Toro 73590 Operator's Manual
FORM NO. 3321–988
Wheel Horse
523Dxi Tractor
Model No. 73590 – 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.
International English (GB)
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. These numbers will
help the Service Dealer or Service Representative
provide exact information about your specific
product. You will find the model and serial number
plate located in a unique place on the product as
shown below.
1
Read this manual carefully to learn how to operate
and maintain your product correctly. Reading this
manual will help you and others avoid personal injury
and damage 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, who 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.
DANGER, WARNING and CAUTION are signal
words used to identify the level of hazard. However,
regardless of the hazard, be extremely careful.
DANGER signals an extreme hazard that will cause
serious injury or death if the recommended
precautions are not followed.
WARNING signals a hazard that may cause serious
injury or death if the recommended precautions are
not followed.
m–2345
1. Model and Serial Number Plate
For your convenience, write the product model and
serial numbers in the space below.
Model No:
Serial No.
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. “Important” calls attention to special
mechanical information and “Note” emphasizes
general information worthy of special attention.
The left and right side of the machine is determined
by sitting on the seat in the normal operator’s
position.
The Toro Company – 1998
All Rights Reserved
Contents
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 7. . . . . . . . . .
Symbols Glossary 8. . . . . . . . . . . . . . . . . . .
Symbols Glossary 9. . . . . . . . . . . . . . . . . . .
Symbols Glossary 10. . . . . . . . . . . . . . . . . . .
Check Before Operating 11. . . . . . . . . . . . . . . . . .
Opening the Hood 11. . . . . . . . . . . . . . . . . . .
Closing the Hood 12. . . . . . . . . . . . . . . . . . . .
Removing the Side Panels 12. . . . . . . . . . . . .
Adding Fuel 13. . . . . . . . . . . . . . . . . . . . . . . .
Draining Water from the Fuel Filter/Water
Separator 14. . . . . . . . . . . . . . . . . . . . . . . . .
Check the Engine Oil Level 14. . . . . . . . . . . .
Check the Cooling System 15. . . . . . . . . . . . .
Check for Debris 16. . . . . . . . . . . . . . . . . . . .
Check the Safety Interlock System 17. . . . . .
Check the Brake 17. . . . . . . . . . . . . . . . . . . . .
Operation 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Think Safety First 18. . . . . . . . . . . . . . . . . . .
Controls 18. . . . . . . . . . . . . . . . . . . . . . . . . . .
“Key Choice” Switch 18. . . . . . . . . . . . . . . . .
Parking Brake 18. . . . . . . . . . . . . . . . . . . . . . .
Starting and Stopping the Engine 19. . . . . . .
Operating the Power Take Off (PTO) 20. . . .
The Safety Interlock System 21. . . . . . . . . . .
Operating–in–Reverse 21. . . . . . . . . . . . . . . .
Gauges and Indicator Lights 23. . . . . . . . . . .
Driving Forward or Backward 25. . . . . . . . . .
Stopping the Machine 25. . . . . . . . . . . . . . . .
Re–centering the Steering Wheel 26. . . . . . . .
Page
Page
Attachment Power Lift 26. . . . . . . . . . . . . . . .
Positioning the Seat 27. . . . . . . . . . . . . . . . . .
Headlights and Taillights 27. . . . . . . . . . . . . .
Positioning the Tilt Steering Wheel 28. . . . . .
Using the Cruise Control 28. . . . . . . . . . . . . .
The Smart Turnt Steering Feature 29. . . . . . .
Pushing the Machine by Hand 29. . . . . . . . . .
Maintenance 30. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Interval Chart 30. . . . . . . . . . . . . . . .
Engine Oil 32. . . . . . . . . . . . . . . . . . . . . . . . .
Changing the Engine Coolant 34. . . . . . . . . .
Greasing and Lubrication 35. . . . . . . . . . . . . .
Tire Pressure 36. . . . . . . . . . . . . . . . . . . . . . . .
Brake 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Tank 38. . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filter 39. . . . . . . . . . . . . . . . . . . . . . . . . .
Front Wheel Toe-In 40. . . . . . . . . . . . . . . . . .
Transaxle Fluid 41. . . . . . . . . . . . . . . . . . . . . .
Fuses 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlights 43. . . . . . . . . . . . . . . . . . . . . . . . .
Taillights 44. . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery 44. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Diagram 48. . . . . . . . . . . . . . . . . . . . .
Wiring Diagram 49. . . . . . . . . . . . . . . . . . . . .
Cleaning and Storage 50. . . . . . . . . . . . . . . . .
Troubleshooting 51. . . . . . . . . . . . . . . . . . . . . . . . .
1
Safety
Safe Operation Practices for
Ride-on (riding) Rotary
Lawnmower Machines
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
WARNING, or DANGER—“personal safety
instruction.” Failure to comply with the
instruction may result in personal injury or death.
symbol, which means CAUTION,
Safe Operating Practices
This product is capable of amputating hands and feet
and throwing objects. Always follow all safety
instructions to avoid serious injury or death.
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 brake. The main reasons for loss of
control are:
insufficient wheel grip;
being driven too fast;
inadequate braking;
the type of machine is unsuitable for its
task;
lack of awareness of the effects of
ground conditions, especially slopes;
incorrect hitching and load distribution.
Preparation
Training
1. Read the instructions carefully. Be familiar with
the controls and the proper use of the equipment.
2. Never allow children or people unfamiliar with
these instructions to use the lawnmower. Local
regulations may restrict the age of the operator.
3. Never mow while people, especially children, or
pets are nearby.
4. Keep in mind that the operator or user is
responsible for accidents or hazards occurring to
other people or their property.
5. Do not carry passengers.
1. While mowing, always wear substantial
footwear and long trousers. Do not operate the
equipment when barefoot or wearing open
sandals.
2. Thoroughly inspect the area where the
equipment is to be used and remove all objects
which may be thrown by the machine.
3. WARNING–Fuel is highly flammable.
• Store fuel in containers specifically
designed for this purpose.
• Refuel outdoors only and do not smoke
while refueling.
• Add fuel before starting the engine. Never
remove the cap of the fuel tank or add fuel
while the engine is running or when the
engine is hot.
2
Safety
• If fuel is spilled, do not attempt to start the
engine but move the machine away from
the area of spillage and avoid creating any
source of ignition until fuel 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. On multi–bladed machines, take care as rotating
one blade can cause other blades to rotate.
Operation
1. Do not operate the engine in a confined space
where dangerous carbon monoxide fumes can
collect.
2. Mow only in daylight or in good artificial light.
3. Before attempting to start the engine, disengage
all blade attachment clutches and shift into
neutral.
4. Use care when pulling loads or using heavy
equipment.
• Use only approved drawbar hitch points.
• Limit loads to those you can safely control.
• Do not turn sharply. Use care when
reversing.
• Use counterweight(s) or wheel weights
when suggested in the instruction
handbook.
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
overspeed the engine. Operating the engine at
excessive speeds may increase the hazard of
personal injury.
10. Before leaving the operator’s position:
• disengage the power take-off and lower the
attachments;
• change into neutral and set the parking
brake;
• stop the engine and remove the ignition and
“key choice” keys.
11. Disengage drive to attachments, stop the engine,
and disconnect the spark plug wire(s) or remove
the ignition and “key choice” keys:
• before cleaning blockages or unclogging
chute;
• before checking, cleaning or working on the
lawnmower;
• after striking a foreign object. Inspect the
lawnmower for damage and make repairs
before restarting and operating the
equipment;
• if the machine starts to vibrate abnormally
(check immediately).
12. Disengage drive to attachments when
transporting or not in use.
5. Watch out for traffic when crossing or near
roadways.
6. Stop the blades rotating before crossing surfaces
other than grass.
13. Stop the engine and disengage drive to
attachment
• before refueling;
• before removing the grass catcher;
3
Safety
• before making height adjustment unless
adjustment can be made from the operator’s
position.
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.
Slope Operation
1. For operation on slopes:
• Never mow side hills over 5
• Never mow uphill over 10
• Never mow downhill over 15
2. Remember there is no such thing as a “safe”
slope. Travel on grass slopes requires particular
care. To guard against overturning:
• do not stop or start suddenly when going up
or downhill;
• engage clutch slowly, always keep machine
in gear, especially when travelling
downhill;
4. To reduce the fire hazard, keep the engine,
silencer, battery compartment and fuel 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 be drained, this should be
done outdoors.
8. On multi-bladed machines, take care as rotating
one blade can cause other blades to rotate.
9. When machine is to be parked, stored or left
unattended, lower the cutting means unless a
positive mechanical lock is used.
Sound Pressure Level
This unit has an equivalent continuous A-weighted
sound pressure at the operator ear of: 90 dB(A), based
on measurements of identical machines per Directive
84/538/EEC.
• machine speeds should be kept low on
slopes and during tight turns;
• stay alert for bumps and hollows and other
hidden hazards;
• never mow across the face of the slope,
unless the lawnmower is designed for this
purpose.
Maintenance and storage
1. Keep all nuts, bolts and screws tight to be sure
the equipment is in safe working condition.
2. Never store the equipment with fuel in 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.
Sound Power Level
This unit has a sound power level of: 105 Lwa, based
on measurements of identical machines per
procedures outlined in Directive 84/538/EEC and
amendments.
Vibration Level
This unit has a maximum hand-arm vibration level of
2.00 m/s2 and whole body vibration level of
0.30 m/s2, based on measurements of identical
machines per EN 1033 and EN 1032.
4
Slope Chart
Read all safety instructions on pages 2–4.
Safety
5
6
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.
Safety
ON DRIVE SHAFT COVER
(Part No. 98–1608)
(1) ON DRIVESHAFT TUNNEL
(2) UNDER SIDE SHIELD
(Part No. 98–5015)
ON SEA T BRACKET
(Part No. 99–2986)
ON SEA T BRACKET
(Part No. 99–5340)
(2) INSIDE FRONT GRILL
(Part No. 93–8069)
ON RADIA T OR FAN
SHROUD
(Part No. 95–4143)
ON REAR FENDER
(Part No. 98–3088)
7
Safety
Symbols Glossary
Safety alert symbol
Safety alert symbol
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
Dismemberment–Mower
in rearward motion
Stay a safe distance
from the machine
Stay a safe distance
from the mower
Keep children a safe distance
from machine
Machine rollover
side hill
Severing toes or foot–
mower blade
Severing fingers or hand–
mower blade
Rotating blade can cut off
toes or fingers. Stay clear
of blade as long as engine
is running
Do not open or
remove safety shields
while engine is running
Machine rollover
up hill
Machine rollover
down hill
Machine rollover
Operating in reverse not
allowed unless deactivated
by ”Key Choice” key
8
Symbols Glossary
Safety
Cutting element–
basic symbol
Cutting element–
height adjustment
Cutting unit–lower
Cutting unit-raised
Cutting or entanglement
of foot–Rotating auger
Severing of fingers or hand–
impeller blade
Keep a safe distance from
snowthrower
Riding on this machine is allowed
only on a passenger seat & only
if the driver’s view is not hindered
Crushing of fingers
or hands–Force applied
from side
Kickback or upward
motion–Stored energy
Shut off engine & remove key
before performing maintenance
or repair work
Machine travel direction–
combined
Stay a safe distance
from the snowthrower
Tractors must be equipped
with 45kg rear wheel weight
with this attachment installed
Machine rollover
ROPS snowthrower
Severing of hand–
Rotating knives
Severing of foot–
Rotating knives
Low
High
Reverse
Neutral
First gear
Second gear
Third gear up to
maximum # of
forward gears
9
Safety
Symbols Glossary
Fast
Slow
Decreasing/Increasing
On/Run
Off/Stop
Engine
Engine start
Engine stop
Fuel
Fuel level
Volume empty
Volume full
Battery charging conditin
Head lights–
Main/high beam
Brake system
Choke
Engine temperature
Engine lubricating
oil pressure
Engine lubricating oil level
”Key Choice” switch
Parking brake
Clutch
PTO (Power Take Off)
Engage
Disengage
Unlock
Lock
10
Check Before Operating
Each time before operating your tractor, check the
following:
• Fuel level
• Water drained from the fuel filter
• 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
Some of these steps will require that you open the
hood or remove the side panels on the tractor.
Opening the Hood
To open the hood:
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.
1
Figure 1
1. Slot for hood latch access
POTENTIAL 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.
m–3584
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.
11
Check Before Operating
Closing the Hood
The hood latch is located at the left hand corner of the
grille.
1. Press rearward on the hood catch as you begin to
lower the hood (Fig. 2).
2. Push the hood down until the latch closes.
1
2
2
Front of tractor
Figure 2
1. Hood catch 2. Hood hinges
2
Figure 3
1. Side panel latch 2. Open slot
1
POTENTIAL HAZARD
• Rotating fan and drive shaft can cause
injury.
m–3318
Removing the Side Panels
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. Raise the hood.
3. To remove 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.
WHAT CAN HAPPEN
• Fingers, hands or loose clothing can get
caught by rotating fan and drive shaft.
HOW TO AVOID THE HAZARD
• Do not operate the tractor without the side
panels and hood in place.
• Keep fingers, hands and clothing clear of
rotating fan and drive shaft.
• Shut off the engine and remove the ignition
key before performing maintenance.
12
Adding Fuel
Check Before Operating
The engine runs on clean, fresh diesel fuel with a
minimum cetane rating of 40. Purchase fuel in
quantities that can be used within 30 days to assure
fuel freshness.
Use summer grade diesel fuel (No. 2–D) at
temperatures above 20 F (–7 C) and winter grade
diesel fuel (No. 1–D or No. 1–D/2–D blend) below
20 F (–7 C). Use of winter grade diesel fuel at
lower temperatures provides lower flash point and
pour point characteristics, therefore easing startability
and lessening chances of chemical separation of the
fuel due to lower temperatures (wax appearance,
which may plug filters).
Use of summer grade diesel fuel above 20 F (–7 C)
will contribute toward longer life of the pump
components.
IMPORTANT: Do not use kerosene or
gasoline instead of diesel fuel. Failure to
observe this caution will damage the engine.
POTENTIAL HAZARD
• Under certain conditions, fuel is extremely
flammable and highly explosive.
WHAT CAN HAPPEN
• A fire or explosion from fuel can burn you,
others, and cause property damage.
HOW TO AVOID THE HAZARD
• Use a funnel and fill the fuel tank outdoors,
in an open area, when the engine is cold.
Wipe up any fuel that spills.
• Do not fill the fuel tank completely full.
Add fuel to the fuel tank until the level is
1/4” to 1/2” (6 mm to 13 mm) below the
bottom of the filler neck. This empty space
in the tank allows fuel to expand.
• Never smoke when handling fuel, and stay
away from an open flame or where fuel
fumes may be ignited by a spark.
• Store fuel in an approved container and
keep it out of the reach of children. Never
buy more than a 30-day supply.
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. 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.
3. Install the fuel cap securely. Wipe up any fuel
that may have spilled.
4. If possible, fill the fuel tank after each use. This
will minimize possible buildup of condensation
inside the fuel tank.
13
Check Before Operating
Draining Water from the Fuel
Filter/W ater Separator
Any water accumulation should be drained from the
fuel filter/water separator before each use.
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. Remove the left–hand side panel.
4. Open the drain valve on the fuel filter/water
separator and drain any accumulated water
(Fig. 4).
Note: Because the accumulated water will be
mixed with diesel fuel, drain the fuel
filter into a suitable container and
dispose of properly.
Check the Engine Oil Level
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. Clean around the oil dipstick (Fig. 5) 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. 6).
5. Slide the oil dipstick fully into the tube. Pull the
dipstick out and look at the metal end. If the oil
level is near or below the lower hole on the
dipstick, remove the filler cap and add oil only
to the upper hole on the dipstick. (Refer to
Engine Oil, page 32, for the correct oil type and
viscosity to use in different temperature
conditions).
1
1. Fuel filter drain valve
1
Figure 4
6. After filling with or changing the oil, close the
hood, start the engine, and run it at idle for 30
seconds. Shut off the engine. Wait 30 seconds
and check the oil level. Add oil, if required, to
bring the level to the upper hole on the dipstick.
IMPORTANT: Do not overfill the crankcase
with oil because this may result in engine
damage.
m–3708
14
Check Before Operating
1
Figure 5
1. Dipstick 2. Filler Cap
Figure 6
1. Filler Cap
2
Check the Cooling System
Check Radiator Coolant
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.
POTENTIAL HAZARD
• Coolant is hot and pressurized.
m–3741
WHAT CAN HAPPEN
• Discharge of hot pressurized coolant can
cause severe burns.
HOW TO AVOID THE HAZARD
• Do not remove the radiator cap to check
coolant. Follow the directions below for
checking coolant.
• Do not remove the radiator cap when the
.95 l
m–3742
engine is hot. Always 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 should be between
the two lines on the reserve tank when the
engine is cold (Fig. 7).
15
Check Before Operating
1
3
4
1. Reserve tank cap
2. Reserve tank
2
Figure 7
3. Maximum level line (cold)
4. Minimum level line (cold)
m–3764
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 for Debris
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. 8). Wipe away debris before each use
and/or during use, if required.
1
m–3412
Figure 8
Arrows show air intake and exhaust path
1. Air intake screens (1 of 3 shown)
1
m–3424
Figure 9
1. Radiator screen
3. The radiator screen (Fig. 9) 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.
16
5. Debris can build up in the engine area. Clean
any debris build–up with a brush or blower
before each use.
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