Preface
This publications provides the service technician with
information for troubleshooting, testing, and repair of the
Hydroject. Additional information is available in the
Hydroject 3000/4000 Troubleshooting Guide, Part
No. 97928SL
REFER TO THE HYDROJECT OPERATOR’S MANUAL FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. Space is provided in
Chapter 2 of this book to insert the Operator ’s Manual
and Parts Catalog for your machine. A replacement
Operator’s Manual is available by sending the complete
Model and Serial Number of the machine to:
The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420
The T oro Company reserves the right to change product
specifications or this publication without notice.
.
Part No. 91764SL Rev. C
Service Manual
Hydroject ® 3000/4000
means DANGER,Th is safety symbol
WARNING, or CAUTION, PERSONAL SAFETY
INSTRUCTION. When you see this symbol,
carefully read the instructions that follow.
Failure to obey the instructions may result in
personal injury.
NOTE: A NOTE will give general information about the
correct operation, maintenance, service, testing or repair of the machine.
IMPORTANT: The IMPORTANT notice will give important instructions which must be followed to prevent damage to systems or components on the
machine.
©
The Toro Company 1991-1997
Hydroject 3000/4000
Table Of Contents
Chapter 1 - Safety
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1
Safety and Instruction Decals
Chapter 2 - Product Records and Manuals
Product Records. . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1
Equivalents and Conversions
Torque Specifications
Lubrication
Equipment Operation and Service History Forms 2 - 5
Chapter 3 - Engine
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2
Onan Engine Service Manual
Chapter 4 - Hydraulic System
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2
General Information
Hydraulic Diagram
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 7
Troubleshooting
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 9
Adjustments
Repairs
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 11
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 14
. . . . . . . . . . . . . . . . . . . . . . 2 - 3
. . . . . . . . . . . . . . . . . . . . . . . 4 - 3
. . . . . . . . . . . . . . . . . . . . . . . . 4 - 6
. . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 8
. . . . . . . . . . . . . . . . 1 - 4
. . . . . . . . . . . . . . . . 2 - 2
Chapter 5 - Electrical System
Wiring Schematics and Diagrams. . . . . . . . . . . . . 5 - 2
Special Tools
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 9
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 17
Repairs
Chapter 6 - Water System
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 2
Water System Schematic
Special Tools
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 9
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 12
Adjustments
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 20
Chapter 7 - Wheels, Steering and Brakes
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 2
Repairs
Chapter 8 - Hydroject 4000 Addendum
Safety and Instruction Decals . . . . . . . . . . . . . . . . 8 - 2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 3
Maintenance Schedule
Electrical Schematic
Water System Diagram. . . . . . . . . . . . . . . . . . . . 8 - 13
Service and Repairs
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 26
. . . . . . . . . . . . . . . . . . . 6 - 3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 18
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 3
. . . . . . . . . . . . . . . . . . . . . 8 - 7
. . . . . . . . . . . . . . . . . . . . . . 8 - 11
. . . . . . . . . . . . . . . . . . . . . . 8 - 14
Hydroject 3000/4000
Rev. B
Hydroject 3000/4000
Table of Contents
Chapter 1
Safety
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 1
Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety Instructions
Although hazard control and accident prevention partially are dependent upon the design and configuration
of the machine, these factors are also dependent upon
the awareness, concern, and proper training of the per
sonnel involved in the operation, transport, maintenance, and storage of the machine. Improper use or
maintenance of the machine can result in injury or
death. T o reduce the potential for injury or death, comply
with the following safety instructions.
Before Operating
1. Read and understand the contents of this manual
before starting and operating the machine. Become fa
miliar with all controls and know how to stop quickly. A
free replacement manual is available by sending com
plete Model and Serial Numbers to:
The Toro Company
8111 Lyndale Avenue South
Bloomington, Minnesota 55420
Use the Model and Serial Number when referring to your
machine. If you have questions about this Service
Manual, please contact:
The Toro Company
Commercial Service Department
8111 Lyndale Avenue South
Bloomington, Minnesota 55420
2. Never allow children to operate the machine. Do not
allow adults to operate machine without proper instruc
tion. Only trained operators who have read this manual
should operate this machine.
-
-
-
-
Maintenance and Service . . . . . . . . . . . . . . . . . . . . . 3
SAFETY AND INSTRUCTION DECALS
. . . . . . . . . . 4
CAUTION
TO REDUCE THE POTENTIAL FOR INJURY
OR DEA TH, COMPL Y WITH THE FOLLOWING
SAFETY INSTRUCTIONS.
3. Never operate the machine when under the influ-
ence of drugs or alcohol.
4. Before attempting to start engine engage parking
brake.
5. Remove all debris or other objects that might interfere with operation. Keep all bystanders away from the
work area.
6. Keep all shields and safety devices in place. If a
shield, safety device or decal is defective or damaged,
repair or replace it before operation is commenced. Also
tighten any loose nuts, bolts and screws to assure ma
chine is in safe operating condition.
7. Do not operate machine while wearing sandals, tennis shoes, sneakers or shorts. Also, do not wear loose
fitting clothing which could get caught in moving parts.
Always wear long pants and substantial shoes. Wearing
safety glasses, safety shoes, ear protection and a hel
met is advisable and required by some local ordinances
and insurance regulations.
-
-
Hydroject 3000
Page 1 – 1
Rev. B
Safety
8. Fill fuel tank with gasoline before starting the en-
gine. Avoid spilling gasoline. Since gasoline is flammable, handle it carefully.
A. Use an approved gasoline container.
B. Do not fill tank while engine is hot or
running.
C. Do not smoke while handling gasoline.
While Operating
D. Fill fuel tank outdoors and up to about one
inch (25 mm) from top of the tank, not the
filler neck.
E. Wipe up any spilled gasoline.
9. Check interlock switches daily for proper operation.
If a switch fails, replace it before operating the machine.
The interlock system is for your protection, so do not bypass it. Replace all interlock switches every two years.
10. DON’T TAKE AN INJUR Y RISK! When a person or
pet appears unexpectedly in or near the WORKING
area, STOP AERATING.
11. Keep hands and feet away from nozzle and roller
area. High velocity water jets can penetrate hands and
feet. Penetration by the high velocity water jets can
cause serious personal injury. If accidental penetration
occurs, seek medical attention immediately.
12. Never use chemicals in the water supply system.
13. Do not operate water injection system on concrete
or asphalt because water jets will permanently damage
these surfaces.
14. Start engine with parking brake engaged.
15. Do not run the engine in a confined area without ad-
equate ventilation. Exhaust fumes are hazardous and
could possibly be deadly.
16. Using the machine demands attention, and to prevent loss of control:
Maintenance
A. Use only in daylight or when there is good
artificial light.
B. Watch for holes or other hidden hazards.
C. Do not transport machine close to a sand
trap, ditch, creek or other hazard.
17. If the machine starts to vibrate abnormally , shut the
engine off. Remove wires from spark plugs to prevent
possibility of accidental starting. Check machine for
damage and defective parts. Repair any damage before
restarting the engine and operating the machine.
18. Do not touch engine or muffler while engine is running or soon after it is stopped. These areas could be hot
enough to cause a burn.
19. Before leaving the operator’s position–behind handle–engage parking brake.
20. When leaving the machine unattended, engage
parking brake , shut engine OFF and remove key from
ignition switch.
21. Disconnect wires from spark plugs to prevent accidental starting of the engine when servicing, adjusting or
storing the machine.
22. If machine must be tipped to perform maintenance
or an adjustment, close fuel shut–off valve, drain gaso
line from fuel tank, oil from crankcase and remove battery .
23. T o reduce potential fire hazard, keep the engine free
of excessive grease, grass, leaves and accumulations
of dirt.
24. Be sure machine is in safe operating condition by
keeping nuts, bolts and screws tight. Check all bolts and
nuts frequently to be sure they are tightened to specification.
25. If the engine must be running to perform a maintenance adjustment, keep hands, feet, clothing and other
parts of the body away from any moving parts.
26. Make sure all hydraulic line connectors are tight, and
all hydraulic hoses and lines are in good condition be
fore applying pressure to the system.
Safety
Page 1 – 2 Rev. B
27. Keep body and hands away from pin hole leaks or
nozzles that eject water or hydraulic fluid under high
pressure. Use paper or cardboard, not hands, to search
for leaks. Hydraulic fluid or water escaping under pres
sure can have sufficient force to penetrate skin and do
serious damage. If either of these fluids are ejected into
the skin they must be surgically removed within a few
hours by a doctor familiar with this form of injury or gan
grene may result.
28. Before disconnecting or performing any work on the
hydraulic oil system, all pressure in system must be re
lieved by stopping engine and opening by–pass valve.
29. Make sure all water line connectors are tight, and all
hoses and lines are in good condition before applying
pressure to the system.
-
Hydroject 3000
-
-
-
30. Before disconnecting or performing any work on the
water system, all pressure in system must be relieved by
stopping engine and opening bleed valve. Opening the
the bleed valve allows any trapped water to escape from
the system and also allows the accumulator piston to
move to the bottom of the accumulator cylinder.
31. The accumulator in this machine contains high
pressure dry nitrogen. Accumulator servicing requires
special tools and precautions. Accumulators do not contain user serviceable components. Improper accumulator servicing can cause dismemberment or death. Do
not attempt to disassemble a accumulator, have this
work done by a Authorized Toro Distributor.
32. Do not overspeed the engine by changing governor
settings. T o be sure of safety and accuracy , have an Au
thorized T0R0 Distributor check maximum engine
speed with a tachometer.
33. Engine must be shut off before checking oil or adding oil to the crankcase.
-
34. Allow engine to cool before storing machine in any
enclosure such as a garage or storage shed. Make sure
the fuel tank is empty if machine is to be stored in excess
of 30 days. Do not store machine near any open flame or
where gasoline fumes may be ignited by a spark. Always
store gasoline in a safety approved, red metal container.
35. When storing or transporting machine (trailering),
make sure fuel shut–off valve is closed.
36. Perform only those maintenance instructions described in this manual. If major repairs are ever needed
or assistance is desired, contact an Authorized T oro Dis
tributor. To ensure optimum performance and safety , always purchase genuine TORO replacement parts and
accessories to keep the Toro all TORO. NEVER USE
“WILL–FIT” REPLACEMENT P ARTS AND ACCESSORIES MADE BY OTHER MANUFACTURERS. Look for
the TORO logo to assure genuineness. Using unap
proved replacement parts and accessories could void
the warranty of The Toro Company.
-
-
Hydroject 3000
Page 1 – 3
Rev. B
Safety
Safety and Instruction Decals
The following decals are installed on the machine. If any become damaged or illegible, replace it. The decal part number is listed below and in your parts catalog. Replacement can be ordered from your Authorized T oro Distributor . Foreign language decal sets are also available from your Authorized Toro Distributor.
On Each Side Of Engine (2)
On Drive Shaft Shield
(Part No. 80–8000)
(Part No. 80–9350)
On Top Of Tiller Arm
(Part No. 80–8070)
On Accumulator body
(Part No. 80–8880)
On Trans. Pump Bracket – under shield
(Part No. 80–8760)
On Control Panel
(Part No. 80–8150)
On Underside of Tiller Control Panel
(Part No. 80–8020)
On Muffler Shield (3)
(Part No. 80–8290)
On Control Panel
(Part No. 80–8110)
On Wheel Motor Fork
(Part No. 72–4080)
On Sides and Behind Rollers (3
(Part No. 80–8090)
On Lift Actuator
(Part No. 80–8010)
On Drive Shaft Guard
(Part No. 80–8040)
IMPORTANT
THE FIVE MICRON FILTER ELEMENT (86–8620) MUST
D
BE IN PLACE AT ALL TIMES.
OPERATION WITHOUT PROPER FILTRATION WILL
D
RESULT IN PREMATURE WEAR AND FAILURE OF THE
WATER SYSTEM COMPONENTS.
DUSE OF ADDITIONAL FILTRATION OR POTABLE WATER
MAY BE NECESSARY TO PROLONG THE LIFE OF THE
FILTRATION SYSTEM.
DSEE OPERATOR’S MANUAL FOR MORE INFORMATION.
On Each Side Of Machine (2)
(Part No. 92–9542)
Safety
On Tiller Control Panel
(Part No. 80–9240)
On Tiller Arm
(Part No. 93–9429)
Page 1 – 4 Rev. B
On Accumulator body
(Part No. 80–8030)
Hydroject 3000
Product Records and Maintenance
Table of Contents
Chapter 2
PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . 1
EQUIVALENTS AND CONVERSIONS 2
Decimal and Millimeter Equivalents 2
U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . .
. . . . . . . . . . . .
Product Records
Record information about your Hydroject 3000 on the
OPERATION AND SERVICE HISTORY REPORT
form. Use this information when referring to your
machine.
. .
3
3
.
3
4
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . .
Capscrew Markings and Torque Values – U.S.
Capscrew Markings and Torque Values – Metric
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION AND SERVICE HISTORY REPORTS 5
Insert Operator’s Manuals and Parts Catalogs for your
Hydroject 3000 at the end of this section.
Hydroject 3000
Page 2 – 1
Rev. B
Product Records and Maintenance
Equivalents and Conversions
Product Records and Maintenance
Page 2 – 2
Hydroject 3000
Torque Specifications
Hydroject 3000 Product Records and Maintenance
Page 2 – 3
Lubrication
The Hydroject 3000 has 5 grease fittings that must be
lubricated every 50 hours of operation with No. 2 Gener
al Purpose Lithium Base Grease. Lubricate all fittings
immediately after every washing, regardless of interval
listed.
The bearings and bushings that must be Iubricated are
the steering pivot shaft (Fig. 1), limit switch housing (2)
on lift arm shaft (Fig. 2) and neutral pivot shaft (Fig. 3).
1. Wipe grease fitting clean so foreign matter cannot
be forced into the bearing or bushing.
2. Pump grease into the bearing or bushing.
3. Wipe up excess grease.
-
Figure 1
Figure 2
Figure 3
Product Records and Maintenance
Page 2 – 4
Rev. B
Hydroject 3000
EQUIPMENT OPERATION AND SERVICE HISTORY REPORT
for
HYDROJECTR 3000
TORO Model and Serial Number: ______________–______________
Engine Numbers: _____________________________
Transmission Numbers: _____________________________
Drive Axle(s) Numbers: _____________________________
Date Purchased: _____________________________ Warranty Expires____________
Purchased From: _____________________________
_____________________________
_____________________________
Contacts: Parts _____________________________ Phone____________________
Service _____________________________ Phone____________________
Hydroject 3000
Sales _____________________________ Phone____________________
Page 2 – 5
Rev. B
Product Records and Maintenance
Hydroject 3000 Maintenance Schedule
Minimum Recommended Maintenance Intervals
Maintenance Procedure
Check Battery Fluid Level
Check Battery Cable Connections
Lubricate All Grease Fittings
{ Change Engine Oil
{ Change Engine Oil Filter
Change Engine Pre–cleaner (Air Filter)
Replace Air Filter Element
Replace Fuel Filter
Adjust Water System Cam–Valve Clearance
Clean Engine Crankcase Breather
{ Change Gear Case Oil and Filter
{ Change Pump Case Oil
Torque Wheel Lug Nuts
{
Service Accumulator
Adjust Parking Brake
Calibrate Aeration Traction Speed
Service Injector Nozzles and Springs
Replace Spark Plugs
Decarbon Combustion Chambers
Torque Head and Adjust Valves
}
} Check Engine RPM (idle and full throttle)
Maintenance Interval & Service
Every
400hrs
D Service
Every
50hrs
A Service
Every
100hrs
B Service
Every
200hrs
C Service
{ Initial break in at 25 hours
} Initial break in at 50 hours
Replace Moving Hoses
Replace Safety Switches
Fuel Tank – Drain/Flush
Hydraulic Tank – Drain/Flush
Annual Recommendations:
Items listed are recommended every 1000
hours or 2 years, whichever occurs first.
(See Operator’s and Service Manual for specifications and procedures)
Product Records and Maintenance
Page 2 – 6
Rev. B
Hydroject 3000
Hydroject 3000 Daily Maintenance Check List
Maintenance
Check Item b
n Safety Interlock Operation
n Brake Operation
n Engine Oil Level
n Engine Air Filter Pre–Cleaner
n Engine Cooling FIns for
Daily Maintenance Check For Week Of _________________
MON TUES WED THURS FRI SAT SUN
Debris
n Unusual Engine Noises
n Unusual Operating Noises
n Water Filter/Pressure
n Water Prefilter
n Gear Case Oil Level
n Pump Case Oil Level
n Hydraulic Hose for Damages
n Fluid Leaks
n Tire Pressure
n Instrument Operations
Lubricate All Grease Fittings
1
Touch–up Damaged Paint
1
= Immediately after every washing, regardless of the interval listed.
Notation for areas of concern: Inspection performed by_____________________________
Item Date Information
1
2
3
4
5
6
7
8
Hydroject 3000
Page 2 – 7
Rev. B
Product Records and Maintenance
Date: ________________
C – Service (every 200 hours)
B – Service (every 100 hours)
Replace air filter element
Replace fuel filter
Adjust water system cam–valve clearance
Clean engine crankcase breather
Change gear case oil and filter
Change pump case oil
Change engine oil
Change engine oil filter
Change engine pre–cleaner (air filter)
A – Service Required
_______________________________
_______________________________
_______________________________
Torque wheel lug nuts
_______________________________
_______________________________
A and B – Service Required
_______________________________
_______________________________
_______________________________
Replace Moving Hoses
Replace Safety Switches
Other – Annual Service & Specials
Drain & flush fuel tank
Drain & flush hydraulic tank
_______________________________
_______________________________
A B C D E Other
__________________–__________________
TORO I.D. #: Remarks:
Hydroject 3000 Supervisor Maintenance Work Order
Unit Designation:
(Duplicate this page for routine use.)
Product Records and Maintenance
Service to perform (circle):
A– Service (every 50 hours)
Hours:
Technician:
Check battery fluide level
Check battery cable connections
________________________________
Lubricate all grease fittings
________________________________
________________________________
Page 2 – 8
________________________________
Service accumulator
Adjust parking brake
Calibrate aeration traction speed
Service injector nozzle & springs
D – Service (every 400 hours)
Rev. B
Replace spark plugs
Decarbon combustion chambers
Torque head and adjust valves
Check engine RPM (idle & full throttle)
Hydroject 3000
________________________________
A, B and C – Service Required
________________________________
(See Operator’s and Service Manual for specifications and procedures.)
Chapter 3
Engine
Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 1
REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Engine Removal and Installation . . . . . . . . . . . . . 2
ONAN SERVICE MANUAL
Specifications
Item Description
___________________________________________________________________________________________
Make / Designation Onan P224G-I/10999C
________________________________________________________________________________________________________________________________________________________
Displacement 59.7 cu. in.
________________________________________________________________________________________________________________________________________________________
Weight 127 lbs. dry
________________________________________________________________________________________________________________________________________________________
Oil Capacity 3 qt. with filter
________________________________________________________________________________________________________________________________________________________
Oil SAE 30W SF, SG, SF/CC or SG/CC
________________________________________________________________________________________________________________________________________________________
Fuel Unleaded regular gasoline
________________________________________________________________________________________________________________________________________________________
High Idle Speed 3500 ± 50 RPM no load
________________________________________________________________________________________________________________________________________________________
Low Idle Speed 1500 - 1800 RPM
HydroJect™ 3000 Page 3 - 1 Specifications
Repairs
30
18
19
23
Engine Removal and Installation (Fig. 1)
1. Park the machine on a level surface, engage the
parking brake, and remove the hood.
2. Disconnect both the positive (+) and negative (–)
cables from the battery. Loosen the battery clamp
(Item 2) and remove the battery (Item 1).
3. Remove the drain cap (Item 33) and let the oil drain
into a container. Clean and install the drain cap.
4. Disconnect the drive coupl ing from the clutch a dapter
(see Drive Coupling Removal and I nstallation in Water
System Service).
5. Remove the water pump drive belt and hydraulic
pump drive belt.
6. Disconnect the engine wiring harness connector.
Disconnect and plug the fuel hose (Item 30).
7. Remove four nuts (Item 35), washers (Item 3), capscrews (Item 39) and spacers (Item 38) securing the
engine to the frame.
11
10
9
8
7
4
3
2
1
6
5
8. Attach an engine lifting chain to the engine lifting
straps. Connect the cha in to a ho is t or b loc k and tackle
and remove slack from the chai n and lifting device. One
person should operate the hoist or block and tackle and
the other person should help guide the engine out of the
frame. Remove the engine from the frame.
9. Mount the engine in an engine rebuilding stand or put
it on a sturdy workbench. Before disassembling the
engine, remove external accessories, such as the muf fler guard (Item 11), muffler (Item 7), hydraulic pump
clutch, hydraulic pump pulle y, water pump clutch and
clutch key (see Drive Coupling Re moval and Installation
in Water System Service).
10. To install the engine, perform steps 2 - 9 in reverse
order. Make sure the ground cable (Item 36) is connected to the frame with an engine mounting nut.
11. Replace the oil filter and fill the engine with the
correct oil.
13
5
12
17
14
15
16
16
18
12
5
8
9
28
27
26
20
21
22
24
25
29
40
39
38
37
36
3
35
3
35
34
31
32
33
Figure 1
Repairs Page 3 - 2 HydroJect
™
3000
Table of Contents
Chapter 4
Hydraulic System
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . 3
Hydraulic Hose and Fitting Information . . . . . . . . 3
Pushing or Towing . . . . . . . . . . . . . . . . . . . . . . . . 5
HYDRAULIC DIAGRAM. . . . . . . . . . . . . . . . . . . . . . 6
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Hydraulic Tester. . . . . . . . . . . . . . . . . . . . . . . . . . 7
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 8
Transmission Operates in One Direction Only . . 8
System Operates Hot, Looses Power or
Will Not Operate in Either Direction
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hydraulic Tests . . . . . . . . . . . . . . . . . . . . . . . . . 10
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Traction Cable Adjustment . . . . . . . . . . . . . . . . . 11
. . . . . . . . . 8
Speed Control Adjustment. . . . . . . . . . . . . . . . . 11
Transmission Neutral Adjustment . . . . . . . . . . . 12
Aeration Speed Adjustment . . . . . . . . . . . . . . . . 12
Pump Drive Belt Adjustment . . . . . . . . . . . . . . . 13
REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pump Drive Belt Replacement . . . . . . . . . . . . . 14
Hydraulic Pump Removal and Installation . . . . . 15
Pump Shaft Seal Replacement . . . . . . . . . . . . 16
Pump Charge Check Valve Service . . . . . . . . . 17
Pump Bypass Valve Service . . . . . . . . . . . . . . . 17
Charge Pump Service . . . . . . . . . . . . . . . . . . . . 18
Major Pump Repair . . . . . . . . . . . . . . . . . . . . . . 18
Wheel Motor Removal and Installation . . . . . . . 22
Wheel Motor Repair. . . . . . . . . . . . . . . . . . . . . . 23
HydroJect™ 3000 Page 4 - 1 Table of Contents
Specifications
Item Description
__________________________________________________________________________________________
Pump Sundstrand Series 70, BDP-10L Variable Displacement Pump
Rated system pressure 2100 PSI maximum, 1000 PSI continuous
Rated system flow 8.5 GPM maximum at 3200 RPM
Charge relief pressure 25 to 70 PSI psi at 3200 RPM
Oil filter 25 micron screw-on type. No by-pass
________________________________________________________________________________________________________________________________________________________
Wheel Motor Nichols-Gray, orbit rotor type
________________________________________________________________________________________________________________________________________________________
Hydraulic Oil * Mobil DTE 26 or equivalent
________________________________________________________________________________________________________________________________________________________
Reservoir (gear case) Approximately 4 - 5 quarts
3
Figure 1
1. Sight gauge
2. Fill plug
3. Breather
* Equivalent Hydraulic Oils
2
1
Conoco Super Hydraulic Oil 68
Kendall Kenoil R & O AW 68
Chevron AW Hydraulic Oil 68
(interchangeable):
Shell Tellus 68
Amoco Rykon Oil 68
Exxon Nuto H 68
Pennzoil Penreco 68
Phillips Magnus A 68
Standard Energol HLP 68
Sun Sunvis 831 WR
Union Unax AW 68
Specifications Page 4 - 2 HydroJect™ 3000
General Information
Nut
Ma
an
Hydraulic Hoses
Hydraulic hoses are sub ject to extreme co nditions suc h
as, pressure differentials during operation and exposure
to weather, sun, chemicals, very warm storage conditions or mishandling during operation or maintena nce.
These conditions can cause damage or premat ure deterioration. Some hoses, such as reel motor h oses, ar e
more susceptible to these conditions than others. Inspect the hoses frequently for signs of deterioratio n or
damage.
When replacing a hydraulic hose, be sure that the hose
is straight (not twisted) b efore tightening the fittings. Th is
can be done by observi ng the imprint on th e hose. Use
two wrenches; one to hold the hose straight and one to
tighten the hose swivel nut onto the fitting.
CAUTION
Before disconnecting or performing any work
on the hydraulic system, all pressure in the
system must be relieved by stopping the engine and opening the bypass valve.
Keep body and hands away from pin hole
leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard,
not hands, to search for leaks. Hydraulic fluid
escaping under pressure can have sufficient
force to penetrate the skin and do serious
damage. If fluid is injected into the skin, it
must be surgically removed within a few
hours by a doctor familiar with this type of
injury or gangrene may result.
Hydraulic Fitting Installation
O-Ring Face Seal (Fig. 2, 3)
1. Make sure both threads an d sealing surfaces are free
of burrs, nicks, scratches, or any foreign material.
2. Make sure the O-ring is installed and properly seated
in the groove. It is recommended that the O-ring be
replaced any time the connection is opened.
3. Lubricate the O-ring with a light coating of oil.
4. Put the tube and nut square ly into position on the fac e
seal end of the fitting and tighten the nut until finger tight.
5. Mark the nut and fitting body. Hold the body with a
wrench. Use another wrenc h to tighten the nut to the
correct flats from finger tight (F .F.F.T.). The markings on
the nut and fitting body will verify that the connection has
been tightened.
Size F.F.F.T.
4 (1/4 in. nominal hose or tubing) .75 ± .25
6 (3/8 in.) .75 ± .25
8 (1/2 in.) .75 ± .25
10 (5/8 in.) 1.00 ± .25
12 (3/4 in.) .75 ± .25
16 (1 in.) .75 ± .25
Body
Sleeve
Seal
Figure 2
rk Nut
d Body
Finger Tight After Proper Tightening
Final
Position
Extend Line
Initial
Position
Figure 3
HydroJect™ 3000 Page 4 - 3 General Information
SAE Straight Thread O-Ring Port - Non-adjustable
(Fig. 4)
1. Make sure both threads and sealing surfaces are free
of burrs, nicks, scratches, or any foreign material.
2. Always replace the O-ring seal when this type of fitting
shows signs of leakage.
3. Lubricate the O-ring with a light coating of oil.
4. Install the fitting into th e port and tig hten it down full
length until finger tight.
5. Tighten the fitting to the correct flats from finger tight
(F.F.F.T.).
Size F.F.F.T.
4 (1/4 in. nominal hose or tubing) 1.00 ± .25
6 (3/8 in.) 1.50 ± .25
8 (1/2 in.) 1.50 ± .25
10 (5/8 in.) 1.50 ± .25
12 (3/4 in.) 1.50 ± .25
16 (1 in.) 1.50 ± .25
SAE Straight Thread O-Ring Port - Adjustable
(Fig. 5, 6)
1. Make sure both threads and sealing surfaces are free
of burrs, nicks, scratches, or any foreign material.
2. Always replace the O-ring seal when this type of fitting
shows signs of leakage.
3. Lubricate the O-ring with a light coating of oil.
4. Turn back the jam nut as far as possible. Make sure
the back up washer is not loose and is pushed up as fa r
as possible (Step 1).
O-Ring
Figure 4
Lock Nut
Back-Up Washer
O-Ring
5. Install the fitting into the port and tighten finger tight
Figure 5
until the washer contacts the face of th e po rt (Ste p 2).
6. T o put the fitting in the desired position, unscrew it by
the required amount, but no more than one full turn
Step 1
Step 3
(Step 3).
7. Hold the fitting in the desired position with a wrench
and turn the jam nut wit h an ot he r wr e nch to the correct
flats from finger tight (F.F .F.T.) (Step 4)
Size F.F.F.T.
4 (1/4 in. nominal hose or tubing) 1.00 ± .25
6 (3/8 in.) 1.50 ± .25
8 (1/2 in.) 1.50 ± .25
10 (5/8 in.) 1.50 ± .25
12 (3/4 in.) 1.50 ± .25
16 (1 in.) 1.50 ± .25
Step 2
Step 4
Figure 6
General Information Page 4 - 4 HydroJect™ 3000
Pushing or Towing (Fig. 7)
The machine can be pushed or towed for very short
distances with the engine off, if necessary.
IMPORT ANT: Do not push or tow the machine faster
than 5 MPH because the hydraulic pump may be
damaged. If the machine must be moved further
than a few feet, transport it on a trailer or pull with
traction wheel raised and secured to a dolly. Whenever the machine is pushed or towed, the by-pass
valve must be open. Hook on front of handle is used
for a tie-down only , not a hitch point.
1. Stop the engine and raise the hood.
1
2. Open the by-pass valve by turning it counterclockwi se
(2 turns maximum).
3. After moving the machine, close the by-pass valve by
turning it clockwise. Tighten the by-pass valve to a
torque of 7 to 10 ft-lb.
IMPORTANT: Operating the machine with the bypass valve open will cause improper operation and
overheating of the hydraulic system.
Figure 7
1. By-pass valve
HydroJect™ 3000 Page 4 - 5 General Information
Hydraulic Diagram
Val
By-pass
ve
Variable Displacement Pump
Cooling
Orifice
Input
(Belt Drive)
Variable
sp. Pump
Di
Charge
Pump
Charge Relief
ve
Val
Inlet
Filter
Reservo
(Gear Case)
ir
Figure 8
Charge
Check
Valves
Wheel
Motor
Hydraulic Diagram Page 4 - 6 HydroJect™ 3000
Special Tools
Gauge
High Pressure
NOTE: Order special tools from the
TORO SPECIAL
TOOLS AND APPLICATIONS GUIDE (COMMERCIAL
PRODUCTS)
. Some tools may be listed in the
HydroJect 3000 Parts Catalog. Some tools may also be
available from a local supplier.
Hydraulic Tester - With Pressure and Flow Capabilities (Fig. 9)
Load Valve
Low Pressure
Gauge
Outlet
Hose
Gauge
Protector Valve
Inlet Hose
Figure 9
You must have o-ring face seal (ORFS) adapter fittings
for this tester to use it on the HydroJect 3000.
1. INLET HOSE: Hose connected from the system
circuit to the inlet side of the hydraulic tester.
2. LOAD VALV E: If required, upon turning the valve to
restrict flow, a simulated working load is created in the
circuit.
3. LOW PRESSURE GAUGE: Low range gauge to
provide accurate reading at low pressure , 0 - 10 00 psi .
This gauge has a protector valve which cuts out
when pressure is about to exceed the normal range
for the gauge. The cutout pressure is adjustable.
Flow Meter
4. HIGH PRESSURE GAUGE: High range gauge to
accommodate pressure beyond the capacity of the low
pressure gauge, 0 - 5000.
5. FLOW METER: This meter measures actual oil flow
in the operation circuit, wi th a ga u ge r a te d at 15 G PM.
6. OUTLET HOSE: Hose from the outlet side of the
hydraulic tester to be connected to the hydraulic system
circuit.
HydroJect™ 3000 Page 4 - 7 Special Tools
Troubleshooting
The cause of an improperly functioning hyd raulic system is best diagnosed with the use of proper testing
system could lead to extensive internal component
damage.
equipment and a thorough unde rstanding of the complete hydraulic system.
The charts that follow contain detailed information to
assist in troubleshoot ing. There may pos sibly be more
A hydraulic system with an excessive increase in heat
or noise is a potential failure. Should either of these
conditions be noticed, immediately stop the machine,
than one cause for a machine malfunction. All causes
should be checked in the order in which they are listed
on the charts.
turn off the engine, locate the cause of the trouble, and
correct it before allowing the machine to be us ed again.
Continued use of an improperly functioning hydraulic
Refer to the Testing section of this Chapter for precau-
tions and specific test procedures.
T ransmission Operates in One Direction Only
Cause Correction
__________________________________________________________________________________________
Faulty traction control linkage. Repair linkage
________________________________________________________________________________________________________________________________________________________
Transmission char ge che ck va lv e de fe cti ve . Inspect and clean or replace charge/check.
System Operates Hot, Looses Power or Will Not Operate in Either Direction
Cause Correction
__________________________________________________________________________________________
Faulty control linkage. Repair linkage
________________________________________________________________________________________________________________________________________________________
Parking brake engaged. Disengage parking brake.
________________________________________________________________________________________________________________________________________________________
Hydraulic oil level too low. Fill to proper level.
________________________________________________________________________________________________________________________________________________________
By-pass valve open. Close by-pass valve.
________________________________________________________________________________________________________________________________________________________
Clogged hydraulic filter. Replace filter.
________________________________________________________________________________________________________________________________________________________
Low charge pressure - Test A. Inspect charge relief valve and replace if faulty.
________________________________________________________________________________________________________________________________________________________
Low traction pump flow/pressure - Test B. Repair or replace pump.
________________________________________________________________________________________________________________________________________________________
Inspect charge pump and rep lace if faulty.
Low traction motor efficiency - Test C. Repair or replace traction motor.
Troubleshooting Page 4 - 8 HydroJect™ 3000
Testing
The most effective method for i solati ng pro blems in the
hydraulic system is by using hydraulic te st equipment
such as pressure gauges an d flow meters i n the circuits
during various operational checks. (See the Special
Tools section in this Chapter.)
CAUTION
Failure to use gauges with the recommended
pressure (psi) rating as listed in the test procedures could result in damage to the gauge
and possible personal injury from leaking hot
oil.
Before Performing Hydraulic Tests
All obvious areas such as oil supply, filter, binding linkage, loose fasteners, or improper adjustments must be
checked before assuming th at a hydraulic component
is the source of the problem being experienced.
WARNING
Before disconnecting or performing any work
on the hydraulic system, all pressure in the
system must be relieved by stopping the engine and opening the bypass valve.
Keep body and hands away from pin hole
leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard,
not hands, to search for leaks. Hydraulic fluid
escaping under pressure can have sufficient
force to penetrate skin and do serious damage. If fluid is injected into the skin, it must be
surgically removed within a few hours by a
doctor familiar with this type of injury or gangrene may result.
1. Thoroughly clean the machine befor e disconne cting
or disassembling any hydraulic components. Always
keep in mind the need for cleanliness when working on
hydraulic equipment.
2. Put caps or plugs on any hydraulic line s lef t open o r
exposed during testing or removal of components.
3. The engine must be in good operating condition. Use
a tachometer when making a hydraulic test. Engine
speed can affect the accuracy of the tester readings.
4. To prevent damage to tester or components, the inlet
and the outlet hoses must be properly connecte d, and
not reversed (tester with pressure and flow capabilities).
5. To minimize the possibility of damaging components,
completely open the load valv e by turning it counterclockwise (tester with pressure and flow capabilities).
6. Install fittings finger tight, far enough t o insure that
they are not cross-threaded, before tightening with a
wrench.
7. Position the tester hoses so that rotating machine
parts will not make contact with them and result in hose
or tester damage.
8. Check the oil level in the reservoir.
9. Check the control lin kage for improper adjustment,
binding or broken parts.
10. All hydraulic tests should be made with the hydraulic
oil at normal operating temperature.
HydroJect™ 3000 Page 4 - 9 Testing
Hydraulic Tests (Fig. 10, 11)
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10
minutes.
2. Engage parking brake and stop the engine. Make
sure parking brake is properly adjusted before performing hydraulic tests.
3. With engine off, disconnect hose from bulkhead fitting
and install tester in ser ies between traction pump and
wheel motor. Make sure tester flow control valve is
OPEN.
IMPORTANT: Make sure that the oil flow indicator
arrow on the flow gauge is showing that oil will flow
from pump, through tester and to wheel motor.
Test A: Charge Pressure
4. Start the engine and move throttle to full engine RPM
(approx. 3200 RPM).
GAUGE READING: 25 to 70 PSI no load.
5. If there is no pressure, or pre ssure i s low, inspect for
restriction in pump intake line and inlet filter. Inspect
charge relief valve and valve seat. I nspect fo r sheared
charge pump key. Disassemble charge pump and inspect for internal damage or worn parts. If charge pump
is in good condition (no scoring, s cratches, or excessive
wear), piston pump and motor might be suspected of
wear and inefficiency, thus charge pump is unable to
keep up with internal leakage.
NOTE: At pressures above approximately 500 PSI,
mechanical override in handle will cause pump to begin
to de-stroke.
11. If you cannot get 7 GPM or 500 PSI , traction pump
may have internal damage or excessive wear.
TEST C: Traction Motor Efficiency
12. Lower drive wheel to ground and engage park ing
brake. Block front and rear of all wheels. Chain machine
to an immovable object and remove slack from chain.
13. With tester flow control valve open, slowly move
traction handle (up or dow n) so flow is f rom the pump,
through the tester, then to the wheel motor. Move trac-
tion handle until maximum pressure is attained with
wheel not rotating and read flow gauge.
14. If flow reading is higher than 1.5 GPM, motor may
have internal damage or excessive wear.
1
2
TEST B: Traction Pump Flow
6. Lift the drive wheel off the grou nd using a jack. Block
front and rear of the other whe els. Make sure the tes ter
flow control valve is OPEN.
7. Start the engine and release the parking brake.
8. While watching flow and pressure gauges, move
traction handle (up or dow n) so flow is f rom the pump,
through the tester, then to the wheel motor. Move traction handle until 6 GPM is obtained.
9. If pressure is less than 200 to 300 PSI g o to ste p 10.
If pressure is more than 200 to 300 PSI stop the engine
and inspect for binding parking b rake. Inspect for restrictioninlines to and from motor . If there are no restricti ons,
motor should be suspected of having internal damage.
10. While watching flow and pressure gauges, move
traction handle (up or down) to full speed position so
flow is from the pump, through the tester, then to the
wheel motor. Slowly close flow control valve until you
get readings of 7 GPM and 500 PSI.
Figure 10
1. Hose 2. Bulkhead fitting
Variable Displacement Pump
Tester
Figure 11
Wheel
Motor
Testing Page 4 - 10 HydroJect™ 3000
Adjustments
10
T raction Cable Adjustment (Fig. 12)
1. Park machine on a level surface, stop the engine and
open the hood. Remove lower cover from handle.
1
2. Adjust pump end of push-pull cable wit h pump leve r
in neutral starting position by adjusting jam nuts so
distance from seal to threads is 1.00 ± 0.05 in.
3. Adjust jam nuts at tiller end of push-pull cable so
2
traction handle is centered on control handle.
Figure 12
1. Jam nuts - pump end 2. Jam nuts - tiller end
Speed Control Adjustment (Fig. 13)
1. Park machine on a level surface, stop the engine and 3. Adjust speed rods (Item 14) so rod end mounting
open the hood. holes in pivot arms (Items 11, 23) are located vertically
in line with pivot pin (Item 22).
2. Adjust speed control cable (I tem 26) so speed stop
lever (Item 9) can move to horizontal position.
24
1
2
28
30
29
27
28
26
3
7
25
4
5
6
17
16
8
9
24
8
8
11
12
19
20
19
14
13
8
23
15
15
13
19
21
18
20
8
22
18
HydroJect
Figure 13
™
3000 Page 4 - 11 Adjustments
Tr ansmission Neutral Adjustment (Fig. 14)
1
If machine moves when l eve r i s released, transmissi o n
neutral adjustment is needed.
1. Park machine on a level surface, stop th e engine and
open the hood.
2. Lift drive wheel off the ground using a jack. Block front
and rear of other wheels.
3. Start engine and release parking brake.
4. Slightly loosen loc knut on top of neutr al adjustment
cam and rotate cam hex until traction wheel stops
rotating. Tighten the locknut.
5. Move traction bail completely up and down. Release
handle and check for wheel rotation. If wheel continues
rotating, repeat step 4.
6. If problem continues, stop the engine, check linkage
for binding or damage, then d o adjustment procedure
again.
7. Loosen two (2) screws and adjust switch tab so
switches are actuated when pump control is in neutral
and not actuated when pump control is stroked.
3
1
2
Figure 14
1. Neutral adjustment cam
2. Locknut
3. Switch tab
Aeration Speed Adjustment (Fig. 15)
1. Park machine on a level surface, stop th e engine and
open the hood.
2. Put speed control lever into second slot from left
(while facing control panel).
3. Lower machine into aerate mo de so transport wheel s
are off the ground.
4. Lift drive wheel off ground using a jack.
5. Start the engine and release the parking brake.
6. Operate engine at full speed.
7. Move traction handle UP to full speed position.
8. Loosen jam nuts and adjust LOWER speed rod until
traction wheel rotates at 20-22 RPM. Tighten jam nuts.
9. Move traction handle DOWN to full speed position.
10. Adjust UPPER speed rod until traction wheel rotates
at 20-22 RPM. Tighten jam nuts.
3
2
Figure 15
1. Speed control lever
2. Lower speed rod
3. Upper speed rod
Adjustments Page 4 - 12 HydroJect™ 3000
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