MODEL: 316, 318, & 420 Lawn & Garden Tractors

Transcription

1 John Deere MODEL: 316, 318, & 420 Lawn & Garden Tractors THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF JOHN DEERE OR IT'S SUCCESSORS. JOHN DEERE AND IT'S SUCCESSORS ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL. TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS, AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS. JD-S-

2 316, 318 and 420. Lawn and Garden Tractors John Deere Lawn & Grounds Care Division LITHO IN U.S.A. ENGLISH

3 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 20-ENGINE REPAIR Group 05-Engine SECTION 40-ELECTRICAL REPAIR Group 05-Front PTO Clutch SECTION 50-POWER TRAIN REPAIR Group 05-Transmission Group 10-Transmission Control Linkage Group 15-Differential Group 20-Rear Axles Group 25-Drive Shaft SECTION 60-STEERING AND BRAKE REPAIR Group 05-Steering-316 Groap 06-Steering-318 and 420 Group 10-Brakes SECTION 70-HYDRAULIC REPAIR Group 05-Hydraulic Control Valve SECTION SO-MISCELLANEOUS REPAIR Group 05-Front Axle Group 10-Mower Spindle and Jack Sheave Repair Group 15-Mower Gear Case Repair Group 15-Component Location and Operation Group 20-Electrical System Diagnosis Group 25-Electrical System Component Tests and Adjustments SECTION 250-POWER TRAIN CHECKOUT, OPERATION AND DIAGNOSIS Group 05-Power Train Checkout Group 10-Theory of Operation Group 15-Diagnosis, Tests and Adjustments SECTION 260-5TEERING AND BRAKES CHECKOUT, OPERATION AND DIAGNOSIS Group 05-Steering And Brakes System Checkout Group 10-Theory of Operation Group 15-Diagnosis, Tests and Adjustments SECTION 270-HYDRAULIC SYSTEM CHECKOUT, OPERATION AND DIAGNOSIS Group 05-Hydraulic System Checkout Group 10-Hydraulic Schematics Group 15-Theory of Operation Group 20-Diagnosis, Tests and Adjustments SECTION 299-DEALER FABRICATED TOOLS Group OO-Dealer Fabricated Tools Index SECTION 220-ENGINE, FUEL AND AIR SYSTEM CHECKOUT AND DIAGNOSIS Group 05-Engine, Fuel and Air System Checkout Group 10-Diagnosis, Tests and Adjustments SECTION 240-ELECTRICAL CHECKOUT, OPERATION AND DIAGNOSIS Group 05-Electrical System Checkout Group 10-Electrical Schematics 316, 318 & 420 Lawn and Garden Tractors

4 Section 10 GENERAL INFORMATION Group 05-Safety Group 10-General Specifications Machine Specifications Group 15-Repair Specifications Repair Specifications Metric Series Torque Chart I nch Series Torque Chart Metric Torque Values-Grade Set Screw Torque Chart Service Recommendations a-ring Boss Fittings Flat Face a-ring Seal Fittings Tube and Hose Fitting, 37" Flare and 30 0 Cone Seat Connectors Group 20-Test and Adjustment Specifications Group 25-Fuels and Lubricants Fuel Storing Fuel Engine Oil Transmission and Hydraulic Oil Grease Mower Deck Gear Case Oil Alternative and Synthetic Lubricants Lubricant Storage Mixing of Lubricants Group 30-Serial Number Locations Serial Numbers Product Identification Engine Transmission Differential Control Valve , 318 & 420 Lawn and Garden Tractors

5 General Specifications/Machine Specifications PTO Front... Standard... Standard... Standard Rear... Optional... Optional... Optional Type... Electric Clutch... Electric Clutch... Electric Clutch Control... Elec. Switch on Dash.. Elec. Switch on Dash.. Elec. Switch on Dash PTO rpm (No Load) Front Rear MOWER ATTACHMENT Compatibility... 38, 46 and 50 Inch... 38, 46 and 50 Inch and 60 Inch 260 Rotary Rotary Lift System... Hydraulic... Hydraulic... Hydraulic WHEEL TREAD Front mm (32 in.) mm (32 in.) mm (36 in.) Rear Narrow mm (30.5 in.) mm (30.5 in.) mm (32 in.) Wide mm (32.8 in.) mm (32.8 in.) mm (38.6 in.) TIRES Standard Tires Front Turf x , 2 PR x , 2 PR x , 4 PR Rear Turf or Bar x , 2 PR x , 2 PR x , 2 PR Optional Tires Front (Turf) x , 4 PR x , 4 PR... NI A Rear (Turf or Bar) x , 2 PR x , 2 PR... NI A I nflation Pressure Front kpa (6-16 psi) kpa (6-16 psi) kpa (6-22 psi) Rear kpa (5-10 psi) kpa (5-10 psi) kpa (5-10 psi) SEAT Style... High-Back... High-Back... High-Back Suspension... 2 Spring... 2 Spring... 2 Spring Adjustment... Slide Rail... Slide Rail... Slide Rail DIMENSIONS Wheel Base m (46 in.) m (46 in.) m (52 in.) Overall Length m (69.5 in.) m (69.5 in.) m (77 in.) Overall Height m (44.5 in.) m (44.5 in.) m (47.5 in.) Overall Width (max.) m (43.3 in.) m (43.3 in.) m (51.5 in.) Overall Width (min.) m (41 in.) m (41 in.) m (45 in.) Turning Radius Inside Rear Wheel mm (26 in.) mm (26 in.) mm (26 in.) Outside Front Wheel m (80 in.) m (80 in.) m (86 in.) NET WEIGHT (No Fuel) kg (780 Ibs) kg (780 Ibs) kg (913 Ibs) SHIPPING WEIGHT kg (852 Ibs) kg (852 Ibs) kg (993 Ibs) (Specifications and design subject to change without notice.) , 318 & 420 Lawn and Garden Tractors

6 Section 20 ENGINE REPAIR Group 05-Engine Repair-Use CTM2 Remove and Install , 318 & 420 Lawn and Garden Tractors

7 Section 40 ELECTRICAL REPAIR Group OS-Front PTO Clutch Remove Disassemble, Inspect and Assemble Install , 318 & 420 Lawn and Garden Tractors

8 Section 50 POWER TRAIN REPAIR 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 Install Transmission Group 25-0rive Shaft Other Materials Remove and Install Remove and Install-318 and Disassemble and Inspect Assemble Group 10-Transmission Control Linkage Inspect and Repair Control Linkage Version One Version Two-316 and Version Two Version Three Version Four Differential Lock and Two-Speed Control Linkage (420) Group 15-0ifferential Other Materials Service Parts Kits Remove and Install Disassemble and Inspect Assemble Group 20-Rear Axles Other Materials Remove Install , 318 & 420 Lawn and Garden Tractors

9 Transmission/Disassemble 5. Inspect both cylinder blocks. Check ball guide area (A) for scoring, wear and damage. Check nine cylinder bores (8) for burrs and scoring. Check lapped surface (C) for wear and damage. Check spring assembly (D) for damage and free movement. If any part of the cylinder block is damaged, the cylinder block assembly must be replaced JAN85 IMPORTANT: Do not scratch machined surfaces of thrust plates or swashplates. 6. Remove pump and motor thrust plates using a brass O-ring pick. 7. Inspect thrust plates. Check plates for scoring and smeared bronze material. M45,5005A, JAN85 DISASSEMBLE PUMP AND MOTOR HOUSING 1. Remove snap ring and washer (A) from both trunnion and control shafts MX, ,22 316, 318 & 420 Lawn and Garden Tractors

10 Section 60 STEERING AND BRAKE REPAIR Group OS-Steering-316 Special or Essential Tools Service Parts Kits Gearbox Remove and Install Disassemble and Inspect Assemble Group 06-Steering-318 and 420 Other Materials Service Parts Kits Steering Valve Remove and Install Disassemble and Inspect Assemble Steering Cylinder Remove and Install Group 10-Brakes Other Materials Brakes Remove Install Adjust Brake Pedal(s) and Neutral Return Linkage Inspect and Repair Inspect and Repair Inspect and Repair Inspect and Repair Park Brake Lever , 318 & 420 Lawn and Garden Tractors

11 Section 70 HYDRAULIC REPAIR Group 05-Hydraulic Control Valve Other Materials Service Parts Kits Remove and Install 316 and Disassemble, Inspect and Assemble Single-Spool Two-Spool Three-Spool , 318 & 420 Lawn and Garden Tractors

12 Hydraulic Control Valve/Disassemble, Inspect and Assemble A-Check Valve Plug (3 used) B-O-Ring (3 used) C-Spring (3 used) D-Poppet (3 used) E-Spools and Body F-Q-Ring (6 used) G-Washer (4 used) H-Spring (2 used) l-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-Sprlng Version Four IMPORTANT: Spools and body are matched and must be replaced as a unit. Spools must be installed into the same bores from which they were removed for proper operation of each function. Always use new O-rings. Damaged or used parts will leak. NOTE: Note location and position of fittings and linkages to aid in assembly. Lubricate all a-rings with petroleum jelly during assembly. Apply clean John Deere Low Viscosity HY-GARD oil on all internal parts during assembly. Clean threads in end of spools, detent (0) and screws (J) using Clean and Cure Primer. Apply thread lock and sealer (medium strength) on threads of detent (0) and screws (J). Apply MPG-2 Multi-Purpose Polymer Grease on springs (H and S) and inside of caps (K and P). Tighten detent (0), screws (J), screw and washers (L) and plugs (A) to specifications. TORQUE SPECIFICATIONS Inspect all parts for wear or damage. Replace as necessary. Detent (Q), Screws (J) and Screw and Washers (L) 0 Plugs (A) 0 Nom (35 Ib-ino) Nom (23 Ib-ft) , 318 & 420 Lawn and Garden Tractors

13 Section 80 MISCELLANEOUS REPAIR 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 Inspect and Replace Wheel Bearings. " Adjust Toe-in Group 10-Mower Spindle and Jack Sheave Repair Mower Blade Spindles 38 (Early), 46 and 50-Inch Mower lnch Mower (Later) Early 60-lnch and 260 Rotary Mower Later 60-lnch and 260 Rotary Mower Mower Blade Jack Sheaves 46 and 50-Inch Mower Group 15-Mower Gear Case Repair Other Materials Inch Mower Disassemble and Inspect Assemble Early 60-lnch Mower (Curtis) Disassemble and Inspect Assemble " Later 60-lnch Mower (Peerless) Disassemble and Inspect... " Assemble Rotary Mower Disassemble and Inspect Assemble , 318 & 420 Lawn and Garden Tractors

14 L~ ----~ Section 220 ENGINE, FUEL AND AIR SYSTEM CHECKOUT AND DIAGNOSIS Group OS-Engine, Fuel and Air System 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 Group 10-Diagnosis, Tests and Adjustments AboutJhis Group Troubleshooting Guide Ignition Spark Test Throttle Cable Adjustment Choke Cable Adjustment Idle Mixture and Speed Adjustment Governor Linkage Adjustment Dashpot Adjustment (B43E, B43G and B48G)..., Fuel Filter Test Fuel Transfer Pump Test Crankcase Vacuum Test Timing Adjustment (B43E, B43G and B48G) Compression Pressure Test Engi ne Oi I Pressu re Test Oil Pressure Regulating Valve Check Throttle Lever Adjustment ,318 & 420 Lawn and Garden Tractors

15 Section 240 ELECTRICAL CHECKOUT, OPERATION AND DIAGNOSIS Group OS-Electrical System Checkout Before You Start Dash Lamp Circuit Check Starting Circuit Check Ignition Circuit (Spark) Check PTO Clutch and LampCheck Brake Neutral Start Check Transmission Neutral Start Check PTO Neutral Start Check Seat Switch Check for PTO Seat Switch Check for Ignition Hour Meter Check Lighting Check Operator Complaint Not Identified Group 10-Electrical Schematics Single PTO Dual PTO Seat Switch Test For Ignition Time Delay Hour Meter Circuit Test Lighting Test Group 2S-Electrical System Component Tests and Adjustments Before You Start..., Key Switch Test Circuit Breaker Test Starter Tests..., Alternator and Regulator/Rectifier Tests PTO Clutch Adjustment Check System Short Circuit Tests 20-Amp Fuse or 3-Amp Fuses Group 1S-Component Location and Operation Electrical Component Location Theory of Operation Starting Circuit Ignition Circuit PTO Circuit Charging Circuit Engine Oil Pressure Lamp Circuit Group 20-Electrical System Diagnosis About This Group Verify System Grounds Battery Tests Dash Lamp Circuit Tests Starting Circuit Tests Ignition Circuit Tests PTO Clutch and Lamp Tests Brake Neutral Start Safety Switch Test Transmission Neutral Start Safety Switch Test PTO Neutral Start Safety Switch Test Seat Switch Test For PTO Time Delay ,318 & 420 Lawn and Garden Tractors

16 Section 250 POWER TRAIN CHECKOUT, OPERATION AND DIAGNOSIS Group OS-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 Two-Speed Axle Lever Linkage Check (420) Differential Lock Linkage Check (420) Group 10-Theory of Operation Hydrostatic Transmission Operation Group 1S-Diagnosis, Tests and Adjustments About This Group Troubleshooting Guide Check Valve Debris Check Charge Pump Pressure Test Suction Li ne Check Charge Relief Valve Check Adjustment Implement Relief Valve Pressure Test Check Adjustment Charge Pump Flow Test Welch Plug Location Check Hydraulic Oil Warm-Up Procedure Steering Valve Neutral Check (318 and 420) Hydrostatic Lever Friction Adjustment Neutral Return Linkage Adjustment (Early Models) Neutral Adjustment (Early Models) Neutral and Neutral Return Linkage Adjustment (Later Models) , 318 & 420 Lawn and Garden Tractors

17 Section 260 STEERING AND BRAKES CHECKOUT, OPERATION AND DIAGNOSIS Group OS-5teering 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 Group 10-Theory of Operation Steering Valve/System Operation Four-Port Valve ~1 Five-Port Valve Group 1S-Diagnosis, Tests and Adjustments About This Group Troubleshooting Guide Hydraulic Oil Warm-up Procedure Steering System Leakage Test Steering Valve Leakage Test , 318 & 420 Lawn and Garden Tractors

18 Section 270 HYDRAULIC SYSTEM CHECKOUT, OPERATION AND DIAGNOSIS 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 Early Later Early Later Group 15-Theory of Operation Hydraulic Lift System Operation Three-Position Spool Four-Position Spool...' Group 20-Diagnosis, Tests and Adjustments About This Group Troubleshooting Guide Hydraulic Oil Warm-Up Procedure Rockshaft Cylinder Leakage Test Control Valve Leakage Test Bleed Hydraulic System , 318 & 420 Lawn and Garden Tractors

19 Index A Alternator, Tests B Battery, Charge and Test Bleed Hydraulic System Brake Neutral Start Check Safety Switch, Test Brake Pedal Linkage Brakes Adjust Install Remove c Ch~lrge Pump Assemble Disassemble and Inspect Flow Test Pressure Test Remove and Install Suction Line Check Charge Relief Valve Adjustment Check Remove and Install Check Valve Debris Check Choke Cable Adjustment Choke Lever Check Circuit Breaker, Test Crankcase Vacuum Test o Dash Lamp Circuit Check Tests Dashpot Adjustment (B43E, B43G and B48G) Dealer Fabricated Tools DFMX1 Steering Valve Fixture DFMX2 Alignment Shims Differential Assemble Disassemble and Inspect Remove and Install Differential Lock (420) Check Linkage Check Differential Lock Linkage (420) Drive Shaft Assemble Disassemble and Inspect Remove and Install Remove and Install-318 and E Electrical Component Location Electrical Schematics Dual PTa Single PTa Electrical System Grounds, Verify Electrical-Theory Of Operation Charging Circuit Engine Oil Pressure Lamp Circuit Ignition Circuit PTa Circuit Starting Circuit Engine Compression Pressure Test Oil Oil and Leak Check Oil Pressure Check Oil Pressure Test Performance Check Remove and install Repair Start Check Troubleshooting F Front Axle Spindles I nspect and Replace Bushings Remove and Install Front Axle-316 and 318 Inspect and Replace Pivot Bushings Remove and Install Index-1

20 Index 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 Storage Fuel Filter Test Fuel Leak Check Fuel Transfer Pump Test G Gasoline fuel Governor Linkage Adjustment Grease Extreme pressure and multipurpose H Hour Meter Check Circuit Test Hydraulic circuit symbols Hydraulic Control Valve Assemble-Single-Spool Assemble-Three-Spool Assemble-Two-Spool Disassemble & Inspect-Single-Spool Disassemble & I nspect-three-spool Disassemble & Inspect-Two-Spool Leakage Test Remove and Install-316 and Remove and Install Hydraulic oil Hydraulic Oil Warm-Up Procedure , , Hydraulic Schematics Early Early Hydraulic Schematics-Continued Later Later Hydraulic System Bleed Procedure Checkout Control Valve Leakage Test Rockshaft Cylinder Leakage Test Troubleshooting Hydraulics-Lift System Operation Four-Position Spool Three-Position Spool Hydrostatic Lever Friction Adjustment Friction Check Idle Mixture and Speed Adjustment Ignition Seat Switch Time Delay, Test Seat Switch, Check Ignition Circuit Tests Ignition Circuit (Spark) Check Ignition Spark Test Implement Relief Valve Adjustment Check Pressure Test Remove and Install I nch torque values K Key Switch Test L Lamp Circuit, Dash Check Tests Leakage Test Hydraulic Control Valve Rockshaft Cylinder Lighting Check Test Index-2

21 Index I Lubricant Alternative Mixing Storage Synthetic Oil Engine Hydraulic Mower Deck Gear Case Transmission Oil Pressure Regulating Valve Check M Machine Specifications Metric torque values Mixing lubricants Mower Blade Jack Sheaves 46 and 50-1 nch Mower Mower Blade Spindles Early 60-lnch and 260 Rotary Mower Later 60-1 nch and 260 Rotary Mower (Early), 46 and 50-Inch Mower nch Mower (Later) Mower Deck Gear Case Oil Mower Gear Case-Early 60-lnch Assemble Disassemble and Inspect Mower Gear Case-Later 60-lnch Assemble Disassemble and Inspect Mower Gear Case-260 Rotary Mower Assemble Disassemble and Inspect Mower Gear Case-50-lnch Assemble Disassemble and Inspect p Park Brake Lever, Inspect and Repair PTO Clutch and Lamp Check Tests PTO Clutch, Front Clutch Adjustment, Check Disassemble, Inspect and Assemble Install Remove Seat Switch Time Delay, Test Seat Switch, Check PTO Neutral Start Check Safety Switch, Test R Rear Axle Install Remove Regulator/Rectifier, Tests Repair specifications Rockshaft Cylinder Leakage Test N Neutral Adjustment Early Models Later Models Neutral Return Check Neutral Return Linkage Neutral Return Linkage Adjustment Early Models Later Models o O-ring boss fittings s Seat Switch Ignition Time Delay, Test Ignition, Check PTO Time Delay, Test PTO, Check..., Serial Numbers Control Valve Differential Engine Product Identification Transmission Service Park Brake Check Short Circuit Test 2 or 3-Amp Fuses..., Amp Fuse..., Index-3

22 Index Specifications Machine Repair Test and Adjustment Speed Reduction Check (318 and 420) 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 Steering Gearbox-316 Assemble Disassemble and Inspect... " Remove and Install Steering Shaft-316 Assemble Disassemble and Inspect Remove and Install Steering System Check (318 and 420) Leakage Test Oil Leak Check (318 and 420) T roubleshooti ng Steering Valve/System Operation Five-Port Valve Four-Port Valve Steering Valve-318 and 420 Assemble Disassemble and Inspect Leakage Test Neutral Check Remove and Install Storing lubricants Synthetic Lubricants Torque values Inch Metric Metric-Grade Transmission Assemble Cover Assemble Pump and Motor Assemble Pump and Motor Housing Disassemble Cover Disassemble Pump and Motor Disassemble Pump and Motor Housing Drive Check Install Neutral Check Oil Leak Check Remove..., Theory of Operation Troubleshooting Transmission Control Linkage Version Four Version One Version Three Version Two-316 and Version Two Transmission Neutral Start Check Safety Switch, Test Transmission oil Turn Brake Check (318 and 420) Two-Speed Axle (420) Lever Check Lever Linkage Check Two-Speed Control Linkage (420) W Welch Plug Location Check Wheel Bearings, Inspect and Replace T Test and Adjustment Specifications Throttle Cable Adjustment Throttle Lever Adjustment Throttle Lever Check Timing Adjustment (B43E, B43G and B48G) Toe-In, Adjust Torque value O-Ring boss fitting Index-4