Form No. 3326-686 520xi and 522xi Wheel Horse Garden Tractor Model No.
Page Operating the Power Take Off (PTO) . . . . . . . . . 12 The Safety Interlock System . . . . . . . . . . . . . . . . 13 Gauges and Indicator Lights . . . . . . . . . . . . . . . . 14 Driving Forward or Backward . . . . . . . . . . . . . . . 15 Stopping the Machine . . . . . . . . . . . . . . . . . . . . . 16 Using the Cruise Control . . . . . . . . . . . . . . . . . . . 16 Raising and Lowering Attachments . . . . . . . . . . . 16 Positioning the Seat . . . . . . . . . . . . . . . . . . . . . . .
Introduction Caution signals a hazard that may cause minor or moderate injury if the recommended precautions are not followed. Thank you for purchasing a Toro product. 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.
• Never leave a running machine unattended. Always turn off blades, set parking brake, stop engine, and remove keys before dismounting. • Do not mow on wet grass. Reduced traction could cause sliding. • Do not try to stabilize the machine by putting your foot on the ground. • Turn off blades when not mowing. • Stop the engine before removing the grass catcher or unclogging the chute. • Do not use a grass catcher on steep slopes. • Mow only in daylight or good artificial light.
• Mow up and down slopes greater than 5°, not across. • Grass catcher components are subject to wear, damage and deterioration, which could expose moving parts or allow objects to be thrown. Frequently check components and replace with manufacturer’s recommended parts, when necessary. • Mow downhill only on slopes above 10°, never mow uphill. If a steep slope must be ascended, back up the hill, and drive forward down the hill, keeping the machine in gear. • Mower blades are sharp and can cut.
Slope Chart 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. On the drive shaft cover (Part No. 99-6090) (2) Under the side shield (Part No. 98-5014) Under the hood (Part No. 100-7304) On the front of the seat bracket (Part No. 99-2985) On the battery strap (Part No. 93-1265) On the drive shaft tunnel (Part No. 80-8760) On the engine bulkhead (Part No.
Check Before Operating Closing the Hood Each time before operating your tractor, check the following: 1. Press rearward on the hood catch as you begin to lower the hood. • Fuel level 2. Push the hood down until the latch closes. The hood catch is located at the left hand corner of the grill.
• Cleans the engine while it runs Adding Fuel • Eliminates gum-like varnish buildup in the fuel system, which causes hard starting Use unleaded, regular gasoline suitable for automotive use (85 pump octane minimum). Leaded regular gasoline may be used if unleaded regular is not available. Important Do not use fuel additives containing methanol or ethanol. Important Do not use methanol, gasoline containing methanol, or gasohol containing more than 10% ethanol because the fuel system could be damaged.
4. Pull out the oil dipstick and wipe the metal end clean (Fig. 6). ÓÓÓ ÓÓÓ ÓÓÓ 1 1 m–3412 Figure 7 Arrows show air intake and exhaust path m–3219 1. Air intake screens (1 of 3 shown) Figure 6 1. Metal end 3. Wipe away debris before each use and/or during use, if required. 5. Slide the oil dipstick fully into the dipstick tube (Fig. 5). 4. Wipe away any accumulated debris from the rotating air-intake screen (Fig. 8). 6. Pull the dipstick out and look at the metal end (Fig. 6).
Operation Important If possible, blow dirt out (Fig. 9), rather than washing it out. If water is used, keep it away from electrical items. Think Safety First Please carefully read all the safety instructions on pages 3 through 7. Knowing this information could help you, your family, pets, or bystanders avoid injury. Controls Become familiar with all the controls (Fig. 11) before you start the engine and operate the machine.
Setting the Parking Brake 2 1. Push the brake pedal (Fig. NO TAG) down and hold it. 1 3 2. Lift the parking brake lever (Fig. NO TAG) up and gradually take your foot off the brake pedal. The brake pedal should stay down. Releasing the Parking Brake 4 1. Push down on the brake pedal (Fig. NO TAG). m–3312 The parking brake lever should release. Figure 13 2. Release the brake pedal. 1. Stop 2. Run with lights Starting and Stopping the Engine 3. Run 4. Start 7.
Engaging the PTO Operating in Reverse 1. Press the brake pedal to stop the machine. The tractor has an interlock feature that prevents mowers, snowthrowers, and other PTO powered attachments from operating while the tractor is traveling in reverse. If you shift into reverse with the PTO engaged, the PTO will stop. 2. Move the throttle lever to the fast position. Important For best performance, always use full throttle when the PTO is on.
9. Fully press the brake pedal, set the parking brake, push the PTO switch to the Off position, and start the engine. 1 10. Pull the PTO switch to the On position and rise slightly from the seat; the engine should stop. 11. With the parking brake released, turn the ignition key to the Run position without starting the engine. m–4260 Figure 15 1. Reverse interlock key 12.
Parking Brake Light Fuel Level Gauge When the parking brake light is on, it indicates the parking brake is set. The machine will not drive while the parking brake is set. This gauge shows the level of fuel remaining. PTO Light The hour meter (Fig. NO TAG) records the amount of time the engine has run. Use it to schedule regular maintenance. Hour Meter When the PTO light is on, it indicates the implement is being powered. The PTO clutch must be disengaged before the engine will start.
1 2 1 m–3313 3 Figure 18 1. Cruise control 4 m–3258 Engaging the Cruise Control Figure 17 1. Traction control pedal 2. Brake pedal 3. Forward 4. Backward 1. Drive the tractor forward and obtain the desired speed. 2. While holding your foot steady on the traction control pedal, push the cruise control switch (Fig. 18) to the set position. 5. To slow down, release the pressure on the traction control pedal and step on the brake pedal. This locks the traction control in position. 3.
Lowering Attachments 1 1. Start the tractor. 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 most comfortable. 1. Move the adjustment lever sideways to unlock seat (Fig. 21). m–3258 2. Slide the seat to the desired position and release the lever to lock the seat into position. Figure 19 1.
3. Continue turning the steering wheel by the degree to which it is off center. 1 4. Turn the steering wheel in the other direction until the front wheels aim straight ahead. The steering wheel should now be centered. m–3312 The Smart Turn Steering Feature Figure 22 1. Lights 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 maximum speed reduction of 40 percent.
Maintenance Recommended Maintenance Schedule Maintenance Service Interval Maintenance Procedure Each Use • • • • • • Engine oil—check level Brakes—check Safety System—check Air-intake screens—clean1 Engine area—clean1 Rear transaxle cover—clean1 25 Hours • • • • Engine air precleaner—clean1 Tires—check pressure Battery—check electrolyte level Transaxle—check oil level 50 Hours • Grease fittings—grease • Power take off (PTO) belt—check tension 100 Hours • Engine oil—change2 • Engine air filter—rep
Caution If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the ignition and disconnect the wire from the spark plug before you do any maintenance. Set the wire aside so that it does not accidentally contact the spark plug. Servicing the Air Cleaner 2 Foam Element: Clean and oil after every 25 operating hours, or yearly, whichever occurs first.
Servicing the Engine Oil 2 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 oil change. 1 Oil Type: Detergent oil (API service SG or SH) Crankcase Capacity: w/filter, 2.1 qts. (2.0 l) m–3247 Viscosity: Refer to the following table. Figure 25 1. Foam element 2. Oil USE THESE SAE VISCOSITY OILS 5. Squeeze the element to distribute the oil.
3 2 1 1 1256 m–3262 Figure 27 Figure 29 1. Oil drain 1. Oil filter 2. Gasket 7. When the oil has drained completely, close the drain by pushing it in and turning it clockwise, 1/8 turn. 3. Adapter 3. Wipe the filter adapter gasket surface (Fig. 29). 8. Dispose of the used oil at a certified recycling center. 4. Apply a thin coat of new oil to the rubber gasket on the replacement filter (Fig. 29). 9. Slowly pour approximately 80% of the specified amount of oil into the oil filler tube (Fig.
Installing the Spark Plugs 4. Clean around the spark plugs to prevent dirt from falling into the engine and potentially causing damage. 1. Install the spark plugs and metal washers. 5. Remove the spark plugs and metal washers. 2. Ensure that the air gap is set correctly. 3. Tighten the spark plugs to 18 to 22 ft-lb (24.4 to 29.8 Nm). 2 4. Push the wires onto the spark plugs (Fig. 30). 5. Close the hood.
m–3420 Figure 35 1 m–3422 7. If your tractor has manual steering, put one pump of grease into the steering housing (from underneath the frame) (Fig. 36). Figure 33 1. Drive shaft maintenance cover Danger The rotating, cooling fan and drive shaft can catch fingers, hands, feet, hair, and loose clothing, causing amputation or other severe injury. m–3409 • Do not operate the tractor without the drive shaft cover in place. • Keep fingers, hands and clothing clear of the rotating, fan and drive shaft.
Checking the Brake Important 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 immediately. 1. Park the machine on a level surface, disengage the PTO, put the High-Low range lever in the neutral position. 2. Set the parking brake, stop the engine, and remove the ignition key. Draining the Fuel Tank 3. Push the tractor forward.
5. Remove the filter from the fuel lines. 1 3 2 2 1 m–2487 1. Hose clamp 2. Fuel line 4 3 Figure 41 3. Fuel shut-off valve m–3365 Figure 42 1. Hose clamp 2. Fuel line 4. Loosen the hose clamp and slide it up the fuel line away from the fuel shut-off valve (Fig. 41). 3. Filter 4. Flow direction arrow 6. Install a new filter and move the hose clamps close to the filter. 5. Pull the fuel line off the fuel shut-off valve (Fig. 41).
Changing Transaxle Fluid The front measurement should be 1/8 to 1/4 in. (3 to 6 mm) less than the rear measurement. If adjustment is needed, refer to Adjusting Toe-In. Check the fluid level every 25 hours. Always keep the fluid level in the 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.
2 1 3 m–2467 2 Figure 47 1. Operating range 2. FULL line 1 8. If the oil level is low, slowly pour only enough SAE 10W-30 detergent oil into the filler tube to raise the level to the full line. 1256 Figure 49 1. Transaxle filter 2. Gasket Important Do not fill above the full line because the fluid may overflow. 3. Adapter Draining the Transaxle Oil 2. Wipe the filter adapter gasket surface (Fig. 49). 1. Warm up the transaxle oil by driving the tractor. 3.
Replacing Fuses 5. Push and rotate the bulb counterclockwise until it stops (approx. 1/4 turn) and remove the bulb from the bulb holder (Fig. 52). 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. 1 To replace a fuse, pull it out of the fuse box and insert a new fuse of the same type and size that you removed (Fig. 50). 2 2 4 3 4 1 2 3 Figure 52 4 1. Bulb 2.
Removing the Battery 1. Disengage the PTO, set the parking brake, lower the attachment lift, stop the engine, and remove the ignition key. 2. Remove the front grill by pulling it outward toward you. 4 3 1 3. Remove the battery shield (Fig. 54). 2 m–3321 1 Figure 53 1. Lens 2. Screws 3 3. Bulb 4. Socket 6 4 5 2 8 3. Pull the lens out far enough so you can remove the bulb socket (Fig. 53). 4. Pull the bulb from the socket (Fig. 53). Installing the Bulb 7 m–5073 1.
Warning Danger Incorrect battery cable routing could damage the tractor and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns. • Do not drink electrolyte and avoid 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.
Cleaning and Storage 1. Remove the battery from the chassis; refer to Removing the Battery, page 30. 1. Disengage the PTO, set the parking brake, stop the engine, and remove the ignition and KeyChoice keys. 2. Check the electrolyte level; refer to Checking the Electrolyte Level, page 31. 2. Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine. 3. Make sure the vent caps are installed in the battery.
10. Remove the spark plugs and check their condition; refer to Changing Spark Plugs, page 22. 11. With the spark plugs removed from the engine, pour two tablespoons of engine oil into the spark plug hole. 12. Use the electric starter to crank the engine and distribute the oil inside the cylinder. 13. Install the spark plugs and tighten to recommended torque; refer to Changing Spark Plugs, page 22. Note: Do not install the wire on the spark plug(s). 14.
BK OR A B Y BN 2 5 K4 VIO BU W PK OR PK BK B+D A D C B J A H K E F BATTERY LIGHT MODULE VOLTAGE COMPARATOR BK #194 LAMPOR #194 LAMP PARK BATTERY #194 LAMP GN #194 LAMP #194 LAMPT #194 LAMP PTO OIL OVER RIDE CRUISE BN 1 VIO 2 OR BK BU W PK GN T VIO SW7 PARK BRAKE IS ENGAGED SWITCH CLOSES WHEN I BK #194 LAMP G L PK VIO W I S Y TEMP. GAUGE GND TEMP.
Troubleshooting Problem The starter does not crank. The engine cranks, but will not start. Possible Causes Corrective Action 1. The PTO is on. 1. Move the PTO to the off position. 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.
Problem The engine starts, but does not g keep running The engine runs, but knocks or misses. The engine will not idle. Possible Causes Corrective Action 1. Misadjusted or broken 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. Replace the fuel filter. 5.
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. The 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. Clean with every use. 1.
Problem The tractor will not operate in either direction. The tractor operates erratically. The tractor operates in both directions, but with a loss of power. This condition becomes worse as th the ttransmission i i becomes hot. Abnormal vibration or noise. Possible Causes Corrective Action 1. The High-Low range lever is in neutral (N). 1. Move the High-Low range lever to L or H. 2. The transmission oil is low. 2. Fill to the full mark on the transmission oil dipstick when the transmission is cold.
Problem PTO belt comes off of pulleys, slips, or fails. Possible Causes Corrective Action 1. Belt tension is incorrect. 1. Refer to the attachment operator’s manual. 2. Mower level is incorrect 2. Refer to the attachment operator’s manual. 3. Blade slope in transport is incorrect. 3. Refer to the attachment operator’s manual. 4. Cutter deck belt guide is loose or incorrectly adjusted. 4. Adjust and tighten belt guide. 5. Belt is worn or damaged. 5. Refer to the attachment operator’s manual. 6.
Setup Loose Parts Note: Use the chart below to identify parts for assembly. DESCRIPTION QTY. USE Bolt, 1/4-20 x 0.88 in. 2 Washer, 1/4 in. 2 Hex Nut, 1/4-20 in. 2 Hitch Pin 1 Hairpin Cotter 1 Flat Washer, 0.
Activating the Battery Warning 2 3 Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling. 1 m-5004 Figure 58 Purchase bulk electrolyte with 1.265 specific gravity battery supply outlet. 1. Filler caps 2. Upper line 3. Lower line Danger 7. Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns.
Installing the Drawbar Hitch Pin 6. As applicable, check and test the operation of the following: • Engine, choke and throttle controls Insert the drawbar hitch pin into the drawbar hitch and secure it with a 0.50 in. inside diameter flat washer and hairpin cotter (Fig. 60). • Gauges • Headlights and taillights • Indicator lights • PTO clutch and brake • Lift system • Service and parking brakes • Transmission controls • Steering • Tractor operation in forward and reverse 1 2 7.
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.
