Toro 91764SL User Manual

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

BE IN PLACE AT ALL TIMES. OPERATION WITHOUT PROPER FILTRATION WILL

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

Touch–up Damaged Paint

= 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

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.

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.

5 12

3 35

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

Figure 1

1. Sight gauge

2. Fill plug

3. Breather

* Equivalent Hydraulic Oils

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.

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

Variable Displacement Pump

Cooling Orifice

Input (Belt Drive)

Variable

sp. Pump

Charge Pump

Charge Relief

Val

Inlet Filter

Reservo (Gear Case)

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.

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

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.

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

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.

HydroJect

Figure 13

™

3000 Page 4 - 11 Adjustments

Tr ansmission Neutral Adjustment (Fig. 14)

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.

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.

Figure 15

1. Speed control lever

2. Lower speed rod

3. Upper speed rod

Adjustments Page 4 - 12 HydroJect™ 3000

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