Toro HYDROJECT 3000 Operator's Manual

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