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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.

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. Loosen hydraulic pump belt tension and remove
small belt from hydraulic pump pulley (see Pump Drive
Belt Adjustment in Chapter 4 - Hydraulic System).

Figure 31

6. Loosen water pump idler pulley and work belt off of

1. Water pump belt

large pulley. Carefully pull this belt out from under the
electric clutches.

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

Summary of Contents for HydroJect 3010

Page 1: ...1 Lyndale Avenue South Bloomington MN 55420 The Toro Company reserves the right to change product specifications or this publication without notice Service Manual Hydroject 3010 INSTRUCTION When you s...

Page 2: ...Hydroject 3010...

Page 3: ...ting 4 8 Testing 4 9 Adjustments 4 11 Repairs 4 14 Chapter 5 Electrical System Wiring Schematics and Diagrams 5 2 Special Tools 5 5 Troubleshooting 5 7 Testing 5 15 Repairs 5 24 Chapter 6 Water System...

Page 4: ...Hydroject 3000 4000...

Page 5: ...While Operating 2 Safety Instructions Although hazard control and accident prevention par tially are dependent upon the design and configuration of the machine these factors are also dependent upon t...

Page 6: ...ulic line connectors are tight and all hydraulic hoses and lines are in good condition be fore applying pressure to the system Safety Hydroject 3010 D Fill fuel tank outdoors and up to about one inch...

Page 7: ...ine must be shut off before checking oil or add ing oil to the crankcase 34 Allow engine to cool before storing machine in any enclosure such as a garage or storage shed Make sure the fuel tank is emp...

Page 8: ...cals 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...

Page 9: ...ert Operator s Manual and Parts Catalog for your Hy droject 3010 at the end of this chapter Additionally if any optional equipment or accessories have been installed to your Hyroject insert the Instal...

Page 10: ...Equivalents and Conversions Product Records and Maintenance Page 2 2 Hydroject 3010...

Page 11: ...neath the fastener s head or similar condition which affects the installation Fastener Identification Grade 1 Inch Series Bolts and Screws Grade 5 Grade 8 Figure 1 As noted in the following tables tor...

Page 12: ...39 4 55 5 75 7 77 7 104 9 1 2 13 UNC 30 3 48 7 65 9 75 8 102 11 105 10 142 14 1 2 20 UNF 32 3 53 7 72 9 85 8 11 120 10 163 14 65 10 88 12 16 150 15 203 20 210 20 285 27 5 8 18 UNF 75 10 95 15 129 20 1...

Page 13: ...33 ft lb 440 45 N m 450 37 ft lb 610 50 N m Thread Size Regular Height Nuts Regular Height Nuts 92 125 166 NOTE Reduce torque values listed in the table above by 25 for lubricated fasteners Lubricated...

Page 14: ...crews Thread Cutting Screws Zinc Plated Steel Zinc Plated Steel Thread Size No 6 32 UNC 20 5 in lb No 8 32 UNC 30 5 in lb No 10 24 UNC 38 7 in lb 1 4 20 UNC 85 15 in lb 5 16 18 UNC 20 in lb 3 8 16 UNC...

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Page 19: ...ction 8 TESTING 9 Hydraulic Tests 10 ADJUSTMENTS 11 Traction Cable Adjustment 11 Speed Control Adjustment 11 Transmission Neutral Adjustment 12 Aeration Speed Adjustment 12 Pump Drive Belt Adjustment...

Page 20: ...________________________________________________________________________________________________________________________________________________________ Specifications Item Description Pump Rated syst...

Page 21: ...can cause damage or premature de terioration Some hoses such as reel motor hoses are more susceptible to these conditions than others In When replacing a hydraulic hose be sure that the hose is strai...

Page 22: ...s 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 4 Turn back the jam nut as far as possibl...

Page 23: ...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 1 Stop the engine and raise the hood 2 Open the by pass valve by turnin...

Page 24: ...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...

Page 25: ...inlet side of the hydraulic tester 2 LOAD VALVE If required upon turning the valve to restrict flow a simulated working load is created in the circuit 3 LOW PRESSURE GAUGE Low range gauge to provide...

Page 26: ...erly 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 increa...

Page 27: ...nd do serious dam age If fluid is injected into the skin it must be surgically removed within a few hours by a WARNING 1 Thoroughly clean the machine before disconnecting or disassembling any hydrauli...

Page 28: ...8 While watching flow and pressure gauges move traction handle up or down so flow is from the pump through the tester then to the wheel motor Move trac tion handle until 6 GPM is obtained 9 If pressu...

Page 29: ...centered on control handle 1 2 Figure 12 1 Jam nuts pump end 2 Jam nuts tiller end Speed Control Adjustment Fig 13 1 Park machine on a level surface stop the engine and 3 Adjust speed rods Item 14 so...

Page 30: ...itches are actuated when pump control is in neutral and not actuated when pump control is stroked 1 2 3 Figure 14 1 Neutral adjustment cam 2 Locknut 3 Switch tab Aeration Speed Adjustment Fig 15 1 Par...

Page 31: ...ring pump and pump mount to slotted pump support Figure 16 C Loose three 3 capscrews securing pulley guard bracket Fig 20 Item 21 to control panel and pump 1 Traction pump belt support D Use a pry bar...

Page 32: ...ectrical connector 5 Remove valve clutch stops 6 Loosen pivot nut securing pump mount to pump support 7 Loosen adjusting nut securing pump and pump mount to slotted pump support 8 Push pump towards in...

Page 33: ...fittings to prevent contamination Put labels on hydraulic lines for proper reinstallation 7 Remove locknut Item 46 capscrew Item 5 and washers Item 47 Remove locknut Item 54 and cap screw Item 57 8 Re...

Page 34: ...pring may push shaft partially out of housing Do not attempt to pull shaft out of housing Internal parts could move out of alignment or fall into pump requiring major disassembly of pump 3 Inspect sea...

Page 35: ...15 to 35 ft lb Turn pump over and repeat installation procedure for other check valve 2 4 1 installed in machine 3 5 15 to 35 ft lb Top of pump when Torque to Figure 22 1 Check valve plug 2 O ring 3...

Page 36: ...ump cover screws and tighten to a torque of 84 to 120 in lb 2 4 1 installed in machine 3 5 84 to 120 in lb Top of pump when Torque to Figure 24 1 Charge pump cover 2 O ring 3 Gerotor assembly 4 Charge...

Page 37: ...em 6 and two 2 alignment pins Item 15 from housing 5 Remove cylinder block kit Item 7 from shaft Item 19 6 Remove cylinder block spring Item 8 and washer Item 9 from shaft 7 Remove swashplate assembly...

Page 38: ...de surface of housing 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 3 Install displacement control shaft Item...

Page 39: ...properly installed the internal springs will hold it away from the housing approximately 3 8 in 22 Install the four 4 capscrews which retain end cap to housing Tighten screws to a torque of 138 to 180...

Page 40: ...tuds and remove wheel hub Item 19 and brake drum Item 18 Remove key Item 7 from wheel motor shaft IMPORTANT To prevent damage to wheel motor DO NOT hit wheel hub with a hammer during re moval or insta...

Page 41: ...ng and seal areas If the shaft is lightly scratched in these areas polish with fine emery paper in a circumferential direc tion However if the shaft has any pitting or deep scratches entire motor shou...

Page 42: ...assembly must be replaced 6 Remove the two check balls Item 6 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...

Page 43: ...with check ball holes facing down ward over balls Align the eight bolt holes in locating ring with eight holes in body The holes align in only one position NOTE Be sure not to dislodge body square ri...

Page 44: ...Repairs Page 4 26 Hydroject 3010...

Page 45: ...nic Control System Test 16 Ignition Key Switch 17 Controller 18 Traction Switch 1 and 2 18 Wheel Position Switch 19 Aerator Engage and Disengage Switches 19 Lift Switch 22 Linear Actuator 20 Brake Swi...

Page 46: ...X O Switch Closed Momentarily Switch Conditon Not Relevent Start Key Switch B L S Run Key Switch B L A Traction Switch 1 Water Pressure Switch Traction Switch 2 Lift Switch UP Transport ming below Co...

Page 47: ...f red and yellow lights are on green light will stay on until either red or yellow goes off Yellow Wheel position switch closed machine low ered to aerate position water pressure switch closed water p...

Page 48: ...Electrical Schematic and Wiring Diagrams See Chapter 8 Electrical Diagrams Wiring Schematics and Diagrams Page 5 4 Hydroject 3010...

Page 49: ...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 d...

Page 50: ...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 Hydro...

Page 51: ...be checked in the order in which they are listed If the machine being repaired has any interlock switches by passed they must be reconnected for proper trou bleshooting and safety Condition Possible...

Page 52: ...ystem loose Engine problem or no fuel Find problem and correct see Chapter 3 Engine Engine cranks but should not See Safety Interlock System Prob with traction bail in neutral lems Engine starts but s...

Page 53: ...ch and replace if faulty Loose or broken wire in oil pres Check all wiring and connections sure switch circuit and repair as necessary Engine does not stop when igni Engine timing or carburetor out of...

Page 54: ...Possible Cause Correction Machine does not raise to trans Lift Lower switch faulty Test switch and replace if faulty port position Ignition key switch faulty Test ignition switch and replace if faulty...

Page 55: ...ace if faulty should not with inlet water pres sure of less than 20 to 30 PSI or Water pressure switch wiring faulty Check for short in pressure machine does not stop aerating if switch controller con...

Page 56: ...ircuit and repair as necessary Valve clutch faulty Test valve clutch and repair or re place if faulty Valve clutch relay faulty Test relay and replace if faulty Controller faulty Replace controller Ma...

Page 57: ...as necessary Machine continues to aerate but Red light on controller is ON Make sure traction switch 2 is in should not with traction bail in should be OFF with traction bail stalled and adjusted prop...

Page 58: ...rlock it will not hold a charge Clean system and tighten connections Circuit breaker open Reset circuit breaker Find cause for open circuit breaker and cor rect Replace circuit breaker if faulty Fault...

Page 59: ...rely entirely on safety switches use common To do a functional check of interlock system 1 Put machine in a flat open area on rough turf away from buried wires plumbing etc Stop the engine 2 Move tra...

Page 60: ...valve clutch should engage NOTE Touch clutches with a metal object such as a screw driver to help check for clutch engagement clutch will be magnetized 5 NEUTRAL shut down test A Release traction bai...

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Page 62: ...l Traction switch 2 is nor mally closed N C and is open when the traction bail is in neutral IMPORTANT Traction switch 1 and 2 have three 3 terminals Traction switch 1 must have the wires connected to...

Page 63: ...could also cause it to not open and close properly 1 Wheel position switch Aerator Start and Stop Water Engage and Disengage Switches Fig 14 The aeration start ENGAGE switch is normally open N O and...

Page 64: ...Disconnect the wiring connector 2 Connect a 12 volt battery so the negative terminal is connected to the red wire of the actuator connector When the positive battery terminal is connected to the yell...

Page 65: ...tch connector The switch should show continuity when inlet water pressure reaches 20 to 30 PSI on gauge The switch should break continuity as water pressure goes below 10 PSI Figure 18 1 1 Pressure ga...

Page 66: ...85 with terminal 86 connected to ground Resistance specifications Terminals 85 and 86 80 to 90 Ohms Terminals 30 and 87a normally closed continuity Terminals 30 and 87 normally open continuity when 12...

Page 67: ...across the terminals of the clutch connector Resistance measured through the clutch coil should be approximately 3 ohms The clutch can also be tested by connecting a 12 VDC battery across the clutch...

Page 68: ...cap tubes If the level is below the plates add water only until the plates are covered and then charge the battery After charging fill the battery to the proper level warm to 60o F 15 5o tery posts CA...

Page 69: ...ch 1 or N C terminal traction switch 2 Figure 26 IMPORTANT Traction switch 1 and 2 have three 3 1 Traction switch 1 N O gray black wires terminals If the two 2 wires are not connected to 2 Traction sw...

Page 70: ...prevent damage to the electrical sys tem 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 t...

Page 71: ...nd disconnect engine spark plug wires 3 Open the hood 4 Disconnect linear actuator wire connector 5 Disconnect extension springs 6 Remove capscrew and nut securing each end of linear actuator Figure 2...

Page 72: ...Repairs Page 5 28 Hydroject 3010...

Page 73: ...HOOTING 9 Troubleshooting Water System Problems 9 TESTING 12 Before Performing Water System Tests 12 TEST NO 1 Accumulator Pre Charge Pressure and Adding Dry Nitrogen 13 TEST NO 2 Water System Pressur...

Page 74: ...fold outlet All high pressure water flows in and out through the valve body Pressure balanced valve spool with floating patent pending hardened stainless seat aligns during assembly Bleed valve in bas...

Page 75: ...ch Metric Size mm Quantity of Nozzles Open Blocked 86 8130 56 0465 1 181 86 8131 53 0595 0 4 6 86 8133 46 0810 2 057 6 5 6 8 Use only with varied size configurations NOZZLE SIZE AND APPROXIMATE DEPTH...

Page 76: ...v B CLOSED BLOCKED NOZZLE OPEN NOZZLE Spring Spring 70 80 ft lb Aluminum washer P N 86 8150 is required with any nozzle change Check Valve Ball Check Valve Ball Specifications Page 6 2 2 Hydroject 301...

Page 77: ...I 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 WATER VALVE RELIEF VALV...

Page 78: ...rging the accumulator The charging valve can also be used to measure accumulator pre charge pres sure without significant loss of accumulator pre charge NOTE The charging tool is equipped with a Com p...

Page 79: ...measuring water pressure available to the water valve Figure 5 Flow Meter TOR4006 Fig 6 The in line flow meter with a battery powered electronic digital display is installed in the water supply line t...

Page 80: ...asures cam wear and deter mines 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 val...

Page 81: ...install the pump displacement rod seal into the pump head Use Insertion Mandril with this seal guide Seal Installation Mandril TOR4011 Use Insertion Mandril with both seal guides Seal Inser tion Mandr...

Page 82: ...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 Wea...

Page 83: ...med in the order listed even if the apparent problem has been isolated such as low accumulator pre charge pressure This will verify that all components are operating properly i l El l i i i El l l l E...

Page 84: ...pth is shallow or incons stent Air in system Soil density or mo sture content ugged nozz es worn nozz es or improper nozz e conf guration NOTE Check operation of nozz by aerating over a piece of cardb...

Page 85: ...r valve open rotate gear so cam is off of valve lifter If water is exiting relief valve out let hose replace relief valve DO NOT attempt to adjust Rebuild water valve Low water system flow pressure is...

Page 86: ...e operating properly j High pressure water system components can cause personal in ury if disassembled incor rectly Discharge water pressure at bleed valve before attempting any water system servicing...

Page 87: ...ve cap 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 accumulator can cause an EX PLOSION AND DE...

Page 88: ...ct charging tool from accumulator Reinstall the yellow protective cap and valve protector bracket Adding Dry Nitrogen to Accumulator 10 With charging tool connected to accumulator attach a charged tan...

Page 89: ...d incor rectly Discharge water pressure at bleed valve before attempting any water system servicing Open bleed valve slowly and avoid contact with high velocity water stream WARNING Figure 18 1 High p...

Page 90: ...in closed position A large quantity of water exiting valve side of tube indicates a leaking valve Figure 22 ceramic sleeve or seal Reconnect small tube If pressure is low but flow is OK make sure cam...

Page 91: ...ft Indicator TOR4007 into this opening Make sure dial indicator contacts top of water valve then zero out dial indicator 5 Make sure cam lobe is not contacting follower by rotating coupling assembly s...

Page 92: ...mponents can cause personal in ury if disassembled incor rectly Discharge water pressure at bleed valve before attempting any water system servicing Open bleed valve slowly and avoid contact with high...

Page 93: ...al to or greater by 0 002 inch to amount measured For example if 0 015 is measured while follower is on lead in portion of cam add a 0 015 shim If 0 009 is measured add 0 010 shim two 0 005 shims and...

Page 94: ...tch bumper gap should be 0 22 03 in 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 Ho...

Page 95: ...ner bracket Fig 30 Item 39 5 Loosen hydraulic pump belt tension and remove small belt from hydraulic pump pulley see Pump Drive Belt Adjustment in Chapter 4 Hydraulic System Figure 31 1 6 Loosen water...

Page 96: ...counterclockwise as viewed from top Remove filter and discard 4 Rinse out filter body and insert a new filter 5 Clean filter head to prevent contamination of water system Thread body with filter onto...

Page 97: ...ater to escape 3 Remove lower plug and let oil drain out of pump crankcase into a container Install drain plug 4 Remove drive belt from driven pulley 5 Remove four 4 water valve inlet bolts Inset Item...

Page 98: ...m 11 away from pump crankcase Turn pump crankcase to help in removal of pump head Check Valve Replacement replace as a set 1 Remove the six caps Item 7 and pull out check valve assemblies 2 Discard ol...

Page 99: ...010 making sure V groove will mate with high pressure seal Insert Installation Guide into cylinder head cavity and use Insertion Mandril TOR4011 to completely install seal support This seal support fi...

Page 100: ...crankcase Inspect crank rod for gall ing or wear 7 Pull connecting rods Item 12 out through crankcase Check for wear on plunger 12 and plunger guides Item 28 If plunger guides are worn use Wear Sleeve...

Page 101: ...crankshaft input shaft and secure to water pump housing Tighten fasteners to a torque of 18 20 ft lb 6 Install end cap bearing housing over output shaft and secure with fasteners but do not tighten 7...

Page 102: ...This page is intentionally blank Repairs Page 6 28 HydroJect 3010...

Page 103: ...s identical to the pump head displacement rod seal The major difference is the different brass insert If the oil seal leaks oil will leak down and through the gear case shims If low pressure water sea...

Page 104: ...1 Press a new sleeve bushing Item17 into gear case pilot until bushing is flush with recessed oil side sur face 2 Use a shaft to install oil seal Item 19 and seal back up Item 20 into gear box pilot...

Page 105: ...ews Item13 to a torque of 14 18 ft lb 12 Install compression spring Item16 onto valve spool 13 Install valve spring studs through Valve Spring Com pressor TOR4008 and into threaded holes of water valv...

Page 106: ...7 on the gear Only the cam contacts the roller cam follower The weight block is for balance Make sure you inspect the cam and not the weight block when checking for wear DO NOT INSTALL TWO CAMS ONTO T...

Page 107: ...re easily replaced if they wear Occa sionally inspect the springs especially if one nozzle leaks water after the machine is shut down 4 For normal operation install nozzle springs with the narrow spir...

Page 108: ...nder Failure to open bleed valve before servicing high pressure water components can cause personal in ury DIS MEMBERMENT OR DEATH Charged accumulators cannot be shipped via air freight DANGER 2 Slowl...

Page 109: ...IRXU ORFDWLRQV 7RUTXH WR IW OE LJXUH GURMHFW 3DJH 5HSDLUV...

Page 110: ...rs cannot be shipped via air freight 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 a...

Page 111: ...and tighten to a torque of 125 ft lbs 14 Special grease is supplied with a new piston Apply coating of special grease to piston Make sure spaces between seals on piston are filled with special grease...

Page 112: ...emove and drain the water filter container Install new filter and replace the filter container Engine 1 Drain the engine oil from the oil pan and replace the drain cap 2 Remove and discard the oil fil...

Page 113: ...Chapter 7 Wheels Brakes and Steering Table of Contents ADJUSTMENTS 2 REPAIRS 3 Brake Adjustment 2 Brake Service 3 Wheel Bearing Service 4 Hydroject 3010 Page 7 1 Table of Contents...

Page 114: ...securing cover to under side of tiller handle Remove cover 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...

Page 115: ...om wheel motor shaft IMPORTANT To prevent damage to wheel motor DO NOT hit wheel hub with a hammer during re moval or installation 4 Remove brake shoe springs Item 16 and brake shoes Item 17 5 Repair...

Page 116: ...No 2 general purpose lithium base grease containing E P additive Install one bearing into cup on inboard side of wheel hub Lubricate inside of new lip seal and press it into wheel hub IMPORTANT The l...

Page 117: ...Electrical Schematic 3 Main Harness Drawing 4 Main Harness Wiring Diagram 5 Control Panel Harness Drawing 6 Control Panel Wiring Diagram 7 Tiller Harness Drawing and Wiring Diagram 8 Hydroject 3010 P...

Page 118: ...This page is intentionally blank Electrical Diagrams Page 8 2 Hydroject 3010...

Page 119: ...Page 8 3 Electrical Schematic Hydroject 3010...

Page 120: ...Hydroject 3010 Main Harness Page 8 4...

Page 121: ...Page 8 5 Main Wiring Diagram Hydroject 3010...

Page 122: ...Hydroject 3010 Control Panel Harness Page 8 6...

Page 123: ...Hydroject 3010 Tiller Wire Harness and Diagram Page 8 7...

Page 124: ......

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