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

T raction Pump Belt Adjustment (Fig. 16, 17)

1. Park machine on a level surface, stop the engine and open the hood.

2. Check belt tension by depressing belt midway between pulleys with 3 lb. of force. Belt should deflect 1/4 in.

3. If adjustment is necessary: A. Loosen pivot nut securing pump mount to pump

support. B. Loosen adjusting nut securing pump and pump

mount to slotted pump support. C. Loose three (3) capscr ews secu ring p ull ey gua rd

bracket (Fig. 20, Item 21) to contro l panel and pump support.

D. Use a pry bar in hole on pump bracket to pull pump towards outside of machine until you get proper belt tension, then tighten adjusting nut to secure pump and pump mount to pump support.

E. Tighten pivot nut. Tighten three (3) capscrews securing pulley guard bracket.

Figure 16

1. Traction pump belt

Figure 17

1. Adjusting nut

2. Pivot nut

HydroJect™ 3000 Page 4 - 13

Rev . A

Adjustments

Repairs

T r action Pump Belt Replacement (Fig. 18, 19)

1. Park machine on a level surface, engage parking brake, open hood and disconnect engine spark plug wires.

2. Remove pulley guard bracket (Fig. 20, Item 21).

3. Remove drive coupling (see Drive Coup ling Removal and Installation in Chapter 6 - Water System).

4. Disconnect valve clutch electrical connector.

5. Remove valve clutch stops.

6. Loosen pivot nut securing pump mount to pump support.

Figure 18

7. Loosen adjusting nut securing pump and pump mount to slotted pump support.

8. Push pump towards inside of machine to loosen belt tension and remove the belt.

9. Reverse steps 2 - 8 to install new belt.

10. Adjust belt tension (see Traction Pump Belt Adjustment).

1. Pump drive belt

2. Drive coupling

3. Valve clutch

4. Valve clutch stops

Figure 19

1. Adjusting nut

2. Pivot nut

Repairs Page 4 - 14

Rev . A

HydroJect™ 3000

Hydraulic Pump Removal and Installation (Fig. 20)

1. Park machine on a level surface, engage parking

brake, open hood and disconnect engine spark plug wires.

2. Disconnect wires from neutral and pump switches

(Item 31) on hydraulic pump. Label wires for proper reinstallation.

3. Remove extension spring (Item 17).

4. Disconnect stroke control cable ball joint (Item 43)

from pump lever (Item 30). Disconnec t upper and lower speed adjustment rods from pump lever (see Fig. 14).

5. Loosen belt tension and remove belt from pump

pulley (see Pump Belt Tension Adjustment).

6. Disconnect hydraulic lines from fittings on pump. Put

caps on open lines and fittings to prevent contamination. Put labels on hydraulic lines for proper reinstallation.

13 14

19 20

7. Remove locknut (Item 46), capscrew (Item 5) and washers (Item 47). Remove locknut (Item 54) and capscrew (Item 57).

8. Remove pump assembly from pump support (Item 55) and put pump on a work bench.

9. Loosen jam nuts (Item 3) and set screws (Item 2). Remove pulley (Item 4) from pump shaft.

10. Remove pump mount (Item 6) from pump.

11. Loosen locknuts (Item 36) and remove roll pin (Item 34). Pull pump lever (Item 30) off of pump control shaft.

12. Remove hydraulic fittings from pump and plug ports.

13. Reverse steps 2 - 12 to install pump.

40 41

33 32

Figure 20

HydroJect™ 3000 Page 4 - 15 Repairs

Pump Shaft Seal Replacement (Fig. 21)

Lip type seals are used on input shaft and displacement controlshaft. These seals can be repl aced without major disassembly of pump.

1. Remove retaining ring f rom ho usin g (inp ut sha ft seal only).

2. Carefully pull seal out of housing bore. A “hook” type tool may be used to grasp seal and pul l it out, o r a slide hammer type puller may be used to remove seal. Be careful not to damage housing bor e, shaft se aling surface, or bearing. After the sea l is remo ved, i t cann ot b e used again.

IMPORTANT: When input shaft seal is removed, pump block spring may push shaft partially out of housing. Do not attempt to pull shaft out of housing. Internal parts could move out of alignment or fall into pump, requiring major disassembly of pump.

3. Inspect sealing area of shaft for rust, wear or contamination. Polish sealing ar ea on s ha ft if necessary.

4. Lubricate new seal with petroleum jelly.

Top of pump when installed in machine

Figure 21

1. Retaining ring

2. Seal (input shaft)

3. Spacer

4. Seal (displacement control shaft)

5. Wrap shaft with thin plastic or use a seal protector to prevent damage to seal lip during installation.

6. Slide seal over shaft and press it into housing bore. Be careful not to damage the seal.

7. Install seal retaining ring into housing (input shaft seal only).

Repairs Page 4 - 16 HydroJect™ 3000

Pump Charge Check Valve Service (Fig. 22)

T installe

T ins

1. Remove check valve plug with a 1/4 in. internal hex

wrench.

2. Remove valve spring and check ball from pump end

cap.

IMPORTANT: Do not allow check balls to fall into closed loop passages in end cap.

3. Inspect check balls and ma ting seats in en d cap for

damage or foreign mate ri al .

4. Lay pump on its side and reinstall check ball, sp ring

and plug (with O-ring) into end cap. Make sure check ball does not fall into closed loop passage inside pump. Tighten plug to a torque of 15 to 35 ft-lb. Turn pump over and repeat installation procedure for other check valve.

op of pump when

d in machine

Figure 22

1. Check valve plug

2. O-ring

3. Check valve spring

4. Check ball

5. Pump end cap

Torque to 15 to 35 ft-lb.

Pump Bypass Valve Service (Fig. 23)

1. Unscrew bypass valve from end cap of pump.

2. Inspect valve and mating seat in end cap for damage

and foreign material. It is recommended that the O-ring and back-up ring be replaced.

3. Reinstall bypass valve into end cap. Tighten to a

torque of 7 to 10 ft-lb.

Torque to 7 to 10 ft-lb.

op of pump when

talled in machine

Figure 23

1. Bypass valve

2. Back-up ring

3. O-ring

4. Pump end cap

HydroJect™ 3000 Page 4 - 17 Repairs

Charge Pump Service (Fig. 24)

1. Use a 5 mm internal hex wrench to remove the two (2) screws holding charg e pump cover to pump end cap.

NOTE: Charge pump rotation is determined by orientation of charge pump cover on pump end cap. Cast boss on charge pump cover indi cates orientation. No te orientation of cast boss before remo ving charge pump cove r .

2. Remove charge pump cover and O-ring.

3. Remove charge pump gerotor assembly.

4. Remove charge relief valve spring and ball.

5. Inspect gerotor assembly, charge pump cover and end cap for abnormal wea r , damage or fo reign material. Inspect charge relief valve seat in end cap for damage or foreign material.

6. Before installing charge pump, ap ply a sm all amount of petroleum jelly to inside diamete r, outside diameter and slide faces of gerotor assembly.

7. Install charge relief ball and spring.

Top of pump when installed in machine

Torque to 84 to 120 in-lb.

Figure 24

1. Charge pump cover

2. O-ring

3. Gerotor assembly

4. Charge relief ball

5. Charge relief spring

8. Install charge pump gerotor assembly.

9. Install charge pump cover and O-ring. Make sure charge relief spring enters recess in cover.

10. Install charge pump cover s crews and tighten to a torque of 84 to 120 in-lb.

Major Pump Repair (Fig. 25, 26)

The procedures on the following pages are for complete disassembly and reassembly of the pump.

Cleanliness is a primary means of assuring sati sfactory transmission life, on either new or repair units. Cleaning parts by using a clean solvent wash and air drying is usually adequate. As with any precision equipment, all parts must be kept free of foreign materials and chemicals. Protect all sealing surfaces and open cavities from damage and foreign material.

During assembly of the p ump, all surf aces which hav e relative motion between two parts should be coated with a film of clean hydraulic oil. This will ass ure that these surfaces will be lubricated during start-up.

It is recommended that all gaskets, o-rings and seals be replaced. Lightly lubricate all o-rings with clean petroleum jelly before assembly. All gasket sealing surfaces must be cleaned before installing new gaskets.

Repairs Page 4 - 18 HydroJect™ 3000

33 31 32

Figure 25

Disassembly of Hydraulic Pump

1. Before performing major repairs on the pump, remove

external components as described in previous procedures. These include the following:

Shaft Seals Charge Check Valves Bypass Valve Charge Pump

2. Lay pump on its side. Use a 6 mm internal hex wrench

to remove the four (4) screws (Item 30) which retain end cap to variable pump housing.

3. Internal springs will separate end cap from h ousing.

Remove end cap (Item 31) from housing (Item 18).

IMPORT ANT: Pump cylinder block (Item 7) will stick to surface of end cap. Be careful to prevent damage to end cap and cylinder block.

4. Remove gasket (Item 6) and two (2) alignment pins

(Item 15) from housing.

5. Remove cylinder block kit (Item 7) from shaft

(Item 19).

6. Remove cylinder block spring (Item 8) and washer (Item 9) from shaft.

7. Remove swashplate assembly (Item 25) from housing.

8. Remove thrust plate (Item 11) from swashplate. The bearing guide is pressed into the swashplate and is usually not removed. The inner thrust washer is retained by the bearing guide.

9. Remove slot guide block (Item 13) from displacement control shaft (Item 12).

10. Remove swashplate cradle bearings (Item 14) from housing.

11. Remove input shaft seal retaining ring (Item 24).

12. Carefully pull input shaft seal (Item 23) out of housing bore. A h ook may be used to pry seal o ut, or a sl ide hammer type puller may be used to remove the seal. Be careful not to damage housing bore, shaft sealing surface, or bearing. After seal is removed it cannot be used again.

13. Remove bearing spacer washer (Item 22).

HydroJect™ 3000

Page 4 - 19 Repairs

14. Remove pump shaft (Item 19) and bearing assembly from housing.

3. Install displaceme nt control shaft (I tem 12) into ho using.

15. Remove outer bearing retaining ring (Item 21) (and washer, i f used). Press shaft out of beari ng.

16. If pump block retaining spring retaining ring (Item 10) requires replacement, remove it from pump shaft.

17. Remove displacement control shaft from housing.

18. Pry displacement c ontro l shaft s eal ou t of h ousing. Care must be taken so as not t o dama ge housin g bo re.

19. If displacement co ntrol shaft journal bearing requires replacement, press it out of housing.

Inspection and Replacement of Pump Parts

After disassembly, thoroughly clean all parts in a suitable solvent. Replace all o-rings, gaskets and seals.

Inspect all parts for damage, nicks or unusual wear patterns. Replace all part s having unusua l or excessive wear or discoloration.

Inspect seal surf aces, bearing s urfaces and s haft splines. Polish sealing areas on shafts if necessary. Replace any worn or damaged parts.

4. If block spring retaining ring (Item 10) was re moved from pump shaft, install a new retaining ring at this time.

5. Install inner bearing retaining ring (Item 20) onto shaft. Press bearing (Item 21) onto shaft, install washer (if used) and new outer bearing re taining ring. Be careful not to stretch or deform retaining rings.

IMPORT ANT : Be careful not to damage shaft sealing surface.

6. Install pump shaft and bearing assembly into housing.

7. Install bearing spacer washer (Item 22).

8. Wrap shaft with thin pl asti c or u se a se al prote ctor to prevent damage to seal during installation. Lubricate new pump shaft seal (Item 23) with petroleum jelly.

9. Slide seal over shaft and press it into housing bore. Be careful not to damage the seal.

10. Install retaining ring (Item 24).

11. Install swashplate cradle bearings (Item 14) into housing, making sure they ar e located on cast-in pins in housing.

The pump shaft bushing (Item 5) is pressed into end cap and is usually not removed.

The running surfaces of cylinder blocks MUST be flat and free from scratches. I f scratc hes or wear are fou nd on running surfaces of cylinder blocks or end cap, polish or replace the parts. When polishing these surfaces, up to 0.0004 in. may be removed. If this is not sufficient to obtain a flat surface, free of scratches, the part should be replaced.

Assembly of Hydraulic Pump

1. Clean and lightly oil parts before assembly. Tig hten all threaded parts to recommended torque value.

IMPORTANT: Most parts have critical, high tolerance surfaces. Use caution to prevent damage to these surfaces during assembly. Protect exposed surfaces, openings and ports from damage and foreign material.

2. If displacement control shaf t bearing (Item 17) has been removed, press a new bearing into housing using a suitable press pin. Surface of bearing should be flush with inside surface of housing.

12. Install slot guide block (Item 13) onto displacement control shaft.

13. Install thrust plate (Item 11) into swashplate (Item 25). Slot on swashplate must engage guide block (Item 13) on displacement control shaft (Item 12). Use a tool such as a screwdrive r or magnet to hold guide block in position while installing swashplate.

14. Hold swashplate in position and use a dial indicator or depth gauge to meas ure side play of displacement control shaft. Using a suitable sle eve, press control shaft bearing into housing until cont rol shaft end play is between 0.020 and 0.060 in.

15. Install thrust washer (Item 9) and cylinder block spring (Item 8) onto pump shaft.

16. Install springs (Item 29), pis ton washers (Item 28) and pistons (Item 27) into cylinder block kits. The pistons must move freely in their bores.

17. With pump swashplate in “neutral” (0 angl e) position and pump housing laying on its side, install pump cylinder block kit onto pump shaft in housing .

NOTE: The position of the bearing in the housing determines control shaft end play. Do not press bearing deeper into housing at this time.

Repairs Page 4 - 20

HydroJect

™

3000

18. Check that piston springs are c entered in cylinder

block bores, If necessary, move springs into position with a small screwdriver.

21. When end cap is properly installed, the internal springs will hold it away from the housing approximately 3/8 in.

IMPORTANT: Do not damage running surfaces of cylinder blocks.

19. Install two (2) alignment pins (Item 15) and install a

new gasket (Item 6) onto housing.

20. Lubricate running surfaces of end cap (Item 31) and

cylinder blocks (Item 7). Position housing opening UP and install end cap onto housing (Item 18).

IMPORTANT: Make sure all parts are properly aligned. Do not force end cap into position on housing. Be careful to prevent damage to end cap and cylinder block sealing surfaces.

22. Install the four (4) capscrews which retain end cap to housing. Tighten screws to a torque of 138 to 180 in-lb.

23. Rotate shafts to assure correct assembly. When properly assembled, minimal torque should be required to turn shafts.

24. Wrap end of displacement control shaft with thin plastic or use a seal protector to prevent damage to seal during installation. Lubricate new displacement controls shaft seal (Item 16) with p etrol eum jell y. Slide seal over shaft and press it into housing bore. Be careful not to damage seal. Install seal flush to bottomed in bore.

33 31 32

Figure 26

HydroJect™ 3000 Page 4 - 21 Repairs

Wheel Motor Removal and Installation (Fig. 27)

37 36

Torque to 250 to 400 ft-lb.

23 24

Figure 27

1. Park machine on a level surface, engage parking brake, open hood and disconnect engine spark plug wires. Lift drive wheel off the ground using a jack. Block front and rear of other wheels.

2. Remove wheel nuts (Item 23) and remove wheel. Remove large nut (Item 22) from wheel hub.

3. Mount a wheel puller to wheel mount studs and remove wheel hub (Item 19) and brake drum (Item 18). Remove key (Item 7) from wheel mot or shaft.

IMPORTANT: To prevent damage to wheel motor, DO NOT hit wheel hub with a hammer during removal or installation.

4. Disconnect hydraulic lines from fittings on wheel motor. Put caps on open lines and fittings to p revent contamination. Put labels on hydraulic lines for pro per reinstallation.

5. Remove four (4) capscrews (Item 1), nuts (Item 27) and lockwashers (Item 28) to remove wheel motor (Item 6) and brake brackets (Item 29) from steering arm (Item 37).

6. Reverse steps 1 - 6 to install wheel motor. When installing wheel hub onto motor shaft, t ighten large nut (Item 22) to 250 - 400 ft-lb.

Repairs Page 4 - 22

Rev . A

HydroJect™ 3000

Wheel Motor Shaft Seal and/or Shaft Replacement (Fig. 28)

Figure 28

Disassembly of Shaft and Front Seal Assembly

1. Put motor on a clean, flat surface with shaft facing up.

Clean front end of motor to avoid contaminating internal parts during procedure.

2. Remove key (Item 11) from shaft.

3. Remove snap ring (Item 14) using a snap ri ng pliers.

scratches, entire motor should be disassembled for inspection.

Assembly of Shaft and Front Seal Assembly

1. Assemble thrust washers (Item 19) and thrust bearing (Item 20) on shaft using the sn ap ring (Item 21). Sna p ring sharp edges MUST face away from thrust washers with thrust bearing (Item 20) between washers.

4. Pull shaft (Item 10) out vertically.

2. Slowly lower spline end of shaft (Item 10) assembly into motor body using caution not to rotate internal parts

IMPORTANT: When pulling shaft vertically, do not

once shaft spline starts to engage.

rotate shaft or move motor as this may alter internal timing.

3. Put lightly oiled o-ring (Item 12) into groov e in body bore.

5. With seal retainer assembly and shaft assembly

removed, remove all parts from sh aft and inspect v arious parts of seal assembly (Item 15, 16, 17), shaft (Item 10) and thrust bearing assembly (Item 19, 20, 21). Replace any worn or damaged parts. Always replace

4. Gently slide oiled seal retainer assembly (Item 15, 16,

17) over shaft, chamfered side first, and press into body bore. When fully in place, body snap ring groove will be

visible. seal retainer assembly (Item 15, 16, 17). The shaft should have smooth polis hed surfaces in bearing and seal areas. If the shaft is lightly scratched in these areas, polish with fine emery paper in a circum ferential direction. However, if the shaft has any pitting or deep

5. Install snap ring (Item 14 ) into its body groove with

snap ring’s sharp edges facing outward and retainer pin

between snap ring lugs. Be sure snap ring is completely

seated in groove.

HydroJect™ 3000 Page 4 - 23 Repairs

Wheel Motor Repair (Fig. 29)

Figure 29

IMPORTANT: Before DISASSEMBLING motor, plug open ports and clean all dirt from outside of motor.

IMPORT ANT: Before ASSEMBLING motor, lightly oil all seals, rollers and threaded bolt ends.

NOTE: The check balls may fall into body tapered holes or into body valve p orts during disassembly . Be sure tha t the check balls are removed.

Disassembly of Shaft Section of Motor

Disassembly of Cover Section of Motor

(See Disassembly of Shaft and Front Seal Assembly under Main Shaft Seal and/or Shaft Replacement.)

1. Remove key (Item 11) from shaft.

Assembly of Complete Motor

2. Mount motor in a vice or other holding device with shaft facing down.

1. Before assembly, all parts must be cleaned with a suitable solvent and free of nicks and burrs.

3. Remove the eight capscrews (Item 1).

2. Mount body with pilot and bearing facing up in a vise

4. Remove cover & bearing assembly (Item 2) and

or other holding mechanism.

square ring seal (Item 4).

3. Insert shaft (Item 10) and install seals and thrust

5. Remove IGR assembly (Item 5) starting with outer locating ring, rollers, outer rolls, inner rotor and valve plate (Item 7). If any of these components are damaged,

bearings. (See Assembly of Shaft and Front Seal Assembly under Main Shaft Seal and/or Shaft Replacement.)

entire IGR assembly must be repla ced.

4. Mount body with pilot and bearing facing down in a

6. Remove the two check balls (Item 6).

vise or other holding fixture.

5. Put rotary valve (Item 7) on shaft spline with “T” shaped slots on first.

Repairs Page 4 - 24 HydroJect™ 3000

6. Next put IGR inner member on shaft spline with semi-circular roll pockets between rotary valve ports.

NOTE: Be sure not to dislodge body square ring seal

while moving locating ring.

7. Put contour member of IGR over inner and insert seven rolls into inner pockets (large diameter rolls).

8. Lightly oil square ring seal (Item 4) and put in bo dy groove.

9. Put check balls (Item 6) over the two 1/8" inch diameter holes in body. Be sure the check balls do not fall into body tapped holes.

10. Put locating ring section (4.5 inch diameter) of IGR (Item 5) onto body with che ck ball holes facing downward over balls. Align the eight bolt holes in locating ring with eight holes in body. The holes align in only one position.

1 1. Install the eight locating ring rollers into their pockets

and oil lightly.

12. Put other lightly oiled square ring seal (Item 4) into

groove in cover and put cover over s haft end and align

bolt holes.

13. Install the eight bolts with lightly oiled thread ends

into bolt holes and tighten diagonally to 30 ft-lb.

NOTE: The shaft may not turn fre ely afte r assemb ly. A

short running period may be required.

HydroJect

™

3000 Page 4 - 25 Repairs

Repairs Page 4 - 26 HydroJect™ 3000

Table of Contents

Chapter 5

Electrical System

WIRING SCHEMATICS AND DIAGRAMS . . . . . . . . 2

Logic Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Controller lights . . . . . . . . . . . . . . . . . . . . . . . . . 2.1

Wiring Schematic

Wiring Diagram – Main . . . . . . . . . . . . . . . . . . . . 4

Wiring Diagram – Control Panel . . . . . . . . . . . . . 5

Wiring Diagram – Tiller . . . . . . . . . . . . . . . . . . . . 6

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 9

Starting Problems . . . . . . . . . . . . . . . . . . . . . . . . 9

General Run and Transport Problems. . . . . . . . . 11

Aerate Operation Problems. . . . . . . . . . . . . . . . 13

Safety Interlock System Problems . . . . . . . . . . 15

TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Verify Safety Interlock System Operation . . . . . 17

Clutch Engagement /

Electronic Control System Test

Ignition Key Switch . . . . . . . . . . . . . . . . . . . . . . 19

Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Neutral Switch and Transport Switch . . . . . . . . 20

. . . . . . . . . . . . . . . . . . . . . . . . 3

. . . . . . . . . . . . . 18

Lift Limit and Pump Start Limit Switches . . . . . . 21

Aerator Start and Stop Switches . . . . . . . . . . . . 21

Lift Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Linear Actuator . . . . . . . . . . . . . . . . . . . . . . . . . 22

Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Pressure Gauge/Switch. . . . . . . . . . . . . . . . . . . 23

Accumulator Charge Switch . . . . . . . . . . . . . . . 23

Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Pump Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Valve Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . 26

Neutral Switch and Pump Switch

Replacement and Adjustment

Fuse and Circuit Breaker. . . . . . . . . . . . . . . . . . 28

Controller Replacement. . . . . . . . . . . . . . . . . . . 28

Linear Actuator Replacement . . . . . . . . . . . . . . 29

Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

. . . . . . . . . . . . 27

HydroJect 3000 Page 5 - 1

Rev. B

Table of Contents

Wiring Schematics and Diagrams

Logic Chart

Each line on the Logic Chart shows the combination of switch conditions that must be made for the listed action to occur. Example - START, under ACTIONS: For the engine to start the Key Switch must be moved to Start (making terminals B + I + S) and the hydraulic pump must be in Neutral (neutral switch CLOSED).

KEY

Switch Closed

Switch Open

⊗

Switch Closed Momentarily Switch Conditon Not Re

levent

SWITCHES

Start - Key Switch B + I + S

Run - Key Switch B + I + A / X + Y

Neutral Switch (HJ3000 only)

Oil Pressure Switch

Water Pressure Switch

Pump Start Limit Switch

Lift Limit Switch

Transport Switch (HJ3000 only)

Aerator Start (Engage) Switch

Aerator Stop (Disengage) Switch

Lift Switch UP (HJ3000 only)

Lift Switch DOWN (HJ3000 only)

ACTIONS

1. Start X X

2. Run X X

3. Machine Lower (aerate posi tion) X X O X

4. Aerate

5. Machine Raise (transport position) X X O

(see Controller Timing below)

Machine Moving (out of neutral) X X X X Machine Stationary (neutral) X X X X X X

⊗

X X

Controller Timing

Aerate START-UP Sequence

1. Pump clutch engages immediately.

2. Valve clutch engages 5 seconds after pump clutch engages.

Aerate SHUT-DOWN Sequence (Neutral Delay)

1. Pump clutch disengages and green light goes off 4 seconds after transport switch opens (red light goes off).

2. After another 3 seconds, valve clutch will disengage. NOTE: Keeping aerate start (engage) switch pushed in (closed) will keep green light on and override neutral delay shut-down.

Brake Switch

Accumulator Charge Switch

Aerate SHUT-DOWN Sequence (Disengage Delay)

1. Pump clutch disengages and green light goes off immediately when stop (disengage) switch is pushed in (opens) or if pump start limit switch or water pressure switch opens (yellow light goes off).

2. After another 3 seconds, valve clutch will disengage.

Wiring Schematics and Diagrams Page 5 - 2

Rev . B

HydroJect 3000

Controller Lights

Lights (LED’s) on the controller indicate when the following inputs are made to the controller:

Red: Transport switch closed (traction bail in neu tral).

Green: Aerate start (engage) switch closed. If red and yellow lights are on, green light will stay on until either red or yellow goes off.

Yellow: Pump start limit switch closed (machine lowered to aerate position) and water pressure switch closed (water pressure of more than 30 psi) and accumulator charge pressure switch (nitrogen pressure more than 1800 psi).

1. Red Light 2. Green Light 3. Yellow Light

Hydroject 3000

Page 5–2.1

Rev. B

Wiring Schematics and Diagrams

Page 5 – 2.2 Rev. B

Hydroject 3000

Electrical Schematic

(Model 09800)

Figure 1

HydroJect 3000 Page 5 - 3 Wiring Schematics and Diagrams

Wiring Diagram – Main

(Model 09800)

Figure 2

Wiring Schematics and Diagrams Page 5 - 4 HydroJect 3000

Wiring Diagram – Control Panel

(Model 09800)

Figure 4

HydroJect 3000 Page 5 - 5 Wiring Schematics and Diagrams

Wiring Diagram – Tiller

(Model 09800)

Figure 3

Wiring Schematics and Diagrams Page 5 - 6 HydroJect 3000

Electrical Schematic (Model 09801)

Hydroject 3000

Page 5 – 6.1

Rev. B

Wiring Schematics and Diagrams

Wiring Diagram – Main

(Model 09801)

TRANS

CLOSED

CONTROL PANEL

CB ADC

B A

OPEN

P < 1400

TRANSPORT

PRESSURE SWITCH

ACCUMULATOR CHARGE

CLOSED

P > 1800

AERATE

BLUE/RED

ORANGE

BLACK

GRAY

YELLOW BROWN

RED

OPEN

TRANSPORT

PUMP START LIMIT

CLOSED

AERATE

VALVE

BLACK

CLUTCH

BLACK

RED

PUMP

CLUTCH

RED

BLUE

GRAY

YELLOW

RED/BLUE

GRAY

YELLOW

RED

LINEAR

ACTUATOR

YELLOW

GREEN

OPEN OPEN

AERATE

NEUTRAL SWITCH

COM

BLACK

NEUTRAL

RED/BLUE

RED

BLUE

CLOSED

OPEN

CLOSED

YELLOW

AERATE

TRANSPORT SWITCH

NEUTRAL

COM

OPEN CLOSED

OPEN

CLOSED

GRAY

PURPLE

START

PUMP CLUTCH

RELAY RELAY

BLACK

YELLOW

GRAY

BLACK

BROWN

C B A

PURPLE PINK PURPLE YELLOW

RED/BLUE

Wiring Schematics and Diagrams

YELLOW

BLACK

RED

GREEN

BROWN

PURPLE

BLUE

Page 5 – 6.2

PINK

TILLER

BLACK

YELLOW

BLACK

ORANGE

Rev. B

BLACK

LIFT DOWN

BLACK

RED

BLACK

PINK

GRAY

BROWN

RELAY

LIFT UP

VALVE CLUTCH

RELAY RELAY

Hydroject 3000

Wiring Diagram – Control Panel (Model 09801)

HOUR

METER

BLACK

GREEN

ORANGE

YELLOW

KEY

SWITCH

ORANGE

BLUE/RED

BLACK

RED

GRAY

20 AMP

CURCUIT BREAKER

B A

PRESSURE

GAGE/SWITCH

KEY SWITCH

OFF NONE

RUN B+I+A X+Y

START B+I+S

ENGINE

VOLTAGE RECTIFIER

B+

ALTERNATOR

FUSE

30 AMP

PURPLE

DIODE

BLUE

BROWN

IGNITION

RED

N.O.

OIL PRESSURE

– +

BATTERY

STARTER

Hydroject 3000

Page 5 – 6.3

Rev. B

Wiring Schematics and Diagrams

Wiring Diagram – Tiller (Model 09801)

ALARM

–

NORMALLY

CLOSED

BLUE

PURPLE

BROWN

BAC

GREEN

PINK

BLACK

ORANGE

ED C B A

YELLOW

GREEN

N.O.

BRAKE

SWITCH

N.C.

AERATOR

STOP

COMMON

OPEN

NORMALLY

N.O.

AERATOR

START

SWITCH

COMMON

Wiring Schematics and Diagrams

ORANGE

PINK

Page 5 – 6.4 Rev. B

ORANGE

DOWN

BROWN

Hydroject 3000

LIFT

SWITCH

Special Tools

NOTE: Order special tools from the

TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS)

supplier.

. Some tools may be available from a local

TORO SPECIAL

Digital Multimeter (Fig. 6)

The meter can test electrical components and circuits for current, resistance, or voltage drop.

NOTE: Toro recommends the use of a DIGITAL meter when testing electrical circuits. The high impedance (internal resistance) of a digital meter will ensure that excess current is not allowed through the meter. Excess current can cuase damage to a circuit that is not designed to carry it.

Figure 6

HydroJect 3000 Page 5 - 7

Rev. B

Special Tools

Skin-Over Grease (Fig. 7)

Special non-conductive grease which forms a light protective skin to help waterproof electrical switches and contacts.

Toro P/N

505-47

8 oz. (.24 L) can

Figure 7

Special Tools Page 5 - 8

Rev. B

HydroJect 3000

Troubleshooting

CAUTION

Remove all jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Disconnect the battery cables unless the test requires battery voltage.

Study the operating characteristics preceding the electrical failure to help ide ntify the ar ea of difficulty. Try to isolate the failure to a specific functional system; then check that area, repairing one component at a time. Attempting to repair more than one system at one time will lead to confusion.

Possible Causes and Corrections in the troublesho oting charts should be checked in t he order i n which they are listed.

For effective troubleshooting and repairs, you MUST have a good understanding of the electrical circuits and components used on this machine. (See Electrical Schematic.)

If the machine being repaired has any interlock switches by-passed, they must be reconnected for proper troubleshooting and safety.

Starting Problems

Condition Possible Cause Correction

___________________________________________________________________________________________

Engine fails to crank, regardless Loose or corroded battery connecof traction bail position. tions.

Low battery charge.

Circuit breaker open.

Clean and tighten connections.

Charge battery. Replace battery if it will not hold a charge (also see Battery does not charge under General Run and Transport Problems).

Reset circuit breaker. Find cause for open circuit breaker and correct. Replace circuit breaker if

faulty. Ignition key switch faulty. Neutral switch faulty.

Start relay faulty. Starter solenoid faulty.

Starter is faulty.

Engine is seized. Loose or damaged wiring.

HydroJect™ 3000 Page 5 - 9 Troubleshooting

Test switch and replace if faulty.

Make sure switch is properly in-

stalled and adjuste d. Test switch

and replace if faulty.

Test relay and replace if faulty.

Test starter solenoid and replace

if faulty.

Test starter and repair replace if

faulty.

Repair engine.

Check connections. Repair wiring.

Starting Problems (continued)

Condition Possible Cause Correction

__________________________________________________________________________________________

Engine cranks, but does not start.

Engine or rectifier plug loose.

Connect wire. NOTE: If engine cranks, cause of problem is UNRELATED to inter- “I” terminal on ignition key switch

Connect wire. lock system. loose.

Diode in wire harness faulty. Engine problem, or no fuel.

________________________________________________________________________________________________________________________________________________________

Replace diode

Find problem and correct (see

Chapter 3 - Engine).

Engine cranks (but should not) See Safety Interlock System Probwith traction bail in neutral.

________________________________________________________________________________________________________________________________________________________

Engine starts, but shuts down when ignition key switch is re-

lems.

Not electrical - regulate choke dur- Normal condition. ing cold start-up.

leased to RUN position.

Not electrical - low engine oil pres- Find and correct cause of low ensure.

gine oil pressure.

Oil pressure switch faulty. Test switch and replace if faulty. Loose or broken wire in oil pres- Check all wiring and connections

________________________________________________________________________________________________________________________________________________________

sure switch circuit.

and repair as necessary.

Starter does not disengage whe n key switch is released to RUN position.

Ignition switch faulty. Test ignition key switch and re-

place if faulty.

Short in start circuit wiring.

Check all wiring and connections

and repair as necessary.

Diode in wire harness faulty. Replace diode. Start relay faulty. Test start relay and replace if nec-

essary.

Starter solenoid faulty. Test starter solenoid and replace

if necessary.

Starter failed (mechanical). Test starter and replace if neces-

sary .

Troubleshooting Page 5 - 10 HydroJect™ 3000

General Run and Transport Problems

Condition Possible Cause Correction

___________________________________________________________________________________________

Engine shuts down during transport or when idling (not in Aerate

Not electrical - low engine oil pres- Find and correct cause of engine sure, no fuel, etc. shut down.

mode).

Oil pressure switch faulty.

Test switch and replace if faulty.

Loose or broken wire in oil pres- Check all wiring and connections

________________________________________________________________________________________________________________________________________________________

Engine does not stop when ignition key switch is rotated to OFF

sure switch circuit.

Engine timing or carburetor out of Adjust carburetor or engine timadjustment. ing.

and repair as necessary.

position.

Ignition switch faulty.

Test ignition switch and replace if faulty.

Short in ignition circuit wiring. Check all wiring and connections

________________________________________________________________________________________________________________________________________________________

and repair as necessary.

Battery does not charge. Open or missing 30 AMP fuse. Install new fuse. Find and correct

cause of open fuse.

Loose wire(s) in electrical system. Check for loose wire at “X” or “Y”

terminal of ignition switch. Check all other connections and wires on engine regulator.

Regulator or engine charging circuit faulty.

Battery faulty.

________________________________________________________________________________________________________________________________________________________

Ignition switch faulty.

Install new regulator or repair engine charging circuit.

Test battery and replace if faulty. Test switch and replace if faulty.

Machine does not lower (to aer- Circuit breaker open. Reset circuit breaker. Find cause ate position).

for open circuit breaker and correct. Replace circuit breaker if faulty.

Lift/lower switch faulty.

Lift DOWN relay faulty. Ignition key switch faulty.

Test switch and replace if faulty.

Test relay and replace if faulty. Test ignition switch and replace if

faulty.

Loose or broken wire in lift down circuit.

Linear actuator faulty.

Check all wiring and connections and repair as necessary.

Test actuator and repair or replace if faulty.

HydroJect™ 3000 Page 5 - 11 Troubleshooting

General Run and Transport Problems (continued)

Condition Possible Cause Correction

__________________________________________________________________________________________

Machine does not raise (to trans- Circuit breaker open. Reset circuit breaker. Fi n d cau se port position). for open circuit breaker and cor-

rect. Replace circuit breaker if

faulty.

Lift/Lower switch faulty.

Lift UP relay faulty. Ignition key switch faulty.

Test switch and replace if faulty.

Test relay and replace if faulty.

Test ignition switch and replace if

faulty.

Loose or broken wire in lift up circuit.

Linear actuator faulty.

________________________________________________________________________________________________________________________________________________________

Linear actuator continues to oper-

Lift limit switch faulty. Make sure switch is installed ate (but should not) after machine is lowered to aerate position.

Check all wiring and connections and repair as necessary.

Test actuator and repair or replace if faulty.

properly. Test switch and replace if faulty.

Troubleshooting Page 5 - 12 HydroJect™ 3000

Aerate Operation Problems

Condition Possible Cause Correction

___________________________________________________________________________________________

Machine continues to aerate (but should not) with traction bail in neutral.

________________________________________________________________________________________________________________________________________________________

Machine aerates (but should not) with with machine raised in transport position.

________________________________________________________________________________________________________________________________________________________

Machine starts aerating (but

See Safety Interlock System Problems.

Water pressure switch faulty. Test switch and replace if faulty. should not) with inlet water pressure of less than 20 to 30 PSI, or machine does not stop aerating if inlet water pressure drops to

Water pressure switch wiring faulty. Check for short in pressure

switch/controller connections and wiring and repair as necessary.

10 PSI.

________________________________________________________________________________________________________________________________________________________

Machine does not start aerating when engage button is pushed in

Controller faulty.

Problem not electrical (see Chap-

ter 6 - Water System.)

Replace controller.

(pump drive belt does NOT rotate).

Circuit breaker open.

Reset circuit breaker. Find cause for open circuit breaker. Replace circuit breaker if faulty.

Loose or broken wire.

Check all connections and wiring and repair as necessary.

Accumulator charge switch faulty

(Model 09801).

Pressure gauge switch faulty.

Pump clutch faulty.

Pump relay faulty.

Aerator stop (disengage) switch

faulty.

Pump start limit switch faulty.

Aerator start (engage) switch faulty.

Controller faulty.

Test switch and replace if faulty.

Test switch and replace if faulty. Test clutch and replace if faulty. Test relay and replace if faulty. Test switch and replace if faulty.

Make sure switch is installed properly. Test switch and replace if faulty.

Test switch and replace if faulty. Replace controller.

HydroJect 3000

Page 5 - 13

Rev. B

Troubleshooting

Aerate Operation Problems (continued)

Condition Possible Cause Correction

__________________________________________________________________________________________

Machine does not start aerating when engage button is pushed in

V alve clutch out of adjustment.

Check air gap on valve clutch

and adjust if necessary. (pump belt IS rotating, but gearcase drive shaft is NOT rotating).

Loose or broken wire in valve clutch / controller circuit.

Valve clutch faulty.

Check all connections and wiring

and repair as necessary.

Test valve clutch and repair or re-

place if faulty.

Valve clutch relay faulty.

________________________________________________________________________________________________________________________________________________________

Controller faulty.

Machine stops aerating when not It is normal for pump clutch and moving (traction bail in neutral). water clutch to disengage when

traction bail is neutral for 3 to 4 sec-

________________________________________________________________________________________________________________________________________________________

Machine stops aerating while machine is moving (traction bail out of neutral).

onds.

Problem not electrical (see Troubleshooting in Chapter 6 - Water System.)

Transport switch faulty.

Test relay and replace if faulty.

Replace controller.

Educate operator. NOTE: Holding

Aerate start switch in ENGAGE

position will override neutral de-

lay shut-down.

Make sure switch is installed and

adjusted properly. Test switch

and replace if faulty.

Loose or broken wire in transport switch / controller circuit.

Also see possible causes in (Water pump clutch does not engage) and (Water pump clutch engages, but water valve clutch does not engage.)

Check all connections and wiring

and repair as necessary.

Troubleshooting Page 5 - 14

HydroJect 3000

Safety Interlock System Problems

Condition Possible Cause Correction

___________________________________________________________________________________________

Engine cranks (but should not) Neutral switch faulty. Make sure switch is installed and with traction bail in neutral. adjusted properly. Test neutral

switch and replace if faulty.

Neutral switch wiring faulty. Check for short in neutral switch

wiring and connections and repair

________________________________________________________________________________________________________________________________________________________

as necessary.

Machine continues to aerate (but should not) with traction bail in neutral.

Red light on controller is ON (should be OFF) with traction bail in neutral.

Make sure transport switch is installed and adjusted properly. Test transport switch and replace if faulty.

Check for short in transport switch/controller connections and wiring and repair as necessary.

Green light on controller stays ON (should be OFF) with aerate engage switch released.

Test aerate engage (start) switch and replace if faulty (make sure switch action is momentary and comes comes back out after being pushed in).

________________________________________________________________________________________________________________________________________________________

Machine aerates (but should not) with with machine raised in transport position.

Controller faulty.

Yellow light on controller is ON T est pump start limit switch and (should be OFF) with machine replace if faulty. raised in transport position.

Replace controller.

Check for short in pump start limit switch connections and wiring and repair as necessary.

Controller faulty. Replace controller.

HydroJect™ 3000 Page 5 - 15 Troubleshooting

Safety Interlock System Problems (continued)

Condition Possible Cause Correction

__________________________________________________________________________________________

No lights on controller come on when troubleshooting i n te rl o ck system.

Battery is dead or disconnected.

Circuit breaker open.

Charge battery. Replace battery if it will not hold a charge. Clean and tighten connections.

Reset circuit breaker. Find cause for open circuit breaker and correct. Replace circuit breaker if faulty.

Faulty controller ground.

Check controller ground connection and wiring and repair as necessary.

Ignition key switch faulty.

Test ignition switch and replace if faulty.

Loose or damaged wiring in key switch/controller circuit.

________________________________________________________________________________________________________________________________________________________

Green light on controller glows

Controller faulty.

Normal condition.

Check all connections and wiring and repair as necessary.

Replace controller.

faintly when only red light should be on (traction bail out of neutral and aerate engage switch released).

Troubleshooting Page 5 - 16 HydroJect™ 3000

Testing

It is often to the technician’s advantage to leave the components intact in the electrical system, and by studying the electrical tr oubleshoo ting charts and sch ematics, determine which component is at fault. However, thi s section will define given compo nents, and the tests that can be perfor med on those components, when those parts are disconnected from the el ectrical system.

For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit.

Verify Safety Interlock System Operation

CAUTION

When testing electrical components for continuity with a volt-ohm meter or continuity tester, make sure that power to the circuit has been disconnected.

NOTE: Electrical troublesho oting of any 12 Volt power connection can also be performed through voltage drop tests without disconnection of the component.

The safety interlock system prevents the engine from cranking or starting, unless tracti on bail is in NEUTRAL and prevents the water system from engaging if machine is in the transport (ra ised) position. It also stops aeration if traction bail is release d while operating or if machine is raised to the transport position.

CAUTION

The interlock switches are for the operator’s protection, DO NOT disconnect them. Check operation of switches daily to make sure interlock system is operating. If a switch is defective, replace it before operating. Regardless if switches are operating properly or not, replace interlock switches every two (2) years to assure maximum safety. Do not rely entirely on safety switches; use common sense!

To do a functional check of interlock system:

1. Put machine in a flat, open area on rough turf away from buried wires, plumbing, etc. Stop the engine.

2. Move traction bail up and down while trying to start the engine. If engine cranks there is a malfunction in the interlock system that must be correct ed. If en gine does not crank, go to step 3.

3. Connect water supply to machine. Turn on water supply and bleed all air out of the system. Water pressure must be 20 to 30 PSI or more. Start the engine. Raise machine to transport position (up off of rollers). Push aerate ENGAGE button. If water pump engages and machine begins aerating, there is a malfunction in the interlock system that must be corrected. If machine does not begin aerating, go to step 4.

4. Lower machine to aerate position (on rollers). Engage traction bail to start machine moving. Push, then release aerate ENGAGE button. Water pump should engage immediately , then mach ine should begin aeratin g 5 seconds after pump engages. Release traction bail to neutral position so machine sto ps moving. The wa ter pump should disengage 4 seconds after traction bail returns to neutral, then stop aerating a fter another 3 sec onds. If machine does not stop aerating when traction bail returns to neutral, there is a malfunction in the interlock system that must be corrected. If machine stops aerating, go to step 5.

5. Engage traction bail to start machine moving, then push aerate ENGAGE button to begin aerating. Push aerate DISENGAGE button. The water pump should disengage immediately, then stop aerating after 3 seconds. If machine does not stop aerating, there is a malfunction in the interlock system that must be corrected.

HydroJect™ 3000 Page 5 - 17 Testing

Clutch Engagement / Electronic Control System Test (Fig. 8)

This test can be used to check for proper operation of the electronic contro l sys te m and clu tche s wi tho ut co n necting the machine to a water s our ce or op era ti n g th e machine.

1. Park machine on a level surface, stop the engine, engage the parking brake, open the hood and disconnect the engine spark plug wires.

2. Disconnect wiring harness connector from bottom of water pressure gauge. Install a jumper wire across terminals of disconnected wire connector. This will electrically by-pass the water pressure switch.

3. Turn ignition key switch to ON position. DO NOT start the engine.

4. ENGAGE test: A. Lower machine to aerate position (on rollers).

Yellow light should be ON. B. Move traction bail out of neutral. Red light should

come ON.

B. After clutches are engaged, push red aerate DISENGAGE button.

C. Green light should immediately turn OFF and pump clutch should disenga g e.

D. After 3 seconds, valve clutch should disengage. E. System must not restart wit hout pushing green

aerate ENGAGE button.

IMPORTANT: When test is completed, water pressure switch by-pass must be removed to prevent damage to water system from low inlet water pressure.

7. Remove by-pass jumper wire that was connected in step 2 and connect wire harness connector to terminals on bottom of water pressure gauge.

C. With traction bail out of neut ral, push, then release, green aerate ENGAGE button. Green light should come ON and pump clutch should engage. After 5 seconds valve clutch should engage.

NOTE: Touch clutches with a metal object, such as a screw driver, to help che ck for cl utch e ngage ment (clutch will be magnetized).

5. NEUTRAL shut-down test: A. Release traction bail. Red light should turn OFF. B. After 4 seconds, pump clutch should disengage

and green light should go OFF. C. After another 3 seconds, valve clutch should

disengage.

6. DISENGAGE test: A. Move traction bail out of neutral and push green

aerate ENGAGE button.

Figure 8A

1. Red light

2. Green light

3. Yellow light

Testing Page 5 - 18

Rev . A

Figure 8B

1. Red light

2. Green light

3. Yellow light

HydroJect™ 3000

Ignition Key Switch (Fig. 9, 10)

CONT AM TE

NONE

The ignition (key) switch has three positions (OFF, ST ART and RUN). The terminals are marke d as shown.

Figure 9

The circuitry of the ignition switch is shown in the chart. With the use of a continuity tester, the switch functions may be tested to determine whether all circuits are being completed while the key is moved to each position.

POSITION

1. OFF

2. RUN

3. START

INUITY

ONG

RMINALS

B + I + A

B + I + S

Figure 10

OTHER CIRCUITS MADE

NONE

X + Y

NONE

HydroJect™ 3000 Page 5 - 19 Testing

Controller (Fig. 11)

The controller senses the condition of various switches, such as the transport switch a nd aerate start switch an d directs power output to allow certa in machine function s, such as aerate engage, disengage and ti ming o f thos e functions.

Because of the solid state circuitry built into the controller, there is no method to test it directly. The controller may be damaged if an attempt is made to test it wi th an electrical test device, such as a volt-ohm meter.

IMPORTANT: Before welding on the machine, disconnect both battery cables from the battery, disconnect both wire harness plugs from the electronic control unit and disconnect the terminal connector from the alternator to prevent damage to the electrical system.

Lights (LED’s) on the controller indicate the condition of the interlock switches. The LED’s, in conjunction with the following tests fo r interlock switches, should be used to help isolate a problem in an interlock switch, wiring or the controller (see Wiring Schematics and Diagrams).

Neutral Switch and Tr ansport Switch (Fig. 12)

The neutral switch is normally open (N.O.) and is closed when traction bail is neutral. The transport switch is normally closed (N.C.) andis open when the traction ba il is in neutral.

IMPORTANT: The neutral and transport switches have three (3) terminals. The NEUTRAL SWITCH must have the wires connected to the “COMMON” and “N.O.” terminals. The TRANSPORT SWITCH must have the wires connected to the “COMMON” and “N.C.” terminals. If the wires are not connected to the correct terminals, on each switch the safety interlock circuit will not function properly .

Figure 11

1. Red light

2. Yellow light

3. Green light

Test the switch by disconnecting the wires from the

Figure 12

switch terminals and connecting a continuity tester across the two terminals that had wires connected to them. With the engine turned off, slowly push the traction bail in a forward and reverse direction while watch-

1. Neutral switch –– N.O. (black & red/blue wires)

2. Transport sw itch –– N.C. (yellow & gray wires)

3. Switch tab

ing the continuity tester. There should be indications that the switch is opening and closing. Allow the traction bail to return to neutral. There should be continuity across the terminals of the neutral switch and no continuity across the terminals of the transport switch. (See Neutral Switch and T rans port Switch Re place ment a nd Adjustment in the Repairs section of this chapter for replacement and adjustment procedures.)

Testing Page 5 - 20 HydroJect™ 3000

Lift Limit Switch and Pump Start Limit Switch (Fig. 13)

Test the switch by disconnecting the wire connector and installing a continuity tester or ohm meter across the two leads of the switch.

Lift Limit Switch

Aerate (machine lowered) Transport (machine raised) OPEN CLOSED

Pump Start Limit Switch

Aerate (machine lowered) Transport (machine raised) CLOSED OPEN

NOTE: For proper operation, the switch must be screwed all the way in. A damaged pivot shaft or bushings could cause the switch to not open and close properly. Debris in the switch could also cause it to not open and close properly.

Aerator Start and Stop Switches (Fig. 14)

The aeration start (ENGAGE) switch is nor mally open (N.O.) and closes when the button is pushed down. Th e aeration stop (DISENGAGE) switch is normally closed (N.C.) and opens when the button is pushed down.

Test the switch by disconnecting the wires from the switch terminals and connecting a continuity tester or ohm meter across the two switch terminals.

Figure 13

1. Pump start limit switch (blue/red & red/blue wires)

2. Lift limit switch (white & black wires)

Figure 14

1. Aeration start switch (pink & orange wires)

2. Aeration stop switch (blue & purple wires)

HydroJect™ 3000 Page 5 - 21 Testing

Lift Switch (Fig. 15)

The lift switch is a three position switch. Switch position is maintained in center position with no circuits made.

Test the switch by disconnecting the wires from the switch terminals and connectin g a continuity tester or ohm meter across terminal 2 (common) and terminal 1 or 3. With switch pushed toward keyway in threads, terminals 1 and 2 are made. With switc h pushe d away from keyway in threads, terminals 2 and 3 are made.

Linear Actuator (Fig. 16)

The linear actuator has a bi-dire ctional electric motor which engages a clutch and screw mechanism to extend or retract a rod and raise or lower the transport wheels.

Figure 15

1. Lift switch

To test the actuator:

1. Disconnect the wiring connector.

2. Connect a 12 volt battery so the negative (–) terminal

is connected to the red wire of the actuator connector. When the positive (+) bat tery terminal is connected to the yellow wire the actuator motor should operate to extend the actuator cylinder , raising the wheels to ae rate position.

3. Connect a 12 volt battery so the negative (–) terminal

is connected to the yello w wire of the actuator connector . When the positive (+) bat tery terminal is connected to the red wire the actuator motor should operate to retract the actuator cylinder, lowering the wheels to transport position.

Linear Actuator Specifications

Rod end play 0.070 max. Current draw 26 amps max. Voltage 12 VDC Speed 3/4 in. per second at maximum

load

Figure 16

1. Linear actuator 2. Wiring connector

Testing Page 5 - 22 HydroJect™ 3000

Brake Switch (Fig. 17)

The brake switch is a normally open (N.O.) switch that closes when the brake is engaged.

To test the brake switch disconnect the wires from the switch terminals and connect a continuity tester or ohm meter across the terminals of the switch. With the brake disengaged, the switch should show no continuity . With the brake engaged, the switch should show continuity.

Pressure Gauge/Switch (Fig. 18)

The pressure gauge switch is normally open and closes when inlet water pressure goes above 20 to 30 PSI. The switch opens when inlet water pressure goes below approximately 10 PSI.

T o test the pressure switch, disconnect the wire connector and connect a continuity tester or ohm meter across the terminals of the switch connector. The switch should show continuity when inlet water pressure reaches 20 to 30 PSI on gauge. The switch should break continuity as water pressure goes below 10 PSI.

Figure 17

1. Brake switch

Accumulator Charge Switch (Fig. 18a)

(Model 09801)

The accumulator charge switch is normally open and closes when accumulator charge pressure is greater than 1800 PSI. The switch opens when accumulator charge pressure goes below 1400 PSI.

Figure 18

1. Pressure gauge/switch

Figure 18a

1. Accumulator charge switch

HydroJect 3000

Page 5 - 23

Rev. B

Testing

Relays (Fig. 19, 20)

To test a relay, disconnect the relay wire connector and install a continuity tester between the relay terminals (terminals 30 and 87). The relay should make and break continuity at terminals 30 and 87 as 12 V.D.C. is connected and disconnected to terminal 85 with terminal 86 connected to ground.

Resistance specifications:

Terminals 85 and 86 = 80 to 90 Ohms Terminals 30 and 87a (normally closed) = continuity

Terminals 30 and 87 (normally open) = continuity when 12V DC is applied to terminals 85 and 86

Figure 19

RELAY (WIRE COLORS)

1. Valve clutch (brown, gray, red, pink)

2. Lift up –– transport (green, black, red, green, black)

3. Lift down –– aerate (brown, white, blue, red, black)

4. Pump clutch (blue, yellow, purple, red)

5. Start (yellow, red/blue, brown, red)

Figure 20

Battery

Use a hydrometer to test the battery. Charge the battery if necessary (see Battery Service).

Electrolyte Specific Gravity

Fully charged: 1.250 - 1.280 Discharged: less than 1.240

Testing Page 5 - 24

Rev. B

HydroJect 3000

Pump Clutch (Fig. 21)

To test the pump clutch, disconnect the wire connector and connect a continuity tester or ohm meter across the terminals of the clutch wire connector. There should be continuity across the terminals of the clutch connector. Resistance measured through the clutch coil should be approximately 3 ohms.

The clutch can also be tested by connecting a 12 VDC battery across the clutch connector terminals. The clutch should engage as 12 VDC is connected to the clutch connector terminals.

Clutch coil resistance:

3.79 Ohms

+ 5% at 20

C (68o F)

Valve Clutch (Fig. 22)

To test the valve clutch, disconnect the wire connector and connect a continuity tester or ohm meter across the terminals of the clutch wire connector. There should be continuity across the terminals of the clutch connector. Resistance measured through the clutch coil should be approximately 3 ohms.

Figure 21

1. Pump clutch

The clutch can also be tested by connecting a 12 VDC battery across the clutch connector terminals. The clutch should engage as 12 VDC is connected to the clutch connector terminals.

Clutch coil resistance:

3.5 Ohms

+ 5% at 20

C (68o F)

Figure 22

1. Valve clutch

HydroJect 3000

Page 5 - 25

Rev. B

Testing

Repairs

Battery Service (Fig. 23, 24)

IMPORTANT: To prevent damage to the electrical components, do not operate the engine with the battery cables disconnected.

Keep the terminals and entire battery case clean. To clean the battery, wash the entire case with a solution of baking soda and water . Rinse with clea r water . Do not get the soda solution into the battery because damage to the battery will result. Coat the battery posts and cable connectors with skin-over grease, or petroleum jelly to prevent corrosion.

Check for loose battery hold-downs. A loose battery may crack or cause the container to wear and leak acid.

Check the electrolyte solution to make sure the level is above the plates. If the l evel is low (but abo ve the plates inside the battery), ad d water so the level is to the bottom of the cap tubes. If t he level is below the plates, add water only until the plates are covered and then charge the battery. After charging, fill the battery to the proper level.

CAUTION

Do not charge a frozen battery because it can explode and cause injury. Let the battery warm to 60 a charger.

o o

F (15.5 C) before connecting to

Electrolyte Specific Gravity

Fully charged: 1.250 - 1.280 Discharged: less than 1.240

Battery Specifications

BCI Group 28 Battery:

525 Amp Cranking Performance at 0 110 min. Reserve Capacity at 80

Figure 23

1. Positive (+) terminal

2. Negative (–) terminal

F (–17 o C)

F (27 o C)

Charge the battery in a well-ventilated place so that gases produced while charging can dissipate. Since the gases are explosive, keep open flame and electrical spark away from the battery; do not smoke. Nausea may result if the gases are inhaled. Unplug the charger from the electrical outlet before connecting or disconnecting the charger leads from the battery posts.

Figure 24

Repairs Page 5 - 26 HydroJect™ 3000

Neutral and Transport Switch Replacement and Adjustment (Fig. 25)

1. Disconnect wires from switch terminals.

2. Have a helper push traction bail down into either FORWARD or REVERSE position or disconnect extension spring; this will take switch arm tension off of switch. Loosen two (2) screws and remove switch.

3. Have a helper push traction bail down and Install new switch. DO NOT over-tighte n screws as the switch case could break.

4. Reconnect wires to new switch. Make sure one wire is connected to “COMMON” terminal, and one wire is connected to N.O. terminal (neutral switch) or N.C. terminal (pump switch).

IMPORTANT: The neutral and transport switches have three (3) terminals. If the two (2) wires are not connected to the “COMMON” and “N.O.” terminals on neutral switch and “COMMON” and “N.C.” terminals on transport switch, the safety interlock circuit will not function properly.

CAUTION

If the wires are not correctly installed to the neutral switch, the engine could start with the traction bail in forward or reverse.

5. Coat switch terminals and wires with skin-over grease.

Figure 25

1. Neutral switch – N.O. (black & red/blue wires)

2. Transport switch – N.C. (yellow & gray wires)

3. Switch tab

6. Loosen two (2) screws and adjust switch tab so switches are actuated, but not bottomed out, when pump control is in neutral.

HydroJect™ 3000 Page 5 - 27 Repairs

Fuse and Circuit Breaker (Fig. 26)

The electrical system is protected by a 30 AMP fuse located under the control panel and a 20 AMP circuit breaker with reset button.

NOTE: It is not always possible to see if the fuse is faulty . It is recommended that you check for faulty fuses with a continuity tester, not visually.

Controller Replacement (Fig. 27)

IMPORTANT: Before welding on the machine, disconnect both battery cables from the battery, disconnect both wire harness plugs from the controller and disconnect the terminal connector from the alternator to prevent damage to the electrical system.

1. Stop the engine and disconnec t battery c ables fro m

battery.

Figure 26

1. Circuit breaker 2. Fuse

2. Disconnect wiring harness connecto rs from control-

ler.

3. Remove two (2) nuts securing controller to frame and

remove controller.

4. Install new controller and secure to frame with nuts

removed in step 3.

5. Connect wiring harness connectors to controller.

6. Connect battery cables.

Figure 27

1. Controller

Repairs Page 5 - 28 HydroJect™ 3000

Linear Actuator Replacement (Fig. 28)

1. Put wheels in transport position (machine raised).

2. Put the machine on a level surface, stop the engine, engage the parking brake and di sconnect engine spark plug wires.

3. Open the hood.

4. Disconnect linear actuator wire connector.

5. Disconnect extension springs.

6. Remove capscrew and nut securing each end of linear actuator.

7. Reverse steps 3 - 6 to install the linear actuator.

Diode (Fig. 29)

The diode is located in the wire harness under the side control panel near the fuse.

Figure 28

1. Linear actuator 3. Extension spring

2. Wire connector 4. Capscrew & nut

Figure 28

1. Diode

HydroJect™ 3000 Page 5 - 29 Repairs

Repairs Page 5 - 30 HydroJect™ 3000

Table of Contents

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Nozzle Size and Approximate Depth Chart . . . . . 2

WATER SYSTEM SCHEMATIC . . . . . . . . . . . . . . . . 3

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Accumulator Charging Valve

and Pressure Gauge

Accumulator Seal Installation Tool . . . . . . . . . . . 4

Accumulator Cap Wrenc h . . . . . . . . . . . . . . . . . . 5

Water System Pressure Gauge . . . . . . . . . . . . . . 5

Flow Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Va l ve Lift Indicator . . . . . . . . . . . . . . . . . . . . . . . . 6

V a l ve Spring Compressor . . . . . . . . . . . . . . . . . . 6

Water Valve Seal Installation Guide . . . . . . . . . . 7

Pump Seal Installation Guide . . . . . . . . . . . . . . . 7

Seal Installation Mandril . . . . . . . . . . . . . . . . . . . 7

Filter Body Wrench . . . . . . . . . . . . . . . . . . . . . . . 7

Pump Seal Extraction Tool . . . . . . . . . . . . . . . . . 8

Pump Seal Outlet Cover . . . . . . . . . . . . . . . . . . . 8

Pump Wear Sleeve Driver . . . . . . . . . . . . . . . . . . 8

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 9

Troubleshooting Water System Problems . . . . . . 9

. . . . . . . . . . . . . . . . . . . . 4

Chapter 6

Water System

TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Before Performing Water System Tests . . . . . . 12

TEST NO. 1: Accumulator Pre-Charge Pressure

and Adding Dry; Nitrogen TEST NO. 2: Water System Pressure and Flow 15

TEST NO. 3: Water Valve Lift . . . . . . . . . . . . . . 17

ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Electric Clutch Adjustment . . . . . . . . . . . . . . . . . 18

Water Valve Lift . . . . . . . . . . . . . . . . . . . . . . . . . 18

REP AIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Drive Coupling and Clutch

Removal and Installation

Pump Drive Belt Replacement . . . . . . . . . . . . . 21

Water Filter Replacement . . . . . . . . . . . . . . . . . 22

Water Pump Removal and Installation . . . . . . . 23

Water Pump Head Service . . . . . . . . . . . . . . . . 24

Water Pump Crankcase Service . . . . . . . . . . . . 26

Water Valve Service . . . . . . . . . . . . . . . . . . . . . 27

Gear Case Service . . . . . . . . . . . . . . . . . . . . . . 30

Nozzle Service and Replacement . . . . . . . . . . . 31

Accumulator Replacement . . . . . . . . . . . . . . . . 32

Accumulator Service . . . . . . . . . . . . . . . . . . . . . 34

GENERAL INF ORM ATION . . . . . . . . . . . . . . . . . . . 36

Cold Weather Storage . . . . . . . . . . . . . . . . . . . . 36

. . . . . . . . . . . . . . . . 13

. . . . . . . . . . . . . . . . 20

HydroJect™ 3000 Page 6 - 1 Table of Contents

Specifications

Water Pump Clutch: Electromagnetic, dual groove belt

drive for water pump and driveshaft flange brake/clutch for main valve gearbox.

Air gap 0.018 in.

Pre Filter – Spin down type with washable cartridge in clear plastic housing and plastic ball valve for flushing.

Supply Filter – Replaceable 5 micron cartridge in plastic housing with air bleed button.

Water Filter Cartridge: Toro part no. 86–8630

Water Pressure Switch – Senses for water pressure after filter.

Switch closes when pressure is over 20–28 PSI and opens when pressure drops below 7–13 PSI.

Pump – Current pump (Model 09801) is a Toro exclusive design (patent pending) with cast stainless steel head and 3 piston plungers. Vee packing seals and Ke vlar guides. Forged crankshaft with plasma sprayed ceramic on stainless steel plungers and cast iron connecting rods.

Nominal performance is 4 GPM at 5000 PSI with 1400 RPM input.

Accumulator – Toro exclusive design with low charge pressure sensor.

Charged with nitrogen gas charged to 2500 PSI maximum pressure.

Cam and Gearbox – Reduction gear drive for cam that actuates main water valve. Roller cam follower rides on cam specifically designed (patent pending) to control water injection at 5.3 cycles per second (320 rpm) and store energy in accumulator between injections. Cast iron case also serves as 4 quart hydraulic reservoir.

Valve – Cast stainless steel valve body functions as mounting base for accumulator, gearbox and manifold outlet. All high pressure water flows in and out through the valve body. Pressure balanced valve spool with floating (patent pending), hardened stainless seat aligns during assembly. Bleed valve in base allows for bleed–off of high pressure and drain down for cold weather storage. Bolted flanges and polyurethane O– rings mate all components to valve body.

Pressure Relief V alve – Poppet–type valve with corrosion resistant stainless and brass materials.

5000 + 300 PSI relief valve pressure.

Manifold and Nozzles – Extruded stainless steel manifold with1 1 flanged nozzle extensions containing check valves and hardened stainless discharge orifice. Check valves may be reversed in housing to block unused nozzles.

Aeration Width: 33 inches with 11 nozzles on 3 inch centers.

Aeration Depth: 4 to 6 inches depending on turf conditions and nozzle configuration.

Hole Pattern: V ariable from 1.5” to 6” spacing in the direction of travel, and 3 or 6” increments in width.

Water Pump Case Oil – Mobil DTE Extra Heavy or other interchangeable ISO Grade 150 PE–700–A (Heavy Inhibited Hydraulic & General Purpose) See following chart for equivalent oils.

Mobil DTE EH (Extra Heavy) Shell Turbo 150 Amoco American Ind. Oil 150 Chevron AW Machine Oil 150 Conoco Dectol R & O150 Exxon Terresstic 150 Kendall Ken–Tran 080 Pennzoil Penreco 150/AW150 Phillips Magnus Oil 150 Standard Energol HLP 150 Sun Sunvis 150 Union Unax RX 150/Turbine Oil 150 Valvoline ETC (R&O) #70

Water Supply – Recommend a source with 7–8 gallons per minute. A minimum pressure of 30 psi at the ma chine is required for the pump to engage. Maximum allowable pressure of 200 psi. Although irrigation water pumped from ponds or effluent holding pools can be used, not all conditions can be handled by the machines filtration system, additional or alternative filtration may be required.

DO NOT USE CHEMICALS – Concern for environmental issues and corrosive affects on machine components.

Valve lift: 0.100

Rollers – Pivoting aluminum rollers uniformly smooth the turf and provide protection from the nozzle dis charge. Adjustable flow (0 – 3 GPM) spray wash system with 6 flood tip nozzles maintain clean rollers.

Specifications

+0.002

inch (with new cam)

–0.04

Page 6 – 2 Rev. B

Hydroject 3000

Depths and Nozzle Configurations: All nozzles are identified with numbers indicating the drill size of the orifice. The standard configuration is 1 1 nozzles producing depths of 4 to 6 inches depending on turf conditions. Blocked nozzle locations are obtained by reversing the nozzle check valve ball and spring. See nozzle size chart and illustrations below:

IMPORTANT: Use only nozzle configurations shown or damage to the machine may occur.

NOZZLE SIZE AND APPROXIMATE DEPTH CHART

Part No.

Drill Size Decimal Size

(inch)

Metric Size

(mm)

Quantity of Nozzles

Open

Blocked **

86–8130 #56 .0465 1.181 * * 86–8131 #53 .0595 1.511 11 0 86–8133 #46 .0810 2.057 6 5 *

Use only with varied size configurations

Aluminum Washer is required with any nozzle change:

(S/N 29999 & Below) Part no. 80–6680 (S/N 30001 & Up) Part no. 86–8150

OPTIONAL STAGGERED SIZE NOZZLE CONFIGURATION

Part No.

86–8130 86–8133

Aluminum Washer is required with any nozzle change:

(S/N 29999 & Below) Part no. 80–6680 (S/N 30001 & Up) Part no. 86–8150

Drill Size Decimal Size

(inch)

Metric Size

(mm)

Quantity of Nozzles

Open

Blocked **

#56 .0465 1.181 6 and 0** #46 .0810 2.057 5 0**

Approx. Depth

* 4–6” 6–8”

Approx. Depth

3–4” 6–8”

**Additional nozzles may be blocked to compensate for pump wear.

Hydroject 3000

Page 6 – 2.1

Rev. B

Specifications

OPEN NOZZLE CLOSED (BLOCKED) NOZZLE

S/N 29999 & Below

Tighten to

60 ft–lb

Aluminum washer (P/N 80–6680) is required with any nozzle change.

Check Valve Ball

Spring

S/N 30001 & Up

Spring

Check Valve Ball

Tighten nut to

70 – 80 ft–lb

CLOSED (BLOCKED) NOZZLEOPEN NOZZLE

Aluminum washer (P/N 86–8150) is required with any nozzle change.

Specifications

Page 6 – 2.2 Rev. B

Hydroject 3000

Water System Schematic

Model 09800

ENGINE

ELECTRIC

CLUTCH

FILTER

ACCUMULATOR

2500 PSI

NITROGEN PRE–CHARGE

WATER

PUMP

ELECTRIC

BRAKE CLUTCH

PRESSURE

SWITCH

20 PSI – ON

10 PSI – OFF

PRESSURE GAUGE

SPRAY WASH

VALVE

RELIEF VALVE

5000 PSI

WATER

VALVE

GEARBOX CAM

ROLLER WASH

NOZZLES

HIGH PRESSURE

AERATION NOZZLES

ROLLER WASH

NOZZLES

Model 09801

Hydroject 3000

PRESSURE REDUCING

VALVE

Page 6 – 3

PRE–FILTER

Rev. B

WATER SUPPLY

QUICK COUPLER

Water System Schematic

Special Tools

The following special tools are required for servicing the Order special tools from the HydroJect 3000.

AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS)

Accumulator Charging Valve and Pressure Gauge - TOR4001 (Fig. 2)

The charging valve connects the accumulator to a high pressure (3000-3500 or 6000 PSIG) Nitrogen tank for pre-charging the accumulator. The charging valve can also be used to measure acc umulator pr e-charge pressure without significant loss of accumulator pre-charge.

NOTE: The charging tool is equipped with a Compressed Gas Association No. 677 tank connection.

TORO SPECIAL TOOLS

1. Accumulator connector 4. Inlet valve

2. Pressure gauge 5. Relief valve

3. Outlet valve with diffuser 6. Nitrogen tank connector

Accumulator Seal Installation To ol - TOR4002 (Fig. 3)

Used for installing piston seal during accumulator rebuilding.

Figure 2

Figure 3

Special Tools Page 6 - 4 HydroJect™ 3000

Accumulator Cap Wrench - TOR4003 (Fig. 4)

After discharging accumulator, use this special wrench to remove accumulator cap for accumulator rebuilding.

Water System Pressure Gauge - TOR4005 (Fig. 5)

The Water System Pressure Gauge and Adapter is temporarily connected into the high pressure water system for measuring water pressure available to the water valve.

Figure 4

Figure 5

Flow Meter - TOR4006 (Fig. 6)

The in-line flow meter with a battery-powered electronic digital display is installed in the water supply line to measure pump efficiency. The flow meter is equipped with a pressure gauge to measure inlet water pressure. This gauge used in conjunction with the pressure gauge on the machine can be used to measure pressure drop across the filter to show filter condition.

Figure 6

HydroJect™ 3000 Page 6 - 5 Special Tools

Valve Lift Indicator - TOR4007 (Fig. 7)

A special dial indicator and adaptor is temporarily installed into the inspection port on the side of the high pressure manifold to measure water valve lift. This indicator is also used to measures cam wear and determines correct shim size to get proper valve lift.

Valve Spring Compressor - TOR4008 (Fig. 8)

The valve spring compressor and hardware is used for compressing the water valv e spring allowing removal and installation of the valve spring retainer. The spring retainer must be remove before servicing the water valve, water valve seals, and water valve seat.

Figure 7

Figure 8

Special Tools Page 6 - 6 HydroJect™ 3000

Seal Installation Tools (Fig. 9)

Water Val ve Seal Installation Guide - TOR4009

The Water V alve Installation Guide (small) is needed to properly install the water valve seal into the water valve body. Use Insertion Mandril with this seal guide.

Pump Seal Installation Guide - TOR4010

The Pump Seal Installation Guide (large) is needed to properly install the pump displacement rod seal into the pump head. Use Insertion Mandril with this seal guide.)

Seal Installation Mandril - TOR4011

Use Insertion Mandril with both seal guides. Seal Insertion Mandril is necessary to properly install seals in the water valve and pump head.

Filter Body Wrench - TOR4012 (Fig. 10)

Special spanner wrench use for servicing the inlet wat er filter.

Figure 9

1. Water Valve Seal Installation Guide

2. Pump Seal Installation Guide

3. Seal Installation Mandril

Figure 10

HydroJect™ 3000 Page 6 - 7 Special Tools

Pump Seal Extraction Tools (Fig. 11)

Pump Seal Extraction Tool - TOR4013

Rod used to hydraulically ext ract pump seals from the pump cylinder head. Use with Pump Seal Outlet Cover and heavy mallet or hammer.

Pump Seal Outlet Cover - TOR4014

Cover plate with O-ring used with Seal Extraction Tool to hydraulically extract pump seals from pump head.

Pump Wear Sleeve Driver - TOR4015 (Fig. 12)

Driver used for removal and installation of plunger guides in pump crankcase.

Figure 1 1

Figure 12

Special Tools Page 6 - 8 HydroJect™ 3000

Troubleshooting

The cause of an improperly functioning water system is best diagnosed with the use of proper testing equipment and a thorough understanding of the complete system.

The charts that foll ow contain detailed information to assist in troubleshooting. There may possibly be more than one cause for a machine malfunction.

ALL POSSIBLE CAUSES SHOULD BE CHECKED IN THE ORDER IN WHICH THEY ARE LISTED ON THE CHARTS.

Refer to the Testing section of this Chapter for precautions and specific test procedures.

NOTE: The water aeration syst em operat es under very high pressures and severe duty cycl es. Perform ance of the water system will be gradually reduced over a period of time due to normal wear in the pump, valve and accumulator. If you perform water system tests to isolate a possible problem, such as reduced hole depth, it is recommended that ALL tests be performed in t he or der listed even if t he apparent problem has been isolat ed, such as low accumulator pre-charge pressure. This will verify that all components are operating properly.

Troubleshooting Water System Problems

Condition Possible Cause Correction

___________________________________________________________________________________________

Machine does not start aerating when engage button is pushed in (pump belt does NOT rotate).

Transport wheels not fully raised (unit lowered to aerate mode).

Check to make sure transport wheel arms are fully raised (unit in aerate mode).

Low inlet water pressure.

Sheared pump clutch key. Electrical problem.

________________________________________________________________________________________________________________________________________________________

Machine does not start aerating when engage button is pushed in (pump belt IS rotating but gearcase drive shaft is NOT rotating.).

________________________________________________________________________________________________________________________________________________________

Machine makes unusual noise Air in system. NOTE: Rel i ef val ve when first starting aeration.

Electric brake clutch (valve clutch) Check air gap at electric brake out of adjustment. clutch and adjust if necessary.

Sheared valve clutch key. Repair. Electrical problem. See Troubleshooting in

may “squeal” for a short period of time during initial startup due to air in the system.

Check that water pressure gauge reads 20 to 30 PSI or more. If pressure is low, obtain proper water supply source.

Repair. See Troubleshooting in

Chapter 5 - Electrical System

With engine OFF and water supply connected, open high pressure bleed valve and bleed air out of system. Repeat procedure if noise continues.

Damaged component.

HydroJect™ 3000 Page 6 - 9 Troubleshooting

Check for damaged components and repair or replace as necessary.

Condition Possible Cause Correction

__________________________________________________________________________________________

Machine stops aerating (pump Machine not moving. Normal condition of interlock sysshuts down during aeration). tem. Operator must hold engage

button in to aerate with traction bail in neutral.

Inadequate water supply.

Check for kinked water supply hose, restriction in line or partially open valve at water source.

Plugged inlet water filter.

Check water pressure at gauge when pump is engaged. If pressure drops to less than 15 PSI, but was initially higher, replace water filter.

Electrical problem.

________________________________________________________________________________________________________________________________________________________

Water system engages (pump

Air in system. belt and gear case drive shaft rotate), but no aeration holes are produced or aeration hole depth

See Troubleshooting in Chapter 5 - Electrical System

With engine OFF and water supply connected, open high pressure bleed valve and bleed air out of system.

is shallow or inconsistent.

Soil density or moisture content.

If hole depth was satisfactory before in another area, different nozzle configuration may be required.

Plugged nozzles, worn nozzles or improper nozzle configuration. NOTE: Check operation of nozzles by aerating over a piece of cardboard, then inspecting cardboard.

Stop engine, open high pressure bleed valve, then inspect nozzles. Check for plugged nozzles. Verify size and quantity (see Nozzle Size and Approximate Depth Chart). Nozzles that are too large will cause loss in pressure and could cause damage to the accumulator and other water system components.

Gear or cam damage in gear case.

Inspect gear case for gear or cam damage and repair as necessary.

Leak in high pressure water system.

Check for leaks with water system engaged. Stop engine, open high pressure bleed valve and repair leaks as necessary.

NOTE: Excessive water exiting between pump head and crankcase indicates pump wear or damage. Excessive water exiting from shim area below gearcase indicates valve wear or damage. Do water system tests and make repairs as necessary .

Troubleshooting Page 6 - 10 HydroJect™ 3000

Condition Possible Cause Correction

___________________________________________________________________________________________

Machine aerates, but aeration hole depth is shallow or inconsistent (continued).

Low accumulator pre-charge or damaged accumulator - TEST NO. 1.

Low water system pressure AND flow - TE ST NO. 2.

Low water system pressure (flow is OK) - TEST NO. 2.

Low water system flo w (p re ss u re is OK) - TEST NO. 2.

Improper water valve lift - TEST NO. 3.

Charge accumulator with dry Nitrogen. Rebuild or replace accumulator if nec e ssary.

Rebuild pump.

NOTE: When testing, make sure cam is not holding water valve open - rotate gear so cam is off of valve lifter.

If water is exiting relief valve outlet hose, replace relief valve.

Rebuild water valve. Check engine speed and correct

if necessary. Rebuild pump. Perform valve lift adjustment.

Repair valve or replace cam if necessary.

Worn or damaged water valve -

________________________________________________________________________________________________________________________________________________________

TEST NO. 2.

Rebuild water valve.

Water in gear case Worn or damaged water valve low Rebuild water valve. (milky or brown color in oil)

________________________________________________________________________________________________________________________________________________________

pressure water seal and oil seal.

Oil leaking from below gear case Worn or damaged water valve oil Rebuild water valve. shim area.

________________________________________________________________________________________________________________________________________________________

Water in pump crankcase Worn or damaged water pump low (milky or brown color in oil)

________________________________________________________________________________________________________________________________________________________

seal.

pressure seal or cracked ceramic plunger.

Rebuild pump head and plunger sleeves.

Engine dies when water system Low engine RPM. Throttle must be in FAST posiis engaged.

tion. Adjust carburetor fast setting to 3450 to 3550 RPM - no load.

Relief pressure too high - TEST

Replace relief valve.

NO. 2. Low engine power.

Check for contaminated fuel, plugged fuel filter or fuel line, plugged air cleaner, bad s par k plug. (see Chapter 3 - Engine).

Jammed or siezed pump or gearcase.

Inspect components and repair as necessary.

HydroJect™ 3000 Page 6 - 11 Troubleshooting

Testing

Before Performing Water System Tests

1. The water aeration system operates under very high pressures and severe duty cycles. Performance of the water system will be gradually reduced over a period of time due to normal wear in t he pump, valve and accumulator. If you perform water system tests to isolate a possible problem, such as reduced hole depth, it is recommended that ALL tests be performed in t he or der listed even if t he apparent problem has been isolat ed, such as low accumulator pre-charge pressure. This will verify that all components are operating properly.

WARNING

High pressure water system components can cause personal in ury if disassembled incorrectly. Discharge water pressure at bleed valve before attempting any water system servicing. Open bleed valve slowly and avoid contact with high velocity water stream.

2. With engine OFF, open high pres sure bleed valve, and inspect aeration nozzles. Check for plugged nozzles. Verify size and quantity (see Nozz le Servic e and Replacement). Nozzles that are too large will cause loss in pressure and could cause damage to the ac cumulator and other water system components.

NOTE: You can check for plugged nozzles by aerating over a piece of cardboard, then inspecting cardboard.

Figure 13

1. High pressure blee d valve

Testing Page 6 - 12 HydroJect™ 3000

TEST NO. 1: Accumulator Pre-Charge Pressure (Fig. 14, 15, 16, 17)

Pre-charge pressure is measured and corrected when the piston is resting on bottom cap of accumulator (high pressure bleed valve open). By temporarily installing Charging Tool (TOR4001) to top of accumulator, Nitrogen pressure can be measured and if required, more Nitrogen can be added.

Obtain a 3000 - 3500 PSI or 6000 PSI Nitrogen tank from a local compressed gas or welding supply shop. The charging tool is equipped with a Compressed Gas Association No. 677 tank connection. These tanks contain enough Nitrogen for 20-30 fills.

NOTE: During operation, working pressure of Nitrogen in accumulator will be equal to the operating pressure

Figure 14

of the water system.

1. High pressure blee d valve

1. Park machine on a level surface, stop t he engine, engage the parking brake, open the hood and disconnect the engine spark plug wires.

DANGER

Charged accumulators contain high pressure nitrogen. Nitroge n is the only gas to use f or accumulator charging. Installing IMPROPER gases in an accumulator can cause an EXPLOSION AND DEATH. Charging requires special tools and precautions. Charge cumulators well ventilated area. It is

in a

recommended that the accumulator

ac-

be checked and charged by an Authorized TORO Distributor.

Wear eye protection. Keep hands and face away from gas valve.

Slowly open high pressure water bleed valve before servicing any component connected to high pressure water system. Opening the high pressure bleed valve allows any trapped water to escape from the system and also allows accumulator piston to move to bottom of accumulator cylinder. Failure to open bleed valve before servicing high pressure water components can cause personal in ury, DIS-

MEMBERMENT OR DEATH.

Figure 15

1. Protective cover 2. Valve cap

Charged accumulators cannot be shipped via air freight.

2. Slowly open t he high pressure bl eed valv e allowing any pressurized water to escape.

3. Remove protective cover and yellow valve cap fr om top side of accumulator.

HydroJect™ 3000 Page 6 - 13 Testing

4. Attach and gently tighten special fitting of Charging Tool (TOR4001) to inlet on top of accumulator.

5. Close outlet valve on right hand side of charging tool to prevent loss of pressurized Nitrogen from accumulator. Close inlet valve on left hand side of charging tool to prevent back flow through the tank tube.

6. Rotate the jam nut (not the fitting) of the accumulator valve two (2) turns counterclockwise as viewed from the top. This opens the valv e and pres s urizes t he t ool and gauge.

Service range of Nitrogen pre-charge pressure: 1800 to 2800 PSI. Allow +200 PSI if accumulator body is warm.

7. If pre-charge pressure is WITHIN service range, go to step 8. If pre-charge pressure is ABOVE service range, accumulator has internal damage and should be rebuilt or replaced. I f pre-charge pressure is BELOW service range, go to step 10 under Adding Dry Nitrogen to Accumul ator .

8. Tighten nut of accumulator valve c lockwise and depressurize tool by slowly openi ng outlet valve on right hand side of pressure gauge.

Figure 16

9. Disconnect charging tool from accumulator. Reinstall the yellow protective cap and valve protector bracket.

Adding Dry Nitrogen to Accumulator

10. With charging tool connected to accumulator, attach a charged tank of dry Nitrogen to high pressure tube on charging tool. Tighten tank fitting by turning hose fitting counterclockwise.

11. The accumulator tool, attached to the accumulator, has a pressurized manifold. Open inlet valve on left hand slide of charging tool to pressurize supply tube. While watching pressure gauge on tool, slowly open supply tank valve. Pressure reading on gauge will start to rise. Close supply tank valve when gauge pressure reaches 2500 PSI Wait a few minutes to make sure system pressure has equalized then add additional Nitrogen if necessary for 2500 PSI pre-charge.

12. Close accumulator valve by turning lower nut clockwise.

13. Slowly open knob on right hand side of charging tool de-pressurize the tool, then remove tool from accumulator. Reinstall yellow protective cap and valve protector bracket.

Figure 17

NOTE: After completion, install a tag on accumulator indentifying the charging pressure and charging date.

14. Do Test No. 2: Water Pump Pressure and Flow.

Testing Page 6 - 14

Rev. A

HydroJect™ 3000

TEST NO. 2: Wat er Syst em Pr essu r e and Flow (Fi g. 18, 19, 20, 21, 22, 23)

1. The engine must be in good oper ating condition. Use a tachometer to verify that the engine is operating at specified full governed RPM (3450 to 3550 RPM no load). Engine speed will affect accuracy of f low meter reading.

2. Stop the engine, engage the parking brake and open the hood.

WARNING

3. Slowly open t he high pressure bl eed valv e allowing any pressurized water to escape.

4. Install Water System Pressure Gauge (TOR4005) into port in water valve housing as shown.

Figure 18

1. High pressure blee d valve

Figure 19

1. Water sy stem pressure gauge (TOR4005)

5. Disconnect wir e har nes s c onnec ti on for water valve clutch to prevent the water valve from operating during the test.

Figure 20

1. Water valve clutch

HydroJect™ 3000 Page 6 - 15 Testing

6. Install Flow Meter (TOR4006) between water supply hose and hose adapter. Connect hose adapter to quick connector on side of machine.

7. Turn on water supply. Open high pressure bleed valve until all air is out of the system. Close high pressure bleed valve for pump testing. NOTE: Air in system wi ll cause improper test readings.

8. Disconnect hose from relief valve fitting.

9. THIS IS A TWO (2) PERSON OPERATION. Start engine and operate at full speed. WEAR SAFETY GLASSES! Have one person press and HOLD engage button while other person stands to side of machine and observes pressure gauge and flow meter readings.

PRESSURE should be 5000 ± 300 PSI and FLOW more than 3.4 GPM.

If pressure is too high, replace relief valve. If pressure AND flow is low, disconnect small tube

running from bottom side of valve housing to water pump inlet by backing out small 1/16" NPT fitting (Fig. 39, Item 31). Plug open port with a 1/16" NPT plug. Do this test procedure again beginning with step 1. If pressure AND flow is still low, rebuild pump. After rebuilding pump, do this test procedure again beginning with step 1, to verify that valve is sealing properly in closed position. A large quantity of water exiting valve side of tube indicates a leaking valve ceramic sleeve or seal. Reconnect small tube.

If pressure is low, but flow is OK, make sure cam is not on roller follower, keeping valve in open position. If water is exiting outlet fitting on relief valve, replace relief valve. If water is not exiting outlet fitting on relief valve, rebuild water valve. After replacing relief valve or rebuilding water valve, do this test procedure again, beginning with step 1, to verify that pump has adequate flow at specified operating pressure.

Figure 21

1. Water supply quick connector

Figure 22

1. Flow meter/pres sure ga uge (T OR4006 )

If pressure is OK, but flow is low, rebuild pump.

10. Perform Test No. 3: Water Valve Lift. 1 1. Do steps 2 - 4 and 6 - 8 of this pressure and flow test

again, with valve clutch connected to wire harness.

Pressure gauge needle will go rapidly to the relief

1. Relief valve 2 . Hose

Figure 23

setting (5000 ± 300 PSI) for 3 to 4 seconds, then begin to fluctuate rapidly when the unit begins aerating. Note the highest pressure. If highest pressure is 4000 to 4500 PSI, plan to rebuild the valve. If pressure is less than 4000 PSI, rebuild the valve.

12. After testing is completed, open high pressure bleed valve, then remove water system pressure gauge. Reinstall plug in open port of water valve housing. Connect relief valve hose. Remove flow meter.

Testing Page 6 - 16 Rev. A HydroJect™ 3000

TEST NO. 3: Water Valve Lift (Fig. 24, 25)

If valve lift is too high t he v alv e may not seat correct ly. If valve lift is too small, the pulses may not release enough pressurized water and the relief valve will open (wasting energy). Improper valve l ift can also result in high contact stresses and rapid cam wear.

WARNING

1. Park machine on a level surface, stop t he engine, engage the parking brake, open the hood and disconnect the engine spark plug wires.

2. Slowly open t he high pressure bl eed valv e allowing any pressurized water to escape.

3. Remove belt guard to expose the drive shaft.

4. Remove test cap from the feeder manifold and install Valve Lift Indicator (TOR4007) into this opening. Make sure dial indicator contacts top of water valve, then zero out dial indicator.

5. Make sure cam lobe is not contacting follower by rotating coupling assembly several turns and observing dial indicator.

6. Rotate coupling, moving cam lobe past cam follower and observe maximum reading on dial indicator.

IMPORTANT: A reading of 0.090 t o 0.102 does not guarantee a properly adjusted cam. When in do ubt, inspect cam. A worn cam which has been adjusted to 0.090 to 0.102 will not perform properly. A worn cam can cause opening of valve on lead-in portion of cam in this range.

Cam lobe Lead-in portion

Lead-out

i l is

Lead- n to ead-out two (2) rev. of p nion.

Figure 24

1. Coupling 2. Cam 3. Follower

Dial indicator should move 0.090 to 0.102. There should be no movement of dial indicator gauge on lead-in or lead-out portion of cam.

7. If indicator moves more than 0.102, cam lobe is probably contacting follower on l ead-in portion of cam and must be adjusted (see Valve Lift Adjustment). If indicator moves less than 0.090, remove gear case cover and inspect cam for wear . Use your hand to rotate coupling to position working cam on top. Visually inspect top of cam lobe for wear. There is a thin area on this

replaceable cam that does not contact the cam follower. If cam is worn, a r idge will develop between tip of c am and unused surface. If the ridge is deep enough to catch a fingernail, replace the cam (see Gear Case Service). If cam is not worn, adjust valve lift.

1. Valve lift indi cator (TOR 4007)

Figure 25

8. Go to step 11 under TEST NO. 2 - Water System Pressure and Flow.

HydroJect™ 3000 Page 6 - 17 Testing

Adjustments

Electric Brake Clutch Adjustment (Fig. 26)

1. Park machine on a level surface, stop t he engine, engage the parking brake, open the hood and disconnect engine spark plug wires.

2. Adjust air gap to .018" by inserting a thickness gauge into the clutch openings. Evenl y tighten the three lock nuts on clutch to reduce the air gap. Failure to maintain the correct air gap could result in clutch not engaging even though it is electrically energized.

NOTE: It may be necessary to remove clutch retainer to allow clutch rotation for acc ess to all three (3) adjustment nuts.

Water Valve Lift Adjustment (Fig. 27, 28, 29)

Figure 26

1. Locknut (3)

1. Park machine on a level surface, stop t he engine, engage the parking brake, open the hood and disconnect the engine spark plug wires.

WARNING

2. Slowly open high pressure bleed valve allowing any pressurized water to escape.

3. Remove belt guard to expose drive shaft. Remove gear case cover.

4. Use your hand to rotate coupling assembly, positioning working cam on top. Visually inspect top of cam lobe for wear. There is a thin area on this replaceable cam that does not contact the cam follower. If cam is worn, a ridge will develop between tip of cam and unused surface. If the ridge is deep enough to catch a fingernail, replace the cam lobe. Do not measure valve lift using a worn cam lobe. Rotate cam to make sure cam lobe is not contacting follower.

Cam lobe Lead-in portion

Lead-out

i l is

Lead-n to ead-out two (2) rev. of pin on.

Figure 27

1. Coupling 2. Cam 3. Follower

Adjustments Page 6 - 18 HydroJect™ 3000

Toro 91764SL User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Preface

Specifications

Repairs

Specifications

Hydraulic Diagram

Special Tools

Troubleshooting

Testing

Adjustments

Repairs

Special Tools

Troubleshooting

Testing

Repairs

Specifications

Special Tools

Troubleshooting

Testing

Adjustments