Toro 74538 Operator'S Manual Download Page 9

Page: 9 / 64

115-4186

Interval

Power Take-off (PTO)

Parking brake

Neutral

Operator presence switch

Battery

115-4212

Hydraulic oil level

Warning—do not touch
the hot surface.

Read the

Operator’s

Manual

116-3267

116-3290

117-0456

Height of cut (HOC)—high

Height of cut (HOC)—low

Height of cut
(HOC)—medium

119-0217

Warning—stop the engine; stay away from moving parts;
keep all guards and shields in place.

119-1854

Adjustment knob for traction drive speed.

Summary of Contents for 74538

Page 1: ... No 74548 Serial No 311000001 and Up Model No 74549 Serial No 311000001 and Up Model No 74553 Serial No 311000001 and Up Model No 79548 Serial No 311000001 and Up Model No 79549 Serial No 311000001 and Up Model No 79553 Serial No 311000001 and Up To register your product or download an Operator s Manual or Parts Catalog at no charge go to www Toro com Original Instructions EN ...

Page 2: ...awns on residential or commercial properties It is not designed for cutting brush or for agricultural uses Read this information carefully to learn how to operate and maintain your product properly and to avoid injury and product damage You are responsible for operating the product properly and safely You may contact Toro directly at www Toro com for product and accessory information help finding ...

Page 3: ... Access 29 Release the Cushion for Rear Access 30 Lubrication 31 How to Grease 31 Lubricating the Machine 31 Greasing the Front Caster Pivots 31 Lubricate Caster Wheel Hubs 32 Engine Maintenance 33 Servicing the Air Cleaner 33 Servicing the Engine Oil 33 Servicing the Spark Plug 36 Fuel System Maintenance 37 Draining the Fuel Tank 37 Servicing the Fuel Filter 38 Electrical System Maintenance 38 Se...

Page 4: ...line and other fuels They are flammable and vapors are explosive Use only an approved container Never remove gas cap or add fuel with engine running Allow engine to cool before refueling Do not smoke Never refuel or drain the machine indoors Check that operator s presence controls safety switches and shields are attached and functioning properly Do not operate unless they are functioning properly ...

Page 5: ... adjustments with the engine running Keep all parts in good working condition and all hardware tightened Replace all worn or damaged decals Toro Mower Safety The following list contains safety information specific to Toro products and other safety information you must know This product is capable of amputating hands and feet and throwing objects Always follow all safety instructions to avoid serio...

Page 6: ... slopes greater than 20 degrees Service Never store the machine or fuel container inside where there is an open flame such as near a water heater or furnace Keep nuts and bolts tight especially the blade attachment bolts Keep equipment in good condition Never tamper with safety devices Check safety systems for proper operation before each use Use only genuine replacement parts to ensure that origi...

Page 7: ... degrees Use the slope chart to determine the degree of slope of hills before operating Do not operate this machine on a slope greater than 20 degrees Fold along the appropriate line to match the recommended slope 2 Align this edge with a vertical surface a tree building fence pole etc 3 Example of how to compare slope with folded edge 7 ...

Page 8: ... ft lb 115 149 N m Battery Symbols Some or all of these symbols are on your battery 1 Explosion hazard 6 Keep bystanders a safe distance from the battery 2 No fire open flame or smoking 7 Wear eye protection explosive gases can cause blindness and other injuries 3 Caustic liquid chemical burn hazard 8 Battery acid can cause blindness or severe burns 4 Wear eye protection 9 Flush eyes immediately w...

Page 9: ...level 3 Warning do not touch the hot surface 2 Read the Operator s Manual 116 3267 116 3290 117 0456 1 Height of cut HOC high 3 Height of cut HOC low 2 Height of cut HOC medium 119 0217 1 Warning stop the engine stay away from moving parts keep all guards and shields in place 119 1854 1 Adjustment knob for traction drive speed 9 ...

Page 10: ... do not operate this machine unless you are trained 6 Warning engage the parking brake stop the engine and remove the spark plug wire before performing any maintenance on the machine 3 Thrown object hazard keep deflector in place 7 Warning engage the parking brake and stop the engine before leaving the machine 4 Cutting dismemberment hazard of hand or foot stay away from moving parts and keep all ...

Page 11: ...perator presence switch 2 Fast 4 Neutral 6 Power Take off PTO disengage 119 8728 1 Parking brake disengage 3 Power Take off PTO engage 5 Engine speed 7 Continuous variable setting 2 Parking brake engage 4 Power Take off PTO disengage 6 Fast 8 Slow 11 ...

Page 12: ...ff valve behind cushion 10 Hydraulic tank 5 Fuel tank 11 Mower deck 6 Controls 12 Front caster wheel g015395 1 2 3 4 5 6 7 8 9 10 11 12 Figure 4 60 inch machine 1 Side discharge chute 7 Control levers 2 Battery 8 Manual tube 3 Engine 9 Platform down position 4 Fuel shut off valve behind cushion 10 Hydraulic tank 5 Fuel tank 11 Mower deck 6 Controls 12 Front caster wheel 12 ...

Page 13: ...5 Fuel gauge 12 Blade control switch PTO 6 Height of cut lever 13 Left motion control lever 7 Height of cut pin Hour Meter The hour meter records the number of hours the engine has operated It operates when the engine is running Use these times for scheduling regular maintenance Figure 7 Fuel Gauge The fuel gauge is located on the top middle of the tank Figure 5 Safety Interlock Indicators There a...

Page 14: ... when transporting or storing the mower Attachments Accessories A selection of Toro approved attachments and accessories are available for use with the machine to enhance and expand its capabilities Contact your Authorized Service Dealer or Distributor or go to www Toro com for a list of all approved attachments and accessories Specifications Note Specifications and design are subject to change wi...

Page 15: ...ctricity can be released causing a spark which can ignite the gasoline vapors A fire or explosion from gasoline can burn you and others and can damage property Always place gasoline containers on the ground away from your vehicle before filling Do not fill gasoline containers inside a vehicle or on a truck or trailer bed because interior carpets or plastic truck bed liners may insulate the contain...

Page 16: ...load on the engine Allow 40 to 50 hours of break in time for new machines to develop full power and best performance Think Safety First Carefully read all the safety instructions and decals in the safety section Knowing this information could help you or any bystanders avoid injury The use of protective equipment for eyes hearing feet and head is recommended CAUTION This machine produces sound lev...

Page 17: ...osition G008945 Figure 10 Disengaging the Mower Blades PTO The following are two options for disengaging the mower blades Push the blade control switch PTO down to the off position Move the motion control levers to neutral and move the right side motion control lever into the neutral lock position G009174 Figure 11 Operating the Throttle The throttle control can be moved between Fast and Slow posi...

Page 18: ...ely STA RT RU N STO P G008947 Figure 14 2 Turn the ignition key to stop to stop the engine Using the Fuel Shut Off Valve Close the fuel shut off valve for transport maintenance and storage Figure 15 Ensure the fuel shut off valve is open when starting the engine g015365 G008948 1 2 Figure 15 1 On 2 Off Starting and Stopping the Engine Starting the Engine 1 Connect the wires to the spark plugs 2 Op...

Page 19: ... completely STA RT RU N STO P G008947 Figure 17 1 Off 3 Start 2 Run Stopping the Engine CAUTION Children or bystanders may be injured if they move or attempt to operate the tractor while it is unattended Always remove the ignition key and set the parking brake when leaving the machine unattended even if just for a few minutes Let the engine idle at slow throttle turtle for 60 seconds before turnin...

Page 20: ...otate 4 Move the motion control levers forward The engine should kill 5 Start the engine and release the parking brake 6 Move the right side motion control lever to the center un locked position 7 Continue holding the right side motion control lever in the center un locked position and pull up on the blade control switch PTO and release The clutch should engage and the mower blades begin rotating ...

Page 21: ...ded when Mowing most areas Driving across slopes Driving down slopes To lower the platform push the platform forward against the cushion to release pressure on the latch pin and then pull the knob out and lower the platform G015233 Figure 20 1 Platform up 3 Pull the knob out to release the platform 2 Platform down Driving Forward or Backward The throttle control regulates the engine speed as measu...

Page 22: ...ed The farther you move the motion control levers in either direction the faster the machine will move in that direction To stop pull the motion control levers back to the neutral position Figure 22 Driving Backward 1 Move the right side motion control lever to the center un locked position 2 Slowly pull the motion control levers rearward Figure 23 Figure 23 Stopping the Machine To stop the machin...

Page 23: ...chine by hand Never tow the machine because hydraulic damage may occur To Push the Machine 1 Disengage the PTO move the motion control levers to the neutral locked position and set the parking brake 2 Open the by pass valve on both pumps by turning them counter clockwise 1 to 2 turns This allows hydraulic fluid to by pass the pumps and the wheels to turn Figure 25 Note Rotate the by pass valves a ...

Page 24: ...be long enough so that the angles do not exceed 20 degrees Figure 27 A steeper angle may cause mower components to get caught as the unit moves from ramp to trailer or truck Steeper angles may also cause the unit to tip backward If loading on or near a slope position the trailer or truck so it is on the down side of the slope and the ramp extends up the slope This will minimize the ramp angle The ...

Page 25: ...ing to the height of cut desired and insert the pin Figure 28 3 Lower the height of cut lever to the pin Figure 28 Figure 28 1 Height of cut holes 3 Height of cut lever 2 Height of cut pin Adjusting the Anti Scalp Rollers 60 inch Mower Decks Only Whenever you change the height of cut it is recommended to adjust the height of the anti scalp rollers 1 Disengage the blade control switch PTO move the ...

Page 26: ... and height of grass Note If the engine power draws down and the mower ground speed is the same open up the baffle Position A This is the full rear position see Figure 31 The suggested use for this position is a follows Use for short light grass mowing conditions Use in dry conditions For smaller grass clippings Propels grass clippings farther away from the mower Figure 31 Position B Use this posi...

Page 27: ...recommended that weights be added or removed one at a time until the desired handing and balance is achieved Note Contact an Authorized Service Dealer to order a Weight Kit WARNING Excessive weight changes can effect handling and operation of the machine This could cause serious injury to you or bystanders Make weight changes is small increments only Evaluate the mower after each weight change to ...

Page 28: ... belt Check the pump drive belt Check the hydraulic hoses Every 200 hours Replace the paper air cleaner element Change the engine oil filter Every 250 hours Change the hydraulic filter and hydraulic oil when using Mobil 1 oil Every 500 hours Adjust the caster pivot bearing Change the hydraulic filter and hydraulic oil when using Toro HYPR OIL 500 hydraulic oil Every 800 hours Grease the front whee...

Page 29: ... Draining the Fuel Tank in Maintenance 4 Remove the cap of the hydraulic tank and place a piece of plastic over the opening and install the hydraulic cap This will seal the hydraulic tank and prevent it from leaking out g015408 1 2 3 Figure 35 1 Cap 3 Hydraulic tank 2 Piece of plastic 5 With two people raise the front of the mower so it rests on the drive tires and the platform in the up position ...

Page 30: ...ide of the cushion 3 Slide the large washers with plastic bushings to the inside 4 Remove the cushion and lower it to the platform 5 Perform any maintenance or adjustment on the machine 6 Raise the cushion and slide it onto the pins on both sides of the machine Figure 37 7 Slide the large washers plastic bushings into the cushion bracket and secure them with a hairpin cotter pin Figure 37 Figure 3...

Page 31: ...eck spindles more often in dirty or dusty conditions Every 800 hours Yearly whichever comes first Grease the front wheel bearings more often in dirty or dusty conditions Every 800 hours Yearly whichever comes first Grease the front caster pivots more often in dirty or dusty conditions Use the following graphics for locating the grease points Figure 38 G015236 Figure 39 g015589 Figure 40 Greasing t...

Page 32: ... thread spacer nut all of the way onto the end of the axle Leave approximately 1 8 inch 3 mm from the outer surface of the spacer nut to the end of the axle inside the nut 9 Insert the assembled nut and axle into the wheel on the side of the wheel with the new seal and bearing 10 With the open end of the wheel facing up fill the area inside the wheel around the axle full of general purpose grease ...

Page 33: ...squeezing it in a clean cloth Important Replace the foam element if it is torn or worn Servicing the Paper Air Cleaner Element Service Interval Every 50 hours Check the paper air cleaner element Every 200 hours Replace the paper air cleaner element 1 Do not clean the paper filter replace it Figure 42 2 Inspect the element for tears an oily film or damage to the rubber seal 3 Replace the paper elem...

Page 34: ...ands feet face clothing and other body parts away the muffler and other hot surfaces Important Do not overfill the crankcase with oil because damage to the engine may result Do not run engine with oil below the low mark because the engine may be damaged 1 Disengage the PTO move the motion control levers to the neutral locked position and set the parking brake 2 Stop the engine remove the key and w...

Page 35: ...796 2 3 4 5 6 1 Figure 46 Changing the Engine Oil Filter Note Change the engine oil filter more frequently when operating conditions are extremely dusty or sandy 1 Drain the oil from the engine refer to Changing the Engine Oil 2 Place a rag under the oil filter to soak up any spilled oil Important Spilled oil may drain under the engine and onto the clutch Oil spilled on the clutch may damage the c...

Page 36: ...k plug s if necessary Type for all Engines NGK BPR4ES or equivalent Air Gap 0 030 inch 0 75 mm Removing the Spark Plug 1 Disengage the PTO move the motion control levers to the neutral locked position and set the parking brake 2 Stop the engine remove the key and wait for all moving parts to stop before leaving the operating position g015238 Figure 48 Checking the Spark Plug Important Never clean ...

Page 37: ...ain gasoline from the fuel tank when the engine is cold Do this outdoors in an open area Wipe up any gasoline that spills Never smoke when draining gasoline and stay away from an open flame or where a spark may ignite the gasoline fumes 1 Park the machine on a level surface Disengage the power take off PTO set the parking brake turn the ignition key to Off and remove the key 2 Clean around the fue...

Page 38: ...ery 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 Voltage 12 V WARNING CALIFORNIA Proposition 65 Warning Battery posts terminals and related accessories contain lead and lead compounds chemi...

Page 39: ...h a nut washer and bolt Figure 53 Slide the rubber cover over the post 4 Then install the negative battery cable and ground wire to the negative battery terminal with a nut washer and bolt Figure 53 Slide the rubber cover over the post Figure 53 1 Wing nut 4 Positive battery cable 2 Battery cover 5 Battery 3 Negative battery cable Charging the Battery WARNING Charging the battery produces gasses t...

Page 40: ...oth control levers forward the same distance 2 Check if the machine pulls to one side If it does stop the machine and set the parking brake 3 Release the cushion from the rear of the machine 4 Rotate the right cable adjustment to position the right motion control in the center of the control panel neutral lock slot Figure 57 g015241 Figure 56 1 Left motion control lever 3 Neutral locked position 2...

Page 41: ...adjust the proximity switch until the target aligns with bolt attached to the motion control lever Figure 58 3 Check the distance of the bolt to the proximity switch It needs to be between 0 050 and 0 090 inches 1 27 to 2 29 mm Figure 58 4 If adjustment is needed loosen the jam nut and adjust the bolt to the correct distance Tighten the jam nut after adjusting the bolt Figure 58 5 Test the safety ...

Page 42: ... turn to properly set the pre load on the bearings Figure 60 Important Make sure spring washers are installed correctly as shown in Figure 60 5 Install the dust cap Figure 60 Figure 60 1 Spring Washers 3 Dust Cap 2 Lock Nut Servicing the Caster Wheel and Bearings The caster wheels rotate on a roller bearing supported by a spanner bushing If the bearing is kept well lubricated wear will be minimal ...

Page 43: ...he fitting on the caster wheel Adjusting the Electric Clutch Service Interval Every 100 hours Check the electric clutch The clutch is adjustable to ensure proper engagement and proper braking 1 Insert a 0 015 0 021 inch 0 381 0 533 mm feeler gauge through one inspection slot in the side of the assembly Make sure it is between the armature and the rotor friction surfaces The gap needs to be at leas...

Page 44: ...er and fan housing Figure 63 2 g015409 1 Figure 63 1 Guard and engine air intake screen 2 Fan housing Brake Maintenance Servicing the Brake Before each use check brakes on both a level surface and slope Always set the parking brake when you stop the machine or leave it unattended If the parking brake does not hold securely an adjustment is required Checking the Parking Brake Service Interval Befor...

Page 45: ...air pin cotter and clevis pin from the lower brake lever and yoke Figure 65 6 Loosen the jam nut Figure 65 7 Rotate the yoke To tighten the brake rotate the yoke up To loosen the brake rotate the yoke down Figure 65 8 Secure the yoke to lower brake lever with the hair pin cotter pin and clevis pin Figure 65 9 Tighten the jam nut Figure 65 10 Check the brake operation again refer to Checking the Br...

Page 46: ...ns are evident 1 Disengage the PTO and set the parking brake 2 Stop the engine remove the key and wait for all moving parts to stop before leaving the operating position 3 Unlatch and remove the belt covers 4 Loosen the front idler pulley by loosening the nut 5 Remove the worn mower belt Figure 67 6 Install the new mower belt around the deck pulleys and clutch pulley Figure 67 7 Using a ratchet in...

Page 47: ...beginning of the Maintenance Section 5 Remove the shoulder bolt nut and washer from the engine deck and connected to the spring Figure 68 G015402 1 2 3 5 4 6 Figure 68 1 Hydraulic pumps 4 Clutch retainer 2 Idler pulley 5 Pump drive belt 3 Clutch pulley 6 Shoulder bolt nut and washer connected to engine deck 6 Remove the pump drive belt Figure 68 7 Install the new belt around clutch and the two pum...

Page 48: ...igure 69 Figure 69 1 Left motion control lever 3 Check the horizontal alignment here 2 Right motion control lever in neutral locked position 4 Right motion control lever 5 To adjust the right motion control lever horizontally the cam needs to be adjusted 6 Release the cushion from the rear of the machine 7 Loosen the nut and bolt holding the cam Figure 70 8 Adjust the cam until it aligns with the ...

Page 49: ... neutral lock position adjustment is required 1 After the horizontal alignment is finished check the front to back alignment Figure 72 g015241 Figure 72 1 Left motion control lever 3 Neutral locked position 2 Right motion control lever 4 Align the control levers front to back 2 Rotate the right cable adjustment to place the right motion control lever in the center of the neutral lock slot in the c...

Page 50: ...el while the fluid is warm If required add fluid to the reservoir until it is between the hot level and the cold level Note The fluid level should be below the hot level of the baffle when the fluid is warm Figure 74 9 Install cap on filler neck WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury If hydraulic fluid is injected into the skin it must be surgically rem...

Page 51: ... leaks If one or both wheels will not drive refer to Bleeding Hydraulic System 12 Check the level of the fluid and add fluid if required Do not overfill Replacing the Hydraulic Filter Service Interval After the first 8 hours WARNING Hot hydraulic fluid can cause severe burns Allow the hydraulic fluid to cool before performing any maintenance to the hydraulic system 1 Disengage the PTO and set the ...

Page 52: ...it drops add fluid as required to maintain the proper level 6 Repeat this procedure for the opposite wheel 7 Thoroughly clean the area around each of the charge pump housings Checking the Hydraulic Lines Service Interval Every 100 hours Check hydraulic hoses and hoses for leaks loose fittings kinked hoses loose mounting supports wear weather and chemical deterioration Make necessary repairs before...

Page 53: ...ear slot Forming 2 Curved Area 4 Crack Checking for Bent Blades 1 Disengage the PTO move the motion control levers to the neutral locked position and set the parking brake 2 Stop the engine remove the key and wait for all moving parts to stop before leaving the operating position 3 Rotate the blades until the ends face forward and backward Measure from a level surface to the cutting edge position ...

Page 54: ...e is balanced and can be used If the blade is not balanced file some metal off the end of the sail area only Figure 80 Repeat this procedure until the blade is balanced Figure 82 1 Blade 2 Balancer Installing the Blades 1 Install the blade onto the spindle shaft Figure 83 Important The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting 2 Instal...

Page 55: ...hanging the Mower Deck Side to Side Height Changing the Mower Deck Side to Side Height Changing the side to side height is done by adjusting the rear tire pressure and U plates on the side of the engine deck 1 Change the rear tire pressure Do this to the corresponding side that needs adjustment 2 Locate the U plates on the side of the engine deck Figure 85 3 Loosen the U plate on one side and adju...

Page 56: ...88 3 For 60 inch mower decks loosen both the front and rear nuts and lift links on the adjustment rods Figure 89 4 The weight of the mower deck must be resting on all three of the 2x4 s Figure 88 The back lip of the mower deck is built a 1 4 inch 6mm lower than the front lip of the mower deck 5 For 60 inch mower decks tighten the lift links Figure 89 6 Tighten both the front and rear nuts 7 Check ...

Page 57: ...ace 2 Measure blade at point A 4 The measurement should be 3 inch 7 6 cm 5 If it does not measure correctly locate the height of cut rod on the right side of the machine Figure 91 6 Adjust the adjustment bolt until the blade tips match 3 inches 7 6 cm Figure 91 g015336 1 2 Figure 91 1 Height of cut rod 2 Adjustment bolt Replacing the Grass Deflector WARNING An uncovered discharge opening could all...

Page 58: ...igure 92 Important The grass deflector must be able to rotate Lift the deflector up to the full open position and ensure that it rotates into the full down position Cleaning Cleaning Under the Mower Service Interval Before each use or daily Remove the grass buildup under the mower daily 1 Disengage the PTO move the motion control levers to the neutral locked position and set the parking brake 2 St...

Page 59: ...storage A Add stabilizer conditioner additive to fuel in the tank B Run engine to distribute conditioned fuel through the fuel system 5 minutes C Stop engine allow to cool and drain the fuel tank refer to Servicing the Fuel Tank in Fuel System Maintenance page 37 or operate engine until it stops D Restart engine and run until it stops Repeat on Choke until engine will not restart E Dispose of fuel...

Page 60: ...horized Service Dealer 1 Engine load is excessive 1 Reduce the ground speed 2 Oil level in the crankcase is low 2 Add oil to the crankcase Engine overheats 3 Cooling fins and air passages under the engine blower housing are plugged 3 Remove the obstruction from the cooling fins and air passages 1 Hydraulic oil reservoir low 1 Add hydraulic oil to the reservoir 2 Air in the hydraulic system 2 Bleed...

Page 61: ...all deck pulley and check the idler pulley idler arm and spring for correct position and function 5 Broken or missing idler spring 5 Replace the spring 6 Electric clutch out of adjustment 6 Adjust the clutch air gap 7 Clutch connector or wire damaged 7 Contact an Authorized Service Dealer 8 Damaged electric clutch 8 Contact an Authorized Service Dealer 9 Safety interlock system prevents blade rota...

Page 62: ...Schematics Hydraulic Schematic Rev A 62 ...

Page 63: ...G015606 Electrical Schematic Rev A 63 ...

Page 64: ...ith the Service Dealer s analysis or with the assistance provided contact us at RLC Customer Care Department Toro Warranty Company 8111 Lyndale Avenue South Bloomington MN 55420 1196 888 865 5676 U S Customers 888 865 5691 Canada customers Owner Responsibilities You must maintain your Toro Product by following the maintenance procedures described in the Operator s Manual Such routine maintenance w...

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