Form No. 3437-109 Rev C ProLine Commercial Walk-Behind Mower with 91cm or 122cm Cutting Unit Model No. 44410TE—Serial No. 406500000 and Up Model No. 44424TE—Serial No. 406500000 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. Model No. Serial No. Please refer to the engine manufacturer’s information included with the machine. This manual identifies potential hazards and has safety messages identified by the safety-alert symbol (Figure 2), which signals a hazard that may cause serious injury or death if you do not follow the recommended precautions.
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 EN ISO 5395. • 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.
decal139-2874 139-2874 1. Traction controls 2. Fast 3. Slow decal139-7936 139-7936 4. Neutral 5. Reverse 6. PTO—disengage 1. Belt routing Decal 139-7936 is for 91cm (36-inch) models only. 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 5). 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) Deck Only General Safety Whenever you change the height-of-cut, adjust the height of the anti-scalp rollers. 1. Park the machine on a level surface, disengage the blade-control switch, 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.
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 300 hours • Check and adjust the valve clearance. Contact an Authorized Service Dealer. Every 500 hours • Adjust the caster-pivot bearing. • 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) Every 800 hours • Replace the fuel filter. Yearly • Grease the front caster pivots (more often in dirty or dusty conditions).
Lubrication Machines with 122cm (48-inch) Decks 1. 2. 3. Greasing the Machine Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. Grease the machine more often in dirty or dusty conditions. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Grease Type: No. 2 lithium or molybdenum grease Remove the 2 bolts securing the deck cover and remove the deck cover (Figure 27). 1.
Greasing the Caster Wheel Bearings Service Interval: Every 25 hours—Grease the caster wheel bearings. Grease Type: No. 2 lithium grease 1. Park the machine on a level surface, disengage the blade-control switch, 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. Clean the grease fittings (Figure 29) with a rag. Note: Scrape any paint off the front of the fitting(s). g301977 Figure 29 1.
Engine Maintenance Engine Safety • Do not change the governor speed or overspeed 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. Servicing the Air Cleaner Service Interval: Every 25 hours—Clean the foam air-cleaner element. g012619 Figure 30 Every 50 hours—Check the paper air-cleaner element. Every 200 hours—Replace the paper air-cleaner element.
Servicing the Engine Oil Engine-Oil Specifications Oil Type: Detergent oil (API service SF, SG, SH, SJ, or SL) Engine Oil Capacity: 1.5 L (51 fl oz) without filter; 1.7 L (57 fl oz) with filter g299569 Viscosity: Refer to the table below. g004216 Figure 31 Checking the Engine-Oil Level Service Interval: Before each use or daily Note: Check the oil when the engine is cold. WARNING Contact with hot surfaces may cause personal injury.
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 g036784 Figure 33 5.
g299569 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. 1. 2. Drain the oil from the engine; refer to Changing the Engine Oil (page 28). g027477 Figure 35 Change the engine-oil filter (Figure 35).
Servicing the Spark Plug Checking the Spark Plug Service Interval: Every 100 hours Important: Do not clean the spark plug(s). Ensure that the air gap between the center and side electrodes is correct before installing the spark plug. Always replace the spark plug(s) when it has a black coating, worn electrodes, an oily film, or cracks. 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.
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. g300374 Figure 39 Refer to Fuel Safety (page 10) for a complete list of fuel related precautions. 1. Fuel cap Draining the Fuel Tank Replacing the Fuel Filter Note: Use a syphon pump to drain fuel from the tank.
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.
Charging the Battery 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. Charging the battery produces gasses that can explode. • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable. Important: Always keep the battery fully charged WARNING Never smoke near the battery and keep sparks and flames away from battery. (1.
Servicing the Fuses Drive System Maintenance 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. 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. Pull out the fuse to remove or replace it.
If the machine pulls to the right, decrease the speed for the left lever or increase the speed for the right lever. g300245 Figure 45 1. Nut 2. Lower control rod 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. g299908 Figure 46 1. Adjustment screw Tighten the nut (Figure 45). Important: Ensure that the rod does not 4.
Important: Make sure that the spring washers are installed correctly as shown in Figure 47. 5. Install the dust cap (Figure 47). g009453 Figure 48 1. Locknut 4. Roller bearing 2. Bushing 5. Caster wheel 3. Spanner bushing 6. Wheel bolt g001297 Figure 47 1. Spring washers 2. Remove 1 bushing, then pull the spanner bushing and roller bearing out of the wheel hub (Figure 48). 3. Remove the other bushing from the wheel hub and clean any grease and dirt from the wheel hub (Figure 48). 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. Cleaning the Cooling System g001472 Figure 49 1. Air-intake screen 2.
Brake Maintenance Adjusting the Parking Brake Testing the Parking Brake 1. Park the machine on a level surface and disengage the PTO. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Release the parking brake. 4. Loosen the bolt on the cable clamp on the left side of the machine (Figure 50). Service Interval: Before each use or daily Before each use, test the parking brake on both a level surface and slope.
Belt Maintenance hook to remove tension on the idler pulley, and roll the belt off the pulleys (Figure 52 or Figure 53). 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.
8. Check the length of the spring. If it is less than 15.2 cm (6 inches), adjust the idler pulley arm; proceed to step 4 in Adjusting the Idler Pulley Arm (page 40). 9. For 91 cm (36-inch) decks, install the pulley covers (Figure 51). 10. Install the deck guards; refer to Removing the Mower Deck Guards (page 23). Adjusting the Idler Pulley Arm g302008 Figure 55 122cm (48-inch) deck shown Service Interval: Yearly—Check the mower deck idler arm for wear. If the length of the spring is less than 15.
g300384 Figure 59 1. Belt 2. Idler pulley g300383 Figure 57 1. Clutch pulley 10. Install the spring to the spring anchor. Use the drive ratchet to apply tension to the spring to allow the belt to pass over the lip of the idler pulley (Figure 58). 11. Release the tension in the spring to apply tension to the belt. 12. Check that the belt is seated properly in all the pulleys. 13. Install the clutch pulley (Figure 57). Torque the bolt to 68 to 81 N∙m (50 to 60 ft-lb). 14.
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. g300397 Figure 61 Push the motion-control levers down to the operating position . 1. Nut 6. 2.
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. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Allow the engine to cool. 4. Remove the 2 bolts and guard plate Figure 63). g010254 Figure 65 Right side shown g308540 Figure 63 1. Guard plate 1. Transaxle drive 2. Filter 2. Bolt (2) 4. Screws 5. Vent plug 3. Filter guard 5. Remove the 2 bolts and nuts from both transaxle guards (Figure 64). 9. Carefully clean the area around the filters.
10. Continue to add fluid through the expansion reservoir until it reaches the FULL COLD line on the expansion reservoir. 11. Proceed to Bleeding the Hydraulic System (page 45). Important: Failure to bleed the hydraulic system after changing the hydraulic filters and fluid can result in irreparable damage to the transaxle drive system. Bleeding the Hydraulic System 1. Park the machine on a level surface, disengage the PTO, and engage the parking brake. 2.
6. Slowly move the motion-control levers between the full forward and full reverse positions 5 times. 7. Shut off the engine and move the bypass levers forward through the keyhole and down to lock them in place (Figure 67). 8. Start the engine. 9. Slowly move the motion-control levers between the full forward and full reverse positions 5 times. 10. Shut off the engine and check the hydraulic fluid level as it drops, and add fluid as required to maintain the proper level. 11.
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 68 1. Cutting edge 3. Wear/slot forming 2. Curved area 4. Crack Removing the Blades Replace the blade if a blade hits a solid object, is out of balance, or is bent.
g000552 Figure 71 1. Sharpen at original angle. 2. Check the balance of the blade by putting it on a blade balancer (Figure 72). 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 71). g004536 Figure 73 1. Sail area of the blade 2. Blade g000553 3. Curved washer 4. Blade bolt Figure 72 1. Blade 2. Balancer Leveling the Mower Deck 3.
4. If the front-to-rear pitch is not correct, refer to Leveling the Mower Deck (page 48). Leveling the Mower Deck g006888 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.
Replacing the Grass Deflector Service Interval: Before each use or daily—Inspect the grass deflector for damage. WARNING An uncovered discharge opening could allow the machine to throw objects toward you or bystanders, resulting in serious injury. Also, contact with the blade could occur. Never operate the machine unless you install a mulch plate, discharge deflector, or grass collection system. 1.
3. Position the new discharge deflector with the bracket ends between the welded brackets on the deck as shown in Figure 79. Cleaning 4. Install the spring onto the straight end of the rod. Cleaning under the Mower 5. Position the spring on the rod as shown in Figure 79 so that the shorter spring end comes from under the rod before the bend and going over the rod as it returns from the bend. Service Interval: Before each use or daily 6. Remove the grass buildup under the mower daily.
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—139-2853 (Rev.
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