5XI SERIES TRACTOR HYDRAULIC SYSTEMS SERVICE MANUAL Table of Contents – Page 1 of 2 SAFETY INFORMATION GENERAL INFORMATION THINK SAFETY FIRST SPECIFICATIONS TRANSMISSION (EATON MODEL) TRANSAXLE (WHEEL HORSE) 5XI AUTOMATIC TRANSMISSION SYSTEM SPEEDS OIL BOLT TORQUE EPOXY PATCH SCREWS SINGLE-USE FASTENERS CRITICAL FASTENERS MAINTENANCE SERVICE SCHEDULE TABLE TRANSAXLE FLUID GENERAL INFORMATION CHECKING FLUID LEVEL FLUID CHANGE FILTER CHANGE BRAKE GENERAL INFORMATION ADJUSTMENT NEUTRAL ADJUSTMENT GENERAL INFOR
5XI SERIES TRACTOR HYDRAULIC SYSTEMS SERVICE MANUAL Table of Contents – Page 2 of 2 TROUBLESHOOTING TABLES - Continued TRANSMISSION OVERHEATING ABNORMAL VIBRATION OR NOISE HYDRAULIC LIFT SYSTEM DOES NOT OPERATE OR DOES NOT OPERATE PROPERLY OIL IS LEAKING OUT HIGH-LOW SHIFT FORK HOLE DURING OPERATION TROUBLESHOOTING FLOW CHARTS TRACTOR WILL NOT OPERATE IN EITHER DIRECTION TRACTOR OPERATES, BUT LOSES POWER AS OIL BECOMES HOT AND/OR TRANSMISSION OVERHEATS TRACTOR DOES NOT RETURN TO NEUTRAL TRACTOR OPERATES NOR
TORO ® 5xi Series Tractor Hydraulic Systems 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 service and repair manual has been compiled to provide authorized Wheel Horse service personnel with the proper procedures and techniques for servicing the Wheel Horse automatic transaxle with Eaton Model 11 hydrostatic transmission. Basic mechanical/electrical skills are assumed.
TABLE OF CONTENTS QUICK REFERENCE SECTION Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1a Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1b Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1c TROUBLESHOOTING Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
QUICK REFERENCE Table of Contents SAFETY INFORMATION General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5 Think Safety First. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5 SPECIFICATIONS Transmission (Eaton Model 11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6 Transaxle (Wheel Horse) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
QUICK REFERENCE BRAKE General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 12 NEUTRAL ADJUSTMENT General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 12 Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 13 POWER STEERING General Information . . .
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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 Transmission (Eaton Model 11) Item Description Radial ball piston pump and motor with auxiliary charge pump 1b Displacement, Pump Variable 0 - 1.10 cu. in./rev. (18.03 cu. cm) Displacement, Motor Fixed 2.09 cu. in./rev. (34.2 cu. cm) Speed, Input 3400 RPM Speed, Output 0 - 1842 RPM Torque Output 360 in·lb - Continuous (40.7 N·m) Torque Output 540 in·lb - Intermittent (61 N·m) Operating Temperature Maximum continuous 180° Cooling - Air 8” diameter fan (20.
SPECIFICATIONS Oil Item 73470, 73540, 73541 73560, 73545, 73546, 73550, 73551 Capacity 6 Quarts (5.7l) Approx. (refill 4.5 Quarts (4.3l)) 7 Quarts (6.6l) Approx. (refill 4.5 Quarts (4.3l)) Type 10W-30 or 10W-40 API service SH or higher 10W-30 or 10W-40 API service SH or higher 1b Bolt Torque Size - Thread Pitch Torque 1/4 - 20 8 ft·lb (.9 N·m) 5/16 - 18 17 - 22 ft·lb (23 - 30.
SPECIFICATIONS Single-Use Fasteners Torque Value Part Number Description/Where Used In-Lbs 1b Ft-Lbs N·m 911423 & 108881 Bolts and nuts / differential assembly; replace when rebuilding 39 - 47 52.9 - 63.7 95-4245 Bolt / nylon patch bolt - Used on front end of lift cylinder; replace, do not reuse 17 - 21 23.2 - 28.8 108881 Nut / Used to attach mid-attach-a-matic side plates to frame; replace, do not reuse 39 - 47 52.9 - 63.
MAINTENANCE Service Schedule Item Interval Oil Level Check Every 25 hrs. Oil Change Every 200 hrs. Oil Filter Change @ 50 hrs. Every 200 hrs. Clean Power Steering Screen @ 50 hrs. Every 200 hrs. 1c @ = initial service NOTE: Service more frequently under dry/dirty/dusty conditions. NOTE: When cleaning the unit, use compressed air vs. water to avoid contamination of the transaxle fluid.
MAINTENANCE Checking Fluid Level 1. The transaxle fluid level must be checked when the machine is cold and parked on a level surface. 2. Tilt the seat forward. 1c 3. Clean around the dipstick to prevent dirt from falling into the system when the dipstick is removed. NOTE: Allowing dirt in the reservoir may result in severe damage to the transmission. 0757-015 4. Remove the dipstick. If necessary, add oil to the FULL line on the dipstick.
MAINTENANCE Filter Change The transaxle is equipped with a 10 micron spinon oil filter. This filter should be changed after the first 50 hours of operation and then every 200 hours thereafter. 1c 0144-031 When replacing the filter, coat the gasket with oil. Tighten until the gasket contacts the base, then an additional 1/2 turn. 0144-014 BRAKE General Information The 5xi series tractor is equipped with an external band parking brake which is located on the right side of the transaxle.
MAINTENANCE Adjustment 1. Place the transmission in neutral. 2. Depress the brake pedal. There should be 2” (51mm) of free travel before resistance is felt. 1c 0109-005 3. Turn the adjustment nut until the above condition is met. CAUTION: Do not overtighten the adjustment nut. 0109-010 NEUTRAL ADJUSTMENT General Information The hydrostatic transmission linkage is designed to be self-centering or “return to neutral”.
MAINTENANCE Adjustment Procedure 1. Place the rear axle on jack stands, and remove the rear wheels. NOTE: Do not set the parking brake. 2. Bring the hydrostatic transmission up to operating temperature (at least 15 minutes’ operation). The neutral eccentric is accessed through the hole indicated by the arrow. 1c 3653-006 3. To gain access to the adjustment eccentric, turn the front wheels in either direction to the steering stop. This causes the linkage rod to move up, out of the way. 0144-072 4.
MAINTENANCE 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. 1c 0144-071 6. Center the eccentric between these points, and tighten the through bolt while holding the eccentric. (A) Pivot Point NOTE: Do not turn the eccentric more than 90° in either direction. Notch in eccentric must be away from pivot point of control arm.
MAINTENANCE When the tractor is not running, some oil will drain from the power steering system. On engine start-up, purge air from the system by turning the steering wheel fully left and right, at full engine rpm, until full steering performance is restored. 1c 0109-044 Maintenance The power steering system is equipped with an in-line filter screen. It should be cleaned after the initial 50 hours, then every 200 hours, or if the power steering gets noisy. To clean the power steering screen: 1.
MAINTENANCE 6. Inspect the O-rings which seal the lines and housings. Replace them if there are any signs of cuts and deterioration (i.e. hardening or swelling of the rubber). Lubricate the O-rings before reassembly. 1c 0144-086 7. Reassemble the housing, replace the lines, and secure to the steering tower. 8. Start the engine. Bleed air from the system by turning the steering wheel from stop to stop several times. 9. Check the transaxle fluid level.
THEORY OF OPERATION QUICK REFERENCE SECTION Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1a Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1b Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1c TROUBLESHOOTING Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THEORY OF OPERATION Table of Contents General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 3 Transmission Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 4 Hydrostatic Transmission Flow Diagram With Power Steering . . . . . . . . . . . . . . 2 - 5 Hydrostatic Transmission Flow Diagram Without Power Steering . . . . . . . . . . . . 2 - 6 Power Steering Cylinder Hydraulic Hose Routing . . . .
THEORY OF OPERATION General Information The Eaton Model 11 hydrostatic transmission, as used on the 5xi series, is equipped with an internal charge pressure valve, forward and reverse check and acceleration valves, and vibration dampening pistons. The transmission has a splined output shaft and keyed input shaft, both of which are supported by ball bearings. A charge pump is located externally on the transmission case and is driven by the input shaft.
THEORY OF OPERATION Transmission Operation Transmission input shaft is driven at engine speed by drive shaft. Both charge pump and transmission pump are driven by input shaft. Charge pump draws oil from transaxle to “supercharge” transmission pump, make up for normal internal leakage, and provide a cooling oil flow. Oil travels from the outlet of the charge pump through a hydraulic hose to the power steering valve (on units equipped with power steering).
THEORY OF OPERATION The power steering and hydraulic lift circuit are also operated by the charge pump. When the lift control valve is moved to Raise or Lower position, the charge pump output is diverted to one of the hoses attached to the lift cylinder. The other hose is connected through the lift valve to charge pressure hose leading to the oil filter, permitting bleed-off of oil on that side of lift cylinder’s piston.
THEORY OF OPERATION HYDROSTATIC TRANSMISSION FLOW DIAGRAM WITHOUT POWER STEERING A C G D B I F 2 Illustrator Files/5xi wo ps.eps H E (A) (B) (C) (D) (E) (F) Charge Pump Transaxle Sump Filter Lift Valve Lift Cylinder Relief Valve Setting on manual steering units 700-800 PSI (48.2 - 55.2 bar) (G) Charge Pressure Test Point: 30-90 PSI (2.1 - 6.2 bar) (H) Lift Pressure Test Point: 700-800 PSI (48.2 - 55.
THEORY OF OPERATION POWER STEERING CYLINDER HYDRAULIC HOSE ROUTING 2 LIFT CYLINDER HYDRAULIC HOSE ROUTING 5xi Series Tractor Hydraulic Service Manual 2-7
THEORY OF OPERATION Flow diagrams show hydraulic circuits inside hydrostatic unit and illustrate high and low pressure areas during operation. Pressurized oil from the charge pump is maintained between 30 and 90 PSI (2.1 - 6.2 bar) by the charge relief valve located inside the hydrostatic unit. When the valve opens, excess oil pressure is bled back to the transaxle sump through a hole in the housing.
THEORY OF OPERATION The operator controls the transmission by moving the control shaft connected to the cam ring within the pump. With the control shaft in neutral, or its centered position, no flow is generated by the pump and, therefore, the motor portion is at rest. When the control shaft is moved from neutral in the “forward” direction, the cam ring in the pump is moved off center and the pump ball-pistons create a flow of fluid.
THEORY OF OPERATION Due to internal leakage, fluid being returned to the inlet side of the pump from the exhaust side of the motor is less than required by the pump. To replace this needed fluid, check valves are located in each side of closed loop. The check valve located on the low pressure side of the pump will open allowing fluid to enter loop, from the charge pump circuit, to make up leakage losses.
THEORY OF OPERATION Model 11 has two dampening pistons (A), which rest against the cam ring and are controlled by system pressure. In operation, they reduce control shaft vibration and transmission noise.
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TROUBLESHOOTING QUICK REFERENCE SECTION Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1a Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1b Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1c TROUBLESHOOTING Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING Table of Contents Tractor will not operate in either direction; 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 functions properly. 4. Cruise control is turned off. Tractor will not operate in either direction; engine bogs down or stalls. Possible Cause Corrective Action Low transmission oil level Fill to full “F” mark on dipstick (when trans.
TROUBLESHOOTING Tractor operates erratically. Possible Cause Corrective Action The transmission control linkage needs adjustment or replacement Adjust, repair, or replace The transmission oil level is low Fill to the full “F” mark on the transmission dipstick when transmission is cold The transmission is faulty Repair/replace Tractor operates in both directions but with loss of power and condition becomes worse as transmission becomes hot.
TROUBLESHOOTING Hydraulic lift system does not operate or does not operate properly, but tractor operates normally. Possible Cause Corrective Action Oil level is low Fill to proper level Faulty control valve* Repair or replace Restricted, plugged, or leaking hoses or fittings Repair or replace Low charge pump pressure Check pressure Faulty lift cylinder Repair or replace cylinder Oil is leaking out high-low shift fork hole during operation.
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TROUBLESHOOTING QUICK REFERENCE SECTION Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1a Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1b Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1c TROUBLESHOOTING Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING Table of Contents Tractor Will Not Operate In Either Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3 Tractor Operates In Both Directions, But Loses Power As Oil Becomes Hot and/or Transmission Overheats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 4 Tractor Does Not Return To Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING TRACTOR WILL NOT OPERATE IN EITHER DIRECTION NOTE: IF THE HYDRAULIC LIFT SYSTEM OPERATES NORMALLY THE TRANSMISSION CHARGE PUMP IS WORKING.
TROUBLESHOOTING TRACTOR OPERATES IN BOTH DIRECTIONS, BUT LOSES POWER AS OIL BECOMES HOT TRANSMISSION OVERHEATS CHECK OIL LEVEL CHECK OIL CONDITION OK OK SIGNS OF OVERHEATING OR WATER LOW FILL TO PROPER LEVEL CHECK COOLING FAN & TRANS. COOLING FINS CHECK APPLICATION TRACTOR OVERLOADED FAULTY DIRTY REPLACE OIL AND FILTER OK REPLACE FAN CLEAN TRANS.
TROUBLESHOOTING TRACTOR DOES NOT RETURN TO NEUTRAL. TRACTOR OPERATES NORMALLY IN ONE DIRECTION, BUT IS VERY SLOW IN OPPOSITE DIRECTION. TRACTOR OPERATES IN ONLY ONE DIRECTION.
TROUBLESHOOTING HYDRAULIC LIFT SYSTEM DOES NOT OPERATE, OR DOES NOT OPERATE PROPERLY; TRACTOR OPERATES NORMALLY.
HYDRAULIC SYSTEMS TESTING QUICK REFERENCE SECTION Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1a Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1b Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1c TROUBLESHOOTING Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING Table of Contents Testing System Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3 Pressure Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 4 Lift System Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 4 Charge Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HYDRAULIC SYSTEMS TESTING Testing System Performance A test for observing transmission system performance under load can be helpful when checking a “low power”, or “tractor loses power” condition. 1. Operate tractor to bring engine and drive train to normal operating temperature. 2. Anchor rear of tractor to an immovable object (tree, beam, etc.) with a chain secured to transaxle case. Rear wheels must be on a high friction surface, such as unfinished concrete or asphalt.
HYDRAULIC SYSTEMS TESTING Pressure Checks When performing hydraulic system pressure checks do not connect a pressure gauge in a way that cuts off flow to the hydraulic valve (manual steering) or power steering valve, which eliminates the pressure relief valve from the system. Charge pump pressure will build until internal failure occurs. A suggested gauge system is illustrated.
HYDRAULIC SYSTEMS TESTING Charge Pressure 1. Remove the pipe plug and connect gauge directly to filter base. Although thread is ¼-18 NPT, it will accept ½-20 SAE fitting for test purposes. 1118-03 2. Operate engine. Normal charge pressure is 30 - 90 PSI (2.1 - 6.2 bar). Refer to appropriate Troubleshooting Chart for troubleshooting procedures. NOTE: Always check implement lift pressure relief valve for signs of tampering if charge pressure is low.
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CHASSIS QUICK REFERENCE SECTION Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1a Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1b Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1c TROUBLESHOOTING Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS Table of Contents REAR FENDERS, FOOTRESTS, & TUNNEL General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 3 TRANSAXLE R & R Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 3 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 13 Smart Turn™ Linkage Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . .
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. 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. 0109-021 6 2. Remove the brake and motion control pedals.
CHASSIS 3. Remove the four bolts securing the fender to the frame (two on each side of the seat). 0109-004 4. Remove the nuts from the front footrest supports and the clamps from the rear supports. 0109-019 6 5. Remove the three air intake screens.
CHASSIS 6. Remove the knob for the transaxle range selector. 0109-017 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. CAUTION: Do not dislodge the fuel tank from the mount. If there is fuel in the tank, it will be unbalanced and can tip. 0109-014 6 Remove wiring for the fuel gauge sender (white rheostat, black ground).
CHASSIS On diesel powered units, disconnect the fuel return line (A). Remove the vent line from the bracket (B), then remove the bracket. 3031-13 Close the fuel shut off valve, remove the supply line from the valve. 3606-003 6 Lift the fuel tank from the mounting bracket.
CHASSIS TRANSAXLE R & R Clean area around dipstick, then remove the dipstick tube from the axle and cover the hole with tape to prevent dirt from entering the transmission. 3606-008 Remove the link (A) connecting the lower steering plate to the bell crank (B). 3606-012 6 Unplug the safety switch.
CHASSIS Remove the hydraulic line from the power steering valve. Hold the 45° fitting in position while removing the hydraulic line. 3606-046 To remove the 45° fitting from the charge pump, loosen the jam nut and remove the fitting, washer, and O-ring. 0202-009 6 Disconnect the drive shaft from the transmission input yoke.
CHASSIS Remove brake rod by first removing the adjusting nut and spring. 3606-020 Then remove the cotter pin and washer from the other end of the rod at the brake pivot plate. 0202-011 6 Remove the rod by pulling it forward.
CHASSIS Remove the two 1/4” bolts securing the guard below the transmission cooling fan and remove the guard. 3606-029 Remove the two carriage bolts securing the rear transaxle brace to the frame rails. 3606-038 6 Remove the frame crossmember/tank mount.
CHASSIS Place a floor jack under the transaxle, raise the rear of the tractor and support the frame with safety stands. 0202-12 Support the transaxle with a floor jack. Remove the five 3/8” bolts attaching the transaxle to the frame. 0202-013/0202-014 6 Lower the transaxle until the Smart Turn™ Steering (A) clears the range selector pivot (B).
CHASSIS Remove the transaxle assembly from the frame rails by carefully lowering it while rolling it out from the rear of the tractor. 3606-05-c To remove the Smart Turn™ Steering mechanism, first loosen the nut securing the control lever to the tapered shaft one turn. 3606-060 6 Wedge a large straight blade screwdriver behind the control lever. Then tap the retaining nut sharply to separate the control lever from the shaft.
CHASSIS Remove the nut from the control shaft along with the three bolts securing the Smart Turn™ Steering assembly to the transaxle. 3606-068 Reassembly When installing the Smart Turn™ steering assembly, first slide the plastic locator plate over the speed control shaft on the hydrostatic transmission.
CHASSIS Install Smart Turn™ Steering assembly on transaxle. Wire the actuating rod up to assist in properly locating it in the chassis. 3606-065 Place transaxle on floor jack and carefully slide it between the frame rails keeping it low enough so that the Smart Turn™ Steering assembly (A) clears the range selector crossbar (B).
CHASSIS Guide the drive shaft bolts through the spacers in the rubber coupling. 0202-019 As the transaxle moves into place make sure the range selector pin is properly located in the shift fork. NOTE: If oil is being forced out through HighLow shift fork hole during operation, the air vent in dipstick is plugged. 3031-06 6 Install the five 3/8” mounting bolts and torque to 27-33 ft·lb. (37.8 - 46.2 N·m).
CHASSIS Install the rear frame crossmember/fuel tank mount. 3606-041 Install the brake rod from the pivot to the brake band. 3606-020 6 Adjust the brake by turning the adjustment nut (A) in until there is 2” (51mm) of free travel in the brake pedal.
CHASSIS Install the Smart Turn™ Steering linkage. 3606-009 Secure the drive shaft; torque bolts to 17-21ft·lb. (33-28 N·m). 0202-010 6 Replace the O-rings on the 45° charge pump outlet fitting.
CHASSIS Install the 45° fitting in the charge pump outlet by first backing off the locknut. 0202-021 Coat the O-rings with oil, then thread the fitting into the charge pump outlet. 0202-022 6 Install the hydraulic line from the power steering valve. Hold the 45° fitting in position while securing the hydraulic line.
CHASSIS Then tighten the jam nut. 0202-023 Coat the O-ring with oil and install the hydraulic fitting into the filter adapter. 0202-024 6 Replace the dipstick tube.
CHASSIS Fasten the lower fan shield to the fender support. 3606-029 Place the fuel tank on the mounting plate. CAUTION: Do not pinch the fuel lines or wiring. 3606-005 6 Route the 1/4” fuel return line (diesel tractor) through the bracket on the fuel tank. Install on fitting and install hose clamp.
CHASSIS For gasoline units, route the fuel vent lines as shown. 1999 and later. 0099-03 1998 models. Use tape to hold lines in place, as needed. 0202-025 6 Route the 3/8“ vent line through the bracket and under the tank. CAUTION: Do not pinch off vent line.
CHASSIS Install the 5/16” fuel supply line to the shut-off valve and install hose clamp. 3606-004 Route cruise control wires (A) behind and behind/below the bracket as shown (B). 0202-026 6 Smart Turn™ Linkage Adjustments IMPORTANT: The adjustment procedure must be performed in the sequence given. 1. Remove the fender assembly.
CHASSIS 2. Check the adjustment of link (A) which connects the lower steering plate (B) to the bell crank (C). To do this: 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 rest support (B). NOTE: Keep wheels aligned straight ahead except where noted. 1489-002 6 B.
CHASSIS 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. 0144-088 Test the adjustment of link F, below, by looking at the position of the bushing (A) in the slot of the brake pivot plate (B).
CHASSIS Check the bushing (A) making sure it is centered in the slot in the brake pivot plate (B). If the bushing contacts the sides of the slot, loosen jam nuts (G), and turn the link until the bushing is centered in the slot. 0144-089 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. 7233-073 6 Test the adjustment by cycling the brake.
CHASSIS Replace the fender and tunnel assembly. NOTE: It is suggested that the fuel tank vent orifice be checked for restriction before reinstalling the fender - see the photo/ instructions on page 6 - 29. 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.
CHASSIS Adjust bolt. “Feel” for the neutral detent and tighten the bolt. 0202-027 Install the knob for the transaxle range selector. 0109-017 6 Replace the nuts from the front footrest supports and the clamps from the rear supports.
CHASSIS Replace the four bolts securing the fenders to the frame (two on each side of the seat). 0109-004 Replace the three air intake screens. 0109-015 6 Connect the plug for the seat switch, cruise control, and seat switch. NOTE: The cruise control and taillights share the same connector, which is located under the right fender.
CHASSIS Install the brake and motion control pedals. 0109-003 / 0109-020 Test to make sure the fuel vent system is functioning properly before and after repairs involving removal of the rear fender. 1. Modify a carburetor needle and seat tester by installing a 3/8” (3.17mm) copper tube at the discharge side of the tester. 0202-029 6 2. Connect the test gauge to the vent hose and pressurize to 7 - 14 psi (.5 - 1 bar). The pressure should drop to “0” in one second or less.
CHASSIS If the pressure does not drop, the vent is restricted. Check for a pinched or kinked vent line, 3031-07 If the vent line is plugged, loosen the fill cap. Connect the vent hose to 50 - 100 psi (3.4 - 7 bar) compressed air hose for 1-2 seconds and retest. 0202-030 6 If the vent is still restricted, remove the vent hose at the fitting. Clear the orifice with a .024” (.61mm) or smaller wire.
HYDROSTATIC DRIVE QUICK REFERENCE SECTION Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1a Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1b Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1c TROUBLESHOOTING Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HYDROSTATIC DRIVE Table of Contents TRANSMISSION/TRANSAXLE Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 3 Differential Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 8 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 9 HYDROSTATIC TRANSMISSION Transmission Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HYDROSTATIC DRIVE TRANSMISSION/TRANSAXLE Disassembly Drain oil from transaxle, if not already done. Transmission will still have oil in it, up to the level of the outlet hole in the transmission body. Remove the 4 bolts attaching the transmission to the axle assembly. 3095-004 Then separate the transmission and transaxle. NOTE: During reassembly replace the gasket and torque the bolts to 30-35 ft·lbs (42-49 N·m). 3095-007 7 To remove the hubs, loosen the lock nuts and set screws.
HYDROSTATIC DRIVE Attach a puller and tighten the forcing screw to remove the hubs. 3095-014 Remove the woodruff key and washer. File smooth any burrs caused by the set screws and axle keys. These may cause damage to the needle bearings if not removed before disassembly. Replace the axle seals after reassembly. NOTE: Use seal bullet or other cover over keyway when installing new seal. 3095-015 7 Remove the bolts securing the brake band.
HYDROSTATIC DRIVE Remove bolt securing the brake drum, and remove the brake drum. 3095-019 Remove the 6 bolts securing the right-hand case half. NOTE: Bolt “A” is an epoxy patch bolt. Use a new bolt on reassembly. Replace brake shaft oil seal after reassembly. NOTE: Use seal bullet or other cover over keyway when installing new seal. 3095-021 7 Use a soft faced mallet to break the gasket seal and remove the right-hand case half.
HYDROSTATIC DRIVE Remove washer from intermediate gear and drive gear shaft. These are the only washers used in the transaxle. 3095-028 Pull intermediate gear from case. 3095-032 7 Remove the hi-low range reduction gear.
HYDROSTATIC DRIVE Remove differential assembly. 3095-038 Remove allen head screw. Use a magnet to remove detent ball and spring from case. 3095-042 7 Pull shifter shaft/yoke from case.
HYDROSTATIC DRIVE Use a straight punch to drive out the roll pin securing the shift selector. 3095-047 Differential Disassembly Remove the 4 bolts holding the differential assembly together. During reassembly replace the nuts and bolts and torque to 39 - 47 ft·lbs (52.9 - 63.7 N·m). NOTE: A washer is used under the bolt heads. 3095-049 7 Separate the axles and pinions from the ring gear.
HYDROSTATIC DRIVE Inspect gears, bearings, and shafts for wear or damage. Replace as necessary. 3095-070 Reassembly The snap ring should be installed with the sharp edge facing away from the gear. The rounded side of the gear teeth should be towards the end cap. 3095-067 7 Lubricate the pinion bearing surfaces and install in the differential end cap.
HYDROSTATIC DRIVE Follow the disassembly instructions in reverse order using new gaskets and seals to complete the transaxle reassembly.
HYDROSTATIC DRIVE HYDROSTATIC TRANSMISSION Transmission Disassembly Drain the transaxle fluid from transmission case. (A) Transmission Drain 3095-095 Remove snap ring securing the drive gear to the output shaft. 3095-096 7 Remove gear.
HYDROSTATIC DRIVE Separate body from cover assembly. NOTE: Ball pistons are a select fit in each position. If a ball is removed, make sure it goes back into the same rotor bore it came from. 3095-103 Place large rubber band around motor rotor to hold ball pistons in place. 3095-104 7 Lift off motor rotor assembly.
HYDROSTATIC DRIVE Remove O-ring and pintle assembly. 3095-111 Remove pump rotor. 3095-113 Place rubber band around pump rotor to hold ball pistons in place. NOTE: Ball pistons are a select fit in each position. If a ball is removed, make sure it goes back into the same rotor bore it came from.
HYDROSTATIC DRIVE Mark the pivot pin so it can be installed in the same direction. Then remove the cam ring by sliding it off the pivot pin along with the cam ring insert. 3094-045 Finally, remove the two buttons from the case. 3094-047 7 Remove the snap ring from the input shaft.
HYDROSTATIC DRIVE Remove the allen bolts holding the charge pump to the cover. 3095-124 Install a two jaw puller on charge pump housing. NOTE: Charge pump housing must be removed in this manner; do NOT attempt to press input shaft through the transmission housing, or damage will occur. 3095-127 Remove charge pump housing along with the six carrier rollers (A).
HYDROSTATIC DRIVE Remove the snap ring, charge pump rotor, and the carrier drive pin. (A) On reassembly, it is important that the charge pump rotor is installed with the correct side up. Note the direction of the arms and mark the top of the rotor. (B) Remove the wear plate and inspect for wear and flatness. (C) Remove the rotor key pin from the shaft. 3094-005 Press output shaft from bearing. Remove snap ring and press bearing out of transmission body.
HYDROSTATIC DRIVE Use an allen wrench to remove the charge pressure relief valve plug. 3094-017 The relief valve assembly consists of relief ball, spring, and plug. Use a 1/4” allen wrench to remove the plug. 3094-018 7 NOTE: Servicing the pintle is usually not needed, unless oil was severely contaminated. To remove the dampening pistons from the pintle. Glue a bolt head to the piston, then use the bolt to pull the piston from its bore. Inspect for wear or scratches at (A) and (B).
HYDROSTATIC DRIVE NOTE: Servicing check balls and acceleration valves is normally not needed. To remove the check balls and acceleration valves from the pintle, first drive the roll pin and solid pin retaining the assemblies.
HYDROSTATIC DRIVE Reassembly Seal Kit Part Number: 56-3310. Apply a coating of oil to the input shaft and install through bushing. 3094-052 Place cover assembly over wooden block to support input shaft. 3094-056 Lubricate and install a new O-ring seal and install pump plate. Align holes in pump plate with holes in cover.
HYDROSTATIC DRIVE 1. Install the carrier drive pin in input shaft. 2. Install rotor on shaft with witness mark up. 3094-059 / 3094-061 Remove the snap ring, seal, and bearing from the charge pump housing. 3094-068 7 Use seal driver to install a new input shaft seal.
HYDROSTATIC DRIVE NOTE: Use caution when installing the charge pump housing to avoid damaging the seal on the snap ring grooves. Use a Post-It® note, plastic wrap, or similar material to cover the groves while installing housing. Secure housing in place. Lubricate and place rollers into the charge pump carrier. Install a new O-ring in charge pump housing and install the housing. 3094-072 There are two snap rings - one below and one above the input shaft bearing. Install the lower snap ring.
HYDROSTATIC DRIVE Install snap rings to input shaft and charge pump housing. 3094-084 Install two buttons (A) in cover. Install cam ring insert, with hole away from cam ring. Align cam ring with control shaft pin and cam ring pivot pin. 0202-036 7 Install the small rotor into the pump housing. Leave the rubber band in place until the rotor is in place. Rotate the rotor until the slot in the rotor is aligned with the input shaft and the rotor drops in place. Apply oil liberally to all components.
HYDROSTATIC DRIVE Install the pintle assembly with the roller bearing up (damping pistons down). 3095-111 Install a new square ring seal over pintle assembly. 3095-108 7 Install motor rotor on pintle with rubber band in place. Apply oil liberally to motor section.
HYDROSTATIC DRIVE 1. Press the seal into the housing. 2. Press the bearing into the housing. Apply force to the outer race of the bearing only. 3. Install the snap ring. 3094-010 Install the output shaft by supporting the bearing inner race while pressing the shaft in place. 0202-037 7 Install the motor housing so that the slots in the rotor align with the cross pin in the output shaft. Secure with two bolts.
HYDROSTATIC DRIVE Install the output gear and snap ring. NOTE: If output shaft appears to be “too short”, it has been pushed back into the housing. Either draw press it back out, or remove the housing and press it back out from the inside.
THIS PAGE INTENTIONALLY LEFT BLANK 7 - 26 5xi Series Tractor Hydraulic Service Manual
HYDRAULIC SYSTEMS QUICK REFERENCE SECTION Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1a Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1b Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1c TROUBLESHOOTING Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HYDRAULIC SYSTEMS Table of Contents LIFT CYLINDER R & R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 53 LIFT CYLINDER DISASSEMBLY / REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 8 - 55 STEERING CYLINDER R & R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 58 POWER STEERING CYLINDER DISASSEMBLY / REASSEMBLY . . . . . . . . . 8 - 60 POWER STEERING VALVE R & R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HYDRAULIC SYSTEMS LIFT CYLINDER R & R Remove the fender assembly as outlined on pages 6 - 3 through 6 - 5. 0109-014 Remove the drive shaft. Refer to the 5xi Service Manual (492-4715) for the complete procedure. 0202-010 Remove the bolt anchoring the lift cylinder case to the frame using a long extension and a 1/2” universal socket. 8 NOTE: On reassembly, use a new bolt.
HYDRAULIC SYSTEMS Remove the clip and pin securing the cylinder ram from the attachment lift bell crank. 3606-086 Lift the cylinder out from between the frame rails and remove the hydraulic hoses. NOTE: Use a back-up wrench on the fittings. Cover all open fittings to prevent contamination.
HYDRAULIC SYSTEMS LIFT CYLINDER DISASSEMBLY / REASSEMBLY Thoroughly clean the outside of the cylinder to prevent contamination. Always work in a clean environment. 0722-01 Using a spanner wrench, remove the cylinder rod guide from the cylinder body. 0722-02 Pull the rod and piston from the cylinder body.
HYDRAULIC SYSTEMS Remove the piston nut while holding the rod. CAUTION: Do not damage the cylinder rod by clamping in a vise, vise grip, pliers, etc. 0722-04 Note the position and orientation of the piston seals. Carefully remove the seals. Seal Kit Part Number: 95-4007 0722-05 Install new piston seals and rod guide O-ring.
HYDRAULIC SYSTEMS Apply a light coating of transaxle fluid to the seals and O-rings. 0722-07 Carefully insert the piston in the cylinder and tighten the rod guide.
HYDRAULIC SYSTEMS STEERING CYLINDER R & R Remove the fender assembly as outlined on pages 6 - 3 through 6 - 5. 0109-014 Remove the drive shaft. Refer to the 5xi Service Manual (492-4715) for the complete procedure. 0202-010 Remove the hydraulic lines from the steering cylinder and cap them to keep out dirt.
HYDRAULIC SYSTEMS Remove the bolt at the steering bell crank. NOTE: Use a new bolt on reassembly. 0202-040 Remove the bolt and nut and spacer securing the cylinder to the frame.
HYDRAULIC SYSTEMS POWER STEERING CYLINDER DISASSEMBLY / REASSEMBLY Thoroughly clean the outside of the cylinder to prevent contamination. Always work in a clean environment. 0105-01 Using a spanner wrench, remove the cylinder rod guide from the cylinder body. 0105-02 Pull the rod and piston from the cylinder body.
HYDRAULIC SYSTEMS Remove the piston nut while holding the rod. CAUTION: Do not damage the cylinder rod by clamping in a vise, vise grip, pliers, etc. 0722-04 Note the position and orientation of the piston seals. Carefully remove the seals. Seal Kit Part Number: 95-4008. 0105-05 Install new piston seals and rod guide O-ring.
HYDRAULIC SYSTEMS Apply a light coating of transaxle fluid to the seals and O-rings. 0722-09 Carefully insert the piston in the cylinder and tighten the rod guide.
HYDRAULIC SYSTEMS POWER STEERING VALVE R & R Remove the fender assembly as outlined on pages 6 - 3 through 6 - 5. 0109-014 Raise the base of the boot which seals the steering column to the instrument panel and place the column in the lowest position. 3606-094 Remove the top bolt securing the steering column and valve to the steering valve bracket. Note where all the hydraulic hoses are located and that they must clear all rotating and moving parts at all positions of the tilt steering.
HYDRAULIC SYSTEMS Remove the remaining three bolts securing the steering valve to the bracket. 3606-099 Remove the bolt at the bottom of the bracket. Remove the steering valve bracket. 3606-111 8 Separate the steering valve from the steering column and remove the fittings from the steering valve. NOTE: Cover all open lines and fittings to protect them from contamination.
HYDRAULIC SYSTEMS Power steering valve hose connections. Refer to page 2 - 5 for a larger drawing. 0099-02 Power steering hose routing. Refer to page 2 - 7 for larger drawings.
HYDRAULIC SYSTEMS POWER STEERING VALVE DISASSEMBLY / REASSEMBLY Steering Valve Disassembly NOTE: Cleanliness is extremely important when repairing hydraulic Steering Control Units (SCU). Work in a clean area. Before disconnecting the hydraulic lines, clean the port area of the SCU. Before disassembly, drain the oil, then plug the ports and thoroughly clean the exterior of the SCU. During repairs, always protect machined surfaces.
HYDRAULIC SYSTEMS Slide the spool and sleeve assembly from the housing. 3605-014 Remove the thrust bearing and races. 3605-016 Remove the quad seal.
HYDRAULIC SYSTEMS Using a small screwdriver, carefully pry the dust seal from the housing. CAUTION: Do not damage the dust seal seat. 3605-020 Remove the pin that holds the spool and sleeve together. Carefully slide the spool out of the sleeve. The springs and retaining ring will stay with the spool as it’s removed. 3605-022 Remove the retaining ring and springs. 8 CAUTION: The centering springs are under tension; remove the retaining ring carefully.
HYDRAULIC SYSTEMS Reassembly Check all mating surfaces. Replace the steering valve if parts are worn, scratched, or have damage that could cause leakage. Wash all metal parts in clean solvent. Blow them dry with pressurized air. Do not wipe parts dry with paper towels or cloth. Lint in a hydraulic system will cause damage. NOTE: Always use new seals when reassembling hydraulic steering control units. Seal Kit Part Number: 94-4099.
HYDRAULIC SYSTEMS Lubricate and install the dust seal, see drawing for correct seal orientation. (A) Dust Seal (B) Thrust Bearing and Race (2) (C) Quad Seal 0202-044 Install the centering springs in the spool. It is best to install the two flat pieces first. Next, install the curved pieces, three at a time. Fit the retaining ring over the centering springs. Centering Spring Kit Part Number: 94-4095. 3605-025 8 Apply a light coating of 10W-30 oil to the spool (A) and slide it into the sleeve (B).
HYDRAULIC SYSTEMS Apply a light coating of petroleum jelly to the inner edge of the dust and quad seals. Put the thrust bearing and races into the housing. The thrust bearing goes between the two races. 3605-047 Apply a light coating of clean 10W-30 oil to the spool and sleeve assembly and slide it into the housing. IMPORTANT: Do not damage the dust or quad seals. 3605-049 Clamp the housing in a vise. Use just enough clamping force to hold the housing securely.
HYDRAULIC SYSTEMS Install the wear plate (A) and align the holes in the wear plate with threaded holes in the housing. NOTE: The holes in the wear plate are symmetrical. Install the drive (B); be sure the slot in the drive engages the pin. 3605-053 Lubricate and install a new O-ring seal in the groove in the wear plate. 3605-055 Install the gerotor and align the screw holes. 8 Lubricate and install a new O-ring seal in the groove in the gerotor ring.
HYDRAULIC SYSTEMS Install the spacer. 3605-061 Install the end cap and seven cap screws. Tighten the cap screws, in a crisscross pattern to 140 - 160 lb·in (16 - 18 N·m). 3605-064 Remove the SCU from the vise. Install the relief valve/check or check ball and plug. Use a new O-ring and tighten the plug to 150 lb·in (17 N·m).
HYDRAULIC SYSTEMS LIFT VALVE R & R Remove steering valve as outlined on pages 8 - 16 through 8 - 18 (power steering models only). Leave hoses connected. 3606-114 Remove the four screws securing the instrument panel. 3606-116 Disconnect the white wiring harness plug.
HYDRAULIC SYSTEMS Disconnect the fitting on the return oil line (steel) from the “T” fitting at the bottom of the lift valve. 3606-122 Remove the two lift valve mounting bolts and nuts. 3606-128 Using a back-up wrench, remove the hydraulic lines and fittings from the valve. 8 NOTE: Cover the lines and fittings to prevent contamination.
HYDRAULIC SYSTEMS On installation, orient the fittings as shown (power steering shown). 3605-001 Power steering lift valve hose connections. Refer to page 2 - 5 for a larger diagram. Refer to page 2 - 6 for manual steering lift valve hose connections. 0099-02 Power steering hose routing. Refer to page 2 - 7 for larger diagrams.
