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Toro Wheel Horse 520xi, Operator'S Manual

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Toro Wheel Horse 520xi Operator'S Manual Download Page 34

34

Wiring Diagram

PK

BK

OR

VOL

TAGE 

COMP

ARA

TOR

B+

BA

TTERY LIGHT MODULE

F

A

D

#194 LAMP

#194 LAMP

#194 LAMP

#194 LAMP

B

A

K

J

H

E

GN

GN

PK

W

W

OR

BK

BK

OR

PK

BU

BU

OIL

BATTERY

PTO

PARK

PK

PK

BK

FUEL GAUGE

SWITCH CLOSES WHEN 

PARK BRAKE IS ENGAGED

SW6

(P

ARK SWITCH)

FUEL

SENDER

#194

LAMP

L

S

G

I

#194 LAMP

L

S

G

I

BK

W

WARNING LIGHT HARNESS

CRUISE

OVER RIDE

VIO

VIO

T

T

D

C

#194 LAMP

#194 LAMP

D2

1N4004

1

2

4

5

3

K5

1

2

4

5

3

K4

47uF

C1

47uF

C2

BK

PK

BN

VIO

1

3

5

(BRAKE SWITCH)

SW2

CLUTCH

NMIR

MODULE

1

3

2

4

6

5

SEAT SWITCH IS CLOSED 

WHEN OPERATOR IS IN

THE SEAT

DEPRESSED

WHEN BRAKE IS

BRAKE SWITCH CLOSES

Y

PK

BU

BK

GN

T

W

BU

BU

BK

(REVERSE SWITCH)

SW5

-

+

HOUR METER

TEMP

.

GAUGE

TEMP

. 

SENDER

GND

SWITCH OPENS WHEN HYDRO PEDAL IS MOVED TO REVERSE

SWITCH CLOSES

WHEN KEY IS

TURNED

(KEY OVER RIDE)

SW9

BK

BK

GN

GN

BK

BK

Y

T

2

6

4

D

C

E

A B

PK

PK

Y

BK

OR

BK

OR

Y

BN

BN

VIO

CRUISE SWITCH OPERATION

OFF             NO CONNECTION

ON               3 AND 2 CONNECTED

MOMENTARY    3 AND 2 CONNECTED      5 AND 6 CONNECTED

2

3

5

6

(MOMENTARY)

SW8

CRUISE SWITCH

SWITCH OPENS WHEN

BRAKE IS DEPRESSED

SW7

(CRUISE DISENGAGE SWITCH)

TAIL LIGHTS

W

GY

CRUISE MAGNET

Cruise Module

REAR HARNESS

20/22 Kohler GT

HEADLIGHT  HARNESS

PTO SWITCH IS 

SHOWN IN OFF

 POSITION

PTO 

CLUTCH

1

2

5

4 
7

8

(PTO SWITCH)

SW3

10A

F4

OR

BK

BN

BN

W

GY

PK

GY

OR

BK

OR

Y

W

OR

GY

VIO

R

VIO

R

PK

OR

PK

PK

BN

OR

VIO

R

BN

GREY

ORANGE

2

3

5

4

1

K3

(INTERL

OCK RELA

Y)

25A

F2

30A

F1

IGNITION SWITCH TERMINAL 

LOCA

TIONS VEIWED FROM BACK.

10A

F3

3

I

4

L

2

R

1

S

5

B

WIRE COL

OR CODES

GREEN

S

R

L

B

I

SW4

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

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

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

ST

ART--------------B I R S

(IGNITION SWITCH)

BLUE

BROWN

BLACK

GN

BK BN BU

R T

PK

VIO

TA

N

RED

PINK

VIOLET WHITE

YELL

OW

GN

Y

R

VIO

BU W

GN

W

BK

+

-

B+

CLOSES WITH 

PRESSURE

SP

ARK PLUG

SP

ARK PLUG

IGNITION MODULES

AC

AC

MAG

REG

OIL

ST

ART

5

3

2

1

SOLINOID SHIFT ST

ARTER

OIL SWITCH

FUEL  SOLINIOD

2

3

5

4

1

(KILL RELA

Y)

K1

GND

GN

T

Y

BU

OR

BN

T

BK

2

3

5

4

1

(ST

ART RELA

Y)

K2

SW1

(SEA

T SWITCH)

Summary of Contents for Wheel Horse 520xi

Page 1: ...Operator s Manual Domestic English EN Form No 3326 686 520xi and 522xi Wheel Horse Garden Tractor Model No 73542 and 73561 220000001 and Up...

Page 2: ...ide Panels 8 Adding Fuel 9 Checking the Engine Oil Level 9 Check for Debris 10 Check the Safety Interlock System 11 Check the Brake 11 Operation 11 Think Safety First 11 Controls 11 Using the Parking...

Page 3: ...ecautions are not followed Caution signals a hazard that may cause minor or moderate injury if the recommended precautions are not followed Two other words are also used to highlight information Impor...

Page 4: ...unless necessary and then turn slowly and gradually downhill if possible Do not mow near drop offs ditches or embankments The machine could suddenly turn over if a wheel goes over the edge of a cliff...

Page 5: ...nds feet hair and loose clothing away from attachment discharge area underside of mower and any moving parts while engine is running Do not touch equipment or attachment parts which may be hot from op...

Page 6: ...6 Slope Chart...

Page 7: ...n the drive shaft tunnel Part No 80 8760 2 Under the side shield Part No 98 5014 On the drive shaft cover Part No 99 6090 On the front of the seat bracket Part No 99 5339 On the front of the seat brac...

Page 8: ...nning If you touch hot components you may be burned Allow the tractor to cool before performing maintenance or touching components under the hood Caution Closing the Hood The hood catch is located at...

Page 9: ...container rather than from a gasoline dispenser nozzle If a gasoline dispenser nozzle must be used keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fue...

Page 10: ...e attachment lift stop the engine and remove the ignition key 2 Check for debris on the air intake screens Fig 7 1 m 3412 Figure 7 Arrows show air intake and exhaust path 1 Air intake screens 1 of 3 s...

Page 11: ...13 Check the Brake Refer to Checking and Adjusting the Brake page 24 Operation Think Safety First Please carefully read all the safety instructions on pages 3 through 7 Knowing this information could...

Page 12: ...usly for more than 10 seconds at a time If the engine does not start allow a 60 second cool down period between starting attempts Failure to follow these guidelines can burn out the starter 8 After th...

Page 13: ...r you can temporarily deactivate this interlock Do not mow while backing up unless it is absolutely necessary Danger A child or bystander could be backed over by a riding mower with blades engaged and...

Page 14: ...n and start the engine 8 With the engine running release the parking brake and rise slightly from the seat the engine should stop 9 Fully press the brake pedal set the parking brake push the PTO switc...

Page 15: ...e 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 If the gauge does not show temperatures dropping stop the engine imme...

Page 16: ...desired speed 2 While holding your foot steady on the traction control pedal push the cruise control switch Fig 18 to the set position This locks the traction control in position 3 Remove your foot f...

Page 17: ...r 2 Push the lift lever down to lower the attachment Fig 20 Positioning the Seat You can move the seat forward and backward Position the seat where you have the best control of the machine and are mos...

Page 18: ...t Turn Steering Feature The Smart Turn Steering feature automatically lowers the speed of the tractor in tight turns The decrease in speed is directly proportional to the sharpness of the turn up to a...

Page 19: ...d 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 inta...

Page 20: ...ments 1 Disengage the PTO set the parking brake lower the attachment lift stop the engine and remove the ignition key 2 Open the hood 3 Clean around the air cleaner to prevent dirt from getting into t...

Page 21: ...24 5 Close the hood Servicing the Engine Oil Change oil after the first 5 operating hours and then after every 100 operating hours Change the oil filter every 200 hours of operation or every other oi...

Page 22: ...hin coat of new oil to the rubber gasket on the replacement filter Fig 29 5 Install the replacement oil filter to the filter adapter Turn the oil filter clockwise until the rubber gasket contacts the...

Page 23: ...e that the air gap is set correctly 3 Tighten the spark plugs to 18 to 22 ft lb 24 4 to 29 8 Nm 4 Push the wires onto the spark plugs Fig 30 5 Close the hood Greasing the Tractor Grease the machine af...

Page 24: ...secure the cover 6 Grease the fitting on the brake pedal Fig 35 m 3420 Figure 35 7 If your tractor has manual steering put one pump of grease into the steering housing from underneath the frame Fig 36...

Page 25: ...ant With the parking brake released the rear wheels must rotate freely when you push the tractor If brake action and free wheel rotation cannot be achieved contact your Authorized Service Dealer immed...

Page 26: ...41 3 Open the hood and remove the side panels 4 Squeeze the ends of the hose clamps together and slide them away from the filter Fig 42 5 Remove the filter from the fuel lines m 3365 1 2 3 4 Figure 4...

Page 27: ...correct operating range on the dipstick when the transaxle is cold Replace the transaxle fluid and filter at 50 hours initially then every 200 hours thereafter Fluid Type SAE 10W 30 Detergent oil API...

Page 28: ...nsaxle filter Fig 49 1256 1 2 3 Figure 49 1 Transaxle filter 2 Gasket 3 Adapter 2 Wipe the filter adapter gasket surface Fig 49 3 Apply a thin coat of new oil to the rubber gasket on the replacement f...

Page 29: ...51 1 2 3 4 4 5 5 Figure 51 1 Bulb holder 2 Reflector 3 Tabs 4 Slots 5 Terminals 5 Push and rotate the bulb counterclockwise until it stops approx 1 4 turn and remove the bulb from the bulb holder Fig...

Page 30: ...re 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 Battery size 12 v 380 Cold Cranking Am...

Page 31: ...void 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 Add...

Page 32: ...irt and grime from the external parts of the entire machine especially the engine 3 Clean dirt and chaff from the outside of the engine s cylinder head fins and blower housing refer to Check for Debri...

Page 33: ...attery 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 maint...

Page 34: ...VIO CRUISE SWITCH OPERATION OFF NO CONNECTION ON 3 AND 2 CONNECTED MOMENTARY 3 AND 2 CONNECTED 5 AND 6 CONNECTED 2 3 5 6 MOMENTARY SW8 CRUISE SWITCH SWITCH OPENS WHEN BRAKE IS DEPRESSED SW7 CRUISE DIS...

Page 35: ...horized Service Dealer 9 A broken starter or starter solenoid 9 Contact your Authorized Service Dealer 10 Seized internal engine components 10 Contact your Authorized Service Dealer The engine cranks...

Page 36: ...ut knocks or misses 1 Dirt water or stale fuel is in the fuel system 1 Drain and flush the fuel system add fresh fuel 2 A spark plug lead is loose 2 Reconnect the spark plug lead 3 A spark plug is bro...

Page 37: ...ystem 3 Drain and flush the fuel system add fresh fuel 4 The engine is overheated 4 See Engine Overheats 5 A spark plug is damaged or dirty 5 Replace the spark plug 6 Low compression 6 Contact your Au...

Page 38: ...eplacement 2 Contact your Authorized Service Dealer 3 The transmission is broken 3 Contact your Authorized Service Dealer The tractor operates in both directions but with a loss of power This conditio...

Page 39: ...Dealer 7 The engine is not at full throttle 7 Always operate engine powered attachments at full throttle 8 The PTO is being engaged when cutter deck is in tall uncut grass or weeds 8 Engage PTO only i...

Page 40: ...For instructions on adjusting toe in refer to Servicing the Front Wheel Toe in page 26 Ensuring that the Steering Linkage is Centered 1 With the tractor on a level surface turn the steering wheel ful...

Page 41: ...lectrolyte into each battery cell until the level is up to the upper line Fig 58 on the battery case Important Do not overfill the battery because electrolyte sulfuric acid can cause severe corrosion...

Page 42: ...oil level in the crankcase refer to Checking the Engine Oil page 9 2 Check the oil level in the transaxle refer to Checking the Transaxle Oil page 27 3 Grease the tractor refer to Greasing the Tractor...

Page 43: ...43...

Page 44: ...ion Toro Warranty Company 8111 Lyndale Avenue South Bloomington MN 55420 1196 800 348 2424 U S customers 877 484 9255 Canada customers Owner Responsibilities You must maintain your Toro Product by fol...

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