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Service Manual
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.
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Table of Contents
Related Manuals for Toro 73541
Summary of Contents for Toro 73541
- Page 1 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...
- Page 2 Read this manual carefully to learn how to operate and maintain your product correctly. Reading this All of us at Toro want you to be completely satisfied manual will help you and others avoid personal injury with your new product, so feel free to contact your and damage to the product.
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Page 3: Table Of Contents
Contents Page Page Positioning the Seat ....Safety ....... . . Headlights and Taillights . -
Page 4: Safety
Safety This machine meets or exceeds the B71.1–1996 General Operation specifications of the American National Standards Read, understand, and follow all instructions in Institute, in effect at the time of production. the operator’s manual and on the machine before However, improper use or maintenance by the starting. -
Page 5: Slope Operation
Safety 13. Mow only in daylight or good artificial light. Keep all movement on slopes slow and gradual. Do not make sudden changes in speed or 14. Do not operate the machine while under the direction. influence of alcohol or drugs. Avoid starting or stopping on a slope. - Page 6 Safety Children Keep nuts and bolts tight, especially the blade attachment bolts. Keep equipment in good Tragic accidents can occur if the operator is not alert condition. to the presence of children. Children are often Never tamper with safety devices. Check safety attracted to the machine and the mowing activity.
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Page 7: Slope Chart
Safety Slope Chart Read all safety instructions on pages 2–4. -
Page 9: Safety And Instruction Decals
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 DRIVE SHAFT TUNNEL ON ENGINE BULKHEAD ON BATTERY STRAP (2) UNDER SIDE SHIELD... -
Page 10: Check Before Operating
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 m–3584 Figure 1 The safety interlock system 1. -
Page 11: Closing The Hood
Check Before Operating Closing the Hood Lift up on the prop rod as you begin to lower the hood (Fig. 2). Push the hood down until the latch closes. m–3438 Figure 2 m–3318 1. Prop rod Figure 3 1. Side panel latch 2. -
Page 12: Adding Fuel
Check Before Operating Adding Fuel Filling the Fuel Tank Park the machine on a level surface, disengage Use UNLEADED Regular Gasoline suitable for the power take off (PTO), set the parking brake, automotive use (85 pump octane minimum). Leaded lower the attachment lift, and turn the ignition regular gasoline may be used if unleaded regular is key to “STOP”... -
Page 13: Check The Engine Oil Level
Check Before Operating Check the Engine Oil Level 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. -
Page 14: Check For Debris
Check Before Operating Check for Debris IMPORTANT: Operating the engine with a POTENTIAL HAZARD blocked grass screen, dirty or plugged cooling Rotating air intake screen and drive shaft fins, and/or cooling shrouds removed, will can cause injury. result in engine damage from overheating. WHAT CAN HAPPEN Park the machine on a level surface, disengage Fingers, hands or loose clothing can get... -
Page 15: Check The Safety Interlock System
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. -
Page 16: Operation
Operation Think Safety First Parking Brake Please carefully read all the safety instructions on Always set the parking brake when you stop the pages 2–7. Knowing this information could help you, machine or leave it unattended. your family, pets or bystanders avoid injury. Setting the Parking Brake Controls Push the brake pedal (Fig. -
Page 17: Starting And Stopping The Engine
Operation Starting and Stopping the Engine Starting Sit down on the seat. Depress the brake pedal. Note: The engine will not start unless you fully depress the brake pedal. m–3257 Figure 11 Push the PTO (power take off) switch to OFF 1. -
Page 18: Operating The Power Take Off (Pto)
Operation Operating the The Safety Interlock System Power Take Off (PTO) Understanding the Safety Interlock System The power take–off (PTO) switch engages and disengages power to the electric clutch. The safety interlock system is designed to prevent the engine from starting unless: If the ignition key is in the RUN or LIGHTS position and the power take off (PTO) is engaged, the PTO You are sitting on the seat... -
Page 19: Gauges And Indicator Lights
Operation Fully depress the brake pedal and set the parking Battery Light brake. Push the PTO switch to OFF and start the The battery light will be ON when the key is in the engine. Pull the PTO switch to ON. Rise RUN or LIGHTS positions if the battery voltage is slightly from the seat;... -
Page 20: Driving Forward Or Backward
Operation Hour Meter Place your foot on the traction control pedal and slowly press on the top of the pedal to move The hour meter (Fig. 10) records the amount of time forward, or on the bottom of the pedal to move the engine has run. -
Page 21: Stopping The Machine
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;... -
Page 22: Lowering Attachments
Operation Lowering Attachments Headlights and Taillights Start the tractor. The headlights and taillights are turned on by turning the ignition key to the LIGHTS position. They can Push the lift lever DOWN to lower the be turned on even if the engine is not running. attachment (Fig. -
Page 23: Positioning The Tilt Steering Wheel
Operation Positioning the Tilt Steering Engaging the Cruise Control Wheel Begin driving the tractor; refer to Driving Forward or Backward, page 18. While holding your foot steady on the traction control pedal, The steering wheel has four tilt locations. Position the push the cruise control switch (Fig. -
Page 24: The Smart Turn Steering Feature
Operation The Smart Turn Steering Pushing the Machine by Hand Feature IMPORTANT: Always push the machine by hand. Never tow the machine because The Smart Turn Steering feature automatically transmission damage may occur. lowers the speed of the tractor in tight turns. The decrease in speed is directly proportional to the To Push the Machine sharpness of the turn, up to a maximum speed... -
Page 25: Maintenance
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. -
Page 26: Air Cleaner
Maintenance Air Cleaner Service Interval/Specification Foam Element: Clean and re-oil after every 25 operating hours, or yearly, whichever occurs first. Paper Element: Replace after every 100 operating hours or yearly, whichever occurs first. Note: Service the air cleaner more frequently (every few hours) if operating conditions are extremely dusty or sandy. - Page 27 Maintenance Cleaning the Foam Element Wash the foam element in liquid soap and warm water. When the element is clean, rinse it thoroughly. Dry the element by squeezing it in a clean cloth. Put one or two ounces of oil on the element (Fig. 23).
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Page 28: Engine Oil
Maintenance Engine Oil Service Interval/Specification POTENTIAL HAZARD Components under the hood will be hot if Change oil: the tractor has been running. After the first 5 operating hours. WHAT CAN HAPPEN Touching hot components can cause burns. After every 100 operating hours. HOW TO AVOID THE HAZARD Oil Type: Detergent oil (API service SG or SH) Allow the tractor to cool before performing... -
Page 29: Spark Plugs
Maintenance Changing the Engine Oil Filter Spark Plugs Service Interval/Specification Service Interval/Specification Replace the oil filter every 200 hours of operation or Change the spark plugs after every 200 operating every other oil change. hours. Make sure the air gap between the center and side electrodes is correct before installing the spark Drain the oil from the engine;... -
Page 30: Greasing And Lubrication
Maintenance Checking the Spark Plugs Greasing and Lubrication Look at the center of the spark plug(s) (Fig. 28). Service Interval/Specification If you see light brown or gray on the insulator, the engine is operating properly. A black coating Grease the machine after every 50 operating hours or on the insulator usually means the air cleaner is yearly, whichever occurs first. - Page 31 Maintenance 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 m–3422 Replace and secure the cover. Figure 30 1.
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Page 32: Tire Pressure
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 Park the machine on a level surface, disengage the power take off (PTO), put the High–Low range lever in “N,”... -
Page 33: Fuel Tank
Maintenance Turn the brake adjustment nut (Fig. 36) until Fuel Tank there is 2” (51 mm) of free travel. 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. -
Page 34: Fuel Filter
Maintenance Fuel Filter Service Interval/Specification Replace the fuel filter after every 100 operating hours. Replacing the Fuel Filter Disengage the power take off (PTO), set the m–2487 parking brake, lower the attachment lift, and turn Figure 38 the ignition key to “STOP” to stop the engine. Remove the key. -
Page 35: Front Wheel Toe-In
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. -
Page 36: Transaxle Fluid
Maintenance Recheck the toe–in; refer to Measuring Toe–In, If the oil level is low, slowly pour only enough page 33. SAE 10W–30 detergent oil into the filler tube to raise the level to the FULL line. IMPORTANT: Do not fill above the FULL Transaxle Fluid line as fluid may overflow. - Page 37 Maintenance Changing the Transaxle Filter Service Interval/Specification Replace the transaxle filter after the first 50 hours; then every 200 hours. Drain the oil from the transaxle; refer to Changing/Draining Transaxle Fluid, page 34. Remove the transaxle filter and wipe the filter adapter (Fig.
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Page 38: Fuses
Maintenance Fuses Service Interval/Specification 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. -
Page 39: Taillights
Maintenance Taillights Installing the Bulb Reverse the bulb removal procedure. Bulb: GE 194 Removing the Bulb 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. -
Page 40: Battery
Maintenance Battery 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 Service Interval/Specification below the plates. Check the electrolyte level in the battery every 25 If the electrolyte is low, add the required amount hours. - Page 41 Maintenance Adding Water to the Battery Removing the Battery IMPORTANT: Use only distilled water. Disengage the power take off (PTO), set the parking brake, lower the attachment lift, and turn The best time to add distilled water to the battery is the ignition key to “STOP”...
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Page 42: Installing The Battery
Maintenance Installing the Battery Place the battery onto the chassis (Fig. 53). POTENTIAL HAZARD Secure the battery shield to the chassis with The battery terminals could short against hold–down rods. the metal tractor components. WHAT CAN HAPPEN Using the bolt and wing nut, connect the positive Sparks can cause the battery gasses to (red) cable to the positive (+) battery post explode. - Page 43 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). Remove the battery from the chassis; refer to Removing the Battery, page 39. Check the electrolyte level;...
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Page 44: Wiring Diagram
Maintenance Wiring Diagram... - Page 45 Maintenance Wiring Diagram...
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Page 46: Cleaning And Storage
Maintenance Cleaning and Storage fully charged battery maintains its charge for about 50 days at temperatures lower than 40 F (4 C). If the temperatures will be above Disengage the power take off (PTO), set the 40 F (4 C), check the water level in the parking brake, and turn the ignition key to battery and charge it every 30 days. -
Page 47: Troubleshooting
Troubleshooting PROBLEM POSSIBLE CAUSES CORRECTIVE ACTION The starter does not crank. The PTO is ON. Move the PTO to OFF. The brake is not depressed or Set the parking brake. the parking brake is not on. The operator is not seated. Sit on the seat. - Page 48 Troubleshooting PROBLEM POSSIBLE CAUSES CORRECTIVE ACTION The engine starts, but does not Misadjusted or faulty choke or Contact your Authorized keep running eep u throttle control cable. Service Dealer. The fuel tank vent is Contact your Authorized restricted. Service Dealer. Dirt or water in the fuel Drain and flush the fuel system.
- Page 49 Troubleshooting PROBLEM POSSIBLE CAUSES CORRECTIVE ACTION The engine overheats. The crankcase oil level is Fill or drain to the full mark. incorrect. The fuel mixture is lean. Contact your Authorized Service Dealer. Excessive loading. Reduce load; use lower ground speed. (3) air intake screens are Clean with every use.
- Page 50 Troubleshooting PROBLEM POSSIBLE CAUSES CORRECTIVE ACTION The tractor will not operate in The High–Low range lever is Move the High–Low range either direction. e t e d ect o in “N.” lever to “L” or “H.” The transmission oil is low. Fill to the full “F”...
- Page 51 Rev. 7/21/97...