Part No. 91764SL Rev. C Service Manual Hydroject ® 3000/4000 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. 97928SL. REFER TO THE HYDROJECT OPERATOR’S MANUAL FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. Space is provided in Chapter 2 of this book to insert the Operator’s Manual and Parts Catalog for your machine.
Hydroject 3000/4000
Table Of Contents Chapter 1 - Safety Chapter 5 - Electrical System Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1 Safety and Instruction Decals. . . . . . . . . . . . . . . . 1 - 4 Wiring Schematics and Diagrams. . . . . . . . . . . . . 5 - 2 Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 9 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 17 Repairs .
Hydroject 3000/4000
Chapter 1 Safety Table of Contents SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 1 Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Maintenance and Service . . . . . . . . . . . . . . . . . . . . . 3 SAFETY AND INSTRUCTION DECALS . . . . . . . . . .
D. Fill fuel tank outdoors and up to about one inch (25 mm) from top of the tank, not the filler neck. 8. Fill fuel tank with gasoline before starting the engine. Avoid spilling gasoline. Since gasoline is flammable, handle it carefully. E. Wipe up any spilled gasoline. A. Use an approved gasoline container. 9. Check interlock 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 bypass it.
30. Before disconnecting or performing any work on the water system, all pressure in system must be 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. 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.
Safety and Instruction Decals The following decals are installed on the machine. If any become damaged or illegible, replace it. The decal part number is listed below and in your parts catalog. Replacement can be ordered from your Authorized Toro Distributor. Foreign language decal sets are also available from your Authorized Toro Distributor. On Each Side Of Engine (2) (Part No. 80–9350) On Drive Shaft Shield (Part No. 80–8000) On Accumulator body (Part No. 80–8880) On Top Of Tiller Arm (Part No.
Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . 1 2 2 2 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . Capscrew Markings and Torque Values – U.S. . . Capscrew Markings and Torque Values – Metric . LUBRICATION . . . . . . . . . . . . . . . . . .
Equivalents and Conversions Product Records and Maintenance Page 2 – 2 Hydroject 3000
Torque Specifications Hydroject 3000 Page 2 – 3 Product Records and Maintenance
Lubrication The Hydroject 3000 has 5 grease fittings that must be lubricated every 50 hours of operation with No. 2 General 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 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.
EQUIPMENT OPERATION AND SERVICE HISTORY REPORT for HYDROJECTR 3000 TORO Model and Serial Number: ______________–______________ Engine Numbers: _____________________________ Transmission Numbers: _____________________________ Drive Axle(s) Numbers: _____________________________ Date Purchased: _____________________________ Warranty Expires____________ Purchased From: _____________________________ _____________________________ _____________________________ Contacts: Hydroject 3000 Parts ________
Hydroject 3000 Maintenance Schedule Minimum Recommended Maintenance Intervals Maintenance Procedure Maintenance Interval & Service Every 50hrs Check Battery Fluid Level Check Battery Cable Connections Lubricate All Grease Fittings Every 100hrs Every 200hrs Every 400hrs A Service { Change Engine Oil { 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 { Chang
Hydroject 3000 Daily Maintenance Check List Daily Maintenance Check For Week Of _________________ Maintenance Check Item b MON 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 Engine Noises n Unusual Operating Noises n Water Filter/Pressure n Water Prefilter n Gear Case Oil Level n Pump Case Oil Level n Hydraulic Hose for Damages n Fluid Leaks n Tire Pressure n Instrument Operations T
Product Records and Maintenance Page 2 – 8 Rev. B Hydroject 3000 A B C D E Other Service to perform (circle): __________________–__________________ TORO I.D. #: _______________________________ _______________________________ Drain & flush hydraulic tank Drain & flush fuel tank Replace Safety Switches Replace Moving Hoses Other – Annual Service & Specials _______________________________ (See Operator’s and Service Manual for specifications and procedures.
Chapter 3 Engine Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 1 REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Engine Removal and Installation . . . . . . . . . . . . .
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.
Chapter 4 Hydraulic System Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . 3 Hydraulic Hose and Fitting Information . . . . . . . . 3 Pushing or Towing . . . . . . . . . . . . . . . . . . . . . . . . 5 HYDRAULIC DIAGRAM. . . . . . . . . . . . . . . . . . . . . . 6 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Hydraulic Tester. . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications Item Description __________________________________________________________________________________________ Pump Rated system pressure Rated system flow Charge relief pressure Oil filter Sundstrand Series 70, BDP-10L Variable Displacement Pump 2100 PSI maximum, 1000 PSI continuous 8.5 GPM maximum at 3200 RPM 25 to 70 PSI psi at 3200 RPM 25 micron screw-on type.
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. In spect the hoses frequently for signs of deterioration or damage.
SAE Straight 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. O-Ring 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 4 (1/4 in.
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.
Hydraulic Diagram Variable Displacement Pump Cooling Orifice Charge Pump Input (Belt Drive) Charge Check Valves Variable Disp.
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.
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.
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.) 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.
Hydraulic Tests (Fig. 10, 11) 1. Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes. NOTE: At pressures above approximately 500 PSI, mechanical override in handle will cause pump to begin to de-stroke. 2. Engage parking brake and stop the engine. Make sure parking brake is properly adjusted before perform ing hydraulic tests. 11. If you cannot get 7 GPM or 500 PSI, traction pump may have internal damage or excessive wear.
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. 1 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. 2 3. Adjust jam nuts at tiller end of push-pull cable so traction handle is centered on control handle. Figure 12 1. Jam nuts - pump end 2. Jam nuts - tiller end Speed Control Adjustment (Fig.
Transmission Neutral Adjustment (Fig. 14) If machine moves when lever is released, transmission neutral adjustment is needed. 1. Park machine on a level surface, stop the engine and open the hood. 3 2 1 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.
Traction Pump Belt 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 lb. of force. Belt should deflect 1/4 in. 1 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.
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. 1 2. Remove pulley guard bracket (Fig. 20, Item 21). 3. Remove drive coupling (see Drive Coupling Removal and Installation in Chapter 6 - Water System). 3 4. Disconnect valve clutch electrical connector. 4 5. Remove valve clutch stops. 2 6. Loosen pivot nut securing pump mount to pump support. Figure 18 7.
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. 7. Remove locknut (Item 46), capscrew (Item 5) and washers (Item 47). Remove locknut (Item 54) and cap screw (Item 57). 2. Disconnect wires from neutral and pump switches (Item 31) on hydraulic pump. Label wires for proper reinstallation. 8. Remove pump assembly from pump support (Item 55) and put pump on a work bench. 9.
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. Top of pump when installed in machine 4 3 2 1 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.
Pump Charge Check Valve Service (Fig. 22) 1. Remove check valve plug with a 1/4 in. internal hex wrench. Top of pump when installed in machine 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. Torque to 15 to 35 ft-lb. 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.
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. Top of pump when installed in machine 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 2. Remove charge pump cover and O-ring. 3 3. Remove charge pump gerotor assembly. 4.
23 24 22 19 20 21 18 16 17 12 15 13 14 8 1 6 2 7 9 10 5 3 11 4 26 25 27 40 39 35 28 38 36 29 37 34 33 32 31 30 4 3 2 1 Figure 25 Disassembly of Hydraulic Pump 6. Remove cylinder block spring (Item 8) and washer (Item 9) from shaft. 1. Before performing major repairs on the pump, remove external components as described in previous proce dures. These include the following: 7. Remove swashplate assembly (Item 25) from hous ing. 8. Remove thrust plate (Item 11) from swashplate.
14. Remove pump shaft (Item 19) and bearing assembly from housing. 3. Install displacement control shaft (Item 12) into hous ing. 15. Remove outer bearing retaining ring (Item 21) (and washer, if used). Press shaft out of bearing. 4. If block spring retaining ring (Item 10) was removed from pump shaft, install a new retaining ring at this time. 16. If pump block retaining spring retaining ring (Item 10) requires replacement, remove it from pump shaft. 5.
18. Check that piston springs are centered in cylinder block bores, If necessary, move springs into position with a small screwdriver. 21. When end cap is properly installed, the internal springs will hold it away from the housing approximately 3/8 in. IMPORTANT: Do not damage running surfaces of cylinder blocks. 22. Install the four (4) capscrews which retain end cap to housing. Tighten screws to a torque of 138 to 180 in-lb. 19.
Wheel Motor Removal and Installation (Fig. 27) 3 2 1 4 9 10 5 8 6 11 7 12 37 13 36 14 15 16 35 17 18 19 34 30 32 20 31 Torque to 250 to 400 ft-lb. 21 33 29 28 27 17 25 26 24 23 22 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. 4. Disconnect hydraulic lines from fittings on wheel motor.
Wheel Motor Shaft Seal and/or Shaft Replacement (Fig. 28) 12 11 10 13 16 17 4 7 14 15 19 6 20 5 19 4 21 3 1 9 2 Figure 28 Disassembly of Shaft and Front Seal Assembly scratches, entire motor should be disassembled for inspection. 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.
Wheel Motor Repair (Fig. 29) 12 11 10 13 16 17 4 7 14 15 19 6 20 5 19 4 21 3 1 9 2 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 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.
6. Next put IGR inner member on shaft spline with semi-circular roll pockets between rotary valve ports. NOTE: Be sure not to dislodge body square ring seal while moving locating ring. 7. Put contour member of IGR over inner and insert seven rolls into inner pockets (large diameter rolls). 11. Install the eight locating ring rollers into their pockets and oil lightly. 8. Lightly oil square ring seal (Item 4) and put in body groove. 12.
Repairs Page 4 - 26 HydroJect™ 3000
Chapter 5 Electrical System Table of Contents WIRING SCHEMATICS AND DIAGRAMS . . . . . . . . 2 Logic Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Controller lights . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 Wiring Schematic . . . . . . . . . . . . . . . . . . . . . . . . 3 Wiring Diagram – Main . . . . . . . . . . . . . . . . . . . . 4 Wiring Diagram – Control Panel . . . . . . . . . . . . . 5 Wiring Diagram – Tiller . . . . . . . . . . . . . . . . . . . . 6 SPECIAL TOOLS .
Wiring Schematics and Diagrams Logic Chart X Accumulator Charge Switch Lift Switch DOWN (HJ3000 only) O Brake Switch Lift Switch UP (HJ3000 only) Aerator Stop (Disengage) Switch Aerator Start (Engage) Switch Transport Switch (HJ3000 only) Lift Limit Switch SWITCHES Switch Conditon Not Relevent Pump Start Limit Switch Switch Closed Momentarily Water Pressure Switch Switch Open ⊗ Oil Pressure Switch O B+I+S Switch Closed Start - Key Switch X Neutral Switch (HJ3000 only) KEY Run - Key
Controller Lights Lights (LED’s) on the controller indicate when the following inputs are made to the controller: Red: Transport switch closed (traction bail in neutral). 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.
Wiring Schematics and Diagrams Page 5 – 2.2 Rev.
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
Electrical Schematic (Model 09801) Hydroject 3000 Page 5 – 6.1 Rev.
A B C D D C B A YELLOW BLACK ORANGE PINK GREEN BROWN PURPLE BLUE RED BLACK GRAY Page 5 – 6.2 Rev.
Hydroject 3000 IGNITION – AC B+ Page 5 – 6.3 BATTERY + Rev. B B S M DIODE 30 AMP FUSE STARTER OIL PRESSURE N.O.
DOWN ORANGE COMMON Page 5 – 6.4 Rev. B LIFT SWITCH ORANGE PINK NORMALLY OPEN ORANGE BROWN COMMON UP AERATOR STOP N.C. NORMALLY CLOSED GREEN Wiring Schematics and Diagrams + ALARM – N.O. BRAKE SWITCH YELLOW BLACK ORANGE PINK GREEN BROWN PURPLE BLUE B A D C E E D C B A YELLOW AERATOR START SWITCH N.O.
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 meter when testing electrical circuits. The high impedance (internal resistance) of a digital meter will ensure that excess current is not allowed through the meter.
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 Page 5 - 8 Rev.
Troubleshooting 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. CAUTION Remove all jewelry, especially rings and watches, before doing any electrical trou bleshooting or testing.
Starting Problems (continued) Condition Possible Cause Correction __________________________________________________________________________________________ Engine cranks, but does not start. NOTE: If engine cranks, cause of problem is UNRELATED to interlock system. Engine or rectifier plug loose. Connect wire. “I” terminal on ignition key switch loose. Connect wire. Diode in wire harness faulty. Replace diode Engine problem, or no fuel. Find problem and correct (see Chapter 3 - Engine).
General Run and Transport Problems Condition Possible Cause Correction ___________________________________________________________________________________________ Engine shuts down during transport or when idling (not in Aerate mode). Not electrical - low engine oil pressure, no fuel, etc. Find and correct cause of engine shut down. Oil pressure switch faulty. Test switch and replace if faulty. Loose or broken wire in oil pressure switch circuit.
General Run and Transport Problems (continued) Condition Possible Cause Correction __________________________________________________________________________________________ Machine does not raise (to transport position). Circuit breaker open. Reset circuit breaker. Find cause for open circuit breaker and cor rect. Replace circuit breaker if faulty. Lift/Lower switch faulty. Test switch and replace if faulty. Lift UP relay faulty. Test relay and replace if faulty. Ignition key switch faulty.
Aerate Operation Problems Condition Possible Cause Correction ___________________________________________________________________________________________ Machine continues to aerate (but should not) with traction bail in neutral. See Safety Interlock System Prob lems. ________________________________________________________________________________________________________________________________________________________ Machine aerates (but should not) with with machine raised in trans port position.
Aerate Operation Problems (continued) Condition Possible Cause Correction __________________________________________________________________________________________ Machine does not start aerating when engage button is pushed in (pump belt IS rotating, but gear case drive shaft is NOT rotating). Valve clutch out of adjustment. Check air gap on valve clutch and adjust if necessary. Loose or broken wire in valve clutch / controller circuit. Check all connections and wiring and repair as necessary.
Safety Interlock System Problems Condition Possible Cause Correction ___________________________________________________________________________________________ Engine cranks (but should not) with traction bail in neutral. Neutral switch faulty. Make sure switch is installed and adjusted properly. Test neutral switch and replace if faulty. Neutral switch wiring faulty. Check for short in neutral switch wiring and connections and repair as necessary.
Safety Interlock System Problems (continued) Condition Possible Cause Correction __________________________________________________________________________________________ No lights on controller come on when troubleshooting interlock system. Battery is dead or disconnected. Charge battery. Replace battery if it will not hold a charge. Clean and tighten connections. Circuit breaker open. Reset circuit breaker. Find cause for open circuit breaker and cor rect. Replace circuit breaker if faulty.
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, determine 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.
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.
Ignition Key Switch (Fig. 9, 10) The ignition (key) switch has three positions (OFF, START and RUN). The terminals are marked as shown. Y A B S I X Figure 9 The circuitry of the ignition switch is shown in the chart. With the use of a continuity tester, the switch functions may be tested to determine whether all circuits are being completed while the key is moved to each position. POSITION CONTINUITY AMONG TERMINALS 1. OFF NONE 2. RUN B+I+A 3.
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.
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 the two leads of the switch. 2 1 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 screwed all the way in.
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. 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. 1 1 Figure 15 1. Lift switch Linear Actuator (Fig.
Brake Switch (Fig. 17) The brake switch is a normally open (N.O.) switch that closes when the brake is engaged. 1 To test the brake switch disconnect the wires from the 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.
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 terminal 86 connected to ground.
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. 1 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.
Repairs Battery Service (Fig. 23, 24) IMPORTANT: To prevent damage to the electrical components, do not operate the engine with the battery cables disconnected. Electrolyte Specific Gravity 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.
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-tighten screws as the switch case could break. 4. Reconnect wires to new switch.
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. 1 2 Figure 26 1. Circuit breaker 2. Fuse Controller Replacement (Fig.
Linear Actuator Replacement (Fig. 28) 1. Put wheels in transport position (machine raised). 1 2. Put the machine on a level surface, stop the engine, engage the parking brake and disconnect engine spark plug wires. 3 2 3. Open the hood. 4 4. Disconnect linear actuator wire connector. 5. Disconnect extension springs. 4 6. Remove capscrew and nut securing each end of linear actuator. Figure 28 7. Reverse steps 3 - 6 to install the linear actuator. 1. Linear actuator 2. Wire connector 3.
Repairs Page 5 - 30 HydroJect™ 3000
Chapter 6 Water System Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . Nozzle Size and Approximate Depth Chart . . . . . WATER SYSTEM SCHEMATIC . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . Accumulator Charging Valve and Pressure Gauge . . . . . . . . . . . . . . . . . . . . Accumulator Seal Installation Tool . . . . . . . . . . . Accumulator Cap Wrench . . . . . . . . . . . . . . . . . .
Specifications Water Pump Clutch: Electromagnetic, dual groove belt drive for water pump and driveshaft flange brake/clutch for main valve gearbox. Pressure Relief Valve – Poppet–type valve with corrosion resistant stainless and brass materials. 5000 + 300 PSI relief valve pressure. 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 plastic housing with air bleed button.
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 and spring. See nozzle size chart and illustrations below: IMPORTANT: Use only nozzle configurations shown or damage to the machine may occur. NOZZLE SIZE AND APPROXIMATE DEPTH CHART Part No.
OPEN NOZZLE Tighten to 60 ft–lb CLOSED (BLOCKED) NOZZLE S/N 29999 & Below Aluminum washer (P/N 80–6680) is required with any nozzle change. Spring Check Valve Ball Check Valve Ball Spring Tighten nut to 70 – 80 ft–lb OPEN NOZZLE CLOSED (BLOCKED) NOZZLE S/N 30001 & Up Specifications Aluminum washer (P/N 86–8150) is required with any nozzle change. Page 6 – 2.2 Rev.
Water System Schematic Model 09800 ROLLER WASH NOZZLES ACCUMULATOR 2500 PSI NITROGEN PRE–CHARGE WATER VALVE ELECTRIC CLUTCH WATER PUMP RELIEF VALVE 5000 PSI ENGINE ELECTRIC BRAKE CLUTCH GEARBOX CAM PRESSURE SWITCH 20 PSI – ON 10 PSI – OFF ROLLER WASH NOZZLES HIGH PRESSURE AERATION NOZZLES PRESSURE GAUGE SPRAY WASH VALVE FILTER WATER SUPPLY QUICK COUPLER Model 09801 Hydroject 3000 PRE–FILTER PRESSURE REDUCING VALVE Page 6 – 3 Rev.
Special Tools The following special tools are required for servicing the HydroJect 3000. Order special tools from the TORO SPECIAL TOOLS A ND A PP LI CAT IONS GUIDE (COMMERCI AL 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.
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.
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.
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. 1 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.
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.
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.
Condition Possible Cause Correction __________________________________________________________________________________________ Machine stops aerating (pump shuts down during aeration). Machine not moving. Normal condition of interlock sys tem. Operator must hold engage button in to aerate with traction bail in neutral. Inadequate water supply. Check for kinked water supply hose, restriction in line or partially open valve at water source. Plugged inlet water filter.
Condition Possible Cause Correction ___________________________________________________________________________________________ Machine aerates, but aeration hole depth is shallow or inconsis tent (continued). Low accumulator pre-charge or damaged accumulator - TEST NO. 1. Charge accumulator with dry Nitrogen. Rebuild or replace ac cumulator if necessary. Low water system pressure AND flow - TEST NO. 2. Rebuild pump. Low water system pressure (flow is OK) - TEST NO. 2.
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.
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.
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.
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 the hood. WARNING 1 High pressure water system components can cause personal injury if disassembled incorrectly.
6. Install Flow Meter (TOR4006) between water supply hose and hose adapter. Connect hose adapter to quick connector 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.
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 rapid cam wear. 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.
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.
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 follower 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.
Repairs Drive Coupling and Clutch Removal and Installation (Fig. 30) 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. 1. Park the machine on a level surface, engage the parking brake, open the hood and disconnect the engine spark plug wires. Remove guard (Item 38). 2.
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. 1 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.
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.
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 disconnect the engine spark plug wires. 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.
Water Pump Head Service (Fig. 36) Pump Head Removal 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). 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.
Plunger Seal Replacement (See illustration on previous page) Plunger Sleeve Replacement (see Figure 38 on next page) NOTE: Check valves must be in good condition for this procedure to work correctly. 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.
Water Pump Crankcase Service (Model 09800) (Fig. 38a) 5 6 4 35 1 8 1 7 3 2 34 13 12 10 9 14 8 ft–lb 11 15 Loctite 271 10 ft–lb 31 32 33 30 29 28 27 26 25 Apply grease to O.D. of plunger before installing pump head 23 13 14 10 ft–lb 24 10 22 21 20 18 ft–lb 19 18 17 6 16 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 Service). 3.
Water Pump Crankcase Service (Model 09801) (Fig. 38b) 1 10 2 18 – 20 ft–lb 3 4 9 5 6 7 8 29 11 28 12 13 Apply grease to O.D. of plunger before installing pump head 15 16 14 17 18 19 24 25 20 7 10 22 27 8 21 26 14 18 – 20 ft–lb 13 23 18 – 20 ft–lb 22 10 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.
Crankcase Bearing Installation and Shimming (Model 09801) Crankshaft end play from dial indicator Shim thickness removed to get .006 + .001 .010 .016 .009 .015 ,008 .014 3. Install one yellow (.020) shim and one pink (.015) shim onto input shaft bearing housing if required. .007 .014 .006 .012 4. Install three yellow (.020), three blue (.005) and two red (.002) shims onto the end cap bearing housing. .005 .012 .004 .010 5.
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.
11. Inspect sealing surfaces of valve spool and valve seat. If surfaces appear worn, replace or regrind. Both angles are 30 degrees. 13. Remove seal assembly (Items 25–30) by pressing a socket wrench through the casting. Discard all seal components. 12. Remove and inspect sleeve (Item 7) and remove backup (Item 6) and O–ring seals (Item 5). 14. Remove snap ring (Item 21) from gear box pilot (Item18).
13. Install valve spring studs through Valve Spring Compressor (TOR4008) and into threaded holes of water valve. Put spring retainer (Item 15) over spring and under spring compressor. Tighten nuts to compress spring, and install and retaining ring (Item14). Remove special tool. 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.
Gear Case Service (Fig. 41) you inspect the cam and not the weight block, when checking for wear. DO NOT INSTALL TWO CAMS ONTO THE GEAR. 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).
Nozzle Service and Replacement NOTE: See Specifications section of this chapter for more information. sionally inspect the springs especially if one nozzle leaks water after the machine is shut down. 1. Park machine on a level surface, stop the engine, engage the parking brake, open the hood and disconnect the spark plug wires from the engine. 4. For normal operation, install nozzle springs with the narrow spiral pointing up and the check ball on top of the spring.
Accumulator Replacement (Fig. 43) 1. Stop the engine, engage the parking brake, open the hood and disconnect the engine spark plug wires. 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 EXPLOSION AND DEATH. Charging requires special tools and precautions. Charge ac cumulators in a well ventilated area.
8 7 9 6 12 11 10 5 3 1 13 4 2 14 6 47 15 16 17 44 48 49 42 43 44 18 46 19 45 41 21 40 20 22 39 Torque to 40 ft-lb.
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 2 1. Park machine on a level surface, stop the engine, engage the parking brake and open the hood. 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 EXPLOSION AND DEATH.
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 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. 17.
General Information Storage It is very important that the water system be drained to avoid freezing and damaging the components. Drain system as follows: 2. Remove and discard the oil filter. Install a new filter. 1. Stop engine, remove key from ignition switch and remove wires from spark plugs. 4. Start the engine and run at idle speed for two minutes. DO NOT RUN LONGER THAN TWO MINUTES. 2. Remove (2) screws securing drive shield to frame and remove shield. 5. Stop the engine; remove the spark plugs.
Chapter 7 Wheels, Brakes and Steering Table of Contents ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 2 HydroJect™ 3000 REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Brake Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Wheel Bearing Service . . . . . . . . . . . . . . . . . . . .
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. 1 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.
Repairs Brake Service (Fig. 2) 3 2 1 4 9 10 5 8 6 11 7 12 37 13 36 14 15 16 35 17 18 19 34 30 32 20 31 Torque to 250 to 400 ft-lb. 21 33 29 28 27 17 25 26 24 23 22 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.
Wheel Bearing Service (Fig. 3) 1. Park machine on a level surface and raise wheels to aerate position. Engage parking brake, open hood and disconnect engine spark plug wires. 22 23 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. 24 25 26 35 27 34 4. Pull seal (Item 34) out of wheel hub (Item 23). 32 5. Remove bearings (Item 32) from both sides of wheel hub.
Chapter 8 Hydrojectr 4000 Addendum Table of Contents SAFETY AND INSTRUCTION DECALS . . . . . . . . . . 2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . 7 ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . 11 WATER SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . 13 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 14 Boost Pump Belt Adjustment . . . . . . . . . . . . . . . . .
Safety and Instruction Decals On Each Side Of Engine (2) (Part No. 80–9350) On Accumulator body (Part No. 80–8880) On Drive Shaft Shield (Part No. 80–8000) On Muffler Shield (3) (Part No. 80–8290) On Drive Shaft Guard (Part No. 80–8040) On Sides (2) (Part No. 80–8090) IMPORTANT D THE FIVE MICRON FILTER ELEMENT (86–8620) MUST BE IN PLACE AT ALL TIMES. On Water Pump (Part No. 80–9450) D OPERATION WITHOUT PROPER FILTRATION WILL RESULT IN PREMATURE WEAR AND FAILURE OF THE WATER SYSTEM COMPONENTS.
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. 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 assembly.
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 and spring. See nozzle size chart and illustrations below: IMPORTANT: Use only nozzle configurations shown or damage to the machine may occur. NOZZLE SIZE AND APPROXIMATE DEPTH CHART Part No.
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 interchangeable equivalent. See chart below for equivalent oils.
Comparison between Hydroject 3000 and Hydroject 4000 Addendum Page 8 – 6 Rev.
EQUIPMENT OPERATION AND SERVICE HISTORY REPORT for HYDROECTR 4000 TORO Model and Serial Number: ______________–______________ Engine Numbers: _____________________________ Transmission Numbers: _____________________________ Drive Axle(s) Numbers: _____________________________ Date Purchased: _____________________________ Warranty Expires____________ Purchased From: _____________________________ _____________________________ _____________________________ Contacts: Hydroject 4000 Parts _________
Hydroject 4000 Maintenance Schedule Maintenance Procedure Maintenance Interval & Service Check Battery Fluid Level Check Battery Cable Connections Lubricate All Grease Fittings Every 50hrs Every 100hrs Every 200hrs Every 400hrs A Service { Change Engine Oil { 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
Hydroject 4000 Daily Maintenance Check List Daily Maintenance: (duplicate this page for routine use) Check proper section of Operator’s Manual for fluid specifications Daily Maintenance Check For Week Of _________________ Maintenance Check Item b MON TUES WED THURS FRI SAT SUN n Engine Oil Level n Engine Air Filter Pre–Cleaner n Engine Cooling Fins for Debris n Unusual Engine Noises n Unusual Operating Noises n Water Filter/Pressure n Gear Case Oil Level n Pump Case Oil Level n Fluid Leaks
Addendum Page 8 – 10 Rev. B Hydroject 4000 A B C D E Other Service to perform (circle): __________________–__________________ TORO I.D. #: _______________________________ _______________________________ ________________________________ ________________________________ (See Operator’s and Service Manual for specifications and procedures.
2 CHOKE SWITCH BLUE/RED YELLOW A Y X IGNITION A B C PURPLE BLUE/WHITE GREEN B S I N.C 8 N.O.
Controller Lights Lights (LED’s) on the controller indicate when the following 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 red or yellow goes off. Yellow: Light comes on after ignition switch is in RUN position and accumulator charge pressure switch is closed (nitrogen pressure more than 1800 psi). 3 2 1 Figure 1 1.
Water System Diagram ACCUMULATOR 2500 PSI NITROGEN PRE–CHARGE WATER VALVE ELECTRIC CLUTCH RELIEF VALVE 5000 PSI WATER PUMP ELECTRIC BRAKE CLUTCH HIGH PRESSURE AERATION NOZZLES PRESSURE SWITCH 20 PSI – ON 10 PSI – OFF PRESSURE GAUGE RELIEF VALVE 70–90 PSI FILTER 5 MICRON BOOST PUMP 6 GPM AT 70–90 PSI Hydroject 4000 QUICK COUPLER Page 8 – 13 Rev.
Service and Repairs Boost Pump Belt Adjustment Make sure boost pump belt is properly tensioned to assure 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 between pulleys with 3 lb. of force. A used belt should deflect .250”. A new belt should deflect .125”. 3. If an adjustment is necessary: A. Loosen pump bracket mounting bolts (2). B.
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