FORM NO. 3318-402 GB Rev A
®
MODEL NO. 09801—60001 & OVER
HYDROJECT® 3000 AERATOR
OPERATOR'S
MANUAL
©The T oro Company—1996
Foreward
The Hydroject 3000 is a water aerification device that penetrates and breaks up the soil with high-velocity water jets. This
machine operates with minimal disruption to the playing surface since there are no cores to remove after aerification.
After a quick rinse or irrigation cycle, the putting surface is ready for play.
The machine was designed to use water and NOT CHEMICALS. Since so many varieties of chemicals are used in the
Golf environment and since these chemicals react differently with Hydroject components, the Toro Company will not
accept responsibility for equipment or environmental damage caused by using chemicals. Using chemicals in your equipment is done at your own risk!
The Hydroject 3000 releases a tremendous energy through the spray nozzles. DO NOT OPERATE THIS UNIT ON CONCRETE OR ASPHALT BECAUSE IT WILL PENETRATE THESE SURFACES.
Since this is a high-quality product, Toro is concerned about the future use of the machine and safety of the user.
Therefore, read this manual to familiarize yourself with safety, operation and maintenance instructions. Certain information in this manual is emphasized. DANGER,WARNING and CAUTION identify personal safety-related information.
IMPORTANT identifies mechanical information demanding special attention. Be sure to read this directive because it
deals with the possibility of damaging a part or parts of the machine. NOTE identifies general information worthy of special attention.
Service Manual
A service manual is available for the Hydroject 3000 Aerator. This publication provides information for trouble shooting,
testing, adjusting and repairing the machine. To order this publication, contact your local authorized Toro Distributor. Ask
for Form 91-764-SL, Hydroject 3000 service manua1l.
Table of Contents
SAFETY INSTRUCTIONS 3-4
SAFETY INSTRUCTIONS & DECALS .5
SPECIFICATIONS 6-7
FLUID RECOMMENDATIONS 8
IDENTIFICA TION AND ORDERING 8
BEFORE OPERATING 10-12
Activate and Charge The battery 10
Check Engine Oil 10
Fill The fuel Tank With Gasoline 11
Check Gear Case Fluid Level 11
Check Pump Case Fluid Level 12
Check Tire Pressure 12
Check Accumulator Charge 12
CONTROLS 13
OPERATING INSTRUCTIONS 14-16
Operating Precautions 14
Starting/Stopping The engine 14
Training Period 14
Operating Procedure 14
Check Interlock System 16
Transport Operation 16
Inspection and Cleanup After Use 16
Pushing or T o wing The machine 16
TROUBLE SHOOTING 18-20
MAINTENANCE 17
Servicing The pre- Filter 21
Replacing Main Water Filter 21
Changing Engine Oil and Filter 22
Servicing The Air Cleaner 22
Checking and Replacing The Spark Plug 24
Cleaning Cylinder Head Fins 24
Changing Gear Case Oil and Filter 25
Changing Pump Case Oil 25
Checking Hydraulic Lines and Hoses 25
Adjusting Roller Spray 27
Servicing Spray Wash Nozzles or Strainers 28
Battery Care 28
SEASONAL STORAGE 29
SERVICE INTERVAL CHART 30
2
Safety Instructions
Hazard control and accident prevention are dependent
upon the awareness, concern, and proper training of the
personnel involved in the operation, transport, maintenance, and storage of the machine. Improper use or
maintenance of the machine can result in injury or
death. To reduce the potential for injury or death, comply with the following safety instructions.
WARNING: Engine exhaust contains carbon monoxide
which is an odorless, deadly poison. Carbon monoxide
is also known to the State of California to cause birth
defects. Do not run the engine indoors or in an enclosed
area.
BEFORE OPERATING
1. Read and understand the contents of this Operator's
Manual before operating the machine. Become
familiar with all controls and know how to stop
quickly.
2. Never allow children to operate the machine. Do
not allow adults to operate the machine without
proper instruction. Only trained operators who have
read this manual should operate this machine.
tial shoes. Wearing safety glasses, safety shoes, ear
protection and a helmet is advisable and required
by some local ordinances and insurance regulations.
8. Fill the fuel tank with gasoline before starting the
engine. Avoid spilling gasoline. Since gasoline is
flammable, handle it carefully.
A. Use an approved gasoline container.
B. Do not fill the tank while the engine is hot or
running.
C. Do not smoke while handling gasoline.
D. Fill the fuel tank outdoors and up to about 25
mm from top of the tank, not the filler neck.
E. Wipe up any spilled gasoline.
9. Check the interlock switches daily for proper oper-
ation. If a switch fails, replace it before operating
the machine. The interlock system is for your protection, so do not bypass it. Replace all interlock
switches every two years.
3. Never operate the machine when under the influ-
ence of drugs or alcohol.
4. Before attempting to start the engine, engage the
parking brake.
5. Remove all debris or other objects that might inter-
fere with operation. Keep all bystanders away from
the work area.
6. Keep all shields and safety devices in place. If a
shield, safety device or decal is defective or damaged, repair or replace it before resuming operation. Also tighten any loose nuts, bolts and screws
to assure the machine is in safe operating condition.
7. Do not operate the machine while wearing sandals,
tennis shoes, sneakers or shorts. Also, do not wear
loose fitting clothing which could get caught in
moving parts. Always wear long pants and substan-
WHILE OPERATING
10. DON'T TAKE AN INJURY RISK! When a person
or pet appears unexpectedly in or near the WORKING area, STOP AERATING.
11. Keep your hands and feet away from nozzle and
roller area. High-velocity water jets can penetrate
hands and feet. Penetration by the high-velocity
water jets can cause serious personal injury. If accidental penetration occurs, seek medical attention
immediately.
12. Never use chemicals in the water supply system.
13. Do not operate the water injection system on con-
crete or asphalt because the water jets will permanently damage these surfaces.
3
14. Start the engine with the parking brake engaged.
15. Do not run the engine in a confined area without ade-
quate ventilation. Exhaust fumes are hazardous and
could possibly be deadly.
16. Using the machine demands attention, and to prevent
loss of control:
A. Use only in daylight or when there is good artifi-
cial light.
B. Watch for holes or other hidden hazards.
24. Be sure the machine is in safe operating condition
by keeping nuts, bolts and screws tight. Check all
bolts and nuts frequently to be sure they are tightened to specification.
25. If the engine must be running to perform a mainte-
nance adjustment, keep your hands, feet, clothing
and other parts of your body away from any moving
parts.
26. Make sure all hydraulic line connectors are tight, and
all hydraulic hoses and lines are in good condition
before applying pressure to the system.
C. Do not transport the machine close to a sand
trap, ditch, creek or other hazard.
17. If the machine starts to vibrate abnormally, shut off
the engine. Remove the wires from the spark plugs to
prevent the possibility of accidental starting. Check
the machine for damage and defective parts. Repair
any damage before restarting the engine and operating the machine.
18. Do not touch the engine or muffler while the engine is
running or soon after it is stopped. These areas could
be hot enough to cause a burn.
19. Before leaving the operator's position behind the han-
dle engage the parking brake.
20. When leaving the machine unattended, engage the
parking brake , shut OFF the engine and remove the
key from the ignition switch.
MAINTENANCE
21. Disconnect the wires from the spark plugs to prevent
accidental starting of the engine when servicing,
adjusting or storing the machine.
27. Keep your body and hands away from pin hole leaks
or nozzles that eject water or hydraulic fluid under
high pressure. Use paper or cardboard, not your
hands, to search for leaks. Hydraulic fluid or water
escaping under pressure can have sufficient force to
penetrate your skin and do serious damage. If either
of these fluids are ejected into your skin they must
be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene
may result.
28. Before disconnecting or performing any work on the
hydraulic oil system, all pressure in the system
must be relieved by stopping the engine and opening the by-pass valve.
29. Make sure all water line connectors are tight, and all
hoses and lines are in good condition before applying pressure to the system.
30. Before disconnecting or performing any work on the
water system, all pressure in the system must be
relieved by stopping the engine and opening the
bleed valve. Opening 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.
22. If the machine must be tipped to perform maintenance
or an adjustment, close the fuel shut-off valve, drain
gasoline from the fuel tank, oil from the crankcase
and remove the battery.
23. To reduce potential fire hazard, keep the engine free
of excessive grease, grass, leaves and accumulations
of dirt.
4
31. The accumulator in this machine contains high-
pressure dry nitrogen. Accumulator servicing
requires special tools and precautions.
Accumulators do not contain user-serviceable components. Improper accumulator servicing can cause
dismemberment or death. Do not attempt to disassemble a accumulator; have this work done by a
Authorized Toro Distributor.
32. Do not overspeed the engine by changing the governor
settings. To be sure of safety and accuracy, have an
Authorized T0R0 Distributor check maximum engine
speed with a tachometer.
33. The engine must be shut off before checking oil or
adding oil to the crankcase.
34. Allow the engine to cool before storing the machine in
any enclosure such as a garage or storage shed. Make
sure the fuel tank is empty if the machine is to be stored
longer than 30 days. Do not store the machine near any
open flame or where gasoline fumes may be ignited by
a spark. Always store gasoline in a safety-approved, red
metal container.
35. When storing or transporting the machine (trailering),
make sure the fuel shut-off valve is closed.
36. Perform only those maintenance instructions described
in this manual. If major repairs are ever needed or assistance is desired, contact an Authorized Toro Distributor.
To ensure optimum performance and safety, always
purchase genuine TORO replacement parts and accessories to keep the Toro all TORO. NEVER USE
WILL-FIT" REPLACEMENT PARTS AND ACCESSORIES MADE BY OTHER MANUFACTURERS.
Look for the TORO logo to assure genuineness. Using
unapproved replacement parts and accessories could
void the warranty of The Toro Company.
5
Symbol Glossary
SAFETY ALERT
SYMBOL
WHOLE BODY ENTANGLEMENT,
IMPLEMENT INPUT DRIVE LINE
GENERAL HAZARD
SAFETY ALERT
CRUSHING OF
WHOLE BODY,
APPLIED FROM
ABOVE
FINGERS OR HAND
ENTANGLEMENT,
CHAIN DRIVE
CRUSHING OF
FINGERS OR HAND,
FORCE APPLIED
FROM SIDE
THROWN OR FLYING
OBJECTS, WHOLE
BODY EXPOSURE
CUTTING OF
FINGERS OR HAND
RUNOVER/BACKOVER,
GREENS AERATOR
RUNOVER/BACKOVER,
HC 4000 AERATOR
CUTTING OF FOOT CRUSHING OR
PUNCTURE OF FOOT,
CORING HEAD
SECURE LIFTING CYLINDER WITH
LOCKING DEVICE BEFORE
GETTING IN HAZARDOUS AREA
INSERT SAFETY LOCK
BEFORE GETTING IN
HAZARDOUS AREA
SHUT OFF ENGINE & REMOVE
KEY BEFORE LEAVING OPERATOR
POSITION, GREENS AERATOR
6
STAY A SAFE DISTANCE FROM MACHINE,
GREENS AERATOR
CONSULT TECHNICAL MANUAL
FOR PROPER SERVICE
PROCEDURES
READ OPERATOR’S
MANUAL
STAY A SAFE DISTANCE FROM MACHINE,
HC 4000 AERATOR
HEARING PROTECTION
MUST BE WORN
BRAKE SYSTEM ENGAGE DISENGAGE
STAY CLEAR OF ARTICULATION
AREA WHILE ENFINE IS RUNNING,
GREENS AERATOR
DO NOT OPEN OR REMOVE
SAFETY SHIELDS WHILE
ENGINE IS RUNNING
ON/START OFF/STOP FAST SLOW CONTINUOUS
1 INCH (25mm)
VARIABLE,
LINEAR
P
ENGINE START ENGINE STOP
PARK UNLEADED FUEL FUEL TANK FILL
LINE
LOCK UNLOCK CORING HEAD
P
TRACTION DRIVE MANUAL CHOCK WHEELS IN PARKED POSITION,
ALWAYS PARK ON LEVEL SURFACE,
FAIRWAY AERATOR
ALWAYS FORK FROM FRONT OR REAR
OF MACHINE, HC 4000 AERATOR
ALWAYS HAVE CORING HEAD
FULLY UP FOR TRANSPORT &
FULLY DOWN FOR CORING
LEVER OPERATION
7
Specifications
Engine: Onan, 4-cycle, opposed-twin, air-cooled, 17.9
kW (24 hp) @ 3600 rpm, 983 cc displacement.
Electric start. Heavy-duty valve package. Extended
service air cleaner. 2.8 l oil capacity. Solid-state
ignition.
Clutches: Electromagnetic, dual-groove belt drive for
the water pump and driveshaft flange brake/clutch
for the main valve gearbox.
Electrical: 12-volt system with 20-amp circuit breaker
protection. Relays for all high-current switching.
Electronic controller and sensors for automatic
start-up and shut-down sequence of the water injection system. Group 28 battery with 525 cold-crank
amps.
Traction Drive: Closed-loop hydrostatic drive consist-
ing of Sundstrand variable volume pump and
Parker low-speed, high-torque wheel motor mounted to steering fork. Hydraulic system contains 4.73
l with 25-micron suction line filter and gearbox
reservoir.
Tires/Wheels: Three, smooth-tread 2-ply, 18 x 9.50-8,
pneumatic tubeless, tires. Demountable drop-center
steel wheels with (4) lug nuts mounted to tapered
roller bearing hubs on the transport arms and brake
hub on the wheel motor. All are interchangeable.
Brake: Drum- and shoe-type parking brake mounted to
the wheel motor. Holds unit on a 30% grade.
Transport Lift: 12-volt Warner Electric linear screw
actuator with 15.24 cm stroke. Raises and lowers
lift arm/transport tires and activates hole spacing
control.
housing with an air bleed button.
Water Pressure Switch—Senses for water pressure
after the filter and turns on when pressure is over
138–193 kPa and turns off when pressure drops
below 48–90 kPa.
Pump—Pump is a Toro exclusive design (patent pend-
ing) with cast stainless steel head and 3 piston
plungers. Vee packing seals and Kevlar guides.
Forged crankshaft with plasma sprayed ceramic on
stainless steel plungers and cast iron connecting
rods. Nominal performance is 4 rpm @ 34,473 kPa
with 1400 rpm input.
Accumulator—Toro exclusive design with low charge
pressure sensor, nitrogen gas charged to a maximum
of 17,237 kPa.
Cam and Gearbox—Reduction gear drive for cam that
actuates the main water valve. Roller cam follower
rides on a cam specifically designed (patent pending) to control water injection at 5.3 cycles per second (320 rpm) and store energy in the accumulator
between injections. Cast iron case also serves as 3.8
l hydraulic reservoir.
Valve—Cast stainless steel valve body functions as a
mounting base for the accumulator, gearbox and
manifold outlet. All high-pressure water flows in
and out through the valve body. Pressure-balanced
valve spool with floating (patent pending), hardened
stainless seat aligns during assembly. Bleed valve in
base allows for bleed-off of high pressure and drain
down for cold weather storage. Bolted flanges and
polyurethane O-rings mate all components to valve
body.
Fuel Capacity: 39.75 l gasoline.
Water Injection System:
Pre Filter—Spin-down type with washable cartridge
in clear plastic housing and plastic ball valve for
flushing.
Supply Filter—Replaceable cartridge in plastic
8
Rollers—Pivoting aluminum rollers uniformly smooth
the turf and provide protection from the nozzle discharge. Adjustable flow (0–3 gpm) spray wash system with 6 flood tip nozzles maintain clean rollers.
Pressure Relief Valve—Circle Seal Controls poppet-
type valve preset to 34,473 kPa with corrosion resistant stainless and brass materials.
Manifold and Nozzles—Extruded stainless steel mani-
fold with 11 flanged nozzle extensions containing
check valves and hardened stainless discharge orifice. Check valves may be reversed in housing to
block unused nozzles.
Aeration Width: 83.8 cm with 11 nozzles on 7.6 cm centers.
Aeration Depth: 10.2–15.2 cm depending on turf conditions and nozzle configuration.
Controls:
Engine Panel—Throttle, choke, spray wash control, hour
meter, water pressure gauge, spacing control lever,
key switch and circuit breaker reset button.
Steering Tiller Panel— Traction bail, water system
engage and disengage buttons, transport / aerate lift
toggle switch and parking brake with buzzer alarm.
Electronic Control Module—Solid state potted device
for sequencing start and stop of the water system.
Interlocks for water pressure, transport lift and traction neutral.
Ground Speed:
Aerating: 0–3.2 kmh (both directions)
Transport: 0–6.4 kmh (both directions)
Dimensions:
Length—244.4 cm
Wheelbase—135.1 cm
Width—160 cm
Height—119.9 cm
Weight—429.2 kg
Hole Pattern: Variable from 3.8–15.2 cm spacing in the
direction of travel, and 7.6–15.2 cm increments in width.
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 10.2–15.2 cm 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.
Aluminum Washer, Toro Part no. 80-6680 is required with
any nozzle change
Aluminum Washer, Toro Part no. 80-6680 is required with
any nozzle change
NOZZLE SIZE AND APPROXIMATE DEPTH CHART
Quantity of Nozzles
Part No. Drill Size Metric Size (mm) Open Blocked Depth
86-8130 #56 1.181 * * *
86-8131 #53 1.511 11 0 10.2–15.2 cm
86-8133 #46 2.057 6 5 15.2–20.3 cm
**Additional nozzles may be blocked to compensate for pump wear.
9
OPTIONAL STAGGERED SIZE NOZZLE CONFIGURATION
Quantity of Nozzles
Part No. Drill Size Metric Size (mm) Open Blocked Depth
86-8130 #56 1.181 6 and 0** 7.6–10.1 cm
86-8133 #46 2.057 5 0** 15.2–20.3 cm
Aluminum Washer, Toro Part no. 80-6680 is required with any nozzle change
**Additional nozzles may be blocked to compensate for pump wear.
Check Valve Ball
Spring
OPEN NOZZLE
Spring
Check Valve Ball
CLOSED (BLOCKED) NOZZLE
10
Fluid Specifications
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.
Mobil DTE 26
Shell Tellus 68
Amoco Rykon Oil #68
Conoco Super Hydraulic Oil 68
Exxon Nuto H 68
Kendall Kenoil R&O 68
Pennzoil Penreco 68
Phillips Magnus A 68
Standard Energol HLP 68
Sun Sunvis 831 WR
Union Unax A W 68
Hydraulic Oil Filter—Toro part no. 67-8110
Water Pump Case Oil—Mobil DTE Extra Heavy or other
interchangeable ISO Grade 150 PE-700-A (Heavy
Inhibited Hydraulic & General Purpose) See following
chart for equivalent oils.
Mobil DTE EH (Extra Heavy)
Shell Turbo 150
Amoco American Ind. Oil 150
Chevron AW Machine Oil 150
Conoco Dectol R & O150
Exxon Terresstic 150
Kendall Ken-Tran 080
Pennzoil Penreco 150/AW150
Phillips Magnus Oil 150
Standard Energol HLP 150
Sun Sunvis 150
Union Unax RX 150/Turbine Oil 150
Valvoline ETC (R&O) #70
Water Supply—Recommend a source with 26.5–30.2 l
per minute. A minimum pressure of 207 kPa at the
machine is required for the pump to engage.
Maximum allowable pressure of 1,379 kPa.
Although irrigation water pumped from ponds or
effluent holding pools can be used, not all conditions can be handled by the machine’s filtration system. Additional or alternative filtration may be
required.
Water Filter Cartridge—Toro part no. 86-8630
DO NOT USE CHEMICALS—Concern for environ-
mental issues and corrosive affects on machine
components.
Identification and Ordering
MODEL AND SERIAL NUMBERS
The HYDROJECT 3000 has two identification numbers: a
model number and a serial number. The two numbers are
stamped on a plate which is riveted to the frame. In any
correspondence concerning the HYDROJECT 3000, supply model and serial numbers to be sure that correct information and replacement parts are obtained.
To order replacement parts from an authorized TORO
Distributor, supply the following information:
1. Model and serial numbers of the machine.
2. Part number, description and quantity of parts
desired.
Note: Do not order by reference number if a parts
catalog is being used; use the part number.
11
Before Operating
ACTIVATE AND CHARGE THE
BATTERY
1. Since the battery is not filled with electrolyte or activated,
bulk electrolyte with 1.260 specific gravity must be purchased from a local battery supply outlet.
WARNING
Electrolyte gases are explosive and can cause serious
injury to eyes, lungs and skin. Wear safety goggles
and rubber gloves when working with electrolyte or
the battery. Charge the battery in a well-ventilated
place so gasses produced while charging can dissipate.
Since the gasses are explosive, keep open flames and
electrical sparks away from the battery; do not smoke.
Nausea may result if the gasses are inhaled. Unplug
the charger from the electrical outlet before connecting
or disconnecting the charger’s leads.
2. Release the hood latches and raise the hood.
3. Loosen the capscrew securing the battery clamp to the
machine and remove the battery. Remove the filler caps
from the battery and slowly fill each cell until electrolyte is
just above the plates.
4. Replace the filler caps and connect a 3- to 4-amp battery
charger to the battery posts. Charge the battery at a rate of 3
to 4 amperes for 4 to 8 hours.
5. When the battery is charged, disconnect the charger from
electrical outlet and battery posts.
6. Remove the filler caps. Slowly add electrolyte to each cell
until the level is up to fill ring. Install the filler caps.
IMPORTANT: Do not overfilI the battery. Electrolyte
will overflow onto other parts of the machine and severe
corrosion and deterioration will result.
7. Install the battery and secure it with the battery clamp.
Figure 1
1. Battery
8. Install the positive cable (rubber boot over end) to the posi-
tive (+) terminal and the negative cable (black) to the nega-
12
tive (-) terminal of the battery and secure with capscrews
and nuts. Slide the rubber boot over the positive terminal to
prevent possible short-out (Fig. 2).
9. Lower the hood and secure the latches.
CHECK THE ENGINE OIL
The Onan engine is shipped with 3 quarts of oil in the crankcase;
however, the oil level must be checked before and after the
engine is first started.
1. Position the machine on a level surface.
2. Unscrew the dipstick and wipe it with a clean cloth. Screw
the dipstick into the filler neck and make sure it is seated
fully. Unscrew the dipstick out of the filler neck and check
the level of oil. If the oil level is low, add enough to raise
the level to the FULL mark on the dipstick.
Note: If the level of oil is at the ADD mark on the dipstick,
add 1 quart of oil to raise the oil level to FULL. Do not
overfill
3. Pour oil into the filler neck until the level is at the FULL
mark on the dipstick. The Onan engine uses any high-quality oil having the American Petroleum Institute— APl—
“service classification” SF or SG. Recommended viscosity
(weight) of oil is SAE 30.
IMPORTANT:The Hydroject 3000 operates at very
high engine loads, so check the level of oil every 8 operating hours or daily. A new engine may consume some
oil until broken in. Initially, change the oil after the first
25 hours of operation; thereafter, under normal conditions, change the oil and filter after every 100 hours of
operation. However, change oil more frequently when
the engine is operated in extremely dusty or dirty conditions.
FILL THE FUEL TANK WITH
GASOLINE
THE TORO COMPANY STRONGLY RECOMMENDS THE
USE OF FRESH CLEAN, UNLEADED REGULAR GRADE
GASOLINE IN TORO GASOLINE POWERED PRODUCTS.
UNLEADED GASOLINE BURNS CLEANER, EXTENDS
ENGINE LIFE, AND PROMOTES GOOD STARTING BY
Figure 2
1. Dipstick
13
REDUCING THE BUILD-UP OF COMBUSTION CHAMBER
DEPOSITS.
DANGER
Because fuel is flammable, caution must be used when
storing or handling it. Do not fill the fuel tank while
the engine is running, hot or when the machine is in an
enclosed area. Vapors may build up and be ignited by
a spark or flame source many feet away. DO NOT
SMOKE while filling the fuel tank to prevent the possibility of an explosion. Always fill the fuel tank outside and wipe up any spilled fuel before starting the
engine. Use a funnel or spout to prevent spilling, and
fill the tank no higher than 2.5 cm (one inch) below
top of the tank, (bottom of the filler neck). DO NOT
OVER FILL.
Store fuel in a clean safety approved container and
keep the cap on the container. Keep fuel in a cool,
well-ventilated place; never in an enclosed area such
as a hot storage shed. To assure volatility, do not buy
more than a 30-day supply of gasoline, or a 6-month
supply of diesel fuel.
Since many children like the smell of gasoline, keep it
out of their reach because the fumes are explosive and
dangerous to inhale.
Note: Do not mix oil with gasoline. Never use methanol, gasoline containing methanol, gasohol, gasoline additives, premium
gasoline, or white gas because the engine/fuel system damage
could result.
1. Remove the cap from the fuel tank and fill the 37.85 l tank
to about 2.5 cm from the top of the tank, bottom of the filler
neck with unleaded gasoline. Install the fuel tank cap tightly.
2. Wipe up gasoline that may have spilled to prevent a fire
hazard.
CHECK GEAR CASE FLUID LEVEL
The gear case, which acts as the reservoir for the hydraulic system, is filled at the factory with approximately 3.8–4.7 l of
Figure 3
1. Fuel tank cap
14
Mobil DTE 26 hydraulic oil. Check the level of hydraulic oil on
the sight gauge before the engine is first started and daily thereafter. Change the filter initially after 25 hours of operation,
thereafter change the oil and filter every 250 hours of operation.
The oil and filter must be changed immediately when any contamination, sludge, water or condensation appears in the oil or on
sight gauge. Determine and correct oil contamination problem
before restarting the engine and operating the machine.
1. Position the machine on a level surface.
2. Release the hood latches and raise the hood.
3. Check the level of hydraulic oil on the sight gauge. Fluid
level should be up to the middle of gauge window.
4. If the fluid level is low, remove the filler cap and add
enough Mobil DTE 26 hydraulic oil or equivalent oil (refer
to fluid recommendation table) to bring oil up to the proper
level.
5. Lower the hood and secure the latches.
CHECK PUMP CASE FLUID LEVEL
The pump crank case is filled at the factory with 1.8 cl of Mobil
DTE Extra Heavy oil. Check the level of oil on the dipstick
before the engine is first started and daily thereafter. Change the
oil initially after 25 hours of operation, thereafter change every
250 hours of operation. The oil must be changed immediately
when any contamination, sludge, water or condensation appears
in oil. Determine and correct oil contamination problem before
restarting the engine and operating the machine.
Figure 4
1. sight gauge
2. Filler cap
1. Position the machine on a level surface.
2. Release the hood latches and raise the hood.
3. Remove the dipstick/filler cap and check the level of oil on
the dipstick. The fluid level should be up to the FULL
mark.
4. If the fluid level is low, add enough Mobil DTE Extra
Heavy oil or equivalent oil (refer to fluid recommendation
table) to bring the oil up to proper level. DO NOT OVERFILL.
5. Lower the hood and secure the latches.
Full
Figure 5
1. Dipstick/Filler cap
15
CHECK TIRE PRESSURE
Tires are over inflated for shipping. Make sure the front
and rear tires are inflated to 55–82 psi.
CHECK THE ACCUMULA TOR
CHARGE
Have the accumulator charge checked before and after
each operating season by an Authorized TORO
Distributor.
WARNING
Charged accumulators contain high-pressure nitrogen.
Nitrogen is the only gas to use for accumulator charing. Installing Improper gasses in an accumulator can
cause an explosion and death.
Charging requires special tools and precautions.
Charge accumulators in a well-ventilated area. Have
the accumulator checked and charged by an authorized
TORO distributor.
Wear eye protection. Keep your hands and face away
from the gas valve.
Slowly open the high-pressure water bleed valve
before servicing any component connected to the highpressure water system. Opening the high-pressure
bleed valve allows any trapped water to escape from
the system and also allows the accumulator platon to
move the bottom of the accumulator cylinder. Failure
to open the bleed valve before servicing high-pressure
water components can cause personal injury, dismemberment or death!
Charged accumulators cannot be shipped via air
freight.
16
Controls
Ignition Switch (Fig. 6)—The ignition switch, which is used to
start and stop the engine, has three positions: OFF, ON and
STAR T.
Choke (Fig. 6)—To start the engine, close the carburetor choke
by pulling the choke control outward to the FULL position.
After the engine starts, regulate the choke to keep the engine
running smoothly. As soon as possible, open the choke by pushing it inward to the OFF position.
Throttle (Fig. 6)—The throttle is used to regulate engine speed.
Moving the throttle forward increases engine speed— FAST;
rearward decreases engine speed—SLOW.
Spray W ash Control (Fig. 6)—Pull the handle upward to activate the roller spray wash system. Move the control knob up or
down to adjust spray rate to keep rollers free of debris.
Hour Meter (Fig. 6)—The hour meter registers accumulated
hours of engine operation. Use the hour meter to determine
intervals for service maintenance and lubrication.
Figure 6
1. Ignition switch
2. Choke
3. Throttle
4. Spray wash control
5. Hour meter
6. Water pressure gauge
7. Circuit breaker reset button
8. Spacing control lever
Water Pressure Gauge (Fig. 6)—Registers supply water pressure in the system. Also acts as a interlock switch preventing the
water pump from starting if water pressure is below 138–193
kPa or stopping the water pump if the water pressure drops
below 48–89.6 kPa. Check the gauge frequently to monitor the
water pressure.
Circuit Breaker Reset Button (Fig. 6)—a push button to reset
breaker, after correcting malfunctions in the electrical system.
The button also serves as a switch to interrupt power to the
relays.
Spacing Control Lever (Fig. 6)—Moving the control away
from handle increases the aerating ground speed and distance
between holes. Moving the control toward the handle decreases
aerating ground speed and distance between holes. The setting
will be overridden when the machine is shifted to the transport
position.
Traction Bail (Fig. 7)—Engages and regulates fore and aft traction operation of the machine. Releasing the bail stops traction
operation and will also stop water injection in 3 to 4 seconds,
unless the bail is engaged. Transport speed is regulated by the
distance the bail is moved.
Figure 7
1. Traction Ball
2. Transport/Aerate toggle switch
3. Aeration engagement button
4. Aeration stop button
5. Parking brake
T ransport/Aerate Toggle Switch (Fig.7 )—Lowers the machine
17
onto rollers to commence aeration. The switch will override
spacing control setting when it is moved to the transport position.
Aeration Engagement Button (Fig. 7)—Depressing the button
starts water injection system only when the water pressure is
above 193 kPa and the rollers are on the ground.
Aeration Stop Button (Fig. 7)—This red button stops the water
injection system. The system continues for a few seconds after
button is pressed.
Parking Brake (Fig. 7)—Push the lever toward the machine to
engage the parking brake. A warning buzzer will sound if you
attempt to move the machine with the parking brake is engaged.
Fuel Shut-Off Valve—Located under the fuel tank. Close the
fuel shut-off valve when storing or transporting (trailering) the
machine.
Figure 7
1. Traction Ball
2. Transport/Aerate toggle switch
3. Aeration engagement button
4. Aeration stop button
5. Parking brake
18
Operation
OPERATING PRECAUTIONS
1. Before aerating, inspect the work area for debris and
determine the best direction and pattern in which to
operate the machine.
2. If the machine starts to vibrate abnormally, shut off the
engine. Remove the wires from the spark plugs to prevent possible accidental starting. Check the machine for
damage and defective parts. Repair any damage before
restarting the engine and operating the machine.
3. Use only in daylight or when there is good artificial
light. Watch for holes or other hidden hazards. Do not
transport the machine close to a sand trap, ditch, creek
or other hazard.
4. Always raise the machine to the transport position
when parked on a green to prevent roller marks.
5. Do not operate the water injection system on concrete
or asphalt because water jets will permanently damage
these surfaces. Do not run over hoses because damage
will occur.
6. Do not operate the aerator with its roller or injection
system over the edge of anything that could be hit,
damaged or injured by high-velocity water blasts.
7. Water jets from the injection system should not damage
irrigation heads on one pass of the machine. Do not
allow multiple shots from the injection system to hit
irrigation heads as damage will occur.
8. Use a good, clean, quality water supply in the system.
If good quality water is not available, additional filtration equipment may be required. DO NOT USE
CHEMICALS IN THE WATER SYSTEM.
9. Do not allow the machine to be subject to freezing tem-
peratures without draining, because damage to the system will occur.
STARTING / STOPPING THE
ENGINE
1. Make sure the wires are installed on the spark plugs
and the fuel shut-off valve is open.
2. Make sure the parking brake is engaged.
3. Pull the choke lever out to the FULL position and
move the throttle lever to the half-throttle position.
Note: When starting a warm the engine, the choke
may not be necessary, but HALF throttle is.
4. Insert the key into the ignition switch and turn it
clockwise to start the engine. Release the key when
the engine starts. Gradually return the choke lever
to the OFF position (lever all the way in) after the
engine starts and warms up.
IMPORTANT:To prevent overheating the
starter motor, do not engage the starter longer
than 30 seconds. After 30 seconds of continuous
cranking, wait 2 minutes before engaging the
starter motor again.
IMPORTANT:The engine is equipped with an
oil pressure interlock switch which interrupts
engine operation if there is not sufficient oil
pressure in the engine during starting or during
engine operation. The engine may start but will
not continue to run due to a lack of oil pressure.
5. To stop the engine, move the throttle control down-
ward to the SLOW position and turn the ignition
key to “OFF".
TRAINING PERIOD
Before aerating with the Hydroject 3000, it is suggested
that you find a clear area and practice starting and stopping, raising and lowering the machine, turning, etc.
This training period will be beneficial in gaining confi-
19
dence in the performance of the Hydroject 3000.
OPERATING PROCEDURE
1. Make sure the wires are installed on the spark plugs and the
fuel shut-off valve is open.
2. Uncoil a garden hose making sure there are no kinks or
bends in the hose. Lay out the hose so there are no obstructions between the machine and the area to be aerated. Turn
on the water supply to purge any air from the hose. Turn off
the water.
3. Connect the hose adapter (Fig. 8) to the garden hose, then
connect the adapter to the quick coupler on the side of the
machine.
4. Turn on the water supply and check the water pressure. The
water pressure must be at least 207 kPa. If system pressure
is not 207 kPa, make sure your hose is not kinked or
obstructed, the water supply is turned on or if the water filter is plugged.
Figure 8
1. Hose adapter
2. Quick coupler
5. Reach under the fuel tank and press the bleed button on the
top of the water filter head (Fig. 9). Hold the bleed button
down until all air is purged from the filter and water comes
out the opening.
6. Reach under the hood and open the bleed valve on the main
valve at rear of the machine (Fig. 10). Bleed the system
until a steady flow of water comes from the outlet, then
close the valve.
7. If desired, the valve on the pre-filter (Fig. 11) may be
opened slightly (cracked) to provide continuous flushing
during machine operation.
8. Start the engine: refer to Starting/Stopping instructions.
Move the throttle to the FAST position and disengage the
parking brake.
9. Engage the traction bail and approach the area to be aerat-
ed. Make sure there are no obstructions between the aerator
and water supply.
10. Engage and hold the transport/aerate toggle switch to fully
lower the machine onto rollers, release the switch when
fully lowered, then press the engagement button to start
water injection.
Figure 9
1. Main water filter head
2. Bleed button
Figure 10
1. Main valve
2. Bleed valve
20
Note: Injection operation starts approximately 4–5 seconds
after pump engages. Also, the injection system will automatically stop if the traction bail is not engaged within 3–4
seconds after starting the water system.
11. When aerating, work moving perpendicular from the water
supply to avoid running over the garden hose. Use front
edge of the hood or rear corner of frame to align rows, if
desired. When at the end of a row, make a "S" maneuver
and reverse direction of aerator. Do not make sharp turns on
a green or scuffing from tire may occur.
12. Regulate the roller spray wash, if required, to remove debris
from rollers.
Note: A small amount of water from the regulator by-pass may
come out the spray wash nozzles even with spray wash in
the “OFF” position.
13. In areas where greater hole depth or more frequent holes
are desired, the engage button can be held down to allow
multiple shots while the machine is stopped.
CAUTION: Hole depths can reach 50.8 cm or more when
making multiple shots, so be aware of what is buried below
turf. Also, an excessive amount of holes and muddy turf
conditions may occur when making multiple shots.
14. To stop water injection, press the red button. The system
continues for a few seconds after the button is pressed.
Raise the machine to the transport position, disconnect the
supply hose and move to next location
CHECK THE INTERLOCK SYSTEM
The purpose of the safety interlock system is to prevent the
engine from cranking or starting unless the traction bail is in
NEUTRAL and to prevent the water system from engaging if the
machine is in the transport (raised) position. It also stops aeration if the traction bail is released while operating or if the
machine is raised to the transport position.
Figure 11
1. Pre-filter
2. Valve
21
CAUTION
THE INTERLOCK SWITCHES ARE FOR THE
OPERATOR’S PROTECTION, SO DO NOT DISCONNECT THEM. CHECK SWITCH OPERATION
DAILY TO ASSURE THE INTERLOCK SYSTEM IS
OPERATING. IF A SWITCH IS DEFECTIVE,
REPLACE IT BEFORE OPERATING THE
MACHINE. REPLACE THE SWITCHES EVERY
TWO YEARS TO ASSURE MAXIMUM SAFETY.
DO NOT RELY ENTIRELY ON SAFETY SWITCHES—USE COMMON SENSE!
To do a functional check of the interlock system:
1. Position the machine in a flat, open area on rough turf away
from buried wires, plumbing, etc. Stop the engine.
2. Move the traction bail up and down while trying to start the
engine. If the engine cranks, there is a malfunction in the
interlock system that must be corrected. If the engine does
not crank, go to step 3.
3. Connect the water supply to the machine. Turn on the water
supply and bleed all air out of the system. Water pressure
must be 30 psi or more. Start the engine. Raise the machine
to the transport position (up off the rollers). Push the aerate
ENGAGE button. If the water pump engages and the
machine begins aerating, there is a malfunction in the interlock system that must be corrected. If the machine does not
begin aerating, go to step 4.
4. Lower the machine to the aerate position (on rollers).
Engage the traction bail to start the machine moving. Push,
then release the aerate ENGAGE button. The water pump
should engage immediately, then the machine should begin
aerating 5 seconds after pump engages. Release the traction
bail to the neutral position so the machine stops moving.
The water pump should disengage 4 seconds after the traction bail returns to neutral, then stop aerating after another
3 seconds. If the machine does not stop aerating when the
traction bail returns to neutral, there is a malfunction in the
interlock system that must be corrected. If the machine
stops aerating, go to step 5.
5. Engage the traction bail to start the machine moving, then
22
push the aerate ENGAGE button to begin aerating. Push the
aerate DISENGAGE button. The water pump should disengage immediately, then stop aerating after 3 seconds. If the
machine does not stop aerating, there is a malfunction in
the interlock system that must be corrected.
Note: Lights (LED's) on the controller (Fig. 12) 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 the red and
yellow lights are on, the green light will stay on until either
red or yellow goes off.
Yellow: Pump start limit switch closed (the machine lowered to aerate position) and the water pressure switch
closed (water pressure of more than 207 kPa) and accumulator charge pressure switch (nitrogen pressure more than
12,410 kPa).
TRANSPORT OPERATION
Figure 12
1. Red light
2. Green light
3. Yellow light
Use the traction bail to slow the machine while crossing undulating terrain to avoid loss of control. The smooth tires do not grip
turf very well so use caution when transporting the machine.
Always approach rough areas at a reduced speed and cross
severe undulations carefully.
INSPECTION AND CLEAN-UP AFTER
USE
At the completion of operation, thoroughly wash the machine
with a garden hose without a nozzle so excessive water pressure
will not cause contamination and damage to seals and bearings.
After cleaning, inspect for possible hydraulic fluid or water
leaks and damage or wear to the hydraulic, water and mechanical components.
PUSHING OR TOWING THE MACHINE
In an emergency, the machine can be pushed or towed for a very
short distance. However, Toro does not recommend this as standard procedure.
IMPORTANT: Do not push or tow the machine faster than
4.8 kmh because pump damage may occur. If the machine
23
must be moved a considerable distance, transport it on a
truck, trailer or pulling it with the traction wheel raised and
secured to a dolly. Whenever the machine is pushed or towed
the by-pass valve must be opened. Hook on front of handle is
used for a tie-down only, not a hitch point.
1. Unlatch and raise the hood.
2. Locate the by-pass valve cap on left side of hydraulic
pump.
3. Turn valve cap counterclockwise, move the machine to the
desired location and close the valve cap.
4. Lower the hood and secure the latches.
Figure 13
1. By-pass valve
24
Maintenance
LUBRICATION
CAUTION
To avoid personal injury from inadvertent start up or
contact with a hot surface, stop the engine, remove the
key from the switch and wait for the unit to cool before
servicing or making adjustments of the machine.
The Hydroject 3000 has 5 grease fittings that must be lubricated
every 25 hours of operation with No. 2 General Purpose Lithium
Base Grease.
The bearings and bushings that must be lubricated are: steering
pivot shaft (Fig.14), limit switch housing (Fig. 15) (2) on lift
arm shaft (Fig. 15) and neutral pivot shaft (Fig. 16).
1. Wipe the grease fitting clean so foreign matter cannot be
forced into the bearing or bushing.
2. Pump grease into the bearing or bushing.
3. Wipe up excess grease.
Figure 14
Figure 15
Figure 16
25
Condition Cause Correction
Unit will not move when traction bail is
engaged *
1. Check that motion occurs at pump
pivot plate when the traction ball is
moved
1. Inspect traction push/pull cable and
override assembly under tiller handle
2. Check oil level In Hydraulic reservoir
(gearbox)
3. Check that by-pass valve is fully
closed (clockwise)
4. Check belt tension on traction drive
Unit will not transport at full speed* 1. Check that unit is fully raised to
transport position
2. Check oil level in Hydraulic reservoir
(gearbox)
3. Check that bypass valve is fully
closed (clockwise)
4. Check belt tension on traction drive
5. Check that motion occurs at pump
pivot plate when the traction bail is
moved
Engine dies during startup * 1. Fuel shut off valve closed
2. Check for fuel in tank
2. Replenish If necessary
3. Close valve
4. Adjust belt tension
1. Hold lift toggle Swatch until slip
clutch in actuator can be heard
ratcheting and spindle lift arms are
nearly vertical with rear axle spindle
tipped away from engine
2. Replenish if necessary
3. Close valve
4. Adjust belt tension
5. Inspect traction push/pull cable and
override assembly under tiller handle
1. Open fuel shut off valve
2. Replenish if necessary
3. Check operation of engine choke
4. Check engine oil level
5. Cold start conditions (30°)
Engine dies when water system is
engaged *
*Make all checks with engine off and parking brake engaged.
1. Throttle in wrong operating position
2. Check engine speed
3. Low engine power
3. Check choke connections and operation. Regulate choke until engine is
warm when starting a cold engine
4. The oil pressure switch is by-passed
during start but must activate to protect engine while running
5. Multiple start attempts may be
required to trip oil pressure Switch
1. Throttle must be in FAST position for
aerating
2. Adjust carburetor fast setting to
3450–3550 rpm
3. Contaminated fuel plugged fuel or air
filter bad spark plug
4. Have system serviced by an
Authorized Toro Distributor
26
Condition Cause Correction
Engine does not start will not engage
starter
1. Traction bail not in neutral position
2. Neutral switch tab out of adjustment
3. Battery voltage low
4. Malfunction in electrical system
1. Correct position of traction bail
2. Adjust switch tab until Red traction
light is OFF in neutral.
3. Check battery
4. Check circuit breaker and electrical
connections
Unit not producing aeration holes
(Pump or water valve will not start)
Unit not producing aeration holes
(Pump shuts down intermittently)*
Unit stops aerating In one direction or
stops aerating in the lowest hole
spacing
1. Check to ensure that transport arms
are fully retracted
2. Check that water pressure gauge
reads
3. Check that yellow LED is lit on electronic controller
1. Check for kinked supply hose restriction in the line or partially open valve
at water source
2. Inadequate water pressure or flow
from source
3. Check water pressure at gauge when
pump is engaged If pressure drops
to less than 25 psi but was initially
higher
1. Check for kinked supply hose restriction in the line or partially open valve
at water source
2. Inadequate water pressure or flow
from source
3. Check water pressure at gauge when
pump is engaged If pressure drops
to less than 25 psi but was initially
higher
4. Neutral switch tab out of adjustment
1. Unit in aerate mode
2. Gauge must read 30 psl or more
3. Check for loose wires or connections.
Have machine checked by an
Authorized Toro Distributor.
1. Correct condition
2. Check water pressure (from water
source) at inlet (8 gpm - 40 psi)
3. Replace water filter.
1. Correct condition
2. Check water pressure (from water
source) at inlet (8 gpm - 40 ps&)
3. Replace water filter.
4. Adjust switch tab until Red traction
light is ON while traction bail is actuated in both directions
5. Red traction light must be OFF when
in neutral to allow engine start interlock to function
Unit not producing aeration holes
(Pump and valve operating correctly)*
*Make all checks with engine off and parking brake engaged.
1. Air in system
2. Plugged nozzle(s)
3 . Soil composition (hard)
1. Open main bleed valve to purge air
from system
2. Inspect nozzles
3. Different nozzle configuration
required
4. Have water system checked by an
Authorized Toro Distributor
27
Condition Cause Correction
Unit not producing aeration holes
(Injection pump stops after unit stops
moving) *
Shallow or Improper hole depth * 1. Air in system
Water Injection system making unusual
noise when aerating *
1. Normal condition of neutral interlock
system
2. If hole depth was satisfactory earlier
check density and moisture content
In soil.
3. Soil composition (hard)
4. Too many large nozzles will cause a
loss in pressure and could damage
accumulator or other water system
components
1. Air in system
2. Missing nozzle or too many large nozzles installed
3. Broken springs in nozzle extension
check valve.
4. Gear box drive shaft or couplers worn
1. Operator must hold Engage (start)
button to aerate without moving
1. Open main bleed valve to purge air
from system
2. Different nozzle configuration may be
required
3. Different nozzle configuration may be
required
4. Open bleed valve and examine nozzles. Verify size and quantity per the
recommendation chart.
5. Have water system checked by
Authorized Toro Distributor
1. With water supply on open bleed
valve under accumulator/ valve body.
If mechanical noise continues during
aeration stop unit and have it serviced by an Authorized Toro
Distributor.
2. Open bleed valve and examine nozzles. Verify size and quantity per the
recommendation chart.
*Make all checks with engine off and parking brake engaged.
28
3. Replace springs inspect ball and seat.
4. Remove drive shaft guard and repair
or replace as necessary.
SER VICING THE PRE-FILTER (Fig. 17)
Sediment can be removed by opening the ball valve, with the
water source attached, to flush. The reusable filter screen may be
removed for cleaning by untwisting the clear cover from the filter by hand. Replace the clear cover and hand tighten only.
IMPORTANT: Use of tools will damage the filter.
REPLACING THE MAIN WA TER
FILTER (Fig. 18)
The machine is a precision piece of equipment and the quality or
cleanliness of your water supply is very important in determining its useful life. If your water supply contains silt, sand or
other debris, you may be required to install additional filtration
or separation equipment between your supply source and the
machine. Depending on the quality of your water, frequency of
filter change will vary greatly. When pump inlet pressure
decreases or the water system shuts down, it usually means the
water filter is restricted and must be replaced. Never operate the
machine without a water filter as severe damage may occur.
Figure 17
1. Body
2. Clear cover
3. Ball valve for flushing
1. Position the machine on a level surface and make sure the
engine is shut off. Shut off the water supply.
2. Locate the main water filter assembly mounted below the
fuel tank. Press the bleed button to release air pressure
from the filter body.
3. Unscrew the filter body of the assembly counterclockwise
(as viewed from the bottom). Remove the filter cartridge
and discard.
Note: To ease the removal of the filter body from the filter
head, a filter wrench is available. Contact your Authorized
Toro Distributor.
CAUTION:The water filter body is very heavy when
filled with water and filter. Use caution when unscrewing the filter body from the filter head.
4. Thoroughly rinse out the filter body to avoid contaminating
the water system. Make sure the “O” ring is in the groove.
If it has come out, wipe it dry, lubricate it with a light coating of petroleum jelly and replace it in the groove.
5. Thoroughly clean the filter head mounting surface to avoid
Figure 18
1. Filter body
2. Filter Cartridge
3. Filter head
4. Bleed button
5. O-ring
29
contaminating the water system when the filter is installed.
6. Insert the new filter cartridge into the filter body.
7. Thread the filter body with the filter onto the filter head.
Hand tighten.
8. Turn on the water supply and press the bleed button on the
top of the water filter head. Hold the bleed button down
until all air is purged from the filter and water comes out
opening.
CHANGING THE ENGINE OIL AND
FILTER
For new engines, change the oil after first 25 operating hours.
Thereafter, under normal conditions, change the oil and filter
after every 100 hours of operation. However, an engine operated
in dusty or dirty conditions requires more frequent oil changes.
If possible, run the engine just before changing the oil. Warm oil
flows more freely and carries more contaminants than cold oil.
Figure 19
1. Drain cap
1. Position the machine on a level surface.
2. Disengage the hood latches and open the hood.
3. Place an oil drain pan below the drain cap on the bottom of
the crankcase. Clean the area around the drain cap.
4. Remove the drain cap and allow the oil to flow into the
drain pan. After the oil is drained, install the oil drain cap.
5. Remove the oil filter and discard. Thoroughly clean the fil-
ter mounting surface and make sure a new gasket is
installed in the new filter.
6. Apply a thin film of clean oil to gasket. Install the new filter
by hand until the gasket just touches the mounting surface,
then turn an additional 1/2 to 3/4 turn.
7. Remove the filler cap and pour 3 quarts of oil having the
API “service classification" SF or SG into the filler neck.
Recommended viscosity (weight) of oil is SAE 30.
8. Start the engine and check for leaks around the oil filter.
tighten the filter only enough to eliminate leaks. DO NOT
OVERTIGHTEN.
Figure 20
1. Oil filter
Figure 21
1. Filter cap
30
9. Turn off the engine and allow the machine to stand for 2
minutes.
10. Check the oil and make sure the level is up to the FULL
mark on the dipstick. Add more oil if the level is low; however, DO NOT OVERFlLL.
11. Lower the hood and secure the latches.
SER VICING THE AIR CLEANER
The foam pre-cleaner must be cleaned and re-oiled and the paper
element must be checked and/or replaced after every 100 hours
of engine operation . However, the air cleaner must be cleaned
more frequently if operating conditions are extremely dusty or
sandy.
1. Remove the knob and cover from the air cleaner.
2. Remove the foam pre-cleaner by sliding it off the paper ele-
ment.
3. A. Wash the foam pre-cleaner in detergent soap and
warm water.
B. Wrap the foam pre-cleaner in a cloth and squeeze dry.
Do not wring the precleaner.
C. Add and evenly distribute one tablespoon of engine oil
to the foam pre-cleaner. Squeeze the foam pre-cleaner
to remove excess oil.
4. Reinstall the precleaner on the paper element.
Inspect the paper element every 100 hours of operation and
replace when dirty or damaged. Do not wash the paper element or do not clean it with compressed air as damage will
occur.
Note: With the air cleaner disassembled, check the air
cleaner components for damage. Replace if necessary.
5. Reinstall the paper element with the foam pre-cleaner, air
cleaner element cover, nut, air cleaner cover and knob.
Figure 23
1. Air cleaner
2. Air cleaner cover
3. Knob
6. Tighten the knob 1/2 to 1 turn after it contacts cover. Do not
overtighten.
Figure 24
1. Foam pre-cleaner
2. Paper element
31
CHECKING AND REPLACING THE
SPARK PLUG
Since the air gap between center and side electrodes increases
gradually during normal engine operation, check condition of
the electrodes at 100 hour intervals. The correct spark plug to
use in the engine is a Champion RS14 YC or equivalent. Set the
air gap at ,06 mm.
CLEANING THE CYLINDER HEAD
FINS
To avoid overheating and possible engine damage, clean the
cooling fins on the cylinder head every day if necessary.
1. Disengage the hood latches and open the hood.
2. Pull the wires off the spark plugs.
3. Clean dirt, grass and chaff from the outside of the cylinder,
cylinder head fins and the air intake screen.
4. Push the wires onto the spark plugs.
5. Lower the hood and secure the latches.
CHANGING THE GEAR CASE OIL
AND FILTER
Change the hydraulic oil and filter initially after 25 hours of
operation; thereafter change every 250 hours of operation. The
gear case oil and filter must be changed immediately when any
contamination, sludge, water or condensation appears.
1. Disengage the hood latches and open the hood.
2. Place a drain pan under the bottom of the gear case. Clean
the area around the drain plug.
Note: When draining oil, use a funnel or some type of
channel to divert draining oil away from machine components and into the drain pan.
3. Remove the drain plug and allow the oil to flow into the
drain pan. After the oil is drained, install the oil drain plug.
Figure 24
1. Drain plug location
4. Remove the oil filter (Fig. 25), mounted below the control
32
panel base, and discard the filter. Thoroughly clean the filter mounting surface and make sure a new gasket is
installed in the new filter.
5. Fill the new filter with new Mobil DTE 26 hydraulic oil or
equivalent oil (refer to fluid recommendation table). Apply
a thin film of clean oil to the filter gasket.
6. Install the new filter by hand until the gasket just touches
the mounting surface, then turn an additional 1/2 to 3/4
turn.
7. Remove the filler cap and add 3.8–4.7 l of Mobil DTE 26
hydraulic oil or equivalent oil (refer to fluid recommendation table) to the gear case reservoir. Install the filler cap.
8. Check for leaks around the oil filter. Tighten the filter only
enough to eliminate leaks. DO NOT OVERTIGHTEN.
9. Lower the hood and secure the latches.
CHANGING THE PUMP CASE OIL (Fig.
26)
Figure 25
1. Oil filter
Change pump oil initially after 25 hours of operation, thereafter
change every 250 hours of operation. The pump case oil must be
changed immediately when any contamination, sludge, water or
condensation appears.
1. Disengage the hood latches and open the hood.
2. Place a drain pan under pump case. Clean area around the
drain plug on bottom of case.
Note: When draining oil, use a funnel or some type of
channel to divert draining oil away from machine components and into the drain pan.
3. Remove the drain plug and allow the oil to flow into the
drain pan. After the oil is drained, install the oil drain plug.
4. Remove the dipstick/filler cap and add approximately 1182
ml of Mobil DTE Extra-Heavy oil or equivalent oil (refer to
fluid recommendation table) to the pump case. Install the
filler cap.
5. Check the oil level. If the fluid level is low, add enough
Mobil DTE Extra-Heavy oil or equivalent to bring the oil
Figure 26
1. Drain plug location
33
up to proper level. DO NOT OVERFILL.
6. Check for possible leaks. Lower the hood and secure the
latches.
CHECKING HYDRA ULIC LINES AND
HOSES
After every 100 operating hours, check hydraulic lines and hoses
for leaks, kinked lines, loose mounting supports, wear, loose fittings, weather deterioration and chemical deterioration. Make all
necessary repairs before operating.
ADJUSTING ROLLER SPRAY WASH
SYSTEM (Fig. 27)
If the spray wash system (Fig. 27) on the rollers needs to be
adjusted, proceed as follows:
1. Loosen the cap on bottom of the fitting.
2. Rotate nozzle so the slot in tip is parallel to the roller.
3. Tighten the cap and check the adjustment.
SER VICING SPRAY WASH NOZZLES
or STRAINERS (Fig. 28)
To clean or replace strainers in the spray wash nozzles proceed
as follows:
1. Loosen and remove the cap on the bottom of the fitting.
2. Remove the nozzle and strainer assembly. Clean or replace
the strainer and replace it in the nozzle.
3. Loosely secure the nozzle and strainer to the fitting with the
cap.
4. Rotate the nozzle so that the slot in its tip is parallel to the
roller.
5. Tighten the cap and check the adjustment.
Figure 27
1. Roller spray wash system
Figure 28
1. Fitting cap
2. Nozzle
3. Fitting
4. Strainer
5. Hex nut
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BATTERY CARE
1. Battery electrolyte level must be properly maintained and
the top of the battery must be kept clean. If the Aerator is
stored in a location where temperatures are extremely high,
the battery will run down more rapidly than if the machine
is stored in a location where temperatures are cool.
2. Check the electrolyte level every 25 operating hours or, if
the machine is in storage, every 30 days.
3. Maintain cell level with distilled or demineralized water.
Do not fill the cells above the bottom of the split ring inside
each cell.
4. Keep the top of the battery clean by washing it periodically
with a brush dipped in ammonia or bicarbonate of soda
solution. Flush the top surface with water after cleaning. Do
not remove the caps while cleaning.
5. Battery cables must be tight on the terminals to provide
good electrical contact.
6. If corrosion occurs at terminals, disconnect the cables—
negative (–) cable first—and scrape the clamps and terminals separately. Reconnect the cables—positive cable
first—and coat the terminals with petroleum jelly.
7. If the machine will be stored more than 30 days, remove the
battery and charge it fully. Either store it on the shelf or on
the machine. Leave the cables disconnected if stored on the
machine. Store the battery in a cool atmosphere to avoid
quick deterioration of the battery charge.
SEASONAL STORAGE
Water System
It is important that the water system be drained to avoid freezing
and damaging the components. Drain the system as follows:
1. Stop the engine, remove the key from the ignition switch
and remove the wires from the spark plugs.
2. Remove the (2) screws securing the drive shield to the
frame and remove the shield.
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3. With the engine "OFF" and the key removed from the
ignition, rotate the drive coupling by hand until resistance is felt. Continue to turn the coupling about 1/4
revolution, opening the the cycling valve.
8. Reinstall the spark plugs.
9. Drain the gasoline from the fuel tank and fuel lines.
Reinstall all lines and secure all connections.
4. Using the appropriate reducers, connect a source of
compressed air (maximum pressure 1,034 kPa; minimum pressure 621 kPa;) to the water inlets on either
side of the machine.
DANGER: Compressed air can penetrate the skin and
cause physical harm. Use extreme caution and wear
protective goggles and gloves when working with highpressure air. Get prompt medical attention if an injury
occurs.
5. Let compressed air flow through the machine for 3 min-
utes. While compressed air is flowing, temporarily open
the spray wash and high-pressure drain valve, purging
water from the spray wash and the high-pressure system.
6. Disconnect compressed air and reducers. Install the
drive shield previously removed and tighten the relief
valve tube.
7. Remove and drain the water filter container. Install the
new filter and replace the filter container.
Engine
1. Drain the engine oil from the oil pan and replace the
drain cap.
10. Thoroughly clean and service the air cleaner.
11. Check the oil filler cap and the fuel tank cap to
ensure they securely in place.
Traction Unit
1. Thoroughly clean the machine.
2. Grease or oil all fittings or pivot points.
3. Check to make sure all tires are over inflated to
137–207 kPa.
4. Lightly sand and use touch up paint on all areas
that are scratched, chipped or rusted.
5. Drain and replace the hydraulic oil and filter on the
cam gear case.
6. Drain and replace the oil in the water pump case.
7. Clean the battery, terminals and posts with a wire
brush and baking soda solution. Coat the cable terminals and battery posts with grease or petroleum
jelly. Recharge the battery.
2. Remove and discard the oil filter. Install a new filter.
3. Refill the engine with 3 qts. of recommended SAE 30
wt. motor oil.
4. Start the engine and run at idle speed for two minutes.
DO NOT RUN LONGER THAN TWO MINUTES.
5. Stop the engine; remove the spark plugs.
6. Pour 29 ml of clean engine oil into the spark plug holes.
7. With the spark plugs removed, crank the engine with
the starter for a least 12 revolutions to distribute the oil
in the cylinders.
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Service Interval Chart
Check Pump Case Oil Daily
Check Engine Oil Level Daily
Check Hydraulic Oil Level Daily
Check Safety Interlock Switch Operation Daily
Check W ater Filter/Pressure Daily
Change Gear Case Hydraulic Oil & Filter(Initial) 25 hours
Change Engine Oil (Initial) 25 hours
Change Pump Case Oil (Initial) 25 hours
Check Tire Pressure 25 hours
Check Hoses, Lines & Housings for Leaks 25 hours
Lubricate Grease Fittings (5 locations) 25 hours
Check Battery 25 hours
Clean Spray Wash Tips & Strainer 100 hours
Change Engine Oil & Filter 100 hours
Clean Air Cleaner (Clean & re-oil Foam Pre Cleaner) 100 hours
Check Accumulator Pre Charge* 100 hours
Check Engine RPM 100 hours
Adjust Parking Brake 250 hours
Change Gear Case Hydraulic Oil & Filter 250 hours/Seasonal
Change Pump Case Case Oil 250 hours/Seasonal
Check/Adjust Water System Cam/Valve 250 hours/Seasonal
Change Fuel Filter 250 hours/Seasonal
Clean Engine Cooling Fins 250 hours/Seasonal
Adjust Traction Spacing 250 hours/Seasonal
Adjust Clutch / Brake* 250 hours/Seasonal
Change Air Filter Element 250 hours/Seasonal
Recharge Accumulator* 250 hours/Seasonal
Clean/Decarbon Combustion Chamber & Intake Port (If using leaded fuel)* 250 hours
Replace Spark Plugs 500 hours
Adjust Engine Valve Lash* 500 hours
Clean Engine Breather* 500 hours
Inspect Nozzles/Springs* 500 hours
Check Water System Performance 500 hours
* Have machine serviced by an Authorized Toro Distributor.
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