Toro Hydroject 3000, Hydroject 4000 Troubleshooting Manual
Commercial Products
®
Hydroject
3000/4000
Troubleshooting Guide
PART NO.97928SL, Rev. A
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TORO® Hydroject® 3000/4000 1
Table of Contents
Troubleshooting
• Product Overview....................................................................................................................2
• Components............................................................................................................................6
• Water System Operation......................................................................................................48
• Water System Testing ..........................................................................................................58
• Unit Storage...........................................................................................................................78
• Maintenance Chart................................................................................................................80
Use of This Manual
The information contained in this manual is supplementary to material found in other sources,
it is not a replacement for them. You should always consult Service Manuals, Service
Bulletins, Operator’s Manuals and Parts Books when necessary.
Service Manual Updates and Service Bulletins can be found on the internet at:
www.toro.com/golf/custsvc.html
This Manual and the training program, which it supports, are both designed to help you gain
knowledge of the product, and to inform you of when and why to make the necessary repairs.
We have also included tips for performing those repairs.
This program is designed for you. Your input and participation is appreciated.
There is plenty of space in this manual for you to add your own notes and observations
Overview TORO Hydroject® 3000/40002
TORO Hydroject® 3000/4000 Overview
The Hydroject® is a patented machine that aerates the ground with “water jets”.
These jets are pulses of high velocity water, released at regular intervals.
For this machine to operate properly, the owner or operator should understand the individual components and
their relationship to the complete system.
The Hydroject® 3000 is a hydrostatic driven walk aerator. The unit needs to be connected to a clean water
supply to aerate.
3
The Hydroject® 4000 is a pull behind aerator. The higher transport speeds make the 4000 suitable for tees and
problem areas on the fairway. The Hydroject® 4000 usually gets its water from a tank on the towing vehicle.
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Overview TORO Hydroject® 3000/40004
2 cylinder Onan Engine
Quick Coupler
5 Micron inlet Filter
Pressure Switch
Pressure Gauge
Engine driven water pump
Accumulator
Accumulator charge pressure switch
5000 psi relief valve
Cycling valve (water valve)
Rollers
Roller washer
High pressure aeration nozzles
Hydroject 3000 Hydroject 4000Comparison
Drain valve
Hydrostatic drive
Boost Pump
Boost pump relief valve
25 micron pre-filter
Regulator Valve
TORO Hydroject® 3000/4000 Overview
The Hydroject® 3000/4000 aerators use most of the same components in the water injection system.
While there are differences in the machine drive, the main water injection system is the same.
The chart on the previous page shows the similarities and differences between the two units.
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NOTES
Components TORO Hydroject® 3000/40006
TORO Hydroject® 3000/4000 Components
Engine
The Hydroject® is powered by an Onan, 24 HP, air cooled, twin cylinder, electric start, gas engine. The engine
is equipped with solid state ignition, and powers the water pump, water valve, and on the 3000, the hydrostatic
transmission.
The engine uses 3 quarts of 30-weight engine oil and the oil should be changed every 100 hours, after the initial
25-hour change.
Oil Filter PN. 57-8530
The air filter should be serviced every 100 hrs, and the filter element replaced every 200 hrs.
Air Filter foam pre-cleaner PN 82-0670.
Air Filter element PN. 82-0670.
During aeration, operate the Hydroject® at full engine RPM.
Proper engine idle speeds.
Low idle 1500 - 1800 RPM.
High Idle 3500 ± 50 RPM.
7
Fuel
The fuel tank holds 10 gallons of regular unleaded gasoline (9 gallons on the Hydroject® 4000) and should
operate the unit for approximately 4 hours. There is a fuel shut off valve located below the fuel tank and this
valve should be closed during periods of non-use.
NOTE: Take care in filling any fuel tank, and fill the tank to 1 inch below the top of the tank.
Always wipe up any spilled fuel to prevent a fire hazard.
The Fuel Filter should be replaced every 200 hrs.
Fuel Filter PN. 71-5960.
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Components TORO Hydroject® 3000/40008
TORO Hydroject® 3000/4000 Components
Hydrostatic Pump (3000 Hydroject® Only)
The Sundstrand, series 70 hydrostatic pump, is belt driven and provides variable oil flow to operate the traction
wheel motor, the traction bail, located on the tiller handle, is connected to the swash plate in the hydrostatic
pump and provides speed and directional control. The unit aerates in both directions.
NOTE: There is a bypass valve located on top of the hydrostatic pump, this valve provides for limited
movement of the unit with the engine off.
9
Cam Gear Box
The cam gearbox operates the cycling valve and also serves as the hydrostatic oil reservoir, on the
Hydroject® 3000.
The hydrostatic transmission uses 5 quarts of DTE 26.
NOTE: The oil level can be checked through the sight glass on the side of the reservoir.
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Components TORO Hydroject® 3000/400010
TORO Hydroject® 3000/4000 Components
Transmission Filter (3000 Hydroject® Only)
A 25-micron filter, located below the frame, filters the transmission oil.
NOTE: The transmission filter should be changed at 25 hours and then every 250 hours after that.
Prefill the filter before installation.
Transmission filter PN. 67-8110.
11
Wheel Motor (3000 Hydroject® Only)
The hydrostatic wheel motor is a low speed, high torque, bi-directional motor, which propels the unit and
provides smooth directional changes.
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Components TORO Hydroject® 3000/400012
TORO Hydroject® 3000/4000 Components
Tiller Controls (3000 Hydroject® Only)
The tiller handle contains some controls for aerating. These controls include traction direction, aerate-transport
switch, and water systems start and stop buttons, and the parking brake lever.
NOTE: The parking brake is connected to a limit switch that activates an alarm if the unit
is moved while the parking brake is engaged.
NOTE: The traction handle moves the swash plate on the hydrostat, controlling direction
and speed.
NOTE: The raise and lower switch positions the transport wheels in aerate or transport.
NOTE: The ENGAGE (Green) and DISENGAGE (Red) buttons start and stop the water pump and
cycling valve. Holding the ENGAGE button down will energize the water system, overriding the
neutral delay, allowing multiple shots at one location.
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Remote Control Panel (4000 Hydroject® Only)
The remote control panel for the Hydroject® 4000 contains the controls for aerating.
These controls include:
1. The key switch.
2. The engine choke switch.
3. The engine low\high idle switch.
4. The water system, start and stop buttons.
NOTE: The ENGAGE (Green) and DISENGAGE (Red) buttons start and stop the water pump and
cycling valve.
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Components TORO Hydroject® 3000/400014
TORO Hydroject® 3000/4000 Components
15
Traction Linkage (3000 Hydroject® Only)
The traction linkage connects the traction bail to the swash plate. During aeration, a steel cable pulls the left link
toward the hole spacing lever, limiting swash plate movement to the required speed. In this mode, the hole
spacing lever is spring-loaded and will snap towards the key switch when removed from the indexing latches.
NOTE: Do not adjust hole spacing with out lowering the unit.
Control Panel (3000 Hydroject® shown)
The control panel controls or monitors the Hydroject® functions. The controls, (from right to left) include:
hourmeter, throttle, hole spacing lever, ignition key switch, 20 amp circuit breaker reset, inlet water pressure
gauge, spray roller wash knob and choke.
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Components TORO Hydroject® 3000/400016
TORO Hydroject® 3000/4000 Components
17
Lift Mechanism (3000 Hydroject® Only)
A 12-volt, Warner electric, linear screw actuator with a 6-inch stroke, accomplishes transport lift. The actuator
raises and lowers the transport wheels and activates the hole spacing control. A safety switch prevents aeration
during transport.
Rollers (3000 Hydroject® Only)
The two large aluminum rollers support the Hydroject® 3000 during aeration. These rollers smooth down the turf
after aeration and protect the operator from the high velocity water jet blasts.
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Components TORO Hydroject® 3000/400018
TORO Hydroject® 3000/4000 Components
Roller Cleaning System (3000 Hydroject® Only)
The spray wash nozzles prevent debris buildup on the rollers. A knob on the instrument panel regulates the
volume of water going to these nozzles. Pulling or pushing the spray wash knob increases or decreases the
spray rate. These nozzles also help purge air from the water system after connecting the water supply.
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Battery
The battery is specially designed to withstand vibration. It is a group 28 with 525 cold cranking amps.
NOTE: The battery is shipped dry.
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Components TORO Hydroject® 3000/400020
TORO Hydroject® 3000/4000 Components
21
Controller
The controller is a solid state timing device used to regulate/monitor the input functions. 3 colored lights monitor
these functions. (Red, Yellow and Green).
Hydroject® 3000
NOTE: The RED LED illuminates when the Hydroject® is moving, (transmission not in neutral).
The micro switch that controls this function in normally closed.
NOTE: The YELLOW LED illuminates when the transport wheels are up, the accumulator nitrogen
pressure is above 1800 PSI*, and the water pressure (after the filter) is adequate (15-20 PSI).
This light stays illuminated during aeration. *(Switch is not on early production units)
NOTE: The GREEN LED illuminates when the aeration start button is depressed. This light stays
illuminated during aeration.
Hydroject® 4000
NOTE: The RED LED illuminates, when the water pressure (after the filter) is adequate (15-20 PSI).
This light stays illuminated during aeration.
NOTE: The YELLOW LED illuminates when the accumulator nitrogen pressure is above 1800 PSI.
NOTE: The GREEN LED illuminates when the aeration start button is depressed. This light stays
illuminated during aeration.
Relays
The relays are used to energize specific components including:
1. The starter.
2. The pump clutch.
3. The cycling valve clutch.
4. The lift raise. (3000 Hydroject® Only).
5. The lift lower. (3000 Hydroject® Only).
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Components TORO Hydroject® 3000/400022
TORO Hydroject® 3000/4000 Components
Transport Limit Switch (3000 Hydroject® Only)
The transport limit switch signals the controller when the wheels are in the transport position.
In the transport position (wheels down) the switch is closed.
In the aerate position (wheels up) the switch is open.
NOTE: On earlier units, there were 2 switches for this function.
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2 Transmission Switches (3000 Hydroject® Only)
The top switch is normally open, and closes to enables the engine to start when the hydrostatic control is in the
neutral position.
The lower switch is normally closed and is connected to the controller. If the Hydroject® is pumping water and
the operator leaves the traction drive in neutral, this switch signals the controller to shut down the high-pressure
pump and the cycling valve after 4 seconds.
NOTES
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Components TORO Hydroject® 3000/400024
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