Toro 3010 - Manuals

Safety and Instruction Decals Numerous safety and instruction decals are affixed to the Hyroject 3010. If any decal becomes illegible or damaged, install a new decal. Part numbers for replace-ment decals are listed in your Parts Catalog. Order re-placement decals from your authorized Toro Distributo...

Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . 1 Standard Torque for Dry, Zinc Plated and MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Steel Fasteners (Inch Series) . . . . . . . . . . . . . ....

Equivalents and Conversions Product Records and Maintenance Page 2 – 2 Hydroject 3010

Torque Specifications Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and spe-cified in this Service Manual. These Torque Specifi...

Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Thread Size Square Head Hex Socket 1/4 – 20 UNC 140 + 20 in–lb 73 + 12 in–lb 5/16 – 18 UNC 215 + 35 in–lb 145 + 20 in–lb 3/8 – 16 UNC 35 + 10 ft–lb 18 + 3 ft–lb 1/2 – 13 UNC 75 + 15 ft–lb 50 + 10 ft–lb Thread Size 7/16...

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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 H...

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paper or with this Figure 2 Body Sleeve Seal Final General Information Hydraulic Hoses spect the hoses frequently for signs of deterioration or damage. gine and opening the bypass valve. Keep body and hands away from pin hole der high pressure. Use cardboard, escaping under pressure can have suffici...

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 tra...

Hydraulic Diagram Charge Check Val Val Wheel Motor Disp. Pump (Gear Case) Inlet Filter Charge Relief Val Cooling Charge Pump Input (Belt Drive) ves By-pass ve Variable Reservoir ve Orifice Figure 8 Hydraulic Diagram Page 4 - 6 Hydroject 3010

Special Tools NOTE: Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS) . S o m e t o o l s m a y b e l i s t e d i n t h e Hydroject 3010 Parts Catalog. Some tools may also be available from a local supplier. Hydraulic Tester - With Pressure and Flow Capabil...

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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.) pressure (psi) rating as listed in the tes...

Hydraulic Tests (Fig. 10, 11) 1. Make sure hydraulic oil is at normal operating tem­perature by operating the machine for approximately 10 minutes. 2. Engage parking brake and stop the engine. Make sure parking brake is properly adjusted before perform­ing hydraulic tests. 3. With engine off, discon...

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. 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 r 0...

Traction Pump Belt Adjustment (Fig. 16, 17) 1. Park machine on a level surface, stop the engine and open the hood. 2. Check belt tension by depressing belt midway be­tween pulleys with 3 lb. of force. Belt should deflect 1/4 in. 3. If adjustment is necessary: A. Loosen pivot nut securing pump mount ...

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. 2. Remove pulley guard bracket (Fig. 20, Item 21). 3. Remove drive coupling (see Drive Coupling Removal and Installation in Chapter 6 - Wat...

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. 2. Disconnect wires from neutral and pump switches (Item 31) on hydraulic pump. Label wires for proper reinstallation. 3. Remove extension spr...

Pump Shaft Seal Replacement (Fig. 21) Lip type seals are used on input shaft and displacement control shaft. These seals can be replaced without major disassembly of pump. 1. Remove retaining ring from housing (input shaft seal only). 2. Carefully pull seal out of housing bore. A “hook” type tool ma...

Pump Charge Check Valve Service (Fig. 22) 1. Remove check valve plug with a 1/4 in. internal hex wrench. 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. 3. Inspect check balls and mating seats in end cap for d...

24 23 22 21 20 19 16 18 5 26 27 28 29 25 6 7 8 9 10 35 36 37 38 39 11 12 13 14 15 17 1 2 3 4 40 34 33 31 32 30 4 3 2 1 Figure 25 Disassembly of Hydraulic Pump 1. Before performing major repairs on the pump, remove external components as described in previous proce­dures. These include the following:...

14. Remove pump shaft (Item 19) and bearing assemblyfrom housing. 15. Remove outer bearing retaining ring (Item 21) (and washer, if used). Press shaft out of bearing. 16. If pump block retaining spring retaining ring (Item 10) requires replacement, remove it from pump shaft. 17. Remove displacement ...

Chapter 5 Electrical System Table of Contents WIRING SCHEMATICS AND DIAGRAMS . . . . . . . . 2 Logic Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Controller lights . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . ....

X Wiring Schematics and Diagrams 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 + L + S) and the hy...

Contoller Lights Lights (LEF’s) on the controller indicate when the follow­ing inputs are made to the contoller: Red: Traction switch 1 closed (traction bail in neu­ tral). Green: Aerate start (engage) switch closed. If red and yellow lights are on, green light will stay on until either red or yello...

Electrical Schematic and Wiring Diagrams See Chapter 8 - Electrical Diagrams. Wiring Schematics and Diagrams Page 5 - 4 Hydroject 3010

________________________________________________________________________________________________________________________________________________________ Troubleshooting voltage. CAUTION Remove all jewelry, especially rings and watches, before doing any electrical trou-bleshooting or testing. Disconn...

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________________________________________________________________________________________________________________________________________________________ General Run and Transport Problems (continued) Condition Possible Cause Correction Machine does not raise (to trans- Lift/Lower switch faulty. Test...

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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 sche­matics, determine which component is at fault. How­ever, this section will define given components, and the tests that can be perf...

Wheel Position Switch (Fig. 13) leads of the switch. Wheel Position Switch Aerate (machine lowered) CLOSED OPEN Figure 13 1 Test the switch by disconnecting the wire connector and installing a continuity tester or ohm meter across the two Transport (machine raised) NOTE: For proper operation, the sw...

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 the terminals. Terminals 2-3 and 5-6 s...

Brake Switch (Fig. 17) The brake switch is a normally open (N.O.) switch that closes when the brake is engaged. 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 swit...

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 con­nected and disconnected to terminal 85 with terminal 86 c...

Repairs Battery Service (Fig. 24, 25) IMPORTANT: To prevent damage to the electrical components, do not operate the engine with the battery cables disconnected. Keep the terminals and entire battery case clean. To clean the battery, wash the entire case with a solution of baking soda and water. Rins...

Traction Switch 1 and 2 Replacement and Adjustment (Fig. 26) 1. Disconnect wires from switch terminals. 2. Have a helper push traction bail down into either FORWARD or REVERSE position or disconnect exten­sion spring; this will take switch arm tension off of switch. Loosen two (2) screws and remove ...

Linear Actuator Replacement (Fig. 28) 1. Put wheels in transport position (machine raised). 2. Put the machine on a level surface, stop the engine, engage the parking brake and disconnect engine spark plug wires. 3. Open the hood. 4. Disconnect linear actuator wire connector. 5. Disconnect extension...

Chapter 6 Water System Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Nozzle Size and Approximate Depth Chart . . . . . 2 WATER SYSTEM SCHEMATIC . . . . . . . . . . . . . . . . 3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Accumulator...

Rev. B Water System Schematic QUICK COUPLER ENGINE ELECTRIC CLUTCH PUMP ELECTRIC BRAKE CLUTCH PRESSURE SWITCH 20 PSI – ON 10 PSI – OFF PRESSURE GAUGE 2500 PSI NITROGEN PRE–CHARGE 5000 PSI GEARBOX CAM HIGH PRESSURE NOZZLES NOZZLES PRESSURE REDUCING WATER SUPPLY WATER SPRAY WASH VALVE ACCUMULATOR WATE...

Special Tools The following special tools are required for servicing the Order special tools from the TORO SPECIAL TOOLS HydroJect 3010. A N D A P P L I C AT I O N S G U I D E ( C O M M E R C I A L PRODUCTS). Accumulator Charging Valve and Pressure Gauge - TOR4001 (Fig. 2) The charging valve connect...

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 Ins...

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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 tes...

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 ...

1 1 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. ...

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 rap...

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 th...

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. j High pressure water system components can cause personal in ury if disassembled incor- rectly. Discharge water pre...

Rev. B Plunger Seal Replacement (See illustration on previous page) NOTE: Check valves must be in good condition for this procedure to work correctly. 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 ...

Repairs Page 6 – 26 Hydroject 3010 Rev. B Water Pump Crankcase Service (Fig. 38) 1 2 3 4 5 6 7 8 9 22 15 18 19 20 21 23 24 25 26 27 28 29 10 11 12 13 14 7 8 14 13 22 10 17 16 10 Apply grease to O.D. of plunger before installing pump head 18 – 20 ft–lb 18 – 20 ft–lb 18 – 20 ft–lb Figure 38 NOTE: Repl...

Rev. B Crankcase Bearing Installation and Shimming (Model 09801) 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 (.00...

This page is intentionally blank. Repairs Page 6 - 28 HydroJect 3010

Hydroject 3010 Page 6 – 30 Repairs Rev. B 11. Inspect sealing surfaces of valve spool and valveseat. If surfaces appear worn, replace or regrind. Bothangles are 30 degrees. 12. Remove and inspect sleeve (Item 7) and removebackup (Item 6) and O–ring seals (Item 5). 13. Remove seal assembly (Items 25–...

. B 9. Hold spool and seat in place so O–ring does not fallout of place, then carefully slide valve spool, new sleeve seals, and valve seat, through ceramic sleeve. 10. Install flat washer (Item 23) onto valve spool. ApplyLoctite 271 or equivalent to threads and install jam nut (Item 22). Tighten to...

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...

Rev. B Nozzle Service and Replacement NOTE: See Specifications section of this chapter for more information. 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. 2. Inspect nozzle configuration and diameter...

Accumulator Replacement (Fig. 43) 1. Stop the engine, engage the parking brake, open the hood and disconnect the engine spark plug wires. in a be j Charged accumulators contain high pressure nitrogen. Nitrogen is the only gas to use for accumulator charging. Installing IMPROPER gases in an accumulat...

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Rev. A in a be j 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 well ventilate...

8. Remove gas valve (Item 4) from top of accumulator. 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 ch...

Rev. B General Information Storage It is very important that the water system be drained to avoid freezing and damaging the components. Drain system as follows: 1. Stop engine, remove key from ignition switch and remove wires from spark plugs. 2. Remove (2) screws securing drive shield to frame and ...

Chapter 7 Wheels, Brakes and Steering Table of Contents ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 2 Brake Service . . . . . . . . ....

Chapter 8 Electrical Diagrams Table of Contents Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Main Harness Drawing . . . . . . . . . . . . . . . . . . . . . . . . . 4 Main Harness Wiring Diagram . . . . . . . . . . . . . . . . . . 5 Control Panel Harness Drawing . . . ...

Hydroject 3010 Tiller Wire Harness and Diagram Page 8 – 7