Toro 09802, HydroJect 3010 Operator's Manual

FormNo.3360-899RevB

HydroJect

ModelNo.09802—SerialNo.280000001andUp

®

3010Aerator

ToregisteryourproductordownloadanOperator'sManualorPartsCatalogatnocharge,gotowww.T oro.com.OriginalInstructions(EN)

Introduction

Important:Theengineinthisproductisnot

equippedwithasparkarrestermufer.Itisa
violationofCaliforniaPublicResourceCode
Section4442touseoroperatethisengineonany
forest-covered,brush-covered,orgrass-covered
landasdenedinCPRC4126.Otherstatesor
federalareasmayhavesimilarlaws.

Readthisinformationcarefullytolearnhowtooperate
andmaintainyourproductproperlyandtoavoidinjury
andproductdamage.Youareresponsibleforoperating
theproductproperlyandsafely.

YoumaycontactTorodirectlyatwww .T oro.comfor
productandaccessoryinformation,helpndinga
dealer,ortoregisteryourproduct.

Thismanualidentiespotentialhazardsandhas
safetymessagesidentiedbythesafetyalertsymbol
(Figure1),whichsignalsahazardthatmaycauseserious
injuryordeathifyoudonotfollowtherecommended
precautions.

Figure1

1.Safetyalertsymbol

Thismanualuses2otherwordstohighlightinformation.
Importantcallsattentiontospecialmechanical
informationandNoteemphasizesgeneralinformation
worthyofspecialattention.

Warning

Wheneveryouneedservice,genuineToroparts,or
additionalinformation,contactanAuthorizedService
DealerorToroCustomerServiceandhavethemodel
andserialnumbersofyourproductready.Themodel
andserialnumbersareonaplateontheproduct.Write
thenumbersinthespaceprovided.

ModelNo.

SerialNo.

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

ThissparkignitionsystemcomplieswithCanadian
ICES-002.

©2008—TheT oro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420

Contactusatwww.T oro.com.

2

PrintedintheUSA.

AllRightsReserved

Contents

Introduction.................................................................2

Safety...........................................................................4

SafeOperatingPractices.......................................4

SafetyandInstructionalDecals.............................6

Setup............................................................................9

1InstallingtheRearWheels..................................9

2ActivatingandChargingtheBattery....................9

3CheckingtheTirePressure...............................11

ProductOverview......................................................12

Controls.............................................................12

Specications.....................................................13

Attachments/Accessories...................................13

DepthsandNozzleCongurations.....................14

..........................................................................14

Operation...................................................................15

ThinkSafetyFirst...............................................15

CheckingtheEngineOil.....................................15

FillingtheGasTank...........................................15

CheckingtheGearCaseFluidLevel....................16

CheckingthePumpCaseOilLevel......................17

WaterSystemAccumulator.................................18

OperatingPrecautions........................................18

StartingandStoppingtheEngine........................18

TrainingPeriod...................................................18

WaterSupply......................................................19

OperatingProcedure..........................................19

CheckingtheInterlockSystem............................20

TransportOperation..........................................21

InspectionandClean-UpAfterUse.....................21

PushingorTowingtheMachine..........................21

Maintenance...............................................................23

RecommendedMaintenanceSchedule(s)................23

WaterSystemAccumulator.................................23

DailyMaintenanceChecklist...............................24

LubricatingtheMachine.....................................25

ServicingthePre-Filter.......................................26

ReplacingtheMainWaterFilter..........................26

ChangingtheEngineOilandFilter.....................27

GeneralAirCleanerMaintenance.......................27

ServicingtheAirCleaner....................................27

CheckingandReplacingtheSparkPlugs..............28

ChangingtheGearCaseOilandFilter.................29

ChangingthePumpCaseOil..............................30

CheckingtheHydraulicLinesandHoses.............30

AdjustingtheTractionPumpBelt.......................30

AdjustingtheTransmissionforNeutral...............31

AdjustingtheAerationSpeed..............................32

AdjustingtheParkingBrake................................32

AdjustingtheRollerSprayWashSystem..............33

ServicingtheSprayWashNozzlesor

Strainers.........................................................33

CaringfortheBattery.........................................33

Storage.......................................................................34

PreparingtheWaterSystem................................34

PreparingtheEngine..........................................34

PreparingtheTractionUnit................................34

Troubleshooting.........................................................35

Schematics.................................................................38

3

Safety

Improperuseormaintenancebytheoperatoror
ownercanresultininjury.Toreducethepotential
forinjury,complywiththesesafetyinstructions
andalwayspayattentiontothesafetyalert
symbol,whichmeansCAUTION,WARNING,or
DANGER-"personalsafetyinstruction."Failureto
complywiththeinstructionmayresultinpersonal
injuryordeath.

SafeOperatingPractices

–Neverrefuelordraintheaeratorindoors.

•Checkthattheoperatorpresencecontrols,safety
switchesandshieldsareattachedandfunctioning
properly.Donotoperateunlesstheyarefunctioning
properly.

Operation

•Onlyoperateingoodlight,keepingawayfromholes
andhiddenhazards.

•Besurealldrivesareinneutralandparkingbrakeis
engagedbeforestartingengine.Starttheengineonly
fromtheoperatorsposition.

ThefollowinginstructionsarefromANSIstandard
B71.4-2004.

Training

•ReadtheOperator’sManualandothertraining
material.Iftheoperator(s)ormechanic(s)cannot
readEnglishitistheowner’sresponsibilitytoexplain
thismaterialtothem.

•Becomefamiliarwiththesafeoperationofthe
equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained.The
ownerisresponsiblefortrainingtheusers.

•Neverletchildrenoruntrainedpeopleoperateor
servicetheequipment.Localregulationsmayrestrict
theageoftheoperator.

•Theowner/usercanpreventandisresponsiblefor
accidentsorinjuriesoccurringtohimselforherself,
otherpeopleorproperty.

Preparation

•Evaluatetheterraintodeterminewhataccessories
andattachmentsareneededtoproperlyand
safelyperformthejob.Onlyuseaccessoriesand
attachmentsapprovedbythemanufacturer.

•Wearappropriateclothingincludinghardhat,safety
glassesandhearingprotection.Longhair,loose
clothingorjewelrymaygettangledinmovingparts.

•Inspecttheareawheretheequipmentistobeused
andremoveallobjectssuchasrocks,toysandwire
whichcanbecontactedbytheaerator.

•Useextracarewhenhandlinggasolineandother
fuels.Theyareammableandvaporsareexplosive.

–Useonlyanapprovedcontainer.

•Neveroperatewithouttheshields,coversorother
guardssecurelyinplace.Besureallinterlocksare
functioningproperly .

•Keephandsandfeetawayfromthenozzleand
rollerarea.Highvelocitywaterjetscanpenetrate
handsandfeet.Penetrationbythehighvelocity
waterjetscancauseseriouspersonalinjury.If
accidentalpenetrationoccurs,seekmedicalattention
immediately.

•Neverusechemicalsinthewatersupplysystem.

•Donotoperatethewaterinjectionsystem
onconcreteorasphaltbecausewaterjetswill
permanentlydamagethesesurfaces.

•Beforedisconnectingorperforminganyworkon
thewatersystem,allpressureinthesystemmust
berelievedbystoppingtheengineandopeningthe
bleedvalve.Openingthebleedvalveallowsany
trappedwatertoescapefromthesystemandalso
allowstheaccumulatorpistontomovetothebottom
oftheaccumulatorcylinder.

•Donotchangetheenginegovernorsettingor
overspeedtheengine.

•Theaccumulatorinthismachinecontainshigh
pressuredrynitrogen.Accumulatorservicing
requiresspecialtoolsandprecautions.Accumulators
donotcontainuserserviceablecomponents.
Improperaccumulatorservicingcancause
dismembermentordeath.Donotattemptto
disassembleanaccumulator;havethisworkdoneby
anAuthorizedToroDistributor.

•Stoponlevelground,disengagedrives,engage
parkingbrake,shutoffenginebeforeleavingthe
operator’spositionforanyreason.

•Nevercarrypassengersandkeeppetsandbystanders
away.

–Neverremovegascaporaddfuelwithengine

running.Allowenginetocoolbeforerefueling.
Donotsmoke.

•Bealert,slowdownandusecautionwhenmaking
turns.Lookbehindandtothesidebeforechanging
directions.

4

•Slowdownandusecautionwhencrossingroads
andsidewalks.

•Donotoperatetheaeratorundertheinuenceof
alcoholordrugs.

•Useextremecarewhenloadingorunloadingthe
aeratorintoatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs,
trees,orotherobjectsthatmayobscurevision.

•Alwaysbeawareofobstaclesthatmaybeinthe
areaofoperation.Planyouraerationpathtoavoid
contactwithanyobstaclebyyouorthemachine.

SlopeOperation

•Donotoperateneardrop-offs,ditches,steepbanks
orwater.Wheelsorrollersdroppingoveredgescan
causerollovers,whichmayresultinseriousinjury
ordeath.

•Donotoperateonslopeswhengrassiswet.Slippery
conditionsreducetractionandcouldcausesliding
andlossofcontrol.

•Makesureallhydrauliclineconnectorsaretightand
allhydraulichosesandlinesareingoodcondition
beforeapplyingpressuretothesystem.

•Keepyourbodyandhandsawayfrompinhole
leaksornozzlesthatejecthydraulicuidunder
highpressure.Usepaperorcardboard,notyour
hands,tosearchforleaks.Hydraulicuidescaping
underpressurecanhavesufcientforcetopenetrate
theskinandcauseseriousinjury.Seekimmediate
medicalattentionifuidisinjectedintoskin.

•Beforedisconnectingorperforminganyworkon
thewatersystem,allpressureinthesystemmust
berelievedbystoppingtheengineandopeningthe
bleedvalve.Openingthebleedvalveallowsany
trappedwatertoescapefromthesystemandalso
allowstheaccumulatorpistontomovetothebottom
oftheaccumulatorcylinder.

•Letenginecoolbeforestoringanddonotstorenear
ame.

•Shutofffuelwhilestoringortransportingontrailers.
Donotstorefuelnearamesordrainindoors.

•Donotmakesuddenturnsorrapidspeedchanges.

•Reducespeedanduseextremecautiononslopes.

•Removeormarkobstaclessuchasrocks,treelimbs,
etc.fromtheoperatingarea.Tallgrasscanhide
obstacles.

•Watchforditches,holes,rocks,dips,andrisesthat
changetheoperatingangle,asroughterraincould
overturntheaerator.

•Beawarethatlossoftractionmayoccurgoing
downhill.Weighttransfermaycausedrivewheelto
slipandcauselossofbrakingandsteering.

•Beawarethatlossoftractionmayoccurgoing
downhill.Weighttransfermaycausedrivewheelto
slipandcauselossofbrakingandsteering.

•Alwaysavoidsuddenstartingorstoppingonaslope.
Iftirelosestraction,disengagethewaterinjection
systemandproceedslowlyofftheslope.

MaintenanceandStorage

•Parkmachineonlevel,hardground.Neverallow
untrainedpersonneltoservicemachine.

•Usejackstandsorsafetylatchestosupport
componentswhenrequired.

•Carefullyreleasepressurefromcomponentswith
storedenergy.

•Disconnectbatteryorremovesparkplugwirebefore
makinganyrepairs.Disconnectthenegativeterminal
rstandthepositivelast.Reconnectpositiverst
andnegativelast.

•Keephandsandfeetawayfrommovingparts.If
possible,donotmakeadjustmentswiththeengine
running.

•Chargebatteriesinanopenwellventilatedarea,
awayfromsparkandames.Unplugchargerbefore
connectingordisconnectingfrombattery.W ear
protectiveclothinganduseinsulatedtools.

•Keepallpartsingoodworkingconditionandall
hardwaretightened.Replaceallwornordamaged
decals.

Engineexhaustcontainscarbonmonoxide,
whichisanodorless,deadlypoisonthatcan
killyou.

Donotrunengineindoorsorinanenclosed
area.

•UseonlyToro-approvedattachments.W arrantymay
bevoidedifusedwithunapprovedattachments.

5

SoundPressureLevel

VibrationLevel

ThisunithasanequivalentcontinuousA-weighted
soundpressurelevelattheoperatorearof93dBA,based
onmeasurementsofidenticalmachinesperDirective
98/37/ECandamendments.

SoundPowerLevel

Thisunithasaguaranteedsoundpowerlevelof:
108dBA/1pW ,basedonmeasurementsofidentical
machinesperDirective2000/14/ECandamendments.

SafetyandInstructionalDecals

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaof
potentialdanger.Replaceanydecalthatisdamagedorlost.

Thisunitdoesnotexceedavibrationlevelof4.0m/s
thehandsbasedonmeasurementsofidenticalmachines
perISO5349procedures.

2

at

80-8000

93-9363

1.Parkingbrake3.Unlocked

2.Locked

80-8880

80-8090

80-8760

80-8040

6

92-9542

108-1316

72-4080

80-8010

93-9429

108-1317

7

80-9450

108-1263

1.Choke

108-1264

108-1265

8

Setup

LooseParts

Usethechartbelowtoverifythatallpartshavebeenshipped.

ProcedureDescription

Wheel3

1
2

3

Lugnut12

Bulkelectrolyte,notsupplied

Nopartsrequired

MediaandAdditionalParts

Description

IgnitionKey1Useinignitionswitch.

HoseAdapter1

SpannerWrench

Operator’sManual

PartsCatalog

Qty.

Mounttoquickcoupleronsideofmachine.

1

1

1

Useforinstallationandremovalofwaterlter.

Readbeforeoperatingtheaerator

Usetoreferencepartnumbers.

Qty.

A/R

Use

Installtherearwheels

Activateandchargethebattery .

–

Checkthetirepressure.

Use

1

InstallingtheRearWheels

Partsneededforthisprocedure:

3Wheel

12Lugnut

Procedure

1.Removethewheelsfromtheshippingpallet.

2.Mountthewheelstothehubswiththelugnuts
(suppliedinlooseparts)(Figure2)andtorquethe
nutsto45-55ft./lb.(61-75N-m).

Figure2

1.Wheel2.Lugnuts

3.Removeanyshippingblocksorbraces,whichmay
obstructmachineremovalfromthepallet.

9

Warning

2

ActivatingandChargingthe
Battery

Partsneededforthisprocedure:

Bulkelectrolyte,notsupplied

A/R

Procedure

Warning

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandleadcompounds,

chemicalsknowntotheStateofCalifornia

tocausecancerandreproductiveharm.

Washhandsafterhandling .

CALIFORNIA

Proposition65Warning

Batteryterminalsormetaltoolscouldshort

againstmetaltractorcomponentscausing

sparks.Sparkscancausethebatterygasses

toexplode,resultinginpersonalinjury.

•Whenremovingorinstallingthebattery,
donotallowthebatteryterminalstotouch

anymetalpartsofthetractor.

•Donotallowmetaltoolstoshort
betweenthebatteryterminalsand

metalpartsofthetractor.

1.Sincethebatteryisnotlledwithelectrolyteor
activated,bulkelectrolytewith1.265specicgravity
mustbepurchasedfromalocalbatterysupplyoutlet

Warning

CALIFORNIA

Proposition65Warning

Batteryelectrolytecontainssulfuricacidwhich

isadeadlypoisonandcausessevereburns.

•Donotdrinkelectrolyteandavoidcontact
withskin,eyesorclothing.Wearsafety

glassestoshieldyoureyesandrubber

glovestoprotectyourhands.

•Fillthebatterywherecleanwaterisalways
availableforushingtheskin.

2.Releasethehoodlatchesandraisethehood.

Important:Donotaddelectrolytewhilethe
batteryisinthemachine.Youcouldspillit,
causingcorrosion.

3.Loosenthecapscrewsecuringthebatteryclampto
themachineandremovethebattery(Figure3).

Figure3

1.Battery

4.Cleanthetopofthebatteryandremovethevent
caps.

5.Carefullylleachcellwithelectrolyteuntiltheplates
arecoveredwithabout1/4inch(6mm)ofuid.

6.Allowapproximately20to30minutesforthe
electrolytetosoakintotheplates.Rellasnecessary
tobringtheelectrolytetowithinabout1/4inch(6
mm)ofthebottomofthellwell.

Chargingthebatteryproducesgassesthatcan
explode.

Neversmokenearthebatteryandkeepsparks
andamesawayfrombattery.

7.Connecta3to4ampbatterychargertothebattery
posts.Chargethebatteryatarateof3to4amps

10

untilthespecicgravityis1.250orhigherandthe
temperatureisatleast60degreesF(16degreesC)
withallcellsgassingfreely.

8.Whenthebatteryischarged,disconnectthecharger
fromtheelectricaloutletandbatteryposts.

3

CheckingtheTirePressure

Note:Afterthebatteryhasbeenactivated,add

onlydistilledwatertoreplacenormalloss,although
maintenance–freebatteriesshouldnotrequirewater
undernormaloperatingconditions.

9.Installthebatteryandsecureitwiththebattery
clamp.

10.First,installthepositivecable(red)tothepositive
(+)terminalandthenthenegativecable(black)to
thenegative(–)terminalofthebattery.Slidethe
rubberbootoverthepositiveterminaltopreventa
possibleshortfromoccurring.

Warning

CALIFORNIA

Proposition65Warning

Incorrectbatterycableroutingcoulddamage

themachineandcablescausingsparks.Sparks

cancausethebatterygassestoexplode,

resultinginpersonalinjury.

•Alwaysdisconnectthenegative(black)
batterycablebeforedisconnectingthe

positive(red)cable.

NoPartsRequired

Procedure

Thetiresareover–inatedforshipping.Therefore,
releasesomeoftheairtoreducethepressure.Correct
airpressureinfrontandreartiresis8–12psi.

•Alwaysconnectthepositive(red)
batterycablebeforeconnectingthe

negative(black)cable.

Warning

CALIFORNIA

Proposition65Warning

Connectingcablestothewrongpost

coulddamagetheelectricalsystemand

resultinpersonalinjury.

Note:Makesurebatterycablesareroutedaway
fromanysharpedgesormovingparts.

11.Lowerthehoodandsecurethelatches.

11

ProductOverview

Controls

HourMeter

Thehourmeter(Figure4)registersaccumulatedhours
ofengineoperation.Usethehourmetertodetermine
intervalsforservicemaintenanceandlubrication.

IgnitionSwitch

Theignitionswitch(Figure4),whichisusedtostart
andstoptheengine,hasthreepositions:OFF ,ON,and
START.

Figure4

1.Ignitionswitch6.Waterpressuregauge

2.Choke7.Circuitbreakerreset

3.Throttle

4.Spraywashcontrol

5.Hourmeter

button

8.Spacingcontrollever

9.Accumulatorpressure
lights

WaterPressureGauge

Thewaterpressuregauge(Figure4)registerssupply
waterpressureinthesystem.Italsoactsasaninterlock
switch,preventingthewaterpumpfromstartingifthe
waterpressureisbelow20-28p.s.i.,orstoppingthewater
pumpifthewaterpressuredropsbelow7-13p.s.i.Check
thegaugefrequentlytomonitorthewaterpressure.

CircuitBreakerResetButton

Pushthebutton(Figure4)toresetthebreakerafter
correctingamalfunctionintheelectricalsystem.The
buttonalsoservesasaswitchtointerruptpowertothe
relays.

SpacingControlLever

Movingthecontrol(Figure4)awayfromthehandle
increasestheaeratinggroundspeedandthedistance
betweenholes.Movingthecontroltowardthehandle
decreasestheaeratinggroundspeedandthedistance
betweenholes.Thesettingwillbeoverriddenwhenthe
machineisshiftedtothetransportposition.

AccumulatorPressureLights

Choke

Tostarttheengine,closethecarburetorchokebypulling
thechokecontrol(Figure4)outwardtotheFULL
position.Aftertheenginestarts,regulatethechoketo
keeptheenginerunningsmoothly.Assoonaspossible,
openthechokebypushingitinwardtotheOFFposition

Throttle

Thethrottle(Figure4)isusedtoregulatetheengine
speed.Movingthethrottleforwardincreasestheengine
speed(FAST);rearwarddecreasestheenginespeed
(SLOW).

SprayWashControl

Pullthehandle(Figure4)upwardtoactivatetheroller
spraywashsystem.Movethecontrolknobupordown
toadjustthesprayratetokeeptherollersfreeofdebris.

Thehighorlowpressurelights(Figure4)willonly
illuminateifahighorlowpressureconditionoccurs
intheaccumulator.Ifalightilluminatesthesystem
willlnotoperateorwillshutdown,ifoperating.Refer
toWaterSystemAccumulatorinformationinthe
Operationsection.

TractionBail

Thetractionbail(Figure5)engagesandregulatesfore
andafttractionoperationofthemachine.Releasingthe
bailstopstractionoperationandwillalsostopwater
injectionin3to4seconds,unlessthebailisre-engaged.
Thetransportspeedisregulatedbytheamountthebail
ismoved.

12

Specications

Note:Specicationsanddesignaresubjecttochange

withoutnotice.

Figure5

1.Tractionbail4.Aerationstopbutton

2.Transport/aeraterocker
switch

3.Aerationengagement
button

5.Parkingbrake

Transport/AerateRockerSwitch

Theswitch(Figure5)lowersmachineontotherollers
tocommenceaeration.Theswitchwilloverridethe
spacingcontrolsettingwhenitismovedtothetransport
position.

Length

Wheelbase

Width

Height

Weight

96.2inches(244cm)

53.2inches(135cm)

63inches(160cm)

38.2inches(97cm

1120lb.(508kg)

Attachments/Accessories

AselectionofToroapprovedattachmentsand
accessoriesareavailableforusewiththemachineto
enhanceandexpanditscapabilities.Contactyour
AuthorizedServiceDealerorDistributororgoto
www.Toro.comforalistofallapprovedattachments
andaccessories.

AerationEngagementButton

Depressingthebutton(Figure5),startsthewater
injectionsystemonlywhenthewaterpressureisabove
28p.s.i.andtherollersareontheground.

AerationStopButton

Theredbutton(Figure5)stopsthewaterinjection
system.Thesystemcontinuesforafewsecondsafter
thebuttonispressed.

ParkingBrake

Pushthelever(Figure5)towardthemachinetoengage
theparkingbrake.Awarningbuzzerwillsoundif
youattempttomovethemachinewithparkingbrake
engaged.

FuelShut-OffValve

Thefuelshut-offvalveislocatedunderthefueltank.
Closethevalvewhenstoringortransporting(trailering)
themachine.

13

DepthsandNozzleCongurations

Allnozzlesareidentiedwithnumbersindicatingthedrillsizeoftheorice.Thestandardcongurationis11
nozzlesproducingdepthsof4to6inchesdependingonturfconditions.Blockednozzlelocationsareobtainedby
reversingthenozzlecheckvalveballandspring.Seenozzlesizechartandillustrationsbelow:

Important:Useonlynozzlecongurationsshownordamagetothemachinemayoccur.

NozzleSizeandApproximateDepthChart

PartNo.

86-8130

86-8131

86-8133

DrillSize

#56

#53

#46

DecimalSize

(inch)

0.04651.181

0.05951.5111104-6inches

0.0812.0576

*Useonlywithvariedsizecongurations

MetricSize

(mm)

QuantityofNozzles

Open

***

Important:AluminumWasher,ToroPartno.80-6680,isrequiredwithanynozzlechange.

OptionalStaggeredSizeNozzleConguration

PartNo.

86-8130

86-8133

DrillSize

#56

#46

**Additionalnozzlesmaybeblockedtocompensateforpumpwear .

DecimalSize

(inch)

0.04651.1816and

0.0812.057

MetricSize

(mm)

QuantityofNozzles

OpenBlocked**

5

Important:AluminumWasher,ToroPartno.80-6680,isrequiredwithanynozzlechange.

Approximate.

Blocked

5

0**

0**

Depth

6-8inches

Approximate.

Depth

3-4inches

6-8inches

Figure6

OpenNozzle

1.Checkvalveball2.Spring

Figure7

Closed(Blocked)Nozzle

1.Spring2.Checkvalveball

14