FORM NO. 3321–980 Wheel Horse 520Lxi Tractor Model No. 73580 – 9900001 & 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 Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Safe Operation Practices for Ride-on (riding) Rotary Lawnmower Machines . . . . . . . . . 2 Safe Operating Practices . . . . . . . . . . . . . . 2 Sound Pressure Level . . . . . . . . . . . . . . . . . 4 Sound Power Level . . . . . . . . . . . . . . . . . . 4 Vibration Level . . . . . . . . . . . . . . . . . . . . . 4 Slope Chart . . . . . . . . . . . . . . . . . . . . . . . . . 5 Safety and Instruction Decals . . . . .
Safety Safe Operation Practices for Ride-on (riding) Rotary Lawnmower Machines 6. This machine meets or exceeds European Standards 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.
Safety • If fuel is spilled, do not attempt to start the engine but move the machine away from the are of spillage and avoid creating any source of ignition until petrol vapors have dissipated. • Replace all fuel tanks and container caps securely. 4. Replace faulty silencers. 5. Before using, always visually inspect to see that the blades, blade bolts and cutter assembly are not worn or damaged. Replace worn or damaged blades and bolts in sets to preserve balance. 6.
Safety • before making height adjustment unless adjustment can be made from the operator’s position. 4. To reduce the fire hazard, keep the engine, silencer, battery compartment and petrol storage area free of grass, leaves, or excessive grease. 14. Reduce the throttle setting during engine run-out and, if the engine is provided with a shut-off valve, turn the fuel off at the conclusion of mowing. 5. Check the grass catcher frequently for wear or deterioration. 6.
Safety Slope Chart Read all safety instructions on pages 2–10.
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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 SEAT BRACKET (Part No. 99–2986) ON SEAT BRACKET (Part No. 99–5340) (1) ON DRIVESHAFT TUNNEL (2) UNDER SIDE SHIELD (Part No. 98–5015) ON RADIATOR FAN SHROUD (Part No.95–4143) ON BATTERY STRAP (Part No.
Safety Symbols Glossary Safety alert symbol Dismemberment–Mower in rearward motion Safety alert symbol Stay a safe distance from the machine Read operator’s manual Consult Technical Manual for proper service procedures Thrown or flying objects– Whole body exposure Thrown or flying objects– Rotary side-mounted mower. Keep deflector shield in place Severing toes or foot– mower blade Severing fingers or hand– mower blade Rotating blade can cut off toes or fingers.
Safety Symbols Glossary Cutting element– basic symbol Riding on this machine is allowed only on a passenger seat & only if the driver’s view is not hindered Cutting element– height adjustment Cutting unit–lower Crushing of fingers or hands–Force applied from side Cutting unit-raised Kickback or upward motion–Stored energy Cutting or entanglement of foot–Rotating auger Severing of fingers or hand– impeller blade Keep a safe distance from snowthrower Stay a safe distance from the snowthrower Shut of
Safety Symbols Glossary Fast Slow Fuel Fuel level Decreasing/Increasing On/Run Volume empty Off/Stop Volume full Engine Battery charging conditin Engine start Head lights– Main/high beam Engine stop Brake system Choke Parking brake Engine temperature Clutch PTO (Power Take Off) Engine lubricating oil pressure Engage Disengage Engine lubricating oil level Unlock Lock ”Key Choice” key 10
Check Before Operating Each time before operating your tractor, check the following: • Fuel level • Engine oil level • Cooling system fluid level and radiator screen • 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.
Check Before Operating Closing the Hood 2 1 The hood catch is located at the left hand corner of the grille. 1. Press rearward on the hood catch as you begin to lower the hood. 2. Push the hood down until the latch closes. 1 m–3318 2 Figure 3 1. Side panel latch 2 Front of tractor 2. Open slot Figure 2 1. Hood catch 2. Hood hinges Removing the Side Panels 1. 2.
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. POTENTIAL HAZARD • When fueling, under certain circumstances, a static charge can develop, igniting the gasoline. 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.
Check Before Operating 2. 3. Clean around the fuel tank cap and remove the cap. Use a funnel and add fuel until the fuel level is 1/4 to 1/2 inch (6 mm to 13 mm) below the bottom of the filler neck. This space in the tank allows for expansion of the fuel. When filling the tank, make sure that the machine is on a level surface so that adequate air space is allowed. Do not fill the fuel tank completely. 1 2 Install the fuel tank cap securely. Wipe up any gasoline that may have spilled.
Check Before Operating Check the Cooling System 1 Check Radiator Coolant 2 The cooling system is filled with a 50/50 solution of water and permanent ethylene glycol anti–freeze. Check the level of coolant at the beginning of each day before starting the engine. 3 POTENTIAL HAZARD • Coolant is hot and pressurized. WHAT CAN HAPPEN • Discharge of hot pressurized coolant can cause severe burns. 4 m–3423 Figure 6 1. Reserve tank cap 2. Reserve tank 3. Maximum level line (cold) 4.
Check Before Operating Check for Debris 1 IMPORTANT: Operating the engine with a blocked grass screen and/or cooling shrouds removed, will result in engine damage from overheating. 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 ignition key. 2. Check for debris on the (3) air intake screens (Fig. 7).
Check Before Operating 6. The rear transaxle cover is an air intake area for cooling the transaxle. Clean debris from the rear transaxle cover before operating the tractor (Fig. 10). 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 18. Check the Brake Refer to Checking and Adjusting the Brake, page 38. 1 m–3436 Figure 10 1.
Operation Think Safety First “Key Choice” Key Please carefully read all the safety instructions on pages 2–7. Knowing this information could help you, your family, pets or bystanders avoid injury. A turn and release key used for deactivating the “Operating–In–Reverse” interlock feature. Located on the seat bracket in front of and just below the seat (Fig. 12). Controls Become familiar with all the controls (Fig. 11) before you start the engine and operate the machine.
Operation Releasing the Parking Brake 1. Push down on the brake pedal (Fig. 11). The parking brake lever should release. 2. Release the brake pedal. Note: Starting and Stopping the Engine Allowing the engine to warm up before putting it under load will lengthen engine life. 2 Starting 1 1. Sit down on the seat. 3 2. Depress the brake pedal. m–3257 Note: 3. 4. The engine will not start unless you fully depress the brake pedal. 1. Throttle 2. Choke 3.
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 Before deactivating this feature, be sure 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 feature because the sound of the tractor’s engine might prevent you from being aware that a child or a bystander has entered the area where you are operating the tractor.
Operation 1 m–3330 3. Fully depress the brake pedal and set the parking brake. Push the PTO switch to OFF and rise from the seat. Now turn the ignition key to START. The starter should not crank. 4. Fully depress the brake pedal and set the parking brake. Push the power take–off (PTO) switch to OFF. Now start the engine. While the engine is running, release the parking brake and rise slightly from the seat; the engine should stop. 5.
Operation Gauges and Indicator Lights The indicator lights (Fig. 18) illuminate when certain controls are activated and when major malfunctions occur that need immediate attention. 1 2 3 4 8 5 6 9 Figure 18 Parking brake light PTO (power take off) light Battery light Operating–in–Reverse warning light 5. Oil pressure light Operating–in–Reverse Warning Light The Operating–in–Reverse warning light will illuminate whenever the “Key Choice” key is used to deactivate the operating–in–reverse interlock.
Operation Engine Water Temperature Gauge This gauge shows the water temperature in the engine. If the gauge enters the red zone, disengage the PTO and allow the engine to cool while continuing to run the engine. POTENTIAL HAZARD • Excessive speed on slopes can result in rollover accidents or loss of control. WHAT CAN HAPPEN • Rollover accidents or loss of control can result in serious injury or death.
Operation Re–centering the Steering Wheel 2 1 The power steering will not always return the steering wheel to the centered position. When this happens, the steering wheel will appear to be un–centered when the front wheels return to the straight–ahead position. 3 4 m–3258 Figure 19 1. Traction control pedal 2. Brake pedal 3. Forward 4.
Operation Attachment Power Lift Lowering Attachments The attachment power lift (Fig. 20) is used to raise and lower attachments. 1. Start the tractor. 2. Push the lift lever DOWN to lower the attachment (Fig. 21). 1 1 2 Figure 21 m–3258 1. Lift lever–Up 2. Lift lever–Down Figure 20 1. Attachment power lift Positioning the Seat Raising Attachments 1. Start the tractor. 2. Pull the lift lever UP to raise the attachment (Fig. 21). This will lift and hold the attachment in the raised position.
Operation Headlights and Taillights 2 1 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 ignition key when leaving the machine unattended so that the headlights cannot be turned on and discharge the battery. m–3259 Figure 24 1. Tilt lever 2. Steering wheel 1 Using the Cruise Control m–3312 Figure 23 1. Lights The cruise control is a switch (Fig.
Operation 2. The cruise control has a “speed–up” feature: If you initially set it to any speed other than full speed, you can speed up with your foot on the traction pedal for as long as you wish. When you release the traction pedal, the pre–selected cruise speed resumes automatically. POTENTIAL HAZARD • Excessive speed when turning can result in rollover accidents. WHAT CAN HAPPEN • Rollover accidents can result in serious injury or death. Disengaging the Cruise Control 1.
Maintenance Service Interval Chart Service Operation Each Use 5 Hours 25 Hours 50 Hours 100 Hours 200 Hours Storage Service Engine Oil—check level X X Engine Coolant—check level X X Radiator Screen—check for debris* X X Brake—check X X Safety System—check X X (3) Air Intake Screens—clean* X X Engine Area—clean* X X Rear Transaxle Cover—clean* X X Engine Oil—change Initial X X Engine Air Precleaner—clean* X X Tires—check pressure X X Battery—check electrolyte level
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 Cleaning the Paper Element 1 1. Clean the paper element by tapping it gently on a flat surface to remove dust. 2. Inspect the element for tears, an oily film, and damage. If the element is very dirty or damaged, replace it with a new one. IMPORTANT: Never clean the paper element with pressurized air or liquids, such as solvent, gas, or kerosene. Replace the element if it is damaged or cannot be cleaned thoroughly. 2 m–3426 Figure 27 1. Foam element 5. 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, 1.9 qts. (1.
Maintenance Changing the Engine Oil Filter Service Interval/Specification Replace the oil filter after every 200 hours or every other oil change. 1. Drain the oil from the engine; refer to Changing/Draining Oil, page 32. 2. Place a drip pan beneath the oil drip tray to receive oil from the oil filter and oil passages in the engine. 3. Turn the filter counterclockwise to remove it. 4. Install the new filter. Turn the filter until the seal contacts the mounting surface of the engine.
Maintenance Changing the Engine Coolant POTENTIAL HAZARD • Coolant is hot and pressurized. WHAT CAN HAPPEN • Discharge of hot pressurized coolant can cause severe burns. 3. Open the coolant drain at the bottom of the radiator and allow coolant to flow into a drain pan. When coolant stops flowing, close the drain. 4. Remove the coolant plug from the engine and allow coolant to flow into the drain pan. When coolant stops flowing, install the drain plug. 5.
Maintenance Removing the Spark Plugs Checking the Spark Plugs 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 ignition key. 1. 2. Open the hood. 3. Pull the wire(s) off the spark plug(s) (Fig. 33). Now clean around the spark plug(s) to prevent dirt from falling into the engine and potentially causing damage. 4. Remove the spark plug(s) and metal washer.
Maintenance 3. Push the wire(s) onto the spark plug(s) (Fig. 33). 4. Close the hood. Greasing and Lubrication Service Interval/Specification Grease the machine after every 50 operating hours or yearly, whichever occurs first. Grease more frequently when operating conditions are extremely dusty or sandy. Grease Type: General-purpose grease. How to Grease 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.
Maintenance POTENTIAL HAZARD • Rotating shaft or cooling fan can cause injury. WHAT CAN HAPPEN • Fingers, hands, feet, hair, etc. can get caught by shaft or fan. • Loose clothing can get caught by shaft. m–3420 HOW TO AVOID THE HAZARD Figure 38 • Do not operate the tractor without the drive shaft cover in place. • Keep hands and arms clear of rotating Tire Pressure shaft or fan. Service Interval/Specification 4. Lubricate the three grease fittings (Fig. 37).
Maintenance Brake 2” 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. 2. 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 ignition key.
Maintenance Fuel Tank Draining The Fuel Tank 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. 1 m–3263 Figure 42 1. Fuel shut-off valve HOW TO AVOID THE HAZARD • Drain gasoline from the fuel tank when the engine is cold. Do this outdoors in an open area. Wipe up any gasoline that spills.
Maintenance 5. Install the fuel line onto the fuel shut-off valve. Slide the hose clamp close to the valve to secure the fuel line (Fig. 43). The fuel shut–off valve should normally be left open, except for service on the fuel system or when the tractor is transported on a trailer. Fuel Filter Service Interval/Specification Replace fuel filter after every 100 operating hours. Replacing the Fuel Filter 1.
Maintenance Front Wheel Toe-In Service Interval/Specification Maintaining correct front wheel toe–in is important for safety, Automatic Speed Reduction 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. 45). m–3421 Maintain the following specification: 1/8–1/4 inch (3.5–6.5 mm) toe-in on the front wheels. Figure 45 Measuring Toe-in 1.
Maintenance 1 2 2 1 m–3583 m–3260 Figure 47 View from front of tractor looking at end of tie rod 1. This 4. Figure 48 1. Transmission dipstick and filler tube 2. Not this Recheck the toe–in; refer to Measuring Toe–In, page 41. 5. Pull out the transmission dipstick and wipe the metal end clean (Fig. 48). 6. Slide the dipstick fully into the filler tube (Fig. 5). Pull the dipstick out and look at the metal end.
Maintenance Changing Transaxle Oil 5. Change the transaxle filter; refer to Changing the Transaxle Filter, page 43. Replace the transaxle fluid at 50 hours initially, then every 200 hours thereafter. 6. Slowly pour the specified refill capacity of oil into the filler tube (Fig. 48). Fluid Type: SAE 10W–30 Detergent oil (API service SG, SH or above) 7. Start the engine, let it run for 30 seconds at high idle, and cycle the steering wheel several times to fill the filter and hydraulic lines.
Maintenance 4. 5. 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. 51). Headlights Fill the transaxle with the proper type of new oil; refer to Changing/Draining Transaxle Fluid, page 43. Removing the Bulb Specification: Bulb # 1156 Automotive Type 1.
Maintenance Taillights Installing the Bulb 1. The bulb has metal pins on the side of its base. Align the pins with the slots in the bulb holder and insert the base into the holder (Fig. 54). Push and rotate the bulb clockwise until it stops. 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 ignition key. 2. Remove the two screws. 3.
Maintenance Battery Service Interval/Specification Check the electrolyte level in the battery every 25 hours. Always keep the battery clean and fully charged. Use a paper towel to clean the battery case. 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. 3. Remove the battery shield. 4. Open the cell covers to see into the cells.
Maintenance 3. Slowly pour distilled water into each battery cell until the level is up to the lower part of the tube (Fig. 57). IMPORTANT: Do not overfill the battery because electrolyte (sulfuric acid) can cause severe corrosion and damage to the chassis. 4. Press the cell covers onto the battery. 5. Replace the battery shield. IMPORTANT: Keep the battery shield in place to protect the battery from heat. 6. Replace the grille. Removing the Battery 1.
Maintenance 5. 6 1 4 Replace the front grille of the tractor, securing it with the two previously removed screws and washers (Fig. 56). 3 5 2 Charging the Battery 8 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 47. 2.
Maintenance Wiring Diagram HEADLIGHT HARNESS REAR HARNESS BK OR BK OR TAIL LIGHTS Y E Y 5 BN D BN (MOMENTARY) SW7 Y VIO (CRUISE DISENGAGE SWITCH) SWITCH OPENS WHEN BRAKE IS DEPRESSED CRUISE SWITCH OPERATION Cruise Module 1 VIO PK BU W C2 47uF 2 BU BU BK BN 1 2 4 PK CLUTCH NMIR MODULE 1 BK CRUISE #194 LAMP PTO VIO #194 LAMP W J PARK W #194 LAMP BU H BU A PK BATTERY OVERRIDE #194 LAMP #194 LAMP PK GN GN OR K OR TEMP.
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 S R B R KAWASAKI 4 3 1 2 S B 5 I OR OR PK L IGNITION SWITCH TERMINAL LOCATIONS VEIWED FROM BACK.
Maintenance Cleaning and Storage 1. 2. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to “STOP” to stop the engine. Remove both the ignition and “Key Choice” keys. 3. Check the brake; refer to Brake, page 37. 4. Service the air cleaner; refer to Air Cleaner, page 30. 5. Grease the chassis; refer to Greasing and Lubrication, page 36. 6. Change the crankcase oil; refer to Engine Oil, page 32.
Troubleshooting PROBLEM The starter does not crank. The engine cranks, but will not start. 52 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 the 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. 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 g overheats. POSSIBLE CAUSES CORRECTIVE ACTION 1. More coolant is needed. 1. Check and add coolant. 2. (3) air intake screens are dirty. 2. Clean with every use. 3. Restricted air flow into the engine. 3. Inspect and clean the radiator screen with every use. 4. Radiator fins are dirty. 4. Clean the radiator fins. 5. The crankcase oil level is incorrect. 5. Fill or drain to the full mark. 6. The fuel mixture is lean. 6.
Troubleshooting PROBLEM The tractor will not operate in either direction. e t e d ect o 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. Fill to the full “F” mark on the transmission oil dipstick when the transmission is cold. 3. The transmission is faulty. 3. Contact your Authorized Service Dealer. 4. The control linkage needs adjustment or replacement. 4.
Troubleshooting PROBLEM Abnormal vibration or noise. PTO (cutter deck) belt comes off of pulleys, slips, or fails. 56 POSSIBLE CAUSES CORRECTIVE ACTION 1. The engine mounting bolts are loose. 1. Tighten the engine mounting bolts. 2. The idler pulley or cutter deck blade is loose. 2. Tighten the appropriate pulley. 3. The transaxle cooling fan is loose. 3. Contact your Authorized Service Dealer. 4. There is a problem with the electric clutch 4. Contact your Authorized Service Dealer. 1.
