Toro 44044, Turf Sweeper 4800 Operator's Manual

Turf Sweeper 4800
Model No. 44044—Serial No. 240000001 and Up
Form No. 3350–447 Rev A
Operator’s Manual
English (EN)
Contents
Introduction 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Supervisor’s Responsibilities 3. . . . . . . . . . . . . . . . .
Before Operating 3. . . . . . . . . . . . . . . . . . . . . . . . . .
While Operating 4. . . . . . . . . . . . . . . . . . . . . . . . . . .
While Dumping 5. . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Instruction Decals 7. . . . . . . . . . . . . . . . .
Specifications 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 9. . . . . . . . . . . . . . . . . . . . .
Optional Equipment 10. . . . . . . . . . . . . . . . . . . . . . . .
Loose Parts 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Before Operating 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grass Baffle 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check Tire Pressure 10. . . . . . . . . . . . . . . . . . . . . . . .
Check Crankcase Oil 11. . . . . . . . . . . . . . . . . . . . . . .
Fill Fuel Tank With Gasoline 11. . . . . . . . . . . . . . . . .
Check Hydraulic System Oil 12. . . . . . . . . . . . . . . . .
Check Torque of Wheel Nuts 13. . . . . . . . . . . . . . . . .
Know Your Controls 14. . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Interlock System 17. . . . . . . . . . . . . . . . . .
Operating Characteristics 17. . . . . . . . . . . . . . . . . . . .
Pushing or Towing Sweeper 18. . . . . . . . . . . . . . . . . .
Transporting Sweeper 18. . . . . . . . . . . . . . . . . . . . . .
Sweeper Operation 18. . . . . . . . . . . . . . . . . . . . . . . . .
While Sweeping 19. . . . . . . . . . . . . . . . . . . . . . . . . . .
Dumping the Hopper 19. . . . . . . . . . . . . . . . . . . . . . .
Lubrication 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubricate Fittings and Bearings 20. . . . . . . . . . . . . . .
Maintenance 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Engine Oil and Filter 21. . . . . . . . . . . . . . .
General Precleaner and Air Cleaner Maintenance 22.
Clean and Lubricate Foam Precleaner 22. . . . . . . . . .
Service Air Cleaner Paper Element 22. . . . . . . . . . . .
Clean Air Intake/Cooling Areas 23. . . . . . . . . . . . . . .
Check Spark Plug Gap and Condition 23. . . . . . . . . .
Changing Hydraulic Oil And Filter 23. . . . . . . . . . . .
Checking Hydraulic Lines and Hoses 25. . . . . . . . . .
Fuel Filter Replacement 25. . . . . . . . . . . . . . . . . . . . .
Sweeper Reel Height Adjustment 25. . . . . . . . . . . . .
Belt Removal/Installation 26. . . . . . . . . . . . . . . . . . . .
Clutch Switch Adjustment 26. . . . . . . . . . . . . . . . . . .
Electric Brake Clutch Adjustment 26. . . . . . . . . . . . .
Clutch Testing 27. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting Parking Brake 27. . . . . . . . . . . . . . . . . . . .
Adjusting Traction Pedal 27. . . . . . . . . . . . . . . . . . . .
Steering Chain Adjustment 28. . . . . . . . . . . . . . . . . .
Replacing Sweeper Reel Fingers 28. . . . . . . . . . . . . .
Hopper and Reel Clean Out 28. . . . . . . . . . . . . . . . . .
Wheel Motor Axle Nut Torque 28
Battery Storage 29. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Care 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Schematic 31. . . . . . . . . . . . . . . . . . . . . . .
Electrical Schematic 32. . . . . . . . . . . . . . . . . . . . . . . .
Recommended Maintenance Schedule 33. . . . . . . . .
Daily Maintenance Checklist 34. . . . . . . . . . . . . . . . .
Storage 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Toro General Commercial Products Warranty 36. . .
. . . . . . . . . . . . . . .
All Rights Reserved
Printed in the USA
2
Introduction
Safety
Read this manual carefully to learn how to operate and maintain your product properly. The information in this manual can help you and others avoid injury and product damage. Although Toro designs and produces safe products, you are responsible for operating the product properly and safely.
Whenever you need service, genuine Toro parts, or additional information, contact an Authorized Service Dealer or Toro Customer Service and have the model and serial numbers of your product ready. The two numbers are stamped on a plate which is located on the blower housing.
Write the product model and serial numbers in the space below:
Model No.
Serial No.
This manual identifies potential hazards and has special safety messages that help you and others avoid personal injury and even death. Danger, Warning, and Caution are signal words used to identify the level of hazard. However, regardless of the hazard, be extremely careful.
Danger signals an extreme hazard that will cause serious injury or death if you do not follow the recommended precautions.
Hazard control and accident prevention are dependent upon the awareness, concern, and proper training of the personnel involved in the operation, transport, maintenance, and storage of the machine. Improper use or maintenance of the machine can result in injury or death. To reduce the potential for injury or death, comply with the following safety instructions.
Supervisor’s Responsibilities
Ensure operators are thoroughly trained and familiar with the Operator’s Manual and all decals on the machine.
Establish your own special procedures and work rules for unusual operating conditions (e.g., slopes too steep for machine operation, adverse weather conditions, etc.).
Before Operating
Read, understand and follow the instructions in the Operator’s Manual and on the machine before starting. Become familiar with all controls and know how to stop quickly. A free replacement manual is available by sending complete Model and Serial Number to: The Toro Company 8111 Lyndale Avenue South Minneapolis, Minnesota 55420–1196
Warning signals a hazard that may cause serious injury or death if you do not follow the recommended precautions.
Caution signals a hazard that may cause minor or moderate injury if you do not follow the recommended precautions.
This manual uses two other words to highlight information.
Important calls attention to special mechanical
information and Note: emphasizes general information worthy of special attention.
NEVER allow children to operate the machine. NEVER allow adults to operate the machine without proper instruction. Only trained operators who have read this manual should operate this machine.
NEVER operate the machine while under the influence of drugs or alcohol.
Become familiar with the controls and know how to stop the engine quickly.
Keep all shields, safety devices, and decals in place. If a shield, safety device, or decal becomes damaged, malfunctioning, or illegible, repair or replace it before operation is commenced. Also tighten loose nuts and bolts to ensure machine is in safe operating condition.
Always wear substantial shoes. Do not operate machine while wearing sandals, tennis shoes, or sneakers or when barefoot. Do not wear loose–fitting clothing that could get caught in moving parts and possibly cause injury. Wearing safety glasses, safety shoes, long pants, and a helmet is advisable and required by some local ordinances and insurance regulations.
Do not alter this equipment in any manner which may cause hazardous conditions.
3
Safety interlock switches are for the operators protection. Disconnected or malfunctioning safety interlock switches could allow the machine to operate in an unsafe manner and may cause personal injury.
– Do not disconnect the safety interlock switches.
– Check the operation of the switches daily to be sure
the interlock system is operating correctly.
– If a switch is malfunctioning, replace it before
operating the machine.
– Replace switches every 2 years to be sure of
maximum safety.
In certain conditions gasoline is extremely flammable and highly explosive. A fire or explosion from gasoline can burn you and others and cause property damage. Caution must be used when storing or handling gasoline.
– Do not fill fuel tank while engine is running or hot
or when machine is in an enclosed area. Vapors may build up and be ignited by a spark or flame source many feet away. DO NOT SMOKE while filling the fuel tank to prevent possibility of explosion.
– Always fill fuel tank outside and wipe up any spilled
gasoline before starting engine.
– Use a funnel or spout to prevent spilling gasoline
and fill tank to about 1 inch (25 mm) below the filler neck.
– Store gasoline in a clean, safety approved container
and keep the cap in place on the container.
– Keep gasoline in a cool, well ventilated place; never
in an enclosed area such as a hot storage shed.
– To assure volatility, do not buy more than a 30 day
supply of gasoline.
While Operating
Rotating parts can cause serious personal injury. Keep hands and feet away from sweeper reels while machine is running. Keep hands, feet, hair, and clothing away from all moving parts to prevent injury. NEVER operate the machine with covers, shrouds, or guards removed.
Do not run the engine in a confined area without adequate ventilation. Exhaust fumes are hazardous and could possibly be deadly.
Operator should be seated when starting the engine and remain seated whenever the machine is in motion. Operator should keep both hands on steering wheel whenever possible.
DON’T TAKE AN INJURY RISK! When a person or pet appears unexpectedly in or near the sweeping area, STOP SWEEPING. Careless operation, combined
with terrain angles, ricochets, or missing or damaged guards, can lead to thrown object injuries. Do not resume sweeping until area is cleared.
NEVER carry passengers.
ALWAYS look to the rear of machine before backing up
and assure no one is behind the machine.
When. starting the engine:
– Sit on operator’s seat and engage parking brake.
– Make sure traction pedal is in neutral and Reel PTO
Engagement handle is in the OFF position (disengaged).
– After engine is started, release parking brake and
keep foot off traction pedal. Machine must not move. If movement is evident, the neutral mechanism is adjusted incorrectly; shut off engine and adjust until machine does not move when traction pedal is released. (Refer to Adjusting Traction Pedal, (page 27.) If engine does not crank, check interlock switch connections.
Do not touch engine, muffler, or muffler shield while engine is running or soon after it has stopped because these areas may be hot enough to cause a burn.
Tip over can cause serious injury or death.
– NEVER operate on steep slopes.
– Sweep slopes up and down, never across the face.
– When going uphill or downhill, do not stop or start
suddenly.
– Stay alert for holes in the terrain or other hidden
hazards. To avoid tipping or loss of control, do not drive close to a ditch, creek, or drop off.
– If engine stalls or machine loses headway and
cannot make it to the top of a slope, do not turn machine around. Always back slowly straight down the slope.
Using the machine demands attention. Failure to operate machine safety may result in an accident, tip over of the machine, and possible serious injury or death. Drive carefully. To prevent tipping or loss of control:
– Operate only in daylight or when there is good
artificial light.
– Drive slowly.
– Watch for holes or other hazards.
– Use care when backing machine.
– Do not drive close to a sand trap, ditch, tall curb,
creek, or other hazard.
– Reduce speed when making sharp turns and when
turning on a hillside.
4
– Avoid sudden stops and starts.
– Do not go from reverse to forward or forward to
reverse without first coming to a complete stop.
– Do not attempt sharp turns or abrupt maneuvers or
other unsafe driving actions that may cause loss of control.
– Watch out for traffic when near or crossing roads.
Always yield the right–of–way.
Operator must be skilled and trained in how to drive on hillsides. Failure to use caution on slopes or hills may cause loss of control, possibly resulting in personal injury or death.
Before getting off seat:
– Move traction pedal to neutral position and remove
foot from pedal.
Maintenance
Hydraulic fluid escaping under pressure can penetrate skin and do serious damage. Keep body and hands away from pin hole leaks or nozzles that eject high pressure hydraulic fluid. Use cardboard or paper to find hydraulic leaks. Fluid accidentally injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result.
Accidental starting of engine by others while maintenance is being performed could cause injury. Before servicing or making adjustments to the machine:
– Stop engine.
– Set parking brake.
– Remove key from ignition switch.
– Set parking brake and set Reel PTO Engagement
handle to the OFF position (disengaged).
– Shut engine off and remove key from ignition
switch. Wait for all movement to stop before getting off seat.
Whenever the machine is left unattended, be sure engine is stopped, Reel PTO Engagement handle is in OFF position (disengaged), and key is removed from ignition.
While Dumping
Moving hopper door and dumping debris can cause serious injury. Stay clear of hopper while machine is backing up or dumping.
Keep bystanders a safe distance from hopper when operating to dump debris or when opening and closing hopper door.
Under rare circumstances wet, compressed grass clippings may generate heat. Always empty the hopper before storing the unit.
Raising and lowering of hopper door could cause injury to bystanders or pets. Keep bystanders and pets a safe distance from hopper when operating to dump debris or when opening and closing hopper door.
To avoid the risk of electrical shock, dump hopper only in area clear of overhead wires and other obstructions.
NEVER dump hopper on a slope. Always dump hopper on level ground.
Set Reel PTO Engagement handle to OFF (disengaged) before dumping.
Unexpected movement of the machine caused by an improperly adjusted traction pedal may cause personal injury. When foot is removed from traction pedal, the machine should stop; it must not move in either direction. It machine does move, do not operate until neutral assembly has been repaired or adjusted.
Accidental movement of machine due to parking brake not being set may cause personal injury. The hydrostatic transmission will not, at any time, act as a parking brake for the machine. To engage parking brake, pull back on lever. Whenever the engine is shut off, the parking brake must be engaged to prevent accidental movement of the machine.
Engine must be running so final adjustment of the traction adjustment cam can be performed. To guard against possible personal injury, keep hands, feet, face, and other parts of the body away from the muffler, other hot parts of the engine, and other rotating parts.
Perform only those maintenance instructions described in this manual. If major repairs are ever needed or assistance desired, contact an Authorized TORO Distributor.
Failure to maintain proper torque could result in failure or loss of wheel and may result in personal injury.
– Torque wheel motor axle nuts to 200–400 ft.–lb.
– Torque rear wheel lug nuts to 45–55 ft.–lb.
To reduce potential fire hazard, keep the engine free of excessive grease, grass, leaves, and accumulations of dirt.
Make sure all hydraulic line connectors are tight, and all hydraulic hoses and lines are in good condition before applying pressure to the system.
5
Performing maintenance on machine not properly supported with jack stands may cause machine to fall and could cause injury.
Do not over speed the engine by changing the governor settings. Maximum engine rpm with no load is 3000 rpm. To ensure safety and accuracy, have an Authorized TORO Distributor check maximum engine speed with a tachometer.
Engine must be shut off before checking oil or adding oil to the crankcase.
If wheel is removed for maintenance or repairs on the wheel, brake, or hydraulic wheel motor, when remounting wheel ALWAYS ensure that the wheel motor axle nut is torqued to 200–400 ft.–lb.
To be sure of optimum performance and safety, always purchase genuine TORO replacement parts and accessories. Replacement parts and accessories made by other manufacturers could be dangerous. Altering this machine in any manner may affect the machine’s operation, performance, or durability, or its use may result in injury or death. Such use could void product warranty of The Toro Company.
NEVER attempt to service the gas springs located on hopper and hopper door. These springs are under high loads and improper handling ran result in bodily harm. Special tools are required to replace worn or damaged gas springs; contact an Authorized TORO Distributor.
6
Safety and Instruction 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 lost.
87-6020
53-4420
67-5360
01-506-0080
27-7310
85-7490
98-8880
95-0390
80-9350
7
1. Fast
2. Continuous variable setting
95-0384
01-506-0090
95-0370
3. Slow
95-0387
95-0371
1. Choke—on 2. Choke—off
95-0383
95-0389
95-0388
88-8950
8
Specifications
General Specifications
Type
Engine
Battery
Fuel System 5 gallon (18.9 liter) tank.
Electrical
Traction System
Controls
Three wheeled, front steer, rear drive, one person ride–on turf sweeper with welded steel frame and integral hopper for collecting debris.
Manufacturer: Kohler, Model CH1 BS, air cooled, 4 cycle Horsepower: 18 @ 3600 RPM Maximum Torque: 30 ft.–lb. @ 2500 RPM Compression Ratio: 8.5. I Displacement: 38.1 cu. in. (624 CC) Oil Capacity w/filter: 2.1 quarts (2 liters) Governor: Mechanical Governor Limit: 3000 RPM Idle Speed: 1200 RPM Air Cleaner–High density paper element with oiled foam precleaner Fuel Filter: 15 micron in–line filter
12 volt with 370 cold cranking amps. (CCA) at 0_ F. Type 24.
Type 24. 12 volt with 370 Cold Cranking Amps (CCA) at 0_ F. Electrical circuit is fused at 10.0 Amps.
Sundstrand Series 15 pump coupled to Parker/Ross Model MS 10 wheel motors. Filtration – 25 micron suction line filter (replaceable spin on element). Foot pedal control with cable to ramped neutraling device on hydrostatic pump with eccentric neutral adjust.
Throttle, choke, Reel PTO Engagement handle, parking brake, hopper release handle, and ignition switch are all hand–operated. Forward/reverse traction pedal is foot operated.
Gauges Hour meter, hydraulic vacuum gauge, and engine oil pressure warning light.
Electric clutch with brake. Automatically engages when Reel PTO Engagement
Reel Drive
Steering Manual, 14 in. soft touch, 3 position tilt steering wheel, 6 to 1 ratio.
Brakes Rear 6 in. drums with hand lever actuated to dual cables.
Tires, Wheels
Seat High–back cushion with slide adjust.
Interlock Switches
Hopper
Handle lowers reels (2 heights). Sweeping pick–up with two counter–rotating finger reels, baffles and skirts. Reels rotate at 1100 RPM, and effectively pick up light debris on turf up to 5 mph.
Front (1)–18 x 8.5–8 in. turf tread. Rear (2)–18 x 9.5–8 in. ribbed tread. All tires 4 ply rating, tubeless type.
Prevents engine starting if traction pedal or Reel PTO Engagement handle are engaged. Stops engine if operator leaves seat with either traction pedal or PTO switch engaged.
Stationary, 1.25 cu. yd. capacity, with deflectors and grass filling baffles. Gas strut supported rear dumping door, with integral discharge duct and wire mesh screen for directing dust and air away from operator.
9
General Specifications (continued)
Weight: 1600 lb. Payload/Operator: 740 lb. Ground Speed: 6.5 mph.
General Specifications
(approx.)
Note: Specifications and design subject to change without notice.
Width Overall: 70.0 in. Height Overall: 67.0 in. Height Overall: (with optional ROPS): 86.0 in. Length Overall: 111.0 in. Curb Clearance: 4 in.
Optional Equipment
ROPS/Seat Belt Package Available from
Authorized TORO
Distributor
Spark Arrestor Kohler Part No.
25–189–02
Loose Parts
Note: Use this chart as a checklist to ensure that all parts have been received. Without these parts, total setup cannot be completed.
Description
Operator’s Manual 1 Read before operating the machine.
Kohler Engine Owners Manual 1 Read before operating the machine.
Parts Catalog 1
Registration Card 1 Fill out and return to Toro.
Before Operating
Grass Baffle
The sweeper comes with a hopper baffle extension installed. This extension greatly enhances the filling capacity of the hopper. You may find that the particular debris that you are sweeping tends to fall back into the hopper inlet and clogs the reels. When this occurs removal of the extension should alleviate hopper clogging. It you are sweeping fine dry material such as thatch or grass clippings, the baffle extension should be used. When sweeping larger debris such as oak leaves, you may prefer to remove the extension.
Qty. Use
Check Tire Pressure
Check tire pressure every eight hours or daily to assure proper levels.
1. With lower air pressure, turf compaction and tire marks are minimized. Optimum pressure is 10–15 psi on front and rear tires. Lower pressure should not be used for heavy payloads or tire damage may result. Do not exceed the maximum pressure. Maximum air pressure in front tire is 22 psi and rear tires is 24 psi.
Important When replacing tires, use only replacements
approved for the Turf Sweeper. Use of tires not approved may cause turf damage.
1. To remove the hopper baffle extension, remove the (5) bolts. Store the fasteners and the extension in a safe location.
10
Check Crankcase Oil
The engine is shipped with 2.1 quarts (2 liters) of oil (with filter) in the crankcase; however, level of oil must be checked before the engine is first started.
1. Position the sweeper on a level surface and make sure engine is off.
2. Remove the dipstick and wipe it with a clean rag. Push dipstick down into the tube and ensure it is fully seated. Pull dipstick out of the tube and check level of oil.
1
Figure 1
1. Dipstick 2. Filler cap
3. Install dipstick into tube.
4. If oil is low, use a clean rag to clean area around oil fill
cap. Remove cap and add oil until level is up to, but not over, the F mark on the dipstick. Add the oil slowly and check the level often during this process. DO NOT OVERFILL. The engine requires high–quality detergent oil having the American Petroleum Institute (API) “service classification” SG or SH. Oil viscosity (weight) must be selected according to average anticipated ambient temperature. Temperature/viscosity recommendations are as follows:
A. Above 0_ F (–18_ C)–Use l0W–30 or 10W–40.
B. Below 32_ F (0_ C)–Use 5W–20 or 5W–30.
Note: Using other than service class SG or SH oil or extending oil change intervals longer than recommended can cause engine damage.
2
Fill Fuel Tank With Gasoline
Danger
IN CERTAIN CONDITIONS GASOLINE IS EXTREMELY FLAMMABLE AND HIGHLY EXPLOSIVE. A FIRE OR EXPLOSION FROM GASOLINE CAN BURN YOU AND OTHERS AND CAUSE PROPERTY DAMAG
Caution must be used when storing or handling gasoline.
Do not fill fuel tank while engine is running or hot or when machine is in an enclosed area. Vapors may build up and be ignited by a spark or flame source many feet away.
To prevent the possibility of explosion, DO NOT SMOKE while filling the fuel tank.
Always fill fuel tank outside and wipe up any spilled gasoline before starting engine.
Use a funnel or spout to prevent spilling gasoline before starting engine. Fill tank to about I inch (25 mm) below the filler neck.
Store gasoline in a clean, safety approved container and keep the cap in place on the container.
Keep gasoline in a cool, well ventilated place, never in an enclosed area such as a hot storage shed.
To assure volatility, do not buy more than a 30–day supply of gasoline.
Gasoline is a fuel for internal combustion engines; therefore, do not use it for any other purpose. Since many children like the smell of gas, keep it out of their reach because the fumes are explosive and dangerous to inhale.
Fuel Type – For best results use only clean, fresh,
UNLEADED gasoline with a pump sticker octane rating of 87 or higher. In countries using the Research method, it should be 90 octane minimum.
THE TORO COMPANY STRONGLY RECOMMENDS THE USE OF FRESH, CLEAN, UNLEADED REGULAR GRADE GASOLINE IN TORO GASOLINE–POWERED PRODUCTS. UNLEADED GASOLINE BURNS CLEANER, EXTENDS LIFE, AND PROMOTES GOOD STARTING BY REDUCING THE BUILD–UP OF COMBUSTION CHAMBER DEPOSITS.
E.
Important Check level of oil after every 5 hours of
operation or daily. Change oil and filter after every 50 hours of operation. Change oil and filter more frequently when engine is operated in extremely dusty or dirty conditions.
Note: Gasoline/Alcohol Blends – Gasohol (up to 10% ethyl
alcohol, 90% unleaded gasoline by volume) may be used. Do not use other gasoline/alcohol blends.
Note: Gasoline/Ether Blends–Methyl Tertiary Butyl Ether (MTBE) and unleaded gasoline blends (up to a maximum of 15% MTSE by volume) may be used. Do not use other gasoline/ether blends.
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