Form No. 3432-306 Rev E ProLine Commercial Walk-Behind Mower with 36in, 48in, 54in, or 60in Cutting Unit Model No. Model No. Model No. Model No. Model No. Model No. Model No. Model No. Model No. Model No. Register at www.Toro.com. Original Instructions (EN) 44409—Serial No. 44410—Serial No. 44423—Serial No. 44424—Serial No. 44427—Serial No. 44430—Serial No. 44436—Serial No. 44448—Serial No. 44454—Serial No. 44460—Serial No.
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Contents Servicing the Caster Wheels and Bearings........................................................ 36 Cooling System Maintenance .............................. 37 Cleaning the Air-Intake Screen ......................... 37 Cleaning the Cooling System............................ 37 Brake Maintenance ............................................. 38 Testing the Parking Brake ................................. 38 Adjusting the Parking Brake.............................. 38 Belt Maintenance ..............
Safety • Keep bystanders and children out of the operating area. Do not allow children to operate the machine. Allow only people who are responsible, trained, familiar with the instructions, and physically capable to operate the machine. This machine has been designed in accordance with ANSI B71.4-2017. • Stop the machine, shut off the engine, remove General Safety the ignition key (if equipped), and wait for all moving parts to stop before servicing, fueling, or unclogging the machine.
decal93-7818 93-7818 decal126-1400 126-1400 1. Warning—read the Operator's Manual for instructions on torquing the blade bolt/nut to 115 to 149 N∙m (85 to 110 ft-lb). 1. Warning—read the Operator’s Manual for information about attachments; certain attachments can cause you to fall. decal98-1977 98-1977 decal130-0731 130-0731 1. Entanglement hazard, belt—stay away from moving parts. 1. Warning—thrown object hazard; keep the deflector shield in place. 2.
decal138-8816 decal131-3536 138-8816 131-3536 4. Parking brake 1. PTO—disengage 4. Neutral 2. Time 5. Engine—start 3. Power takeoff (PTO) 6. Engage the handle bars. 2. Fast 3. Slow 5. Reverse 6. Traction controls 1. Battery decal138-8820 decal133-4604 138-8820 133-4604 1. Thrown object hazard—keep bystanders away from the machine. 3. Severing hazard of hand or foot—keep away from moving parts. 2.
Decal 139-7936 is for 91cm (36-inch) models only. decal139-2874 139-2874 1. Traction controls 2. Fast 3. Slow 4. Neutral 5. Reverse 6. PTO—disengage decal139-7936 139-7936 1. Belt routing decal138-8818 138-8818 1. Warning—read the Operator’s Manual. 8. Thrown object hazard—keep bystanders away. 2. Warning—all operators should be trained before operating the machine. 9. Warning—shut off the engine, disconnect the spark plug, and read the Operator’s Manual before performing maintenance. 3.
Controls Product Overview Control Panel g299386 Figure 4 g299567 Figure 3 1. Side discharge 5. Control panel 2. Height-of-cut lever 6. Parking-brake lever 3. Engine 7. Mower deck 4. Fuel tank 8. Anti-scalp roller 1. Parking-brake lever 7. Rear reference bar 2. Adjustable reference bar 8. Blade-control switch (PTO) 3. Left motion-control lever 9. Key switch 4. Hour meter 10. Throttle control 5. Reference bar adjustment 11. Choke control lever 6.
Choke Specifications Use the choke to start a cold engine. Specifications and design are subject to change without notice. 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 4). Safety-Interlock Indicators There are symbols on the hour meter that indicate with a black triangle that the interlock component is positioned correctly (Figure 5).
Operation • If you spill fuel, do not attempt to start the engine; Note: Determine the left and right sides of the machine from the normal operating position. • Do not fill containers inside a vehicle or on a truck avoid creating a source of ignition until the fuel vapors have dissipated. or trailer bed with a plastic liner. Always place containers on the ground, away from the vehicle before filling. Before Operation • Remove equipment from the truck or trailer and refuel it on the ground.
Note: A fuel stabilizer/conditioner is most effective when mixed with fresh fuel. To minimize the chance of varnish deposits in the fuel system, use fuel stabilizer at all times. Filling the Fuel Tank g031282 Figure 7 1. The triangles light up when the interlock components are in the correct position. g302021 Figure 6 Testing the Safety-Interlock System Using the Safety-Interlock System Service Interval: Before each use or daily Test the safety-interlock system before you use the machine each time.
Note: The mower blades should engage. 12. • Keep your hands and feet away from the cutting Press the OFF position for the PTO switch. • Note: The mower blades should disengage. 13. Press the ON position for the PTO switch. • Note: The mower blades should engage. 14. Engage the parking brake. • Note: The mower blades should disengage and 15. 16. the engine should shut off. Press the ON position for the PTO switch. Try starting the engine. • Note: The engine should not crank.
Operating the Parking Brake the blade(s) and not in front of the discharge chute. – Use extreme caution when reversing or pulling the machine toward you. – Stop the blade if you must transport the machine to and from the mowing area and when crossing surfaces other than grass. Always engage the parking brake when you shut off the machine or leave the operator position. Before each use, check the parking brake for proper operation. Pull the parking-brake lever rearward to engage it (Figure 8).
Starting the Engine Note: If you release the motion-control levers and do not engage the parking brake, the engine will shut off after 5 seconds.
Disengaging the Mower Blades (PTO) Operating the Mower-Blade-Control Switch (PTO) Figure 12 and Figure 13 show 2 ways to disengage the mower blades. Use the blade-control switch (PTO) in conjunction with the motion-control levers to engage and disengage the mower blades.
Driving the Machine Note: The farther you move the motion-control levers in either direction, the faster the machine moves in that direction. The throttle control regulates the engine speed as measured in rpm (revolutions per minute). Place the throttle control in the FAST position for best performance. Note: To stop, move the motion-control levers back to the NEUTRAL position.
Using the Adjustable Reference Bar Use the adjustment lever to change the position of the adjustable reference bar and limit the maximum forward speed (Figure 17). Move the lever to the upper position to decrease the maximum speed; move the lever to the lower position to increase the maximum speed. g299434 Figure 17 Side Discharging or Mulching Grass This mower has a hinged grass deflector that disperses clippings to the side and down toward the turf.
Adjusting the Height of Cut You can adjust the height of cut from 38 to 114 mm (1-1/2 to 4-1/2 inches) in 6 mm (1/4 inch) increments.
Adjusting the Anti-Scalp Rollers After Operation After Operation Safety Models with a 122 cm (48 inch), 137 cm (54 inch), or 152 cm (60 inch) Deck Only General Safety • Always shut off the machine, remove the ignition Whenever you change the height-of-cut, adjust the height of the anti-scalp rollers. 1. 2. key (if equipped), wait for all moving parts to stop, and allow the machine to cool before adjusting, servicing, cleaning, or storing it.
Pushing the Machine by Hand Operating the Machine Move the bypass levers forward through the keyhole and down to lock them in place as shown in Figure 21. Important: Always push the machine by hand. Do not tow the machine, because towing may damage it. Note: Do this for each lever. Important: Do not start or operate the machine Transporting the Machine with the bypass valves open. Damage to system may occur. Use a heavy-duty trailer or truck to transport the machine. Use a full-width ramp.
g299488 Figure 23 1. Back the machine up the ramp. 2. Walk the machine down the ramp. 5. Shut off the engine, remove the key, and engage the parking brake. 6. Tie down the machine near the front caster wheels and the rear bumper with straps, chains, cable, or ropes (Figure 24). Refer to local regulations for tie-down requirements. g229507 Figure 22 1. Full-width ramp in stowed position 3. H=height of the trailer or truck bed to the ground 2.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Maintenance Safety • Before adjusting, cleaning, servicing, or leaving • the machine, do the following: – Park the machine on a level surface. – Move the throttle switch to the low-idle position. • – Disengage the cutting units. – Ensure that the transmission is in neutral. • – Engage the parking brake. – Shut off the engine and remove the key. – Wait for all moving parts to stop.
Maintenance Service Interval Maintenance Procedure Every 250 hours • Replace the primary air filter (more often in dirty or dusty conditions)—heavy-duty air cleaners only. • Check the safety air filter (more often in dirty or dusty conditions)—heavy-duty air cleaners only. Every 300 hours • Check and adjust the valve clearance. Contact an Authorized Service Dealer. Every 500 hours • Replace the safety air filter (more often in dirty or dusty conditions)—heavy-duty air cleaners only.
Lubrication Greasing the Caster Wheel Bearings Greasing the Machine Service Interval: Every 25 hours—Grease the caster wheel bearings. Grease the machine more often in dirty or dusty conditions. Grease Type: No. 2 lithium grease Grease Type: No. 2 lithium or molybdenum grease 1. 2. 3. 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. Park the machine on a level surface, disengage the blade-control switch, and engage the parking brake.
Engine Maintenance Engine Safety • Do not change the governor speed or overspeed 4. Unscrew the cover knobs and remove the air-cleaner cover (Figure 28). 5. Unscrew the hose clamp and remove the air-cleaner assembly (Figure 28). 6. Carefully pull the foam element off the paper element (Figure 28). the engine. Run the engine dry or remove the fuel with a hand pump; never siphon the fuel. If you must drain the fuel tank, do it outdoors.
3. 6. Place the air-cleaner cover into position and tighten the cover knob (Figure 28). Remove the safety filter only to replace it. Inspecting the Filters Servicing a Heavy Duty Air Cleaner 1. Service Interval: Every 250 hours—Replace the primary air filter (more often in dirty or dusty conditions)—heavy-duty air cleaners only. Every 250 hours—Check the safety air filter (more often in dirty or dusty conditions)—heavy-duty air cleaners only.
Checking the Engine-Oil Level Servicing the Engine Oil Service Interval: Before each use or daily Engine-Oil Specifications Note: Check the oil when the engine is cold. Model 44409, 44410, 44423, 44424, and 44427 WARNING Oil Type: Detergent oil (API service SF, SG, SH, SJ, or SL) Contact with hot surfaces may cause personal injury. Engine Oil Capacity: 1.5 L (51 fl oz) without filter; 1.
Changing the Engine Oil Service Interval: After the first 8 hours Every 100 hours Note: Dispose of the used oil at a recycling center. 1. Park the machine so that the drain side is slightly lower than the opposite side to assure the oil drains completely. 2. Disengage the PTO and engage the parking brake. 3. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 4. Change the engine oil as shown in Figure 33.
g299570 g235264 Figure 34 6. Start the engine and drive to a flat area. 7. Check the oil level again. Changing the Engine-Oil Filter Service Interval: Every 200 hours Note: Change the engine-oil filter more frequently when operating conditions are extremely dusty or sandy. g036784 Figure 33 5. 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 34). 29 1.
Servicing the Spark Plug Service Interval: Every 100 hours Ensure that the air gap between the center and side electrodes is correct before installing the spark plug. Use a spark plug wrench for removing and installing the spark plug(s) and a gapping tool/feeler gauge to check and adjust the air gap. Install a new spark plug(s) if necessary. g299569 Type: NGK® BPR4ES or equivalent Air gap: 0.75 mm (0.03 inch) Removing the Spark Plug 1.
Fuel System Maintenance 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. g027479 Figure 37 Refer to Fuel Safety (page 10) for a complete list of fuel related precautions. Installing the Spark Plug Draining the Fuel Tank Note: Use a syphon pump to drain fuel from the tank. You can purchase a syphon pump at a hardware store.
g300374 Figure 39 1. Fuel cap Replacing the Fuel Filter Service Interval: Every 800 hours/Yearly (whichever comes first) Do not install a dirty filter if it is removed from the fuel line. Note: Wipe up any spilled fuel. 1. Park the machine on a level surface, disengage the 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.
Electrical System Maintenance WARNING Incorrectly removing the cables from battery could damage the machine and cables, causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. Electrical System Safety • Disconnect the battery before repairing the • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable. machine. Disconnect the negative terminal first and the positive last.
Charging the Battery Servicing the Fuses The electrical system is protected by fuses. It requires no maintenance; however, if a fuse blows, check the component/circuit for a malfunction or short. WARNING Charging the battery produces gasses that can explode. Never smoke near the battery and keep sparks and flames away from battery. Important: Always keep the battery fully charged (1.260 specific gravity). This is especially important to prevent battery damage when the temperature is below 0°C (32°F). 1.
Drive System Maintenance Checking the Tire Pressure g300244 g300245 Figure 45 1. Nut 5. Start the machine and move the throttle control to the FAST position. 6. To find the neutral position, move the lower control rod up or down until the tire stops rotating (Figure 45). 7. Tighten the nut (Figure 45). g300243 Figure 44 2. Lower control rod Important: Ensure that the rod does not move; otherwise, you may need to adjust the rod again. Checking the Wheel-Lug Nuts 8.
If the machine pulls to the right, decrease the speed for the left lever or increase the speed for the right lever. 4. Tighten the locknut until the spring washers are flat, and then back off a 1/4 turn to properly set the preload on the bearings (Figure 47). Important: Make sure that the spring washers are installed correctly as shown in Figure 47. 5. Install the dust cap (Figure 47). g299908 Figure 46 g001297 1. Adjustment screw Figure 47 1. Spring washers 4.
Cooling System Maintenance Cleaning the Air-Intake Screen Remove any buildup of grass, dirt, or other debris from the cylinder and cylinder head cooling fins, the air-intake screen on the flywheel end, and the carburetor-governor levers and linkage. This helps ensure adequate cooling and correct engine speed to reduce the possibility of overheating or mechanical damage to the engine. g009453 1. Locknut 4. Roller bearing 2. Bushing 5. Caster wheel Cleaning the Cooling System 3. Spanner bushing 6.
Brake Maintenance Testing the Parking Brake Service Interval: Before each use or daily Before each use, test the parking brake on both a level surface and slope. Always engage the parking brake when you stop the machine or leave it unattended. If the parking brake does not hold securely, adjust it. 1. Disengage the 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. Disengage the parking brake. 4.
7. Belt Maintenance Check the parking brake function; refer to Testing the Parking Brake (page 38). Inspecting the Belts Service Interval: Every 25 hours—Check the belts for wear or cracks. Replace the belt if it is worn. The signs of a worn belt include squealing while the belt is rotating; the blades slipping while cutting grass; and frayed edges, burn marks, and cracks on the belt. Replacing the Mower-Deck Belt WARNING The spring is under tension when installed and can cause personal injury.
g299742 Figure 54 48in, 54in, and 60in Mower Decks g298962 Figure 52 1. Cover 5. 2. Screw (4) g299741 Figure 53 36in Mower Decks 4. Spring 2. Clutch pulley 5. Spring-removal tool 4. Spring 2. Clutch pulley 5. Spring-removal tool 3. Mower belt Using a spring-removal tool (Toro Part No. 92-5771), remove the idler spring from the deck hook to remove tension on the idler pulley, and roll the belt off the pulleys (Figure 53 or Figure 54). 1. Idler pulley 1. Idler pulley 3. Mower belt 40 6.
Adjusting the Idler Pulley Arm Service Interval: Yearly—Check the mower deck idler arm for wear. If the length of the spring is less than 15.2 cm (6 inches) or if the idler pulley arm contacts the idler stop shown in Figure 55, adjust the idler pulley arm. g302008 Figure 56 122cm (48-inch) deck shown 1. Idler arm 2. Slot g302009 Figure 55 122cm (48-inch) deck shown 1. Spring length at least 15.2 cm (6 inches) 3. Idler pulley 2. Nut 4. Idler stop 1. 2. 3.
g300384 Figure 59 1. Belt 2. Idler pulley g300383 Figure 57 1. Clutch pulley 9. 3. Bolt 2. Washer 5. Insert a drive ratchet in the square hole of the idler arm to release the belt tension (Figure 58). g303781 Figure 58 1. Spring 3. Square hole 2. Idler pulley 6. Remove the belt (Figure 59). 7. Slowly release the driver to release the spring tension. Remove the spring from the anchor on the frame, if needed. 8. Install the new belt, routing it around the pulleys as shown in Figure 59.
Controls System Maintenance Adjusting the Motion-Control Levers If the motion-control levers do not align horizontally, adjust the motion-control levers. 1. Park the machine on a level surface, disengage the 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. g303793 Figure 61 Push the motion-control levers down to the operating position . 1. Nut 2. Cam 6. 3. Bail switch 4. The flat of the cam.
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.
2. Important: Do not allow dirt to enter the Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. hydraulic system, or contamination may occur. 9. 3. Allow the engine to cool. 4. Remove the 2 bolts and nuts from the transaxle guards (Figure 63). Place a drain pan below the filter to catch the fluid that drains when the filter and vent plugs are removed. 10. Locate and remove the vent plug on each transmission 11.
Adding Hydraulic Fluid 1. Verify that the vent plugs are removed before adding the fluid. 2. Slowly pour the specified fluid through the expansion reservoir until fluid comes out of 1 of the vent-plug holes; refer to Hydraulic System Specifications (page 44). 3. Install the vent plug (Figure 64). 4. Torque the plug to 20 N∙m (15 ft-lb). 5. Continue to add fluid through the expansion reservoir until fluid comes out of the remaining vent-plug hole on the second transmission. 6.
Mower Deck Maintenance Blade Safety A worn or damaged blade can break and a piece could be thrown toward you or bystanders, resulting in serious personal injury or death. g006530 Figure 67 • Inspect the blades periodically for excessive wear or damage. • Use care when checking the blades. Wear gloves and use caution when servicing them. Only replace the blades; never straighten or weld them. 1. Cutting edge 3. Wear/slot forming 2. Curved area 4.
WARNING A blade that is bent or damaged could break apart and could critically injure you or bystanders. g000552 Figure 70 • Always replace a bent or damaged blade with a new blade. 1. Sharpen at original angle. • Do not file or create sharp notches in the edges or surfaces of the blade. 2. Removing the Blades Note: If the blade stays in a horizontal position, the blade is balanced and can be used. Replace the blade if a blade hits a solid object, is out of balance, or is bent.
g006888 Figure 73 1. Measure from a level surface g004536 Figure 72 1. Sail area of the blade 2. Blade 3. Curved washer 4. Blade bolt 3. 2. Measure the blade at points B and C The difference between measurements B and C should be no more than 6 mm (1/4 inch). Note: If it is not correct, refer to Leveling the Mower Deck (page 50). Leveling the Mower Deck Checking the Mower Deck Front-to-Rear Pitch Preparing the Machine 1.
4. If the front-to-rear pitch is not correct, refer to Leveling the Mower Deck (page 49). Leveling the Mower Deck 1. Park the machine on a level surface, disengage the 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 the height-of-cut lever to the 76 mm (3 inch) position; refer to Adjusting the Height of Cut (page 18) 4. Place 2 blocks, each having a thickness of 6.
g297573 Figure 78 1. Rod and spring assembly installed 2. Loop end of the spring installed into the notch in the deflector bracket g302010 Figure 77 1. Rod 2. Deflector 4. Deck brackets 5. Hairpin cotter 3. Spring 6. Spring installed over the rod 2. Remove the damaged or worn discharge deflector. 3. Position the new discharge deflector with the bracket ends between the welded brackets on the deck as shown in Figure 78. 4. Install the spring onto the straight end of the rod. 5.
Cleaning Cleaning under the Mower Service Interval: Before each use or daily Remove the grass buildup under the mower daily. 1. Park the machine on a level surface, disengage the PTO, and engage the parking brake. 2. Shut off the engine, remove the key, and disconnect the spark-plug wires from the spark plugs. 3. Raise the front of the machine using a jack and use jack stands to support the machine. 4. Clean the machine with a rag. Do not spray the machine.
Storage A. Add fuel stabilizer/conditioner to fresh fuel in the tank. Follow mixing instructions from the fuel stabilizer manufacturer. Do not use an alcohol-based stabilizer (ethanol or methanol). B. Run the engine to distribute conditioned fuel through the fuel system for 5 minutes. C. Shut off the engine, allow it to cool, and drain the fuel tank. D. Start the engine and run it until it shuts off. E. Dispose of fuel properly. Recycle the fuel according to local codes.
Troubleshooting Problem Possible Cause The fuel tank is showing signs of collapsing or the machine is frequently showing signs of running out of fuel. 1. The air-cleaner paper element clogged. The engine overheats. 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.
Problem The machine does not drive. There is abnormal vibration. The cutting height is uneven. Possible Cause 1. The hydraulic-fluid reservoir is low. 1. Add hydraulic fluid to the reservoir. 2. Air is in the hydraulic system. 3. A pump-drive belt slips. 4. A pump-drive belt idler spring is missing. 5. The pump-bypass valves are open. 2. Bleed the air out the hydraulic system. 3. Replace the pump-drive belt. 4. Replace the pump-drive belt idler spring. 5. Tighten the bypass valves.
Schematics g302778 Electrical Schematic for Machines with Standard Air Cleaner—139-2853 (Rev.
g303695 Electrical Schematic for Machines with Heavy Duty Air Cleaner—138–691 (Rev.
Notes:
Notes:
California Proposition 65 Warning Information What is this warning? You may see a product for sale that has a warning label like the following: WARNING: Cancer and Reproductive Harm—www.p65Warnings.ca.gov. What is Prop 65? Prop 65 applies to any company operating in California, selling products in California, or manufacturing products that may be sold in or brought into California.
