Document Outline

• CONTENTS
• Section 10 - GENERAL INFORMATION
  • Safety
    • RECOGNIZE SAFETY INFORMATION
    • UNDERSTAND SIGNAL WORDS
    • FOLLOW SAFETY INSTRUCTIONS
    • HANDLE FLUIDS SAFELY—AVOID FIRES
    • PREVENT BATTERY EXPLOSIONS
    • PREPARE FOR EMERGENCIES
    • PREVENT ACID BURNS
    • HANDLE CHEMICAL PRODUCTS SAFELY
    • AVOID HIGH-PRESSURE FLUIDS
    • PREPARE MACHINE FOR REPAIR
    • SUPPORT MACHINE PROPERLY
    • WEAR PROTECTIVE CLOTHING
    • WORK IN CLEAN AREA
    • SERVICE MACHINES SAFELY
    • WORK IN VENTILATED AREA
    • ILLUMINATE WORK AREA SAFELY
    • REPLACE SAFETY SIGNS
    • USE PROPER LIFTING EQUIPMENT
    • REMOVE PAINT BEFORE WELDING OR HEATING
    • AVOID HEATING NEAR PRESSURIZED FLUID LINES
    • SERVICE TIRES SAFELY
    • AVOID HARMFUL ASBESTOS DUST
    • PRACTICE SAFE MAINTENANCE
    • USE PROPER TOOLS
    • DISPOSE OF WASTE PROPERLY
    • LIVE WITH SAFETY
  • General Specifications
    • MACHINE SPECIFICATIONS
  • Repair Specifications
    • REPAIR SPECIFICATIONS
    • METRIC BOLT AND CAP SCREW TORQUE VALUES
    • UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUES
    • METRIC CAP SCREW TORQUE VALUES—GRADE 7
    • SERVICE RECOMMENDATIONS FOR O-RING BOSS FITTINGS
    • SERVICE RECOMMENDATIONS FOR FLAT FACE O-RING SEAL FITTINGS
    • TUBE AND HOSE FITTING, 37˚ FLARE AND 30˚ CONE SEAT CONNECTOR SERVICE RECOMMENDATIONS
  • Test and Adjustment Specifications
    • TEST AND ADJUSTMENT SPECIFICATIONS
  • 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
  • Serial Number Locations
    • SERIAL NUMBERS
    • PRODUCT IDENTIFICATION NUMBER
    • ENGINE SERIAL NUMBER
    • TRANSMISSION SERIAL NUMBER
    • DIFFERENTIAL SERIAL NUMBER
    • CONTROL VALVE SERIAL NUMBER
• Section 20 - ENGINE REPAIR
  • Engine
    • ONAN ENGINE REPAIR—USE CTM2
    • REMOVE AND INSTALL ENGINE
• Section 40 - ELECTRICAL REPAIR
  • Front PTO Clutch
    • REMOVE FRONT PTO CLUTCH
    • DISASSEMBLE, INSPECT AND ASSEMBLE FRONT PTO CLUTCH
    • INSTALL FRONT PTO CLUTCH
• Section 50 - POWER TRAIN REPAIR
  • Transmission
    • SERVICE PARTS KITS
    • REMOVE AND INSTALL CHARGE PUMP
    • DISASSEMBLE AND INSPECT CHARGE PUMP
    • ASSEMBLE CHARGE PUMP
    • REMOVE AND INSTALL CHARGE RELIEF VALVE
    • REMOVE AND INSTALL IMPLEMENT RELIEF VALVE
    • REMOVE TRANSMISSION
    • DISASSEMBLE TRANSMISSION COVER
    • DISASSEMBLE PUMP AND MOTOR
    • DISASSEMBLE PUMP AND MOTOR HOUSING
    • ASSEMBLE PUMP AND MOTOR HOUSING
    • ASSEMBLE PUMP AND MOTOR
    • ASSEMBLE TRANSMISSION COVER
    • INSTALL TRANSMISSION
  • Transmission Control Linkage
    • INSPECT AND REPAIR TRANSMISSION CONTROL LINKAGE—VERSION ONE (ALL MODELS)
    • INSPECT AND REPAIR TRANSMISSION CONTROL LINKAGE—VERSION TWO (316 AND 318)
    • INSPECT AND REPAIR TRANSMISSION CONTROL LINKAGE—VERSION TWO (420)
    • INSPECT AND REPAIR TRANSMISSION CONTROL LINKAGE—VERSION THREE (ALL MODELS)
    • INSPECT AND REPAIR TRANSMISSION CONTROL LINKAGE—VERSION FOUR (ALL MODELS)
    • INSPECT AND REPAIR DIFFERENTIAL LOCK AND TWO-SPEED CONTROL LINKAGE (420)
  • Differential
    • SERVICE PARTS KITS
    • REMOVE AND INSTALL DIFFERENTIAL
    • DISASSEMBLE AND INSPECT DIFFERENTIAL
    • ASSEMBLE DIFFERENTIAL
  • Rear Axles
    • REMOVE AXLE
    • INSTALL AXLE
  • Drive Shaft
    • REMOVE AND INSTALL DRIVE SHAFT—316
    • REMOVE AND INSTALL DRIVE SHAFT—318 AND 420
    • DISASSEMBLE AND INSPECT DRIVE SHAFT
    • ASSEMBLE DRIVE SHAFT
• Section 60 - STEERING AND BRAKE REPAIR
  • Steering¯316
    • SPECIAL OR ESSENTIAL TOOLS
    • SERVICE PARTS KITS
    • REMOVE AND INSTALL STEERING GEARBOX AND SHAFT
    • DISASSEMBLE AND INSPECT STEERING GEARBOX AND SHAFT
    • ASSEMBLE STEERING GEARBOX AND SHAFT
  • Steering¯318 and 420
    • SERVICE PARTS KITS
    • REMOVE AND INSTALL STEERING VALVE AND COLUMN
    • DISASSEMBLE AND INSPECT STEERING VALVE AND COLUMN
    • ASSEMBLE STEERING VALVE AND COLUMN
    • REMOVE AND INSTALL STEERING CYLINDER
  • Brakes
    • REMOVE BRAKES
    • INSTALL BRAKES
    • ADJUST BRAKES
    • INSPECT AND REPAIR BRAKE PEDAL AND NEUTRAL RETURN LINKAGE—316
    • INSPECT AND REPAIR BRAKE PEDALS AND NEUTRAL RETURN LINKAGE—318
    • INSPECT AND REPAIR BRAKE PEDALS AND NEUTRAL RETURN LINKAGE—420
    • INSPECT AND REPAIR PARK BRAKE LEVER
• Section 70 - HYDRAULIC REPAIR
  • Hydraulic Control Valve
    • SERVICE PARTS KITS
    • REMOVE AND INSTALL HYDRAULIC CONTROL VALVE—316 AND 318
    • REMOVE AND INSTALL HYDRAULIC CONTROL VALVE—420
    • DISASSEMBLE, INSPECT AND ASSEMBLE HYDRAULIC CONTROL VALVE—SINGLE-SPOOL
    • DISASSEMBLE, INSPECT AND ASSEMBLE HYDRAULIC CONTROL VALVE—TWO-SPOOL
    • DISASSEMBLE, INSPECT AND ASSEMBLE HYDRAULIC CONTROL VALVE—THREE-SPOOL
• Section 80 - MISCELLANEOUS REPAIR
  • Front Axle
    • SPECIAL OR ESSENTIAL TOOLS
    • REMOVE AND INSTALL FRONT AXLE—316 AND 318
    • INSPECT AND REPLACE PIVOT BUSHINGS—316 AND 318
    • REMOVE FRONT AXLE—420
    • DISASSEMBLE AND INSPECT PIVOT PIN—420
    • ASSEMBLE PIVOT PIN—420
    • INSTALL FRONT AXLE—420
    • REMOVE AND INSTALL SPINDLES
    • INSPECT AND REPLACE SPINDLE BUSHINGS
    • INSPECT AND REPLACE WHEEL BEARINGS
    • ADJUST TOE-IN
  • Mower Spindle and Jack Sheave Repair
    • SERVICE MOWER BLADE SPINDLES—38 (EARLY), 46 AND 50-INCH MOWER
    • SERVICE MOWER BLADE SPINDLES—38-INCH MOWER (LATER)
    • SERVICE MOWER BLADE SPINDLES—EARLY 60-INCH AND 260 ROTARY MOWER
    • SERVICE MOWER BLADE SPINDLES—LATER 60-INCH AND 260 ROTARY MOWER
    • SERVICE MOWER BLADE JACK SHEAVES—46 AND 50-INCH MOWER
  • Mower Gear Case Repair
    • DISASSEMBLE AND INSPECT MOWER GEAR CASE—50-INCH MOWER
    • ASSEMBLE MOWER GEAR CASE—50-INCH MOWER
    • DISASSEMBLE AND INSPECT MOWER GEAR CASE—EARLY 60-INCH MOWER (CURTIS)
    • ASSEMBLE MOWER GEAR CASE—EARLY 60-INCH MOWER (CURTIS)
    • DISASSEMBLE AND INSPECT MOWER GEAR CASE—LATER 60-INCH MOWER (PEERLESS)
    • ASSEMBLE MOWER GEAR CASE—LATER 60-INCH MOWER (PEERLESS)
    • DISASSEMBLE AND INSPECT MOWER GEAR CASE—260 ROTARY MOWER
    • ASSEMBLE MOWER GEAR CASE—260 ROTARY MOWER
• Section 220 - ENGINE, FUEL AND AIR SYSTEM CHECKOUT AND DIAGNOSIS
  • Engine, Fuel and Air System Checkout
    • BEFORE YOU START
  • Diagnosis, Tests and Adjustments
    • ABOUT THIS GROUP
• Section 240 - ELECTRICAL CHECKOUT, OPERATION AND DIAGNOSIS
  • Electrical System Checkout
    • BEFORE YOU START
  • Electrical Schematics
    • 316, 318 AND 420 ELECTRICAL SCHEMATIC—SINGLE PTO
    • 316, 318 AND 420 ELECTRICAL SCHEMATIC—DUAL PTO
  • Component Location and Operation
    • ELECTRICAL COMPONENT LOCATION
    • STARTING CIRCUIT OPERATION
    • IGNITION CIRCUIT OPERATION
    • PTO CIRCUIT OPERATION
    • CHARGING CIRUIT OPERATION
    • OIL PRESSURE LAMP CIRCUIT OPERATION
  • Electrical System Diagnosis
    • ABOUT THIS GROUP
  • Electrical System Component Tests and Adjustments
    • BEFORE YOU START
• Section 250 - POWER TRAIN CHECKOUT, OPERATION AND DIAGNOSIS
  • Power Train Checkout
    • BEFORE YOU START
  • Theory of Operation
    • HYDROSTATIC TRANSMISSION OPERATION
  • Diagnosis, Tests and Adjustments
    • Troubleshooting Guide
    • charge pressure test
    • implement relief pressure test
    • charge pump flow test
    • steering valve neutral check
    • hydro neutral return linkage adjustment
    • later version hydro neutral return adjustment
    • 2 speed linkage check
    • differential lock linkage check
• Section 260 - STEERING AND BRAKES CHECKOUT, OPERATION AND DIAGNOSIS
  • Steering And Brakes System Checkout
    • BEFORE YOU START
  • Theory of Operation
    • STEERING VALVE/SYSTEM OPERATION—FOUR-PORT VALVE
    • STEERING VALVE/SYSTEM OPERATION—FIVE-PORT VALVE
  • Diagnosis, Tests and Adjustments
    • Troubleshooting guide
    • steering system leakage test
• Section 270 - HYDRAULIC SYSTEM CHECKOUT, OPERATION AND DIAGNOSIS
  • Hydraulic System Checkout
    • hydraulic control valve check
  • Hydraulic Schematics
    • HYDRAULIC SYSTEM SCHEMATICS
    • HYDRAULIC CIRCUIT SYMBOLS
    • LEGEND FOR HYDRAULIC SYSTEM SCHEMATIC—316
    • LEGEND FOR HYDRAULIC SYSTEM SCHEMATIC—EARLY 318
    • LEGEND FOR HYDRAULIC SYSTEM SCHEMATIC—LATER 318
    • LEGEND FOR HYDRAULIC SYSTEM SCHEMATIC—EARLY 420
    • LEGEND FOR HYDRAULIC SYSTEM SCHEMATIC—LATER 420
  • Theory of Operation
    • HYDRAULIC LIFT SYSTEM OPERATION—THREE-POSITION SPOOL
    • HYDRAULIC LIFT SYSTEM OPERATION—FOUR-POSITION SPOOL
  • Diagnosis, Tests and Adjustments
    • Troubleshooting guide
    • rockshaft cylinder leakage test
    • control valve leakage test
    • test implement relief pressure
    • bleed hydraulic system
• Section 299 - DEALER FABRICATED TOOLS
  • Dealer Fabricated Tools
    • DFMX1 STEERING VALVE FIXTURE
    • DFMX2 ALIGNMENT SHIMS
• Index
  • A
    • Alternator, Tests