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
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.
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).
TABLE OF CONTENTS QUICK REFERENCE SECTION Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1a Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1b Maintenance Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1c SERVICE SECTION Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . .
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 5xi series garden tractor.
SPECIFICATIONS Product Lineup 1b Model Name (International) Engine HP Drive Type 73470 73540 (73541) 73560 73545 (73546) 73550 (73551) Kohler Kohler Kohler Kawasaki Daihatsu 18 20 22 20 23 Eaton 11 Hydro, 2 speed Uni-Drive® transaxle Eaton 11 Hydro, 2 speed Uni-Drive® transaxle Eaton 11 Hydro, 2 speed Uni-Drive® transaxle Eaton 11 Hydro, 2 speed Uni-Drive® transaxle Eaton 11 Hydro, 2 speed Uni-Drive® transaxle 518xi 520xi 522xi 520Lxi 523Dxi Tractor Specifications Item 73470 73540 (73541) 735
SPECIFICATIONS Attachments and Accessories (partial listing) Part # (International) Description Drive Belt Spindle Belt 78353 (78442) 42" Rear Discharge Mower 95-4093 95-4230 78357 (78444) 44" Side Discharge Mower 95-4094 95-4228 78358 44" Recycler® Mower 95-4094 95-4228 78363 (78448) 48" Side Discharge Mower 95-4095 95-3878 78364 48" Recycler® Mower 95-4095 95-3878 78370 (78452) 52" Side Discharge Mower 95-4094 94-2501 78375 52" Recycler® Mower 95-4094 94-2501 78395 (78469)
SPECIFICATIONS Engine Specifications (air-cooled) 1b Item 73470 73540 (73541) 73560 Manufacturer/Model Kohler/CH18S Kohler/CH20S Kohler/CH22S Horsepower (kW) 18 HP (13.4 kW) 20 HP (14.9 kW) 22 HP (16.4 kW) Oil Viscosity Over 0° F (-18° C) Below 32°F (0° C) 10W-30 5W-20 or 5W-30 10W-30 5W-20 or 5W-30 10W-30 5W-20 or 5W-30 Oil Capacity (With Filter) 2.1 Qts. (2 l) U.S. Qts. U.S. Qts. U.S. Qts. Spark Plug (Champion # Shown) RC12YC RC12YC RC12YC Spark Plug Gap .030 in (.76 mm) .
MAINTENANCE TABLE Service Schedule Item Kohler, Manual Steering Kohler, Power Steering Kawasaki Daihatsu Every 50 hrs. Every 50 hrs. Every 50 hrs. Every 50 hrs. Every 25 hrs. Every 50 hrs. Every 50 hrs. Every 50 hrs. Every 50 hrs. Every 25 hrs. Every 50 hrs. Every 50 hrs. Every 50 hrs. Every 50 hrs. Every 25 hrs. Every 50 hrs. Every 50 hrs. Every 50 hrs. Every 50 hrs. Every 25 hrs. Every 50 hrs. Every 25 hrs. Every 50 hrs. Every 25 hrs. Every 50 hrs. Every 25 hrs. Every 50 hrs. Every 25 hrs.
MAINTENANCE TABLE Service Schedule (cont’d) Item Kohler, Manual Steering Kohler, Power Steering Kawasaki Daihatsu 25 hrs. Every 200 hrs. @ 50 hrs.; Every 200 hrs. N/A 25 hrs. Every 200 hrs. @ 50 hrs.; Every 200 hrs. @ 50 hrs.; Every 200 hrs. 25 hrs. Every 200 hrs. @ 50 hrs.; Every 200 hrs. @ 50 hrs.; Every 200 hrs. 25 hrs. Every 200 hrs. @ 50 hrs.; Every 200 hrs. @ 50 hrs.; Every 200 hrs. Every 50 hrs. Every 25 hrs. Every 25 hrs. Every use Every use Every 50 hrs. Every 25 hrs. Every 25 hrs.
CHASSIS QUICK REFERENCE SECTION Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1a Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1b Maintenance Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1c SERVICE SECTION Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . .
CHASSIS MOTION CONTROL PEDAL Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 20 TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 20 FUEL TANK SHUT-OFF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 20 ELECTRIC PTO CLUTCH General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 21 Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
CHASSIS Remove the maintenance panel located in the tunnel in front of the seat. 2.0109.026 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.
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.
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 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. Remove the brake and motion control pedals. 2.0109.
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.
CHASSIS 6. Remove the knob for the transaxle range selector. 2.0109.017 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. 2.0109.014 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.
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.
CHASSIS Adjustment 1. Loosen the jam nuts at the ends of the steering rods. 2.0109.047 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). 2.0109.
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.
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.
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.
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. 2.3653.
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.
CHASSIS 2. Check the adjustment of link (A) which connects the lower steering plate (B) to the bell crank (C). To do this: 2.0144.059 A. Align the front wheels straight ahead so that the front of the lower steering plate is square to the frame rails of the tractor. Verify the alignment by placing a straight edge across the front edge of the lower steering plate (A), aligning it with the foot rest support (B) as described on page 2-10. Note: Keep wheels aligned straight ahead except where noted. 2.0109.
CHASSIS SMART TURN™ STEERING (cont’d) If the slider is not adjusted correctly, loosen jam nuts (E), and turn the link to adjust the length. Then tighten the jam nuts securely. NOTE: The front jam nut is left hand thread, and the rear jam nut is right hand thread. NOTE: Jam nuts “E” are marked with paint at the factory to discourage unnecessary tampering. 2.0144.085 22 3. Test the adjustment of link (F) (see page 2-16). If adjustment is necessary: A. Depress the brake.
CHASSIS Tighten the rear jam nut first. Hold the front rod end fitting while tightening the front jam nut. IMPORTANT: There must be axial looseness in the rod (A) or there may be binding in the pedal linkages. 2.7233.073 2 Test the adjustment by cycling the brake. The slot should travel over bushing (A) without touching. 2.0144.089 4. Check the neutral adjustment.
CHASSIS MOTION CONTROL PEDAL Adjustment 1. Push the motion control pedal to the full reverse position. 2. Check the clearance between the pedal support and the reverse stop. 3. Adjust the rod as necessary to obtain the correct clearance. Clearance: 1/16" (1.7 mm) 2.0144.034 TIRE PRESSURE 22 Pressure: 12 psi (82.7 kPa) front and rear. Check the tire pressure after every 25 operating hours or monthly, whichever occurs first. Check the tires when they are cold to get the most accurate pressure reading.
CHASSIS ELECTRIC PTO CLUTCH General Information The 5xi series garden tractor is equipped with a heavy-duty electric clutch. This clutch is maintenance free and, therefore, requires no air gap adjustment. Note: Troubleshooting procedures, for the electric PTO system, are located in the Electrical section of this manual. If the clutch is replaced, apply high temperature Never Seize to the crankshaft threads, use a new thread locking patch bolt torque to 50 - 60 ft·lb (70 - 84 N·m). 2.0109.
CHASSIS DRIVE SHAFT General Information Power is transmitted from the engine to the transmission by a drive shaft running between the frame rails. The drive shaft is supported by two flexible couplings located at each end. The drive shaft assembly requires no periodic maintenance or adjustments. 2.0144.005 22 Inspection Visually inspect the flexible couplings for tears, fraying, or deterioration. 2.0144.077 Assembly 1.
CHASSIS 3. On the engine end of the driveshaft, slide the front flange over the square key on the engine crankshaft (A). 2.7162.005 Note: On diesel powered tractors, the key is fitted to the flange (B). Then the flange is slid into a hub (C) mounted to the crankshaft’s pulley. 2.3653.011 4. Install the four spacers through the rubber couplings making sure they are properly seated and squared to the coupling.
CHASSIS DRIVE SHAFT (cont’d) 5. Install the drive shaft to the rear flange by sliding the long head spacers over the bolts. Torque the nuts to 170 - 220 in·lbs (231 - 299 N·m). 2.0144.094 22 6. Align the bolt holes in the tall headed spacers (C) in the front flexible coupling with the bolt holes in the flange and slide flange on shaft up to the spacers. Install the nuts, bolts, and washers. Washer and bolt head are against flexible coupling; nut is on back side of flange.
HYDROSTATIC DRIVE QUICK REFERENCE SECTION Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1a Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1b Maintenance Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1c SERVICE SECTION Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HYDROSTATIC DRIVE Table of Contents TROUBLESHOOTING Tractor will not operate in either direction because the engine bogs down or stalls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3 Tractor goes forward only at partial speed and is slow or does not operate in reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3 Tractor will not operate in either direction. . . . . . . . . . . . . . . . . . . . 3 - 3 Tractor operates erratically . . . . . . . . . . . . . . . . .
HYDROSTATIC DRIVE TROUBLESHOOTING Whenever a problem occurs with the hydrostatic drive system, you should always check these items first: 1. Transmission oil is at proper level and air is bled from system. 2. Make sure the high-low speed lever is not in neutral. 3. Speed control linkage is functioning properly. 4. Cruise control is turned off. Tractor will not operate in either direction because the engine bogs down or stalls.
HYDROSTATIC DRIVE TROUBLESHOOTING (cont’d) Tractor operates erratically. Possible Cause Corrective Action The transmission control linkage needs adjustment or replacement The transmission oil level is low Adjust, repair, or replace The transmission is faulty Fill to the full “F” mark on the transmission oil dipstick when transmission is cold Repair/replace Tractor operates in both directions but with loss of power. Condition becomes worse as transmission becomes hot.
HYDROSTATIC DRIVE TRANSAXLE FLUID General Information All models of the 5xi series tractor are equipped with the Toro Wheel Horse transaxle with the Eaton model 11 hydrostatic transmission. The transmission is equipped with a charge pump which supplies hydraulic pressure to operate the attachment lift and power steering on units so equipped . The charge pump also provides pressurized fluid to the transmission pump to make up for normal internal leakage.
HYDROSTATIC DRIVE TRANSAXLE FLUID (cont’d) Fluid Change The hydrostatic fluid should be changed every 200 hours of operation. Remove the drain plug and drain the transaxle fluid into a suitable container. Replace the drain plug, and fill the transaxle to the FULL mark with 10W-30 detergent oil with an API service rating of SH or higher. System Capacity (refill capacity is 4.5 quarts): With power steering: 7 qts. (6.6 l) Without power steering: 6 qts. (5.6 l) 2.0415.
HYDROSTATIC DRIVE BRAKE General Information The 5xi series series tractor is equipped with an external band parking brake which is located on the right side of the transaxle. When the brake pedal is pressed, the linkage returns the transmission to neutral, then applies the brake. The primary function of the brake is to keep the tractor from rolling after it has been stopped. It can also be locked in the applied position and serves as the parking brake. 3.7197.067 Adjustment 1.
HYDROSTATIC DRIVE NEUTRAL ADJUSTMENT General Information The hydrostatic transmission linkage is designed to be self-centering or “return to neutral”. If the wheels continue to drive with no pressure on the control pedal (tractor creeps), neutral adjustment is required. CAUTION: The hydrostatic cooling fan will be spinning. Use extreme caution to avoid making contact with the fan while performing this adjustment. 2.0144.001 Adjustment Procedure 3 1.
HYDROSTATIC DRIVE 4. Loosen the through bolt just enough to allow rotation of the eccentric (A). 2.0144.072 5. With the engine running, rotate the eccentric until the right rear wheel hub begins to turn. Note the position of the eccentric. Rotate the eccentric in the opposite direction until the wheel hub again begins to turn. 3 2.0144.071 6. Center the eccentric between these points, and tighten the through bolt while holding the eccentric.
GASOLINE ENGINE QUICK REFERENCE SECTION Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1a Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1b Maintenance Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1c SERVICE SECTION Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GASOLINE ENGINE Table of Contents TROUBLESHOOTING Engine cranks but will not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3 Starter does not crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3 Engine starts but does not keep running. . . . . . . . . . . . . . . . . . . . . . . . 4 - 3 Engine is difficult to start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3 Engine runs but knocks or misses. . . . . . . . . . .
GASOLINE ENGINE TROUBLESHOOTING Engine cranks but will not start.
GASOLINE ENGINE TROUBLESHOOTING (cont’d) Engine runs but knocks or misses. Possible Cause Corrective Action Dirt, water, or stale fuel is in the fuel system A spark plug lead is loose A spark plug is faulty Loose wires or poor connections Engine overheating Drain and flush the fuel system; add fresh fuel Reconnect the spark plug lead Replace the spark plug Check and tighten wire connections See ENGINE OVERHEATS Engine will not idle.
GASOLINE ENGINE AIR CLEANER Service Interval/Specification Foam Element (A): Clean and re-oil after every 25 operating hours, or yearly, whichever occurs first. Paper Element (B): Replace after every 100 operating hours or yearly, whichever comes first. NOTE: Service the air cleaner more frequently (every few hours) if operating conditions are extremely dusty or sandy. 2.7146.035 Cleaning FOAM ELEMENT 1. Wash the foam element in liquid soap and warm water. When the element is clean, rinse it thoroughly.
GASOLINE ENGINE ENGINE OIL Service Interval Oil Type: Detergent oil (API service SH or higher). Crankcase capacity (with filter): 3.8 pt. (1.8 l). Viscosity: See table. Change oil: • After first 5 operating hours. • After every 100 operating hours. F C -20 -30 0 -20 20 -10 32 40 0 60 10 80 20 100 30 40 3.7197.079 Changing/Draining 1. Run the engine for five minutes. 4 2. Park the machine so the drain side is slightly lower than the opposite side. Set the parking brake and turn the engine off. 3.
GASOLINE ENGINE Changing 1. Drain the oil from the engine. 2. Remove the old filter and wipe the filter adapter gasket surface. 3. Apply a thin coat of new oil to the rubber gasket on the replacement filter. 4. Install the new filter to the filter adapter. Turn the filter clockwise until the gasket contacts the filter adapter, then tighten the filter an additional 1/2 turn. 5. Fill the crankcase with the proper oil. 3.0144.
GASOLINE ENGINE SPARK PLUG (cont’d) Installation Install the spark plugs and metal washer. Make sure the air gap (.028) is set correctly. Torque the spark plugs to specifications. Spark plug torque: Kohler engines 18-22 ft·lbs (24-30 N·m) Kawasaki engines 18 ft·lbs (25 N·m) 2.0144.048 FUEL FILTER Service Interval Replace the fuel filter after every 100 operating hours or yearly, whichever occurs first. 4 2.0144.
GASOLINE ENGINE Maintenance Inspect air intake screens often. Keep cooling and combustion air paths free of debris at all times. Consult the engine manufacturer’s service manual for specific instructions and service intervals. NOTE: Operating the engine with a blocked air intake screen, dirty or plugged cooling fins, and/or cooling shrouds removed, will cause engine damage due to overheating. It is preferable to blow dirt out, rather than washing it out. If water is used, keep it away from electrical items.
GASOLINE ENGINE COOLING SYSTEM, LIQUID (cont’d) Maintenance Inspect the cooling system often. Carefully clean grass clippings and other debris from air intake screens and radiator fins. 2.0144.012 Maintain coolant level in the coolant recovery tank between two lines on reservoir bottle with a 50/50 mix of antifreeze and water. Caution: Do not remove the radiator cap when the engine is hot. Discharge of hot coolant can cause severe burns. 4 2.0144.
DIESEL ENGINE QUICK REFERENCE SECTION Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1a Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1b Maintenance Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1c SERVICE SECTION Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIESEL ENGINE Table of Contents TROUBLESHOOTING Engine cranks but will not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3 Starter does not crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3 Engine starts but does not keep running. . . . . . . . . . . . . . . . . . . . . . . . 5 - 3 Engine is difficult to start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 4 Engine runs but knocks and misses . . . . . . . . . . . .
DIESEL ENGINE TROUBLESHOOTING Warning: Diesel fuel under high pressure. Cover fittings before loosening. High pressure fuel can penetrate skin causing blood poisoning or infection. Engine cranks but will not start.
DIESEL ENGINE TROUBLESHOOTING (cont’d) Engine is difficult to start.
DIESEL ENGINE Engine loses power.
DIESEL ENGINE AIR CLEANER Service Interval/Specification Paper Element: Replace after every 100 operating hours or yearly, whichever comes first. NOTE: Service the air cleaner more frequently (every few hours) if operating conditions are extremely dusty or sandy. 3.7230.079 Cleaning 1. Lightly tap the element on a flat surface to remove dust and dirt. 2. Inspect the element for tears, an oily film, or damage to the rubber seal.
DIESEL ENGINE Changing/Draining 1. Run the engine for five minutes. 2. Park the machine so the drain side is slightly lower than the opposite side. Set the parking brake and turn the engine off. 3. Remove the drain plug. 4. Let oil drain completely. Close drain. 5. Refill to specified level with recommended oil. 2.0757.008 OIL FILTER Service Interval/Specification Replace the oil filter after the first 50 hours of operation. Then replace every 200 hours or every other oil change. 5 2.0757.
DIESEL ENGINE COOLING SYSTEM General Information A belt driven water pump circulates coolant through passages in the engine block and cylinder heads. The coolant carries engine heat to a radiator which transfers the heat stored in the coolant to the surrounding air by drawing the cooler ambient air through fins in the radiator with the fan. 3.7197.100 Engine temperature is maintained by a thermostat which opens at approximately 180° F (82° C).
DIESEL ENGINE • Inspect coolant hoses and fan belt for deterioration every 400 hours or 2 years of operation. Replace when deterioration is noted. • Watch for signs of leaks such as rust streaks or puddles of coolant under the tractor. • Change engine coolant according to the service interval and instructions in the engine manufacturer’s service manual. 2.0757.007 ENGINE MOUNTS Engine Mounting The diesel engine is mounted on vibration dampening rubber isolators.
DIESEL ENGINE GLOW PLUGS Cold Start Up The diesel engines are equipped with glow plugs to provide fast start-ups and minimize white smoke from the exhaust. The glow plug system is activated by turning the ignition switch to the ON position. An indicator light will go out when the engine is ready to start. 2.0757.
ELECTRICAL QUICK REFERENCE SECTION Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1a Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1b Maintenance Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1c SERVICE SECTION Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL Table of Contents BATTERY Service Interval/Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 4 Battery Heat Shield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 4 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 5 Electrolyte Level . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SAFETY INTERLOCK SYSTEM Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 9 Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 9 CRUISE CONTROL General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 10 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 10 Troubleshooting . . . . . . . . . . . . . . .
ELECTRICAL BATTERY Service Interval/Specification Check the electrolyte level in the battery every 25 hours. Always keep the battery clean and fully charged. If the battery terminals are corroded, clean them with a solution of four parts water and one part baking soda. Apply a light coating of grease to the battery terminals to prevent corrosion. Voltage/Cold Cranking Amps Gasoline Engines 12V 380 CCA Diesel Engines 12V 495 CCA 2.0109.012 Removal 1.
ELECTRICAL Installation 1. Install the battery into the chassis. 2. Connect the positive (red) cable to the positive (+) battery post. 3. Connect the negative (black) cable to the negative (-) battery post. 4. Secure the battery with the hold down rods. 5. Install the grille. 2.0109.041 Electrolyte Level 1. With the engine off, remove the covers on the battery. 2. The electrolyte must be up to the lower part of the tube (A). Do not allow electrolyte to get below the top of the plates. 3.
ELECTRICAL BATTERY (cont’d) Charging IMPORTANT: Always keep the battery fully charged (1.260 specific gravity). This helps prevent battery damage when the temperature is below 32° F (0 °C). 1. Remove the battery from the chassis. 2. Check the electrolyte level. 3. Remove the filler caps and connect a 3 to 4 amp battery charger. Charge at a rate of 4 amps (12V) or less for 4 hours. Do not overcharge the battery. Install the filler caps after the battery is charged. 4. Install the battery in the chassis. 2.
ELECTRICAL Bulb Installation 1. Align the pins on the bulb with the slots in the bulb holder and insert. Push and rotate the bulb clockwise until it stops. 2. Align the tabs on the bulb holder with the slots in the reflector, insert and rotate 1/4 turn clockwise until it stops. 3. Push the wire connectors onto the terminals. Bulb Number: GE 1156 2.0757.031 INSTRUMENT PANEL LIGHTS Bulb Removal 1. Disengage the PTO, set the parking brake, turn the ignition key to OFF, and remove the key. 2.
ELECTRICAL TAILLIGHTS Bulb Removal 1. Remove the taillight assembly from the fender. 2. Rotate the bulb holder 1/4 turn counterclockwise and remove it from the housing. 3. Push and rotate the bulb counterclockwise until it stops (approximately 1/4 turn). Bulb Number: GE 194 2.0757.027 ELECTRIC CLUTCH TROUBLESHOOTING General Information Equipment Needed: Volt/Ohm and Ampmeter The following troubleshooting steps will help you determine if the clutch has failed or is the cause of the electrical problem.
ELECTRICAL 4. Connect the meter lead wires to the wires in the clutch connector. The meter should read between 2.40 and 3.40 ohms. If the readings are not within specifications, the coil has failed and the clutch must be replaced. If the resistance is within specifications, the electric clutch is not the source of the problem. 3.7197.122 SAFETY INTERLOCK SYSTEM Purpose The safety interlock system is designed to prevent the engine from starting unless: 1. You are sitting on the seat. 2.
ELECTRICAL SAFETY INTERLOCK SYSTEM (cont’d) If the system fails any of these tests, you will need to troubleshoot the system. The 260 series Electrical Demystification Guide (form no. 492-4404) describes how to test individual switches and circuits. DEMYSTIFICA TION DEMYSTIFICATION GUIDE GUIDE 3.7197.
ELECTRICAL This magnet (A) is mounted below a control plate (B). The control plate is connected to the speed control lever. When the cruise control is activated, the magnet clamps the control plate in position which holds the speed control lever at the desired speed. Tapping the brake pedal or shutting the switch off deactivates the system. The foot pedal can be used to override the cruise control; the pre-set speed will resume when the pedal is released.
ELECTRICAL FUEL GAUGE General Information The fuel gauge consists of a level indicator (gauge) located in the instrument panel and a sender located in the fuel tank. 2.0144.074 2.0144.074 Theory of Operation E F B+ is supplied to one side of the fuel gauge. The other side of the gauge is connected to ground through the sender. 6 3.7197.133 When the ignition switch is in the ON position, current flow through the gauge winding causes the needle to move.
2.0144.084 F E ELECTRICAL The amount of current flow is controlled by the sender which consists of a rheostat connected to a float mounted in the fuel tank. When the tank is Full, the float is high and the resistance of the rheostat is low, allowing more current flow which moves the needle to the Full mark. F E 2.0144.074 As fuel is consumed, the float moves down increasing the resistance and allows less current flow. This causes the needle to move toward empty. 6 3.7197.
ELECTRICAL FUEL GAUGE (cont’d) 2. Connect the wire to ground (maximum current). The gauge should read Full. If conditions 1 and 2 are not met, the problem is in the wiring or the gauge. 2.0144.056 2.0144.075 If conditions 1 and 2 above are met, the problem is with the sender. To test the sender: 1. Remove the sender from the fuel tank. 2. Connect an ohmmeter from the wire terminal to the sender body (ground). 6 3. Move the float through its travel.
ELECTRICAL Tractors powered by liquid-cooled Kawasaki engines have a 20 amp alternator. The voltage regulator on these units is mounted to the tractor. 2.0757.011 Diesel tractors are equipped with a belt driven alternator with an integral voltage regulator. 6 2.0144.032 Testing Connect a voltmeter across the battery. The voltage should read between 13.8 -14.2 VDC at 3400 RPM with the lights on.
ELECTRICAL CHARGING SYSTEM (cont’d) Voltage Regulator Replacement On air-cooled engines, it is necessary to raise the voltage regulator side of the engine (right-hand side) to provide clearance for removal of the voltage regulator. Remove the two engine mounting bolts on the voltage regulator side of the engine. Loosen the engine mounting bolts on the side opposite the voltage regulator. Raise the engine, disconnect the wires, and remove the voltage regulator.
6-17 6 518xi ELECTRICAL S4 (IGNITION SWITCH) WIRE COLOR CODES OFF-----------------------NOCONNECTION RUN/LIGHTS-------------B I R L RUN-----------------------B I R START---------------------B I R S L 18 Kohler I 4 S 3 B 1 S R 5 2 R B BK I L BN BLACK BROWN BLUE BU GREEN GN HEADLIGHT HARNESS OR F4 OR 10A IGNITION SWITCH TERMINAL LOCATIONS VEIWED FROM BACK.
6-17 6 518xi ELECTRICAL S4 (IGNITION SWITCH) WIRE COLOR CODES OFF-----------------------NOCONNECTION RUN/LIGHTS-------------B I R L RUN-----------------------B I R START---------------------B I R S L 18 Kohler I 4 S 3 B 1 S R 5 2 R B BK I L BN BLACK BROWN BLUE BU GREEN GN HEADLIGHT HARNESS OR F4 OR 10A IGNITION SWITCH TERMINAL LOCATIONS VEIWED FROM BACK.
6-17 6 518xi ELECTRICAL S4 (IGNITION SWITCH) WIRE COLOR CODES OFF-----------------------NOCONNECTION RUN/LIGHTS-------------B I R L RUN-----------------------B I R START---------------------B I R S L 18 Kohler I 4 S 3 B 1 S R 5 2 R B BK I L BN BLACK BROWN BLUE BU GREEN GN HEADLIGHT HARNESS OR F4 OR 10A IGNITION SWITCH TERMINAL LOCATIONS VEIWED FROM BACK.
SW4 (IGNITION SWITCH) HEADLIGHT HARNESS OFF--------------------NO CONNECTION RUN/LIGHTS----------B I R L RUN--------------------B I R START-------------------B I R S L I 4 REAR HARNESS BK OR BK OR S 3 B 1 WIRE COLOR CODES S R 5 2 R B BK BLACK P PINK I L BN BROWN R RED BU BLUE T TAN GN GREEN VIO VIOLET GY GREY W WHITE OR ORANGE Y YELLOW TAIL LIGHTS A OR BK GN 10A R VIO IGNITION SWITCH TERMINAL LOCATIONS VEIWED FROM BACK.
SW4 (IGNITION SWITCH) HEADLIGHT HARNESS OFF--------------------NO CONNECTION RUN/LIGHTS----------B I R L RUN--------------------B I R START-------------------B I R S L I 4 REAR HARNESS BK OR BK OR S 3 B 1 WIRE COLOR CODES S R 5 2 R B BK BLACK P PINK I L BN BROWN R RED BU BLUE T TAN GN GREEN VIO VIOLET GY GREY W WHITE OR ORANGE Y YELLOW TAIL LIGHTS A OR BK GN 10A R VIO IGNITION SWITCH TERMINAL LOCATIONS VEIWED FROM BACK.
SW4 (IGNITION SWITCH) HEADLIGHT HARNESS OFF--------------------NO CONNECTION RUN/LIGHTS----------B I R L RUN--------------------B I R START-------------------B I R S L I 4 REAR HARNESS BK OR BK OR S 3 B 1 WIRE COLOR CODES S R 5 2 R B BK BLACK P PINK I L BN BROWN R RED BU BLUE T TAN GN GREEN VIO VIOLET GY GREY W WHITE OR ORANGE Y YELLOW TAIL LIGHTS A OR BK GN 10A R VIO IGNITION SWITCH TERMINAL LOCATIONS VEIWED FROM BACK.
6-19 6 520Lxi SW4 (IGNITION SWITCH) HEADLIGHT HARNESS WIRE COLOR CODES OFF----------------------NO CONNECTION RUN/LIGHTS----------B I R L RUN----------------------B I R START--------------------B IR S L I 4 S 3 1 R S B 2 5 REAR HARNESS BK OR BK OR R B I L TAIL LIGHTS A GN VIO P P K1 (INTERLOCK RELAY) P VIO TAN GN GREEN VIO VIOLET GY GREY W WHITE OR ORANGE Y YELLOW #1 CYL. IGNITION COILS F1 30A F2 25A #2 CYL.
6-19 6 520Lxi SW4 (IGNITION SWITCH) HEADLIGHT HARNESS WIRE COLOR CODES OFF----------------------NO CONNECTION RUN/LIGHTS----------B I R L RUN----------------------B I R START--------------------B IR S L I 4 S 3 1 R S B 2 5 REAR HARNESS BK OR BK OR R B I L TAIL LIGHTS A GN VIO P P K1 (INTERLOCK RELAY) P VIO TAN GN GREEN VIO VIOLET GY GREY W WHITE OR ORANGE Y YELLOW #1 CYL. IGNITION COILS F1 30A F2 25A #2 CYL.
6-19 6 520Lxi SW4 (IGNITION SWITCH) HEADLIGHT HARNESS WIRE COLOR CODES OFF----------------------NO CONNECTION RUN/LIGHTS----------B I R L RUN----------------------B I R START--------------------B IR S L I 4 S 3 1 R S B 2 5 REAR HARNESS BK OR BK OR R B I L TAIL LIGHTS A GN VIO P P K1 (INTERLOCK RELAY) P VIO TAN GN GREEN VIO VIOLET GY GREY W WHITE OR ORANGE Y YELLOW #1 CYL. IGNITION COILS F1 30A F2 25A #2 CYL.
Diesel BK TAIL LIGHTS WIRE COLOR CODES OFF--------------------NO CONNECTION RUN/LIGHTS----------B I R L RUN--------------------B I R START------------------B I R S REAR HARNESS L I S R B 4 3 1 2 5 P PINK R B BN BROWN R RED I L BU BLUE T TAN GN GREEN VIO VIOLET GY GREY W WHITE Y YELLOW S OR IGNITION SWITCH TERMINAL B BK Y E Y BN D BN SWITCH OPENS WHEN BRAKE IS DEPRESSED 15A P VIO SW1 (SEAT SWITCH) W (MOMENTARY) GN SEAT SWITCH IS CLOSED WHEN OPERATOR IS
Diesel BK TAIL LIGHTS WIRE COLOR CODES OFF--------------------NO CONNECTION RUN/LIGHTS----------B I R L RUN--------------------B I R START------------------B I R S REAR HARNESS L I S R B 4 3 1 2 5 P PINK R B BN BROWN R RED I L BU BLUE T TAN GN GREEN VIO VIOLET GY GREY W WHITE Y YELLOW S OR IGNITION SWITCH TERMINAL B BK Y E Y BN D BN SWITCH OPENS WHEN BRAKE IS DEPRESSED 15A P VIO SW1 (SEAT SWITCH) W (MOMENTARY) GN SEAT SWITCH IS CLOSED WHEN OPERATOR IS
Diesel BK TAIL LIGHTS WIRE COLOR CODES OFF--------------------NO CONNECTION RUN/LIGHTS----------B I R L RUN--------------------B I R START------------------B I R S REAR HARNESS L I S R B 4 3 1 2 5 P PINK R B BN BROWN R RED I L BU BLUE T TAN GN GREEN VIO VIOLET GY GREY W WHITE Y YELLOW S OR IGNITION SWITCH TERMINAL B BK Y E Y BN D BN SWITCH OPENS WHEN BRAKE IS DEPRESSED 15A P VIO SW1 (SEAT SWITCH) W (MOMENTARY) GN SEAT SWITCH IS CLOSED WHEN OPERATOR IS
