Form No. 3323-512 Wheel Horse 520xi and 522xi Tractor Model No.
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 . . . . . . . . . . . . . . Toro Riding Mower Safety . . . . . . . . . . . . Slope Chart . . . . . . . . . . . . . . . . . . . . . . . . . Safety and Instruction Decals . . . . . . . . . . . Check Before Operating . . . . . . . . . . . . . . . . . . . Opening the Hood . . . . . . . . . . . . . . . . . . . Closing the Hood . . . . . . . . . . . . . . . . . . . . Removing the Side Panels . . . . . . . .
Safety This machine meets or exceeds the B71.1–1998 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 • Mow up and down slopes, not across. • Remove obstacles such as rocks, tree limbs, etc. • Watch for holes, ruts or bumps. Uneven terrain could overturn the machine. Tall grass can hide obstacles. • Use slow speed. Choose a low gear so that you will not have to stop or shift while on the slope. • Follow Toro’s recommendations for wheel weight or counterweights to improve stability. • Use extra care with grass catchers or other attachments. These can change the stability of the machine.
Safety • • • • Keep hands, 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 operation. Allow to cool before attempting to maintain, adjust or service. • Remove obstacles such as rocks, tree limbs, etc. from the mowing area. Watch for holes, ruts or bumps, as uneven terrain could overturn the machine. Tall grass can hide obstacles.
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 FRONT OF SEAT BRACKET (Part No. 99–5339 ON FRONT OF SEAT BRACKET (Part No. 99–2985 ON BATTERY STRAP (Part No. 93–1265) ON DRIVE SHAFT COVER (Part No. 99–6090) ON DRIVE SHAFT TUNNEL (Part No. 80–8760) (2) UNDER SIDE SHIELD (Part No. 98–5014) ON ENGINE BULKHEAD (Part No. 98–5012) UNDER HOOD (Part No.
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 • The safety interlock system • The brake 1 m–3314 Figure 1 1. Hood latch POTENTIAL HAZARD • Components under the hood will be hot if the tractor has been running. Some of these steps will require that you open the hood or remove the side panels on the tractor.
Check Before Operating 2 1 1 2 2 Front of tractor Figure 2 1. Hood catch 2. Hood hinges m–3318 Figure 3 1. Side panel latch 2. Open slot 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.
Check Before Operating Adding Fuel Use UNLEADED Regular Gasoline suitable for automotive use (85 pump octane minimum). Leaded regular gasoline may be used if unleaded regular is not available. POTENTIAL HAZARD • When fueling, under certain circumstances, a static charge can develop, igniting the gasoline. IMPORTANT: Never use methanol, gasoline containing methanol, or gasohol containing more than 10% ethanol because the fuel system could be damaged. Do not mix oil with gasoline.
Check Before Operating IMPORTANT: Do not use fuel additives containing methanol or ethanol. 4. Pull out the oil dipstick and wipe the metal end clean (Fig. 5). Add the correct amount of gas stabilizer/conditioner to the gas. 5. Slide the oil dipstick fully into the dipstick tube (Fig. 4). Pull the dipstick out and look at the metal end. If the oil level is low, add oil; refer to Engine Oil, page 26. Note: A fuel stabilizer/conditioner is most effective when mixed with fresh gasoline.
Check Before Operating Check for Debris IMPORTANT: Operating the engine with a blocked grass screen, dirty or plugged cooling fins, and/or cooling shrouds removed, will result in engine damage from overheating. 1. 2. POTENTIAL HAZARD • Rotating air intake screen and drive shaft can cause injury. WHAT CAN HAPPEN • Fingers, hands or loose clothing can get caught by rotating air intake screen and drive shaft.
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 m–3615 Refer to Checking and Adjusting the Brake, page 31. Figure 8 IMPORTANT: DO NOT HIGH–PRESSURE WASH. High–pressure washing can damage the electrical system or deplete grease. 5. The rear transaxle cover is an air intake area for cooling the transaxle.
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. 10) down and hold it in the depressed position. Become familiar with all the controls (Fig. 10) before you start the engine and operate the machine. 2.
Operation 6. Turn the ignition key clockwise and hold it in the START position (Fig. 12). When the engine starts, release the key. 2 1 3 IMPORTANT: Do not run the starter motor more than 5 seconds at a time or premature starter failure may 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 44. 7.
Operation Operating the Power Take Off (PTO) The Safety Interlock System Understanding the Safety Interlock System The power take–off (PTO) switch engages and disengages power to the electric clutch. 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 deactivate the interlock because the sound of the tractor’s engine might prevent you from being aware that a child or a bystander has entered the area where you are operating the tractor. POTENTIAL HAZARD • A child or bystander could be backed over by a riding mower with its blade(s) engaged. If you are certain that you can safely mow in reverse or operate an attachment, deactivate the no operating-in-reverse interlock by turning the “Key Choice” switch (Fig.
Operation 4. Fully depress the brake pedal and set the parking brake. Push 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.
Operation Operating–in–Reverse Warning Light Hour Meter 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 is shut off. When the light is on, look behind and use extra caution when backing. Be especially watchful for children and pets. The hour meter (Fig.
Operation 4. 5. Place your foot on the traction control pedal and slowly press on the top of the pedal to move forward, or on the bottom of the pedal to move backward (Fig. 16). The farther you move the pedal in either direction, the faster the machine will move in that direction. POTENTIAL HAZARD • Someone could move or attempt to operate the tractor while it is unattended. To slow down, release the pressure on the traction control pedal and step on the brake pedal.
Operation Lowering Attachments Attachment Power Lift 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 ignition 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 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. IMPORTANT: If you accidentally press the cruise control while the engine is running and you are not moving, the machine will subsequently operate at partial speed in forward and will not operate in reverse.
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 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 Transaxle—check oil level X Battery—check electrolyte level X X Transaxle—change oil Initial X X Tr
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 3. Put one or two ounces of oil on the element (Fig. 24). Squeeze the element to distribute the oil. Installing the Foam and Paper Elements 1. Carefully slide the foam element onto the paper air cleaner element (Fig. 23). 2. Slide the air cleaner assembly and cover onto the long rod. Now screw the cover nut finger-tight against the cover (Fig. 23). IMPORTANT: Replace the foam element if it is torn or worn. 2 Note: 1 3. Install the air cleaner cover and hook latches (Fig. 23). 4.
Maintenance Changing/Draining the Engine Oil 1. Start the engine and let it run for five minutes. This warms the oil so it drains better. 2. Park the machine so that the drain side is slightly lower than the opposite side to assure the oil 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. 1 m–3262 Figure 26 3. Open the hood. 1.
Maintenance Removing the Spark Plug 3 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. Open the hood. 3. Pull the wire(s) off the spark plug(s) (Fig. 28). Now clean around the spark plug(s) to prevent dirt from falling into the engine and potentially causing damage. 4. Remove the spark plug(s) and metal washer. 2 1 1256 Figure 27 1. Oil filter 2. Gasket 4. 5. 3.
Maintenance 2. Check the gap between the center and side electrodes (Fig. 29). Bend the side electrode (Fig. 29) if the gap is not correct. 2 3 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. 1 0.030” (0.76 mm) Where to Add Grease m–3215 1.
Maintenance Manual Steering Models POTENTIAL HAZARD • Rotating shaft or cooling fan can cause injury. Put one pump of grease into the steering housing (from underneath the frame) (Fig. NO TAG) every 50 hours. WHAT CAN HAPPEN • Fingers, hands, feet, hair, etc. can get caught by shaft or fan. • Loose clothing can get caught by shaft. HOW TO AVOID THE HAZARD • Do not operate the tractor without the drive shaft cover in place. • Keep hands and arms clear of rotating m–3409 shaft or fan. 4.
Maintenance Brake 1 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 m–3417 1. 2. 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. Remove the ignition key.
Maintenance 1. 2. Park the machine on a level surface to assure the fuel 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. 3. Loosen the hose clamp and slide it up the fuel line away from the fuel shut-off valve (Fig. 39). 4. Pull the fuel line off the fuel shut-off valve (Fig. 39). Some fuel will flow out from the hose as it is disconnected from the valve.
Maintenance Measuring Toe-In 1 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. Turn 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. 41). 5.
Maintenance Adjusting Toe-In Checking the Fluid Level 1. Loosen the jam nuts at the ends of the steering rods (Fig. 42). 1. Park the machine on a level surface. 2. 2. Rotate both steering rods equal amounts to adjust the toe–in to 1/8” to 1/4” (3 to 6 mm). 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. 3.
Maintenance 2 1 m–2467 Figure 45 1. Operating range 1 2. FULL line m–3322 Figure 46 Changing Transaxle Oil 1. Transaxle drain plug Replace the transaxle fluid at 50 hours initially, then every 200 hours thereafter. 5. Fluid Type: SAE 10W–30 Detergent oil (API service SG, SH or above) Change the transaxle filter; refer to Changing the Transaxle Filter, page 35. 6. Slowly pour the specified refill capacity of oil into the filler tube (Fig. 44). 7.
Maintenance Fuses Service Interval/Specification 3 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. 48). 2 1 1256 Figure 47 1. Transaxle filter 2. Gasket 3. Adapter 1 2 3 4. 5. Install the replacement transaxle filter to the filter adapter.
Maintenance 3. Rotate the bulb holder 1/4 turn counterclockwise and remove it from the reflector (Fig. 49). 4. Push and rotate the bulb counterclockwise until it stops (approx. 1/4 turn) and remove the bulb from the bulb holder (Fig. 50). 2. The bulb holder has two tabs (Fig. 49). Align the tabs with the slots in the reflector, insert the 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.
Maintenance Battery Service Interval/Specification 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 Battery size: 12 v, 380 Cold Cranking Amps Figure 52 Checking the Electrolyte Level 1. 1.
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 ignition key. 2. Remove the front grill by pulling it outward toward you. 3. Remove the battery shield (Fig. 53). IMPORTANT: Always disconnect the negative (black) cable first. 4. Disconnect the negative (black) ground cable from the battery post (Fig. 53). 5.
Maintenance Charging the Battery 6 1 3 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). 4 5 2 1. Remove the battery from the chassis; refer to Removing the Battery, page 39. 2. Check the electrolyte level; refer to Checking the Electrolyte Level, page 38, steps 2–5. 3. Remove the cell covers from the battery and connect a 3– to 4–amp battery charger to the battery posts.
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Maintenance Cleaning and Storage 1. 2. 8. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to “STOP” to stop the engine. Remove the ignition and “Key Choice” keys. 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).
Maintenance 11. Check and tighten all bolts, nuts, and screws. Repair or replace any part that is damaged or defective. 12. Paint all scratched or bare metal surfaces. Paint is available from your Authorized Service Dealer. 13. Store the machine in a clean, dry garage or storage area. Remove the keys from the ignition and “Key Choice” switches and keep them in a memorable place. Cover the machine to protect it and keep it clean.
Troubleshooting PROBLEM The starter does not crank. The engine cranks, but will not start. 44 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 fuse. 6.
Troubleshooting PROBLEM The engine starts, but does not keep running g The engine runs, but knocks or misses. The engine will not idle. 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. The crankcase oil level is incorrect. 1. Fill or drain to the full mark. 2. The fuel mixture is lean. 2. Contact your Authorized Service Dealer. 3. Excessive loading. 3. Reduce load; use lower ground speed. 4. (3) air intake screens are dirty. 4. Clean with every use. 5. The cooling fins and air passages under the engine blower housing and/or the rotating air intake screen are plugged. 5.
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. PTO (cutter deck) belt comes off of pulleys, slips, or fails. 48 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. 1.
Troubleshooting 49
The Toro Total Coverage Guarantee Consumer Riding Products A Two-Year Full Warranty (Limited Warranty for Commercial Use) Conditions and Products Covered The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair any Toro Product used for normal residential purposes* if defective in materials or workmanship.
