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Toro Hydroject 3010 Service Manual

High-velocity water injection system
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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.
This safety symbol means DANGER,
WARNING, or CAUTION, PERSONAL SAFETY
INSTRUCTION. When you see this symbol,
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
Part No. 04134SL (Rev. B)
Service Manual
Hydroject
3010
®

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  • Page 1 Bloomington, MN 55420 IMPORTANT: The IMPORTANT notice will give im- The Toro Company reserves the right to change product portant instructions which must be followed to pre - specifications or this publication without notice. vent damage to systems or components on the machine.
  • Page 2 Hydroject 3010...

  • Page 3: Table Of Contents

    Control Panel Wiring Diagram ....8 - 7 Tiller Harness and Wiring Diagram ... . 8 - 8 Hydroject 3010...
  • Page 4 Hydroject 3000/4000...

  • Page 5: Safety Instructions

    Model and Serial Numbers to: 5. Remove all debris or other objects that might inter- The Toro Company fere with operation. Keep all bystanders away from the 8111 Lyndale Avenue South work area.
  • Page 6 26. Make sure all hydraulic line connectors are tight, and all hydraulic hoses and lines are in good condition be- fore applying pressure to the system. Safety Hydroject 3010 Page 1 – 2...
  • Page 7 If major repairs are ever needed tor servicing can cause dismemberment or death. Do or assistance is desired, contact an Authorized Toro Dis- not attempt to disassemble a accumulator, have this tributor. To ensure optimum performance and safety, al- work done by a Authorized Toro Distributor.

  • Page 8: Safety And Instruction Decals

    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 Distributor. Safety Hydroject 3010 Page 1 – 4...

  • Page 9: Product Records

    Maintenance Maintenance procedures and recommended service in- tervals for the Hydroject 3010 covered in the Operator’s Manual. Refer to that publication when performing regu- lar equipment maintenance. Refer to the Engine Opera- tor’s Manual for additional engine specific maintenance procedures.

  • Page 10: Equivalents And Conversions

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

  • Page 11: Torque Specifications

    For critical applications, as determined reduced by 25% for lubricated fasteners to achieve by Toro, either the recommended torque or a torque that the similar stress as a dry fastener. Torque values may is unique to the application is clearly identified and spe- also have to be reduced when the fastener is threaded cified in this Service Manual.
  • Page 12 The specific torque value should be determined based on the fastener size, the aluminum or base material strength, length of thread engagement, etc. Product Records and Maintenance Hydroject 3010 Page 2 – 4...
  • Page 13 The specific torque value should be determined based on the fastener size, the aluminum or base material strength, length of thread engagement, etc. Hydroject 3010 Product Records and Maintenance Page 2 – 5...
  • Page 14 All torque values are based on non–lubricated fasteners. Conversion Factors in–lb X 11.2985 = N–cm N–cm X 0.08851 = in–lb ft–lb X 1.3558 = N–m N–m X 0.7376 = ft–lb Product Records and Maintenance Hydroject 3010 Page 2 – 6...
  • Page 15 &KDSWHU .RKOHU(QJLQH 7DEOHRI&RQWHQWV ,1752'8&7,21   63(&,),&$7,216  6(59,&($1'5(3$,56   (QJLQH5HPRYDODQG,QVWDOODWLRQ   .2+/(5(1*,1(6(59,&(0$18$/ +\GURMHFW 3DJH² .RKOHU(QJLQH...
  • Page 16 ,QWURGXFWLRQ 7KLV&KDSWHUJLYHVLQIRUPDWLRQDERXWVSHFLILFDWLRQVDQG 0RVWUHSDLUVDQGDGMXVWPHQWVUHTXLUHWRROVZKLFKDUH UHSDLURIWKH.RKOHUHQJLQHXVHGLQWKH3UR&RUH FRPPRQO\ DYDLODEOH LQ PDQ\ VHUYLFH VKRSV 6SHFLDO WRROVDUHGHVFULEHGLQWKH.RKOHU(QJLQH6HUYLFH0DQX *HQHUDOHQJLQHPDLQWHQDQFHSURFHGXUHVDUHGHVFULEHG DO7KHXVHRIVRPHVSHFLDOL]HGWHVWHTXLSPHQWLVH[ LQ\RXU2SHUDWRU·V0DQXDO,QIRUPDWLRQRQHQJLQHWURX SODLQHG+RZHYHUWKHFRVWRIWKHWHVWHTXLSPHQWDQGWKH EOHVKRRWLQJ WHVWLQJ GLVDVVHPEO\ DQG UHDVVHPEO\ LV VSHFLDOL]HGQDWXUHRIVRPHUHSDLUVPD\GLFWDWHWKDWWKH LGHQWLILHGLQWKH.RKOHU(QJLQH6HUYLFH0DQXDOWKDWLVLQ ZRUNEHGRQHDWDQHQJLQHUHSDLUIDFLOLW\ FOXGHGDWWKHHQGRIWKLVVHFWLRQ 6HUYLFHDQGUHSDLUSDUWVIRU.RKOHUHQJLQHVDUHVXSSOLHG WKURXJK\RXUORFDO.RKOHUGHDOHURUGLVWULEXWRU .RKOHU(QJLQH +\GURMHFW 3DJH²...
  • Page 17 6SHFLILFDWLRQV ,WHP 'HVFULSWLRQ 0DNH'HVLJQDWLRQ .RKOHU&RPPDQG3UR&DUE²VWURNH9²7ZLQ $LU&RROHG2+9 1XPEHURI&\OLQGHUV %RUH[6WURNH µ[µ PP[PP 7RWDO'LVSODFHPHQW &XELF,QFKHV FF &RPSUHVVLRQ5DWLR  'U\:HLJKW DSSUR[LPDWH 3RXQGV .LORJUDPV )XHO 8QOHDGHG5HJXODU*DVROLQH 0LQLPXP2FWDQH )XHO7DQN&DSDFLW\ 86*DOORQV /LWHUV *RYHUQRU 0HFKDQLFDO ,GOH6SHHG QRORDG ²530 +LJK,GOH QRORDG ²530 (QJLQH2LO 6HH2SHUDWRU·V0DQXDO 2LO3XPS *HDUGULYHQWURFKRLGW\SH &UDQNFDVH2LO&DSDFLW\ 864XDUW /LWHUV ZLWKILOWHU 6WDUWHU 9'& +\GURMHFW 3DJH² .RKOHU(QJLQH...
  • Page 18 6HUYLFHDQG5HSDLUV (QJLQH5HPRYDODQG,QVWDOODWLRQ 3DUNWKHPDFKLQHRQDOHYHOVXUIDFHHQJDJHWKHSDUN  $WWDFK DQ HQJLQH OLIWLQJ FKDLQ WR WKH HQJLQH OLIWLQJ LQJEUDNHDQGUHPRYHWKHKRRG VWUDSV&RQQHFWWKHFKDLQWRDKRLVWRUEORFNDQGWDFNOH DQGUHPRYHVODFNIURPWKHFKDLQDQGOLIWLQJGHYLFH2QH  'LVFRQQHFW ERWK WKH SRVLWLYH   DQG QHJDWLYH ²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

  • Page 19: Repairs

    Wheel Motor Repair..... . 23 Traction Cable Adjustment ....11 Hydroject 3010 Page 4 - 1...

  • Page 20: Specifications

    25 to 70 PSI psi at 3500 RPM Oil filter 25 micron screw-on type. No by-pass ________________________________________________________________________________________________________________________________________________________ Wheel Motor Orbit rotor type ________________________________________________________________________________________________________________________________________________________ Hydraulic Oil See Operator’s Manual ________________________________________________________________________________________________________________________________________________________ Reservoir (gear case) Approximately 4 - 5 quarts Specifications Page 4 - 2 Hydroject 3010...

  • Page 21: General Information

    6 (3/8 in.) .75 r .25 8 (1/2 in.) Finger Tight After Proper Tightening 10 (5/8 in.) 1.00 r .25 r .25 12 (3/4 in.) 16 (1 in.) .75 r .25 Figure 3 Hydroject 3010 Page 4 - 3 General Information...
  • Page 22 6 (3/8 in.) 1.50 r .25 1.50 r .25 8 (1/2 in.) 10 (5/8 in.) 1.50 r .25 Figure 6 12 (3/4 in.) 1.50 r .25 1.50 r .25 16 (1 in.) General Information Page 4 - 4 Hydroject 3010...

  • Page 23: Pushing Or Towing

    Tighten the by-pass valve to a torque of 7 to 10 ft-lb. IMPORTANT: Operating the machine with the by - pass valve open will cause improper operation and overheating of the hydraulic system. Hydroject 3010 Page 4 - 5 General Information...

  • Page 24: Hydraulic Diagram

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

  • Page 25: Special Tools

    You must have o-ring face seal (ORFS) adapter fittings 4. HIGH PRESSURE GAUGE: High range gauge to for this tester to use it on the HydroJect 3010. accommodate pressure beyond the capacity of the low pressure gauge, 0 - 5000.

  • Page 26: Troubleshooting

    Inspect charge relief valve and replace if faulty. Inspect charge pump and replace if faulty. ________________________________________________________________________________________________________________________________________________________ Low traction pump flow/pressure - Test B. Repair or replace pump. ________________________________________________________________________________________________________________________________________________________ Low traction motor efficiency - Test C. Repair or replace traction motor. Troubleshooting Page 4 - 8 Hydroject 3010...

  • Page 27: Testing

    - age. If fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type of injury or gan - grene may result. Hydroject 3010 Page 4 - 9 Testing...

  • Page 28: Hydraulic Tests

    (up or down) to full speed position so flow is from the pump, through the tester, then to the Figure 11 wheel motor. Slowly close flow control valve until you get readings of 7 GPM and 500 PSI. Testing Page 4 - 10 Hydroject 3010...

  • Page 29: Adjustments

    (Items 11, 23) are located vertically in line with pivot pin (Item 22). 2. Adjust speed control cable (Item 26) so speed stop lever (Item 9) can move to horizontal position. Figure 13 Hydroject 3010 Page 4 - 11 Adjustments...

  • Page 30: Transmission Neutral Adjustment

    1. Speed control lever 9. Move traction handle DOWN to full speed position. 2. Lower speed rod 3. Upper speed rod 10. Adjust UPPER speed rod until traction wheel rotates at 20-22 RPM. Tighten jam nuts. Adjustments Page 4 - 12 Hydroject 3010...
  • Page 31 E. Tighten pivot nut. Tighten three (3) capscrews securing pulley guard bracket. Figure 17 1. Adjusting nut 2. Pivot nut Hydroject 3010 Page 4 - 13 Adjustments...

  • Page 32: Pump Drive Belt Adjustment

    8. Push pump towards inside of machine to loosen belt tension and remove the belt. 9. Reverse steps 2 - 8 to install new belt. 10. Adjust belt tension (see Traction Pump Belt Adjustment). Figure 19 1. Adjusting nut 2. Pivot nut Repairs Page 4 - 14 Hydroject 3010...

  • Page 33: Hydraulic Pump Removal And Installation

    6. Disconnect hydraulic lines from fittings on pump. Put caps on open lines and fittings to prevent contamination. 13. Reverse steps 2 - 12 to install pump. Put labels on hydraulic lines for proper reinstallation. 16 17 28 29 Figure 20 Hydroject 3010 Page 4 - 15 Repairs...

  • Page 34: Pump Shaft Seal Replacement

    6. Slide seal over shaft and press it into housing bore. Be careful not to damage the seal. 7. Install seal retaining ring into housing (input shaft seal only). Repairs Page 4 - 16 Hydroject 3010...

  • Page 35: Pump Charge Check Valve Service

    3. Reinstall bypass valve into end cap. Tighten to a torque of 7 to 10 ft-lb. Figure 23 1. Bypass valve 2. Back-up ring 3. O-ring 4. Pump end cap Hydroject 3010 Page 4 - 17 Repairs...

  • Page 36: Charge Pump Service

    All gasket sealing surfaces cals. Protect all sealing surfaces and open cavities from must be cleaned before installing new gaskets. damage and foreign material. Repairs Page 4 - 18 Hydroject 3010...
  • Page 37 (Item 15) from housing. face, or bearing. After seal is removed it cannot be used again. 5. Remove cylinder block kit (Item 7) from shaft (Item 19). 13. Remove bearing spacer washer (Item 22). Hydroject 3010 Page 4 - 19 Repairs...
  • Page 38 NOTE: The position of the bearing in the housing deter­ mines control shaft end play. Do not press bearing deeper into housing at this time. Repairs Page 4 - 20 Hydroject 3010...
  • Page 39 Be careful to prevent damage to end cap and shaft and press it into housing bore. Be careful not to cylinder block sealing surfaces. damage seal. Install seal flush to bottomed in bore. 9 10 Figure 26 Hydroject 3010 Page 4 - 21 Repairs...

  • Page 40: Wheel Motor Removal And Installation

    IMPORTANT: To prevent damage to wheel motor, (Item 22) to 250 - 400 ft-lb. DO NOT hit wheel hub with a hammer during re- moval or installation. Repairs Page 4 - 22 Hydroject 3010...
  • Page 41 Be sure snap ring is completely tion. However, if the shaft has any pitting or deep seated in groove. Hydroject 3010 Page 4 - 23 Repairs...

  • Page 42: Wheel Motor Repair

    4. Mount body with pilot and bearing facing down in a 6. Remove the two check balls (Item 6). vise or other holding fixture. 5. Put rotary valve (Item 7) on shaft spline with “T” shaped slots on first. Repairs Page 4 - 24 Hydroject 3010...
  • Page 43 (Item 5) onto body with check ball holes facing down­ short running period may be required. ward over balls. Align the eight bolt holes in locating ring with eight holes in body. The holes align in only one position. Hydroject 3010 Page 4 - 25 Repairs...
  • Page 44 Repairs Page 4 - 26 Hydroject 3010...
  • Page 45 Wheel Position Switch....19 Aerator Engage and Disengage Switches ..19 Hydroject 3010 Page 5 - 1 Table of Contents...

  • Page 46: Wiring Schematics And Diagrams

    1. Pump clutch disengages and green light goes off immediately when stop (disengage) switch is pushed in (opens) or if pump start limit switch or water pressure switch opens (yellow light goes off). 2. After another 3 seconds, valve clutch will disengage. Wiring Schematics and Diagrams Page 5 - 2 Hydroject 3010...

  • Page 47: Controller Lights

    (water pressure of more than 30 psi) and accumulator charge pressure switch closed (nitrogen pressure more than 1800 psi). 1. Red Light 2. Green Light 3. Yellow Light Hydroject 3010 Page 5 - 3 Wiring Schematics and Diagrams...
  • Page 48 Electrical Schematic and Wiring Diagrams See Chapter 8 - Electrical Diagrams. Wiring Schematics and Diagrams Page 5 - 4 Hydroject 3010...

  • Page 49: Special Tools

    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.
  • Page 50 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. (.24 L) can Figure 7 Special Tools Page 5 - 6 Hydroject 3010...

  • Page 51: Troubleshooting

    Starter solenoid faulty. Test starter solenoid and replace if faulty. Starter is faulty. Test starter and repair replace if faulty. Engine is seized. Repair engine. Loose or damaged wiring. Check connections. Repair wiring. Hydroject 3010 Page 5 - 7 Troubleshooting...
  • Page 52 Start relay faulty. Test start relay and replace if nec ­ essary. Starter solenoid faulty. Test starter solenoid and replace if necessary. Starter failed (mechanical). Test starter and replace if neces ­ sary. Troubleshooting Page 5 - 8 Hydroject 3010...

  • Page 53: General Run And Transport Problems

    Test ignition switch and replace if faulty. Loose or broken wire in lift down Check all wiring and connections circuit. and repair as necessary. Linear actuator faulty. Test actuator and repair or re ­ place if faulty. Hydroject 3010 Page 5 - 9 Troubleshooting...
  • Page 54 Test ignition switch and replace if faulty. Lose or broken wire in lift up circuit. Check all wiring and connections and repair as necessary. Linear actuator faulty. Test actuator and repair or re ­ place if faulty. Troubleshooting Page 5 - 10 Hydroject 3010...

  • Page 55: Aerate Operation Problems

    Test switch and replace if faulty. faulty. Wheel position switch faulty. Make sure switch is installed properly. Test switch and replace if faulty. Aerator start (engage) switch faulty. Test switch and replace if faulty. Controller faulty. Replace controller. Hydroject 3010 Page 5 - 11 Troubleshooting...
  • Page 56 / controller circuit. and repair as necessary. Also see possible causes in (Water pump clutch does not engage) and (Water pump clutch engages, but water valve clutch does not en ­ gage.) Troubleshooting Page 5 - 12 Hydroject 3010...

  • Page 57: Safety Interlock System Problems

    (should be OFF) with machine place if faulty. port position. raised in transport position. Check for short in wheel position switch connections and wiring and repair as necessary. Controller faulty. Replace controller. Hydroject 3010 Page 5 - 13 Troubleshooting...
  • Page 58 Controller faulty. Replace controller. ________________________________________________________________________________________________________________________________________________________ Green light on controller glows Normal condition. faintly when only red light should be on (traction bail out of neutral and aerate engage switch re­ leased). Troubleshooting Page 5 - 14 Hydroject 3010...

  • Page 59: Testing

    If engine cranks there is a malfunction in the rected. interlock system that must be corrected. If engine does not crank, go to step 3. Hydroject 3010 Page 5 - 15 Testing...

  • Page 60: Clutch Engagement / Electronic Control System Test

    C. After another 3 seconds, valve clutch should disengage. 6. DISENGAGE test: A. Move traction bail out of neutral and push green aerate ENGAGE button. Figure 8B 1. Red light 2. Green light 3. Yellow light Testing Page 5 - 16 Hydroject 3010...
  • Page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

  • Page 62: Controller

    1 and no continuity across the terminals of the traction switch 2. (See Trac­ tion Switch 1 and 2 Replacement and Adjustment in the Repairs section of this chapter for replacement and adjustment procedures.) Testing Page 5 - 18 Hydroject 3010...

  • Page 63: Wheel Position Switch

    Figure 14 1. Aeration start (engage) switch (pink & orange wires) 2. Aeration stop (disengage) switch (gray & white wires) Hydroject 3010 Page 5 - 19 Testing...

  • Page 64: Lift Switch

    Linear Actuator Specifications Rod end play 0.070 max. Current draw 26 amps max. Voltage 12 VDC Speed 3/4 in. per second at maximum load Testing Page 5 - 20 Hydroject 3010...

  • Page 65: Brake Switch

    1. High pressure limit switch 2. Accumulator charge switch releasing pressurized gas from the accumu- lator (see Accumulator Service in Chapter 6 - Water System). Hydroject 3010 Page 5 - 21 Testing...

  • Page 66: Relays

    DC is applied to terminals 85 and 86 Figure 19 Figure 20 Battery Use a hydrometer to test the battery. Charge the battery if necessary (see Battery Service). Electrolyte Specific Gravity Fully charged: 1.250 - 1.280 Discharged: less than 1.240 Testing Page 5 - 22 Hydroject 3010...

  • Page 67: Pump Clutch

    To test the fusible link, check for continuity between terminals J22 and J23 of the control panel wiring harness (see Schematic and Control Panel Wir­ ing Harness in Chapter 8 - Electrical Diagrams). Figure 23 1. Circuit breaker Hydroject 3010 Page 5 - 23 Testing...

  • Page 68: Repairs

    Nausea may result if the gases are inhaled. Unplug the charger from the electrical outlet before connecting or disconnecting the charger leads from the bat- tery posts. Figure 25 Repairs Page 5 - 24 Hydroject 3010...

  • Page 69: Traction Switch 1 And 2 Replacement And Adjustment

    5. Coat switch terminals and wires with skin-over grease. 6. Loosen two (2) screws and adjust switch tab so switches are actuated, but not bottomed out, when pump control is in neutral. Hydroject 3010 Page 5 - 25 Repairs...

  • Page 70: Controller Replacement

    3. Remove two (2) nuts securing controller to frame and remove controller. Figure 27 4. Install new controller and secure to frame with nuts 1. Controller removed in step 3. 5. Connect wiring harness connectors to controller. 6. Connect battery cables. Repairs Page 5 - 26 Hydroject 3010...

  • Page 71: Linear Actuator Replacement

    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 3. Extension spring 2. Wire connector 4. Capscrew & nut Hydroject 3010 Page 5 - 27 Repairs...
  • Page 72 Repairs Page 5 - 28 Hydroject 3010...
  • Page 73 GENERAL INFORMATION ....38 Cold Weather Storage ....38 HydroJect 3010 Page 6 - 1...

  • Page 74: Specifications

    7–13 PSI. 5000 + 300 PSI relief valve pressure. Pump – Toro exclusive design with cast stainless steel Manifold and Nozzles – Extruded stainless steel man- head and 3 piston plungers. Vee packing seals and Ke- ifold with11 flanged nozzle extensions containing check vlar guides.

  • Page 75: Nozzle Size And Approximate Depth Chart

    .0810 2.057 6–8” Aluminum Washer is required with any nozzle change: (S/N 29999 & Below) Part no. 80–6680 Part no. 86–8150 **Additional nozzles may be blocked to compensate for pump wear. Hydroject 3010 Specifications Page 6 – 2.1 Rev. B...

  • Page 76: Specifications

    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 Hydroject 3010 Page 6 – 2.2 Rev. B...

  • Page 77: Water System Schematic

    ROLLER WASH SWITCH NOZZLES 20 PSI – ON 10 PSI – OFF HIGH PRESSURE AERATION NOZZLES PRESSURE GAUGE SPRAY WASH VALVE FILTER WATER SUPPLY QUICK COUPLER PRE–FILTER PRESSURE REDUCING VALVE Hydroject 3010 Water System Schematic Page 6 – 3 Rev. B...

  • Page 78: Special Tools

    Special Tools The following special tools are required for servicing the Order special tools from the TORO SPECIAL TOOLS HydroJect 3010. A ND A PP LI CAT IONS GUIDE (COMMERCI AL PRODUCTS) . Accumulator Charging Valve and Pressure Gauge - TOR4001 (Fig. 2)

  • Page 79: Accumulator Cap Wrench

    This gauge used in conjunction with the pressure gauge on the machine can be used to measure pressure drop across the filter to show filter condition. Figure 6 HydroJect 3010 Page 6 - 5 Special Tools...

  • Page 80: Valve Lift Indicator

    The spring retainer must be remove before servicing the water valve, water valve seals, and water valve seat. Figure 8 Special Tools Page 6 - 6 HydroJect 3010...

  • Page 81: Water Valve Seal Installation Guide

    1. Water Valve Seal Installation Guide 2. Pump Seal Installation Guide 3. Seal Installation Mandril Filter Body Wrench - TOR4012 (Fig. 10) Special spanner wrench use for servicing the inlet water filter. Figure 10 HydroJect 3010 Page 6 - 7 Special Tools...

  • Page 82: Pump Seal Extraction Tool

    Figure 11 Pump Wear Sleeve Driver - TOR4015 (Fig. 12) Driver used for removal and installation of plunger guides in pump crankcase. Figure 12 Special Tools Page 6 - 8 HydroJect 3010...

  • Page 83: Troubleshooting

    Repeat procedure if noise continues. Damaged component. Check for damaged components and repair or replace as neces- sary. HydroJect 3010 Page 6 - 9 Troubleshooting...
  • Page 84 Excess ve water exit- ing from shim area below gear- case indicates valve wear or damage. Do water system tests and make repairs as necessary. Troubleshooting Page 6 - 10 HydroJect 3010...
  • Page 85 Check for contaminated fuel, plugged fuel filter or fuel line, plugged air cleaner, bad spark plug. (see Chapter 3 - Engine). Jammed or siezed pump or gear- Inspect components and repair case. as necessary. Hydroject 3010 Page 6 - 11 Troubleshooting...

  • Page 86: Testing

    Replacement). Nozzles that are too large will cause loss in pressure and could cause damage to the accumulator and other water system components. NOTE: You can check for plugged nozzles by aerating over a piece of cardboard, then inspecting cardboard. Testing Page 6 - 12 HydroJect 3010...

  • Page 87: Test No. 1: Accumulator Pre-Charge Pressure

    Charge ac - cumulators in a well ventilated area. It is Figure 15 recommended that the accumulator checked and charged by an Authorized TORO 1. Protective cover 2. Valve cap Distributor. Wear eye protection. Keep hands and face away from gas valve.
  • Page 88 Reinstall yellow protective cap and valve protector bracket. NOTE: After completion, install a tag on accumulator indentifying the charging pressure and charging date. 14. Do Test No. 2: Water Pump Pressure and Flow. Testing Page 6 - 14 Rev. A HydroJect 3010...

  • Page 89: Test No. 2: Water System Pressure And Flow

    Figure 19 1. Water system pressure gauge (TOR4005) 5. Disconnect wire harness connection for water valve clutch to prevent the water valve from operating during the test. Figure 20 1. Water valve clutch HydroJect 3010 Page 6 - 15 Testing...
  • Page 90 12. After testing is completed, open high pressure bleed valve, then remove water system pressure gauge. Reinstall plug in open port of water valve housing. Connect relief valve hose. Remove flow meter. Testing Page 6 - 16 HydroJect 3010 Rev. A...

  • Page 91: Test No. 3: Water Valve Lift

    TEST NO. 3: Water Valve Lift (Fig. 24, 25) If valve lift is too high the valve may not seat correctly. IMPORTANT: A reading of 0.090 to 0.102 does not If valve lift is too small, the pulses may not release guarantee a properly adjusted cam.

  • Page 92: Adjustments

    If the ridge is deep enough to catch a fingernail, replace the cam lobe. Do not measure valve lift using a worn cam lobe. Rotate cam to make sure cam lobe is not contacting follower. Adjustments Page 6 - 18 HydroJect 3010...
  • Page 93 1. Valve lift indicator (TOR4007) Water (4000 - 5000 PSI operating pressure) Gear case Water valve housing Shims Cam lobe Cam follower (on lead-in portion of cam) Shims Figure 29 HydroJect 3010 Page 6 - 19 Adjustments...

  • Page 94: Repairs

    25 – 30 ft–lb 18 19 Never–seez Never–seez 5 6 7 on engine shaft Loctite 271 or 680 25 – 30 ft–lb Clutch bumper gap 0.19 – 0.25 in. Figure 30 Repairs Hydroject 3010 Page 6 – 20 Rev. B...

  • Page 95: Pump Drive Belt Replacement

    7. Reverse steps 2 - 6 to install the belt. Adjust hydraulic pump belt tension (see Pump Drive Belt Adjustment in Chapter 4 - Hydraulic System). Figure 32 1. Hydraulic pump belt HydroJect 3010 Page 6 - 21 Repairs...

  • Page 96: Water Filter Replacement

    NOTE: The quality and micron rating of this filter is very 1. Filter body important. Do not use any substitutes. This filter has a 2. Filter 5 micron rating. For easier filter removal, use Filter 3. Filter head Wrench (TOR4012). 4. Bleed button Repairs Page 6 - 22 HydroJect 3010...

  • Page 97: Water Pump Removal And Installation

    30 oz. of Mobil DTE Extra 2. Slowly open the high pressure bleed valve allowing Heavy hydraulic oil or equivalent. any pressurized water to escape. Torque to 25 - 33 ft-lb. (Eight locations) Figure 35 HydroJect 3010 Page 6 - 23 Repairs...

  • Page 98: Water Pump Head Service

    If the seal does not move after a few attempts, try using Use Loctite 242 or equivalent heavy oil or grease nstead of water. Torque to 205 - 235 ft-lb. (Six locations) Figure 36 Repairs Page 6 - 24 HydroJect 3010...
  • Page 99 (Item1) into seal retainer (Item 2). Install seal retainer into pump head cavity. Use a soft face (plastic) hammer Figure 37 or arbor press to completely insert backup ring into pump head. Hydroject 3010 Repairs Page 6 – 25 Rev. B...

  • Page 100: Water Pump Crankcase Service

    Check for wear on plunger (12) and plunger guides (Item 28). If plunger guides are worn, use Wear Sleeve Tool (TOR4015) to drive guides out through crankcase. Also use this tool for plunger guide installation. Repairs Page 6 – 26 Rev. B Hydroject 3010...
  • Page 101 7. Measure the crankshaft end play and remove shims from end cap as required to get .006 + .001 INTERFER- ENCE FIT (see chart). 8. Tighten fasteners (Item 10) to a torque of 18 – 20 ft–lb. Repairs Hydroject 3010 Page 6 – 27 Rev. B...
  • Page 102 This page is intentionally blank. Repairs Page 6 - 28 HydroJect 3010...

  • Page 103: Water Valve Service

    Valve seat (Item 2) will come out with the valve. will leak out between shims. If low pressure water seal and oil seal fail water will leak into the gear case. Hydroject 3010 Repairs Page 6 – 29 Rev. B...
  • Page 104 8. Insert valve spool (Item1) through valve seat (Item 2) 4. Install black back–up ring (Item 30) into valve cavity, and install O–ring (Item 3) on inboard side of valve seat. flat side first. Repairs Hydroject 3010 Page 6 – 30 Rev. B...
  • Page 105 Holes in pilot allow only one method of installation. feeder manifold installation (Fig. 29). Tighten screws (Item13) to a torque of 14 – 18 ft–lb. 12. Install compression spring (Item16) onto valve spool. Figure 40 Hydroject 3010 Repairs Page 6 – 31...

  • Page 106: Gear Case Service

    (Item 27) on the gear. Only the cam contacts the roller Adjustments section). cam follower. The weight block is for balance. Make sure 14 15 Torque both capscrews evenly to 22 - 28 ft-lb. Figure 41 Repairs Page 6 - 32 HydroJect 3010...

  • Page 107: Nozzle Service And Replacement

    Occa- Spring Check Valve Ball Check Valve Ball Spring Tighten nut to 70 – 80 ft–lb OPEN NOZZLE CLOSED (BLOCKED) NOZZLE Aluminum washer (P/N 86–8150) is required with any nozzle change. Hydroject 3010 Repairs Page 6 – 33 Rev. B...
  • Page 108 It is are facing forward and securely attached to accumulator. recommended that the accumulator checked and charged by an Authorized TORO 6. Install four (4) NEW special bolts (Item 14) through Distributor. valve body and into base of accumulator. Tighten to a torque of 40 ft-lb.
  • Page 109 7RUTXHWRIW²OE IRXUORFDWLRQV )LJXUH +\GURMHFW 5HSDLUV 3DJH²...
  • Page 110 2. Valve cap (yellow) cumulators in a well ventilated area. It is recommended that the accumulator checked and charged by an Authorized TORO Distributor. Wear eye protection. Keep hands and face away from gas valve. Slowly open high pressure water bleed valve before servicing any component connected to high pressure water system.

  • Page 111: Accumulator Replacement

    16. Move piston to bottom of accumulator cylinder. Add Figure 46 11 oz. of Mobil DTE 26 hydraulic oil to completely fill cup in piston and cover top edges of piston. HydroJect 3010 Page 6 - 37 (Rev. A) Repairs...

  • Page 112: General Information

    Coat cable terminals 1. Drain the engine oil from the oil pan and replace the and battery posts with skin over grease or petroleum jel- drain cap. ly. Recharge battery. General Information Hydroject 3010 Page 6 – 38 Rev. B...
  • Page 113 Brake Service ......3 Wheel Bearing Service ....4 Hydroject 3010 Page 7 - 1...
  • Page 114 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. Brake cable Adjustments Page 7 - 2 Hydroject 3010...
  • Page 115 DO NOT hit wheel hub with a hammer during re- 40 to 50 ft-lb. moval or installation. 10. Adjust and check brakes. 4. Remove brake shoe springs (Item 16) and brake shoes (Item 17). 5. Repair or replace parts as necessary. Hydroject 3010 Page 7 - 3 Repairs...
  • Page 116 Install cotter pin. Correct end play of adjusted assembly is 0.002 to 0.005 inches. 11. Put a coating of grease on inside of dust cap and install dust cap on end of wheel spindle. Repairs Page 7 - 4 Hydroject 3010...
  • Page 117 Control Panel Wiring Diagram ....7 Tiller Harness Drawing and Wiring Diagram ..8 Hydroject 3010 Electrical Diagrams...
  • Page 118 This page is intentionally blank. Electrical Diagrams Hydroject 3010 Page 8 – 2...

  • Page 119: Schematic

    Hydroject 3010 Electrical Schematic Page 8 – 3...

  • Page 120: Main Harness

    Hydroject 3010 Main Harness Page 8 – 4...

  • Page 121: Main Wiring Diagram

    Hydroject 3010 Main Wiring Diagram Page 8 – 5...

  • Page 122: Control Panel Harness

    Hydroject 3010 Control Panel Harness Page 8 – 6...
  • Page 123 Hydroject 3010 Tiller Wire Harness and Diagram Page 8 – 7...

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