John Deere 318 318 420 Lawn &Garden Service Information Manual – PDF DOWNLOAD
DESCRIPTION:
TM1590 (17MAY95)
John Deere 318 318 420 Lawn &Garden Service Information Manual – PDF DOWNLOAD
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. Technical manuals are divided in two parts: repair and diagnostics. Repair sections tell how to repair the components.
- Diagnostic sections help you identify the majority of routine failures quickly. Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, other materials needed to do the job and service parts kits. Section 10, Group 15—Repair Specifications, consist of all applicable specifications, near tolerances and specific torque values for various components on each individual machine.
- Section 10, Group 20—Test and Adjustment Specifications, consist of all applicable test and adjustment specifications for various systems for each individual machine. Binders, binder labels, and tab sets can be ordered by John Deere dealers direct from the John Deere Distribution Service Center. This manual is part of a total product support program. FOS MANUALS—REFERENCE TECHNICAL MANUALS—MACHINE SERVICE COMPONENT MANUALS—COMPONENT SERVICE Fundamentals of Service (FOS) Manuals cover basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.
- FOS Manuals are for training new personnel and for reference by experienced technicians. Technical Manuals are concise guides for specific machines. Technical manuals are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair. Component Technical Manuals are concise service guides for specific components. Component technical manuals are written as stand-alone manuals covering multiple machine applications
TABLE OF CONTENTS:
John Deere 318 318 420 Lawn &Garden Service Information Manual – PDF DOWNLOAD
TM1590 – 316,318,420 Lawn & Garden Tractors 1
CONTENTS 2
Section 10 – GENERAL INFORMATION 9
Safety 11
RECOGNIZE SAFETY INFORMATION 11
UNDERSTAND SIGNAL WORDS 11
FOLLOW SAFETY INSTRUCTIONS 11
HANDLE FLUIDS SAFELY—AVOID FIRES 12
PREVENT BATTERY EXPLOSIONS 12
PREPARE FOR EMERGENCIES 12
PREVENT ACID BURNS 13
HANDLE CHEMICAL PRODUCTS SAFELY 14
AVOID HIGH-PRESSURE FLUIDS 14
PREPARE MACHINE FOR REPAIR 15
SUPPORT MACHINE PROPERLY 15
WEAR PROTECTIVE CLOTHING 16
WORK IN CLEAN AREA 16
SERVICE MACHINES SAFELY 16
WORK IN VENTILATED AREA 17
ILLUMINATE WORK AREA SAFELY 17
REPLACE SAFETY SIGNS 17
USE PROPER LIFTING EQUIPMENT 17
REMOVE PAINT BEFORE WELDING OR HEATING 18
AVOID HEATING NEAR PRESSURIZED FLUID LINES 18
SERVICE TIRES SAFELY 19
AVOID HARMFUL ASBESTOS DUST 19
PRACTICE SAFE MAINTENANCE 20
USE PROPER TOOLS 20
DISPOSE OF WASTE PROPERLY 21
LIVE WITH SAFETY 21
General Specifications 23
MACHINE SPECIFICATIONS 23
Repair Specifications 27
REPAIR SPECIFICATIONS 27
METRIC BOLT AND CAP SCREW TORQUE VALUES 30
UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUES 31
METRIC CAP SCREW TORQUE VALUES—GRADE 7 32
SERVICE RECOMMENDATIONS FOR O-RING BOSS FITTINGS 33
SERVICE RECOMMENDATIONS FOR FLAT FACE O-RING SEAL FITTINGS 34
TUBE AND HOSE FITTING, 37 FLARE AND 30 CONE SEAT CONNECTOR SERVICE RECOMMENDATIONS 35
Test and Adjustment Specifications 37
TEST AND ADJUSTMENT SPECIFICATIONS 37
Fuels and Lubricants 39
FUEL 39
STORING FUEL 39
ENGINE OIL 40
TRANSMISSION AND HYDRAULIC OIL 41
GREASE 42
MOWER DECK GEAR CASE OIL 42
ALTERNATIVE AND SYNTHETIC LUBRICANTS 43
LUBRICANT STORAGE 43
MIXING OF LUBRICANTS 43
Serial Number Locations 45
SERIAL NUMBERS 45
PRODUCT IDENTIFICATION NUMBER 45
ENGINE SERIAL NUMBER 45
TRANSMISSION SERIAL NUMBER 45
DIFFERENTIAL SERIAL NUMBER 46
CONTROL VALVE SERIAL NUMBER 46
Section 20 – ENGINE REPAIR 47
Engine 49
ONAN ENGINE REPAIR—USE CTM2 49
REMOVE AND INSTALL ENGINE 49
Section 40 – ELECTRICAL REPAIR 51
Front PTO Clutch 53
REMOVE FRONT PTO CLUTCH 53
DISASSEMBLE, INSPECT AND ASSEMBLE FRONT PTO CLUTCH 54
INSTALL FRONT PTO CLUTCH 56
Section 50 – POWER TRAIN REPAIR 59
Transmission 61
SERVICE PARTS KITS 61
REMOVE AND INSTALL CHARGE PUMP 62
DISASSEMBLE AND INSPECT CHARGE PUMP 63
ASSEMBLE CHARGE PUMP 64
REMOVE AND INSTALL CHARGE RELIEF VALVE 65
REMOVE AND INSTALL IMPLEMENT RELIEF VALVE 66
REMOVE TRANSMISSION 66
DISASSEMBLE TRANSMISSION COVER 71
DISASSEMBLE PUMP AND MOTOR 74
DISASSEMBLE PUMP AND MOTOR HOUSING 76
ASSEMBLE PUMP AND MOTOR HOUSING 79
ASSEMBLE PUMP AND MOTOR 81
ASSEMBLE TRANSMISSION COVER 82
INSTALL TRANSMISSION 85
Transmission Control Linkage 91
INSPECT AND REPAIR TRANSMISSION CONTROL LINKAGE—VERSION ONE (ALL MODELS) 91
INSPECT AND REPAIR TRANSMISSION CONTROL LINKAGE—VERSION TWO (316 AND 318) 92
INSPECT AND REPAIR TRANSMISSION CONTROL LINKAGE—VERSION TWO (420) 93
INSPECT AND REPAIR TRANSMISSION CONTROL LINKAGE—VERSION THREE (ALL MODELS) 94
INSPECT AND REPAIR TRANSMISSION CONTROL LINKAGE—VERSION FOUR (ALL MODELS) 95
INSPECT AND REPAIR DIFFERENTIAL LOCK AND TWO-SPEED CONTROL LINKAGE (420) 96
Differential 97
SERVICE PARTS KITS 97
REMOVE AND INSTALL DIFFERENTIAL 98
DISASSEMBLE AND INSPECT DIFFERENTIAL 98
ASSEMBLE DIFFERENTIAL108
Rear Axles 117
REMOVE AXLE117
INSTALL AXLE120
Drive Shaft 125
REMOVE AND INSTALL DRIVE SHAFT—316125
REMOVE AND INSTALL DRIVE SHAFT—318 AND 420126
DISASSEMBLE AND INSPECT DRIVE SHAFT127
ASSEMBLE DRIVE SHAFT128
Section 60 – STEERING AND BRAKE REPAIR 131
Steering¯316 133
SPECIAL OR ESSENTIAL TOOLS133
SERVICE PARTS KITS133
REMOVE AND INSTALL STEERING GEARBOX AND SHAFT134
DISASSEMBLE AND INSPECT STEERING GEARBOX AND SHAFT138
ASSEMBLE STEERING GEARBOX AND SHAFT144
Steering¯318 and 420 151
SERVICE PARTS KITS151
REMOVE AND INSTALL STEERING VALVE AND COLUMN152
DISASSEMBLE AND INSPECT STEERING VALVE AND COLUMN153
ASSEMBLE STEERING VALVE AND COLUMN162
REMOVE AND INSTALL STEERING CYLINDER172
Brakes 173
REMOVE BRAKES174
INSTALL BRAKES177
ADJUST BRAKES179
INSPECT AND REPAIR BRAKE PEDAL AND NEUTRAL RETURN LINKAGE—316180
INSPECT AND REPAIR BRAKE PEDALS AND NEUTRAL RETURN LINKAGE—318185
INSPECT AND REPAIR BRAKE PEDALS AND NEUTRAL RETURN LINKAGE—420191
INSPECT AND REPAIR PARK BRAKE LEVER196
Section 70 – HYDRAULIC REPAIR 197
Hydraulic Control Valve 199
SERVICE PARTS KITS199
REMOVE AND INSTALL HYDRAULIC CONTROL VALVE—316 AND 318200
REMOVE AND INSTALL HYDRAULIC CONTROL VALVE—420202
DISASSEMBLE, INSPECT AND ASSEMBLE HYDRAULIC CONTROL VALVE—SINGLE-SPOOL203
DISASSEMBLE, INSPECT AND ASSEMBLE HYDRAULIC CONTROL VALVE—TWO-SPOOL204
DISASSEMBLE, INSPECT AND ASSEMBLE HYDRAULIC CONTROL VALVE—THREE-SPOOL207
Section 80 – MISCELLANEOUS REPAIR 209
Front Axle 211
SPECIAL OR ESSENTIAL TOOLS211
REMOVE AND INSTALL FRONT AXLE—316 AND 318211
INSPECT AND REPLACE PIVOT BUSHINGS—316 AND 318212
REMOVE FRONT AXLE—420212
DISASSEMBLE AND INSPECT PIVOT PIN—420214
ASSEMBLE PIVOT PIN—420216
INSTALL FRONT AXLE—420217
REMOVE AND INSTALL SPINDLES219
INSPECT AND REPLACE SPINDLE BUSHINGS221
INSPECT AND REPLACE WHEEL BEARINGS222
ADJUST TOE-IN222
Mower Spindle and Jack Sheave Repair 225
SERVICE MOWER BLADE SPINDLES—38 (EARLY), 46 AND 50-INCH MOWER225
SERVICE MOWER BLADE SPINDLES—38-INCH MOWER (LATER)225
SERVICE MOWER BLADE SPINDLES—EARLY 60-INCH AND 260 ROTARY MOWER226
SERVICE MOWER BLADE SPINDLES—LATER 60-INCH AND 260 ROTARY MOWER227
SERVICE MOWER BLADE JACK SHEAVES—46 AND 50-INCH MOWER228
Mower Gear Case Repair 229
DISASSEMBLE AND INSPECT MOWER GEAR CASE—50-INCH MOWER229
ASSEMBLE MOWER GEAR CASE—50-INCH MOWER234
DISASSEMBLE AND INSPECT MOWER GEAR CASE—EARLY 60-INCH MOWER (CURTIS)238
ASSEMBLE MOWER GEAR CASE—EARLY 60-INCH MOWER (CURTIS)242
DISASSEMBLE AND INSPECT MOWER GEAR CASE—LATER 60-INCH MOWER (PEERLESS)247
ASSEMBLE MOWER GEAR CASE—LATER 60-INCH MOWER (PEERLESS)251
DISASSEMBLE AND INSPECT MOWER GEAR CASE—260 ROTARY MOWER255
ASSEMBLE MOWER GEAR CASE—260 ROTARY MOWER260
Section 220 – ENGINE, FUEL AND AIR SYSTEM CHECKOUT AND DIAGNOSIS 265
Engine, Fuel and Air System Checkout 267
BEFORE YOU START267
Diagnosis, Tests and Adjustments 271
ABOUT THIS GROUP271
Section 240 – ELECTRICAL CHECKOUT, OPERATION AND DIAGNOSIS 285
Electrical System Checkout 287
BEFORE YOU START287
Electrical Schematics 293
316, 318 AND 420 ELECTRICAL SCHEMATIC—SINGLE PTO294
316, 318 AND 420 ELECTRICAL SCHEMATIC—DUAL PTO301
Component Location and Operation 303
ELECTRICAL COMPONENT LOCATION303
STARTING CIRCUIT OPERATION304
IGNITION CIRCUIT OPERATION306
PTO CIRCUIT OPERATION308
CHARGING CIRUIT OPERATION310
OIL PRESSURE LAMP CIRCUIT OPERATION312
Electrical System Diagnosis 313
ABOUT THIS GROUP313
Electrical System Component Tests and Adjustments 341
BEFORE YOU START341
Section 250 – POWER TRAIN CHECKOUT, OPERATION AND DIAGNOSIS 351
Power Train Checkout 353
BEFORE YOU START353
Theory of Operation 357
HYDROSTATIC TRANSMISSION OPERATION358
Diagnosis, Tests and Adjustments 361
Troubleshooting Guide361
charge pressure test366
implement relief pressure test367
charge pump flow test368
steering valve neutral check369
hydro neutral return linkage adjustment370
later version hydro neutral return adjustment374
2 speed linkage check377
differential lock linkage check377
Section 260 – STEERING AND BRAKES CHECKOUT, OPERATION AND DIAGNOSIS 379
Steering And Brakes System Checkout 381
BEFORE YOU START381
Theory of Operation 385
STEERING VALVE/SYSTEM OPERATION—FOUR-PORT VALVE385
STEERING VALVE/SYSTEM OPERATION—FIVE-PORT VALVE386
Diagnosis, Tests and Adjustments 389
Troubleshooting guide389
steering system leakage test393
Section 270 – HYDRAULIC SYSTEM CHECKOUT, OPERATION AND DIAGNOSIS 395
Hydraulic System Checkout 397
hydraulic control valve check398
Hydraulic Schematics 399
HYDRAULIC SYSTEM SCHEMATICS399
HYDRAULIC CIRCUIT SYMBOLS400
LEGEND FOR HYDRAULIC SYSTEM SCHEMATIC—316402
LEGEND FOR HYDRAULIC SYSTEM SCHEMATIC—EARLY 318409
LEGEND FOR HYDRAULIC SYSTEM SCHEMATIC—LATER 318410
LEGEND FOR HYDRAULIC SYSTEM SCHEMATIC—EARLY 420417
LEGEND FOR HYDRAULIC SYSTEM SCHEMATIC—LATER 420418
Theory of Operation 423
HYDRAULIC LIFT SYSTEM OPERATION—THREE-POSITION SPOOL423
HYDRAULIC LIFT SYSTEM OPERATION—FOUR-POSITION SPOOL424
Diagnosis, Tests and Adjustments 425
Troubleshooting guide426
rockshaft cylinder leakage test429
control valve leakage test430
test implement relief pressure431
bleed hydraulic system432
Section 299 – DEALER FABRICATED TOOLS 433
Dealer Fabricated Tools 435
DFMX1 STEERING VALVE FIXTURE435
DFMX2 ALIGNMENT SHIMS435
Index437
A437
Alternator, Tests 345
B437
Battery, Charge and Test 313
Bleed Hydraulic System 432
Brake Neutral Start 289
Check 289
Safety Switch, Test 337
Brake Pedal Linkage 180
316 180
318 185
420 191
Brakes 179
Adjust 179
Install 177
Remove 174
C437
Charge Pump 64
Assemble 64
Disassemble and Inspect 63
Flow Test 368
Pressure Test 365
Remove and Install 62
Suction Line Check 366
Charge Relief Valve 366
Adjustment 366
Check 366
Remove and Install 65
Check Valve Debris Check 365
Choke Cable Adjustment 277
Choke Lever Check 268
Circuit Breaker, Test 341
Crankcase Vacuum Test 281
D437
Dash Lamp Circuit 287
Check 287
Tests 316
Dashpot Adjustment (B43E, B43G and B48G) 279
Dealer Fabricated Tools 435
DFMX1 Steering Valve Fixture 435
DFMX2 Alignment Shims 435
Differential 108
Assemble 108
Disassemble and Inspect 98
Remove and Install 98
Differential Lock (420) 355
Check 355
Linkage Check 377
Differential Lock Linkage (420) 96
Drive Shaft 128
Assemble 128
Disassemble and Inspect 127
Remove and Install—316 125
Remove and Install—318 and 420 126
E437
Electrical Component Location 303
Electrical Schematics 298
Dual PTO 298
Single PTO 295
Electrical System Grounds, Verify 313
Electrical—Theory Of Operation 310
Charging Circuit 310
Engine Oil Pressure Lamp Circuit 312
Ignition Circuit 306
PTO Circuit 308
Starting Circuit 304
Engine 282
Compression Pressure Test 282
Oil 40
Oil and Leak Check 267
Oil Pressure Check 268
Oil Pressure Test 282
Performance Check 268
Remove and install 49
Repair 49
Start Check 268
Troubleshooting 271
F437
Front Axle Spindles 221
Inspect and Replace Bushings 221
Remove and Install 219
Front Axle—316 and 318 212
Inspect and Replace Pivot Bushings 212
Remove and Install 211
Front Axle—420 216
Assemble Pivot Pin 216
Disassemble and Inspect Pivot Pin 214
Install 217
Remove 212
Front PTO Clutch 347
Clutch Adjustment, Check 347
Disassemble, Inspect and Assemble 54
Install 56
Remove 53
Seat Switch Time Delay, Test 338
Seat Switch, Check 290
Fuel 39
Gasoline 39
Storage 39
Fuel Filter Test 280
Fuel Leak Check 267
Fuel Transfer Pump Test 280
G438
Gasoline fuel 39
Governor Linkage Adjustment 279
Grease 42
Extreme pressure and multipurpose 42
H438
Hour Meter 291
Check 291
Circuit Test 339
Hydraulic circuit symbols 400
Hydraulic Control Valve 203
Assemble—Single-Spool 203
Assemble—Three-Spool 207
Assemble—Two-Spool 204
Disassemble & Inspect—Single-Spool 203
Disassemble & Inspect—Three-Spool 207
Disassemble & Inspect—Two-Spool 204
Leakage Test 430
Remove and Install—316 and 318 200
Remove and Install—420 202
Hydraulic oil 41
Hydraulic Oil Warm-Up Procedure 369
Hydraulic Oil Warm-Up Procedure 392
Hydraulic Oil Warm-Up Procedure 429
Hydraulic Schematics 0
Early 318 0
Early 420 0
Later 318 0
Later 420 0
316 0
Hydraulic System 432
Bleed Procedure 432
Checkout 397
Control Valve Leakage Test 430
Rockshaft Cylinder Leakage Test 429
Troubleshooting 426
Hydraulics—Lift System Operation 424
Four-Position Spool 424
Three-Position Spool 423
Hydrostatic Lever 370
Friction Adjustment 370
Friction Check 353
I438
Idle Mixture and Speed Adjustment 277
Ignition 339
Seat Switch Time Delay, Test 339
Seat Switch, Check 291
Ignition Circuit 326
Tests 326
Ignition Circuit (Spark) 288
Check 288
Ignition Spark Test 276
Implement Relief Valve 367
Adjustment 367
Check 367
Pressure Test 367
Remove and Install 66
Inch torque values 31
K438
Key Switch 341
Test 341
L438
Lamp Circuit, Dash 287
Check 287
Tests 316
Leakage Test 430
Hydraulic Control Valve 430
Rockshaft Cylinder 429
Lighting 291
Check 291
Test 340
Lubricant 43
Alternative 43
Mixing 43
Storage 43
Synthetic 43
M439
Machine Specifications 23
Metric torque values 30
Mixing lubricants 43
Mower Blade Jack Sheaves 228
46 and 50-Inch Mower 228
Mower Blade Spindles 226
Early 60-Inch and 260 Rotary Mower 226
Later 60-Inch and 260 Rotary Mower 227
38 (Early), 46 and 50-Inch Mower 225
38-Inch Mower (Later) 225
Mower Deck Gear Case Oil 42
Mower Gear Case—Early 60-Inch 242
Assemble 242
Disassemble and Inspect 238
Mower Gear Case—Later 60-Inch 251
Assemble 251
Disassemble and Inspect 247
Mower Gear Case—260 Rotary Mower 260
Assemble 260
Disassemble and Inspect 255
Mower Gear Case—50-Inch 234
Assemble 234
Disassemble and Inspect 229
N439
Neutral Adjustment 373
Early Models 373
Later Models 374
Neutral Return Check 354
Neutral Return Linkage 180
316 180
318 185
420 191
Neutral Return Linkage Adjustment 370
Early Models 370
Later Models 374
O439
O-ring boss fittings 33
Oil 40
Engine 40
Hydraulic 41
Mower Deck Gear Case 42
Transmission 41
Oil Pressure Regulating Valve Check 283
P439
Park Brake Lever, Inspect and Repair 196
PTO Clutch and Lamp 289
Check 289
Tests 333
PTO Clutch, Front 347
Clutch Adjustment, Check 347
Disassemble, Inspect and Assemble 54
Install 56
Remove 53
Seat Switch Time Delay, Test 338
Seat Switch, Check 290
PTO Neutral Start 290
Check 290
Safety Switch, Test 338
R439
Rear Axle 120
Install 120
Remove 117
Regulator/Rectifier, Tests 345
Repair specifications 27
Rockshaft Cylinder Leakage Test 429
S439
Seat Switch 339
Ignition Time Delay, Test 339
Ignition, Check 291
PTO Time Delay, Test 338
PTO, Check 290
Serial Numbers 46
Control Valve 46
Differential 46
Engine 45
Product Identification 45
Transmission 45
Service Park Brake Check 383
Short Circuit Test 349
2 or 3-Amp Fuses 349
20-Amp Fuse 348
Specifications 23
Machine 23
Repair 27
Test and Adjustment 37
Speed Reduction Check (318 and 420) 354
Starter, Tests 342
Starting Circuit 288
Check 288
Tests 322
Steering Column—318 and 420 162
Assemble 162
Disassemble and Inspect 153
Remove and Install 152
Steering Cylinder (318 and 420) 172
Remove and Install 172
Steering Gearbox—316 144
Assemble 144
Disassemble and Inspect 138
Remove and Install 134
Steering Shaft—316 144
Assemble 144
Disassemble and Inspect 138
Remove and Install 134
Steering System 382
Check (318 and 420) 382
Leakage Test 393
Oil Leak Check (318 and 420) 381
Troubleshooting 389
Steering Valve/System Operation 386
Five-Port Valve 386
Four-Port Valve 385
Steering Valve—318 and 420 162
Assemble 162
Disassemble and Inspect 153
Leakage Test 393
Neutral Check 369
Remove and Install 152
Storing lubricants 43
Synthetic Lubricants 43
T440
Test and Adjustment Specifications 37
Throttle Cable Adjustment 276
Throttle Lever Adjustment 283
Throttle Lever Check 267
Timing Adjustment (B43E, B43G and B48G) 281
Toe-In, Adjust 222
Torque value 33
O-Ring boss fitting 33
Torque values 31
Inch 31
Metric 30
Metric—Grade 7 32
Transmission 82
Assemble Cover 82
Assemble Pump and Motor 81
Assemble Pump and Motor Housing 79
Disassemble Cover 71
Disassemble Pump and Motor 74
Disassemble Pump and Motor Housing 76
Drive Check 354
Install 85
Neutral Check 353
Oil Leak Check 353
Remove 66
Theory of Operation 358
Troubleshooting 361
Transmission Control Linkage 95
Version Four 95
Version One 91
Version Three 94
Version Two—316 and 318 92
Version Two—420 93
Transmission Neutral Start 290
Check 290
Safety Switch, Test 338
Transmission oil 41
Turn Brake Check (318 and 420) 383
Two-Speed Axle (420) 355
Lever Check 355
Lever Linkage Check 377
Two-Speed Control Linkage (420) 96
W440
Welch Plug Location Check 368
Wheel Bearings, Inspect and Replace 222
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