Form No. 3358–868 Rev A Turf Sweeper 4800 Model No. 44044—Serial No.
Daily Maintenance Checklist . . . . . . . . . . . . . . . . . Lubricate Fittings and Bearings . . . . . . . . . . . . . . . Changing Engine Oil and Filter . . . . . . . . . . . . . . . General Precleaner and Air Cleaner Maintenance . Clean and Lubricate Foam Precleaner . . . . . . . . . . Service Air Cleaner Paper Element . . . . . . . . . . . . Clean Air Intake/Cooling Areas . . . . . . . . . . . . . . . Check Spark Plug Gap and Condition . . . . . . . . . . Changing Hydraulic Oil And Filter . . . . . . .
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. 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.
• 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. 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. – Do not disconnect the safety interlock switches.
Maintenance – Avoid sudden stops and starts. – Do not go from reverse to forward or forward to reverse without first coming to a complete stop. • 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.
• 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.
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.
95-0384 01-506-0090 95-0370 1. Fast 2. Continuous variable setting 3. Slow 95-0387 95-0371 1. Choke—on 2.
Specifications General Specifications Type Three wheeled, front steer, rear drive, one person ride–on turf sweeper with welded steel frame and integral hopper for collecting debris. Engine 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.
General Specifications (continued) General Specifications (approx.) Weight: 1600 lb. Payload/Operator: 740 lb. Ground Speed: 6.5 mph. 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. Note: Specifications and design subject to change without notice. Optional Equipment ROPS/Seat Belt Package Spark Arrestor Available from Authorized TORO Distributor Kohler Part No.
Check Crankcase Oil Important Check oil after each day’s operation or each time machine is used. Change oil and filter after the first 50 hours of operation. Thereafter change oil and filter every 100 hours or operation. The engine is shipped with oil in the crankcase; however, the oil level must be checked before and after the engine is first started. Fill Fuel Tank With Gasoline Crankcase capacity is approximately 2.1 qt. (2 l) with the filter.
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. 3. Wipe up any gasoline that may have spilled to prevent a fire hazard. 1. Use a clean rag to clean area around fuel tank cap. 2. Remove the cap from the fuel tank and fill the 5 gallon tank to within 1 inch (25 mm) from the top with unleaded gasoline. Install fuel cap tightly. 1 Figure 2 1.
Check Torque of Wheel Nuts Important Using Mobil DTE 26 or equivalent ISO VG 68 hydraulic oil when temperature at start–up is less than 40_ F (4.5_ C) could cause serious hydraulic system damage. Warning 1. Position the sweeper on a level surface and make sure engine is off. Failure to maintain proper torque could result in failure or loss of wheel and could result In personal Injury. Torque rear wheel lug nuts to 45–55 ft. lb. 2.
Know Your Controls adding oil does not cause light to go out when engine is restarted, turn off engine immediately and contact your local Authorized TORO Distributor for assistance. Choke (Fig. 5)–To start a cold engine, move the choke control forward to close the choke. After engine starts, regulate choke to keep engine running smoothly. As soon as possible, move the choke backward to open the choke. A warm engine requires little or no choking. 1 2 3 4 5 Ignition Key Switch (Fig.
Seat Adjusting Lever (Fig. 6) – To adjust fore and aft position of seat, move lever on left side of seat outward, slide seat to desired position, and release lever so it will lock in position. Caution UNEXPECTED MOVEMENT OF THE MACHINE CAUSED BY AN IMPROPERLY ADJUSTED TRACTION PEDAL MAY CAUSE PERSONAL INJURY. 2 • When foot is removed from traction pedal, the machine should stop; it must not move In either direction. If machine does move, do not operate until.
Caution 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. 1 Hopper Door Release Handle (Fig. 9) – The hopper is dumped manually with the hopper door release handle. Figure 10 1.
Operation B. A disconnected or malfunctioning safety interlock switch could allow the engine to continue running when the Reel PTO Engagement handle is in the HIGH or LOW (engaged) position or the traction pedal is depressed with the operator off the seat. Warning Caution 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.
reels, thereby decreasing the efficiency of debris pickup. To maintain enough power for the sweeper reels while operating, regulate traction pedal to keep engine speed high and somewhat constant. This allows the engine to provide sufficient power to the sweeper reels while maintaining a satisfactory ground speed. By contrast, pushing down too far on the traction pedal will increase load on the engine and decrease the power available to the sweeper reels.
Dumping the Hopper Important NEVER run the reels In one place for any amount of time because the turf will be damaged. Danger While Sweeping TIP OVER/ELECTRICAL SHOCK COULD CAUSE SERIOUS INJURY OR DEATH. Danger • NEVER dump hopper on a slope. Always dump hopper on level ground. • Dump only in area clear of overhead wires and other obstructions. TIP OVER CAN CAUSE SERIOUS INJURY OR DEATH. • NEVER operate on steep slopes. • Sweep slopes up and down, never across the face.
Maintenance Recommended Maintenance Schedule Maintenance Service Interval Maintenance Procedure After first 50 hours • Change engine oil and filter. After first 10 hours • Check reel drive belts. • Torque wheel lug nuts. Every 25 hours • Clean and lubricate foam pre–cleaner. • Clean reel drive area. • Check reel drive belts. Every 50 hours • • • • Check battery fluid level. Lubricate gate pivots. Lubricate all grease fittings. Check battery cable connections.
Daily Maintenance Checklist Duplicate this page for routine use. For the week of: Maintenance Check Item Mon. Tues. Check safety interlock operation. Check parking brake operation. Check engine oil level. Check hydraulic fluid level. Check air filter precleaner. Check engine cooling fins. Check for unusual engine noises. Check for unusual operating noises. Check tire pressure. Check hydraulic hoses for damage. Check for fluid leaks. Check instrument operation. Check hopper screen.
Lubricate Fittings and Bearings The sweeper has four self–sealing bearings and two grease fittings that must be lubricated regularly with No, 2 General Purpose Lithium Base Grease. it machine is operated under normal conditions, lubricate all bearings and bushings after every 50 hours of operation or immediately after every washing. Bearings and bushings must be lubricated daily when operating conditions are extremely dusty and dirty.
Changing Engine Oil and Filter Important This product contains an exhaust emission certified engine. Always refer to the engine manufacturer’s owner’s manual for maintenance and service requirements concerning the emission control system. Note: For further information on engine operation, maintenance, and repair of engine, refer to engine manufacturer’s owner’s manual. In some cases TORO may recommend more frequent maintenance intervals than the engine manufacturer.
General Precleaner and Air Cleaner Maintenance 1 2 The engine is equipped with a replaceable, high density paper air cleaner element and an oiled foam precleaner which surrounds the paper element. 3 2 4 1 Figure 20 1. Air cleaner cover 2. Air cleaner cover knob 3. Remove precleaner from paper element. 4. Wash precleaner in warm water with detergent. Rinse precleaner thoroughly until all traces of detergent are eliminated. Squeeze out excess water. (Do not wring.) Allow precleaner to air dry.
6. When servicing air cleaner, check the air cleaner base. Make sure it is secured and not bent or damaged. Check element cover for damage or improper fit. Replace all damaged air cleaner components. 0.030 in (0.76mm) Note: Before reassembling air cleaner make sure rubber seal is in position around stud. Inspect and make sure it is not damaged. Seal with the element cover. 7. Reinstall the air cleaner paper element, precleaner, element cover, element cover nut, and air cleaner cover.
Important Using Mobil DTE 26 or equivalent ISO VG 68 hydraulic oil when temperatures average below 80_ F (26.7_ C) could cause serious hydraulic system damage. The hydraulic vacuum gauge measures the vacuum levels within the hydraulic system. When the hydraulic oil filter becomes dirty, the vacuum level within the system will increase. The vacuum level will also increase if the wrong viscosity oil is used. (Refer to Expected Ambient Temperatures table.
mesh) and ensure funnel and oil are clean. This procedure prevents accidental contamination of the hydraulic oil which will damage the hydraulic system. 6. Place all controls in the neutral or disengaged position and start engine. Run engine at idle for 3–5 minutes to circulate hydraulic fluid and remove any air trapped in the system. Stop the engine and re–check the fluid level. (Refer to Check Hydraulic System Oil) 1 7. Check all connections for leaks. Figure 24 Danger 1.
Note: The inside and outside of the belt are not the same. When looking at the front reel pulley (Fig. 25), with the belt installed, there should be two wide grooves on either side visible. Tighten the idler adjustment arm by pulling rearward with approximately 30 lbs. Torque both clamping bolts to 48 ft–lbs. Do not use a lever or a pry–bar for mechanical advantage when tensioning the belt with the idler adjustment arm. 6. Adjust the left–hand side.
1. Position machine on a level surface, shut the engine off, and remove the key from the ignition switch. Do not set the parking brake. 2. Adjust the air gap to .018” (.5mm) by inserting a thickness gauge into the clutch inspection slots. Evenly tighten the three lock nuts on clutch to reduce the air gap. Caution Performing maintenance on machine not properly supported with jack stands may cause machine to fall and could cause injury. 2.
8. Test drive machine to be sure it does not creep. Steering Chain Adjustment The steering chain should be adjusted after 100 hours of operation or when steering system is binding or excessive play in the column occurs. 1. Adjust steering chain idler, by applying 5 lbs. of force to the midpoint of the chain, until it deflects 0.25 inches. Figure 29 Note: The puller may be used in either direction for right or left handed use. 1 To remove reel fingers: 1. Place the end of the puller on the finger. 2.
Danger Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns. • Do not drink electrolyte and avoid contact with skin, eyes or clothing. Wear safety glasses to shield your eyes and rubber gloves to protect your hands. • Fill the battery where clean water is always available for flushing the skin. 1 Figure 30 1.
Troubleshooting Condition Sweeper Not Picking Up Excessive Vibration Possible Causes Corrective Action 1. Missing or broken fingers. 1. Replace missing or broken fingers. 2. Broken belt or improper tension. 2. Replace belt/adjust tension. 3. Check sheaves for sheared key. 3. Replace key. 4. Finger height may be too low or too high. 4. Adjust height. See Sweeper Reel Height Adjustment. 5. Hopper floor not seated inside against the rear cross member.
Storage C. Coat the cable terminals and battery posts with Grafo 112X skin over grease (TORO Part Number 505–46), or petroleum jelly to prevent corrosion. 1. Thoroughly clean the sweeper so it is free of dirt, leaves and debris. D. Slowly recharge the battery every 60 days for 24 hours to prevent lead sulfating of the battery. 2. Inflate tires to 22 psi. 3. Check all fasteners. Tighten as necessary. Engine 4. Grease all grease fittings. Wipe off excess lubricant. 1.
Electrical Schematic 34
The Toro General Commercial Products Warranty A Two-Year Limited Warranty Conditions and Products Covered The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your Toro Commercial Product (“Product”) to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs first.
