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1. ACCUM HIGH SWITCH P8 AB wee fsa LH ACCUM LOW E PRESSURE 0 Ls TRACTION TRACTION P1 8 PUMP CLUTCH HIGH PRESSURE LOW PRESSURE SMITH 1 SMTCHA STOP RELAY LATCH RELAY LIGHT RELAY J 1 J 2 3 52 J 4 P14 P20 P19 CLUTCH PUMP CLUTCH HIGH PRESSURE LOW PRESSURE RELAY 234 RELAY 234 STOP RELAY 234 START RELAY 1 5 1 5 1 5 VALVE CLUTCH 15 P13 P16 17 P12 Pe CONTROL PANEL HARNESS CONTROL MODULE 234 234 234 234 234 P5 P3 P4 1 5 LS HIGH PRESSURE 1 29 1079 1 5 RPACIOATOR 0 40 LATCH DELAY T U DCBA P11 PUMP CLUTCH P6 ABCDE ABCDE m P10 Ge Gre 1 Eten g Et in t3 8 BA ce
2. d ii ip VEN 13 Install valve spring studs through Valve Spring Com pressor TOR4008 and into threaded holes of water valve Put spring retainer Item 15 over spring and un der spring compressor Tighten nuts to compress spring and install and retaining ring Item14 Remove special tool NOTE The manifold feeder keeps the valve seat sta tionary The spring force of the water valve positions the valve seat prior to Feeder Manifold installation Make sure cam lobe does not contact cam follower during feeder manifold installation Fig 29 7 9 9 9 2 3 7 LES N 2 2 2 22 21 RE KZ 55996 Om 5 89 29 08 6 G9 29 62 6 206900 Figure 40 Hydroject 3010 Page6 31 Repairs Gear Case Service Fig 41 The gear case is a pinion and gear reduction drive that actuates the water valve The pinion Item 12 is con nected to the electric brake clutch with a drive coupler The gear Item 22 moves the cam over the roller follower actuating the water valve to control water in jection at 5 3 cycles per second at 320 RPM The gear case also serves as the hydraulic oil reservoir If the gear case is disassembled for repair make sure the taper roller bearings have a light rolling resistance after reassembly by adjusting shim thicknesses Item 16 and 20 Bearing pre load is O to 0 002 in There is a replaceable cam Item
3. 8 3 Main Harness 8 4 Main Wiring Diagram 8 5 Control Panel 8 6 Control Panel Wiring Diagram 8 7 Tiller Harness and Wiring Diagram 8 8 Hydroject 3000 4000 TORO Table of Contents SAFETY INSTRUCTIONS 1 Before Operating 1 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 the awareness concern and proper training of the per sonnel involved in the operation transport mainte nance and storage of the machine Improper use or maintenance of the machine can result in injury or death To reduce the potential for injury or death comply with the following safety instructions Before Operating 1 Read and understand the contents of this manual before starting and operating the machine Become fa miliar with all controls and know how to stop quickly A free replacement manual is available by sending com plete Model and Serial Numbers to The Toro Company 8111 Lyndale Avenue South Bloomington Minnesota 55420 Use the Model and Serial Number when referring to your machine If you have questions about this Service Manual please contact The Toro Company Commercia
4. a 553 px 8 e BK BK START HOUR METER 66 2950 929 e KEY IN START 25 P5 E KEY IN START x 1 Y Y S amp 1 2 8 4 alu T q o 2 N 22 8 PINK WHITE P22 A 5 M e oo dz L WATER PRESSURE GAUGE SWITCH 80 5648 21 o o x E o SHOWN WITH NO WATER PRESSURE 8 m9 a gt 8 S 5 83 0020 lt w E IGNITION SWITCH 1 1 at J 4 5 eae T Se amp N N 70 14 CONTROL PANEL HARNESS 2 8 amp 8745 7921580 106 1110 57 re N RAW 4 87 5 30 1 PK PK P7 B MN 7 e 2 b 6 VALVE CLUTCH 86 8160 a amp 5 56 85 K 2 E Z BN FN OR 5 FONE BLOCK VALVE CLUTCH RELAY 421 E an P ZAR domme L__ lt 5 2 5 4 m ENGINE E n 5 oh og ced POWER VALE M 5 3 E 9 97 NC E zu 870 ae 7 v 2 M N O P3 B NEUTRAL 4 87 30 1 P19 A P10 B START TAB or 2 2 o Y Y 1 B SAW ee PUMP CLUTCH 80 5430 Dd ON STARTER TRACTION SWITCH 2 29 6162 UMP CLU E 1 922 ar SSHOWN IN DRIVE pu PAG MT PUMP sde MSN 2 on p U VI a 1 A 25 87a 70 1480 1 PUMP CLUTCH RELAY pex Tex 22 8 STUD PIS ON STARTER 4 7 1 P9 B P9 A py P3704 t START D Y o o 1 0 2 WHEEL POSITION SWITCH 72 4310 x z D S
5. 20 241 5 16 0 3125 7 938 13 16 0 8125 20 638 21 64 0 328125 8 334 53 64 0 828125 21 034 11 32 0 34375 8 731 27 32 0 84375 21 431 23 64 0 359375 9 128 55 64 0 859375 21 828 3 8 0 3750 9 525 7 8 0 8750 22 225 25 64 0 390625 9 922 57 64 0 890625 22 622 13 32 0 40625 10 319 29 32 0 90625 23 019 27 64 0 421875 10 716 59 64 0 921875 23 416 7 16 0 4375 11 112 15 16 0 9375 23 812 29 64 0 453125 11 509 61 64 0 953125 24 209 15 32 0 46875 11 906 31 32 0 96875 24 606 31 64 0 484375 12 303 63 64 0 984375 25 003 1 2 0 5000 12 700 1 1 000 25 400 1 mm 0 03937 in 0 001 in 0 0254 mm U S to Metric Conversions To Convert Into Multiply By Linear Miles Kilometers 1 609 Measurement Yards Meters 0 9144 Feet Meters 0 3048 Feet Centimeters 30 48 Inches Meters 0 0254 Inches Centimeters 2 54 Inches Millimeters 25 4 Area Square Miles Square Kilometers 2 59 Square Feet Square Meters 0 0929 Square Inches Square Centimeters 6 452 Acre Hectare 0 4047 Volume Cubic Yards Cubic Meters 0 7646 Cubic Feet Cubic Meters 0 02832 Cubic Inches Cubic Centimeters 16 39 Weight Tons Short Metric Tons 0 9078 Pounds Kilograms 0 4536 Ounces Grams 28 3495 Pressure Pounds Sq In Kilopascal 6 895 Pounds Sq In Bar 0 069 Work Foot pounds Newton Meters 1 356 Foot pounds
6. 24 23 22 Figure 2 1 Park machine on a level surface stop the engine and engage the parking brake Open the hood and discon nect 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 3 Mount a wheel puller to wheel mount studs 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 installation 4 Remove brake shoe springs Item 16 and brake shoes Item 17 5 Repair or replace parts as necessary Hydroject 3010 Page 7 3 6 After installing brake shoes install brake shoe springs Item 17 into holes on each brake shoe plate from the outside Springs should be installed in opposite direc tion of each other 7 Mount key Item 7 in wheel motor shaft so top of key is in line with taper in shaft then install wheel hub and brake drum 8 Install spindle nut item 13 and tighten to a torque of 250 400 ft Ib 9 Install wheel and secure with wheel nuts Tighten wheel nuts evenly in a crossing pattern to a torque of 40 to 50 ft lb 10 Adjust and check brakes Repairs Wheel Bearing Service Fig 3 1 Park machine on a level surface and raise wheels to aerate position Engage parking brake open hood and
7. 91 16 J5 9 1 _ _ 16 1 533 W84_BK_16 2 KEY TO WIRE COLORS R RED BK BLACK GN GREEN OR ORANGE Y YELLOW BR BROWN GY GRAY PK PINK W WHITE BU BLUE VIO VIOLET T TAN Hydroject 3010 Tiller Wire Harness and Diagram WATER DISENGAGE SWITCH WATER ENGAGE SWITCH PARKING BRAKE SWITCH PARKING BRAKE ALARM Page 8 7
8. Item Description Pump Sundstrand Series 70 BDP 10L Variable Displacement Pump Rated system pressure 2100 PSI maximum 1000 PSI continuous Rated system flow 8 5 GPM maximum at 3500 RPM Charge relief pressure 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 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 When replacing a hydraulic hose be sure that the hose is straight not twisted before tightening the fittings This can be done by observing the imprint on the hose Use two wrenches one to hold the hose straight and one to tighten the hose swivel nut onto the fitting Hydraulic Fitting Installation O Ring Face Seal Fig 2 3 1 Make sure both threads and sealing surfaces are free of burrs nicks scratches or any foreign material 2 Make sure the O ring is installed and properly seated in the groove It is rec
9. N C orange amp yellow wires the COMMON and terminals on traction 3 Switch tab switch 1 and COMMON and terminals on traction switch 2 the safety interlock circuit will not function properly A CAUTION If the wires are not correctly installed to trac tion switch 1 the engine could start with the traction bail in forward or reverse 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 Controller Replacement Fig 27 IMPORTANT Before welding on the machine dis connect both battery cables from the battery dis connect both wire harness plugs from the controller and disconnect the terminal connector from the alternator to 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 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 Linear Actuator Replacement Fig 28 1 Put wheels in transport position machine raised 2 Put the machine on a level surf
10. o I I nerve pus ve NC UN 1612 3 8 24 UNF NOTE Reduce torque values listed in the table above NOTE The nominal torque values listed above for by 25 for lubricated fasteners Lubricated fasteners Grade 5 and 8 fasteners are based on 75 of the mini are defined as threads coated with a lubricant such as mum proof load specified in SAE J429 The tolerance is oil graphite or thread sealant such as Loctite approximately 1096 of the nominal torque value Thin height nuts include jam nuts NOTE Torque values may have to be reduced when installing fasteners into threaded aluminum or brass 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 Page2 4 Hydroject 3010 Standard Torque for Dry Zinc Plated and Steel Fasteners Metric Fasteners Thread Size M5 X 0 8 Regular Height Nuts 57 5 in lb 96 9 in lb Class 8 8 Bolts Screws and Studs with Class 8 or Stronger Nuts 640 60 N cm 78 7 in lb 885 80 N cm 1018 100 N cm Class 10 9 Bolts Screws and Studs with Regular Height Nuts Class 10 or Stronger Nuts 133 13 in lb 1500 150 M6 X 1 0 M8 X 1 25 19 2 ft lb M10 X 1 5 M12 X 1 75 M16 X 2 0 M20 X 2 5 NOTE Reduce torque values liste
11. 2 Lay pump on its side Use a 6 mm internal hex wrench to remove the four 4 screws Item 30 which retain end cap to variable pump housing 3 Internal springs will separate end cap from housing Remove end cap Item 31 from housing Item 18 IMPORTANT Pump cylinder block Item 7 will stick to surface of end cap Be careful to prevent damage to end cap and cylinder block 4 Remove gasket Item 6 and two 2 alignment pins Item 15 from housing 5 Remove cylinder block kit Item 7 from shaft Item 19 Hydroject 3010 Page 4 19 6 Remove cylinder block spring Item 8 and washer Item 9 from shaft 7 Remove swashplate assembly Item 25 from hous ing 8 Remove thrust plate Item 11 from swashplate The bearing guide is pressed into the swashplate and is usually not removed The inner thrust washer is retained by the bearing guide 9 Remove slot guide block Item 13 from displacement control shaft Item 12 10 Remove swashplate cradle bearings Item 14 from housing 11 Remove input shaft seal retaining ring Item 24 12 Carefully pull input shaft seal Item 23 out of hous ing bore A hook may be used to pry seal out or a slide hammer type puller may be used to remove the seal Be careful not to damage housing bore shaft sealing sur face or bearing After seal is removed it cannot be used again 13 Remove bearing spacer washer Item 22 Repairs 14 Remove pump shaft Item 19
12. Controller faulty Check all connections and wiring and repair as necessary Test switch and replace if faulty Accumulator high pressure switch faulty T Test switch and replace if faulty Test clutch and replace if faulty Test relay and replace if faulty Test switch and replace if faulty Make sure switch is installed properly Test switch and replace if faulty Test switch and replace if faulty Replace controller Hydroject 3010 Page 5 11 Troubleshooting 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 Loose or broken wire in valve clutch controller circuit Valve clutch faulty Valve clutch relay faulty Controller faulty Check air gap on valve clutch and adjust if necessary Check all connections and wiring and repair as necessary Test valve clutch and repair or re place if faulty Test relay and replace if faulty Replace controller Machine stops aerating when not moving traction bail in neutral It is normal for pump clutch and water clutch to disengage when traction bail is neutral for 3 to 4 sec onds Educate operator NOTE Holding Aerate start switch in ENGAGE position will override neutral de lay shut down Machine stops aerating while
13. 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 Part No 04134SL Rev B Service Manual Hydroject 3010 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 Toro Company 2005 2006 2007 Hydroject 3010 Table Of Contents Chapter 1 Safety Safety Instructions Chapter 2 Product Records and Manuals Product Main
14. The terminals are marked as shown in Figure Fig 9a Testing 459 The circuitry of the ignition switch is shown in the chart below With the use of a multimeter ohms setting the switch functions may be tested to determine whether continuity exists between the various terminals for each switch position START Unplug wire harness connectors from switch and verify continuity between switch terminals Reconnect the har Figure 9 ness connectors to the switch after testing POSITION CIRCUIT P gd SWITCH LOCK WASHER Figure 10 Hydroject 3010 Page 5 17 Testing 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 IMPORTANT Before welding on the machine dis connect both battery cables from the battery dis connect both wire harness plugs from the electronic control unit and disconnect the terminal connector from the alternator to prevent damage to the electri cal system Lights LED s on the controller indicate the condition of the interlock swit
15. e ore PBA ON 14 E pen TUA 8K X o 4 ACCUMULATOR HIGH PRESSURE SWITCH 108 1286 Rs 87 5 en 5 pressure 2 ie 4 SHOWN WITH NORMAL PRESSURE 87 lt 85 TRANSPORT SWITCH 70 1480 9 9 j EM SS NTROL PANI KEY TO WIRE COLORS R RED BK BLACK OR ORANGE pe 17 30 87 3 P5 H P25 H YELLOW BR BROWN 5 PSt F PIF P16 EE BU BU BU Bk W WHITE BU BLUE 70 1480 a PAR et Buck ACCUMULATOR HIGH WARNING OR o PK LAMP 219 20 2 8 ter EN 212 1 SECOND 83 2280 J36 JS 1 2 Y o P33 BK E gt HIGH PRESSURE LATCH DELAY PARKING BRAKE SWITCH 40 8200 ALARM 80 9330 g P31 B P1 B BK BK BK e Hydroject 3010 Electrical Schematic Page 8 3 TILLER HARNESS P1 DCBA EFGH
16. i Zen z E 6 2 5 RUTAS TS z oc DC re 5 LE ao 8 5 9 95 g 6 55485 5 22585 56 2 2 o x D Sl TX oum xx gt 2 a 3 Zz TRACTIOX SWITCH 1 START RENAY CONTROL PANEL HARNESS WHEEL LIFT ACTUATOR TILLER HARNESS CONTROL MODULE J3 J4 P12 BS P11 P1 P4 P3 30 85 87A 87 86 1 2 3 41 8 d LII LII PIE bb pt 5 gt 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 W14 BK 16 A 3 E zo Wee zm gt gt bn z nc NE x Ae D P zh em x zx 7 am e m RCM lt 5 1 om oma 1709 m m o 1 1 a T 5 o 55 16 18 58 9982920159 585 2088 5 S W38 PK 16 1 COMMON m W29 OR 16 342 85 B coL aa P158 wc wi2_R W_16 J 4 87 20 gt WB4 BN 16 5 COIL 5 6 I w24 v 18 e W88 OR 16 45 BK 16 48 3 T SP3 carne 102 a RUN POWER SP5 W22_ViIO_ 16 A E a W21_ViO_16 4 1 COMMON 5 4 W35 GN 16 2 85 coL GROUND _GN_ 5 I W57 BK 14 3 87A P139 N C p SE
17. 26 8 Inspect bearings Item 23 for galling and pitting If bearings are worn replace bearings and bearing cups as a set 9 Install new seal Item 11 and O rings Item 7 and install crank rod bearings and caps into crankcase 10 Bearings should have a light pre load eliminating any end play Add or remove end cap shims Item 8 to change pre load see Crankshaft Bearing Installation Shimming Page 6 26 2 Preload 0 005 0 007 Capscrew torque 18 20 ft lbs 11 Install end caps onto connecting rods and torque capscrews Item 10 to 18 ft lbs 12 Install new gasket crankcase cover and torque crankcase cover capscrews Item 10 to 18 ft Ib 13 Install pulley with tapered hub onto pump drive shaft Hydroject 3010 Crankcase Bearing Installation and Shimming Model 09801 1 Remove crankshaft bearing end caps 2 Remove existing shims from both end caps 3 Install one yellow 020 shim and one pink 015 shim onto input shaft bearing housing if required 4 Install three yellow 020 three blue 005 and two red 002 shims onto the end cap bearing housing 5 Install input shaft end cap over 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 Measure the crankshaft end play and remove shims from end cap as required to get 006 00
18. 424 P24 P25 P22 2 d 2 3 x d e x 2 Ls 885 2 Eig 2 zm cB E ES EE 5 cy e lt ENGINE HARNESS IGNITION SWITCH P21 P23 J25 S M L G B 5 4 3 2 1 1121314 5 I w7 EL p bd DI QE i zl zi m gl 3 S el D z lt L W7 4 FL 18 1 3x EE e9spu g e E SP22 POWER W66 R 14 wW67 R W 18 W81 PK 18 2 PK 16 2 5 w70 BK 16 SP21 GROUND W78 BK 16 B wW73 R W 6 C W68 OR 16 D L wW63 16 E We5 Y 18 F w71 VIO 16 G W60_Y_ 16 H E W68_BU_ 16 w71 0 16 778 BK 16 e 2 e alis 1 x LO wm gt a 1 o oo nr KEY TO WIRE COLORS R RED BLACK OR ORANGE ale ale Y YELLOW BR BROWX GRAY PK PINK W WHITE BU BLUE VIO VIOLET P24 i 2 S P23 IGNITION J25 SW
19. Install end seal and back up ring in groove of top end cap Item 12 so O ring is toward the piston Apply Never Seez or equivalent to threads of end cap Carefully install end cap and tighten to a torque of 125 ft Ibs 18 Install gas valve Item 3 using a new O ring Item 4 19 Install accumulator onto water valve housing see Accumulator Replacement 20 Charge accumulator gas chamber with dry Nitrogen see TEST NO 1 Accumulator Pre Charge Pressure Test Adding Dry Nitrogen 13 Apply Never Seez Torque to 125 ft Ib Apply special grease to piston lt ES See 8 and cylinder bore Apply Never Seez Torque to 125 ft lb 10 Figure 46 Repairs General Information Storage Itis very importantthatthe water system be drained to avoid freezing and damaging the components Drain system as follows 1 Stop engine remove key from ignition switch and remove wires from spark plugs 2 Remove 2 screws securing drive shield to frame and remove shield 3 With the engine OFF and key removed from igni tion rotate the drive coupling by hand until resistance is felt Continue to rotate the coupling about 1 4 revolution opening the cycling valve 4 Using the appropriate reducers National Pipe thread connect a source of compressed air maximum pressure 150 psi minimum pressure 90 psi to the wa ter inlets on either side of machine DANGER Compressed air can penetrate t
20. Lift Switch Fig 15 The lift switch is a three position switch Switch position is maintained in center position with no circuits made Test the switch by disconnecting the wires from the switch terminals and connecting a continuity tester or ohm meter across the terminals Terminals 2 3 and 5 6 should have continuity in UP Terminals 2 1 and 5 4 should have continuity in DOWN Figure 15 1 Lift switch Linear Actuator Fig 16 The linear actuator has a bi directional electric motor which engages a clutch and screw mechanism to ex tend or retract a rod and raise or lower the transport wheels To test the actuator 1 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 yellow wire the actuator motor should operate to extend the actuator cylinder raising the wheels to aer ate position Figure 16 3 Connect a 12 volt battery so the negative terminal 1 Linear actuator 2 Wiring connector is connected to the yellow wire of the actuator connec tor When the positive battery terminal is connected to the red wire the actuator motor should operate to retract the actuator cylinder lowering the wheels to transport position Linear Actuator Specifications Rod end play 0 070 max Current draw 26 amps max Voltage 12 VDC Speed 3 4 in
21. Remove gear case pilot Item18 from water valve 9 Use a wrench to keep spool valve Item1 stationary and use a deep wall socket to loosen jam nut Item 22 on valve spool 10 Remove jam nut Item 22 and large washer Item 23 then gently push valve spool through valve Valve seat Item 2 will come out with the valve Repairs 11 Inspect sealing surfaces of valve spool and valve seat If surfaces appear worn replace or regrind Both angles are 30 degrees 12 Remove and inspect sleeve Item 7 and remove backup Item 6 and O ring seals Item 5 Apply grease to O D of sleeve before installing 10 13 Remove seal assembly Items 25 30 by pressing a socket wrench through the casting Discard all seal components 14 Remove snap ring Item 21 from gear box pilot Item18 Insert a shaft into the outboard side of the gear box pilot to push out sleeve bushing Item17 seal back up Item 20 and oil seal Item 19 Torque to 14 18 ft lb Six locations Apply Loctite 271 to threads of spool Figure 39 Water Valve Assembly 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 Install retaining ring Item 21 3 Grease O ring Item 5 and back up ring Item 6 then install onto valve spool Item1 Rubber O ring is furth
22. Starting Problems General Run and Transport Problems Aerate Operation Problems Safety Interlock System Problems TESTING Verify Safety Interlock System Operation Clutch Engagement Electronic Control System Test Ignition Key Switch Controller dees reo ee Traction Switch 1 and 2 Wheel Position Switch Aerator Engage and Disengage Switches Hydroject 3010 Chapter 5 Electrical System 2 Lift Switch 22 2 Linear Actuator 20 3 Brake Switch 20 5 Pressure Gauge Switch 21 7 Accumulator Charge and High Press Switches 21 7 se a RES ne bear Re 21 9 Battery s side te Rae eae CORO P ERR 22 11 Pump Clutch 23 13 Valve 23 15 Circuit Breaker and Fusible Link 23 15 eI REESE 24 Battery Service 24 16 Traction Switch 1 and 2 17 Replacement and Adjustment 25 18 Controller Replacement 26 18 Linear Actuator Replacement 27 19 19 Page 5 1 Table of Contents Wiring Schematics and Diagrams Logic Chart Each line on the Logic Chart shows the combination of switch conditions that must be made for the listed action to occur Example START under ACTIONS For the engine to start the Key Switch must be moved to Start
23. Test switch and replace if faulty Check all wiring and connections and repair as necessary Engine does not stop when igni tion key switch is rotated to OFF position Engine timing or carburetor out of adjustment Ignition switch faulty Short in ignition circuit wiring Adjust carburetor or engine tim ing Test ignition switch and replace if faulty Check all wiring and connections and repair as necessary Battery does not charge Loose or damaged wire s in en gine electrical system Regulator or engine charging cir cuit faulty Battery faulty Check wiring and connections and repair as necessary Repair engine charging circuit Test battery and replace if faulty Machine does not lower to aer ate position Liftlower switch faulty Ignition key switch faulty Loose or broken wire in lift down circuit Linear actuator faulty Test switch and replace if faulty Test ignition switch and replace if faulty Check all wiring and connections and repair as necessary Test actuator and repair or re place if faulty Hydroject 3010 5 9 Troubleshooting General Run and Transport Problems continued Condition Possible Cause Correction Machine does not raise to trans port position Lift Lower switch faulty Ignition key switch faulty Lose or broken wire in lift up circuit Linear actuator faulty Test swi
24. disconnect engine spark plug wires 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 4 Pull seal Item 34 out of wheel hub Item 23 5 Remove bearings Item 32 from both sides of wheel hub Clean bearings in solvent Make sure the bearings are in good operating condition Clean inside of wheel hub Check bearing cups Item 33 for wear pitting or other noticeable damage Replace worn or damaged parts 6 If bearing cups were removed from wheel hub press them into hub until they seat against the shoulder 7 Pack both bearings with grease Use 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 lip seal Item 34 must be pressed in so it is flush with end of hub Lip of seal must be toward the bearing 8 Pack inside of wheel hub with some grease not full Install remaining bearing into bearing cup 9 Slide hub onto spindle shaft and secure it in place with flat washer and slotted nut DO NOT tighten nut or install cotter pin 10 Adjust pre load on wheel bearings by rotating wheel by hand and tightening slotted nut until bearing binds SLIGHTLY Then loosen nut until nearest slot and hole in spindle line up Install cotter pin Correct end pla
25. 23 and weight block Item 27 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 THE GEAR The cam Item 23 can be replaced without removing or disassembling the gear case Evenly torque capscrews securing cam to 22 28 ft Ib NOTE If there is wear on the teeth of the gear Item 22 interchange the locations of the cam Item 22 and weight block Item 27 so higher gear teeth load occurs in a new location After replacing the cam or repairing or replacing the gear case adjust water valve lift see Water Valve Lift in the Adjustments section Torque both capscrews evenly to 22 28 ft Ib Figure 41 Repairs Page 6 32 HydroJect 3010 Nozzle Service and Replacement NOTE See Specifications section of this chapter for more information 1 Park machine on a level surface stop the engine en gage the parking brake open the hood and disconnect the spark plug wires from the engine 2 Inspect nozzle configuration and diameter Nozzles are stamped with numbers indicating the drill size of the orifice Nozzle orifice can be inspected by inserting shank end of drill bit matching size stamped on orifice If drill bit fit is loose the nozzle is worn If nozzles are worn or incorrect replace with new nozzles in correct configuration 3 The nozzle check
26. If pres ing Note the highest pressure If highest pressure is sure is less than 4000 PSI rebuild the valve Do not attempt to adjust or disassemble the relief valve If the relief valve is not working properly it 12 After testing is completed open high pressure bleed must be replaced If adjustment disassembly or repair of the relief valve is attempted it could re sult in machine damage personal injury DIS MEMBERMENT OR DEATH 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 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 A WARNING High pressure water system components can cause personal injury 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 velocity water stream 1 Park machine on a level surface stop the engine engage the parking brake open the hood and discon nect the engine spark plug wires 2 Slowly open the high pressure bleed valve allowing any pressurized water to escape 3 Remove
27. Page 2 1 Chapter 2 Product Records and Maintenance Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series 4 Standard Torque for Dry Zinc Plated and Steel Fasteners Metric Fasteners 5 Other Torque Specifications 6 Conversion Factors Product Records and Maintenance Decimal and Millimeter Equivalents Equivalents and Conversions Fractions Decimals mm Fractions Decimals mm 1 64 0 015625 0 397 33 64 0 515625 13 097 1 32 0 03125 0 794 17 32 0 53125 13 494 3 64 0 046875 1 191 35 64 0 546875 13 891 1 16 0 0625 1 588 9 16 0 5625 14 288 5 64 0 078125 1 984 37 64 0 578125 14 684 3 32 0 9375 2 381 19 32 0 59375 15 081 7 64 0 109275 2 778 39 64 0 609375 15 478 1 8 0 1250 3 175 5 8 0 6250 15 875 9 64 0 140625 3 572 41 64 0 640625 16 272 5 32 0 15625 3 969 21 32 0 65625 16 669 11 64 0 171875 4 366 43 64 0 671875 17 066 3 16 0 1875 4 762 11 16 0 6875 17 462 13 64 0 203125 5 159 45 64 0 703125 17 859 7 32 021875 5 556 23 32 0 71875 18 256 15 64 0 234375 5 953 47 64 0 734375 18 653 1 4 0 2500 6 350 3 4 0 7500 19 050 17 64 0 265625 6 747 49 64 0 765625 19 447 9 32 0 28125 7 144 25 32 0 78125 19 844 19 64 0 296875 7 541 51 64 0 796875
28. 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 traction bail up and down while trying to start the engine If engine cranks there is a malfunction in the interlock system that must be corrected If engine does not crank go to step 3 Hydroject 3010 Page 5 15 A CAUTION When testing electrical components for con tinuity with a volt ohm meter or continuity tester make sure that power to the circuit has been disconnected NOTE Electrical troubleshooting of any 12 Volt power connection can also be performed through voltage drop tests without disconnection of the component 3 Connect water supply to machine Turn on water supply and bleed all air out of the system Water pres sure must be 20 to 30 PSI or more Start the engine Raise machine to transport position up off of rollers Push aerate ENGAGE button If water pump engages and machine begins aerating there is a malfunction in the interlock system that must be corrected If machine does not begin aerating go to step 4 4 Lower machine to aerate position on rollers Engage traction bail to start machine moving Push then release aerate ENGAGE button Water pump should engage immediately then machine should begin aerating 5 sec onds after pump engages Release traction bail to neu tral position so machine stops moving The water pump should di
29. Using unap proved replacement parts and accessories could void the warranty of The Toro Company Safety Safety and Instruction Decals Numerous safety and instruction decals are affixed to the Hyroject 3010 If any decal becomes illegible or damaged install a new decal Part numbers for replace ment decals are listed in your Parts Catalog Order re placement decals from your authorized Toro Distributor Safety Page 1 4 Hydroject 3010 TORO Table of Contents PRODUCT RECORDS 1 MAINTENANCE 1 EQUIVALENTS AND CONVERSIONS 2 Decimal and Millimeter Equivalents 2 U S to Metric Conversions 2 TORQUE SPECIFICATIONS 3 Fastener Identification 3 Product Records Insert 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 Installation Instruc tions Operator s Manuals and Parts Catalogs for those options at the end of this chapter 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 Hydroject 3010
30. Water 4000 5000 PSI operating pressure Water valve housing b Shims 4 Shims P ENS Cam Figure 29 HydroJect 3010 Page 6 19 Adjustments Repairs Drive Coupling and Clutch Removal and Installation Fig 30 1 Parkthe machine on a level surface engage the park ing brake open the hood and disconnect the engine spark plug wires Remove guard Item 38 2 To remove coupling shaft remove four capscrews connecting the rubber couplers Item 11 12 to clutch Item 8 and adapter hub Item 16 then lift shaft away from machine 3 Clutch Item 8 pulley Item 3 and clutch Item 2 can now be removed by removing bolt Item 26 and washer Item 27 A puller tool may be required 4 Apply Never Seez or equivalent to engine shaft and pulley shafts Make sure keys Item 1 and 4 are properly installed then align keyways in clutches and pulley with keys Make sure clutch Item 8 is installed so clutch angle Item 7 clutch stops Item 5 33 and clutch bumpers Item 6 will prevent clutch rotation The clutch bumper gap should be 0 22 03 in Never seez on engine shaft 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 NOTE A tapered hub Item 16 is attached to cam g
31. belt guard to expose the drive shaft 4 Remove test cap from the feeder manifold and install Valve Lift 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 several turns and observing dial indicator 6 Rotate coupling moving cam lobe past cam follower and observe maximum reading on dial indicator Dial indicator should move 0 090 to 0 102 There should be no movement of dial indicator gauge on lead in or lead out portion of cam 7 If indicator moves more than 0 102 cam lobe is probably contacting follower on lead in portion of cam and must be adjusted see Valve Lift Adjustment If indicator moves less than 0 090 remove gear case cover and inspect cam for wear Use your hand to rotate coupling to position working cam on top Visually inspect top of cam lobe for wear There is a thin area on this replaceable cam that does not contact the cam follower If cam is worn a ridge will develop between tip of cam and unused surface If the ridge is deep enough to catch a fingernail replace the cam see Gear Case Service If cam is not worn adjust valve lift 8 Go to step 11 under TEST NO 2 Water System Pressure and Flow HydroJect 3010 Page 6 17 IMPORTANT A reading of 0 090 to 0 102 does not guarantee a properly adjusted cam When in doubt inspect cam A worn cam whi
32. finger tight F F F T Step 4 Size F F F T 4 1 4 in nominal hose or tubing 1 00 25 6 3 8 in 1 50 25 8 1 2 in 1 50 25 10 5 8 in 1 50 25 12 3 4 in 1 50 25 16 1 in 1 50 25 General Information Page4 4 Figure 4 Lock N Lock Nut 1 Back Up Washer O Ring Figure 5 Step 1 Step 3 Step 4 Figure 6 F Hydroject 3010 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 When ever 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 1 Stop the engine and raise the hood 2 Open the by pass valve by turning it counterclockwise Figure 7 2 turns maximum 1 By pass valve 3 After moving the machine close the by pass valve by turning it clockwise 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 Page4 5 General Information Hydraulic Diagram
33. install pump head onto pump crankcase studs and plungers While installing tap evenly on pump head while turning pump crankshaft 2 Install eight 8 nuts onto studs and evenly torque locknuts to 25 33 ft lbs 3 Install water pump assembly into frame see Water Pump Removal and Installation PUMP HEAD Go through numbered sequence two 2 times 25 33 ft lbs Figure 37 Repairs Water Pump Crankcase Service Fig 38 18 20 ft lb 18 20 ft lb Apply grease to O D of plunger before installing Pumphead Figure 38 NOTE Replace parts in complete sets 1 Remove water pump from machine see Water Pump Removal and Installation 2 Remove pump head see Pump Head Service 3 Remove pulley from pump drive shaft using 1 4 in bolts to separate tapered hub 4 Remove rear cover Item 20 5 Remove connecting rod end caps Item 13 and keep them in original order Carefully push connecting rods Item 12 forward 6 Remove crank rod bearing caps Item 9 27 keeping shims Item 8 in their original locations Slide crank rod Item 15 out of the 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 Tool TOR4015 to drive guides out through crankcase Also use this tool for plunger guide installation Repairs Page 6
34. installation of the valve spring retainer 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 Seal Installation Tools Fig 9 Water Valve Seal Installation Guide TOR4009 The Water Valve Installation Guide small is needed to properly install the water valve seal into the water valve body Use Insertion Mandril with this seal guide Pump Seal Installation Guide TOR4010 The Pump Seal Installation Guide large is needed to properly 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 Mandril is necessary to properly install seals in the water valve and pump head Filter Body Wrench TOR4012 Fig 10 Special spanner wrench use for servicing the inlet water filter HydroJect 3010 Page6 7 gt Figure 9 1 Water Valve Seal Installation Guide 2 Pump Seal Installation Guide 3 Seal Installation Mandril Figure 10 Special Tools Pump Seal Extraction Tools Fig 11 Pump Seal Extraction Tool 4013 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 hydrauli
35. isolated such as low accumulator pre charge pressure This will verify that all components are operating properly A WARNING High pressure water system components can Figure 13 cause personal injury if disassembled incor rectly Discharge water pressure at bleed 1 High pressure bleed valve valve before attempting any water system servicing Open bleed valve slowly and avoid contact with high velocity water stream 2 With engine OFF open high pressure bleed valve and inspect aeration nozzles Check for plugged noz zles Verify size and quantity see Nozzle Service and 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 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 The charging tool is equipped with a Compressed Gas Association No 677 tank connection These tanks con tain enough
36. making terminals B L S and the hydraulic pump must be in Neutral Traction Switch 1 CLOSED KEY 5 Switch Clc Be 5 8 E O Switch Op sic a st S 7 ae 5 o oe 6 2 6 9 Switch Closed Momentarily I 2 je o PI le uj Switch Conditon Not Relevent 5 5 2 5 8 5 ja lt S 5 5 e 5 g 2 2 le 5 jo le g z 5 58 gt 55 5 2 ig lt 5 2 5 55 E 9 9 5 E 5 5 5 E mg 5 is 5 2 8 5 5 0 5 2 2 2 5152 ACTIONS 1 Start X X 2 Run X X 3 Machine Lower aerate position X O X 4 Aerate see Controller Timing below Machine Moving out of neutral X X X X X 9 X Machine Stationary neutral X X X X X X 5 Machine Raise transport position X X Controller Timing Aerate START UP Sequence 1 Pump clutch engages immediately 2 Valve clutch engages 5 seconds after pump clutch engages Aerate SHUT DOWN Sequence Neutral Delay 1 Pump clutch disengages and green light goes off 4 seconds after transport switch opens red light goes off 2 After another 3 seconds valve clutch will disengage NOTE Keeping aerate start engage switch pushed in closed will keep green light on and override neutral delay shut down Aerate SHUT DOWN Sequence Disengage Delay 1 Pump clutch dis
37. nozzle change Specifications Page 6 2 2 Hydroject 3010 Water System Schematic ACCUMULATOR 2500 PSI NITROGEN PRE CHARGE ELECTRIC CLUTCH RELIEF VALVE ENGINE 5000 PSI ELECTRIC BRAKE CLUTCH GEARBOX CAM PRESSURE SWITCH 20 PSI ON 10 PSI OFF PRESSURE GAUGE Ne L d SPRAY WASH VALVE FILTER PRE FILTER PRESSURE REDUCING VALVE Hydroject 3010 6 3 ROLLER WASH NOZZLES Q gt o Q Q Q Q HIGH PRESSURE AERATION NOZZLES QUICK COUPLER WATER SUPPLY Water System Schematic Special Tools The following special tools are required for servicing the Order special tools from the TORO SPECIAL TOOLS HydroJect 3010 AND APPLICATIONS GUIDE COMMERCIAL PRODUCTS Accumulator Charging Valve and Pressure Gauge 4001 Fig 2 The charging valve connects the accumulator to a high pressure 3000 3500 or 6000 PSIG Nitrogen tank for pre charging 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 pressed Gas Association No 677 tank connection Figure 2 1 Accumulator connector 4 Inlet valve 2 Pressure gauge 5 Relief valve 3 Outlet valve with diffuser 6 Nitrogen tank connector Accumulator Seal Installation Tool TOR4002 Fig 3 Used for insta
38. or contami nation Polish sealing area on shaft if necessary 4 Lubricate new seal with petroleum jelly 5 Wrap shaft with thin plastic or use a seal protector to prevent damage to seal lip during installation 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 Top of pump when installed in machine Page 4 16 Figure 21 1 Retaining ring 2 Seal input shaft 3 Spacer 4 Seal displacement control shaft Hydroject 3010 Pump Charge Check Valve Service Fig 22 1 Remove check valve plug with a 1 4 in internal hex wrench 2 Remove valve spring and check ball from pump end cap IMPORTANT Do not allow check balls to fall into closed loop passages in end cap 3 Inspect check balls and mating seats in end cap for damage or foreign material 4 Lay pump on its side and reinstall check ball spring and plug with O ring into end cap Make sure check ball does not fall into closed loop passage inside pump Tighten plug to a torque of 15 to 35 ft lb Turn pump over and repeat installation procedure for other check valve Pump Bypass Valve Service Fig 23 1 Unscrew bypass valve from end cap of pump 2 Inspect valve and mating seat in end cap for damage and foreign material It is recommended that the O ring and back up ring be replaced 3 Reinstall bypass valve i
39. out of neutral push then re lease green aerate ENGAGE button Green light should come ON and pump clutch should engage After 5 seconds 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 bail Red light should turn OFF B After 4 seconds pump clutch should disengage and green light should go OFF 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 Testing Page 5 16 B After clutches are engaged push red aerate DISENGAGE button C Green light should immediately turn OFF and pump clutch should disengage D After 3 seconds valve clutch should disengage E System must not restart without pushing green aerate ENGAGE button IMPORTANT When test is completed water pres sure switch by pass must be removed to prevent damage to water system from low inlet water pres sure 7 Remove by pass jumper wire that was connected in step 2 and connect wire harness connector to terminals on bottom of water pressure gauge Figure 8A 1 Red light 2 Green light 3 Yellow light Figure 8B 1 Red light 2 Green light 3 Yellow light Hydroject 3010 Ignition Switch The ignition key switch has three positions OFF RUN and START Fig 9
40. per second at maximum load Testing Page 5 20 Hydroject 3010 Brake Switch Fig 17 The brake switch is a normally open N O switch that closes when the brake is engaged To test the brake switch disconnect the wires from the switch terminals and connect a continuity tester or ohm meter across the terminals of the switch With the brake disengaged the switch should show no continuity With the brake engaged the switch should show continuity Figure 17 1 Brake switch Pressure Gauge Switch Fig 18 The pressure gauge switch is normally open and closes when inlet water pressure goes above 20 to 30 PSI The switch opens when inlet water pressure goes below approximately 10 PSI To test the pressure switch disconnect the wire connec tor and connect a continuity tester or ohm meter across the terminals of the switch 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 Pressure gauge switch Accumulator Charge and High Pressure Limit Switches Fig 18a The accumulator charge switch is normally open and closes when accumulator charge pressure is greater than 1800 PSI The switch opens when accumulator charge pressure goes below 1400 PSI The high pressure limit switch opens at 5500 PSI rising pressure and closes at 5350 PSI falling pressure A DANGER The a
41. remove the hood 2 Disconnect both the positive and negative cables from the battery Loosen the battery clamp Item 31 and remove the battery 3 Drain the oil from the engine into a suitable container 4 Disconnect the drive coupling from the clutch adapter see Drive Coupling Removal and Installation in Water System Service 5 Remove the water pump drive belt and hydraulic pump drive belt 6 Disconnect the engine wiring harness connector Dis connect and plug the fuel hose 7 Remove four nuts Item 24 capscrews Item 28 and washers Item 25 securing the engine to the frame 8 Attach an engine lifting chain to the engine lifting straps Connect the chain to a hoist or block and tackle and remove slack from the chain and lifting device One person should operate the hoist or block and tackle and the other person should help guide the engine out of the frame Remove the engine from the frame 9 Mount the engine in an engine rebuilding stand or put it on a sturdy workbench Before disassembling the en gine remove external accessories such as the muffler air cleaner hydraulic pump clutch hydraulic pump pulley water pump clutch and clutch key see Drive Coupling Removal and Installation in Water System Service 10 To install the engine perform steps 2 9 in reverse order 11 Replace the oil filter and fill the engine with the cor rect oil Figure 1 Kohler Engine Page3 4 H
42. seat aligns during assembly Bleed valve in base allows for bleed off of high pressure and drain down for cold weather storage Bolted flanges and polyurethane rings mate all components to valve body Valve lift 0 100 9 002 _ 94 inch with new Rollers Pivoting aluminum rollers uniformly smooth the turf and provide protection from the nozzle dis charge Adjustable flow 0 3 GPM spray wash system with 6 flood tip nozzles maintain clean rollers Pressure Relief Valve Poppet type valve with corro Sion resistant stainless and brass materials 5000 300 PSI relief valve pressure Manifold and Nozzles Extruded stainless steel man ifold with11 flanged nozzle extensions containing check valves and hardened stainless discharge orifice Check valves may be reversed in housing to block unused nozzles Aeration Width 33 inches with 11 nozzles on 3 inch centers Aeration Depth 4 to 6 inches depending on turf condi tions and nozzle configuration Hole Pattern Variable from 1 5 to 6 spacing in the di rection of travel and 3 or 6 increments in width Water Pump Case Oil See Operator s Manual Water Supply Recommend a source with 7 8 gallons per minute A minimum pressure of 30 psi at the ma chine is required for the pump to engage Maximum al lowable pressure of 200 psi Although irrigation water pumped from ponds or effluent holding pools can be used not all conditions can be handled by th
43. system compo nents can cause personal injury if disassembled in correctly Discharge water pressure at bleed valve before attempting any water system servicing Open bleed valve slowly and avoid contact with high velocity water stream 2 Open High Pressure bleed valve Remove accumula tor see Accumulator Replacement Remove manifold manifold feeder and manifold support as an assembly from water valve 3 Disconnect drive coupler from gear case hub adapter see Drive Coupling and Clutch Removal and Installa tion 4 Drain oil from gearcase Disconnect hydraulic lines from gearcase Remove four 4 capscrews securing gear case to water valve and carefully pull gear case off of gear box pilot on water valve 5 Disconnect valve seal drain tube by unscrewing small fitting at pump inlet Remove two 2 locknuts from studs securing water valve to frame Remove four 4 caps crews connecting water valve to water pump head Re move water valve and put it on a clean work bench 6 Install valve spring tool studs through the Valve Spring Compressor 4008 and into threaded holes of wa ter valve 7 Tighten nuts to compress tool until retaining ring Item14 can be removed from valve spool Remove re taining ring then carefully loosen nuts on special tool re leasing valve spring compression 8 Remove spring retainer Item 15 and spring Item16 from water valve stem Remove screws Item13 from gear case pilot
44. they securely in place Traction Unit 1 Thoroughly clean machine 2 Grease or oil all fittings or pivot points 3 Check to make sure all tires are over inflated to 20 30 p s i 4 Lightly sand and use touch up paint on all areas that are scratched chipped or rusted 5 Drain and replace hydraulic oil and filter on cam gear case 6 Drain and replace oil in water pump case 7 Clean the battery terminals and posts with a wire brush and baking soda solution Coat cable terminals and battery posts with skin over grease or petroleum jel ly Recharge battery Hydroject 3010 Chapter 7 Wheels Brakes and Steering TORO Table of Contents ADJUSTMENTS 2 REPAIRS zuo ne td ane E aan ane 3 Brake Adjustment 2 Brake Service 3 Wheel Bearing Service 4 Hydroject 3010 Page 7 1 Table of Contents 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 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 Repairs Brake Service Fig 2 Torque to 20 250 to 400 ft Ib
45. wheels Chain machine to an immovable object and remove slack from chain 13 With tester flow control valve open slowly 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 maximum pressure is attained with wheel not rotating and read flow gauge 14 If flow reading is higher than 1 5 GPM motor may have internal damage or excessive wear Figure 10 1 Hose 2 Bulkhead fitting Figure 11 Hydroject 3010 Adjustments Traction Cable Adjustment Fig 12 1 Park machine on a level surface stop the engine and open the hood Remove lower cover from handle 2 Adjust pump end of push pull cable with pump lever in neutral starting position by adjusting jam nuts so distance from seal to threads is 1 00 0 05 in 3 Adjust jam nuts at tiller end of push pull cable so traction handle is centered on control handle Speed Control Adjustment Fig 13 1 Park machine on a level surface stop the engine and open the hood 2 Adjust speed control cable Item 26 so speed stop lever Item 9 can move to horizontal position Figure 12 1 Jam nuts pump end 2 Jam nuts tiller end 3 Adjust speed rods Item 14 so rod end mounting holes in pivot arms Items 11 23 are located vertically in line with pivot pin Item 22 Figure 13 Hydroject 3010 Page 4 11 Adjustments Transmission Neutra
46. 1 INTERFER ENCE FIT see chart 8 Tighten fasteners Item 10 to a torque of 18 20 ft lb Repairs Page 6 27 from dial indicator to get 006 001 015 014 014 012 Hydroject 3010 This page is intentionally blank Repairs Page 6 28 HydroJect 3010 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 The water valve consists of atapered valve stem sealing against a captured valve seat The valve seat is sealed on both sides One valve seat seal contacts the water valve body and the other seal contacts the manifold feeder When the manifold feeder is installed on the wa ter valve the seals are compressed locking in and maintaining correct alignment of the water valve and also preventing blow by Any abrasives in the water will rapidly erode the valve surfaces The valve and valve seat can be ground and lapped to renew their working surfaces After grinding adjust the valve lift by measuring the lift and adjusting the shim stack thickness The shim stack is loc
47. CURE 13 R W 16 4 87 55 W38 Y 16 5 COIL W40 BU 16 SP1 B FUSED POWER WB5 GN 16 11 3e COMMON T 1 W44_OR_16 W16 BK 16 42 85 EX COIL 2 ws52 8 1 6 P37 Ww 186 313 874p 1 48 E La 5 7 Y 18 4 8 59 4 W42 BU 16 4 5 86 COIL 5 L wW53 W 16 W43 GN 16 3 1 COMMON x 1 W49 Y 16 W56 BK 16 2 85 Qn COL 0 2 W 9 8K 16 55 16 3 wc B gt 5 2 4 87 88 N O 4 L wW6 VIO 16 W45 BU 16 34 5 88 COIL 5 L W48 W 16 7 OR 6 b E 6 454 W54 PK 18 4 8 gc X0 a wW47 W 16 B L w27 OR 16 W54 PK 16 41 COMMON a 17 14 85 2 col un D KEY WIRE COLORS W46 BU 16 5 87 16 N C 5 R RED SK BLACK GREEN ORANGE aH Bj NO Y YELLOW BR BROWN GY GRAY PK PINK W WHITE BU BLUE VIO VIOLET 85 Gy 16 oe 88 Colle T TAN I 3 QN 16 Wa SER n 2 si W3 _O0R_16 8 Ze 25 Hydroject 3010 Main Wiring Diagram Page8 5 P25 MAIN HARNESS T m v lt NH H0 Z 5 0 2 0 PAN 5 CN lt Bc s ENGINE GROUND PRESSURE GAGE ENGINE GROUND STARTER B IN CIRCUIT BREAKER OUT HOUR METER MAIN HARNESS PRESSURE GAUGE SWITCH J21 J22 425
48. Cause Transport wheels not fully raised unit lowered to aerate mode Low inlet water pressure Sheared pump clutch key Electrical problem Correction Check to make sure transport wheel arms are fully raised unit in aerate mode Check that water pressure gauge reads 20 to 30 PSI or more If pressure is low obtain proper water supply source Repair See Troubleshooting in Chapter 5 Electrical System Machine does not start aerating when engage button is pushed in pump belt IS rotating but gear case drive shaft is NOT rotating Electric brake clutch valve clutch out of adjustment Sheared valve clutch key Electrical problem Check air gap at electric brake clutch and adjust if necessary Repair See Troubleshooting in Chapter 5 Electrical System Machine makes unusual noise when first starting aeration Air in system NOTE Relief valve may squeal for a short period of time during initial startup due to air in the system Damaged component With engine OFF and water supp ly connected open high pressure bleed valve and bleed air out of system Repeat procedure if noise continues Check for damaged components and repair or replace as neces sary HydroJect 3010 Page 6 9 Troubleshooting Condition Machine stops aerating pump shuts down during aeration Possible Cause Machine not moving Inadequate water supply Plugged i
49. Engine cranks but should not with traction bail in neutral See Safety Interlock System Prob lems Engine starts but shuts down when ignition key switch is re leased to RUN position Not electrical regulate choke dur ing cold start up Not electrical low engine oil pres sure Oil pressure switch faulty Loose or broken wire in oil pres sure switch circuit Normal condition Find and correct cause of low en gine oil pressure Test switch and replace if faulty Check all wiring and connections and repair as necessary Starter does not disengage when key switch is released to RUN po sition Ignition switch faulty Short in start circuit wiring Start relay faulty Starter solenoid faulty Starter failed mechanical Test ignition key switch and re place if faulty Check all wiring and connections and repair as necessary Test start relay and replace if nec essary Test starter solenoid and replace if necessary Test starter and replace if neces sary Troubleshooting 5 8 Hydroject 3010 General Run and Transport Problems Condition Possible Cause Correction Engine shuts down during trans port or when idling not in Aerate mode Not electrical low engine oil pres sure no fuel etc Oil pressure switch faulty Loose or broken wire in oil pres sure switch circuit Find and correct cause of engine shut down
50. HOWN IN TRANSPORT p4 TOP P3 E Ewe le 895 2 Pan o 3 3 LOW PRESS STOP E 29 Msc ee 8 Eu 45 SHOWN WITH LOW PRESSURE pup ud m Sirs 2 1 2 0 d 4 5 Sz 55 l SHOWN WITH LOW PRESSURE TET 5 8 BS 48 BS PiB B L 5 LOW PRESSURE WARN 2 ES ES a e OR o 8 CONTROL MODULE E S ES t ACCUMULATOR LOW PRESSURE SWITCH 72 4320 1 Fan a SHOWN WITH LOW PRESSURE CONTROL PANEL HARNESS OR 30 MUR 87 3 P5 c P25 c D P19 Y Y SHOWN WITH NORMAL PRESSURE 4 760 1480 874 HARNESS ACCUMULATOR LOW WARNING NC P31 6 Pie 13 70 1480 NEGATIVE BATTERY CABLE ME 31690 M cei 9 Ps ieu 188 222 TILLER HARNESS 108 1201 eye Im ae a GN zs 5 xo x ox WATER DISENGAGE BUTTON 86 9280 a a i 5286 fn 85 2 ENGINE FRAME 234 NC BU BK e BATTERY d a 0 lt PUMP CLUTCH STOP E c COM J33 P31 E P1 E 5 108 1260 PK PK PK K WATER ENGAGE BUTTON 806 9280 100 1535 3 P31 C P1 C P11 B YEL RED P11A PB2 vF GN GN GN MM SHOWN WITH NORMAL PRESSURE 2 WHEEL LIFT ACTUATOR Se ork 14 5219 5 Pressure uc 2 e A BU BK 59 5 P31 D P1 D BU SHOWN WITH HIGH PRESSURE 5
51. ITCH J23 CIRCUIT J24 BREAKER a HOUR METER P26 LIGHT HIGH PRESSURE P27 LIGHT LOW PRESSURE P26 P27 LIGHT LIGHT HIGH LOW PRESSURE PRESSURE Hydroject 3010 Control Panel Harness Page 8 6 FS MAIN HARNESS ABCD HGFE 2 z EXE 5 lt 9 c ang m gc T A LO 012 355 J 9 1 WATER DISENGAGE J 5 2 SWITCH J 5 3 J34 Teh TRANSPORT m 3 2 TRANSPORT SWITCH oF AGA 7 B P52 e ee a v v 8 lt 5 ERE i FD oS um Er MAIN HARNESS P351 A BIC O E F G H ES gt sl E a d d amp 59959522 1 L ws88 BU 16 W92 GY 16 34 151 W81 OR 18 W93 W 16 12072 2 82 OR 18 W85 GN 16 5 86 GN 16 W89 PK 16 4 J353 4 86 GN 16 W82 OR 16 J34 85 8 16 5 WB4 BK 16 wWB88 BU 16 W90 Y 16 3 J36 6 W87_BU_ 18
52. Item 10 stuck in the pump head 3 Insert new seals Item 10 and check valves Item 9 4 Install new seals Item 8 in check valve caps Apply Loctite 242 or equivalent to threads install caps and tighten to a torque of 205 235 ft lbs PLUNGER SEAL REMOVAL Step 2 Fill the three 3 plunger openings with water Insert Pump Seal Extraction Tool TOR4013 into each water filled cavity Quickly strike the extraction tool with a heavy lead mallet Seal assembly and brass retainer should move about 1 4 in out of the cylinder head If seal does not move add more water and try again If the seal does not move after a few attempts try using heavy oil or grease instead of water HE PLUNGER SEAL REMOVAL Step 1 Fill outlet port of pump head with water and use two capscrews to temporarily install Pump Seal Outlet Cover TOR4014 onto the outlet port of the pump head HS zb Torque to 25 33 ft Ib Eight locations 5 r 17 Use Loctite 242 or equivalent 8 PR Torque to 205 235 ft lb Six locations Figure 36 Repairs Page 6 24 HydroJect 3010 Plunger Seal Replacement See illustration on previous page NOTE Check valves must be in good condition for this procedure to work correctly 1 Fill pump head outlet cavity with water then use two capscrews to temporarily install Pump Seal Outlet Cov er TOR4014 onto outlet port of pump head Check valves must b
53. Kilogram Meters 0 1383 Inch pounds Kilogram Centimeters 1 152144 Liquid Volume Quarts Liters 0 9463 Gallons Liters 3 785 Liquid Flow Gallons Minute Liters Minute 3 785 Temperature Fahrenheit Celsius 1 Subract 32 2 Multiply by 5 9 Product Records and Maintenance Page 2 2 Hydroject 3010 Torque Specifications Recommended fastener torque values are listed in the following tables For critical applications as determined by Toro either the recommended torque or a torque that is unique to the application is clearly identified and spe cified in this Service Manual These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Ser vice Manual The following factors shall be considered when applying torque cleanliness of the fastener use of a thread sealant e g Loctite degree of lubrication on the fastener presence of a prevailing torque feature hardness of the surface underneath the fastener s head or similar condition which affects the installation Fastener Identification Grade 1 Grade 5 Inch Series Bolts and Screws Figure 1 Hydroject 3010 Page 2 3 As noted in the following tables torque values should be reduced by 25 for lubricated fasteners to achieve the similar stress as a dry fastener Torque values may also have to be reduced when the fastener is threaded into aluminum or brass The speci
54. Nitrogen for 20 30 fills NOTE During operation working pressure of Nitrogen in accumulator will be equal to the operating pressure of the water system 1 Park machine on a level surface stop the engine engage the parking brake open the hood and discon nect the engine spark plug wires A DANGER Charged accumulators contain high pressure nitrogen Nitrogen is the only gas to use for accumulator charging Installing IMPROPER gases in an accumulator can cause an EX PLOSION AND DEATH Charging requires special tools and precautions Charge ac cumulators in a well ventilated area It is recommended that the accumulator be 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 Opening the high pressure bleed valve allows any trapped water to escape from the system and also allows accumulator piston to move to bottom of accumulator cylinder Failure to open bleed valve before servicing high pressure water components can cause personal injury DIS MEMBERMENT OR DEATH Charged accumulators cannot be shipped via air freight 2 Slowly open the high pressure bleed valve allowing any pressurized water to escape 3 Remove protective cover and yellow valve cap from top side of accumulator HydroJect 3010 Page 6 13 Figure 14 1 High pre
55. PUMP E Orifice uu Val otor Input Disp Pu Charge Q T Pump By pass Valve EST c Relief Valve EIL YY M EQNPRPUR Inlet Filter e FILTER Reservoir pos 1 Gear Case Figure 8 Hydraulic Diagram Page4 6 Hydroject 3010 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 9 Low Pressure Gauge Inlet Hose Outlet Hose Flow Meter High Pressure Gauge Figure 9 You must have o ring face seal ORFS adapter fittings for this tester to use it on the HydroJect 3010 1 INLET HOSE Hose connected from the system circuit to the 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 accurate reading at low pressure 0 1000 psi This gauge has a protector valve which cuts out when pressure is about to exceed the normal range for the gauge The cutout pressure is adjustable Hydroject 3010 4 7 4 HIGH PRESSURE GAUGE High range gauge to accommodate pressure beyond the capac
56. SASSEMBLING 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 1 Remove key Item 11 from shaft 2 Mount motor in a vice or other holding device with shaft facing down 3 Remove the eight capscrews Item 1 4 Remove cover amp bearing assembly Item 2 and square ring seal Item 4 5 Remove IGR assembly Item 5 starting with outer locating ring rollers outer rolls inner rotor and valve plate Item 7 If any of these components are damaged entire IGR assembly must be replaced 6 Remove the two check balls Item 6 Repairs Page 4 24 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 Disassembly of Shaft Section of Motor See Disassembly of Shaft and Front Seal Assembly under Main Shaft Seal and or Shaft Replacement Assembly of Complete Motor 1 Before assembly all parts must be cleaned with a suitable solvent and free of nicks and burrs 2 Mount body with pilot and bearing facing up in a vise or other holding mechanism 3 Insert shaft Item 10 and install seals and thrust bearings See Assembly of Shaft and Front Seal As sembly under Main Shaft Seal and or Shaft Replace ment 4 Mount body with pilot and bearing facing down in a vise or other holding fi
57. The accumulator tool attached to the accumulator has a pressurized manifold Open inlet valve on left hand slide of charging tool to pressurize supply tube While watching pressure gauge on tool slowly open supply tank valve Pressure reading on gauge will start to rise Close supply tank valve when gauge pressure reaches 2500 PSI Wait a few minutes to make sure system pressure has equalized then add additional Nitrogen if necessary for 2500 PSI pre charge 12 Close accumulator valve by turning lower nut clock wise 13 Slowly open knob on right hand side of charging tool de pressurize the tool then remove tool from ac cumulator 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 Jam nut Figure 16 Figure 17 HydroJect 3010 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 A WARNING High pressure water system components can cause personal injury if disassembled incor the hood rectly Discharge water pressure at ble
58. Tighten all threaded parts to recommended torque value IMPORTANT Most parts have critical high toler ance surfaces Use caution to prevent damage to these surfaces during assembly Protect exposed surfaces openings and ports from damage and foreign material 2 displacement control shaft bearing Item 17 has been removed press a new bearing into housing using a suitable press pin Surface of bearing should be flush with inside 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 Repairs Page 4 20 3 Install displacement control shaft Item 12 into hous ing 4 f block spring retaining ring Item 10 was removed from pump shaft install a new retaining ring at this time 5 Install inner bearing retaining ring Item 20 onto shaft Press bearing Item 21 onto shaft install washer if used and new outer bearing retaining ring Be careful not to stretch or deform retaining rings IMPORTANT Be careful not to damage shaft sealing surface 6 Install pump shaft and bearing assembly into housing 7 Install bearing spacer washer Item 22 8 Wrap shaft with thin plastic or use a seal protector to prevent damage to seal during installation Lubricate new pump shaft seal Item 23 with petroleum jelly 9 Slide seal over shaft and press it into housing bore Be careful not to damage the seal 10 Insta
59. ace stop the engine engage the parking brake and disconnect engine spark plug wires 3 Open the hood 4 Disconnect linear actuator wire connector 5 Disconnect extension springs 6 Remove capscrew and nut securing each end of linear actuator 7 Reverse steps 3 6 to install the linear actuator Hydroject 3010 Page 5 27 1 Linear actuator 2 Wire connector Le Figure 28 3 Extension spring 4 Capscrew amp nut Repairs Repairs Page 5 28 Hydroject 3010 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 Water System Pressure Gauge Flow Valve Lift Indicator Valve Spring Compressor Water Valve Seal Installation Guide Pump Seal Installation Guide Seal Installation Mandril Filter Body Wrench Pump Seal Extraction Tool Pump Seal Outlet Cover Pump Wear Sleeve Driver TROUBLESHOOTING Troubleshooting Water System Problems HydroJect 3010 Page 6 1 Chapter 6 W
60. achine See Electrical bleshooting and safety Schematic Starting Problems Condition Possible Cause Correction Engine fails to crank regardless Loose or corroded battery connec Clean and tighten connections of traction bail position tions Low battery charge Charge battery Replace battery if it will not hold a charge also see Battery does not charge under General Run and Transport Prob lems Circuit breaker open Reset circuit breaker Find cause for open circuit breaker and cor rect Replace circuit breaker if faulty Ignition key switch faulty Test switch and replace if faulty Traction switch 1 faulty Make sure switch is properly in stalled and adjusted Test switch and replace if faulty Start relay faulty Test relay and replace if faulty 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 5 7 Troubleshooting Starting Problems continued Condition Possible Cause Correction Engine cranks but does not start NOTE If engine cranks cause of problem is UNRELATED to inter lock system Engine wire harness loose L terminal on ignition key switch loose Engine problem or no fuel Connect wires Connect wire Find problem and correct see Chapter 3 Engine
61. airs Water Pump Head Service Fig 36 The three major wear components in the high pressure pump that require maintenance include the check val ves plunger sleeves and plunger seals These com ponents will require maintenance after approx 500 pump operating hours approx 750 engine hours A WARNING High pressure water system components can cause personal injury 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 velocity water stream NOTE Because of high torque requirements for check valve caps and difficulty of correctly installing check valves in horizontal position it is recommended that the pump head be removed from the crankcase when ser vicing NOTE Whenever a pump is removed from the machine for preventative maintenance or servicing replace com ponents in complete groups rather than individually Complete servicing will increase the service interval between repairs Pump Head Removal 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 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 old check valves Item 9 and remove any remaining seals
62. and bearing assembly from housing 15 Remove outer bearing retaining ring Item 21 and washer if used Press shaft out of bearing 16 If pump block retaining spring retaining ring Item 10 requires replacement remove it from pump shaft 17 Remove displacement control shaft from housing 18 Pry displacement control shaft seal out of housing Care must be taken so as not to damage housing bore 19 If displacement control shaft journal bearing re quires replacement press it out of housing Inspection and Replacement of Pump Parts After disassembly thoroughly clean all parts in a suit able solvent Replace all o rings gaskets and seals Inspect all parts for damage nicks or unusual wear patterns Replace all parts having unusual or excessive wear or discoloration Inspect seal surfaces bearing surfaces and shaft spli nes Polish sealing areas on shafts if necessary Re place any worn or damaged parts The pump shaft bushing Item 5 is pressed into end cap and is usually not removed The running surfaces of cylinder blocks MUST be flat and free from scratches If scratches or wear are found on running surfaces of cylinder blocks or end cap polish or replace the parts When polishing these surfaces up to 0 0004 in may be removed If this is not sufficient to obtain a flat surface free of scratches the part should be replaced Assembly of Hydraulic Pump 1 Clean and lightly oil parts before assembly
63. ar piston pump and motor might be suspected of wear and inefficiency thus charge pump is unable to keep up with internal leakage TEST B Traction Pump Flow 6 Lift the drive wheel off the ground using a jack Block front and rear of the other wheels Make sure the tester flow control valve is OPEN 7 Start the engine and release the parking brake 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 pressure is less than 200 to 300 PSI go to step 10 If pressure is more than 200 to 300 PSI stop the engine and inspectfor binding parking brake Inspect for restric tion in lines to and from motor If there are no restrictions motor should be suspected of having internal damage 10 While watching flow and pressure gauges move traction handle up or down to full speed position so flow is from the pump through the tester then to the wheel motor Slowly close flow control valve until you get readings of 7 GPM and 500 PSI Testing Page 4 10 NOTE At pressures above approximately 500 PSI mechanical override in handle will cause pump to begin to de stroke 11 If you cannot get 7 GPM or 500 PSI traction pump may have internal damage or excessive wear TEST C Traction Motor Efficiency 12 Lower drive wheel to ground and engage parking brake Block front and rear of all
64. ate running surfaces of end cap Item 31 and cylinder blocks Item 7 Position housing opening UP and install end cap onto housing Item 18 IMPORTANT Make sure all parts are properly aligned Do not force end cap into position on hous ing Be careful to prevent damage to end cap and cylinder block sealing surfaces 21 When end cap is 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 in Ib 23 Rotate shafts to assure correct assembly When properly assembled minimal torque should be required to turn shafts 24 Wrap end of displacement control shaft with thin plastic or use a seal protector to prevent damage to seal during installation Lubricate new displacement controls shaft seal Item 16 with petroleum jelly Slide seal over shaft and press it into housing bore Be careful not to damage seal Install seal flush to bottomed in bore Figure 26 Hydroject 3010 Page 4 21 Repairs Wheel Motor Removal and Installation Fig 27 Torque to 250 to 400 ft Ib 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 2 Remove wheel nuts Item 23 and remove wheel Remove large nu
65. ated be tween the water valve body and gear case flange If the high pressure seal leaks for extended periods of time water may be forced past the oil seal and into the gearbox If the gearbox oil looks milky or brown flush the system immediately replacing oil filter and fluids in hy drostatic transmission and wheel motor The water valve assembly is similar to the pump head It uses the same ceramic sleeve and seals Since the water valve is the junction point for all high pressure liq uid movement and is fairly difficult to access complete rebuilding is recommended when this assembly is re moved Seal Replacement There are two major seals in the water valve that will re quire regular maintenance or replacement One seal keeps high pressure water in the high pressure water system and the other seal keeps the gear case oil within the gear case The high pressure water seal is 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 seal fails water will leak out between shims If low pressure water seal and oil seal fail water will leak into the gear case Hydroject 3010 Page 6 29 Water Valve Disassembly 1 Park machine on a level surface stop the engine en gage the parking brake open the hood and disconnect the engine spark plug wires WARNING High pressure water
66. ater System TESTING e a er etes 12 Before Performing Water System Tests 12 TEST NO 1 Accumulator Pre Charge Pressure and Adding Dry Nitrogen 13 TEST NO 2 Water System Pressure and Flow 15 TEST 3 Water Valve Lift 17 ADJUSTMENTS 18 Electric Clutch Adjustment 18 Water Valve Lift 18 REPAIRS e nef pa E te ee Us ACE Ge 20 Drive Coupling and Clutch Removal and Installation 20 Pump Drive Belt Replacement 21 Water Filter Replacement 22 Water Pump Removal and Installation 23 Water Pump Head Service 24 Water Pump Crankcase Service 26 Water Valve Service 29 Gear Case Service 32 Nozzle Service and Replacement 33 Accumulator Replacement 34 Accumulator Service 36 GENERAL INFORMATION 38 Cold Weather Storage 38 Table of Contents 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 plas tic housing with air bleed
67. bottom side of valve housing to water pump inlet by backing out small 1 16 NPT fitting Fig 39 Item 31 Plug open port with a 1 16 NPT plug Do this test procedure again beginning with step 1 If pressure AND flow is still low rebuild pump After rebuilding pump do this test procedure again beginning with step 1 to verify that valve is sealing properly 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 1 Flow meter pressure gauge TOR4006 If pressure is low but flow is OK make sure cam is not on roller follower keeping valve in open position If water is exiting outlet fitting on relief valve replace relief valve If water is not exiting outlet fitting on relief valve rebuild water valve After replacing relief valve or rebuilding water valve do this test procedure again beginning with step 1 to verify that pump has adequate flow at specified operating pressure If pressure is OK but flow is low rebuild pump 10 Perform Test No 3 Water Valve Lift 11 Do steps 2 4 and 6 8 of this pressure and flow test i p y again with valve clutch connected to wire harness Figure 23 Pressure gauge needle will go rapidly to the relief 1 Relief valve 2 Hose setting 5000 300 PSI for 3 to 4 seconds then begin to fluctuate rapidly when the unit begins aerat WARNING 4000 to 4500 PSI plan to rebuild the valve
68. button Water Filter Cartridge Toro part no 86 8630 Water Pressure Switch Senses for water pressure after filter Switch closes when pressure is over 20 28 PSI and opens when pressure drops below 7 13 PSI Pump Toro exclusive design with cast stainless steel head and 3 piston plungers Vee packing seals and Ke vlar guides Forged crankshaft with plasma sprayed ce ramic on stainless steel plungers and cast iron connecting rods Nominal performance is 4 GPM at 5000 PSI with 1400 RPM input Accumulator Toro exclusive design with low charge pressure sensor Charged with nitrogen gas charged to 2500 PSI maximum pressure Low charge pressure limit switch Closes at 1800 PSI Opens at 1400 PSI High operating pressure limit switch Closes at 5500 PSI rising pressure Opens at 5350 PSI falling pressure Cam and Gearbox Reduction gear drive for cam that actuates main water valve Roller cam follower rides on cam specifically designed patent pending to control water injection at 5 3 cycles per second 320 rpm and store energy in accumulator between injections Cast iron case also serves as 4 quart hydraulic reservoir Valve Cast stainless steel valve body functions as mounting base for accumulator gearbox and manifold Specifications Page 6 2 outlet All high pressure water flows in and out through the valve body Pressure balanced valve spool with floating patent pending hardened stainless
69. c system all pressure in the system must be relieved by stopping the en gine and opening the bypass valve Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid un der high pressure Use paper or cardboard not hands to search for leaks Hydraulic fluid escaping under pressure can have sufficient force to penetrate skin and do serious dam 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 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 Put caps or plugs on any hydraulic lines left open or exposed during testing or removal of components 3 The engine must be in good operating condition Use a tachometer when making a hydraulic test Engine speed can affect the accuracy of the tester readings 4 To prevent damage to tester or components the inlet and the outlet hoses must be properly connected and not reversed tester with pressure and flow capabilities 5 To minimize the possibility of damaging components completely open the load valve by turning it counter clockwise tester with pressure and flow capabilities 6 Install fittings finger tight far enough to insure that they are not cross threaded before tightening w
70. cally 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 Figure 12 Special Tools Page 6 8 HydroJect 3010 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 Troubleshooting Water System Problems Refer to the Testing section of this Chapter for precau tions and specific test procedures NOTE 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 If you perform water system tests to isolate a possible problem such as reduced hole depth it is recommended that ALL tests be performed 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 Condition Machine does not start aerating when engage button is pushed in pump belt does NOT rotate Possible
71. ccumulator contains nitrogen gas under high pressure DO NOT attempt to remove or Figure 18a replace these switches without first opening the high pressure water bleed valve and then 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 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 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 12V DC is applied to terminals 85 and 86 Figure 19 860 87A 87 30 85 Bla 87 85 30 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 5 22 Hydroject 3010 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 cont
72. ch has been adjusted to 0 090 to 0 102 will not perform properly A worn cam can cause opening of valve on lead in portion of cam in this range Cam lobe Lead in portion Lead out Lead in to lead out is two 2 rev of pinion Figure 24 2 Cam 3 Follower Figure 25 1 Valve lift indicator TOR 4007 Testing 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 discon nect 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 NOTE It may be necessary to remove clutch retainer to allow clutch rotation for access to all three 3 adjust ment nuts Figure 26 1 Locknut 3 Water Valve Lift Adjustment Fig 27 28 29 1 Park machine on a level surface stop the engine engage the parking brake open the hood and discon nect the engine spark plug wires A WARNING High pressure water system components can cause personal injury 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 velocity water stream Lead in to lead out is two 2 rev of
73. ches The LED s in conjunction with the following tests for interlock switches should be used to help isolate a problem in an interlock switch wiring orthe controller see Wiring Schematics and Diagrams Traction Switch 1 and 2 Fig 12 Traction switch 1 is normally open N O and is closed when traction bail is neutral 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 the COMMON and terminals The Traction switch 2 must have the wires con nected to the and terminals If the wires are not connected to the correct terminals on each switch the safety interlock circuit will not function properly Test the switch by disconnecting the wires from the switch terminals and connecting a continuity tester across the two terminals that had wires connected to them With the engine turned off slowly push the trac tion bail in a forward and reverse direction while watch ing the continuity tester There should be indications that the switch is opening and closing Allow the traction bail to return to neutral There should be continuity across the terminals of traction switch 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 fo
74. d in the table above by 25 for lubricated fasteners Lubricated fasteners are defined as threads coated with a lubricant such as oil graphite or thread sealant such as Loctite NOTE Torque values may have to be reduced when installing fasteners into threaded aluminum or brass 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 26 3 N m 38 4 ft lb 52 5 N m 53 5 ft lb 72 7 N m 66 7 ft lb 90 10 N m 92 9 ft lb 125 12 N m 166 15 ft lb 225 20 N m 229 22 ft lb 310 30 325 33 ft lb 440 45 N m 450 37 ft lb 610 50 Page 2 5 27 2 ft lb 36 3 N m NOTE The nominal torque values listed above are based 75 of the minimum proof load specified in SAE J1199 The tolerance is approximately 1096 of the nominal torque value Product Records and Maintenance Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Recommended Torque Thread Size Grade 5 14 20 UNC 140 20 inb 1 2 20 UNF 80 10 ft lb 108 14 5 16 18 UNC 215 35 in lIb 145 20 in Ib Grade 5 3 8 16 UNC 35 10 ft lb 18 3 ft lb 108 14 N m Class 8 8 75 15 ft b M12 X 1 5 80 10 ft lb 108 14 E Iu For steel wheels and non lubricated fasteners Thread Cutting Screws Thread Cutting Screws Zinc Plated Steel Z
75. e TEST NO 3 Accumulator Pre Charge Pressure and Adding Dry Nitrogen in the Testing section HydroJect 3010 Torque to 40 ft lb 14 four locations 45 16 Figure 43 Repairs Page 6 35 Hydroject 3010 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 A DANGER Charged accumulators contain high pressure nitrogen Nitrogen is the only gas to use for accumulator charging Installing IMPROPER gases in an accumulator can cause an EX PLOSION AND DEATH Charging requires Figure 44 special tools and precautions Charge ac cumulators in a well ventilated area It is 1 Protective cover 2 Valve cap yellow recommended that the accumulator be 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 Jam nut before servicing any component connected to high pressure water system Opening the high pressure bleed valve allows any trapped water to escape from the system and also allows accumulator piston to move to bottom of accumulator cylinder Failure to open bleed valve before servicing high pressure water Figure 45 components can cause personal i
76. e installed 2 Position pump head on a SOLID workbench or in vise keeping displacement rod openings pointing up wards 3 Fill plunger openings with water Insert Pump Seal Ex traction Tool TOR4013 into each water filled cavity WEAR SAFETY GLASSES Quickly strike the extrac tion tool with a large hammer or mallet The seal assem bly and brass retainer should move about 1 4 out of the cylinder head If seal does not move add more water and try again NOTE If seal does not move after a few attempts try using heavy oil or grease instead of water 4 Remove all seals from pump head and remove outlet cover tool Discard back up ring Item 6 packing vee Item 5 and seal support Item 4 Inspect brass seal re tainer Item 2 for wear and replace if worn If brass seal retainer can be reused remove and replace U cup seal Item 3 and O ring seal Item1 NOTE Apply clean grease to each seal before installing in steps 5 9 5 Insert back up ring Item 6 flat side first into each pump head cavity 6 Insert packing vee Item 5 into Installation Guide TOR4010 making sure that V will mate with back up ring Item6 7 Insert Installation Guide into cylinder head cavity and use Insertion Mandril TOR4011 to completely install the seal 8 Insert seal support Item 4 into Installation Guide TOR4010 making sure V groove will mate with high pressure seal Insert Installation Guide into cylinder head cavit
77. e machines filtration system additional or alternative filtration may be required DO NOT USE CHEMICALS Concern for environ mental issues and corrosive affects on machine components Hydroject 3010 Depths and Nozzle Configurations 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 be low IMPORTANT Use only nozzle configurations shown or damage to the machine may occur NOZZLE SIZE AND APPROXIMATE DEPTH CHART Decimal Size Metric Size Quantity of Nozzles Approx m m mm EC NOE Blocked e 86 8130 30 MA re Feesus we omo zo e Aluminum Washer is required with any nozzle change Part no 86 8150 OPTIONAL STAGGERED SIZE NOZZLE CONFIGURATION Decimal Size Metric Size Quantity of Nozzles Approx mc M mm Se Blocked 86 8130 30 RETZ L JR ME NER Aluminum Washer is required with any nozzle change S N 29999 amp Below Part no 80 6680 Part no 86 8150 Additional nozzles may be blocked to compensate for pump wear Hydroject 3010 Page 6 2 1 Specifications Check Valve Ball 70 80 ft lb OPEN NOZZLE CLOSED BLOCKED NOZZLE Aluminum washer P N 86 8150 is required with any
78. e of 84 to 120 in lb Major Pump Repair Fig 25 26 The procedures on the following pages are for complete disassembly and reassembly of the pump Cleanliness is a primary means of assuring satisfactory transmission life on either new or repair units Cleaning parts by using a clean solvent wash and air drying is usually adequate As with any precision equipment all parts must be kept free of foreign materials and chemi cals Protect all sealing surfaces and open cavities from damage and foreign material Repairs Page 4 18 Top of pump when installed in machine Torque to 84 to 120 in Ib Figure 24 1 Charge pump cover 2 O ring 3 Gerotor assembly 4 Charge relief ball 5 Charge relief spring During assembly of the pump all surfaces which have relative motion between two parts should be coated with a film of clean hydraulic oil This will assure that these surfaces will be lubricated during start up It is recommended that all gaskets o rings and seals be replaced Lightly lubricate all o rings with clean petro leum jelly before assembly All gasket sealing surfaces must be cleaned before installing new gaskets Hydroject 3010 Figure 25 Disassembly of Hydraulic Pump 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
79. ear box input shaft When installing hub be sure to use spe cial hardened washer Item18 apply Loctite 271 or 680 to threads of capscrew Item14 and tighten to a torque of to 15 ft lbs 6 Install all bolts and spacers in drive coupling using il lustration below Position flat of spacer Item10 toward welded flange of drive shaft Item 24 Tighten caps crews until shoulder of spacer is seated then tighten to a torque of 15 ft lb more than prevailing torque required to turn locknut on threads Loctite 271 or 680 25 30 ft lb 1819 Never seez Loctite 271 or 680 25 30 ft lb Clutch bumper gap 0 19 0 25 in Figure 30 Repairs Page 6 20 Hydroject 3010 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 6 Loosen water pump idler pulley and work belt off of 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 te
80. ed Figure 18 valve before attempting any water system servicing Open bleed valve slowly and avoid 1 High pressure bleed valve contact with high velocity water stream 3 Slowly open the high pressure bleed valve allowing any pressurized water to escape 4 Install Water System Pressure Gauge TOR4005 into port in water valve housing as shown 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 6 Install Flow Meter TOR4006 between water supply hose and hose adapter Connect hose adapter to quick connector on side of machine 7 Turnon 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 WEAR SAFETY GLASSES Have one person press and HOLD engage button while other person stands to side of machine and Figure 21 observes pressure gauge and flow meter readings 1 Water supply quick connector PRESSURE should be 5000 300 PSI and FLOW more than 3 4 GPM If pressure is too high replace relief valve If pressure AND flow is low disconnect small tube running from
81. engages 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 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 Yellow Wheel position switch closed machine low ered to aerate position water pressure switch closed 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 Electrical Schematic and Wiring Diagrams See Chapter 8 Electrical Diagrams Wiring Schematics and Diagrams Page 5 4 Hydroject 3010 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 testin
82. er in gear case milky or brown color in oil Worn or damaged water valve low pressure water seal and oil seal Rebuild water valve Oil leaking from below gear case shim area Worn or damaged water valve oil Seal Rebuild water valve Water in pump crankcase milky or brown color in oil Worn or damaged water pump low pressure seal or cracked ceramic plunger Rebuild pump head and plunger sleeves Engine dies when water system is engaged Low engine RPM Relief pressure too high TEST NO 2 Low engine power Jammed or siezed pump or gear case Throttle must be in FAST posi tion Adjust carburetor fast setting to 3450 to 3550 RPM no load Replace relief valve DO NOT at tempt to adjust Check for contaminated fuel plugged fuel filter or fuel line plugged air cleaner bad spark plug see Chapter 3 Engine Inspect components and repair as necessary Hydroject 3010 Page 6 11 Troubleshooting Testing Before Performing Water System Tests 1 The water aeration system operates under very high pressures and severe duty cycles Performance of the water system will be gradually reduced over a period of time due to normal wear in the pump valve and ac cumulator If you perform water system tests to isolate a possible problem such as reduced hole depth it is recommended that ALL tests be performed in the order listed even if the apparent problem has been
83. est away from threads 4 Install black back up ring Item 30 into valve cavity flat side first Repairs Page 6 30 5 Use Valve Seal Installer TOR4009 and Seal Inser tion Mandrel TOR4011 to properly install packing seal Item 29 and seal plunger support Item 28 into valve body Remove installers 6 Insert valve guide Item 27 into valve body Install ring Item 24 and U cup seal Item 26 to seal retainer Item 25 then install into valve cavity 7 Apply grease to outside of sleeve Item 7 Use valve spool inserted through sleeve to gently drive sleeve into seals inserting it from the spring side 8 Insert valve spool Item1 through valve seat Item 2 and install O ring Item 3 on inboard side of valve seat Hydroject 3010 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 Apply Loctite 271 or equivalent to threads and install jam nut Item 22 Tighten to a torque 10 ft lbs 11 Fill snap ring groove in valve spool Item 1 with wax to prevent damage to seal Install gear case pilot Item18 making sure the drain hole is pointing down Holes in pilot allow only one method of installation Tighten screws Item13 to a torque of 14 18 ft lb 12 Install compression spring Item16 onto valve spool 9
84. excessive grease grass leaves and accumulations of dirt 24 Be sure machine is in safe operating condition by keeping nuts bolts and screws tight Check all bolts and nuts frequently to be sure they are tightened to specifi cation 25 If the engine must be running to perform a mainte nance adjustment keep hands feet clothing and other parts of the body away from any moving parts 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 Page 1 2 D Fill fuel tank outdoors and up to about one inch 25 mm from top of the tank not the filler neck E Wipe up any spilled gasoline 9 Check interlock switches daily for proper operation If a switch fails replace it before operating the machine The interlock system is for your protection so do not by pass it Replace all interlock switches every two years A Use only in daylight or when there is good artificial light B Watch for holes or other hidden hazards C Do not transport machine close to a sand trap ditch creek or other hazard 17 If the machine starts to vibrate abnormally shut the engine off Remove wires from spark plugs to prevent possibility of accidental starting Check machine for damage and defective parts Repair any damage before restarting the engine and operating the machine 18 Do not touch engine or muffler while engine is run
85. fic torque value should be determined based on the aluminum or brass material strength fastener size length of thread en gagement etc The standard method of verifying torque shall be per formed by marking a line on the fastener head or nut and mating part then back off fastener 1 4 of a turn Measure the torque required to tighten the fastener until the lines match up Class 8 8 Class 10 9 Metric Bolts and Screws Figure 2 Product Records and Maintenance Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series Grade 1 5 amp SAE Grade 1 Bolts Screws Studs amp SAE Grade 5 Bolts Screws Studs amp SAE Grade 8 Bolts Screws Studs amp Thread Size 8 with Thin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts Height Nuts SAE J995 Grade 2 or Stronger Nuts SAE J995 Grade 2 or Stronger Nuts SAE J995 Grade 5 or Stronger Nuts 147 23 282 30 339 56 599 79 100 10 1125 100 140 15 1580 170 734 113 115 10 1300 100 160 15 1800 170 1186 169 200 25 2250 280 300 30 3390 340 1446 192 225 25 2540 280 325 30 3670 340 6 32 UNC 6 40 UNF 8 32 UNC 8 36 UNF 10 24 UNC 10 32 UNF 1 4 20 UNC 48 7 1 4 28 UNF 65 10 5 16 18 UNC 115 15 105 17 5 16 24 UNF 138 17 128 17 A E E A I I N N N N N
86. g electrical circuits The high impedance internal resistance of a digital meter will ensure that excess current is not allowed through the meter Excess current can cuase damage to a circuit that is not de signed to carry it Hydroject 3010 Page 5 5 Figure 6 Special Tools 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 5 6 Hydroject 3010 Troubleshooting Study the operating characteristics preceding the elec trical failure to help identify the area of difficulty Try to A CAUTION 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 Remove all jewelry especially rings and will lead to confusion watches before doing any electrical trou bleshooting or testing Disconnect the bat tery cables unless the test requires battery Possible Causes and Corrections in the troubleshooting charts should be checked in the order in which they are voltage id listed For effective troubleshooting and repairs MUST If the machine being repaired has any interlock switches have a good understanding of the electrical circuits and by passed they must be reconnected for proper trou components used on this m
87. gen Accumulator servicing requires special tools and precautions Accumulators do not con tain user serviceable components Improper accumula tor servicing can cause dismemberment or death Do not attempt to disassemble a accumulator have this work done by a Authorized Toro Distributor 32 Do not overspeed the engine by changing governor settings To be sure of safety and accuracy have an Au thorized TORO Distributor check maximum engine speed with a tachometer 33 Engine must be shut off before checking oil or add ing oil to the crankcase Hydroject 3010 Page 1 3 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 Do not store machine near any open flame or where gasoline fumes may be ignited by a spark Always store gasoline in a safety approved red metal container 35 When storing or transporting machine trailering make sure fuel shut off valve is closed 36 Perform only those maintenance instructions de scribed in this manual If major repairs are ever needed or assistance is desired contact an Authorized Toro Dis tributor To ensure optimum performance and safety al ways purchase genuine TORO replacement parts and accessories to keep the Toro all TORO NEVER USE WILL FIT REPLACEMENT PARTS AND ACCESSO RIES MADE BY OTHER MANUFACTURERS Look for the TORO logo to assure genuineness
88. he skin and cause physical harm Use extreme caution and wear protective goggles and gloves when working with high pressure air Get prompt medical attention if an injury occurs 5 Let compressed air flow through the machine for 3 minutes While compressed air is flowing temporarily open the spray wash and high pressure drain valve purging water from the spray wash and high pressure system 6 Disconnect compressed air and reducers Reinstall the drive shield previously removed and tighten the re lief valve tube 7 Remove and drain the water filter container Install new filter and replace the filter container Engine 1 Drainthe engine oil from the oil pan and replace the drain cap General Information Page 6 38 2 Remove and discard the oil filter Install a new filter 3 Refill the engine with 3 qts of recommended SAE 30 wt motor oil 4 Start the engine and run at idle speed for two min utes DO NOT RUN LONGER THAN TWO MINUTES 5 Stop the engine remove the spark plugs 6 Pour one ounce of clean engine oil into spark plug holes 7 With the spark plugs removed crank the engine with the starter for a least 12 revolutions to distribute oil in the cylinders 8 Reinstall spark plugs 9 Drain the gasoline from the fuel tank and fuel lines Reinstall all lines and secure all connections 10 Thoroughly clean and service the air cleaner 11 Check the oil filler cap and fuel tank cap to ensure
89. ig 20 Item 21 3 Remove drive coupling see Drive Coupling Removal and Installation in Chapter 6 Water System 4 Disconnect valve clutch electrical connector 5 Remove valve clutch stops 6 Loosen pivot nut securing pump mount to pump support Figure 18 7 Loosen adjusting nut securing pump and pump mount 1 Pump drive belt to slotted pump support 2 Drive coupling 3 Valve clutch 8 Push pump towards inside of machine to loosen belt RENE SOS tension and remove the belt 3m 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 Hydraulic Pump Removal and Installation Fig 20 1 Park machine on a level surface engage parking brake open hood and disconnect engine spark plug wires 2 Disconnect wires from neutral and pump switches Item 31 on hydraulic pump Label wires for proper reinstallation 3 Remove extension spring Item 17 4 Disconnect stroke control cable ball joint Item 43 from pump lever Item 30 Disconnect upper and lower speed adjustment rods from pump lever see Fig 14 5 Loosen belt tension and remove belt from pump pulley see Pump Belt Tension Adjustment 6 Disconnect hydraulic lines from fittings on pump Put caps on open lines and fittings to prevent contamination Put labels on hydraulic lines for proper reinstallation 7 Re
90. inal Do not charge a frozen battery because it can explode and cause injury Let the battery warm to 60 F 15 5 C before connecting to a charger L FILLER CAPS 7 CORRECT WATER Charge the battery in a well ventilated place so that gases produced while charging can dissipate Since the gases are explosive keep open flame and electrical spark away from the battery do not smoke Nausea may result if the gases are inhaled Unplug the charger fromthe electrical outlet before connecting or disconnecting the charger leads from the bat tery posts Figure 25 Repairs Page 5 24 Hydroject 3010 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 Make sure one wire is connected to COMMON terminal and one wire is connected to N O terminal traction switch 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 amp black wires terminals If the two 2 wires are not connected to 2 Traction switch 2
91. inc Plated Steel Type 1 Type 23 or Type F Thread Threads per Inch 2 Baseline Torque Thread Size Baseline Torque Type A Type No 6 32 UNC 20 5 in lb 20 5 in Ib No 8 32 UNC 30 5 in lb 30 5 in lb 1 16 71 No 10 24 UNC 38 7 in lb 1 4 20 UNC 85 15 in lb 5 16 18 UNC 110 20 in lb Hole size material strength material thickness amp finish must be considered when determining specific torque 3 8 16 UNC 200 100 in lb values All torque values are based on non lubricated 8 Pie we fasteners Conversion Factors in lb X 11 2985 X 0 08851 in lb ft lb X 1 3558 N m N m X 0 7376 ft lb Product Records and Maintenance Page2 6 Hydroject 3010 Chapter 3 TORO Kohler Engine Table of Contents INTRODUCTION 2 SPECIFICATIONS 3 SERVICE AND REPAIRS 4 Engine Removal and Installation 4 KOHLER ENGINE SERVICE MANUAL Hydroject 3010 Page 3 1 Kohler Engine Introduction This Chapter gives information about specifications and repair of the Kohler engine used in the ProCore 648 General engine maintenance procedures are described in your Operator s Manual Information on engine trou bleshooting testing disassembly and reassembly is identified in the Kohler Engine Service Manual that is in cluded at the end of this section Kohle
92. inuity 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 connector terminals The clutch should engage as 12 VDC is connected to the clutch connector terminals Clutch coil resistance 3 79 Ohms 5 at 20 C 68 F Valve Clutch Fig 22 To test the valve 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 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 Clutch coil resistance 3 5 Ohms 5 at 20 68 F Circuit Breaker and Fusible Link Fig 23 The electrical system is protected by a 20 AMP circuit breaker with reset button and a fusible link To test the circuit breaker check for continuity between the two terminals The fusible link is located in the control panel wiring harness between the circuit breaker and and starter B terminal 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 Chapte
93. is not scratched or scored it can be reused If bore is scored or damaged it will require resurfacing and nickel plating If cylinder bore is damaged it may be more cost effective to replace the complete accumulator than to continue this repair Accumulator Assembly and Seal Installation 12 If bore not damaged or worn use solvent to thoroughly clean accumulator cylinder 13 Apply clean hydraulic oil to new end seal and back up ring Item 4 Install end seal and back up ring in groove of bottom end cap Item 9 so O ring is toward the piston Apply 2 or equivalent to threads of end cap Carefully install end cap 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 Put a light coating of special grease on accumulator bore and installation tool 15 Use Accumulator Seal Installation tool TOR4002 to prevent seal damage during piston installation CAREFULLY insert this tool into top side of cylinder SLOWLY insert piston large cross facing down through the tool and into the cylinder bore 16 Move piston to bottom of accumulator cylinder Add 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 17 Apply clean hydraulic oil to new end seal and back up ring Item 4
94. ith a wrench 7 Position the tester hoses so that rotating machine parts will not make contact with them and result in hose or tester damage 8 Check the oil level in the reservoir 9 Check the control linkage for improper adjustment binding or broken parts 10 All hydraulic tests should be made with the hydraulic oil at normal operating temperature Testing Hydraulic Tests Fig 10 11 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes 2 Engage parking brake and stop the engine Make sure parking brake is properly adjusted before perform ing hydraulic tests 3 With engine off disconnect hose from bulkhead fitting and install tester in series between traction pump and wheel motor Make sure tester flow control valve is OPEN IMPORTANT Make sure that the oil flow indicator arrow on the flow gauge is showing that oil will flow from pump through tester and to wheel motor Test A Charge Pressure 4 Start the engine and move throttle to full engine RPM approx 3500 RPM GAUGE READING 25 to 70 PSI no load 5 If there is no pressure or pressure is low inspect for restriction in pump intake line and inlet filter Inspect charge relief valve and valve seat Inspect for sheared charge pump key Disassemble charge pump and in spect for internal damage or worn parts If charge pump is in good condition no scoring scratches or excessive we
95. ity of the low pressure gauge 0 5000 5 FLOW METER This meter measures actual oil flow in the operation circuit with a gauge rated at 15 GPM 6 OUTLET HOSE Hose from the outlet side of the hydraulic tester to be connected to the hydraulic system circuit Special Tools 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 Continued use of an improperly functioning hydraulic Transmission Operates in One Direction Only system could lead to extensive internal component damage The charts that follow contain detailed information to assist in troubleshooting There may possibly be more than one cause for a machine malfunction All causes should be checked in the order in which they are listed on the charts Refer to the Testing section of this Chapter for precau tions and specific test procedures Cause Faulty traction control linkage Correction Repair linkage Transmission charge check valve defective Inspect and clean or replace charge check System Operates Hot Loose
96. l 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 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 Figure 14 5 Move traction bail completely up and down Release handle and check for wheel rotation If wheel continues 1 Neutral adjustment cam rotating repeat step 4 2 Locknut 3 Switch tab 6 If problem continues stop the engine check linkage for binding or damage then do adjustment procedure again 7 Loosen two 2 screws and adjust switch tab so switches are actuated when pump control is in neutral and not actuated when pump control is stroked Aeration Speed Adjustment Fig 15 1 Park machine on a level surface stop the engine and open the hood 2 Put speed control lever into second slot from left while facing control panel 3 Lower machine into aerate mode so transport wheels are off the ground 4 Lift drive wheel off ground using a jack 5 Start the engine and release the parking brake AA 7 Move traction handle UP to full speed position E ee 6 Operate engine at full speed 8 Loosen jam nuts and adjust LOWER speed rod u
97. l Service Department 8111 Lyndale Avenue South Bloomington Minnesota 55420 2 Never allow children to operate the machine Do not allow adults to operate machine without proper instruc tion Only trained operators who have read this manual should operate this machine Hydroject 3010 Page 1 1 Chapter 1 Safety Maintenance and Service 3 SAFETY AND INSTRUCTION DECALS 4 A CAUTION TO REDUCE THE POTENTIAL FOR INJURY OR DEATH COMPLY WITH THE FOLLOWING SAFETY INSTRUCTIONS 3 Never operate the machine when under the influ ence of drugs or alcohol 4 Before attempting to start engine engage parking brake 5 Remove all debris or other objects that might inter fere with operation Keep all bystanders away from the work area 6 Keep all shields and safety devices in place If a shield safety device or decal is defective or damaged repair or replace it before operation is commenced Also tighten any loose nuts bolts and screws to assure ma chine is in safe operating condition 7 Do not operate machine while wearing sandals ten nis shoes sneakers or shorts Also do not wear loose fitting clothing which could get caught in moving parts Always wear long pants and substantial shoes Wearing safety glasses safety shoes ear protection and a hel met is advisable and required by some local ordinances and insurance regulations Safety 8 Fill fuel tank with gasoline before sta
98. ll retaining ring Item 24 11 Install swashplate cradle bearings Item 14 into housing making sure they are located on cast in pins in housing 12 Install slot guide block Item 13 onto displacement control shaft 13 Install thrust plate Item 11 into swashplate Item 25 Slot on swashplate must engage guide block Item 13 on displacement control shaft 12 Use a tool such as a screwdriver or magnet to hold guide block in position while installing swashplate 14 Hold swashplate in position and use a dial indicator or depth gauge to measure side play of displacement control shaft Using a suitable sleeve press control shaft bearing into housing until control shaft end play is between 0 020 and 0 060 in 15 Install thrust washer Item 9 and cylinder block spring Item 8 onto pump shaft 16 Install springs Item 29 piston washers Item 28 and pistons Item 27 into cylinder block kits The pis tons must move freely in their bores 17 With pump swashplate in neutral 0 angle position and pump housing laying on its side install pump cylin der block kit onto pump shaft in housing Hydroject 3010 18 Check that piston springs are centered in cylinder block bores If necessary move springs into position with a small screwdriver IMPORTANT Do not damage running surfaces of cylinder blocks 19 Install two 2 alignment pins Item 15 and install a new gasket Item 6 onto housing 20 Lubric
99. lling piston seal during accumulator rebuilding Figure 3 Special Tools Page 6 4 HydroJect 3010 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 4006 Fig 6 The in line flow meter with a battery powered electronic digital display is installed in the water supply line to measure pump efficiency The flow meter is equipped with a pressure gauge to measure inlet water pressure 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 6 5 Special Tools Valve Lift Indicator TOR4007 Fig 7 A special dial indicator and adaptor is temporarily in stalled 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 deter mines correct shim size to get proper valve lift Figure 7 Valve Spring Compressor 4008 Fig 8 The valve spring compressor and hardware is used for compressing the water valve spring allowing removal and
100. ma chine is moving traction bail out of neutral Problem not electrical see Trou bleshooting in Chapter 6 Water System Traction switch 2 faulty Loose or broken wire in traction switch controller circuit Also see possible causes in Water pump clutch does not engage and Water pump clutch engages but water valve clutch does not en gage Make sure switch is installed and adjusted properly Test switch and replace if faulty Check all connections and wiring and repair as necessary Troubleshooting Page 5 12 Hydroject 3010 Safety Interlock System Problems Condition Possible Cause Correction Engine cranks but should not with traction bail in neutral Traction switch 1 faulty Traction switch 1 wiring faulty Make sure switch is installed and adjusted properly Test neutral switch and replace if faulty Check for short in switch wiring and connections and repair as necessary Machine continues to aerate but should not with traction bail in neutral Red light on controller is ON should be OFF with traction bail in neutral Green light on controller stays ON should be OFF with aerate en gage switch released Controller faulty Make sure traction switch 2 is in stalled and adjusted properly Test switch and replace if faulty Check for short in traction switch 2 controller connections and wir ing and repair as necessary Test ae
101. move locknut Item 46 capscrew Item 5 and washers Item 47 Remove locknut Item 54 and cap screw Item 57 8 Remove pump assembly from pump support Item 55 and put pump on a work bench 9 Loosen jam nuts Item 3 and set screws 2 Remove pulley Item 4 from pump shaft 10 Remove pump mount Item 6 from pump 11 Loosen locknuts Item 36 and remove roll pin Item 34 Pull pump lever Item 30 off of pump control shaft 12 Remove hydraulic fittings from pump and plug ports 13 Reverse steps 2 12 to install pump Figure 20 Hydroject 3010 Page 4 15 Repairs Pump Shaft Seal Replacement Fig 21 Lip type seals are used on input shaft and displacement control shaft These seals can be replaced without major disassembly of pump 1 Remove retaining ring from housing input shaft seal only 2 Carefully pull seal out of housing bore A hook type tool may be used to grasp seal and pull it out or a slide hammer type puller may be used to remove seal Be careful not to damage housing bore shaft sealing sur face or bearing After the seal is removed it cannot be used again IMPORTANT When input shaft seal is removed pump block spring 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 sealing area of shaft for rust wear
102. n a well ventilated area It is recommended that the accumulator be 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 Opening the high pressure bleed valve allows any trapped water to escape from the system and also allows accumulator piston to move to bottom of accumulator cylinder Failure to open bleed valve before servicing high pressure water components can cause personal injury DIS MEMBERMENT OR DEATH Charged accumulators cannot be shipped via air freight Repairs Page 6 34 Rev A 2 Slowly open the high pressure bleed valve allowing any pressurized water to escape 3 Remove splash shield from manifold to get access to capscrews securing accumulator Use a socket wrench with long extension to remove four 4 capscrews Item 14 securing accumulator Item 47 to valve hous ing Item 11 Remove the accumulator Discard O ring Item 26 4 Install new O ring seal Item 26 into groove on top of valve housing Carefully install accumulator onto top of valve housing Make sure decals Items 47 2 47 1 are facing forward and securely attached to accumulator 6 Install four 4 NEW special bolts Item 14 through valve body and into base of accumulator Tighten to a torque of 40 ft lb 7 Charge accumulator with dry Nitrogen se
103. ning or soon after it is stopped These areas could be hot enough to cause a burn 19 Before leaving the operator s position behind han dle engage parking brake 20 When leaving the machine unattended engage parking brake shut engine OFF and remove key from ignition switch 27 Keep body and hands away from pin hole leaks or nozzles that eject water or hydraulic fluid under high pressure Use paper or cardboard not hands to search for leaks Hydraulic fluid or water escaping under pres sure can have sufficient force to penetrate skin and do serious damage If either of these fluids are ejected into the skin they must be surgically removed within a few hours by a doctor familiar with this form of injury or gan grene may result 28 Before disconnecting or performing any work on the hydraulic oil system all pressure in system must be re lieved by stopping engine and opening by pass valve 29 Make sure all water line connectors are tight and all hoses and lines are in good condition before applying pressure to the system Hydroject 3010 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 31 The accumulator in this machine contains high pressure dry nitro
104. njury DIS MEMBERMENT OR DEATH Charged accumulators cannot be shipped via air freight 2 Slowly open the high pressure bleed valve allowing any pressurized water to escape 3 Remove protective cover from top of accumulator 4 Attach and gently tighten special fitting of Charging Tool TOR4001 to inlet on top of accumulator 5 Close both valves on charging tool to prevent loss of pressurized Nitrogen from accumulator 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 7 Slowly open outlet valve on right hand side of charg ing tool to release pressurized gas from accumulator When gas stops escaping disconnect the charging tool Repairs Page 6 36 HydroJect 3010 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 4003 into the top cap Item 12 of the accumulator Hold the ac cumulator 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 8 out of top side of accumulator and discard the piston Accumulator Service Evaluation Inspect bore of accumulator cylinder for score marks or wear If barrel of accumulator
105. nlet water filter Electrical problem Correction Normal condition of interlock sys tem Operator must hold engage button in to aerate with traction bail in neutral Check for kinked water supply hose restriction in line or partially open valve at water source Check water pressure at gauge when pump is engaged If pres sure drops to less than 15 PSI but was initially higher replace water filter See Troubleshooting in Chapter 5 Electrical System Water system engages pump belt and gear case drive shaft rotate but no aeration holes are produced or aeration hole depth is shallow or inconsistent Air in system Soil density or moisture content Plugged nozzles worn nozzles or improper nozzle configuration NOTE Check operation of nozzles by aerating over a piece of cardboard then inspecting cardboard Gear or cam damage in gear case Leak in high pressure water sys tem With engine OFF and water supp ly connected open high pressure bleed valve and bleed air out of system If hole depth was satisfactory before in another area different nozzle configuration may be re quired Stop engine open high pressure bleed valve then inspect noz zles Check for plugged nozzles Verify size and quantity see Noz zle Size and Approximate Depth Chart Nozzles that are too large will cause loss in pressure and could cause damage to the ac cumulator and other water sys tem compone
106. nsion see Pump Drive Belt Adjustment in Chapter 4 Hydraulic System HydroJect 3010 Page 6 21 Figure 31 1 Water pump belt Figure 32 1 Hydraulic pump belt Repairs Water Filter Replacement Fig 33 34 When pump inlet pressure decreases or the water sys tem shuts down it usually means the water filter is restricted and must be replaced IMPORTANT Never operate the machine without a water filter Operating without a water filter can cause severe damage to the water system 1 Put the machine on a level surface engage the parking brake stop the engine and disconnect the en gine spark plug wires 2 Locate the water filter assembly which is mounted below the fuel tank NOTE Be careful when removing filter body Filter body is full of water and will be heavy 3 Unscrew the filter body 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 filter head Hand tighten 6 Bleed water system with engine OFF and water supply connected and turned on A Push button on top of filter head to purge air from filter body until water comes out around button B Open high pressure bleed valve below ac cumulator to bleed air from water system Close high pressure bleed valve NOTE The quality and micron rating of this filter is very important Do no
107. ntil Figure 15 traction wheel rotates at 20 22 RPM Tighten jam nuts 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 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 Ib of force Belt should deflect 1 4 in 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 20 Item 21 to control panel and pump 1 Traction pump belt support pp D apry bar in hole on pump bracket to pull pump i towards outside of machine until you get proper belt tension then tighten adjusting nut to secure pump and pump mount to pump support 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 Repairs Traction Pump Belt Replacement Fig 18 19 1 Park machine on a level surface engage parking brake open hood and disconnect engine spark plug wires 2 Remove pulley guard bracket F
108. nto end cap Tighten to a torque of 7 to 10 ft Ib Top of pump when installed in machine Figure 22 1 Check valve plug 2 O ring 3 Check valve spring 4 Check ball 5 Pump end cap Torque to Top of pump when 7 to 10 ft Ib installed in machine Figure 23 1 Bypass valve 2 Back up ring 3 O ring 4 Pump end cap Hydroject 3010 Page 4 17 Repairs 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 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 3 Remove charge pump gerotor assembly 4 Remove charge relief valve spring and ball 5 Inspect gerotor assembly charge pump cover and end cap for abnormal wear damage or foreign material Inspect charge relief valve seat in end cap for damage or foreign material 6 Before installing charge pump apply a small amount of petroleum jelly to inside diameter outside diameter and slide faces of gerotor assembly 7 Install charge relief ball and spring 8 Install charge pump gerotor assembly 9 Install charge pump cover and O ring Make sure charge relief spring enters recess in cover 10 Install charge pump cover screws and tighten to a torqu
109. nts Inspect gear case for gear or cam damage and repair as neces sary Check for leaks with water sys tem engaged Stop engine open high pressure bleed valve and repair leaks as necessary NOTE Excessive water exiting between pump head and crankcase indicates pump wear or damage Excessive 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 Condition Machine aerates but aeration hole depth is shallow or inconsis tent continued Possible Cause Low accumulator pre charge or damaged accumulator TEST NO 1 Low water system pressure AND flow TEST NO 2 Low water system pressure flow is OK TEST NO 2 Low water system flow pressure is OK TEST NO 2 Improper water valve lift TEST NO 3 Worn or damaged water valve TEST NO 2 Correction Charge accumulator with dry Ni trogen Rebuild or replace accu mulator if necessary Rebuild pump NOTE When testing make sure cam is not holding water 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 Check engine speed and correct if necessary Rebuild pump Perform valve lift adjustment Re pair valve or replace cam if nec essary Rebuild water valve Wat
110. ommended that the O ring be replaced any time the connection is opened 3 Lubricate the O ring with a light coating of oil 4 Putthe tube and nut squarely into position on the face seal end of the fitting and tighten the nut until finger tight Figure 2 5 Mark the nut and fitting body Hold the body with a wrench Use another wrench to tighten the nut to the correct flats from finger tight F F F T The markings the nut and fitting body will verify that the connection has been tightened Final Size F F F T B Position 4 1 4 in nominal hose or tubing 75 25 Extend Line 6 3 8 in 75 25 8 1 2 in 75 25 10 5 8 in 100 25 Finger Tight After Proper Tightening 12 3 4 in 75 25 16 1 in 75 25 Figure 3 Hydroject 3010 Page 4 3 General Information A CAUTION Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved by stopping the en gine and opening the bypass valve Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid un der high pressure Use paper or cardboard not hands to search for leaks Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and do serious damage 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 gangrene may result SAE Straight Th
111. otate coupling moving cam toward cam follower and continue to rotate until cam follower is on lead in portion of cam approximately one inch from cam lobe Record amount of valve lift IMPORTANT Make sure shims on both front and rear side are the same thickness Using different thicknesses can cause gear case damage 8 Add shims equal 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 retighten capscrews NOTE If more than a multiple of 0 005 shims are required it is recommended that procedure be done in two steps for example if 0 023 is indicated add 0 02 shim four 0 005 shims first then repeat procedure IMPORTANT Clearances greater than 0 002 in will cause high contact stresses and rapid cam wear 9 Check proper function of cam by again zeroing dial indicator with cam away from cam follower Rotate coupling moving cam toward cam follower and continue to rotate until cam follower is on lead in portion of cam approximately one inch from cam lobe There should be no movement of dial indicator on lead in portion of cam Continue to rotate over cam lobe Lift should measure 0 10 0902 6 004 in with new cam Continue to rotate on lead out portion The dial indicator should read zero for entire lead out portion Figure 28 1 Valve lift indicator TOR4007
112. pinion 2 Slowly open high pressure bleed valve allowing any pressurized water to escape Figure 27 3 Remove belt guard to expose drive shaft Remove 1 Coupling 2 Cam 3 Follower gear case cover 4 Use your hand to rotate coupling assembly position ing working cam on top Visually inspect top of cam lobe for wear There is a thin area on this replaceable cam that does not contact the cam follower If cam is worn a ridge will develop between tip of cam and unused surface If the ridge is deep enough to catch a fingernail replace the cam lobe Do not measure valve lift using worn cam lobe Rotate cam to make sure cam lobe is not contacting follower Adjustments Page 6 18 HydroJect 3010 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 Remove one shim from both front and rear then tighten capscrews Repeat this procedure until some opening of valve occurs on lead in portion to make sure cam follower touches cam 7 Zero dial indicator again with cam follower completely off the cam R
113. r 8 Electrical Diagrams Hydroject 3010 Page 5 23 Figure 21 1 Pump clutch Figure 22 1 Valve clutch Figure 23 1 Circuit breaker Testing Repairs Battery Service Fig 24 25 IMPORTANT To prevent damage to the electrical Electrolyte Specific Gravity p not edes the engine with the Fully charged 1 250 1 280 attery cables disconnected Discharged less than 1 240 Keep the terminals and entire battery case clean To Battery Specifications clean the battery wash the entire case with a solution see f baking soda and water Rinse with clear water Do not o 0 9 1 Water 535 Amp Cranking Performance at 0 F 17 C get the soda solution into the battery because damage 110 min Reserve Capacity at 80 F 27 C to the battery will result Coatthe battery posts and cable connectors with skin over grease or petroleum jelly to prevent corrosion Checkfor loose battery hold downs Aloose battery may crack or cause the container to wear and leak acid Check the electrolyte solution to make sure the level is above the plates If the level is low but above the plates inside the battery add water so the level is to the bottom of the 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 Figure 24 1 Positive terminal A CAUTION 2 Negative term
114. r Engine Page 3 2 Most repairs and adjustments require tools which are commonly available in many service shops Special tools are described in the Kohler Engine Service Manu al The use of some specialized test equipment is ex plained However the cost of the test equipment and the specialized nature of some repairs may dictate that the work be done at an engine repair facility Service and repair parts for Kohler engines are supplied through your local Kohler dealer or distributor Hydroject 3010 Specifications Item Description Make Designation Kohler Command Pro 27 Carb 4 stroke V Twin Air Cooled OHV Number of Cylinders Bore x Stroke 3 3 x 2 6 83 mm x 67 mm Total Displacement 44 Cubic Inches 725 cc Compression Ratio 9 0 1 Dry Weight approximate 94 Pounds 43 Kilograms Fuel Unleaded Regular Gasoline Minimum 87 Octane Fuel Tank Capacity 10 5 U S Gallons 39 7 Liters Governor Mechanical Idle Speed no load 1500 1800 RPM High Idle no load 3450 3550 RPM Engine Oil See Operator s Manual Oil Pump Gear driven trochoid type Crankcase Oil Capacity 2 U S Quart 1 9 Liters with filter Starter 12 VDC Hydroject 3010 Page 3 3 Kohler Engine Service and Repairs Engine Removal and Installation 1 Park the machine on a level surface engage the park ing brake and
115. r replacement and adjustment procedures Testing Page 5 18 Figure 11 1 Red light 2 Yellow light 3 Green light Figure 12 1 Traction switch 1 N O gray amp black wires 2 Traction switch 2 N C orange amp yellow wires 3 Switch tab Hydroject 3010 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 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 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 closes when the button is pushed down The aeration stop DISENGAGE switch is normally closed N C and opens when the button is pushed down Test the switch by disconnecting the wires from the switch terminals and connecting a continuity tester or ohm meter across the two switch terminals Hydroject 3010 Page 5 19 Figure 14 1 Aeration start engage switch pink amp orange wires 2 Aeration stop disengage switch gray amp white wires Testing
116. rate engage start switch and replace if faulty make sure Switch action is momentary and comes comes back out after be ing pushed in Replace controller Machine aerates but should not with with machine raised in trans port position Yellow light on controller is ON should be OFF with machine raised in transport position Controller faulty Test wheel position switch and re place if faulty Check for short in wheel position switch connections and wiring and repair as necessary Replace controller Hydroject 3010 Page 5 13 Troubleshooting Safety Interlock System Problems continued Condition Possible Cause Correction No lights on controller come on when troubleshooting interlock system Battery is dead or disconnected Circuit breaker open Faulty controller ground Ignition key switch faulty Loose or damaged wiring in key switch controller circuit Controller faulty Charge battery Replace battery if it will not hold a charge Clean and tighten connections Reset circuit breaker Find cause for open circuit breaker and cor rect Replace circuit breaker if faulty Check controller ground connec tion and wiring and repair as nec essary Test ignition switch and replace if faulty Check all connections and wiring and repair as necessary Replace controller Green light on controller glows faintly when only red light should be on
117. read 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 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 4 1 4 in nominal hose or tubing 1 00 25 6 3 8 in 1 50 25 8 1 2 in 1 50 25 10 5 8 in 1 50 25 12 3 4 in 1 50 25 16 1 in 1 50 25 SAE Straight Thread O Ring Port Adjustable Fig 5 6 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 4 Turn back the jam nut as far as possible Make sure the back up washer is not loose and is pushed up as far as possible Step 1 5 Install the fitting into the port and tighten finger tight until the washer contacts the face of the port Step 2 6 To put the fitting in the desired position unscrew it by the required amount but no more than one full turn Step 3 7 Hold the fitting in the desired position with a wrench and turn the jam nut with another wrench to the correct flats from
118. rting the en gine Avoid spilling gasoline Since gasoline is flam mable handle it carefully A Use approved gasoline container B Do not fill tank while engine is hot or running C Do not smoke while handling gasoline While Operating 10 DON T TAKE AN INJURY RISK When a person or pet appears unexpectedly in or near the WORKING area STOP AERATING 11 Keep hands and feet away from nozzle and roller area High velocity water jets can penetrate hands and feet Penetration by the high velocity water jets can cause serious personal injury If accidental penetration occurs seek medical attention immediately 12 Never use chemicals in the water supply system 13 Do not operate water injection system on concrete or asphalt because water jets will permanently damage these surfaces 14 Start engine with parking brake engaged 15 Do not run the engine in a confined area without ad equate ventilation Exhaust fumes are hazardous and could possibly be deadly 16 Using the machine demands attention and to pre vent loss of control Maintenance 21 Disconnect wires from spark plugs to prevent acci dental starting of the engine when servicing adjusting or storing the machine 22 1 machine must be tipped to perform maintenance or an adjustment close fuel shut off valve drain gaso line from fuel tank oil from crankcase and remove bat tery 23 To reduce potential fire hazard keep the engine free of
119. s Power or Will Not Operate in Either Direction Cause Faulty control linkage Correction Repair linkage Parking brake engaged Disengage parking brake Hydraulic oil level too low Fill to proper level By pass valve open Close by pass valve Clogged hydraulic filter Replace filter Low charge pressure Test A 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 Page4 8 Hydroject 3010 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 4 CAUTION Failure to use gauges with the recommended pressure psi rating as listed in the test pro cedures could result in damage to the gauge and possible personal injury from leaking hot oil Before Performing Hydraulic Tests All obvious areas such as oil supply filter binding linkage loose fasteners or improper adjustments must be checked before assuming that a hydraulic compo nent is the source of the problem being experienced A WARNING Before disconnecting or performing any work on the hydrauli
120. s parts of seal assembly Item 15 16 17 shaft Item 10 and thrust bearing assembly Item 19 20 21 Replace any worn or damaged parts Always replace seal retainer assembly Item 15 16 17 The shaft should have smooth polished surfaces in bearing and seal areas If the shaftis lightly scratched in these areas polish with fine emery paper in a circumferential direc tion However if the shaft has any pitting or deep Hydroject 3010 Page 4 23 scratches entire motor should be disassembled for inspection Assembly of Shaft and Front Seal Assembly 1 Assemble thrust washers Item 19 and thrust bearing Item 20 on shaft using the snap ring Item 21 Snap ring sharp edges MUST face away from thrust washers with thrust bearing Item 20 between washers 2 Slowly lower spline end of shaft Item 10 assembly into motor body using caution not to rotate internal parts once shaft spline starts to engage 3 Put lightly oiled o ring Item 12 into groove in body bore 4 Gently slide oiled seal retainer assembly Item 15 16 17 over shaft chamfered side first and press into body bore When fully in place body snap ring groove will be visible 5 Install snap ring Item 14 into its body groove with snap ring s sharp edges facing outward and retainer pin between snap ring lugs Be sure snap ring is completely seated in groove Repairs Wheel Motor Repair Fig 29 Figure 29 IMPORTANT Before DI
121. sengage 4 seconds after traction bail returns to neutral then stop aerating after another 3 seconds If machine does not stop aerating when traction bail returns to neutral there is a malfunction in the interlock system that must be corrected If machine stops aerat ing go to step 5 5 Engage traction bail to start machine moving then push aerate ENGAGE button to begin aerating Push aerate DISENGAGE button The water pump should disengage immediately then stop aerating after 3 sec onds If machine does not stop aerating there is a malfunction in the interlock system that must be cor rected Testing 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 1 Park machine on a level surface stop the engine engage the parking brake open the hood and discon nect the engine spark plug wires 2 Disconnect wiring harness connector from bottom of water pressure gauge Install a jumper wire across terminals of disconnected wire connector This will elec trically by pass the water pressure switch 3 Turn ignition key switch to ON position DO NOT start the engine 4 ENGAGE test A Lower machine to aerate position on rollers Yellow light should be ON B Move traction bail out of neutral Red light should come ON C With traction bail
122. ssure bleed valve Figure 15 1 Protective cover 2 Valve cap Testing 4 Attach and gently tighten special fitting of Charging Tool 4001 to inlet on top of accumulator 5 Close outlet valve on right hand side of charging tool to prevent loss of pressurized Nitrogen from ac cumulator 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 Service range of Nitrogen pre charge pressure 1800 to 2800 PSI Allow 200 PSI if accumulator body is warm 7 If pre charge pressure is WITHIN service range go to step 8 If pre charge pressure is ABOVE service range accumulator has internal damage and should be rebuilt or replaced If pre charge pressure is BELOW service range go to step 10 under Adding Dry Nitrogen to Accumulator 8 Tighten nut of accumulator valve clockwise and de pressurize tool by slowly opening outlet valve on right hand side of pressure gauge 9 Disconnect 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 tank of dry Nitrogen to high pressure tube on charging tool Tighten tank fitting by turning hose fitting counterclockwise 11
123. t Item 22 from wheel hub 3 Mount a wheel puller to wheel mount studs 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 installation Repairs Page 4 22 4 Disconnect hydraulic lines from fittings on wheel motor Put caps on open lines and fittings to prevent contamination Put labels on hydraulic lines for proper reinstallation 5 Remove four 4 capscrews Item 1 nuts Item 27 and lockwashers 28 to remove wheel motor Item 6 and brake brackets Item 29 from steering arm Item 37 6 Reverse steps 1 6 to install wheel motor When installing wheel hub onto motor shaft tighten large nut Item 22 to 250 400 ft lb Hydroject 3010 Wheel Motor Shaft Seal and or Shaft Replacement Fig 28 Figure 28 Disassembly of Shaft and Front Seal Assembly 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 Pull shaft Item 10 out vertically IMPORTANT When pulling shaft vertically do not rotate shaft or move motor as this may alter internal timing 5 With seal retainer assembly and shaft assembly removed remove all parts from shaft and inspect vari ou
124. t use any substitutes This filter has a 5 micron rating For easier filter removal use Filter Wrench TOR4012 Repairs Page 6 22 Figure 34 1 Filter body 2 Filter 3 Filter head 4 Bleed button HydroJect 3010 Water Pump Removal and Installation Fig 35 1 Park machine on a level surface stop the engine engage the parking brake open the hood and discon 3 Remove lower plug and let oil drain out of pump crankcase into a container Install drain plug nect the engine spark plug wires A WARNING High pressure water system components can cause personal injury if disassembled incor 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 6 Disconnect inlet water hoses from pump head Lift pump assembly out of frame and put a sturdy clean work bench 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 7 Reverse steps 3 6 to install pump After installing pump fill crankcase with 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 IN 17 Torque to 25 33 ft lb Eight locations Figure 35 HydroJect 3010 Page 6 23 Rep
125. tch and replace if faulty Test ignition switch and replace if faulty Check all wiring and connections and repair as necessary Test actuator and repair or re place if faulty Troubleshooting Page 5 10 Hydroject 3010 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 Machine aerates but should not with with machine raised in trans port position See Safety Interlock System Prob lems Machine starts aerating but should not with inlet water pres sure of less than 20 to 30 PSI or machine does not stop aerating if inlet water pressure drops to 10 PSI Water pressure switch faulty Water pressure switch wiring faulty Controller faulty Test switch and replace if faulty Check for short in pressure switch controller connections and wiring and repair as necessary Replace controller Machine does not start aerating when engage button is pushed in pump drive belt does NOT ro tate Problem not electrical see Chap ter 6 Water System Loose or broken wire Accumulator charge switch faulty Accumulator high pressure switch faulty Pressure gauge switch faulty Pump clutch faulty Pump relay faulty Aerator stop disengage switch faulty Wheel position switch faulty Aerator start engage switch faulty
126. tenance Equivalents and Conversions Torque Specifications Chapter 3 Engine Specifications as gran hat Lou Pea bae Kohler Engine Service Manual Chapter 4 Hydraulic System Specifications General Information Hydraulic Diagram Special Tools dre rede tes Troubleshooting Testirig ete erede s Adjustments ccs aa ROIG UA Hydroject 3010 Chapter 5 Electrical System Wiring Schematics and Diagrams 5 2 Special Tools 5 5 Troubleshooting 5 7 T sting Loses re REDDERE ES 5 15 sat epe D rA qt 5 24 Chapter 6 Water System Specifications 6 2 Water System 6 3 Special 6 4 Troubleshooting 6 9 Testing eiue 6 12 Adjustments 6 18 hi 6 20 Chapter 7 Wheels Steering and Brakes Adjustments rs zen Een x pant nex 7 2 Repairs i Seia mrii bd Peu bbs 7 3 Chapter 8 Electrical Diagrams
127. traction bail out of neutral and aerate engage switch re leased Normal condition Troubleshooting Page 5 14 Hydroject 3010 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 Verify Safety Interlock System Operation The safety interlock system prevents the engine from cranking or starting unless traction bail is in NEUTRAL and prevents the water system from engaging if ma chine is in the transport raised position It also stops aeration if traction bail is released while operating or if machine is raised to the transport position A CAUTION The interlock switches are for the operator s protection so DO NOT disconnect them Check operation of switches daily to make sure interlock system is operating If a switch is defective replace it before operating Re gardless if switches are operating properly or not replace interlock switches every two 2 years to assure maximum safety Do not rely entirely on safety switches use common sense
128. u m ie 4 ts uo U U 440 440 40 440 440 4 440 440 440 SP6 SRO SP4 SP1 SP3 SP7 SP8 LE Los Ll um Lt bat oo E L oo I Lj 24 bat LE 1 WHEEL POSITION SWITCH Hydroject 3010 Main Harness P9 Page8 4 COMMON COIL N C N O COIL COMMON COIL N C N O COIL WHEEL POSITION SWITCH LOW PRESSURE WARN RELAY LOW PRESSURE STOP RELAY ACOUMUAATOR LOW PRESSURE SWITCH TRACTION SWITCH 2 41 42 ES 39 86 19 874 87 86 39 8 P1787 87 86 P18 we N amp E 2 6 e 5 I 5 a lt 5 5 2 n I 3 lt z o nU 5
129. valves and seats are located in the nozzle drops and are easily replaced if they wear Occa Check Valve Ball Check Valve Ball Tighten nut to 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 spiral pointing up and the check ball on top of the spring To block the flow for different nozzle configura tions install the narrow spiral pointing down with the check ball below the spring NOTE Nozzles are stamped with numbers indicating drill size of orifice Standard configuration is 11 nozzles which will produce depths of approximately 4 to 6 inch es depending on soil conditions Blocked nozzle loca tions are obtained by reversing nozzle check valve and spring y N 2777777777 24 v N S N NN lt 70 80 ft lb OPEN NOZZLE CLOSED BLOCKED NOZZLE Aluminum washer P N 86 8150 is required with any nozzle change Hydroject 3010 Page 6 33 Repairs Accumulator Replacement Fig 43 1 Stop the engine engage the parking brake open the hood and disconnect the engine spark plug wires A DANGER Charged accumulators contain high pressure nitrogen Nitrogen is the only gas to use for accumulator charging Installing IMPROPER gases in an accumulator can cause an EX PLOSION AND DEATH Charging requires special tools and precautions Charge ac cumulators i
130. xture 5 Put rotary valve Item 7 on shaft spline with T shaped slots on first Hydroject 3010 6 Next put IGR inner member on shaft spline with semi circular roll pockets between rotary valve ports 7 Put contour member of IGR over inner and insert seven rolls into inner pockets large diameter rolls 8 Lightly oil square ring seal Item 4 and put in body groove 9 Put check balls Item 6 over the two 1 8 inch diameter holes in body Be sure the check balls do not fall into body tapped holes 10 Put locating ring section 4 5 inch diameter of IGR Item 5 onto body 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 Hydroject 3010 Page 4 25 NOTE Be sure not to dislodge body square ring seal while moving locating ring 11 Install the eight locating ring rollers into their pockets and oil lightly 12 Put other lightly oiled square ring seal Item 4 into groove in cover and put cover over shaft end and align bolt holes 13 Install the eight bolts with lightly oiled thread ends into bolt holes and tighten diagonally to 30 ft lb NOTE The shaft may not turn freely after assembly A short running period may be required Repairs Repairs Page 4 26 Hydroject 3010 TORO Table of Contents WIRING SCHEMATICS AND DIAGRAMS Logic Chart Controller lights SPECIAL TOOLS TROUBLESHOOTING
131. y and use Insertion Mandril TOR4011 to completely install seal support This seal support fits tightly in the bore 9 Install new U cup seal Item 3 and O ring seal Item1 into seal retainer Item 2 Install seal retainer into pump head cavity Use a soft face plastic hammer or arbor press to completely insert backup ring into pump head Hydroject 3010 Page 6 25 Plunger Sleeve Replacement Model 09800 see Figure 38 on next page 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 Remove plunger sleeves Item 26 from crankcase plunger rods Item 9 by loosening and removing plung er bolt assemblies Item 30 The plunger sleeves can be gently pulled forward for inspection or replacement Remove large washer Item 25 from rear of plunger rod 2 Remove O Ring Item 29 and PTFE seal Item 28 on plunger bolt assembly Item 30 Install new greased O ring Item 28 next to head on bolt then install PTFE ring Item 28 3 Install new large washer Item 25 then new plungers Item26 onto plunger rods 4 Apply Loctite 271 or equivalent to threads of plunger bolts then install assemblies onto plunger rods Torque plunger bolts to 10 ft lbs Pump Head Installation Fig 37 1 Apply grease to ceramic plunger sleeves Carefully
132. y 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 Figure 3 Repairs 7 4 Hydroject 3010 Chapter 8 TORO Electrical Diagrams Table of Contents 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 Electrical Diagrams Hydroject 3010 Page 8 1 Electrical Diagrams This page is intentionally blank Electrical Diagrams 8 2 Hydroject 3010 CONTROL PANEL HARNESS 108 1276 CONTROL PANEL HARNESS MAIN HARNESS 108 1277 ENGINE START P25 D P5 D B ENGINE START U FUSED POWER P25 B P5 8 FUSED POWER 70 1480 R W R W SENE 4 87 e R W BU BK 0 sde mms 2 s Sk D aw e irl START RELAY TRACTION SWITCH 1 29 6162 E i GROUND SHOWN IN DRIVE P24 1 FUN P24 5 GROUND P25 A 5 5
133. ydroject 3010 Table of Contents Chapter 4 Hydraulic System SPECIFICATIONS 2 Speed Control 11 GENERAL INFORMATION 3 Transmission Neutral Adjustment 12 Hydraulic Hose and Fitting Information 3 Aeration Speed Adjustment 12 Pushing or Towing 5 Pump Drive Belt Adjustment 13 HYDRAULIC DIAGRAM 6 REPAIRS 2s Rx SINE 14 15 7 Pump Drive Replacement 14 Hydraulic 7 Hydraulic Pump Removal and Installation 15 TROUBLESHOOTING 8 Pump Shaft Seal Replacement 16 Transmission Operates in One Direction Only 8 Pump Charge Check Valve Service 17 System Operates Hot Looses Power or Pump Bypass Valve Service 17 Will Not Operate in Either Direction 8 Charge Pump Service 18 TESTING 5 2219 t eite bt xt as 9 Major Pump Repair 18 Hydraulic Tests 10 Wheel Motor Removal and Installation 22 ADJUSTMENTS 11 Wheel Motor Repair 23 Traction Cable Adjustment 11 Hydroject 3010 4 1 Table of Contents Specifications

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