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Toro 520XI Service Manual

Garden tractor
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5XI SERIES TRACTOR SERVICE MANUAL
Table of Contents – Page 1 of 2
SAFETY INFORMATION
SPECIFICATIONS
PRODUCT LINEUP
TRACTOR SPECIFICATIONS
ATTACHMENTS AND ACCESSORIES (PARTIAL LISTING)
ENGINE SPECIFICATIONS (AIR-COOLED)
ENGINE SPECIFICATIONS (LIQUID-COOLED)
MAINTENANCE TABLE
SERVICE SCHEDULE
CHASSIS
MODEL/SERIAL NUMBER LOCATION
GREASING AND LUBRICATION
REAR FENDERS, FOOTRESTS, & TUNNEL
FRONT WHEEL TOE-IN
STEERING WHEEL
POWER STEERING
SMART TURNÉ STEERING
MOTION CONTROL PEDAL
TIRE PRESSURE
FUEL TANK SHUT-OFF VALVE
ELECTRIC PTO CLUTCH
DRIVE SHAFT
HYDROSTATIC DRIVE
TROUBLESHOOTING
TRANSAXLE FLUID
BRAKE
NEUTRAL ADJUSTMENT
GASOLINE ENGINE
TROUBLESHOOTING
ENGINE CRANKS BUT WILL NOT START.
STARTER DOES NOT CRANK.
ENGINE STARTS BUT DOES NOT KEEP RUNNING.
ENGINE IS DIFFICULT TO START.
ENGINE RUNS BUT KNOCKS OR MISSES.
ENGINE WILL NOT IDLE.
ENGINE OVERHEATS.
ENGINE LOSES POWER.
ENGINE KNOCKS.
AIR CLEANER
ENGINE OIL
OIL FILTER
SPARK PLUG
FUEL FILTER

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  • Page 1 5XI SERIES TRACTOR SERVICE MANUAL Table of Contents – Page 1 of 2 SAFETY INFORMATION SPECIFICATIONS PRODUCT LINEUP TRACTOR SPECIFICATIONS ATTACHMENTS AND ACCESSORIES (PARTIAL LISTING) ENGINE SPECIFICATIONS (AIR-COOLED) ENGINE SPECIFICATIONS (LIQUID-COOLED) MAINTENANCE TABLE SERVICE SCHEDULE CHASSIS MODEL/SERIAL NUMBER LOCATION GREASING AND LUBRICATION REAR FENDERS, FOOTRESTS, &...
  • Page 2 5XI SERIES TRACTOR SERVICE MANUAL Table of Contents – Page 2 of 2 GASOLINE ENGINE - continued COOLING SYSTEM, AIR COOLING SYSTEM, LIQUID DIESEL ENGINE TROUBLESHOOTING ENGINE CRANKS BUT WILL NOT START. STARTER DOES NOT CRANK. ENGINE STARTS BUT DOES NOT KEEP RUNNING. ENGINE IS DIFFICULT TO START.
  • Page 3 TORO 5xi Series Tractor Service Manual...

  • Page 4: About This 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.
  • Page 5 TABLE OF CONTENTS QUICK REFERENCE SECTION Safety Information..........Specifications .

  • Page 6: Table Of Contents

    QUICK REFERENCE Table of Contents SAFETY INFORMATION General Information ........1 - 3 Think Safety First .

  • Page 7: Safety Information

    INSTRUCTION - read the operating tips for safe operating practices. Operator’s instruction because it has to do manuals are available through your local Toro with your safety. Failure to comply distributor or: with the instruction may result in personal injury or even death.

  • Page 8: Product Lineup

    (196.9 mm) (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...

  • Page 9: Attachments And Accessories

    SPECIFICATIONS Attachments and Accessories (partial listing) Part # (International) Description Drive Belt Spindle Belt 95-4093 78353 (78442) 42" Rear Discharge Mower 95-4230 95-4094 78357 (78444) 44" Side Discharge Mower 95-4228 95-4094 78358 44" Recycler® Mower 95-4228 95-4095 78363 (78448) 48" Side Discharge Mower 95-3878 95-4095 78364...

  • Page 10: Engine Specifications

    SPECIFICATIONS Engine Specifications (air-cooled) Item 73470 73540 (73541) 73560 Manufacturer/Model Kohler/CH18S Kohler/CH20S Kohler/CH22S Horsepower (kW) 18 HP (13.4 kW) 20 HP (14.9 kW) 22 HP (16.4 kW) Oil Viscosity Over 0° F (-18° C) 10W-30 10W-30 10W-30 Below 32°F (0° C) 5W-20 or 5W-30 5W-20 or 5W-30 5W-20 or 5W-30...

  • Page 11: Maintenance Table

    MAINTENANCE TABLE Service Schedule Item Kohler, Manual Kohler, Power Kawasaki Daihatsu Steering Steering Grease Zerks Front wheel spindles (2) Every 50 hrs. Every 50 hrs. Every 50 hrs. Every 50 hrs. Front axle pivot (1) Every 50 hrs. Every 50 hrs. Every 50 hrs.
  • Page 12 MAINTENANCE TABLE Service Schedule (cont’d) Item Kohler, Manual Kohler, Power Kawasaki Daihatsu Steering Steering Transaxle & Hydraulics Oil level check 25 hrs. 25 hrs. 25 hrs. 25 hrs. Oil change Every 200 hrs. Every 200 hrs. Every 200 hrs. Every 200 hrs. Oil filter change @ 50 hrs.;...
  • Page 13 CHASSIS QUICK REFERENCE SECTION Safety Information ..........Specifications .
  • Page 14 CHASSIS Table of Contents MODEL/SERIAL NUMBER LOCATION ......2 - 4 GREASING AND LUBRICATION Service Interval/Specification......2 - 4 Lubrication Points .
  • Page 15 CHASSIS MOTION CONTROL PEDAL Adjustment ......... . . 2 - 20 TIRE PRESSURE .

  • Page 16: Model/Serial Number Location

    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.
  • Page 17 CHASSIS Remove the maintenance panel located in the tunnel in front of the seat. 2.0109.026 This will allow access to the 3 zerk fittings below. 2.0109.024 The pulley box for the mower deck contains 2 zerk fittings; one at each pulley pivot. 2.0144.023 5xi Series Tractor Service Manual 2 - 5...
  • Page 18 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"...

  • Page 19: General Information

    CHASSIS REAR FENDERS, FOOTRESTS, & TUNNEL General Information The seat, rear fenders, footrests, and tunnel can be removed as a unit providing easy access to chassis components. 2.0109.039 Removal 1. Disconnect the electrical connections for the seat switch, cruise control, and taillights (as applicable) from the wiring harness.
  • Page 20 CHASSIS REAR FENDERS, FOOTRESTS, & TUNNEL (cont’d) 3. Remove the four bolts securing the fenders to the frame (two on each side of the seat). 2.0109.004 4. Remove the nuts from the front footrest supports and the clamps from the rear supports.

  • Page 21: Reassembly

    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. 2.0109.014 Reassembly Reverse steps 1-7 to reassemble the seat, rear...

  • Page 22: Front Wheel Toe-In

    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.

  • Page 23: Adjustment

    CHASSIS Adjustment 1. Loosen the jam nuts at the ends of the steering rods. 2.0109.047 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...

  • Page 24: Steering Wheel

    CHASSIS STEERING WHEEL Remove Steering Wheel 1. Remove plastic trim cover. 2. Loosen the nut securing the wheel. 2.0144.051 3. Install puller as shown. Tighten forcing screw to remove steering wheel. NOTE: Install large flat washers on puller bolts to protect steering wheel. 2.0144.053 Reassembly 1.

  • Page 25: Power Steering

    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.
  • Page 26 CHASSIS POWER STEERING (cont’d) 3. Disassemble the housing, and clean the screen with solvent. 2.0144.076 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”...

  • Page 27: Smart Turn Steering

    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.

  • Page 28: Inspection

    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 Correct adjustment can be verified by checking the position of the bushing (A) in the slot of the brake pivot plate (B).
  • Page 29 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.
  • Page 30 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.
  • Page 31 CHASSIS Tighten the rear jam nut first. Hold the front rod end fitting while tightening the front jam nut. IMPORTANT: There must be axial looseness in the rod (A) or there may be binding in the pedal linkages. 2.7233.073 Test the adjustment by cycling the brake. The slot should travel over bushing (A) without touching.

  • Page 32: Motion Control Pedal

    CHASSIS MOTION CONTROL PEDAL Adjustment 1. Push the motion control pedal to the full reverse position. 2. Check the clearance between the pedal support and the reverse stop. 3. Adjust the rod as necessary to obtain the correct clearance. Clearance: 1/16" (1.7 mm) 2.0144.034 TIRE PRESSURE Pressure: 12 psi (82.7 kPa) front and rear.

  • Page 33: Electric Pto Clutch

    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.

  • Page 34: Drive Shaft

    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.
  • Page 35 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.
  • Page 36 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 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.

  • Page 37: Maintenance Table

    HYDROSTATIC DRIVE QUICK REFERENCE SECTION Safety Information ..........Specifications .
  • Page 38 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 .

  • Page 39: Troubleshooting

    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.

  • Page 40: Tractor Operates Erratically

    HYDROSTATIC DRIVE TROUBLESHOOTING (cont’d) Tractor operates erratically. Possible Cause Corrective Action The transmission control linkage needs adjustment or Adjust, repair, or replace replacement The transmission oil level is low Fill to the full “F” mark on the transmission oil dipstick when transmission is cold The transmission is faulty Repair/replace...

  • Page 41: Transaxle Fluid

    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 .

  • Page 42: Fluid Change

    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.

  • Page 43: Brake

    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.

  • Page 44: Neutral Adjustment

    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.
  • Page 45 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.

  • Page 46: Gasoline Engine

    GASOLINE ENGINE QUICK REFERENCE SECTION Safety Information ..........Specifications .
  • Page 47 GASOLINE ENGINE Table of Contents TROUBLESHOOTING Engine cranks but will not start ....... 4 - 3 Starter does not crank .

  • Page 48: Troubleshooting

    GASOLINE ENGINE TROUBLESHOOTING Engine cranks but will not start. Possible Cause Corrective Action Incorrect starting procedure Ensure throttle is at full, and choke is on The fuel tank is empty Fill with fresh fuel The fuel shut-off valve is closed Open fuel shut-off valve Dirt or water is in the fuel system Drain and flush fuel system;...

  • Page 49: Engine Runs But Knocks Or Misses

    GASOLINE ENGINE TROUBLESHOOTING (cont’d) Engine runs but knocks or misses. Possible Cause Corrective Action Dirt, water, or stale fuel is in the fuel system Drain and flush the fuel system; add fresh fuel A spark plug lead is loose Reconnect the spark plug lead A spark plug is faulty Replace the spark plug Loose wires or poor connections...

  • Page 50: Air Cleaner

    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.

  • Page 51: Service Interval/Specification

    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. 32 40 3.7197.079 Changing/Draining...

  • Page 52: Spark Plug

    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.

  • Page 53: Service Interval/Specification

    2.0144.092 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.

  • Page 54: General Information

    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.

  • Page 55: Maintenance

    GASOLINE ENGINE COOLING SYSTEM, LIQUID (cont’d) Maintenance Inspect the cooling system often. Carefully clean grass clippings and other debris from air intake screens and radiator fins. 2.0144.012 Maintain coolant level in the coolant recovery tank between two lines on reservoir bottle with a 50/50 mix of antifreeze and water.

  • Page 56: Maintenance

    DIESEL ENGINE QUICK REFERENCE SECTION Safety Information ..........Specifications .
  • Page 57 DIESEL ENGINE Table of Contents TROUBLESHOOTING Engine cranks but will not start ....... 5 - 3 Starter does not crank .

  • Page 58: Troubleshooting

    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 Corrective Action Contaminated fuel Clean fuel system Incorrect starting procedure Activate glow plugs before attempting to start The fuel tank is empty Fill with fresh fuel...

  • Page 59: Engine Is Difficult To Start

    DIESEL ENGINE TROUBLESHOOTING (cont’d) Engine is difficult to start. Possible Cause Corrective Action Improper starting procedure Activate glow plugs before attempting to start Air in fuel Bleed nozzles, check for leaks on suction side of system Inoperative glow plugs Check fuse, glow plugs, and wiring Insufficient combustion air supply Check air filter and combustion air path Faulty injection nozzles...

  • Page 60: Engine Loses Power

    DIESEL ENGINE Engine loses power. Possible Cause Corrective Action Insufficient combustion air supply Check air filter and combustion air path Air in fuel Bleed nozzles, check for leaks on suction side of system Dirt, water, or stale fuel is in the fuel system Drain and flush fuel system;...

  • Page 61: Air Cleaner

    DIESEL ENGINE AIR CLEANER Service Interval/Specification Paper Element: Replace after every 100 operating hours or yearly, whichever comes first. NOTE: Service the air cleaner more frequently (every few hours) if operating conditions are extremely dusty or sandy. 3.7230.079 Cleaning 1. Lightly tap the element on a flat surface to remove dust and dirt.

  • Page 62: Changing/Draining

    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.

  • Page 63: Cooling System

    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.

  • Page 64: Engine Mounts

    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. •...

  • Page 65: Glow Plugs

    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.
  • Page 66 ELECTRICAL QUICK REFERENCE SECTION Safety Information ..........Specifications .
  • Page 67 ELECTRICAL Table of Contents BATTERY Service Interval/Specification ......6 - 4 Removal .
  • Page 68 ELECTRICAL SAFETY INTERLOCK SYSTEM Purpose ..........6 - 9 Testing.

  • Page 69: Battery

    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.

  • Page 70: Installation

    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.

  • Page 71: Charging

    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.

  • Page 72: Bulb Installation

    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.

  • Page 73: Bulb Removal

    ELECTRICAL TAILLIGHTS Bulb Removal 1. Remove the taillight assembly from the fender. 2. Rotate the bulb holder 1/4 turn counterclockwise and remove it from the housing. 3. Push and rotate the bulb counterclockwise until it stops (approximately 1/4 turn). Bulb Number: GE 194 2.0757.027 ELECTRIC CLUTCH TROUBLESHOOTING...

  • Page 74: Safety Interlock System

    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.

  • Page 75: Cruise Control

    3.7197.125 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.

  • Page 76: Troubleshooting

    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.

  • Page 77: Fuel Gauge

    ELECTRICAL FUEL GAUGE General Information The fuel gauge consists of a level indicator (gauge) located in the instrument panel and a sender located in the fuel tank. 2.0144.074 2.0144.074 Theory of Operation B+ is supplied to one side of the fuel gauge. The other side of the gauge is connected to ground through the sender.

  • Page 78: Troubleshooting

    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.

  • Page 79: Charging System

    ELECTRICAL FUEL GAUGE (cont’d) 2. Connect the wire to ground (maximum current). The gauge should read Full. If conditions 1 and 2 are not met, the problem is in the wiring or the gauge. 2.0144.056 2.0144.075 If conditions 1 and 2 above are met, the problem is with the sender.

  • Page 80: Testing

    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 Testing Connect a voltmeter across the battery.

  • Page 81: Voltage Regulator Replacement

    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.
  • Page 82 (IGNITION SWITCH) WIRE COLOR CODES OFF-----------------------NOCONNECTION RUN/LIGHTS-------------B I R L RUN-----------------------B I R PINK BLACK START---------------------B I R S BROWN 18 Kohler BLUE GREEN VIOLET IGNITION SWITCH TERMINAL HEADLIGHT HARNESS GREY WHITE LOCATIONS VEIWED FROM BACK. ORANGE YELLOW INDICATOR LIGHT HARNESS #194 LAMP (INTERLOCK...
  • Page 83 18 Kohler HEADLIGHT HARNESS INDICATOR LIGHT HARNESS #194 LAMP #194 LAMP (PTO SWIT REVERSE #168 LAMP PTO SWITC IN OFF POSIT BATTERY #194 LAMP (REVERSE SWITCH) (BRAKE SW REVERSE SWITCH BRAKE SWITC TEMP . GAUGE CLOSES WHEN HYDRO WHEN BRA TRACTION LEVER IS MOVED TO REVERSE #194...
  • Page 84 (IGNITION SWITCH) WIRE COLOR CODES OFF-----------------------NOCONNECTION RUN/LIGHTS-------------B I R L RUN-----------------------B I R PINK BLACK START---------------------B I R S BROWN BLUE GREEN VIOLET IGNITION SWITCH TERMINAL GREY WHITE LOCATIONS VEIWED FROM BACK. ORANGE YELLOW (INTERLOCK RELAY) (PTO SWITCH) PTO SWITCH IS SHOWN IN OFF POSITION ENGINE HARNESS (START...
  • Page 85 20 & 22 Kohler HEADLIGHT HARNESS (IGNITION SWITCH) OFF--------------------NO CONNECTION RUN/LIGHTS----------B I R L WIRE COLOR CODES RUN--------------------B I R START-------------------B I R S PINK BLACK REAR HARNESS BROWN BLUE TAIL LIGHTS GREEN VIOLET IGNITION SWITCH TERMINAL GREY WHITE LOCATIONS VEIWED FROM BACK. ORANGE YELLOW CRUISE SWITCH...
  • Page 86 20 & 22 Kohler HEADLIGHT HARNESS REAR HARNESS TAIL LIGHTS CRUISE SWITCH (CRUISE DISENGAGE SWITCH) CRUISE MAGNET SWITCH OPENS WHEN BRAKE IS DEPRESSED (MOMENTARY) CRUISE SWITCH OPERATION NO CONNECTION 3 AND 2 CONNECTED MOMENTARY 3 AND 2 CONNECTED 5 AND 6 CONNECTED CRUISE MODULE 95-3029 WARNING LIGHT HARNESS...
  • Page 87 (IGNITION SWITCH) OFF--------------------NO CONNECTION RUN/LIGHTS----------B I R L WIRE COLOR CODES RUN--------------------B I R START-------------------B I R S PINK BLACK BROWN BLUE GREEN VIOLET IGNITION SWITCH TERMINAL GREY WHITE LOCATIONS VEIWED FROM BACK. ORANGE YELLOW (PTO SWITCH) PTO SWITCH IS SHOWN IN OFF POSITION (INTERLOCK RELAY) (START RELAY)
  • Page 88 Kawasaki (IGNITION SWITCH) HEADLIGHT HARNESS WIRE COLOR CODES OFF----------------------NO CONNECTION RUN/LIGHTS----------B I R L RUN----------------------B I R PINK BLACK START--------------------B IR S BROWN BLUE REAR HARNESS GREEN VIOLET GREY WHITE TAIL LIGHTS ORANGE YELLOW IGNITION SWITCH TERMINAL LOCATIONS VEIWED FROM BACK. ENGINE HARNESS CRUISE SWITCH #1 CYL.
  • Page 89 Kawasaki HEADLIGHT HARNESS REAR HARNESS TAIL LIGHTS CRUISE SWITCH (CRUISE DISENGAGE SWITCH) CRUISE MAGNET SWITCH OPENS WHEN BRAKE IS DEPRESSED (MOMENTARY) (INTERLOC CRUISE SWITCH OPERATION NO CONNECTION 3 AND 2 CONNECTED MOMENTARY 3 AND 2 CONNECTED 5 AND 6 CONNECTED (PTO SWITCH) PTO SWITCH IS SHO IN OFF POSITION...
  • Page 90 (IGNITION SWITCH) WIRE COLOR CODES OFF----------------------NO CONNECTION RUN/LIGHTS----------B I R L RUN----------------------B I R PINK BLACK START--------------------B IR S BROWN BLUE GREEN VIOLET GREY WHITE ORANGE YELLOW IGNITION SWITCH TERMINAL LOCATIONS VEIWED FROM BACK. ENGINE HARNESS #1 CYL. IGNITION COILS #2 CYL.
  • Page 91 Diesel (IGNITION SWITCH) WIRE COLOR CODES HEADLIGHT HARNESS OFF--------------------NO CONNECTION RUN/LIGHTS----------B I R L RUN--------------------B I R PINK BLACK START------------------B I R S BROWN REAR HARNESS BLUE GREEN VIOLET TAIL LIGHTS GREY WHITE IGNITION SWITCH TERMINAL LOCATIONS VEIWED FROM BACK. ORANGE YELLOW CRUISE SWITCH...
  • Page 92 Diesel (IGNITION SWITCH) HEADLIGHT HARNESS OFF--------------------NO CONNECTION RUN/LIGHTS----------B I R L RUN--------------------B I R START------------------B I R S REAR HARNESS TAIL LIGHTS CRUISE SWITCH (CRUISE DISENGAGE SWITCH) MAGNET SWITCH OPENS WHEN BRAKE IS DEPRESSED (SEAT SWITCH) SEAT SWITCH IS CLOSED (MOMENTARY) WHEN OPERATOR IS IN THE SEAT...
  • Page 93 (IGNITION SWITCH) WIRE COLOR CODES OFF--------------------NO CONNECTION RUN/LIGHTS----------B I R L RUN--------------------B I R PINK BLACK START------------------B I R S BROWN BLUE GREEN VIOLET GREY WHITE IGNITION SWITCH TERMINAL LOCATIONS VEIWED FROM BACK. ORANGE YELLOW (SEAT SWITCH) SEAT SWITCH IS CLOSED WHEN OPERATOR IS IN THE SEAT (INTERLOCK RELAY)

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