Toro 91764SL - Manuals

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 a...

3 3 3 4 Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . 1 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS 2 Capscrew Markings and Torque Values – U.S. . . . . . . . . . . . . . Decim...

Equivalents and Conversions Product Records and Maintenance Page 2 – 2 Hydroject 3000

Torque Specifications Page 2 – 3 Hydroject 3000 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 Iubricated are the s...

_____________________________ _____________________________ EQUIPMENT OPERATION AND SERVICE HISTORY REPORT for HYDROJECT R 3000 TORO Model and Serial Number: ______________–______________ Engine Numbers: _____________________________ Transmission Numbers: _____________________________ Drive Axle(s) ...

Hydroject 3000 Maintenance Schedule Minimum Recommended Maintenance Intervals Maintenance Procedure Check Battery Fluid Level Check Battery Cable Connections Lubricate All Grease Fittings { Change Engine Oil { Change Engine Oil Filter Change Engine Pre–cleaner (Air Filter) Replace Air Filter Element...

Hydroject 3000 Daily Maintenance Check List Maintenance Check Item b Daily Maintenance Check For Week Of _________________ MON TUES WED THURS FRI SAT SUN n Safety Interlock Operation n Brake Operation n Engine Oil Level n Engine Air Filter Pre–Cleaner n Engine Cooling FIns for Debris n Unusual Engin...

________________________________ _______________________________ _______________________________ ________________________________ _______________________________ _______________________________ _______________________________ _______________________________ _______________________________ __________...

___________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________________________ _______________________________________________________...

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...

Chapter 4 Hydraulic System Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . 3 Hydraulic Hose and Fitting Information . . . . . . . . 3Pushing or Towing . . . . . . . . . . . . . . . . . . . . . . . . 5 HY...

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 condi­tions or mishandling during operation or maintenance. These conditions can cause damage or premature...

Hydraulic Diagram Input Val Di ir Val Cooling Pump Charge Check Valves By-pass ve Wheel Motor Variable sp. Pump Reservo(Gear Case) Inlet Filter Charge Relief ve Orifice Charge (Belt Drive) Variable Displacement Pump Figure 8 Hydraulic Diagram Page 4 - 6 HydroJect ™ 3000

Special Tools NOTE: Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS) . S o m e t o o l s m a y b e l i s t e d i n t h e HydroJect 3000 Parts Catalog. Some tools may also be available from a local supplier. Hydraulic Tester - With Pressure and Flow Capabil...

__________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________________________ ________________________________________________________...

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.) oil. Failure to use gauges with the recomm...

Hydraulic Tests (Fig. 10, 11) 1. Make sure hydraulic oil is at normal operating tem­perature by operating the machine for approximately 10 minutes. 2. Engage parking brake and stop the engine. Make sure parking brake is properly adjusted before perform­ing hydraulic tests. 3. With engine off, discon...

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...

24 5 26 27 28 29 22 23 25 6 7 8 9 10 21 35 36 37 38 39 11 12 13 14 15 16 17 18 19 20 1 2 3 4 40 34 33 31 32 30 4 3 2 1 Figure 25 Disassembly of Hydraulic Pump 1. Before performing major repairs on the pump, remove external components as described in previous proce­dures. These include the following:...

14. Remove pump shaft (Item 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...

Chapter 5 Electrical System Table of Contents WIRING SCHEMATICS AND DIAGRAMS . . . . . . . . 2 Logic Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Controller lights . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 Wiring Schematic . . . . . . . . . . . . . . . . . . . . . . ...

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

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 yello...

Electrical Schematic (Model 09800) Figure 1 HydroJect 3000 Page 5 - 3 Wiring Schematics and Diagrams

Wiring Diagram – Main (Model 09800) Figure 2 Wiring Schematics and Diagrams Page 5 - 4 HydroJect 3000

Wiring Diagram – Control Panel (Model 09800) Figure 4 HydroJect 3000 Page 5 - 5 Wiring Schematics and Diagrams

Wiring Diagram – Tiller (Model 09800) Figure 3 Wiring Schematics and Diagrams Page 5 - 6 HydroJect 3000

Skin-Over Grease (Fig. 7) Special non-conductive grease which forms a light pro­tective skin to help waterproof electrical switches and contacts. Toro P/N 505-47 8 oz. (.24 L) can Figure 7 Special Tools Page 5 - 8 Rev. B HydroJect 3000

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

___________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________________________ _______________________________________________________...

__________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________________________ General Run and Transport Problems (continued) Condition...

___________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________________________ _______________________________________________________...

___________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________________________ _______________________________________________________...

__________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________________________ Safety Interlock System Problems (continued) Condition P...

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 sche­matics, determine which component is at fault. How­ever, this section will define given components, and the tests that can be perf...

Relays (Fig. 19, 20) To test a relay, disconnect the relay wire connector and install a continuity tester between the relay terminals (terminals 30 and 87). The relay should make and break continuity at terminals 30 and 87 as 12 V.D.C. is con­nected and disconnected to terminal 85 with terminal 86 c...

Neutral and Transport Switch Replacement and Adjustment (Fig. 25) 1. Disconnect wires from switch terminals. 2. Have a helper push traction bail down into either FORWARD or REVERSE position or disconnect exten­sion spring; this will take switch arm tension off of switch. Loosen two (2) screws and re...

Chapter 6 Water System Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Nozzle Size and Approximate Depth Chart . . . . . 2 WATER SYSTEM SCHEMATIC . . . . . . . . . . . . . . . . 3SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Accumulator ...

Depths and Nozzle Configurations: All nozzles are identified with numbers indicating 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 ...

60 ft–lb OPEN NOZZLE CLOSED (BLOCKED) NOZZLE Tighten to S/N 29999 & Below Aluminum washer (P/N 80–6680) is required with any nozzle change. CLOSED (BLOCKED) NOZZLE OPEN NOZZLE Spring Spring 70 – 80 ft–lb S/N 30001 & Up Aluminum washer (P/N 86–8150) is required with any nozzle change. Check V...

Water System Schematic Model 09800 QUICK COUPLER ENGINE ELECTRIC CLUTCH PUMP ELECTRIC BRAKE CLUTCH PRESSURE SWITCH 20 PSI – ON 10 PSI – OFF PRESSURE GAUGE 2500 PSI NITROGEN PRE–CHARGE 5000 PSI GEARBOX CAM HIGH PRESSURE NOZZLES NOZZLES PRESSURE REDUCING Model 09801 WATER SUPPLY WATER SPRAY WASH VALVE...

1 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 body. Use Insertion Mandril with this seal guide. Pump Seal Installation Guide - TOR4010 The Pump Seal I...

___________________________________________________________________________________________ ________________________________________________________________________________________________________________________ ________________________________ ______________________________________________________...

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 ac­cumulator. If you perform water system tes...

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 ...

TEST NO. 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 rap...

Pump Drive Belt Replacement (Fig. 31, 32) 1. Park the machine on a level surface, engage the parking brake, open 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. ...

Water Filter Replacement (Fig. 33, 34) When pump inlet pressure decreases or the water sys­tem 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 th...

Water Pump Head Service (Fig. 36) The three major wear components in the high pressure pump that require maintenance include: the check val­ves, plunger sleeves, and plunger seals. These com­ponents will require maintenance after approx. 500 pump operating hours (approx 750 engine hours). j High pre...

Water Pump Crankcase Service (Model 09800 ) (Fig. 38a) 31 32 33 1 2 3 5 6 7 8 9 10 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 11 12 13 14 15 1 4 10 13 14 6 34 35 8 ft–lb Loctite 271 10 ft–lb 10 ft–lb Apply grease to O.D. of plunger before installingpump head 18 ft–lb Figure 38a NOTE: Replace parts...

Hydroject 3000 Page 6 – 26.1 Repairs Rev. B Water Pump Crankcase Service (Model 09801 ) (Fig. 38b) 1 2 3 4 5 6 7 8 9 22 15 18 19 20 21 23 24 25 26 27 28 29 10 11 12 13 14 7 8 14 13 22 10 17 16 10 Apply grease toO.D. of plungerbefore installingpump head 18 – 20 ft–lb 18 – 20 ft–lb 18 – 20 ft–lb Figur...

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 con­nected 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...

2 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 ...

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 (TOR4003) into the top cap (Item 12) of the accumulator. Hold the ac­cumulator cylinder (Item 6) stationary using a strap or ch...

General Information Storage It is very important that 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 ...

Chapter 7 Wheels, Brakes and Steering Table of Contents ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 2 Brake Service . . . . . . . . ....

Chapter 8 Hydroject r 4000 Addendum Table of Contents SAFETY AND INSTRUCTION DECALS . . . . . . . . . . 2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . 7 ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . ....

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 o...

Hydroject 4000 Maintenance Schedule Maintenance Procedure Check Battery Fluid Level Check Battery Cable Connections Lubricate All Grease Fittings { Change Engine Oil { Change Engine Oil Filter Change Engine Pre–cleaner (Air Filter) Replace Air Filter Element Replace Fuel Filter Clean Engine Crankcas...

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 Check Item b Daily Maintenance Check For Week Of _________________ MON TUES WED THURS FRI SAT SUN n Engine Oil Level n E...

________________________________ _______________________________ _______________________________ _______________________________ _______________________________ _______________________________ _______________________________ _______________________________ _______________________________ ___________...

Controller Lights Lights (LED’s) on the controller indicate when the follow-ing inputs are made to the controller: Red: Light comes on after pump inlet pressure of 20 psi is attained. Green: Aerate start (engage) switch closed. If red and yellow lights are on, green light will stay on until either r...

Water System Diagram HIGH PRESSURE 5 MICRON 70–90 PSI QUICK COUPLER PRESSURE GAUGE PRESSURE SWITCH 20 PSI – ON 10 PSI – OFF ELECTRIC CLUTCH 5000 PSI 2500 PSI NITROGEN PRE–CHARGE ELECTRIC BRAKE CLUTCH AERATION NOZZLES FILTER RELIEF VALVE WATER PUMP RELIEF VALVE ACCUMULATOR WATER VALVE WATER SUPPLY 0–...

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 pull...