10-3 316, 318 & 420 Lawn and Garden Tractors 020895
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Theory of Operation/Hydrostatic Transmission Operation 250 10 4 TM1590 (17MAY95) 250-10-4 316, 318 & 420 Lawn and Garden Tractors 020895
PAGE 361
Group 15 Diagnosis, Tests and Adjustments ABOUT THIS GROUP Always perform the system checkout procedures in Group 05 BEFORE making any tests or adjustments in this group. The step-by-step procedures in this group provide you with the detailed diagnostic information you will need to isolate a malfunction. Basic diagnostic equipment is used. It is assumed that you are familiar with the machine and its power train components.
PAGE 362
Diagnosis, Tests and Adjustments/Troubleshooting Guide A MACHINE MOVES IN ONE DIRECTION ONLY • Inspect transmission control linkage for wear or damage. See Section 50. • 316 and 318; Test for debris in check valves: GO TO ‘ • Inspect check valves for damaged valve seat, seals or stuck check ball. See Section 50. • Inspect internal transmission components for wear or damage. See Section 50.
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Diagnosis, Tests and Adjustments/Troubleshooting Guide D MACHINE WILL NOT REACH FULL SPEED • Inspect transmission control linkage for wear or damage. See Section 50. • Inspect transmission and differential mounting cap screws for loose condition. • Check engine fast idle speed: See Section 220. • Inspect check valves for damaged seat, seals or stuck check ball. See Section 50. • Inspect internal rotating group for scoring and wear (slippers, pistons and cylinder block, valve plate and cylinder block).
PAGE 364
Diagnosis, Tests and Adjustments/Troubleshooting Guide G HYDRAULIC SYSTEM IS NOISY • Check power steering valve, if equipped, or hydraulic control valve for overheating. If either valve is too hot to touch after 1/2 hour of operation, disassemble valve and repair internal leak. See Section 60 or 70. • Adjust hydrostatic transmission linkage for positive neutral position: GO TO 1Ô • Check steel hydraulic lines for vibration.
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Diagnosis, Tests and Adjustments/Charge Pump ‘ CHECK VALVE DEBRIS CHECK Engine OFF. 316 and 318; Engage Manual Push lever (A) and push machine forward to remove debris from check valves. Service park brake OFF. M49216 -UN-20DEC89 Repeat Transmission Drive Check in Group 05. Early 420; Remove fender deck. Remove and inspect check valves for debris. Repair or replace if necessary. Later 420; Remove fender deck.
PAGE 366
Diagnosis, Tests and Adjustments/Charge Relief Valve A—JT03339 Connector B—JT03107 Adapter C—JT03017 Hose D—JT03344 Gauge, 2000 kPa (300 psi) M36682 -UN-25JAN90 IMPORTANT: Hydraulic control levers must remain in neutral position and engine must be run at slow idle. CHARGE PRESSURE OK: Inspect check valves for wear or damage. See Section 50. Then repeat Æ Pressure gauge will be damaged if a hydraulic function is actuated or test is run at fast idle. CHARGE PRESSURE LOW: REPLACE FILTER, THEN...
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Diagnosis, Tests and Adjustments/Implement Relief Valve Å IMPLEMENT RELIEF VALVE PRESSURE TEST N CAUTION: TO AVOID INJURY FROM ESCAPING HYDRAULIC OIL UNDER PRESSURE, RELIEVE THE PRESSURE IN THE SYSTEM BY STOPPING THE ENGINE AND OPERATING ALL HYDRAULIC CONTROL VALVES. A—JT03339 Connector B—JT03107 Adaptor C—JT03017 Hose D—JT03345 Gauge, 20,000 kPa (3000 psi) M36682 -UN-25JAN90 Make test connections from JT01765 Lawn and Grounds Care Products Hydraulic Fitting Kit. full raise position.
PAGE 368
Diagnosis, Tests and Adjustments/Welch Plug Location Check Ö CHARGE PUMP FLOW TEST N CAUTION: TO AVOID INJURY FROM ESCAPING HYDRAULIC OIL UNDER PRESSURE, RELIEVE THE PRESSURE IN THE SYSTEM BY STOPPING THE ENGINE AND OPERATING ALL HYDRAULIC CONTROL VALVES. Make front outlet connections from JT01765 Lawn and Grounds Care Products Hydraulic Fitting Kit and JT05469 Flowmeter Kit. Heat hydraulic oil to 43˚C (110˚F), See Õ in this group. Run machine at fast idle.
PAGE 369
Diagnosis, Tests and Adjustments/Steering Valve Neutral Check (318 and 420) Õ Remove belly screen/pan. HYDRAULIC OIL WARM-UP PROCEDURE Install JDG282 Temperature Gauge (A) on transmission oil filter. M43008 -UN-18JAN90 Periodically cycle all hydraulic functions to distribute heated oil. NOTE: 316 Shown Ú -UN-12JAN90 STEERING VALVE NEUTRAL CHECK (318 and 420) Start engine and run at full throttle. MX,159025020,22-19-20APR95 Move and hold control lever in implement “raise” position.
PAGE 370
Diagnosis, Tests and Adjustments/Neutral Return Linkage Adjustment (Early Models) Ü HYDROSTATIC LEVER FRICTION ADJUSTMENT Early models; Remove left and right engine side panels, battery and battery base. Connect a scale to hydrostatic control lever. Later models; Remove right-hand pedestal screen/panel. M36674 -UN-25JAN90 MX,159025020,25-19-20APR95 Adjust friction disks by tightening or loosening lock nut (A) until 31—44.5 N (7—10 lb force) is required to move hydrostatic control lever.
PAGE 371
M49225 -UN-04MAY95 M49211 -UN-07APR95 Diagnosis, Tests and Adjustments/Neutral Return Linkage Adjustment (Early Models) A—Cam Plate B—Lock Nut C—Lock Nut D—Neutral Guide E—Neutral Slot F—Eccentric Nut MX,159025020,30-19-20APR95 250 15 11 TM1590 (17MAY95) 250-15-11 316, 318 & 420 Lawn and Garden Tractors 020895
PAGE 372
Diagnosis, Tests and Adjustments/Neutral Return Linkage Adjustment (Early Models) 1¡b Versions One—318 and 420 (J-Bolt Style Linkage) NOTE: For Version One—316 and Version Two—318 (Sliding Lever Linkage): GO TO 1¡a For later Versions of all models (Detented Neutral Style Linkage): GO TO On 318, the J-bolt attached to cam plate (A) with lock nuts (B), faces opposite direction shown. Adjustment procedure is the same.
PAGE 373
M49226 -UN-04MAY95 M49213 -UN-20DEC89 Diagnosis, Tests and Adjustments/Neutral Adjustment (Early Models) 420 Shown A—Cam Plate B—Lock Nuts C—Neutral Guide D—Neutral Slot E—Lock Nut F—Eccentric Nut MX,159025020,33-19-20APR95 1! NEUTRAL ADJUSTMENT (Version One—All Models and Version Two—318) IMPORTANT: This adjustment must be made with pedestal panels installed and hardware tightened. Move hydrostatic control lever to N/STOP position. Remove fender deck.
PAGE 374
Diagnosis, Tests and Adjustments/Neutral and Neutral Return Linkage Adjustment (Later Models) N CAUTION: USE EXTREME CAUTION WHEN PERFORMING THIS ADJUSTMENT BECAUSE DRIVE WHEELS ARE FREE TO SPIN AND DRIVE SHAFT IS CLOSE TO TURNBUCKLE. Loosen lock nuts. Start and run engine at fast idle. Turn turnbuckle (A) as required until the drive wheels stop turning. M36677 -UN-25JAN90 Turn engine OFF. IMPORTANT: Tighten lock nuts to proper torque to prevent loss of neutral.
PAGE 375
Diagnosis, Tests and Adjustments/Neutral and Neutral Return Linkage Adjustment (Later Models) M51871 -UN-26APR95 A—Bolts B—Bolt C—Cam Plate D—Roller E—Eccentric F—Detent Spring Loosen bolts (A and B). Place a screwdriver in slot (H) and move swashplate control arm (I) until roller (G) is centered in detent notch.
PAGE 376
Diagnosis, Tests and Adjustments/Neutral and Neutral Return Linkage Adjustment (Later Models) M51872 -UN-26APR95 A—Bolts B—Roller C—Bolt(s) D—Plate Lock park brake. Loosen bolt(s) (C). (One bolt on 316 and 318, two bolts on 420). Slide plate (D) upward until it firmly contacts roller (B). Tighten bolt(s) (C). Place the hydrostatic shift lever in the N/STOP position in the quadrant. Tighten bolts (A). Unlock park brake.
PAGE 377
Diagnosis, Tests and Adjustments/Differential Lock Linkage Check (420) 1# Remove belly pan. TWO-SPEED AXLE LEVER LINKAGE CHECK (420) Inspect two-speed axle lever linkage for missing pin, broken spring, wear or damage. Plate notch must engage slots easily. M36693 1ƒa -UN-25JAN90 1ƒa LINKAGE DAMAGED: Repair or replace as necessary. MX,159025020,39-19-20APR95 Remove fender deck and fuel tank.
PAGE 378
Diagnosis, Tests and Adjustments/Differential Lock Linkage Check (420) 250 15 18 TM1590 (17MAY95) 250-15-18 316, 318 & 420 Lawn and Garden Tractors 020895
PAGE 379
Section 260 STEERING AND BRAKES CHECKOUT, OPERATION AND DIAGNOSIS 260 Contents Page Group 05—Steering And Brakes System Checkout Before You Start . . . . . . . . . . . . . . . . . Steering System Oil Leak Check (318 and 420) . . . . . . . . . . . . . . . . . . . . . Hydrostatic Steering System Check (318 and 420) . . . . . . . . . . . . . . . . . . . . . Service Park Brake Check . . . . . . . . . . . Turn Brake Check (318 and 420) . . . . . . Operator Complaint Not Identified . . . . . .
PAGE 380
Contents 260 TM1590 (17MAY95) 260-2 316, 318 & 420 Lawn and Garden Tractors 020895
PAGE 381
Group 05 Steering And Brakes System Checkout BEFORE YOU START Always begin with this group to identify a failure in the steering system. The step-by-step procedures will provide you with a quick check of the system. No special tools are required to perform these checks. If a failure is indicated you will be referred to a more detailed check, adjustment, or test. This procedure is designed as a quick check of the system.
PAGE 382
Steering And Brakes System Checkout/Hydrostatic Steering System Check (318 and 420) ‘ HYDROSTATIC STEERING SYSTEM CHECK (318 AND 420) 260 05 2 MX,159026005,3 -19-24APR95 2a Power Steering Check Start engine and run at full throttle. M49195 -UN-02FEB90 Turn steering wheel full left, then full right. OK: CONTINUE WITH FEEL: Smooth, constant effort should be felt. WHEELS CONTINUE TURNING AFTER STEERING WHEEL IS STOPPED: GO TO I, GROUP 15.
PAGE 383
Steering And Brakes System Checkout/Turn Brake Check (318 and 420) Æ SERVICE PARK BRAKE CHECK 260 05 3 MX,159026005,7 -19-24APR95 3a Depress brake pedal(s) and engage service park brake lock. Park Brake Lock Lever Check LOOK: Service park brake must remain in park position. M49000 3b OK: GO TO 3b NOT OK: Adjust park Move park brake knob up and down. brake linkage. See Section 60. FEEL: Slight spring pressure should be felt.
PAGE 384
Steering And Brakes System Checkout/Operator Complaint Not Identified Ö OPERATOR COMPLAINT NOT IDENTIFIED 260 05 4 MX,159026005,11-19-24APR95 If you completed the checkout procedure and did not isolate a malfunction, the problem may be intermittent. Repeat system checkout in this group. Try to duplicate the condition of the malfunction identified by the operator.
PAGE 385
Group 10 Theory of Operation STEERING VALVE/SYSTEM OPERATION—FOUR-PORT VALVE Function: Supply pressurized oil to the proper side of the steering cylinder to turn the wheels, when the engine is running. 260 10 1 Theory of Operation: NOTE: Right-hand turn shown. -UN-03APR95 The “four-port” design steering valve is an open center type valve, consisting of a self-centering fluid control valve section (E) and a fluid metering section (H).
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Theory of Operation/Steering Valve/System Operation STEERING VALVE/SYSTEM OPERATION—FIVE-PORT VALVE 260 10 2 Function: Supply pressurized oil to the proper side of the steering cylinder to turn the wheels, when the engine is running. Theory of Operation: NOTE: Right-hand turn shown. All external oil flow from the transmission is routed through the steering valve. The steering valve is an open center type valve.
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Theory of Operation/Steering Valve/System Operation M78855 -UN-26APR95 260 10 3 A—Steering Cylinder B—Drive Link Assembly C—Steering Valve D—Centering Springs E—Control Valve Section F—Check Valve G—Steering Wheel H—Fluid Metering Section MX,159026010,3 -19-24APR95 TM1590 (17MAY95) 260-10-3 316, 318 & 420 Lawn and Garden Tractors 020895
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Theory of Operation/Steering Valve/System Operation 260 10 4 TM1590 (17MAY95) 260-10-4 316, 318 & 420 Lawn and Garden Tractors 020895
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Group 15 Diagnosis, Tests and Adjustments ABOUT THIS GROUP The step-by-step procedures in this group provide you with the detailed diagnostic information you will need to perform a test. Basic diagnostic equipment is used. Always start with the first step and follow the sequence from left to right. Read each step completely before performing the test. It is assumed that you are familiar with the machine and its steering system components.
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Diagnosis, Tests and Adjustments/Troubleshooting Guide A STEERING WANDER • Check for correct tire size. • Check front tires for incorrect or unequal pressure. 260 15 2 • Check for loose or worn steering linkage parts. • Check for worn wheel bearing or spindle bushings. • Check Toe-In adjustment: See Section 80. MX,159026015,3 -19-24APR95 B STEERING SHIMMY • Check for improperly mounted tire or wheel. • Check for loose or worn steering linkage parts. • Check for worn wheel bearings or spindle bushings.
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Diagnosis, Tests and Adjustments/Troubleshooting Guide D LOST MOTION AT STEERING WHEEL • Check for loose or worn steering linkage. • Check for steering valve loose at mounting. • Bleed hydraulic system: See Section 270, Group 20. 260 15 3 MX,159026015,6 -19-30MAR95 E HIGH STEERING EFFORT IN ONE DIRECTION • Check for binding of linkage or cylinder rod binding in cylinder barrel. • Check for bent or restricted return line.
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Diagnosis, Tests and Adjustments/Hydraulic Oil Warm-up Procedure G WHEELS DO NOT HIT STOP • Check for bent steering linkage, cylinder or cylinder rod. 260 15 4 MX,159026015,9 -19-30MAR95 H STEERING EFFORT IS ERRATIC • Bleed hydraulic system: See Section 270, Group 20. • Test for steering system leakage. GO TO Æ MX,159026015,10-19-30MAR95 I WHEELS CONTINUE TURNING AFTER STEERING WHEEL IS STOPPED • Inspect valve plate for sticking: See Section 60.
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Diagnosis, Tests and Adjustments/Steering Valve Leakage Test Æ STEERING SYSTEM LEAKAGE TEST Heat hydraulic oil to 43˚C (110˚F). See ‘ in this group. With wheels in a maximum right position, turn steering wheel with a constant torque of 6.8 N·m (60 lb-in.) for one minute. Start engine and run at slow idle. LOOK: Count the revolutions. RPM must not exceed 6. M49198 -UN-20DEC89 MX,159026015,12-19-27MAR95 With wheels in a maximum left position, turn steering wheel with a constant torque of 6.
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Diagnosis, Tests and Adjustments/Steering Valve Leakage Test 260 15 6 TM1590 (17MAY95) 260-15-6 316, 318 & 420 Lawn and Garden Tractors 020895
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Section 270 HYDRAULIC SYSTEM CHECKOUT, OPERATION AND DIAGNOSIS Contents Page Group 05—Hydraulic System Checkout Before You Start . . . . . . . . . . . . . . . . . Hydraulic System Oil Leak Check . . . . . . Hydraulic Control Valve Check . . . . . . . . Operator Complaint Not Identified . . . . . . Group 10—Hydraulic Schematics Hydraulic Circuit Symbols . . . . . . Hydraulic System Schematics 316 . . . . . . . . . . . . . . . . . . . Early 318 . . . . . . . . . . . . . . . . Later 318 . . . . . . . . . . .
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Contents 270 TM1590 (17MAY95) 270-2 316, 318 & 420 Lawn and Garden Tractors 020895
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Group 05 Hydraulic System Checkout BEFORE YOU START Always begin with this group to identify a failure in the hydraulic system. The step-by-step procedures will provide you with a quick check of the system. No special tools are required to perform these checks. If a failure is indicated, you will be referred to a more detailed check, adjustment, or test. NOTE: The 316 has manual steering (gearbox), single-spool control valve and rockshaft cylinder.
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Hydraulic System Checkout/Operator Complaint Not Identified ‘ Run engine at full throttle. HYDRAULIC CONTROL VALVE CHECK NOTE: 316; Single lever controls rockshaft cylinder and right-hand front outlets. Pull control valve lever rearward to raise implement. Release lever. 318 Levers; —Inside lever controls right-hand front outlets “float” and optional rear outlets. —Outside lever controls rockshaft cylinder and left-hand front outlets..
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Group 10 Hydraulic Schematics HYDRAULIC SYSTEM SCHEMATICS The hydraulic system schematics on the following pages can be folded out for use while diagnosing malfunctions or while repairing hydraulic components.
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Hydraulic Schematics/Hydraulic Circuit Symbols HYDRAULIC CIRCUIT SYMBOLS M81419AE -19-19NOV92 270 10 2 NX,HYSYM TM1590 (17MAY95) 270-10-2 -19-05APR94 316, 318 & 420 Lawn and Garden Tractors 020895
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Hydraulic Schematics/Hydraulic Circuit Symbols M81440AE -19-19NOV92 270 10 3 NX,HYSYM1 TM1590 (17MAY95) 270-10-3 -19-05APR94 316, 318 & 420 Lawn and Garden Tractors 020895
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Hydraulic Schematics/Hydraulic Circuit Symbols LEGEND FOR HYDRAULIC SYSTEM SCHEMATIC—316 1—Hydrostatic Transmission 2—Output (Motor) Shaft 3—Hydrostatic Drive Motor 4—Transmission Case Drain 5—Charge Relief Valve 6—Implement Relief Valve 7—Check (Freewheel) Valves 8—Charge Pump 9—Filter 10—Variable Hydrostatic Pump 11—Input (Pump) Shaft 12—Control Valve Spool (Three-Position) 13—Check Valve 270 10 4 14—Hydraulic Control Valve 15—Rockshaft Cylinder 16—Right Front Hydraulic Outlets MX,159027010,2 -19-03
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Hydraulic Schematics/Hydraulic System Schematics LEGEND FOR HYDRAULIC SYSTEM SCHEMATIC—EARLY 318 1—Hydrostatic Transmission 2—Output (Motor) Shaft 3—Hydrostatic Drive Motor 4—Transmission Case Drain 5—Charge Relief Valve 6—Implement Relief Valve 7—Check (Freewheel) Valves 8—Charge Pump 9—Filter 10—Variable Hydrostatic Pump 11—Input (Pump) Shaft 12—Steering Wheel 13—Control Valve Section 14—Fluid Metering Section 15—Steering Cylinder 16—Drive Link Assembly 17—Steering Valve (4-Port) 18—Check Valve 19—Oil
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Hydraulic Schematics/Hydraulic System Schematics LEGEND FOR HYDRAULIC SYSTEM SCHEMATIC—LATER 318 270 10 8 1—Hydrostatic Transmission 2—Output (Motor) Shaft 3—Hydrostatic Drive Motor 4—Transmission Case Drain 5—Charge Relief Valve 6—Implement Relief Valve 7—Check (Freewheel) Valves 8—Charge Pump 9—Filter 10—Variable Hydrostatic Pump 11—Input (Pump) Shaft 12—Steering Wheel 13—Control Valve Section 14—Fluid Metering Section 15—Steering Cylinder 16—Drive Link Assembly 17—Steering Valve (5-Port) 18—Check Va
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Hydraulic Schematics/Hydraulic System Schematics LEGEND FOR HYDRAULIC SYSTEM SCHEMATIC—EARLY 420 1—Hydrostatic Transmission 2—Output (Motor) Shaft 3—Hydrostatic Drive Motor 4—Transmission Case Drain 5—Charge Relief Valve 6—Implement Relief Valve 7—Check (Freewheel) Valves 8—Charge Pump 9—Filter 10—Variable Hydrostatic Pump 11—Input (Pump) Shaft 12—Steering Wheel 13—Control Valve Section 14—Fluid Metering Section 15—Steering Cylinder 16—Drive Link Assembly 17—Steering Valve (4-Port) 18—Check Valve 19—Oil
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Hydraulic Schematics/Hydraulic System Schematics LEGEND FOR HYDRAULIC SYSTEM SCHEMATIC—LATER 420 270 10 12 1—Hydrostatic Transmission 2—Output (Motor) Shaft 3—Hydrostatic Drive Motor 4—Transmission Case Drain 5—Charge Relief Valve 6—Implement Relief Valve 7—Check (Freewheel) Valves 8—Charge Pump 9—Filter 10—Variable Hydrostatic Pump 11—Input (Pump) Shaft 12—Steering Wheel 13—Control Valve Section 14—Fluid Metering Section 15—Steering Cylinder 16—Drive Link Assembly 17—Steering Valve (5-Port) 18—Check V
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Hydraulic Schematics/Hydraulic System Schematics 270 10 14 TM1590 (17MAY95) 270-10-14 316, 318 & 420 Lawn and Garden Tractors 020895
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Group 15 Theory of Operation HYDRAULIC LIFT SYSTEM OPERATION—THREE-POSITION SPOOL Function: To control the flow of pressurized oil to the rockshaft cylinder or implement. Theory of Operation: NOTE: Lower position shown. 270 15 1 -UN-03APR95 On later 318 and 420 models, pressurized oil is routed through the steering valve before reaching the hydraulic control valve. This design provides “power beyond” to the auxiliary hydraulic systems only after satisfying steering valve needs.
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Theory of Operation/Hydraulic Lift System Operation HYDRAULIC LIFT SYSTEM OPERATION—FOUR-POSITION SPOOL Function: To control the flow of pressurized oil to the implement. Theory of Operation: NOTE: Float position shown. -UN-03APR95 On later 318 and 420 models, pressurized oil is routed through the steering valve before reaching the hydraulic control valve. This design provides “power beyond” to the auxiliary hydraulic systems only after satisfying steering valve needs.
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Group 20 Diagnosis, Tests and Adjustments ABOUT THIS GROUP The step-by-step procedures in this group provide you with the detailed diagnostic information you will need to perform a test. Basic diagnostic equipment is used. It is assumed that you are familiar with the machine and its hydraulic system components. If you need additional information, read the theory of operation in Group 15 or refer to the overall hydraulic schematics in Group 10.
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Diagnosis, Tests and Adjustments/Troubleshooting Guide ; TROUBLESHOOTING GUIDE If hydraulic system does not operate properly, select the appropriate symptom from the list below. After selecting the appropriate symptom, go to that step and perform the following checks, tests, or adjustments in the order shown to isolate and repair malfunction.
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Diagnosis, Tests and Adjustments/Troubleshooting Guide B LOW OR SLOW HYDRAULIC POWER • Check for dented or restricted lines. • Check for proper engine speed. See Section 220. • Test charge pump pressure. See Section 250. • Check for plugged oil filter. • Check suction line for air leaks. See Section 250. • Test implement relief valve pressure. See Section 250. • Test control valve for leakage. GO TO Å 270 20 3 • Inspect cylinder packings for excessive wear.
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Diagnosis, Tests and Adjustments/Troubleshooting Guide E EXCESSIVE HYDRAULIC PUMP NOISE • Bleed hydraulic system. GO TO Ö • Check suction line for air leaks. See Section 250. • Check for worn or damaged charge pump. See Section 50. MX,159027020,7 -19-24APR95 270 20 4 F CONTROL VALVE STICKS OR HARD TO OPERATE • Check for binding control valve linkage. • Inspect control valve for broken return spring, contaminated or scored valve bore, or bent valve spool. See Section 70.
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Diagnosis, Tests and Adjustments/Rockshaft Cylinder Leakage Test ‘ Remove belly screen/pan. HYDRAULIC OIL WARM-UP PROCEDURE Apply park brake. Start engine and run at full throttle. Install JDG282 Temperature Gauge (A) on transmission oil filter. M43008 -UN-18JAN90 MX,159026015,16-19-24APR95 Move and hold control lever in implement “raise” position. Heat oil to temperature specified in test. NOTE: The hydrostatic transmission should not exceed 93˚C (200˚F) as a continuous operating temperature.
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Diagnosis, Tests and Adjustments/Control Valve Leakage Test Å CONTROL VALVE LEAKAGE TEST N CAUTION: TO AVOID INJURY FROM ESCAPING HYDRAULIC OIL UNDER PRESSURE, RELIEVE THE PRESSURE IN THE SYSTEM BY STOPPING THE ENGINE AND OPERATING ALL HYDRAULIC CONTROL VALVES. IMPORTANT: To avoid putting full pump flow into container, DO NOT return control valve lever to “neutral” or “float” (if equipped) position with engine running. If equipped with power steering, DO NOT move steering wheel.
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Diagnosis, Tests and Adjustments/Control Valve Leakage Test 4b Models 318 and 420 A—JT03339 Connector B—JT03107 Adapter C—JT03017 Hose D—JT03345 Gauge 20,000 kPa (3,000 psi) M36682 Heat hydraulic oil to 43˚C (110˚F). See ‘ in this group. -UN-25JAN90 one minute. Make test port connections from JT01765 Lawn and Grounds Care Products Hydraulic Fitting Kit. Stop engine. Record amount of oil in container. Amount must be less than 15 mL/min (1/2 fl oz/min). Pressure must be 5860—6550 kPa (850—950 psi).
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Diagnosis, Tests and Adjustments/Bleed Hydraulic System Ö BLEED HYDRAULIC SYSTEM After installing a repaired or replacement part, follow this run-in procedure to assure that air is purged from the hydraulic system. 1. Start engine and idle for 10 minutes. 2. Run engine at high idle for one minute. 3. Turn steering wheel full left and hold for five seconds. 4. Turn steering wheel to straight forward for 10 seconds. 270 20 8 5. Turn steering wheel full right and hold for five seconds. 6.
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Section 299 DEALER FABRICATED TOOLS Contents Page Group 00—Dealer Fabricated Tools DFMX1 Steering Valve Fixture . . . . . . . . 299-00-1 DFMX2 Alignment Shims . . . . . . . . . . . .
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Contents 299 TM1590 (17MAY95) 299-2 316, 318 & 420 Lawn and Garden Tractors 020895
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Group 00 Dealer Fabricated Tools DFMX1 STEERING VALVE FIXTURE -UN-28APR89 Steering valve fixture is used to hold steering valve during disassemby and assembly procedures. Material required: One piece of 5 x 102 x 203 mm (3/16 x 4 x 8 in.) 1020 mild steel flat stock. M36877 A—203 mm (8.0 in.) B—9.5 mm (3/8 in.)* C—51 mm (2.0 in.) D—102 mm (4.0 in.) E—51 mm (2.0 in.) Diameter Hole 299 00 1 *Four diameter holes equally spaced on a 83 mm (3-1/4 in.) diameter circle.
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Dealer Fabricated Tools/DFMX2 Alignment Shims 299 00 2 TM1590 (17MAY95) 299-00-2 316, 318 & 420 Lawn and Garden Tractors 020895
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Index Page A Alternator, Tests . . . . . . . . . . . . . . . . . 240-25-5 B Battery, Charge and Test Bleed Hydraulic System . Brake Neutral Start Check . . . . . . . . . . . . Safety Switch, Test . . . Brake Pedal Linkage 316 . . . . . . . . . . . . . 318 . . . . . . . . . . . . . 420 . . . . . . . . . . . . . Brakes Adjust . . . . . . . . . . . . Install . . . . . . . . . . . . Remove . . . . . . . . . . . . . . . . . . . . . 240-20-1 . . . . . . . . . . . 270-20-8 . . . . . . . . . . . 240-05-3 . . . .
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Index Page INDX 2 Front Axle—420 Assemble Pivot Pin . . . . . . . . . . . Disassemble and Inspect Pivot Pin Install . . . . . . . . . . . . . . . . . . . . Remove . . . . . . . . . . . . . . . . . . Front PTO Clutch Clutch Adjustment, Check . . . . . . . Disassemble, Inspect and Assemble Install . . . . . . . . . . . . . . . . . . . . Remove . . . . . . . . . . . . . . . . . . Seat Switch Time Delay, Test . . . . Seat Switch, Check . . . . . . . . . . . Fuel Gasoline . . . . . . . . . . . . . . . . . .
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Index Page Lubricant Alternative Mixing . . . Storage . . Synthetic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25-5 10-25-5 10-25-5 10-25-5 .. .. .. 10-10-1 10-15-4 10-25-5 Page Oil Engine . . . . . . . . . . . . . . . . . . Hydraulic . . . . . . . . . . . . . . . . . Mower Deck Gear Case . . . . . . . Transmission . . . . . . . . . . . . . .
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Index Page INDX 4 Specifications Machine . . . . . . . . . . . . . . . Repair . . . . . . . . . . . . . . . . . Test and Adjustment . . . . . . . Speed Reduction Check (318 and Starter, Tests . . . . . . . . . . . . . Starting Circuit Check . . . . . . . . . . . . . . . . . Tests . . . . . . . . . . . . . . . . . Steering Column—318 and 420 Assemble . . . . . . . . . . . . . . Disassemble and Inspect . . . . Remove and Install . . . . . . . . Steering Cylinder (318 and 420) Remove and Install . . . . . .