FORM NO. 3319–218GB Wheel Horse 520Lxi Tractor Model No. 73546 – 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 . . . . . . . . . . . . . . Sound Pressure Level . . . . . . . . . . . . . . . . . Sound Power Level . . . . . . . . . . . . . . . . . . Vibration Level . . . . . . . . . . . . . . . . . . . . . Slope Chart . . . . . . . . . . . . . . . . . . . . . . . . . Safety and Instruction Decals . . . . . . . . . . Check Before Operating . . . . . . . . . . . . . . . . . . Opening the Hood . . . . . . . . . . .
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 14. Do not operate the machine while under the influence of alcohol or drugs. 15. Watch for traffic when operating near or crossing roadways. • Keep all movement on slopes slow and gradual. Do not make sudden changes in speed or direction. • Avoid starting or stopping on a slope. If tires lose traction, disengage the blades and proceed slowly straight down the slope. 16. Use extra care when loading or unloading the machine onto a trailer or truck. DO NOT 17.
Safety 4. Never carry children. They may fall off and be seriously injured or interfere with safe machine operation. 5. Never allow children to operate the machine. 6. Use extra care when approaching blind corners, shrubs, trees, the end of a fence or other objects that may obscure vision. Service 1. 2. Stop the engine and disconnect spark plug wire(s) before performing any service, repairs, maintenance or adjustments. Use extra care when handling gasoline and other fuels.
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 RADIATOR FAN SHROUD (Part No.95–4143) (1) ON DRIVESHAFT TUNNEL (2) UNDER SIDE SHIELD (Part No.
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 Opening the Hood To open the hood: 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
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 Filling the Fuel Tank 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. Clean around the fuel tank cap and remove the cap. Use a funnel and add unleaded regular gasoline to the fuel tank, until the level is 1/4 to 1/2 inch (6 mm to 13 mm) below the bottom of the filler neck.
Check Before Operating IMPORTANT: Do not overfill the crankcase with oil because this may result in engine damage. Check the Cooling System Check Radiator Coolant 1 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. 2 POTENTIAL HAZARD • Coolant is hot and pressurized. WHAT CAN HAPPEN • Discharge of hot pressurized coolant can cause severe burns.
Check Before Operating 1 1 ÎÎÎ ÎÎÎ ÎÎÎ 2 3 m–3412 Figure 7 Curved arrows show air intake and exhaust path 4 m–3423 1. Air intake screens (2 of 3 shown) Figure 6 1. Reserve tank cap 2. Reserve tank 3. Maximum level line (cold) 4. Minimum level line (cold) 4. If coolant is low, remove the reserve tank cap and add a 50/50 mixture of water and permanent ethylene glycol anti–freeze. DO NOT OVERFILL. 5. Install the reserve tank cap.
Check Before Operating IMPORTANT: It is preferable to blow dirt out (Fig. 9), rather than washing it out. If water is used, keep it away from electrical items. 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 32. m–3615 Figure 9 IMPORTANT: DO NOT HIGH–PRESSURE WASH.
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. 11) down and hold it in the depressed position. Become familiar with all the controls (Fig. 11) 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. 12). 4. Move the choke lever to ON (if the engine is cold) (Fig. 12). 5. Move the throttle lever halfway to FAST (Fig. 12). 6. Turn the ignition key clockwise and hold it in the START position (Fig. 13). When the engine starts, release the key.
Operation Operating the Power Take Off (PTO) Check the Safety Interlock System The power take–off (PTO) switch engages and disengages power to the electric clutch. Understanding the Safety Interlock System 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, 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. 15) illuminate when certain controls are activated and when major malfunctions occur that need immediate attention.
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 Stopping the Machine 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. Re–centering the Steering Wheel The power steering will not always return the steering wheel to the centered position.
Operation Attachment Power Lift Lowering Attachments The attachment power lift (Fig. 17) is used to raise and lower attachments. 1. Start the tractor. 2. Push the lift lever DOWN to lower the attachment (Fig. 18). 1 1 2 Figure 18 m–3258 1. Lift lever–Up 2. Lift lever–Down Figure 17 1. Attachment power lift Positioning the Seat Raising Attachments 1. Start the tractor. 2. Pull the lift lever UP to raise the attachment (Fig. 18). This will lift and hold the attachment in the raised position.
Operation Headlights and Taillights Using the Cruise Control 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. The cruise control is a switch (Fig. 22) on the right fender that maintains a set traction control position without foot pressure.
Operation Disengaging the Cruise Control 1. While holding your foot steady on the traction control, move the cruise control switch (Fig. 11) to the “OFF” position. 2. This unlocks the traction control. You must now use the traction control to move forward. 3. For quick stops, just press the brake pedal. This automatically disengages the cruise control and applies the brake at the same time. POTENTIAL HAZARD • Excessive speed when turning can result in rollover accidents.
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, defective, or cannot be cleaned thoroughly. 2 m–3426 Figure 24 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 26. 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 Spark Plugs Checking the Spark Plugs 1. Service Interval/Specification Look at the center of the spark plug(s) (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. Check the spark plugs and reset the air gap as necessary. Replace the spark plugs after every 100 operating hours.
Maintenance 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. m–3240 Figure 32 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. Remove the key. 2. Clean the grease fittings with a cloth.
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 35 • Do not operate the tractor without the drive shaft cover in place. • Keep hands and arms clear of rotating Tire Pressure shaft or fan. 4. Service Interval/Specification Lubricate the three grease fittings (Fig. 34).
Maintenance Brake 4. Turn the brake adjustment nut (Fig. 38) until there is 2” (51 mm) of free travel. 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. 1 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.
Maintenance Fuel Tank Draining The Fuel Tank 3 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 2 1 m–2487 Figure 40 1. Hose clamp 2. Fuel line 3. Fuel shut-off valve • 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 Fuel Filter Front Wheel Toe-In Service Interval/Specification Service Interval/Specification Replace the fuel filter after every 100 operating hours. 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. 42). Replacing the Fuel Filter 1.
Maintenance Transaxle Fluid Service Interval/Specification 1 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. Fluid Type: SAE 10W–30 Detergent oil (API service SG, SH or above) 2 1 m–3397 Checking the Fluid Level Figure 43 1. Jam nut 2. Steering rod Adjusting Toe-In 1. Loosen the jam nuts at the ends of the steering rods (Fig. 43). 2.
Maintenance 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. 2 1 1 m–3322 Figure 47 m–2467 1. Transaxle drain plug Figure 46 1. Operating range 2. FULL line 5. Change the transaxle filter; refer to Changing the Transaxle Filter, page 37. 6. Slowly pour the specified refill capacity of oil into the filler tube (Fig. 45). 7.
Maintenance Fuse Changing the Transaxle Filter Service Interval/Specification Service Interval/Specification Replace the transaxle filter after the first 50 hours; then every 200 hours. 1. Drain the oil from the transaxle; refer to Changing/Draining Transaxle Fluid, page 36. 2. Remove the transaxle filter and wipe the filter adapter (Fig. 48) gasket surface. 3. Apply a thin coat of new oil to the rubber gasket on the replacement filter (Fig. 48). The electrical system is protected by fuses.
Maintenance Headlights Installing the Bulb Specification: Bulb # 1156 Automotive Type 1. 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. Open the hood. Pull the wire connectors off both bulb holder terminals. 3. Rotate the bulb holder 1/4 turn counterclockwise and remove it from the reflector (Fig. 50). 4.
Maintenance Taillights Battery Bulb: GE 194 Service Interval/Specification Removing the Bulb 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. 1.
Maintenance 4. 5. 6. Open the cell covers to see into the cells. The electrolyte must be up to the lower part of the tube (Fig. 54). Do not allow the electrolyte to get below the plates. If the electrolyte is low, add the required amount of distilled water; refer to Adding Water to the Battery. If the fluid level is correct, press the cell covers onto the battery and replace the battery shield. IMPORTANT: Keep the battery shield in place to protect the battery from heat. 7.
Maintenance 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. 53). Close the hood and remove the grill by pulling it out toward you. 3. Remove the battery shield (Fig. 55). 4.
Maintenance Installing the Battery 1. Place the battery onto the chassis (Fig. 55). 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. 55). 4. Using the bolt and wing nut, connect the negative (black) cable to the negative (–) battery post (Fig. 55). 5. Replace the battery shield. Charging the Battery IMPORTANT: Always keep the battery fully charged (1.260 specific gravity).
Maintenance 43
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 2 5 6 VIO P P CRUISE MAGNET SWITCH OPENS WHEN BRAKE IS DEPRESSED W (MOMENTARY) VIO SW3 (PTO SWITCH) 5 AND 6 CONNECTED 5 OFF NO CONNECTION ON 3 AND 2 CONNECTED MOMENTARY 3 AND 2 CONNECTED P 2 CRUISE SWITCH OPERATION CRUISE MODULE C 7 3 SW7 (CRUISE DISENGAGE SWITCH) 8 4 SW8 1 CRUISE SWITCH OR PTO SWITCH IS SHOWN IN OFF POSITION Y A BK BN
Maintenance Wiring Diagram SW4 (IGNITION SWITCH) WIRE COLOR CODES OFF-----------NO CONNECTION RUN/LIGHTS----------B I R L RUN---------------B I R START--------------B I R S L I 4 3 P F3 F4 1 BN R S B 2 5 VIO R BK BLACK P PINK BN BROWN R RED TAN R B BU BLUE T I L GN GREEN VIO VIOLET GY GREY W WHITE OR ORANGE Y YELLOW IGNITION SWITCH TERMINAL LOCATIONS VEIWED FROM BACK. 10A OR OR S 10A ENGINE HARNESS R P #1 CYL.
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 the fuse. 6.
Troubleshooting PROBLEM The engine starts, but does not keep running The engine runs, but knocks or misses. The engine will not idle. 48 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. 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. The crankcase oil level is incorrect. 4. Fill or drain to the full mark. 5. The fuel mixture is lean. 5. Contact your Authorized Service Dealer. 6. Excessive loading. 6.
Troubleshooting PROBLEM The tractor will not operate in either direction. 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. Contact your Authorized Service Dealer.
Troubleshooting PROBLEM Abnormal vibration or noise. 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.
Consumer Riding Products THE TORO TOTAL COVERAGE GUARANTEE A Full TwoĆYear Warranty (Limited Warranty For Commercial Use) What Is Covered By This Express Warranty? 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
