Page 3 - Table Of Contents; Chapter 2 - Product Records and Manuals
Table Of Contents Chapter 1 - Safety Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1 Chapter 2 - Product Records and Manuals Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1...
Page 5 - Chapter 1; CAUTION; Table of Contents; Before Operating; Safety
Chapter 1 Safety Maintenance and Service . . . . . . . . . . . . . . . . . . . . . 3 SAFETY AND INSTRUCTION DECALS . . . . . . . . . . 4 CAUTION TO REDUCE THE POTENTIAL FOR INJURY OR DEATH, COMPLY WITH THE FOLLOWING SAFETY INSTRUCTIONS. 3. Never operate the machine when under the influ- ence of drug...
Page 6 - While Operating; STOP AERATING; Maintenance
8. Fill fuel tank with gasoline before starting the en- gine. Avoid spilling gasoline. Since gasoline is flam-mable, handle it carefully. A. Use an approved gasoline container. B. Do not fill tank while engine is hot or running. C. Do not smoke while handling gasoline. While Operating 10. DON’T TAKE...
Page 8 - Safety and Instruction Decals
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...
Page 9 - Chapter 2; Standard Torque for Dry, Zinc Plated and; Product Records; Product Records and Maintenance
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) . . . . . . . . . . . . . ....
Page 10 - Equivalents and Conversions
Equivalents and Conversions Product Records and Maintenance Page 2 – 2 Hydroject 3010
Page 11 - Torque Specifications; Fastener Identification; reduced by 25% for lubricated fasteners
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...
Page 14 - Other Torque Specifications; Grade 5; Conversion Factors
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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Page 19 - Chapter 4; Hydraulic System; Transmission Operates in One Direction Only . . 8
Chapter 4 Hydraulic System Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . 3 Hydraulic Hose and Fitting Information . . . . . . . . 3 Pushing or Towing . . . . . . . . . . . . . . . . . . . . . . . . 5 H...
Page 20 - Specifications
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Page 21 - Figure 2; General Information; Hydraulic Hoses; Make sure the O-ring is installed and properly seated; in the groove. It is recommended that the O-ring be
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...
Page 23 - Figure 7
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...
Page 24 - Figure 8; Hydraulic Diagram
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
Page 25 - NOTE: Order special tools from the; Special Tools
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...
Page 26 - Troubleshooting; Transmission Operates in One Direction Only; Cause
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Page 27 - Testing; Check the oil level in the reservoir.
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...
Page 28 - Start the engine and release the parking brake.; TEST C: Traction Motor Efficiency
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...
Page 29 - Park machine on a level surface, stop the engine and; Adjustments
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...
Page 31 - D. Use a pry bar in hole on pump bracket to pull pump
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 ...
Page 32 - Disconnect valve clutch electrical connector.; Repairs
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...
Page 33 - Remove hydraulic fittings from pump and plug ports.
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...
Page 34 - Lubricate new seal with petroleum jelly.
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...
Page 35 - Unscrew bypass valve from end cap of pump.
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...
Page 37 - Disassembly of Hydraulic Pump; Shaft Seals
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:...
Page 38 - Remove displacement control shaft from housing.; Inspection and Replacement of Pump Parts; Install pump shaft and bearing assembly into housing.
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 ...
Page 45 - Chapter 5; Electrical System; Accumulator Charge and High Press. Switches 21
Chapter 5 Electrical System Table of Contents WIRING SCHEMATICS AND DIAGRAMS . . . . . . . . 2 Logic Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Controller lights . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . ....
Page 46 - Wiring Schematics and Diagrams; Logic Chart; SWITCHES
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...
Page 47 - Contoller Lights; closed
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...
Page 48 - Electrical Schematic and Wiring Diagrams
Electrical Schematic and Wiring Diagrams See Chapter 8 - Electrical Diagrams. Wiring Schematics and Diagrams Page 5 - 4 Hydroject 3010
Page 51 - Starting Problems; Condition
________________________________________________________________________________________________________________________________________________________ Troubleshooting voltage. CAUTION Remove all jewelry, especially rings and watches, before doing any electrical trou-bleshooting or testing. Disconn...
Page 53 - General Run and Transport Problems
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Page 54 - General Run and Transport Problems (continued)
________________________________________________________________________________________________________________________________________________________ General Run and Transport Problems (continued) Condition Possible Cause Correction Machine does not raise (to trans- Lift/Lower switch faulty. Test...
Page 55 - Aerate Operation Problems
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Page 57 - Safety Interlock System Problems
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Page 58 - Safety Interlock System Problems (continued)
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Page 59 - Verify Safety Interlock System Operation
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...
Page 63 - leads of the switch.
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...
Page 64 - To test the actuator:
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...
Page 65 - Accumulator Charge and High Pressure Limit Switches (Fig. 18a); The accumulator contains nitrogen gas under
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...
Page 66 - Battery
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...
Page 68 - C) before connecting to
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...
Page 69 - Traction Switch 1 and 2 Replacement and Adjustment (Fig. 26); Disconnect wires from switch terminals.; traction bail in forward or reverse.
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 ...
Page 71 - Disconnect linear actuator wire connector.
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...
Page 73 - Chapter 6; Water System; Accumulator Charging Valve
Chapter 6 Water System Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Nozzle Size and Approximate Depth Chart . . . . . 2 WATER SYSTEM SCHEMATIC . . . . . . . . . . . . . . . . 3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Accumulator...
Page 77 - Water System Schematic
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...
Page 78 - The following special tools are required for servicing the; Figure 3
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...
Page 81 - Figure 9
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...
Page 83 - Troubleshooting Water System Problems
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Page 86 - Before Performing Water System Tests
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...
Page 87 - of the water system.
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 ...
Page 89 - WARNING
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. ...
Page 91 - Remove belt guard to expose the drive shaft.
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...
Page 96 - Rinse out filter body and insert a new filter.
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...
Page 97 - Remove drive belt from driven pulley.
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...
Page 99 - PTFE
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 ...
Page 100 - Install pulley with tapered hub onto pump drive shaft.
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...
Page 101 - Crankcase Bearing Installation and Shimming; Remove existing shims from both end caps.
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...
Page 102 - This page is intentionally blank.
This page is intentionally blank. Repairs Page 6 - 28 HydroJect 3010
Page 104 - Water Valve Assembly
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–...
Page 105 - Rev
. 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...
Page 106 - The gear case also serves as the hydraulic oil reservoir.
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...
Page 107 - Nozzle Service and Replacement; section of this chapter for; Tighten nut to
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...
Page 108 - ) into groove on top of
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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Page 110 - Remove protective cover from top of accumulator.
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...
Page 111 - Move piston to bottom of accumulator cylinder. Add
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...
Page 112 - Storage
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 ...
Page 113 - Chapter 7; Wheels, Brakes and Steering
Chapter 7 Wheels, Brakes and Steering Table of Contents ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 2 Brake Service . . . . . . . . ....
Page 117 - Chapter 8; Electrical Diagrams; Electrical Diagrams
Chapter 8 Electrical Diagrams Table of Contents Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Main Harness Drawing . . . . . . . . . . . . . . . . . . . . . . . . . 4 Main Harness Wiring Diagram . . . . . . . . . . . . . . . . . . 5 Control Panel Harness Drawing . . . ...
Page 119 - Electrical Schematic
Page 120 - Main Harness
Page 121 - Main Wiring Diagram
Page 122 - Control Panel Harness
Page 123 - Tiller Wire Harness and Diagram
Hydroject 3010 Tiller Wire Harness and Diagram Page 8 – 7
