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Hydroject ® 3000/4000

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2. 25 REPAIRS et Oe hh De aus 26 Battery Service 26 Neutral Switch and Pump Switch Replacement and Adjustment 27 Fuse and Circuit 28 Controller 28 Linear Actuator Replacement 29 Diode coe eet PER 29 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 S and the hydraulic pump must be in Neutral neutral switch CLOSED gt 5 Switch Closed 5 5 6 5 p O Switch Open 8 2 S 5 5 8 E 5 9 T S 9 Switch Closed Momentarily NL 8 E 2 5 8 o Switch Conditon Not Relevent 5 5 2 1S EE 2 8 2 g E HME NE js 2 2 ja gt 5 8 2 5 gt 5 Js I 5 9 5 B a t EE C ue TIE x 12 E 5 lt 5 3 5 BP 6 2 5 2 2 5 5 8 ACTIONS 1 Start X X 2 Run X X 3 Machine Lower aerate position X X X 4 Aerate see Controller Timing below Machine Moving out of neutral X X X X Mach
3. 6 REPAIRS Esp 14 SPECIAL 5 7 Pump Drive Replacement 14 Hydraulic 5 71 Hydraulic Pump Removal and Installation 15 8 Pump Shaft Seal Replacement 16 Transmission Operates in One Direction Only 8 Pump Charge Check Valve Service 17 System Operates Hot Looses Power or Pump Bypass Valve Service 17 Will Not Operate in Either Direction 8 Charge Pump 18 TESTING ocan RR RO GU 9 Major Pump Repair 18 Hydraulic Tests 10 Wheel Motor Removal and Installation 22 5 11 Wheel Motor 23 Traction Cable Adjustment 11 HydroJect 3000 Page 4 1 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 q
4. peres MN S ms eee m T i 1 19715 03u73n 8 RES 45718 782 V 2033 T3NYd ANIS ba uoivni5v avant wid T 3187 034 NMOUS 118 034 wann Figure 2 HydroJect 3000 5 4 Wiring Schematics and Diagrams Wiring Diagram Control Panel Model 09800 ___5 1 8 Tavis _ _ ___330 211 5 A33 u33v3u8 1112802 02 211 5 39 9 z 3unssaud 1 XNIS 8 er zin a _ 2 S Avus oe i NIRE ES B Sea eee Q3u 3n18 ang u31uviS AMUSLLIVE Q N 3Unss3ud 710 E 2 3NI9N3 Figure 4 Wiring Schematics and Diagrams 5 5 HydroJect 3000 Wiring Diagram Tiller Model 09800 HOLIMS 131 211 5 NMOUS 39 0 18 m o v o N3d0 93507 ATVIVWYON NOWWO
5. 250 82 0660 cLEAN 82 0670 250 71 5960 80 8590 On Air Cleaner Part No 94 6512 CHECK SERVICE LOCATION ENGINE OIL WATER PUMP OIL CAM HOUSING TIRE PRESSURE FUEL UNLEADED ONLY BATTERY GROUP 28 GREASE LUBE POINTS 6 emm WATER BLEED VALVE AIR CLEANER WRAPPER ELECTRIC CLUTCH GAP 018 IN MAX AIR BLEED FUSES gt On Air Cleaner Part No 94 6513 Addendum Page 8 2 WATER SYSTEM COMPONENTS KEEP COVER AND SHIELDS IN PLACE On Control Panel Part No 94 6550 SLOW ENGINE SPEED ENGAGE OFF 2 gt DISENGAGE V WATER SYSTEM START IGNITION On Control Panel Part No 94 6552 Rev Hydroject 4000 Specifications Engine Onan 4 cycle opposed twin air cooled 24 hp 3600 rpm 60 cu in 983 cc displacement Electric start Heavy duty valve package Extended service air cleaner 3 quart oil capacity Solid state ignition Meets California Exhaust Emission Standard for 1995 Lawn and Garden Equipment Clutches Electromagnetic three groove belt drive for water pump and driveshaft flange brake clutch for main valve gearbox Electrical 12 volt system with fused protection Relays for all high current switching Electronic controller and sensors for automatic start up and shut down se quence of water injection system
6. 1 1 Safety and Instruction 5 1 4 Chapter 2 Product Records and Manuals Product 5 2 1 Equivalents and 5 5 2 2 Torque Specifications 2 3 Lubrication 2 4 Equipment Operation and Service History Forms 2 5 Chapter 3 Engine 3 1 Repair x 3 2 Onan Engine Service Manual Chapter 4 Hydraulic System 4 2 General Information 4 3 Hydraulic Diagram 4 6 Special Tools 4 7 Troubleshooting 4 8 Testing eL sn deer Lu 4 9 4 11 4 14 Hydroject 3000 4000 Chapter 5 Electrical System Wiring Schematics and Diagrams 5 2 Special 5 5 7 Troubleshooting 5 9 Testing ect utor abies So 5 17 awe 5 26 Chapter 6 Water System 5 6 2 Water System Schematic 6 3 Special Tools 6 4 Troubleshooting 6 9
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8. 3 lt JO OON COO uS cz c St E 2 lt gt 5 oc tc 4 a W N 5 Nx lt gt gt 3 5 8 ud lt aS dz ug 2 ui zoo 580 4 qz IND I at o ul 75 28 ao 51 E o ga 2 us LL u e 9 Qe uk 8s 211 E or 5 mo DOD a E of E gt m a da 5 Tow oo aS 2 Water System Diagram Addendum 8 13 Rev B Hydroject 4000 Service and Repairs Boost Pump Belt Adjustment Make sure boost pump belt is properly tensioned to as sure correct operation of unit and unnecessary wear Check belts midway in the span of the belt 1 Disengage hood latches and open hood 2 Check belt tension by depressing belt midway be tween pulleys with 3 Ib of force A used belt should de flect 250 A new belt should deflect 125 3 If an adjustment is necessary A Loosen pump bracket mounting bolts 2 B Use bar to pull pump towards outside of ma chine until proper belt tension is attained then tight en pump bracket mounting bolts 2 Figure 2 1 Boost Pump Belt 2 Pump Bracket 3 Mounting Bolt 2 Addendum 8 14 Rev B Hydroject 4000 This page is blank TORO Commercial Products The Toro Company
9. Hydroject 3000 8 Rev B Page 2 Product Records and Maintenance Chapter 3 TORO Engine Table of Contents SPECIFICATIONS 1 REPAIRS do t DR Pile x Re EE 2 Engine Removal and Installation 2 ONAN SERVICE MANUAL Specifications Item Description Make Designation Onan P224G I 10999C Displacement 59 7 in Weight 127 Ibs 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 coupling from the clutch adapter see Drive Coupling Removal and Installation 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 cap screws Item 39 and spacers Item 38 securing
10. Table of Contents WIRING SCHEMATICS AND DIAGRAMS 2 Logic 2 Controller 5 2 1 Wiring Schematic 3 Wiring Diagram Main 4 Wiring Diagram Control Panel 5 Wiring Diagram Tiller 6 7 3 7 9 Starting 5 9 General Run and Transport Problems 11 Aerate Operation Problems 13 Safety Interlock System Problems 15 TESTING mde sani debui 17 Verify Safety Interlock System Operation 17 Clutch Engagement Electronic Control System 18 Ignition Key Switch 19 Controllers ER eee BIG ES 20 Neutral Switch and Transport Switch 20 HydroJect 3000 Page 5 1 Rev B Chapter 5 Electrical System Lift Limit and Pump Start Limit Switches 21 Aerator Start and Stop Switches 21 Lift Switch 22 Linear Actuator 22 Brake 23 Pressure 5 23 Accumulator Charge Switch 23 ues e a 24 Ballery asides 24 Pump Clutch 25 Valve
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12. 14 Remove pump shaft 19 and bearing assembly from housing 15 Remove outer bearing retaining ring Item 21 and washer if used Press shaft out of bearing 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 control shaft seal out of housing Care must be taken so as not to damage housing bore 19 If displacement control shaft journal bearing requires replacement press it out of housing Inspection and Replacement of Pump Parts After disassembly thoroughly clean all parts in a suit able solvent Replace all o rings gaskets and seals Inspect all parts for damage nicks or unusual wear patterns Replace all parts having unusual or excessive wear or discoloration Inspect seal surfaces bearing surfaces and shaft spli nes Polish sealing areas on shafts if necessary Re place any worn or damaged parts 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 If scratches or wear are found 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
13. 6 12 Adjustments 6 18 Repal S ix ea ated RS Us 6 20 Chapter 7 Wheels Steering and Brakes Adjustments 7 2 5 7 3 Chapter 8 Hydroject 4000 Addendum Safety and Instruction 5 8 2 5 8 3 Maintenance 5 8 7 Electrical 8 11 Water System 8 13 Service and 5 8 14 Rev B 3000 4000 TORO Table of Contents SAFETY INSTRUCTIONS 1 Before Operating 1 While Operating 2 Safety Instructions Although hazard control and accident prevention par tially 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 mainte nance and storage of the machine Improper use or maintenance of the machine can result in injury or death To reduce the potential for injury or death comply with the following safety instructions Before Operating 1 Read and understand the contents of this manual before starting and operating the machine Become fa miliar with
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15. 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 9792851 REFER TO THE HYDROJECT OPERATOR S MAN UAL FOR OPERATING MAINTENANCE AND AD JUSTMENT 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 Toro Company reserves the right to change product specifications or this publication without notice Part No 9176451 Rev C Service Manual Hydroject 3000 4000 This safety symbol means DANGER 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 re pair of the machine IMPORTANT The IMPORTANT notice will give im portant instructions which must be followed to pre vent damage to systems or components on the machine The Toro Company 1991 1997 3000 4000 Table Of Contents Chapter 1 Safety Safety Instructions
16. Replace relief valve Check for contaminated fuel plugged fuel filter or fuel line plugged air cleaner bad spark plug see Chapter 3 Engine 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 the pump valve and ac cumulator 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 the order listed even if the apparent problem has been isolated such as low accumulator pre charge pressure This will verify that all components are operating properly A WARNING High pressure water system components can Figure 13 cause personal injury if disassembled incor rectly Discharge water pressure at bleed 1 High pressure bleed valve 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 pressure bleed valve and inspect aeration nozzles Check for plugged noz zles Verify size and quantity see Nozzle Service and Replacement Nozzles that are too large will cause loss in pressure and could cause damage to the accumulator and other water system compon
17. TASAS Annual Recommendations Replace Safety Switches Items listed are recommended every 1000 Fuel Tank Drain Flush hours or 2 years whichever occurs first Hydraulic Tank Drain Flush See Operator s and Service Manual for specifications and procedures Addendum Page8 8 Rev B Hydroject 4000 Hydroject 4000 Daily Maintenance Check List Daily Maintenance duplicate this page for routine use Check proper section of Operator s Manual for fluid specifications Maintenance Daily Maintenance Check For Week Check ltem ues web THURS S 50 ep esu Engine Cooling Fins for Debris Lubricate All Grease Fittings Touch up Damaged Paint 1 Immediately after every washing regardless of the interval listed ro for areas of concern Inspection performed _ 4222 2222 E E NNNM Eo EN pou 22829 4000 Page 8 9 Rev B Addendum pue y eseo jlo 19 9 14 ooueJe9 o 5 5 1sn py eoejdeu eoejdeu sanoy 002 BDIAIBS 2 9184 E ESSE TEST LES vs Cg e seunpeooud pue suomeoyioeds 10 enue
18. 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 Testing Page 5 18 Rev A B After clutches are engaged push red DISENGAGE button C Green light should immediately turn OFF and pump clutch should disengage D After 3 seconds valve clutch should disengage E System must not restart without pushing green aerate ENGAGE button IMPORTANT When test is completed water pres sure switch by pass must be removed to prevent damage to water system from low inlet water pres sure 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 Figure 8A 1 Red light 2 Green light 3 Yellow light Figure 8B 1 Red light 2 Green light 3 Yellow light HydroJect 3000 Ignition Key Switch Fig 9 10 The ignition key switch has three positions OFF START and RUN The terminals are marked as shown X Figure 9 POSITION CONTINUITY OTHER The circuitry of the ignition switch is shown in the chart AMONG CIRCUITS With the use of a continuity tester the switch functions TERMINALS MADE may be tested to determine whether all circuits are being comp
19. Check air gap at electric brake clutch and adjust if necessary Repair See Troubleshooting in Chapter 5 Electrical System Machine makes unusual noise when first starting aeration Air in system NOTE Relief valve may squeal for a short period of time during initial startup due to air in the system Damaged component With engine OFF and water supp ly connected open high pressure bleed valve and bleed air out of system Repeat procedure if noise continues Check for damaged components and repair or replace as neces sary HydroJect 3000 Page 6 9 Troubleshooting Condition Machine stops aerating pump shuts down during aeration Possible Cause Machine not moving Inadequate water supply Plugged inlet water filter Electrical problem Correction Normal condition of interlock sys tem Operator must hold engage button in to aerate with traction bail in neutral Check for kinked water supply hose restriction in line or partially open valve at water source Check water pressure at gauge when pump is engaged If pres sure drops to less than 15 PSI but was initially higher replace water filter See Troubleshooting in Chapter 5 Electrical System Water system engages pump belt and gear case drive shaft rotate but no aeration holes are produced or aeration hole depth is shallow or inconsistent Air in system Soil density or mois
20. With switch pushed toward keyway in threads terminals 1 and 2 are made With switch pushed away from keyway in threads terminals 2 and 3 are made Linear Actuator Fig 16 The linear actuator has a bi directional electric motor which engages a clutch and screw mechanism to ex tend or retract a rod and raise or lower the transport wheels 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 battery terminal is connected to the yellow wire the actuator motor should operate to extend the actuator cylinder raising the wheels to aerate position 3 Connect a 12 volt battery so the negative terminal is connected to the yellow wire ofthe actuator connector When the positive battery 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 Testing Page 5 22 Figure 15 1 Lift switch Figure 16 1 Linear actuator 2 Wiring connector 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 th
21. replaced any time the connection is opened 3 Lubricate the O ring with a light coating of oil 4 Put the tube and nut squarely into position on the face seal end of the fitting and tighten the nut until finger tight Figure 2 5 Mark the nut and fitting body Hold the body with a wrench Use another wrench 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 Final Initial Size F F F T Mark Nut Position Position and Body 4 1 4 in nominal hose or tubing 75 25 Extend Line 6 3 8 in 75 25 8 1 2 in 75 25 Finger Tight After Proper Tightening 10 5 8 in 1 00 25 12 3 4 in 75 25 16 1 in 75 25 Figure 3 3000 4 General Information A CAUTION Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved by stopping the en gine and opening the bypass valve Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid un der 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 SAE St
22. 21 Disconnect wires from spark plugs to prevent acci dental starting of the engine when servicing adjusting or storing the machine 22 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 bat tery 23 Toreduce 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 specifi cation 25 If the engine must be running to perform a mainte nance 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 Page1 2 Rev B 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 Checkinterlock 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 by pass it Replace all interlock switches every two years 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 c
23. 64 0 203125 5 159 45 64 0 703125 17 859 7 32 0 21875 5 556 23 32 0 71875 18 256 15 64 0 234375 5 953 47 64 0 734375 18 653 1 4 0 2500 6 350 3 4 0 7500 19 050 17 64 0 265625 6 747 49 64 0 765625 19 447 9 32 0 28125 7 144 25 32 0 78125 19 844 19 64 0 296875 7 541 51 64 0 796875 20 241 5 16 0 3125 7 938 13 16 0 8125 20 638 21 64 0 328125 8 334 53 64 0 828125 21 034 11 32 0 34375 8 731 27 32 0 84375 21 431 23 64 0 359375 9 128 55 64 0 859375 21 828 3 8 0 3750 9 525 7 8 0 8750 22 225 25 64 0 390625 9 922 57 64 0 890625 22 622 13 32 0 40625 10 319 29 32 0 90625 23 019 27 64 0 421875 10 716 59 64 0 921875 23 416 7 6 0 4375 11 112 15 16 0 9375 23 812 29 64 0 453125 11 509 61 64 0 953125 24 209 15 32 0 46875 11 906 31 32 0 96875 24 606 31 64 0 484375 12 303 63 64 0 984375 25 003 1 2 0 5000 12 700 1 1 000 25 400 1 mm 0 03937 in 0 001 in 0 0254 mm U S to Metric Conversions To Convert Into Multiply By Linear Miles Kilometers 1 609 Measurement Yards Meters 0 9144 Feet Meters 0 3048 Feet Centimeters 30 48 Inches Meters 0 0254 Inches Centimeters 2 54 Inches Millimeters 25 4 Area Square Miles Square Kilometers 2 59 Square Feet Square Meters 0 0929 Square Inches Square
24. Centimeters 6 452 Acre Hectare 0 4047 Volume Cubic Yards Cubic Meters 0 7646 Cubic Feet Cubic Meters 0 02832 Cubic Inches Cubic Centimeters 16 39 Weight Tons Short Metric Tons 0 9078 Pounds Kilograms 0 4536 Ounces Avdp Grams 28 3495 Pressure Pounds Sq In Kilopascal 6 895 Pounds Sq In Bar 0 069 Work Foot pounds Newton Meters 1 356 Foot pounds Kilogram Meters 0 1383 Inch pounds Kilogram Centimeters 1 152144 Liquid Volume Quarts Liters 0 9463 Gallons Liters 3 785 Liquid Flow Gallons Minute Liters Minute 3 785 Temperature Fahrenheit Celsius 1 Subract 32 2 Multiply by 5 9 Product Records and Maintenance Page 2 2 Hydroject 3000 Torque Specifications Use these torque values when specific torque values specified values Torque values listed are for lubricated are not given DO NOT use these values in place of threads Plated threads are considered to be lubricated Capscrew Markings and Torque Values U S Customary SAE Grade Number Capscrew Head Markings 8 9t Capscrew Torque Grade 5 Capscrew Torque Grade 8 Capscrew Body Size Cast Iron Aluminum Cast Iron Aluminum Nm ft lb Nm Nm ft lb Nm 1 4 20 9 6 8 15 9 12 28 12 7 9 18 10 14 5 16 18 20 12 16 30 18 24 24 23 14 19 33 19 25 3 8 16 40 20 25 55 30 40 24 40 25 35 60 35 45 7 16 14 60 35 45 90 50 65 20 65 40 55 95 55 75 1 2 13 95 55 75 130 75 100 20 100 60 80 150 90 120 9 16 12 135 80 190 110 150 18 150 85 210 12
25. Charge ac cumulators in a well ventilated area It is recommended that the accumulator 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 injury DIS MEMBERMENT OR DEATH Charged accumulators cannot be shipped via air freight Repairs Page 6 32 2 Slowly open the high pressure bleed valve allowing any pressurized water to escape 3 Remove splash shield from manifold to get access to capscrews securing accumulator Use a socket wrench with long extension to remove four 4 capscrews Item 21 securing accumulator Item 14 to valve hous ing Item 17 Remove the accumulator Discard O ring Item 15 4 Install new O ring seal Item 15 into groove on top of valve housing Carefully install accumulator onto top of valve housing Make sure decals Items 12 13 are facing forward and securely attached to accumulator 6 Install four 4 NEW special bolts Item 20 through valve body and into base of accumulator Tighten to a torque of 40 ft lb 7 Charge accumulator with dry
26. Controller faulty Test pump start limit switch and replace if faulty Check for short in pump start limit switch connections and wiring and repair as necessary Replace controller HydroJect 3000 Page 5 15 Troubleshooting Safety Interlock System Problems continued Condition No lights on controller come on when troubleshooting interlock system Possible Cause Battery is dead or disconnected Circuit breaker open Faulty controller ground Ignition key switch faulty Loose or damaged wiring in key switch controller circuit Controller faulty Correction 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 cor rect Replace circuit breaker if faulty Check controller ground connec tion and wiring and repair as nec essary Test ignition switch and replace if faulty Check all connections and wiring and repair as necessary Replace controller Green light on controller glows faintly when only red light should be on traction bail out of neutral and aerate engage switch re leased Normal condition Troubleshooting Page 5 16 3000 Testing It is often to the technician s advantage to leave the components intact in the electrical system and by studying the electrical troubleshooting charts and sche matics de
27. DIS MEMBERMENT OR DEATH Charged accumulators cannot be shipped via air freight 2 Slowly open the high pressure bleed valve allowing any pressurized water to escape 3 Remove protective cover from top of accumulator 4 Attach and gently tighten special fitting of Charging Tool TOR4001 to inlet on top of accumulator 5 Close both valves on charging tool to prevent loss of pressurized Nitrogen from accumulator 6 Rotate the jam nut not the fitting of the accumulator valve two 2 turns counterclockwise as viewed from the top This opens the valve and pressurizes the tool and gauge 7 Slowly open outlet valve on right hand side of charg ing tool to release pressurized gas from accumulator When gas stops escaping disconnect the charging tool Repairs Page 6 34 Rev A HydroJect 3000 8 Remove gas valve Item 4 from top of accumulator 9 Remove accumulator from top of water valve housing see Accumulator Replacement 10 Insert Accumulator Cap Wrench 4003 into the top cap Item 12 of the accumulator Hold the ac cumulator cylinder Item 6 stationary using a strap or chain wrench and remove the top cap Item 12 and bottom cap Item 9 of the accumulator 11 Use a brass or aluminum shaft to force the piston Item 8 out of top side of accumulator and discard the piston Accumulator Service Evaluation Inspect bore of accumulator cylinder for score marks or wear If barrel of accumulat
28. DO NOT INSTALL TWO CAMS ONTO THE GEAR The cam Item 23 can be replaced without removing or disassembling the gear case Evenly torque capscrews securing cam to 22 28 ft lb NOTE If there is wear on the teeth of the gear Item 22 interchange the locations of the cam Item 22 and weight block Item 27 so higher gear teeth load occurs in a new location After replacing the cam or repairing or replacing the gear case adjust water valve lift see Water Valve Lift in the Adjustments section Torque both capscrews evenly to 22 28 ft Ib Figure 41 Repairs Page 6 30 HydroJect 3000 Nozzle Service and Replacement NOTE See Specifications section of this chapter for more information 1 Park machine on a level surface stop the engine en gage the parking brake open the hood and disconnect the spark plug wires from the engine 2 Inspect nozzle configuration and diameter Nozzles are stamped with numbers indicating the drill size of the orifice Nozzle orifice can be inspected by inserting shank end of drill bit matching size stamped on orifice If drill bit fit is loose the nozzle is worn If nozzles are worn or incorrect replace with new nozzles in correct configuration 3 The nozzle check valves and seats are located in the nozzle drops and are easily replaced if they wear Occa Check Valve Ball OPEN NOZZLE S N 29999 amp Below Check Valve Ball WA WAAAY N
29. Group 28 battery with 525 cold crank amps Fuel Capacity 9 gallons gasoline Water Injection System Pre Filter A 20 mesh strainer is required in the supply line to the inlet port Supply Filter Replaceable cartridge in plastic housing with air bleed button Water Pressure Switch Senses for water pres sure after filter and turns on when pressure is over 20 28 psi and turns off when pressure drops below 7 13 psi Pump Pump is a Toro exclusive design with cast stainless steel head and 3 piston plungers Vee packing seals and Kevlar guides Forged crankshaft with plasma sprayed ceramic on stainless steel plungers and cast iron connecting rods Nominal performance is 4 gpm 5000 psi with 1400 rpm in put Accumulator Toro exclusive design with low charge pressure sensor nitrogen gas charged to a maximum of 2500psi Cam and Gearbox Reduction gear drive for cam that actuates main water valve Roller cam follower rides on cam specifically designed 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 res ervoir Valve Cast stainless steel valve body functions as mounting base for accumulator gearbox and man Hydroject 4000 Page8 3 Rev B ifold outlet All high pressure water flows in and out through the valve body Pressure balanced valve spool with floating hardened stainless seat aligns during
30. Mo MEE NMOUG AVHO NOLLINSI zd m ania i 2 uy HRS 3504 av 5 div E MOTISA TX 9 YOLVNYSLIV V N3349 S 431411934 3OVL10A Wiring Schematics and Diagrams Rev B Page 5 6 3 ANISNA Hydroject 3000 Wiring Diagram Tiller Model 09801 HOLIMS HOLIMS 3xvug O N lt 9 m Cc m 2 e I I gt gt 2 2 MOTISA O 9 5 ywovid gt N33H5 A 5 FONVHO 2 N3dO ATIVINHON NONINOO ATIVINHON NONWOO Fo XN 7 7 O N INHV IV 4015 HOLIMS 18915 3000 5 6 4 Rev B Wiring Schematics Diagrams Special Tools NOTE Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE COMMERCIAL PRODUCTS Some tools may be available from a local supplier 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 m
31. N N N Spring Check Valve Ball Tighten to 60 ft lb sionally inspect the springs especially if one nozzle leaks water after the machine is shut down 4 For normal operation install nozzle springs with the narrow spiral pointing up and the check ball on top of the spring To block the flow for different nozzle configura tions install the narrow spiral pointing down with the check ball below the spring NOTE Nozzles are stamped with numbers indicating drill size of orifice Standard configuration is 11 nozzles which will produce depths of approximately 4 to 6 inch es depending on soil conditions Blocked nozzle loca tions are obtained by reversing nozzle check valve and spring CLOSED BLOCKED NOZZLE Aluminum washer P N 80 6680 is required with any nozzle change Spring Check Valve Ball Tighten nut to 70 80 ft lb OPEN NOZZLE S N 30001 amp Up Hydroject 3000 Page 6 31 CLOSED BLOCKED NOZZLE Aluminum washer P N 86 8150 is required with any nozzle change Rev B Repairs Accumulator Replacement Fig 43 1 Stop the engine engage the parking brake open the hood and disconnect the engine spark plug wires A DANGER Charged accumulators contain high pressure nitrogen Nitrogen is the only gas to use for accumulator charging Installing IMPROPER gases in an accumulator can cause an EX PLOSION AND DEATH Charging requires special tools and precautions
32. N any gt Tighten nut to 70 80 ft lb OPEN NOZZLE CLOSED BLOCKED NOZZLE S N 30001 amp Up Aluminum washer P N 86 8150 is required with any nozzle change Specifications 6 2 2 Rev Hydroject 3000 Water System Schematic ACCUMULATOR 2500 PSI NITROGEN PRE CHARGE ROLLER WASH NOZZLES ROLLER WASH NOZZLES gt LEC RAKE CLUTCH ENGINE gt RELIEF VALVE 5000 PSI PRESSURE l SWITCH 20 PSI 10PSI OFF 43 PRESSURE GAUGE GEAR BOX CAM HIGH PRESSURE SPRAY WASH VALVE INLET FILTER 7 BMICRON QUICK COUPLER Model 09800 WATER SUPPLY ACCUMULATOR 2500 PSI NITROGEN ELECTRIC CLUTCH ENGINE ELECTRIC BRAKE CLUTCH PRESSURE SWITCH 20 PSI ON 10 PSI OFF PRESSURE GAUGE SZ SPRAY WASH VALVE FILTER RELIEF VALVE 5000 PSI GEARBOX CAM om OI ROLLER WASH NOZZLES lt HIGH PRESSURE AERATION NOZZLES AERATION NOZZLES 11 ROLLER WASH NOZZLES M WATER SUPPLY QUICK COUPLER PRE FILTER PRESSURE REDUCING VALVE Model 09801 Hydroject 3000 Page 6 3 Rev B Water System Schematic Special Tools The following special tools are required for servicing
33. 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 1 Pump drive belt to slotted pump support 2 Drive coupling 3 Valve clutch 8 Push pump towards inside of machine to loosen belt Ao Valvecl tch stops tension and remove the belt 9 Reverse steps 2 8 to install new belt 10 Adjust belt tension see Traction Pump Belt Adjustment 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 Disconnect 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 7 Remove locknut Item 46 capscrew Item 5 and washers Ite
34. 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 Valve Circle Seal Controls pop pet type valve preset to 5000 psi with corrosion re sistant stainless and brass materials Manifold and Nozzles Extruded stainless steel manifold with11 flanged nozzle extensions contain ing check valves and hardened stainless discharge orifice Check valves may be reversed in housing to block unused nozzles Controls Engine Panel Hour meter water pressure gauge and fuse block Control Panel Throttle choke water system engage and disengage buttons Electronic Control Module Solid state potted de vice for sequencing start and stop of water system Interlocks for water pressure Ground Speed Dependant on tow vehicle Aerating 1 2 mph 4 Hole Spacing 1 8 mph 6 Hole Spacing Transport Up to 24 mph Dimensions Length 44 inches w o hitch Wheelbase 37 5 inches Width 53 inches Height 39 inches Weight 900 pounds Aeration Width 38 7 inches with 11 nozzles on 3 87 inch centers Aeration Depth 4 to 6 inches depending on turf condi tions and nozzle configuration Hole Pattern Dependant on tow vehicle in the direction of travel and 3 87 or 7 74 increments in width Addendum Depths and Nozzle Configurations All nozzles are identified with numbers indicati
35. bypass valve Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid un der 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 dam age 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 gan grene may result 3000 4 9 1 Thoroughly clean the machine before disconnecting 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 lines left open or 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 connected and not reversed tester with pressure and flow capabilities 5 To minimize the possibility of damaging components completely open the load valve by turning it counter clockwise tester with pressure and flow capabilities 6 Install fittings finger tight far enough to insure that they are not cross threaded before tightening with a wrench 7 Position the tester hoses so that rotating machine parts wi
36. charge pressure switch nitrogen pressure more than 1800 psi ENGAGE 1 Red Light 2 Green Light 3 Yellow Light Hydroject 3000 Page 5 2 1 Rev B Wiring Schematics and Diagrams Wiring Schematics and Diagrams Page5 2 2 Rev B Hydroject 3000 435675 014 34vu8 es NOILINOI 1 0 45 IVH103N M 3unss3ud 110 3NION3 AW311V8 pipi ie u3lviS IV 318 15 Wiring Schematics and Diagrams Electrical Schematic Model 09800 02 yaxv3ug 1112412 035012 93507 340 1uOdSNvut 31 013 211 5 180 lt 45 1 dWnd x 100007 19 HDLNID H21012 2 Es 9 po 9000 ___ 435017 19045 1 3lvu3v 15 15 01 3 Pac 11811 18V1S SNVHL 113 N3349 7 gt 831411238 801v1n53y 35v17104 211 5 HydroJect 3000 Wiring Diagram Main Model 09800 AY138 dune AY an 1317 21012 1 5 4 id Tai h ame Mi 1111 Hind Y H 3 E
37. 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 1 50 25 12 3 4 1 50 25 16 1 in 1 50 25 General Information Page 4 4 Figure 4 pee Lock Nut 1 Back Up Washer O Ring Figure 5 Step 1 Step 2 F Step 4 H Figure 6 3000 Pushing or Towing Fig 7 The machine can be pushed or towed for very short distances with the engine off if necessary IMPORTANT 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 When ever 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 counterclockwise Figure 7 2 turns maximum 1 By pass valve 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 by pass valve open will cause improper operation and overheating of the hydraulic system HydroJect 3000 Page4 5 General Information Hydraulic Diagram Vari
38. low engine oil pres sure no fuel etc Oil pressure switch faulty Loose or broken wire in oil pres sure switch circuit Correction Find and correct cause of engine shut down Test switch and replace if faulty Check all wiring and connections and repair as necessary Engine does not stop when igni tion key switch is rotated to OFF position Engine timing or carburetor out of adjustment Ignition switch faulty Short in ignition circuit wiring Adjust carburetor or engine tim ing Test ignition switch and replace if faulty Check all wiring and connections and repair as necessary Battery does not charge Open or missing 30 AMP fuse Loose wire s in electrical system Regulator or engine charging cir cuit faulty Battery faulty Ignition switch faulty Install new fuse Find and correct cause of open fuse Check for loose wire at X or Y terminal of ignition switch Check all other connections and wires on engine regulator Install new regulator or repair en gine charging circuit Test battery and replace if faulty Test switch and replace if faulty Machine does not lower to aer ate position Circuit breaker open Lift lower switch faulty Lift DOWN relay faulty Ignition key switch faulty Loose or broken wire in lift down circuit Linear actuator faulty Reset circuit breaker Find cause for open circuit breaker and cor
39. necessary 4 Lubricate new seal with petroleum jelly 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 Top of pump when installed in machine Repairs Page 4 16 Figure 21 1 Retaining ring 2 Seal input shaft 3 Spacer 4 Seal displacement control shaft 3000 Pump Charge Check Valve Service Fig 22 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 mating seats in end cap for damage or foreign material 4 Lay pump on its side and reinstall check ball spring 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 Ib Turn pump over and repeat installation procedure for other check valve 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 f
40. 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 hous ing Be careful to prevent damage to end cap and cylinder block sealing surfaces 21 When end cap is properly installed the internal springs will hold it away from the housing approximately 3 8 in 22 Install the four 4 capscrews which retain end cap to housing Tighten screws to a torque of 138 to 180 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 petroleum jelly Slide seal over shaft and press it into housing bore Be careful not to damage seal Install seal flush to bottomed in bore Figure 26 3000 4 21 Repairs Wheel Motor Removal and Installation Fig 27 Torque to 250 to 400 ft Ib 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 Re
41. 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 condi tions and nozzle configuration Hole Pattern Variable from 1 5 to 6 spacing in the di rection of travel and 3 or 6 increments in width Water Pump Case Oil Mobil DTE Extra Heavy or oth er interchangeable ISO Grade 150 700 Heavy Inhibited Hydraulic amp 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 amp 0150 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 amp 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 al lowable 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 environ mental issues and corrosive affects on machine components Hydroject 3000 Dep
42. occurs first Hydraulic Tank Drain Flush See Operator s and Service Manual for specifications and procedures Product Records and Maintenance Page2 6 Rev B Hydroject 3000 Hydroject 3000 Daily Maintenance Check List Daily Maintenance Check Week O Check Safety Interlock Operation Engine Air Filter Pre Cleaner Engine Cooling Fins for Debris Unusual Operating Noises Engi Unus Water Filter Pressure Water Prefiter Gear Case Oil Level Hydr eese Instrument Operations X v c 3 D o i lt X T o Operation Oil Level al Engine Noises Prefilter ulic Hose for Dam ressure Lubricate All Grease Fittings Touch up Damaged Paint 1 Immediately after every washing regardless of the interval listed Notation for areas of concern Inspection performed by iem Date EE ES ES RENE Hydroject 3000 Page2 7 Rev B Product Records and Maintenance seunpeooud pue 10 enuen pue s 10jeJedQ ees 2 pue g ysny POUR Wd YUE jen YSN ureJq 1 pue peau enbJo Ajay
43. rect Replace circuit breaker if faulty Test switch and replace if faulty Test relay and replace if faulty Test ignition switch and replace if faulty Check all wiring and connections and repair as necessary Test actuator and repair or re place if faulty 3000 5 11 Troubleshooting General Run and Transport Problems continued Condition Machine does not raise to trans port position Possible Cause Circuit breaker open Lift Lower switch faulty Lift UP relay faulty Ignition key switch faulty Loose or broken wire in lift up cir cuit Linear actuator faulty Correction Reset circuit breaker Find cause for open circuit breaker and cor rect Replace circuit breaker if faulty Test switch and replace if faulty Test relay and replace if faulty Test ignition switch and replace if faulty Check all wiring and connections and repair as necessary Test actuator and repair or re place if faulty Linear actuator continues to oper ate but should not after machine is lowered to aerate position Lift limit switch faulty Make sure switch is installed properly Test switch and replace if faulty Troubleshooting Page 5 12 3000 Aerate Operation Problems Condition Machine continues to aerate but should not with traction bail in neutral Possible Cause See Safety Interlo
44. shafts Make sure keys Item 1 and 4 are properly installed then align keyways in clutches and pulley with keys Make sure clutch Item 8 is installed so clutch angle Item 7 clutch stops Item 5 33 and clutch bumpers Item 6 will prevent clutch rotation The clutch bumper gap should be 0 22 03 in Never seez on engine shaft 5 Apply Loctite 271 or 680 to threads of bolt item 26 Use special washer Item 27 and install bolt Remove engine air cleaner feed hose to access teeth of flywheel Hold flywheel and tighten bolt to a torque of 25 30 ft lb NOTE A tapered hub Item 16 is attached to cam gear box input shaft When installing hub be sure to use spe cial hardened washer Item18 apply Loctite 271 or 680 to threads of capscrew Item14 and tighten to a torque of to 15 ft lbs 6 Install all bolts and spacers in drive coupling using il lustration below Position flat of spacer Item10 toward welded flange of drive shaft Item 24 Tighten caps crews until shoulder of spacer is seated then tighten to a torque of 15 ft lb more than prevailing torque required to turn locknut on threads Loctite 271 or 680 25 30 ft lb 1819 Never seez Loctite 271 or 680 25 30 ft lb Clutch bumper gap 0 19 0 25 in Figure 30 Repairs 6 20 Rev Hydroject 3000 Pump Drive Replacement Fig 31 32 1 Park the machine on a level surface engage the parking brake ope
45. the engine to the frame 8 Attach an engine lifting chain to the engine lifting straps Connect the chain to a hoist or block and tackle and remove slack from the chain 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 pulley water pump clutch and clutch key see Drive Coupling Removal 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 con nected to the frame with an engine mounting nut 11 Replace the oil filter and fill the engine with the correct oil Figure 1 Repairs Page 3 2 3000 TORO Table of Contents Chapter 4 Hydraulic System SPECIFICATIONS 2 Speed Control 11 GENERAL INFORMATION 3 Transmission Neutral Adjustment 12 Hydraulic Hose and Fitting Information 3 Aeration Speed Adjustment 12 Pushing or 5 Pump Drive Belt Adjustment 13 HYDRAULIC
46. the Order special tools from the TORO SPECIAL TOOLS 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 accumulator pre charge pres sure without significant loss of accumulator pre charge NOTE The charging tool is equipped with a Com pressed Gas Association No 677 tank connection Figure 2 1 Accumulator connector 4 Inlet valve 2 Pressure gauge 5 Relief valve Outlet valve with diffuser 6 Nitrogen tank connector Accumulator Seal Installation Tool TOR4002 Fig 3 Used for installing piston seal during accumulator rebuilding 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 Figure 4 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 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 flo
47. 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 Figure 13 screwed all the way in A damaged pivot shaft or bush ings could cause the switch to not open and close 1 Pump start limit switch blue red amp red blue wires properly Debris in the switch could also cause it to not Switch white amp black wires open and close properly Aerator Start and Stop Switches Fig 14 The aeration start ENGAGE switch is normally open and closes when the button is pushed down The 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 14 1 Aeration start switch pink amp orange wires 2 Aeration stop switch blue amp 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 connecting a continuity tester or ohm meter across terminal 2 common and terminal 1 or 3
48. to step 3 3000 5 17 A CAUTION When testing electrical components for con tinuity with a volt ohm meter or continuity tester make sure that power to the circuit has been disconnected NOTE Electrical troubleshooting of any 12 Volt power connection can also be performed through voltage drop tests without disconnection of the component 3 Connect water supply to machine Turn on water supply and bleed all air out of the system Water pres sure 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 machine should begin aerating 5 sec onds after pump engages Release traction bail to neu tral position so machine stops moving The water pump should disengage 4 seconds after traction bail returns to neutral then stop aerating after another 3 seconds 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 aerat ing go to step 5 5 Engage traction bail to start mac
49. 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 satisfactory 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 chemi cals Protect all sealing surfaces and open cavities from damage and foreign material Repairs Top of pump when installed in machine Torque to 84 to 120 in Ib Page 4 18 Figure 24 1 Charge pump cover 2 O ring 3 Gerotor assembly 4 Charge relief ball 5 Charge relief spring During assembly of the pump all surfaces which have relative motion between two parts should be coated with a film of clean hydraulic oil This will assure 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 petro leum jelly before assembly All gasket sealing surfaces must be cleaned before installing new gaskets 3000 Figure 25 Disassembly of Hydraulic Pump 1 Before performing major repairs on the pump remove external components as described in previous proce dures These include the following Shaft Seals Charge Check Valves Bypass V
50. 0 to 400 ft Ib Figure 2 1 Park machine on a level surface stop the engine and engage the parking brake Open the hood and discon nect 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 spindle 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 motor shaft IMPORTANT To prevent damage to wheel motor DO NOT hit wheel hub with a hammer during re or installation 4 Remove brake shoe springs Item 16 and brake shoes Item 17 5 Repair or replace parts as necessary 3000 Page 7 3 Rev A 6 After installing brake shoes install brake shoe springs Item 17 into holes on each brake shoe plate from the outside Springs should be installed in opposite direction of each other 7 Mount key 7 in wheel motor shaft so top of key is in line with taper in shaft then install wheel hub and brake drum 8 Install spindle nut item 13 and tighten to a torque of 250 400 ft lb 9 Install wheel and secure with wheel nuts Tighten wheel nuts evenly in a crossing pattern to a torque of 40 to 50 ft lb 10 Adjust and check brakes Repairs Wheel Bearing Service Fig 3 1 Park machine on a level surface and raise wheels to aerate position Engage park
51. 00 EQUIPMENT OPERATION AND SERVICE HISTORY REPORT for HYDROJECT e 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 Sales Phone Hydroject 3000 Page2 5 Rev B Product Records and Maintenance Hydroject 3000 Maintenance Schedule Minimum Recommended Maintenance Intervals Maintenance Procedure Maintenance Interval amp Service Every E Check Battery Fluid Level E neha SOS 400hrs Check Battery Cable Connections Lubricate All Grease Fittings A Service 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 C Service 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 D Service Initial break at 25 hours Initial break in at 50 hours Replace Moving Hoses Replace Safety Switches Annual Recommendations Items listed are recommended every 1000 Fuel Tank Drain Flush hours or 2 years whichever
52. 1 Low water system pressure AND flow TEST NO 2 Low water system pressure flow is OK TEST NO 2 Low water system flow pressure is OK TEST NO 2 Improper water valve lift TEST NO 3 Worn or damaged water valve TEST NO 2 Correction Charge accumulator with dry Nitrogen Rebuild or replace ac cumulator if necessary 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 out let 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 Rebuild water valve Water in gear case milky or brown color in oil Worn or damaged water valve low pressure water seal and oil seal Rebuild water valve Oil leaking from below gear case shim area Worn or damaged water valve oil seal Rebuild water valve Water in pump crankcase milky or brown color in oil Worn or damaged water pump low pressure seal or cracked ceramic plunger Rebuild pump head and plunger sleeves Engine dies when water system is engaged Low engine RPM Relief pressure too high TEST NO 2 Low engine power Jammed or siezed pump or gear case Throttle must be in FAST posi tion Adjust carburetor fast setting to 3450 to 3550 RPM no load
53. 13 With tester flow control valve open slowly move traction handle up or down so flow is from 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 Figure 10 1 Hose 2 Bulkhead fitting Variable Displacement Pump Figure 11 HydroJect 3000 Adjustments Traction 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 with pump lever 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 Speed Control Adjustment Fig 13 1 Park machine on a level surface stop the engine and open the hood 2 Adjust speed control cable Item 26 so speed stop lever Item 9 can move to horizontal position Figure 12 1 Jam nuts pump end 2 Jam nuts tiller end 3 Adjust speed rods Item 14 so rod end mounting holes in pivot arms Items 11 23 are located vertically in line with pivot pin Item 22 Figure 13 HydroJect 3000 Page 4 11 Adjustments Transmission Neutral Adjustment Fig 14 If machine moves w
54. 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 rings mate all components to valve body Valve lift 0 100 0 002 _ 94 inch with new cam 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 Page 6 2 Rev B Pressure Relief Valve Poppet type valve with corro sion resistant stainless and brass materials 5000 300 PSI relief valve pressure Manifold and Nozzles Extruded stainless steel man ifold with11 flanged
55. 29 1 Park machine on a level surface stop the engine engage the parking brake open the hood and discon nect the engine spark plug wires A WARNING High pressure water system components can cause personal injury if disassembled incor rectly Discharge water pressure at bleed valve before attempting any water system servicing Open bleed valve slowly and avoid contact with high velocity water stream Lead in to lead out is two 2 rev of pinion 2 Slowly open high pressure bleed valve allowing any pressurized water to escape Figure 27 3 Remove belt guard to expose drive shaft Remove 1 Coupling 2 Cam 3 Follower gear case cover 4 Use your hand to rotate coupling assembly position ing 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 Adjustments Page 6 18 3000 5 Remove test cap from manifold feeder and install Valve Lift Indicator TOR4007 into this opening Make sure dial indicator contacts top of water valve then zero out dial indicator 6 Rotate coupling moving cam toward cam follower Continue to rotate until cam followe
56. 3 Remove lower plug and let oil drain out of pump crankcase into a container Install drain plug 4 Remove drive belt from driven pulley 5 Remove four 4 water valve inlet bolts Inset Item 16 Remove two 2 nuts Item 16 from studs securing pump head Item 2 to frame 6 Disconnect inlet water hoses from pump head Lift pump assembly out of frame and put a sturdy clean work bench 7 Reverse steps 3 6 to install pump After installing pump fill crankcase with 30 oz of Mobil DTE Extra Heavy hydraulic oil or equivalent Torque to 25 33 ft Ib Eight locations 16 14 15 14 Figure 35 HydroJect 3000 Page 6 23 Repairs Water Pump Head Service Fig 36 The three major wear components in the high pressure pump that require maintenance include the check val ves plunger sleeves and plunger seals These com ponents will require maintenance after approx 500 pump operating hours approx 750 engine hours A WARNING High pressure water system components can cause personal injury if disassembled incor rectly Discharge water pressure at bleed valve before attempting any water system servicing Open bleed valve slowly and avoid contact with high velocity water stream NOTE Because of high torque requirements for check valve caps and difficulty of correctly installing check valves in horizontal position it is recommended that the pump head be removed from the cra
57. 5 170 5 8 11 180 255 150 205 18 210 290 170 230 3 4 10 325 460 270 365 16 365 515 300 410 7 8 9 490 745 440 600 14 530 825 490 660 1 8 720 1100 660 890 14 800 1200 710 960 Capscrew Markings and Torque Values Metric Commercial Steel Class 8 8 Capscrew Head Markings Thread Capscrew Torque Class 8 8 Capscrew Torque Class 10 9 Capscrew Torque Class 12 9 Diameter Cast Iron Aluminum Cast Iron Aluminum Cast Iron Aluminum mm ft lb Nm ft lb Nm ft lb Nm ft lb Nm ft lb Nm ft lb Nm 5 9 4 7 9 14 7 11 9 14 7 11 9 14 7 11 14 18 11 14 18 23 18 18 25 14 18 23 32 18 25 27 36 28 30 40 25 30 45 60 35 45 50 70 55 55 70 40 55 75 60 80 95 85 65 90 95 Hydroject 3000 rage z 5 Product Records and Maintenance 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 lubricated 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 3 Product Records and Maintenance Page2 4 Rev B Hydroject 30
58. ATION SYSTEM eSTOP ENGINE BEFORE SERVICING MACHIN Part No 72 4080 USING BLEED VALVE BEFORE SERVICING D SEE OPERATOR S MANUAL FOR MORE INFORMATION COVER AND SHIELDS IN PLACE WHILE OPERATING eREAD AND UNDERSTAND OPERATOR S MANUAL BEFORE OPERATING WARNING HIGH VELOCITY WATER JETS CAN PENETRATE HANDS AND FEET IMPROPER TOWING CAN CAUSE SEVERE PERSONAL INJURY OR DAMAGE THIS MACHINE BEFORE TOWING SEE OPERATOR S MANUAL FOR SPECIAL INSTRUCTIONS On Each Side Of Machine 2 On Underside of Tiller Control Panel Part No 92 9542 Part No 80 8020 AWARNING Z DANGER ANGER ie sud ENGAGE Br wi WHEELS CAN CRUSH OE BREAK FEET OR ANKLES AVOID EXPLOSION CHARGE THIS ACCUMULA vee DO NOT OPERATE MACHINE AERATE BETWEEN HANDLE amp UNIT DISENGAGE FAILURE TO OPERATE Ter AED WEAR EYE PROTECTION KEEP FACE AND HANDS CRUSHED FEET OR BROKEN CHARGING ACCUMULATOR NOT DISASSEMBLE ACCUMULATOR UNLESS On Tiller Control Panel ANKLES 93 9429 TOTALLY FAMILIAR WITH SERVICE OVERHAUL Part No 80 9240 On Tiller Arm On Accumulator body Part No 80 8030 Part No 93 9429 Safety Pagei 4 Rev Hydroject 3000 TORO Table of Contents PRODUCT 85 EQUIVALENTS AN
59. D CONVERSIONS Decimal and Millimeter Equivalents U S to Metric Conversions Product Records Record information about your Hydroject 3000 on the OPERATION AND SERVICE HISTORY REPORT form Use this information when referring to your machine Hydroject 3000 Page2 1 Rev B Chapter 2 Product Records and Maintenance TORQUE SPECIFICATIONS 3 Capscrew Markings and Torque Values U S 3 Capscrew Markings and Torque Values Metric 3 LUBRICATION 4 OPERATION AND SERVICE HISTORY REPORTS 5 Insert Operator s Manuals and Parts Catalogs for your Hydroject 3000 at the end of this section Product Records and Maintenance Decimal and Millimeter Equivalents Fractions Decimals mm Fractions Decimals mm 1 64 0 015625 0 397 33 64 0 515625 13 097 1 32 0 03125 0 794 17 32 0 53125 13 494 3 64 0 046875 1 191 35 64 0 546875 13 891 1 16 0 0625 1 588 9 16 0 5625 14 288 5 64 0 078125 1 984 37 64 0 578125 14 684 3 32 0 9375 2 381 19 32 0 59375 15 081 7 64 0 109275 2 778 39 64 0 609375 15 478 1 8 0 1250 3 175 5 8 0 6250 15 875 9 64 0 140625 3 572 41 64 0 640625 16 272 5 32 0 15625 3 969 21 32 0 65625 16 669 11 64 0 171875 4 366 43 64 0 671875 17 066 3 16 0 1875 4 762 11 16 0 6875 17 462 13
60. IONS Nozzle Size and Approximate Depth Chart WATER SYSTEM SCHEMATIC SPECIAL TOOLS MEMBERS hd Accumulator Charging Valve and Pressure Gauge Accumulator Seal Installation Tool Accumulator Cap Wrench Water System Pressure Gauge Flow Valve Lift Indicator Valve Spring Compressor Water Valve Seal Installation Guide Pump Seal Installation Guide Seal Installation Mandril Filter Body Wrench Pump Seal Extraction Tool Pump Seal Outlet Cover Pump Wear Sleeve Driver TROUBLESHOOTING Troubleshooting Water System Problems HydroJect 3000 Page 6 1 Chapter 6 Water System TESTING dab acp ni dete 12 Before Performing Water System Tests 12 TEST NO 1 Accumulator Pre Charge Pressure and Adding Dry Nitrogen 13 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 REPAIRS 5 eren ken cg 20 Drive Coupling and Clutch Removal and Installation 20 Pump Drive Belt Replacem
61. Inser tion Mandrel TOR4011 to properly install packing seal Item 29 and seal plunger support Item 28 into valve body Remove installers Insert valve guide Item 27 into valve Install ring Item 24 and U cup seal Item 26 to seal retainer Item 25 then install into valve cavity 7 Apply grease to outside of sleeve Item 7 Use valve spool inserted through sleeve to gently drive sleeve into seals inserting it from the spring side 8 Insert valve spool Item1 through valve seat Item 2 and install O ring Item 3 on inboard side of valve seat Hydroject 3000 9 Hold spool and seat in place so O ring does not fall out of place then carefully slide valve spool new sleeve seals and valve seat through ceramic sleeve 10 Install flat washer Item 23 onto valve spool Apply Loctite 271 or equivalent to threads and install jam nut Item 22 Tighten to a torque 10 ft lbs 11 Fill snap ring groove in valve spool Item 1 with wax to prevent damage to seal Install gear case pilot Item18 making sure the drain hole is pointing down Holes in pilot allow only one method of installation Tighten screws Item13 to a torque of 14 18 ft lb 12 Install compression spring Item16 onto valve spool 0 G 9 d 2 ip gm N 13 Install valve spring studs through Valve Spring Com pressor TOR4008 and into threaded holes of water valve Put spring r
62. K On Drive Shaft Shield 80 8000 Of Tiller Arm Part No 80 8070 DANGER AWARNING DO NOT OPERATE THIS UNIT gt HOT E DRIVE SHAFT GUARD IS NOT IN PLACE On Each Side Of Engine 2 Part No 80 9350 On Accumulator body Part No 80 8880 WARNING HIGH VELOCITY WATER JETS CAN PENETRATE HANDS AND FEET PENETRATION BY THE HIGH VELOCITY WATER JET CAN CAUSE 2581008 Mis INJURY FEET AWAY FROM NOZZLE AND ROLLER AREA t ACCIDENTAL PENETRATION OCCURS SEEK MEDICAL ATTENTION IMMEDIATELY 60 8090 On Sides and Behind Rollers 3 Part No 80 8090 WARNING KEEP HANDS AWAY FROM THIS AREA WHILE OPERATING LIFT 206 SURFACES On Trans Pump Bracket under shield On Muffler Shield 3 Part No 80 8760 Part No 80 8290 pull for ROLLER WASHER 4 HOLE SPACING On Lift Actuator IGNITION Part No 80 8010 CIRCUIT BREAKER push to reset ROTATING MEMBERS _ On Control Panel On Control Panel On Driv e Shaft Guard Part No 80 8150 Part No 80 8110 Part No 80 8040 m mmc IMPORTANT D THE FIVE MICRON FILTER ELEMENT 86 8620 MUST BE IN PLACE AT ALL TIMES D OPERATION WITHOUT PROPER FILTRATION WILL RESULT IN PREMATURE WEAR AND FAILURE OF THE WATER SYSTEM COMPONENTS D USE OF ADDITIONAL FILTRATION OR POTABLE WATER On Wheel Motor Fork MAY BE NECESSARY TO PROLONG THE LIFE OF THE KEEP BYSTANDERS AWAY FROM WORK AREA roo FILTR
63. MOBIL DTE EH OR SIMILAR 40 WEIGHT NON FOAMING OIL SEE TABLE OF EQUI VALENT OILS IN FLUID RECOM MENDATIONS SECTION OF THE OPERATOR S MANUAL 80 9450 On Water Pump Part No 80 9450 eTO AVOID EXPLOSION CHARGE THIS ACCUMULA TOR WITH DRY NITROGEN ONLY HIGH PRESSURE VESSELS CAN CAUSE PERSONAL INJURY IF SERVICED INCORRECTLY CHECK OR CHARGE ACCUMULATOR USE ONLY HIGH PRESSURE CHARGING 0 084001 HAVE AN AUTHORIZED TORO TECHNICIAN PER FORM CHARGING AS OUTLINED IN THE SERVICE OVERHAUL MANUAL WEAR EYE PROTECTION KEEP FACE AND HANDS AWAY FROM GAS VALVE GUARD MUST BEIN PLACE AT ALL TIMES EXCEPT WHILE CHARGING ACCUMULATOR 900 NOT DISASSEMBLE ACCUMULATOR UNLESS TOTALLY FAMILIAR WITH SERVICE OVERHAUL PROCEDURES 80 8030 OOH25 93 9360 On Accumulator body Part No 80 8030 SURFACES On Each Side Of Engine 2 Part No 80 9350 4 WARNING HIGH PRESSURE WATER SYSTEM COMPONENTS CAN CAUSE PERSONAL INJURY IF DISASSEMBLED INGORRECTLY DISCHARGE WATER PRESSURE AT BLEED VALVE BEFORE ATTEMPTING ANY WATER SYSTEM HOT SERVICING OPEN BLEED VALVE SLOWLY AND AVOID CONTACT WITH HIGH VELOGITY WATER STREAM SEE OPERATOR S MANUAL FOR COMPLETE PROGEDURES erate On Accumulator body Part No 80 8880 HIGH VELOCITY WATER JETS CAN PENETRATE HANDS AND FEET PENETRATION BY THE HIGH VELOCITY WATER JET CAN CAUSE SERIOUS PERSONAL INJURY KEEP HAND
64. NT Before welding on the machine dis connect both battery cables from the battery dis connect both wire harness plugs from the controller and disconnect the terminal connector from the alternator to prevent damage to the electrical sys tem 1 Stop the engine and disconnect battery cables from battery 2 Disconnect wiring harness connectors from control ler 3 Remove two 2 nuts securing controller to frame and remove controller Figure 27 4 Install new controller and secure to frame with nuts 1 Controller removed in step 3 5 Connect wiring harness connectors to controller 6 Connect battery cables 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 disconnect 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 NET Figure 28 7 Reverse steps 3 6 to install the linear actuator 1 Linear actuator 3 Extension spring 2 Wire connector 4 Capscrew amp nut Diode Fig 29 The diode is located in the wire harness under the side control panel near the fuse Figure 28 1 Diode HydroJect 3000 Page 5 29 Repairs Repairs Page 5 30 HydroJect 3000 Table of Contents SPECIFICAT
65. Nitrogen see TEST NO 3 Accumulator Pre Charge Pressure and Adding Dry Nitrogen in the Testing section HydroJect 3000 Torque to 40 ft Ib four locations Figure 43 HydroJect 3000 Page 6 33 Repairs Accumulator Service Fig 44 45 46 The accumulator piston seals will wear over a period of time As seals wear the accumulator will require more frequent recharging and eventually it will not hold gas 1 Park machine on a level surface stop the engine engage the parking brake and open the hood A DANGER Charged accumulators contain high pressure nitrogen Nitrogen is the only gas to use for accumulator charging Installing IMPROPER gases in an accumulator can cause an EX PLOSION AND DEATH Charging requires Figure 44 special tools and precautions Charge ac cumulators in a well ventilated area It is 1 Protective cover 2 Valve cap yellow recommended that the accumulator 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 Figure 45 components can cause personal injury
66. S AND FEET AWAY FROM NOZZLE AND ROLLER AREA IF ACCIDENTAL PENETRATION OCCURS SEEK MEDICAL ATTENTION IMMEDIATELY 60 8090 On Sides 2 Part No 80 8090 IMPORTANT D THE FIVE MICRON FILTER ELEMENT 86 8620 MUST BE IN PLACE AT ALL TIMES D OPERATION WITHOUT PROPER FILTRATION WILL RESULT IN PREMATURE WEAR AND FAILURE OF THE WATER SYSTEM COMPONENTS D USE OF ADDITIONAL FILTRATION OR POTABLE WATER MAY BE NECESSARY TO PROLONG THE LIFE OF THE FILTRATION SYSTEM D SEE OPERATOR S MANUAL FOR MORE INFORMATION On Front Of Machine Part No 92 9542 J WARNING On Water Pump Part No 93 9360 Replaces 8 9450 for CE HYDROJECT 4000 QUICK REFERENCE AID FLUID SPECIFICATIONS CHANGE INTERVALS FLUID TYPE IMPORTANT SERVICE FILTER A ENGINE OIL saEsosEsa sor 26 250 szsmns C WATER PUMP MOBILDTEEH 1207 3 F FUEL SYSTEM UNLEADED ONLY 9 0GALS G WAER ALTER H ACCUMULATOR DRY NITROGEN 2500 HIGH VELOCITY WATER JETS CAN PENETRATE HANDS AND FEET KEEP BYSTANDERS AWAY FROM WORK AREA STOP ENGINE BEFORE SERVICING MACHINE SLOWLY RELEASE PRESSURE USING BLEED VALVE BEFORE SERVICING WHILE OPERATING READ amp UNDERSTAND OPERATOR S MANUAL BEFORE OPERATING 57 8530 100 HRS 250 67 810 250
67. TOR4011 Use Insertion Mandril with both seal guides Seal Inser tion 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 water filter HydroJect 3000 6 7 gt Figure 9 1 Water Valve Seal Installation Guide 2 Pump Seal Installation Guide 3 Seal Installation Mandril Figure 10 Special Tools Pump Seal Extraction Tools Fig 11 Pump Seal Extraction Tool TOR4013 Rod used to hydraulically extract 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 Figure 11 Pump Wear Sleeve Driver TOR4015 Fig 12 Driver used for removal and installation of plunger guides in pump crankcase 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 follow 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 Troubleshoot
68. able Displacement Pump Cooling Input Belt Drive Charge Check Valves Charge Relief Valve By pass Inlet Filter Reservoir Gear Case Figure 8 Hydraulic Diagram Page4 6 HydroJect 3000 Special Tools 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 Inlet Hose Outlet Hose Flow Meter High Pressure Gauge 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 VALVE 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 1000 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 3000 4 7 4 HIGH PRESSURE GAUGE 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 operati
69. action bail 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 terminals If the wires are not connected to the correct terminals on each switch the safety interlock circuit will not function properly 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 1 Neutral switch N O black amp red blue wires them With the engine turned off slowly push the trac 2 Transport switch N C yellow amp gray wires tion bail in a forward and reverse direction while watch 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 Neu tral Switch and Transport Switch Replacement and Ad justment 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
70. airs Wheel Motor Repair Fig 29 Figure 29 IMPORTANT Before DISASSEMBLING motor plug open ports and clean all dirt from outside of motor IMPORTANT Before ASSEMBLING motor lightly oil all seals rollers and threaded bolt ends Disassembly of Cover Section of Motor 1 Remove key Item 11 from shaft 2 Mount motor in a vice or other holding device with shaft facing down 3 Remove the eight capscrews ltem 1 4 Remove cover amp bearing assembly Item 2 and square ring seal Item 4 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 entire IGR assembly must be replaced 6 Remove the two check balls Item 6 Repairs Page 4 24 NOTE The check balls may fall into body tapered holes or into body valve ports during disassembly Be sure that the check balls are removed Disassembly of Shaft Section of Motor See Disassembly of Shaft and Front Seal Assembly under Main Shaft Seal and or Shaft Replacement Assembly of Complete Motor 1 Before assembly all parts must be cleaned with a suitable solvent and free of nicks and burrs 2 Mount body with pilot and bearing facing up in a vise or other holding mechanism 3 Insert shaft Item 10 and install seals and thrust bearings See Assembly of Shaft and Front Seal As sembly under Main Shaft Seal and or Shaft Replace m
71. al Item 11 and O rings Item 7 and install crank rod bearings and caps into crankcase 10 Bearings should have a light pre load eliminating any end play Add or remove end cap shims Item 8 to change pre load see Crankshaft Bearing Installation and Shimming Page 6 26 2 Preload 0 005 0 007 Capscrew torque 18 20 ft lbs 11 Install end caps onto connecting rods and torque capscrews Item 10 to 18 ft lbs 12 Install new gasket crankcase cover and torque crankcase cover capscrews Item 10 to 18 ft lb 13 Install pulley with tapered hub onto pump drive shaft Rev B Repairs Crankcase Bearing Installation and Shimming Model 09801 1 Remove crankshaft bearing end caps 2 Remove existing shims from both end caps 3 Install one yellow 020 shim and one pink 015 shim onto input shaft bearing housing if required 4 Install three yellow 020 three blue 005 and two red 002 shims onto the end cap bearing housing 5 Install input shaft end cap over crankshaft input shaft and secure to water pump housing Tighten fasteners to a torque of 18 20 ft lb 6 Install end cap bearing housing over output shaft and secure with fasteners but do not tighten 7 Measure the crankshaft end play and remove shims from end cap as required to get 006 001 INTERFER ENCE FIT see chart 8 Tighten fasteners Item 10 to a torque of 18 20 ft lb Repairs Page 6 26 2 Rev B from dial
72. 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 Usethe 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 Neverallow 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 Hydroject 3000 Page 1 1 Chapter 1 Safety Maintenance and Service 3 SAFETY AND INSTRUCTION DECALS 4 A CAUTION TO REDUCE THE POTENTIAL FOR INJURY OR DEATH COMPLY 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 inter fere 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 Donot operate machine while wearing sand
73. all new gasket crankcase cover and torque crankcase cover capscrews Item 15 to 8 ft lb 14 Rebuild plunger sleeves see Plunger Sleeve Re placement 15 Install pulley with tapered hub onto pump drive shaft Hydroject 3000 Water Pump Crankcase Service Model 09801 Fig 38b 18 20 ft lb 18 20 ft lb Apply grease to O D of plunger before installing Pump head Figure 38b NOTE Replace parts in complete sets 1 Remove water pump from machine see Water Pump Removal and Installation 2 Remove pump head see Pump Head Service 3 Remove pulley from pump drive shaft using 1 4 in bolts to separate tapered hub 4 Remove rear cover Item 20 5 Remove connecting rod end caps Item 13 and keep them in original order Carefully push connecting rods Item 12 forward 6 Remove crank rod bearing caps Item 9 27 keeping shims Item 8 in their original locations Slide crank rod Item 15 out ofthe crankcase Inspect crank rod for gall ing or wear 7 Pull connecting rods Item 12 outthrough crankcase Check for wear on plunger 12 and plunger guides Item 28 If plunger guides are worn use Wear Sleeve Tool TOR4015 to drive guides out through crankcase Also use this tool for plunger guide installation Hydroject 3000 Page 6 26 1 8 Inspect bearings Item 23 for galling and pitting If bearings are worn replace bearings and bearing cups as a set 9 Install new se
74. als ten nis 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 Rev B Safety 8 Fill fuel tank with gasoline before starting the en gine Avoid spilling gasoline Since gasoline is flam mable handle it carefully A Use approved gasoline container B Do not fill tank while engine is hot or running C Do not smoke while handling gasoline While Operating 10 DON T TAKE AN INJURY 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 Donotrunthe engine in a confined area without ad equate ventilation Exhaust fumes are hazardous and could possibly be deaaly 16 Using the machine demands attention and to pre vent loss of control Maintenance
75. alve 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 housing Remove end cap Item 31 from housing Item 18 IMPORTANT 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 3000 4 6 Remove cylinder block spring 8 and washer Item 9 from shaft 7 Remove swashplate assembly Item 25 from hous ing 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 15 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 hous ing bore A hook may be used to pry seal out or a slide hammer type puller may be used to remove the seal Be careful not to damage housing bore shaft sealing sur face or bearing After seal is removed it cannot be used again 13 Remove bearing spacer washer Item 22 19 Repairs
76. an cause personal injury if disassembled incor rectly Discharge water pressure at bleed valve before attempting any water system servicing Open bleed valve slowly and avoid contact with high velocity water stream 1 Park machine on a level surface stop the engine engage the parking brake open the hood and discon nect the engine spark plug wires 2 Slowly open the high pressure bleed valve 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 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 f indicator moves more than 0 102 cam lobe is probably contacting follower on lead 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 c
77. arge pump is unable to keep up with internal leakage TEST B Traction Pump Flow 6 Lift the drive wheel off the ground using a jack Block front and rear of the other wheels Make sure the tester 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 down so flow is from the pump through the tester then to the wheel motor Move trac tion handle until 6 GPM is obtained 9 If pressure is less than 200 to 300 PSI go to step 10 If pressure is more than 200 to 300 PSI stop the engine and inspect for binding parking brake Inspect for restric tion in lines to and from motor If there are no restrictions 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 Testing Page 4 10 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 parking brake Block front and rear of all wheels Chain machine to an immovable object and remove slack from chain
78. be heavy 3 Unscrew the filter body counterclockwise as viewed from top Remove filter and discard 4 Rinse out filter body and insert a new filter 5 Clean filter head to prevent contamination of water system Thread body with filter onto filter head Hand tighten 6 Bleed water system with engine OFF and water supply connected and turned on A Push button on top of filter head to purge air from filter body until water comes out around button B Open high pressure bleed valve below ac cumulator to bleed air from water system Close high pressure bleed valve NOTE The quality and micron rating of this filter is very important Do not use any substitutes This filter has a 5 micron rating For easier filter removal use Filter Wrench 4012 Repairs Page 6 22 Figure 34 1 Filter body 2 Filter 3 Filter head 4 Bleed button HydroJect 3000 Water Pump Removal and Installation Fig 35 1 Park machine on a level surface stop the engine engage the parking brake open the hood and discon nect the engine spark plug wires A WARNING High pressure water system components can cause personal injury if disassembled incor rectly 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 Slowly open the high pressure bleed valve allowing any pressurized water to escape
79. below for equivalent oils Mobil DTE 26 Shell Tellus 68 Amoco Rykon Oil 68 Conoco Super Hydraulic Oil 68 Exxon Nuto H 68 Kendall Kenoil R amp O 68 Pennzoil Penreco 68 Phillips Magnus A 68 Standard Energol HLP 68 Sun Sunvis 831 WR Union Unax AW 68 Water Pump Case Oil Mobil DTE Extra Heavy or other interchangeable ISO Grade 150 PE 700 A Heavy Inhibited Hydraulic amp 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 amp 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 amp O 70 Water Supply Recommend a source with 4 5 gal lons per minute A pressure range of zero to 10 psi atthe machine is required Maximum allowable inlet pressure is 25 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 Water Filter Cartridge Toro part no 86 8630 DO NOT USE CHEMICALS Concern for environmental issues and corrosive affects on machine compo nents Page8 5 Rev B Addendum Comparison between Hydroject 3000 and Hydroject 4000 2 cylinder Onan Engine Quick Coupler 5 Micron inlet Filter Pressure Swi
80. ch and replace if faulty Test switch and replace if faulty Replace controller HydroJect 3000 5 13 Rev B Troubleshooting Aerate Operation Problems continued Condition Machine does not start aerating when engage button is pushed in pump belt IS rotating but gear case drive shaft is NOT rotating Possible Cause Valve clutch out of adjustment Loose or broken wire in valve clutch controller circuit Valve clutch faulty Valve clutch relay faulty Controller faulty Correction Check air gap on valve clutch and adjust if necessary Check all connections and wiring and repair as necessary Test valve clutch and repair or re place if faulty Test relay and replace if faulty Replace controller Machine stops aerating when not moving traction bail in neutral It is normal for pump clutch and water clutch to disengage when traction bail is neutral for 3 to 4 sec onds Educate operator NOTE Holding Aerate start switch in ENGAGE position will override neutral de lay shut down Machine stops aerating while ma chine is moving traction bail out of neutral Problem not electrical see Trou bleshooting in Chapter 6 Water System Transport switch 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 do
81. ck System Prob lems Correction Machine aerates but should not with with machine raised in trans port position See Safety Interlock System Prob lems Machine starts aerating but should not with inlet water pres sure of less than 20 to 30 PSI or machine does not stop aerating if inlet water pressure drops to 10 PSI Water pressure switch faulty Water pressure switch wiring faulty Controller faulty Test switch and replace if faulty Check for short in pressure switch controller connections and wiring and repair as necessary Replace controller Machine does not start aerating when engage button is pushed in pump drive belt does NOT ro tate Problem not electrical see Chap ter 6 Water System Circuit breaker open Loose or broken wire 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 Reset circuit breaker Find cause for open circuit breaker Replace circuit breaker if faulty Check all connections and wiring and repair as necessary 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 swit
82. connecting or performing any work on the water system all pressure in system must 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 specialtools and precautions Accumulators do not con tain user serviceable components Improper accumula tor 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 To be sure of safety and accuracy have an Au thorized TORO Distributor check maximum engine speed with a tachometer 33 Engine must be shut off before checking oil or add ing oil to the crankcase Hydroject 3000 1 3 Rev B 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 de sc
83. d 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 injury DIS MEMBERMENT OR DEATH Charged accumulators cannot be shipped via air freight 2 Slowly open the high pressure bleed valve allowing any pressurized water to escape 3 Remove protective cover and yellow valve cap from top side of accumulator 3000 6 13 Figure 14 1 High pressure bleed valve Figure 15 1 Protective cover 2 Valve cap 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 ac cumulator 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 valve and pressurizes the tool and gauge Service range of Nitrogen pre charge pressure 1800 to 2800 PSI Allow 200 PSI if accumulator body is warm 7 lf pre charge pressur
84. d shaft assembly removed remove all parts from shaft and inspect vari ous 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 seal retainer assembly Item 15 16 17 The shaft should have smooth polished surfaces in bearing and seal areas If the shaftis lightly scratched in these areas polish with fine emery paper in a circumferential direc tion However if the shaft has any pitting or deep 3000 4 23 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 snap ring Item 21 Snap ring sharp edges MUST face away from thrust washers with thrust bearing Item 20 between washers 2 Slowly lower spline end of shaft Item 10 assembly into motor body using caution not to rotate internal parts once shaft spline starts to engage 3 Put lightly oiled o ring Item 12 into groove in body bore 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 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 Rep
85. e 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 Figure 17 1 Brake switch 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 Totestthe pressure switch disconnect the wire connec tor 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 18 1 Pressure gauge 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 18a 1 Accumulator charge switch HydroJect 3000 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 con nected and disconnected to terminal 85 with termina
86. e 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 If pre charge pressure is BELOW service range go to step 10 under Adding Dry Nitrogen to Accumulator 8 Tighten nut of accumulator valve clockwise and de pressurize tool by slowly opening outlet valve on right hand side of pressure gauge 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 clock wise 13 Slowly open knob on right hand side of charging tool de pressurize the tool then remove tool from ac cumulator Reinstall yellow protective cap and valve protector bracket NOTE Afte
87. ent 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 INFORMATION 36 Cold Weather Storage 36 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 plas tic 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 exclu sive design patent pending with cast stainless steel head and 3 piston plungers Vee packing seals and Ke vlar guides Forged crankshaft with plasma sprayed ce ramic on stainless steel plungers and cast iron connecting rods Nominal performance is 4 GPM at 5000 PSI with
88. ent 4 Mount body with pilot and bearing facing down in a vise or other holding fixture 5 Put rotary valve Item 7 on shaft spline with shaped slots on first 3000 6 Next put IGR inner member on shaft spline with semi circular roll pockets between rotary valve ports 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 body 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 check ball holes facing down ward over balls Align the eight bolt holes in locating ring with eight holes in body The holes align in only one position 3000 4 25 NOTE Be sure to dislodge body square ring seal while moving locating ring 11 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 shaft 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 freely after assembly A short running period may be required Repairs Repairs Page 4 26 3000
89. ents NOTE You can check for plugged nozzles by aerating over a piece of cardboard then inspecting cardboard 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 con tain enough Nitrogen for 20 30 fills NOTE During operation working pressure of Nitrogen in accumulator will be equal to the operating pressure of the water system 1 Park machine on a level surface stop the engine engage the parking brake open the hood and discon nect the engine spark plug wires A DANGER Charged accumulators contain high pressure nitrogen Nitrogen is the only gas to use for accumulator charging Installing IMPROPER gases in an accumulator can cause an EX PLOSION AND DEATH Charging requires special tools and precautions Charge ac cumulators in a well ventilated area It is recommended that the accumulator be checked and charged by an Authorized TORO Distributor Wear eye protection Keep hands an
90. ervice 3 Remove pulley from pump drive shaft using 1 4 in bolts to separate tapered hub 4 Remove plunger sleeve assembly Items 25 30 5 Remove rear cover Item 19 using a 5 mm allen wrench 6 Use a 5 mm allen wrench to remove connecting rod end caps Item 10 and keep them in original order Carefully push connecting rods Item 9 forward 7 Remove crank rod bearing caps Item 1 keeping shims Item 2 in their original locations Slide crank rod Item 11 outofthe crankcase Inspect crank rod for gall ing or wear 8 Pull connecting rods Item 9 out through crankcase and check for wear on plunger guides Item 3 If plunger guides 3 are worn use Wear Sleeve Tool TOR4015 to drive guides out through crankcase Also use this tool for plunger guide installation Repairs Page6 26 Rev B 9 Inspect roller bearings Item 13 for galling and pitting If bearings are worn replace bearings and bearing cups as a set 10 Install new seals Item 14 and O rings Item 31 into bearing caps and install crank rod bearings and caps into crankcase 11 Bearings should have a light pre load eliminating any end play Add or remove end cap shims Item 2 to change pre load Shaft should rotate easily by hand Preload 0 015 0 020 in aluminum crankcase Capscrew torque 10 ft lbs aluminum crankcase 12 Install end caps onto connecting rods and torque capscrews Item 21 to 18 ft lbs 13 Inst
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92. es not en gage Make sure switch is installed and adjusted properly Test switch and replace if faulty Check all connections and wiring and repair as necessary Troubleshooting Page 5 14 HydroJect 3000 Safety Interlock System Problems Condition Engine cranks but should not with traction bail in neutral Possible Cause Neutral switch faulty Neutral switch wiring faulty Correction Make sure switch is installed and adjusted properly Test neutral switch and replace if 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 Green light on controller stays ON should be OFF with aerate en gage switch released Controller faulty Make sure transport switch is in stalled and adjusted properly Test transport switch and replace if faulty Check for short in transport switch controller connections and wiring and repair as necessary Test aerate engage start switch and replace if faulty make sure Switch action is momentary and comes comes back out after be ing pushed in Replace controller Machine aerates but should not with with machine raised in trans port position Yellow light on controller is ON should be OFF with machine raised in transport position
93. etainer Item 15 over spring and un der spring compressor Tighten nuts to compress spring and install and retaining ring Item14 Remove special tool NOTE The manifold feeder keeps the valve seat sta tionary The spring force of the water valve positions the valve seat prior to Feeder Manifold installation Make sure cam lobe does not contact cam follower during feeder manifold installation Fig 29 7 9 G3 9 8 2 3 aN N N AN 2 2 22 21 SN x Nd Om 5 89 7 G9 DAS 206900 Figure 40 Hydroject 3000 Page 6 29 Rev B Repairs Gear Case Service Fig 41 The gear case is a pinion and gear reduction drive that actuates the water valve The pinion Item 12 is con nected to the electric brake clutch with a drive coupler The gear Item 22 moves the cam over the roller follower actuating the water valve to control water in jection at 5 3 cycles per second at 320 RPM The gear case also serves as the hydraulic oil reservoir If the gear case is disassembled for repair make sure the taper roller bearings have a light rolling resistance after reassembly by adjusting shim thicknesses Item 16 and 20 Bearing pre load is 0 to 0 002 in There is a replaceable cam Item 23 and weight block Item 27 on the gear Only the cam contacts the roller cam follower The weight block is for balance Make sure you inspect the cam and not the weight block when checking for wear
94. eter 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 de signed to carry it HydroJect 3000 5 7 Rev Figure 6 Special Tools Skin Over Grease Fig 7 Special non conductive grease which forms a light pro tective skin to help waterproof electrical switches and contacts Toro P N 505 47 8 oz 24 L can Figure 7 Special Tools Page5 8 Rev B HydroJect 3000 Troubleshooting A CAUTION Remove all jewelry especially rings and watches before doing any electrical trou bleshooting or testing Disconnect the bat tery cables unless the test requires battery voltage For effective troubleshooting and repairs you MUST have a good understanding of the electrical circuits and components used on this machine See Electrical Schematic Starting Problems Study the operating characteristics preceding the elec trical failure to help identify the area 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 troubleshooting charts should be checked in the order in which they are listed If the machine being repaired has an
95. fter 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 If pressure is OK but flow is low rebuild pump 10 Perform Test No 3 Water Valve Lift 11 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 setting 5000 300 PSI for 3 to 4 seconds then begin to fluctuate rapidly when the unit begins aerat ing Note the highest pressure If highest pressure is 4000 to 4500 PSI plan to rebuild the valve If pres sure 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 Figure 21 1 Water supply quick connector Figure 22 1 Flow meter pressure gauge TOR4006 Figure 23 1 Relief valve 2 Hose Testing Page 6 16 Rev A HydroJect 3000 TEST 3 Water Valve Lift Fig 24 25 If valve lift is too high the valve may not seat correctly If valve lift is too small the pulses may not release enough pressurized water and the relief valve will open wasting energy Improper valve lift can also result in high contact stresses and rapid cam wear A WARNING High pressure water system components c
96. g moving cam toward cam follower and continue to rotate until cam follower is on lead in portion of cam approximately one inch from cam lobe There should be no movement of dial indicator on lead in portion of cam Continue to rotate over cam lobe Lift should measure 0 10 0002 in with new cam Continue to rotate on lead out portion The dial indicator should read zero for entire lead out portion Figure 28 1 Valve lift indicator TOR4007 Water 4000 5000 PSI operating pressure Water valve housing S SJ N TAANS 24 Ce SRE BS D O 5 SZ Shims lt ILI LL SESS EREWUL Y O 2 2 Figure 29 HydroJect 3000 6 19 Adjustments Repairs Drive Coupling and Clutch Removal and Installation Fig 30 1 Parkthe machine on a level surface engage the park ing brake open the hood and disconnect the engine spark plug wires Remove guard Item 38 2 To remove coupling shaft remove four capscrews connecting the rubber couplers Item 11 12 to clutch Item 8 and adapter hub Item 16 then lift shaft away from machine 3 Clutch Item 8 pulley Item 3 and clutch Item 2 can now be removed by removing bolt Item 26 and washer Item 27 A puller tool may be required 4 Apply Never Seez or equivalent to engine shaft and pulley
97. gearbox oil looks milky or brown flush the System immediately replacing oil filter and fluids in hy drostatic transmission and wheel motor The water valve assembly is similar to the pump head It uses the same ceramic sleeve and seals Since the water valve is the junction point for all high pressure lig uid movement and is fairly difficult to access complete rebuilding is recommended when this assembly is re moved Seal Replacement There are two major seals in the water valve that will re quire regular maintenance or replacement One seal keeps high pressure water in the high pressure water System and the other seal keeps the gear case oil within the gear case The high pressure water seal is identical to the pump head displacement rod seal The major difference is the different brass insert If the oil seal leaks oil will leak down and through the gear case shims If low pressure water seal fails water will leak out between shims If low pressure water seal and oil seal fail water will leak into the gear case Hydroject 3000 Page 6 27 Water Valve Disassembly 1 Park machine on a level surface stop the engine en gage the parking brake open the hood and disconnect the engine spark plug wires WARNING High pressure water system compo nents can cause personal injury if disassembled in correctly Discharge water pressure at bleed valve before attempting any water system servicing Open bleed valve slowly a
98. hen lever is released transmission neutral adjustment is needed 1 Park machine on a level surface stop the 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 locknut on top of neutral 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 do 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 Aeration Speed Adjustment Fig 15 1 Park machine on a level surface stop the engine and open the hood 2 Put speed control lever into second slot from left while facing control panel 3 Lower machine into aerate mode so transport wheels 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
99. hine moving then push aerate ENGAGE button to begin aerating Push aerate DISENGAGE button The water pump should disengage immediately then stop aerating after 3 sec onds If machine does not stop aerating there is a malfunction in the interlock system that must be cor rected Testing Clutch Engagement Electronic Control System Test Fig 8 This test can be used to check for proper operation of the electronic control system and clutches without con necting the machine to a water source or operating the machine 1 Park machine on a level surface stop the engine engage the parking brake open the hood and discon nect 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 elec trically 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 C With traction bail out of neutral push then re lease 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 check for clutch engagement clutch will be magnetized 5 NEUTRAL shut down test
100. hten 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 Figure 25 IMPORTANT The neutral and transport switches 1 Neutral switch N O black amp red blue wires have three 3 terminals If the two 2 wires are not 2 Transport switch yellow amp gray wires connected to the COMMON and terminals 3 Switch tab on neutral switch and COMMON and termi nals on transport switch the safety interlock circuit will not function properly A 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 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 Figure 26 1 Circuit breaker 2 Fuse Controller Replacement Fig 27 IMPORTA
101. indicator to get 006 001 015 008 014 007 014 012 3000 Water Valve Service Fig 39 40 The water valve controls the release of high pressure water The water valve is opened when a cam contacts and moves a roller follower The follower moves the valve stem against spring pressure which opens the water valve After discharge the valve spring closes the water valve diverting pump flow into the accumulator for storage The valve stem is installed completely through the water valve body and guided through a replaceable bushing and two sealing assemblies The water valve consists of atapered valve stem sealing against a captured valve seat The valve seat is sealed on both sides One valve seat seal contacts the water valve body and the other seal contacts the manifold feeder When the manifold feeder is installed on the wa ter valve the seals are compressed locking in and maintaining correct alignment of the water valve and also preventing blow by Any abrasives in the water will rapidly erode the valve surfaces The valve and valve seat can be ground and lapped to renew their working surfaces After grinding adjust the valve lift by measuring the lift and adjusting the shim stack thickness The shim stack is located be tween the water valve body and gear case flange If the high pressure seal leaks for extended periods of time water may be forced past the oil seal and into the gearbox If the
102. ine Stationary neutral X X X X 5 Machine Raise transport position 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 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 Page5 2 Rev B HydroJect 3000 Controller Lights Lights LED s on the controller indicate when the follow ing 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 TRACTION lowered to aerate position and water pressure switch closed water pressure of more than 30 psi and accumulator
103. ing Water System Problems Refer to the Testing section of this Chapter for precau tions and specific test procedures NOTE 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 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 the order listed even if the apparent problem has been isolated such as low accumulator pre charge pressure This will verify that all components are operating properly Condition Machine does not start aerating when engage button is pushed in pump belt does NOT rotate Possible Cause Transport wheels not fully raised unit lowered to aerate mode Low inlet water pressure Sheared pump clutch key Electrical problem Correction Check to make sure transport wheel arms are fully raised unit in aerate mode 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 Machine does not start aerating when engage button is pushed in pump belt IS rotating but gear case drive shaft is NOT rotating Electric brake clutch valve clutch out of adjustment Sheared valve clutch key Electrical problem
104. ing brake open hood and disconnect engine spark plug wires 2 Remove dust cap Item 28 from end of wheel spindle 3 Remove cotter pin Item 27 slotted nut Item 29 and washer Item 30 Slide wheel and hub off of spindle shaft 4 Pull seal Item 34 out of wheel hub Item 23 5 Remove bearings Item 32 from both sides of wheel hub Clean bearings in solvent Make sure the bearings are in good operating condition Clean inside of wheel hub Check bearing cups Item 33 for wear pitting or other noticeable damage Replace worn or damaged parts 6 If bearing cups were removed from wheel hub press them into hub until they seat against the shoulder 7 Pack both bearings with grease Use No 2 general purpose lithium base grease containing E P additive Install one bearing into cup on inboard side of wheel hub Lubricate inside of new lip seal and press it into wheel hub IMPORTANT The lip seal Item 34 must be pressed in so it is flush with end of hub Lip of seal must be toward the bearing 8 Pack inside of wheel hub with some grease not full Install remaining bearing into bearing cup 9 Slide hub onto spindle shaft and secure it in place with flat washer and slotted nut DO NOT tighten nut or install cotter pin 10 Adjust pre load on wheel bearings by rotating wheel by hand and tightening slotted nut until bearing binds SLIGHTLY Then loosen nut until nearest slot and hole in spindle line up Install cot
105. l 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 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 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 5 24 Rev B Figure 20 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 68 F Valve Clutch Fig 22 To test the valve clutch disconnect the wire connector and connect a con
106. leted while the key is moved to each position 1 OFF NONE NONE 2 RUN 3 START NONE Figure 10 HydroJect 3000 Page 5 19 Testing Controller Fig 11 The controller senses the condition of various switches such as the transport switch and aerate start switch and directs power output to allow certain machine functions such as aerate engage disengage and timing of those functions Because of the solid state circuitry built into the control ler there is no method to test it directly The controller may be damaged if an attempt is made to test it with an electrical test device such as a volt ohm meter IMPORTANT Before welding on the machine dis connect both battery cables from the battery dis connect both wire harness plugs from the electronic control unit and disconnect the terminal connector Figure 11 from the alternator to prevent damage to the electri cal system 1 Red light 2 Yellow light Lights LED s on the controller indicate the condition of 3 Green light the interlock switches The LED s in conjunction with the following tests for 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 Transport 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 and is open when the tr
107. lightly oil parts before assembly Tighten all threaded parts to recommended torque value IMPORTANT Most parts have critical high toler ance 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 shaft 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 NOTE The position of the bearing in the housing deter mines control shaft end play Do not press bearing deeper into housing at this time Repairs Page 4 20 3 Install displacement control shaft Item 12 into hous ing 4 If block spring retaining ring Item 10 was removed 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 retaining ring Be careful not to stretch or deform retaining rings IMPORTANT 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 plastic or use a seal protector 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
108. 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 Inspect charge pump and replace if faulty Low traction pump flow pressure Test B Repair or replace pump Low traction motor efficiency Test C Repair or replace traction motor Troubleshooting 4 8 3000 Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks See the Special Tools section in this Chapter A CAUTION Failure to use gauges with the recommended pressure psi rating as listed in the test pro cedures 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 link age loose fasteners or improper adjustments must be checked before assuming that a hydraulic component is the source of the problem being experienced A WARNING Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved by stopping the en gine and opening the
109. ll not make contact with them and result in hose or tester damage 8 Check the oil level in the reservoir 9 Check the control linkage for improper adjustment binding or broken parts 10 All hydraulic tests should be made with the hydraulic oil at normal operating temperature Testing Hydraulic Tests Fig 10 11 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes 2 Engage parking brake and stop the engine Make sure parking brake is properly adjusted before perform ing hydraulic tests 3 With engine off disconnect hose from bulkhead fitting and install tester in series 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 pressure is low inspect for restriction in pump intake line and inlet filter Inspect charge relief valve and valve seat Inspect for sheared charge pump key Disassemble charge pump and in spect for internal damage or worn parts If charge pump is in good condition no scoring scratches or excessive wear piston pump and motor might be suspected of wear and inefficiency thus ch
110. loosening and removing plung er bolt assemblies Item 30 The plunger sleeves can be gently pulled forward for inspection or replacement Remove large washer Item 25 from rear of plunger rod 2 Remove O Ring Item 29 and Teflon seal Item 28 on plunger bolt assembly Item 30 Install new greased O ring Item 28 next to head on bolt then install Teflon ring Item 28 3 Install new large washer Item 25 then new plungers Item26 onto plunger rods 4 Apply Loctite 271 or equivalent to threads of plunger bolts then install assemblies onto plunger rods Torque plunger bolts to 10 ft lbs Pump Head Installation Fig 37 1 Apply grease to ceramic plunger sleeves Carefully install pump head onto pump crankcase studs and plungers While installing tap evenly on pump head while turning pump crankshaft 2 Install eight 8 nuts onto studs and evenly torque locknuts to 25 33 ft lbs 3 Install water pump assembly into frame see Water Pump Removal and Installation PUMP HEAD Go through numbered sequence two 2 times 25 33 ft lbs Figure 37 Rev B Repairs Water Pump Crankcase Service Model 09800 Fig 38a Loctite 271 29 8 10 ft lb Apply grease to O D of plunger before installing pump head 18 ft lb Figure 38a NOTE Replace parts in complete sets 1 Remove water pump from machine see Water Pump Removal and Installation 2 Remove pump head see Pump Head S
111. lose 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 run ning or soon after itis stopped These areas could be hot enough to cause a burn 19 Before leaving the operator s position behind han dle engage parking brake 20 When leaving the machine unattended engage parking brake shut engine OFF and remove key from ignition switch 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 dis
112. m 47 Remove locknut Item 54 and cap screw 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 Figure 20 3000 Page 4 15 Repairs Pump Shaft Seal Replacement Fig 21 Lip type seals are used on input shaft and displacement control shaft These seals can be replaced without major disassembly of pump 1 Remove retaining ring from housing input shaft seal only 2 Carefully pull seal out of housing bore A hook type tool may be used to grasp seal and pull it out or a slide hammer type puller may be used to remove seal Be careful not to damage housing bore shaft sealing sur face or bearing After the seal is removed it cannot be 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 contami nation Polish sealing area on shaft if
113. m nut Item 22 and large washer Item 23 then gently push valve spool through valve Valve seat Item 2 will come out with the valve Rev B Repairs 11 Inspect sealing surfaces of spool and valve seat If surfaces appear worn replace or regrind Both angles are 30 degrees 12 Remove and inspect sleeve Item 7 and remove backup Item 6 and O ring seals Item 5 Apply grease to O D of sleeve before installing 10 13 Remove seal assembly Items 25 30 by pressing a socket wrench through the casting Discard all seal components 14 Remove snap ring Item 21 from gear box pilot Item18 Insert a shaft into the outboard side of the gear box pilot to push out sleeve bushing Item17 seal back up Item 20 and oil seal Item 19 Torque to 14 18 ft lb Six locations Apply Loctite 271 to threads of spool Figure 39 Water Valve Assembly 1 Press a new sleeve bushing Item17 into gear case pilot until bushing is flush with recessed oil side sur face 2 Use a shaft to install oil seal Item 19 and seal back up Item 20 into gear box pilot Install retaining ring Item 21 3 Grease Item 5 and back up ring Item 6 then install onto valve spool Item1 Rubber O ring is furthest away from threads 4 Install black back up ring Item 30 into valve cavity flat side first Repairs Page 6 28 Rev B 5 Use Valve Seal Installer TOR4009 and Seal
114. move 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 motor shaft IMPORTANT To prevent damage to wheel motor DO NOT hit wheel hub with a hammer during re or installation Repairs Page4 22 Rev A 4 Disconnect hydraulic lines from fittings on wheel motor Put caps on open lines and fittings to prevent contamination Put labels on hydraulic lines for proper 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 tighten large nut Item 22 to 250 400 ft Ib 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 ring pliers 4 Pull shaft Item 10 out vertically IMPORTANT When pulling shaft vertically do not rotate shaft or move motor as this may alter internal timing 5 With seal retainer assembly an
115. n eoiues pue s 10jeJedo ees yue 9 YSN 8 pounbay 9 2 pue g y seuows eoe deu IIN eipi Wd 9 PUNON ISNIpe pue peau enbJo s eioeds eoiAJeg jenuuy 19410 SJequieuo yieds eoejdeyu sBuuds 9 e zzou 10joefui 9 95 S 5 00 9 A eseejb eyeougn aged A yeq 9 C Jang Ajegeq 7 sunoy 001 51 0 19 9 Y L1 DJ E L1 EJ C1 EJ E31 DJ 19403 qa 94V woad 5 OHOL uoneubiseq esn 5 gadna 1osiAJedns ooor 12 Hydroject 4000 10 Rev B Page 8 Addendum
116. n the hood and disconnect the engine spark plug wires 2 Remove the drive coupling see Drive Coupling Removal and Installation 3 Disconnect electrical connectors for both clutches 4 Remove clutch stops Fig 30 Item 5 and clutch retainer bracket Fig 30 Item 39 5 Loosen hydraulic pump belt tension and remove small belt from hydraulic pump pulley see Pump Drive Belt Adjustment in Chapter 4 Hydraulic System 6 Loosen water pump idler pulley and work belt off of large pulley Carefully pull this belt out from under the electric clutches 7 Reverse steps 2 6 to install the belt Adjust hydraulic pump belt tension see Pump Drive Belt Adjustment in Chapter 4 Hydraulic System HydroJect 3000 Page 6 21 Figure 31 1 Water pump belt t 4 Figure 32 1 Hydraulic pump belt Repairs Water Filter Replacement Fig 33 34 When pump inlet pressure decreases or the water sys tem shuts down it usually means the water filter is restricted and must be replaced IMPORTANT Never operate the machine without a water filter Operating without a water filter can cause severe damage to the water system 1 Put the machine on a level surface engage the parking brake stop the engine and disconnect the en gine spark plug wires 2 Locate the water filter assembly which is mounted below the fuel tank NOTE Be careful when removing filter body Filter body is full of water and will
117. nd avoid contact with high velocity water stream 2 Open High Pressure bleed valve Remove accumula tor see Accumulator Replacement Remove manifold manifold feeder and manifold support as an assembly from water valve body 3 Disconnect drive coupler from gear case hub adapter see Drive Coupling and Clutch Removal and Installa tion 4 Drain oil from gearcase Disconnect hydraulic lines from gearcase Remove four 4 capscrews securing gear case to water valve and carefully pull gear case off of gear box pilot on water valve 5 Disconnect valve seal drain tube by unscrewing small fitting at pump inlet Remove two 2 locknuts from studs securing water valve to frame Remove four 4 caps crews connecting water valve to water pump head Re move water valve and put it on a clean work bench 6 Install valve spring tool studs through the Valve Spring Compressor TOR4008 and into threaded holes of wa ter valve 7 Tighten nuts to compress tool until retaining ring Item14 can be removed from valve spool Remove re taining ring then carefully loosen nuts on special tool re leasing valve spring compression 8 Remove spring retainer Item 15 and spring Item16 from water valve stem Remove screws Item13 from gear case pilot Remove gear case pilot Item18 from water valve 9 Use a wrench to keep spool valve Item1 stationary and use a deep wall socket to loosen jam nut Item 22 on valve spool 10 Remove ja
118. ng the drill size of the orifice The standard configuration is 11 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 be low IMPORTANT Use only nozzle configurations shown or damage to the machine may occur NOZZLE SIZE AND APPROXIMATE DEPTH CHART Decimal Size Quantity of Nozzles Approx inch Open Blocked Depth 86 8130 56 _ 0465 86 8131 53 0595 __ Ae me omo _ Le s Aluminum Washer Toro Part no 86 8150 is required with any nozzle change OPTIONAL STAGGERED SIZE NOZZLE CONFIGURATION Part No Drill Size Decimal Size Metric Size Quantity of Nozzles Approx inch Open Blocked Depth 0 Aluminum Washer Toro Part no 86 8150 is required with any nozzle change Additional nozzles may be blocked to compensate for pump wear Check Valve Ball Spring OPEN NOZZLE CLOSED BLOCKED NOZZLE Addendum Page8 4 Rev B Hydroject 4000 Hydroject 4000 Fluid Recommendations Fuel Unleaded regular gasoline recommended to minimize engine intake valve and combustion chamber deposits Engine Oil Service classification API SF SG SF CC or SG CC in a 30 weight viscosity grade Engine Oil Filter Toro part no 57 8530 Hydraulic Oil Mobil DTE 26 or other interchange able equivalent See chart
119. nkcase when ser vicing NOTE Whenever a pump is removed from the machine for preventative maintenance or servicing replace com ponents in complete groups rather than individually Complete servicing will increase the service interval between repairs Pump Head Removal 1 Remove pump from machine see Water Pump Removal and Installation 2 Remove eight 8 nuts Item 17 Carefully move pump head Item 11 away from pump crankcase Turn pump crankcase to help in removal of pump head Check Valve Replacement replace as a set 1 Remove the six caps Item 7 and pull out check valve assemblies 2 Discard old check valves Item 9 and remove any remaining seals Item 10 stuck in the pump head 3 Insert new seals Item 10 and check valves Item 9 4 Install new seals Item 8 in check valve caps Apply Loctite 242 or equivalent to threads install caps and tighten to a torque of 205 235 ft lbs Ly a Of gt 204 PLUNGER SEAL REMOVAL Step 2 Fill the three 3 plunger openings with water Insert Pump Seal Extraction Tool TOR4013 into each water filled cavity Quickly strike the extraction tool with a heavy lead mallet Seal assembly and brass retainer should move about 1 4 in out of the cylinder head If seal does not move add more water and try again If the seal does not move after a few attempts try using heavy oil or grease instead of water HET PLUNGER SEAL REMOVAL Step 1 Fill
120. not to damage the seal 10 Install retaining ring Item 24 11 Install swashplate cradle bearings Item 14 into housing making sure they are located on cast in pins in 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 screwdriver 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 measure side play of displacement control shaft Using a suitable sleeve press control shaft bearing into housing until control shaft end play is be tween 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 piston 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 angle position and pump housing laying on its side install pump cylin der block kit onto pump shaft in housing 3000 18 Check that piston springs are centered in cylinder block bores If necessary move springs into position with a small screwdriver IMPORTANT Do not damage running surfaces of cylinder blocks 19 Install two 2 alignment pins Item 15 and install a
121. nsure they securely in place Traction Unit 1 Thoroughly clean machine 2 Grease or oil all fittings or pivot points 3 Checkto make sure alltires are over inflated to 20 30 p s i 4 Lightly sand and use touch up paint on all areas that are scratched chipped or rusted 5 Drain and replace hydraulic oil and filter on cam gear case 6 Drain and replace oil in water pump case 7 Clean the battery terminals and posts with a wire brush and baking soda solution Coat cable terminals and battery posts with skin over grease or petroleum jel ly Recharge battery Hydroject 3000 Chapter 7 Wheels Brakes and Steering TORO Table of Contents 5 2 REPAIRS deni 3 Brake Adjustment 2 Brake Service 3 Wheel Bearing Service 4 HydroJect 3000 Page 7 1 Table of Contents Adjustments Brake Adjustment Fig 1 1 Park machine on a level surface and stop the engine 2 Remove screws securing cover to under side of tiller handle Remove cover 3 Loosen upper jam nut securing brake cable to bracket 4 Tighten lower jam nut until 25 to 30 pounds of force are required to actuate brake lever Tighten jam nut 5 Install lower cover Figure 1 1 Brake cable Adjustments Page 7 2 HydroJect 3000 Repairs Brake Service Fig 2 Torque to 20 25
122. on circuit with a gauge rated at 15 GPM 6 OUTLET HOSE Hose from the outlet side of the hydraulic tester to be connected to the hydraulic system circuit Special Tools Troubleshooting The cause of an improperly functioning hydraulic sys tem is best diagnosed with the use of proper testing equipment and a thorough understanding of the com plete hydraulic system 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 turn off the engine locate the cause of the trouble and correct it before allowing the machine to be used again Continued use of an improperly functioning hydraulic Transmission Operates in One Direction Only system could lead to extensive internal component damage The charts that follow contain detailed information to assist in troubleshooting There may possibly be more than one cause for a machine malfunction All causes should be checked in the order in which they are listed on the charts Refer to the Testing section of this Chapter for precau tions and specific test procedures Cause Faulty traction control linkage Correction Repair linkage Transmission charge check valve defective Inspect and clean or replace charge check System Operates Hot Looses Power or Will Not Operate in Either Direction Cause Faulty control linkage Correction Repair
123. onnector 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 will 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 A
124. ontact 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 see Gear Case Service If cam is not worn adjust valve lift 8 Go to step 11 under TEST NO 2 Water System Pressure and Flow HydroJect 3000 Page 6 17 IMPORTANT A reading of 0 090 to 0 102 does not guarantee a properly adjusted cam When in doubt 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 out Lead in to lead out is two 2 rev of pinion Figure 24 1 Coupling 2 Cam 3 Follower Figure 25 1 Valve lift indicator TOR 4007 Testing Adjustments Electric Brake Clutch Adjustment Fig 26 1 Park machine on a level surface stop the engine engage the parking brake open the hood and discon nect engine spark plug wires 2 Adjust air gap to 018 by inserting a thickness gauge into the clutch openings Evenly 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 access to all three 3 adjust ment nuts Figure 26 1 Locknut 3 Water Valve Lift Adjustment Fig 27 28
125. or is not scratched or scored it can be reused If bore is scored or damaged it will require resurfacing and nickel plating If cylinder bore is damaged it may be more cost effective to replace the complete accumulator than to continue this repair Accumulator Assembly and Seal Installation 12 If bore not damaged or worn use solvent to thoroughly clean accumulator cylinder 13 Apply clean hydraulic oil to new end seal and back up ring Item 4 Install end seal and back up ring in groove of bottom end cap Item 9 so O ring is toward the piston Apply 2 or equivalent to threads of end cap Carefully install end cap and tighten to a torque of 125 ft lbs 14 Special grease is supplied with a new piston Apply coating of special grease to piston Make sure spaces between seals on piston are filled with special grease Put a light coating of special grease on accumulator bore and installation tool 15 Use Accumulator Seal Installation tool TOR4002 to prevent seal damage during piston installation CAREFULLY insert this tool into top side of cylinder SLOWLY insert piston large cross facing down through the tool and into the cylinder bore 16 Move piston to bottom of accumulator cylinder Add 11 oz of Mobil DTE 26 hydraulic oil to completely fill cup in piston and cover top edges of piston HydroJect 3000 6 35 Rev C 17 Apply clean hydraulic oil to new end seal and back up ring I
126. outlet port of pump head with water and use two capscrews to temporarily install Pump Seal Outlet Cover TOR4014 onto the outlet port of the pump head ya Torque to 25 33 ft Ib Eight locations j 18 S 17 Use Loctite 242 or equivalent Torque to 205 235 ft lb Six locations Figure 36 Repairs Page 6 24 HydroJect 3000 Plunger Seal Replacement See illustration on previous page NOTE Check valves must be in good condition for this procedure to work correctly 1 Fill pump head outlet cavity with water then use two capscrews to temporarily install Pump Seal Outlet Cov er TOR4014 onto outlet port of pump head Check valves must be installed 2 Position pump head on a SOLID workbench or in a vise keeping displacement rod openings pointing up wards 3 Fill plunger openings with water Insert Pump Seal Ex traction Tool TOR4013 into each water filled cavity WEAR SAFETY GLASSES Quickly strike the extrac tion tool with a large hammer or mallet The seal assem bly and brass retainer should move about 1 4 out of the cylinder head If seal does not move add more water and try again NOTE If seal does not move after a few attempts try using heavy oil or grease instead of water 4 Remove all seals from pump head and remove outlet cover tool Discard back up ring Item 6 packing vee Item 5 and seal support Item 4 Inspect brass seal re tainer Item 2 for wear and re
127. place if worn If brass seal retainer can be reused remove and replace U cup seal Item 3 and O ring seal Item1 NOTE Apply clean grease to each seal before installing in steps 5 9 5 Insert back up ring Item 6 flat side first into each pump head cavity 6 Insert packing vee Item 5 into Installation Guide TOR4010 making sure that V will mate with back up ring Item6 7 Insert Installation Guide into cylinder head cavity and use Insertion Mandril TOR4011 to completely install the seal 8 Insert seal support Item 4 into Installation Guide TOR4010 making sure V groove will mate with high pressure seal Insert Installation Guide into cylinder head cavity and use Insertion Mandril TOR4011 to completely install seal support This seal support fits tightly in the bore 9 Install new U cup seal Item 3 and O ring seal Item1 into seal retainer Item 2 Install seal retainer into pump head cavity Use a soft face plastic hammer or arbor press to completely insert backup ring into pump head Hydroject 3000 Page 6 25 Plunger Sleeve Replacement Model 09800 see Figure 38 on next page The plunger sleeves are installed on and sealed to stainless steel plunger rods This assembly is inserted through a special high pressure seal in the pump head During pump servicing a complete repair kit should be installed 1 Remove plunger sleeves Item 26 from crankcase plunger rods Item 9 by
128. r 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 Figure 16 Figure 17 HydroJect 3000 TEST NO 2 Water System Pressure and Flow Fig 18 19 20 21 22 23 1 The engine must be in good operating 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 flow meter reading 2 Stop the engine engage the parking brake and open A WARNING High pressure water system components can cause personal injury if disassembled incor the hood rectly Discharge water pressure at bleed Figure 18 valve before attempting any water system servicing Open bleed valve slowly and avoid 1 High pressure bleed valve contact with high velocity water stream 3 Slowly open the high pressure bleed valve allowing any pressurized water to escape 4 Install Water System Pressure Gauge TOR4005 into port in water valve housing as shown Figure 19 1 Water system pressure gauge TOR4005 5 Disconnect wire harness connection 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 c
129. r is on lead in portion of cam approximately one inch slightly less than 1 2 turn of coupler from cam lobe If dial indicator shows no lifting of valve loosen four 4 capscrews holding gear case to valve body Remove one shim from both front and rear then tighten capscrews Repeat this procedure until some opening of valve occurs on lead in portion to make sure cam follower touches cam 7 Zero dial indicator again with cam follower completely off the cam Rotate coupling moving cam toward cam follower and continue to rotate until cam follower is on lead in portion of cam approximately one inch from cam lobe Record amount of valve lift IMPORTANT Make sure shims on both front and rear side are the same thickness Using different thicknesses can cause gear case damage 8 Add shims equal to or greater by 0 002 inch to amount measured For example if 0 015 is measured while follower is on lead in portion of cam add a 0 015 shim If 0 009 is measured add 0 010 shim two 0 005 shims and retighten capscrews NOTE If more than a multiple of 0 005 shims are required it is recommended that procedure be done in two steps for example if 0 023 is indicated add 0 02 shim four 0 005 shims first then repeat procedure IMPORTANT Clearances greater than 0 002 in will cause high contact stresses and rapid cam wear 9 Check proper function of cam by again zeroing dial indicator with cam away from cam follower Rotate couplin
130. r no fuel Correction Connect wire Connect wire Replace diode Find problem and correct see Chapter 3 Engine Engine cranks but should not with traction bail in neutral See Safety Interlock System Prob lems Engine starts but shuts down when ignition key switch is re leased to RUN position Not electrical regulate choke dur ing cold start up Not electrical low engine oil pres sure pressure switch faulty Loose or broken wire in oil pres sure switch circuit Normal condition Find and correct cause of low en gine oil pressure Test switch and replace if faulty Check all wiring and connections and repair as necessary Starter does not disengage when key switch is released to RUN po sition Ignition switch faulty Short in start circuit wiring Diode in wire harness faulty Start relay faulty Starter solenoid faulty Starter failed mechanical Test ignition key switch and re place if faulty Check all wiring and connections and repair as necessary Replace diode Test start relay and replace if nec essary Test starter solenoid and replace if necessary Test starter and replace if neces sary Troubleshooting Page 5 10 3000 General Run and Transport Problems Condition Engine shuts down during trans port or when idling not in Aerate mode Possible Cause Not electrical
131. raight 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 the port and tighten 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 far as possible Step 1 5 Install the fitting into the port and tighten finger tight until the washer contacts the face of the port Step 2 6 To put the fitting in the desired position unscrew it by the required amount but no more than one full turn Step 3 7 Hold the fitting in the desired position with a wrench and turn the jam nut with another wrench to the correct flats
132. ribed in this manual If major repairs are ever needed or assistance is desired contact an Authorized Toro Dis tributor To ensure optimum performance and safety al ways purchase genuine TORO replacement parts and accessories to keep the Toro all TORO NEVER USE WILL FIT REPLACEMENT PARTS AND ACCESSO RIES 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 Safety Safety and Instruction Decals The following decals are installed on the machine If any become damaged or illegible replace it The decal part num ber is listed below and in your parts catalog Replacement can be ordered from your Authorized Toro Distributor For eign language decal sets are also available from your Authorized Toro Distributor 8 Lock AWARNING HIGH PRESSURE WATER SYSTEM COMPONENTS CAUSE HIGH PRESSURE WATER SYSTEM COMPONENTS CAN CAUSE PERSONAL INJURY IF DISASSEMBLED PERSONAL INJURY IF DISASSEMBLED INGORREGTLY HOT i INCORRECTLY DISCHARGE ALL WATER PRESSURE AT BLEED VALVE BEFORE PARKING SURFACES BEFORE ATTEMPTING ANY WATER SYSTEM DISASSEMBLING ANY FASTENER OR PLUG FROM THIS BRAKE AVOID CONTACT WITH HIGH VELOGITY WATER STREAM SEE OPERATOR S MANUAL FOR COMPLETE PROCEDURES idiin COMPONENT SEE OPERATOR S MANUAL FOR COMPLETE PROCEDURES UNLOC
133. t Ib 3000 Top of pump when installed in machine Torque to 15 to 35 ft lb Figure 22 1 Check valve plug 2 O ring 3 Check valve spring 4 Check ball 5 Pump end cap Torque to 7 to 10 ft lb Top of pump when installed in machine Figure 23 1 Bypass valve 2 Back up ring 3 O ring 4 Pump end cap Page 4 17 Repairs Charge Pump Service Fig 24 1 Use a 5 mm internal hex wrench to remove the two 2 screws holding charge pump cover to pump end cap NOTE Charge pump rotation is determined by orienta tion of charge pump cover on pump end cap Cast boss on charge pump cover indicates orientation Note orien tation of cast boss before removing charge pump cover 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 wear damage or foreign material Inspect charge relief valve seat in end cap for damage or foreign material 6 Before installing charge pump apply a small amount of petroleum jelly to inside diameter outside diameter and slide faces of gerotor assembly 7 Install charge relief ball and 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 screws and tighten to a
134. tch Pressure Gauge Hydroject 4000 Engine driven water pump Accumulator charge pressure switch 5000 psi relief valve Rollers Hydrostatic drive Boost Pump Boost pump relief valve 25 micron pre filter Addendum Page8 6 Rev B Hydroject 4000 EQUIPMENT OPERATION AND SERVICE HISTORY REPORT for HYDROECT 9 4000 TORO Model and Serial Number Engine Numbers Transmission Numbers Drive Axle s Numbers Date Purchased Purchased From Contacts Parts Service Sales Hydroject 4000 Page8 7 Rev B Warranty Expires Phone Phone Phone Addendum Hydroject 4000 Maintenance Schedule Maintenance Procedure Maintenance Interval amp Service Every Ever Check Battery Fluid Level E SOULS 400hrs Check Battery Cable Connections Lubricate All Grease Fittings A Service Change Engine Change Engine Oil Filter Change Engine Pre cleaner Air Filter B Service Replace Air Filter Element Replace Fuel Filter Adjust Water System Cam Valve Clearance Clean Engine Crankcase Breather Change Gear Case Oil Change Pump Case Oil C Service Service Accumulator Service Injector Nozzles and Springs Replace Spark Plugs Decarbon Combustion Chambers Torque Head and Adjust Valves Check Engine RPM idle and full throttle Initial break in at 25 hours Initial break in at 50 hours Repl Moving H
135. te the skin and cause physical harm Use extreme caution and wear protective goggles and gloves when working with high pressure air Get prompt medical attention if an injury occurs 5 Let compressed air flow through the machine for 3 minutes While compressed air is flowing temporarily open the spray wash and high pressure drain valve purging water from the spray wash and high pressure system 6 Disconnect compressed air and reducers Reinstall the drive shield previously removed and tighten the re lief valve tube 7 Remove and drain the water filter container Install new filter and replace the filter container Engine 1 Drain the engine oil from the oil pan and replace the drain cap General Information Page6 36 Rev B 2 Remove and discard the oil filter Install a new filter 3 Refill the engine with 3 qts of recommended SAE 30 wt motor oil 4 Start the engine and run at idle speed for two min utes DO NOT RUN LONGER THAN TWO MINUTES 5 Stop the engine remove the spark plugs 6 Pour one ounce of clean engine oil into spark plug holes 7 With the spark plugs removed crank the engine with the starter for a least 12 revolutions to distribute oil in the cylinders 8 Reinstall spark plugs 9 Drain the gasoline from the fuel tank and fuel lines Reinstall all lines and secure all connections 10 Thoroughly clean and service the air cleaner 11 Check the oil filler cap and fuel tank cap to e
136. tem 4 Install end seal and back up ring in groove of top end cap Item 12 so O ring is toward the piston Apply Never Seez or equivalent to threads of end cap Carefully install end cap and tighten to a torque of 125 ft Ibs 18 Install gas valve Item 3 using a new O ring Item 4 19 Install accumulator onto water valve housing see Accumulator Replacement 20 Charge accumulator gas chamber with dry Nitrogen see TEST NO 1 Accumulator Pre Charge Pressure Test Adding Dry Nitrogen 13 Apply Never Seez Torque to 125 ft Ib Apply special grease to piston ES 8 and cylinder bore Apply Never Seez Torque to 125 ft Ib 278 10 Figure 46 Repairs General Information Storage Itis very importantthat the water system be drained to avoid freezing and damaging the components Drain system as follows 1 Stop engine remove key from ignition switch and remove wires from spark plugs 2 Remove 2 screws securing drive shield to frame and remove shield 3 With the engine OFF and key removed from igni tion rotate the drive coupling by hand until resistance is felt Continue to rotate the coupling about 1 4 revolution opening the cycling valve 4 Using the appropriate reducers National Pipe thread connect a source of compressed air maximum pressure 150 psi minimum pressure 90 psi to the wa ter inlets on either side of machine DANGER Compressed air can penetra
137. ter pin Correct end play of adjusted assembly is 0 002 to 0 005 inches 11 Put a coating of grease on inside of dust cap and install dust cap on end of wheel spindle Repairs Page7 4 35 3130 2 28 Figure 3 3000 Chapter 8 Hydroject 4000 Addendum Table of Contents SAFETY AND INSTRUCTION DECALS 2 WATER SYSTEM DIAGRAM 13 SPECIFICATIONS 3 SERVICE AND REPAIRS 14 MAINTENANCE SCHEDULE 7 Boost Pump Belt Adjustment 14 ELECTRICAL SCHEMATIC 11 NOTE See other sections of this manual for service in formation common to the Hydroject 3000 and 4000 See the Hydroject 4000 Operator s Manual for Operation and Maintenance information Hydroject 4000 Page8 1 Rev B Addendum Safety and Instruction Decals A WARNING HIGH PRESSURE WATER SYSTEM COMPONENTS CAN CAUSE PERSONAL INJURY IF DISASSEMBLED INCORRECTLY DISCHARGE ALL WATER PRESSURE AT BLEED VALVE BEFORE DISASSEMBLING ANY FASTENER OR PLUG FROM THIS COMPONENT SEE OPERATOR S MANUAL FOR COMPLETE PROCEDURES On Drive Shaft Shield Part No 80 8000 On Drive Shaft Guard Part No 80 8040 ROTATING MEMBERS 74 kn On Muffler Shield 3 Part No 80 8290 CHANGE WATER PUMP CRANKCASE OIL AFTER THE INITIAL 25 HOURS OF OPERATION USE ONLY
138. termine which component is at fault How ever this section will define given components and the tests that can be performed on those components when those parts are disconnected from the electrical system For accurate resistance and or continuity checks elec trically disconnect the component being tested from the circuit Verify Safety Interlock System Operation The safety interlock system prevents the engine from cranking or starting unless traction bail is in NEUTRAL and prevents the water system from engaging if ma chine is in the transport raised position It also stops aeration if traction bail is released while operating or if machine is raised to the transport position A CAUTION The interlock switches are for the operator s protection so 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 Re gardless 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 corrected If engine does not crank go
139. the plates are covered and then charge the battery After charging fill the battery to the proper level A CAUTION Do not charge a frozen battery because it can explode and cause injury Let the battery warm to 60 F 15 5 C before connecting to a charger 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 bat tery posts Repairs 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 F 17 C 110 min Reserve Capacity at 80 27 C Figure 23 1 Positive terminal 2 Negative terminal ju FILLER CAPS Wi CORRECT WATER LEVEL Page 5 26 Figure 24 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 exten sion 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 tig
140. ths and Nozzle Configurations nozzles are identified with numbers indicating the drill size ofthe orifice The standard configuration is 11 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 be low IMPORTANT Use only nozzle configurations shown or damage to the machine may occur NOZZLE SIZE AND APPROXIMATE DEPTH CHART Decimal Size Metric Size Quantity of Nozzles Approx inch mm Open Blocked Depth 86 8130 Aluminum Washer is required with any nozzle change S N 29999 amp Below Part no 80 6680 S N 30001 amp Up Part no 86 8150 OPTIONAL STAGGERED SIZE NOZZLE CONFIGURATION Decimal Size Metric Size Quantity of Nozzles Approx ET mm EIE Blocked Depth 86 8130 Gand 0 _ IE mE M AM ME EE 22 Aluminum Washer is required with any nozzle change S N 29999 amp Below Part no 80 6680 S N 30001 amp Up Part no 86 8150 Additional nozzles be blocked to compensate for pump wear Hydroject 3000 Page 6 2 1 Rev B Specifications Check Valve M OPEN NOZZLE 60 16 CLOSED BLOCKED NOZZLE S N 29999 amp Below Aluminum washer P N 80 6680 is required with any nozzle change Check Valve Ball LA Check Valve Ball SS
141. tinuity 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 5 Ohms 5 at 20 68 F HydroJect 3000 Page5 25 Rev B Figure 21 1 Pump clutch Figure 22 1 Valve clutch 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 clear water Do not get the soda solution into the battery because damage to the battery will result Coatthe battery posts and cable connectors with skin over grease or petroleum jelly to prevent corrosion Check for loose battery hold downs Aloose 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 level is low but above the plates inside the battery add water so the levelis to the bottom of the cap tubes If the level is below the plates add water only until
142. ture content Plugged nozzles worn nozzles or improper nozzle configuration NOTE Check operation of nozzles by aerating over a piece of cardboard then inspecting cardboard Gear or cam damage in gear case Leak in high pressure water sys tem With engine OFF and water supp ly connected open high pressure bleed valve and bleed air out of system If hole depth was satisfactory before in another area different nozzle configuration may be re quired Stop engine open high pressure bleed valve then inspect noz zles Check for plugged nozzles Verify size and quantity see Noz zle Size and Approximate Depth Chart Nozzles that are too large will cause loss in pressure and could cause damage to the ac cumulator and other water sys tem components Inspect gear case for gear or cam damage and repair as neces sary Check for leaks with water sys tem 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 exit ing from shim area below gear case indicates valve wear or damage Do water system tests and make repairs as necessary Troubleshooting Page 6 10 HydroJect 3000 Condition Machine aerates but aeration hole depth is shallow or inconsis tent continued Possible Cause Low accumulator pre charge or damaged accumulator TEST NO
143. uarts Equivalent Hydraulic Oils interchangeable Shell Tellus 68 Amoco Rykon Oil 68 Conoco Super Hydraulic Oil 68 Exxon Nuto H 68 Kendall Kenoil R amp O AW 68 Pennzoil Penreco 68 Phillips Magnus A 68 Standard Energol HLP 68 Sun Sunvis 831 WR Union Unax AW 68 Chevron AW Hydraulic Oil 68 Figure 1 1 Sight gauge 2 Fill plug 3 Breather Specifications Page 4 2 HydroJect 3000 General Information Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather sun chemicals very warm storage condi tions or mishandling during operation or maintenance These conditions can cause damage or premature de terioration Some hoses such as reel motor hoses are more susceptible to these conditions than others spect the hoses frequently for signs of deterioration or damage When replacing a hydraulic hose be sure that the hose is straight not twisted before tightening the fittings This can be done by observing the imprint on the hose Use two wrenches one to hold the hose straight and one to tighten the hose swivel nut onto the fitting Hydraulic Fitting Installation O Ring Face Seal Fig 2 3 1 Make sure both threads and 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
144. until traction wheel rotates at 20 22 RPM Tighten jam nuts Adjustments Page 4 12 Figure 14 1 Neutral adjustment cam 2 Locknut 3 Switch tab Figure 15 1 Speed control lever 2 Lower speed rod 3 Upper speed rod HydroJect 3000 Traction Pump 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 be tween pulleys with 3 Ib 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 Figure 16 C Loose three 3 capscrews securing pulley guard bracket Fig 20 Item 21 to control panel and pump 1 Traction pump belt support D Usea 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 17 1 Adjusting nut 2 Pivot nut HydroJect 3000 Page 4 13 Rev Adjustments Repairs Traction 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 Coupling Removal
145. w 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 6 5 Special Tools Valve Lift Indicator TOR4007 Fig 7 A special dial indicator and adaptor is temporarily in stalled 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 deter mines correct shim size to get proper valve lift Figure 7 Valve Spring Compressor TOR4008 Fig 8 The valve spring compressor and hardware is used for compressing the water valve 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 8 Special Tools Page 6 6 HydroJect 3000 Seal Installation Tools Fig 9 Water Valve Seal Installation Guide TOR4009 The Water Valve Installation Guide small is needed to properly install the water valve seal into the water valve 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
146. y interlock switches by passed they must be reconnected for proper trou bleshooting and safety Condition Engine fails to crank regardless of traction bail position Possible Cause Loose or corroded battery connec tions Low battery charge Circuit breaker open Ignition key switch faulty Neutral switch faulty Start relay faulty Starter solenoid faulty Starter is faulty Engine is seized Loose or damaged wiring Correction 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 Prob lems Reset circuit breaker Find cause for open circuit breaker and cor rect Replace circuit breaker if faulty Test switch and replace if faulty Make sure switch is properly in stalled and adjusted 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 3000 5 9 Troubleshooting Starting Problems continued Condition Engine cranks but does not start NOTE If engine cranks cause of problem is UNRELATED to inter lock system Possible Cause Engine or rectifier plug loose terminal on ignition key switch loose Diode in wire harness faulty Engine problem o

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Hydroject ® 3000/4000