Toro Hydroject 3000 Troubleshooting Manual
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Toro Hydroject 3000 Troubleshooting Manual

Aerators
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Commercial Products
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Hydroject
3000/4000
Troubleshooting Guide
PART NO.97928SL, Rev. A

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Summary of Contents for Toro Hydroject 3000

  • Page 1 Commercial Products ® Hydroject 3000/4000 Troubleshooting Guide PART NO.97928SL, Rev. A...
  • Page 2 This page is intentionally blank.
  • Page 3 ® ® TORO Hydroject 3000/4000 Table of Contents Troubleshooting • Product Overview........................2 • Components ..........................6 • Water System Operation......................48 • Water System Testing ......................58 • Unit Storage...........................78 • Maintenance Chart........................80 Use of This Manual The information contained in this manual is supplementary to material found in other sources, it is not a replacement for them.
  • Page 4 Overview TORO Hydroject® 3000/4000...
  • Page 5 TORO Hydroject® 3000/4000 Overview The Hydroject® is a patented machine that aerates the ground with “water jets”. These jets are pulses of high velocity water, released at regular intervals. For this machine to operate properly, the owner or operator should understand the individual components and their relationship to the complete system.
  • Page 6 Overview TORO Hydroject® 3000/4000 Comparison Hydroject 3000 Hydroject 4000 2 cylinder Onan Engine Quick Coupler 5 Micron inlet Filter Pressure Switch Pressure Gauge Engine driven water pump Accumulator Accumulator charge pressure switch 5000 psi relief valve Cycling valve (water valve)
  • Page 7 TORO Hydroject® 3000/4000 Overview The Hydroject® 3000/4000 aerators use most of the same components in the water injection system. While there are differences in the machine drive, the main water injection system is the same. The chart on the previous page shows the similarities and differences between the two units.
  • Page 8 Components TORO Hydroject® 3000/4000...
  • Page 9 TORO Hydroject® 3000/4000 Components Engine The Hydroject® is powered by an Onan, 24 HP, air cooled, twin cylinder, electric start, gas engine. The engine is equipped with solid state ignition, and powers the water pump, water valve, and on the 3000, the hydrostatic transmission.
  • Page 10 Components TORO Hydroject® 3000/4000...
  • Page 11 TORO Hydroject® 3000/4000 Components Hydrostatic Pump (3000 Hydroject® Only) The Sundstrand, series 70 hydrostatic pump, is belt driven and provides variable oil flow to operate the traction wheel motor, the traction bail, located on the tiller handle, is connected to the swash plate in the hydrostatic pump and provides speed and directional control.
  • Page 12 Components TORO Hydroject® 3000/4000...
  • Page 13 TORO Hydroject® 3000/4000 Components Transmission Filter (3000 Hydroject® Only) A 25-micron filter, located below the frame, filters the transmission oil. NOTE: The transmission filter should be changed at 25 hours and then every 250 hours after that. Prefill the filter before installation.
  • Page 14 Components TORO Hydroject® 3000/4000...
  • Page 15 TORO Hydroject® 3000/4000 Components Tiller Controls (3000 Hydroject® Only) The tiller handle contains some controls for aerating. These controls include traction direction, aerate-transport switch, and water systems start and stop buttons, and the parking brake lever. NOTE: The parking brake is connected to a limit switch that activates an alarm if the unit is moved while the parking brake is engaged.
  • Page 16 Components TORO Hydroject® 3000/4000...
  • Page 17 TORO Hydroject® 3000/4000 Components Traction Linkage (3000 Hydroject® Only) The traction linkage connects the traction bail to the swash plate. During aeration, a steel cable pulls the left link toward the hole spacing lever, limiting swash plate movement to the required speed. In this mode, the hole spacing lever is spring-loaded and will snap towards the key switch when removed from the indexing latches.
  • Page 18 Components TORO Hydroject® 3000/4000...
  • Page 19 TORO Hydroject® 3000/4000 Components Lift Mechanism (3000 Hydroject® Only) A 12-volt, Warner electric, linear screw actuator with a 6-inch stroke, accomplishes transport lift. The actuator raises and lowers the transport wheels and activates the hole spacing control. A safety switch prevents aeration during transport.
  • Page 20 Components TORO Hydroject® 3000/4000...
  • Page 21 TORO Hydroject® 3000/4000 Components Roller Cleaning System (3000 Hydroject® Only) The spray wash nozzles prevent debris buildup on the rollers. A knob on the instrument panel regulates the volume of water going to these nozzles. Pulling or pushing the spray wash knob increases or decreases the spray rate.
  • Page 22 Components TORO Hydroject® 3000/4000...
  • Page 23 TORO Hydroject® 3000/4000 Components Controller The controller is a solid state timing device used to regulate/monitor the input functions. 3 colored lights monitor these functions. (Red, Yellow and Green). Hydroject® 3000 NOTE: The RED LED illuminates when the Hydroject® is moving, (transmission not in neutral).
  • Page 24 Components TORO Hydroject® 3000/4000...
  • Page 25 TORO Hydroject® 3000/4000 Components Transport Limit Switch (3000 Hydroject® Only) The transport limit switch signals the controller when the wheels are in the transport position. In the transport position (wheels down) the switch is closed. In the aerate position (wheels up) the switch is open.
  • Page 26 Components TORO Hydroject® 3000/4000...
  • Page 27 TORO Hydroject® 3000/4000 Components 2 Electric Clutches There are two electric clutches that connect the engine to the water pump and the cycling valve. When the operator depresses the ENGAGE button, the first clutch energizes, engaging the water pump. After the water pump builds the required pressure, the control module engages the second clutch, engaging the cycling valve and starting the aeration cycle.
  • Page 28 Components TORO Hydroject® 3000/4000...
  • Page 29 TORO Hydroject® 3000/4000 Components Pre-filter The Hydroject® aerators use a water inlet pre-filter. The pre-filter is a “spin down, swirl type” sediment pre-filter. The filter has a reusable polyester 100-mesh (150-micron) screen. Screen PN 86-9140 The clear bowl allows the operator to see when the pre-filter needs to be flushed or cleaned.
  • Page 30 Components TORO Hydroject® 3000/4000...
  • Page 31 TORO Hydroject® 3000/4000 Components Pressure Regulator Valve (3000 Hydroject® Only) The pressure regulator valve is used to reduce the inlet water pressure, to protect the water filter and the rest of the water system from high-pressure water spikes. Early units were not equipped with the pressure regulator but it can be installed.
  • Page 32 Components TORO Hydroject® 3000/4000...
  • Page 33 TORO Hydroject® 3000/4000 Components Water Filter The water filter is a replaceable 5-micron cartridge filter located in a blue plastic housing. It is located under the machine on the Hydroject® 3000 and on the top left side on the Hydroject® 4000.
  • Page 34 Components TORO Hydroject® 3000/4000...
  • Page 35 TORO Hydroject® 3000/4000 Components Bleed Valve Located on the top of the filter is a red water filter bleed valve. This valve is used to bleed air from the system after changing the filter or prior to aerating. NOTE: The air must be bled from the system each time the water system is initially connected to, or reconnected to the supply hose.
  • Page 36 Components TORO Hydroject® 3000/4000...
  • Page 37 Components Water Pump The current water pump is a Toro designed water pump. The pump supplies the pressurized water, which is stored in the accumulator. The pump requires 3.4 to 4.0 GPM supply water flow to pressurize the system to 5000 PSI and maintain adequate water flow.
  • Page 38 Components TORO Hydroject® 3000/4000...
  • Page 39 TORO Hydroject® 3000/4000 Components Piston Type Accumulator The piston type accumulator stores high pressure water from the water pump. The water is stored until it is needed for the injection cycle. When the cycling valve opens, the high volume discharge is directed to the injection nozzles.
  • Page 40 Components TORO Hydroject® 3000/4000 Accumulator Operation Status Unit not running Accumulator charged Nitgogen pressure 2500 PSI Piston at bottom of accumulator Status Unit running System Startup Nitgogen pressure at 2500 PSI Piston begins to move upward Status Unit running Ready for aeration...
  • Page 41 TORO Hydroject® 3000/4000 Components Accumulator Operation Charged accumulator. 1. The accumulator will have a nitrogen pre-charge of 2500 PSI. 2. The piston is at the bottom the cylinder. 3. There is very little water in the bottom end. Start up.
  • Page 42 Components TORO Hydroject® 3000/4000...
  • Page 43 TORO Hydroject® 3000/4000 Components Water Cycling Valve The water cycling valve is connected to the bottom of the accumulator. The cycling valve is a cam driven valve. The cycling valve releases the high-pressure water to the injection nozzles. The cycling valve opens at a rate of 5.3 times a second.
  • Page 44 Components TORO Hydroject® 3000/4000...
  • Page 45 TORO Hydroject® 3000/4000 Components Relief Valve The relief valve limits the water pressure to 5000 PSI. On the 3000, the extra water is bled off through the roller wash circuit. On the 4000 the extra water is returned to the water inlet circuit.
  • Page 46 Components TORO Hydroject® 3000/4000...
  • Page 47 TORO Hydroject® 3000/4000 Components Injection Nozzles The Hydroject® is equipped with 11 injection nozzles. These nozzles convert the high pressure, high volume water into a high-pressure water jet that aerates the turf. The injection nozzle consists of the nozzle body, check ball, spring, nozzle tip and nut.
  • Page 48 Components TORO Hydroject® 3000/4000 Maintenance Parts Helpful Hints Air Filter 82-0660 1. When servicing the air filter Pre-cleaner, add 1 Air Filter Foam Pre-cleaner 82-0670 tablespoon of engine oil to the foam and squeeze to remove excess. Engine Oil Filter 57-8530 2.
  • Page 49 TORO Hydroject® 3000/4000 Components 47 Review Questions 1. Excess water from the relief valve on the 6. The main water filter should be cleaned when Hydroject® 3000 is routed to the: dirty: A. Water inlet circuit. A. True. B. Roller wash circuit.
  • Page 50 Water System Operation TORO Hydroject® 3000/4000 Hydroject® 3000 Hydroject® 4000...
  • Page 51 TORO Hydroject® 3000/4000 Water System Operation System Operation 1. Water is supplied to the unit by a water supply hose or a portable water supply tank. 2. The water passes through the pre-filter 3. On the Hydroject® 3000 the inlet water flows to the pressure-reducing valve, where the water pressure is reduced to 90 PSI.
  • Page 52 Water System Operation TORO Hydroject® 3000/4000 System Startup STATUS Engine Running Water supply connected Wheels up (3000) STATUS Cycling valve is closed Set Throttle to Accumulator is charged Full Throttle to 2500 PSI There is no water in the accumulator...
  • Page 53 TORO Hydroject® 3000/4000 Water System Operation System Startup 1. With the engine running, water supply connected • The transport wheels up (3000 only). • The accumulator is charged to 2500 PSI. • The cycling valve is closed. 2. The operator must set the throttle to high idle. 3500 ± 50 3.
  • Page 54 Water System Operation TORO Hydroject® 3000/4000...
  • Page 55 TORO Hydroject® 3000/4000 Water System Operation Water Flow Through the System 1. Water enters the unit through the pre-filter. 2. The water then flows to the engine driven pump. 3. The water flow is stopped at the cycling valve and is forced into the accumulator.
  • Page 56 Water System Operation TORO Hydroject® 3000/4000 Start up Sequence Depress engage switch Pump Begins to Pump Water Pressure Builds Relief valve opens Cycling valve engages Shut down Sequence Depress disengage switch Pump stops Water pressure drops Cycling valve stops...
  • Page 57 TORO Hydroject® 3000/4000 Water System Operation Start Up Sequence 1. When the engage switch is depressed. 2. The pump begins to pump. 3. Water pressure starts to build almost immediately. 4. After about three seconds, the water pressure reaches about 5000 PSI and the relief valve opens.
  • Page 58 Water System Operation TORO Hydroject® 3000/4000 Section Review 1. Inlet water quality is extremely important to the overall life of the water system. 2. During the initial start up, the pump will operate for 5 seconds before the cycling valve opens. During these 5 seconds, the pressure should initially go up to 4500-5000 PSI and then the relief valve should open.
  • Page 59 TORO Hydroject® 3000/4000 Water System Operation 57 Review Questions 1. During start up, the components start in this 6. High pressure water is stored in the order: accumulator until needed. A. Cycling valve, relief valve, water pump. A. True. B. Water pump, relief valve, cycling valve.
  • Page 60 Water System Testing TORO Hydroject® 3000/4000 Operational Checks Using control module lights (Unit won't operate) Check Red Light on the Control Module Red light on Check transport with traction bail switch actuated Repair transport switch Check Yellow Light on the...
  • Page 61 TORO Hydroject® 3000/4000 Water System Testing Operational Checks, 3000 1. Check red light on the control module. • The red light is on whenever the unit is moving, or the traction control linkage is not in neutral. • The red light is on while the unit is aerating.
  • Page 62 Water System Testing TORO Hydroject® 3000/4000 Shallow Hole Depth Disconnect Cycling valve clutch wire, and check for relief valve pressure of 5000 PSI Shallow hole depth could be minimum. caused by soil contitions Test High Pressure Check Relief Rebuild or Replace...
  • Page 63 TORO Hydroject® 3000/4000 Water System Testing Complaint: Shallow Hole Depth 1. Test high pressure water. • Low water pressure can be an indication of a faulty relief valve or water pump. ∗ To check the high pressure water circuit, disconnect the wire to the cycling valve and remove the return hose from the relief valve.
  • Page 64 Water System Testing TORO Hydroject® 3000/4000 Water spray not Slit inTurf Between Holes stopping between cycles Valve lift to high can Check Water Valve Adjust valve prevent valve from Lift lift completely closing Within Spec. Water leaking through rebuild or...
  • Page 65 TORO Hydroject® 3000/4000 Water System Testing Complaint: Slit in Turf Between Holes 1. Check water valve lift. • If the valve lift is too high, the valve may stay open too long and this makes the water injection cycle too long.
  • Page 66 Water System Testing TORO Hydroject® 3000/4000...
  • Page 67 TORO Hydroject® 3000/4000 Water System Testing Servicing high pressure water components can cause personal injury if the system pressure is not relieved before servicing any components. To bleed the high pressure water, open the bleed valve, and slowly relieve the water pressure. Avoid contact with the high pressure water stream.
  • Page 68 Water System Testing TORO Hydroject® 3000/4000...
  • Page 69 TORO Hydroject® 3000/4000 Water System Testing Water Pressure Test Install the water system pressure gauge (TOR4005) into the port in the water valve housing. NOTE: Operating the machine for an extended period of time with the gauge installed can damage the gauge.
  • Page 70 Water System Testing TORO Hydroject® 3000/4000...
  • Page 71 TORO Hydroject® 3000/4000 Water System Testing Performing the Accumulator Pressure Test 1. With the unit shut off, and the pressure relieved from the high-pressure water circuit. 2. Remove the protective cover from the accumulator service valve. 3. Connect the accumulator charging tool.
  • Page 72 Water System Testing TORO Hydroject® 3000/4000...
  • Page 73 TORO Hydroject® 3000/4000 Water System Testing Interpreting Test Results and Operational Effects Low Accumulator Pressure. Cause: Leaking piston O-Rings. Leaking accumulator service valve. Normal operational leakage. Effect: Low accumulator pressure decreases the water available for delivery to the aeration nozzles.
  • Page 74 Water System Testing TORO Hydroject® 3000/4000...
  • Page 75 TORO Hydroject® 3000/4000 Water System Testing Water Flow Test Connect the flow meter (TOR4006) to the water inlet. Water flow with the unit operating and the spray wash closed, should be more than 3.4 GPM. Low Water Flow Cause: Leaking waterpump valves.
  • Page 76 Water System Testing TORO Hydroject® 3000/4000...
  • Page 77 TORO Hydroject® 3000/4000 Water System Testing Valve Lift Test Remove the test cap from the feeder manifold and install the valve lift indicator (TOR4007). Make sure that the dial indicator contacts the water valve. Zero out the dial indicator. Rotate the engine drive coupling and watch the dial indicator. The proper valve lift should be 0.090 to 0.102.
  • Page 78 Water System Testing TORO Hydroject® 3000/4000 Test Equipment Troubleshooting Tips 1. Accumulator Test/Recharge tool. TOR4001 1. Before connecting any test equipment to the water system, fully relieve water pressure by 2. Water system pressure gauge. TOR4005 opening the water system drain valve.
  • Page 79 TORO Hydroject® 3000/4000 Water System Testing 77 Review Questions 1. Minimum water system inlet flow is: 6. Low water system pressure is caused by : A. 4.3 GPM. A. Leaking relief valve. B. 3.4 GPM. B. Low water supply flow.
  • Page 80 Storage TORO Hydroject® 3000/4000 Preparation for winter storage Storage or if unit is out of service for an extended period With the engine off and the key removed, rotate Rotate engine engine until resistance is until cycling valve felt, then continue to rotate is open.
  • Page 81 TORO Hydroject® 3000/4000 Storage Storage The unit must be properly prepared for storage. If the unit is being stored for the winter the water must be drained to prevent freezing and damage to the components. Due to varying water quality and the use of “gray water” the water should also be drained from the unit if the unit will be out of service for an extended period of time.
  • Page 82 Maintenance TORO Hydroject® 3000/4000...
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  • Page 84 © The Toro Company...

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