Part No. 04134SL (Rev. B) Service Manual Hydroject ® 3010 Preface This publications provides the service technician with information for troubleshooting, testing, and repair of the Hydroject. REFER TO THE HYDROJECT OPERATOR’S MANUAL FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. Space is provided in Chapter 2 of this book to insert the Operator’s Manual and Parts Catalog for your machine.
Hydroject 3010
Table Of Contents Chapter 1 - Safety Chapter 5 - Electrical System Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1 Wiring Schematics and Diagrams. . . . . . . . . . . . . 5 - 2 Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 7 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 15 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydroject 3000/4000
Chapter 1 Safety Table of Contents SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 1 Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Maintenance and Service . . . . . . . . . . . . . . . . . . . . . 3 SAFETY AND INSTRUCTION DECALS . . . . . . . . . .
8. Fill fuel tank with gasoline before starting the engine. Avoid spilling gasoline. Since gasoline is flammable, 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 or running. 9. Check interlock switches daily for proper operation. If a switch fails, replace it before operating the machine.
30. Before disconnecting or performing any work on the water system, all pressure in system must be relieved by 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.
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 replacement decals are listed in your Parts Catalog. Order replacement decals from your authorized Toro Distributor.
Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . Fastener Identification . . . . . . . . . . . . . . . . . . . . . . .
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 specified in this Service Manual. These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Service Manual.
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series) Thread Size Grade 1, 5 & 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) in–lb in–lb N–cm 10 + 2 13 + 2 147 + 23 # 6 – 32 UNC # 6 – 40 UNF # 8 – 32 UNC 13 + 2 25 + 5 # 10 – 24 UNC 30 + 5 SAE Grade 8 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 5 or Stronger Nuts) in–lb N–cm in–lb N–cm 15 + 2 170 + 20 23 + 2 260 + 20
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Fasteners) Thread Size Class 8.8 Bolts, Screws and Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws and Studs with Regular Height Nuts (Class 10 or Stronger Nuts) M5 X 0.8 57 + 5 in–lb 640 + 60 N–cm 78 + 7 in–lb 885 + 80 N–cm M6 X 1.0 96 + 9 in–lb 1018 + 100 N–cm 133 + 13 in–lb 1500 + 150 N–cm M8 X 1.25 19 + 2 ft–lb 26 + 3 N–m 27 + 2 ft–lb 36 + 3 N–m M10 X 1.
Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Recommended Torque** 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 7/16 – 20 UNF Grade 5 65 + 10 ft–lb 88 + 14 N–m 1/2 – 20 UNF Grade 5 80 + 10 ft–lb 108 + 14 N–m M12 X 1.25 Class 8.
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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 HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . 6 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Hydraulic Tester. . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications Item Description __________________________________________________________________________________________ Sundstrand Series 70, BDP-10L Variable Displacement Pump 2100 PSI maximum, 1000 PSI continuous 8.5 GPM maximum at 3500 RPM 25 to 70 PSI psi at 3500 RPM 25 micron screw-on type.
General Information Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as, pressure differentials during operation and exposure to weather, sun, chemicals, very warm storage condi tions or mishandling during operation or maintenance. These conditions can cause damage or premature de terioration. Some hoses, such as reel motor hoses, are more susceptible to these conditions than others. In spect the hoses frequently for signs of deterioration or damage.
SAE Straight Thread O-Ring Port - Non-adjustable (Fig. 4) 1. Make sure both threads and sealing surfaces are free of burrs, nicks, scratches, or any foreign material. 2. Always replace the O-ring seal when this type of fitting shows signs of leakage. 3. Lubricate the O-ring with a light coating of oil. O-Ring 4. Install the fitting into the port and tighten it down full length until finger tight. 5. Tighten the fitting to the correct flats from finger tight (F.F.F.T.). Size 4 (1/4 in.
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 trailer or pull with traction wheel raised and secured to a dolly. Whenever the machine is pushed or towed, the by-pass valve must be open. Hook on front of handle is used for a tie-down only, not a hitch point.
Hydraulic Diagram Cooling Orifice Input (Belt Drive) Charge Check Valves Variable Disp.
Special Tools NOTE: Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). Some tools may be listed in the Hydroject 3010 Parts Catalog. Some tools may also be available from a local supplier. Hydraulic Tester - With Pressure and Flow Capabilities (Fig.
Troubleshooting The cause of an improperly functioning hydraulic sys tem is best diagnosed with the use of proper testing equipment and a thorough understanding of the com plete hydraulic system. A hydraulic system with an excessive increase in heat or noise is a potential failure. Should either of these conditions be noticed, immediately stop the machine, turn off the engine, locate the cause of the trouble, and correct it before allowing the machine to be used again.
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.) 1. Thoroughly clean the machine before disconnecting or disassembling any hydraulic components. Always keep in mind the need for cleanliness when working on hydraulic equipment. 2.
Hydraulic Tests (Fig. 10, 11) 1. Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes. NOTE: At pressures above approximately 500 PSI, mechanical override in handle will cause pump to begin to de-stroke. 2. Engage parking brake and stop the engine. Make sure parking brake is properly adjusted before perform ing hydraulic tests. 11. If you cannot get 7 GPM or 500 PSI, traction pump may have internal damage or excessive wear.
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. 1 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 0.05 in. 2 3. Adjust jam nuts at tiller end of push-pull cable so traction handle is centered on control handle. Figure 12 1. Jam nuts - pump end 2. Jam nuts - tiller end Speed Control Adjustment (Fig.
Transmission Neutral Adjustment (Fig. 14) If machine moves when lever is released, transmission neutral adjustment is needed. 1. Park machine on a level surface, stop the engine and open the hood. 3 2 1 2. Lift drive wheel off the ground using a jack. Block front and rear of other wheels. 3. Start engine and release parking brake. 4. Slightly loosen locknut on top of neutral adjustment cam and rotate cam hex until traction wheel stops rotating. Tighten the locknut. 5.
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 be tween pulleys with 3 lb. of force. Belt should deflect 1/4 in. 1 3. If adjustment is necessary: A. Loosen pivot nut securing pump mount to pump support. B. Loosen adjusting nut securing pump and pump mount to slotted pump support. Figure 16 C. Loose three (3) capscrews securing pulley guard bracket (Fig.
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. 1 2. Remove pulley guard bracket (Fig. 20, Item 21). 3. Remove drive coupling (see Drive Coupling Removal and Installation in Chapter 6 - Water System). 3 4. Disconnect valve clutch electrical connector. 4 5. Remove valve clutch stops. 2 6. Loosen pivot nut securing pump mount to pump support. Figure 18 7.
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. 7. Remove locknut (Item 46), capscrew (Item 5) and washers (Item 47). Remove locknut (Item 54) and cap screw (Item 57). 2. Disconnect wires from neutral and pump switches (Item 31) on hydraulic pump. Label wires for proper reinstallation. 8. Remove pump assembly from pump support (Item 55) and put pump on a work bench. 9.
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. Top of pump when installed in machine 4 3 2 1 1. Remove retaining ring from housing (input shaft seal only). 2. Carefully pull seal out of housing bore. A “hook” type tool may be used to grasp seal and pull it out, or a slide hammer type puller may be used to remove seal.
Pump Charge Check Valve Service (Fig. 22) 1. Remove check valve plug with a 1/4 in. internal hex wrench. Top of pump when installed in machine 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. Torque to 15 to 35 ft-lb. 3. Inspect check balls and mating seats in end cap for damage or foreign material. 4. Lay pump on its side and reinstall check ball, spring and plug (with O-ring) into end cap.
Charge Pump Service (Fig. 24) 1. Use a 5 mm internal hex wrench to remove the two (2) screws holding charge pump cover to pump end cap. Top of pump when installed in machine NOTE: Charge pump rotation is determined by orienta tion of charge pump cover on pump end cap. Cast boss on charge pump cover indicates orientation. Note orien tation of cast boss before removing charge pump cover. 2. Remove charge pump cover and O-ring. 2 3 3. Remove charge pump gerotor assembly. 4.
23 24 22 19 20 21 18 16 17 12 15 13 14 8 1 6 2 7 9 10 5 3 11 4 26 25 27 40 39 35 28 38 36 34 29 37 33 32 31 30 4 3 2 1 Figure 25 Disassembly of Hydraulic Pump 6. Remove cylinder block spring (Item 8) and washer (Item 9) from shaft. 1. Before performing major repairs on the pump, remove external components as described in previous proce dures. These include the following: Shaft Seals Charge Check Valves Bypass Valve Charge Pump 7.
14. Remove pump shaft (Item 19) and bearing assembly from housing. 3. Install displacement control shaft (Item 12) into housing. 15. Remove outer bearing retaining ring (Item 21) (and washer, if used). Press shaft out of bearing. 4. If block spring retaining ring (Item 10) was removed from pump shaft, install a new retaining ring at this time. 16. If pump block retaining spring retaining ring (Item 10) requires replacement, remove it from pump shaft. 5.
18. Check that piston springs are centered in cylinder block bores, If necessary, move springs into position with a small screwdriver. 21. When end cap is properly installed, the internal springs will hold it away from the housing approximately 3/8 in. IMPORTANT: Do not damage running surfaces of cylinder blocks. 22. Install the four (4) capscrews which retain end cap to housing. Tighten screws to a torque of 138 to 180 in-lb. 19.
Wheel Motor Removal and Installation (Fig. 27) 3 2 1 4 9 10 5 8 6 11 7 12 37 13 36 14 15 16 35 17 18 19 34 30 32 20 31 Torque to 250 to 400 ft-lb. 21 33 29 28 27 17 25 26 24 23 22 Figure 27 1. Park machine on a level surface, engage parking brake, open hood and disconnect engine spark plug wires. Lift drive wheel off the ground using a jack. Block front and rear of other wheels. 4. Disconnect hydraulic lines from fittings on wheel motor.
Wheel Motor Shaft Seal and/or Shaft Replacement (Fig. 28) 12 11 10 13 16 17 4 7 14 15 19 6 20 5 19 4 21 3 1 9 2 Figure 28 Disassembly of Shaft and Front Seal Assembly scratches, entire motor should be disassembled for inspection. 1. Put motor on a clean, flat surface with shaft facing up. Clean front end of motor to avoid contaminating internal parts during procedure. 2. Remove key (Item 11) from shaft. 3. Remove snap ring (Item 14) using a snap ring pliers. 4.
Wheel Motor Repair (Fig. 29) 12 11 10 13 16 17 4 7 14 15 19 6 20 5 19 4 21 3 1 9 2 Figure 29 IMPORTANT: Before DISASSEMBLING motor, plug open ports and clean all dirt from outside of motor. IMPORTANT: Before ASSEMBLING motor, lightly oil all seals, rollers and threaded bolt ends. Disassembly of Cover Section of Motor NOTE: The check balls may fall into body tapered holes or into body valve ports during disassembly. Be sure that the check balls are removed.
6. Next put IGR inner member on shaft spline with semi-circular roll pockets between rotary valve ports. NOTE: Be sure not to dislodge body square ring seal while moving locating ring. 7. Put contour member of IGR over inner and insert seven rolls into inner pockets (large diameter rolls). 11. Install the eight locating ring rollers into their pockets and oil lightly. 8. Lightly oil square ring seal (Item 4) and put in body groove. 12.
Repairs Page 4 - 26 Hydroject 3010
Chapter 5 Electrical System Table of Contents WIRING SCHEMATICS AND DIAGRAMS . . . . . . . . 2 Logic Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Controller lights . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 7 Starting Problems . . . . . . . . . . . . . . . . . . . . . . . . 7 General Run and Transport Problems. . . . . . . . .
Wiring Schematics and Diagrams Logic Chart X Brake Switch Lift Switch DOWN (Aerate) O Accumulator High Press Switch Lift Switch UP (Transport) Aerator Start (Engage) Switch Traction Switch 2 Accumulator Charge Switch Wheel Position Switch Water Pressure Switch SWITCHES Switch Conditon Not Relevent Oil Pressure Switch Switch Closed Momentarily Traction Switch 1 Switch Open Run - Key Switch B + L + A Switch Closed O Start - Key Switch X B+L+S KEY Aerator Stop (Disengage) Switch Each
Contoller Lights Lights (LEF’s) on the controller indicate when the follow ing 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 yellow goes off.
Electrical Schematic and Wiring Diagrams See Chapter 8 - Electrical Diagrams.
Special Tools NOTE: Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). Some tools may be available from a local supplier. Digital Multimeter (Fig. 6) The meter can test electrical components and circuits for current, resistance, or voltage drop. NOTE: Toro recommends the use of a DIGITAL meter when testing electrical circuits. The high impedance (internal resistance) of a digital meter will ensure that excess current is not allowed through the meter.
Skin-Over Grease (Fig. 7) Special non-conductive grease which forms a light pro tective skin to help waterproof electrical switches and contacts. Toro P/N 505-47 8 oz. (.
Troubleshooting Study the operating characteristics preceding the elec trical failure to help identify the area of difficulty. Try to isolate the failure to a specific functional system; then check that area, repairing one component at a time. Attempting to repair more than one system at one time will lead to confusion. CAUTION Remove all jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Disconnect the battery cables unless the test requires battery voltage.
Starting Problems (continued) Condition Possible Cause Correction ________________________________________________________________________________________________________________________________________________________ Engine cranks, but does not start. NOTE: If engine cranks, cause of problem is UNRELATED to interlock system. Engine wire harness loose. Connect wires. “L” terminal on ignition key switch loose. Connect wire. Engine problem, or no fuel.
General Run and Transport Problems Condition Possible Cause Correction ________________________________________________________________________________________________________________________________________________________ Engine shuts down during transport or when idling (not in Aerate mode). Not electrical - low engine oil pressure, no fuel, etc. Find and correct cause of engine shut down. Oil pressure switch faulty. Test switch and replace if faulty.
General Run and Transport Problems (continued) Condition Possible Cause Correction ________________________________________________________________________________________________________________________________________________________ Machine does not raise (to transport position). Lift/Lower switch faulty. Test switch and replace if faulty. Ignition key switch faulty. Test ignition switch and replace if faulty. Lose or broken wire in lift up circuit.
Aerate Operation Problems Condition Possible Cause Correction ________________________________________________________________________________________________________________________________________________________ Machine continues to aerate (but should not) with traction bail in neutral. See Safety Interlock System Prob lems.
Aerate Operation Problems (continued) Condition Possible Cause Correction ________________________________________________________________________________________________________________________________________________________ Machine does not start aerating when engage button is pushed in (pump belt IS rotating, but gear case drive shaft is NOT rotating). Valve clutch out of adjustment. Check air gap on valve clutch and adjust if necessary. Loose or broken wire in valve clutch / controller circuit.
Safety Interlock System Problems Condition Possible Cause Correction ________________________________________________________________________________________________________________________________________________________ Engine cranks (but should not) with traction bail in neutral. Traction switch 1 faulty. Make sure switch is installed and adjusted properly. Test neutral switch and replace if faulty. Traction switch 1 wiring faulty.
Safety Interlock System Problems (continued) Condition Possible Cause Correction ________________________________________________________________________________________________________________________________________________________ No lights on controller come on when troubleshooting interlock system. Battery is dead or disconnected. Charge battery. Replace battery if it will not hold a charge. Clean and tighten connections. Circuit breaker open. Reset circuit breaker.
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 sche matics, determine which component is at fault. How ever, this section will define given components, and the tests that can be performed on those components, when those parts are disconnected from the electrical system. For accurate resistance and/or continuity checks, elec trically disconnect the component being tested from the circuit.
Clutch Engagement / Electronic Control System Test (Fig. 8) This test can be used to check for proper operation of the electronic control system and clutches without con necting the machine to a water source or operating the machine. B. After clutches are engaged, push red aerate DISENGAGE button. C. Green light should immediately turn OFF and pump clutch should disengage. 1.
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Controller (Fig. 11) The controller senses the condition of various switches, such as the transport switch and aerate start switch and directs power output to allow certain machine functions, such as aerate engage, disengage and timing of those functions. Because of the solid state circuitry built into the control ler, there is no method to test it directly. The controller may be damaged if an attempt is made to test it with an electrical test device, such as a volt-ohm meter.
Wheel Position Switch (Fig. 13) Test the switch by disconnecting the wire connector and installing a continuity tester or ohm meter across the two leads of the switch. 1 Wheel Position Switch Aerate (machine lowered) Transport (machine raised) CLOSED OPEN NOTE: For proper operation, the switch must be screwed all the way in. A damaged pivot shaft or bush ings could cause the switch to not open and close properly. Debris in the switch could also cause it to not open and close properly. Figure 13 1.
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. 1 Terminals 2-3 and 5-6 should have continuity in UP. Terminals 2-1 and 5-4 should have continuity in DOWN. 1 Figure 15 1. Lift switch Linear Actuator (Fig.
Brake Switch (Fig. 17) The brake switch is a normally open (N.O.) switch that closes when the brake is engaged. 1 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 switch should show no continuity. With the brake engaged, the switch should show continuity. Figure 17 1. Brake switch Pressure Gauge/Switch (Fig.
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 con nected and disconnected to terminal 85 with terminal 86 connected to ground.
Pump Clutch (Fig. 21) To test the pump clutch, disconnect the wire connector and connect a continuity tester or ohm meter across the terminals of the clutch wire connector. There should be continuity across the terminals of the clutch connector. Resistance measured through the clutch coil should be approximately 3 ohms. 1 The clutch can also be tested by connecting a 12 VDC battery across the clutch connector terminals. The clutch should engage as 12 VDC is connected to the clutch connector terminals.
Repairs Battery Service (Fig. 24, 25) IMPORTANT: To prevent damage to the electrical components, do not operate the engine with the battery cables disconnected. Electrolyte Specific Gravity Keep the terminals and entire battery case clean. To clean the battery, wash the entire case with a solution of baking soda and water. Rinse with clear water. Do not get the soda solution into the battery because damage to the battery will result.
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 exten sion spring; this will take switch arm tension off of switch. Loosen two (2) screws and remove switch. 3. Have a helper push traction bail down and Install new switch. DO NOT over-tighten screws as the switch case could break. 4. Reconnect wires to new switch.
Controller Replacement (Fig. 27) IMPORTANT: Before welding on the machine, disconnect both battery cables from the battery, disconnect both wire harness plugs from the controller and disconnect the terminal connector from the alternator to prevent damage to the electrical system. 1 1. Stop the engine and disconnect battery cables from battery. 2. Disconnect wiring harness connectors from control ler. 3. Remove two (2) nuts securing controller to frame and remove controller. 4.
Linear Actuator Replacement (Fig. 28) 1. Put wheels in transport position (machine raised). 1 2. Put the machine on a level surface, stop the engine, engage the parking brake and disconnect engine spark plug wires. 3 2 3. Open the hood. 4 4. Disconnect linear actuator wire connector. 5. Disconnect extension springs. 4 6. Remove capscrew and nut securing each end of linear actuator. Figure 28 7. Reverse steps 3 - 6 to install the linear actuator. 1. Linear actuator 2.
Repairs Page 5 - 28 Hydroject 3010
Chapter 6 Water System Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . Nozzle Size and Approximate Depth Chart . . . . . WATER SYSTEM SCHEMATIC . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . Accumulator Charging Valve and Pressure Gauge . . . . . . . . . . . . . . . . . . . . Accumulator Seal Installation Tool . . . . . . . . . . . Accumulator Cap Wrench . . . . . . . . . . . . . . . . . .
Specifications Water Pump Clutch: Electromagnetic, dual groove belt drive for water pump and driveshaft flange brake/clutch for main valve gearbox. Air gap 0.018 in. Pre Filter – Spin down type with washable cartridge in clear plastic housing and plastic ball valve for flushing. Supply Filter – Replaceable 5 micron cartridge in plastic housing with air bleed button. Water Filter Cartridge: Toro part no. 86–8630 Water Pressure Switch – Senses for water pressure after filter.
Depths and Nozzle Configurations: All nozzles are identified with numbers indicating the drill size of the orifice. The standard configuration is 11 nozzles producing depths of 4 to 6 inches depending on turf conditions. Blocked nozzle locations are obtained by reversing the nozzle check valve ball and spring. See nozzle size chart and illustrations below: IMPORTANT: Use only nozzle configurations shown or damage to the machine may occur. NOZZLE SIZE AND APPROXIMATE DEPTH CHART Part No.
Spring Check Valve Ball Check Valve Ball Spring 70 – 80 ft–lb OPEN NOZZLE CLOSED (BLOCKED) NOZZLE Aluminum washer (P/N 86–8150) is required with any nozzle change. Specifications Page 6 – 2.2 Rev.
Water System Schematic ROLLER WASH NOZZLES ACCUMULATOR 2500 PSI NITROGEN PRE–CHARGE WATER VALVE ELECTRIC CLUTCH WATER PUMP RELIEF VALVE 5000 PSI ENGINE ELECTRIC BRAKE CLUTCH GEARBOX CAM PRESSURE SWITCH 20 PSI – ON 10 PSI – OFF ROLLER WASH NOZZLES HIGH PRESSURE AERATION NOZZLES PRESSURE GAUGE SPRAY WASH VALVE FILTER WATER SUPPLY QUICK COUPLER PRE–FILTER PRESSURE REDUCING VALVE Hydroject 3010 Page 6 – 3 Rev.
Special Tools The following special tools are required for servicing the HydroJect 3010. Order special tools from the TORO SPECIAL TOOLS A ND A PP LI CAT IONS GUIDE (COMMERCI AL PRODUCTS). Accumulator Charging Valve and Pressure Gauge - TOR4001 (Fig. 2) The charging valve connects the accumulator to a high pressure (3000-3500 or 6000 PSIG) Nitrogen tank for pre-charging the accumulator.
Accumulator Cap Wrench - TOR4003 (Fig. 4) After discharging accumulator, use this special wrench to remove accumulator cap for accumulator rebuilding. Figure 4 Water System Pressure Gauge - TOR4005 (Fig. 5) The Water System Pressure Gauge and Adapter is temporarily connected into the high pressure water system for measuring water pressure available to the water valve. Figure 5 Flow Meter - TOR4006 (Fig.
Valve Lift Indicator - TOR4007 (Fig. 7) A special dial indicator and adaptor is temporarily installed into the inspection port on the side of the high pressure manifold to measure water valve lift. This indicator is also used to measures cam wear and determines correct shim size to get proper valve lift. Figure 7 Valve Spring Compressor - TOR4008 (Fig. 8) The valve spring compressor and hardware is used for compressing the water valve spring allowing removal and installation of the valve spring retainer.
Seal Installation Tools (Fig. 9) Water Valve Seal Installation Guide - TOR4009 1 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 Installation Guide (large) is needed to properly install the pump displacement rod seal into the pump head. Use Insertion Mandril with this seal guide.
Pump Seal Extraction Tools (Fig. 11) Pump Seal Extraction Tool - TOR4013 Rod used to hydraulically extract pump seals from the pump cylinder head. Use with Pump Seal Outlet Cover and heavy mallet or hammer. Pump Seal Outlet Cover - TOR4014 Cover plate with O-ring used with Seal Extraction Tool to hydraulically extract pump seals from pump head. Figure 11 Pump Wear Sleeve Driver - TOR4015 (Fig. 12) Driver used for removal and installation of plunger guides in pump crankcase.
Troubleshooting The cause of an improperly functioning water system is best diagnosed with the use of proper testing equipment and a thorough understanding of the complete system. The charts that follow contain detailed information to assist in troubleshooting. There may possibly be more than one cause for a machine malfunction. ALL POSSIBLE CAUSES SHOULD BE CHECKED IN THE ORDER IN WHICH THEY ARE LISTED ON THE CHARTS.
Condition Possible Cause Correction __________________________________________________________________________________________ Machine stops aerating (pump shuts down during aeration). Machine not moving. Normal condition of interlock system. Operator must hold engage button in to aerate with traction bail in neutral. Inadequate water supply. Check for kinked water supply hose, restriction in line or partially open valve at water source. Plugged inlet water filter.
Condition Possible Cause Correction ___________________________________________________________________________________________ Machine aerates, but aeration hole depth is shallow or inconsis tent (continued). Low accumulator pre-charge or damaged accumulator - TEST NO. 1. Charge accumulator with dry Ni trogen. Rebuild or replace accu mulator if necessary. Low water system pressure AND flow - TEST NO. 2. Rebuild pump. Low water system pressure (flow is OK) - TEST NO. 2.
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 accumulator.
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 measured and if required, more Nitrogen can be added. Obtain a 3000 - 3500 PSI or 6000 PSI Nitrogen tank from a local compressed gas or welding supply shop.
4. Attach and gently tighten special fitting of Charging Tool (TOR4001) to inlet on top of accumulator. 5. Close outlet valve on right hand side of charging tool to prevent loss of pressurized Nitrogen from accumulator. Close inlet valve on left hand side of charging tool to prevent back flow through the tank tube. 6. Rotate the jam nut (not the fitting) of the accumulator valve two (2) turns counterclockwise as viewed from the top. This opens the valve and pressurizes the tool and gauge.
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. 2. Stop the engine, engage the parking brake and open the hood. WARNING 1 High pressure water system components can cause personal injury if disassembled incorrectly.
6. Install Flow Meter (TOR4006) between water supply hose and hose adapter. Connect hose adapter to quick connector on side of machine. 7. Turn on water supply. Open high pressure bleed valve until all air is out of the system. Close high pressure bleed valve for pump testing. NOTE: Air in system will cause improper test readings. 8. Disconnect hose from relief valve fitting. 9. THIS IS A TWO (2) PERSON OPERATION. Start engine and operate at full speed.
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 rapid cam wear. IMPORTANT: A reading of 0.090 to 0.102 does not guarantee a properly adjusted cam. When in doubt, inspect cam. A worn cam which has been adjusted to 0.090 to 0.102 will not perform properly.
Adjustments Electric Brake Clutch Adjustment (Fig. 26) 1. Park machine on a level surface, stop the engine, engage the parking brake, open the hood and disconnect engine spark plug wires. 2. Adjust air gap to .018" by inserting a thickness gauge into the clutch openings. Evenly tighten the three lock nuts on clutch to reduce the air gap. Failure to maintain the correct air gap could result in clutch not engaging even though it is electrically energized.
5. Remove test cap from manifold feeder and install Valve Lift Indicator (TOR4007) into this opening. Make sure dial indicator contacts top of water valve, then zero out dial indicator. 6. Rotate coupling, moving cam toward cam follower. Continue to rotate until cam follower is on lead-in portion of cam, approximately one inch (slightly less than 1/2 turn of coupler) from cam lobe. If dial indicator shows no lifting of valve, loosen four (4) capscrews holding gear case to valve body.
Repairs Drive Coupling and Clutch Removal and Installation (Fig. 30) 1. Park the machine on a level surface, engage the parking brake, open the hood and disconnect the engine spark plug wires. Remove guard (Item 38). 5. Apply Loctite 271 or 680 to threads of bolt (item 26). Use special washer (Item 27) and install bolt. Remove engine air cleaner feed hose to access teeth of flywheel. Hold flywheel and tighten bolt to a torque of 25 – 30 ft–lb. 2.
Pump Drive Belt Replacement (Fig. 31, 32) 1. Park the machine on a level surface, engage the parking brake, open the hood and disconnect the engine spark plug wires. 1 2. Remove the drive coupling (see Drive Coupling Removal and Installation). 3. Disconnect electrical connectors for both clutches. 4. Remove clutch stops (Fig. 30, Item 5) and clutch retainer bracket (Fig. 30, Item 39). 5.
Water Filter Replacement (Fig. 33, 34) When pump inlet pressure decreases or the water system 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 the water system. 1. Put the machine on a level surface, engage the parking brake, stop the engine and disconnect the engine spark plug wires. 2.
Water Pump Removal and Installation (Fig. 35) 3. Remove lower plug and let oil drain out of pump crankcase into a container. Install drain plug. 1. Park machine on a level surface, stop the engine, engage the parking brake, open the hood and disconnect the engine spark plug wires. 4. Remove drive belt from driven pulley. 5. Remove four (4) water valve inlet bolts (Inset Item 16). Remove two (2) nuts (Item 16), from studs securing pump head (Item 2) to frame.
Water Pump Head Service (Fig. 36) Pump Head Removal The three major wear components in the high pressure pump that require maintenance include: the check valves, plunger sleeves, and plunger seals. These components will require maintenance after approx. 500 pump operating hours (approx 750 engine hours). 1. Remove pump from machine (see Water Pump Removal and Installation). 2. Remove eight (8) nuts (Item 17). Carefully move pump head (Item 11) away from pump crankcase.
Plunger Seal Replacement (See illustration on previous page) Plunger Sleeve Replacement (see Figure 38 on next page) NOTE: Check valves must be in good condition for this procedure to work correctly. The plunger sleeves are installed on, and sealed to stainless steel plunger rods. This assembly is inserted through a special high pressure seal in the pump head. During pump servicing, a complete repair kit should be installed. 1.
Water Pump Crankcase Service (Fig. 38) 1 10 2 18 – 20 ft–lb 3 4 9 5 6 7 8 29 11 28 12 13 Apply grease to O.D. of plunger before installing pump head 15 16 14 17 18 19 24 25 20 7 10 22 27 8 21 26 14 18 – 20 ft–lb 13 23 18 – 20 ft–lb 22 10 Figure 38 NOTE: Replace parts in complete sets. 1. Remove water pump from machine (see Water Pump Removal and Installation). 9. Install new seal (Item 11) and O–rings (Item 7) and install crank rod, bearings and caps into crankcase. 2.
Crankcase Bearing Installation and Shimming (Model 09801) Crankshaft end play from dial indicator Shim thickness removed to get .006 + .001 .010 .016 .009 .015 ,008 .014 3. Install one yellow (.020) shim and one pink (.015) shim onto input shaft bearing housing if required. .007 .014 .006 .012 4. Install three yellow (.020), three blue (.005) and two red (.002) shims onto the end cap bearing housing. .005 .012 .004 .010 5.
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Water Valve Service (Fig. 39, 40) The water valve controls the release of high pressure water. The water valve is opened when a cam contacts and moves a roller follower. The follower moves the valve stem against spring pressure, which opens the water valve. After discharge, the valve spring closes the water valve, diverting pump flow into the accumulator for storage. The valve stem is installed completely through the water valve body and guided through a replaceable bushing and two sealing assemblies.
11. Inspect sealing surfaces of valve spool and valve seat. If surfaces appear worn, replace or regrind. Both angles are 30 degrees. 13. Remove seal assembly (Items 25–30) by pressing a socket wrench through the casting. Discard all seal components. 12. Remove and inspect sleeve (Item 7) and remove backup (Item 6) and O–ring seals (Item 5). 14. Remove snap ring (Item 21) from gear box pilot (Item18).
13. Install valve spring studs through Valve Spring Compressor (TOR4008) and into threaded holes of water valve. Put spring retainer (Item 15) over spring and under spring compressor. Tighten nuts to compress spring, and install and retaining ring (Item14). Remove special tool. 9. Hold spool and seat in place so O–ring does not fall out 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.
Gear Case Service (Fig. 41) you inspect the cam and not the weight block, when checking for wear. DO NOT INSTALL TWO CAMS ONTO THE GEAR. The gear case is a pinion and gear reduction drive that actuates the water valve. The pinion (Item 12) is connected 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 injection at 5.3 cycles per second (at 320 RPM).
Nozzle Service and Replacement NOTE: See Specifications section of this chapter for more information. sionally inspect the springs especially if one nozzle leaks water after the machine is shut down. 1. Park machine on a level surface, stop the engine, engage the parking brake, open the hood and disconnect the spark plug wires from the engine. 4. For normal operation, install nozzle springs with the narrow spiral pointing up and the check ball on top of the spring.
Accumulator Replacement (Fig. 43) 1. Stop the engine, engage the parking brake, open the hood and disconnect the engine spark plug wires. 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 EXPLOSION AND DEATH. Charging requires special tools and precautions. Charge accumulators in a well ventilated area.
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Accumulator Service (Fig. 44, 45, 46) The accumulator piston seals will wear over a period of time. As seals wear, the accumulator will require more frequent recharging and eventually, it will not hold gas. 1. Park machine on a level surface, stop the engine, engage the parking brake and open the hood. 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 EXPLOSION AND DEATH.
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 accumulator cylinder (Item 6) stationary using a strap or chain wrench and remove the top cap (Item 12) and bottom cap (Item 9) of the accumulator. 11. Use a brass or aluminum shaft to force the piston (Item 8) out of top side of accumulator and discard the piston. 17.
General Information Storage 2. Remove and discard the oil filter. Install a new filter. It is very important that the water system be drained to avoid freezing and damaging the components. Drain system as follows: 3. Refill the engine with 3 qts. of recommended SAE 30 wt. motor oil. 1. Stop engine, remove key from ignition switch and remove wires from spark plugs. 4. Start the engine and run at idle speed for two minutes. DO NOT RUN LONGER THAN TWO MINUTES. 2.
Chapter 7 Wheels, Brakes and Steering Table of Contents ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 2 Hydroject 3010 REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Brake Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Wheel Bearing Service . . . . . . . . . . . . . . . . . . . .
Adjustments Brake Adjustment (Fig. 1) 1. Park machine on a level surface and stop the engine. 2. Remove screws securing cover to under side of tiller handle. Remove cover. 1 3. Loosen upper jam nut securing brake cable to bracket. 4. Tighten lower jam nut until 25 to 30 pounds of force are required to actuate brake lever. Tighten jam nut. 5. Install lower cover. Figure 1 1.
Repairs Brake Service (Fig. 2) 3 2 1 4 9 10 5 8 6 11 7 12 37 13 36 14 15 16 35 17 18 19 34 32 31 30 20 Torque to 250 to 400 ft-lb. 21 33 29 28 27 17 26 25 24 23 22 Figure 2 1. Park machine on a level surface, stop the engine and engage the parking brake. Open the hood and disconnect engine spark plug wires. Lift drive wheel off the ground using a jack. Block front and rear of other wheels. 2. Remove wheel nuts (Item 23) and remove wheel. Remove spindle nut (Item 22) from wheel hub.
Wheel Bearing Service (Fig. 3) 1. Park machine on a level surface and raise wheels to aerate position. Engage parking brake, open hood and disconnect engine spark plug wires. 22 23 2. Remove dust cap (Item 28) from end of wheel spindle. 3. Remove cotter pin (Item 27), slotted nut (Item 29) and washer (Item 30). Slide wheel and hub off of spindle shaft. 24 25 26 35 27 34 4. Pull seal (Item 34) out of wheel hub (Item 23). 32 5. Remove bearings (Item 32) from both sides of wheel hub.
Chapter 8 Electrical Diagrams Table of Contents 3 4 5 6 7 8 Electrical Diagrams Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Harness Drawing . . . . . . . . . . . . . . . . . . . . . . . . . Main Harness Wiring Diagram . . . . . . . . . . . . . . . . . . Control Panel Harness Drawing . . . . . . . . . . . . . . . . . Control Panel Wiring Diagram . . . . . . . . . . . . . . . . . . . Tiller Harness Drawing and Wiring Diagram . . . . . . .
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Hydroject 3010 Electrical Schematic Page 8 – 3
Hydroject 3010 Main Harness Page 8 – 4
Hydroject 3010 Main Wiring Diagram Page 8 – 5
Hydroject 3010 Control Panel Harness Page 8 – 6
Hydroject 3010 Tiller Wire Harness and Diagram Page 8 – 7