Toro 523Dxi Garden Tractor Riding Product Manual
5XI SERIES TRACTOR SERVICE MANUAL
Table of Contents – Page 1 of 2
SPECIFICATIONS
ATTACHMENTS AND ACCESSORIES (PARTIAL LISTING)
ENGINE SPECIFICATIONS (AIR-COOLED)
ENGINE SPECIFICATIONS (LIQUID-COOLED)
MAINTENANCE TABLE
CHASSIS
REAR FENDERS, FOOTRESTS, & TUNNEL
HYDROSTATIC DRIVE
GASOLINE ENGINE
ENGINE CRANKS BUT WILL NOT START.
ENGINE STARTS BUT DOES NOT KEEP RUNNING.
ENGINE RUNS BUT KNOCKS OR MISSES.
5XI SERIES TRACTOR SERVICE MANUAL
Table of Contents – Page 2 of 2
GASOLINE ENGINE - continued
DIESEL ENGINE
ENGINE CRANKS BUT WILL NOT START.
ENGINE STARTS BUT DOES NOT KEEP RUNNING.
ENGINE RUNS BUT KNOCKS OR MISSES.
EXCESSIVE BLACK SMOKE FROM EXHAUST.
EXCESSIVE WHITE SMOKE FROM EXHAUST.
ELECTRICAL
ELECTRIC CLUTCH TROUBLESHOOTING
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
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
5xi series garden tractor. The tractor and attachment operator’s manuals contain safety information and operating tips for safe operating practices. Operator’s manuals are available through your local Toro distributor or:
The Toro Company
Publications Department
8111 Lyndale Avenue South
Bloomington, MN 55420
1a
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 1 - 3
SPECIFICATIONS
1b
Product Lineup
Model
(International)
Name
73470 518xi
73540 (73541) 520xi
73560 522xi
73545 (73546) 520Lxi
73550 (73551) 523Dxi
Engine HP
Kohler 18
Kohler
Kohler
20
22
Kawasaki 20
Daihatsu 23
Drive Type
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
Tractor Specifications
Item
Fuel Tank Capacity
73470
4.25 gal
(16.1l)
73560
4.25 gal
(16.1l)
Hydraulic System Capacity
Battery Size (Cold Cranking Amps)
Ground Speed Forward (High Range) 0-7.4 mph
(11.9 km/hr)
Ground Speed Forward (Low Range) 0-4.4 mph
(7.1 km/hr)
Ground Speed Reverse (High Range)
0-3.4 mph
(5.48 km/hr)
Tire Size - Front
6 Qts (5.7l) 6 Qts (6.6 l) 7 Qts (6.6 l) 7 Qts (6.6 l) 7 Qts (6.6 l)
12V 380CCA 12V 380CCA 12V 380CCA 12V 380CCA 12V 495CCA
16 x 7.5-8
0-7.4 mph
(11.9 km/hr)
0-4.4 mph
(7.1 km/hr)
0-3.4 mph
(5.48 km/hr)
16 x 7.5-8
0-7.4 mph
(11.9 km/hr)
0-4.4 mph
(7.1 km/hr)
0-3.4 mph
(5.48 km/hr)
16 x 7.5-8
0-7.4 mph
(11.9 km/hr)
0-4.4 mph
(7.1 km/hr)
0-3.4 mph
(5.48 km/hr)
16 x 7.5-8
0-7.4 mph
(11.9 km/hr)
0-4.4 mph
(7.1 km/hr)
0-3.4 mph
(5.48 km/hr)
16 x 7.5-8
Tire Size - Rear
Tire Pressure
73540
(73541)
4.25 gal
(16.1l)
73545
(73546)
4.25 gal
(16.1l)
73550
(73551)
4.25 gal
(16.1l)
Wheel Base
Turning Radius
Total Width
Length
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
12 psi
(82.7 kPa)
12 psi
(82.7 kPa)
12 psi
(82.7 kPa)
12 psi
(82.7 kPa)
12 psi
(82.7 kPa)
52 in
(132.1 cm)
20 in
(50.8 cm)
52 in
(132.1 cm)
20 in
(50.8 cm)
52 in
(132.1 cm)
20 in
(50.8 cm)
52 in
(132.1 cm)
20 in
(50.8 cm)
52 in
(132.1 cm)
20 in
(50.8 cm)
40.5 in
(102.8 cm)
76.5 in
(196.9 mm)
40.5 in
(102.8 cm)
76.5 in
(196.9 mm)
40.5 in
(102.8 cm)
76.5 in
(196.9 mm)
40.5 in
(102.8 cm)
76.5 in
(196.9 mm)
40.5 in
(102.8 cm)
76.5 in
(196.9 mm)
Note:
Specifications shown are for 1998 models. Subsequent production may vary. As part of a continuous improvement process, the Toro Company reserves the right to change specifications without notice.
1 - 4 5xi Series Tractor Service Manual
SPECIFICATIONS
Attachments and Accessories (partial listing)
Part # (International) Description
78353 (78442) 42" Rear Discharge Mower
78357 (78444)
78358
78363 (78448)
78364
78370 (78452)
78375
78395 (78469)
79375*
44" Side Discharge Mower
44" Recycler
48" Side Discharge Mower
48" Recycler
52" Side Discharge Mower
52" Recycler
® Mower
® Mower
® Mower
60" Side Discharge Mower
36" Tiller
94-7800
94-4090
95-4091
95-7858
86041
79195
79185
79948
79355*
79356*
79305 (79444)
79310 (79448)
79977
79365
79366 ***
79919
79210
95-4220
79947**
94-2050
48" Snow/Dozer Blade
50" Mid-Mount Grader Blade
44" Vac/Bagger
48" Vac/Bagger
Front Mount Dethatcher
42" Single Stage Snowthrower
44" Two Stage Snowthrower
Snow Cab
Roll-Over-Protection System (ROPS)
Rear Attach-A-Matic® (from Parts)
Bucket Loader
Dual Wheel Adapter Kit (From Parts)
Clevis Hitch (From Parts)
48" Blade Retrofit Kit (From Parts)
Diesel Block Heater (From Parts)
Sidelight Kit (From Parts)
44" Recycler ® Kit
48" Recycler ® Kit
52" Recycler ® Kit
Weight Box
* Requires 95-4220 Rear Attach-A-Matic®
** Requires 79948 weight Box
***Requires rear wheel weights, 95-4220 Rear Attach-A-Matic®
Drive Belt
95-4093
95-4094
95-4094
95-4095
95-4095
95-4094
95-4094
95-4093
Front
94-7877
93-8007
79-7490
95-3918
95-3917
Spindle Belt
95-4230
95-4228
95-4228
95-3878
95-3878
94-2501
94-2501
95-4229
Rear
94-7878
1b
5xi Series Tractor Service Manual 1 - 5
SPECIFICATIONS
Engine Specifications (air-cooled)
Item
Manufacturer/Model
73470
Kohler/CH18S
1b
Horsepower (kW)
Oil Viscosity Over 0° F (-18° C)
Below 32°F (0° C)
18 HP (13.4 kW)
10W-30
5W-20 or 5W-30
Oil Capacity (With Filter) 2.1 Qts. (2 l) U.S. Qts.
Spark Plug (Champion # Shown)
Spark Plug Gap
Recommended Engine Speed
(No Load) (International Unit)
Idle Speed
Charging System Output
Head Bolt Torque
RC12YC
.030 in (.76 mm)
3400 RPM
2300 RPM
1400 RPM
15 amps
Connecting Rod Torque
Flywheel Torque
30 ft·lb (40.7 N·m)
130 in·lb (17.3 N·m)
49 ft·lb (66.4 N·m)
73540 (73541)
Kohler/CH20S
20 HP (14.9 kW)
10W-30
5W-20 or 5W-30
U.S. Qts.
RC12YC
.030 in (.76 mm)
3400 RPM
2300 RPM
1400 RPM
15 amps
30 ft·lb (40.7 N·m)
130 in·lb (17.3 N·m)
49 ft·lb (66.4 N·m)
73560
Kohler/CH22S
22 HP (16.4 kW)
10W-30
5W-20 or 5W-30
U.S. Qts.
RC12YC
.030 in (.76 mm)
3400 RPM
2300 RPM
1400 RPM
15 amps
30 ft·lb (40.7 N·m)
130 in·lb (17.3 N·m)
49 ft·lb (66.4 N·m)
Engine Specifications (liquid-cooled)
Item
Manufacturer/Model
Horsepower (kW)
Oil Viscosity Over 40° F (5°C)
Below 40 ° F (5° C)
Oil Capacity (With Filter)
Coolant Capacity
Spark Plug (NGK # Shown)
Spark Plug Gap
Recommended Engine Speed
(International Units)
Idle Speed
Charging System Output
Head Bolt Torque
Connecting Rod Torque
Flywheel Torque
73545 (73546)
Kawasaki/FD620D
20 HP (14.9 kW)
10W-30 or 10W-40 Above 0°F (-18°C)
5W-20 or 5W-30 Below 32° F (0° C)
1.9 U.S. Qts. (1.8l)
4.1 Qts.
BMR4A
.024 -.028 in (0.6 - 0.7 mm)
3400 RPM
2300 RPM
1550
20 amps
15 ft·lb (21 N·m)
15 ft·lb (21 N·m)
80 ft·lb (110 N·m)
73550 (73551)
Daihatsu/582447 Diesel
23 HP (17.1)
10W-30 or 10W-40 Above 0°F (-18°C)
5W-30 Below 50° F (10°C)
3.5 U.S. Qts. (3.3 l )
5 Qts.
N/A
N/A
3400 RPM
2200 RPM
1850
40 amps
25 ft·lb (34 N·m)
27 ft·lb (36 N·m)
35 ft·lb (47 N·m)
1 - 6 5xi Series Tractor Service Manual
MAINTENANCE TABLE
Service Schedule
Item Kohler, Manual
Steering
Grease Zerks
Front wheel spindles (2)
Front axle pivot (1)
Maintenance panel (3)
Pulley box (2)
Deck spindles (3) until resistance is felt
Every 50 hrs.
Every 50 hrs.
Every 50 hrs.
Every 50 hrs.
Every 25 hrs.
Deck idler & wheels (3) 60" Every 50 hrs.
60" deck gage wheels grease
Every 25 hrs.
Foot pedal shaft (1)
Steering (1) one pump
Every 50 hrs.
Every 50 hrs.
Engine
Check oil level
Oil change
Oil filter change
Every use
@ 5 hrs.
Every 100 hrs.
Every 200 hrs.
Air filter
Precleaner clean & oil
Fuel filter
Radiator level check
Radiator screen clean
Radiator flush
Every 100 hrs.
Every 25 hrs.
Every 100 hrs.
N/A
N/A
N/A
Change spark plugs Every 200 hrs.
Drain water from fuel filter N/A
Check fan belt N/A
Kohler, Power
Steering
Every 50 hrs.
Every 50 hrs.
Every 50 hrs.
Every 50 hrs.
Every 25 hrs.
Every 50 hrs.
Every 25 hrs.
Every 50 hrs.
N/A
Every use
@ 5 hrs.
Every 100 hrs.
Every 200 hrs.
Every 100 hrs.
Every 25 hrs.
Every 100 hrs.
N/A
N/A
N/A
Every 200 hrs.
N/A
N/A
Kawasaki Daihatsu
Every 50 hrs.
Every 50 hrs.
Every 50 hrs.
Every 50 hrs.
Every 25 hrs.
Every 50 hrs.
Every 25 hrs.
Every 50 hrs.
N/A
Every 50 hrs.
Every 50 hrs.
Every 50 hrs.
Every 50 hrs.
Every 25 hrs.
Every 50 hrs.
Every 25 hrs.
Every 50 hrs.
N/A
Every use
@ 5 hrs.
Every 100 hrs.
Every 200 hrs.
Every 100 hrs.
Every 25 hrs.
Every 100 hrs.
Every use
Every use
Every 400 hrs. or
2 yrs.
Every 100 hrs.
N/A
Every 100 hrs.
Every use
@ 5 hrs.
Every 100 hrs.
@ 50 hrs.
Every 200 hrs.
Every 100 hrs.
N/A
Every 400 hrs.
Every use
Every use
Every 400 hrs. or
2 yrs.
N/A
Every use
Every 100 hrs.
1c
@ = initial service
NOTE:
Service more frequently under dry/dirty/dusty conditions
5xi Series Tractor Service Manual 1 - 7
MAINTENANCE TABLE
1c
Service Schedule (cont’d)
Item Kohler, Manual
Steering
Transaxle & Hydraulics
Oil level check
Oil change
Oil filter change
25 hrs.
Every 200 hrs.
@ 50 hrs.;
Every 200 hrs.
N/A Clean power steering screen
Miscellaneous
Check PTO belt tension Every 50 hrs.
Check battery electrolyte Every 25 hrs.
Tire pressure Every 25 hrs.
Safety interlock
Clean clippings from deck
Check under hood for grass build up
Every use
Every use
Every use
Check service brake function
Every use
Clean 3 air intake screens Every use
Clean rear transaxle cover Every use
Kohler, Power
Steering
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 use
Every use
Every use
Every use
Kawasaki
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 use
Every use
Every use
Every use
@ = initial service
Daihatsu
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 use
Every use
Every use
Every use
1 - 8 5xi Series Tractor Service Manual
CHASSIS
QUICK REFERENCE SECTION
SERVICE SECTION
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
Hydrostatic Drive
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5xi Series Tractor Service Manual 2 - 1
CHASSIS
2 2
2 - 2
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
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
5xi Series Tractor Service Manual
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 21
DRIVE SHAFT
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 22
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 22
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 22
2
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 2
GREASING AND LUBRICATION
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
2.0757.015
Lubrication Points
There are 3 grease zerks on the front axle; one on at each spindle and one at the center pivot.
2.0109.033
2 - 4
2.0109.043
5xi Series Tractor Service Manual
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
2.0109.024
2.0144.023
5xi Series Tractor Service Manual
The pulley box for the mower deck contains 2 zerk fittings; one at each pulley pivot.
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 2
There is 1 zerk fitting located on the foot pedal shaft which requires greasing.
2.0415.001
2 - 6
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).
2.0415.012
2.0144.069
5xi Series Tractor Service Manual
2.0109.039
2.0109.021
2.0109.003
2.0109.020
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.
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
2. Remove the brake and motion control pedals.
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 2
4. Remove the nuts from the front footrest supports and the clamps from the rear supports.
2.0109.004
5. Remove the three air intake screens.
2.0109.019
2 - 8
2.0109.015
5xi Series Tractor Service Manual
CHASSIS
6. Remove the knob for the transaxle range selector.
2.0109.017
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.
2
2.0109.014
2.0109.039
5xi Series Tractor Service Manual
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.
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
2 2
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 - 10
2.0109.035
5xi Series Tractor Service Manual
CHASSIS
Adjustment
1. Loosen the jam nuts at the ends of the steering rods.
2.0109.047
2.0109.048
2.0109.046
5xi Series Tractor Service Manual
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
Spindle Alignment
When installing the spindle to the steering arm, you must align the wheel so that it is parallel to the steering arm as shown.
2 - 11
CHASSIS
STEERING WHEEL
Remove Steering Wheel
1. Remove plastic trim cover.
2. Loosen the nut securing the wheel.
2 2
3. Install puller as shown. Tighten forcing screw to remove steering wheel.
NOTE
: Install large flat washers on puller bolts to protect steering wheel.
2.0144.051
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 - 12
2.0144.052
5xi Series Tractor Service Manual
3.7195.029
CHASSIS
POWER STEERING
General Information
The 22 HP, 20 HP liquid-cooled and 23 HP diesel tractors are equipped with power steering.
This system routes pressurized hydraulic fluid supplied by the hydrostatic transmission to a directional valve located at the base of the steering column. When the steering wheel is turned, this valve directs pressure to a double acting hydraulic cylinder, causing the steering plate to pivot as the cylinder extends or contracts. Tie rods attached to the steering plate turn the front spindles.
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
2.0109.044
2.0144.16
5xi Series Tractor Service Manual
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 - 13
CHASSIS
POWER STEERING (cont’d)
3. Disassemble the housing, and clean the screen with solvent.
2 2
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.
2.0144.076
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.
2.0144.086
2 - 14
2.0144.16
5xi Series Tractor Service Manual
2.3653.005
CHASSIS
SMART TURN™ STEERING
General Information
The Smart Turn Steering™ feature automatically lowers the speed of the tractor in tight turns.
The decrease in speed is directly proportional to the sharpness of the turn, up to a maximum speed reduction of approximately 40% .
The Smart Turn Steering feature permits sharp turns to be made without always having to change speed control position. The original speed is restored as the turn is completed.
Theory of Operation
The steering plate (A) is attached to the speed control lever (B) on the hydrostatic transmission through a system of linkage and levers.
2
2.0144.059
2.0144.63
5xi Series Tractor Service Manual
When the steering wheel is turned, the linkage pushes the speed control lever (A) on the hydrostatic transmission towards the neutral position and slows the tractor.
2 - 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
2 2
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 - 16
2.0109.014
5xi Series Tractor Service Manual
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.
2
Note:
Keep wheels aligned straight ahead except where noted.
2.0109.043
2.0144.087
5xi Series Tractor Service Manual
B. Check the slider (D) making sure it is all the way down, flush with top of spacer (E).
IMPORTANT:
There must be a slight vertical looseness (F) in the slider or there may be binding in the pedal linkages. Lift up on the slider to check.
2 - 17
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 2
3. Test the adjustment of link (F) (see page
2-16). If adjustment is necessary:
A. Depress the brake. Push forward lightly on link (F) to remove slack from the system.
G - Rear Jam Nut (Right Hand Thread)
H - Front Jam Nut (Left Hand Thread)
I - Front Rod End Fitting
2.0144.085
2.0144.059
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 H), and turn the link until the bushing is centered in the slot.
2 - 18
2.0144.089
5xi Series Tractor Service Manual
2.7233.073
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.
Test the adjustment by cycling the brake.
The slot should travel over bushing (A) without touching.
2
2.0144.089
2.0144.072
5xi Series Tractor Service Manual
4. Check the neutral adjustment. If the tractor creeps in neutral, adjust the motion control lever following the procedure on page 3-8,
Neutral Adjustment in the Hydrostatic Drive section of this manual.
2 - 19
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 2
TIRE PRESSURE
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.
Since tire pressure affects the position of the mower deck, it is important to check the tire pressure before leveling the mower and to maintain the the correct tire pressure to preserve the level adjustment.
2.0144.034
FUEL TANK SHUT-OFF VALVE
The fuel shut-off valve is located on the bottom of the fuel tank.
Normally the shut-off valve is kept in the ON position. However, if transporting the tractor on a trailer or truck, it is good practice to place the valve in the OFF position. Although unlikely with this tractor’s fuel system design, closing the fuel valve will prevent the possibility of the carburetor flooding over while going over bumps and filling the crankcase with gasoline.
2.0109.045
2.0109.29
2 - 20 5xi Series Tractor Service Manual
2.0109.042
2.0757.021
2.0109.022
5xi Series Tractor Service Manual
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).
Break-In
The following break-in procedure must be performed as part of predelivery service or when a new clutch is installed.
NOTE:
There must be a PTO driven attachment installed to provide a load in order to burnish the clutch facings properly.
NOTE:
After burnish procedure is complete to maximize deck drive life, always engage clutch at full throttle.
2
1. Run the engine at full throttle and engage the clutch bringing the load to full speed.
Then disengage the clutch.
2. Let the load come to a full stop, then engage again.
3. Repeat these procedures (1 and 2) 5 times.
2 - 21
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 2
Inspection
Visually inspect the flexible couplings for tears, fraying, or deterioration.
2.0144.005
2.0144.077
Assembly
1. Insert the two drive shaft retaining screws
(B) through the rear flange with the bolt heads toward the transmission. Place the rear flange over the woodruff key on the transmission input shaft. Torque the retaining bolt (A) to 90 - 120 in·lbs (122 - 163
N·m).
2. Torque the two set screws (C) to
120 - 160 in·lbs (163 - 217 N·m).
IMPORTANT:
Assembly procedure must be performed in the correct sequence.
2 - 22
2.3653.013
5xi Series Tractor Service Manual
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
2.3653.011
2.3653.014
5xi Series Tractor Service Manual
4. Install the four spacers through the rubber couplings making sure they are properly seated and squared to the coupling.
Note:
The spacers with the tall heads (A) attach the coupling to the flange on the transmission.
2 - 23
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
2 2
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. Then torque the bolts to
170 - 220 in·lbs (231 - 299 N·m).
7. Torque the two set screws(A) and (B) to
120 - 160 in· lbs (163 - 217 N·m).
The flex coupling should be deformed no more than 1/8" out of flat.
2.0144.077
Rotate the drive shaft, and check for excessive run out which can cause vibration.
2 - 24
2.0144.094
5xi Series Tractor Service Manual
HYDROSTATIC DRIVE
QUICK REFERENCE SECTION
SERVICE SECTION
Hydrostatic Drive
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
5xi Series Tractor Service Manual 3 - 1
3
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 4
Tractor operates in both directions but with loss of power.
Condition becomes worse as transmission becomes hot.. . . . . . . 3 - 4
Transmission overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 4
Abnormal vibration or noise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 4
TRANSAXLE FLUID
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5
Checking Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5
Fluid Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 6
Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 6
BRAKE
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 7
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 7
NEUTRAL ADJUSTMENT
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 8
Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 8
3 - 2 5xi Series Tractor Service Manual
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.
Possible Cause
Low transmission oil level
Motion control linkage
The brake is sticking
Brake adjustment it too tight
Corrective Action
Fill to full “F” mark on dipstick (when trans. is cold)
Adjust, repair, or replace
Repair linkage; replace brake assembly
Adjust the brake
Tractor goes forward only at partial speed and is slow or does not operate in reverse.
Possible Cause
The cruise control was engaged when the High-Low range lever was in “N.”
The engine is running at partial speed
The Linkage is out of adjustment
There is Internal hydro wear
Corrective Action
Turn the cruise control off
Move the throttle to “FAST.”
Verify full motion is obtain on motion control shaft.
Adjust if necessary.
Repair/replace transmission
3
Tractor will not operation in either direction.
Possible Cause Corrective Action
The transmission oil is low Fill to full “F” mark on transmission oil dipstick when transmission is cold
The control linkage needs adjustment or replacement Adjust, repair, or replace
The parking brake was not released or the parking brake is not releasing
Release the parking brake or check the linkage
The drive shaft or wheel hub key has been damaged
Faulty transmission/transaxle
The power steering filter is dirty
Replace
Repair/replace transmission/transaxle
Clean power steering filter
5xi Series Tractor Service Manual 3 - 3
HYDROSTATIC DRIVE
TROUBLESHOOTING (cont’d)
Tractor operates erratically.
Possible Cause
The transmission control linkage needs adjustment or replacement
The transmission oil level is low
The transmission is faulty
Corrective Action
Adjust, repair, or replace
Fill to the full “F” mark on the transmission oil dipstick when transmission is cold
Repair/replace
3
Tractor operates in both directions but with loss of power.
Condition becomes worse as transmission becomes hot.
Possible Cause
The transmission oil level is low
Corrective Action
Fill to the full “F” mark on the transmission dipstick when transmission is cold
Replace the transmission oil and filter The transmission shows signs of overheating or water contamination
The cooling fan and/or transmission cooling fins are faulty or dirty
The engine is not operating at full throttle
The power steering filter is dirty
Clean the transmission and/or replace the fan.
Increase the engine speed to full throttle
Clean the power steering filter
Transmission overheating.
Possible Cause
Not operating engine at full throttle
Low oil level
Accumulation of dirt and debris on hydrostatic trans.
Loose fan or broken blades
Corrective Action
Increase engine speed to full throttle
Fill full “F” mark on dipstick (when trans. is cold)
Clean
Repair or replace
Abnormal vibration or noise.
Possible Cause
The engine mounting bolts are loose
The idler pulley or cutter deck blade is loose
The transaxle cooling fan is loose
There is a problem with the electric clutch
Corrective Action
Tighten the engine mounting bolts
Tighten the appropriate pulley
Repair or replace as necessary
Repair or replace as necessary
3 - 4 5xi Series Tractor Service Manual
2.0144.029
2.0757.015
2.0109.007
5xi Series Tractor Service Manual
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.
FLUID TYPE: SAE 10W-30 detergent oil
(API service SH or higher).
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.
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.
3
4. Remove the dipstick. If necessary, add oil to the Full line on the dipstick.
IMPORTANT:
Do not fill the reservoir above the FULL line as the reservoir may overflow during use.
3 - 5
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:
Without power steering:
7 qts. (6.6 l)
6 qts. (5.6 l)
2.0415.004
3
Filter change
The transaxle is equipped with a 10 micron spin-on oil filter. This filter should be changed after the first 50 hours of operation and then every 200 hours thereafter.
When replacing the filter, coat the gasket with transaxle fluid. Tighten until the gasket contacts the base, then an additional 1/2 turn.
2.0144.031
3 - 6
2.0144.014
5xi Series Tractor Service Manual
3.7197.067
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.
Adjustment
1. Place the transmission in neutral.
2. Depress the brake pedal. There should be 2"
(51 mm) of free travel.
3
2.0109.005
2.0109.010
5xi Series Tractor Service Manual
4. Turn the adjustment nut until the above condition is met.
CAUTION
: Do not overtighten the adjustment nut.
3 - 7
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
3
Adjustment Procedure
1. Bring the hydrostatic transmission up to operating temperature.
2. Place the rear axle on jack stands, and remove the rear wheels.
NOTE:
Do not set the parking brake.
3. To gain access to the adjustment eccentric, turn the front wheels in either direction to the steering stop.
2.3653.006
3 - 8
2.0144.072
5xi Series Tractor Service Manual
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
2.144.72
5xi Series Tractor Service Manual
6. Center the eccentric between these points, and tighten the through bolt while holding the eccentric.
NOTE
: Do not turn the eccentric more than
90° in either direction. Notch in eccentric must be away from pivot point of control arm.
3 - 9
GASOLINE ENGINE
QUICK REFERENCE SECTION
SERVICE SECTION
Gasoline Engine
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
5xi Series Tractor Service Manual 4 - 1
GASOLINE ENGINE
4
4 - 2
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 4
Engine will not idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 4
Engine overheats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 4
Engine loses power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 4
Engine knocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 4
AIR CLEANER
Service Interval/Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 5
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 5
ENGINE OIL
Service Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 6
Changing/Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 6
OIL FILTER
Service Interval/Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 6
Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 7
SPARK PLUG
Specification/Service Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 7
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 8
FUEL FILTER
Service Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 8
COOLING SYSTEM, AIR
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 8
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 9
COOLING SYSTEM, LIQUID
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 9
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 10
5xi Series Tractor Service Manual
GASOLINE ENGINE
TROUBLESHOOTING
Engine cranks but will not start.
Possible Cause
Incorrect starting procedure
The fuel tank is empty
The fuel shut-off valve is closed
Dirt or water is in the fuel system
Clogged fuel line
The spark plug lead is disconnected
The kill relay not energized
A spark plug is faulty
Faulty ignition module
Starter does not crank.
Possible Cause
Blown or loose fuse
Battery is discharged
Safety interlock system malfunctioning
Faulty starter or starter solenoid
Seized internal engine components
Poor ground; loose connections
Corrective Action
Ensure throttle is at full, and choke is on
Fill with fresh fuel
Open fuel shut-off valve
Drain and flush fuel system; add fresh fuel
Clean or replace
Reconnect spark plug
Inspect safety switches and wiring
Replace spark plug
Replace ignition module
Corrective Action
Determine cause, correct and replace fuse
Charge battery or replace if necessary
Inspect safety switches and wiring harness
Replace
Replace
Clean and tighten
Engine starts but does not keep running.
Possible Cause
Misadjusted or faulty choke or throttle control cable
The fuel tank vent is restricted
Dirt or water in the fuel system
The fuel filter is clogged
The fuel pump is faulty
The carburetor is faulty
Loose wires or poor connections
The cylinder head gasket is faulty
Corrective Action
Adjust or replace
Vent system hoses kinked or plugged, clean or repair
Drain and flush fuel system; add fresh fuel
Replace the fuel filter
Repair or replace
Clean or rebuild
Check and tighten wire connections
Replace
Engine is difficult to start.
Possible Cause
Improper starting procedure
Dirt or water in the fuel system
Clogged fuel filter
Loose wires or poor connections
Misadjusted or faulty choke or throttle control cable
Faulty spark plug
Low compression
Corrective Action
Ensure throttle is at full, and choke is on
Drain and flush fuel system, add fresh fuel
Replace
Troubleshoot and repair
Adjust or replace
Replace
Test compression, correct as needed
4
5xi Series Tractor Service Manual 4 - 3
GASOLINE ENGINE
TROUBLESHOOTING (cont’d)
Engine runs but knocks or misses.
Possible Cause
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
Engine will not idle.
Possible Cause
The fuel tank is restricted
Dirt or water is in the fuel system
A spark plug is faulty
Carburetor idle passages are plugged
The Idle speed adjusting screw is incorrectly set
The fuel pump is faulty
Low compression
Engine overheats.
4
Possible Cause
(3) air intake screens are dirty
Restricted air flow into the engine or radiator
The crankcase oil level is incorrect
The fuel mixture is lean
Excessive loading
Defective thermostat
More coolant is needed
Engine loses power.
Possible Cause
The crankcase oil level is incorrect
The air cleaner element is dirty
Dirt, water, or stale fuel is in the fuel system
The engine is overheated
A spark plug is faulty
Low compression
Engine knocks.
Possible Cause
Old or improper fuel
Internal wear or damage
4 - 4
Corrective Action
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
Corrective Action
Check hoses, clean or replace
Drain and flush fuel system; add fresh fuel
Replace the spark plug
Clean or replace carburetor
Reset to factory specifications
Repair or replace
Test compression, correct as needed
Corrective Action
Clean with every use
Inspect & clean the (3) air intake screens & radiator screen
Fill or drain to the full mark
Clean carburetor, check float level, and inspect main jet
Reduce load; use lower ground speed
Replace the thermostat
Check and add coolant
Corrective Action
Fill or drain to the full mark
Clean or replace
Drain and flush fuel system; add fresh fuel
See ENGINE OVERHEATS
Replace the spark plug
Test compression, correct as needed
Corrective Action
Drain system and add fresh fuel
Inspection required
5xi Series Tractor Service Manual
2.7146.035
2.0144.019
2.0144.099
5xi Series Tractor Service Manual
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.
Cleaning
FOAM ELEMENT
1. Wash the foam element in liquid soap and warm water. When the element is clean, rinse it thoroughly.
2. Dry the element by squeezing it in a clean cloth.
3. Put one or two ounces of oil in the element.
Squeeze the element to distribute the oil.
IMPORTANT:
Replace the foam element if it is torn or worn.
4
PAPER ELEMENT
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.
IMPORTANT:
Never clean the paper element with pressurized air or liquids, such as solvent, gasoline, or kerosene. Replace the paper element if it is damaged or defective.
4 - 5
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.
-20
F
C
-30
3.7197.079
-20
0 20
-10
32 40
0 10
60
20
80
30
100
40
4
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. Slide a piece of 1/2" (12 mm) hose over the oil drain.
4. Open the drain by turning it clockwise 1/8 turn and pull it out.
5. Let oil drain completely. Close drain.
6. Refill with recommended oil.
OIL FILTER
Service Interval/Specification
Replace the oil filter every 200 hours or every other oil change.
NOTE:
Change the oil filter more frequently when operating conditions are extremely dusty.
2.0144.054
4 - 6
2.0144.092
5xi Series Tractor Service Manual
3.0144.014
2.0144.040
2.0144.011
5xi Series Tractor Service Manual
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.
SPARK PLUG
Service Interval/Specification
Kohler Engines
Type: Champion RC12YC (or equivalent)
Air Gap: 0.030 in (.76 mm)
Kawasaki Engines
Type: NGK BMR4A
Air Gap: .024 - .028 in (0.6 - 0.7 mm)
Install new spark plugs after every 100 operating hours/Kawasaki, 200 hours/Kohler.
Check the spark plugs after every 25 operating hours. Make sure the air gap is correct before installing the the spark plug.
4
If the insulator on the spark plug is light brown or gray, the engine is running properly. A black coating on the insulator indicates the air cleaner may be dirty.
IMPORTANT:
Never clean the spark plugs.
Always replace the spark plugs when it has a black coating, worn electrodes, an oily film, or cracks.
4 - 7
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
Kawasaki engines
18-22 ft·lbs (24-30 N·m)
18 ft·lbs (25 N·m)
4
FUEL FILTER
Service Interval
Replace the fuel filter after every 100 operating hours or yearly, whichever occurs first.
2.0144.048
COOLING SYSTEM, AIR
General Information
Models 518xi, 520xi, and 522xi are equipped with air-cooled engines.
The engine is cooled by air drawn through the air intake screen by a fan attached to the flywheel. Engine heat is carried away when shrouds attached to the engine direct the air flow through fins located on the cylinders and cylinder heads.
2.0144.092
4 - 8
2.0109.40
5xi Series Tractor Service Manual
2.0415.008
2.7163.09
2.7163.013
5xi Series Tractor Service Manual
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.
COOLING SYSTEM, LIQUID
General Information
Models 520Lxi are equipped with a liquid-cooled engine.
This engine uses a gear driven water pump to circulate 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 a belt driven fan.
4
Engine temperature is maintained by a thermostat which opens at approximately 150 °
F (66° C). When the thermostat is open, it allows coolant to flow through the radiator.
When the coolant temperature falls below 150°
F (66°
C) the thermostat closes, bypassing the radiator allowing faster warm-up and consistent operating temperature.
The cooling system is pressurized at operating temperature to prevent evaporation and raise the boiling point of the coolant .
4 - 9
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.
4
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.
2.0144.012
Inspect coolant hoses and fan belt for deterioration every 100 hours 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.
2.0144.049
4 - 10
2.0144.039
5xi Series Tractor Service Manual
DIESEL ENGINE
QUICK REFERENCE SECTION
SERVICE SECTION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5xi Series Tractor Service Manual 5 - 1
DIESEL ENGINE
5
5 - 2
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 4
Engine will not idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 4
Engine overheats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 4
Engine loses power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 4
Engine knocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5
Excessive black smoke from exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5
Excessive white smoke from exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5
AIR CLEANER
Service Interval/Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 6
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 6
ENGINE OIL
Service Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 6
Changing/Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 7
OIL FILTER
Service Interval/Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 7
Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 7
COOLING SYSTEM
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 8
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 8
ENGINE MOUNTS
Engine Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 9
FUEL SYSTEM
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 9
GLOW PLUGS
Cold Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 10
5xi Series Tractor Service Manual
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.
Possible Cause
Contaminated fuel
Incorrect starting procedure
The fuel tank is empty
The fuel shut-off valve is closed
Dirt or water is in the fuel system
Clogged fuel line
Air in fuel
Inoperative glow plugs
Inoperative fuel solenoid
Slow cranking speed
Insufficient combustion air supply
Low compression
Corrective Action
Clean fuel system
Activate glow plugs before attempting to start
Fill with fresh fuel
Open the fuel shut- off valve
Drain and flush fuel system; add fresh fuel
Clean or replace
Bleed nozzles, check for leaks on suction side of system
Check fuse, glow plugs, and wiring
Check wiring, start switch, and fuel solenoid
Check battery, oil viscosity,and starter motor
Check air filter and combustion air path
Perform cylinder leak down test. Adjust, repair, or replace affected parts.
Starter does not crank.
Possible Cause
The fuse is blown or loose
Corrective Action
Correct or replace the fuse
The battery is discharged
The safety interlock system is malfunctioning
Charge the battery or replace it
Inspect safety switches and wiring harness
A faulty starter, starter solenoid, relay, or ignition switch Replace
Seized internal engine components Replace
Engine starts but does not keep running.
Possible Cause
Contaminated fuel
Air in fuel
Waxing fuel below 32° F (0° C)
The fuel filter is clogged
Dirt or water in the fuel system
The fuel tank vent is restricted
Loose wires or poor connectors
Corrective Action
Clean fuel system
Bleed nozzles, check for leaks on suction side of system
Use a winter blend fuel when the ambient temperature is below freezing
Replace the fuel filter
Drain fuel filter. Flush fuel system if necessary
Vent system hoses kinked or plugged, clean or replace
Check and tighten wire connections
5xi Series Tractor Service Manual 5 - 3
5
DIESEL ENGINE
TROUBLESHOOTING (cont’d)
Engine is difficult to start.
Possible Cause
Improper starting procedure
Air in fuel
Inoperative glow plugs
Insufficient combustion air supply
Faulty injection nozzles
Clogged fuel filter
Incorrect injection pump timing
Low ambient temperature
Worn injection pump (hard starting warm)
Low compression
Corrective Action
Activate glow plugs before attempting to start
Bleed nozzles, check for leaks on suction side of system
Check fuse, glow plugs, and wiring
Check air filter and combustion air path
Test nozzles, clean or replace as necessary
Replace
Perform complete timing procedure
Activate block heater, check oil viscosity
Check fuel supply from nozzles
Perform cylinder leakage test
Engine runs but knocks or misses.
Possible Cause
Air in fuel
Dirt, water, or stale fuel in fuel system
Faulty injection nozzle(s)
Low compression
Corrective Action
Bleed nozzles, check for leaks on suction side of system
Drain and flush fuel filter; add fresh fuel
Test nozzles, clean or replace as necessary
Perform cylinder leakage test
5
Engine will not idle.
Possible Cause
Air in fuel
Idle speed too low
The fuel injection pump is faulty
The fuel tank vent is restricted
Dirt or water is in the fuel system
Engine overheats.
Possible Cause
(3) air intake screens are dirty
More coolant is needed
Restricted air flow through radiator
Defective thermostat
The crankcase oil level is incorrect
Faulty thermostat
Excessive loading
Corrective Action
Bleed nozzles, check for leaks on suction side of system
Adjust idle speed
Repair or replace as necessary
Check hoses, clean, or replace
Drain and flush fuel system; add fresh fuel
Corrective Action
Clean with every use
Check and add coolant
Clean debris from radiator and cooling air path
Replace the thermostat
Fill or drain to the full mark
Replace
Reduce load; use lower ground speed
5 - 4 5xi Series Tractor Service Manual
DIESEL ENGINE
Engine loses power.
Possible Cause
Insufficient combustion air supply
Air in fuel
Dirt, water, or stale fuel is in the fuel system
Faulty injection nozzle(s)
Incorrect injection pump timing
Faulty injection pump
Low compression
The vent hole in the fuel tank vent fitting is plugged
The engine load is excessive
The crankcase oil level is incorrect
Corrective Action
Check air filter and combustion air path
Bleed nozzles, check for leaks on suction side of system
Drain and flush fuel system; add fresh fuel
Test nozzles, clean or replace as necessary
Perform complete timing procedure
Repair or replace as necessary
Perform cylinder leakage test
Repair or replace vent system
Reduce ground speed
Fill or drain to the full mark
Engine knocks.
Possible Cause
Sticking injection nozzles
Incorrect injection pump timing
Excessive carbon build-up
Internal wear or damage
Corrective Action
Clean or replace nozzles
Perform complete timing procedure
Clean carbon from cylinder head and piston
Inspection required
Excessive black smoke from exhaust.
Possible Cause
Insufficient combustion air supply
Incorrect injection pump timing
Improper fuel
Faulty injection nozzles
Corrective Action
Check air filter and combustion air path
Perform complete timing procedure
Drain fuel system and refill with specified fuel
Clean or replace nozzles
Excessive white smoke from exhaust.
Possible Cause
Low engine temperature
Inoperative glow plugs
Faulty injection nozzles
Incorrect injection pump timing
Low compression
Corrective Action
Check thermostat
Check fuse, glow plugs, and wiring
Clean or replace nozzles
Perform complete timing procedure
Perform cylinder leakage test
5xi Series Tractor Service Manual 5 - 5
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
5
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.
IMPORTANT:
Never clean the paper element with pressurized air or liquids, such as solvent, gasoline, or kerosene. Replace the paper element if it is damaged, defective, or cannot be cleaned thoroughly.
2.3653.007
ENGINE OIL
Service Interval
Oil Type: Detergent oil (API service CD or higher).
Crankcase capacity (with filter): 3.5 Qts (3.3 l).
Viscosity: See table.
Change oil:
•
After first 50 operating hours.
•
After every 100 operating hours
5 - 6
-20
F
C
-30
3.7197.079
-20
0 20
-10
32 40
0 10
60
20
80
30
100
40
5xi Series Tractor Service Manual
2.0757.008
2.0757.038
2.0144.014
5xi Series Tractor Service Manual
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.
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
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 to the specified level with the proper oil.
5 - 7
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
5
Engine temperature is maintained by a thermostat which opens at approximately 180°
F (82° C). When the thermostat is open, it allows coolant to flow through the radiator.
When the coolant temperature falls below 180°
F (82° C), the thermostat closes, bypassing the radiator allowing faster warm-up and consistent operating temperature.
The cooling system is pressurized at operating temperature to prevent evaporation and raise the boiling point of the coolant.
2.7163.26
5 - 8
Maintenance
Inspect cooling system often. Carefully clean grass clippings and other debris from air intake screens and radiator fins.
Maintain coolant level in the coolant recovery tank between the two lines 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.
2.0757.030
5xi Series Tractor Service Manual
2.0757.007
2.0757.034
2.0757.038
5xi Series Tractor Service Manual
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.
ENGINE MOUNTS
Engine Mounting
The diesel engine is mounted on vibration dampening rubber isolators. Inspect these engine mounts for damage from chemicals, deterioration of the rubber, or loose fasteners.
5
FUEL SYSTEM
Fuel Filter
The diesel fuel system is equipped with a fuel filter/water separator. This filter should be replaced every 400 hours of operation. Any water accumulation should be drained by opening the petcock (A) before each use.
5 - 9
5
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.
2.0757.006
5 - 10 5xi Series Tractor Service Manual
ELECTRICAL
QUICK REFERENCE SECTION
SERVICE SECTION
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
5xi Series Tractor Service Manual 6-1
6
ELECTRICAL
Table of Contents
BATTERY
Service Interval/Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 4
Battery Heat Shield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 4
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 5
Electrolyte Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 5
Adding Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 5
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 6
FUSE
General Information/Specification . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 6
HEADLIGHTS
Bulb Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 6
Bulb Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 7
INSTRUMENT PANEL LIGHTS
Bulb Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 7
Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 7
TAILLIGHTS
Bulb Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 8
ELECTRIC CLUTCH TROUBLESHOOTING
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 8
Coil Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 8
6-2 5xi Series Tractor Service Manual
ELECTRICAL
SAFETY INTERLOCK SYSTEM
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 9
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 9
CRUISE CONTROL
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 10
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 10
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 11
FUEL GAUGE
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 12
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 12
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 13
CHARGING SYSTEM
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 14
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 15
Voltage Regulator Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 16
ELECTRICAL SCHEMATIC
518xi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 16
520/522xi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 17
520Lxi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 18
520Dxi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 19
6
5xi Series Tractor Service Manual 6-3
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
6
Removal
1. Disengage the PTO, set the parking brake, turn the ignition key to
OFF
and remove the key.
2. Remove the grille.
3. Remove the battery hold down.
4. Disconnect the negative (black) ground cable from the battery post.
5. Disconnect the positive (red) cable from the battery post.
IMPORTANT:
Always hold the battery vertical to avoid spilling battery acid.
WARNING:
When removing or installing the battery, do not allow the battery terminals to touch any metal parts of the tractor (below the headlights).
2.0109.038
Battery Heat Shield
All gasoline engines are equipped with a heat shield which is incorporated into the battery hold down. Replace the heat shield after servicing to protect the battery from heat.
NOTE:
Failure to reinstall the heat shield after servicing the battery can result in shortened battery life and/or battery damage.
6-4
2.0109.016
5xi Series Tractor Service Manual
2.0109.041
3.7197.111
2.0144.093
5xi Series Tractor Service Manual
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.
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. If the electrolyte is low, add distilled water to achieve the specified level. (See: Adding
Water)
Adding Water
The best time to add distilled water to the battery is just before you operate the machine.
1. Clean the top of the battery.
2. Remove the filler caps.
3. Slowly pour distilled water into each battery cell until the level is up to the lower part of the tube.
IMPORTANT:
Do not overfill the battery.
Electrolyte (sulfuric acid) can cause severe corrosion and damage to the chassis.
4. Replace the filler caps.
6-5
6
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.
FUSE
6
General Information/Specification
The electrical system is protected by fuses. If a fuse blows, check component/circuit for a malfunction or short.
Fuse:
1. Main/Starter - 30 amp, blade type.
2. Alternator - 25 amp, blade type.
3. Dash, Interlock, and Cruise Control - 10 amp, blade type.
4. Headlights/Taillights - 10 amp, blade type.
NOTE:
The number 2 fuse on diesel tractors is for the starter and is 15 amp.
HEADLIGHTS
Bulb Removal
1. Disengage the PTO, set the parking brake, turn the ignition key to
OFF
, and remove the key.
2. Pull the wire connectors off both bulb holder terminals.
3. Rotate the bulb holder 1/4 turn counterclockwise and remove it from the reflector.
4. Push and rotate the bulb counterclockwise until it stops (approximately 1/4 turn) and remove.
2.0144.070
2.7152.024
2.0109.030
6-6 5xi Series Tractor Service Manual
2.0757.031
2.0144.024
2.0144.018
5xi Series Tractor Service Manual
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
INSTRUMENT PANEL LIGHTS
Bulb Removal
1. Disengage the PTO, set the parking brake, turn the ignition key to
OFF
, and remove the key.
2. Turn the bulb holder 1/4 turn counterclockwise, and remove it from the panel
3. Pull the bulb straight out of the bulb holder.
Bulb Number: GE 194
6
Bulb Replacement
1. Align the bulb with the slot in the bulb holder and push the bulb into the slot.
2. Align the tabs on the bulb holder with the slots in the panel. Insert the bulb being careful not to damage the printed circuit connectors.
Rotate the bulb approximately 1/4 turn until it stops.
Bulb Number: GE 194
6-7
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
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.
2.0757.027
6
Coil Resistance Measurement
Equipment:
Volt/Ohmmeter
1. Disengage the PTO, set the parking brake, turn the ignition key to
OFF
, and remove the key.
2. Disconnect the clutch wire connector.
3. Set the volt/ohmmeter to check resistance
(ohms).
2.0144.006
2.0144.080
6-8 5xi Series Tractor Service Manual
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. The brake pedal is depressed.
3. The power take off (PTO) is
OFF.
The system will also kill the engine if you attempt to operate the clutch or drive system when you are not in the seat.
2.0109.028
Test
PTO
Switch
Starting On
Starting Off
Starting Off
Running Off
Parking
Brake
On
Off
On
Off
Seat
Operator
On
Operator
On
Operator
Off
Operator
Off
Expected
Result
No
Start
No
Start
No
Start
Engine
Stalls
Testing
1. Set the parking brake. Move the PTO to
ON
.
Now turn the ignition key to
START
; the engine should not crank.
2. Push the PTO to
OFF
and release the parking brake. Now turn the ignition to
START
; the engine should not crank.
3. Set the parking brake and move the PTO to
OFF
. Start the engine. While the engine is running, release the parking brake and rise from the seat; the engine should stop.
6
5xi Series Tractor Service Manual 6-9
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.
DEMYSTIFICATION
GUIDE
6
CRUISE CONTROL
General Information
The 520xi and larger tractors are equipped with an electric cruise control that, when activated, locks the motion control lever in position to maintain a constant speed. The Smart Turn
Steering system overrides the cruise control in a sharp turn slowing the tractor until the turn is completed. The tractor then accelerates to resume the set speed.
3.7197.125
2.0757.001
Theory of Operation
The cruise control is activated with a switch located on the right side fender. When the tractor is at the desired speed, activating the switch energizes an electromagnet.
6-10
2.0757.004
5xi Series Tractor Service Manual
2.0144.45
3.7230.132
2.3653.010
5xi Series Tractor Service Manual
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.
NOTE:
Activating cruise in neutral or at very slow speeds will prevent full speed operation.
Troubleshooting
Disconnect the three pin connector from the cruise control module. Turn the ignition switch to the “on” position. Make sure the parking brake is disengaged. Measure the voltage at each of the pins in the following conditions:
Wire Color
Cruise
Off
Yellow
Brown
Black
0 V
0 V
0 V
Cruise
On
12 V
0 V
0 V
Cruise held in engage position
12 V
12 V
0 V
If you do not get these results, the problem is in the switches or wiring between the module and the switches or magnet.
6
Reconnect the three pin connector to the module. Measure the voltage at each of the pins on the connector in the following conditions:
Wire Color Cruise
Off
Yellow
Brown
Black (see note 2
0 V
0 V
0 V
Cruise On
See note 1
12 V
0 V
0 V
Cruise held in engage position
0.6 to 1.3 V
0.6 to 1.3 V
0 V
If you do not get the results shown above and have successfully completed the test described in the test above, replace the module.
Note 1:
Press and release brake to reset circuit .
Note 2:
Voltage at black wire indicates faulty ground
6-11
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.
Theory of Operation
B+ is supplied to one side of the fuel gauge.
The other side of the gauge is connected to ground through the sender.
2.0144.074
2.0144.074
E
F
6
When the ignition switch is in the ON position, current flow through the gauge winding causes the needle to move. The greater the current, the closer the needle moves to the Full mark.
3.7197.133
6-12
2.0144.075
5xi Series Tractor Service Manual
E
F
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.
2.0144.084
2.0144.074
E
F
As fuel is consumed, the float moves down increasing the resistance and allows less current flow. This causes the needle to move toward empty.
3.7197.134
Troubleshooting
If the fuel gauge is inoperative:
1. Disconnect the wire from the sender. When the circuit is open (no current flow), the gauge should read empty.
6
2.0144.083
2.0144.075
5xi Series Tractor Service Manual 6-13
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.
2.0144.075
2.0144.056
6
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).
3. Move the float through its travel. The resistance should range from 20-35 ohms when the float is up. When the float is all the way down, the resistance should be 240-265 ohms.
CHARGING SYSTEM
General Information
All gasoline fueled tractor charging systems consist of a permanent magnet flywheel alternator and a separate voltage regulator/rectifier.
The air-cooled Kohler engines have a 15 amp charging system.
The regulator on these units is mounted on the engine.
2.0144.015
2.0757.028
6-14 5xi Series Tractor Service Manual
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.
2.0144.032
2.0144.056
5xi Series Tractor Service Manual
Testing
Connect a voltmeter across the battery. The voltage should read between 13.8 -14.2 VDC at
3400 RPM with the lights on. If the voltage is low or you suspect a charging system fault, follow the troubleshooting instructions in the engine manufacturer’s service manual.
6
6-15
6
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.
6-16 5xi Series Tractor Service Manual
18 Kohler
INDICATOR LIGHT
HARNESS
PTO
#194 LAMP
OIL
REVERSE
BATTERY
#194 LAMP
#168 LAMP
#194 LAMP
P
W
A
J
GN
T
OR
B
C
K
GN
T
OR
P
W
VOLTAGE
COMPARATOR
OSCILLATOR
B+
2
5
3
4
ELECTRONICS MODULE
PN 94-7612
1
OR
T
Layer 1P
GY
BK
HEADLIGHT HARNESS
OR OR
F4
10A
S4
(IGNITION SWITCH)
OFF-----------------------NOCONNECTION
RUN/LIGHTS-------------B I R L
RUN-----------------------B I R
START---------------------B I R S
4
L
3
I
2
R
OR
P BN R VIO
I
R
S
B
L
IGNITION SWITCH TERMINAL
LOCATIONS VEIWED FROM BACK.
GY
OR
BU
GN
BK
BN
BLACK
BROWN
BLUE
GREEN
GREY
ORANGE
WIRE COLOR CODES
P
R
T
VIO
W
Y
PINK
RED
TAN
VIOLET
WHITE
YELLOW
F3
10A
VIO
BK BK
W
GY
S5
(REVERSE
SWITCH)
REVERSE SWITCH
CLOSES WHEN HYDRO
TRACTION LEVER IS
MOVED TO REVERSE
P P
L
I
#194
LAMP
S
W
BK
FUEL
SENDER
L
P P
I
#194
LAMP
G
BK
TEMP
SENDER
GND
Y
BK
TEMP. GAUGE
S
+
HOUR
METER
-
BK
P
OR BN
W
P
BK BN
GY
Y
S3
(PTO SWITCH)
PTO SWITCH IS SHOWN
IN OFF POSITION
T
S1
(SEAT
SWITCH)
SEAT SWITCH IS CLOSED
WHEN OPERATOR IS IN
THE SEAT
S2
(BRAKE SWITCH)
BRAKE SWITCH CLOSES
WHEN BRAKE IS DEPRESSED
Y
BK
K3
(INTERLOCK
RELAY)
K2
(START
RELAY)
GN BU
OR BN
R
R
F1
30A
VIO
F2
25A
VIO
GN
GN
BU
W
BN
PTO CLUTCH
Y GN
W
K1
(KILL RELAY)
R
BK
BK
BK
GND
REG
OIL
START
MAG
B+
OIL
SWITCH
+
ENGINE HARNESS
SPARK PLUG
IGNITION
MODULES
SPARK PLUG
AC
AC
SOLINOID
SHIFT
STARTER FUEL
SOLINOID
18 Kohler
INDICATOR LIGHT
HARNESS
PTO
#194 LAMP
OIL
REVERSE
BATTERY
#194 LAMP
#168 LAMP
#194 LAMP
P
W
A
J
GN
T
OR
B
C
K
GN
T
OR
P
W
VOLTAGE
COMPARATOR
OSCILLATOR
B+
2
5
3
4
ELECTRONICS MODULE
PN 94-7612
1
OR
T
Layer 1P
GY
BK
HEADLIGHT HARNESS
OR OR
F4
10A
S4
(IGNITION SWITCH)
OFF-----------------------NOCONNECTION
RUN/LIGHTS-------------B I R L
RUN-----------------------B I R
START---------------------B I R S
4
L
3
I
2
R
OR
P BN R VIO
I
R
S
B
L
IGNITION SWITCH TERMINAL
LOCATIONS VEIWED FROM BACK.
GY
OR
BU
GN
BK
BN
BLACK
BROWN
BLUE
GREEN
GREY
ORANGE
WIRE COLOR CODES
P
R
T
VIO
W
Y
PINK
RED
TAN
VIOLET
WHITE
YELLOW
F3
10A
VIO
BK BK
W
GY
S5
(REVERSE
SWITCH)
REVERSE SWITCH
CLOSES WHEN HYDRO
TRACTION LEVER IS
MOVED TO REVERSE
P P
L
I
#194
LAMP
S
W
BK
FUEL
SENDER
L
P P
I
#194
LAMP
G
BK
TEMP
SENDER
GND
Y
BK
TEMP. GAUGE
S
+
HOUR
METER
-
BK
P
OR BN
W
P
BK BN
GY
Y
S3
(PTO SWITCH)
PTO SWITCH IS SHOWN
IN OFF POSITION
T
S1
(SEAT
SWITCH)
SEAT SWITCH IS CLOSED
WHEN OPERATOR IS IN
THE SEAT
S2
(BRAKE SWITCH)
BRAKE SWITCH CLOSES
WHEN BRAKE IS DEPRESSED
Y
BK
K3
(INTERLOCK
RELAY)
K2
(START
RELAY)
GN BU
OR BN
R
R
F1
30A
VIO
F2
25A
VIO
GN
GN
BU
W
BN
PTO CLUTCH
Y GN
W
K1
(KILL RELAY)
R
BK
BK
BK
GND
REG
OIL
START
MAG
B+
OIL
SWITCH
+
ENGINE HARNESS
SPARK PLUG
IGNITION
MODULES
SPARK PLUG
AC
AC
SOLINOID
SHIFT
STARTER FUEL
SOLINOID
18 Kohler
INDICATOR LIGHT
HARNESS
PTO
#194 LAMP
OIL
REVERSE
BATTERY
#194 LAMP
#168 LAMP
#194 LAMP
P
W
A
J
GN
T
OR
B
C
K
GN
T
OR
P
W
VOLTAGE
COMPARATOR
OSCILLATOR
B+
2
5
3
4
ELECTRONICS MODULE
PN 94-7612
1
OR
T
Layer 1P
GY
BK
HEADLIGHT HARNESS
OR OR
F4
10A
S4
(IGNITION SWITCH)
OFF-----------------------NOCONNECTION
RUN/LIGHTS-------------B I R L
RUN-----------------------B I R
START---------------------B I R S
4
L
3
I
2
R
OR
P BN R VIO
I
R
S
B
L
IGNITION SWITCH TERMINAL
LOCATIONS VEIWED FROM BACK.
GY
OR
BU
GN
BK
BN
BLACK
BROWN
BLUE
GREEN
GREY
ORANGE
WIRE COLOR CODES
P
R
T
VIO
W
Y
PINK
RED
TAN
VIOLET
WHITE
YELLOW
F3
10A
VIO
BK BK
W
GY
S5
(REVERSE
SWITCH)
REVERSE SWITCH
CLOSES WHEN HYDRO
TRACTION LEVER IS
MOVED TO REVERSE
P P
L
I
#194
LAMP
S
W
BK
FUEL
SENDER
L
P P
I
#194
LAMP
G
BK
TEMP
SENDER
GND
Y
BK
TEMP. GAUGE
S
+
HOUR
METER
-
BK
P
OR BN
W
P
BK BN
GY
Y
S3
(PTO SWITCH)
PTO SWITCH IS SHOWN
IN OFF POSITION
T
S1
(SEAT
SWITCH)
SEAT SWITCH IS CLOSED
WHEN OPERATOR IS IN
THE SEAT
S2
(BRAKE SWITCH)
BRAKE SWITCH CLOSES
WHEN BRAKE IS DEPRESSED
Y
BK
K3
(INTERLOCK
RELAY)
K2
(START
RELAY)
GN BU
OR BN
R
R
F1
30A
VIO
F2
25A
VIO
GN
GN
BU
W
BN
PTO CLUTCH
Y GN
W
K1
(KILL RELAY)
R
BK
BK
BK
GND
REG
OIL
START
MAG
B+
OIL
SWITCH
+
ENGINE HARNESS
SPARK PLUG
IGNITION
MODULES
SPARK PLUG
AC
AC
SOLINOID
SHIFT
STARTER FUEL
SOLINOID
20 & 22 Kohler
HEADLIGHT HARNESS
SW4
(IGNITION SWITCH)
OFF--------------------NO CONNECTION
RUN/LIGHTS----------B I R L
RUN--------------------B I R
START-------------------B I R S
L
4 3
I
1
S B
5
R
2
REAR HARNESS
TAIL LIGHTS
BK
BK
OR
OR
OR
P BN R VIO
OR
A
OR
BK
B
BK
CRUISE SWITCH
SW8
2
3
6
(MOMENTARY)
5
CRUISE SWITCH OPERATION
OFF
ON
NO CONNECTION
3 AND 2 CONNECTED
MOMENTARY 3 AND 2 CONNECTED
GN
Y
BN
C
E
D
GN
Y
BN
5 AND 6 CONNECTED
CRUISE MODULE
C
A
B
95-3029
Y
BN
BK
SW7
(CRUISE DISENGAGE SWITCH)
SWITCH OPENS WHEN
BRAKE IS DEPRESSED
VIO
CRUISE MAGNET
P
WARNING LIGHT HARNESS
CRUISE
PARK
OIL
PTO
REVERSE
BATTERY
#194 LAMP
#194 LAMP
#194 LAMP
#194 LAMP
#168 LAMP
#194 LAMP
VOLTAGE
COMPARATOR
OSCILLATOR
ELECTRONICS MODULE
PN 94-7612
B+
2
5
3
4
1
T
OR
D
VIO
W
P
H
BU
GRN
B
J
A
C
K
VIO
BU
GRN
T
W
P
OR
T
P
GY
BK
BU
SW6
(PARK SWITCH)
PARK SWITCH CLOSES WHEN PARKING
BRAKE LEVER IS ENGAGED
BK
W
GY
SW5
(REVERSE SWITCH)
REVERSE SWITCH
CLOSES WHEN HYDRO
TRACTION LEVER IS
MOVED TO REVERSE
P
L
P
I
FUEL
GAUGE
S
#194
LAMP
G
BK
FUEL
SENDER
W
L
#194
LAMP
I
TEMP.
GAUGE
S
Y
G
BK
TEMP.
SENDER
+
GRN
GND
BK
HOUR
METER
OR
F4
10A
P
W P
BK
BN
GY
SW3
(PTO SWITCH)
PTO SWITCH IS SHOWN
IN OFF POSITION
P
BN
OR
K3
(INTERLOCK RELAY)
T
BK
K2
(START RELAY)
OR BN
SEAT SWITCH IS CLOSED
WHEN OPERATOR IS IN
THE SEAT
Y
GRN
BU
SW2
(BRAKE SWITCH)
GY
BRAKE SWITCH CLOSES WHEN
BRAKE IS DEPRESSED
Y
BN
BK
PTO CLUTCH
BK
Y
GRN
W
GND
K1
(KILL RELAY)
I
R
S
B
L
IGNITION SWITCH TERMINAL
LOCATIONS VEIWED FROM BACK.
VIO
R
R
F1
30A
VIO
F2
25A
VIO
GRN
BU
W
R
BK
BN
BU
GN
GY
OR
WIRE COLOR CODES
BLACK
BROWN
BLUE
GREEN
GREY
ORANGE
P
R
T
VIO
W
Y
PINK
RED
TAN
VIOLET
WHITE
YELLOW
ENGINE HARNESS
SPARK PLUG
IGNITION
MODULES
SPARK PLUG
REG
OIL
START
MAG
B+
OIL
SWITCH
OIL SWITCH OPENS
WITH OIL PRESSURE
-
AC
AC
+
SOLINOID
SHIFT
STARTER
FUEL
SOLINOID
20 & 22 Kohler
HEADLIGHT HARNESS
SW4
(IGNITION SWITCH)
OFF--------------------NO CONNECTION
RUN/LIGHTS----------B I R L
RUN--------------------B I R
START-------------------B I R S
L
4 3
I
1
S B
5
R
2
REAR HARNESS
TAIL LIGHTS
BK
BK
OR
OR
OR
P BN R VIO
OR
A
OR
BK
B
BK
CRUISE SWITCH
SW8
2
3
6
(MOMENTARY)
5
CRUISE SWITCH OPERATION
OFF
ON
NO CONNECTION
3 AND 2 CONNECTED
MOMENTARY 3 AND 2 CONNECTED
GN
Y
BN
C
E
D
GN
Y
BN
5 AND 6 CONNECTED
CRUISE MODULE
C
A
B
95-3029
Y
BN
BK
SW7
(CRUISE DISENGAGE SWITCH)
SWITCH OPENS WHEN
BRAKE IS DEPRESSED
VIO
CRUISE MAGNET
P
WARNING LIGHT HARNESS
CRUISE
PARK
OIL
PTO
REVERSE
BATTERY
#194 LAMP
#194 LAMP
#194 LAMP
#194 LAMP
#168 LAMP
#194 LAMP
VOLTAGE
COMPARATOR
OSCILLATOR
ELECTRONICS MODULE
PN 94-7612
B+
2
5
3
4
1
T
OR
D
VIO
W
P
H
BU
GRN
B
J
A
C
K
VIO
BU
GRN
T
W
P
OR
T
P
GY
BK
BU
SW6
(PARK SWITCH)
PARK SWITCH CLOSES WHEN PARKING
BRAKE LEVER IS ENGAGED
BK
W
GY
SW5
(REVERSE SWITCH)
REVERSE SWITCH
CLOSES WHEN HYDRO
TRACTION LEVER IS
MOVED TO REVERSE
P
L
P
I
FUEL
GAUGE
S
#194
LAMP
G
BK
FUEL
SENDER
W
L
#194
LAMP
I
TEMP.
GAUGE
S
Y
G
BK
TEMP.
SENDER
+
GRN
GND
BK
HOUR
METER
OR
F4
10A
P
W P
BK
BN
GY
SW3
(PTO SWITCH)
PTO SWITCH IS SHOWN
IN OFF POSITION
P
BN
OR
K3
(INTERLOCK RELAY)
T
BK
K2
(START RELAY)
OR BN
SEAT SWITCH IS CLOSED
WHEN OPERATOR IS IN
THE SEAT
Y
GRN
BU
SW2
(BRAKE SWITCH)
GY
BRAKE SWITCH CLOSES WHEN
BRAKE IS DEPRESSED
Y
BN
BK
PTO CLUTCH
BK
Y
GRN
W
GND
K1
(KILL RELAY)
I
R
S
B
L
IGNITION SWITCH TERMINAL
LOCATIONS VEIWED FROM BACK.
VIO
R
R
F1
30A
VIO
F2
25A
VIO
GRN
BU
W
R
BK
BN
BU
GN
GY
OR
WIRE COLOR CODES
BLACK
BROWN
BLUE
GREEN
GREY
ORANGE
P
R
T
VIO
W
Y
PINK
RED
TAN
VIOLET
WHITE
YELLOW
ENGINE HARNESS
SPARK PLUG
IGNITION
MODULES
SPARK PLUG
REG
OIL
START
MAG
B+
OIL
SWITCH
OIL SWITCH OPENS
WITH OIL PRESSURE
-
AC
AC
+
SOLINOID
SHIFT
STARTER
FUEL
SOLINOID
20 & 22 Kohler
HEADLIGHT HARNESS
SW4
(IGNITION SWITCH)
OFF--------------------NO CONNECTION
RUN/LIGHTS----------B I R L
RUN--------------------B I R
START-------------------B I R S
L
4 3
I
1
S B
5
R
2
REAR HARNESS
TAIL LIGHTS
BK
BK
OR
OR
OR
P BN R VIO
OR
A
OR
BK
B
BK
CRUISE SWITCH
SW8
2
3
6
(MOMENTARY)
5
CRUISE SWITCH OPERATION
OFF
ON
NO CONNECTION
3 AND 2 CONNECTED
MOMENTARY 3 AND 2 CONNECTED
GN
Y
BN
C
E
D
GN
Y
BN
5 AND 6 CONNECTED
CRUISE MODULE
C
A
B
95-3029
Y
BN
BK
SW7
(CRUISE DISENGAGE SWITCH)
SWITCH OPENS WHEN
BRAKE IS DEPRESSED
VIO
CRUISE MAGNET
P
WARNING LIGHT HARNESS
CRUISE
PARK
OIL
PTO
REVERSE
BATTERY
#194 LAMP
#194 LAMP
#194 LAMP
#194 LAMP
#168 LAMP
#194 LAMP
VOLTAGE
COMPARATOR
OSCILLATOR
ELECTRONICS MODULE
PN 94-7612
B+
2
5
3
4
1
T
OR
D
VIO
W
P
H
BU
GRN
B
J
A
C
K
VIO
BU
GRN
T
W
P
OR
T
P
GY
BK
BU
SW6
(PARK SWITCH)
PARK SWITCH CLOSES WHEN PARKING
BRAKE LEVER IS ENGAGED
BK
W
GY
SW5
(REVERSE SWITCH)
REVERSE SWITCH
CLOSES WHEN HYDRO
TRACTION LEVER IS
MOVED TO REVERSE
P
L
P
I
FUEL
GAUGE
S
#194
LAMP
G
BK
FUEL
SENDER
W
L
#194
LAMP
I
TEMP.
GAUGE
S
Y
G
BK
TEMP.
SENDER
+
GRN
GND
BK
HOUR
METER
OR
F4
10A
P
W P
BK
BN
GY
SW3
(PTO SWITCH)
PTO SWITCH IS SHOWN
IN OFF POSITION
P
BN
OR
K3
(INTERLOCK RELAY)
T
BK
K2
(START RELAY)
OR BN
SEAT SWITCH IS CLOSED
WHEN OPERATOR IS IN
THE SEAT
Y
GRN
BU
SW2
(BRAKE SWITCH)
GY
BRAKE SWITCH CLOSES WHEN
BRAKE IS DEPRESSED
Y
BN
BK
PTO CLUTCH
BK
Y
GRN
W
GND
K1
(KILL RELAY)
I
R
S
B
L
IGNITION SWITCH TERMINAL
LOCATIONS VEIWED FROM BACK.
VIO
R
R
F1
30A
VIO
F2
25A
VIO
GRN
BU
W
R
BK
BN
BU
GN
GY
OR
WIRE COLOR CODES
BLACK
BROWN
BLUE
GREEN
GREY
ORANGE
P
R
T
VIO
W
Y
PINK
RED
TAN
VIOLET
WHITE
YELLOW
ENGINE HARNESS
SPARK PLUG
IGNITION
MODULES
SPARK PLUG
REG
OIL
START
MAG
B+
OIL
SWITCH
OIL SWITCH OPENS
WITH OIL PRESSURE
-
AC
AC
+
SOLINOID
SHIFT
STARTER
FUEL
SOLINOID
Kawasaki
REAR HARNESS
TAIL LIGHTS
OR
A
BK
B
CRUISE SWITCH
SW8
3
2
6
5
(MOMENTARY)
CRUISE SWITCH OPERATION
OFF
ON
NO CONNECTION
3 AND 2 CONNECTED
MOMENTARY 3 AND 2 CONNECTED
GN
Y
BN
C
E
D
5 AND 6 CONNECTED
GN
Y
BN
OR
BK
CRUISE MODULE
C
A
B
Y
BN
BK
95-3029
SW7
(CRUISE DISENGAGE SWITCH)
SWITCH OPENS WHEN
VIO
CRUISE
PTO
PARK
OIL
BATTERY
REVERSE
TEMP.
VOLTAGE
COMPARATOR
ELECTRONICS MODULE
PN 94-7613
#194 LAMP
#194 LAMP
#194 LAMP
#194 LAMP
#194 LAMP
#168 LAMP
#194 LAMP
OSCILLATOR
4
B+
6
2
3
1
5
D
J
H
A
B
K
E
C
G
T
Y
P
GRN
OR
BK
VIO
W
BU
VIO
W
BU
P
GRN
OR
BK
T
Y
T
P
GY
VIO
BK
SW5
(REVERSE SWITCH)
CLOSES WHEN HYDRO
MOVED TO REVERSE
GY
BU
VIO
CRUISE MAGNET
P
L
I
BK
G
SW6
(PARK SWITCH)
BK
P
FUEL
GAUGE
S
FUEL
SENDER
W
L
I
BK
G
VIO
S
TEMP
GAUGE
BK
BK
HEADLIGHT HARNESS
SW4
(IGNITION SWITCH)
OFF----------------------NO CONNECTION
RUN/LIGHTS----------B I R L
RUN----------------------B I R
START--------------------B IR S
3
I
I
R
S
B
L
OR
OR
OR P BN VIO R
IGNITION SWITCH TERMINAL
LOCATIONS VEIWED FROM BACK.
OR
F4
10A
F3
10A
R
P
VIO
P
OR
W
P
K1
(INTERLOCK RELAY)
SW3
(PTO SWITCH)
BK
BN
GY
SW1
(SEAT SWITCH)
SEAT SWITCH IS CLOSED
WHEN OPERATOR IS IN
THE SEAT
GY
SW2
(BRAKE SWITCH)
BRAKE SWITCH CLOSES WHEN
BRAKE IS DEPRESSED
Y
T
BK
K2
(START RELAY)
BK
BU
BN
VIO
F2
25A
R
F1
30A
NOTE: WIRE COLORS CHANGE
AT THE ENGINE CONNECTOR.
BU
2
GRN
Y
VIO
5
1
3
W
6
GY
4
Y
BK
BK
R
Y/W
BU/R
SOLINOID
SHIFT
STARTER
WIRE COLOR CODES
BK
BN
BU
BLACK
BROWN
BLUE
GN
GY
OR
GREEN
GREY
ORANGE
P
R
T
VIO
W
Y
PINK
RED
TAN
VIOLET
WHITE
YELLOW
+ -
ENGINE HARNESS
#1 CYL.
IGNITION COILS
#2 CYL.
FUEL
SOLINOID
#2 CYL.
PULSER COILS
FLYWHEEL
CHARGING
COIL
OIL PRESSURE SWITCH
(SWITCH OPENS WITH OIL PRESSURE)
WATER TEMP. SENDER
BN
GRN
BK
PTO CLUTCH
HOUR
METER -
+
BK
P
BK
FUEL PUMP
GY
W
VIO
OR
P
BK
6
AC
VOLTAGE REGULATOR
4
AC
1
5
REG. DC
2
3
CHARGE LAMP
B+
GND
GND
#1 CYL.
IGNITER
MODULE
Kawasaki
REAR HARNESS
TAIL LIGHTS
OR
A
BK
B
CRUISE SWITCH
SW8
3
2
6
5
(MOMENTARY)
CRUISE SWITCH OPERATION
OFF
ON
NO CONNECTION
3 AND 2 CONNECTED
MOMENTARY 3 AND 2 CONNECTED
GN
Y
BN
C
E
D
5 AND 6 CONNECTED
GN
Y
BN
OR
BK
CRUISE MODULE
C
A
B
Y
BN
BK
95-3029
SW7
(CRUISE DISENGAGE SWITCH)
SWITCH OPENS WHEN
VIO
CRUISE
PTO
PARK
OIL
BATTERY
REVERSE
TEMP.
VOLTAGE
COMPARATOR
ELECTRONICS MODULE
PN 94-7613
#194 LAMP
#194 LAMP
#194 LAMP
#194 LAMP
#194 LAMP
#168 LAMP
#194 LAMP
OSCILLATOR
4
B+
6
2
3
1
5
D
J
H
A
B
K
E
C
G
T
Y
P
GRN
OR
BK
VIO
W
BU
VIO
W
BU
P
GRN
OR
BK
T
Y
T
P
GY
VIO
BK
SW5
(REVERSE SWITCH)
CLOSES WHEN HYDRO
MOVED TO REVERSE
GY
BU
VIO
CRUISE MAGNET
P
L
I
BK
G
SW6
(PARK SWITCH)
BK
P
FUEL
GAUGE
S
FUEL
SENDER
W
L
I
BK
G
VIO
S
TEMP
GAUGE
BK
BK
HEADLIGHT HARNESS
SW4
(IGNITION SWITCH)
OFF----------------------NO CONNECTION
RUN/LIGHTS----------B I R L
RUN----------------------B I R
START--------------------B IR S
3
I
I
R
S
B
L
OR
OR
OR P BN VIO R
IGNITION SWITCH TERMINAL
LOCATIONS VEIWED FROM BACK.
OR
F4
10A
F3
10A
R
P
VIO
P
OR
W
P
K1
(INTERLOCK RELAY)
SW3
(PTO SWITCH)
BK
BN
GY
SW1
(SEAT SWITCH)
SEAT SWITCH IS CLOSED
WHEN OPERATOR IS IN
THE SEAT
GY
SW2
(BRAKE SWITCH)
BRAKE SWITCH CLOSES WHEN
BRAKE IS DEPRESSED
Y
T
BK
K2
(START RELAY)
BK
BU
BN
VIO
F2
25A
R
F1
30A
NOTE: WIRE COLORS CHANGE
AT THE ENGINE CONNECTOR.
BU
2
GRN
Y
VIO
5
1
3
W
6
GY
4
Y
BK
BK
R
Y/W
BU/R
SOLINOID
SHIFT
STARTER
WIRE COLOR CODES
BK
BN
BU
BLACK
BROWN
BLUE
GN
GY
OR
GREEN
GREY
ORANGE
P
R
T
VIO
W
Y
PINK
RED
TAN
VIOLET
WHITE
YELLOW
+ -
ENGINE HARNESS
#1 CYL.
IGNITION COILS
#2 CYL.
FUEL
SOLINOID
#2 CYL.
PULSER COILS
FLYWHEEL
CHARGING
COIL
OIL PRESSURE SWITCH
(SWITCH OPENS WITH OIL PRESSURE)
WATER TEMP. SENDER
BN
GRN
BK
PTO CLUTCH
HOUR
METER -
+
BK
P
BK
FUEL PUMP
GY
W
VIO
OR
P
BK
6
AC
VOLTAGE REGULATOR
4
AC
1
5
REG. DC
2
3
CHARGE LAMP
B+
GND
GND
#1 CYL.
IGNITER
MODULE
Kawasaki
REAR HARNESS
TAIL LIGHTS
OR
A
BK
B
CRUISE SWITCH
SW8
3
2
6
5
(MOMENTARY)
CRUISE SWITCH OPERATION
OFF
ON
NO CONNECTION
3 AND 2 CONNECTED
MOMENTARY 3 AND 2 CONNECTED
GN
Y
BN
C
E
D
5 AND 6 CONNECTED
GN
Y
BN
OR
BK
CRUISE MODULE
C
A
B
Y
BN
BK
95-3029
SW7
(CRUISE DISENGAGE SWITCH)
SWITCH OPENS WHEN
VIO
CRUISE
PTO
PARK
OIL
BATTERY
REVERSE
TEMP.
VOLTAGE
COMPARATOR
ELECTRONICS MODULE
PN 94-7613
#194 LAMP
#194 LAMP
#194 LAMP
#194 LAMP
#194 LAMP
#168 LAMP
#194 LAMP
OSCILLATOR
4
B+
6
2
3
1
5
D
J
H
A
B
K
E
C
G
T
Y
P
GRN
OR
BK
VIO
W
BU
VIO
W
BU
P
GRN
OR
BK
T
Y
T
P
GY
VIO
BK
SW5
(REVERSE SWITCH)
CLOSES WHEN HYDRO
MOVED TO REVERSE
GY
BU
VIO
CRUISE MAGNET
P
L
I
BK
G
SW6
(PARK SWITCH)
BK
P
FUEL
GAUGE
S
FUEL
SENDER
W
L
I
BK
G
VIO
S
TEMP
GAUGE
BK
BK
HEADLIGHT HARNESS
SW4
(IGNITION SWITCH)
OFF----------------------NO CONNECTION
RUN/LIGHTS----------B I R L
RUN----------------------B I R
START--------------------B IR S
3
I
I
R
S
B
L
OR
OR
OR P BN VIO R
IGNITION SWITCH TERMINAL
LOCATIONS VEIWED FROM BACK.
OR
F4
10A
F3
10A
R
P
VIO
P
OR
W
P
K1
(INTERLOCK RELAY)
SW3
(PTO SWITCH)
BK
BN
GY
SW1
(SEAT SWITCH)
SEAT SWITCH IS CLOSED
WHEN OPERATOR IS IN
THE SEAT
GY
SW2
(BRAKE SWITCH)
BRAKE SWITCH CLOSES WHEN
BRAKE IS DEPRESSED
Y
T
BK
K2
(START RELAY)
BK
BU
BN
VIO
F2
25A
R
F1
30A
NOTE: WIRE COLORS CHANGE
AT THE ENGINE CONNECTOR.
BU
2
GRN
Y
VIO
5
1
3
W
6
GY
4
Y
BK
BK
R
Y/W
BU/R
SOLINOID
SHIFT
STARTER
WIRE COLOR CODES
BK
BN
BU
BLACK
BROWN
BLUE
GN
GY
OR
GREEN
GREY
ORANGE
P
R
T
VIO
W
Y
PINK
RED
TAN
VIOLET
WHITE
YELLOW
+ -
ENGINE HARNESS
#1 CYL.
IGNITION COILS
#2 CYL.
FUEL
SOLINOID
#2 CYL.
PULSER COILS
FLYWHEEL
CHARGING
COIL
OIL PRESSURE SWITCH
(SWITCH OPENS WITH OIL PRESSURE)
WATER TEMP. SENDER
BN
GRN
BK
PTO CLUTCH
HOUR
METER -
+
BK
P
BK
FUEL PUMP
GY
W
VIO
OR
P
BK
6
AC
VOLTAGE REGULATOR
4
AC
1
5
REG. DC
2
3
CHARGE LAMP
B+
GND
GND
#1 CYL.
IGNITER
MODULE
Diesel
REAR HARNESS
TAIL LIGHTS
CRUISE
PTO
BATTERY
GLOW PLUGS
TEMP
OIL
PARK
REVERSE
WARNING LIGHT HARNESS
BK
P
E
A
VIO
D
J
W
OR
K
BU
T
GY
Y
GN
F
G
B
H
C
FUEL
BN
1
VOLTAGE
COMPARATOR
OSCILLATOR
ELECTRONICS MODULE
PN 94-7614
B+
3
1
6
4
2
5
BN
P
T
GY
W
BK
BK
P
VIO
W
OR
T
BU
GY
Y
GN
HEADLIGHT HARNESS
BK
BK
OR
OR
L
4
OR
SW4
(IGNITION SWITCH)
OFF--------------------NO CONNECTION
RUN/LIGHTS----------B I R L
RUN--------------------B I R
START------------------B I R S
I
3
PK
S
1
BU
R
2
B
5
R
I
R
S
L
B
WIRE COLOR CODES
BK
BN
BU
BLACK
BROWN
BLUE
GN
GY
GREEN
GREY
OR
F1
30A
ORANGE
R
Y
VIO
W
P
T
R
PINK
RED
TAN
VIOLET
WHITE
YELLOW
OR
A
BK
B
CRUISE SWITCH
GN
C
SW8
2
3
6
(MOMENTARY)
5
Y
BN
CRUISE SWITCH OPERATION
OFF
ON
NO CONNECTION
3 AND 2 CONNECTED
MOMENTARY 3 AND 2 CONNECTED 5 AND 6 CONNECTED
E
D
CRUISE MODULE
C
A
B
Y
BN
BK
OR
BK
GN
BN
Y
95-3029
SW7
(CRUISE DISENGAGE SWITCH)
SWITCH OPENS WHEN
BRAKE IS DEPRESSED
VIO
L2
MAGNET
P
F4
10A
F3
10A
BU
F2
15A
BU
P
R
W
P
W
SW5
(REVERSE SWITCH)
REVERSE SWITCH
CLOSES WHEN HYDRO
TRACTION LEVER IS
MOVED TO REVERSE
W
FUEL
GAUGE
S
I
L
G
#194
LAMP
SW6
(PARK SWITCH)
PARK SWITCH CLOSES
WHEN PARKING BRAKE
LEVER IS ENGAGED
BU
FUEL SENDER
BK
BK
P
BK
GY
SW3
SW1
(SEAT SWITCH)
SEAT SWITCH IS CLOSED
WHEN OPERATOR IS IN
THE SEAT
(PTO SWITCH)
PTO SWITCH IS SHOWN
IN OFF POSITION
T
GN
K2
(INTERLOCK RELAY)
GN BU
OR
P
L
I
B
ALTERNATOR
FUSIBLE LINK
BN
SW2
(BRAKE SWITCH)
BRAKE SWITCH CLOSES WHEN
BRAKE IS DEPRESSED
Y
BN
BK
PTO
CLUTCH
GN
+
HOUR
METER
BK
OR
K1
(STARTER
RELAY)
K3
(SEAT RELAY)
BK
BK VIO
FUSIBLE LINK
Y
FUEL
SOLENOID
GN
GND
P
OIL PRESS
L
#194
LAMP
I
TEMP
GAUGE
S
G
BK
T
TEMP SENDER
GND
GND
Y
TEMP SWITCH
GND
GY
BK
GY
4
3
5
1
2
K4
(GLOW PLUG RELAY)
R
W
P
BU
BK
GLOW PLUGS
BK
GND
6
5
GLOW PLUG
TIMER
MODULE
4
1
B
ST
STARTER
+ -
Diesel
REAR HARNESS
TAIL LIGHTS
CRUISE
PTO
BATTERY
GLOW PLUGS
TEMP
OIL
PARK
REVERSE
WARNING LIGHT HARNESS
BK
P
E
A
VIO
D
J
W
OR
K
BU
T
GY
Y
GN
F
G
B
H
C
FUEL
BN
1
VOLTAGE
COMPARATOR
OSCILLATOR
ELECTRONICS MODULE
PN 94-7614
B+
3
1
6
4
2
5
BN
P
T
GY
W
BK
BK
P
VIO
W
OR
T
BU
GY
Y
GN
HEADLIGHT HARNESS
BK
BK
OR
OR
L
4
OR
SW4
(IGNITION SWITCH)
OFF--------------------NO CONNECTION
RUN/LIGHTS----------B I R L
RUN--------------------B I R
START------------------B I R S
I
3
PK
S
1
BU
R
2
B
5
R
I
R
S
L
B
WIRE COLOR CODES
BK
BN
BU
BLACK
BROWN
BLUE
GN
GY
GREEN
GREY
OR
F1
30A
ORANGE
R
Y
VIO
W
P
T
R
PINK
RED
TAN
VIOLET
WHITE
YELLOW
OR
A
BK
B
CRUISE SWITCH
GN
C
SW8
2
3
6
(MOMENTARY)
5
Y
BN
CRUISE SWITCH OPERATION
OFF
ON
NO CONNECTION
3 AND 2 CONNECTED
MOMENTARY 3 AND 2 CONNECTED 5 AND 6 CONNECTED
E
D
CRUISE MODULE
C
A
B
Y
BN
BK
OR
BK
GN
BN
Y
95-3029
SW7
(CRUISE DISENGAGE SWITCH)
SWITCH OPENS WHEN
BRAKE IS DEPRESSED
VIO
L2
MAGNET
P
F4
10A
F3
10A
BU
F2
15A
BU
P
R
W
P
W
SW5
(REVERSE SWITCH)
REVERSE SWITCH
CLOSES WHEN HYDRO
TRACTION LEVER IS
MOVED TO REVERSE
W
FUEL
GAUGE
S
I
L
G
#194
LAMP
SW6
(PARK SWITCH)
PARK SWITCH CLOSES
WHEN PARKING BRAKE
LEVER IS ENGAGED
BU
FUEL SENDER
BK
BK
P
BK
GY
SW3
SW1
(SEAT SWITCH)
SEAT SWITCH IS CLOSED
WHEN OPERATOR IS IN
THE SEAT
(PTO SWITCH)
PTO SWITCH IS SHOWN
IN OFF POSITION
T
GN
K2
(INTERLOCK RELAY)
GN BU
OR
P
L
I
B
ALTERNATOR
FUSIBLE LINK
BN
SW2
(BRAKE SWITCH)
BRAKE SWITCH CLOSES WHEN
BRAKE IS DEPRESSED
Y
BN
BK
PTO
CLUTCH
GN
+
HOUR
METER
BK
OR
K1
(STARTER
RELAY)
K3
(SEAT RELAY)
BK
BK VIO
FUSIBLE LINK
Y
FUEL
SOLENOID
GN
GND
P
OIL PRESS
L
#194
LAMP
I
TEMP
GAUGE
S
G
BK
T
TEMP SENDER
GND
GND
Y
TEMP SWITCH
GND
GY
BK
GY
4
3
5
1
2
K4
(GLOW PLUG RELAY)
R
W
P
BU
BK
GLOW PLUGS
BK
GND
6
5
GLOW PLUG
TIMER
MODULE
4
1
B
ST
STARTER
+ -
Diesel
REAR HARNESS
TAIL LIGHTS
CRUISE
PTO
BATTERY
GLOW PLUGS
TEMP
OIL
PARK
REVERSE
WARNING LIGHT HARNESS
BK
P
E
A
VIO
D
J
W
OR
K
BU
T
GY
Y
GN
F
G
B
H
C
FUEL
BN
1
VOLTAGE
COMPARATOR
OSCILLATOR
ELECTRONICS MODULE
PN 94-7614
B+
3
1
6
4
2
5
BN
P
T
GY
W
BK
BK
P
VIO
W
OR
T
BU
GY
Y
GN
HEADLIGHT HARNESS
BK
BK
OR
OR
L
4
OR
SW4
(IGNITION SWITCH)
OFF--------------------NO CONNECTION
RUN/LIGHTS----------B I R L
RUN--------------------B I R
START------------------B I R S
I
3
PK
S
1
BU
R
2
B
5
R
I
R
S
L
B
WIRE COLOR CODES
BK
BN
BU
BLACK
BROWN
BLUE
GN
GY
GREEN
GREY
OR
F1
30A
ORANGE
R
Y
VIO
W
P
T
R
PINK
RED
TAN
VIOLET
WHITE
YELLOW
OR
A
BK
B
CRUISE SWITCH
GN
C
SW8
2
3
6
(MOMENTARY)
5
Y
BN
CRUISE SWITCH OPERATION
OFF
ON
NO CONNECTION
3 AND 2 CONNECTED
MOMENTARY 3 AND 2 CONNECTED 5 AND 6 CONNECTED
E
D
CRUISE MODULE
C
A
B
Y
BN
BK
OR
BK
GN
BN
Y
95-3029
SW7
(CRUISE DISENGAGE SWITCH)
SWITCH OPENS WHEN
BRAKE IS DEPRESSED
VIO
L2
MAGNET
P
F4
10A
F3
10A
BU
F2
15A
BU
P
R
W
P
W
SW5
(REVERSE SWITCH)
REVERSE SWITCH
CLOSES WHEN HYDRO
TRACTION LEVER IS
MOVED TO REVERSE
W
FUEL
GAUGE
S
I
L
G
#194
LAMP
SW6
(PARK SWITCH)
PARK SWITCH CLOSES
WHEN PARKING BRAKE
LEVER IS ENGAGED
BU
FUEL SENDER
BK
BK
P
BK
GY
SW3
SW1
(SEAT SWITCH)
SEAT SWITCH IS CLOSED
WHEN OPERATOR IS IN
THE SEAT
(PTO SWITCH)
PTO SWITCH IS SHOWN
IN OFF POSITION
T
GN
K2
(INTERLOCK RELAY)
GN BU
OR
P
L
I
B
ALTERNATOR
FUSIBLE LINK
BN
SW2
(BRAKE SWITCH)
BRAKE SWITCH CLOSES WHEN
BRAKE IS DEPRESSED
Y
BN
BK
PTO
CLUTCH
GN
+
HOUR
METER
BK
OR
K1
(STARTER
RELAY)
K3
(SEAT RELAY)
BK
BK VIO
FUSIBLE LINK
Y
FUEL
SOLENOID
GN
GND
P
OIL PRESS
L
#194
LAMP
I
TEMP
GAUGE
S
G
BK
T
TEMP SENDER
GND
GND
Y
TEMP SWITCH
GND
GY
BK
GY
4
3
5
1
2
K4
(GLOW PLUG RELAY)
R
W
P
BU
BK
GLOW PLUGS
BK
GND
6
5
GLOW PLUG
TIMER
MODULE
4
1
B
ST
STARTER
+ -
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