QAS Bunker Pump

• Read and understand the contents of this Operator’s Manual and the Sand Pro Operator’s Manual before operating the machine. Become familiar with all of the controls and know how to stop quickly.

• Never allow children to operate the machine. Do not allow adults to operate machine without proper instruction. Only trained operators who have read this manual should operate this machine.

• Never operate the machine when under the influence of drugs or alcohol.

• Keep all bystanders away from the operating area.

• Keep all shields and safety devices in place. If a shield, safety device, or decal is illegible or damaged, repair or replace it before operation is commenced. Also tighten any loose nuts, bolts, and screws to ensure that the machine is in safe operating condition.

• Do not operate the machine while wearing sandals, tennis shoes, sneakers, or shorts. Also, do not wear loose fitting clothing which could get caught in moving parts. Always wear long pants and substantial, slip-resistant footwear. Wearing safety glasses, safety shoes, and a helmet is advisable and required by some local ordinances and insurance regulations.

• Do not operate the engine in a confined space where dangerous carbon monoxide and other exhaust gasses can collect.

• The maximum seating capacity is one person. Never carry passengers.

• Sit on the seat when starting the engine and operating the machine.

• Using the machine demands attention. To prevent loss of control:

  • Operate only in daylight or when there is good artificial light.

  • Drive slowly and watch for holes or other hidden hazards.

  • Use extreme caution when driving into a sand trap, ditch, creek, or other hazard.

  • Reduce your speed when making sharp turns and when turning on hillsides.

  • Avoid sudden starts and stops.

  • Before backing up, look to the rear and ensure that no one is behind the machine.

  • Watch out for traffic when near or crossing roads. Always yield the right-of-way.

• Stay away from the discharge opening when the machine is operating. Keep all bystanders away from the discharge opening and don’t direct discharge toward bystanders.

• If the engine stalls or the machine loses headway and cannot make it to the top of a slope, do not turn the machine around. Always back slowly straight down the slope.

• Do not take an injury risk! When a person or pet appears unexpectedly in or near the operating area, stop operation. Careless operation, combined with terrain angles, ricochets, or improperly positioned guards can lead to thrown object injuries. Do not resume operation until the area is cleared.

• Lightning can cause severe injury or death. If lightning is seen or thunder is heard in the area, do not operate the machine; seek shelter.

• Do not touch the engine or muffler while the engine is running or soon after it is stopped. These areas could be hot enough to cause a burn.

• Remove the key from the ignition switch to prevent accidental starting of the engine when servicing, adjusting, or storing the machine.

• Perform only those maintenance instructions described in this manual. If major repairs are ever needed or assistance is desired, contact an Authorized Toro Distributor.

• To reduce a potential fire hazard, keep the engine free of excessive grease, grass, leaves, and accumulations of dirt. Never wash a warm engine or any electrical parts with water.

• Be sure that the machine is in safe operating condition by keeping nuts, bolts, and screws tight.

• Make sure that all hydraulic line connectors are tight and all hydraulic hoses and lines are in good condition before applying pressure to the system.

• Keep your body and hands away from pin hole leaks in hydraulic lines that eject high pressure hydraulic fluid. Use cardboard or paper to find hydraulic leaks. Hydraulic fluid escaping under pressure can penetrate skin and cause injury. Fluid accidentally injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result.

• Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved by stopping the engine and lowering the pump to the ground.

• If the engine must be running to perform a maintenance adjustment, keep hands, feet, clothing, and other parts of the body away from the fan and other moving parts.

• Do not overspeed the engine by changing the governor settings. To be sure of safety and accuracy, have an Authorized Toro Distributor check the maximum engine speed with a tachometer.

• The engine must be shut off before checking the oil or adding oil to the crankcase.

• To ensure optimum performance and safety, always purchase genuine Toro replacement parts and accessories to keep the machine all Toro. Never use “will-fit” replacement parts and accessories made by other manufacturers. Look for the Toro logo to ensure genuineness. Using unapproved replacement parts and accessories could void the warranty.

Parts needed for this procedure:

1. Remove any attachment from the machines adapter.

2. Move the machine into position behind the attachment adapter.

   Note: Make sure the locking lever (Figure 3) is pivoted to the left (unlocked position) as viewed from the rear of the machine.

   

   Figure 3

   1. Attachment adapter
   2. Locking lever

3. Raise the machine adapter into the attachment adapter.

4. Pivot the locking lever to the right to lock the adapters together.

5. Make sure the engine and the remote hydraulics kit are OFF.

6. Plug the hydraulic hoses into the Sand Pro machine remote hydraulics. Position the hoses in the hose guide (Figure 4). Avoid kinks and sharp bends to the hydraulic hoses.

   

   Figure 4

   1. Hose guide

   Important: Whenever the hydraulic hose couplers are disconnected, make sure the dust plugs are installed to prevent contamination from entering either hydraulic system.

7. During operation the bunker pump hydraulic hoses will displace a small amount of the machine's hydraulic oil. Check the hydraulic oil level in the machine as follows:

   1. Start the machine engine and the remote hydraulics.

   2. Start the bunker pump and allow it to run a few seconds. It does not have to be submerged in water.

   3. Stop the pump, the remote hydraulics and the engine.

   4. Check the hydraulic oil level in the machine and replenish as required. Refer to machine Operator's Manual for hydraulic oil requirements.

1. With the bunker pump mounted and secured on the machine, raise the attachment.

2. Measure the gap between the top washer and the spacer in the link assembly on the attachment adapter as shown in Figure 5.

   Note: Ensure the gap between the washer and the shoulder is between 1.52 to 2.03 mm (0.060 to 0.080 inch).

   

   Figure 5

   1. 1.52 to 2.03 mm (0.060 to 0.080 inch)
   2. Jam nut
   3. Adjustment nut

The discharge nozzle (Figure 6) can be adjusted up and down or from side to side to direct the flow to the desired location.

1. To adjust the flow distance, proceed as follows

   • Rotate the lockup handle (Figure 6) to unlock the pivot tower.

     

     Figure 6

     1. Lockup handle
     2. Discharge nozzle

   • Rotate the pivot tower front or back to the desired position.

   • Tighten the lockup handle.

     Note: When the pump is mounted to the front of the machine, the lockup handle should be removed and reinstalled on the opposite side of the frame.

     Caution

     Do not move the lockup handle to the opposite side of the frame when the pump is mounted to the rear of the machine.

2. To adjust the flow direction, rotate the nozzle handle (Figure 7) to the desired position.

   Note: The resistance on the handle nozzle (Figure 7) may be increased or decreased by adjusting the torque on the large nut on top of the pivot tower.

   

   Figure 7

   1. Nozzle handle

1. Measure the water depth in the lowest part of the bunker. If the water depth is less than 63.5 mm (2–1/2 inches) (halfway up the slots on the pump), dig a 30.5 cm x 30.5 cm x 5 to 7.6 cm (1 ft x 1 ft x 2 to 3 inches) deep hole to lower the pump into the hole (Figure 8).

   

   Figure 8

   1. Water level (63.5 cm (2-1/2 inches))

2. Make sure the pump clamp (Figure 9) and the lockup handle (Figure 10) are secure before commencing operation.

   

   Figure 9

   1. Pump clamp
   

   Figure 10

   1. Lockup handle
   2. Discharge nozzle

3. Check and adjust the pump discharge direction. Refer to Adjusting the Discharge Nozzle.

1. Start the Sand Pro machine and slowly back into the shallowest part of the bunker. Do not drive into water that is deeper than the wheel hubs of the Sand Pro machine (Figure 11).

   

   Figure 11

   Note: If the Sand Pro machine cannot be moved into the desired position, the pump can be removed from the housing and placed into the water. To remove the pump, pivot the pump clamp forward, slide the pump to the rear of the frame and lift the pump out with the handle.

2. Start the remote hydraulics to activate the pump before inserting the pump into the water. This prevents debris from stalling the pump impeller to the housing if debris gets lodged in the pump.

3. Lower the pump into the water.

   Note: If the pump does not start pumping once it is in the water, cycle the remote hydraulics on for 1 second and off for 2 seconds to help the pump prime.

4. Check the flow and redirect as required.

• Make sure nozzle collar is free of debris so it drains properly.

• Do not use the bunker pump in salt water.

Note: If the attachment adapter becomes stuck to the traction unit adapter, insert a pry bar/screwdriver into the pry slot to disengage the parts (Figure 12).

Figure 12

1. Pry slot

If foreign matter gets into the bunker pump, the flow may decrease or stop. If this occurs, the pump will have to be removed from the frame, disassembled, cleaned, reassembled and installed back into the frame.

1. Stop the Sand Pro machine, apply the parking brake and remove the key from the ignition switch.

2. Disconnect the pump hydraulic hoses from the machine. Insert dust caps onto the exposed hydraulic couplers.

3. Release the latches and uncouple the discharge hose from the pump (Figure 13).

   

   Figure 13

   1. Discharge hose
   2. Latch

4. Pivot the pump clamp forward (Figure 14).

   

   Figure 14

   1. Pump clamp

5. Slide the pump to the rear of the frame and lift the pump out with the handle.

   Disassembly (Figure 15)

6. Remove the (5) cover plate mounting screws and remove the cover.

7. Try to turn the impeller to free any debris from the pump impeller and housing. If the debris cannot be freed, proceed to the next step.

8. Remove the (3) screws securing the suction flange and remove the suction flange.

9. Remove the (2) handle screws and remove the handle.

10. Remove the (4) hydraulic motor screws and remove the hydraulic motor cover, gerotor element with drive pin, and the thrust plate.

11. While holding the impeller, unthread the impeller from the shaft using a wrench on the flats at the ball bearing. The thread is a left hand thread that requires opposite rotation for removal.

12. Remove the shaft and bearing assembly by first removing the retaining ring, then apply pressure to slide the shaft and bearing out of the motor side of the pump housing.

13. Remove the (2) lip seals by pushing the seals out through the motor side of the pump body.

    Inspect the pump components

• Clean all foreign material off the parts. Do not use abrasive cleaning methods on the hydraulic parts or shaft.

• Check the motor shaft for wear at the lip seal surface. If it has grooves greater than 0.076 mm (.003 inches) deep, the shaft should be replaced.

• Check the hydraulic motor parts for wear. Any appearance of displaced metal or surface smearing will require replacing all of the motor parts.

• Check the impeller blade surface between the impeller and the suction flange. If the surfaces are severely worn, or the impeller blades are bent, replace each item

• Clean the parts that are to be reused using a solvent or mild cleaner. Remove abrasive material. Cleanliness of the hydraulic motor parts is very important.

Figure 15

1. Cover plate
2. Suction flange
3. Impeller
4. Shaft
5. Pump housing
6. Thrust plate
7. Hydraulic motor
8. Handle

Reassembly (Figure 15)

1. Press the new lip seals into the pump housing using a suitable bushing or socket. A light lubricant may be used to aid the assembly. The proper assembly is to install the seals back to back, installing one seal at a time.

2. Press the new ball bearing onto the shaft by pressing against the inner face of the bearing until it is seated against the shaft shoulder. The first lip seal should be installed open face down and flat side facing out. The second lip seal should be installed flat side in.

3. Lubricate the impeller side of the shaft with oil. Push the shaft/bearing into the body using care to align the shaft at the center of the lip seal until it is at the bottom of the shoulder in the body. Install the snap ring to secure the shaft assembly.

4. Secure the shaft with a wrench on the flats of the shaft and thread the impeller onto the shaft (note left hand thread). Tighten the impeller until it shoulders onto the shaft.

5. Place new quad rings onto the thrust plate. Use a small amount of grease to hold the quad rings from moving out of position. Place the thrust plate over the shaft with the kidney slot up away from the bearing. Kidney should be on the pressure side of the motor.

6. Place the drive pin onto the shaft slot and hold it in position with a screwdriver while sliding the gerotor over the shaft and stopping at the thrust plate. Line up the gerotor and thrust plate.

7. Install the cover onto the shaft; some sideways movement of the gerotor is necessary. The dowel pins should go through the thrust plate and into the body. Do not force this assembly by using a hammer or press, it will slide together when it is in position.

8. Install the four motor cover screws and torque to 23.0 N-m (17 ft-lb) in a cross pattern with the first torque at 13.6 N-m (10 ft-lb).

9. Install the suction flange and screws.

10. Install the handle and screws.

11. Check for free rotation by rotating the impeller by hand. If it does not rotate, remove the motor cover, clean the motor parts, and reassemble. Dust and dirt granules will impede motor rotation.

12. Install the cover plate using five screws and lockwashers.

13. Insert the pump into the frame and slide it forward until the keeper tab fits into the slots of the pump (Figure 16).

    

    Figure 16

    1. Keeper tab

14. Pivot the pump clamp rearward onto the pump (Figure 14).

15. Couple the discharge hose to the pump and secure the latches (Figure 13).

16. Connect the hydraulic hoses to the machine.

Checking the Nozzle Sleeve

The nozzle sleeve (Figure 17) in the handle assembly is slotted to allow water and debris to drain without back flowing into the hose. Make sure the slot and hole are free of debris.

Figure 17

1. Nozzle sleeve
2. Slot
3. Hole

Greasing the Attachment Adapter

If the locking lever on the attachment adapter does not pivot freely and easily, apply a light coat of grease to the area shown in Figure 18.

Figure 18