Page 3 - Table Of Contents; Chapter 2 - Product Records and Manuals
Table Of Contents Chapter 1 - Safety Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1 Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 - 4 Chapter 2 - Product Records and Manuals Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1 Equival...
Page 5 - Chapter 1; Table of Contents; Before Operating; The Toro Company; CAUTION; Safety
Chapter 1 Safety Table of Contents SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 1 Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Safety Instructions Although hazard control and ...
Page 6 - While Operating; Never use chemicals in the water supply system.; Watch for holes or other hidden hazards.; Maintenance
8. Fill fuel tank with gasoline before starting the en-gine. Avoid spilling gasoline. Since gasoline is flam-mable, handle it carefully. A. Use an approved gasoline container. B. Do not fill tank while engine is hot or running. C. Do not smoke while handling gasoline. D. Fill fuel tank outdoors and ...
Page 8 - Safety and Instruction Decals; IMPORTANT
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...
Page 9 - Chapter 2; Product Records and Maintenance
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...
Page 10 - Equivalents and Conversions
Equivalents and Conversions Product Records and Maintenance Page 2 – 2 Hydroject 3000
Page 11 - Torque Specifications
Torque Specifications Page 2 – 3 Hydroject 3000 Product Records and Maintenance
Page 12 - Lubrication; Pump grease into the bearing or bushing.; Figure 1
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...
Page 13 - Transmission Numbers:
_____________________________ _____________________________ EQUIPMENT OPERATION AND SERVICE HISTORY REPORT for HYDROJECT R 3000 TORO Model and Serial Number: ______________–______________ Engine Numbers: _____________________________ Transmission Numbers: _____________________________ Drive Axle(s) ...
Page 14 - Hydroject 3000 Maintenance Schedule; Minimum Recommended Maintenance Intervals; Annual Recommendations:
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...
Page 15 - Hydroject 3000 Daily Maintenance Check List
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...
Page 16 - Hydroject 3000 Supervisor Maintenance W; A, B and C – Service Required; Other –
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Page 17 - Chapter 3; Engine; Specifications
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Page 18 - Repairs
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...
Page 19 - Chapter 4; Hydraulic System
Chapter 4 Hydraulic System Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . 3 Hydraulic Hose and Fitting Information . . . . . . . . 3Pushing or Towing . . . . . . . . . . . . . . . . . . . . . . . . 5 HY...
Page 21 - Hydraulic Hoses; General Information
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...
Page 24 - Hydraulic Diagram
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
Page 25 - TORO SPECIAL; Special Tools
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...
Page 26 - Troubleshooting; Transmission Operates in One Direction Only; Cause
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Page 27 - Before Performing Hydraulic Tests; WARNING; Testing
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...
Page 28 - TEST C: Traction Motor Efficiency
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...
Page 29 - Adjustments
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...
Page 37 - Disassembly of Hydraulic Pump
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:...
Page 38 - Inspection and Replacement of Pump Parts
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...
Page 45 - Chapter 5; Electrical System; Neutral Switch and Pump Switch
Chapter 5 Electrical System Table of Contents WIRING SCHEMATICS AND DIAGRAMS . . . . . . . . 2 Logic Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Controller lights . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 Wiring Schematic . . . . . . . . . . . . . . . . . . . . . . ...
Page 46 - Logic Chart; SWITCHES; Wiring Schematics and Diagrams
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...
Page 47 - Controller Lights; and yellow lights are on, green light will stay on until; Yellow: Pump start limit switch closed (machine; lowered to aerate position) and water pressure
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...
Page 49 - Electrical Schematic
Electrical Schematic (Model 09800) Figure 1 HydroJect 3000 Page 5 - 3 Wiring Schematics and Diagrams
Page 50 - Wiring Diagram – Main
Wiring Diagram – Main (Model 09800) Figure 2 Wiring Schematics and Diagrams Page 5 - 4 HydroJect 3000
Page 51 - Wiring Diagram – Control Panel; Figure 4
Wiring Diagram – Control Panel (Model 09800) Figure 4 HydroJect 3000 Page 5 - 5 Wiring Schematics and Diagrams
Page 52 - Wiring Diagram – Tiller; Figure 3
Wiring Diagram – Tiller (Model 09800) Figure 3 Wiring Schematics and Diagrams Page 5 - 6 HydroJect 3000
Page 58 - Figure 7
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
Page 59 - Condition
___________________________________________________________________________________________ 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 ...
Page 61 - General Run and Transport Problems
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Page 62 - General Run and Transport Problems (continued)
__________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________________________ General Run and Transport Problems (continued) Condition...
Page 63 - Aerate Operation Problems
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Page 65 - Safety Interlock System Problems
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Page 66 - Safety Interlock System Problems (continued)
__________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________________________ Safety Interlock System Problems (continued) Condition P...
Page 67 - so; To do a functional check of interlock system:
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...
Page 74 - Battery
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...
Page 77 - Neutral and Transport Switch Replacement and Adjustment (Fig. 25)
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...
Page 81 - Chapter 6; Water System; Accumulator Charging Valve
Chapter 6 Water System Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Nozzle Size and Approximate Depth Chart . . . . . 2 WATER SYSTEM SCHEMATIC . . . . . . . . . . . . . . . . 3SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Accumulator ...
Page 83 - NOZZLE SIZE AND APPROXIMATE DEPTH CHART; Use only with varied size configurations; OPTIONAL STAGGERED SIZE NOZZLE CONFIGURATION; Aluminum Washer is required with any nozzle change:
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 ...
Page 84 - Tighten to; Tighten nut to
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...
Page 85 - Water System Schematic
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...
Page 89 - Figure 9
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...
Page 91 - Troubleshooting Water System Problems
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Page 94 - Before Performing Water System Tests
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...
Page 95 - of the water system.; in a; DANGER
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 ...
Page 99 - Remove belt guard to expose the drive shaft.
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...
Page 103 - Disconnect electrical connectors for both clutches.
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. ...
Page 104 - Rinse out filter body and insert a new filter.
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...
Page 106 - Pump Head Removal
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...
Page 108 - Water Pump Crankcase Service; Install pulley with tapered hub onto pump drive shaft.
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...
Page 109 - Install pulley with tapered hub onto pump drive shaft.
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...
Page 114 - The gear case also serves as the hydraulic oil reservoir.
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...
Page 118 - well ventilated area. It is; Remove protective cover from top of accumulator.
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 ...
Page 119 - Move piston to bottom of accumulator cylinder. Add
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...
Page 120 - Storage; Remove and discard the oil filter. Install a new filter.; Traction Unit; Grease or oil all fittings or pivot points.
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 ...
Page 121 - Chapter 7; Wheels, Brakes and Steering
Chapter 7 Wheels, Brakes and Steering Table of Contents ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 2 Brake Service . . . . . . . . ....
Page 125 - Chapter 8; Hydroject; Addendum
Chapter 8 Hydroject r 4000 Addendum Table of Contents SAFETY AND INSTRUCTION DECALS . . . . . . . . . . 2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . 7 ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . ....
Page 129 - Fluid Recommendations
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...
Page 132 - Hydroject 4000 Maintenance Schedule; Maintenance Procedure
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...
Page 133 - Hydroject 4000 Daily Maintenance Check List; Notation for areas of concern:; Inspection performed
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...
Page 134 - B C D E Other
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Page 136 - Yellow: Light comes on after ignition switch is in; RUN position and accumulator charge pressure
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...
Page 137 - Water System Diagram
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–...
Page 138 - Service and Repairs; Boost Pump Belt Adjustment; Disengage hood latches and open hood.
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...
Page 140 - Commercial Products; © The Toro Company
