Part No. 91764SL Rev. C
Service Manual
®
Hydroject 3000/4000
Preface
This publications provides the service technician with
information for troubleshooting, testing, and repair of the
Hydroject. Additional information is available in the
Hydroject 3000/4000 Troubleshooting Guide, Part
No. 97928SL.
This safety symbol means DANGER,
WARNING, or CAUTION, PERSONALSAFETY
INSTRUCTION. When you see this symbol,
carefully read the instructions that follow.
Failure to obey the instructions may result in
personal injury.
REFER TO THE HYDROJECT OPERATOR’S MAN-
UAL FOR OPERATING, MAINTENANCE AND AD-
JUSTMENT INSTRUCTIONS. Space is provided in
Chapter 2 of this book to insert the Operator’s Manual
and Parts Catalog for your machine. A replacement
Operator’s Manual is available by sending the complete
Model and Serial Number of the machine to:
NOTE: A NOTE will give general information about the
correct operation, maintenance, service, testing or re-
pair of the machine.
The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420
IMPORTANT: The IMPORTANT notice will give im-
portant instructions which must be followed to pre-
vent damage to systems or components on the
machine.
The Toro Company reserves the right to change product
specifications or this publication without notice.
© The Toro Company 1991-1997
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Table Of Contentsꢀ
Chapter 1 - Safety
Chapter 5 - Electrical System
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1
Safety and Instruction Decals. . . . . . . . . . . . . . . . 1 - 4
Wiring Schematics and Diagrams. . . . . . . . . . . . . 5 - 2
Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 7
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 9
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 17
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 26
Chapter 2 - Product Records and Manuals
Product Records. . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1
Equivalents and Conversions. . . . . . . . . . . . . . . . 2 - 2
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . 2 - 3
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 4
Equipment Operation and Service History Forms 2 - 5
Chapter 6 - Water System
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 2
Water System Schematic . . . . . . . . . . . . . . . . . . . 6 - 3
Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 9
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 12
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 18
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 20
Chapter 3 - Engine
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2
Onan Engine Service Manual
Chapter 7 - Wheels, Steering and Brakes
Chapter 4 - Hydraulic System
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 2
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2
General Information . . . . . . . . . . . . . . . . . . . . . . . 4 - 3
Hydraulic Diagram . . . . . . . . . . . . . . . . . . . . . . . . 4 - 6
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 7
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 8
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 9
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 11
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 14
Chapter 8 - Hydroject 4000 Addendum
Safety and Instruction Decals. . . . . . . . . . . . . . . . 8 - 2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 3
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . 8 - 7
Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . 8 - 11
Water System Diagram. . . . . . . . . . . . . . . . . . . . 8 - 13
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . 8 - 14
Hydroject 3000/4000
Rev. B
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Hydroject 3000/4000
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Chapter 1
Safety
Table of Contents
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 1
Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Maintenance and Service . . . . . . . . . . . . . . . . . . . . . 3
SAFETY AND INSTRUCTION DECALS . . . . . . . . . . 4
Safety Instructions
Although hazard control and accident prevention par-
tially are dependent upon the design and configuration
of the machine, these factors are also dependent upon
the awareness, concern, and proper training of the per-
sonnel involved in the operation, transport, mainte-
nance, 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.
CAUTION
TO REDUCE THE POTENTIAL FOR INJURY
OR DEATH, COMPLY WITH THE FOLLOWING
SAFETY INSTRUCTIONS.
Before Operating
1. Read and understand the contents of this manual
before starting and operating the machine. Become fa-
miliar with all controls and know how to stop quickly. A
free replacement manual is available by sending com-
plete Model and Serial Numbers to:
3. Never operate the machine when under the influ-
ence of drugs or alcohol.
4. Before attempting to start engine engage parking
brake.
5. Remove all debris or other objects that might inter-
fere with operation. Keep all bystanders away from the
work area.
The Toro Companyꢀ
8111 Lyndale Avenue Southꢀ
Bloomington, Minnesota 55420ꢀ
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 operation is commenced. Also
tighten any loose nuts, bolts and screws to assure ma-
chine is in safe operating condition.
UsetheModelandSerialNumberwhenreferringtoyour
machine. If you have questions about this Service
Manual, please contact:
The Toro Companyꢀ
7. Do not operatemachinewhilewearingsandals, ten-
nis shoes, sneakers or shorts. Also, do not wear loose
fitting clothing which could get caught in moving parts.
Always wear long pants and substantial shoes. Wearing
safety glasses, safety shoes, ear protection and a hel-
met is advisable and required by some local ordinances
and insurance regulations.
Commercial Service Departmentꢀ
8111 Lyndale Avenue Southꢀ
Bloomington, Minnesota 55420ꢀ
2. Never allow children to operate the machine. Do not
allow adults to operate machine without proper instruc-
tion. Only trained operators who have read this manual
should operate this machine.
Hydroject 3000
Safety
Rev. B
Page 1 – 1
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8. Fill fuel tank with gasoline before starting the en-
gine. Avoid spilling gasoline. Since gasoline is flam-
mable, handle it carefully.
D.ꢀ Fill fuel tank outdoors and up to about one
inch (25 mm) from top of the tank, not the
filler neck.
A.ꢀ Use an approved gasoline container.
E.ꢀ Wipe up any spilled gasoline.
B.ꢀ Do not fill tank while engine is hot orꢀ
running.ꢀ
9. Check interlock switches daily for proper operation.
If a switch fails, replace it before operating the machine.
The interlock system is for your protection, so do not by-
pass it. Replace all interlock switches every two years.
C.ꢀ Do not smoke while handling gasoline.
While Operating
10. DON’T TAKE AN INJURY RISK! When a person or
pet appears unexpectedly in or near the WORKING
area, STOP AERATING.
A.ꢀ Use only in daylight or when there is good
artificial light.
B.ꢀ Watch for holes or other hidden hazards.
11. Keep 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.
C.ꢀ Do not transport machine close to a sand
trap, ditch, creek or other hazard.
17. If the machine starts to vibrate abnormally, shut the
engine off. Remove wires from spark plugs to prevent
possibility of accidental starting. Check machine for
damage and defective parts. Repair any damage before
restarting the engine and operating the machine.
12. Never use chemicals in the water supply system.
13. Do not operate water injection system on concrete
or asphalt because water jets will permanently damage
these surfaces.
18. Do not touch engine or muffler while engine is run-
ning or soon after it is stopped. These areas could be hot
enough to cause a burn.
14. Start engine with parking brake engaged.
15. Do not run the engine in a confined area without ad-
equate ventilation. Exhaust fumes are hazardous and
could possibly be deadly.
19. Before leaving the operator’s position–behind han-
dle–engage parking brake.
20. When leaving the machine unattended, engage
parking brake , shut engine OFF and remove key from
ignition switch.
16. Using the machine demands attention, and to pre-
vent loss of control:
Maintenance
21. Disconnect wires from spark plugs to prevent acci-
dentalstartingoftheenginewhenservicing, adjustingor
storing the machine.
27. Keep body and hands away from pin hole leaks or
nozzles that eject water or hydraulic fluid under high
pressure. Use paper or cardboard, not hands, to search
for leaks. Hydraulic fluid or water escaping under pres-
sure can have sufficient force to penetrate skin and do
serious damage. If either of these fluids are ejected into
the skin they must be surgically removed within a few
hours by a doctor familiar with this form of injury or gan-
grene may result.
22. If machine must be tipped to perform maintenance
or an adjustment, close fuel shut–off valve, drain gaso-
line from fuel tank, oil from crankcase and remove bat-
tery.
23. Toreducepotentialfirehazard, keeptheenginefree
of excessive grease, grass, leaves and accumulations
of dirt.
28. Before disconnecting or performing any work on the
hydraulic oil system, all pressure in system must be re-
lieved by stopping engine and opening by–pass valve.
24. Be sure 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 specifi-
cation.
29. Make sure all water line connectors are tight, and all
hoses and lines are in good condition before applying
pressure to the system.
25. If the engine must be running to perform a mainte-
nance adjustment, keep hands, feet, clothing and other
parts of the 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 be-
fore applying pressure to the system.
Safety
Hydroject 3000
Page 1 – 2 Rev. B
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30. Before disconnecting or performing any work on the
watersystem, allpressureinsystemmustberelievedby
stopping engine and opening bleed valve. Opening the
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.
34. Allow engine to cool before storing machine in any
enclosure such as a garage or storage shed. Make sure
the fuel tank is empty if machine is to be stored in excess
of 30 days. Do not store machine near any open flame or
wheregasolinefumesmaybeignitedbyaspark. Always
store gasoline in a safety approved, red metal container.
31. The accumulator in this machine contains high
pressure dry nitrogen. Accumulator servicing requires
special tools and precautions. Accumulators do not con-
tain user serviceable components. Improper accumula-
tor servicing can cause dismemberment or death. Do
not attempt to disassemble a accumulator, have this
work done by a Authorized Toro Distributor.
35. When storing or transporting machine (trailering),
make sure fuel shut–off valve is closed.
36. Perform only those maintenance instructions de-
scribed in this manual. If major repairs are ever needed
orassistanceisdesired, contactanAuthorizedToroDis-
tributor. To ensure optimum performance and safety, al-
ways purchase genuine TORO replacement parts and
accessories to keep the Toro all TORO. NEVER USE
“WILL–FIT” REPLACEMENT PARTS AND ACCESSO-
RIES MADE BY OTHER MANUFACTURERS. Look for
the TORO logo to assure genuineness. Using unap-
proved replacement parts and accessories could void
the warranty of The Toro Company.
32. Do not overspeed the engine by changing governor
settings. To be sure of safety and accuracy, have an Au-
thorized T0R0 Distributor check maximum engine
speed with a tachometer.
33. Engine must be shut off before checking oil or add-
ing oil to the crankcase.
Hydroject 3000
Safety
Rev. B
Page 1 – 3
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Safety and Instruction Decals
The following decals are installed on the machine. If any become damaged or illegible, replace it. The decal part num-
ber is listed below and in your parts catalog. Replacement can be ordered from your Authorized Toro Distributor. For-
eign language decal sets are also available from your Authorized Toro Distributor.
On Each Side Of Engine (2)
(Part No. 80–9350)
On Accumulator body
(Part No. 80–8880)
On Drive Shaft Shield
(Part No. 80–8000)
On Top Of Tiller Arm
(Part No. 80–8070)
On Trans. Pump Bracket – under shield
(Part No. 80–8760)
On Muffler Shield (3)
(Part No. 80–8290)
On Sides and Behind Rollers (3
(Part No. 80–8090)
On Lift Actuator
(Part No. 80–8010)
On Control Panelꢀ
(Part No. 80–8110)
On Control Panel
(Part No. 80–8150)
On Drive Shaft Guardꢀ
(Part No. 80–8040)
IMPORTANT
D THE FIVE MICRON FILTER ELEMENT (86–8620) MUST
BE IN PLACE AT ALL TIMES.
D OPERATION WITHOUT PROPER FILTRATION WILL
RESULT IN PREMATURE WEAR AND FAILURE OF THE
WATER SYSTEM COMPONENTS.
D USE OF ADDITIONAL FILTRATION OR POTABLE WATER
MAY BE NECESSARY TO PROLONG THE LIFE OF THE
FILTRATION SYSTEM.
On Wheel Motor Fork
(Part No. 72–4080)
D SEE OPERATOR’S MANUAL FOR MORE INFORMATION.
On Each Side Of Machine (2)
(Part No. 92–9542)
On Underside of Tiller Control Panel
(Part No. 80–8020)
On Tiller Control Panel
(Part No. 80–9240)
On Tiller Arm
(Part No. 93–9429)
On Accumulator body
(Part No. 80–8030)
Safety
Hydroject 3000
Page 1 – 4 Rev. B
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Chapter 2
Product Records and Maintenance
Table of Contents
PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . 1ꢀ
EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . 2ꢀ
Decimal and Millimeter Equivalents . . . . . . . . . . . . 2ꢀ
U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . 2ꢀ
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . 3
Capscrew Markings and Torque Values – U.S. . . 3
Capscrew Markings and Torque Values – Metric . 3
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OPERATION AND SERVICE HISTORY REPORTS 5
Product Records
Record information about your Hydroject 3000 on the
OPERATION AND SERVICE HISTORY REPORT
form. Use this information when referring to your
machine.
Insert Operator’s Manuals and Parts Catalogs for your
Hydroject 3000 at the end of this section.
Hydroject 3000
Product Records and Maintenance
Rev. B
Page 2 – 1
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Equivalents and Conversionsꢀ
Product Records and Maintenance
Hydroject 3000ꢀ
Page 2 – 2
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Torque Specifications
Hydroject 3000
Product Records and Maintenance
Page 2 – 3ꢀ
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Lubrication
The Hydroject 3000 has 5 grease fittings that must be
lubricated every 50 hours of operation with No. 2 Gener-
al Purpose Lithium Base Grease. Lubricate all fittings
immediately after every washing, regardless of interval
listed.
The bearings and bushings that must be Iubricated are
the steering pivot shaft (Fig. 1), limit switch housing (2)
on lift arm shaft (Fig. 2) and neutral pivot shaft (Fig. 3).
1. Wipe 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 1
Figure 2
Figure 3
Product Records and Maintenance
Hydroject 3000
Rev. B
Page 2 – 4
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EQUIPMENT OPERATION AND SERVICE HISTORY REPORT
for
HYDROJECTR 3000
TORO Model and Serial Number: ______________–______________ꢀ
Engine Numbers:
_____________________________ꢀ
Transmission Numbers:
Drive Axle(s) Numbers:
Date Purchased:
_____________________________ꢀ
_____________________________ꢀ
_____________________________ Warranty Expires____________ꢀ
_____________________________ꢀ
Purchased From:
_____________________________
_____________________________
Contacts:
Parts
_____________________________ Phone____________________
_____________________________ Phone____________________
_____________________________ Phone____________________
Service
Sales
Hydroject 3000
Product Records and Maintenance
Rev. B
Page 2 – 5
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Hydroject 3000 Maintenance Schedule
Minimum Recommended Maintenance Intervalsꢀ
Maintenance Procedure
Maintenance Interval & Service
Every
400hrs
Every
200hrs
Every
100hrs
Check Battery Fluid Level
Every
50hrs
Check Battery Cable Connections
Lubricate All Grease Fittings
A Service
{ꢀ Change Engine Oil
{ꢀ Change Engine Oil Filter
Change Engine Pre–cleaner (Air Filter)
B Service
Replace Air Filter Element
Replace Fuel Filter
Adjust Water System Cam–Valve Clearance
Clean Engine Crankcase Breather
{ꢀ Change Gear Case Oil and Filter
{ꢀ Change Pump Case Oil
C Service
{ꢀ Torque Wheel Lug Nuts
Service Accumulator
Adjust Parking Brake
Calibrate Aeration Traction Speed
Service Injector Nozzles and Springs
Replace Spark Plugs
Decarbon Combustion Chambers
}ꢀ Torque Head and Adjust Valves
}ꢀ Check Engine RPM (idle and full throttle)
D Service
{ꢀ Initial break in at 25 hours
}ꢀ Initial break in at 50 hours
Replace Moving Hoses
Replace Safety Switches
Fuel Tank – Drain/Flush
Hydraulic Tank – Drain/Flush
Annual Recommendations:
Items listed are recommended every 1000
hours or 2 years, whichever occurs first.
(See Operator’s and Service Manual for specifications and procedures)
Product Records and Maintenance
Hydroject 3000ꢀ
Rev. B
Page 2 – 6
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Hydroject 3000 Daily Maintenance Check List
Daily Maintenance Check For Week Of _________________
Maintenance
Check Item bꢀ
MON
TUES
WED
THURS
FRI
SAT
SUN
nꢀ Safety Interlock Operation
nꢀ Brake Operation
nꢀ Engine Oil Level
nꢀ Engine Air Filter Pre–Cleaner
nꢀ Engine Cooling FIns for
Debris
nꢀ Unusual Engine Noises
nꢀ Unusual Operating Noises
nꢀ Water Filter/Pressure
nꢀ Water Prefilter
nꢀ Gear Case Oil Level
nꢀ Pump Case Oil Level
nꢀ Hydraulic Hose for Damages
nꢀ Fluid Leaks
nꢀ Tire Pressure
nꢀ Instrument Operations
1
Lubricate All Grease Fittings
Touch–up Damaged Paint
1
= Immediately after every washing, regardless of the interval listed.ꢀ
Notation for areas of concern: Inspection performed by_____________________________ꢀ
Item
Date
Information
1
2
3
4
5
6
7
8
Hydroject 3000
Product Records and Maintenance
Rev. B
Page 2 – 7
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Product Records and Maintenance
Hydroject 3000
Rev. B
Page 2 – 8
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Chapter 3
Engine
Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 1
REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Engine Removal and Installation. . . . . . . . . . . . . 2
ONAN SERVICE MANUAL
Specifications
Item
Description
___________________________________________________________________________________________
Make / Designation
Onan P224G-I/10999C
________________________________________________________________________________________________________________________________________________________
Displacement
59.7 cu. in.
________________________________________________________________________________________________________________________________________________________
Weight
127 lbs. dry
________________________________________________________________________________________________________________________________________________________
Oil Capacity
3 qt. with filter
________________________________________________________________________________________________________________________________________________________
Oil
SAE 30W SF, SG, SF/CC or SG/CC
________________________________________________________________________________________________________________________________________________________
Fuel
Unleaded regular gasoline
________________________________________________________________________________________________________________________________________________________
High Idle Speed
3500 ± 50 RPM no load
________________________________________________________________________________________________________________________________________________________
Low Idle Speed
1500 - 1800 RPM
HydroJect 3000
Page 3 - 1
Specifications
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Repairs
Engine Removal and Installation (Fig. 1)
1. Park the machine on a level surface, engage the
parking brake, and remove the hood.
8. Attach an engine lifting chain to the engine lifting
straps. Connect the chain to a hoist or block and tackle
and remove slack from the chain and lifting device. One
person should operate the hoist or block and tackle and
the other person should help guide the engine out of the
frame. Remove the engine from the frame.
2. Disconnect both the positive (+) and negative (–)
cables from the battery. Loosen the battery clamp
(Item 2) and remove the battery (Item 1).
3. Remove the drain cap (Item 33) and let the oil drain
into a container. Clean and install the drain cap.
9. Mount the engine in an engine rebuilding stand or put
it on a sturdy workbench. Before disassembling the
engine, remove external accessories, such as the muf-
fler guard (Item 11), muffler (Item 7), hydraulic pump
clutch, hydraulic pump pulley, water pump clutch and
clutch key (see Drive Coupling Removal and Installation
in Water System Service).
4. Disconnect the drive coupling from the clutch adapter
(see Drive Coupling Removal and Installation in Water
System Service).
5. Remove the water pump drive belt and hydraulic
pump drive belt.
10. To install the engine, perform steps 2 - 9 in reverse
order. Make sure the ground cable (Item 36) is con-
nected to the frame with an engine mounting nut.
6. Disconnect the engine wiring harness connector.
Disconnect and plug the fuel hose (Item 30).
11. Replace the oil filter and fill the engine with the
correct oil.
7. Remove four nuts (Item 35), washers (Item 3), cap-
screws (Item 39) and spacers (Item 38) securing the
engine to the frame.
13
5
12
11
14
20
15
19
16
21
10
9
8
16
22
23
18
12
5
7
17
6
4
3
24
25
5
26
2
27
8
9
1
18
28
29
30
40
31
39
38
32
33
37
36
3
35
3
35
34
Figure 1
Page 3 - 2
Repairs
HydroJect 3000
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Chapter 4
Hydraulic System
Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . 3
Hydraulic Hose and Fitting Information . . . . . . . . 3
Pushing or Towing. . . . . . . . . . . . . . . . . . . . . . . . 5
HYDRAULIC DIAGRAM. . . . . . . . . . . . . . . . . . . . . . 6
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Hydraulic Tester. . . . . . . . . . . . . . . . . . . . . . . . . . 7
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 8
Transmission Operates in One Direction Only . . 8
System Operates Hot, Looses Power or
Will Not Operate in Either Direction. . . . . . . . . 8
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hydraulic Tests . . . . . . . . . . . . . . . . . . . . . . . . . 10
ADJUSTMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Traction Cable Adjustment . . . . . . . . . . . . . . . . . 11
Speed Control Adjustment. . . . . . . . . . . . . . . . . 11
Transmission Neutral Adjustment . . . . . . . . . . . 12
Aeration Speed Adjustment. . . . . . . . . . . . . . . . 12
Pump Drive Belt Adjustment . . . . . . . . . . . . . . . 13
REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pump Drive Belt Replacement . . . . . . . . . . . . . 14
Hydraulic Pump Removal and Installation. . . . . 15
Pump Shaft Seal Replacement . . . . . . . . . . . . 16
Pump Charge Check Valve Service . . . . . . . . . 17
Pump Bypass Valve Service . . . . . . . . . . . . . . . 17
Charge Pump Service . . . . . . . . . . . . . . . . . . . . 18
Major Pump Repair . . . . . . . . . . . . . . . . . . . . . . 18
Wheel Motor Removal and Installation . . . . . . . 22
Wheel Motor Repair. . . . . . . . . . . . . . . . . . . . . . 23
HydroJect 3000
Page 4 - 1
Table of Contents
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Specifications
Item
Description
__________________________________________________________________________________________
Pump
Rated system pressure
Rated system flow
Charge relief pressure
Oil filter
Sundstrand Series 70, BDP-10L Variable Displacement Pump
2100 PSI maximum, 1000 PSI continuous
8.5 GPM maximum at 3200 RPM
25 to 70 PSI psi at 3200 RPM
25 micron screw-on type. No by-pass
________________________________________________________________________________________________________________________________________________________
Wheel Motor
Nichols-Gray, orbit rotor type
________________________________________________________________________________________________________________________________________________________
Hydraulic Oil
* Mobil DTE 26 or equivalent
________________________________________________________________________________________________________________________________________________________
Reservoir (gear case)
Approximately 4 - 5 quarts
* Equivalent Hydraulic Oils
(interchangeable):
Shell Tellus 68
Amoco Rykon Oil 68
Conoco Super Hydraulic Oil 68
Exxon Nuto H 68
3
2
Kendall Kenoil R & O AW 68
Pennzoil Penreco 68
Phillips Magnus A 68
Standard Energol HLP 68
Sun Sunvis 831 WR
Union Unax AW 68
Chevron AW Hydraulic Oil 68
1
Figure 1
1. Sight gauge
2. Fill plug
3. Breather
Specifications
Page 4 - 2
HydroJect 3000
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General Information
Hydraulic Hoses
Hydraulic hoses are subject to extreme conditions such
as, pressure differentials during operation and exposure
to weather, sun, chemicals, very warm storage condi-
tions or mishandling during operation or maintenance.
These conditions can cause damage or premature de-
terioration. Some hoses, such as reel motor hoses, are
more susceptible to these conditions than others. In-
spect the hoses frequently for signs of deterioration or
damage.
CAUTION
Before disconnecting or performing any work
on the hydraulic system, all pressure in the
system must be relieved by stopping the en-
gine and opening the bypass valve.
Keep body and hands away from pin hole
leaks or nozzles that eject hydraulic fluid un-
der high pressure. Use paper or cardboard,
not hands, to search for leaks. Hydraulic fluid
escaping under pressure can have sufficient
force to penetrate the skin and do serious
damage. If fluid is injected into the skin, it
must be surgically removed within a few
hours by a doctor familiar with this type of
injury or gangrene may result.
When replacing a hydraulic hose, be sure that the hose
is straight (not twisted) before tightening thefittings. This
can be done by observing the imprint on the hose. Use
two wrenches; one to hold the hose straight and one to
tighten the hose swivel nut onto the fitting.
Hydraulic Fitting Installation
O-Ring Face Seal (Fig. 2, 3)
Nut
Sleeve
Body
1. Make sure both threads and sealing surfaces are free
of burrs, nicks, scratches, or any foreign material.
Seal
2. Make sure the O-ring is installed and properly seated
in the groove. It is recommended that the O-ring be
replaced any time the connection is opened.
3. Lubricate the O-ring with a light coating of oil.
4. Put the tube and nut squarely into position on the face
seal end of the fitting and tighten the nut until finger tight.
Figure 2
5. Mark the nut and fitting body. Hold the body with a
wrench. Use another wrench to tighten the nut to the
correct flats from finger tight (F.F.F.T.). The markings on
the nut and fitting body will verify that the connection has
been tightened.
Final
Initial
Position
Mark Nut
and Body
Position
Size
F.F.F.T.
4 (1/4 in. nominal hose or tubing)
6 (3/8 in.)
8 (1/2 in.)
10 (5/8 in.)
12 (3/4 in.)
.75 ± .25
.75 ± .25
.75 ± .25
1.00 ± .25
.75 ± .25
.75 ± .25
Extend Line
Finger Tight
After Proper Tightening
16 (1 in.)
Figure 3
HydroJect 3000
Page 4 - 3
General Information
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SAE Straight Thread O-Ring Port - Non-adjustable
(Fig. 4)
1. Make sure both threads and sealing surfaces are free
of burrs, nicks, scratches, or any foreign material.
2. Always replace the O-ring seal when this type of fitting
shows signs of leakage.
O-Ring
3. Lubricate the O-ring with a light coating of oil.
4. Install the fitting into the port and tighten it down full
length until finger tight.
5. Tighten the fitting to the correct flats from finger tight
(F.F.F.T.).
Figure 4
Size
F.F.F.T.
4 (1/4 in. nominal hose or tubing)
6 (3/8 in.)
8 (1/2 in.)
10 (5/8 in.)
12 (3/4 in.)
1.00 ± .25
1.50 ± .25
1.50 ± .25
1.50 ± .25
1.50 ± .25
1.50 ± .25
16 (1 in.)
SAE Straight Thread O-Ring Port - Adjustable
(Fig. 5, 6)
1. Make sure both threads and sealing surfaces are free
of burrs, nicks, scratches, or any foreign material.
2. Always replace the O-ring seal when this type of fitting
shows signs of leakage.
Lock Nut
3. Lubricate the O-ring with a light coating of oil.
Back-Up Washer
O-Ring
4. Turn back the jam nut as far as possible. Make sure
the back up washer is not loose and is pushed up as far
as possible (Step 1).
5. Install the fitting into the port and tighten finger tight
until the washer contacts the face of the port (Step 2).
Figure 5
6. To put the fitting in the desired position, unscrew it by
the required amount, but no more than one full turn
(Step 3).
Step 3
Step 1
7. Hold the fitting in the desired position with a wrench
and turn the jam nut with another wrench to the correct
flats from finger tight (F.F.F.T.) (Step 4)
Step 4
Step 2
Size
F.F.F.T.
4 (1/4 in. nominal hose or tubing)
6 (3/8 in.)
8 (1/2 in.)
10 (5/8 in.)
12 (3/4 in.)
1.00 ± .25
1.50 ± .25
1.50 ± .25
1.50 ± .25
1.50 ± .25
1.50 ± .25
Figure 6
16 (1 in.)
General Information
Page 4 - 4
HydroJect 3000
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Pushing or Towing (Fig. 7)
The machine can be pushed or towed for very short
distances with the engine off, if necessary.
IMPORTANT: Do not push or tow the machine faster
than 5 MPH because the hydraulic pump may be
damaged. If the machine must be moved further
than a few feet, transport it on a trailer or pull with
traction wheel raised and secured to a dolly. When-
ever the machine is pushed or towed, the by-pass
valve must be open. Hook on front of handle is used
for a tie-down only, not a hitch point.
1
1. Stop the engine and raise the hood.
2. Open the by-pass valve by turning it counterclockwise
(2 turns maximum).
Figure 7
1. By-pass valve
3. After moving the machine, close the by-pass valve by
turning it clockwise. Tighten the by-pass valve to a
torque of 7 to 10 ft-lb.
IMPORTANT: Operating the machine with the by-
pass valve open will cause improper operation and
overheating of the hydraulic system.
HydroJect 3000
Page 4 - 5
General Information
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Hydraulic Diagram
Variable Displacement Pump
Cooling
Orifice
Charge
Pump
Charge
Check
Valves
Input
(Belt Drive)
Variable
Disp. Pump
Wheel
Motor
By-pass
Valve
Charge Relief
Valve
Inlet
Filter
Reservoir
(Gear Case)
Figure 8
Hydraulic Diagram
Page 4 - 6
HydroJect 3000
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Special Tools
NOTE: Order special tools from the TORO SPECIAL
TOOLS AND APPLICATIONS GUIDE (COMMERCIAL
PRODUCTS). Some tools may be listed in the
HydroJect 3000 Parts Catalog. Some tools may also be
available from a local supplier.
Hydraulic Tester - With Pressure and Flow Capabilities (Fig. 9)
Load Valve
Low Pressure
Gauge
Outlet
Hose
Flow Meter
Gauge
Protector Valve
High Pressure
Gauge
Inlet Hose
Figure 9
You must have o-ring face seal (ORFS) adapter fittings
for this tester to use it on the HydroJect 3000.
4. HIGH PRESSURE GAUGE: High range gauge to
accommodate pressure beyond the capacity of the low
pressure gauge, 0 - 5000.
1. INLET HOSE: Hose connected from the system
circuit to the inlet side of the hydraulic tester.
5. FLOW METER: This meter measures actual oil flow
in the operation circuit, with a gauge rated at 15 GPM.
2. LOAD VALVE: If required, upon turning the valve to
restrict flow, a simulated working load is created in the
circuit.
6. OUTLET HOSE: Hose from the outlet side of the
hydraulic tester to be connected to the hydraulic system
circuit.
3. LOW PRESSURE GAUGE: Low range gauge to
provide accurate reading at low pressure, 0 - 1000 psi.
This gauge has a protector valve which cuts out
when pressure is about to exceed the normal range
for the gauge. The cutout pressure is adjustable.
HydroJect 3000
Page 4 - 7
Special Tools
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Troubleshooting
The cause of an improperly functioning hydraulic sys-
tem is best diagnosed with the use of proper testing
equipment and a thorough understanding of the com-
plete hydraulic system.
system could lead to extensive internal component
damage.
The charts that follow contain detailed information to
assist in troubleshooting. There may possibly be more
than one cause for a machine malfunction. All causes
should be checked in the order in which they are listed
on the charts.
A hydraulic system with an excessive increase in heat
or noise is a potential failure. Should either of these
conditions be noticed, immediately stop the machine,
turn off the engine, locate the cause of the trouble, and
correct it before allowing the machine to be used again.
Continued use of an improperly functioning hydraulic
Refer to the Testing section of this Chapter for precau-
tions and specific test procedures.
Transmission Operates in One Direction Only
Cause
Correction
__________________________________________________________________________________________
Faulty traction control linkage. Repair linkage
________________________________________________________________________________________________________________________________________________________
Transmission charge check valve defective.
Inspect and clean or replace charge/check.
System Operates Hot, Looses Power or Will Not Operate in Either Direction
Cause
Correction
__________________________________________________________________________________________
Faulty control linkage.
Repair linkage
________________________________________________________________________________________________________________________________________________________
Parking brake engaged.
Disengage parking brake.
________________________________________________________________________________________________________________________________________________________
Hydraulic oil level too low.
Fill to proper level.
________________________________________________________________________________________________________________________________________________________
By-pass valve open.
Close by-pass valve.
________________________________________________________________________________________________________________________________________________________
Clogged hydraulic filter.
Replace filter.
________________________________________________________________________________________________________________________________________________________
Low charge pressure - Test A.
Inspect charge relief valve and replace if faulty.
Inspect charge pump and replace if faulty.
________________________________________________________________________________________________________________________________________________________
Low traction pump flow/pressure - Test B.
Repair or replace pump.
________________________________________________________________________________________________________________________________________________________
Low traction motor efficiency - Test C.
Repair or replace traction motor.
Troubleshooting
Page 4 - 8
HydroJect 3000
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Testing
The most effective method for isolating problems in the
hydraulic system is by using hydraulic test equipment
such as pressure gauges and flow meters in the circuits
during various operational checks. (See the Special
Tools section in this Chapter.)
1. Thoroughly clean the machine before disconnecting
or disassembling any hydraulic components. Always
keep in mind the need for cleanliness when working on
hydraulic equipment.
2. Put caps or plugs on any hydraulic lines left open or
exposed during testing or removal of components.
CAUTION
3. The engine must be in good operating condition. Use
a tachometer when making a hydraulic test. Engine
speed can affect the accuracy of the tester readings.
Failure to use gauges with the recommended
pressure (psi) rating as listed in the test pro-
cedures could result in damage to the gauge
and possible personal injury from leaking hot
oil.
4. To prevent damage to tester or components, the inlet
and the outlet hoses must be properly connected, and
not reversed (tester with pressure and flow capabilities).
Before Performing Hydraulic Tests
5. To minimize the possibility of damaging components,
completely open the load valve by turning it counter-
clockwise (tester with pressure and flow capabilities).
All obvious areas such as oil supply, filter, binding link-
age, loose fasteners, or improper adjustments must be
checked before assuming that a hydraulic component
is the source of the problem being experienced.
6. Install fittings finger tight, far enough to insure that
they are not cross-threaded, before tightening with a
wrench.
7. Position the tester hoses so that rotating machine
parts will not make contact with them and result in hose
or tester damage.
WARNING
Before disconnecting or performing any work
on the hydraulic system, all pressure in the
system must be relieved by stopping the en-
gine and opening the bypass valve.
8. Check the oil level in the reservoir.
9. Check the control linkage for improper adjustment,
binding or broken parts.
Keep body and hands away from pin hole
leaks or nozzles that eject hydraulic fluid un-
der high pressure. Use paper or cardboard,
not hands, to search for leaks. Hydraulic fluid
escaping under pressure can have sufficient
force to penetrate skin and do serious dam-
age. If fluid is injected into the skin, it must be
surgically removed within a few hours by a
doctor familiar with this type of injury or gan-
grene may result.
10. All hydraulic tests should be made with the hydraulic
oil at normal operating temperature.
HydroJect 3000
Page 4 - 9
Testing
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Hydraulic Tests (Fig. 10, 11)
1. Make sure hydraulic oil is at normal operating tem-
perature by operating the machine for approximately 10
minutes.
NOTE: At pressures above approximately 500 PSI,
mechanical override in handle will cause pump to begin
to de-stroke.
2. Engage parking brake and stop the engine. Make
sure parking brake is properly adjusted before perform-
ing hydraulic tests.
11. If you cannot get 7 GPM or 500 PSI, traction pump
may have internal damage or excessive wear.
TEST C: Traction Motor Efficiency
3. With engine off, disconnect hose from bulkhead fitting
and install tester in series between traction pump and
wheel motor. Make sure tester flow control valve is
OPEN.
12. Lower drive wheel to ground and engage parking
brake. Block front and rear of all wheels. Chain machine
to an immovable object and remove slack from chain.
IMPORTANT: Make sure that the oil flow indicator
arrow on the flow gauge is showing that oil will flow
from pump, through tester and to wheel motor.
13. With tester flow control valve open, slowly move
traction handle (up or down) so flow is from the pump,
through the tester, then to the wheel motor. Move trac-
tion handle until maximum pressure is attained with
wheel not rotating and read flow gauge.
Test A: Charge Pressure
4. Start the engine and move throttle to full engine RPM
(approx. 3200 RPM).
14. If flow reading is higher than 1.5 GPM, motor may
have internal damage or excessive wear.
GAUGE READING: 25 to 70 PSI no load.
1
5. If there is no pressure, or pressure is low, inspect for
restriction in pump intake line and inlet filter. Inspect
charge relief valve and valve seat. Inspect for sheared
charge pump key. Disassemble charge pump and in-
spect for internal damage or worn parts. If charge pump
is in good condition (no scoring, scratches, or excessive
wear), piston pump and motor might be suspected of
wear and inefficiency, thus charge pump is unable to
keep up with internal leakage.
2
TEST B: Traction Pump Flow
Figure 10
6. Lift the drive wheel off the ground using a jack. Block
front and rear of the other wheels. Make sure the tester
flow control valve is OPEN.
1. Hose
2. Bulkhead fitting
7. Start the engine and release the parking brake.
Variable Displacement Pump
8. While watching flow and pressure gauges, move
traction handle (up or down) so flow is from the pump,
through the tester, then to the wheel motor. Move trac-
tion handle until 6 GPM is obtained.
Wheel
Motor
9. If pressure is less than 200 to 300 PSI go to step 10.
If pressure is more than 200 to 300 PSI stop the engine
and inspect for binding parking brake. Inspect for restric-
tion in lines to and from motor. If there are no restrictions,
motor should be suspected of having internal damage.
Tester
10. While watching flow and pressure gauges, move
traction handle (up or down) to full speed position so
flow is from the pump, through the tester, then to the
wheel motor. Slowly close flow control valve until you
get readings of 7 GPM and 500 PSI.
Figure 11
Testing
Page 4 - 10
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Adjustments
Traction Cable Adjustment (Fig. 12)
1. Park machine on a level surface, stop the engine and
open the hood. Remove lower cover from handle.
1
2. Adjust pump end of push-pull cable with pump lever
in neutral starting position by adjusting jam nuts so
distance from seal to threads is 1.00 ± 0.05 in.
2
3. Adjust jam nuts at tiller end of push-pull cable so
traction handle is centered on control handle.
Figure 12
1. Jam nuts - pump end
2. Jam nuts - tiller end
Speed Control Adjustment (Fig. 13)
1. Park machine on a level surface, stop the engine and
open the hood.
3. Adjust speed rods (Item 14) so rod end mounting
holes in pivot arms (Items 11, 23) are located vertically
in line with pivot pin (Item 22).
2. Adjust speed control cable (Item 26) so speed stop
lever (Item 9) can move to horizontal position.
1
3
2
4
5
6
17
16
7
13
15
8
9
8
14
10
24
13
8
18
19
11
12
20
22
15
21
8
28
18
19
29
20
30
28
27
24
19
8
23
26
25
Figure 13
HydroJect 3000
Page 4 - 11
Adjustments
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Transmission Neutral Adjustment (Fig. 14)
If machine moves when lever is released, transmission
neutral adjustment is needed.
1. Park machine on a level surface, stop the engine and
open the hood.
3
2
1
2. Lift drive wheel off the ground using a jack. Block front
and rear of other wheels.
3. Start engine and release parking brake.
4. Slightly loosen locknut on top of neutral adjustment
cam and rotate cam hex until traction wheel stops
rotating. Tighten the locknut.
Figure 14
5. Move traction bail completely up and down. Release
handle and check for wheel rotation. If wheel continues
rotating, repeat step 4.
1. Neutral adjustment cam
2. Locknut
3. Switch tab
6. If problem continues, stop the engine, check linkage
for binding or damage, then do adjustment procedure
again.
7. Loosen two (2) screws and adjust switch tab so
switches are actuated when pump control is in neutral
and not actuated when pump control is stroked.
Aeration Speed Adjustment (Fig. 15)
1. Park machine on a level surface, stop the engine and
open the hood.
2. Put speed control lever into second slot from left
(while facing control panel).
1
3
3. Lower machine into aerate mode so transport wheels
are off the ground.
4. Lift drive wheel off ground using a jack.
5. Start the engine and release the parking brake.
6. Operate engine at full speed.
2
7. Move traction handle UP to full speed position.
8. Loosen jam nuts and adjust LOWER speed rod until
traction wheel rotates at 20-22 RPM. Tighten jam nuts.
Figure 15
1. Speed control lever
2. Lower speed rod
3. Upper speed rod
9. Move traction handle DOWN to full speed position.
10. Adjust UPPER speed rod until traction wheel rotates
at 20-22 RPM. Tighten jam nuts.
Adjustments
Page 4 - 12
HydroJect 3000
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Traction Pump Belt Adjustment (Fig. 16, 17)
1. Park machine on a level surface, stop the engine and
open the hood.
1
2. Check belt tension by depressing belt midway be-
tween pulleys with 3 lb. of force. Belt should deflect
1/4 in.
3. If adjustment is necessary:
A. Loosen pivot nut securing pump mount to pump
support.
B. Loosen adjusting nut securing pump and pump
mount to slotted pump support.
Figure 16
C. Loose three (3) capscrews securing pulley guard
bracket (Fig. 20, Item 21) to control panel and pump
support.
1. Traction pump belt
D. Use a pry bar in hole on pump bracket to pull pump
towards outside of machine until you get proper belt
tension, then tighten adjusting nut to secure pump
and pump mount to pump support.
1
E. Tighten pivot nut. Tighten three (3) capscrews
securing pulley guard bracket.
2
Figure 17
1. Adjusting nut
2. Pivot nut
Rev. A
HydroJect 3000
Page 4 - 13
Adjustments
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Repairs
Traction Pump Belt Replacement (Fig. 18, 19)
1. Park machine on a level surface, engage parking
brake, open hood and disconnect engine spark plug
wires.
1
2. Remove pulley guard bracket (Fig. 20, Item 21).
3. Remove drive coupling (see Drive Coupling Removal
and Installation in Chapter 6 - Water System).
3
4. Disconnect valve clutch electrical connector.
5. Remove valve clutch stops.
4
2
6. Loosen pivot nut securing pump mount to pump
support.
Figure 18
7. Loosen adjusting nut securing pump and pump mount
to slotted pump support.
1. Pump drive belt
2. Drive coupling
3. Valve clutch
4. Valve clutch stops
8. Push pump towards inside of machine to loosen belt
tension and remove the belt.
9. Reverse steps 2 - 8 to install new belt.
10. Adjust belt tension (see Traction Pump Belt
Adjustment).
1
2
Figure 19
1. Adjusting nut
2. Pivot nut
Rev. A
Repairs
Page 4 - 14
HydroJect 3000
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Hydraulic Pump Removal and Installation (Fig. 20)
1. Park machine on a level surface, engage parking
brake, open hood and disconnect engine spark plug
wires.
7. Remove locknut (Item 46), capscrew (Item 5) and
washers (Item 47). Remove locknut (Item 54) and cap-
screw (Item 57).
2. Disconnect wires from neutral and pump switches
(Item 31) on hydraulic pump. Label wires for proper
reinstallation.
8. Remove pump assembly from pump support
(Item 55) and put pump on a work bench.
9. Loosen jam nuts (Item 3) and set screws (Item 2).
Remove pulley (Item 4) from pump shaft.
3. Remove extension spring (Item 17).
4. Disconnect stroke control cable ball joint (Item 43)
from pump lever (Item 30). Disconnect upper and lower
speed adjustment rods from pump lever (see Fig. 14).
10. Remove pump mount (Item 6) from pump.
11. Loosen locknuts (Item 36) and remove roll pin
(Item 34). Pull pump lever (Item 30) off of pump control
shaft.
5. Loosen belt tension and remove belt from pump
pulley (see Pump Belt Tension Adjustment).
12. Remove hydraulic fittings from pump and plug ports.
13. Reverse steps 2 - 12 to install pump.
6. Disconnect hydraulic lines from fittings on pump. Put
caps on open lines and fittings to prevent contamination.
Put labels on hydraulic lines for proper reinstallation.
13
14
39
38
37
12
15
16
33
36
11
17
35
32
31
10
18
24
34
25
26
30
9
27
29
28
50
40
41
19
20
8
7
42
6
19
13
43
44
22
23
51
5
41
2
4
3
1
45
46
47
14
53
48
52
47
49
59
54
55
47
57
56
5
Figure 20
HydroJect 3000
Page 4 - 15
Repairs
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Pump Shaft Seal Replacement (Fig. 21)
Lip type seals are used on input shaft and displacement
control shaft. These sealscanbereplacedwithout major
disassembly of pump.
Top of pump when
installed in machine
1
2
3
4
1. Remove retaining ring from housing (input shaft seal
only).
2. Carefully pull seal out of housing bore. A “hook” type
tool may be used to grasp seal and pull it out, or a slide
hammer type puller may be used to remove seal. Be
careful not to damage housing bore, shaft sealing sur-
face, or bearing. After the seal is removed, it cannot be
used again.
IMPORTANT: When input shaft seal is removed,
pump block spring may push shaft partially out of
housing. Do not attempt to pull shaft out of housing.
Internal parts could move out of alignment or fall
into pump, requiring major disassembly of pump.
Figure 21
1. Retaining ring
2. Seal (input shaft)
3. Spacer
3. Inspect sealing area of shaft for rust, wear or contami-
nation. Polish sealing area on shaft if necessary.
4. Seal (displacement control shaft)
4. Lubricate new seal with petroleum jelly.
5. Wrap shaft with thin plastic or use a seal protector to
prevent damage to seal lip during installation.
6. Slide seal over shaft and press it into housing bore.
Be careful not to damage the seal.
7. Install seal retaining ring into housing (input shaft seal
only).
Repairs
Page 4 - 16
HydroJect 3000
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Pump Charge Check Valve Service (Fig. 22)
1. Remove check valve plug with a 1/4 in. internal hex
wrench.
Top of pump when
installed in machine
2. Remove valve spring and check ball from pump end
cap.
IMPORTANT: Do not allow check balls to fall into
closed loop passages in end cap.
Torque to
15 to 35 ft-lb.
3. Inspect check balls and mating seats in end cap for
damage or foreign material.
4. Lay pump on its side and reinstall check ball, spring
and plug (with O-ring) into end cap. Make sure check
ball does not fall into closed loop passage inside pump.
Tighten plug to a torque of 15 to 35 ft-lb. Turn pump over
and repeat installation procedure for other check valve.
5
4
3
2
1
Figure 22
1. Check valve plug
2. O-ring
3. Check valve spring
4. Check ball
5. Pump end cap
Pump Bypass Valve Service (Fig. 23)
1. Unscrew bypass valve from end cap of pump.
Torque to
7 to 10 ft-lb.
Top of pump when
installed in machine
2. Inspect valve and mating seat in end cap for damage
and foreign material. It is recommended that the O-ring
and back-up ring be replaced.
3. Reinstall bypass valve into end cap. Tighten to a
torque of 7 to 10 ft-lb.
1
2
3
4
Figure 23
1. Bypass valve
2. Back-up ring
3. O-ring
4. Pump end cap
HydroJect 3000
Page 4 - 17
Repairs
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Charge Pump Service (Fig. 24)
1. Use a 5 mm internal hex wrench to remove the two
(2) screws holding charge pump cover to pump end cap.
Top of pump when
installed in machine
NOTE: Charge pump rotation is determined by orienta-
tion of charge pump cover on pump end cap. Cast boss
on charge pump cover indicates orientation. Note orien-
tation of cast boss before removing charge pump cover.
2
3
2. Remove charge pump cover and O-ring.
3. Remove charge pump gerotor assembly.
4. Remove charge relief valve spring and ball.
5
4
1
5. Inspect gerotor assembly, charge pump cover and
end cap for abnormal wear, damage or foreign material.
Inspect charge relief valve seat in end cap for damage
or foreign material.
Torque to
84 to 120 in-lb.
Figure 24
6. Before installing charge pump, apply a small amount
of petroleum jelly to inside diameter, outside diameter
and slide faces of gerotor assembly.
1. Charge pump cover
2. O-ring
3. Gerotor assembly
4. Charge relief ball
5. Charge relief spring
7. Install charge relief ball and spring.
8. Install charge pump gerotor assembly.
9. Install charge pump cover and O-ring. Make sure
charge relief spring enters recess in cover.
10. Install charge pump cover screws and tighten to a
torque of 84 to 120 in-lb.
Major Pump Repair (Fig. 25, 26)
The procedures on the following pages are for complete
disassembly and reassembly of the pump.
During assembly of the pump, all surfaces which have
relative motion between two parts should be coated with
a film of clean hydraulic oil. This will assure that these
surfaces will be lubricated during start-up.
Cleanliness is a primary means of assuring satisfactory
transmission life, on either new or repair units. Cleaning
parts by using a clean solvent wash and air drying is
usually adequate. As with any precision equipment, all
parts must be kept free of foreign materials and chemi-
cals. Protect all sealing surfaces and open cavities from
damage and foreign material.
It is recommended that all gaskets, o-rings and seals be
replaced. Lightly lubricate all o-rings with clean petro-
leum jelly before assembly. All gasket sealing surfaces
must be cleaned before installing new gaskets.
Repairs
Page 4 - 18
HydroJect 3000
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24
23
22
21
20
19
18
16
17
12
15
14
13
8
7
11
1
10
6
9
2
5
3
4
25
26
27
40
28
39
29
38
37
36
35
34
1
33 32 31 30
3
2
4
Figure 25
Disassembly of Hydraulic Pump
6. Remove cylinder block spring (Item 8) and washer
(Item 9) from shaft.
1. Before performing major repairs on the pump, remove
external components as described in previous proce-
dures. These include the following:
7. Remove swashplate assembly (Item 25) from hous-
ing.
Shaft Seals
Charge Check Valves
Bypass Valve
8. Remove thrust plate (Item 11) from swashplate. The
bearing guide is pressed into the swashplate and is
usually not removed. The inner thrust washer is retained
by the bearing guide.
Charge Pump
2. Lay pump on its side. Use a 6 mm internal hex wrench
to remove the four (4) screws (Item 30) which retain end
cap to variable pump housing.
9. Remove slot guide block (Item 13) from displacement
control shaft (Item 12).
10. Remove swashplate cradle bearings (Item 14) from
housing.
3. Internal springs will separate end cap from housing.
Remove end cap (Item 31) from housing (Item 18).
11. Remove input shaft seal retaining ring (Item 24).
IMPORTANT: Pump cylinder block (Item 7) will stick
to surface of end cap. Be careful to prevent damage
to end cap and cylinder block.
12. Carefully pull input shaft seal (Item 23) out of hous-
ing bore. A hook may be used to pry seal out, or a slide
hammer type puller may be used to remove the seal. Be
careful not to damage housing bore, shaft sealing sur-
face, or bearing. After seal is removed it cannot be used
again.
4. Remove gasket (Item 6) and two (2) alignment pins
(Item 15) from housing.
5. Remove cylinder block kit (Item 7) from shaft
(Item 19).
13. Remove bearing spacer washer (Item 22).
HydroJect 3000
Page 4 - 19
Repairs
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14. Remove pump shaft (Item 19) and bearing assembly
from housing.
3. Install displacement control shaft (Item 12) into hous-
ing.
15. Remove outer bearing retaining ring (Item 21) (and
washer, if used). Press shaft out of bearing.
4. If block spring retaining ring (Item 10) was removed
from pump shaft, install a new retaining ring at this time.
16. If pump block retaining spring retaining ring
(Item 10) requires replacement, remove it from pump
shaft.
5. Install inner bearing retaining ring (Item 20) onto shaft.
Press bearing (Item 21) onto shaft, install washer (if
used) and new outer bearing retaining ring. Be careful
not to stretch or deform retaining rings.
17. Remove displacement control shaft from housing.
IMPORTANT: Be careful not to damage shaft sealing
surface.
18. Pry displacement control shaft seal out of housing.
Care must be taken so as not to damage housing bore.
6. Install pump shaft and bearing assembly into housing.
7. Install bearing spacer washer (Item 22).
19. If displacement control shaft journal bearingrequires
replacement, press it out of housing.
Inspection and Replacement of Pump Parts
8. Wrap shaft with thin plastic or use a seal protector to
prevent damage to seal during installation. Lubricate
new pump shaft seal (Item 23) with petroleum jelly.
After disassembly, thoroughly clean all parts in a suit-
able solvent. Replace all o-rings, gaskets and seals.
9. Slide seal over shaft and press it into housing bore.
Be careful not to damage the seal.
Inspect all parts for damage, nicks or unusual wear
patterns. Replace all parts having unusual or excessive
wear or discoloration.
10. Install retaining ring (Item 24).
Inspect seal surfaces, bearing surfaces and shaft spli-
nes. Polish sealing areas on shafts if necessary. Re-
place any worn or damaged parts.
11. Install swashplate cradle bearings (Item 14) into
housing, making sure they are located on cast-in pins in
housing.
The pump shaft bushing (Item 5) is pressed into end cap
and is usually not removed.
12. Install slot guide block (Item 13) onto displacement
control shaft.
The running surfaces of cylinder blocks MUST be flat
and free from scratches. If scratches or wear are found
on running surfaces of cylinder blocks or end cap, polish
or replace the parts. When polishing these surfaces, up
to 0.0004 in. may be removed. If this is not sufficient to
obtain a flat surface, free of scratches, the part should
be replaced.
13. Install thrust plate (Item 11) into swashplate
(Item 25). Slot on swashplate must engage guide block
(Item 13) on displacement control shaft (Item 12). Use
a tool such as a screwdriver or magnet to hold guide
block in position while installing swashplate.
14. Hold swashplate in position and use a dial indicator
or depth gauge to measure side play of displacement
control shaft. Using a suitablesleeve, presscontrolshaft
bearing into housing until control shaft end play is be-
tween 0.020 and 0.060 in.
Assembly of Hydraulic Pump
1. Clean and lightly oil parts before assembly. Tighten
all threaded parts to recommended torque value.
15. Install thrust washer (Item 9) and cylinder block
spring (Item 8) onto pump shaft.
IMPORTANT: Most parts have critical, high toler-
ance surfaces. Use caution to prevent damage to
these surfaces during assembly. Protect exposed
surfaces, openings and ports from damage and
foreign material.
16. Install springs (Item 29), piston washers (Item 28)
and pistons (Item 27) intocylinder blockkits. The pistons
must move freely in their bores.
2. If displacement control shaft bearing (Item 17) has
been removed, press a new bearing into housing using
a suitable press pin. Surface of bearing should be flush
with inside surface of housing.
17. With pump swashplate in “neutral” (0 angle) position
and pump housing laying on its side, install pump cylin-
der block kit onto pump shaft in housing.
NOTE: The position of the bearing in the housing deter-
mines control shaft end play. Do not press bearing
deeper into housing at this time.
Repairs
Page 4 - 20
HydroJect 3000
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18. Check that piston springs are centered in cylinder
block bores, If necessary, move springs into position
with a small screwdriver.
21. When end cap is properly installed, the internal
springs will hold it away from the housing approximately
3/8 in.
IMPORTANT: Do not damage running surfaces of
cylinder blocks.
22. Install the four (4) capscrews which retain end cap
to housing. Tighten screws to a torque of 138 to 180
in-lb.
19. Install two (2) alignment pins (Item 15) and install a
new gasket (Item 6) onto housing.
23. Rotate shafts to assure correct assembly. When
properly assembled, minimal torque should be required
to turn shafts.
20. Lubricate running surfaces of end cap (Item 31) and
cylinder blocks (Item 7). Position housing opening UP
and install end cap onto housing (Item 18).
24. Wrap end of displacement control shaft with thin
plastic or use a seal protector to prevent damage to seal
during installation. Lubricate new displacement controls
shaft seal (Item 16) with petroleum jelly. Slide seal over
shaft and press it into housing bore. Be careful not to
damage seal. Install seal flush to bottomed in bore.
IMPORTANT: Make sure all parts are properly
aligned. Do not force end cap into position on hous-
ing. Be careful to prevent damage to end cap and
cylinder block sealing surfaces.
24
23
22
21
20
19
18
16
17
12
15
14
13
8
7
11
1
10
6
9
2
5
3
4
25
26
27
40
28
39
29
38
37
36
35
34
1
33 32 31 30
3
2
4
Figure 26
HydroJect 3000
Page 4 - 21
Repairs
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Wheel Motor Removal and Installation (Fig. 27)
3
2
1
4
9
10
11
5
8
6
7
12
13
37
14
15
36
35
16
17
18
19
34
Torque to
250 to 400 ft-lb.
30
20
31
32
21
33
29
28
27
17
25
26
22
24 23
Figure 27
1. Park machine on a level surface, engage parking
brake, open hood and disconnect engine spark plug
wires. Lift drive wheel off the ground using a jack. Block
front and rear of other wheels.
4. Disconnect hydraulic lines from fittings on wheel
motor. Put caps on open lines and fittings to prevent
contamination. Put labels on hydraulic lines for proper
reinstallation.
2. Remove wheel nuts (Item 23) and remove wheel.
Remove large nut (Item 22) from wheel hub.
5. Remove four (4) capscrews (Item 1), nuts (Item 27)
and lockwashers (Item 28) to remove wheel motor
(Item 6) and brake brackets (Item 29) from steering arm
(Item 37).
3. Mount a wheel puller to wheel mount studs and
remove wheel hub (Item 19) and brake drum (Item 18).
Remove key (Item 7) from wheel motor shaft.
6. Reverse steps 1 - 6 to install wheel motor. When
installing wheel hub onto motor shaft, tighten large nut
(Item 22) to 250 - 400 ft-lb.
IMPORTANT: To prevent damage to wheel motor,
DO NOT hit wheel hub with a hammer during re-
moval or installation.
Rev. A
Repairs
Page 4 - 22
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Wheel Motor Shaft Seal and/or Shaft Replacement (Fig. 28)
12
11
10
13
14
15
16
17
4
7
19
6
5
20
19
4
21
3
1
9
2
Figure 28
Disassembly of Shaft and Front Seal Assembly
scratches, entire motor should be disassembled for
inspection.
1. Put motor on a clean, flat surface with shaft facing up.
Clean front end of motor to avoid contaminating internal
parts during procedure.
Assembly of Shaft and Front Seal Assembly
1. Assemble thrust washers (Item 19) and thrust bearing
(Item 20) on shaft using the snap ring (Item 21). Snap
ring sharp edges MUST face away from thrust washers
with thrust bearing (Item 20) between washers.
2. Remove key (Item 11) from shaft.
3. Remove snap ring (Item 14) using a snap ring pliers.
4. Pull shaft (Item 10) out vertically.
2. Slowly lower spline end of shaft (Item 10) assembly
into motor body using caution not to rotate internal parts
once shaft spline starts to engage.
IMPORTANT: When pulling shaft vertically, do not
rotate shaft or move motor as this may alter internal
timing.
3. Put lightly oiled o-ring (Item 12) into groove in body
bore.
5. With seal retainer assembly and shaft assembly
removed, remove all parts from shaft and inspect vari-
ous parts of seal assembly (Item 15, 16, 17), shaft
(Item 10) and thrust bearing assembly (Item 19, 20, 21).
Replace any worn or damaged parts. Always replace
seal retainer assembly (Item 15, 16, 17). The shaft
should have smooth polished surfaces in bearing and
seal areas. If the shaft is lightly scratched in these areas,
polish with fine emery paper in a circumferential direc-
tion. However, if the shaft has any pitting or deep
4. Gently slide oiled seal retainer assembly (Item 15, 16,
17) over shaft, chamfered side first, and press into body
bore. When fully in place, body snap ring groove will be
visible.
5. Install snap ring (Item 14) into its body groove with
snap ring’s sharp edges facing outward and retainer pin
between snap ring lugs. Be sure snap ring is completely
seated in groove.
HydroJect 3000
Page 4 - 23
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Wheel Motor Repair (Fig. 29)
12
11
10
13
14
15
16
17
4
7
19
6
5
20
19
4
21
3
1
9
2
Figure 29
IMPORTANT: Before DISASSEMBLING motor, plug
open ports and clean all dirt from outside of motor.
NOTE: The check balls may fall into body tapered holes
or into body valve ports during disassembly. Be sure that
the check balls are removed.
IMPORTANT: Before ASSEMBLING motor, lightly oil
all seals, rollers and threaded bolt ends.
Disassembly of Shaft Section of Motor
Disassembly of Cover Section of Motor
(See Disassembly of Shaft and Front Seal Assembly
under Main Shaft Seal and/or Shaft Replacement.)
1. Remove key (Item 11) from shaft.
Assembly of Complete Motor
2. Mount motor in a vice or other holding device with
shaft facing down.
1. Before assembly, all parts must be cleaned with a
suitable solvent and free of nicks and burrs.
3. Remove the eight capscrews (Item 1).
2. Mount body with pilot and bearing facing up in a vise
or other holding mechanism.
4. Remove cover & bearing assembly (Item 2) and
square ring seal (Item 4).
3. Insert shaft (Item 10) and install seals and thrust
bearings. (See Assembly of Shaft and Front Seal As-
sembly under Main Shaft Seal and/or Shaft Replace-
ment.)
5. Remove IGR assembly (Item 5) starting with outer
locating ring, rollers, outer rolls, inner rotor and valve
plate (Item 7). If any of these components are damaged,
entire IGR assembly must be replaced.
4. Mount body with pilot and bearing facing down in a
vise or other holding fixture.
6. Remove the two check balls (Item 6).
5. Put rotary valve (Item 7) on shaft spline with “T”
shaped slots on first.
Repairs
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6. Next put IGR inner member on shaft spline with
semi-circular roll pockets between rotary valve ports.
NOTE: Be sure not to dislodge body square ring seal
while moving locating ring.
7. Put contour member of IGR over inner and insert
seven rolls into inner pockets (large diameter rolls).
11. Install the eight locating ring rollers into their pockets
and oil lightly.
8. Lightly oil square ring seal (Item 4) and put in body
groove.
12. Put other lightly oiled square ring seal (Item 4) into
groove in cover and put cover over shaft end and align
bolt holes.
9. Put check balls (Item 6) over the two 1/8" inch
diameter holes in body. Be sure the check balls do not
fall into body tapped holes.
13. Install the eight bolts with lightly oiled thread ends
into bolt holes and tighten diagonally to 30 ft-lb.
10. Put locating ring section (4.5 inch diameter) of IGR
(Item 5) onto body with check ball holes facing down-
ward over balls. Align the eight bolt holes in locating ring
with eight holes in body. The holes align in only one
position.
NOTE: The shaft may not turn freely after assembly. A
short running period may be required.
HydroJect 3000
Page 4 - 25
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Repairs
Page 4 - 26
HydroJect 3000
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Chapter 5
Electrical System
Table of Contents
WIRING SCHEMATICS AND DIAGRAMS. . . . . . . . 2ꢀ
Logic Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2ꢀ
Controller lights . . . . . . . . . . . . . . . . . . . . . . . . . 2.1ꢀ
Wiring Schematic . . . . . . . . . . . . . . . . . . . . . . . . 3ꢀ
Wiring Diagram – Main . . . . . . . . . . . . . . . . . . . . 4ꢀ
Wiring Diagram – Control Panel . . . . . . . . . . . . . 5ꢀ
Wiring Diagram – Tiller . . . . . . . . . . . . . . . . . . . . 6ꢀ
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 7ꢀ
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 9ꢀ
Starting Problems . . . . . . . . . . . . . . . . . . . . . . . . 9ꢀ
General Run and Transport Problems. . . . . . . . . 11ꢀ
Aerate Operation Problems. . . . . . . . . . . . . . . . 13ꢀ
Safety Interlock System Problems . . . . . . . . . . 15ꢀ
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17ꢀ
Verify Safety Interlock System Operation . . . . . 17ꢀ
Clutch Engagement /ꢀ
Lift Limit and Pump Start Limit Switches . . . . . . 21ꢀ
Aerator Start and Stop Switches . . . . . . . . . . . . 21ꢀ
Lift Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22ꢀ
Linear Actuator . . . . . . . . . . . . . . . . . . . . . . . . . 22ꢀ
Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 23ꢀ
Pressure Gauge/Switch. . . . . . . . . . . . . . . . . . . 23ꢀ
Accumulator Charge Switch . . . . . . . . . . . . . . . 23ꢀ
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24ꢀ
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24ꢀ
Pump Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . 25ꢀ
Valve Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . 25ꢀ
REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26ꢀ
Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . 26ꢀ
Neutral Switch and Pump Switch
Replacement and Adjustment . . . . . . . . . . . . 27ꢀ
Fuse and Circuit Breaker. . . . . . . . . . . . . . . . . . 28ꢀ
Controller Replacement. . . . . . . . . . . . . . . . . . . 28ꢀ
Linear Actuator Replacement . . . . . . . . . . . . . . 29ꢀ
Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29ꢀ
Electronic Control System Test . . . . . . . . . . . . . 18ꢀ
Ignition Key Switch . . . . . . . . . . . . . . . . . . . . . . 19ꢀ
Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20ꢀ
Neutral Switch and Transport Switch . . . . . . . . 20ꢀ
HydroJect 3000
Page 5 - 1
Table of Contents
Rev. B
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Wiring Schematics and Diagramsꢀ
Logic Chart
Each line on the Logic Chart shows the combination of
switch conditions that must be made for the listed action
to occur. Example - START, under ACTIONS: For the
engine to start the Key Switch must be moved to Start
(making terminals B + I + S) and the hydraulic pump
must be in Neutral (neutral switch CLOSED).
KEY
X
Switch Closed
O
Switch Open
Switch Closed Momentarily
Switch Conditon Not Relevent
ACTIONS
1. Start
X
X
2. Run
X
X
X
3. Machine Lower (aerate position)
4. Aerate (see Controller Timing below)
Machine Moving (out of neutral)
Machine Stationary (neutral)
5. Machine Raise (transport position)
X
O
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
O
Controller Timing
Aerate START-UP Sequence
1. Pump clutch engages immediately.
2. Valve clutch engages 5 seconds after pump clutch engages.
Aerate SHUT-DOWN Sequence (Neutral Delay)
1. Pump clutch disengages and green light goes off 4 seconds after transport switch opens (red light goes off).
2. After another 3 seconds, valve clutch will disengage.ꢀ
NOTE: Keeping aerate start (engage) switch pushed in (closed) will keep green light on and override neutral delayꢀ
shut-down.ꢀ
Aerate SHUT-DOWN Sequence (Disengage Delay)
1. Pump clutch disengages and green light goes off immediately when stop (disengage) switch is pushed in (opens)
or if pump start limit switch or water pressure switch opens (yellow light goes off).
2. After another 3 seconds, valve clutch will disengage.
Wiring Schematics and Diagrams
Page 5 - 2 Rev. B
HydroJect 3000
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Controller Lights
Lights(LED’s)onthecontrollerindicatewhenthefollow-
ing inputs are made to the controller:
Red: Transport switch closed (traction bail in neu-
tral).
3
Green: Aerate start (engage) switch closed. If redꢀ
and yellow lights are on, green light will stay on untilꢀ
either red or yellow goes off.ꢀ
2
Yellow: Pump start limit switch closed (machineꢀ
lowered to aerate position) and water pressureꢀ
switch closed (water pressure of more than 30 psi)ꢀ
and accumulator charge pressure switch (nitrogenꢀ
pressure more than 1800 psi).ꢀ
1
1. Red Light
2. Green Light
3. Yellow Light
Hydroject 3000
Wiring Schematics and Diagrams
Rev. B
Page 5–2.1
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Wiring Schematics and Diagrams
Hydroject 3000
Page 5 – 2.2 Rev. B
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Electrical Schematic (Model 09800)
Figure 1
HydroJect 3000
Page 5 - 3
Wiring Schematics and Diagrams
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Wiring Diagram – Main (Model 09800)
Figure 2ꢀ
Wiring Schematics and Diagrams
Page 5 - 4
HydroJect 3000ꢀ
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Wiring Diagram – Control Panel (Model 09800)
Figure 4ꢀ
HydroJect 3000
Page 5 - 5
Wiring Schematics and Diagrams
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Wiring Diagram – Tiller (Model 09800)
Figure 3ꢀ
Wiring Schematics and Diagrams
Page 5 - 6
HydroJect 3000ꢀ
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Electrical Schematic (Model 09801)
Hydroject 3000
Wiring Schematics and Diagrams
Rev. B
Page 5 – 6.1
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Wiring Diagram – Main (Model 09801)
Y E L L O W
B L U E / R E D
O R A N G E
P U R P L E
R E D
Y
G R A
Y E L L O W
B R O W N
R E D
B L A C K
B L A C K
B L A C K
R E D
B L A C K
Y E L L O W
P I N K
Y
G R A
Y
G R A
B L A C K
B R O W N
B R O W N
P U R P L E
P I N K
P U R P L E
Y E L L O W
R E D / B L U E
T I L L E R
Wiring Schematics and Diagrams
Hydroject 3000ꢀ
Page 5 – 6.2 Rev. B
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Wiring Diagram – Control Panel (Model 09801)
Hydroject 3000
Wiring Schematics and Diagrams
Rev. B
Page 5 – 6.3
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Wiring Diagram – Tiller (Model 09801)
A
B
C
E
D
Y E L L O W
G R E E N
O R A N G E
O R A N G E
B R O W N
P I N K
Wiring Schematics and Diagrams
Hydroject 3000ꢀ
Page 5 – 6.4 Rev. B
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Special Tools
NOTE: Order special tools from the TORO SPECIAL
TOOLS AND APPLICATIONS GUIDE (COMMERCIAL
PRODUCTS). Some tools may be available from a local
supplier.
Digital Multimeter (Fig. 6)
The meter can test electrical components and circuits
for current, resistance, or voltage drop.
NOTE: Toro recommends the use of a DIGITAL meter
when testing electrical circuits. The high impedance
(internal resistance) of a digital meter will ensure that
excess current is not allowed through the meter. Excess
current can cuase damage to a circuit that is not de-
signed to carry it.
Figure 6
HydroJect 3000
Page 5 - 7 Rev. B
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Special Tools
Skin-Over Grease (Fig. 7)
Special non-conductive grease which forms a light pro-
tective skin to help waterproof electrical switches and
contacts.
Toro P/N 505-47 8 oz. (.24 L) canꢀ
Figure 7ꢀ
Special Tools
Page 5 - 8 Rev. B
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HydroJect 3000ꢀ
Troubleshooting
Study the operating characteristics preceding the elec-
trical failure to help identify the area of difficulty. Try to
isolate the failure to a specific functional system; then
check that area, repairing one component at a time.
Attempting to repair more than one system at one time
will lead to confusion.
CAUTION
Remove all jewelry, especially rings and
watches, before doing any electrical trou-
bleshooting or testing. Disconnect the bat-
tery cables unless the test requires battery
voltage.
Possible Causes and Corrections in the troubleshooting
charts should be checked in the order in which they are
listed.
For effective troubleshooting and repairs, you MUST
have a good understanding of the electrical circuits and
components used on this machine. (See Electrical
Schematic.)
If the machine being repaired has any interlock switches
by-passed, they must be reconnected for proper trou-
bleshooting and safety.
Starting Problems
Condition
Possible Cause
Correction
___________________________________________________________________________________________
Engine fails to crank, regardless
of traction bail position.
Loose or corroded battery connec-
tions.
Clean and tighten connections.
Low battery charge.
Circuit breaker open.
Charge battery. Replace battery if
it will not hold a charge (also see
Battery does not charge under
General Run and Transport Prob-
lems).
Reset circuit breaker. Find cause
for open circuit breaker and cor-
rect. Replace circuit breaker if
faulty.
Ignition key switch faulty.
Neutral switch faulty.
Test switch and replace if faulty.
Make sure switch is properly in-
stalled and adjusted. Test switch
and replace if faulty.
Start relay faulty.
Test relay and replace if faulty.
Starter solenoid faulty.
Test starter solenoid and replace
if faulty.
Starter is faulty.
Test starter and repair replace if
faulty.
Engine is seized.
Repair engine.
Loose or damaged wiring.
Check connections. Repair wiring.
HydroJect 3000
Page 5 - 9
Troubleshooting
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Starting Problems (continued)
Condition
Possible Cause
Correction
__________________________________________________________________________________________
Engine cranks, but does not start.
NOTE: If engine cranks, cause of
problem is UNRELATED to inter-
lock system.
Engine or rectifier plug loose.
Connect wire.
Connect wire.
“I” terminal on ignition key switch
loose.
Diode in wire harness faulty.
Engine problem, or no fuel.
Replace diode
Find problem and correct (see
Chapter 3 - Engine).
________________________________________________________________________________________________________________________________________________________
Engine cranks (but should not)
with traction bail in neutral.
See Safety Interlock System Prob-
lems.
________________________________________________________________________________________________________________________________________________________
Engine starts, but shuts down
when ignition key switch is re-
leased to RUN position.
Not electrical - regulate choke dur-
ing cold start-up.
Normal condition.
Not electrical - low engine oil pres-
sure.
Find and correct cause of low en-
gine oil pressure.
Oil pressure switch faulty.
Test switch and replace if faulty.
Loose or broken wire in oil pres-
sure switch circuit.
Check all wiring and connections
and repair as necessary.
________________________________________________________________________________________________________________________________________________________
Starter does not disengage when
key switch is released to RUN po-
sition.
Ignition switch faulty.
Test ignition key switch and re-
place if faulty.
Short in start circuit wiring.
Check all wiring and connections
and repair as necessary.
Diode in wire harness faulty.
Start relay faulty.
Replace diode.
Test start relay and replace if nec-
essary.
Starter solenoid faulty.
Test starter solenoid and replace
if necessary.
Starter failed (mechanical).
Test starter and replace if neces-
sary.
Troubleshooting
Page 5 - 10
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General Run and Transport Problems
Condition
Possible Cause
Correction
___________________________________________________________________________________________
Engine shuts down during trans-
port or when idling (not in Aerate
mode).
Not electrical - low engine oil pres-
sure, no fuel, etc.
Find and correct cause of engine
shut down.
Oil pressure switch faulty.
Test switch and replace if faulty.
Loose or broken wire in oil pres-
sure switch circuit.
Check all wiring and connections
and repair as necessary.
________________________________________________________________________________________________________________________________________________________
Engine does not stop when igni-
tion key switch is rotated to OFF
position.
Engine timing or carburetor out of
adjustment.
Adjust carburetor or engine tim-
ing.
Ignition switch faulty.
Test ignition switch and replace if
faulty.
Short in ignition circuit wiring.
Check all wiring and connections
and repair as necessary.
________________________________________________________________________________________________________________________________________________________
Battery does not charge.
Open or missing 30 AMP fuse.
Install new fuse. Find and correct
cause of open fuse.
Loose wire(s) in electrical system.
Check for loose wire at “X” or “Y”
terminal of ignition switch. Check
all other connections and wires
on engine regulator.
Regulator or engine charging cir-
cuit faulty.
Install new regulator or repair en-
gine charging circuit.
Battery faulty.
Test battery and replace if faulty.
Ignition switch faulty.
Test switch and replace if faulty.
________________________________________________________________________________________________________________________________________________________
Machine does not lower (to aer-
ate position).
Circuit breaker open.
Lift/lower switch faulty.
Reset circuit breaker. Find cause
for open circuit breaker and cor-
rect. Replace circuit breaker if
faulty.
Test switch and replace if faulty.
Test relay and replace if faulty.
Lift DOWN relay faulty.
Ignition key switch faulty.
Test ignition switch and replace if
faulty.
Loose or broken wire in lift down
circuit.
Check all wiring and connections
and repair as necessary.
Linear actuator faulty.
Test actuator and repair or re-
place if faulty.
HydroJect 3000
Page 5 - 11
Troubleshooting
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General Run and Transport Problems (continued)
Condition
Possible Cause
Correction
__________________________________________________________________________________________
Machine does not raise (to trans-
port position).
Circuit breaker open.
Reset circuit breaker. Find cause
for open circuit breaker and cor-
rect. Replace circuit breaker if
faulty.
Lift/Lower switch faulty.
Test switch and replace if faulty.
Test relay and replace if faulty.
Lift UP relay faulty.
Ignition key switch faulty.
Test ignition switch and replace if
faulty.
Loose or broken wire in lift up cir-
cuit.
Check all wiring and connections
and repair as necessary.
Linear actuator faulty.
Test actuator and repair or re-
place if faulty.
________________________________________________________________________________________________________________________________________________________
Linear actuator continues to oper-
ate (but should not) after machine
is lowered to aerate position.
Lift limit switch faulty.
Make sure switch is installed
properly. Test switch and replace
if faulty.
Troubleshooting
Page 5 - 12
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Aerate Operation Problems
Condition
Possible Cause
Correction
___________________________________________________________________________________________
Machine continues to aerate (but
should not) with traction bail inꢀ
neutral.ꢀ
See Safety Interlock System Prob-ꢀ
lems.ꢀ
________________________________________________________________________________________________________________________________________________________
Machine aerates (but should not)
with with machine raised in trans-ꢀ
port position.ꢀ
See Safety Interlock System Prob-ꢀ
lems.ꢀ
________________________________________________________________________________________________________________________________________________________
Machine starts aerating (but
should not) with inlet water pres-ꢀ
sure of less than 20 to 30 PSI, orꢀ
machine does not stop aerating ifꢀ
inlet water pressure drops toꢀ
10 PSI.ꢀ
Water pressure switch faulty.
Test switch and replace if faulty.ꢀ
Water pressure switch wiring faulty.
Check for short in pressureꢀ
switch/controller connections andꢀ
wiring and repair as necessary.ꢀ
Controller faulty.ꢀ
Replace controller.
________________________________________________________________________________________________________________________________________________________
Machine does not start aerating
when engage button is pushed in
(pump drive belt does NOT ro-
tate).
Problem not electrical (see Chap-
ter 6 - Water System.)
Circuit breaker open.
Reset circuit breaker. Find cause
for open circuit breaker. Replace
circuit breaker if faulty.
Loose or broken wire.
Check all connections and wiring
and repair as necessary.
Accumulator charge switch faultyꢀ
(Model 09801).ꢀ
Test switch and replace if faulty.
Pressure gauge switch faulty.ꢀ
Pump clutch faulty.ꢀ
Test switch and replace if faulty.
Test clutch and replace if faulty.
Test relay and replace if faulty.
Test switch and replace if faulty.
Pump relay faulty.ꢀ
Aerator stop (disengage) switchꢀ
faulty.ꢀ
Pump start limit switch faulty.ꢀ
Make sure switch is installed
properly. Test switch and replace
if faulty.
Aerator start (engage) switch faulty.ꢀ Test switch and replace if faulty.
Controller faulty.ꢀ Replace controller.
Rev. B
HydroJect 3000
Page 5 - 13
Troubleshooting
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Aerate Operation Problems (continued)
Condition
Possible Cause
Correction
__________________________________________________________________________________________
Machine does not start aerating
when engage button is pushed in
(pump belt IS rotating, but gear-
case drive shaft is NOT rotating).
Valve clutch out of adjustment.
Check air gap on valve clutchꢀ
and adjust if necessary.ꢀ
Loose or broken wire in valve
clutch / controller circuit.
Check all connections and wiringꢀ
and repair as necessary.ꢀ
Valve clutch faulty.
Test valve clutch and repair or re-ꢀ
place if faulty.ꢀ
Valve clutch relay faulty.
Controller faulty.
Test relay and replace if faulty.ꢀ
Replace controller.ꢀ
________________________________________________________________________________________________________________________________________________________
Machine stops aerating when not
moving (traction bail in neutral).
It is normal for pump clutch and
water clutch to disengage when
traction bail is neutral for 3 to 4 sec-
onds.
Educate operator. NOTE: Holding
Aerate start switch in ENGAGE
position will override neutral de-
lay shut-down.
________________________________________________________________________________________________________________________________________________________
Machine stops aerating while ma-
chine is moving (traction bail out
of neutral).
Problem not electrical (see Trou-
bleshooting in Chapter 6 - Water
System.)
Transport switch faulty.
Make sure switch is installed and
adjusted properly. Test switch
and replace if faulty.
Loose or broken wire in transport
switch / controller circuit.
Check all connections and wiring
and repair as necessary.
Also see possible causes in (Water
pump clutch does not engage) and
(Water pump clutch engages, but
water valve clutch does not en-
gage.)
Troubleshooting
Page 5 - 14
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Safety Interlock System Problems
Condition
Possible Cause
Correction
___________________________________________________________________________________________
Engine cranks (but should not)
with traction bail in neutral.
Neutral switch faulty.
Make sure switch is installed and
adjusted properly. Test neutral
switch and replace if faulty.
Neutral switch wiring faulty.
Check for short in neutral switch
wiring and connections and repair
as necessary.
________________________________________________________________________________________________________________________________________________________
Machine continues to aerate (but
should not) with traction bail in
neutral.
Red light on controller is ON
(should be OFF) with traction bail
in neutral.
Make sure transport switch is in-
stalled and adjusted properly.
Test transport switch and replace
if faulty.
Check for short in transport
switch/controller connections and
wiring and repair as necessary.
Green light on controller stays ON
(should be OFF) with aerate en-
gage switch released.
Test aerate engage (start) switch
and replace if faulty (make sure
switch action is momentary and
comes comes back out after be-
ing pushed in).
Controller faulty.
Replace controller.
________________________________________________________________________________________________________________________________________________________
Machine aerates (but should not)
with with machine raised in trans-
port position.
Yellow light on controller is ON
(should be OFF) with machine
raised in transport position.
Test pump start limit switch and
replace if faulty.
Check for short in pump start limit
switch connections and wiring
and repair as necessary.
Controller faulty.
Replace controller.
HydroJect 3000
Page 5 - 15
Troubleshooting
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Safety Interlock System Problems (continued)
Condition
Possible Cause
Correction
__________________________________________________________________________________________
No lights on controller come on
when troubleshooting interlock
system.
Battery is dead or disconnected.
Circuit breaker open.
Charge battery. Replace battery if
it will not hold a charge. Clean
and tighten connections.
Reset circuit breaker. Find cause
for open circuit breaker and cor-
rect. Replace circuit breaker if
faulty.
Faulty controller ground.
Ignition key switch faulty.
Check controller ground connec-
tion and wiring and repair as nec-
essary.
Test ignition switch and replace if
faulty.
Loose or damaged wiring in key
switch/controller circuit.
Check all connections and wiring
and repair as necessary.
Controller faulty.
Replace controller.
________________________________________________________________________________________________________________________________________________________
Green light on controller glows
faintly when only red light should
be on (traction bail out of neutral
and aerate engage switch re-
leased).
Normal condition.
Troubleshooting
Page 5 - 16
HydroJect 3000
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Testing
It is often to the technician’s advantage to leave the
components intact in the electrical system, and by
studying the electrical troubleshooting charts and sche-
matics, determine which component is at fault. How-
ever, this section will define given components, and the
tests that can be performed on those components, when
those parts are disconnected from the electrical system.
CAUTION
When testing electrical components for con-
tinuity with a volt-ohm meter or continuity
tester, make sure that power to the circuit has
been disconnected.
For accurate resistance and/or continuity checks, elec-
trically disconnect the component being tested from the
circuit.
NOTE: Electrical troubleshooting of any 12 Volt power
connection can also be performed through voltage drop
tests without disconnection of the component.
Verify Safety Interlock System Operation
The safety interlock system prevents the engine from
cranking or starting, unless traction bail is in NEUTRAL
and prevents the water system from engaging if ma-
chine is in the transport (raised) position. It also stops
aeration if traction bail is released while operating or if
machine is raised to the transport position.
3. Connect water supply to machine. Turn on water
supply and bleed all air out of the system. Water pres-
sure must be 20 to 30 PSI or more. Start the engine.
Raise machine to transport position (up off of rollers).
Push aerate ENGAGE button. If water pump engages
and machine begins aerating, there is a malfunction in
the interlock system that must be corrected. If machine
does not begin aerating, go to step 4.
CAUTION
4. Lower machine to aerate position (on rollers). Engage
traction bail to start machine moving. Push, then release
aerate ENGAGE button. Water pump should engage
immediately, then machine should begin aerating 5 sec-
onds after pump engages. Release traction bail to neu-
tral position so machine stops moving. The water pump
should disengage 4 seconds after traction bail returns
to neutral, then stop aerating after another 3 seconds.
If machine does not stop aerating when traction bail
returns to neutral, there is a malfunction in the interlock
system that must be corrected. If machine stops aerat-
ing, go to step 5.
The interlock switches are for the operator’s
protection, so DO NOT disconnect them.
Check operation of switches daily to make
sure interlock system is operating. If a switch
is defective, replace it before operating. Re-
gardless if switches are operating properly or
not, replace interlock switches every two (2)
years to assure maximum safety. Do not rely
entirely on safety switches; use common
sense!
To do a functional check of interlock system:
5. Engage traction bail to start machine moving, then
push aerate ENGAGE button to begin aerating. Push
aerate DISENGAGE button. The water pump should
disengage immediately, then stop aerating after 3 sec-
onds. If machine does not stop aerating, there is a
malfunction in the interlock system that must be cor-
rected.
1. Put machine in a flat, open area on rough turf away
from buried wires, plumbing, etc. Stop the engine.
2. Move traction bail up and down while trying to start
the engine. If engine cranks there is a malfunction in the
interlock system that must be corrected. If engine does
not crank, go to step 3.
HydroJect 3000
Page 5 - 17
Testing
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Clutch Engagement / Electronic Control System Test (Fig. 8)
This test can be used to check for proper operation of
the electronic control system and clutches without con-
necting the machine to a water source or operating the
machine.
B. After clutches are engaged, push red aerate
DISENGAGE button.
C. Green light should immediately turn OFF and
pump clutch should disengage.
1. Park machine on a level surface, stop the engine,
engage the parking brake, open the hood and discon-
nect the engine spark plug wires.
D. After 3 seconds, valve clutch should disengage.
E. System must not restart without pushing green
aerate ENGAGE button.
2. Disconnect wiring harness connector from bottom of
water pressure gauge. Install a jumper wire across
terminals of disconnected wire connector. This will elec-
trically by-pass the water pressure switch.
IMPORTANT: When test is completed, water pres-
sure switch by-pass must be removed to prevent
damage to water system from low inlet water pres-
sure.
3. Turn ignition key switch to ON position. DO NOT start
the engine.
7. Remove by-pass jumper wire that was connected in
step 2 and connect wire harness connector to terminals
on bottom of water pressure gauge.
4. ENGAGE test:
A. Lower machine to aerate position (on rollers).
Yellow light should be ON.
B. Move traction bail out of neutral. Red light should
come ON.
C. With traction bail out of neutral, push, then re-
lease, green aerate ENGAGE button. Green light
should come ON and pump clutch should engage.
After 5 seconds valve clutch should engage.
1
2
3
NOTE: Touch clutches with a metal object, such as
a screw driver, to help check for clutch engagement
(clutch will be magnetized).
Figure 8A
5. NEUTRAL shut-down test:
1. Red light
2. Green light
3. Yellow light
A. Release traction bail. Red light should turn OFF.
B. After 4 seconds, pump clutch should disengage
and green light should go OFF.
C. After another 3 seconds, valve clutch should
disengage.
6. DISENGAGE test:
A. Move traction bail out of neutral and push green
aerate ENGAGE button.
Figure 8B
1. Red light
2. Green light
3. Yellow light
Rev. A
Testing
Page 5 - 18
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Ignition Key Switch (Fig. 9, 10)
The ignition (key) switch has three positions (OFF,
START and RUN). The terminals are marked as shown.
A
Y
B
S
I
X
Figure 9
CONTINUITY
AMONG
TERMINALS
OTHER
CIRCUITS
MADE
POSITION
1. OFF
The circuitry of the ignition switch is shown in the chart.
With the use of a continuity tester, the switch functions
may be tested to determine whether all circuits are being
completed while the key is moved to each position.
NONE
NONE
2. RUN
X + Y
B + I + A
B + I + S
NONE
3. START
Figure 10
HydroJect 3000
Page 5 - 19
Testing
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Controller (Fig. 11)
The controller senses the condition of various switches,
such as the transport switch and aerate start switch and
directs power output to allow certain machine functions,
such as aerate engage, disengage and timing of those
functions.
Because of the solid state circuitry built into the control-
ler, there is no method to test it directly. The controller
may be damaged if an attempt is made to test it with an
electrical test device, such as a volt-ohm meter.
1
2
3
IMPORTANT: Before welding on the machine, dis-
connect both battery cables from the battery, dis-
connect both wire harness plugs from the electronic
control unit and disconnect the terminal connector
from the alternator to prevent damage to the electri-
cal system.
Figure 11
1. Red light
2. Yellow light
3. Green light
Lights (LED’s) on the controller indicate the condition of
the interlock switches. The LED’s, in conjunction with
the following tests for interlock switches, should be used
to help isolate a problem in an interlock switch, wiring or
the controller (see Wiring Schematics and Diagrams).
Neutral Switch and Transport Switch (Fig. 12)
The neutral switch is normally open (N.O.) and is closed
when traction bail is neutral. The transport switch is
normally closed (N.C.) and is open when the traction bail
is in neutral.
3
IMPORTANT: The neutral and transport switches
have three (3) terminals. The NEUTRAL SWITCH
must have the wires connected to the “COMMON”
and “N.O.” terminals. The TRANSPORT SWITCH
must have the wires connected to the “COMMON”
and “N.C.” terminals. If the wires are not connected
to the correct terminals, on each switch the safety
interlock circuit will not function properly.
1
2
Test the switch by disconnecting the wires from the
switch terminals and connecting a continuity tester
across the two terminals that had wires connected to
them. With the engine turned off, slowly push the trac-
tion bail in a forward and reverse direction while watch-
ing the continuity tester. There should be indications that
the switch is opening and closing. Allow the traction bail
to return to neutral. There should be continuity across
the terminals of the neutral switch and no continuity
across the terminals of the transport switch. (See Neu-
tral Switch and Transport Switch Replacement and Ad-
justment in the Repairs section of this chapter for
replacement and adjustment procedures.)
Figure 12
1. Neutral switch –– N.O. (black & red/blue wires)
2. Transport switch –– N.C. (yellow & gray wires)
3. Switch tab
Testing
Page 5 - 20
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Lift Limit Switch and Pump Start Limit Switch (Fig. 13)
Test the switch by disconnecting the wire connector and
installing a continuity tester or ohm meter across the two
leads of the switch.
2
1
Lift Limit Switch
Aerate (machine lowered)
OPEN
Transport (machine raised)
CLOSED
Pump Start Limit Switch
Aerate (machine lowered)
CLOSED
Transport (machine raised)
OPEN
Figure 13
NOTE: For proper operation, the switch must be
screwed all the way in. A damaged pivot shaft or bush-
ings could cause the switch to not open and close
properly. Debris in the switch could also cause it to not
open and close properly.
1. Pump start limit switch (blue/red & red/blue wires)
2. Lift limit switch (white & black wires)
Aerator Start and Stop Switches (Fig. 14)
The aeration start (ENGAGE) switch is normally open
(N.O.) and closes when the button is pushed down. The
aeration stop (DISENGAGE) switch is normally closed
(N.C.) and opens when the button is pushed down.
1
2
1
Test the switch by disconnecting the wires from the
switch terminals and connecting a continuity tester or
ohm meter across the two switch terminals.
2
Figure 14
1. Aeration start switch (pink & orange wires)
2. Aeration stop switch (blue & purple wires)
HydroJect 3000
Page 5 - 21
Testing
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Lift Switch (Fig. 15)
The lift switch is a three position switch. Switch position
is maintained in center position with no circuits made.
Test the switch by disconnecting the wires from the
switch terminals and connecting a continuity tester or
ohm meter across terminal 2 (common) and terminal 1
or 3. With switch pushed toward keyway in threads,
terminals 1 and 2 are made. With switch pushed away
from keyway in threads, terminals 2 and 3 are made.
1
1
Figure 15
1. Lift switch
Linear Actuator (Fig. 16)
The linear actuator has a bi-directional electric motor
which engages a clutch and screw mechanism to ex-
tend or retract a rod and raise or lower the transport
wheels.
2
1
To test the actuator:
1. Disconnect the wiring connector.
2. Connect a 12 volt battery so the negative (–) terminal
is connected to the red wire of the actuator connector.
When the positive (+) battery terminal is connected to
the yellow wire the actuator motor should operate to
extend the actuator cylinder, raisingthewheels toaerate
position.
Figure 16
3. Connect a 12 volt battery so the negative (–) terminal
is connected totheyellow wireof theactuator connector.
When the positive (+) battery terminal is connected to
the red wire the actuator motor should operate to retract
the actuator cylinder, lowering the wheels to transport
position.
1. Linear actuator
2. Wiring connector
Linear Actuator Specifications
Rod end play
Current draw
Voltage
0.070 max.
26 amps max.
12 VDC
Speed
3/4 in. per second at maximum
load
Testing
Page 5 - 22
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Brake Switch (Fig. 17)
The brake switch is a normally open (N.O.) switch that
closes when the brake is engaged.
1
To test the brake switch disconnect the wires from the
switch terminals and connect a continuity tester or ohm
meter across the terminals of the switch. With the brake
disengaged, the switch should show no continuity. With
the brake engaged, the switch should show continuity.
Figure 17
1. Brake switch
Pressure Gauge/Switch (Fig. 18)
The pressure gauge switch is normally open and closes
when inlet water pressure goes above 20 to 30 PSI. The
switch opens when inlet water pressure goes below
approximately 10 PSI.
1
To test the pressure switch, disconnect the wire connec-
tor and connect a continuity tester or ohm meter across
the terminals of the switch connector. The switch should
show continuity when inlet water pressure reaches 20
to 30 PSI on gauge. The switch should break continuity
as water pressure goes below 10 PSI.
Figure 18
1. Pressure gauge/switch
Accumulator Charge Switch (Fig. 18a)
(Model 09801)
1
The accumulator charge switch is normally open and
closes when accumulator charge pressure is greater
than 1800 PSI. The switch opens when accumulator
charge pressure goes below 1400 PSI.
Figure 18a
1. Accumulator charge switch
Rev. B
HydroJect 3000
Page 5 - 23
Testing
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Relays (Fig. 19, 20)
To test a relay, disconnect the relay wire connector and
install a continuity tester between the relay terminals
(terminals 30 and 87). The relay should make and break
continuity at terminals 30 and 87 as 12 V.D.C. is con-
nected and disconnected to terminal 85 with terminal 86
connected to ground.
1
2
3
Resistance specifications:
Terminals 85 and 86 = 80 to 90 Ohms
Terminals 30 and 87a (normally closed) = continuity
5
Terminals 30 and 87 (normally open) = continuity when 12V
DC is applied to terminals 85 and 86
4
Figure 19
RELAY (WIRE COLORS)
1. Valve clutch (brown, gray, red, pink)
2. Lift up –– transport (green, black, red, green, black)
3. Lift down –– aerate (brown, white, blue, red, black)
4. Pump clutch (blue, yellow, purple, red)
5. Start (yellow, red/blue, brown, red)
Figure 20
Battery
Use a hydrometer to test the battery. Charge the battery
if necessary (see Battery Service).
Electrolyte Specific Gravity
Fully charged: 1.250 - 1.280ꢀ
Discharged: less than 1.240ꢀ
Rev. B
Page 5 - 24
HydroJect 3000
Testing
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Pump Clutch (Fig. 21)
To test the pump clutch, disconnect the wire connector
and connect a continuity tester or ohm meter across the
terminals of the clutch wire connector. There should be
continuity across the terminals of the clutch connector.
Resistance measured through the clutch coil should be
approximately 3 ohms.
1
The clutch can also be tested by connecting a 12 VDC
battery across the clutch connector terminals. The
clutch should engage as 12 VDC is connected to the
clutch connector terminals.
Clutch coil resistance:
3.79 Ohms + 5% at 20oC (68o F)ꢀ
Figure 21ꢀ
1. Pump clutch
Valve Clutch (Fig. 22)
To test the valve clutch, disconnect the wire connector
and connect a continuity tester or ohm meter across the
terminals of the clutch wire connector. There should be
continuity across the terminals of the clutch connector.
Resistance measured through the clutch coil should be
approximately 3 ohms.
The clutch can also be tested by connecting a 12 VDC
battery across the clutch connector terminals. The
clutch should engage as 12 VDC is connected to the
clutch connector terminals.
1
Clutch coil resistance:
3.5 Ohms + 5% at 20oC (68o F)ꢀ
Figure 22ꢀ
1. Valve clutch
Rev. B
HydroJect 3000
Page 5 - 25
Testing
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Repairs
Battery Service (Fig. 23, 24)
Electrolyte Specific Gravity
IMPORTANT: To prevent damage to the electrical
components, do not operate the engine with the
battery cables disconnected.
Fully charged: 1.250 - 1.280
Discharged: less than 1.240
Battery Specifications
Keep the terminals and entire battery case clean. To
clean the battery, wash the entire case with a solution
of baking soda and water. Rinse with clear water. Do not
get the soda solution into the battery because damage
to the battery will result. Coat the battery posts and cable
connectors with skin-over grease, or petroleum jelly to
prevent corrosion.
BCI Group 28 Battery:
525 Amp Cranking Performance at 0o F (–17 o C)
110 min. Reserve Capacity at 80o F (27 o C)
2
1
Check forloosebatteryhold-downs. Aloosebatterymay
crack or cause the container to wear and leak acid.
Check the electrolyte solution to make sure the level is
above the plates. If the level is low (but above the plates
inside the battery), addwatersothelevelistothebottom
of the cap tubes. If the level is below the plates, add
water only until the plates are covered and then charge
the battery. After charging, fill the battery to the proper
level.
Figure 23
1. Positive (+) terminal
2. Negative (–) terminal
CAUTION
Do not charge a frozen battery because it can
explode and cause injury. Let the battery
o
o
warm to 60 F (15.5 C) before connecting to
a charger.
Charge the battery in a well-ventilated place
so that gases produced while charging can
dissipate. Since the gases are explosive, keep
open flame and electrical spark away from the
battery; do not smoke. Nausea may result if
the gases are inhaled. Unplug the charger
from the electrical outlet before connecting or
disconnecting the charger leads from the bat-
tery posts.
Figure 24
Repairs
Page 5 - 26
HydroJect 3000
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Neutral and Transport Switch Replacement and Adjustment (Fig. 25)
1. Disconnect wires from switch terminals.
2. Have a helper push traction bail down into either
FORWARD or REVERSE position or disconnect exten-
sion spring; this will take switch arm tension off of switch.
Loosen two (2) screws and remove switch.
3
3. Have a helper push traction bail down and Install new
switch. DO NOT over-tighten screws as the switch case
1
could break.
2
4. Reconnect wires to new switch. Make sure one wire
is connected to “COMMON” terminal, and one wire is
connected to N.O. terminal (neutral switch) or N.C.
terminal (pump switch).
Figure 25
IMPORTANT: The neutral and transport switches
have three (3) terminals. If the two (2) wires are not
connected to the “COMMON” and “N.O.” terminals
on neutral switch and “COMMON” and “N.C.” termi-
nals on transport switch, the safety interlock circuit
will not function properly.
1. Neutral switch – N.O. (black & red/blue wires)
2. Transport switch – N.C. (yellow & gray wires)
3. Switch tab
CAUTION
If the wires are not correctly installed to the
neutral switch, the engine could start with the
traction bail in forward or reverse.
5. Coat switch terminals and wires with skin-over
grease.
6. Loosen two (2) screws and adjust switch tab so
switches are actuated, but not bottomed out, when
pump control is in neutral.
HydroJect 3000
Page 5 - 27
Repairs
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Fuse and Circuit Breaker (Fig. 26)
The electrical system is protected by a 30 AMP fuse
located under the control panel and a 20 AMP circuit
breaker with reset button.
NOTE: It is not always possible to see if the fuse is faulty.
It is recommended that you check for faulty fuses with
a continuity tester, not visually.
1
2
Figure 26
1. Circuit breaker
2. Fuse
Controller Replacement (Fig. 27)
IMPORTANT: Before welding on the machine, dis-
connect both battery cables from the battery, dis-
connect both wire harness plugs from the controller
and disconnect the terminal connector from the
alternator to prevent damage to the electrical sys-
tem.
1
1. Stop the engine and disconnect battery cables from
battery.
2. Disconnect wiring harness connectors from control-
ler.
3. Remove two (2) nuts securing controller to frame and
remove controller.
Figure 27
4. Install new controller and secure to frame with nuts
removed in step 3.
1. Controller
5. Connect wiring harness connectors to controller.
6. Connect battery cables.
Repairs
Page 5 - 28
HydroJect 3000
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Linear Actuator Replacement (Fig. 28)
1. Put wheels in transport position (machine raised).
1
2. Put the machine on a level surface, stop the engine,
engage the parking brake and disconnect engine spark
plug wires.
3
2
3. Open the hood.
4
4. Disconnect linear actuator wire connector.
5. Disconnect extension springs.
4
6. Remove capscrew and nut securing each end of
linear actuator.
Figure 28
7. Reverse steps 3 - 6 to install the linear actuator.
1. Linear actuator
2. Wire connector
3. Extension spring
4. Capscrew & nut
Diode (Fig. 29)
The diode is located in the wire harness under the side
control panel near the fuse.
1
Figure 28
1. Diode
HydroJect 3000
Page 5 - 29
Repairs
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Repairs
Page 5 - 30
HydroJect 3000
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Chapter 6
Water System
Table of Contents
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Before Performing Water System Tests . . . . . . 12
TEST NO. 1: Accumulator Pre-Charge Pressure
and Adding Dry; Nitrogen . . . . . . . . . . . . . . . . 13
TEST NO. 2: Water System Pressure and Flow 15
TEST NO. 3: Water Valve Lift . . . . . . . . . . . . . . 17
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Electric Clutch Adjustment . . . . . . . . . . . . . . . . . 18
Water Valve Lift . . . . . . . . . . . . . . . . . . . . . . . . . 18
REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Drive Coupling and Clutch
Removal and Installation . . . . . . . . . . . . . . . . 20
Pump Drive Belt Replacement . . . . . . . . . . . . . 21
Water Filter Replacement . . . . . . . . . . . . . . . . . 22
Water Pump Removal and Installation . . . . . . . 23
Water Pump Head Service . . . . . . . . . . . . . . . . 24
Water Pump Crankcase Service . . . . . . . . . . . . 26
Water Valve Service . . . . . . . . . . . . . . . . . . . . . 27
Gear Case Service . . . . . . . . . . . . . . . . . . . . . . 30
Nozzle Service and Replacement . . . . . . . . . . . 31
Accumulator Replacement . . . . . . . . . . . . . . . . 32
Accumulator Service . . . . . . . . . . . . . . . . . . . . . 34
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . 36
Cold Weather Storage . . . . . . . . . . . . . . . . . . . . 36
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Nozzle Size and Approximate Depth Chart . . . . . 2
WATER SYSTEM SCHEMATIC . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Accumulator Charging Valve
and Pressure Gauge . . . . . . . . . . . . . . . . . . . . 4
Accumulator Seal Installation Tool . . . . . . . . . . . 4
Accumulator Cap Wrench . . . . . . . . . . . . . . . . . . 5
Water System Pressure Gauge . . . . . . . . . . . . . . 5
Flow Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Valve Lift Indicator . . . . . . . . . . . . . . . . . . . . . . . . 6
Valve Spring Compressor . . . . . . . . . . . . . . . . . . 6
Water Valve Seal Installation Guide . . . . . . . . . . 7
Pump Seal Installation Guide . . . . . . . . . . . . . . . 7
Seal Installation Mandril . . . . . . . . . . . . . . . . . . . 7
Filter Body Wrench . . . . . . . . . . . . . . . . . . . . . . . 7
Pump Seal Extraction Tool . . . . . . . . . . . . . . . . . 8
Pump Seal Outlet Cover . . . . . . . . . . . . . . . . . . . 8
Pump Wear Sleeve Driver . . . . . . . . . . . . . . . . . . 8
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 9
Troubleshooting Water System Problems . . . . . . 9
™
HydroJect 3000
Page 6 - 1
Table of Contents
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Specifications
Water Pump Clutch: Electromagnetic, dual groove belt
drive for water pump and driveshaft flange brake/clutch
for main valve gearbox.
Pressure Relief Valve – Poppet–type valve with corro-
sion resistant stainless and brass materials.
5000 + 300 PSI relief valve pressure.
Air gap 0.018 in.
Manifold and Nozzles – Extruded stainless steel man-
ifold with11 flanged nozzle extensions containing check
valves and hardened stainless discharge orifice. Check
valves may be reversed in housing to block unused
nozzles.
Pre Filter – Spin down type with washable cartridge in
clear plastic housing and plastic ball valve for flushing.
Supply Filter – Replaceable 5 micron cartridge in plas-
tic housing with air bleed button.
Aeration Width: 33 inches with 11 nozzles on 3 inch
centers.
Water Filter Cartridge: Toro part no. 86–8630
Water Pressure Switch – Senses for water pressure
after filter.
Aeration Depth: 4 to 6 inches depending on turf condi-
tions and nozzle configuration.
Switch closes when pressure is over 20–28 PSI and
opens when pressure drops below 7–13 PSI.
Hole Pattern: Variable from 1.5” to 6” spacing in the di-
rection of travel, and 3 or 6” increments in width.
Pump – Current pump (Model 09801) is a Toro exclu-
sive design (patent pending) with cast stainless steel
head and 3 piston plungers. Vee packing seals and Ke-
vlar guides. Forged crankshaft with plasma sprayed ce-
ramic on stainless steel plungers and cast iron
connecting rods.
Water Pump Case Oil – Mobil DTE Extra Heavy or oth-
er interchangeable ISO Grade 150 PE–700–A (Heavy
Inhibited Hydraulic & General Purpose) See following
chart for equivalent oils.
Mobil
DTE EH (Extra Heavy)
Turbo 150
Shell
Nominal performance is 4 GPM at 5000 PSI with
1400 RPM input.
Amoco
Chevron
Conoco
Exxon
Kendall
Pennzoil
Phillips
American Ind. Oil 150
AW Machine Oil 150
Dectol R & O150
Terresstic 150
Ken–Tran 080
Penreco 150/AW150
Magnus Oil 150
Accumulator – Toro exclusive design with low charge
pressure sensor.
Charged with nitrogen gas charged to 2500 PSI
maximum pressure.
Standard Energol HLP 150
Sun
Union
Sunvis 150
Unax RX 150/Turbine Oil 150
Cam and Gearbox – Reduction gear drive for cam that
actuates main water valve. Roller cam follower rides on
cam specifically designed (patent pending) to control
water injection at 5.3 cycles per second (320 rpm) and
store energy in accumulator between injections. Cast
iron case also serves as 4 quart hydraulic reservoir.
Valvoline ETC (R&O) #70
Water Supply – Recommend a source with 7–8 gallons
per minute. A minimum pressure of 30 psi at the ma-
chine is required for the pump to engage. Maximum al-
lowable pressure of 200 psi. Although irrigation water
pumped from ponds or effluent holding pools can be
used, not all conditions can be handled by the machines
filtration system, additional or alternative filtration may
be required.
Valve – Cast stainless steel valve body functions as
mounting base for 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.
DO NOT USE CHEMICALS – Concern for environ-
mental issues and corrosive affects on machine
components.
+0.002
Valve lift: 0.100
inch (with new cam)
–0.04
Rollers – Pivoting aluminum rollers uniformly smooth
the turf and provide protection from the nozzle dis-
charge. Adjustable flow (0 – 3 GPM) spray wash system
with 6 flood tip nozzles maintain clean rollers.
Specifications
Hydroject 3000
Page 6 – 2 Rev. B
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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 4 to 6 inches depending on turf conditions. Blocked nozzle
locations are obtained by reversing the nozzle check valve ball and spring. See nozzle size chart and illustrations be-
low:
IMPORTANT: Use only nozzle configurations shown or damage to the machine may occur.
NOZZLE SIZE AND APPROXIMATE DEPTH CHART
Part No.
Drill Size Decimal Size Metric Size
Quantity of Nozzles
Approx.
Depth
(inch)
(mm)
Open
Blocked **
86–8130
86–8131
86–8133
#56
#53
#46
.0465
.0595
.0810
1.181
1.511
2.057
*
*
*
11
6
0
5
4–6”
6–8”
* Use only with varied size configurations
Aluminum Washer is required with any nozzle change:
(S/N 29999 & Below) Part no. 80–6680
(S/N 30001 & Up) Part no. 86–8150
OPTIONAL STAGGERED SIZE NOZZLE CONFIGURATION
Part No.
Drill Size Decimal Size Metric Size
Quantity of Nozzles
Approx.
Depth
(inch)
(mm)
Open
Blocked **
86–8130
86–8133
#56
#46
.0465
.0810
1.181
2.057
6 and
0**
0**
3–4”
6–8”
5
Aluminum Washer is required with any nozzle change:
(S/N 29999 & Below) Part no. 80–6680
(S/N 30001 & Up) Part no. 86–8150
**Additional nozzles may be blocked to compensate for pump wear.
Hydroject 3000
Specifications
Rev. B
Page 6 – 2.1
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Tighten to
60 ft–lb
OPEN NOZZLE
CLOSED (BLOCKED) NOZZLE
Aluminum washer (P/N 80–6680)
is required with any nozzle change.
S/N 29999 & Below
Spring
Check Valve Ball
Spring
Check Valve Ball
Tighten nut to
70 – 80 ft–lb
OPEN NOZZLE
CLOSED (BLOCKED) NOZZLE
Aluminum washer (P/N 86–8150)
is required with any nozzle change.
S/N 30001 & Up
Specifications
Hydroject 3000ꢀ
Page 6 – 2.2 Rev. B
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Water System Schematicꢀ
Model 09800
ROLLER WASH
NOZZLES
ACCUMULATOR
2500 PSI
NITROGEN PRE–CHARGE
WATER
VALVE
ELECTRIC
CLUTCH
WATER
PUMP
RELIEF VALVE
5000 PSI
ENGINE
ELECTRIC
BRAKE CLUTCH
GEARBOX CAM
PRESSURE
SWITCH
20 PSI – ON
10 PSI – OFF
ROLLER WASH
NOZZLES
HIGH PRESSURE
AERATION NOZZLES
PRESSURE GAUGE
SPRAY WASH
VALVE
FILTER
WATER SUPPLY
QUICK COUPLER
PRE–FILTER
Model 09801
PRESSURE REDUCING
VALVE
Hydroject 3000
Water System Schematic
Rev. B
Page 6 – 3
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Special Tools
The following special tools are required for servicing the
HydroJect 3000.
Order special tools from the TORO SPECIAL TOOLS
AND APPLICATIONS GUIDE (COMMERCIAL
PRODUCTS).
Accumulator Charging Valve and Pressure Gauge - TOR4001 (Fig. 2)
The charging valve connects the accumulator to a high
pressure (3000-3500 or 6000 PSIG) Nitrogen tank for
pre-charging the accumulator. The charging valve can
also be used to measure accumulator pre-charge pres-
sure without significant loss of accumulator pre-charge.
6
NOTE: The charging tool is equipped with a Com-
pressed Gas Association No. 677 tank connection.
5
2
4
1
3
Figure 2
1. Accumulator connector
2. Pressure gauge
4. Inlet valve
5. Relief valve
3. Outlet valve with diffuser 6. Nitrogen tank connector
Accumulator Seal Installation Tool - TOR4002 (Fig. 3)
Used for installing piston seal during accumulator
rebuilding.
Figure 3
™
Special Tools
Page 6 - 4
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Accumulator Cap Wrench - TOR4003 (Fig. 4)
After discharging accumulator, use this special wrench
to remove accumulator cap for accumulator rebuilding.
Figure 4
Figure 5
Figure 6
Water System Pressure Gauge - TOR4005 (Fig. 5)
The Water System Pressure Gauge and Adapter is
temporarily connected into the high pressure water
system for measuring water pressure available to the
water valve.
Flow Meter - TOR4006 (Fig. 6)
The in-line flow meter with a battery-powered electronic
digital display is installed in the water supply line to
measure pump efficiency. The flow meter is equipped
with a pressure gauge to measure inlet water pressure.
This gauge used in conjunction with the pressure gauge
on the machine can be used to measure pressure drop
across the filter to show filter condition.
™
HydroJect 3000
Page 6 - 5
Special Tools
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Valve Lift Indicator - TOR4007 (Fig. 7)
A special dial indicator and adaptor is temporarily in-
stalled into the inspection port on the side of the high
pressure manifold to measure water valve lift. This
indicator is also used to measures cam wear and deter-
mines correct shim size to get proper valve lift.
Figure 7
Valve Spring Compressor - TOR4008 (Fig. 8)
The valve spring compressor and hardware is used for
compressing the water valve spring allowing removal
and installation of the valve spring retainer. The spring
retainer must be remove before servicing the water
valve, water valve seals, and water valve seat.
Figure 8
™
Special Tools
Page 6 - 6
HydroJect 3000
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Seal Installation Tools (Fig. 9)
Water Valve Seal Installation Guide - TOR4009
The Water Valve Installation Guide (small) is needed to
properly install the water valve seal into the water valve
body. Use Insertion Mandril with this seal guide.
Pump Seal Installation Guide - TOR4010
The Pump Seal Installation Guide (large) is needed to
properly install the pump displacement rod seal into the
pump head. Use Insertion Mandril with this seal guide.)
2
Seal Installation Mandril - TOR4011
3
Use Insertion Mandril with both seal guides. Seal Inser-
tion Mandril is necessary to properly install seals in the
water valve and pump head.
Figure 9
1. Water Valve Seal Installation Guide
2. Pump Seal Installation Guide
3. Seal Installation Mandril
Filter Body Wrench - TOR4012 (Fig. 10)
Special spanner wrench use for servicing the inlet water
filter.
Figure 10
™
HydroJect 3000
Page 6 - 7
Special Tools
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Pump Seal Extraction Tools (Fig. 11)
Pump Seal Extraction Tool - TOR4013
Rod used to hydraulically extract pump seals from the
pump cylinder head. Use with Pump Seal Outlet Cover
and heavy mallet or hammer.
Pump Seal Outlet Cover - TOR4014
Cover plate with O-ring used with Seal Extraction Tool
to hydraulically extract pump seals from pump head.
Figure 11
Pump Wear Sleeve Driver - TOR4015 (Fig. 12)
Driver used for removal and installation of plunger
guides in pump crankcase.
Figure 12
™
Special Tools
Page 6 - 8
HydroJect 3000
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Troubleshooting
The cause of an improperly functioning water system is
best diagnosed with the use of proper testing equipment
and a thorough understanding of the complete system.
Refer to the Testing section of this Chapter for precau-
tions and specific test procedures.
NOTE: The water aeration system operates under very
high pressures and severe duty cycles. Performance of
the water system will be gradually reduced over a period
of time due to normal wear in the pump, valve and
accumulator. Ifyou perform water system tests to isolate
a possible problem, such as reduced hole depth, it is
recommended that ALL tests be performed in the order
listed even if the apparent problem has been isolated,
such as low accumulator pre-charge pressure. This will
verify that all components are operating properly.
The charts that follow contain detailed information to
assist in troubleshooting. There may possibly be more
than one cause for a machine malfunction.
ALL POSSIBLE CAUSES SHOULD BE CHECKED IN
THE ORDER IN WHICH THEY ARE LISTED ON THE
CHARTS.
Troubleshooting Water System Problems
Condition
Possible Cause
Correction
___________________________________________________________________________________________
Machine does not start aerating
when engage button is pushed in
(pump belt does NOT rotate).
Transport wheels not fully raised
(unit lowered to aerate mode).
Check to make sure transport
wheel arms are fully raised (unit
in aerate mode).
Low inlet water pressure.
Check that water pressure gauge
reads 20 to 30 PSI or more. If
pressure is low, obtain proper
water supply source.
Sheared pump clutch key.
Electrical problem.
Repair.
See Troubleshooting in
Chapter 5 - Electrical System
________________________________________________________________________________________________________________________________________________________
Machine does not start aerating
when engage button is pushed in
(pump belt IS rotating but gear-
case drive shaft is NOT rotating.).
Electric brake clutch (valve clutch)
out of adjustment.
Check air gap at electric brake
clutch and adjust if necessary.
Sheared valve clutch key.
Electrical problem.
Repair.
See Troubleshooting in
Chapter 5 - Electrical System
________________________________________________________________________________________________________________________________________________________
Machine makes unusual noise
when first starting aeration.
Air in system. NOTE: Relief valve
may “squeal” for a short period of
time during initial startup due to air
in the system.
With engine OFF and water supp-
ly connected, open high pressure
bleed valve and bleed air out of
system. Repeat procedure if
noise continues.
Damaged component.
Check for damaged components
and repair or replace as neces-
sary.
™
HydroJect 3000
Page 6 - 9
Troubleshooting
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Condition
Possible Cause
Correction
__________________________________________________________________________________________
Machine stops aerating (pump
shuts down during aeration).
Machine not moving.
Normal condition of interlock sys-
tem. Operator must hold engage
button in to aerate with traction
bail in neutral.
Inadequate water supply.
Plugged inlet water filter.
Check for kinked water supply
hose, restriction in line or partially
open valve at water source.
Check water pressure at gauge
when pump is engaged. If pres-
sure drops to less than 15 PSI,
but was initially higher, replace
water filter.
Electrical problem.
See Troubleshooting in
Chapter 5 - Electrical System
________________________________________________________________________________________________________________________________________________________
Water system engages (pump
belt and gear case drive shaft
rotate), but no aeration holes are
produced or aeration hole depth
is shallow or inconsistent.
Air in system.
With engine OFF and water supp-
ly connected, open high pressure
bleed valve and bleed air out of
system.
Soil density or moisture content.
If hole depth was satisfactory
before in another area, different
nozzle configuration may be re-
quired.
Plugged nozzles, worn nozzles or
improper nozzle configuration.
NOTE: Check operation of nozzles
by aerating over a piece of
cardboard, then inspecting
cardboard.
Stop engine, open high pressure
bleed valve, then inspect noz-
zles. Check for plugged nozzles.
Verify size and quantity (see Noz-
zle Size and Approximate Depth
Chart). Nozzles that are too large
will cause loss in pressure and
could cause damage to the ac-
cumulator and other water sys-
tem components.
Gear or cam damage in gear case.
Inspect gear case for gear or
cam damage and repair as neces-
sary.
Leak in high pressure water sys-
tem.
Check for leaks with water sys-
tem engaged. Stop engine, open
high pressure bleed valve and
repair leaks as necessary.
NOTE: Excessive water exiting
between pump head and
crankcase indicates pump wear
or damage. Excessive water exit-
ing from shim area below gear-
case indicates valve wear or
damage. Do water system tests
and make repairs as necessary.
™
Troubleshooting
Page 6 - 10
HydroJect 3000
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Condition
Possible Cause
Correction
___________________________________________________________________________________________
Machine aerates, but aeration
hole depth is shallow or inconsis-
tent (continued).
Low accumulator pre-charge or
damaged accumulator - TEST
NO. 1.
Charge accumulator with dry
Nitrogen. Rebuild or replace ac-
cumulator if necessary.
Low water system pressure AND
flow - TEST NO. 2.
Rebuild pump.
Low water system pressure (flow is
OK) - TEST NO. 2.
NOTE: When testing, make sure
cam is not holding water valve
open - rotate gear so cam is off of
valve lifter.
If water is exiting relief valve out-
let hose, replace relief valve.
Rebuild water valve.
Low water system flow (pressure is
OK) - TEST NO. 2.
Check engine speed and correct
if necessary.
Rebuild pump.
Improper water valve lift - TEST
NO. 3.
Perform valve lift adjustment.
Repair valve or replace cam if
necessary.
Worn or damaged water valve -
TEST NO. 2.
Rebuild water valve.
________________________________________________________________________________________________________________________________________________________
Water in gear case
Worn or damaged water valve low
pressure water seal and oil seal.
Rebuild water valve.
(milky or brown color in oil)
________________________________________________________________________________________________________________________________________________________
Oil leaking from below gear case
shim area.
Worn or damaged water valve oil
seal.
Rebuild water valve.
________________________________________________________________________________________________________________________________________________________
Water in pump crankcase
(milky or brown color in oil)
Worn or damaged water pump low
pressure seal or cracked ceramic
plunger.
Rebuild pump head and plunger
sleeves.
________________________________________________________________________________________________________________________________________________________
Engine dies when water system
is engaged.
Low engine RPM.
Throttle must be in FAST posi-
tion. Adjust carburetor fast setting
to 3450 to 3550 RPM - no load.
Relief pressure too high - TEST
NO. 2.
Replace relief valve.
Low engine power.
Check for contaminated fuel,
plugged fuel filter or fuel line,
plugged air cleaner, bad spark
plug. (see Chapter 3 - Engine).
Jammed or siezed pump or gear-
case.
Inspect components and repair
as necessary.
™
HydroJect 3000
Page 6 - 11
Troubleshooting
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Testing
Before Performing Water System Tests
1. The water aeration system operates under very high
pressures and severe duty cycles. Performance of the
water system will be gradually reduced over a period of
time due to normal wear in the pump, valve and ac-
cumulator. If you perform water system tests to isolate
a possible problem, such as reduced hole depth, it is
recommended that ALL tests be performed in the order
listed even if the apparent problem has been isolated,
such as low accumulator pre-charge pressure. This will
verify that all components are operating properly.
1
WARNING
Figure 13
High pressure water system components can
cause personal injury if disassembled incor-
rectly. Discharge water pressure at bleed
valve before attempting any water system
servicing. Open bleed valve slowly and avoid
contact with high velocity water stream.
1. High pressure bleed valve
2. With engine OFF, open high pressure bleed valve,
and inspect aeration nozzles. Check for plugged noz-
zles. Verify size and quantity (see Nozzle Service and
Replacement). Nozzles that are too large will cause loss
in pressure and could cause damage to the accumulator
and other water system components.
NOTE: You can check for plugged nozzles by aerating
over a piece of cardboard, then inspecting cardboard.
™
Testing
Page 6 - 12
HydroJect 3000
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TEST NO. 1: Accumulator Pre-Charge Pressure (Fig. 14, 15, 16, 17)
Pre-charge pressure is measured and corrected when
the piston is resting on bottom cap of accumulator (high
pressure bleed valve open). By temporarily installing
Charging Tool (TOR4001) to top of accumulator,
Nitrogen pressure can be measured and if required,
more Nitrogen can be added.
Obtain a 3000 - 3500 PSI or 6000 PSI Nitrogen tank
from a local compressed gas or welding supply shop.
The charging tool is equipped with a Compressed Gas
Association No. 677 tank connection. These tanks con-
tain enough Nitrogen for 20-30 fills.
1
NOTE: During operation, working pressure of Nitrogen
in accumulator will be equal to the operating pressure
of the water system.
Figure 14
1. High pressure bleed valve
1. Park machine on a level surface, stop the engine,
engage the parking brake, open the hood and discon-
nect the engine spark plug wires.
1
2
DANGER
Charged accumulators contain high pressure
nitrogen. Nitrogen is the only gas to use for
accumulator charging. Installing IMPROPER
gases in an accumulator can cause an EX-
PLOSION AND DEATH. Charging requires
special tools and precautions. Charge ac-
cumulators in a well ventilated area. It is
recommended that the accumulator be
checked and charged by an Authorized TORO
Distributor.
Figure 15
1. Protective cover
2. Valve cap
Wear eye protection. Keep hands and face
away from gas valve.
Slowly open high pressure water bleed valve
before servicing any component connected
to high pressure water system. Opening the
high pressure bleed valve allows any trapped
water to escape from the system and also
allows accumulator piston to move to bottom
of accumulator cylinder. Failure to open bleed
valve before servicing high pressure water
components can cause personal injury, DIS-
MEMBERMENT OR DEATH.
Charged accumulators cannot be shipped via
air freight.
2. Slowly open the high pressure bleed valve allowing
any pressurized water to escape.
3. Remove protective cover and yellow valve cap from
top side of accumulator.
™
HydroJect 3000
Page 6 - 13
Testing
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4. Attach and gently tighten special fitting of Charging
Tool (TOR4001) to inlet on top of accumulator.
5. Close outlet valve on right hand side of charging tool
to prevent loss of pressurized Nitrogen from ac-
cumulator. Close inlet valve on left hand side ofcharging
tool to prevent back flow through the tank tube.
6. Rotate the jam nut (not the fitting) of the accumulator
valve two (2) turns counterclockwise as viewed from the
top. This opens the valve and pressurizes the tool and
gauge.
Service range of Nitrogen pre-charge pressure:
1800 to 2800 PSI. Allow +200 PSI if accumulator
body is warm.
Figure 16
7. If pre-charge pressure is WITHIN service range, go
to step 8. If pre-charge pressure is ABOVE service
range, accumulator has internal damage and should be
rebuilt or replaced. If pre-charge pressure is BELOW
service range, go to step 10 under Adding Dry Nitrogen
to Accumulator.
8. Tighten nut of accumulator valve clockwise and de-
pressurize tool by slowly opening outlet valve on right
hand side of pressure gauge.
9. Disconnect charging tool from accumulator. Reinstall
the yellow protective cap and valve protector bracket.
Adding Dry Nitrogen to Accumulator
10. With charging tool connected to accumulator, attach
a charged tank of dry Nitrogen to high pressure tube on
charging tool. Tighten tank fitting by turning hose fitting
counterclockwise.
11. The accumulator tool, attached to the accumulator,
has a pressurized manifold. Open inlet valve on left
hand slide of charging tool to pressurize supply tube.
While watching pressure gauge on tool, slowly open
supply tank valve. Pressure reading on gauge will start
to rise. Close supply tank valve when gauge pressure
reaches 2500 PSI Wait a few minutes to make sure
system pressure has equalized then add additional
Nitrogen if necessary for 2500 PSI pre-charge.
12. Close accumulator valve by turning lower nut clock-
wise.
Figure 17
13. Slowly open knob on right hand side of charging tool
de-pressurize the tool, then remove tool from ac-
cumulator. Reinstall yellow protective cap and valve
protector bracket.
NOTE: After completion, install a tag on accumulator
indentifying the charging pressure and charging date.
14. Do Test No. 2: Water Pump Pressure and Flow.
™
Testing
Page 6 - 14 Rev. A
HydroJect 3000
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TEST NO. 2: Water System Pressure and Flow (Fig. 18, 19, 20, 21, 22, 23)
1. The engine must be in good operating condition. Use
a tachometer to verify that the engine is operating at
specified full governed RPM (3450 to 3550 RPM no
load). Engine speed will affect accuracy of flow meter
reading.
2. Stop the engine, engage the parking brake and open
the hood.
WARNING
1
High pressure water system components can
cause personal injury if disassembled incor-
rectly. Discharge water pressure at bleed
valve before attempting any water system
servicing. Open bleed valve slowly and avoid
contact with high velocity water stream.
Figure 18
1. High pressure bleed valve
3. Slowly open the high pressure bleed valve allowing
any pressurized water to escape.
4. Install Water System Pressure Gauge (TOR4005)
into port in water valve housing as shown.
1
Figure 19
1. Water system pressure gauge (TOR4005)
1
5. Disconnect wire harness connection for water valve
clutch to prevent the water valve from operating during
the test.
Figure 20
1. Water valve clutch
™
HydroJect 3000
Page 6 - 15
Testing
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6. Install Flow Meter (TOR4006) between water supply
hose and hose adapter. Connect hose adapter to quick
connector on side of machine.
7. Turn on water supply. Open high pressure bleed valve
until all air is out of the system. Close high pressure
bleed valve for pump testing. NOTE: Air in system will
cause improper test readings.
8. Disconnect hose from relief valve fitting.
9. THIS IS A TWO (2) PERSON OPERATION. Start
engine and operate at full speed. WEAR SAFETY
GLASSES! Have one person press and HOLD engage
button while other person stands to side of machine and
observes pressure gauge and flow meter readings.
Figure 21
1. Water supply quick connector
PRESSURE should be 5000 ± 300 PSI and
FLOW more than 3.4 GPM.
If pressure is too high, replace relief valve.
If pressure AND flow is low, disconnect small tube
running from bottom side of valve housing to water
pump inlet by backing out small 1/16" NPT fitting
(Fig. 39, Item 31). Plug open port with a 1/16" NPT
plug. Do this test procedure again beginning with
step 1. If pressure AND flow is still low, rebuild pump.
After rebuilding pump, do this test procedure again
beginning with step 1, to verify that valve is sealing
properly in closed position. A large quantity of water
exiting valve side of tube indicates a leaking valve
ceramic sleeve or seal. Reconnect small tube.
Figure 22
1. Flow meter/pressure gauge (TOR4006)
If pressure is low, but flow is OK, make sure cam is
not on roller follower, keeping valve in open position.
If water is exiting outlet fitting on relief valve, replace
reliefvalve. Ifwaterisnotexitingoutletfittingonrelief
valve, rebuild water valve. After replacing relief valve
or rebuilding water valve, do this test procedure
again, beginning with step 1, to verify that pump has
adequate flow at specified operating pressure.
1
2
If pressure is OK, but flow is low, rebuild pump.
10. Perform Test No. 3: Water Valve Lift.
11. Do steps 2 - 4 and 6 - 8 of this pressure and flow test
again, with valve clutch connected to wire harness.
Figure 23
Pressure gauge needle will go rapidly to the relief
setting (5000 ± 300 PSI) for 3 to 4 seconds, then
begin to fluctuate rapidly when the unit begins aerat-
ing. Note the highest pressure. If highest pressure is
4000 to 4500 PSI, plan to rebuild the valve. If pres-
sure is less than 4000 PSI, rebuild the valve.
1. Relief valve
2. Hose
12. After testing is completed, open high pressure bleed
valve, then remove water system pressure gauge.
Reinstall plug in open port of water valve housing.
Connect relief valve hose. Remove flow meter.
™
Testing
Page 6 - 16 Rev. A
HydroJect 3000
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TEST NO. 3: Water Valve Lift (Fig. 24, 25)
If valve lift is too high the valve may not seat correctly.
If valve lift is too small, the pulses may not release
enough pressurized water and the relief valve will open
(wasting energy). Improper valve lift can also result in
high contact stresses and rapid cam wear.
IMPORTANT: A reading of 0.090 to 0.102 does not
guarantee a properly adjusted cam. When in doubt,
inspect cam. A worn cam which has been adjusted
to 0.090 to 0.102 will not perform properly. A worn
cam can cause opening of valve on lead-in portion
of cam in this range.
WARNING
High pressure water system components can
cause personal injury if disassembled incor-
rectly. Discharge water pressure at bleed
valve before attempting any water system
servicing. Open bleed valve slowly and avoid
contact with high velocity water stream.
1. Park machine on a level surface, stop the engine,
engage the parking brake, open the hood and discon-
nect the engine spark plug wires.
2. Slowly open the high pressure bleed valve allowing
any pressurized water to escape.
3
3. Remove belt guard to expose the drive shaft.
1
4. Remove test cap from the feeder manifold and install
Valve Lift Indicator (TOR4007) into this opening. Make
sure dial indicator contacts top of water valve, then zero
out dial indicator.
Cam lobe
Lead-out
Lead-in portion
2
Lead-in to lead-out is
two (2) rev. of pinion.
5. Make sure cam lobe is not contacting follower by
rotating coupling assembly several turns and observing
dial indicator.
Figure 24
6. Rotate coupling, moving cam lobe past cam follower
and observe maximum reading on dial indicator.
1. Coupling
2. Cam
3. Follower
Dial indicator should move 0.090 to 0.102. There
should be no movement of dial indicator gauge on
lead-in or lead-out portion of cam.
7. If indicator moves more than 0.102, cam lobe is
probably contacting follower on lead-in portion of cam
and must be adjusted (see Valve Lift Adjustment). If
indicator moves less than 0.090, remove gear case
cover and inspect cam for wear. Use your hand to rotate
coupling to position working cam on top. Visually inspect
top of cam lobe for wear. There is a thin area on this
replaceable cam that does not contact the cam follower.
If cam is worn, a ridge will develop between tip of cam
and unused surface. If the ridge is deep enough to catch
a fingernail, replace the cam (see Gear Case Service).
If cam is not worn, adjust valve lift.
1
Figure 25
1. Valve lift indicator (TOR 4007)
8. Go to step 11 under TEST NO. 2 - Water System
Pressure and Flow.
™
HydroJect 3000
Page 6 - 17
Testing
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Adjustments
Electric Brake Clutch Adjustment (Fig. 26)
1. Park machine on a level surface, stop the engine,
engage the parking brake, open the hood and discon-
nect engine spark plug wires.
2. Adjust air gap to .018" by inserting a thickness gauge
into the clutch openings. Evenly tighten the three lock
nuts on clutch to reduce the air gap. Failure to maintain
the correct air gap could result in clutch not engaging
even though it is electrically energized.
NOTE: It may be necessary to remove clutch retainer to
allow clutch rotation for access to all three (3) adjust-
ment nuts.
1
Figure 26
1. Locknut (3)
Water Valve Lift Adjustment (Fig. 27, 28, 29)
1. Park machine on a level surface, stop the engine,
engage the parking brake, open the hood and discon-
nect the engine spark plug wires.
3
WARNING
1
High pressure water system components can
cause personal injury if disassembled incor-
rectly. Discharge water pressure at bleed
valve before attempting any water system
servicing. Open bleed valve slowly and avoid
contact with high velocity water stream.
Cam lobe
Lead-out
Lead-in portion
2
Lead-in to lead-out is
two (2) rev. of pinion.
2. Slowly open high pressure bleed valve allowing any
pressurized water to escape.
Figure 27
3. Remove belt guard to expose drive shaft. Remove
gear case cover.
1. Coupling
2. Cam
3. Follower
4. Use your hand to rotate coupling assembly, position-
ing working cam on top. Visually inspect top of cam lobe
for wear. There is a thin area on this replaceable cam
that does not contact the cam follower. If cam is worn,
a ridge will develop between tip of cam and unused
surface. If the ridge is deep enough to catch a fingernail,
replace the cam lobe. Do not measure valve lift using a
worn cam lobe. Rotate cam to make sure cam lobe is
not contacting follower.
™
Adjustments
Page 6 - 18
HydroJect 3000
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5. Remove test cap from manifold feeder and install
Valve Lift Indicator (TOR4007) into this opening. Make
sure dial indicator contacts top of water valve, then zero
out dial indicator.
two steps - for example if 0.023 is indicated, add 0.02
shim (four 0.005 shims) first, then repeat procedure.
IMPORTANT: Clearances greater than 0.002 in. will
cause high contact stresses and rapid cam wear.
6. Rotate coupling, moving cam toward cam follower.
Continue to rotate until cam follower is on lead-in portion
of cam, approximately one inch (slightly less than 1/2
turn of coupler) from cam lobe. If dial indicator shows
no lifting of valve, loosen four (4) capscrews holding
gear case to valve body. Remove one shim from both
front and rear, then tighten capscrews. Repeat this
procedure until some opening of valve occurs on lead-in
portion to make sure cam follower touches cam.
9. Check proper function of cam by again zeroing dial
indicator with cam away from cam follower. Rotate
coupling, moving camtoward camfollower and continue
to rotate until cam follower is on lead-in portion of cam,
approximately one inch from cam lobe. There should be
no movement of dial indicator on lead-in portion of cam.
Continue to rotate over cam lobe. Lift should measure
+0.002
0.10
/
in. (with new cam). Continue to rotate
–0.004
on lead-out portion. The dial indicator should read zero
for entire lead-out portion.
7. Zero dial indicator again with cam follower completely
off the cam. Rotate coupling, moving cam toward cam
follower and continue to rotate until cam follower is on
lead-in portion of cam, approximately one inch from cam
lobe. Record amount of valve lift.
IMPORTANT: Make sure shims on both front and
rear side are the same thickness. Using different
thicknesses can cause gear case damage.
8. Add shims, equal to or greater by 0.002 inch, to
amount measured. For example, if 0.015 is measured
while follower is on lead-in portion of cam, add a 0.015
shim. If 0.009 is measured, add 0.010 shim (two 0.005
shims) and retighten capscrews.
1
Figure 28
NOTE: If more than a multiple of 0.005 shims are
required, it is recommended that procedure be done in
1. Valve lift indicator (TOR4007)
Water (4000 - 5000 PSI
operating pressure)
Gear case
Water valve
housing
Shims
Cam lobe
Cam follower
(on lead-in portion of cam)
Cam
Shims
Figure 29
Page 6 - 19
™
HydroJect 3000
Adjustments
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Repairs
Drive Coupling and Clutch Removal and Installation (Fig. 30)
1. Park the machine on a level surface, engage the park-
ing brake, open the hood and disconnect the engine
spark plug wires. Remove guard (Item 38).
5. Apply Loctite 271 or 680 to threads of bolt (item 26).
Use special washer (Item 27) and install bolt. Remove
engine air cleaner feed hose to access teeth of flywheel.
Hold flywheel and tighten bolt to a torque of 25 – 30 ft–lb.
2. To remove coupling shaft, remove four capscrews
connecting the rubber couplers (Item 11, 12) to clutch
(Item 8) and adapter hub (Item 16), then lift shaft away
from machine.
NOTE: A tapered hub (Item 16) is attached to cam gear-
box input shaft. When installing hub, be sure to use spe-
cial hardened washer (Item18), apply Loctite 271 or 680
to threads of capscrew (Item14) and tighten to a torque
of to 15 ft–lbs.
3. Clutch (Item 8), pulley (Item 3) and clutch (Item 2) can
now be removed by removing bolt (Item 26) and washer
(Item 27). A puller tool may be required.
6. Install all bolts and spacers in drive coupling using il-
lustration below. Position flat of spacer (Item10) toward
welded flange of drive shaft (Item 24). Tighten caps-
crews until shoulder of spacer is seated, then tighten to
a torque of 15 ft–lb more than prevailing torque required
to turn locknut on threads.
4. Apply “Never–Seez“ or equivalent to engine shaft and
pulleyshafts. Makesurekeys(Item1and4)areproperly
installed, then align keyways in clutches and pulley with
keys. Make sure clutch (Item 8) is installed so clutch
angle (Item 7), clutch stops (Item 5, 33) and clutch
bumpers (Item 6) will prevent clutch rotation. The clutch
bumper gap should be 0.22 + .03 in.
Loctite 271 or 680
41
25 – 30 ft–lb
18 19
40
39
38
17
42
16
15
14
13
10
12
11
10
9
21
18
37
8
22
20
23
14
Never–seez
24
25
Never–seez
on engine shaft
18
1
2
3
4
6
5
6
7
Loctite 271 or 680
25 – 30 ft–lb
26
31
32
27
28
29
30
33
34
Clutch bumper gap
0.19 – 0.25 in.
32
31
35
36
Figure 30
Repairs
Hydroject 3000
Page 6 – 20 Rev. B
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Pump Drive Belt Replacement (Fig. 31, 32)
1. Park the machine on a level surface, engage the
parking brake, open the hood and disconnect the engine
spark plug wires.
1
2. Remove the drive coupling (see Drive Coupling
Removal and Installation).
3. Disconnect electrical connectors for both clutches.
4. Remove clutch stops (Fig. 30, Item 5) and clutch
retainer bracket (Fig. 30, Item 39).
5. Loosen hydraulic pump belt tension and remove
small belt from hydraulic pump pulley (see Pump Drive
Belt Adjustment in Chapter 4 - Hydraulic System).
Figure 31
6. Loosen water pump idler pulley and work belt off of
large pulley. Carefully pull this belt out from under the
electric clutches.
1. Water pump belt
1
7. Reverse steps 2 - 6 to install the belt. Adjust hydraulic
pump belt tension (see Pump Drive Belt Adjustment in
Chapter 4 - Hydraulic System).
Figure 32
1. Hydraulic pump belt
™
HydroJect 3000
Page 6 - 21
Repairs
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Water Filter Replacement (Fig. 33, 34)
When pump inlet pressure decreases or the water sys-
tem shuts down, it usually means the water filter is
restricted and must be replaced.
IMPORTANT: Never operate the machine without a
water filter. Operating without a water filter can
cause severe damage to the water system.
1. Put the machine on a level surface, engage the
parking brake, stop the engine and disconnect the en-
gine spark plug wires.
2. Locate the water filter assembly, which is mounted
below the fuel tank.
Figure 33
NOTE: Be careful when removing filter body. Filter body
is full of water and will be heavy.
4
3
3. Unscrew the filter body counterclockwise (as viewed
from top). Remove filter and discard.
4. Rinse out filter body and insert a new filter.
5. Clean filter head to prevent contamination of water
system. Thread body with filter onto filter head. Hand
tighten.
2
6. Bleed water system with engine OFF and water
supply connected and turned on:
A. Push button on top of filter head to purge air from
filter body until water comes out around button.
1
B. Open high pressure bleed valve below ac-
cumulator to bleed air from water system. Close high
pressure bleed valve.
Figure 34
NOTE: The quality and micron rating of this filter is very
important. Do not use any substitutes. This filter has a
5 micron rating. For easier filter removal, use Filter
Wrench (TOR4012).
1. Filter body
2. Filter
3. Filter head
4. Bleed button
™
Repairs
Page 6 - 22
HydroJect 3000
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Water Pump Removal and Installation (Fig. 35)
1. Park machine on a level surface, stop the engine,
engage the parking brake, open the hood and discon-
nect the engine spark plug wires.
3. Remove lower plug and let oil drain out of pump
crankcase into a container. Install drain plug.
4. Remove drive belt from driven pulley.
5. Remove four (4) water valve inlet bolts (Inset -
Item 16). Remove two (2) nuts (Item 16), from studs
securing pump head (Item 2) to frame.
WARNING
High pressure water system components can
cause personal injury if disassembled incor-
rectly. Discharge water pressure at bleed
valve before attempting any water system
servicing. Open bleed valve slowly and avoid
contact with high velocity water stream.
6. Disconnect inlet water hoses from pump head. Lift
pump assembly out of frame and, put a sturdy, clean
work bench.
7. Reverse steps 3 - 6 to install pump. After installing
pump, fill crankcase with 30 oz. of Mobil DTE Extra
Heavy hydraulic oil or equivalent.
2. Slowly open the high pressure bleed valve allowing
any pressurized water to escape.
15
16
47
44
17
24
43
46
18
44
45
1
22
23
21
2
21
23
20
7
24
8
22
8
9
19
10
18
Torque to 25 - 33 ft-lb.
(Eight locations)
11
17
12
13
16
14
14
15
Figure 35
™
HydroJect 3000
Page 6 - 23
Repairs
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Water Pump Head Service (Fig. 36)
The three major wear components in the high pressure
pump that require maintenance include: the check val-
ves, plunger sleeves, and plunger seals. These com-
ponents will require maintenance after approx. 500
pump operating hours (approx 750 engine hours).
Pump Head Removal
1. Remove pump from machine (see Water Pump
Removal and Installation).
2. Remove eight (8) nuts (Item 17). Carefully move
pump head (Item 11) away from pump crankcase. Turn
pump crankcase to help in removal of pump head.
WARNING
Check Valve Replacement (replace as a set)
High pressure water system components can
cause personal injury if disassembled incor-
rectly. Discharge water pressure at bleed
valve before attempting any water system
servicing. Open bleed valve slowly and avoid
contact with high velocity water stream.
1. Remove the six caps (Item 7) and pull out check valve
assemblies.
2. Discard old check valves (Item 9) and remove any
remaining seals (Item 10) stuck in the pump head.
NOTE: Because of high torque requirements for check
valve caps and difficulty of correctly installing check
valves in horizontal position, it is recommended that the
pump head be removed from the crankcase when ser-
vicing.
3. Insert new seals (Item 10) and check valves (Item 9).
4. Install new seals (Item 8) in check valve caps. Apply
Loctite 242 or equivalent to threads, install caps and
tighten to a torque of 205 - 235 ft-lbs.
NOTE: Whenever a pump is removed from the machine
for preventative maintenance or servicing, replace com-
ponents in complete groups rather than individually.
Complete servicing will increase the service interval
between repairs.
PLUNGER SEAL REMOVAL - Step 1:
Fill outlet port of pump head with water and
use two capscrews, to temporarily install
7
1
2
3
Pump Seal Outlet Cover (TOR4014) onto
the outlet port of the pump head.
8
13
12
9
4
11
5
10
6
16
15
14
PLUNGER SEAL REMOVAL - Step 2:
Torque to 25 - 33 ft-lb.
(Eight locations)
Fill the three (3) plunger openings with water.
Insert Pump Seal Extraction Tool (TOR4013) into
each water filled cavity. Quickly, strike the
extraction tool with a heavy lead mallet. Seal
assembly and brass retainer should move about
1/4 in. out of the cylinder head. If seal does not
move, add more water and try again. If the seal
does not move after a few attempts, try using
heavy oil or grease instead of water.
18
10
17
9
Use Loctite 242 or equivalent
Torque to 205 - 235 ft-lb.
(Six locations)
8
7
Figure 36
Page 6 - 24
™
Repairs
HydroJect 3000
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Plunger Seal Replacement
Plunger Sleeve Replacement (Model 09800)
(See illustration on previous page)
(see Figure 38 on next page)
NOTE: Check valves must be in good condition for this
procedure to work correctly.
The plunger sleeves are installed on, and sealed to
stainless steel plunger rods. This assembly is inserted
through a special high pressure seal in the pump head.
During pump servicing, a complete repair kit should be
installed.
1. Fill pump head outlet cavity with water, then use two
capscrews to temporarily install Pump Seal Outlet Cov-
er (TOR4014) onto outlet port of pump head. Check
valves must be installed.
1. Remove plunger sleeves (Item 26) from crankcase
plunger rods (Item 9) by loosening and removing plung-
er bolt assemblies (Item 30). The plunger sleeves can
be gently pulled forward for inspection or replacement.
Removelargewasher(Item25)fromrearofplungerrod.
2. Position pump head on a SOLID workbench or in a
vise keeping displacement rod openings pointing up-
wards.
3. Fillplungeropeningswithwater. InsertPumpSealEx-
traction Tool (TOR4013) into each water filled cavity.
WEAR SAFETY GLASSES. Quickly, strike the extrac-
tion tool with a large hammer or mallet. The seal assem-
bly and brass retainer should move about 1/4” out of the
cylinder head. If seal does not move, add more water
and try again. NOTE: If seal does not move after a few
attempts, try using heavy oil or grease instead of water.
2. Remove O–Ring (Item 29) and Teflon seal (Item 28)
on plunger bolt assembly (Item 30). Install new greased
O–ring (Item 28) next to head on bolt, then install Teflon
ring (Item 28).
3. Install new large washer (Item 25), then new plungers
(Item26), onto plunger rods.
4. Apply Loctite 271 or equivalent to threads of plunger
bolts, then install assemblies onto plunger rods. Torque
plunger bolts to 10 ft–lbs.
4. Remove all seals from pump head and remove outlet
cover tool. Discard back–up ring (Item 6), packing vee
(Item 5) and seal support (Item 4). Inspect brass seal re-
tainer (Item 2) for wear and replace if worn. If brass seal
retainer can be reused, remove and replace U–cup seal
(Item 3) and O–ring seal (Item1).
Pump Head Installation (Fig. 37)
1. Apply grease to ceramic plunger sleeves. Carefully
install pump head onto pump crankcase studs and
plungers. While installing, tap evenly on pump head
while turning pump crankshaft.
NOTE: Apply clean grease to each seal before installing
in steps 5 – 9.
2. Install eight (8) nuts onto studs and evenly torque
locknuts to 25 – 33 ft–lbs.
5. Insert back–up ring (Item 6), flat side first, into each
pump head cavity.
3. Install water pump assembly into frame (see Water
Pump Removal and Installation).
6. Insert packing vee (Item 5) into Installation Guide
(TOR4010) making sure that “V“ will mate with back–up
ring (Item6).
7. Insert Installation Guide into cylinder head cavity and
use Insertion Mandril (TOR4011) to completely install
the seal.
8. Insert seal support (Item 4) into Installation Guide
(TOR4010) making sure “V“ groove will mate with high
pressure seal. Insert Installation Guide into cylinder
head cavity and use Insertion Mandril (TOR4011) to
completely install seal support. This seal support fits
tightly in the bore.
9. Install new U–cup seal (Item 3) and O–ring seal
(Item1) into seal retainer (Item 2). Install seal retainer
into pump head cavity. Use a soft face (plastic) hammer
or arbor press to completely insert backup ring into
pump head.
Figure 37
Hydroject 3000
Repairs
Rev. B
Page 6 – 25
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Water Pump Crankcase Service (Model 09800) (Fig. 38a)
5
6
4
1
8
7
35
34
3
2
1
14
13
8 ft–lb
12
10
11
9
15
25
26
27
28
Loctite 271
10 ft–lb
29
30
Apply grease to
O.D. of plunger
before installing
pump head
31
32
33
23
13
14
24
10
10 ft–lb
22
21
20
19
18 17
6
16
18 ft–lb
Figure 38a
NOTE: Replace parts in complete sets.
9. Inspect roller bearings (Item 13) for galling andpitting.
If bearings are worn, replace bearings and bearing cups
as a set.
1. Remove water pump from machine (see Water Pump
Removal and Installation).
10. Installnewseals(Item14)andO–rings(Item31)into
bearing caps and install crank rod, bearings and caps
into crankcase.
2. Remove pump head (see Pump Head Service).
3. Remove pulley from pump drive shaft using 1/4 in.
bolts to separate tapered hub.
11. Bearings should have a light pre–load, eliminating
any end play. Add or remove end cap shims (Item 2) to
change pre–load. Shaft should rotate easily by hand..
4. Remove plunger sleeve assembly (Items 25 – 30).
5. Remove rear cover (Item 19) using a 5 mm allen
wrench.
Preload:
0.015 – 0.020 in. aluminum crankcase
Capscrew torque:
10 ft–lbs aluminum crankcase
6. Use a 5 mm allen wrench to remove connecting rod
end caps (Item 10) and keep them in original order.
Carefully push connecting rods (Item 9) forward.
12. Install end caps onto connecting rods and torque
capscrews (Item 21) to 18 ft–lbs.
7. Remove crank rod bearing caps (Item 1), keeping
shims (Item 2) in their original locations. Slide crank rod
(Item 11) out of the crankcase. Inspect crank rod for gall-
ing or wear.
13. Install new gasket, crankcase cover, and torque
crankcase cover capscrews (Item 15) to 8 ft–lb.
14. Rebuild plunger sleeves (see Plunger Sleeve Re-
placement.
8. Pull connecting rods (Item 9) out through crankcase
and check for wear on plunger guides (Item 3). If plunger
guides (Item 3) are worn, use Wear Sleeve Tool
(TOR4015) to drive guides out through crankcase. Also
use this tool for plunger guide installation.
15. Install pulley with tapered hub onto pump drive shaft.
Repairs
Hydroject 3000
Page 6 – 26 Rev. B
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Water Pump Crankcase Service (Model 09801) (Fig. 38b)
1
2
10
18 – 20 ft–lb
3
4
9
5
6
7
8
29
11
28
Apply grease to
O.D. of plunger
before installing
12
pump head
15
13
16
14
17
18
19
24
25
20
7
8
27
22
10
21
26
14
13
18 – 20 ft–lb
23
22
18 – 20 ft–lb
10
Figure 38b
NOTE: Replace parts in complete sets.
8. Inspect bearings (Item 23) for galling and pitting. If
bearings are worn, replace bearings and bearing cups
as a set.
1. Remove water pump from machine (see Water Pump
Removal and Installation).
9. Install new seal (Item 11) and O–rings (Item 7) and
install crank rod, bearings and caps into crankcase.
2. Remove pump head (see Pump Head Service).
3. Remove pulley from pump drive shaft using 1/4 in.
bolts to separate tapered hub.
10. Bearings should have a light pre–load, eliminating
any end play. Add or remove end cap shims (Item 8) to
change pre–load (see Crankshaft Bearing Installation
and Shimming Page 6–26.2).
4. Remove rear cover (Item 20).
5. Remove connecting rod end caps (Item 13) and keep
them in original order. Carefully push connecting rods
(Item 12) forward.
Preload: 0.005 – 0.007
Capscrew torque: 18–20 ft–lbs
11. Install end caps onto connecting rods and torque
capscrews (Item 10) to 18 ft–lbs.
6. Remove crank rod bearing caps (Item 9, 27), keeping
shims (Item 8) in their original locations. Slide crank rod
(Item 15) out of the crankcase. Inspect crank rod for gall-
ing or wear.
12. Install new gasket, crankcase cover, and torque
crankcase cover capscrews (Item 10) to 18 ft–lb.
7. Pull connecting rods (Item 12) out through crankcase.
Check for wear on plunger (12) and plunger guides
(Item 28). If plunger guides are worn, use Wear Sleeve
Tool (TOR4015) to drive guides out through crankcase.
Also use this tool for plunger guide installation.
13. Install pulley with tapered hub onto pump drive shaft.
Hydroject 3000
Repairs
Rev. B
Page 6 – 26.1
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Crankcase Bearing Installation and Shimming
(Model 09801)
Crankshaft end play
from dial indicator
Shim thickness removed
to get .006 + .001
.010
.009
,008
.007
.006
.005
.004
.003
.002
.001
.000
.016
.015
.014
.014
.012
.012
.010
.009
.008
.007
.006
1. Remove crankshaft bearing end caps.
2. Remove existing shims from both end caps.
3. Install one yellow (.020) shim and one pink (.015)
shim onto input shaft bearing housing if required.
4. Install three yellow (.020), three blue (.005) and two
red (.002) shims onto the end cap bearing housing.
5. Install input shaft end cap over crankshaft input shaft
and secure to water pump housing. Tighten fasteners to
a torque of 18 – 20 ft–lb.
6. Install end cap bearing housing over output shaft and
secure with fasteners, but do not tighten.
7. Measure the crankshaft end play and remove shims
from end cap as required to get .006 + .001 INTERFER-
ENCE FIT (see chart).
8. Tighten fasteners (Item 10) to a torque of 18 – 20 ft–lb.
Repairs
Hydroject 3000
Page 6 – 26.2 Rev. B
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Water Valve Service (Fig. 39, 40)
The water valve controls the release of high pressure
water. The water valve is opened when a cam contacts
and moves a roller follower. The follower moves the
valve stem against spring pressure, which opens the
water valve. After discharge, the valve spring closes the
watervalve, divertingpumpflowintotheaccumulatorfor
storage. The valve stem is installed completely through
the water valve body and guided through a replaceable
bushing and two sealing assemblies.
Water Valve Disassembly
1. Park machine on a level surface, stop the engine, en-
gage the parking brake, open the hood and disconnect
the engine spark plug wires.
WARNING: High pressure water system compo-
nents can cause personal injury if disassembled in-
correctly. Discharge water pressure at bleed valve
before attempting any water system servicing.
Open bleed valve slowly and avoid contact with
high velocity water stream.
Thewatervalveconsistsofataperedvalvestemsealing
against a captured valve seat. The valve seat is sealed
on both sides. One valve seat seal contacts the water
valve body and the other seal contacts the manifold
feeder. When the manifold feeder is installed on the wa-
ter valve, the seals are compressed, locking in and
maintaining correct alignment of the water valve and
also preventing blow by.
2. Open High Pressure bleed valve. Remove accumula-
tor (see Accumulator Replacement). Remove manifold,
manifold feeder and manifold support as an assembly
from water valve body.
3. Disconnect drive coupler from gear case hub adapter
(see Drive Coupling and Clutch Removal and Installa-
tion).
Any abrasives in the water will rapidly erode the valve
surfaces. The valve and valve seat can be ground and
lapped to renew their working surfaces. After grinding,
adjust the valve lift by measuring the lift and adjusting
the shim stack thickness. The shim stack is located be-
tween the water valve body and gear case flange.
4. Drain oil from gearcase. Disconnect hydraulic lines
from gearcase. Remove four (4) capscrews securing
gear case to water valve and carefully pull gear case off
of gear box pilot on water valve.
If the high pressure seal leaks for extended periods of
time, water may be forced past the oil seal and into the
gearbox. Ifthegearboxoillooksmilkyorbrown, flushthe
system immediately, replacing oil, filter, and fluids in hy-
drostatic transmission and wheel motor.
5. Disconnect valve seal drain tube by unscrewing small
fitting at pump inlet. Remove two (2) locknuts from studs
securing water valve to frame. Remove four (4) caps-
crews connecting water valve to water pump head. Re-
move water valve and put it on a clean work bench.
The water valve assembly is similar to the pump head.
It uses the same ceramic sleeve and seals. Since the
water valve is the junction point for all high pressure liq-
uid movement and is fairly difficult to access, complete
rebuilding is recommended when this assembly is re-
moved.
6. InstallvalvespringtoolstudsthroughtheValveSpring
Compressor (TOR4008) and into threaded holes of wa-
ter valve.
7. Tighten nuts to compress tool until retaining ring
(Item14) can be removed from valve spool. Remove re-
taining ring, then carefully loosen nuts on special tool re-
leasing valve spring compression.
Seal Replacement
There are two major seals in the water valve that will re-
quire regular maintenance or replacement. One seal
keeps high pressure water in the high pressure water
system and the other seal keeps the gear case oil within
the gear case.
8. Remove spring retainer (Item 15) and spring (Item16)
from water valve stem. Remove screws (Item13) from
gear case pilot. Remove gear case pilot (Item18) from
water valve.
9. Use a wrench to keep spool valve (Item1) stationary
and use a deep wall socket to loosen jam nut (Item 22)
on valve spool.
The high pressure water seal is identical to the pump
head displacement rod seal. The major difference is the
different brass insert.
10. Remove jam nut (Item 22) and large washer (Item
23), then gently push valve spool through valve body.
Valve seat (Item 2) will come out with the valve.
If the oil seal leaks, oil will leak down and through the
gear case shims. If low pressure water seal fails water
will leak out between shims. If low pressure water seal
and oil seal fail water will leak into the gear case.
Hydroject 3000
Repairs
Rev. B
Page 6 – 27
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11. Inspect sealing surfaces of valve spool and valve
seat. If surfaces appear worn, replace or regrind. Both
angles are 30 degrees.
13. Remove seal assembly (Items 25–30) by pressing
a socket wrench through the casting. Discard all seal
components.
12. Remove and inspect sleeve (Item 7) and remove
backup (Item 6) and O–ring seals (Item 5).
14. Remove snap ring (Item 21) from gear box pilot
(Item18). Insert a shaft into the outboard side of the gear
box pilot to push out sleeve bushing (Item17), seal
back–up (Item 20) and oil seal (Item 19).
1
2
3
5
8
6
7
38
11
12
Apply grease to
O.D. of sleeve
before installing
37
Torque to 14 – 18 ft–lb
(Six locations)
30
29
28
13
27
26
36
25
24
23
31
22
21
19
32
33
20
35
34
10 ft–lb
Apply Loctite 271
to threads of spool
18
17
15
16
14
Figure 39
Water Valve Assembly
5. Use Valve Seal Installer (TOR4009) and Seal Inser-
tion Mandrel (TOR4011) to properly install packing seal
(Item 29) and seal/plunger support (Item 28) into valve
body. Remove installers.
1. Press a new sleeve bushing (Item17) into gear case
pilot until bushing is flush with recessed (oil side) sur-
face.
6. Insert valve guide (Item 27) into valve body. Install O–
ring (Item 24) and U–cup seal (Item 26) to seal retainer
(Item 25), then install into valve cavity.
2. Use a shaft to install oil seal (Item 19) and seal back–
up (Item 20) into gear box pilot. Install retaining ring
(Item 21).
7. Apply grease to outside of sleeve (Item 7). Use valve
spool inserted through sleeve to gently drive sleeve into
seals, inserting it from the “spring“ side.
3. Grease O–ring (Item 5) and back–up ring (Item 6),
then install onto valve spool (Item1). Rubber O–ring is
furthest away from threads.
8. Insert valve spool (Item1) through valve seat (Item 2)
and install O–ring (Item 3) on inboard side of valve seat.
4. Install black back–up ring (Item 30) into valve cavity,
flat side first.
Repairs
Hydroject 3000
Page 6 – 28 Rev. B
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9. Hold spool and seat in place so O–ring does not fall
out of place, then carefully slide valve spool, new sleeve
seals, and valve seat, through ceramic sleeve.
13. Install valve spring studs through Valve Spring Com-
pressor (TOR4008) and into threaded holes of water
valve. Put spring retainer (Item 15) over spring and un-
der spring compressor. Tighten nuts to compress
spring, and install and retaining ring (Item14). Remove
special tool.
10. Install flat washer (Item 23) onto valve spool. Apply
Loctite 271 or equivalent to threads and install jam nut
(Item 22). Tighten to a torque 10 ft–lbs.
NOTE: The manifold feeder keeps the valve seat sta-
tionary. The spring force of the water valve positions the
valve seat prior to Feeder Manifold installation. Make
sure cam lobe does not contact cam follower during
feeder manifold installation (Fig. 29).
11. Fill snap ring groove in valve spool (Item 1) with wax
to prevent damage to seal. Install gear case pilot
(Item18) making sure the drain hole is pointing down.
Holes in pilot allow only one method of installation.
Tighten screws (Item13) to a torque of 14 – 18 ft–lb.
12. Install compression spring (Item16) onto valve
spool.
26
1
3
6
7
19 18
13
16
14
23
17
29 28 27
30
25
22
35
21
2
5
36 20
24
15
Figure 40
Hydroject 3000
Repairs
Rev. B
Page 6 – 29
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Gear Case Service (Fig. 41)
The gear case is a pinion and gear reduction drive that
actuates the water valve. The pinion (Item 12) is con-
nected to the electric brake clutch with a drive coupler.
The gear (Item 22) moves the cam over the roller
follower, actuating the water valve to control water in-
jection at 5.3 cycles per second (at 320 RPM).
you inspect the cam and not the weight block, when
checking for wear. DO NOT INSTALL TWO CAMS
ONTO THE GEAR.
The cam (Item 23) can be replaced without removing or
disassembling the gear case. Evenly torque capscrews
securing cam to 22 - 28 ft-lb.
The gear case also serves as the hydraulic oil reservoir.
NOTE: If there is wear on the teeth of the gear (Item 22),
interchange the locations of the cam (Item 22) and
weight block (Item 27) so higher gear teeth load occurs
in a new location.
If the gear case is disassembled for repair, make sure
the taper roller bearings have a light rolling resistance
after reassembly by adjusting shim thicknesses
(Item 16 and 20). Bearing pre-load is 0 to 0.002 in.
After replacing the camor repairing or replacing the gear
case, adjust water valve lift (see Water Valve Lift in the
Adjustments section).
There is a replaceable cam (Item 23) and weight block
(Item 27) on the gear. Only the cam contacts the roller
cam follower. The weightblock is for balance. Make sure
17
6
16
18
15
14
7
13
12
8
5
4
18
11
9
10
19
20
21
10
11
22
1
2
23
3
11
10
26
24
25
27
36
35
34
8
28
29
30
31
Torque both capscrews
evenly to 22 - 28 ft-lb.
33
7
8
32
Figure 41
™
Repairs
Page 6 - 30
HydroJect 3000
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Nozzle Service and Replacement
NOTE: See Specifications section of this chapter for
more information.
sionally inspect the springs especially if one nozzle
leaks water after the machine is shut down.
1. Park machine on a level surface, stop the engine, en-
gage the parking brake, open the hood and disconnect
the spark plug wires from the engine.
4. For normal operation, install nozzle springs with the
narrow spiral pointing up and the check ball on top of the
spring. To block the flow for different nozzle configura-
tions, install the narrow spiral pointing down with the
check ball below the spring.
2. Inspect nozzle configuration and diameter. Nozzles
are stamped with numbers indicating the drill size of the
orifice. Nozzle orifice can be inspected by inserting
shank end of drill bit matching size stamped on orifice.
If drill bit fit is loose, the nozzle is worn. If nozzles are
worn or incorrect, replace with new nozzles in correct
configuration.
NOTE: Nozzles are stamped with numbers indicating
drill size of orifice. Standard configuration is 11 nozzles,
which will produce depths of approximately 4 to 6 inch-
es, depending on soil conditions. Blocked nozzle loca-
tions are obtained by reversing nozzle check valve and
spring.
3. The nozzle check valves and seats are located in the
nozzle drops and are easily replaced if they wear. Occa-
Tighten to
60 ft–lb
OPEN NOZZLE
CLOSED (BLOCKED) NOZZLE
Aluminum washer (P/N 80–6680)
is required with any nozzle change.
S/N 29999 & Below
Spring
Check Valve Ball
Spring
Check Valve Ball
Tighten nut to
70 – 80 ft–lb
OPEN NOZZLE
CLOSED (BLOCKED) NOZZLE
Aluminum washer (P/N 86–8150)
is required with any nozzle change.
S/N 30001 & Up
Hydroject 3000
Repairs
Rev. B
Page 6 – 31
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Accumulator Replacement (Fig. 43)
1. Stop the engine, engage the parking brake, open the
hood and disconnect the engine spark plug wires.
2. Slowly open the high pressure bleed valve allowing
any pressurized water to escape
3. Remove splash shield from manifold to get access to
capscrews securing accumulator. Use a socket wrench
with long extension to remove four (4) capscrews
(Item 21) securing accumulator (Item 14) to valve hous-
ing (Item 17). Remove the accumulator. Discard O-ring
(Item 15).
DANGER
Charged accumulators contain high pressure
nitrogen. Nitrogen is the only gas to use for
accumulator charging. Installing IMPROPER
gases in an accumulator can cause an EX-
PLOSION AND DEATH. Charging requires
special tools and precautions. Charge ac-
cumulators in a well ventilated area. It is
recommended that the accumulator be
checked and charged by an Authorized TORO
Distributor.
4. Install new O-ring seal (Item 15) into groove on top of
valve housing. Carefully install accumulator onto top of
valve housing. Make sure decals (Items 12, 13) are
facing forward and securely attached to accumulator.
6. Install four (4) NEW special bolts (Item 20) through
valve body and into base of accumulator. Tighten to a
torque of 40 ft-lb.
Wear eye protection. Keep hands and face
away from gas valve.
7. Charge accumulator with dry Nitrogen (see TEST
NO. 3: Accumulator Pre-Charge Pressure and Adding
Dry Nitrogen in the Testing section).
Slowly open high pressure water bleed valve
before servicing any component connected
to high pressure water system. Opening the
high pressure bleed valve allows any trapped
water to escape from the system and also
allows accumulator piston to move to bottom
of accumulator cylinder. Failure to open bleed
valve before servicing high pressure water
components can cause personal injury, DIS-
MEMBERMENT OR DEATH.
Charged accumulators cannot be shipped via
air freight.
™
Repairs
Page 6 - 32
HydroJect 3000
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8
9
7
12
11
6
10
5
4
13
14
3
2
1
6
47
15
16
17
44
48
49
42
43
46
18
44
19
45
41
40
20
21
22
39
38
Torque to 40 ft-lb.
(four locations)
23
15
24
23
25
37
36
27
26
28
29
35
34
33
32
31
30
Figure 43
™
HydroJect 3000
Page 6 - 33
Repairs
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Accumulator Service (Fig. 44, 45, 46)
The accumulator piston seals will wear over a period of
time. As seals wear, the accumulator will require more
frequent recharging and eventually, it will not hold gas.
1
1. Park machine on a level surface, stop the engine,
engage the parking brake and open the hood.
DANGER
Charged accumulators contain high pressure
nitrogen. Nitrogen is the only gas to use for
accumulator charging. Installing IMPROPER
gases in an accumulator can cause an EX-
PLOSION AND DEATH. Charging requires
special tools and precautions. Charge ac-
cumulators in a well ventilated area. It is
recommended that the accumulator be
checked and charged by an Authorized TORO
Distributor.
Figure 44
1. Protective cover
2. Valve cap (yellow)
Wear eye protection. Keep hands and face
away from gas valve.
Slowly open high pressure water bleed valve
before servicing any component connected
to high pressure water system. Opening the
high pressure bleed valve allows any trapped
water to escape from the system and also
allows accumulator piston to move to bottom
of accumulator cylinder. Failure to open bleed
valve before servicing high pressure water
components can cause personal injury, DIS-
MEMBERMENT OR DEATH.
Figure 45
Charged accumulators cannot be shipped via
air freight.
2. Slowly open the high pressure bleed valve allowing
any pressurized water to escape.
3. Remove protective cover from top of accumulator.
4. Attach and gently tighten special fitting of Charging
Tool (TOR4001) to inlet on top of accumulator.
5. Close both valves on charging tool to prevent loss of
pressurized Nitrogen from accumulator.
6. Rotate the jam nut (not the fitting) of the accumulator
valve two (2) turns counterclockwise as viewed from the
top. This opens the valve and pressurizes the tool and
gauge.
7. Slowly open outlet valve on right hand side of charg-
ing tool to release pressurized gas from accumulator.
When gas stops escaping, disconnect the charging tool.
™
Repairs
Page 6 - 34 Rev. A
HydroJect 3000
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8. Remove gas valve (Item 4) from top of accumulator.
17. Apply clean hydraulic oil to new end seal and back-
up ring (Item 4). Install end seal and back-up ring in
groove of top end cap (Item 12) so O-ring is toward the
piston. Apply “Never-Seez” or equivalent to threads of
end cap. Carefully install end cap and tighten to a torque
of 125 ft-lbs.
9. Remove accumulator from top of water valve housing
(see Accumulator Replacement).
10. Insert Accumulator Cap Wrench (TOR4003) into the
top cap (Item 12) of the accumulator. Hold the ac-
cumulator cylinder (Item 6) stationary using a strap or
chain wrench and remove the top cap (Item 12) and
bottom cap (Item 9) of the accumulator.
18. Install gas valve (Item 3) using a new O-ring (Item 4).
19. Install accumulator onto water valve housing (see
Accumulator Replacement).
11. Use a brass or aluminum shaft to force the piston
(Item 8) out of top side of accumulator and discard the
piston.
20. Charge accumulator gas chamber with dry Nitrogen
(see TEST NO. 1: Accumulator Pre-Charge Pressure
Test / Adding Dry Nitrogen).
Accumulator Service Evaluation
1
Inspect bore of accumulator cylinder for score marks or
wear. If barrel of accumulator is not scratched or scored,
it can be reused. If bore is scored or damaged, it will
require resurfacing and nickel plating. If cylinder bore is
damaged, it may be more cost effective to replace the
complete accumulator than to continue this repair.
13
2
Apply Never-Seez
Torque to 125 ft-lb.
3
4
12
Accumulator Assembly and Seal Installation
4
5
12. If bore not damaged or worn, use solvent to
thoroughly clean accumulator cylinder.
13. Apply clean hydraulic oil to new end seal and back-
up ring (Item 4). Install end seal and back-up ring in
groove of bottom end cap (Item 9) so O-ring is toward
the piston. Apply “Never-Seez” or equivalent to threads
of end cap. Carefully install end cap and tighten to a
torque of 125 ft-lbs.
6
7
Apply special
8
4
grease to piston
and cylinder bore
14. Special grease is supplied with a new piston. Apply
coating of special grease to piston. Make sure spaces
between seals on piston are filled with special grease.
Put a light coating of special grease on accumulator
bore and installation tool.
Apply Never-Seez
Torque to 125 ft-lb.
9
15. Use Accumulator Seal Installation tool (TOR4002)
to prevent seal damage during piston installation.
CAREFULLY insert this tool into top side of cylinder.
SLOWLY insert piston (large cross facing down) through
the tool and into the cylinder bore.
10
11
16. Move piston to bottom of accumulator cylinder. Add
11 oz. of Mobil DTE 26 hydraulic oil to completely fill cup
in piston and cover top edges of piston.
Figure 46
™
HydroJect 3000
Page 6 - 35 Rev. C
Repairs
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General Informationꢀ
Storage
It is very important that the water system be drained
to avoid freezing and damaging the components.
Drain system as follows:
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.
1. Stop engine, remove key from ignition switch and
remove wires from spark plugs.
4. Start the engine and run at idle speed for two min-
utes. DO NOT RUN LONGER THAN TWO MINUTES.
2. Remove (2) screws securing drive shield to frame
and remove shield.
5. Stop the engine; remove the spark plugs.
6. Pour one ounce of clean engine oil into spark plug
holes.
3. With the engine ”OFF” and key removed from igni-
tion, rotate the drive coupling by hand until resistance is
felt. Continue to rotate the coupling about 1/4 revolution,
opening the cycling valve.
7. With the spark plugs removed, crank the engine
with the starter for a least 12 revolutions to distribute oil
in the cylinders.
4. Using the appropriate reducers (National Pipe
thread), connect a source of compressed air (maximum
pressure 150 psi – minimum pressure 90 psi) to the wa-
ter inlets on either side of machine.
8. Reinstall spark plugs.
9. Drain the gasoline from the fuel tank and fuel lines.
Reinstall all lines and secure all connections.
DANGER: Compressed air can penetrate the skin
and cause physical harm. Use extreme caution and
wear protective goggles and gloves when working
with high pressure air. Get prompt medical attention
if an injury occurs.
10. Thoroughly clean and service the air cleaner.
11. Check the oil filler cap and fuel tank cap to ensure
they securely in place.
Traction Unit
5. Let compressed air flow through the machine for 3
minutes. While compressed air is flowing, temporarily
open the spray wash and high pressure drain valve,
purging water from the spray wash and high pressure
system.
1. Thoroughly clean machine.
2. Grease or oil all fittings or pivot points.
3. Check to make sure all tires are over inflated to 20 –
30 p.s.i.
6. Disconnect compressed air and reducers. Reinstall
the drive shield previously removed and tighten the re-
lief valve tube.
4. Lightly sand and use touch up paint on all areas that
are scratched, chipped or rusted.
5. Drain and replace hydraulic oil and filter on cam
gear case.
7. Remove and drain the water filter container. Install
new filter and replace the filter container.
6. Drain and replace oil in water pump case.
Engine
7. Clean the battery, terminals and posts with a wire
brush and baking soda solution. Coat cable terminals
and battery posts with skin over grease or petroleum jel-
ly. Recharge battery.
1. Drain the engine oil from the oil pan and replace the
drain cap.
General Information
Hydroject 3000
Page 6 – 36 Rev. B
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Chapter 7
Wheels, Brakes and Steering
Table of Contents
ADJUSTMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 2
REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Brake Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Wheel Bearing Service . . . . . . . . . . . . . . . . . . . . 4
HydroJect 3000
Page 7 - 1
Table of Contents
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Adjustments
Brake Adjustment (Fig. 1)
1. Park machine on a level surface and stop the engine.
2. Remove screws securing cover to under side of tiller
handle. Remove cover.
1
3. Loosen upper jam nut securing brake cable to
bracket.
4. Tighten lower jam nut until 25 to 30 pounds of force
are required to actuate brake lever. Tighten jam nut.
5. Install lower cover.
Figure 1
1. Brake cable
Adjustments
Page 7 - 2
HydroJect 3000
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Repairs
Brake Service (Fig. 2)
3
5
2
1
4
9
10
11
8
6
7
12
13
37
36
14
15
16
17
35
34
18
19
Torque to
250 to 400 ft-lb.
30
20
31
32
21
33
29
28
27
17
25
26
22
24 23
Figure 2
1. Park machine on a level surface, stop the engine and
engage the parking brake. Open the hood and discon-
nect engine spark plug wires. Lift drive wheel off the
ground using a jack. Block front and rear of other
wheels.
6. After installing brake shoes, install brake shoe springs
(Item 17) into holes on each brake shoe plate from the
outside. Springs should be installed in opposite direction
of each other.
7. Mount key (Item 7) in wheel motor shaft so top of key
is in line with taper in shaft, then install wheel hub and
brake drum.
2. Remove wheel nuts (Item 23) and remove wheel.
Remove spindle nut (Item 22) from wheel hub.
3. Mount a wheel puller to wheel mount studs and
remove wheel hub (Item 19) and brake drum (Item 18).
Remove key (Item 7) from wheel motor shaft.
8. Install spindle nut (item 13) and tighten to a torque of
250 - 400 ft-lb.
9. Install wheel and secure with wheel nuts. Tighten
wheel nuts evenly in a crossing pattern to a torque of
40 to 50 ft-lb.
IMPORTANT: To prevent damage to wheel motor,
DO NOT hit wheel hub with a hammer during re-
moval or installation.
10. Adjust and check brakes.
4. Remove brake shoe springs (Item 16) and brake
shoes (Item 17).
5. Repair or replace parts as necessary.
Rev. A
HydroJect 3000
Page 7 - 3
Repairs
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Wheel Bearing Service (Fig. 3)
1. Park machine on a level surface and raise wheels to
aerate position. Engage parking brake, open hood and
disconnect engine spark plug wires.
22
23
2. Remove dust cap (Item 28) from end of wheel spindle.
24
25
26
3. Remove cotter pin (Item 27), slotted nut (Item 29) and
washer (Item 30). Slide wheel and hub off of spindle
shaft.
27
35
34
4. Pull seal (Item 34) out of wheel hub (Item 23).
32
33
5. Remove bearings (Item 32) from both sides of wheel
hub. Clean bearings in solvent. Make sure the bearings
are in good operating condition. Clean inside of wheel
hub. Check bearing cups (Item 33) for wear, pitting or
other noticeable damage. Replace worn or damaged
parts.
33
32
31 30 29 28
Figure 3
6. If bearing cups were removed from wheel hub, press
them into hub until they seat against the shoulder.
7. Pack both bearings with grease. Use No. 2 general
purpose lithium base grease containing E.P. additive.
Install one bearing into cup on inboard side of wheel
hub. Lubricate inside of new lip seal and press it into
wheel hub.
IMPORTANT: The lip seal (Item 34) must be pressed
in so it is flush with end of hub. Lip of seal must be
toward the bearing.
8. Pack inside of wheel hub with some grease (not full).
Install remaining bearing into bearing cup.
9. Slide hub onto spindle shaft and secure it in place with
flat washer and slotted nut. DO NOT tighten nut or install
cotter pin.
10. Adjust pre-load on wheel bearings by rotating wheel
by hand and tightening slotted nut until bearing binds
SLIGHTLY. Then, loosen nut until nearest slot and hole
in spindle line up. Install cotter pin. Correct end play of
adjusted assembly is 0.002 to 0.005 inches.
11. Put a coating of grease on inside of dust cap and
install dust cap on end of wheel spindle.
Repairs
Page 7 - 4
HydroJect 3000
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Chapter 8
Hydrojectr 4000 Addendum
Table of Contents
SAFETY AND INSTRUCTION DECALS . . . . . . . . . . 2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . 7
ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . 11
WATER SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . 13
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 14
Boost Pump Belt Adjustment . . . . . . . . . . . . . . . . . 14
NOTE: See other sections of this manual for service in-
formation common to the Hydroject 3000 and 4000. See
the Hydroject 4000 Operator’s Manual for Operation
and Maintenance information.
Hydroject 4000
Addendum
Rev. B
Page 8 – 1
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Safety and Instruction Decalsꢀ
On Each Side Of Engine (2)
(Part No. 80–9350)
On Accumulator body
(Part No. 80–8880)
On Drive Shaft Shieldꢀ
(Part No. 80–8000)ꢀ
On Muffler Shield (3)
(Part No. 80–8290)
On Drive Shaft Guardꢀ
(Part No. 80–8040)ꢀ
On Sides (2)
(Part No. 80–8090)
IMPORTANT
D THE FIVE MICRON FILTER ELEMENT (86–8620) MUST
BE IN PLACE AT ALL TIMES.
D OPERATION WITHOUT PROPER FILTRATION WILL
RESULT IN PREMATURE WEAR AND FAILURE OF THE
WATER SYSTEM COMPONENTS.
On Water Pump
(Part No. 80–9450)
D USE OF ADDITIONAL FILTRATION OR POTABLE WATER
MAY BE NECESSARY TO PROLONG THE LIFE OF THE
FILTRATION SYSTEM.
D SEE OPERATOR’S MANUAL FOR MORE INFORMATION.
On Front Of Machine
(Part No. 92–9542)
On Water Pumpꢀ
(Part No. 93–9360)ꢀ
On Accumulator
body
Replaces 8–9450 for CEꢀ
(Part No. 80–8030)
On Control Panel
(Part No. 94–6550)
On Air Cleaner
(Part No. 94–6512)
On Control Panel
(Part No. 94–6552)
On Air Cleaner
(Part No. 94–6513)
Addendum
Hydroject 4000
Page 8 – 2 Rev. B
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Specifications
Engine: Onan, 4 cycle, opposed twin, air cooled, 24 hp
@ 3600 rpm, 60 cu. in (983 cc) displacement. Electric
start. Heavy duty valve package. Extended service air
cleaner. 3 quart oil capacity. Solid state ignition. Meets
California Exhaust Emission Standard for 1995 Lawn
and Garden Equipment.
ifold outlet. All high pressure water flows in and out
through the valve body. Pressure balanced valve
spool with floating, 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.
Pressure Relief Valve – Circle Seal Controls pop-
pet–type valve preset to 5000 psi with corrosion re-
sistant stainless and brass materials.
Manifold and Nozzles – Extruded stainless steel
manifold with11 flanged nozzle extensions contain-
ing check valves and hardened stainless discharge
orifice. Check valves may be reversed in housing to
block unused nozzles.
Clutches: Electromagnetic, three groove belt drive for
water pump and driveshaft flange brake/clutch for main
valve gearbox.
Electrical: 12 volt system with fused protection. Relays
for all high current switching. Electronic controller and
sensors for automatic start–up and shut–down se-
quence of water injection system. Group 28 battery with
525 cold crank amps.
Fuel Capacity: 9 gallons gasoline.
Controls:
Water Injection System:
Engine Panel – Hour meter, water pressure gaugeꢀ
and fuse block.ꢀ
Control Box Panel– Throttle, choke, watersystemꢀ
engage and disengage buttons.ꢀ
Electronic Control Module–Solidstatepotteddeꢀ-
vice for sequencing start and stop of water system.ꢀ
Interlocks for water pressure.ꢀ
Pre Filter – A 20 mesh strainer is required in theꢀ
supply line to the inlet port.ꢀ
Supply Filter – Replaceable cartridge in plasticꢀ
housing with air bleed button.ꢀ
Water Pressure Switch – Senses for water presꢀ-
sure after filter and turns on when pressure is overꢀ
20–28 psi and turns off when pressure drops belowꢀ
7–13 psi.ꢀ
Pump – Pump is a Toro exclusive design with castꢀ
stainless steel head and 3 piston plungers. Veeꢀ
packingsealsandKevlarguides. Forgedcrankshaftꢀ
with plasma sprayed ceramic on stainless steelꢀ
plungers and cast iron connecting rods. Nominalꢀ
performance is 4 gpm @ 5000 psi with 1400 rpm inꢀ-
put.ꢀ
Ground Speed (Dependant on tow vehicle):
Aerating: 1.2 mph
1.8 mph
4” Hole Spacing
6” Hole Spacing
Transport: Up to 24 mph
Dimensions:
Length – 44 inches (w/o hitch).
Wheelbase – 37.5 inches
Width – 53 inches.
Accumulator – Toro exclusive design with lowꢀ
charge pressure sensor, nitrogen gas charged to aꢀ
maximum of 2500psi.ꢀ
Cam and Gearbox – Reduction gear drive for camꢀ
that actuates main water valve. Roller cam followerꢀ
rides on cam specifically designed to control waterꢀ
injection at 5.3 cycles per second (320 rpm) andꢀ
store energy in accumulator between injections.ꢀ
Cast iron case also serves as 4 quart hydraulic resꢀ-
ervoir.ꢀ
Height – 39 inches.
Weight –900 pounds.
Aeration Width: 38.7 inches with 11 nozzles on 3.87
inch centers.
Aeration Depth: 4 to 6 inches depending on turf condi-
tions and nozzle configuration.
Hole Pattern: Dependant on tow vehicle in the direction
of travel, and 3.87 or 7.74” increments in width.
Valve – Cast stainless steel valve body functions asꢀ
mounting base for accumulator, gearbox and man-ꢀ
Hydroject 4000
Addendum
Rev. B
Page 8 – 3
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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 4 to 6 inches depending on turf conditions. Blocked nozzle
locations are obtained by reversing the nozzle check valve ball and spring. See nozzle size chart and illustrations be-
low:
IMPORTANT: Use only nozzle configurations shown or damage to the machine may occur.
NOZZLE SIZE AND APPROXIMATE DEPTH CHART
Part No.
Drill Size Decimal Size Metric Size
Quantity of Nozzles
Approx.
Depth
(inch)
(mm)
Open
Blocked **
86–8130
86–8131
86–8133
#56
#53
#46
.0465
.0595
.0810
1.181
1.511
2.057
*
*
*
11
6
0
5
4–6”
6–8”
* Use only with varied size configurations
Aluminum Washer, Toro Part no. 86–8150 is required with any nozzle change
OPTIONAL STAGGERED SIZE NOZZLE CONFIGURATION
Part No.
Drill Size Decimal Size Metric Size
Quantity of Nozzles
Approx.
Depth
(inch)
(mm)
Open
Blocked **
86–8130
86–8133
#56
#46
.0465
.0810
1.181
2.057
6 and
0**
0**
3–4”
6–8”
5
Aluminum Washer, Toro Part no. 86–8150 is required with any nozzle change
**Additional nozzles may be blocked to compensate for pump wear.
Check Valve Ball
Spring
Spring
Check Valve Ball
70 – 80 ft–lb
OPEN NOZZLE
CLOSED (BLOCKED) NOZZLE
Addendum
Hydroject 4000
Page 8 – 4 Rev. B
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Fluid Recommendations
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 interchange-
able equivalent. See chart below for equivalent oils.
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
Shell
DTE EH (Extra Heavy)
Turbo 150
Amoco
Chevron
Conoco
Exxon
American Ind. Oil 150
AW Machine Oil 150
Dectol R & O150
Terresstic 150
Mobil
Shell
DTE 26
Tellus 68
Kendall
Pennzoil
Phillips
Standard
Sun
Ken–Tran 080
Penreco 150/AW150
Magnus Oil 150
Amoco
Conoco
Exxon
Kendall
Pennzoil
Phillips
Standard
Sun
Rykon Oil #68
Super Hydraulic Oil 68
Nuto H 68
Energol HLP 150
Sunvis 150
Kenoil R&O 68
Penreco 68
Magnus A 68
Energol HLP 68
Sunvis 831 WR
Unax AW 68
Union
Valvoline
Unax RX 150/Turbine Oil 150
ETC (R&O) #70
WaterSupply–Recommendasourcewith4–5gal-
lons per minute. A pressure range of zero to 10 psi
at the machine is required. Maximum allowable inlet
pressureis25psi. Althoughirrigationwaterpumped
from ponds or effluent holding pools can be used,
not all conditions can be handled by the machines
filtration system, additional or alternative filtration
may be required.
Union
Water Filter Cartridge – Toro part no. 86–8630
DO NOT USE CHEMICALS – Concern for environmental issues and corrosive affects on machine compo-
nents.
Hydroject 4000
Addendum
Rev. B
Page 8 – 5
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Comparison between Hydroject 3000 and Hydroject 4000
Addendum
Hydroject 4000ꢀ
Page 8 – 6 Rev. B
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EQUIPMENT OPERATION AND SERVICE HISTORY REPORT
for
HYDROECTR 4000
TORO Model and Serial Number: ______________–______________ꢀ
Engine Numbers:
_____________________________ꢀ
Transmission Numbers:
Drive Axle(s) Numbers:
Date Purchased:
_____________________________ꢀ
_____________________________ꢀ
_____________________________ Warranty Expires____________ꢀ
_____________________________ꢀ
Purchased From:
_____________________________
_____________________________
Contacts:
Parts
_____________________________ Phone____________________
_____________________________ Phone____________________
_____________________________ Phone____________________
Service
Sales
Hydroject 4000
Addendum
Rev. B
Page 8 – 7
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Hydroject 4000 Maintenance Schedule
Maintenance Procedure
Maintenance Interval & Service
Every
400hrs
Every
200hrs
Every
100hrs
Check Battery Fluid Level
Every
50hrs
Check Battery Cable Connections
Lubricate All Grease Fittings
A Service
{ꢀ Change Engine Oil
{ꢀ Change Engine Oil Filter
Change Engine Pre–cleaner (Air Filter)
B Service
Replace Air Filter Element
Replace Fuel Filter
Adjust Water System Cam–Valve Clearance
Clean Engine Crankcase Breather
{ꢀ Change Gear Case Oil
C Service
{ꢀ Change Pump Case Oil
Service Accumulator
Service Injector Nozzles and Springs
Replace Spark Plugs
Decarbon Combustion Chambers
}ꢀ Torque Head and Adjust Valves
}ꢀ Check Engine RPM (idle and full throttle)
D Service
{ꢀ Initial break in at 25 hours
}ꢀ Initial break in at 50 hours
Replace Moving Hoses
Replace Safety Switches
Fuel Tank – Drain/Flush
Hydraulic Tank – Drain/Flush
Annual Recommendations:
Items listed are recommended every 1000
hours or 2 years, whichever occurs first.
(See Operator’s and Service Manual for specifications and procedures)
Addendum
Hydroject 4000ꢀ
Page 8 – 8 Rev. B
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Hydroject 4000 Daily Maintenance Check List
Daily Maintenance: (duplicate this page for routine use)ꢀ
Check proper section of Operator’s Manual for fluid specificationsꢀ
Daily Maintenance Check For Week Of _________________
Maintenance
Check Item bꢀ
MON
TUES
WED
THURS
FRI
SAT
SUN
nꢀ Engine Oil Level
nꢀ Engine Air Filter Pre–Cleaner
nꢀ Engine Cooling Fins for
Debris
nꢀ Unusual Engine Noises
nꢀ Unusual Operating Noises
nꢀ Water Filter/Pressure
nꢀ Gear Case Oil Level
nꢀ Pump Case Oil Level
nꢀ Fluid Leaks
nꢀ Tire Pressure
nꢀ Instrument Operations
1
Lubricate All Grease Fittings
Touch–up Damaged Paint
1
= Immediately after every washing, regardless of the interval listed.
Notation for areas of concern:
Inspection
performed
by_____________________________
Item
Date
Information
1
2
3
4
5
6
7
8
Hydroject 4000
Addendum
Rev. B
Page 8 – 9
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Addendum
Hydroject 4000
Page 8 – 10 Rev. B
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Electrical Schematic
+
–
R E D / W H I T E
+
A C
B +
A C
G R O U N D
G R O U N D
G R O U N D
G R O U N D
B L A C K
B L A C K
B L A C K
B L A C K
3 A M P
3 A M P
3 A M P
3 A M P
P I N K
B R O W N
G R E E N
B R O W N
Y E L L O W
B L A C K
B R O W N
B L U E
Y E L L O W
B L U E / R E D
B L U E
G R E E N
B L A C K
R E D / B L A C K
P I N K
B L A C K
Y
G R A
B R O W N
P I N K
B L U E
R E D
P U R P L E
B R O W N
B L U E / W H I T E
G R E E N
Y
G R A
P I N K
B L U E / R E D
Y E L L O W
G R A
Y
Y
G R A
Hydroject 4000
Addendum
Rev. B
Page 8 – 11
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Controller Lights
Lights(LED’s)onthecontrollerindicatewhenthefollow-
ing inputs are made to the controller:
Red: Light comes on after pump inlet pressure of 20
psi is attained.
3
Green: Aerate start (engage) switch closed. If redꢀ
and yellow lights are on, green light will stay on untilꢀ
either red or yellow goes off.ꢀ
2
Yellow: Light comes on after ignition switch is inꢀ
RUN position and accumulator charge pressureꢀ
switch is closed (nitrogen pressure more than 1800ꢀ
psi).ꢀ
1
Figure 1
1. Red Light
2. Green Light
3. Yellow Light
Addendum
Hydroject 4000
Page 8 – 12 Rev. B
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Water System Diagramꢀ
ACCUMULATOR
2500 PSI
NITROGEN PRE–CHARGE
WATER VALVE
ELECTRIC
CLUTCH
RELIEF VALVE
5000 PSI
WATER PUMP
ELECTRIC
BRAKE CLUTCH
HIGH PRESSURE
AERATION NOZZLES
PRESSURE SWITCH
20 PSI – ON
10 PSI – OFF
PRESSURE GAUGE
RELIEF VALVE
70–90 PSI
FILTER
5 MICRON
WATER SUPPLY
0–10 PSI
QUICK COUPLER
BOOST PUMP
SUCTION STRAINER
20 MESH
6 GPM AT 70–90 PSI
Hydroject 4000
Addendum
Rev. B
Page 8 – 13
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Service and Repairsꢀ
Boost Pump Belt Adjustment
Make sure boost pump belt is properly tensioned to as-
sure correct operation of unit and unnecessary wear.
Check belts midway in the span of the belt.
1. Disengage hood latches and open hood.
2. Check belt tension by depressing belt midway be-
tween pulleys with 3 lb. of force. A used belt should de-
flect .250”. A new belt should deflect .125”.
3. If an adjustment is necessary:
1
A. Loosen pump bracket mounting bolts (2).
B. Use a pry bar to pull pump towards outside of ma-
chine until proper belt tension is attained, then tightꢀ-
en pump bracket mounting bolts (2).ꢀ
2
3
Figure 2
1. Boost Pump Belt
2. Pump Bracket
3. Mounting Bolt (2)
Addendum
Hydroject 4000
Page 8 – 14 Rev. B
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Commercial Products
© The Toro Company
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