Toro Hydroject 3000 User manual

Commercial Products

Hydroject®

3000/4000

Troubleshooting Guide

PART NO.97928SL, Rev. A

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TORO®Hydroject®3000/4000 1

Table of Contents

Troubleshooting

•Product Overview....................................................................................................................2

•Components............................................................................................................................6

•Water System Operation......................................................................................................48

•Water System Testing ..........................................................................................................58

•Unit Storage...........................................................................................................................78

•Maintenance Chart................................................................................................................80

Use of This Manual

The information contained in this manual is supplementary to material found in other sources,

it is not a replacement for them. You should always consult Service Manuals, Service

Bulletins, Operator’s Manuals and Parts Books when necessary.

Service Manual Updates and Service Bulletins can be found on the internet at:

www.toro.com/golf/custsvc.html

This Manual and the training program, which it supports, are both designed to help you gain

knowledge of the product, and to inform you of when and why to make the necessary repairs.

We have also included tips for performing those repairs.

This program is designed for you. Your input and participation is appreciated.

There is plenty of space in this manual for you to add your own notes and observations

Overview TORO Hydroject® 3000/40002

TORO Hydroject® 3000/4000 Overview

NOTES

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3

The Hydroject® is a patented machine that aerates the ground with “water jets”.

These jets are pulses of high velocity water, released at regular intervals.

For this machine to operate properly, the owner or operator should understand the individual components and

their relationship to the complete system.

The Hydroject® 3000 is a hydrostatic driven walk aerator. The unit needs to be connected to a clean water

supply to aerate.

The Hydroject® 4000 is a pull behind aerator. The higher transport speeds make the 4000 suitable for tees and

problem areas on the fairway. The Hydroject® 4000 usually gets its water from a tank on the towing vehicle.

Overview TORO Hydroject® 3000/40004

2 cylinder Onan Engine

Quick Coupler

5 Micron inlet Filter

Pressure Switch

Pressure Gauge

Engine driven water pump

Accumulator

Accumulator charge pressure switch

5000 psi relief valve

Cycling valve (water valve)

Rollers

Roller washer

High pressure aeration nozzles

Drain valve

Hydrostatic drive

Boost Pump

Boost pump relief valve

25 micron pre-filter

Hydroject 3000 Hydroject 4000Comparison

Regulator Valve

TORO Hydroject® 3000/4000 Overview

NOTES

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5

The Hydroject® 3000/4000 aerators use most of the same components in the water injection system.

While there are differences in the machine drive, the main water injection system is the same.

The chart on the previous page shows the similarities and differences between the two units.

Components TORO Hydroject® 3000/40006

TORO Hydroject® 3000/4000 Components

NOTES

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7

Engine

The Hydroject® is powered by an Onan, 24 HP, air cooled, twin cylinder, electric start, gas engine. The engine

is equipped with solid state ignition, and powers the water pump, water valve, and on the 3000, the hydrostatic

transmission.

The engine uses 3 quarts of 30-weight engine oil and the oil should be changed every 100 hours, after the initial

25-hour change.

Oil Filter PN. 57-8530

The air filter should be serviced every 100 hrs, and the filter element replaced every 200 hrs.

Air Filter foam pre-cleaner PN 82-0670.

Air Filter element PN. 82-0670.

During aeration, operate the Hydroject® at full engine RPM.

Proper engine idle speeds.

Low idle 1500 - 1800 RPM.

High Idle 3500 ±50 RPM.

Fuel

The fuel tank holds 10 gallons of regular unleaded gasoline (9 gallons on the Hydroject® 4000) and should

operate the unit for approximately 4 hours. There is a fuel shut off valve located below the fuel tank and this

valve should be closed during periods of non-use.

NOTE: Take care in filling any fuel tank, and fill the tank to 1 inch below the top of the tank.

Always wipe up any spilled fuel to prevent a fire hazard.

The Fuel Filter should be replaced every 200 hrs.

Fuel Filter PN. 71-5960.

Components TORO Hydroject® 3000/40008

TORO Hydroject® 3000/4000 Components

NOTES

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9

Hydrostatic Pump (3000 Hydroject® Only)

The Sundstrand, series 70 hydrostatic pump, is belt driven and provides variable oil flow to operate the traction

wheel motor, the traction bail, located on the tiller handle, is connected to the swash plate in the hydrostatic

pump and provides speed and directional control. The unit aerates in both directions.

NOTE: There is a bypass valve located on top of the hydrostatic pump, this valve provides for limited

movement of the unit with the engine off.

Cam Gear Box

The cam gearbox operates the cycling valve and also serves as the hydrostatic oil reservoir, on the

Hydroject® 3000.

The hydrostatic transmission uses 5 quarts of DTE 26.

NOTE: The oil level can be checked through the sight glass on the side of the reservoir.

Components TORO Hydroject® 3000/400010

TORO Hydroject® 3000/4000 Components

NOTES

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11

Transmission Filter (3000 Hydroject® Only)

A 25-micron filter, located below the frame, filters the transmission oil.

NOTE: The transmission filter should be changed at 25 hours and then every 250 hours after that.

Prefill the filter before installation.

Transmission filter PN. 67-8110.

Wheel Motor (3000 Hydroject® Only)

The hydrostatic wheel motor is a low speed, high torque, bi-directional motor, which propels the unit and

provides smooth directional changes.

Components TORO Hydroject® 3000/400012

TORO Hydroject® 3000/4000 Components

NOTES

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13

Tiller Controls (3000 Hydroject® Only)

The tiller handle contains some controls for aerating. These controls include traction direction, aerate-transport

switch, and water systems start and stop buttons, and the parking brake lever.

NOTE: The parking brake is connected to a limit switch that activates an alarm if the unit

is moved while the parking brake is engaged.

NOTE: The traction handle moves the swash plate on the hydrostat, controlling direction

and speed.

NOTE: The raise and lower switch positions the transport wheels in aerate or transport.

NOTE: The ENGAGE (Green) and DISENGAGE (Red) buttons start and stop the water pump and

cycling valve. Holding the ENGAGE button down will energize the water system, overriding the

neutral delay, allowing multiple shots at one location.

Remote Control Panel (4000 Hydroject® Only)

The remote control panel for the Hydroject® 4000 contains the controls for aerating.

These controls include:

1. The key switch.

2. The engine choke switch.

3. The engine low\high idle switch.

4. The water system, start and stop buttons.

NOTE: The ENGAGE (Green) and DISENGAGE (Red) buttons start and stop the water pump and

cycling valve.

Components TORO Hydroject® 3000/400014

TORO Hydroject® 3000/4000 Components

NOTES

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15

Traction Linkage (3000 Hydroject® Only)

The traction linkage connects the traction bail to the swash plate. During aeration, a steel cable pulls the left link

toward the hole spacing lever, limiting swash plate movement to the required speed. In this mode, the hole

spacing lever is spring-loaded and will snap towards the key switch when removed from the indexing latches.

NOTE: Do not adjust hole spacing with out lowering the unit.

Control Panel (3000 Hydroject® shown)

The control panel controls or monitors the Hydroject® functions. The controls, (from right to left) include:

hourmeter, throttle, hole spacing lever, ignition key switch, 20 amp circuit breaker reset, inlet water pressure

gauge, spray roller wash knob and choke.

Components TORO Hydroject® 3000/400016

TORO Hydroject® 3000/4000 Components

NOTES

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17

Lift Mechanism (3000 Hydroject® Only)

A 12-volt, Warner electric, linear screw actuator with a 6-inch stroke, accomplishes transport lift. The actuator

raises and lowers the transport wheels and activates the hole spacing control. A safety switch prevents aeration

during transport.

Rollers (3000 Hydroject® Only)

The two large aluminum rollers support the Hydroject® 3000 during aeration. These rollers smooth down the turf

after aeration and protect the operator from the high velocity water jet blasts.

Components TORO Hydroject® 3000/400018

Toro Hydroject 3000 User manual

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