Toro 5XI Series Tractor Service Manual

5XI SERIES TRACTOR HYDRAULIC SYSTEMS SERVICE MANUAL Table of Contents – Page 1 of 2 SAFETY INFORMATION GENERAL INFORMATION THINK SAFETY FIRST SPECIFICATIONS TRANSMISSION (EATON MODEL) TRANSAXLE (WHEEL HORSE) 5XI AUTOMATIC TRANSMISSION SYSTEM SPEEDS OIL BOLT TORQUE EPOXY PATCH SCREWS SINGLE-USE FASTENERS CRITICAL FASTENERS MAINTENANCE SERVICE SCHEDULE TABLE TRANSAXLE FLUID GENERAL INFORMATION CHECKING FLUID LEVEL FLUID CHANGE FILTER CHANGE BRAKE GENERAL INFORMATION ADJUSTMENT NEUTRAL ADJUSTMENT GENERAL INFORMATION ADJUSTMENT PROCEDURE POWER STEERING GENERAL INFORMATION TROUBLESHOOTING THEORY OF OPERATION GENERAL INFORMATION TRANSMISSION OPERATION HYDROSTATIC TRANSMISSION FLOW DIAGRAM WITH POWER STEERING HYDROSTATIC TRANSMISSION FLOW DIAGRAM WITHOUT POWER STEERING POWER STEERING CYLINDER HYDRAULIC HOSE ROUTING LIFT CYLINDER HYDRAULIC HOSE ROUTING HYDROSTATIC TRANSMISSION FLOW DIAGRAM, UNITS WITHOUT POWER STEERING TROUBLESHOOTING TABLES TRACTOR WILL NOT OPERATE IN EITHER DIRECTION; ENGINE BOGS DOWN OR STALLS TRACTOR GOES FORWARD ONLY AT PARTIAL SPEED AND IS SLOW OR DOES NOT OPERATE IN REVERSE TRACTOR WILL NOT OPERATE IN EITHER DIRECTION TRACTOR OPERATES ERRATICALLY TRACTOR OPERATES IN BOTH DIRECTIONS BUT WITH LOSS OF POWER (WORSENS AS BECOMES HOT)

5XI SERIES TRACTOR HYDRAULIC SYSTEMS SERVICE MANUAL Table of Contents – Page 2 of 2 TROUBLESHOOTING TABLES - Continued TRANSMISSION OVERHEATING ABNORMAL VIBRATION OR NOISE HYDRAULIC LIFT SYSTEM DOES NOT OPERATE OR DOES NOT OPERATE PROPERLY OIL IS LEAKING OUT HIGH-LOW SHIFT FORK HOLE DURING OPERATION TROUBLESHOOTING FLOW CHARTS TRACTOR WILL NOT OPERATE IN EITHER DIRECTION TRACTOR OPERATES, BUT LOSES POWER AS OIL BECOMES HOT AND/OR TRANSMISSION OVERHEATS TRACTOR DOES NOT RETURN TO NEUTRAL TRACTOR OPERATES NORMALLY IN ONE DIRECTION, BUT IS VERY SLOW IN OPPOSITE DIRECTION TRACTOR OPERATES IN ONLY ONE DIRECTION TRACTOR OPERATES ERRATICALLY HYDRAULIC LIFT SYSTEM DOES NOT OPERATE, OR DOES NOT OPERATE PROPERLY HYDRAULIC SYSTEMS TESTING TESTING SYSTEM PERFORMANCE PRESSURE CHECKS LIFT SYSTEM PRESSURE CHARGE PRESSURE REPAIR PROCEDURES CHASSIS REAR FENDERS, FOOTRESTS, & TUNNEL GENERAL INFORMATION TRANSAXLE R & R REMOVAL REASSEMBLY SMART TURN™ LINKAGE ADJUSTMENTS HYDROSTATIC DRIVE TRANSMISSION/TRANSAXLE DISASSEMBLY DIFFERENTIAL DISASSEMBLY REASSEMBLY HYDROSTATIC TRANSMISSION TRANSMISSION DISASSEMBLY REASSEMBLY HYDRAULIC SYSTEMS LIFT CYLINDER R & R LIFT CYLINDER DISASSEMBLY / REASSEMBLY STEERING CYLINDER R & R POWER STEERING CYLINDER DISASSEMBLY / REASSEMBLY POWER STEERING VALVE R & R POWER STEERING VALVE DISASSEMBLY / REASSEMBLY STEERING VALVE DISASSEMBLY REASSEMBLY LIFT VALVE R & R

TORO® 5xi Series Tractor Hydraulic Systems Service Manual

ABOUT THIS MANUAL This service manual was written expressly for Toro Wheel Horse 5xi series garden tractors. The Toro Company has made every effort to make the information in this manual complete and correct. This service and repair manual has been compiled to provide authorized Wheel Horse service personnel with the proper procedures and techniques for servicing the Wheel Horse automatic transaxle with Eaton Model 11 hydrostatic transmission. Basic mechanical/electrical skills are assumed. The Table of Contents lists the systems and the related topics covered in this manual. It is advisable to read all the introductory sections first to gain a proper understanding of the Wheel Horse automatic transmission system. For information on the electrical system, please refer to the Toro Electrical Demystification Guide (492-4404). For general service procedures, refer to the 5xi Series Tractor Service Manual (492-4715). 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. The automatic transmission and transaxle are sophisticated pieces of machinery. Maintain strict cleanliness control during all stages of service and repair. Cover or cap all hose ends and fittings whenever they are exposed. Even a small amount of dirt or other contamination can severely damage the system. NOTE: This manual uses the terms “transmission, hydrostatic transmission, and hydrostatic unit” to refer to the Eaton Model 11 Hydrostatic Transmission. The term “transaxle” is used to refer to the assembly of intermediate gears, differential and case halves, less hydrostatic unit. “Transmission System” and “Automatic Transmission System” are used to refer to entire drive train as an assembly, including engine, transmission, transaxle, hydraulic lift system, and all related parts. Copyright© All Rights Reserved ©1999 The Toro Company

TABLE OF CONTENTS 5xi Series Tractor Hydraulic Service Manual 1 - 1 QUICK REFERENCE SECTION Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting Flow Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Systems Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPAIR PROCEDURES Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydrostatic Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1a 1b 1c 2 3 4 5 6 7 8

QUICK REFERENCE 1 - 2 5xi Series Tractor Hydraulic Service Manual Table of Contents SAFETY INFORMATION General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5 Think Safety First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5 SPECIFICATIONS Transmission (Eaton Model 11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6 Transaxle (Wheel Horse) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6 5xi Automatic Transmission System Speeds . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6 Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7 Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7 Epoxy Patch Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7 Single-Use Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8 Critical Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8 MAINTENANCE Service Schedule Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 9 TRANSAXLE FLUID General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 9 Checking Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 10 Fluid Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 10 Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11

QUICK REFERENCE 5xi Series Tractor Hydraulic Service Manual 1 - 3 BRAKE General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 12 NEUTRAL ADJUSTMENT General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 12 Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 13 POWER STEERING General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 14

1 - 4 5xi Series Tractor Hydraulic Service Manual THIS PAGE INTENTIONALLY LEFT BLANK

SAFETY INFORMATION 5xi Series Tractor Hydraulic Service Manual 1 - 5 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 Toro parts source or: The Toro Company Publications Department 8111 Lyndale Avenue South Bloomington, MN 55420 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 section in the 5xi Service Manual for more information. THINK SAFETY FIRST 1a

SPECIFICATIONS 1 - 6 5xi Series Tractor Hydraulic Service Manual 1b Transmission (Eaton Model 11) Item Description Radial ball piston pump and motor with auxiliary charge pump Displacement, Pump Variable 0 - 1.10 cu. in./rev. (18.03 cu. cm) Displacement, Motor Fixed 2.09 cu. in./rev. (34.2 cu. cm) Speed, Input 3400 RPM Speed, Output 0 - 1842 RPM Torque Output 360 in·lb - Continuous (40.7 N·m) Torque Output 540 in·lb - Intermittent (61 N·m) Operating Temperature Maximum continuous 180° Cooling - Air 8” diameter fan (20.3 cm) Cooling - Oil Oil flow from charge pump Oil Filter Spin-on, Full flow 10 Micron Charge Pump Flow @ 3400 RPM input 3.8 GPM (14.4 lpm) free flow 1.4 GPM (5.3 lpm) @ 700 PSI (48.21 bar) Transaxle (Wheel Horse) Item Description Two speed unidrive 8 pinion differential, double reduction gears Gear Ratio 16:1 high; 27:1 low Gears and Shafts Heat-treated steel Bearings Ball (2) Needle (8) Case Halves and Hubs Cast iron Seals (3) double-lip, spring-loaded Overall reduction ratio 30:1 high; 50:1 low Axle shaft speed 115 RPM @ 1842 RPM trans output, high 68 RPM @ 1842 RPM trans output, low Tractor Speed, Forward 0 - 7.4 MPH (11.8 km/h) Tractor Speed, Reverse 0 - 4.35 MPH (6.96 km/h) 5xi Automatic Transmission System Speeds Engine Speed Brake Shaft Axle Shaft MPH (Kmh) High Range 3400 RPM 1319 RPM 115 RPM 7.40 (11.9 km/h) Low Range 3400 RPM 775 RPM 68 RPM 4.35 (7.01 km/h)

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Toro 5XI Series Tractor Service Manual

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