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
Download from Www.Somanuals.com. All Manuals Search And Download.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
Hydroject 3000/4000
Download from Www.Somanuals.com. All Manuals Search And Download.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
|