John Deere 318- User Manual

Contents TM1590 (17MAY95) iv 316, 318 & 420 Lawn and Garden Tractors 020895 260 270 299 INDX

FOREWORD This manual is written for an experienced technician.Essential tools required in performing certain servicework are identified in this manual and arerecommended for use. Live with safety: Read the safety messages in theintroduction of this manual and the cautionspresented throughout the tex...

JOHN DEERE DEALERS IMPORTANT: Please remove this page and route through your service department. This is a complete revision for models 316, 318 and 420found in TM1277 and TM1345. The complete revision ofremaining machines (322, 330, 332 and 430) can befound in TM1591. AFTER recieving both TM1590 an...

Section 10 GENERAL INFORMATION Contents Page Group 05—Safety . . . . . . . . . . . . . . . . 10-05-1 Group 10—General SpecificationsMachine Specifications . . . . . . . . . . . . . 10-10-1 Group 15—Repair SpecificationsRepair Specifications . . . . . . . . . . . . . . 10-15-1Metric Series Torque Cha...

RECOGNIZE SAFETY INFORMATION This is the safety-alert symbol. When you see thissymbol on your machine or in this manual, be alert tothe potential for personal injury. Follow recommended precautions and safe operatingpractices. T81389 -UN -07DEC88 UNDERSTAND SIGNAL WORDS A signal word—DANGER, WARNING...

HANDLE FLUIDS SAFELY—AVOID FIRES When you work around fuel, do not smoke or work nearheaters or other fire hazards. Store flammable fluids away from fire hazards. Do notincinerate or puncture pressurized containers. Make sure machine is clean of trash, grease, and debris. Do not store oily rags; the...

PREVENT ACID BURNS Sulfuric acid in battery electrolyte is poisonous. It isstrong enough to burn skin, eat holes in clothing, andcause 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...

PREPARE MACHINE FOR REPAIR 1. Move hydrostatic control lever to STOP position. 2. Disengage PTO’s 3. Lower all equipment to the ground. 4. Engage park brake. 5. Stop the engine and remove the key. 6. Operate all hydraulic control levers to releasehydraulic pressure in the system. Before you leave th...

SERVICE TIRES SAFELY Explosive separation of a tire and rim parts can causeserious injury or death. Do not attempt to mount a tire unless you have theproper equipment and experience to perform the job. Always maintain the correct tire pressure. Do not inflatethe tires above the recommended pressure....

MACHINE SPECIFICATIONS 316 318 420 ENGINEManufacturer . . . . . . . . . . . . . . . . Onan . . . . . . . . . . . . Onan . . . . . . . . . . . . OnanType . . . . . . . . . . . . . . . . . . . . . Gasoline . . . . . . . . . . Gasoline . . . . . . . . . . GasolineModel Number Early . . . . . . . . . . ...

316 318 420 ELECTRICAL SYSTEM, continuedBattery Type . . . . . . . . . . . . . . . . BCI Group 22F . . . . . . BCI Group 22F . . . . . . BCI Group 22FBattery Voltage . . . . . . . . . . . . . . . 12V . . . . . . . . . . . . . . 12V . . . . . . . . . . . . . . 12VBattery Reserve Capacity @ 25 amp . ....

REPAIR SPECIFICATIONS Item Specifications ENGINEFor all repair specifications—Use CTM2Engine Mounting Cap Screw/Nut Torque 316 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 N·m (29 lb-ft) 318 and 420 . . . . . . . . . . . ....

Item Specifications STEERING AND BRAKESSteering—316 Gearbox Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 N·m (70 lb-ft) Steering Wheel-to-Shaft Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N·m (133 l...

METRIC BOLT AND CAP SCREW TORQUE VALUES Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9 Size Lubricated a Dry a Lubricated a Dry a Lubricated a Dry a Lubricated a Dry a 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 4.8 3.5 6 4.5 9 6.5 11 8.5 13 9.5 17 12 15 11.5...

UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUES Grade 1 Grade 2 b Grade 5, 5.1, or 5.2 Grade 8 or 8.2 Size Lubricated a Dry a Lubricated a Dry a Lubricated a Dry a Lubricated a Dry a 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 3.7 2.8 4.7 3.5 6 4.5 7.5 5.5 9.5 7...

METRIC CAP SCREW TORQUEVALUES—GRADE 7 NOTE: When bolting aluminum parts, tighten to 80% of torque specified in table. Size N·m (lb-ft) M6 9.5 - 12.2 (7-9) M8 20.3 - 27.1 (15-20) M10 47.5 - 54.2 (35-40) M12 81.4 - 94.9 (60-70) M14 128.8 - 146.4 (95-108) M16 210.2 - 240 (155-177) NOTE: Allow a toleran...

SERVICE RECOMMENDATIONS FOR O-RINGBOSS FITTINGS STRAIGHT FITTING 1. Inspect O-ring boss seat for dirt or defects. 2. Lubricate O-ring with petroleum jelly. Place electricaltape over threads to protect O-ring. Slide O-ring overtape and into O-ring groove of fitting. Remove tape. 3. Tighten fitting to...

TEST AND ADJUSTMENT SPECIFICATIONS Item Specifications ENGINESpark Plug Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.64 mm (0.025 in.)Slow Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

FUEL N CAUTION: Handle fuel carefully. If the engineis hot or running, do not fill the fuel tank. Donot smoke while you fill the fuel tank orservice the fuel system. Fill fuel tank only tobottom of filler neck. IMPORTANT: DO NOT mix oil with gasoline. 1. Unleaded fuel is recommended. Regular leadedg...

ENGINE OIL Use oil viscosity based on the expected air temperaturerange 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 thefollowing: • API Service Classification SH• API Service ...

TRANSMISSION AND HYDRAULIC OIL Use oil viscosity based on the expected air temperaturerange during the period between oil changes. The following oils are preferred: • John Deere HY-GARD ® • John Deere Low Viscosity HY-GARD ® The following oils are also recommended: • John Deere UNI-GARD™• John Deere...

GREASE Use grease based on the expected air temperaturerange during the service interval. The following greases are preferred: • John Deere MOLY HIGH TEMPERATURE EPGREASE• John Deere HIGH TEMPERATURE EP GREASE• John Deere GREASE-GARD™ Other greases may be used if they meet one of thefollowing: • SAE...

ALTERNATIVE AND SYNTHETIC LUBRICANTS Conditions in certain geographical areas may requirelubricant recommendations different from thoseprinted in this manual. Some John Deere lubricantsmay not be available in your location. Consult yourJohn Deere dealer to obtain information andrecommendations. Synt...

SERIAL NUMBERS When working on machines or components that arecovered by warranty, it is IMPORTANT that you includethe tractor Product Identification Number and thecomponent serial number on the warranty claim form. The location of component serial number plates areshown below. PRODUCT IDENTIFICATIO...

DIFFERENTIAL SERIAL NUMBER Serial number plate (A) location. M38479 -UN -29AUG88 CONTROL VALVE SERIAL NUMBER M38480 -UN -29AUG88 MX,15901030,4 -19-12MAY95 MX,15901030,5 -19-12MAY95 Serial Number Locations/Serial Numbers TM1590 (17MAY95) 10-30-2 316, 318 & 420 Lawn and Garden Tractors 020895 10 3...

Section 20 ENGINE REPAIR Contents Page Group 05—EngineRepair—Use CTM2 . . . . . . . . . . . . . . . 20-05-1Remove and Install . . . . . . . . . . . . . . . 20-05-1 TM1590 (17MAY95) 20-1 316, 318 & 420 Lawn and Garden Tractors 020895 20

ONAN ENGINE REPAIR—USE CTM2 For complete repair information, the component technicalmanual (CTM) is also required. Use the componenttechnical manual in conjunction with this machinemanual. TS225 -UN -17JAN89 REMOVE AND INSTALL ENGINE 1. Disconnect battery negative (—) cable. 2. Disconnect headlight ...

5. Disconnect items (A—F). 6. Disconnect drive shaft at engine. 7. Loosen PTO belt tension and remove belts fromengine. 8. Remove engine mounting cap screws. 9. Attach load positioning sling to lift eyes and removeengine. 10. Make repairs as necessary. (See CTM2.) A—Positive Battery CableB—Choke Cab...

Section 40 ELECTRICAL REPAIR Contents Page Group 05—Front PTO ClutchRemove . . . . . . . . . . . . . . . . . . . . . . . 40-05-1Disassemble, Inspect and Assemble . . . . 40-05-2Install . . . . . . . . . . . . . . . . . . . . . . . . . 40-05-4 TM1590 (17MAY95) 40-1 316, 318 & 420 Lawn and Garden ...

REMOVE FRONT PTO CLUTCH 1. Remove grille and right-hand side panel. 2. Loosen PTO belt tension and remove belts from PTOclutch sheaves. 3. Disconnect PTO clutch wire lead. NOTE: On some models, the brake plate may be assembled to the armature assembly. 4. On 316 and 318: Early 420 Shown —Remove arma...

IMPORTANT: Support the armature assembly on the spring rivets when installingbearing/hub assembly into armatureassembly, or damage to armature andsprings will occur. 10. Support armature on spring rivets and installbearing/hub assembly into pulley hub with a press and a2-15/16 in. driver disk. 11. I...

INSTALL FRONT PTO CLUTCH IMPORTANT: Make sure clutch wire lead is in same position as when removed, to preventshorting of wires. 1. Install field coil and fasten with four cap screws andlock washers. Be sure coil assembly pilots, on backsideof coil, are seated in engine face. Tighten cap screws. 2. ...

7. Put a 0.46 mm (0.018 in.) flat feeler gauge throughslots in brake plate between rotor and armature. Turnlock nuts until space between rotor and armature is 0.46mm (0.018 in.). Be sure all three nuts are adjusted sospace between armature and rotor is adjusted tospecification at each of three slots...

Section 50 POWER TRAIN REPAIR Contents Page Group 05—TransmissionOther Materials . . . . . . . . . . . . . . . . . . 50-05-1Service Parts Kits . . . . . . . . . . . . . . . . 50-05-1Charge Pump Remove and Install . . . . . . . . . . . . . . 50-05-2Disassemble and Inspect . . . . . . . . . . 50-05-3A...

OTHER MATERIAL Number Name Use M79292 MPG-2 ® Multi-Purpose Polymer Prevents parts from seizing. Apply Grease to splines of transmission inputshaft. ® MPG-2 is a registered trademark of DuBois USA. SERVICE PARTS KITS The following kits are available through your partscatalog: Charge Relief Valve Shi...

REMOVE AND INSTALL CHARGE PUMP 1. Remove fender deck and fuel tank. 2. Remove drive shaft. (See procedure in Group 25.) N CAUTION: To avoid injury from escaping fluidunder pressure, stop engine and relieve thepressure in the system before disconnecting orconnecting hydraulic or other lines. Tighten ...

NOTE: Transmission is removed for photographic purpose only. 4. Remove pin (A). Inspect pin for straightness androunded ends. Replace if necessary. 5. Inspect machined surface (B) of transmission forsevere scoring. If scoring is noted replace transmission. 6. Make repairs as necessary. (See Disassem...

3. Inspect inner ring key way for damage or shear pindebris. 4. Inspect rotor ring (A) for cracks or signs of scoring onthe outer edge. 5. Inspect gerotor set for wear or damage. If anycomponent is worn or damaged, replace gerotor set asan assembly. M36086 -UN -29JAN90 6. Pry out seal using a screwd...

4. Install new O-ring (B). Apply petroleum jelly to sealand housing to hold O-ring in its groove. 5. Install rotor ring (A) and inner ring. The gerotor setmust spin freely in housing. M36085 -UN -29AUG88 REMOVE AND INSTALL CHARGE RELIEFVALVE 1. Remove fender deck and fuel tank. 2. Remove charge reli...

REMOVE AND INSTALL IMPLEMENT RELIEFVALVE 1. Remove fender deck and fuel tank. 2. Remove implement relief valve plug from top oftransmission housing. IMPORTANT: If relief valve is being disassembled to be cleaned, the same number andthicknesses of shims must be installedwhen assembled. 420 Shown 3. R...

NOTE: There are different versions of the swashplate control arm. Also, attaching swashplate controlarm to the control shaft on transmission isdifferent. Some machines use a safety wire androll pin, others use a nut and cap screw. 6. Remove safety wire and roll pin (A) or nut and capscrew to disconn...

12. Use a floor jack to support transmission and placejack stands under tractor frame. NOTE: Early models have two bolts (A) attaching differential to frame support bracket (C). Latermodels have one shoulder bolt (A) or one boltwith a washer and spacer. 13. Remove two bolts or shoulder bolt (A) or b...

NOTE: Disconnect brakes on both sides of machine. 17. Disconnect spring (A). 18. Remove nut (B), plate or washer (D) and spring (C). 19. Bend tabs (F) flat. Remove two cap screws (E) fromeach side of machine. 20. Lower differential and transmission assembly and rollaway from frame. Early Models A—Re...

DISASSEMBLE TRANSMISSION COVER 1. Thoroughly clean outside surface of transmissionusing a steam cleaner or cleaning solvent. 2. Install transmission on a bench fixture. 3. Remove charge pump (B). (See procedure in thisgroup.) 4. Remove implement relief valve (D). (See procedure inthis group.) 5. Rem...

10. Remove O-ring, backup ring (B), and O-ring (A). NOTE: Originally equipped 420 Lawn and Garden Tractor transmissions do no have manuallyoperated check valves. If check valves havebeen replaced; service replacements will havemanually operated check valves. 11. Internal valve (C) must move freely i...

18. Inspect bearing plates. Bearing plates should be flat,free of all nicks, burrs, scratches and erosion around theports. The bronze metal should show no scoring,smearing or be discolored. NOTE: Scoring is indicated by fine scratches or grooves cut into the plate. When these scratches can be detect...

2. Inspect cylinder block assemblies. IMPORTANT: Do not interchange pistons between motor and pump cylinder blocks.Pistons and cylinder blocks arematched. Lift piston retainer and pistons from cylinder block.Check for free movement of pistons in cylinder bores. M36111 -UN -29AUG88 3. Remove and insp...

IMPORTANT: Pump shaft and bearing assembly could restrict movement of swashplate.Full swashplate movement isapproximately 25 mm (1 in.) in eachdirection. If necessary tap shaft with asoft faced hammer. 2. Push top of swashplate (C) down until it contacts thestops in the housing. IMPORTANT: DO NOT dr...

10. Inspect bearing, replace if necessary. IMPORTANT: Be sure to hold shaft while removing bearing. 11. Remove bearing using a 1 in. driver disk (A), bearingpuller attachment and a press. M36120 -UN -29AUG88 12. Remove three seals from housing. M36121 -UN -29AUG88 NOTE: Some transmissions will have ...

16. Inspect bearing, replace if necessary. IMPORTANT: Be sure to hold shaft while removing bearing. 17. Remove bearing using a 1 in. driver disk (A), bearingpuller attachment and a press. M36124 -UN -29AUG88 ASSEMBLE PUMP AND MOTOR HOUSING IMPORTANT: Always use new seals and O-rings. Damaged or used...

6. Push pump shaft into bearing until it is on the shaftshoulder using a 1-in. driver disk (A) bearing pullerattachment and a press. M36130 -UN -29AUG88 NOTE: Tape over splines to protect seals from possible damage when installing shafts, remove tape afterinstallation. 7. Install pump shaft. 8. Inst...

ASSEMBLE PUMP AND MOTOR IMPORTANT: Do not nick or scratch lapped surface of cylinder blocks. Piston-to-Bore relationship need not bemaintained; keep pump and motorcomponents separate, they are notinterchangeable. 1. Put clean John Deere Low Viscosity HY-GARD ® oil or an equivalent on all internal pa...

ASSEMBLE TRANSMISSION COVER IMPORTANT: Do not nick or scratch lapped or machined surfaces of the centersection, valve plates or cylinder block. Keep pump and motor componentsseparate. They are not interchangeable. Always use new seals and O-rings.Damaged or used parts will leak. NOTE: Lubricate all ...

IMPORTANT: Use extreme care when assembling the center section, valve plates andcylinder block to avoid dropping,nicking or scratching lapped surfaces. 4. Install center section and gasket (A) on housing andinstall eight cap screws. Tighten cap screws evenly. NOTE: Center section will seem springy, ...

13. Install new filter (A). 14. Install charge relief valve (C), implement relief valve(D) and charge pump (B). (See procedures in thisgroup.) A—Oil FilterB—Charge PumpC—Charge Relief ValveD—Implement Relief Valve M77333 -UN -21FEB95 INSTALL TRANSMISSION IMPORTANT: Always use new seals and O-rings. ...

4. Position differential assembly under tractor. 5. On 420; Hold differential lock linkage away fromdifferential using wire, tape, etc. 6. Lift and position differential assembly. Put drive shafton transmission input shaft. Turn pump shaft to alignsplines. 420 Shown M36578 -UN -25JAN90 7. Position b...

10. Lock brake pedals together (318 and 420) and applypark brake. 11. Loosen lock nut (A). 12. Turn nut until spring is 42 mm (1.650 in.) long.Tighten lock nut. M36554 -UN -25JAN90 NOTE: Early models have two bolts (A) attaching differential to frame support bracket (C). Latermodels have one shoulde...

INSPECT AND REPAIR TRANSMISSION CONTROL LINKAGE—VERSION ONE (ALLMODELS) A—Knob F—Bracket K—Guide P—Swashplate Arm B—Clip G—Pin L—Speed Control Rod Q—Wire C—Speed Control Lever H—Shock Absorber M—Turnbuckle R—Spring Pin D—Torsion Spring I—Brake Plate (2 used) N—Stud (Early Models) S—Eyebolt (Later Mo...

INSPECT AND REPAIR TRANSMISSION CONTROL LINKAGE—VERSION TWO (420) A—Knob F—Bracket K—Guide P—Cap Screw (Later Models) B—Clip G—Pin L—Speed Control Rod Q—Swashplate Arm (Later C—Speed Control Lever H—Shock Absorber M—Turnbuckle Models) D—Torsion Spring I—Brake Plate (2 used) N—Eyebolt R—Swashplate Ar...

OTHER MATERIAL Number Name Use LOCTITE ® PRODUCTS U.S./Canadian/LOCTITE No. TY6305/TY9485/764 Clean and Cure Primer Cleans parts and speeds cure ofsealant. T43512/TY9473/242 Thread Lock and Sealer (Medium Apply to threads of carrier cap Strength) screws. TY6304/TY9484/518 Flexible Sealant Apply to m...

REMOVE AND INSTALL DIFFERENTIAL 1. Remove transmission (D). (See procedure in Group05.) 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. M36557 -UN -19JAN95 DISASSEMBLE AND INSPECTDIFFERENTIAL NOTE...

NOTE: Early models have FLAT thrust washers. Later models have TABBED thrust washers. All serviceor replacement thrust washers will have the tabs. IMPORTANT: It is recommended to replace the early model (flat) thrust washers with thelater model (tabbed) thrust washers.The early model washers may spi...

15. Remove and inspect intermediate shaft assembly; ifequipped with two-speed differential, remove shift rodassembly with intermediate shaft. Inspect intermediate gears (B and C) for worn ordamaged teeth. Inspect intermediate shaft (D) for worn or damagedsplines or bearing surfaces. NOTE: Early mode...

20. Inspect differential case and cover for wear, cracksor 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. Ifdepth of...

ASSEMBLE DIFFERENTIAL NOTE: This assembly procedure is for the One-Speed Differential (316 and 318) and the Two-SpeedDifferential with Differential Lock (420). Thedifferences are noted. Lubricate all seals with petroleum jelly duringassembly. Early models have FLAT thrust washers. Latermodels have T...

5. Assemble gear (C) and shaft (B). 6. Install output shaft assembly through tabbed thrustwasher (A). One-Speed Differential Two-Speed Differential M77336 -UN -21FEB95 M77337 -UN -21FEB95 7. Two-speed differential; assemble shift rod by installingfork (B) and two E-rings (A). M36236 -UN -22NOV89 MX,...

IMPORTANT: If replacement gasket is made of rubber coated laminated metal, clean matingsurfaces of differential case and coverand install gasket. Do not applysealant. It will cause oil to leak. If replacement gasket is made of paper,clean mating surfaces of differentialcase and cover, apply recommen...

OTHER MATERIAL Number Name Use M79292 MPG-2 ® Multi-Purpose Polymer Prevents parts from seizing. Apply Grease to axle shafts. LOCTITE ® PRODUCTS U.S./Canadian/LOCTITE No. TY6305/TY9485/764 Clean and Cure Primer Cleans parts and speeds cure ofsealant. T43512/TY9473/242 Thread Lock and Sealer (Medium ...

13. Inspect bearing (A), replace if necessary. IMPORTANT: Be sure to hold shaft while removing bearing. 14. Remove bearing using a bearing puller (B) and apress. M31951 -UN -25AUG88 15. Remove two cap screws (A) to disconnect axle fromhitch plate (B). 16. Remove six cap screws to remove axle housing...

INSTALL AXLE IMPORTANT: Always use new seals. Damaged or used parts will leak. NOTE: Lubricate all seals with petroleum jelly during assembly. 1. Install new seal 3 mm (0.118 in.) below machinedsurface of differential using a 2-1/16 in. driver disk. M36567 -UN -25JAN90 2. Install spacer. M36565 -UN ...

16. Lock brake pedals together (318 and 420) and applypark brake. 17. Loosen lock nut (A). 18. Turn nut until spring is 42 mm (1.650 in.) long.Tighten lock nut. M36554 -UN -25JAN90 19. Apply MPG-2 ® Multi-Purpose Polymer Grease on axle shaft. 20. Install key and brake drum. 21. Install washer and nu...

OTHER MATERIAL Number Name Use M79292 MPG-2 ® Multi-Purpose Polymer Prevents parts from seizing. Apply Grease to splines of transmission inputshaft. ® MPG-2 is a registered trademark of DuBois USA. REMOVE AND INSTALL DRIVE SHAFT—316 1. Disconnect battery negative (—) cable. 2. Remove right-hand engi...

N CAUTION: To avoid injury from escaping fluidunder pressure, stop engine and relieve thepressure in the system before disconnecting orconnecting hydraulic or other lines. Tighten allconnections before applying pressure. NOTE: Fender deck and fuel tank removed for photographic purpose only. 7. On 31...

2. Remove four snap rings (A). M43748 -UN -12JAN90 3. Remove cross and bearing assembly using soft metalrod. Push bearing down until it can be removed. 4. Turn cross and bearing assembly over. Push downuntil bearing can be removed. 5. Separate end yoke from splined yoke. M43739 -UN -12JAN90 6. Remov...

Section 60 STEERING AND BRAKE REPAIR Contents Page Group 05—Steering—316Special or Essential Tools . . . . . . . . . . . 60-05-1Service Parts Kits . . . . . . . . . . . . . . . . 60-05-1Gearbox Remove and Install . . . . . . . . . . . . . . 60-05-2Disassemble and Inspect . . . . . . . . . . 60-05-6A...

SPECIAL OR ESSENTIAL TOOLS NOTE: Order tools according to information given in the U.S. SERVICE-GARD™ Catalog or in theEuropean Microfiche Tool Catalog (MTC). Steering Gear Service Set....................JDG457 Used to service steering gearbox. SERVICE PARTS KITS The following kits are available thr...

20. Inspect steering shaft bushings for wear or damage.Replace if necessary. 21. Remove bushings using a pilot bearing puller. 22. Installation is done in the reverse order of removal. • If removed, install steering shaft bushings using adriver set. • Apply multipurpose grease to I.D. of steering sh...

10. Remove preload adjuster and shim, if equipped, fromside cover. M33972 -UN -03OCT89 11. Remove worm bearing adjuster lock nut using apunch and hammer. M33973 -UN -03OCT89 12. Remove worm bearing adjuster. M33974 -UN -08NOV89 IMPORTANT: Do not allow worm shaft to turn to the end of its travel or d...

14. Pry out lower bearing retainer using a screwdriver. 15. Remove lower worm bearing cone. M33976 -UN -03OCT89 NOTE: Bearing cup is press-fit in bearing adjuster. Remove bearing cup only if replacement isnecessary. Bearing cups and cones are matched and mustbe replaced as complete assemblies. 16. I...

22. Remove pitman shaft and worm shaft seals fromgearbox housing. Pitman Shaft Seal Worm Shaft Seal M34019 -UN -03OCT89 M34020 -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 isnecessary. Lip (B) is ...

NOTE: A steering gearlash adjustment shim is available through the parts catalog. 27. Check preload adjuster (A) end clearance with afeeler gauge as shown. If clearance is greater than 0.05mm (0.002 in.), order and install shim (B). M33989 -UN -03OCT89 ASSEMBLE STEERING GEARBOX ANDSHAFT IMPORTANT: A...

3. Install new pitman shaft and worm shaft seals intogearbox housing using drivers from JDG457 SteeringGear Service Set. 4. Apply multipurpose grease to lip of seals. Pitman Shaft Seal Worm Shaft Seal M34161 -UN -08NOV89 M34158 -UN -08NOV89 IMPORTANT: Install ball nut onto worm shaft as shown. An im...

IMPORTANT: Tape splined end of worm shaft to prevent seal damage during shaftinstallation. 12. Apply tape around splined end of worm shaft. 13. Install ball nut (A) and worm shaft (B) with bearingcone, into gearbox housing. Remove tape. M33978 -UN -03OCT89 14. Install new bearing cup in worm bearing...

22. Assemble pitman shaft (A) with preload adjuster (B)and shim (C), if equipped. 23. Install side cover (D) onto shaft with preloadadjuster. 24. Turn preload adjuster screw counterclockwise until itbottoms. Then, back screw off one-half turn. A—Pitman ShaftB—Preload AdjusterC—Shim (if equipped)D—Si...

• Carefully turn worm shaft all the way to end of travel,then turn back one-half turn. M34003 -UN -03OCT89 NOTE: Due to tolerances, some 11/16 in. sockets require a wrapping of card stock around theserrations on end of worm shaft. • Install 1-1/8 in. socket with ratchet on worm bearingadjuster and a...

31. Adjust over center preload: • Back off preload adjuster until it stops, then turn it inone full turn. • Center gear travel by rotating shaft. • Check torque required to turn worm shaft. Recordreading. M34002 -UN -03OCT89 • Turn preload adjuster in, until rolling torque required toturn worm shaft...

OTHER MATERIAL Number Name Use LOCTITE ® PRODUCTS U.S./Canadian/LOCTITE No. TY6305/TY9485/764 Clean and Cure Primer Cleans parts and speeds cure ofsealant. TY9369/NA/222 Thread Lock and Sealer (Low Apply to threads of metering Strength) assembly screws. ® LOCTITE is a registered trademark of the Loc...

REMOVE AND INSTALL STEERING VALVEAND COLUMN NOTE: Removal and installation procedures for later models may vary slightly. 1. Remove fender deck. 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 ci...

11. Remove steering unit from bottom of machine. 12. Make repairs as necessary. (See procedure in thisgroup.) 13. Installation is done in the revese order of removal. • Install steering unit with marks made during removal orwith alignment grooves in port manifold and cover, facingtoward engine. • Ti...

4. Four-port and early five-port; Loosen plug one turn. M77338 -UN -21FEB95 IMPORTANT: Do not damage fittings during nut removal. Do not nick or scratch themachined surfaces of the steeringvalve. 5. Remove nuts to remove port cover assembly (fourplates bonded together). Early Five-Port Shown M43841 ...

NOTE: Port manifold has three springs which may come loose during disassembly. 10. Carefully remove port manifold (three plates bondedtogether). IMPORTANT: Do not interchange springs. The steering valve has two sets of springs.Keep springs with respective manifold. 11. Remove three springs (A). NOTE...

21. Remove metering ring and upper and lower seals(A). If the bore (B) is scored, the metering ring must bereplaced. M36843 -UN -29AUG88 IMPORTANT: Do not clamp metering assembly in a vise. 22. Remove metering assembly. Put assembly on aclean surface. M36844 -UN -29AUG88 23. Remove commutator seal (...

IMPORTANT: DO NOT use a screwdriver to remove commutator. Commutator can bedamaged. 27. Remove commutator and five pins (A) using a wooddowel or equivalent. NOTE: The commutator is made up of two plates bonded together. It is a permanent assembly andcannot be disassembled. 28. Check commutator machi...

32. Lift the rotor and stator from the drive plate. 33. Check the drive plate side of the rotor assembly fornicks, grooves, or scoring. A spiral pattern due to rotormovement is normal. The thrust bearing side of the plate should also show anormal wear pattern without grooves, flaking, or dents. The ...

36. Remove upper cover plate (four plates bondedtogether). 37. Check plate surface for grooves, dents, or metalflakes. A polished pattern due to the action of the seal isnormal. M36854 -UN -29AUG88 38. Remove steering shaft and snap ring (A). 39. Inspect steering shaft serrations, threads, and flats...

6. Install steering tube (A) on bolts. Be sure the squareholes in the steering tube are seated on the squareshoulders of the bolts. 7. Apply multipurpose grease on retainer plate (B) andwasher. 8. Install washer. M36856 -UN -29AUG88 9. Install snap ring (A) on steering shaft. 10. Install steering sh...

19. Install commutator (A) on rotor, with long grooves (B)upward. IMPORTANT: Pins must be installed below the surface of the commutator to preventcommutator cover damage. 20. Align commutator holes with rotor holes and installfive pins. 21. Put a few drops of clean John Deere Low ViscosityHY-GARD ® ...

IMPORTANT: The following procedure must be used to minimize an out-of-round conditionbetween commutator ring and driveplate. The commutator ring isself-centering when the drive plate isshimmed. Use DFMX2 AlignmentShims. 26. Install metering assembly, with drive plate (A) up intometering ring (B). 27...

IMPORTANT: Valve plate must be installed with “PORT SIDE” (A) directly opposite (12o’clock position) from alignment groves(B) for proper operation. Valve platespring slots and springs must bealigned to prevent spring damage wheninstalling port manifold. 44. Install valve plate, with “PORT SIDE” up, ...

48. Four-port and early five-port; Install new O-ring (B)on plug (A). Install check ball (C). Be sure check ball isseated in bottom of hole. Install plug. Do not tighten. Five-Port Shown M43832 -UN -08JAN90 NOTE: Four-port not shown. Unit is similar to early five-port. 49. Later five-port; Install c...

OTHER MATERIAL Number Name Use M79292 MPG-2 ® Multi-Purpose Polymer Prevents parts from seizing. Apply Grease to axle shafts. LOCTITE ® PRODUCTS U.S./Canadian/LOCTITE No. TY6305/TY9485/764 Clean and Cure Primer Cleans parts and speeds cure ofsealant. T43512/TY9473/242 Thread Lock and Sealer (Medium ...

REMOVE BRAKES N CAUTION: Avoid breathing dust that may begenerated when handling componentscontaining asbestos fibers. Inhaled asbestosfibers may cause lung cancer. Normal handlingis not hazardous as long as airborne dustcontaining asbestos is not generated. Avoid creating dust. Never use compressed...

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 screwsand threaded axle housing using Clean and Cure Primer. 4 Apply thread lock and sealer (medium strength) onthreads of brake plate cap screws. 5....

14. Apply MPG-2 ® Multi-Purpose Polymer Grease to axle shaft. 15. Install key and brake drum. 16. Install washer and nut. Tighten nut to specifications. 17. Bend one side of washer over nut to lock nut inplace. 18. Install wheel. Tighten cap screws to specifications. 19. Remove support stands. 20. C...

6. Lock brake pedals together (318 and 420) and applyparking brake. 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. 9. Loosen lock nut (A). 10. Turn nut until spring is 42 mm (1.650 in.) long.Tighten lock ...

A—Neutral Return Cam Plate F—Brake Pedal I—Bracket L—Neutral Return Arm B—Spacer G—Neutral Return Link J—Neutral Return Shaft M—Neutral Return Sliding C—Left-Hand Brake Arm H—Neutral Return Shaft (Early Models) Lever D—Bearing (4 used) (Later Models) K—Lock Wire and Spring Pin N—Eccentric Adjustment...

7. Install all parts. 8. Connect brake rods to brake pedal. 9. Install spring (C), plate or washer (D) and nut (B). 10. Connect return spring (A). A—Return SpringB—NutC—SpringD—Plate (Early Models) —Washer (Later Models) Early Models Later Models M78048 -UN -13FEB95 M78049 -UN -13FEB95 11. Apply par...

7. Install all parts. 8. Connect brake rods to brake pedal. 9. Install spring (C), plate or washer (D) and nut (B). 10. Connect return spring (A). A—Return SpringB—NutC—SpringD—Plate (Early Models) —Washer (Later Models) Early Models Later Models M78048 -UN -13FEB95 M78049 -UN -13FEB95 11. Lock brak...

INSPECT AND REPAIR PARK BRAKELEVER 1. Remove belly screen/pan. 2. Inspect all parts for wear or damage. Replace asnecessary. A—KnobB—Lock WasherC—WasherD—Weld NutE—Park Brake RodF—Lock PlateG—PinH—Torsion Spring M77913 -UN -13FEB95 MX,15906010,18 -19-12MAY95 Brakes/Inspect and Repair Park Brake Leve...

Section 70 HYDRAULIC REPAIR Contents Page Group 05—Hydraulic Control ValveOther Materials . . . . . . . . . . . . . . . . . . 70-05-1Service Parts Kits . . . . . . . . . . . . . . . . 70-05-1Remove and Install 316 and 318 . . . . . . . . . . . . . . . . . . 70-05-2420 . . . . . . . . . . . . . . . ....

OTHER MATERIAL Number Name Use M79292 MPG-2 ® Multi-Purpose Polymer Prevents parts from seizing. Apply Grease to spool springs and end capcavities. LOCTITE ® PRODUCTS U.S./Canadian/LOCTITE No. TY6305/TY9485/764 Clean and Cure Primer Cleans parts and speeds cure ofsealant. T43512/TY9473/242 Thread Lo...

DISASSEMBLE, INSPECT AND ASSEMBLE HYDRAULIC CONTROLVALVE—SINGLE-SPOOL A—Spool E—Spring H—Cap K—O-Ring B—Body F—Spring Retainer I—Screw (2 used) L—Spring C—O-Ring G—Screw J—Plug M—Poppet D—Washer IMPORTANT: Spool and body are matched and must be replaced as a unit. Always use new O-rings. Damagedor u...

DISASSEMBLE, INSPECT AND ASSEMBLE HYDRAULIC CONTROL VALVE—TWO-SPOOL A—Check Valve Plug (2 F—Float Detent Spool L—Detent R—Snap Ring used) G—Body M—Spring S—Washer B—O-Ring (2 used) H—O-Ring (2 used) N—Ball (2 used) T—Spring C—Spring (2 used) I—Bushing (2 used) O—Cap U—Snap Ring D—Poppet (2 used) J—W...

DISASSEMBLE, INSPECT AND ASSEMBLE HYDRAULIC CONTROLVALVE—THREE-SPOOL A—Check Valve Plug (3 F—Cap M—Bushing (3 used) T—Plug (2 used, Version used) G—Shim (as required) N—Washer (2 used) Two only) B—O-Ring (3 used) H—O-Ring O—Spacer (2 used) U—Cap C—Spring (3 used) I—Spring P—Spring (2 used) V—Ball (2...

Section 80 MISCELLANEOUS REPAIR Contents Page Group 05—Front AxleSpecial or Essential Tools . . . . . . . . . . . 80-05-1Front Axle—316 and 318 Remove and Install . . . . . . . . . . . . . . 80-05-1Inspect and Replace Pivot Bushings . . . 80-05-2 Front Axle—420 Remove . . . . . . . . . . . . . . . ....

SPECIAL OR ESSENTIAL TOOLS NOTE: Order tools according to information given in the U.S. SERVICE-GARD™ Catalog or in theEuropean Microfiche Tool Catalog (MTC). Installer Sleeve.............................JDM8-3 For 420 tractor; Used to install PTO shaft asssembly intopivot pin. REMOVE AND INSTALL FR...

6. Place a floor jack under center of axle. 7. Remove cotter pin from pivot bolt. 8. Remove pivot bolt nut and remove bolt through axle(towards rear). Remove axle. 9. Inspect axle and pivot bushings for damage or wear.(See procedure in this group.) 10. Installation is done in the reverse order of re...

5. Loosen axle deflector adjustment bolts and turn in toallow maximum clearance. M31970 -UN -03AUG89 6. Remove front grille. 7. Remove two nuts (A) and belt guard. M31991 -UN -03AUG89 8. Loosen belt adjuster (A), using a screwdriver or bar tokeep the adjuster from cocking as it is loosened. 9. Remov...

ASSEMBLE PIVOT PIN—420 1. Support pivot pin on a press. Put a driver disk (A) onbearing (B). Install bearing using a press until diskbottoms on pivot pin. M36808 -UN -25JAN90 2. Install snap ring (A) on PTO shaft. 3. Support bearing on a knife-edge puller. Press PTOshaft (B) into bearing until it bo...

4. Support pivot pin on a press. Install PTO shaftassembly into pivot pin. 5. Put JDM8-3 Installation Sleeve (A) or a piece of pipeover PTO shaft. Put a suitable size driver disk (B) onSleeve or pipe. 6. Press shaft assembly into pivot pin until bearingbottoms in bore. M36810 -UN -25JAN90 7. Install...

4. Slide drive pulley onto PTO shaft. 5. Install snap ring in PTO shaft groove. 6. Install belts on lower drive sheave and work ontoupper sheave. M31994 -UN -03AUG89 7. Tighten belt adjuster: When adjusting PTO belt tension on horizontal adjuster,tighten bolt until spring measures 41 mm (1.600 in.)....

10. Connect steering cylinder to spindle. 11. Install bolt and nut through steering arm andcylinder. 12. Install cotter pin, if equipped, in steering arm bolt. M31963 -UN -28JUL89 13. Adjust axle deflector bolts for smooth up and downoperation of axle. 14. Test for proper axle deflector adjustment, ...

INSPECT AND REPLACE WHEEL BEARINGS 1. Remove front wheels. 2. The front wheels are equipped with sealed rollerbearings in both the front and rear of hub. Check thebearings for damage by spinning the inner race by hand.If the bearing binds or shows excessive wear, it must bereplaced. 3. Tap the beari...

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 endof the spindle shaft. If, for any reason the spindle must be disassembled, besure to lubricate and torque parts as required. When assembling bea...

SERVICE MOWER BLADESPINDLES—EARLY 60-INCH AND 260ROTARY MOWER If, for any reason the spindle must be disassembled, besure to lubricate and torque parts as required. When assembling bearings and spacer, fill cavities (Eand H) 75 percent full of multipurpose grease. TORQUE SPECIFICATIONS Lock Nut (A) ...

SERVICE MOWER BLADE JACKSHEAVES—46 AND 50-INCH MOWER Mower blade jack sheaves normally require no lubricationor service. If, for any reason the jack sheave must bedisassembled, be sure to lubricate and torque parts asrequired. When assembling bearings and spacer, fill cavities (Kand N) 75 percent fu...

OTHER MATERIAL Number Name Use LOCTITE ® PRODUCTS U.S./Canadian/LOCTITE No. TY6305/TY9485/764 Clean and Cure Primer Cleans parts and speeds cure ofsealant. TY15130/NA/395 Form-In-Place Gasket Sealant Early 60-Inch Mower and 260Rotary Mower; Apply to matingsurfaces of gear case and caps. ® LOCTITE is...

2. Remove four cap screws (A) and input shaftassembly. 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) arematched and must be rep...

7. Press on threaded end of input shaft (C) to removeseal (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. Bear...

ASSEMBLE MOWER GEAR CASE—50-INCHMOWER 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 partsduring assembly. 1. Install snap ring (F), key (G) and bevel gear (E).I...

5. Install new bearing cup (F), if removed, using a driverset. 6. Press plug (E) into gear case (C) with lip facing awayfrom 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 ...

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 seatedagainst snap ring and housing. 18. Install snap ring (B) on input shaft (C). 19. Press bearing cone (D) on input shaft with smallO.D. facing away from snap ring (...

3. Remove four cap screws and lock plates (A). 4. Remove cap (B) and input shaft assembly from gearcase (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 ...

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 mustbe replaced as complete assemblies. 24. Inspect bearing cups (D and E) for wear or damage.Replace if necessary. IM...

ASSEMBLE MOWER GEAR CASE—EARLY60-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). 2. Install new bearing cups (E and D), if removed, usin...

4. Install key (L) and bevel gear (J), shoulder end first,onto shaft (H). 5. Align holes in bevel gear and shaft and install springpin (I). 6. Press bearing cone (K) on shaft with small O.D.facing away from bevel gear (J). Install bearing coneuntil seated. 7. Slide bearing cone (G) onto other end of...

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 beflat to inst...

19. Install key (L) and bevel gear (J), shoulder end first,onto shaft (H). 20. Align holes in bevel gear and shaft and install springpin (I). 21. Press bearing cone (K) on shaft with small O.D.facing away from bevel gear (J). Install bearing untilseated. 22. Slide bearing cone (G) onto other end of ...

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). Removetape. NOTE: Flat sides of cap must align with flat sides of gear case. Gear case mounting surface must beflat to install...

DISASSEMBLE AND INSPECT MOWERGEAR CASE—LATER 60-INCH MOWER(PEERLESS) 1. Remove drain plugs (A and B) and drain oil from gearcase. M77311 -UN -24FEB95 2. Remove four cap screws (A) and input shaftassembly. 3. Remove lock nut (B), washer (C) and bevel gear (E)and bearing from shaft. NOTE: Bearing cone...

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 shaftwith 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...

ASSEMBLE MOWER GEAR CASE—LATER60-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 partsduring assembly. 1. Install snap ring (G) in first gro...

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 sealis recessed 2.54 mm (0.100 in.) below gear casesurface. 8. Apply multipurpose grease to lip of seal. 9. Install vent plug (A). IMPORTANT: A new crush ring must ...

15. Install new bearing cups (F and G), if removed,using a driver set. Press into pillow block (H) until seatedagainst housing. 16. Install snap ring (B) onto input shaft (C). 17. Press bearing cone (D) on input shaft with smallO.D. facing away from snap ring (B). Install bearing untilit bottoms aga...

DISASSEMBLE AND INSPECT MOWERGEAR CASE—260 ROTARY MOWER 1. Remove drain plugs (A and B) and drain oil from gearcase. M77323 -UN -24FEB95 MX,15908015,29 -19-22FEB95 Mower Gear Case Repair/260 Rotary Mower TM1590 (17MAY95) 80-15-27 316, 318 & 420 Lawn and Garden Tractors 020895 80 15 27

ASSEMBLE MOWER GEAR CASE—260ROTARY 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...

25. Install new bearing cups (K and J), if removed, intohousing (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 too...

Section 220 ENGINE, FUEL AND AIR SYSTEM CHECKOUT AND DIAGNOSIS Contents Page Group 05—Engine, Fuel and Air System Checkout Before You Start . . . . . . . . . . . . . . . . . 220-05-1Engine Oil and Leak Check . . . . . . . . . . 220-05-1Fuel Leak Check . . . . . . . . . . . . . . . . . 220-05-1Thrott...

BEFORE YOU START Always begin with this group to identify a failure inthe engine, fuel or air system. The step-by-stepprocedures will provide you with a quick check of thesystem. No special tools are required to performthese checks. If a failure is indicated, you will bereferred to a more detailed c...

Å ENGINE STARTCHECK Operator on seat. Put hydrostatic controllever in N/STOPposition. Put PTO lever in OFFposition. Pull choke knob all theway out. Depress brake pedal(s). M55029 -UN-09DEC89 Turn key switch toSTART position. Starter must crankengine. Engine muststart. OK: GO TO Ö NOT OK: GO TO ; , G...

ABOUT THIS GROUP Always perform the system checkout procedures inGroup 05 BEFORE making any tests or adjustmentsin this group. The step-by-step procedures in thisgroup provide you with the detailed diagnosticinformation you will need to isolate a malfunction.Basic diagnostic equipment is used. It is...

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): ...

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 ins...

M37457 -UN-25JAN90 IMPORTANT: DO NOT hold dashpot using apliers. Dashpot can be damaged. If adjustment is necessary, loosen lock nut (A). Turn dashpot until clearance is obtained. Holddashpot while tightening lock nut. AFTER ADJUSTMENT:GO TO Ò and adjust governor linkage. Ú FUEL FILTER TEST M37079 -...

1@ COMPRESSIONPRESSURE TEST Start and run engineapproximately fiveminutes at fast idle, tobring it to normaloperating temperature. Stop engine. M55108 -UN-09DEC89 Disconnect and ground spark plug wires awayfrom spark plug holes. Remove spark plugs. Install JDM59 Compression Gauge. Make sure choke pl...

NOT OK: GO TO 1$ 1$ OIL PRESSUREREGULATINGVALVE CHECK Remove air cleanerbase. Move air cleanerbracket until oilpressure regulatingvalve cap screw can beremoved. M37435 -UN-31JAN90 Measure cap screw (A) thread length. Remove oil pressure regulating valve (B). Inspectspring (C) for weak or broken coil...

Section 240 ELECTRICAL CHECKOUT, OPERATION AND DIAGNOSIS Contents Page Group 05—Electrical System CheckoutBefore You Start . . . . . . . . . . . . . . . . . 240-05-1Dash Lamp Circuit Check . . . . . . . . . . . 240-05-1Starting Circuit Check . . . . . . . . . . . . . . 240-05-2Ignition Circuit (Spar...

BEFORE YOU START Always begin with this group to identify a failure inthe electrical system. The step-by-step procedures willprovide you with a quick check of the system. Nospecial tools are required to perform these checks. Ifa failure is indicated, you will be referred to a moredetailed check, adj...

Å PTO CLUTCH ANDLAMP CHECK Sit on seat. PTO switch OFF. Turn key switch to RUNposition. M55019 -UN-09DEC89 M36492 -UN-29JAN90 Move PTO switch toON position. LISTEN: Clutch must“click” ON. LOOK: PTO lamp mustcome ON. OK: GO TO Ö NOT OK: GO TO 4a 4a PTO DOES NOTOPERATEPROPERLY Key switch OFF. NOTE:A—2...

Ò TRANSMISSIONNEUTRAL STARTCHECK M55018 -UN-09DEC89 PTO switch OFF. Later Models; Depressbrake pedal(s). Pull hydrostatic leveraway from N/STOPswitch slot. Turn key switch toSTART position. LISTEN: Engine mustNOT crank. OK: GO TO Õ NOT OK: GO TO Ò , Group 20. Õ PTO NEUTRALSTART CHECK PTO switch OFF....

Ü SEAT SWITCHCHECK FORIGNITION M55018 -UN-09DEC89 PTO switch OFF. Sit on seat. Later Models; Depress brake pedal(s). Hydrostatic lever in N/STOP position. Start engine and operate at low idle. Move hydrostatic lever to SLOW FORWARDposition. Raise off seat for 2—3 seconds. LISTEN: Engine must stop. R...

1@ OPERATORCOMPLAINT NOTIDENTIFIED If you completed thecheckout procedure anddid not isolate amalfunction, theproblem may beintermittent. Try to duplicate theconditions of themalfunction identified bythe operator. Verify system groundsand battery condition.(See steps A and B in Group 20.) PERFORM BA...

Group 10 Electrical Schematics TM1590 (17MAY95) 240-10-1 316, 318 & 420 Lawn and Garden Tractors 020895 240 10 1

316, 318 AND 420 ELECTRICAL SCHEMATIC—DUAL PTO A1—TDC Module M2—Starter Motor: X4—Front PTO Switch 3-Pin X17—Headlight Harness A2—Ignition Module 316 (S.N. —362983) Connector Connector (S.N. 420001— ) 318 (S.N. —364137) X5—Rear PTO Harness 3-Pin 1-Pin (S.N. —475000) B1—Engine Oil Pressure 420 (S.N. ...

ELECTRICAL COMPONENT LOCATION 1—Tail Light (2 used) 10—Battery 19—Ignition Coil 27—Starter Motor: 2—Seat Switch 11—Positive (+) Battery 20—Condenser 316 (S.N. —362983) 3—Rear Electric PTO Clutch Cable 21—Hour Meter 318 (S.N. —364137) (Optional) 12—Negative (—) Battery 22—Circuit Breaker 420 (S.N. —3...

STARTING CIRCUIT OPERATION The function of the starting circuit is to crank theengine by energizing starter motor (M1). PTOswitches (S2 and S3), transmission neutral switch(S5), and brake switch (S4) are used as interlocksafety switches within the starter circuit. For thestarter motor to energize, t...

A—Starter Solenoid Main S4—Brake Switch: X3—Front PTO Switch 2-Pin X9—Transmission Neutral Contact 316 (S.N. 596121— ) Connector Switch 1-Pin Connector F1—20 Amp Fuse 318 (S.N. 600305— ) X5—Rear PTO Harness 3-Pin X10—Transmission Neutral F3—25 Amp Circuit Breaker 420 (S.N. 595881— ) Connector Switch...

IGNITION CIRCUIT OPERATION The function of the ignition circuit is to produce sparkacross the gap of spark plugs (E1 and E2). Thecircuit is a battery ignition type that fires both sparkplugs simultaniously, thus eliminating the need for adistributor. The ignition circuit automatically stops theengin...

PTO CIRCUIT OPERATION The function of the PTO circuit is to energize thePTO clutch(es) and turn on the PTO lamp(s). Also,the PTO circuit automatically disengages the PTOclutch(es) anytime the operator rises off the seat formore than one second. To engage the PTO clutch(es), the followingconditions m...

CHARGING CIRUIT OPERATION The function of the charging circuit is to keep thebattery properly charged by supplying approximately13.6—14.7 VDC to the battery while the engine isoperating. The charging system is a permanent magnet andstator type. The magnets are located in the flywheel,which rotates a...

OIL PRESSURE LAMP CIRCUIT OPERATION B1—Engine Oil Pressure M1—Starter Motor X2—Key Switch 1-Pin X16—Headlight Switch 2-Pin Switch P5—Engine Oil Pressure Connector Connector F1—20 Amp Fuse Lamp X3—Front PTO Switch 2-Pin X23—TDC Module 8-Pin F3—25 Amp Circuit Breaker S1—Key Switch Connector Connector ...

ABOUT THIS GROUP Always perform the system checkout procedures inGroup 05 BEFORE doing any tests in this group. Thestep-by-step procedures in this group provide youwith the detailed diagnostic information you will needto isolate a malfunction. Always start with the firststep and follow the sequence ...

M78971 -UN-09MAY95 Check specific gravityof each cell with ahydrometer. 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...

—% Load Test Battery M36665 -UN-29AUG88 Connect JT05685Tester to battery. Follow instructions onback of meter fortesting battery. REPLACE BATTERYAS NEEDED. ; DASH LAMP CIRCUIT TESTS Listed at right are symptoms that may occur in amalfunctioning dash lamp circuit. Locate thesymptom that applies, then...

‘ STARTING CIRCUITTESTS Listed at right aresymptoms that mayoccur in amalfunctioning startingcircuit. Locate thesymptom that applies,then proceed to theappropriate test. IMPORTANT: Testbattery and verifygrounds beforetesting startingcircuit. (See steps A and B at the beginning of thisgroup.) STARTIN...

2j Starter CircuitTest at PTO Switch Turn key switch to RUNposition. M55146 -UN-11DEC89 Check for voltage atterminal (A) with yellowand purple wires, thenat terminal with singlepurple wire. VOLTAGE ONETERMINAL: Replaceswitch. VOLTAGE BOTHTERMINALS: Purplewire between jumperconnector and PTOswitch is...

3i Ignition ControlModule Test—For Machines(S.N. 420001— ) Connect coil wires. Ground spark plugwires. M45246 -UN-12JAN90 NOTE: Terminal (A) islarger in diameter ofthe two posts. Measure ignitionmodule voltage.Connect voltmeter redlead to negative (—)coil terminal (A) andblack lead to engineground. ...

3k Ignition TimingCheck—For Machines(S.N. 420001— ) NOTE: Ignition timing isnot adjustable. If amisfire condition exists,the flywheel key maybe partially sheared.This can be verified bychecking the ignitiontiming. M45246 -UN-12JAN90 N CAUTION: FAILURE TO REMOVE SPARK PLUGS BEFORE TURNING FLYWHEEL BY...

3m Main Power Testfor TDC Module Turn key switch to RUNposition. M37173 -UN-25JAN90 At both sides of TDC8-pin connector, checkfor voltage at terminalwith pink and purplewires and terminal withsingle purple wire (A). VOLTAGE: Verify goodground at TDC 2-pinconnector, then GO TO 3n VOLTAGE AT ONETERMIN...

Ò TRANSMISSIONNEUTRAL STARTSAFETY SWITCHTEST Key switch OFF. Put hydrostatic lever inREVERSE position. M45195 -UN-08JAN90 With switch arm (A)fully released, check forcontinuity acrossterminals (B). CONTINUITY: Replaceand adjust switch. NO CONTINUITY: Pushswitch arm (A) fully in. Check for continuity...

Ü SEAT SWITCH TESTFOR IGNITION TIMEDELAY Key switch OFF. M37289 -UN-25JAN90 Check the black leads(A) of the TDC 2-pinconnector for goodground. GOOD GROUND:Replace TDC module,then GO TO ; , Group 05. POOR GROUND:Clean and tighten allground connectionsthen GO TO Ü , Group 05. 1Ô HOUR METERCIRCUIT TEST...

1! LIGHTING TEST Check bulbs and20-amp fuse. NOTE: If lights comeon when key switch isin the RUN position,but light switch is inOFF position, replacelight switch. Turn key switch to RUNposition. NOTE: If either head ortail lamp comes onwhen light switch ispulled to the ONposition, light switch isOK:...

BEFORE YOU START Always perform the system checkout procedures inGroup 05 and the System Diagnosis in Group 20BEFORE making any tests in this group. Theseprocedures include any special tooling required to identifya failure. Make the repair and perform the SystemCheckout in Group 05 to be certain all...

Section 250 POWER TRAIN CHECKOUT, OPERATION AND DIAGNOSIS Contents Page Group 05—Power Train CheckoutBefore You Start . . . . . . . . . . . . . . . . . 250-05-1Transmission Oil Leak Check . . . . . . . . . 250-05-1Hydrostatic Lever Friction Check . . . . . . . 250-05-1Transmission Neutral Check . . ...

BEFORE YOU START Always begin with this group to identify a failure inthe power train. The step-by-step procedures willprovide you with a quick check of the system. Notools are required to perform these checks. If a failureis indicated, you will be referred to a more detailedcheck, adjustment, or te...

Å NEUTRAL RETURNCHECK 318 and 420; Lockpedals together. M36667 -UN-25JAN90 M36668 -UN-25JAN90 Move hydrostatic leverto full forward orreverse position. Depress brake pedal(s). LOOK: Hydrostaticlever must move to“STOP” position fromforward or reverse. OK: GO TO Ö NOT OK: GO TO 1Ô , GROUP 15. Ö TRANSM...

Move hydrostatic leverto full forward position. M36671 -UN-25JAN90 Depress left brakepedal. LOOK: Hydrostaticlever must move toslow forward position.Left wheel must stop;right wheel mustcontinue to turn. OK: GO TO Õ NOT OK: GO TO Ü , GROUP 15. Õ TWO-SPEED AXLELEVER CHECK (420) Start and run engine a...

Group 10 Theory of Operation TM1590 (17MAY95) 250-10-1 316, 318 & 420 Lawn and Garden Tractors 020895 250 10 1

HYDROSTATIC TRANSMISSION OPERATION Function:Transfers power from the input (pump) shaft to thegear drive components of the transmission. It alsoprovides infinitely variable speed and torque within arange in forward and reverse directions. Also supplies pressurized oil to the hydraulic lift andsteeri...

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 component...

G HYDRAULIC SYSTEM IS NOISY • Check power steering valve, if equipped, or hydraulic control valve for overheating. If either valve is toohot 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 ...

‘ CHECK VALVEDEBRIS CHECK Engine OFF. Service park brakeOFF. M49216 -UN-20DEC89 316 and 318; EngageManual Push lever (A)and push machineforward to removedebris from checkvalves. Early 420; Removefender deck. Removeand inspect checkvalves for debris.Repair or replace ifnecessary. Later 420; Removefen...

M36682 -UN-25JAN90 A—JT03339 ConnectorB—JT03107 AdapterC—JT03017 HoseD—JT03344 Gauge, 2000kPa (300 psi) IMPORTANT:Hydraulic controllevers must remain inneutral position andengine must be run atslow idle. Pressure gauge willbe damaged if ahydraulic function isactuated or test is runat fast idle. Make...

Å IMPLEMENT RELIEFVALVE PRESSURETEST N CAUTION: TO AVOID INJURY FROMESCAPINGHYDRAULIC OILUNDER PRESSURE,RELIEVE THEPRESSURE IN THESYSTEM BYSTOPPING THEENGINE ANDOPERATING ALLHYDRAULICCONTROL VALVES. M36682 -UN-25JAN90 A—JT03339 ConnectorB—JT03107 AdaptorC—JT03017 HoseD—JT03345 Gauge,20,000 kPa (3000...

Ö CHARGE PUMPFLOW TEST N CAUTION: TO AVOID INJURY FROM ESCAPING HYDRAULIC OIL UNDERPRESSURE, RELIEVE THE PRESSURE IN THESYSTEM BY STOPPING THE ENGINE ANDOPERATING ALL HYDRAULIC CONTROLVALVES. Make front outlet connections from JT01765Lawn and Grounds Care Products HydraulicFitting Kit and JT05469 Fl...

M36677 -UN-25JAN90 N CAUTION: USE EXTREME CAUTION WHEN PERFORMING THIS ADJUSTMENT BECAUSEDRIVE WHEELS ARE FREE TO SPIN ANDDRIVE SHAFT IS CLOSE TO TURNBUCKLE. Loosen lock nuts. Start and run engine at fast idle. Turn turnbuckle(A) as required until the drive wheels stopturning. Turn engine OFF. IMPOR...

Section 260 STEERING AND BRAKES CHECKOUT, OPERATION AND DIAGNOSIS Contents Page Group 05—Steering And Brakes System Checkout Before You Start . . . . . . . . . . . . . . . . . 260-05-1Steering System Oil Leak Check (318 and 420) . . . . . . . . . . . . . . . . . . . . . 260-05-1 Hydrostatic Steering...

BEFORE YOU START Always begin with this group to identify a failure inthe steering system. The step-by-step procedures willprovide you with a quick check of the system. Nospecial tools are required to perform these checks. Ifa failure is indicated you will be referred to a moredetailed check, adjust...

‘ HYDROSTATIC STEERING SYSTEM CHECK (318 AND 420) 2a Power SteeringCheck Start engine and run atfull throttle. M49195 -UN-02FEB90 Turn steering wheel fullleft, then full right. FEEL: Smooth,constant effort shouldbe felt. LOOK: Wheels muststop turning whensteering wheel isstopped. LOOK: Wheels mustmo...

Æ SERVICE PARK BRAKE CHECK 3a Park Brake LockLever Check M49000 -UN-08JAN90 Depress brake pedal(s)and engage servicepark brake lock. LOOK: Service parkbrake must remain inpark position. Disengage service parkbrake. Move park brake knobup and down. FEEL: Slight springpressure should be felt. OK: GO T...

Ö OPERATOR COMPLAINT NOT IDENTIFIED If you completed the checkout procedure and didnot isolate a malfunction, the problem may beintermittent. Try to duplicate the condition of the malfunctionidentified by the operator. Repeat systemcheckout in this group. IF A MALFUNCTION IS NOT IDENTIFIEDAFTER REPE...

STEERING VALVE/SYSTEM OPERATION—FIVE-PORT VALVE Function:Supply pressurized oil to the proper side of thesteering cylinder to turn the wheels, when the engineis running. Theory of Operation: NOTE: Right-hand turn shown. All external oil flow from the transmission is routedthrough the steering valve....

G WHEELS DO NOT HIT STOP • Check for bent steering linkage, cylinder or cylinder rod. H STEERING EFFORT IS ERRATIC • Bleed hydraulic system: See Section 270, Group 20. • Test for steering system leakage. GO TO Æ I WHEELS CONTINUE TURNING AFTER STEERING WHEEL IS STOPPED • Inspect valve plate for stic...

Æ STEERING SYSTEMLEAKAGE TEST Heat hydraulic oil to43˚C (110˚F). See ‘ in this group. Start engine and run atslow idle. M49198 -UN-20DEC89 With wheels in a maximum right position, turnsteering wheel with a constant torque of 6.8 N·m(60 lb-in.) for one minute. LOOK: Count the revolutions. RPM must no...

BEFORE YOU START Always begin with this group to identify a failure inthe hydraulic system. The step-by-step procedureswill provide you with a quick check of the system. Nospecial tools are required to perform these checks. Ifa failure is indicated, you will be referred to a moredetailed check, adju...

‘ HYDRAULIC CONTROL VALVE CHECK NOTE: 316; Single lever controls rockshaftcylinder and right-hand front outlets. 318 Levers;—Inside lever controls right-hand front outlets “float” and optional rear outlets.—Outside lever controls rockshaft cylinder and left-hand front outlets.. 420 Levers;—Inside le...

HYDRAULIC SYSTEM SCHEMATICS The hydraulic system schematics on the following pagescan be folded out for use while diagnosing malfunctionsor while repairing hydraulic components. MX,159027010,1 -19-24APR95 Group 10 Hydraulic Schematics TM1590 (17MAY95) 270-10-1 316, 318 & 420 Lawn and Garden Trac...

HYDRAULIC CIRCUIT SYMBOLS M81419AE -19 -19NOV92 NX,HYSYM -19-05APR94 Hydraulic Schematics/Hydraulic Circuit Symbols TM1590 (17MAY95) 270-10-2 316, 318 & 420 Lawn and Garden Tractors 020895 270 10 2

LEGEND FOR HYDRAULIC SYSTEM SCHEMATIC—316 1—Hydrostatic Transmission 6—Implement Relief Valve 11—Input (Pump) Shaft 14—Hydraulic Control Valve 2—Output (Motor) Shaft 7—Check (Freewheel) Valves 12—Control Valve Spool 15—Rockshaft Cylinder 3—Hydrostatic Drive Motor 8—Charge Pump (Three-Position) 16—Ri...

LEGEND FOR HYDRAULIC SYSTEM SCHEMATIC—EARLY 318 1—Hydrostatic Transmission 10—Variable Hydrostatic 17—Steering Valve (4-Port) 24—Front Hydraulic 2—Output (Motor) Shaft Pump 18—Check Valve Outlets—Right Side 3—Hydrostatic Drive Motor 11—Input (Pump) Shaft 19—Oil Cooler 25—Front Hydraulic 4—Transmissi...

LEGEND FOR HYDRAULIC SYSTEM SCHEMATIC—LATER 318 1—Hydrostatic Transmission 10—Variable Hydrostatic 17—Steering Valve (5-Port) 24—Front Hydraulic 2—Output (Motor) Shaft Pump 18—Check Valve Outlets—Right Side 3—Hydrostatic Drive Motor 11—Input (Pump) Shaft 19—Oil Cooler 25—Front Hydraulic 4—Transmissi...

LEGEND FOR HYDRAULIC SYSTEM SCHEMATIC—EARLY 420 1—Hydrostatic Transmission 10—Variable Hydrostatic 17—Steering Valve (4-Port) 24—Front Hydraulic 2—Output (Motor) Shaft Pump 18—Check Valve Outlets—Right Side 3—Hydrostatic Drive Motor 11—Input (Pump) Shaft 19—Oil Cooler 25—Front Hydraulic 4—Transmissi...

LEGEND FOR HYDRAULIC SYSTEM SCHEMATIC—LATER 420 1—Hydrostatic Transmission 10—Variable Hydrostatic 17—Steering Valve (5-Port) 24—Front Hydraulic 2—Output (Motor) Shaft Pump 18—Check Valve Outlets—Right Side 3—Hydrostatic Drive Motor 11—Input (Pump) Shaft 19—Oil Cooler 25—Front Hydraulic 4—Transmissi...

HYDRAULIC LIFT SYSTEMOPERATION—THREE-POSITION SPOOL Function:To control the flow of pressurized oil to the rockshaftcylinder or implement. Theory of Operation: NOTE: Lower position shown. On later 318 and 420 models, pressurized oil isrouted through the steering valve before reachingthe hydraulic co...

HYDRAULIC LIFT SYSTEMOPERATION—FOUR-POSITION SPOOL Function:To control the flow of pressurized oil to the implement. Theory of Operation: NOTE: Float position shown. On later 318 and 420 models, pressurized oil isrouted through the steering valve before reachingthe hydraulic control valve. This desi...

Å CONTROL VALVELEAKAGE TEST N CAUTION: TO AVOID INJURY FROM ESCAPING HYDRAULIC OIL UNDERPRESSURE, RELIEVE THE PRESSURE IN THESYSTEM BY STOPPING THE ENGINE ANDOPERATING ALL HYDRAULIC CONTROLVALVES. IMPORTANT: To avoid putting full pump flowinto container, DO NOT return control valvelever to “neutral”...

Ö BLEED HYDRAULIC SYSTEM After installing a repaired or replacement part, follow this run-in procedure to assure that air is purged fromthe 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...

Section 299 DEALER FABRICATED TOOLS Contents Page Group 00—Dealer Fabricated ToolsDFMX1 Steering Valve Fixture . . . . . . . . 299-00-1DFMX2 Alignment Shims . . . . . . . . . . . . 299-00-1 TM1590 (17MAY95) 299-1 316, 318 & 420 Lawn and Garden Tractors 020895 299

DFMX1 STEERING VALVE FIXTURE Steering valve fixture is used to hold steering valveduring disassemby and assembly procedures. Material required: One piece of 5 x 102 x 203 mm (3/16x 4 x 8 in.) 1020 mild steel flat stock. 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 ...

Dealer Fabricated Tools/DFMX2 Alignment Shims TM1590 (17MAY95) 299-00-2 316, 318 & 420 Lawn and Garden Tractors 020895 299 00 2

Page A Alternator, Tests . . . . . . . . . . . . . . . . . 240-25-5 B Battery, Charge and Test . . . . . . . . . . . 240-20-1Bleed Hydraulic System . . . . . . . . . . . . 270-20-8Brake Neutral Start Check . . . . . . . . . . . . . . . . . . . . . . . 240-05-3Safety Switch, Test . . . . . . . . . . ...