notes - Toro
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1. 68 Water System Testing TORO Hydroject 3000 4000 TORO Hydroject 3000 4000 Water System Testing 69 Performing the Accumulator Pressure Test With the unit shut off and the pressure relieved from the high pressure water circuit Remove the protective cover from the accumulator service valve Connect the accumulator charging tool Verify that both shut off valves are closed Turn the valve jam nut counter clockwise approximately 2 turns Read pressure on the gauge Pressure should be 1800 to 2800 PSI when recharging charge the accumulator to 2500 PSI 4 65 2 gt NOTES 70 Water System Testing TORO Hydroject 3000 4000 TORO Hydroject 3000 4000 Water System Testing 71 Interpreting Test Results and Operational Effects Low Accumulator Pressure Cause Leaking piston O Rings Leaking accumulator service valve Normal operational leakage Effect Low accumulator pressure decreases the water available for delivery to the aeration nozzles If the accumulator is completely discharged 0 Psi the water forced into the accumulator will not be forced out when the cycling valve opens The only water available to the nozzles is the water from the pump High Accumulator Pressure Cause Accumulator over charged with nitrogen Water leaking past the O rings Water collecting on top of the piston decreasing the available area for nit2. 26 Components TORO Hydroject 3000 4000 IMPORTANT THE FIVE PLTN 656 2620 wot T PLACE KT ALL HATIA ACT Con Camas MARGS KUIP MARGA ANG 001 AWAY 50604 NOTE ARO ROLLER Al TAL PYNETRAPIDN OCCURT 5418 8 16 8 j SEE OPERATOR S AMAL FOR MORE PUFCHaMWTICN 6711 W 000441 TL A MIN VELOCITY WATER JETS CAN PURETRATI KANOS 6 55 8 87 THE WON 811 1 TORO Hydroject 3000 4000 Components 27 Pre filter The Hydroject aerators use a water inlet pre filter The pre filter is a spin down swirl type sediment pre filter The filter has a reusable polyester 100 mesh 150 micron screen Screen PN 86 9140 The clear bowl allows the operator to see when the pre filter needs to be flushed or cleaned NOTE Early units were not equipped with a pre filter A kit is available to install one on older units if water conditions warrant Kit Number 92 9544 Flush Valve When dirt or debris accumulates in the pre filter the filter needs to be flushed or cleaned To flush the pre filter open the flush valve while the water is connected to the unit This will clean the collected debris from the bottom of the pre filter NOTE In areas with high levels of water contamination the flush valve can be left slightly open while operating the Hydroject to keep the pre filter clean NOTE Opening the flush valve after initially connec
3. Accumulator Precharge pressure is 150 PSI 5000 PSI 90 PSI 2500 PSI The boost pump relief valve on the Hydroject 4000 is set at 150 PSI 5000 PSI 90 PSI 2500 PSI The accumulator is Pre charged with Air Water Liquid Helium Dry Nitrogen 6 g O gt N gt The main water filter should be cleaned when dirty True False What is the correct air gap for the electric clutches 250 inch 018 inch 1 inch 0018 inch The hydrostatic drive on the Hydroject 3000 has a separate oil reservoir True False Hole spacing on the Hydroject 4000 is controlled by the hole spacing lever True False 10 On the Hydroject 3000 which machine function control is not located in the tiller handle A Aerate engage B Aerate disengage C Hole spacing D Hydrostatic drive direction E Transport aerate switch lift and lower 48 Water System Operation TORO Hydroject 3000 4000 Hydroject 3000 EZ ACCUMULATOR 2500 PSI NITROGEN PRE CHARGE lt Te gt gt m Ke en i H ked ELES TRIC WATER VALVE CLUTCH gt He gt W Ik RELIEF VALVE WAT
4. Calibrate Aeration Traction Speed 3000 Only Service Injection Nozzles and Springs Replace Spark Plugs Decarbon Combustion Chambers Torque Head and Adjust Valves Check Engine RPM idle and full throttle Initial break in at 25 hours Initial break in at 50 hours Replace Moving Hoses Replace Safety Switches Fuel Tank Drain Flush Hydraulic Tank Drain Flush Every 50hrs A Level Service B Level Service C Level Service D Level Service Annual Recommendations Items listed are recommended every 1000 hours or 2 years whichever occurs first See Operators and Service Manual for specifications and procedures This page is intentionally blank The Toro Company
5. Cycling valve Opens and closes 5 3 times a second System Operating TORO Hydroject 3000 4000 Water System Operation 51 System Startup 99 e m e 9 9 ew eof With the engine running water supply connected The transport wheels up 3000 only The accumulator is charged to 2500 PSI The cycling valve is closed The operator must set the throttle to high idle 3500 50 The operator presses the red engage button When the engage switch is pushed the pump starts to pump The cycling valve is closed so the pump forces water into the accumulator The accumulator is half full of nitrogen and water The water pressure builds to 5000 PSI and the relief valve opens The timer module engages the cycling valve clutch after about 5 seconds The cycling valve open about 5 3 times a second Water flows through the cycling valve to the high pressure manifold and out the nozzles NOTES 52 Water System Operation ACCUMULATOR 2500 PSI NITROGEN PRE CHARGE ELECTRIC CLUTCH WATER PUMP ede ta TORO Hydroject 3000 4000 RELIEF VALVE 5000 PSI 4 ELECTRIC BRAKE CLUTCH PRESSURE eU pel 10 PSI SWITCH ON OFF PRESSURE AUGE e WATER VALVE FILTER 5 MICRON PRESSURE REDUCING VALVE PRE FIL
6. Commercial Products Hydroject 3000 4000 Troubleshooting Guide This page is intentionally blank TORO Hydroject 3000 4000 1 Table of Contents Troubleshooting Product Va Owen KA eis oto Meu 2 6 e Water System Opera On ea acest estat maa Men KK KRA 48 e Water System Testing et ei 58 gt UJI STOL ACS 78 Maintenance Chan on a am 80 Use of This Manual The information contained in this manual is supplementary to material found in other sources itis 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 2 Overview TORO Hydroject 3000 4000 TORO Hydroject 3000 4000 Overview 3 The Hydroject is a pat
7. 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 NOTES 8 Components TORO Hydroject 3000 4000 TORO Hydroject 3000 4000 Components 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 NOTES 10 Components TORO Hydroject 3000 4000 TORO Hydroject 3000 4000 Components 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
8. True False The water pump is engaged when The water pressure reaches 90 PSI The operator depresses the engage switch 4 seconds after the cycling valve engages When the unit is in neutral The cycling valve is engaged when The water pressure reaches 90 PSI The operator depresses the engage switch 4seconds after the Water pump engages When the unit is in neutral When aerating the unit is operated at Low idle High idle 3500 RPM Mid idle 2800 RPM 6 High pressure water is stored in the accumulator until needed A True w O gt False The cycling valve opens 1 time per second 7 1 times per second Whenever the engine is running 5 3 times a second During shut down the components stop in this order Cycling valve relief valve water pump Water pump relief valve cycling valve Relief valve cycling valve water pump Water pump cycling valve relief valve The timer control module controls aeration start up and shut down True False 10 During shutdown the cycling valve runs after A B the water pump stops True False 58 Water System Testing Using control module lights Unit won t operate Check Red Operational Checks Light on the Control Module Yes v Check Yellow Light on the Control module ellow light on with
9. est Water Flow Flow should be more than 3 4 GPM est Accumulato Pressure Pressure 1800 to 2800 PSI Yes Check Nozzle Correct size and number Yes Low water flow can Check Water Pump Yes Inspect pump seals and check valves Repair or Replace Water Pump T Yes E Recheck Hole Depth Caused by low nitrogen charge Pressure Low gt Charge Accumulator Replace Nozzles Pressure High Caused by water leaking past seals or over charged Rebuild Accumulator Yes gt Recheck Hole Depth TORO Hydroject 3000 4000 Water System Testing 61 Complaint Shallow Hole Depth 1 Test high pressure water e Low water pressure can be an indication of a faulty relief valve or water pump To check the high pressure water circuit disconnect the wire to the cycling valve and remove the return hose from the relief valve With the pressure gauge connected to the water system engage the water system and check the pressure Should be 5000 psi fthe pressure is low repair or replace the relief valve 2 Test water flow e Low water flow can be an indication of a water supply problem or a pump problem If there is a water supply problem the yellow light on the control module will be off If the light is on there is adequate water supply and the
10. 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 NOTES 12 Components TORO Hydroject 3000 4000 DISENGAGE E ENGAG C AN FTA WATER SYSTEM TORO Hydroject 3000 4000 Components 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
11. 4000 Components 43 Relief Valve The relief valve limits the water pressure to 5000 PSI On the 3000 the extra water is bled off through the roller wash circuit On the 4000 the extra water is returned to the water inlet circuit NOTE There is a complete rebuild kit available to rebuild the valve Part number 86 8550 Gear Box An engine driven cam gearbox operates the cycling valve The gearbox has a cam mounted to the face of the gear which actuates the spool and opens the valve releasing the high pressure water The driven gear RPM is 320 NOTE The cam gearbox also serves as the oil reservoir for the hydrostatic transmission on the 3000 Hydroject NOTES 44 Components TORO Hydroject 3000 4000 TORO Hydroject 3000 4000 Components 45 Injection Nozzles The Hydroject is equipped with 11 injection nozzles These nozzles convert the high pressure high volume water into a high pressure water jet that aerates the turf The injection nozzle consists of the nozzle body check ball spring nozzle tip and nut The function of the ball and spring is the keep the high pressure manifold full of water between injection cycles The check ball is unseated when the injection pressure reaches 110 PSI NOTE Whenever a nozzle is removed or replaced a new sealing washer should be used where the nozzle mounts to the manifold NOTE With the new style nozzle the nut is torqued to 70 80 ft
12. Ibs Blocked Nozzle Depending on the desired nozzle spacing and configuration some nozzles may need to be blocked This is done by disassembling the nozzle and reversing the ball and spring By locating the ball at the bottom of the nozzle this prevents water flow through the nozzle NOTES 46 Components TORO Hydroject 3000 4000 Maintenance Parts Helpful Hints Air Filter 82 0660 1 When servicing the air filter Pre cleaner add 1 Air Filter Foam Pre cleaner 82 0670 tablespoon of engine oil to the foam and squeeze to remove excess Engine Oil Filter 57 8530 2 Verify engine RPM to insure proper operation e Low Idle 1500 to 1800 RPM Fuel Filter 71 5960 e High Idle 3450 to 3550 RPM Water Filter 86 8630 ge Engine oil 3 quarts No 30 wt oil Water Filter Sesling O Ring 92 9945 e Cam gearbox 4 to 5 quarts of mobile DTE 26 hydraulic oil screen eee ie e Water Pump Approx 40 ounces Mobile DTE Hydro Filter 3000 only 67 8110 Sx heavy oll e Fuel Tank 10 5 gal 9 gal on Hydroject 4000 TORO Hydroject 3000 4000 Components 47 gom com e com gt com 5 A B C D Review Questions Excess water from the relief valve on the Hydroject 3000 is routed to the Water inlet circuit Roller wash circuit Water filter Accumulator The Regulator limits water inlet pressure to 150 PSI 5000 PSI 90 PSI 2500 PSI
13. main water injection system is the same The chart on the previous page shows the similarities and differences between the two units NOTES 6 Compone nts TORO Hydroject 3000 4000 ji 2 md at i HYDROJECT 3000 QUICK REFERENCE ND FLUID SPECIFICATIONS SERVICE INTERVALS FLUID TYPE geo HEZ RE Su WYDROSIAT Boa 3 TORO Hydroject 3000 4000 Components 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
14. start if the nitrogen precharge is below 1800 PSI Accumulator Components The accumulator consists of the following components Accumulator body Top cap Bottom cap Piston and seals Nitrogen service valve test and recharge Low nitrogen switch CO NS NOTES 38 Components Accumulator Operation Accumulator charged System Startup Ready for aeration Cycling Valve Opens Cycling Valve Closes TORO Hydroject 3000 4000 Status Unit not running Nitgogen pressure 2500 PSI Piston at bottom of accumulator Status Unit running Nitgogen pressure at 2500 PSI Piston begins to move upward Status Unit running Nitgogen pressure equals water pressure Piston halfway up Accumulator is half full of 5000 PSI water Results As the cycling valve opens The piston moves down as water from lower half of accumulator flows to the injection nozzles Results As the Cycling valve closes The piston moves back up as water from the water pump refills the lower portion of the accumulator TORO Hydroject 3000 4000 Components 39 Accumulator Operation Charged accumulator 1 The accumulator will have a nitrogen pre charge of 2500 PSI 2 The piston is at the bottom the cylinder 3 There is very little water in the bottom end Start up 1 As th
15. water connected and wheels up Red light on with traction bail actuated Yes eck pre filtery main water filter and water supply hose No Change main water filter Check supply hose Repair transport switch TORO Hydroject 3000 4000 Check transport Yes switch No Check Accumulator Pressure Yes Contact Distributor Yes Replace pump start limit switch Replace Pressure switch v Check Green Light on the Control Module Yes Contact Distributor Green Light On with aerate start button depressed Check aeration switch and wiring OK A No Repair wiring No Yes TORO Hydroject 3000 4000 Water System Testing 59 Operational Checks 3000 1 Check red light on the control module The red light is on whenever the unit is moving or the traction control linkage is not in neutral The red light is on while the unit is aerating If the red light is not on check the transport switch and the switch wiring This is the bottom switch on the hydrostatic pump control lever Repair or replace the switch or wiring as needed If the switch and wiring is OK contact your distributor 2 Check the yellow light on the control module The yellow light is on whenever the following conditions are met Water supply pressure over 20 psi Wheels up Accu
16. 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 NOTES 14 Components TORO Hydroject 3000 4000 START sum CIRCUIT BREAKER push to reset tee THROTTLE A TORO Hydroject 3000 4000 Components 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 NOTES 16 Components TORO Hydroject 3000 4000 TORO Hydroject 3000 4000 Components 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 whe
17. ER PUMP 5000 PSI Lo A 2 C po ELECTRIC gt CS gt BRAKE CLUTCH A HIGH PRESSURE AERATION NOZZLES PRESSURE SWITCH 4 1 20 PSI ON A 10 PSI OFF 6 PRESSURE AUGE FILTER acit 5 MICRON 1 Pat Ni WATER SUPPLY j QUICK COUPLER PRESSURE REDUCING VALVE E ACCUMULATOR 2500 PSI CS NITROGEN PRE CHARGE C gt Z9 E t es Em 4 ELECTRIC WATER VALVE CLUTCH HG Md RELIEF VALVE WATER PUMP 50D0 PSI HC Lim E S 2 ELECTRIC gt BRAKE CLUTCH gt HIGH PRESSURE AERATION NOZZLES PRESSURE SWITCH lw 20 PSI ON z 19 PSI OFF 8 PRESSURE GAUGE RELIEF VALVE 70 90 PSI Lael FILTER 5 MICRON WATER SUPPLY Xw 0 10 PSI QUICK COUPLER BOOST PUMP SUCTION STRAINER GPM AT 70 90 PSI 20 MESH TORO Hydroject 3000 4000 Water System Operation 49 System Operation 1 2 10 Water is supplied to the unit by a water supply hose or a portable water supply tank The water passes through the pre filter On the Hydroject amp 3000 the inlet water flows to the pressure reducing valve where the water pressure is reduced to 90 PSI The Hydroject amp 4000 does not have the pressure reducing valve it is replaced by a water boost pump The boost pump supplies water to the unit The water then flows through the main 5 micron inlet filter The water then flows to an engine driven wa
18. OW LED illuminates when the transport wheels are up the accumulator nitrogen pressure is above 1800 PSI and the water pressure after the filter is adequate 15 20 PSI This light stays illuminated during aeration Switch is not on early production units NOTE The GREEN LED illuminates when the aeration start button is depressed This light stays illuminated during aeration Hydroject 4000 NOTE The RED LED illuminates when the water pressure after the filter is adequate 15 20 PSI This light stays illuminated during aeration NOTE The YELLOW LED illuminates when the accumulator nitrogen pressure is above 1800 PSI NOTE The GREEN LED illuminates when the aeration start button is depressed This light stays illuminated during aeration Relays The relays are used to energize specific components including 1 The starter 2 The pump clutch 3 The cycling valve clutch 4 The lift raise 3000 Hydroject Only 5 The lift lower 3000 Hydroject Only NOTES 22 Components TORO Hydroject 3000 4000 TORO Hydroject 3000 4000 Components 23 Transport Limit Switch 3000 Hydroject Only The transport limit switch signals the controller when the wheels are in the transport position In the transport position wheels down the switch is closed In the aerate position wheels up the switch is open NOTE On earlier units there were 2 switches for this function 2 Transmissi
19. TER QUICK COUPLER HIGH PRESSURE AERATION NOZZLES WATER SUPPLY TORO Hydroject 3000 4000 Water System Operation 53 Water Flow Through the System 1 Water enters the unit through the pre filter 2 The water then flows to the engine driven pump 3 The water flow is stopped at the cycling valve and is forced into the accumulator 4 When the cycling valve opens the water is allowed to flow to the nozzles NOTES 54 Water System Operation TORO Hydroject 3000 4000 Start up Sequence Depress engage switch Pump Begins to Pump Water Pressure Builds Relief valve opens Cycling valve engages Shut down Sequence Depress disengage switch Pump stops Water pressure drops Cycling valve stops TORO Hydroject 3000 4000 Water System Operation 55 Start Up Sequence When the engage switch is depressed The pump begins to pump Water pressure starts to build almost immediately After about three seconds the water pressure reaches about 5000 PSI and the relief valve opens After about five seconds the timer module engages the cycling clutch and the cycling valve begins to open The relief valve opens and closes to limit maximum pressure to 5000 PSI DR Shut Down Sequence The operator depresses the disengage switch T
20. Water System Testing 77 _ com O gt UOOUrP cou wm e OOU gt Review Questions Minimum water system inlet flow is 4 3 GPM 3 4 GPM 5 4 GPM 1 1 GPM Accumulator pre charge pressure is 5000 PSI 1000 PSI 90 PSI 2500 PSI Maximum water system relief valve pressure setting is 5000 PSI 1000 PSI 90 PSI 2500 PSI Correct valve lift is 125 250 090 102 009 0102 0125 0250 Low accumulator pre charge pressure is cause by Water leaking past the seals and collecting on top of the piston Accumulator overcharged with nitrogen Leaking water relief valve Accumulator undercharged with nitrogen gt N mmoogo o mUOw gt Low water system pressure is caused by Leaking relief valve Low water supply flow Low pump output Worn injection nozzles All of the above None of the above Normal operating pressure of the water system while aerating is 5000 to 5500 PSI 3500 to 4000 PSI 2500 to 3500 PSI 1000 to 3000 PSI Low valve lift is caused by Water valve housing not correctly shimmed to cam housing Worn cam lobe None of the above All of the above High accumulator pressure is caused by Water leaking past the seals and collecting on top of the piston Accumulator overcharged with nitrogen Leaking water relief valve Accumulator undercharg
21. ause the valve to leak or continue to spray after the valve has closed e A sticking valve spool can cause water to continue to spray when the valve should be closed e The valve needs to be repaired or replaced NOTES 64 Water System Testing TORO Hydroject 3000 4000 j cum TORO Hydroject 3000 4000 Water System Testing 65 Servicing high pressure water components can cause personal injury if the system pressure is not relieved before servicing any components To bleed the high pressure water open the bleed valve and slowly relieve the water pressure Avoid contact with the high pressure water stream NOTES 66 Water System Testing TORO Hydroject 3000 4000 TORO Hydroject 3000 4000 Water System Testing 67 Water Pressure Test Install the water system pressure gauge TOR4005 into the port in the water valve housing NOTE Operating the machine for an extended period of time with the gauge installed can damage the gauge Interpreting Test Results and Operational Effects High water pressure exceeds 5000 PSI Cause Relief valve sticking or misadjusted Effect Engine kills high horsepower requirements Pump damage Shortened drive belt life Low Water Pressure Cause Leaking relief valve Leaking cycling valve Worn pump seals Low water supply Air in the system Effect Shallow hole depth NOTES
22. e Preparation for Storage 1 2 With the engine off and the key removed rotate the engine until resistance is felt than continue to rotate the engine an additional 1 4 turn This opens the cycling valve Using the appropriate fittings connect a compressed air supply to the water inlet of the machine Maximum pressure 150 PSI Minimum 90 PSI Remove one aeration nozzle from each end of the nozzle manifold see service bulletin Specialty 08 07 The spring check in the nozzle prevents water from being forced out by the air pressure Removing the nozzles insure that the pump and manifold is drained Let the compressed air flow through the system for three minutes Temporarily open the high pressure drain valve and the spray wash valve if eguipped NOTES 80 Maintenance TORO Hydroject 3000 4000 HYDROJECT 3000 4000 Maintenance Schedule Minimum Recommended Maintenance Intervals Maintenance Procedure Maintenance Interval amp Service Check Battery Fluid Level Check Battery Cable Connections Lubricate All Grease Fittings Change Engine Oil Replace Engine Oil Filter Clean Engine Pre cleaner Air Filter Replace Air Filter Element Replace Fuel Filter Adjust Water System Cam Valve Clearance Clean Engine Crankcase Breather Change Gear Case Oil and Filter 3000 Only Change Pump Case Oil Torque Wheel Lug Nuts Service Accumulator Adjust Parking Brake 3000 Only
23. e water pressure gauge reads low water pressure this indicates that the water filter needs to be serviced Remove the filter body with the filter wrench and discard the old filter element Thoroughly clean the body and inspect the sealing O Ring Install a new filter and lubricate the sealing O Ring with a light coat of petroleum jelly Thread the filter body into the filter head and hand tighten NOTE Water quality will affect the service life of the filter NOTE A filter wrench is included with each machine NOTES 32 Components TORO Hydroject 3000 4000 TORO Hydroject 3000 4000 Components 33 Bleed Valve Located on the top of the filter is a red water filter bleed valve This valve is used to bleed air from the system after changing the filter or prior to aerating NOTE The air must be bled from the system each time the water system is initially connected to or reconnected to the supply hose Water Pressure Gauge The water pressure supply gauge displays the water pressure available after the filter Check this gauge to ensure the water system is pressurized Check the gauge during operation to observe the pressure drop across the filter This gauge also includes a pressure sender If the water inlet pressure drops below 20 PSI the sender will shut the water system down This prevents cavitation of the high pressure water pump NOTE A plugged pre filter or water filter will cause th
24. e water pressure to drop below 20 PSI This will shut the water system down NOTES 34 Components TORO Hydroject 3000 4000 TORO Hydroject 3000 4000 Components 35 Water Pump The current water pump is a Toro designed water pump The pump supplies the pressurized water which is stored in the accumulator The pump requires 3 4 to 4 0 GPM supply water flow to pressurize the system to 5000 PSI and maintain adequate water flow NOTE The pump uses non detergent 40 wt oil Mobil DTE EXTRA HEAVY Water Pump Head This is the internal components of the water pump head A steel sleeve with a sprayed on ceramic coating has replaced the ceramic sleeve on the end of the piston rod Longer life and less maintenance NOTES 36 Components TORO Hydroject 3000 4000 TORO Hydroject 3000 4000 Components 37 Piston Type Accumulator The piston type accumulator stores high pressure water from the water pump The water is stored until it is needed for the injection cycle When the cycling valve opens the high volume discharge is directed to the injection nozzles NOTE The accumulator is precharged with 2500 PSI Dry Nitrogen NO SUBSTITUTE NOTE Later units are equipped with a low nitrogen pressure switch This switch will not allow the water system to
25. e water pump begins to pump water is forced into the accumulator 2 The piston moves upwards as water is forced into the accumulator compressing the nitrogen gas 3 The nitrogen pressure and the water pressure are the same Ready for aeration 1 The piston in the accumulator is about half way up 2 The water pressure and the nitrogen pressure are the same approximately 5000 PSI relief valve setting Cycling valve opens 1 As the cycling valve opens water is discharged to the injection nozzles 2 The piston moves downward approximately 1 4 in Cycling valve closes 1 As the cycling valve closed the water stop flowing to the nozzles 2 The water from the water pump flows into the accumulator and the piston moves up The cycle begins again 5 3 times a second NOTES 40 Components TORO Hydroject 3000 4000 Water Flow TORO Hydroject 3000 4000 Components 41 Water Cycling Valve The water cycling valve is connected to the bottom of the accumulator The cycling valve is a cam driven valve The cycling valve releases the high pressure water to the injection nozzles The cycling valve opens at a rate of 5 3 times a second NOTE The water is released as the spool Item 2 lifts off the seat Item 1 NOTES 42 Components TORO Hydroject 3000 4000 DENN Vu War AND Br TORO Hydroject 3000
26. ed with nitrogen Both A amp B 10 The Accumulator pre charge may decrease A B because of normal operational losses True false 78 Storage Storage Rotate engine until cycling valve is open Remove one aeration nozzle on each end of manifold Connecta compressed air supply to the water inlet Let compressed air flow through the machine for 3 minutes emporarily ope high pressure drain valve and spray wash valve if equipped Ready for storage TORO Hydroject 3000 4000 Preparation for winter storage or if unit is out of service for an extended period With the engine off and the key removed rotate engine until resistance is felt then continue to rotate coupling an additional 1 4 turn opening the cycling valve The spring check in the nozzle prevents water from being forced out by the air pressure removing a nozzle insures that the pump and manifold is drained Minimum Pressure 90 Psi TORO Hydroject 3000 4000 Storage 79 Storage The unit must be properly prepared for storage If the unit is being stored for the winter the water must be drained to prevent freezing and damage to the components Due to varying water quality and the use of gray water the water should also be drained from the unit if the unit will be out of service for an extended period of tim
27. els 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 NOTES 18 Components TORO Hydroject 3000 4000 TORO Hydroject 3000 4000 Components 19 Roller Cleaning System 3000 Hydroject Only The spray wash nozzles prevent debris buildup on the rollers A knob on the instrument panel regulates the volume of water going to these nozzles Pulling or pushing the spray wash knob increases or decreases the spray rate These nozzles also help purge air from the water system after connecting the water supply Battery The battery is specially designed to withstand vibration It is a group 28 with 525 cold cranking amps NOTE The battery is shipped dry NOTES 20 Components TORO Hydroject 3000 4000 TORO Hydroject 3000 4000 Components 21 Controller The controller is a solid state timing device used to regulate monitor the input functions 3 colored lights monitor these functions Red Yellow and Green Hydroject 3000 NOTE The RED LED illuminates when the Hydroject is moving transmission not in neutral The micro switch that controls this function in normally closed NOTE The YELL
28. ented 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 NOTES 4 Overview TORO Hydroject 3000 4000 Comparison Hydroject 3000 Hydroject 4000 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 Regulator Valve TORO Hydroject 3000 4000 Overview 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
29. fect Short pulse duration does not release adequate water and hole depth can be affected Relief valve opens frequently wasting energy Excessive clearance between cam and valve can cause stress on the valve NOTES 76 Water System Testing TORO Hydroject 3000 4000 Test Equipment 1 Accumulator Test Recharge tool TOR4001 2 Water system pressure gauge TOR4005 3 Water flow meter TOR4006 4 Valve lift indicator TOR4007 Troubleshooting Tips Before connecting any test equipment to the water system fully relieve water pressure by opening the water system drain valve Troubleshooting the system consists of performing logical tests along the path of the water If any test is incorrect the component must be repaired before continuing with the test The most important test equipment is the flow meter and the water system pressure gauge Bleed air form the system and operate the unit at high idle Operating a correct unit is very helpful to understand how it works and what it sounds like 4 seconds after startup the cycling valve clutch is engaged The minimum operating pressure should be no less than 3500 PSI and should be closer to 4000 PSI If the pressure cycles down to 0 PSI within 10 15 seconds pump input flow is low or nozzle output flow is high If the gauge swings wildly from 0 5000 PSI the accumulator precharge is very low or empty TORO Hydroject 3000 4000
30. he pump stops Water pressure begins to drop the pump has stopped but the cycling valve continues to operate After about 3 seconds the cycling valve clutch is disengaged and the cycling valve stops The cycling valve continues to run after the pump stops to bleed some of the pressure from the water circuit PON gt NOTES 56 Water System Operation TORO Hydroject 3000 4000 Section Review 1 Inlet water quality is extremely important to the overall life of the water system 2 During the initial start up the pump will operate for 5 seconds before the cycling valve opens During these 5 seconds the pressure should initially go up to 4500 5000 PSI and then the relief valve should open 3 On the Hydroject 3000 when the relief valve opens you should hear water spraying from the roller wash nozzles 4 High pressure water supplied by the pump is stored in the accumulator until needed 5 After about 5 seconds the cycling valve opens and aeration starts TORO Hydroject 3000 4000 Water System Operation 57 c com Domz gt Um Ow gt Review Questions During start up the components start in this order Cycling valve relief valve water pump Water pump relief valve cycling valve Relief valve cycling valve water pump Water pump cycling valve relief valve The engagement of the cycling valve is controlled by the accumulator pressure switch
31. mulator pressure over 1800 psi If the yellow light is not on check the water inlet pressure at the pressure gauge If pressure is inadequate check the pre filter main water filter and supply hose If the water pressure is adequate check the pump start limit switch this is the switch on the transport axle The switch should be closed when the wheels are up unit down Replace switch as needed The final check is the accumulator pressure If accumulator pressure is below 1800 psi the accumulator switch will be open and the light will not be on Contact your distributor to have accumulators checked or serviced 3 Check the Green light on the control module e The green light is on when the aerate switch is pressed e This light stays on while the unit is aerating If this light does not light when the aerate switch is depressed check the switch and wiring Repair or replace as necessary NOTES 60 Water System Testing TORO Hydroject 3000 4000 Shallow Hole Depth Shallow hole depth could be caused by soil contitions Test High Pressure Water No 3500 4000 PSI While operatin Yes Disconnect Cycling valve clutch wire and check for relief valve pressure of 5000 PSI minimum Check Relief Valve With in Spec Rebuild or Replace Releif Valve Yes Yes affect hole depth Accumulator not kept full
32. on Switches 3000 Hydroject Only The top switch is normally open and closes to enables the engine to start when the hydrostatic control is in the neutral position The lower switch is normally closed and is connected to the controller If the Hydroject is pumping water and the operator leaves the traction drive in neutral this switch signals the controller to shut down the high pressure pump and the cycling valve after 4 seconds NOTES 24 Components TORO Hydroject 3000 4000 Mad If m LOC NES YA Mew im N r TORO Hydroject 3000 4000 Components 25 2 Electric Clutches There are two electric clutches that connect the engine to the water pump and the cycling valve When the operator depresses the ENGAGE button the first clutch energizes engaging the water pump After the water pump builds the required pressure the control module engages the second clutch engaging the cycling valve and starting the aeration cycle If at any time the water supply pressure drops below 15 20 PSI or if the traction unit stops the water pump clutch and cycling valve will disengage Electric Clutch Testing and Adjustment Both clutches should measure 3 Ohms of resistance across the coil when tested with an Ohmmeter For the clutches to operate properly the correct air gap must be maintained The air gap is checked with a feeler gauge and set to 018 NOTES
33. problem could be with the pump e Repair or replace the pump as necessary 3 Test accumulator pressure e The accumulator stores high pressure water until the cycling valve opens e Accumulator pressure effects the water available for delivery Low pressure caused by nitrogen leaking from the accumulator High pressure caused by water leaking past the O Rings trapped on top of the pistons 4 Check nozzle hole size e Worn aeration nozzles will increase water flow and decrease the aeration pressure NOTES 62 Water System Testing TORO Hydroject 3000 4000 Water spray not Slit inTurf Between Holes stopping between cycles Kahane Valve lift to high can ia prevent valve from completely closing Within Spec Yes Yes Water leaking through Check Water Valve rebuild or valve or spool sticking Spool and seat No replace can prevent water from Within spec watervalve stopping between cycles Yes Yes Check Holes lt TORO Hydroject 3000 4000 Water System Testing 63 Complaint Slit in Turf Between Holes 1 Check water valve lift e If the valve lift is too high the valve may stay open too long and this makes the water injection cycle too long Adjust the valve lift height 2 Check valve e A bad seat or spool can c
34. rogen Effect With the higher accumulator pressure the area in the accumulator to store the water from the pump decreases and the capacity of the accumulator is decreased NOTES 72 Water System Testing TORO Hydroject 3000 4000 TORO Hydroject 3000 4000 Water System Testing 73 Water Flow Test Connect the flow meter TOR4006 to the water inlet Water flow with the unit operating and the spray wash closed should be more than 3 4 GPM Low Water Flow Cause Leaking waterpump valves Effect Low water flow through the system can cause shallow penetration depth because the accumulator may not adequately fill between injection cycles NOTES 74 Water System Testing TORO Hydroject 3000 4000 TORO Hydroject 3000 4000 Water System Testing 75 Valve Lift Test Remove the test cap from the feeder manifold and install the valve lift indicator TOR4007 Make sure that the dial indicator contacts the water valve Zero out the dial indicator Rotate the engine drive coupling and watch the dial indicator The proper valve lift should be 0 090 to 0 102 Valve lift too high Cause Water valve housing not correctly shimmed the cam housing Effect Water valve is open longer than necessary May leave slits between aeration holes Valve lift to low Water valve housing not correctly shimmed to the cam housing Worn cam lobe or valve roller Ef
35. ter pump The water pump is capable of delivering water in excess of 5000 PSI The water is then pumped to the accumulator The accumulator stores the high pressure water until it is needed at the aeration nozzles The relief valve limits the water pressure to 5000 PSI The water valve cycling valve is a cam operated valve driven by the unit s engine This valve opens and closes to direct the high pressure water stream to the aeration nozzles From the cycling valve the water flows to the aeration nozzles the nozzles contain a spring loaded check ball which prevents water from leaking out of the manifold and air getting in the system NOTES 50 Water System Operation TORO Hydroject 3000 4000 System Startup STATUS Engine Running Water supply connected Wheels up 3000 STATUS Cycling valve is closed Set Throttle to Accumulator is charged Full Throttle to 2500 PSI There is no water in the accumulator RESULT Pump starts to fill the accumulator with water Operator depresses engage button 5 seconds after pump System pressure engagement reaches 5000 PSI the timer Accumulator is half full module of water and nitrogen engages Relief valve opens cycling valve As the cycling valve opens the accumulator releases water through the cycling valve the manifold and out the nozzles
36. ting the supply hose will bleed air from the supply hose NOTES 28 Components TORO Hydroject 3000 4000 TORO Hydroject 3000 4000 Components 29 Pressure Regulator Valve 3000 Hydroject Only The pressure regulator valve is used to reduce the inlet water pressure to protect the water filter and the rest of the water system from high pressure water spikes Early units were not equipped with the pressure regulator but it can be installed NOTE The pressure regulator is set to 90 PSI NOTE Kit number for the pressure regulator pre filter kit 92 9541 NOTE This kit also includes the pre filter and all necessary water fittings Boost Pump 4000 Hydroject Only The 4000 Hydroject uses a boost pump to supply water to the system NOTE There is a 90 PSI relief valve connected into the circuit to protect the system components NOTES 30 Components TORO Hydroject 3000 4000 P TORO Hydroject 3000 4000 Components 31 Water Filter The water filter is a replaceable 5 micron cartridge filter located in a blue plastic housing It is located under the machine on the Hydroject 3000 and on the top left side on the Hydroject 4000 NOTE NEVER OPERATE THE MACHINE WITH OUT THIS FILTER The filter stops harmful particles from entering the high pressure water system Filter Element PN 86 8630 O Ring PN 92 9543 Water Filter Replacement When th
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