SPECIFICATIONS
PRODUCT LINEUPTRACTOR SPECIFICATIONSATTACHMENTS AND ACCESSORIES (PARTIAL LISTING)ENGINE SPECIFICAT IONS (AIR- CO O LED)ENGINE SPECIFICATIO NS (LIQUI D- COO LED)
MAINTENANCE TABLE
SERVICE SCHEDULE
CHASSIS
MODEL/SERIAL NUMBER LOCATIONGREASING AND LUBRICATIONREAR FENDERS, FOOTRESTS, & TUNNELFRONT WHEEL TOE-INSTEERING WHEELPOWER STEERINGSMART TURNÉ STEERINGMOTION CONTROL PEDALTIRE PRESSUREFUEL TANK SHUT-OFF VALVEELECTRIC PTO CLUTCHDRIVE SHAFT
GASOLINE ENGINE
TROUBLESHOOTINGENGINE CRANKS BUT WILL NOT START.STARTER DOES NOT CRANK.ENGINE STARTS BUT DOES NOT KEEP RUNNING.ENGINE IS DIFFICULT TO START.ENGINE RUNS BUT KNOCKS OR MISSES.ENGINE WILL NOT IDLE.ENGINE OVERHEATS.ENGINE LOSES POWER.ENGINE KNOCKS.AIR CLEANERENGINE OILOIL FILTERSPARK PLUGFUEL FILTER
5XI SERIES TRACTOR SERVICE MANUAL
Table of Contents – Page 2 of 2
GASOLINE ENGINE - continued
COOLING SYSTEM, AIRCOOLING SYSTEM, LIQUID
DIESEL ENGINE
TROUBLESHOOTINGENGINE CRANKS BUT WILL NOT START.STARTER DOES NOT CRANK.ENGINE STARTS BUT DOES NOT KEEP RUNNING.ENGINE IS DIFFICULT TO START.ENGINE RUNS BUT KNOCKS OR MISSES.ENGINE WILL NOT IDLE.ENGINE OVERHEATS.ENGINE LOSES POWER.ENGINE KNOCKS.EXCESSIVE BLACK SMOKE FROM EXHAUST.EXCESSIVE W H IT E SMOKE FRO M EX HAU ST.AIR CLEANERENGINE OILOIL FILTERCOOLING SYSTEMENGINE MOUNTSFUEL SYSTEMGLOW PLUGS
This service manual was written expressly for Toro Wheel Horse 5xi series garden tractors. The Toro Company
has made every effort to make the information in this manual complete and correct.
This manual was written for the service technician; basic mechanical/electrical skills are assumed. The Table of
Contents lists the systems and the related topics covered in this manual.
For information on the electrical system, please refer to the Toro Electrical Demystification Guide (492-4404). For
information specific to the engines used on these garden tractors, refer to the appropriate engine manufacturer’s
service and repair instructions.
We are hopeful that you will find this manual a valuable addition to your service shop. If you have any questions
or comments regarding this manual, please contact us at the following address:
The Toro Company
Consumer Service Training Department
8111 Lyndale Avenue South
Bloomington, MN 55420
The Toro Company reserves the right to change product specifications or this manual without notice.
This symbol means WARNING or
PERSONAL SAFETY
INSTRUCTION - read the
instruction because it has to do
with your safety. Failure to comply
with the instruction may result in
personal injury or even death.
This manual is intended as a service and repair
manual only. The safety instructions provided herein
THINK SAFETY FIRST
Avoid unexpected starting of engine...
Always turn off the engine and disconnect the spark
plug wire(s) before cleaning, adjusting, or repair.
Avoid lacerations and amputations...
Stay clear of all moving parts whenever the engine is
running. Treat all normally moving parts as if they
were moving whenever the engine is running or has
the potential to start.
are for troubleshooting, service, and repair of the
5xi series garden tractor. The tractor and attachment
operator’s manuals contain safety information and
operating tips for safe operating practices. Operator’s
manuals are available through your local Toro
distributor or:
The Toro Company
Publications Department
8111 Lyndale Avenue South
Bloomington, MN 55420
Avoid injury from batteries...
Battery acid is poisonous and can cause burns. Avoid
contact with skin, eyes, and clothing. Battery gases
can explode. Keep cigarettes, sparks, and flames
away from the battery.
Avoid injury due to inferior parts...
Use only original equipment parts to ensure that
important safety criteria are met.
1a
Avoid burns...
Do not touch the engine, muffler, or other
components which may increase in temperature
during operation, while the unit is running or shortly
after it has been running.
Avoid fires and explosions...
Avoid spilling fuel and never smoke while working
with any type of fuel or lubricant. Wipe up any spilled
fuel or oil immediately. Never remove the fuel cap or
add fuel when the engine is running. Always use
approved, labeled containers for storing or
transporting fuel and lubricants.
Avoid asphyxiation...
Never operate an engine in a confined area without
proper ventilation.
Avoid injury to bystanders...
Always clear the area of bystanders before starting or
testing powered equipment.
Avoid injury due to projectiles...
Always clear the area of sticks, rocks, or any other
debris that could be picked up and thrown by the
powered equipment.
Avoid modifications...
Never alter or modify any part unless it is a factory
approved procedure.
Avoid unsafe operation...
Always test the safety interlock system after making
adjustments or repairs on the machine. Refer to the
Electrical chapter later in this manual for more
information.
Tire Size - Front16 x 7.5-816 x 7.5-816 x 7.5-816 x 7.5-816 x 7.5-8
Tire Size - Rear23 x 10.5-1223 x 10.5-1223 x 10.5-1223 x 10.5-1223 x 10.5-12
Tire Pressure12 psi
Wheel Base52 in
Turning Radius20 in
Total Width40.5 in
Length76.5 in
0-3.4 mph
(5.48 km/hr)
(82.7 kPa)
(132.1 cm)
(50.8 cm)
(102.8 cm)
(196.9 mm)
0-3.4 mph
(5.48 km/hr)
12 psi
(82.7 kPa)
52 in
(132.1 cm)
20 in
(50.8 cm)
40.5 in
(102.8 cm)
76.5 in
(196.9 mm)
0-3.4 mph
(5.48 km/hr)
12 psi
(82.7 kPa)
52 in
(132.1 cm)
20 in
(50.8 cm)
40.5 in
(102.8 cm)
76.5 in
(196.9 mm)
0-3.4 mph
(5.48 km/hr)
12 psi
(82.7 kPa)
52 in
(132.1 cm)
20 in
(50.8 cm)
40.5 in
(102.8 cm)
76.5 in
(196.9 mm)
0-3.4 mph
(5.48 km/hr)
12 psi
(82.7 kPa)
52 in
(132.1 cm)
20 in
(50.8 cm)
40.5 in
(102.8 cm)
76.5 in
(196.9 mm)
Note: Specifications shown are for 1998 models. Subsequent production may vary. As part of
a continuous improvement process, the Toro Company reserves the right to change
specifications without notice.
1-45xi Series Tractor Service Manual
SPECIFICATIONS
Attachments and Accessories (partial listing)
Part # (International) DescriptionDrive BeltSpindle Belt
The tractor model and serial number plate
location is shown in the illustration.
The engine has its own model and serial
number identification. Consult the appropriate
engine manufacturer’s service literature for the
location and translation of the engine model
and serial number information.
GREASING AND LUBRICATION
2.0757.015
22
Service Interval/Specification
The machine should be greased every 50 hours
or yearly, whichever occurs first. You should
grease more frequently when operating
conditions are extremely dusty or sandy. See
the maintenance table in section 1c.
Grease Type: General-purpose lithium base
grease
2.0109.033
Lubrication Points
There are 3 grease zerks on the front axle; one
on at each spindle and one at the center pivot.
2.0109.043
2-45xi Series Tractor Service Manual
2.0109.026
CHASSIS
Remove the maintenance panel located in the
tunnel in front of the seat.
2.0109.024
This will allow access to the 3 zerk fittings below.
The pulley box for the mower deck contains 2
zerk fittings; one at each pulley pivot.
2
2.0144.023
5xi Series Tractor Service Manual2-5
CHASSIS
GREASING AND LUBRICATION (cont’d)
There are 3 zerk fittings located on the mower
deck spindles. Apply grease until resistance is
felt from the grease gun handle (2-3 pumps).
Also lubricate the mower deck idler arm on
decks so equipped.
The 60" deck has zerk fittings on the gage
wheels, grease every 25 hours of operation.
2.0415.001
22
There is 1 zerk fitting located on the foot pedal
shaft which requires greasing.
2.0415.012
Models with manual steering have a lubrication
point on the steering gear. Do not force
excessive amounts of grease into this fitting
(one pump of the grease gun handle only).
2.0144.069
2-65xi Series Tractor Service Manual
2.0109.039
CHASSIS
REAR FENDERS, FOOTRESTS, & TUNNEL
General Information
The seat, rear fenders, footrests, and tunnel can
be removed as a unit providing easy access to
chassis components.
2.0109.021
Removal
1. Disconnect the electrical connections for the
seat switch, cruise control, and taillights (as
applicable) from the wiring harness.
NOTE: The cruise control and taillights
share the same connector, which is located
under the right fender.
2. Remove the brake and motion control
pedals.
2
2.0109.003
5xi Series Tractor Service Manual2-7
2.0109.020
CHASSIS
REAR FENDERS, FOOTRESTS, & TUNNEL (cont’d)
3. Remove the four bolts securing the fenders
to the frame (two on each side of the seat).
2.0109.004
22
4. Remove the nuts from the front footrest
supports and the clamps from the rear
supports.
2.0109.019
5. Remove the three air intake screens.
2.0109.015
2-85xi Series Tractor Service Manual
2.0109.017
CHASSIS
6. Remove the knob for the transaxle range
selector.
2.0109.014
7. With the help of an assistant, lift the rear of
the fender assembly until it clears the
transaxle shift lever. Then remove the
assembly to the rear of the tractor.
Reassembly
Reverse steps 1-7 to reassemble the seat, rear
fenders, footrests, and tunnel.
NOTE: Failure to keep all hoses in place on the
top of the fuel tank could result in improper
operation of the fuel vent or supply system.
2
NOTE: Do not pinch any wiring between the
fender assembly and the top edges of the frame.
2.0109.039
5xi Series Tractor Service Manual2-9
CHASSIS
FRONT WHEEL TOE-IN
Specification/Service Interval
If there is uneven tire wear, lawn scuffing, or
hard steering, toe-in may need to be adjusted.
Toe-in should be 1/8" - 1/4" (3 to 6 mm) on the
front wheels. This should be checked every
100 hours or once a year, whichever occurs first.
2.0109.043
22
Measurement
1. Disengage the PTO, set the parking brake,
and turn the ignition key to OFF to stop the
engine. Remove the key.
2. Turn wheels straight ahead. Square the
lower steering plate to the center line of the
frame rails by aligning a straight edge (A)
with the footrest support (B) as shown.
3. Push the front of the tires out to remove
normal looseness in the linkage.
2.0144.050
4. Measure the distance between both front
tires at spindle level (at the front and rear of
the wheels).
5. The front measurement should be 1/8" to
1/4" (3 to 6 mm) less than the rear
measurement.
If adjustment is needed, follow the steps
outlined on the next page.
Note: The black steering tie rod end goes to the
front and has right hand threads.
2.0109.035
2-105xi Series Tractor Service Manual
2.0109.047
CHASSIS
Adjustment
1. Loosen the jam nuts at the ends of the
steering rods.
2.0109.048
2. Rotate both steering rods equal amounts to
adjust the toe-in to 1/8" to 1/4" (3 to 6 mm) .
3. Recheck the toe-in as described earlier.
IMPORTANT: Make sure that the flat surface
on the top of the front tie rod ends are
parallel to the bottom of the steering arms
(inset).
Spindle Alignment
When installing the spindle to the steering arm,
you must align the wheel so that it is parallel to
the steering arm as shown.
2
2.0109.046
5xi Series Tractor Service Manual2-11
CHASSIS
STEERING WHEEL
Remove Steering Wheel
1. Remove plastic trim cover.
2. Loosen the nut securing the wheel.
2.0144.051
22
3. Install puller as shown. Tighten forcing
screw to remove steering wheel.
NOTE: Install large flat washers on puller
bolts to protect steering wheel.
Reassembly
1. Place the steering wheel on the shaft,
carefully aligning the splines.
NOTE: On manual steering models, be sure to
align steering wheel in the “straight ahead”
position. There is
position on power steering models.
no fixed “straight ahead”
2.0144.053
2. Torque the retaining nut to 45 - 50 ft·lbs.
3. Replace the trim cover.
2.0144.052
2-125xi Series Tractor Service Manual
3.7195.029
CHASSIS
POWER STEERING
General Information
The 22 HP, 20 HP liquid-cooled and 23 HP
diesel tractors are equipped with power
steering.
This system routes pressurized hydraulic fluid
supplied by the hydrostatic transmission to a
directional valve located at the base of the
steering column. When the steering wheel is
turned, this valve directs pressure to a double
acting hydraulic cylinder, causing the steering
plate to pivot as the cylinder extends or
contracts. Tie rods attached to the steering
plate turn the front spindles.
2.0109.044
When the tractor is not running, some oil will
drain from the power steering system. When
this happens, it will be necessary to purge the
air from the system. This is done by turning the
steering wheel with the engine running until the
wheels turn fully and smoothly in both
directions.
Maintenance
The power steering system is equipped with an
in-line filter screen. It should be cleaned after
initial 50 hours, then every 200 hours, or if the
power steering gets noisy.
2
To clean the power steering screen:
1. Remove the left and center air intake
screens.
2. Remove the screen housing from the clamp
securing it to the left-hand side of steering
tower.
.3. Remove the top hose first to prevent oil from
back-flushing the screen.
4. Remove the hydraulic lines, and seal the
2.0144.16
5xi Series Tractor Service Manual2-13
ends to keep out dirt.
CHASSIS
POWER STEERING (cont’d)
3. Disassemble the housing, and clean the
screen with solvent.
2.0144.076
22
4. Inspect the “O” rings that seal the lines and
housing. Replace them if there are any
signs of cuts or deterioration, (i.e. hardening
or swelling of the rubber).
Lubricate the “O” rings before reassembly.
2.0144.086
5. Reassemble the housing, replace the lines,
and secure to steering tower.
6. Bleed air from the system by turning the
steering wheel from stop to stop several
times.
7. Check the hydrostatic transmission
fluid level.
2.0144.16
2-145xi Series Tractor Service Manual
2.3653.005
CHASSIS
SMART TURN™ STEERING
General Information
The Smart Turn Steering™ feature automatically
lowers the speed of the tractor in tight turns.
The decrease in speed is directly proportional
to the sharpness of the turn, up to a maximum
speed reduction of approximately 40% .
The Smart Turn Steering feature permits sharp
turns to be made without always having to
change speed control position. The original
speed is restored as the turn is completed.
2.0144.059
Theory of Operation
The steering plate (A) is attached to the speed
control lever (B) on the hydrostatic transmission
through a system of linkage and levers.
When the steering wheel is turned, the linkage
pushes the speed control lever (A) on the
hydrostatic transmission towards the neutral
position and slows the tractor.
2
2.0144.63
5xi Series Tractor Service Manual2-15
CHASSIS
SMART TURN™ STEERING (cont’d)
Inspection
The Smart Turn Steering system was set-up at
the factory and should not need any
adjustment. Adjustment must be verified if the
transaxle is removed and reinstalled.
2.0144.059
22
Correct adjustment can be verified by checking
the position of the bushing (A) in the slot of the
brake pivot plate (B). The bushing should not
contact either side of the slot.
Correct adjustment can be verified by removing
the maintenance panel and visually checking
the position of bushing (A). It should be
centered in the slot in the brake pivot (B). The
bushing should not contact either side of the
slot when the brake is applied.
2.0144.066
Adjustments
IMPORTANT: The adjustment procedure must
be performed in the sequence given.
If adjustment of the system is necessary:
1. Remove the rear fenders and tunnel from the
tractor as outlined on page 2-7.
NOTE: It is important that the toe-in is properly
adjusted before adjusting the Smart Turn
Steering linkage. Verify setting by following the
procedure starting on page 2-10.
2.0109.014
2-165xi Series Tractor Service Manual
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