Form No. 3440-334 Rev B 2000 Series HDX RD 122cm Riding Mower Model No. 74456TE—Serial No. 400000000 and Up Register at www.Toro.com.
This product complies with all relevant European directives; for details, please see the separate product specific Declaration of Conformity (DOC) sheet. Please refer to the engine manufacturer’s information included with the machine. Gross or Net Torque: The gross or net torque of this engine was laboratory rated by the engine manufacturer in accordance with the Society of Automotive Engineers (SAE) J1940 or J2723.
Contents Replacing the Emissions-Air Intake Filter.............................................................. 40 Fuel System Maintenance ................................... 40 Replacing the Fuel Filter ................................... 40 Servicing the Fuel Tank..................................... 41 Electrical System Maintenance ........................... 41 Electrical System Safety ................................... 41 Servicing the Battery.........................................
Safety This machine has been designed in accordance with EN ISO 5395. General Safety This product is capable of amputating hands and feet and of throwing objects. Always follow all safety instructions to avoid serious personal injury. • Read and understand the contents of this Operator’s Manual before starting the engine. • Keep bystanders and children away. • Do not allow children or untrained people to operate or service the machine.
Slope Indicator g011841 Figure 3 You may copy this page for personal use. 1. The maximum slope you can operate the machine on is 15 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 15 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.
Safety and Instructional 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 missing. decaloemmarkt Manufacturer's Mark decal106-5517 1. Indicates the blade is identified as a part from the original machine manufacturer. 106-5517 1. Warning—do not touch the hot surface. decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery. 1. Explosion hazard 6.
decal112-3858 112-3858 1. Read the Operator's Manual. 3. Remove the key before adjusting the height of cut. 2. Read the Operator's Manual before performing maintenance. 4. Height-of-cut settings decal116-8588 116-8588 1. Read the Operator’s Manual. 2. Rotate the drive release knob to loosen, slide the knob, and tighten. decal112-9028 3. Push the machine. 112-9028 1. Warning—stay away from moving parts; keep all guards and shields in place. decal116-5610 116–5610 1. Hour meter 2.
decal126-9939 126-9939 1. Read the Operator’s Manual. 2. Fill to the bottom of the filler neck; warning—do not overfill the tank. decal126-7816 126-7816 1. Height of cut decal127-6663 127-6663 1. Warning—read the Operator's Manual. decal126-8172 126-8172 1. Parking brake disengaged 2. Parking brake engaged 8 2. Crushing hazard—engage the parking brake, shut off the engine, and remove the key; support the machine using jackstands.
decal135-0664 135-0664 1. Thrown object hazard—keep bystanders away. 2. Cutting/dismemberment hazard of hands and feet—stay away from moving parts; keep all guards and shields in place. decal136-8992 136-8992 3. Fuel—empty 1. Fuel—full 2. Fuel—50% decal136-1672 136-1672 1. Warning—do not step; do not carry passenger. decal137-9240 137-9240 3. Fast 4. Slow 1. Choke 2. Work light decal136-9024 136-9024 1. Read the Operator’s Manual before performing maintenance. 2. Operating hours 5.
decaltransportlock Transport Lock 1. Height of cut 2. Pull up to unlock the transport lock. decalmotioncntrlrh-126-6183 Right Motion Control 1. Machine speed 4. Neutral 2. Fast 3. Slow 5. Reverse decalmotioncntrllh-126-6194 Left Motion Control 1. Machine speed 4. Neutral 2. Fast 3. Slow 5. Reverse decal136-1720 136-1720 1. Cam lock 2.
decal132-0871 132-0871 Note: This machine complies with the industry standard stability test in the static lateral and longitudinal tests with the maximum recommended slope indicated on the decal. Review the instructions for operating the machine on slopes in the Operator’s Manual as well as the conditions in which you would operate the machine to determine whether you can operate the machine in the conditions on that day and at that site.
Controls Product Overview Become familiar with all the controls before you start the engine and operate the machine. Control Panel g271171 Figure 5 1. Position for optional power 5. Blade-control switch (power takeoff) point 2. Choke control 6. Key switch 3. Throttle control 7. Switch position for optional light kit 4. Hour meter g327985 Figure 4 1. Height-of-cut deck-lift pedal 7. Shock assembly Key Switch 2. Height-of-cut positions 8. Fuel cap 3. Transport lock 9.
Battery-Indicator Light Blade-Control Switch (Power Takeoff) If you turn the key switch to the ON position for a few seconds, the battery voltage displays in the area where the hours are normally displayed. The blade-control switch, represented by a power-takeoff (PTO) symbol, engages and disengages power to the mower blades (Figure 5). The battery light turns on when the key switch is turned on and when the charge is below the correct operating level (Figure 6).
Specifications Note: Specifications and design are subject to change without notice.
Fuel Safety Operation • Fuel is extremely flammable and highly explosive. Note: Determine the left and right sides of the machine from the normal operating position. Before Operation Before Operation Safety General Safety • Do not allow children or untrained people to operate or service the machine. Local regulations may restrict the age of the operator. The owner is responsible for training all operators and mechanics.
Adding Fuel Note: Do not fill the fuel tank completely full. The empty space in the tank allows the fuel to expand. Recommended Fuel • For best results, use only clean, fresh (less than 30 days old), unleaded gasoline with an octane rating of 87 or higher ((R+M)/2 rating method). • Ethanol: Gasoline with up to 10% ethanol (gasohol) or 15% MTBE (methyl tertiary butyl ether) by volume is acceptable. Ethanol and MTBE are not the same. Gasoline with 15% ethanol (E15) by volume is not approved for use.
Using the Rollover-Protection System (ROPS) WARNING To avoid injury or death from rollover, keep the roll bar in the fully raised, locked position and use the seat belt. Ensure that the seat is secured to the machine. WARNING There is no rollover protection when the roll bar is in the down position. • Lower the roll bar only when absolutely necessary. • Do not wear the seat belt when the roll bar is in the down position. g036746 • Drive slowly and carefully.
Using the Safety-Interlock System Test the safety-interlock system before you use the machine each time. If the safety system does not operate as described below, have an Authorized Service Dealer repair the safety system immediately. WARNING If the safety-interlock switches are disconnected or damaged, the machine could operate unexpectedly, causing personal injury. • Do not tamper with the interlock switches.
Positioning the Seat Adjusting the Rear-Shock Assemblies The seat can move forward and backward. Position the seat where you have the best control of the machine and are most comfortable (Figure 10). The MyRide™ suspension system adjusts to provide a smooth and comfortable ride. You can adjust the rear 2-shock assemblies to quickly and easily change the suspension system. Position the suspension system where you are most comfortable.
Using Attachments and Accessories Use only Toro approved attachments and accessories. If you add more than 1 accessory-mount kit (i.e., bucket kit or universal mount kit) is added to any of the 4 locations shown in Figure 13, add a front-weight kit. Contact an Authorized Service Dealer for the front-weight kit. g329642 g037417 Figure 13 1. Add a front-weight kit when 2 or more accessory-mount kits are installed at these positions.
• Operate the machine only in good visibility and appropriate weather conditions. Do not operate the machine when there is the risk of lightning. • Keep your hands and feet away from the cutting units. Keep clear of the discharge opening. • Do not mow in reverse unless it is absolutely g229846 Figure 14 necessary. Always look down and behind you before moving the machine in reverse. 1. Wear hearing protection.
• Check carefully for overhead objects before you machine to lose traction. Loss of traction to the drive wheels may result in sliding and a loss of braking and steering. The machine can slide even if the drive wheels are stopped. drive under them, and do not contact them. • Replace damaged ROPS components. Do not repair or alter them. • Remove or mark obstacles such as ditches, holes, • There is no rollover protection when the roll bar ruts, bumps, rocks, or other hidden hazards.
Disengaging the Parking Brake Entering the Operator’s Position Use the mower deck as a step to get into the operator’s position (Figure 16). g192635 g029797 Figure 18 Figure 16 1. Step here. Operating the Parking Brake Always engage the parking brake when you stop the machine or leave it unattended. Engaging the Parking Brake Park the machine on a level surface.
Operating the Mower Operating the Throttle Blade-Control Switch (PTO) You can move the throttle control between FAST and SLOW positions (Figure 21). The blade-control switch (PTO) starts and stops the mower blades and any powered attachments. Always use the FAST position when engaging the PTO. Engaging the Blade-Control Switch (PTO) Note: Engaging the blade-control switch (PTO) with the throttle position at half or less causes excessive wear to the drive belts.
Starting the Engine Shutting Off the Engine Note: A warm or hot engine may not require choking. CAUTION Important: Do not engage the starter for more Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended. than 5 seconds at a time. Engaging the starter motor for more than 5 seconds can damage the starter motor. If the engine fails to start, wait 10 seconds before operating the engine starter again.
Using the Motion-Control Levers WARNING The machine can spin very rapidly. You may lose control of the machine and cause personal injury or damage to the machine. • Use caution when making turns. • Slow the machine down before making sharp turns. Driving Forward Note: The engine shuts off when you move the traction-control with the parking brake engaged. To stop the machine, pull the motion-control levers to the NEUTRAL position. 1.
Adjusting the Height of Cut Using the Transport Lock The transport lock has 2 positions, and is used with the deck-lift pedal. There is a LOCK position and an UNLOCK position for the transport position of the mower deck (Figure 28). g008953 Figure 27 g037050 Figure 28 Transport-Lock Positions 1. Transport lock knob 2. LOCK position—The mower deck locks into the transport position. 27 3. UNLOCK position—The mower deck does not lock into the transport position.
Adjusting the Height-of-Cut Pin Adjusting the Anti-Scalp Rollers Adjust the height-of-cut from 38 to 127 mm (1-1/2 to 5 inches) in 6 mm (1/4 inch) increments by moving the height-of-cut pin into different hole locations. 1. Move the transport lock to the LOCK position. 2. Push on the deck-lift pedal with your foot and raise the mower deck to the TRANSPORT position (also the 127 mm or 5 inch cutting-height position) as shown in Figure 29. 3. 4. 5.
Operating Tips drop onto your lawn. To avoid this, move onto a previously cut area with the blades engaged or you can disengage the mower deck while moving forward. Using the Fast Throttle Setting For best mowing and maximum air circulation, operate the engine at the FAST position. Air is required to thoroughly cut grass clippings, so do not set the height-of-cut so low as to totally surround the mower deck in uncut grass.
2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Locate the bypass levers behind the seat, down on the left and right side of the frame. 4. To push the machine, move both bypass knobs rearward and lock them into place (Figure 33). 5. Disengage the parking brake before pushing the machine. g036849 g008948 Figure 32 1. ON position 2. OFF position Using the Drive-Wheel Release Valves g035062 Figure 33 WARNING 1.
Transporting the Machine Use a heavy-duty trailer or truck to transport the machine. Use a full-width ramp. Ensure that the trailer or truck has all the necessary brakes, lighting, and marking as required by law. Please carefully read all the safety instructions. Knowing this information could help you or bystanders avoid injury. Refer to your local ordinances for trailer and tie-down requirements.
1. If using a trailer, connect it to the towing vehicle and connect the safety chains. 2. If applicable, connect the trailer brakes and lights. 3. Lower the ramp, ensuring that the angle between the ramp and the ground does not exceed 15 degrees (Figure 34). 4. Back the machine up the ramp (Figure 35). g028043 Figure 35 1. Back the machine up the ramp. 2. Drive the machine forward down the ramp. 5. Shut off the engine, remove the key, and engage the parking brake. 6.
Maintenance • Check the parking brake operation frequently. • Maintenance Safety • • If you leave the key in the switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the switch before you perform any maintenance. • • Before you leave the operator’s position, do the following: • – Park the machine on a level surface. – Disengage the drives. • – Engage the parking brake. – Shut off the engine and remove the key.
Maintenance Service Interval Maintenance Procedure • • • • • Every 500 hours Replace the safety air filter (more often in dirty or dusty conditions). Replace the emissions-air intake filter. Replace the fuel filter (more often in dusty, dirty conditions). Check the parking brake adjustment. After the initial change—change the hydraulic-system filters and fluid when using Toro® HYPR-OIL™ 500 fluid. (Change it more often under dirty or dusty conditions) • Check the battery charge.
Lubrication Engine Maintenance Greasing the Machine Engine Safety • Keep your hands, feet, face, clothing, and other Service Interval: Every 25 hours—Grease the front caster axles. (more often in dirty or dusty conditions). Every 50 hours—Grease the pump-idler pivot. body parts away from the muffler and other hot surfaces. Allow engine components to cool before performing maintenance. Do not change the engine governor speed or overspeed the engine.
4. Clean the inside of the air-cleaner cover with compressed air. 5. Gently slide the primary filter out of the air-cleaner body (Figure 40). Servicing the Engine Oil Service Interval: Before each use or daily Every 100 hours (more often in dirty or dusty conditions). Note: Avoid knocking the filter into the side of Every 200 hours—Change the engine-oil filter (more often in dirty or dusty conditions). the body. 6. Remove the safety filter only to replace it.
3. To keep dirt, grass clippings, etc., out of the engine, clean the area around the oil-fill cap and dipstick before removing it (Figure 42). g027734 Figure 43 g235263 Figure 42 Changing the Engine Oil Note: Dispose of the used oil at a recycling center. 1. Start the engine and let it run for 5 minutes. Note: This warms the oil so that it drains better. 2. Park the machine so that the drain side is slightly lower than the opposite side to ensure that the oil drains completely. 3.
6. Slowly pour approximately 80% of the specified oil into the filler tube and slowly add the additional oil to bring it to the Full mark (Figure 44). g027660 g027477 Figure 44 Figure 45 7. Start the engine and drive to a flat area. Note: Ensure that the oil-filter gasket touches 8. Check the oil level again. the engine, and then turn the oil filter an extra 3/4 turn. Changing the Engine-Oil Filter 1. Drain the oil from the engine; refer to Changing the Engine Oil (page 37). 2.
2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Clean the area around the base of the plug to keep dirt and debris out of the engine. 4. Locate and remove the spark plug(s) as shown in Figure 46. Installing the Spark Plug(s) g036857 g027960 Figure 48 Cleaning the Cooling System g027478 Figure 46 Checking the Spark Plug(s) Important: Do not clean the spark plug(s).
Checking the Spark Arrester Fuel System Maintenance For Machines with a Spark Arrester DANGER In certain conditions, fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you and others and can damage property. Service Interval: Every 50 hours WARNING Hot exhaust-system components may ignite fuel vapors even after you shut off the engine. Hot particles exhausted during engine operation may ignite flammable materials, resulting in personal injury or property damage.
Electrical System Maintenance Electrical System Safety • Disconnect the battery before repairing the machine. Disconnect the negative terminal first and the positive last. Connect the positive terminal first and the negative last. • Charge the battery in an open, well-ventilated area, away from sparks and flames. Unplug the charger before connecting or disconnecting the battery. Wear protective clothing and use insulated tools.
2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Remove the battery as shown in Figure 50. 4. Install the battery in the machine and connect the battery cables; refer to Installing the Battery (page 43). Note: Do not run the machine with the battery disconnected; electrical damage may occur. g036853 g000960 Figure 51 g036855 Figure 50 Charging the Battery WARNING Charging the battery produces gasses that can explode.
Installing the Battery Servicing the Fuses 1. Position the battery in the tray with the terminal posts opposite from the hydraulic tank (Figure 50). 2. Install the positive (red) battery cable to the positive (+) battery terminal. 3. Install the negative (black) battery cable and ground wire to the negative (-) battery terminal. The electrical system is protected by fuses. It requires no maintenance; however, if a fuse blows check the component and circuit for a malfunction or short.
Drive System Maintenance Checking the Seat Belt Service Interval: Before each use or daily Inspect the seat belt for wear, cuts, and proper operation of the retractor and buckle. Replace the seat belt if it is damaged. Checking the Roll-Bar Knobs Service Interval: Before each use or daily WARNING To avoid injury or death from rollover, keep the roll bar in the fully raised, locked position and use the seat belt. Ensure that the seat is secured to the machine.
Adjusting the Tracking 1. Disengage the blade-control switch (PTO). 2. Drive to an open, flat area and move the motion-control levers to the NEUTRAL-LOCK position. Checking the Tire Pressure For Machines with Pneumatic Tires Only 3. Move the throttle midway between the FAST and SLOW positions. 4. Move both motion-control levers forward until they both hit the stops in the T-slot. 5. Check which way the machine tracks. 6.
Brake Maintenance Adjusting the Parking Brake Service Interval: Every 500 hours Note: Perform this procedure whenever you remove or replace a brake component. 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Set up the machine to be pushed by hand. Refer to Using the Drive-Wheel Release Valves (page 30). 4.
9. Belt Maintenance Rotate the brake-linkage shaft until the end aligns with the hole in the lever. • Shorten the linkage by turning it clockwise. Inspecting the Belts • Lengthen the linkage by turning it counterclockwise. 10. Insert the brake-linkage shaft into the parking-brake hole and secure with the cotter pin. Repeat step 5 and adjust if necessary. 11. When adjustment is complete, remove the jack stands or equivalent support and lower the machine. 12.
Replacing the Hydraulic-Pump-Drive Belt 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Remove the mower belt; refer to Replacing the Mower Belt (page 47). 4. Raise the machine and support it with jack stands. 5. Remove the clutch stop (Figure 63). g327986 Figure 61 1. Mower belt 3. Spring 2. Idler pulley 4.
Controls System Maintenance Adjusting the Control-Handle Position If the ends of the levers hit against each other, refer to Adjusting the Motion-Control Linkage (page 50). Adjusting the Height You can adjust the motion control levers higher or lower for maximum comfort. g036859 Figure 64 1. Idler pulley 4. Pump-drive belt 2. Idler-spring post 5. Right hydraulic-pump pulley 3. Engine pulley 6. Left hydraulic-pump pulley 9. 10. Install the clutch stop (Figure 63). 1.
Adjusting the Tilt 1. 2. 3. 4. 5. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Loosen the upper bolt holding the control lever to the control arm shaft. Loosen the lower bolt just enough to pivot the control lever fore or aft. Tighten both bolts to secure the control in the new position.
Hydraulic System Maintenance Hydraulic System Safety • Seek immediate medical attention if fluid is injected into skin. Injected fluid must be surgically removed within a few hours by a doctor. • Ensure that all hydraulic-fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to the hydraulic system. • Keep your body and hands away from pinhole leaks or nozzles that eject high-pressure hydraulic fluid.
Checking the Hydraulic Fluid Level after purging. Failure to properly perform this procedure can result in irreparable damage to the transaxle drive system. Service Interval: Before each use or daily 1. Allow the hydraulic fluid to cool down. Check the oil level when the fluid is cold. 2. Check expansion reservoir and if necessary add Toro® HYPR-OIL™ 500 hydraulic fluid to the FULL COLD line. Removing Hydraulic-System Filters 1.
Installing the Hydraulic-System Filters 1. Apply a thin coat of hydraulic fluid on the surface of the rubber seal of each filter. 2. Turn the filter clockwise until the rubber seal contacts the filter adapter, then tighten the filter an additional 3/4 to 1 full turn. 3. Repeat for the opposite filter. 4. Install the filter guards over each filter that you previously removed. 5. Use the 3 screws to secure the filter guards. 6. Verify that the vent plugs are removed before adding the fluid. 7.
Mower Deck Maintenance Bleeding the Hydraulic System 1. Raise the rear of machine and support it with jack stands (or equivalent support) just high enough to allow the drive wheels to turn freely. Blade Safety • Inspect the blades periodically for wear or damage. • Use care when checking the blades. Wrap the blades or wear gloves, and use caution when servicing the blades. Only replace or sharpen the blades; never straighten or weld them.
WARNING A blade that is bent or damaged could break apart and could critically injure you or bystanders. • Always replace a bent or damaged blade with a new blade. • Do not file or create sharp notches in the edges or surfaces of the blade. g006530 Figure 72 1. Cutting edge 3. Wear/slot forming 2. Curved area 4. Crack Removing the Blades Replace the blades if they hit a solid object, or if the blade is out of balance or bent. Checking for Bent Blades 1.
g000552 Figure 75 1. Sharpen at original angle. 2. Check the balance of the blade by putting it on a blade balancer (Figure 76). Note: If the blade stays in a horizontal position, the blade is balanced and can be used. Note: If the blade is not balanced, file some metal off the end of the sail area only (Figure 75). g000553 Figure 76 1. Blade 3. 2. Balancer Repeat this procedure until the blade is balanced. Installing the Blades 1. Install the blade onto the spindle shaft (Figure 74).
Adjusting the Side-to-Side Leveling and the Blade Slope Check to ensure that the mower deck is level any time you install the mower or when you see an uneven cut on your lawn. Check the mower deck for bent blades prior to leveling, and remove and replace any bent blades; refer to Checking for Bent Blades (page 55) before continuing. Level the mower deck side-to-side first; then you can adjust the front-to-rear slope. g329616 Requirements: • The machine must be on a level surface.
Block Height and Rake Table Block Height Rake Front blocks—73 mm (2-7/8 inches) Rear blocks—78 mm (3-1/16 inches) 12. Carefully rotate the blades side to side (Figure 79). 13. Loosen the locknuts (Figure 80) on all 4 corners and ensure that the mower deck is sitting securely on all 4 blocks. 14. Remove any slack from the deck hangers and make sure the deck-lift foot lever is pushed back against the stop. 15. Tighten the 4 locknuts. g329619 Figure 78 1. Blades front to rear 3.
Removing the Mower Deck 1. 2. Cleaning Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. Cleaning under the Mower Deck Shut off the engine, remove the key, and disconnect the spark-plug wires from the spark plugs. 3. Place the height-adjustment pin in the 7.6 cm (3 inch) cutting-height location. 4. Remove the belt covers. 5. Loosen the mower deck idler and remove the mower belt; refer to Belt Maintenance (page 47). 6.
Storage 12. Check the condition of the blades; refer to Servicing the Cutting Blades (page 54). Storage Safety 13. Prepare the machine for storage when non-use occurs over 30 days. Prepare the machine for storage as follows: • Shut off the engine, remove the key, and wait for all moving parts to stop before you leave the operator’s position. Allow the machine to cool before adjusting, servicing, cleaning, or storing it. A.
Troubleshooting Problem The engine overheats. Possible Cause 1. The engine load is excessive. 1. Reduce the ground speed. 2. The oil level in the crankcase is low. 3. The cooling fins and air passages under the engine-blower housing are plugged. 4. The air cleaner is dirty. 2. Add oil to the crankcase. 3. Remove the obstruction from the cooling fins and air passages. 5. Dirt, water, or stale fuel is in the fuel system. The starter does not crank.
Problem The machine pulls to the left or right (with the motion-control levers fully forward). The machine does not drive. The machine vibrates abnormally. The cutting height is uneven. The blades do not rotate. Possible Cause 1. The tracking needs adjustment 1. Adjust the tracking. 2. The tire pressure in the drive tires is not correct. 2. Adjust the tire pressure in the drive tires. 1. The bypass valves are not closed tight. 1. Tighten the bypass valves. 2.
Schematics g037072 Wire Diagram (Rev.
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