FORM NO. 3319–217GB Rev. A Wheel Horse 520xi Tractor Model No. 73541 – 8900001 & UP Operator’s Manual IMPORTANT: Read this manual carefully. It contains information about your safety and the safety of others. Also become familiar with the controls and their proper use before you operate the product.
Introduction Thank you for purchasing a Toro product. All of us at Toro want you to be completely satisfied with your new product, so feel free to contact your local Authorized Service Dealer for help with service, genuine replacement parts, or other information you may require. Whenever you contact your Authorized Service Dealer or the factory, always know the model and serial numbers of your product.
Contents Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safe Operating Practices . . . . . . . . . . . . . . Slope Chart . . . . . . . . . . . . . . . . . . . . . . . . . Safety and Instruction Decals . . . . . . . . . . Check Before Operating . . . . . . . . . . . . . . . . . . Opening the Hood . . . . . . . . . . . . . . . . . . . Closing the Hood . . . . . . . . . . . . . . . . . . . . Removing the Side Panels . . . . . . . . . . . . . Adding Fuel . . . . . . . . . . . . . . . .
Safety This machine meets or exceeds the B71.1–1996 specifications of the American National Standards Institute, in effect at the time of production. However, improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert symbol, which means CAUTION, WARNING, or DANGER—“personal safety instruction.” Failure to comply with the instruction may result in personal injury or death.
Safety 13. Mow only in daylight or good artificial light. 14. Do not operate the machine while under the influence of alcohol or drugs. 15. Watch for traffic when operating near or crossing roadways. 16. Use extra care when loading or unloading the machine onto a trailer or truck. • Keep all movement on slopes slow and gradual. Do not make sudden changes in speed or direction. • Avoid starting or stopping on a slope.
Safety Children Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the machine and the mowing activity. Never assume that children will remain where you last saw them. The following requirements must be followed to prevent injury to children. 1. Keep children out of the mowing area and under the watchful care of another responsible adult. 2. Be alert and turn the machine off if children enter the area. 3.
Safety Slope Chart Read all safety instructions on pages 2–4.
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Safety Safety and Instruction Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost. ON DRIVE SHAFT COVER (Part No. 98–1608) ON BATTERY STRAP (Part No. 93–1265) ON DRIVE SHAFT TUNNEL ON ENGINE BULKHEAD (2) UNDER SIDE SHIELD (Part No.
Check Before Operating Each time before operating your tractor, check the following: • Fuel level • Engine oil level • Debris on the (3) air intake screens • Debris in the engine area • Debris on the rear transaxle cover • The safety interlock system • The brake 1 m–3584 Figure 1 1. Slot for hood latch access Some of these steps will require that you open the hood or remove the side panels on the tractor. Opening the Hood To open the hood: 1.
Check Before Operating Closing the Hood 2 1. Lift up on the prop rod as you begin to lower the hood (Fig. 2). 2. Push the hood down until the latch closes. 1 1 m–3438 Figure 2 m–3318 1. Prop rod Figure 3 1. Side panel latch 2. Open slot Removing the Side Panels 1. 2. Park the machine on a level surface, disengage the power take off (PTO), set the parking brake, lower the attachment lift, and turn the ignition key to “STOP” to stop the engine. Remove the key. To remove a side panel: A.
Check Before Operating Adding Fuel Use UNLEADED Regular Gasoline suitable for automotive use (85 pump octane minimum). Leaded regular gasoline may be used if unleaded regular is not available. IMPORTANT: Never use methanol, gasoline containing methanol, or gasohol containing more than 10% ethanol because the fuel system could be damaged. Do not mix oil with gasoline. POTENTIAL HAZARD • In certain conditions gasoline is extremely flammable and highly explosive.
Check Before Operating Check the Engine Oil Level 1. Park the machine on a level surface, disengage the power take off (PTO), set the parking brake, lower the attachment lift, and turn the ignition key to “STOP” to stop the engine. Remove the key. 2. Open the hood. 3. Clean around the oil dipstick (Fig. 4) so dirt cannot fall into the dipstick tube and damage the engine. 1 m–3219 Figure 5 1. Metal end 4. Pull out the oil dipstick and wipe the metal end clean (Fig. 5). 5.
Check Before Operating Check for Debris IMPORTANT: Operating the engine with a blocked grass screen, dirty or plugged cooling fins, and/or cooling shrouds removed, will result in engine damage from overheating. 1. 2. POTENTIAL HAZARD • Rotating air intake screen and drive shaft can cause injury. WHAT CAN HAPPEN • Fingers, hands or loose clothing can get caught by rotating air intake screen and drive shaft.
Check Before Operating Check the Safety Interlock System Always check the interlock system before operating the tractor. Instructions for checking the interlock system are found in the Operation section, page 14. Check the Brake Refer to Checking and Adjusting the Brake, page 30. Figure 8 IMPORTANT: DO NOT HIGH–PRESSURE WASH. High–pressure washing can damage the electrical system or deplete grease. 5. The rear transaxle cover is an air intake area for cooling the transaxle.
Operation Think Safety First Parking Brake Please carefully read all the safety instructions on pages 2–7. Knowing this information could help you, your family, pets or bystanders avoid injury. Always set the parking brake when you stop the machine or leave it unattended. Setting the Parking Brake Controls 1. Push the brake pedal (Fig. 10) down and hold it in the depressed position. Become familiar with all the controls (Fig. 10) before you start the engine and operate the machine. 2.
Operation Starting and Stopping the Engine Starting 2 1. Sit down on the seat. 2. Depress the brake pedal. 1 Note: 3 The engine will not start unless you fully depress the brake pedal. 3. Push the PTO (power take off) switch to OFF (Fig. 11). 4. Move the choke lever to ON (if the engine is cold) (Fig. 11). 5. Move the throttle lever halfway to FAST (Fig. 11). 6. Turn the ignition key clockwise and hold it in the START position (Fig. 12). When the engine starts, release the key.
Operation Operating the Power Take Off (PTO) The Safety Interlock System Understanding the Safety Interlock System The power take–off (PTO) switch engages and disengages power to the electric clutch. If the ignition key is in the RUN or LIGHTS position and the power take off (PTO) is engaged, the PTO indicator light will be on. When this light is on, it is a reminder: the implement is being powered and the starter will not crank while the PTO is engaged.
Operation 5. Fully depress the brake pedal and set the parking brake. Push the PTO switch to OFF and start the engine. Pull the PTO switch to ON. Rise slightly from the seat; the engine should stop. Gauges and Indicator Lights The indicator lights (Fig. 14) illuminate when certain controls are activated and when major malfunctions occur that need immediate attention.
Operation Hour Meter 4. Place your foot on the traction control pedal and slowly press on the top of the pedal to move forward, or on the bottom of the pedal to move backward (Fig. 15). The farther you move the pedal in either direction, the faster the machine will move in that direction. 5. To slow down, release the pressure on the traction control pedal and step on the brake pedal. The hour meter (Fig. 10) records the amount of time the engine has run. Use it to schedule regular maintenance.
Operation Stopping the Machine 1 To stop the machine, release the traction control pedal, step on the brake pedal, disengage the power take off (PTO), lower the attachment lift, and turn the ignition key to STOP. Also set the parking brake if you leave the machine unattended; refer to Setting the Parking Brake, page 14. Remember to remove the key from the ignition switch. POTENTIAL HAZARD • Someone could move or attempt to operate the tractor while it is unattended. m–3258 Figure 16 1.
Operation Lowering Attachments Headlights and Taillights 1. Start the tractor. 2. Push the lift lever DOWN to lower the attachment (Fig. 17). The headlights and taillights are turned on by turning the ignition key to the LIGHTS position. They can be turned on even if the engine is not running. Remove the key when leaving the machine unattended so that the headlights cannot be turned on and discharge the battery. 1 2 1 m–3315 Figure 17 1. Lift lever–Up m–3312 2. Lift lever–Down Figure 19 1.
Operation Positioning the Tilt Steering Wheel Engaging the Cruise Control 1. Begin driving the tractor; refer to Driving Forward or Backward, page 18. While holding your foot steady on the traction control pedal, push the cruise control switch (Fig. 21) to the “SET” position. This locks the traction control pedal in position and your foot can then be removed from the traction control. A constant pedal position will be maintained. 2.
Operation The Smart Turn Steering Feature 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 40 percent. This allows you to make turns at higher speeds without having to change the speed control position. After the turn, the original speed is automatically restored. Pushing the Machine by Hand IMPORTANT: Always push the machine by hand.
Maintenance POTENTIAL HAZARD • If you leave the key in the ignition switch, someone could start the engine. WHAT CAN HAPPEN • Accidental starting of the engine could seriously injure you or other bystanders. HOW TO AVOID THE HAZARD • Remove the key from the ignition switch and pull the wire(s) off the spark plug(s) before you do any maintenance. Also push the wire(s) aside so it does not accidentally contact the spark plug(s).
Maintenance Air Cleaner 2 Service Interval/Specification 1 Foam Element: Clean and re-oil after every 25 operating hours, or yearly, whichever occurs first. 4 3 Paper Element: Replace after every 100 operating hours or yearly, whichever occurs first. Note: 5 7 Service the air cleaner more frequently (every few hours) if operating conditions are extremely dusty or sandy. 6 8 Figure 22 Removing the Foam and Paper Elements 1.
Maintenance Cleaning the 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 on the element (Fig. 23). Squeeze the element to distribute the oil. 1 2 IMPORTANT: Replace the foam element if it is torn or worn. m–3248 2 Figure 24 1. Paper element 2.
Maintenance Engine Oil Service Interval/Specification POTENTIAL HAZARD • Components under the hood will be hot if the tractor has been running. Change oil: • After the first 5 operating hours. • After every 100 operating hours. WHAT CAN HAPPEN • Touching hot components can cause burns. HOW TO AVOID THE HAZARD • Allow the tractor to cool before performing maintenance or touching components under the hood. Oil Type: Detergent oil (API service SG or SH) Crankcase Capacity: w/filter, 2.1 qts. (2.
Maintenance Spark Plugs Changing the Engine Oil Filter Service Interval/Specification Service Interval/Specification Replace the oil filter every 200 hours of operation or every other oil change. 1. Drain the oil from the engine; refer to Changing/Draining Oil, page 26. 2. Remove the old filter and wipe the filter adapter (Fig. 26) gasket surface. 3. Apply a thin coat of new oil to the rubber gasket on the replacement filter (Fig. 26). Change the spark plugs after every 200 operating hours.
Maintenance Greasing and Lubrication Checking the Spark Plugs 1. Look at the center of the spark plug(s) (Fig. 28). If you see light brown or gray on the insulator, the engine is operating properly. A black coating on the insulator usually means the air cleaner is dirty. IMPORTANT: Never clean the spark plug(s). Always replace the spark plug(s) when it has: a black coating, worn electrodes, an oily film, or cracks.
Maintenance 4. 3. Lubricate the three grease fittings (Fig. 31). Open the drive shaft maintenance cover on the tractor tunnel near the seat by unscrewing the two screws securing it, then raising it (Fig. 30). m–3419 Figure 31 1 m–3422 Figure 30 1. Drive shaft maintenance cover 5. Replace and secure the cover. 6. Grease the fitting on the brake pedal (Fig. 32). POTENTIAL HAZARD • Rotating shaft or cooling fan can cause injury. WHAT CAN HAPPEN • Fingers, hands, feet, hair, etc.
Maintenance Brake Always set the parking brake when you stop the machine or leave it unattended. Check the brake before each use. If the parking brake does not hold securely, an adjustment is required. Checking the Brake 1. Park the machine on a level surface, disengage the power take off (PTO), put the High–Low range lever in “N,” set the parking brake, and turn the ignition key to “STOP” to stop the engine. Remove the key. 2.
Maintenance 4. Turn the brake adjustment nut (Fig. 36) until there is 2” (51 mm) of free travel. Fuel Tank Draining The Fuel Tank 1 POTENTIAL HAZARD • In certain conditions gasoline is extremely flammable and highly explosive. WHAT CAN HAPPEN • A fire or explosion from gasoline can burn you, others, and cause property damage. HOW TO AVOID THE HAZARD • Drain gasoline from the fuel tank when the m–3417 engine is cold. Do this outdoors in an open area. Wipe up any gasoline that spills.
Maintenance Fuel Filter Service Interval/Specification 3 Replace the fuel filter after every 100 operating hours. Replacing the Fuel Filter 2 1 1. Disengage the power take off (PTO), set the parking brake, lower the attachment lift, and turn the ignition key to “STOP” to stop the engine. Remove the key. 2. Close the fuel shut–off valve at the fuel tank (Fig. 37 & 38). 3. Open the hood. 4. Squeeze the ends of the hose clamps together and slide them away from the filter (Fig. 39). 5.
Maintenance Front Wheel Toe-In Service Interval/Specification Maintaining correct front wheel toe–in is important for safety, Smart Turn Steering operation, and ease of use. If uneven tire wear, lawn scuffing, or hard steering develop, adjustment may be required. Check the toe-in after every 100 operating hours or once a year, whichever occurs first (Fig. 40). 2 Maintain the following specification: 1/8–1/4 inch (3.5–6.5 mm) toe-in on the front wheels. 2 1 1 m–3397 Figure 41 1. Jam nut 2.
Maintenance 4. Recheck the toe–in; refer to Measuring Toe–In, page 33. 6. If the oil level is low, slowly pour only enough SAE 10W–30 detergent oil into the filler tube to raise the level to the FULL line. IMPORTANT: Do not fill above the FULL line as fluid may overflow. Transaxle Fluid Service Interval/Specification 2 Check the fluid level every 25 hours. Always keep the fluid level in the correct operating range on the dipstick when the transaxle is cold.
Maintenance Changing the Transaxle Filter Service Interval/Specification Replace the transaxle filter after the first 50 hours; then every 200 hours. 1 1. Drain the oil from the transaxle; refer to Changing/Draining Transaxle Fluid, page 34. 2. Remove the transaxle filter and wipe the filter adapter (Fig. 46) gasket surface. 3. Apply a thin coat of new oil to the rubber gasket on the replacement filter (Fig. 46). m–3322 Figure 45 1. Transaxle drain plug 5.
Maintenance Fuses 5 5 Service Interval/Specification 1 3 The electrical system is protected by fuses. They require no maintenance. However, if a fuse blows, check the component and circuit for a malfunction or short. To replace a fuse, pull it out of the fuse box (Fig. 47). 4 2 4 Figure 48 1 4. Slots 5. Terminals 1. Bulb holder 2. Reflector 3. Tabs 2 3 4 m–3316 Figure 47 1. F1; main–30 amp 2. F2; regulator–25 amp 3. F3; dash, interlock, and cruise control–10 amp 4.
Maintenance Taillights Installing the Bulb Reverse the bulb removal procedure. Bulb: GE 194 Removing the Bulb 1. Disengage the power take off (PTO), set the parking brake, lower the attachment lift, and turn the ignition key to “STOP” to stop the engine. Remove the key. 2. Remove the two screws. 3. Pull the lens out far enough so that you can remove the bulb socket. 4. Pull the bulb from the socket. 4 3 1 2 m–3321 Figure 50 1. Lens 2. Screws 3. Bulb 4.
Maintenance Battery 4. Open the cell covers to see into the cells. The electrolyte must be up to the lower part of the tube (Fig. 52). Do not allow the electrolyte to get below the plates. 5. If the electrolyte is low, add the required amount of distilled water; refer to Adding Water to the Battery. 6. If the fluid level is correct, press the cell covers onto the battery and replace the battery shield. Service Interval/Specification Check the electrolyte level in the battery every 25 hours.
Maintenance Adding Water to the Battery IMPORTANT: Use only distilled water. Removing the Battery 1. Disengage the power take off (PTO), set the parking brake, lower the attachment lift, and turn the ignition key to “STOP” to stop the engine. Remove the key. 2. Remove the tractor’s front grill by raising the hood and unscrewing the two screws and washers securing it in place (Fig. 51). Close the hood and remove the grill by pulling it out toward you. 3. Remove the battery shield (Fig. 53). 4.
Maintenance Installing the Battery 1. Place the battery onto the chassis (Fig. 53). 2. Secure the battery shield to the chassis with hold–down rods. 3. Using the bolt and wing nut, connect the positive (red) cable to the positive (+) battery post (Fig. 53). • When removing or installing the battery, do 4. not allow the battery terminals to touch any metal parts of the tractor (below the headlights). • Always keep the battery shield and hold–down rods in place to protect and secure the battery.
Maintenance Charging the Battery IMPORTANT: Always keep the battery fully charged (1.260 specific gravity). This is especially important to prevent battery damage when the temperature is below 32°F (0°C). 1. Remove the battery from the chassis; refer to Removing the Battery, page 39. 2. Check the electrolyte level; refer to Checking the Electrolyte Level, page 38, steps 2–5. 3. Remove the cell covers from the battery and connect a 3– to 4–amp battery charger to the battery posts.
Maintenance Wiring Diagram HEADLIGHT HARNESS REAR HARNESS BK OR BK OR TAIL LIGHTS OR A OR BK B BK GN C GN Y E Y BN D BN CRUISE SWITCH SW8 2 3 5 6 OR SW7 (CRUISE DISENGAGE SWITCH) SWITCH OPENS WHEN BRAKE IS DEPRESSED P CRUISE MAGNET VIO P (MOMENTARY) W CRUISE SWITCH OPERATION OFF NO CONNECTION ON 3 AND 2 CONNECTED MOMENTARY 3 AND 2 CONNECTED 5 AND 6 CONNECTED CRUISE MODULE C Y A BN B BK 95-3029 WARNING LIGHT HARNESS PARK #194 LAMP OIL #194 LAMP PTO #194 LAMP
Maintenance Wiring Diagram SW4 (IGNITION SWITCH) OFF-----------NO CONNECTION RUN/LIGHTS----------B I R L RUN---------------B I R START--------------B I R S L I 4 OR OR S 3 B 1 P WIRE COLOR CODES S R 5 2 BN R VIO R B BK BLACK P PINK I L BN BROWN R RED BU BLUE T TAN GN GREEN VIO VIOLET GY GREY W WHITE OR ORANGE Y YELLOW IGNITION SWITCH TERMINAL LOCATIONS VEIWED FROM BACK.
Maintenance Cleaning and Storage 1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to “STOP” to stop the engine. Remove the key. 2. Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine. Clean dirt and chaff from the outside of the engine’s cylinder head fins and blower housing; refer to Check for Debris, page 12. IMPORTANT: You can wash the machine with mild detergent and water.
Troubleshooting PROBLEM The starter does not crank. The engine cranks, but will not start. POSSIBLE CAUSES CORRECTIVE ACTION 1. The PTO is ON. 1. Move the PTO to OFF. 2. The brake is not depressed or the parking brake is not on. 2. Set the parking brake. 3. The operator is not seated. 3. Sit on the seat. 4. The electrical connections are corroded or loose. 4. Check the electrical connections for good contact. 5. A fuse is blown or loose. 5. Correct or replace fuse. 6.
Troubleshooting PROBLEM The engine starts, but does not keep eep running u g The engine runs, but knocks or misses. sses The engine will not idle. 46 POSSIBLE CAUSES CORRECTIVE ACTION 1. Misadjusted or faulty choke or throttle control cable. 1. Contact your Authorized Service Dealer. 2. The fuel tank vent is restricted. 2. Contact your Authorized Service Dealer. 3. Dirt or water in the fuel system. 3. Drain and flush the fuel system; add fresh fuel. 4. The fuel filter is clogged. 4.
Troubleshooting PROBLEM The engine overheats. POSSIBLE CAUSES CORRECTIVE ACTION 1. The crankcase oil level is incorrect. 1. Fill or drain to the full mark. 2. The fuel mixture is lean. 2. Contact your Authorized Service Dealer. 3. Excessive loading. 3. Reduce load; use lower ground speed. 4. (3) air intake screens are dirty. 4. Clean with every use. 5. The cooling fins and air passages under the engine blower housing and/or the rotating air intake screen are plugged. 5.
Troubleshooting PROBLEM The tractor will not operate in either direction. e t e d ect o The tractor operates erratically. The tractor operates in both directions, but with a loss of power. This condition becomes p worse as th the ttransmission i i becomes hot. Abnormal vibration or noise. 48 POSSIBLE CAUSES CORRECTIVE ACTION 1. The High–Low range lever is in “N.” 1. Move the High–Low range lever to “L” or “H.” 2. The transmission oil is low. 2.
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Consumer Riding Products A Full TwoĆYear Warranty (Limited Warranty For Commercial Use) ! + * &- ) 0 !"* /') ** )) %+0 The Toro Company promises to repair any TORO Product used for normal residential purposes* if defective in materials or workmanship for a period of two years from the date of purchase with the following exceptions: D Batteries are warranted for one year This warranty covers the cost of parts and labor as well as transportation within a 15 mil
