Toro 73547 Wheel Horse 520Lxi Operator'S Manual Download Page 52

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Maintenance

Wiring Diagram

BRAKE SWITCH CLOSES WHEN

BRAKE IS DEPRESSED

SEAT SWITCH IS CLOSED

WHEN OPERATOR IS IN

THE SEAT

(SEAT SWITCH)

SW1

(BRAKE SWITCH)

SW2

(INTERLOCK RELAY)

HOUR

METER

KAWASAKI

10A

ORANGE

BLACK
BROWN
BLUE
GREEN

WIRE COLOR CODES

GREY

VIO

10A

BK
BN
BU
GN
GY
OR

R
T
VIO
W

OFF-----------NO CONNECTION

RUN/LIGHTS----------B I R L

RUN---------------B I R

START--------------B I R S

(IGNITION SWITCH)

SW4

IGNITION SWITCH TERMINAL

LOCATIONS VEIWED FROM BACK.

ORBN VIO

YELLOW

PINK
RED
TAN
VIOLET
WHITE

#1 CYL.

ENGINE HARNESS

IGNITION COILS

WATER TEMP. SENDER

R
Y/W
BU/R

SOLINOID

SHIFT

STARTER

FUEL

SOLINIOD

#2 CYL.

PULSER COILS

OIL PRESSURE SWITCH

(SWITCH OPENS WITH OIL PRESSURE)

#2 CYL.

CHARGING

COIL

FLYWHEEL

#1 CYL.

IGNITER

MODULE

GND

VOLTAGE REGULATOR

REG. DC

CHARGE LAMP

B+

GND

FUEL PUMP

VIO

30A

NOTE: WIRE COLORS CHANGE

AT THE ENGINE CONNECTOR.

25A

VIO

(START RELAY)

Summary of Contents for 73547 Wheel Horse 520Lxi

Page 1: ...y 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 International English GB FORM NO 3321 980 Wheel Horse 520Lxi Tractor Model No 73580 9900001 UP ...

Page 2: ...mage to the product Although we design produce and market safe state of the art products you are responsible for using the product properly and safely You are also responsible for training persons you allow to use the product about safe operation The warning system in this manual identifies potential hazards and has special safety messages that help you and others avoid personal injury even death ...

Page 3: ...g and Stopping the Engine 19 Operating the Power Take Off PTO 20 The Safety Interlock System 20 Operating in Reverse 20 Gauges and Indicator Lights 23 Driving Forward or Backward 24 Stopping the Machine 25 Page Re centering the Steering Wheel 25 Attachment Power Lift 26 Positioning the Seat 26 Headlights and Taillights 27 Positioning the Tilt Steering Wheel 27 Using the Cruise Control 27 The Smart...

Page 4: ...ator or user is responsible for accidents or hazards occurring to other people or their property 5 Do not carry passengers 6 All drivers should seek and obtain professional and practical instruction Such instruction should emphasize the need for care and concentration when working with ride on machines control of a ride on machine sliding on a slope will not be regained by the application of the b...

Page 5: ...5 Watch out for traffic when crossing or near roadways 6 Stop the blades before crossing surfaces other than grass 7 When using any attachments never direct discharge of material toward bystanders nor allow anyone near the machine while in operation 8 Never operate the lawnmower with damaged guards or without safety protective devices in place 9 Do not change the engine governor settings or oversp...

Page 6: ...the tank inside a building where fumes may reach an open flame or spark 3 Allow the engine to cool before storing in any enclosure 4 To reduce the fire hazard keep the engine silencer battery compartment and petrol storage area free of grass leaves or excessive grease 5 Check the grass catcher frequently for wear or deterioration 6 Replace worn or damaged parts for safety 7 If the fuel tank has to...

Page 7: ...Safety 5 Slope Chart Read all safety instructions on pages 2 10 ...

Page 8: ...6 ...

Page 9: ...located near any area of potential danger Replace any decal that is damaged or lost ON DRIVE SHAFT COVER Part No 98 1608 ON RADIATOR FAN SHROUD Part No 95 4143 ON BATTERY STRAP Part No 93 1265 1 ON DRIVESHAFT TUNNEL 2 UNDER SIDE SHIELD Part No 98 5015 ON SEAT BRACKET Part No 99 2986 ON SEAT BRACKET Part No 99 5340 ...

Page 10: ...afe distance from the machine Machine rollover Machine rollover Machine rollover side hill up hill down hill Stay a safe distance from the mower Machine rollover Safety alert symbol of blade as long as engine is running Keep deflector shield in place Consult Technical Manual for proper service procedures Safety alert symbol Keep children a safe distance from machine Severing toes or foot mower bla...

Page 11: ...a passenger seat only if the driver s view is not hindered Severing of hand Rotating knives Severing of foot Rotating knives Cutting or entanglement of foot Rotating auger Severing of fingers or hand impeller blade Stay a safe distance from the snowthrower Keep a safe distance from snowthrower Tractors must be equipped with 45kg rear wheel weight with this attachment installed Machine rollover ROP...

Page 12: ...lutch Engage Disengage Brake system Parking brake On Run Battery charging conditin Off Stop Engine Head lights Main high beam Fuel Engine lubricating oil pressure PTO Power Take Off Unlock Lock Engine lubricating oil level Engine temperature Fuel level Volume empty Volume full Key Choice key ...

Page 13: ... 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 Slide a screwdriver into the right hand side of the slot shown in Figure 1 and push the hood latch to the left 3 Raise the hood to full height m 3584 1 Figure 1 1 Slot for hood latch access POTENTIAL HAZARD Compo...

Page 14: ...e a side panel A Lift up and twist each of the two side panel latches 90 or until they line up with the open slot Fig 3 B Pull the top of the side panel toward you until the side panel latches pass through the open slot C Lift the side panel from the tractor m 3318 1 2 Figure 3 1 Side panel latch 2 Open slot POTENTIAL HAZARD Rotating fan and drive shaft can cause injury WHAT CAN HAPPEN Fingers han...

Page 15: ... of children Never buy more than a 30 day supply of gasoline IMPORTANT Never use fuel additives containing methanol or ethanol POTENTIAL HAZARD When fueling under certain circumstances a static charge can develop igniting the gasoline WHAT CAN HAPPEN A fire or explosion from gasoline can burn you and others and cause property damage HOW TO AVOID THE HAZARD Always place gasoline containers on the g...

Page 16: ...g brake lower the attachment lift and turn the ignition key to STOP to stop the engine Remove the ignition key 2 Open the hood 3 Clean around the oil dipstick Fig 4 so dirt cannot fall into the dipstick hole and damage the engine 4 Pull out the oil dipstick and wipe the metal end clean Fig 5 5 Slide the oil dipstick fully into the tube Pull the dipstick out and look at the metal end If the oil lev...

Page 17: ...ways allow the engine to cool at least 15 minutes or until the radiator cap is cool enough to touch without burning your hand before removing the radiator cap 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 Open the hood 3 Check coolant level Coolant...

Page 18: ...own 3 The radiator screen Fig 8 is located between the radiator and the dash in the tractor To remove it pull it up from its retention slot Wipe or wash off all accumulated debris from the screen then reinstall it 4 In dry or dusty conditions dust can build up on the radiator fins and reduce cooling efficiency Remove the radiator screen and blow or low pressure wash the radiator cooling fins 1 m 3...

Page 19: ...e cover before operating the tractor Fig 10 1 m 3436 Figure 10 1 Rear transaxle cover 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 ...

Page 20: ...ition switch 11 Brake pedal 12 Parking brake lever 13 High Low range lever 14 Cruise control switch 15 Steering wheel tilt lever 16 Traction control pedal Key Choice Key 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 m 4260 1 Figure 12 1 Key Choice Key Parking Brake Always set the parkin...

Page 21: ...ay result If the engine fails to start after 5 seconds turn the key to the OFF position recheck the controls and procedures wait 10 additional seconds and repeat the starting operation refer to Troubleshooting page 52 7 After the engine starts gradually move the choke lever to OFF Fig 13 If the engine stalls or hesitates move the choke lever back to ON for a few seconds Then move the throttle leve...

Page 22: ...terlock System Understanding the Safety Interlock System The safety interlock system is designed to prevent the engine from starting unless You are sitting on the seat The brake pedal is depressed The power take off PTO is OFF The safety interlock system is designed to stop the engine if You rise from the seat when the brake pedal is released You rise from the seat when the power take off PTO is O...

Page 23: ... up and the console light stays on until either the blade PTO is disengaged or the engine is turned off Note Do not insert the Key Choice key unless it is absolutely necessary to mow in reverse or operate an attachment The Key Choice key should also be removed from the unit if it will be operated by someone other than a responsible experienced operator This will prevent the PTO from operating when...

Page 24: ...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 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 6 With the parking brake released turn the ignition ke...

Page 25: ... important to have your battery and electrical system checked and the problem corrected 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 It is a reminder that the interlock system is deactivated The light goes out whenever the power take off PTO is disengaged or the engine ...

Page 26: ...d with the High Low lever Fig 11 Use Low for best mowing performance and smoothest operation with all attachments Use High for transporting or where conditions permit higher speed 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 HOW TO AVOID THE HAZARD Never shi...

Page 27: ...oth the ignition and Key Choice keys and set the parking brake when leaving the machine unattended even if just for a few minutes Re centering the Steering Wheel 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 This is not a mechanical ...

Page 28: ...achment as it lowers HOW TO AVOID THE HAZARD Always lower the attachment lift each time you shut off the tractor Lowering Attachments 1 Start the tractor 2 Push the lift lever DOWN to lower the attachment Fig 21 1 2 Figure 21 1 Lift lever Up 2 Lift lever Down Positioning the Seat The seat can move forward and backward Position the seat where you have the best control of the machine and are most co...

Page 29: ...ock Fig 24 2 Move the steering wheel to a comfortable position then release the lever to lock it in place 1 2 m 3259 Figure 24 1 Tilt lever 2 Steering wheel Using the Cruise Control The cruise control is a switch Fig 25 on the right fender that maintains a set traction control position without foot pressure The cruise control only operates when moving forward m 3313 1 Figure 25 1 Cruise control En...

Page 30: ...ht 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 The Smart Turnt Steering feature does not affect engine speed This system was set at the factory and should no...

Page 31: ...gine Air Precleaner clean X X Tires check pressure X X Battery check electrolyte level X X Transaxle check oil level X Transaxle change oil Initial X X Transaxle change oil filter Initial X X Power Steering Filter clean Initial X X Lubrication X X PTO Power Take Off Belt check tension Initial X X Engine Air Filter replace X X Spark Plug s change X X Fuel Filter replace X X Fan Belt check X X Engin...

Page 32: ...g 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 Removing the Foam and Paper Elements 1 Disengage the power take off PTO set the parking brake lower the attachment lift and turn the ignition key to STOP to s...

Page 33: ... 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 m 3363 2 1 Figure 29 1 Paper element 2 Rubber seal...

Page 34: ...AL HAZARD Components under the hood will be hot if the tractor has been running 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 4 Place a pan below the oil drain Open the drain by turning it counterclockwise 1 8 turn and pulling out on it Fig 31 5 When the oil has drained c...

Page 35: ...y 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 Then turn the filter BY HAND 3 4 turn more 5 Remove the oil filler cap and refill the engine with a high quality API Service SG or SH engine oil see viscosity chart page 32 6 Run the e...

Page 36: ...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 Slowly fill the radiator with a 50 50 mixture of water and permanent ethylene glycol anti freeze Install the radiator cap 6 Slowly fill the reserve tank until the level reaches the upper line DO N...

Page 37: ... at the center of the spark plug s Fig 34 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 2 Check the gap between the center and side electrodes Fig 34 Bend ...

Page 38: ... stop the engine Remove the ignition key 2 Clean the grease fittings with a cloth Make sure to scrape off any paint from the front of the fitting s 3 Connect a grease gun to the fitting Pump grease into the fittings until grease begins to ooze out of the bearings 4 Wipe up any excess grease Where to Add Grease 1 Lubricate the left hand and right hand spindles until grease begins to ooze out of the...

Page 39: ... fan 4 Lubricate the three grease fittings Fig 37 m 3419 Figure 37 5 Replace and secure the cover 6 Grease the fitting on the brake pedal Fig 38 m 3420 Figure 38 Tire Pressure Service Interval Specification Maintain the air pressure in the front and rear tires as specified Check the pressure at the valve stem after every 25 operating hours or monthly whichever occurs first Fig 39 Check the tires w...

Page 40: ...justing the Brake Adjusting the Brake The brake adjustment is at the rear of the tractor Fig 41 If the parking brake does not hold securely an adjustment is required 1 Check the brake before you adjust it refer to Checking the Brake 2 Place the transmission in neutral 3 Depress the brake pedal There should be 2 51 mm of free travel Fig 40 before the brake begins to engage 2 m 3418 Figure 40 4 Turn...

Page 41: ... tank drains completely Then 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 Close the fuel shut off valve at the fuel tank Fig 42 43 m 3263 1 Figure 42 1 Fuel shut off valve 1 2 3 m 2487 Figure 43 1 Hose clamp 2 Fuel line 3 Fuel shut off valve 3 Loosen the hose clamp and slide it up the...

Page 42: ...2 Close the fuel shut off valve at the fuel tank Fig 42 43 Open the hood and remove the side panels 3 Remove the filter mounting bolt and remove the filter Fig 44 4 Squeeze the ends of the hose clamps together and slide away from the filter Fig 44 Remove the fuel lines from the filter 1 2 3 5 m 4309 3 4 6 Figure 44 1 Filter 2 Mounting bolt 3 Hose clamp 4 Fuel line from tank 5 Fuel line to engine f...

Page 43: ...rn the wheels straight ahead 3 Push the front of the tires out to remove normal looseness in the linkage 4 Measure the distance between both of the front tires at spindle level at the front and rear of the wheels Fig 45 5 The front measurement should be 1 8 to 1 4 3 to 6 mm less than the rear measurement If adjustment is needed follow the instructions in Adjusting Toe In page 41 m 3421 Figure 45 1...

Page 44: ...ion key to STOP to stop the engine Remove the ignition key 3 Tilt the seat up 4 Clean around the transmission dipstick Fig 48 so dirt cannot fall into the filler hole and damage the transaxle m 3260 1 Figure 48 1 Transmission dipstick and filler tube 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 ...

Page 45: ...ycling center m 3322 1 Figure 50 1 Transaxle drain plug 5 Change the transaxle filter refer to Changing the Transaxle Filter page 43 6 Slowly pour the specified refill capacity of oil into the filler tube Fig 48 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 Then shut off the engine 8 Now check the fluid l...

Page 46: ...heck the component and circuit for a malfunction or short To replace a fuse pull it out of the fuse box Fig 52 m 3316 4 3 2 1 Figure 52 1 F1 main 30 amp 2 F2 regulator 25 amp 3 F3 dash interlock and cruise control 10 amp 4 F4 headlights and taillights 10 amp Headlights Specification Bulb 1156 Automotive Type Removing the Bulb 1 Disengage the power take off PTO set the parking brake lower the attac...

Page 47: ...he bulb holder into the reflector and rotate it 1 4 turn clockwise until it stops 3 Push the wire connectors onto the terminals on the bulb holder Taillights 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 Pull the lens out far enou...

Page 48: ...grille by pulling it out toward you m 3558 1 Figure 56 1 Grille screw 1 of 2 3 Remove the battery shield 4 Open the cell covers to see into the cells The electrolyte must be up to the lower part of the tube Fig 57 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 c...

Page 49: ...e battery post Fig 58 6 Remove the battery by lifting it up then pulling it out directly toward you from the tractor IMPORTANT Always hold the battery vertical to avoid spilling battery acid POTENTIAL HAZARD Either the battery terminals or metal tools could short against metal tractor components Incorrect battery cable routing could damage the cables WHAT CAN HAPPEN Sparks can cause the battery ga...

Page 50: ...t with the two previously removed screws and washers Fig 56 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 47 2 Check the electrolyte level refer to Checking the Electrolyte Level page 46 ...

Page 51: ...UTCH NMIR MODULE 1 3 2 4 6 5 PK BU GN T W BK BK KEY OVER RIDE SW9 REVERSE SWITCH SW5 SWITCH OPENS WHEN HYDRO PEDAL IS MOVED TO REVERSE SWITCH CLOSES WHEN KEY IS TURNED VIO GN BK BK T VIO BN GY W Cruise Module 4 6 2 1 D2 1N4004 CRUISE SWITCH OPERATION OFF NO CONNECTION ON 3 AND 2 CONNECTED MOMENTARY 3 AND 2 CONNECTED 5 AND 6 CONNECTED CRUISE SWITCH 2 3 5 6 MOMENTARY SW8 BN Y OR BK PK B A E C D BN O...

Page 52: ... START B I R S IGNITION SWITCH SW4 S R L B I IGNITION SWITCH TERMINAL LOCATIONS VEIWED FROM BACK R OR BN VIO PK YELLOW PINK RED TAN VIOLET WHITE 1 2 4 5 3 6 1 CYL ENGINE HARNESS IGNITION COILS WATER TEMP SENDER R Y W BU R BK BK Y SOLINOID SHIFT STARTER FUEL SOLINIOD 2 CYL PULSER COILS OIL PRESSURE SWITCH SWITCH OPENS WITH OIL PRESSURE 2 CYL CHARGING COIL FLYWHEEL 1 CYL IGNITER MODULE GND VOLTAGE R...

Page 53: ...8 Remove the battery from the chassis check the electrolyte level and charge it fully refer to Battery page 46 Do not connect the battery cables to the battery posts during storage IMPORTANT The battery must be fully charged to prevent it from freezing and being damaged at temperatures below 32 F 0 C A fully charged battery maintains its charge for about 50 days at temperatures lower than 40 F 4 C...

Page 54: ... Authorized Service Dealer 9 A faulty starter or starter solenoid 9 Contact your Authorized Service Dealer 10 Seized internal engine components 10 Contact your Authorized Service Dealer The engine cranks but will not start 1 Incorrect starting procedure 1 Refer to Starting and Stopping the Engine page 19 2 The fuel tank is empty 2 Fill with fresh fuel 3 The fuel shut off valve is closed 3 Open the...

Page 55: ...The engine runs but knocks or misses 1 Dirt water or stale fuel is in the fuel system 1 Drain and flush the fuel system add fresh fuel sses 2 A spark plug lead is loose 2 Reconnect the spark plug lead 3 A spark plug is faulty 3 Replace the spark plug 4 Loose wires or poor connections 4 Check and tighten wire connections 5 Engine overheating 5 See ENGINE OVERHEATS The engine will not idle 1 The fue...

Page 56: ...tem 3 Drain and flush the fuel system add fresh fuel 4 The engine is overheated 4 See ENGINE OVERHEATS 5 A spark plug is faulty 5 Replace the spark plug 6 Low compression 6 Contact your Authorized Service Dealer 7 The vent hole in the fuel tank vent fitting is plugged 7 Contact your Authorized Service Dealer 8 The engine load is excessive 8 Reduce ground speed The tractor will not operate in eithe...

Page 57: ...mission control linkage needs adjustment or replacement 2 Contact your Authorized Service Dealer 3 The transmission is faulty 3 Contact your Authorized Service Dealer The tractor operates in both directions but with a loss of power This condition becomes th t i i 1 The transmission oil level is low 1 Fill to the full F mark on the transmission oil dipstick when the transmission is cold p worse as ...

Page 58: ...l throttle 8 PTO is being engaged when cutter deck is in tall uncut grass or weeds 9 Cutter deck is overloaded because mulching or bagging requires more power 10 Cutter deck is overloaded because too much grass is being cut at a time 11 Cutter deck is overloaded because deck is clogged with grass clippings 12 Cutter deck is overloaded because tractor is mowing too fast for conditions 1 See cutter ...

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