Toro 73540, 73541, 73542, 73545, 73546 Service Manual
...5XI SERIES TRACTOR SERVICE MANUAL
Table of Contents – Page 1 of 2
SAFETY INFORMATION
SPECIFICATIONS PRODUCT LINEUP
TRACTOR SPECIFICATIONS
ATTACHMENTS AND ACCESSORIES (PARTIAL LISTING) ENGINE SPECIFICATIONS (AIR-COOLED)
ENGINE SPECIFICATIONS (LIQUID-COOLED)
MAINTENANCE TABLE
SERVICE SCHEDULE
CHASSIS
MODEL/SERIAL NUMBER LOCATION GREASING AND LUBRICATION
REAR FENDERS, FOOTRESTS, & TUNNEL FRONT WHEEL TOE-IN
STEERING WHEEL
POWER STEERING SMART TURNÉ STEERING MOTION CONTROL PEDAL TIRE PRESSURE
FUEL TANK SHUT-OFF VALVE ELECTRIC PTO CLUTCH DRIVE SHAFT
HYDROSTATIC DRIVE
TROUBLESHOOTING
TRANSAXLE FLUID
BRAKE
NEUTRAL ADJUSTMENT
GASOLINE ENGINE TROUBLESHOOTING
ENGINE 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 CLEANER
ENGINE OIL
OIL FILTER
SPARK PLUG
FUEL FILTER
5XI SERIES TRACTOR SERVICE MANUAL
Table of Contents – Page 2 of 2
GASOLINE ENGINE - continued
COOLING SYSTEM, AIR
COOLING SYSTEM, LIQUID
DIESEL ENGINE TROUBLESHOOTING
ENGINE 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 WHITE SMOKE FROM EXHAUST.
AIR CLEANER
ENGINE OIL
OIL FILTER COOLING SYSTEM ENGINE MOUNTS FUEL SYSTEM GLOW PLUGS
ELECTRICAL
BATTERY
FUSE
HEADLIGHTS
INSTRUMENT PANEL LIGHTS
TAILLIGHTS
ELECTRIC CLUTCH TROUBLESHOOTING
SAFETY INTERLOCK SYSTEM
CRUISE CONTROL
FUEL GAUGE
CHARGING SYSTEM
SCHEMATICS
TORO
5xi Series
Tractor
Service Manual
ABOUT THIS MANUAL
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.
Copyright© All Rights Reserved
©1997 The Toro Company
TABLE OF CONTENTS
QUICK REFERENCE SECTION
Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE SECTION
1a
1b
1c
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydrostatic Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gasoline Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
3
4
5
6
5xi Series Tractor Service Manual |
1 - 1 |
QUICK REFERENCE
Table of Contents
SAFETY INFORMATION
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3
Think Safety First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3
SPECIFICATIONS
Product Lineup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4
Tractor Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4
Attachments and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5
Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6
MAINTENANCE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7
1 - 2 |
5xi Series Tractor Service Manual |
SAFETY INFORMATION
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
are for troubleshooting, service, and repair of the |
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5xi series garden tractor. The tractor and attachment |
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operator’s manuals contain safety information and |
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operating tips for safe operating practices. Operator’s |
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manuals are available through your local Toro |
1a |
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distributor or: |
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The Toro Company |
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Publications Department |
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8111 Lyndale Avenue South |
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Bloomington, MN 55420 |
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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.
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 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.
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.
5xi Series Tractor Service Manual |
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SPECIFICATIONS
Product Lineup
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Model |
Name |
Engine |
HP |
Drive Type |
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(International) |
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73470 |
518xi |
Kohler |
18 |
Eaton 11 Hydro, 2 speed Uni-Drive® transaxle |
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73540 (73541) |
520xi |
Kohler |
20 |
Eaton 11 |
Hydro, 2 speed Uni-Drive® transaxle |
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73560 |
522xi |
Kohler |
22 |
Eaton 11 |
Hydro, 2 speed Uni-Drive® transaxle |
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1b |
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73545 (73546) |
520Lxi |
Kawasaki |
20 |
Eaton 11 |
Hydro, 2 speed Uni-Drive® transaxle |
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73550 (73551) |
523Dxi |
Daihatsu |
23 |
Eaton 11 |
Hydro, 2 speed Uni-Drive® transaxle |
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Tractor Specifications
Item |
73470 |
73540 |
73560 |
73545 |
73550 |
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(73541) |
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(73546) |
(73551) |
Fuel Tank Capacity |
4.25 gal |
4.25 gal |
4.25 gal |
4.25 gal |
4.25 gal |
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(16.1l) |
(16.1l) |
(16.1l) |
(16.1l) |
(16.1l) |
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Hydraulic System Capacity |
6 Qts (5.7l) |
6 Qts (6.6 l) |
7 Qts (6.6 l) |
7 Qts (6.6 l) |
7 Qts (6.6 l) |
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Battery Size (Cold Cranking Amps) |
12V 380CCA |
12V 380CCA |
12V 380CCA |
12V 380CCA |
12V 495CCA |
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Ground Speed Forward (High Range) |
0-7.4 mph |
0-7.4 mph |
0-7.4 mph |
0-7.4 mph |
0-7.4 mph |
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(11.9 km/hr) |
(11.9 km/hr) |
(11.9 km/hr) |
(11.9 km/hr) |
(11.9 km/hr) |
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Ground Speed Forward (Low Range) |
0-4.4 mph |
0-4.4 mph |
0-4.4 mph |
0-4.4 mph |
0-4.4 mph |
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(7.1 km/hr) |
(7.1 km/hr) |
(7.1 km/hr) |
(7.1 km/hr) |
(7.1 km/hr) |
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Ground Speed Reverse (High Range) |
0-3.4 mph |
0-3.4 mph |
0-3.4 mph |
0-3.4 mph |
0-3.4 mph |
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(5.48 km/hr) |
(5.48 km/hr) |
(5.48 km/hr) |
(5.48 km/hr) |
(5.48 km/hr) |
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Tire Size - Front |
16 x 7.5-8 |
16 x 7.5-8 |
16 x 7.5-8 |
16 x 7.5-8 |
16 x 7.5-8 |
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Tire Size - Rear |
23 x 10.5-12 |
23 x 10.5-12 |
23 x 10.5-12 |
23 x 10.5-12 |
23 x 10.5-12 |
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Tire Pressure |
12 psi |
12 psi |
12 psi |
12 psi |
12 psi |
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(82.7 kPa) |
(82.7 kPa) |
(82.7 kPa) |
(82.7 kPa) |
(82.7 kPa) |
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Wheel Base |
52 in |
52 in |
52 in |
52 in |
52 in |
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(132.1 cm) |
(132.1 cm) |
(132.1 cm) |
(132.1 cm) |
(132.1 cm) |
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Turning Radius |
20 in |
20 in |
20 in |
20 in |
20 in |
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(50.8 cm) |
(50.8 cm) |
(50.8 cm) |
(50.8 cm) |
(50.8 cm) |
Total Width |
40.5 in |
40.5 in |
40.5 in |
40.5 in |
40.5 in |
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(102.8 cm) |
(102.8 cm) |
(102.8 cm) |
(102.8 cm) |
(102.8 cm) |
Length |
76.5 in |
76.5 in |
76.5 in |
76.5 in |
76.5 in |
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(196.9 mm) |
(196.9 mm) |
(196.9 mm) |
(196.9 mm) |
(196.9 mm) |
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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 - 4 |
5xi Series Tractor Service Manual |
SPECIFICATIONS
Attachments and Accessories (partial listing)
Part # (International) |
Description |
Drive Belt |
Spindle Belt |
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78353 |
(78442) |
42" Rear Discharge Mower |
95-4093 |
95-4230 |
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78357 |
(78444) |
44" Side Discharge Mower |
95-4094 |
95-4228 |
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78358 |
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44" Recycler® Mower |
95-4094 |
95-4228 |
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1b |
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78363 |
(78448) |
48" Side Discharge Mower |
95-4095 |
95-3878 |
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78364 |
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48" Recycler® Mower |
95-4095 |
95-3878 |
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78370 |
(78452) |
52" Side Discharge Mower |
95-4094 |
94-2501 |
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78375 |
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52" Recycler® Mower |
95-4094 |
94-2501 |
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78395 |
(78469) |
60" Side Discharge Mower |
95-4093 |
95-4229 |
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79375* |
36" Tiller |
Front |
Rear |
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94-7877 |
94-7878 |
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79355* |
48" Snow/Dozer Blade |
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79356* |
50" Mid-Mount Grader Blade |
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79305 |
(79444) |
44" Vac/Bagger |
93-8007 |
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79310 |
(79448) |
48" Vac/Bagger |
79-7490 |
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79977 |
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Front Mount Dethatcher |
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79365 |
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42" Single Stage Snowthrower |
95-3918 |
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79366 |
*** |
44" Two Stage Snowthrower |
95-3917 |
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79919 |
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Snow Cab |
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79210 |
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Roll-Over-Protection System (ROPS) |
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95-4220 |
Rear Attach-A-Matic® (from Parts) |
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79947** |
Bucket Loader |
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94-2050 |
Dual Wheel Adapter Kit (From Parts) |
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94-7800 |
Clevis Hitch (From Parts) |
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94-4090 |
48" Blade Retrofit Kit (From Parts) |
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95-4091 |
Diesel Block Heater (From Parts) |
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95-7858 |
Sidelight Kit (From Parts) |
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86041 |
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44" Recycler®Kit |
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79195 |
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48" Recycler®Kit |
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79185 |
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52" Recycler®Kit |
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79948 |
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Weight Box |
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* Requires 95-4220 Rear Attach-A-Matic® ** Requires 79948 weight Box
***Requires rear wheel weights, 95-4220 Rear Attach-A-Matic®
5xi Series Tractor Service Manual |
1 - 5 |
SPECIFICATIONS
Engine Specifications (air-cooled)
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Item |
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73470 |
73540 (73541) |
73560 |
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Manufacturer/Model |
Kohler/CH18S |
Kohler/CH20S |
Kohler/CH22S |
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Horsepower (kW) |
18 HP (13.4 kW) |
20 HP (14.9 kW) |
22 HP (16.4 kW) |
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1b |
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Oil Viscosity |
Over 0° F (-18° C) |
10W-30 |
10W-30 |
10W-30 |
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Below 32°F (0° C) |
5W-20 or 5W-30 |
5W-20 or 5W-30 |
5W-20 or 5W-30 |
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Oil Capacity (With Filter) 2.1 Qts. (2 l) |
U.S. Qts. |
U.S. Qts. |
U.S. Qts. |
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Spark Plug (Champion # Shown) |
RC12YC |
RC12YC |
RC12YC |
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Spark Plug Gap |
.030 in (.76 mm) |
.030 in (.76 mm) |
.030 in (.76 mm) |
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Recommended Engine Speed |
3400 RPM |
3400 RPM |
3400 RPM |
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(No Load) (International Unit) |
2300 RPM |
2300 RPM |
2300 RPM |
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Idle Speed |
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1400 RPM |
1400 RPM |
1400 RPM |
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Charging System Output |
15 amps |
15 amps |
15 amps |
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Head Bolt Torque |
30 ft·lb (40.7 N·m) |
30 ft·lb (40.7 N·m) |
30 ft·lb (40.7 N·m) |
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Connecting Rod Torque |
130 in·lb (17.3 N·m) |
130 in·lb (17.3 N·m) |
130 in·lb (17.3 N·m) |
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Flywheel Torque |
49 ft·lb (66.4 N·m) |
49 ft·lb (66.4 N·m) |
49 ft·lb (66.4 N·m) |
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Engine Specifications (liquid-cooled)
Item |
73545 (73546) |
73550 (73551) |
Manufacturer/Model |
Kawasaki/FD620D |
Daihatsu/582447 Diesel |
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Horsepower (kW) |
20 HP (14.9 kW) |
23 HP (17.1) |
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Oil Viscosity Over 40° F (5°C) |
10W-30 or 10W-40 Above 0°F (-18°C) |
10W-30 or 10W-40 Above 0°F (-18°C) |
Below 40° F (5° C) |
5W-20 or 5W-30 Below 32° F (0° C) |
5W-30 Below 50° F (10°C) |
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Oil Capacity (With Filter) |
1.9 U.S. Qts. (1.8l) |
3.5 U.S. Qts. (3.3 l ) |
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Coolant Capacity |
4.1 Qts. |
5 Qts. |
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Spark Plug (NGK # Shown) |
BMR4A |
N/A |
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Spark Plug Gap |
.024 -.028 in (0.6 - 0.7 mm) |
N/A |
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Recommended Engine Speed |
3400 RPM |
3400 RPM |
(International Units) |
2300 RPM |
2200 RPM |
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Idle Speed |
1550 |
1850 |
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Charging System Output |
20 amps |
40 amps |
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Head Bolt Torque |
15 ft·lb (21 N·m) |
25 ft·lb (34 N·m) |
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Connecting Rod Torque |
15 ft·lb (21 N·m) |
27 ft·lb (36 N·m) |
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Flywheel Torque |
80 ft·lb (110 N·m) |
35 ft·lb (47 N·m) |
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1 - 6 |
5xi Series Tractor Service Manual |
MAINTENANCE TABLE
Service Schedule
Item |
Kohler, Manual |
Kohler, Power |
Kawasaki |
Daihatsu |
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Steering |
Steering |
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Grease Zerks |
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Front wheel spindles (2) |
Every 50 hrs. |
Every 50 hrs. |
Every 50 hrs. |
Every 50 hrs. |
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Front axle pivot (1) |
Every 50 hrs. |
Every 50 hrs. |
Every 50 hrs. |
Every 50 hrs. |
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Maintenance panel (3) |
Every 50 hrs. |
Every 50 hrs. |
Every 50 hrs. |
Every 50 hrs. |
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Pulley box (2) |
Every 50 hrs. |
Every 50 hrs. |
Every 50 hrs. |
Every 50 hrs. |
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Deck spindles (3) until |
Every 25 hrs. |
Every 25 hrs. |
Every 25 hrs. |
Every 25 hrs. |
1c |
resistance is felt |
|
|
|
|
|
|
|
|
|
|
|
Deck idler & wheels (3) 60" |
Every 50 hrs. |
Every 50 hrs. |
Every 50 hrs. |
Every 50 hrs. |
|
|
|||||
60" deck gage wheels |
Every 25 hrs. |
Every 25 hrs. |
Every 25 hrs. |
Every 25 hrs. |
|
grease |
|
|
|
|
|
Foot pedal shaft (1) |
Every 50 hrs. |
Every 50 hrs. |
Every 50 hrs. |
Every 50 hrs. |
|
Steering (1) one pump |
Every 50 hrs. |
N/A |
N/A |
N/A |
|
Engine |
|
|
|
|
|
Check oil level |
Every use |
Every use |
Every use |
Every use |
|
Oil change |
@ 5 hrs. |
@ 5 hrs. |
@ 5 hrs. |
@ 5 hrs. |
|
|
Every 100 hrs. |
Every 100 hrs. |
Every 100 hrs. |
Every 100 hrs. |
|
Oil filter change |
Every 200 hrs. |
Every 200 hrs. |
Every 200 hrs. |
@ 50 hrs. |
|
|
|
|
|
Every 200 hrs. |
|
Air filter |
Every 100 hrs. |
Every 100 hrs. |
Every 100 hrs. |
Every 100 hrs. |
|
Precleaner clean & oil |
Every 25 hrs. |
Every 25 hrs. |
Every 25 hrs. |
N/A |
|
Fuel filter |
Every 100 hrs. |
Every 100 hrs. |
Every 100 hrs. |
Every 400 hrs. |
|
Radiator level check |
N/A |
N/A |
Every use |
Every use |
|
Radiator screen clean |
N/A |
N/A |
Every use |
Every use |
|
Radiator flush |
N/A |
N/A |
Every 400 hrs. or |
Every 400 hrs. or |
|
|
|
|
2 yrs. |
2 yrs. |
|
Change spark plugs |
Every 200 hrs. |
Every 200 hrs. |
Every 100 hrs. |
N/A |
|
Drain water from fuel filter |
N/A |
N/A |
N/A |
Every use |
|
Check fan belt |
N/A |
N/A |
Every 100 hrs. |
Every 100 hrs. |
|
|
|
|
|
|
|
@ = initial service
NOTE: Service more frequently under dry/dirty/dusty conditions
5xi Series Tractor Service Manual |
1 - 7 |
MAINTENANCE TABLE
Service Schedule (cont’d)
|
|
Item |
Kohler, Manual |
Kohler, Power |
Kawasaki |
Daihatsu |
|
|
|
Steering |
Steering |
|
|
|
|
|
|
|
|
|
|
|
Transaxle & Hydraulics |
|
|
|
|
|
|
Oil level check |
25 hrs. |
25 hrs. |
25 hrs. |
25 hrs. |
|
|
Oil change |
Every 200 hrs. |
Every 200 hrs. |
Every 200 hrs. |
Every 200 hrs. |
|
|
Oil filter change |
@ 50 hrs.; |
@ 50 hrs.; |
@ 50 hrs.; |
@ 50 hrs.; |
|
|
|
Every 200 hrs. |
Every 200 hrs. |
Every 200 hrs. |
Every 200 hrs. |
1c |
|
Clean power steering |
N/A |
@ 50 hrs.; |
@ 50 hrs.; |
@ 50 hrs.; |
|
screen |
|
Every 200 hrs. |
Every 200 hrs. |
Every 200 hrs. |
|
|
|
Miscellaneous |
|
|
|
|
|
|
Check PTO belt tension |
Every 50 hrs. |
Every 50 hrs. |
Every 50 hrs. |
Every 50 hrs. |
|
|
Check battery electrolyte |
Every 25 hrs. |
Every 25 hrs. |
Every 25 hrs. |
Every 25 hrs. |
|
|
Tire pressure |
Every 25 hrs. |
Every 25 hrs. |
Every 25 hrs. |
Every 25 hrs. |
|
|
Safety interlock |
Every use |
Every use |
Every use |
Every use |
|
|
Clean clippings from |
Every use |
Every use |
Every use |
Every use |
|
|
deck |
|
|
|
|
|
|
Check under hood for |
Every use |
Every use |
Every use |
Every use |
|
|
grass build up |
|
|
|
|
|
|
Check service brake |
Every use |
Every use |
Every use |
Every use |
|
|
function |
|
|
|
|
|
|
Clean 3 air intake screens |
Every use |
Every use |
Every use |
Every use |
|
|
Clean rear transaxle cover |
Every use |
Every use |
Every use |
Every use |
|
|
|
|
|
|
|
@ = initial service
1 - 8 |
5xi Series Tractor Service Manual |
CHASSIS
QUICK REFERENCE SECTION
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE SECTION
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydrostatic Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gasoline Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1a
1b
1c
2
3
4
5
6
5xi Series Tractor Service Manual |
2 - 1 |
CHASSIS
Table of Contents
|
MODEL/SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . |
2 - 4 |
|
|
GREASING AND LUBRICATION |
|
|
|
Service Interval/Specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
2 - 4 |
|
|
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
2 - 4 |
|
|
REAR FENDERS, FOOTREST, & TUNNEL |
|
|
|
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
2 - 7 |
|
|
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
2 - 7 |
|
|
Reassembly |
2 - 9 |
|
22 |
|||
|
|
||
|
FRONT WHEEL TOE-IN |
|
|
|
Specification/Service Interval. . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
2 - 10 |
|
|
Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
2 - 10 |
|
|
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
2 - 11 |
|
|
Spindle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
2 - 11 |
|
|
STEERING WHEEL |
|
|
|
Remove Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
2 - 12 |
|
|
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
2 - 12 |
|
|
POWER STEERING |
|
|
|
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
2 - 13 |
|
|
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
2 - 13 |
|
|
SMART TURN STEERING |
|
|
|
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
2 - 15 |
|
|
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
2 - 15 |
|
|
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
2 - 16 |
|
|
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
2 - 16 |
2 - 2 |
5xi Series Tractor Service Manual |
CHASSIS
MOTION CONTROL PEDAL
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 20 TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 20 FUEL TANK SHUT-OFF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRIC PTO CLUTCH
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 21
Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 21
|
2 |
DRIVE SHAFT |
|
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
2 - 22 |
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
2 - 22 |
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
2 - 22 |
5xi Series Tractor Service Manual |
2 - 3 |
CHASSIS
MODEL/SERIAL NUMBER LOCATION
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.
2.0757.015
|
GREASING AND LUBRICATION |
|
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 - 4 |
5xi Series Tractor Service Manual |
CHASSIS
Remove the maintenance panel located in the tunnel in front of the seat.
2.0109.026
2
This will allow access to the 3 zerk fittings below.
2.0109.024
The pulley box for the mower deck contains 2 zerk fittings; one at each pulley pivot.
2.0144.023
5xi Series Tractor Service Manual |
2 - 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 - 6 |
5xi Series Tractor Service Manual |
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.
2.0109.039
Removal 2
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.
2.0109.021 |
|
2.0109.003 |
2.0109.020 |
2.Remove the brake and motion control pedals.
5xi Series Tractor Service Manual |
2 - 7 |
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 - 8 |
5xi Series Tractor Service Manual |
2.0109.017
2.0109.014
2.0109.039
CHASSIS
6.Remove the knob for the transaxle range selector.
2
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.
NOTE: Do not pinch any wiring between the fender assembly and the top edges of the frame.
5xi Series Tractor Service Manual |
2 - 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 - 10 |
5xi Series Tractor Service Manual |
2.0109.047
2.0109.048
2.0109.046
CHASSIS
Adjustment
1.Loosen the jam nuts at the ends of the steering rods.
2
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.
5xi Series Tractor Service Manual |
2 - 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.
2.0144.053
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 no fixed “straight ahead” position on power steering models.
2.Torque the retaining nut to 45 - 50 ft·lbs.
3.Replace the trim cover.
2.0144.052
2 - 12 |
5xi Series Tractor Service Manual |
CHASSIS
3.7195.029 |
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
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.
2.0109.044
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.
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
ends to keep out dirt.
2.0144.16
5xi Series Tractor Service Manual |
2 - 13 |
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 - 14 |
5xi Series Tractor Service Manual |
2.3653.005
2.0144.059
2.0144.63
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.
Theory of Operation |
|
2 |
|
|
|
|
|
|
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.
5xi Series Tractor Service Manual |
2 - 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 - 16 |
5xi Series Tractor Service Manual |
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