Toro HydroJect 3010 Manuals

Operator’s Manual Domestic English (EN) Form No. 3356–184 Rev B HydroJect� 3010 Aerator Model No. 09802—250000001 and Up 2 All Rights Reserved Printed in the USA � 2005 by The Toro Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196 The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Warning This spark ignition system complies with Canadian ICES-002. Ce système d’allumage par étincelle de véhicule est conforme à la norme NMB-002 du Canada. Contents Page Introduction 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safe Operating Practices 3 . . . . . . . . . . . . . . . . . . . . Sound Pressure Level 5 . . . . . . . . . . . . . . . . . . . . . . . Sound Power Level 5 . . . . . . . . . . . . . . . . . . . . . . . . Vibration Level 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety and Instruction Decals 5 . . . . . . . . . . . . . . . . . Specifications 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Specifications 9 . . . . . . . . . . . . . . . . . . . . . Controls 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water Injection System 10 . . . . . . . . . . . . . . . . . . . . . Dimensions 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Depths and Nozzle Configurations 11 . . . . . . . . . . . . Setup 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loose Parts 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing the Rear Wheels 12 . . . . . . . . . . . . . . . . . . . Before Operating 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Activating and Charging the Battery 13 . . . . . . . . . . . Checking the Engine Oil 14 . . . . . . . . . . . . . . . . . . . . Filling the Gas Tank 14 . . . . . . . . . . . . . . . . . . . . . . . . Checking the Gear Case Fluid Level 15 . . . . . . . . . . . Checking the Pump Case Fluid Level 16 . . . . . . . . . . Checking the Tire Pressure 16 . . . . . . . . . . . . . . . . . . Checking the Accumulator Charge 16 . . . . . . . . . . . . Operation 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controls 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating Precautions 18 . . . . . . . . . . . . . . . . . . . . . . Starting and Stopping the Engine 18 . . . . . . . . . . . . . . Training Period 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water Supply 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating Procedure 19 . . . . . . . . . . . . . . . . . . . . . . . Checking the Interlock System 20 . . . . . . . . . . . . . . . Transport Operation 21 . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Clean-Up After Use 21 . . . . . . . . . . . . Pushing or Towing the Machine 21 . . . . . . . . . . . . . . Maintenance 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended Maintenance Schedule 23 . . . . . . . . . Daily Maintenance Checklist 24 . . . . . . . . . . . . . . . . . Lubricating the Machine 25 . . . . . . . . . . . . . . . . . . . . Servicing the Pre-Filter 26 . . . . . . . . . . . . . . . . . . . . . Replacing the Main Water Filter 26 . . . . . . . . . . . . . . Changing the Engine Oil and Filter 27 . . . . . . . . . . . . General Air Cleaner Maintenance 27 . . . . . . . . . . . . . Servicing the Air Cleaner 27 . . . . . . . . . . . . . . . . . . . . Checking and Replacing the Spark Plugs 28 . . . . . . . Changing the Gear Case Oil and Filter 29 . . . . . . . . . Changing the Pump Case Oil 30 . . . . . . . . . . . . . . . . . Checking the Hydraulic Lines and Hoses 30 . . . . . . . Adjusting the Traction Pump Belt 30 . . . . . . . . . . . . . Adjusting the Transmission for Neutral 31 . . . . . . . . . Adjusting the Aeration Speed 31 . . . . . . . . . . . . . . . . Adjusting the Parking Brake 32 . . . . . . . . . . . . . . . . . Adjusting the Roller Spray Wash System 32 . . . . . . . Servicing the Spray Wash Nozzles or Strainers 33 . . . Caring for the Battery 33 . . . . . . . . . . . . . . . . . . . . . . Seasonal Storage 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preparing the Water System 34 . . . . . . . . . . . . . . . . . . Preparing the Engine 34 . . . . . . . . . . . . . . . . . . . . . . . Preparing the Traction Unit 34 . . . . . . . . . . . . . . . . . . Troubleshooting 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Schematic 39 . . . . . . . . . . . . . . . . . . . . . . . Electrical Schematic 40 . . . . . . . . . . . . . . . . . . . . . . . . Electrical Schematic 41 . . . . . . . . . . . . . . . . . . . . . . . . Water System Schematic 42 . . . . . . . . . . . . . . . . . . . . The Toro Aerator Commercial Products Warranty 44 . . . 3 Introduction Read this manual carefully to learn how to operate and maintain your product properly. The information in this manual can help you and others avoid injury and product damage. Although Toro designs and produces safe products, you are responsible for operating the product properly and safely. Whenever you need service, genuine Toro parts, or additional information, contact an Authorized Service Dealer or Toro Customer Service and have the model and serial numbers of your product ready. The model and serial numbers are stamped on a plate which is riveted to the frame. Write the product model and serial numbers in the space below: Model No. Serial No. This manual identifies potential hazards and has special safety messages that help you and others avoid personal injury and even death. Danger, Warning, and Caution are signal words used to identify the level of hazard. However, regardless of the hazard, be extremely careful. Danger signals an extreme hazard that will cause serious injury or death if you do not follow the recommended precautions. Warning signals a hazard that may cause serious injury or death if you do not follow the recommended precautions. Caution signals a hazard that may cause minor or moderate injury if you do not follow the recommended precautions. This manual uses two other words to highlight information. Important calls attention to special mechanical information and Note: emphasizes general information worthy of special attention. Safety Improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert symbol, which means CAUTION, WARNING, or DANGER—“personal safety instruction.” Failure to comply with the instruction may result in personal injury or death. Safe Operating Practices The following instructions are from ANSI standard B71.4—2004. Training • Read the Operator’s Manual and other training material. If the operator(s) or mechanic(s) can not read English it is the owner’s responsibility to explain this material to them. • Become familiar with the safe operation of the equipment, operator controls, and safety signs. • All operators and mechanics should be trained. The owner is responsible for training the users. • Never let children or untrained people operate or service the equipment. Local regulations may restrict the age of the operator. • The owner/user can prevent and is responsible for accidents or injuries occurring to himself or herself, other people or property. Preparation • Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job. Only use accessories and attachments approved by the manufacturer. • Wear appropriate clothing including hard hat, safety glasses and hearing protection. Long hair, loose clothing or jewelry may get tangled in moving parts. • Inspect the area where the equipment is to be used and remove all objects such as rocks, toys and wire which can be contacted by the aerator. • Use extra care when handling gasoline and other fuels. They are flammable and vapors are explosive. • Use only an approved container • Never remove gas cap or add fuel with engine running. Allow engine to cool before refueling. Do not smoke. • Never refuel or drain the aerator indoors. • Check that operator’s presence controls, safety switches and shields are attached and functioning properly. Do not operate unless they are functioning properly. Operation • Never run an engine in an enclosed area. • Only operate in good light, keeping away from holes and hidden hazards. 4 • Be sure all drives are in neutral and parking brake is engaged before starting engine. Start the engine only from the operator’s position. • Never operate without the shields, covers or other guards securely in place. Be sure all interlocks are functioning properly. • Keep hands and feet away from the 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. • Never use chemicals in the water supply system. • Do not operate the water injection system on concrete or asphalt because water jets will permanently damage these surfaces. • Before disconnecting or performing any work on the water system, all pressure in the system must be relieved by stopping the engine and opening the bleed valve. Opening the bleed valve allows any trapped water to escape from the system and also allows the accumulator piston to move to the bottom of the accumulator cylinder. • Do not change the engine governor setting or overspeed the engine. • The accumulator in this machine contains high pressure dry nitrogen. Accumulator servicing requires special tools and precautions. Accumulators do not contain user serviceable components. Improper accumulator servicing can cause dismemberment or death. Do not attempt to disassemble an accumulator; have this work done by an Authorized Toro Distributor. • Stop on level ground, disengage drives, engage parking brake, shut off engine before leaving the operator’s position for any reason. • Never carry passengers and keep pets and bystanders away. • Be alert, slow down and use caution when making turns. Look behind and to the side before changing directions. • Slow down and use caution when crossing roads and sidewalks. • Do not operate the aerator under the influence of alcohol or drugs. • Use extreme care when loading or unloading the aerator into a trailer or truck. • Use care when approaching blind corners, shrubs, trees, or other objects that may obscure vision. Slope Operation • Do not operate near drop–offs, ditches, steep banks or water. Wheels or rollers dropping over edges can cause rollovers, which may result in serious injury or death. • Do not operate on slopes when grass is wet. Slippery conditions reduce traction and could cause sliding and loss of control. • Do not make sudden turns or rapid speed changes. • Reduce speed and use extreme caution on slopes. • Remove or mark obstacles such as rocks, tree limbs, etc. from the operating area. Tall grass can hide obstacles. • Watch for ditches, holes, rocks, dips, and rises that change the operating angle, as rough terrain could overturn the aerator. • Be aware that loss of traction may occur going downhill. Weight transfer may cause drive wheel to slip and cause loss of braking and steering. • Always avoid sudden starting or stopping on a slope. If tire loses traction, disengage the water injection system and proceed slowly off the slope. Maintenance and storage Engine exhaust contains carbon monoxide, which is an odorless, deadly poison that can kill you. Do not run engine indoors or in an enclosed area. Warning • Make sure all hydraulic line connectors are tight and all hydraulic hoses and lines are in good condition before applying pressure to the system. • Keep your body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not your hands, to search for leaks. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury. Seek immediate medical attention if fluid is injected into skin. • Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved by stopping the engine and lowering the deck and attachments to the ground. • Let engine cool before storing and do not store near flame. • Shut off fuel while storing or transporting on trailers. Do not store fuel near flames or drain indoors.

Form No. 3360-899 Rev B HydroJect® 3010 Aerator Model No. 09802—Serial No. 280000001 and Up To register your product or download an Operator's Manual or Parts Catalog at no charge, go to www.Toro.com. Original Instructions (EN) Introduction Important: The engine in this product is not equipped with a spark arrester muffler. It is a violation of California Public Resource Code Section 4442 to use or operate this engine on any forest-covered, brush-covered, or grass-covered land as defined in CPRC 4126. Other states or federal areas may have similar laws. Read this information carefully to learn how to operate and maintain your product properly and to avoid injury and product damage. You are responsible for operating the product properly and safely. You may contact Toro directly at www.Toro.com for product and accessory information, help finding a dealer, or to register your product. Whenever you need service, genuine Toro parts, or additional information, contact an Authorized Service Dealer or Toro Customer Service and have the model and serial numbers of your product ready. The model and serial numbers are on a plate on the product. Write the numbers in the space provided. Model No. Serial No. This manual identifies potential hazards and has safety messages identified by the safety alert symbol (Figure 1), which signals a hazard that may cause serious injury or death if you do not follow the recommended precautions. Figure 1 1. Safety alert symbol This manual uses 2 other words to highlight information. Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention. Warning CALIFORNIA Proposition 65 Warning The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. This spark ignition system complies with Canadian ICES-002. © 2008—The Toro® Company 8111 Lyndale Avenue South Bloomington, MN 55420 2 Contact us at www.Toro.com. Printed in the USA. All Rights Reserved Contents Introduction.................................................................2 Safety ...........................................................................4 Safe Operating Practices.......................................4 Safety and Instructional Decals.............................6 Setup............................................................................9 1 Installing the Rear Wheels..................................9 2 Activating and Charging the Battery....................9 3 Checking the Tire Pressure............................... 11 Product Overview...................................................... 12 Controls............................................................. 12 Specifications ..................................................... 13 Attachments/Accessories................................... 13 Depths and Nozzle Configurations..................... 14 .......................................................................... 14 Operation................................................................... 15 Think Safety First............................................... 15 Checking the Engine Oil..................................... 15 Filling the Gas Tank ........................................... 15 Checking the Gear Case Fluid Level .................... 16 Checking the Pump Case Oil Level...................... 17 Water System Accumulator................................. 18 Operating Precautions........................................ 18 Starting and Stopping the Engine........................ 18 Training Period................................................... 18 Water Supply...................................................... 19 Operating Procedure.......................................... 19 Checking the Interlock System............................ 20 Transport Operation .......................................... 21 Inspection and Clean-Up After Use..................... 21 Pushing or Towing the Machine.......................... 21 Maintenance............................................................... 23 Recommended Maintenance Schedule(s) ................ 23 Water System Accumulator................................. 23 Daily Maintenance Checklist............................... 24 Lubricating the Machine..................................... 25 Servicing the Pre-Filter....................................... 26 Replacing the Main Water Filter .......................... 26 Changing the Engine Oil and Filter ..................... 27 General Air Cleaner Maintenance ....................... 27 Servicing the Air Cleaner .................................... 27 Checking and Replacing the Spark Plugs.............. 28 Changing the Gear Case Oil and Filter................. 29 Changing the Pump Case Oil .............................. 30 Checking the Hydraulic Lines and Hoses............. 30 Adjusting the Traction Pump Belt ....................... 30 Adjusting the Transmission for Neutral............... 31 Adjusting the Aeration Speed.............................. 32 Adjusting the Parking Brake................................ 32 Adjusting the Roller Spray Wash System .............. 33 Servicing the Spray Wash Nozzles or Strainers......................................................... 33 Caring for the Battery ......................................... 33 Storage....................................................................... 34 Preparing the Water System ................................ 34 Preparing the Engine.......................................... 34 Preparing the Traction Unit ................................ 34 Troubleshooting......................................................... 35 Schematics ................................................................. 38 3 Safety Improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert symbol, which means CAUTION, WARNING, or DANGER - "personal safety instruction." Failure to comply with the instruction may result in personal injury or death. Safe Operating Practices The following instructions are from ANSI standard B71.4-2004. Training • Read the Operator’s Manual and other training material. If the operator(s) or mechanic(s) can not read English it is the owner’s responsibility to explain this material to them. • Become familiar with the safe operation of the equipment, operator controls, and safety signs. • All operators and mechanics should be trained. The owner is responsible for training the users. • Never let children or untrained people operate or service the equipment. Local regulations may restrict the age of the operator. • The owner/user can prevent and is responsible for accidents or injuries occurring to himself or herself, other people or property. Preparation • Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job. Only use accessories and attachments approved by the manufacturer. • Wear appropriate clothing including hard hat, safety glasses and hearing protection. Long hair, loose clothing or jewelry may get tangled in moving parts. • Inspect the area where the equipment is to be used and remove all objects such as rocks, toys and wire which can be contacted by the aerator. • Use extra care when handling gasoline and other fuels. They are flammable and vapors are explosive. – Use only an approved container. – Never remove gas cap or add fuel with engine running. Allow engine to cool before refueling. Do not smoke. – Never refuel or drain the aerator indoors. • Check that the operator presence controls, safety switches and shields are attached and functioning properly. Do not operate unless they are functioning properly. Operation • Only operate in good light, keeping away from holes and hidden hazards. • Be sure all drives are in neutral and parking brake is engaged before starting engine. Start the engine only from the operators position. • Never operate without the shields, covers or other guards securely in place. Be sure all interlocks are functioning properly. • Keep hands and feet away from the 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. • Never use chemicals in the water supply system. • Do not operate the water injection system on concrete or asphalt because water jets will permanently damage these surfaces. • Before disconnecting or performing any work on the water system, all pressure in the system must be relieved by stopping the engine and opening the bleed valve. Opening the bleed valve allows any trapped water to escape from the system and also allows the accumulator piston to move to the bottom of the accumulator cylinder. • Do not change the engine governor setting or overspeed the engine. • The accumulator in this machine contains high pressure dry nitrogen. Accumulator servicing requires special tools and precautions. Accumulators do not contain user serviceable components. Improper accumulator servicing can cause dismemberment or death. Do not attempt to disassemble an accumulator; have this work done by an Authorized Toro Distributor. • Stop on level ground, disengage drives, engage parking brake, shut off engine before leaving the operator’s position for any reason. • Never carry passengers and keep pets and bystanders away. • Be alert, slow down and use caution when making turns. Look behind and to the side before changing directions. 4

Part No. 04134SL (Rev. B) Preface This publications provides the service technician with information for troubleshooting, testing, and repair of the Hydroject. 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: The Toro Company 8111 Lyndale Avenue South Bloomington, MN 55420 The Toro Company reserves the right to change product specifications or this publication without notice. Service Manual Hydroject ® 3010 INSTRUCTION. When you see this symbol, This safety symbol means DANGER, WARNING, or CAUTION, PERSONAL SAFETY carefully read the instructions that follow. Failure to obey the instructions may result in personal injury. NOTE: A NOTE will give general information about the correct operation, maintenance, service, testing or re­ pair of the machine. 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 2005, 2006, 2007 Hydroject 3010 Table Of Contents Chapter 1 - Safety Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1 Chapter 2 - Product Records and Manuals Product Records. . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1 Equivalents and Conversions . . . . . . . . . . . . . . . . 2 - 2 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . 2 - 3 Chapter 3 - Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2 Kohler Engine Service Manual Chapter 4 - Hydraulic System 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 5 - Electrical System Wiring Schematics and Diagrams. . . . . . . . . . . . . 5 - 2 Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 7 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 15 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 24 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 7 - Wheels, Steering and Brakes Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 2 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 3 Chapter 8 - Electrical Diagrams Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 3 Main Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 4 Main Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . 8 - 5 Control Panel Harness . . . . . . . . . . . . . . . . . . . . . 8 - 6 Control Panel Wiring Diagram . . . . . . . . . . . . . . . 8 - 7 Tiller Harness and Wiring Diagram . . . . . . . . . . . . 8 - 8 Hydroject 3010