ProLine Commercial Walk-Behind Mower with 91cm or 122cm Cutting Unit

Before starting the machine each day, perform the Each Use/Daily procedures listed in .

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).

Push the parking-brake lever forward to disengage it.

Note: The engine shuts off if you move the motion-control levers while the parking brake is engaged or if the machine idles for 5 seconds while the parking brake is disengaged.

Figure 8

1. Parking brake—engaged
2. Parking brake—disengaged

Note: If you release the motion-control levers and do not engage the parking brake, the engine will shut off after 5 seconds.

Figure 9

Use the blade-control switch (PTO) in conjunction with the motion-control levers to engage and disengage the mower blades.

Engaging the Mower Blades (PTO)

Figure 11

Disengaging the Mower Blades (PTO)

Figure 12 and Figure 13 show 2 ways to disengage the mower blades.

Figure 12

Figure 13

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: The engine shuts off if you move the motion-control levers while the parking brake is engaged or if the machine idles for 5 seconds while the parking brake is disengaged.

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.

Figure 17

This mower has a hinged grass deflector that disperses clippings to the side and down toward the turf.

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.

Figure 18

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. Remove the nut and bolt position the anti-scalp rollers and install the nut and bolt.

4. Ensure that the spacers and bushings are installed (Figure 19).

   

   Figure 19

   1. Bushing
   2. Anti-scalp roller
   3. Spacer
   4. Bolt
   5. Nut

Close the fuel-shutoff valve for transport, maintenance, and storage (Figure 20).

Ensure that the fuel-shutoff valve is open when starting the engine.

Figure 20

1. OFF position
2. ON position

Important: Always push the machine by hand. Do not tow the machine, because towing may damage it.

Important: Do not start or operate 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. 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.

Selecting a Trailer

Warning

Loading a machine onto a trailer or truck increases the possibility of tip-over and could cause serious injury or death (Figure 22).

• Use only a full-width ramp; do not use individual ramps for each side of the machine.

• Ensure that the length of ramp is at least 4 times as long as the height of the trailer or truck bed to the ground.

Figure 22

1. Full-width ramp in stowed position
2. Ramp is at least 4 times as long as the height of the trailer or truck bed to the ground
3. H=height of the trailer or truck bed to the ground
4. Trailer

Grease the machine more often in dirty or dusty conditions.

Grease Type: No. 2 lithium or molybdenum grease

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. Clean the grease fittings with a rag.

   Note: Scrape any paint off the front of the fitting(s).

4. Pump grease into the fittings until grease begins to ooze out of the bearings.

5. Wipe up any excess grease.

Grease type: Lithium or molybdenum grease

1. Remove the dust cap and adjust the caster pivots; refer to Adjusting the Caster-Pivot Bearing.

   Note: Keep the dust cap off until you have finished greasing the caster pivots.

2. Remove the hex plug.

3. Thread a grease fitting into the hole.

4. Pump grease into the fitting until it oozes out around the top bearing.

5. Remove the grease fitting from the hole.

6. Install the hex plug and dust cap.

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).

   

   Figure 29

   1. Front caster grease fitting

4. Connect a grease gun to each fitting (Figure 29).

5. Pump grease into the fittings until grease begins to ooze out of the bearings.

6. Wipe up any excess grease.

Note: Service the air cleaner more frequently (every few operating hours) if the operating conditions are extremely dusty or sandy.

Important: Do not apply oil to the foam or paper element.

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.

Type: NGK® BPR4ES or equivalent

Air gap: 0.75 mm (0.03 inch)

Checking the Spark Plug

Important: Do not clean the spark plug(s). Always replace the spark plug(s) when it has a black coating, worn electrodes, an oily film, or cracks.

If you see light brown or gray on the insulator, the engine is operating properly. A black coating on the insulator usually means the air cleaner is dirty.

Set the gap to 0.75 mm (0.03 inch).

Figure 37

Installing the Spark Plug

Figure 38

Note: Use a syphon pump to drain fuel from the tank. You can purchase a syphon pump at a hardware store.

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. Clean around the fuel cap to prevent debris from getting into the fuel tank (Figure 39).

4. Remove the fuel cap.

5. Insert a syphon pump into the fuel tank.

6. Using the syphon pump, drain the fuel into a clean fuel can (Figure 39).

7. Wipe up any spilled fuel.

   

   Figure 39

   1. Fuel cap

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. Close the fuel-shutoff valve; refer to Using the Fuel-Shutoff Valve.

4. Replace the fuel filter as shown in Figure 40.

   

   Figure 40

Always keep the battery 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 1 part baking soda. Apply a light coating of grease to the battery terminals to prevent corrosion.

Voltage: 12 V

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.

   

   Figure 43

   1. Main fuse (15 A)
   2. Charging fuse (25 A)

Check and torque the wheel-lug nuts to 115 to 142 N∙m (85 to 105 ft-lb).

If the machine creeps while the motion-control levers are in neutral, adjust the neutral traction.

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. Raise the rear of the machine onto jack stands high enough to raise the drive wheels off the ground.

4. Loosen the nut for control-rod assembly (Figure 45).

   

   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. Tighten the nut (Figure 45).

   Important: Ensure that the rod does not move; otherwise, you may need to adjust the rod again.

8. Repeat for the other lever.

Note: You may need to adjust the tracking after adjusting the neutral traction; refer to Adjusting the Tracking.

If you push both motion-control levers forward full speed across a flat, level surface and the machine pulls to 1 side, adjust the tracking as follows.

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. Rotate the adjustment screw shown in Figure 45 to increase or decrease the speed for that lever.

   Note: Rotate the screw clockwise to decrease the speed; rotate it counterclockwise to increase the speed.If the machine pulls to the left, decrease the speed for the right lever or increase the speed for the left lever.If the machine pulls to the right, decrease the speed for the left lever or increase the speed for the right lever.

   

   Figure 46

   1. Adjustment screw

4. Start the machine and drive forward across a flat, level surface with the motion-control levers fully forward to check if the machine tracks straight. Repeat the procedure as needed.

Note: For 91 cm (36 inch) machines, tighten the top bolt on the caster wheels. For 122 cm (48-inch machines), follow the procedure.

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. Remove the dust cap from the caster and tighten the locknut (Figure 47).

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).

   

   Figure 47

   1. Spring washers
   2. Locknut
   3. Dust cap

The caster wheels rotate on a roller bearing supported by a spanner bushing. If the bearing is kept well lubricated, wear will be minimal. Failure to keep the bearing well lubricated causes rapid wear. A wobbly caster wheel usually indicates a worn bearing.

1. Remove the locknut and wheel bolt holding the caster wheel to the caster fork (Figure 48).

   

   Figure 48

   1. Locknut
   2. Bushing
   3. Spanner bushing
   4. Roller bearing
   5. Caster wheel
   6. Wheel bolt

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. Inspect the roller bearing, bushings, spanner bushing and the inside of the wheel hub for wear.

   Note: Replace any damaged or worn parts (Figure 48).

5. Place 1 bushing into the wheel hub (Figure 48).

6. Grease the roller bearing and spanner bushing, and slide them into the wheel hub (Figure 48).

7. Place the second bushing into the wheel hub (Figure 48).

8. Install the caster wheel into the caster fork and secure it with the wheel bolt and locknut (Figure 48).

9. Tighten the locknut until the spanner bushing bottoms against the inside of the caster forks (Figure 48).

10. Grease the fitting on the caster wheel.

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.

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. Remove the air-intake screen, recoil starter, and fan housing (Figure 49).

4. Clean the debris and grass from the engine parts.

5. Install the air-intake screen, recoil starter, and fan housing (Figure 49).

   

   Figure 49

   1. Air-intake screen
   2. Fan housing
   3. Recoil starter
   4. Bolt
   5. Nut

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. Engage the brake lever and ensure that the machine does not move.

5. Adjust the brake if needed.

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).

   

   Figure 50

   1. Cable
   2. Cable clamp
   3. Bolt and nut

5. Pull down on the cables until they are tight.

6. Tighten the nut.

7. Check the parking brake function; refer to Testing the Parking Brake.

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.

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. Remove the deck guards; refer to Removing the Mower Deck Guards.

4. For 122 cm (48-inch) decks, loosen the 4 screws for both pulley covers and remove the covers (Figure 51).

   

   Figure 51

   1. Cover
   2. Screw (4)

5. 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 52 or Figure 53).

   

   Figure 52

   91cm Mower Decks

   1. Idler pulley
   2. Clutch pulley
   3. Mower belt
   4. Spring
   5. Spring-removal tool
   

   Figure 53

   122cm Mower Decks

   1. Idler pulley
   2. Clutch pulley
   3. Mower belt
   4. Spring
   5. Spring-removal tool

6. Route the new belt around the clutch pulley and mower pulleys (Figure 52 or Figure 53).

7. Install the idler spring to the deck hook (Figure 52 or Figure 53).

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.

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.

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 54, adjust the idler pulley arm.

Figure 54

122cm (48-inch) deck shown

1. Spring length at least 15.2 cm (6 inches)
2. Nut
3. Idler pulley
4. Idler stop

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. Remove the deck guards; refer to Removing the Mower Deck Guards

4. Loosen the nut on the idler pulley (Figure 54).

5. Adjust the pulley in the slot as needed (Figure 55).

   Slide the pulley to the left of the slot for a worn belt or if the spring length is more than 15.2 cm (6 inches).

   Slide the pulley to the right of the slot for a new belt or if the spring length is less than 15.2 cm (6 inches)

   

   Figure 55

   122cm (48-inch) deck shown

   1. Idler arm
   2. Slot
   3. Slide pulley to the left for worn belt.
   4. Slide pulley to the right for new belt

6. Tighten the nut (Figure 54).

7. Install the deck guard; refer to Removing the Mower Deck Guards.

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. Remove the mower-deck belt from the clutch pulley; refer to Replacing the Mower-Deck Belt.

4. Remove the 2 bolts and guard plate (Figure 56).

   

   Figure 56

   1. Guard plate
   2. Bolt (2)

5. Remove the clutch pulley (Figure 57).

   

   Figure 57

   1. Clutch pulley
   2. Washer
   3. Bolt

6. Insert a drive ratchet in the square hole of the idler arm to release the belt tension (Figure 58).

   

   Figure 58

   1. Spring
   2. Idler pulley
   3. Square hole

7. Remove the belt (Figure 59).

8. Slowly release the driver to release the spring tension. Remove the spring from the anchor on the frame, if needed.

9. Install the new belt, routing it around the pulleys as shown in Figure 59.

   

   Figure 59

   1. Belt
   2. Idler 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. Install the guard plate (Figure 57).

15. Install the mower-deck belt to the clutch pulley; refer to Replacing the Mower-Deck Belt.

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. Push the motion-control levers down to the operating position .

   

   Figure 60

   1. Left motion-control lever in operating position
   2. Right motion-control lever in neutral position
   3. Check the horizontal alignment here.
   4. Right motion-control lever in operating position

4. Check the horizontal alignment of the motion-control levers (Figure 60).

5. Loosen the nut holding the cam for the motion-control lever you are adjusting (Figure 61).

   

   Figure 61

   1. Nut
   2. Cam

6. Adjust the cam until it aligns with the other motion-control lever and tighten the nut for the cam (Figure 61).

   Note: Moving the cam clockwise lowers the lever; moving the cam counterclockwise raises the lever.

   Important: Do not rotate the flat of the cam past vertical. The operator-presence control switch should never contact the flat of the cam.

Hydraulic Fluid Type: Toro® HYPR-OIL™ 500 hydraulic fluid

Hydraulic System Fluid Capacity: 4.7 L (159 fl oz)

Important: Use the fluid specified. Other fluids could damage the system.

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. All the machine to cool completely.

4. Check the fluid level on the side of the hydraulic tank (Figure 62). Continue the procedure if the level is below the cold fill level.

5. Clean the area around the cap of the hydraulic tank (Figure 62).

6. Remove the cap from the filler neck and add fluid to the reservoir until it reaches the cold fill level (Figure 62).

7. Install the cap on the tank (Figure 62).

Figure 62

To replace the hydraulic fluid, the filters need to be removed. Replace both at the same time; refer to Hydraulic System Specifications for fluid specifications.

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. Raise the rear of the machine onto jack stands high enough to raise the drive wheels off the ground.

4. Move both bypass levers rearward through the key hole and down to lock them in place (Figure 67).

   

   Figure 67

   1. Bypass-lever locations
   2. Lever position for operating the machine
   3. Lever position for bleeding the transmission

5. Start the engine. and move the throttle control to half throttle.

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. Repeat the procedure until air is completely purged from the system.

    Note: Air is purged from the system when the transaxle operates at normal noise levels and moves smoothly forward and in reverse at normal speeds.

12. Check the hydraulic fluid level in the expansion reservoir a final time, and add fluid as required.

1. Disengage the spring from the notch in the deflector bracket and slide the rod out of the welded deck brackets, spring, and discharge deflector (Figure 78).

   

   Figure 78

   1. Rod
   2. Deflector
   3. Spring
   4. Deck brackets
   5. Hairpin cotter
   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 79.

4. Install the spring onto the straight end of the rod.

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.

6. Lift the loop end of the spring and place it into the notch on the deflector bracket (Figure 79).

   

   Figure 79

   1. Rod and spring assembly installed
   2. Loop end of the spring installed into the notch in the deflector bracket
   3. Rod, short end, moved behind the mower bracket
   4. Short end, retained by mower bracket.

7. Secure the rod and spring assembly by twisting it so that the short end of the rod is behind the mower bracket welded to the deck (Figure 79).

   Important: The grass deflector must be spring loaded in the down position. Lift the deflector up to test that it snaps to the full down position.

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.

Engine oil, batteries, hydraulic fluid, and engine coolant are pollutants to the environment. Dispose of these according to your state and local regulations.