Form No. 3325-552 520xi Wheel Horse Garden Tractor Model No.
This spark ignition system complies with Canadian ICES-002. Page Centering the Steering Wheel (Power Steering Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 The Smart Turn Steering Feature . . . . . . . . . . . . 19 Pushing the Machine by Hand . . . . . . . . . . . . . . . 20 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Recommended Maintenance Schedule . . . . . . . . 20 Servicing the Air Cleaner . . . . . . . . . . . . . . . . . .
Safe Operating Practices For your convenience, write the product model and serial numbers in the space below. The following instructions are from the CEN standard EN 836:1997. Model No: This product is capable of amputating hands and feet and throwing objects. Always follow all safety instructions to avoid serious injury or death. Serial No. Read this manual carefully to learn how to operate and maintain your product correctly.
• Do not turn sharply. Use care when reversing. • Refuel outdoors only and do not smoke while refuelling. • Use counterweight(s) or wheel weights when suggested in the instruction handbook. • Add fuel before starting the engine. Never remove the cap of the fuel tank or add fuel while the engine is running or when the engine is hot. • Watch out for traffic when crossing or near roadways. • Stop the blades rotating before crossing surfaces other than grass.
• Never store the equipment with fuel in the tank inside a building where fumes can reach an open flame or spark. • Remove obstacles such as rocks, tree limbs, etc. from the mowing area. Watch for holes, ruts or bumps, as uneven terrain could overturn the machine. Tall grass can hide obstacles. • Allow the engine to cool before storing in any enclosure. • Battery acid is poisonous and can cause burns. Avoid contact with skin, eyes and clothing.
Slope Chart 6
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. Part No. 98-1608 1. Press the traction control pedal forward to move forward and rearward to back up. 2. To set the parking brake, press the brake pedal and lift the parking brake lever. 3. To release the parking brake, press the brake pedal 4. To stop the tractor, press the brake pedal. 5.
Part No. 93-1265 1. Hot surface hazard—stay away. Part No. 99-5340 1. KeyChoice, turn to mow in reverse Part No. 104-4164 1. Contains lead, do not throw the battery in the garbage 2. Recycle 3. Wear eye protection—explosive gases can cause blindness and other injuries 4. No sparks, flame, or smoking 5. Sulfuric acid can cause blindness or severe burns 6. Flush eyes immediately with water and get medical help fast. 8 7. Maximum fill line 8. Minimum fill line 9.
1 m–3314 Figure 2 Part No. 104-4163 1. Explosion hazard 2. No sparks, flame, or smoking 3. Caustic liquid hazard—burns to hand and damage to items 1. Hood latch 4. Wear eye protection 5. Read the operator’s manual 6. Keep bystanders away 3. Raise the hood to full height. Caution Components under the hood will be hot if the tractor has been running. If you touch hot components you may be burned.
Removing the Side Panels Danger 1. Park the machine on a level surface, disengage the PTO, set the parking brake, lower the attachment lift, stop the engine, and remove the ignition key. In certain conditions, gasoline is extremely flammable and highly explosive. A fire or explosion from gasoline can burn you and others and can damage property. 2. Raise the hood. 3. Lift up and twist each of the two side panel latches until they line up with the open slot (Fig. 4).
Note: A fuel stabilizer/conditioner is most effective when mixed with fresh gasoline. Filling the Fuel Tank 1. Park the machine on a level surface, disengage the PTO, set the parking brake, lower the attachment lift, stop the engine, and remove the ignition key. 1 Note: When filling the tank, make sure that the machine is on a level surface so that adequate air space is allowed. 2. Clean around the fuel tank cap and remove the cap. m–3219 3. Add fuel until the fuel level is 1/4 to 1/2 in.
6. Clean debris from the rear transaxle cover (Fig. 10). 3. Wipe away debris before each use and/or during use, if required. Note: The rear transaxle cover is an air-intake area for cooling the transaxle. 4. Wipe away any accumulated debris from the rotating air-intake screen (Fig. 8). Danger The rotating air-intake screen and drive shaft can catch fingers, hands, and loose clothing, causing amputation or other severe injury when moving.
Starting and Stopping the Engine 7 5 15 8 2 6 Starting 1. Sit down on the seat. 11 2. Push the brake pedal down. Note: The engine will not start unless you push the brake pedal down fully. 9 1 16 3 3. Push the PTO switch to the off position (Fig. 12). 10 4 12 2 13 14 1 3 m–3257 Figure 12 m–3597 Figure 11 1. 2. 3. 4. 5. Throttle Choke PTO switch Seat adjustment lever Engine water temperature gauge 6. Attachment lift lever 7. Indicator lights 8. Fuel gauge 9. 10. 11. 12. 13. 14. 15. 16.
The Safety Interlock System 8. After the engine starts, move the choke lever to the off position (Fig. 12). Understanding the Safety Interlock System If the engine stalls or hesitates, move the choke lever back to the on position for a few seconds. Then, move the throttle lever to the desired setting. Repeat this as required. The safety interlock system is designed to prevent the engine from starting unless the following conditions are met: 9. Allow the engine to warm up before using it.
Testing the Safety Interlock System Before deactivating this interlock, ensure that there are no children present on or near the property where you are using the tractor, and that none are likely to appear while you are mowing or operating an attachment. Be extra observant after you have chosen to deactivate the interlock because the sound of the tractor’s engine might prevent you from being aware that a child or bystander has entered the area.
Operating–in–Reverse Warning Light 17. Move the foot pedal to reverse; the PTO and PTO light on the dash should remain on. The Operating–in–Reverse warning light will illuminate whenever the KeyChoice key is used to deactivate the operating–in–reverse interlock. It is a reminder that the interlock system is deactivated. The light goes out whenever the PTO is disengaged or the engine is shut off. When the light is on, look behind and use extra caution when backing.
5. Turn the ignition key to the stop position to stop the engine. Note: Use low for best mowing performance and smoothest operation with all attachments. Use high for transporting or where conditions permit higher speed. 6. Set the parking brake before getting off; refer to Setting the Parking Brake, page 13. Danger 7. Remove the ignition and KeyChoice keys from the switches.
forward and will not operate in reverse. To correct this situation, move the cruise control switch to the off position or press the brake pedal to disengage the cruise control. 1 2 Disengaging the Cruise Control To disengage the cruise control, complete one of the following steps: m–3315 • While holding your foot steady on the traction control, move the cruise control switch to the off position (Fig. 18). Figure 20 1. Lift lever, Up • Press the brake pedal. 2. Lift lever, Down 3.
2 1 1 M 3320 m–3259 Figure 21 Figure 23 1. Adjustment lever 1. Tilt lever Lights Centering the Steering Wheel (Power Steering Models) The lights turn on whenever you turn the ignition key to or past the lights position (Fig. 22). You can turn then on even if the engine is not running; therefore remove the ignition key when leaving the machine unattended so that no one can accidentally turn on the lights and discharge the battery. 2.
Pushing the Machine by Hand Danger Important Do not tow the machine because transmission damage may occur. Always push the machine by hand. Driving with excessive speed while turning can cause you to rollover, resulting in serious injury or death to you or bystanders. 1. Disengage the PTO and stop the engine. • Do not rely on the Smart Turn steering feature to avoid accidents while turning. • Read, understand, and follow all instructions in the Operator’s Manual and on the machine before starting. 2.
Maintenance Service Interval Maintenance Procedure 200 Hours • • • • Engine oil filter—change Transaxle oil and oil filter—change3 Power steering filter—have it cleaned by your Authorized Service Dealer3 Spark plugs—change Yearly/Storage Service • • • • • • • • • • • • • • • • Chipped surfaces—paint Brakes—check Safety System—check Air-intake screens—clean Rear transaxle cover—clean Engine air precleaner—clean Tires—check pressure Battery—check electrolyte level Grease fittings—grease Power take off
5. Squeeze the element to distribute the oil. 2 Checking the Paper Element 1 Inspect the element for tears, an oily film, damage to the rubber seal, excessive dirt, or other damage (Fig. 26). If any of these conditions exit, replace the filter. 4 3 Important Do not clean the paper element with pressurized air or liquids, such as solvent, gas, or kerosene. 5 7 6 8 1 m–3214 Figure 24 1. 2. 3. 4. Air cleaner cover Knob Cover nut Cover 5. 6. 7. 8.
USE THESE SAE VISCOSITY OILS 7. When the oil has drained completely, close the drain by pushing it in and turning it clockwise, 1/8 turn. 8. Dispose of the used oil at a certified recycling center. 9. Slowly pour approximately 80% of the specified amount of oil into the oil filler tube (Fig. 28). 1 –20 °F 0 –30 °C –20 20 –10 32 40 0 80 60 10 20 100 30 40 Changing the Engine Oil m–3246 1. Start the engine and let it run for five minutes. This warms the oil so it drains better. Figure 28 1.
Checking the Spark Plugs 5. Install the replacement oil filter to the filter adapter. Turn the oil filter clockwise until the rubber gasket contacts the filter adapter, then tighten the filter an additional 1/2 turn (Fig. 29). 1. Look at the center of the spark plugs (Fig. 31). 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. 6.
How to Add Grease Danger 1. Disengage the PTO, set the parking brake, lower the attachment lift, stop the engine, and remove the ignition key. The rotating, cooling fan and drive shaft can catch fingers, hands, feet, hair, and loose clothing, causing amputation or other severe injury. 2. Clean the grease fittings with a cloth. • Do not operate the tractor without the drive shaft cover in place. • Keep fingers, hands and clothing clear of the rotating, fan and drive shaft.
Adjusting the Brake 1. Place the transmission in neutral. 2. Depress the brake pedal. There should be 2 in. (51 mm) of free travel (Fig. 38) before the brake begins to engage. m–3409 2” Figure 36 Maintaining the Tire Pressure m–3418 Check the pressure at the valve stem after every 25 operating hours or monthly, whichever occurs first (Fig. 37). Check the tires when they are cold to get the most accurate pressure reading.
1. Park the machine on a level surface to ensure that the fuel tank drains completely. Important valve. 2. Disengage the PTO, set the parking brake, lower the attachment lift, stop the engine, and remove the ignition key. 8. Remove the drain hose. 3. Close the fuel shut-off valve at the fuel tank (Fig. 40 & 41). 10. Slide the hose clamp close to the valve to secure the fuel line (Fig. 41). Do not turn or unscrew the fuel shut-off 9. Install the fuel line onto the fuel shut-off valve.
Servicing the Front Wheel Toe-In 1 2 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, you may need to adjust the toe-in of the front wheels. Check the toe-in after every 100 operating hours or once a year, whichever occurs first. 2 1 m–3397 Figure 44 Maintain the following specification: 1/8–1/4 inch (3.5–6.5 mm) toe-in on the front wheels. 1. Jam nut Measuring Toe-In 2.
Checking the Transaxle Oil Draining the Transaxle Oil 1. Park the machine on a level surface. 1. Warm up the transaxle oil by driving the tractor. 2. Disengage the PTO, set the parking brake, lower the attachment lift, stop the engine, and remove the ignition key. 2. Park the machine on a level surface to ensure that the oil drains completely. 3. Turn off the PTO, set the parking brake, lower the attachment lift, stop the engine, and remove the ignition key. 3. Tilt the seat up. 4.
4. Install the replacement transaxle filter to the filter adapter. Turn the filter clockwise until the rubber gasket contacts the filter adapter, then tighten the filter an additional 3/4 turn (Fig. 49). Removing the Bulb Filling the Transaxle Oil 2. Open the hood. 1. Slowly pour the specified refill capacity of oil into the filler tube (Fig. 46). 3. Pull the wire connectors off both bulb holder terminals. 2.
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. 4. Push the wire connectors onto the terminals on the bulb holder. 5. Close the hood. Battery size: 12 v, 380 Cold Cranking Amps Replacing Taillights Specification: Bulb GE 194 Removing the Battery Removing the Bulb 1.
Warning Danger Incorrect battery cable routing could damage the tractor and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns. • Do not drink electrolyte and avoid contact with skin, eyes or clothing. Wear safety glasses to shield your eyes and robber gloves to protect your hands. • Fill the battery where clean water is always available for flushing the skin.
Cleaning and Storage 1. Remove the battery from the chassis; refer to Removing the Battery, page 31. 1. Disengage the PTO, set the parking brake, stop the engine, and remove the ignition and KeyChoice keys. 2. Check the electrolyte level; refer to Checking the Electrolyte Level, page 32. 2. Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine. 3. Make sure the vent caps are installed in the battery.
11. With the spark plugs removed from the engine, pour two tablespoons of engine oil into the spark plug hole. 12. Use the electric starter to crank the engine and distribute the oil inside the cylinder. 13. Install the spark plugs and tighten to recommended torque; refer to Changing Spark Plugs, page 24. Note: Do not install the wire on the spark plug(s). 14. Remove the battery from the chassis, check the electrolyte level, and charge it fully; refer to Servicing the Battery, page 31.
BK OR A B Y BN 2 5 K4 VIO BU W PK PK BK B+D A BATTERY LIGHT MODULE OR D C B J A H K E F BK #194 LAMPOR #194 LAMP #194 LAMP GN #194 LAMP #194 LAMPT #194 LAMP VOLTAGE COMPARATOR BATTERY PARK PTO OIL OVER RIDE CRUISE BN 1 VIO 2 OR BK BU W PK GN T VIO SW7 PARK BRAKE IS ENGAGED SWITCH CLOSES WHEN PK VIO W I S Y TEMP. GAUGE GND TEMP.
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 the off position. 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.
Problem The engine starts, but does not g keep running The engine runs, but knocks or misses. The engine will not idle. Possible Causes Corrective Action 1. Misadjusted or broken 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. Replace the fuel filter. 5.
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. The 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. Clean with every use. 1.
Problem The tractor will not operate in either direction. The tractor operates erratically. The tractor operates in both directions, but with a loss of power. This condition becomes worse as th the ttransmission i i becomes hot. Abnormal vibration or noise. Possible Causes Corrective Action 1. The High-Low range lever is in neutral (N). 1. Move the High-Low range lever to L or H. 2. The transmission oil is low. 2. Fill to the full mark on the transmission oil dipstick when the transmission is cold.
Problem PTO belt comes off of pulleys, slips, or fails. Possible Causes Corrective Action 1. Belt tension is incorrect. 1. Refer to the attachment operator’s manual. 2. Mower level is incorrect 2. Refer to the attachment operator’s manual. 3. Blade slope in transport is incorrect. 3. Refer to the attachment operator’s manual. 4. Cutter deck belt guide is loose or incorrectly adjusted. 4. Adjust and tighten belt guide. 5. Belt is worn or damaged. 5. Refer to the attachment operator’s manual. 6.
