Toro 3010 User Manual

Page 1

Preface

This publications provides the service technician with information for troubleshooting, testing, and repair of the Hydroject.

Part No. 04134SL (Rev. B)

Service Manual

Hydroject ® 3010

REFER TO THE HYDROJECT OPERATOR’S MANUAL FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. Space is provided in Chapter 2 of this book to insert the Operator’s Manual and Parts Catalog for your machine. 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 T oro Company reserves the right to change product specifications or this publication without notice.

This safety symbol means DANGER, WARNING, or CAUTION, PERSONAL SAFETY INSTRUCTION. When you see this symbol, carefully read the instructions that follow. Failure to obey the instructions may result in personal injury.

NOTE: A NOTE will give general information about the correct operation, maintenance, service, testing or repair of the machine.

IMPORTANT: The IMPORTANT notice will give important instructions which must be followed to prevent damage to systems or components on the machine.

Page 2

Hydroject 3010

Page 3

Chapter 1 - Safety

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1

Chapter 2 - Product Records and Manuals

Product Records. . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1

Maintenance

Equivalents and Conversions . . . . . . . . . . . . . . . . 2 - 2

Torque Specifications . . . . . . . . . . . . . . . . . . . . . . 2 - 3

Chapter 3 - Engine

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1

Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2

Kohler Engine Service Manual

Chapter 4 - Hydraulic System

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2

General Information Hydraulic Diagram

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 7

Troubleshooting

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 9

Adjustments

Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 14

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1

. . . . . . . . . . . . . . . . . . . . . . . 4 - 3

. . . . . . . . . . . . . . . . . . . . . . . . 4 - 6

. . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 8

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 11

Chapter 5 - Electrical System

Wiring Schematics and Diagrams. . . . . . . . . . . . . 5 - 2

Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5

Troubleshooting Testing

Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 24

Chapter 6 - Water System

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 2

Water System Schematic . . . . . . . . . . . . . . . . . . . 6 - 3

Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 4

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 9

Testing Adjustments

Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 20

Chapter 7 - Wheels, Steering and Brakes

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 2

Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 3

Chapter 8 - Electrical Diagrams

Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 3

Main Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 4

Main Wiring Diagram

Control Panel Harness . . . . . . . . . . . . . . . . . . . . . 8 - 6

Control Panel Wiring Diagram . . . . . . . . . . . . . . . 8 - 7

Tiller Harness and Wiring Diagram

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 15

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 12

. . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 7

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 18

. . . . . . . . . . . . . . . . . . . . . . 8 - 5

. . . . . . . . . . . . 8 - 8

Hydroject 3010

Page 4

Hydroject 3000/4000

Page 5

Table of Contents

Chapter 1

Safety

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 1

Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Safety Instructions

Although hazard control and accident prevention partially 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, maintenance, 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 Commercial 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.

Maintenance and Service . . . . . . . . . . . . . . . . . . . . . 3

SAFETY AND INSTRUCTION DECALS

. . . . . . . . . . 4

CAUTION

TO REDUCE THE POTENTIAL FOR INJURY OR DEATH, COMPLY WITH THE FOLLOWING SAFETY INSTRUCTIONS.

3. Never operate the machine when under the influ-

ence of drugs or alcohol.

4. Before attempting to start engine engage parking brake.

5. Remove all debris or other objects that might interfere 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, tennis 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.

Hydroject 3010

Page 1 – 1

Safety

Page 6

8. Fill fuel tank with gasoline before starting the en-

gine. Avoid spilling gasoline. Since gasoline is flammable, handle it carefully.

A. Use an approved gasoline container. B. Do not fill tank while engine is hot or

running.

C. Do not smoke while handling gasoline.

While Operating

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.

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 prevent loss of control:

Maintenance

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 running or soon after it is stopped. These areas could be hot enough to cause a burn.

19. Before leaving the operator’s position–behind handle–engage parking brake.

20. When leaving the machine unattended, engage parking brake , shut engine OFF and remove key from ignition switch.

21. Disconnect wires from spark plugs to prevent accidental starting of the engine when servicing, adjusting or storing the machine.

22. If 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 battery.

23. To reduce potential fire hazard, keep the engine free of 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 maintenance 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 Hydroject 3010

Page 1 – 2

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.

Page 7

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 nitrogen. Accumulator servicing requires special tools and precautions. Accumulators do not con tain user serviceable components. Improper accumulator 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 T0R0 Distributor check maximum engine speed with a tachometer.

33. Engine must be shut off before checking oil or adding oil to the crankcase.

34. Allow engine to cool before storing machine in any enclosure such as a garage or storage shed. Make sure the fuel tank is 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 described 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, always purchase genuine TORO replacement parts and accessories to keep the Toro all TORO. NEVER USE “WILL–FIT” REPLACEMENT PARTS AND ACCESSORIES MADE BY OTHER MANUFACTURERS. Look for the TORO logo to assure genuineness. Using unap proved replacement parts and accessories could void the warranty of The Toro Company.

Hydroject 3010

Page 1 – 3

Safety

Page 8

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 replacement decals from your authorized Toro Distributor.

Safety

Page 1 – 4

Hydroject 3010

Page 9

Product Records and Maintenance

Table of Contents

Chapter 2

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 Hydroject 3010 at the end of this chapter. Additionally, if any optional equipment or accessories have been installed to your Hyroject, insert the Installation Instructions, Operator’s Manuals and Parts Catalogs for those options at the end of this chapter.

Maintenance

Maintenance procedures and recommended service intervals for the Hydroject 3010 covered in the Operator’s Manual. Refer to that publication when performing regular equipment maintenance. Refer to the Engine Operator’s Manual for additional engine specific maintenance procedures.

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 . . . . . . . . . . . . . . . . . . . . . . . . . 6

Hydroject 3010

Page 2 – 1

Product Records and Maintenance

Page 10

Equivalents and Conversions

Product Records and Maintenance

Page 2 – 2

Hydroject 3010

Page 11

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

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 specific 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 performed 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.

Grade 1

Grade 5 Grade 8

Inch Series Bolts and Screws

Figure 1

Class 8.8 Class 10.9

Metric Bolts and Screws

Figure 2

Hydroject 3010

Page 2 – 3

Product Records and Maintenance

Page 12

Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series)

Grade 1, 5 &

Thread Size

# 6 – 32 UNC 15 + 2 170 + 20 23 + 2 260 + 20

# 6 – 40 UNF

# 8 – 32 UNC 29 + 3 330 + 30 41 + 4 460 + 45

# 8 – 36 UNF

# 10 – 24 UNC 42 + 4 475 + 45 60 + 6 675 + 70

# 10 – 32 UNF

1/4 – 20 UNC 48 + 7 53 + 7 599 + 79 100 + 10 100 140 + 15 1580 + 170

1/4 – 28 UNF 53 + 7 65 + 10 734 + 10 1300 + 100 160 + 15 1800 + 170

5/16 – 18 UNC 15 105 + 17 169 200 + 25 2250 + 280 300 + 30 3390 + 340

5/16 – 24 UNF 138 + 17 128 + 17 1446 + 192 225 + 25 2540 + 280 325 + 30 3670 + 340

3/8 – 16 UNC 16 + 2 16 + 2 22 + 3 30 + 3 41 + 4 43 + 4 58 + 5

8 with Thin

Height Nuts

in–lb in–lb N–cm in–lb N–cm in–lb N–cm

10 + 2 13 + 2 147 + 23

13 + 2 25 + 5 282 + 30

18 + 2 30 + 5 339 + 56

115 + 1186 +

ft–lb ft–lb N–m ft–lb N–m ft–lb N–m

SAE Grade 1 Bolts, Screws, Studs &

Sems with Regular Height Nuts

(SAE J995 Grade 2 or Stronger Nuts)

113 115 +

SAE Grade 5 Bolts, Screws, Studs &

Sems with Regular Height Nuts

(SAE J995 Grade 2 or Stronger Nuts)

17 + 2 190 + 20 25 + 2 280 + 20

31 + 3 350 + 30 43 + 4 485 + 45

48 + 4 540 + 45 68 + 6 765 + 70

1125 +

SAE Grade 8 Bolts, Screws, Studs &

Sems with Regular Height Nuts

(SAE J995 Grade 5 or Stronger Nuts)

3/8 – 24 UNF 17 + 2 18 + 2 24 + 3 35 + 3 47 + 4 50 + 4 68 + 5

7/16 – 14 UNC 27 + 3 27 + 3 37 + 4 50 + 5 68 + 7 70 + 7 95 + 9

7/16 – 20 UNF 29 + 3 29 + 3 39 + 4 55 + 5 75 + 7 77 + 7 104 + 9

1/2 – 13 UNC 30 + 3 48 + 7 65 + 9 75 + 8 102 + 11 105 + 10 142 + 14

1/2 – 20 UNF 32 + 3 53 + 7 72 + 9 85 + 8 11 120 + 10 163 + 14

5/8 – 11 UNC 119 +

5/8 – 18 UNF 75 + 10 95 + 15 129 + 20 170 + 15 230 + 20 240 + 20 325 + 27

3/4 – 10 UNC 93 + 12 140 + 20 190 + 27 265 + 25 359 + 34 375 + 35 508 + 47

3/4 – 16 UNF 15 165 + 25 224 + 34 300 + 25 407 + 34 420 + 35 569 + 47

7/8 – 9 UNC 140 + 20 225 + 25 305 + 34 430 + 45 583 + 61 600 + 60 813 + 81

7/8 – 14 UNF 155 + 25 260 + 30 353 + 41 475 + 45 644 + 61 660 + 60 895 + 81

NOTE: Reduce torque values listed 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.

65 + 10 88 + 12 16 150 + 15 203 + 20 210 + 20 285 + 27

115 +

NOTE: The nominal torque values listed above for Grade 5 and 8 fasteners are based on 75% of the mini mum proof load specified in SAE J429. The tolerance is approximately +

115 +

10% 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

Page 2 – 4

Hydroject 3010

Page 13

Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Fasteners)

Class 8.8 Bolts, Screws and Studs with Class 10.9 Bolts, Screws and Studs with

Thread Size Regular Height Nuts

(Class 8 or Stronger Nuts)

M5 X 0.8 57 + 5 in–lb 640 + 60 N–cm 78 + 7 in–lb 885 + 80 N–cm

M6 X 1.0 96 + 9 in–lb 1018 + 100 N–cm 133 + 13 in–lb 1500 + 150 N–cm

M8 X 1.25 19 + 2 ft–lb 26 + 3 N–m 27 + 2 ft–lb 36 + 3 N–m

M10 X 1.5 38 + 4 ft–lb 52 + 5 N–m 53 + 5 ft–lb 72 + 7 N–m

Regular Height Nuts

(Class 10 or Stronger Nuts)

M12 X 1.75 66 + 7 ft–lb 90 + 10 N–m 9 ft–lb 12 N–m

M16 X 2.0 15 ft–lb 225 + 20 N–m 229 + 22 ft–lb 310 + 30 N–m

M20 X 2.5 325 + 33 ft–lb 440 + 45 N–m 450 + 37 ft–lb 610 + 50 N–m

166 +

NOTE: The nominal torque values listed above are based on 75% of the minimum proof load specified in SAE J1199. The tolerance is approximately + nominal torque value.

92 + 125 +

10% of the

Hydroject 3010

Page 2 – 5

Product Records and Maintenance

Page 14

Other Torque Specifications

SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts

Recommended Torque

Thread Size

Square Head Hex Socket

1/4 – 20 UNC 140 + 20 in–lb 73 + 12 in–lb

5/16 – 18 UNC 215 + 35 in–lb 145 + 20 in–lb

3/8 – 16 UNC 35 + 10 ft–lb 18 + 3 ft–lb

1/2 – 13 UNC 75 + 15 ft–lb 50 + 10 ft–lb

Thread Cutting Screws

(Zinc Plated Steel)

Type 1, Type 23 or Type F

Thread Size

No. 6 – 32 UNC 20 + 5 in–lb

No. 8 – 32 UNC 30 + 5 in–lb

Baseline Torque*

Thread Size

7/16 – 20 UNF

Grade 5

1/2 – 20 UNF

Grade 5

M12 X 1.25

Class 8.8

M12 X 1.5

Class 8.8

** For steel wheels and non–lubricated fasteners.

Thread Cutting Screws

(Zinc Plated Steel)

Thread

Size

No. 6 18 20 20 + 5 in–lb

No. 8 15 18 30 + 5 in–lb

Threads per Inch

Type A Type B

Recommended Torque**

65 + 10 ft–lb 88 + 14 N–m

80 + 10 ft–lb 108 + 14 N–m

Baseline Torque*

No. 10 – 24 UNC 38 + 7 in–lb

1/4 – 20 UNC 85 + 15 in–lb

5/16 – 18 UNC 20 in–lb

3/8 – 16 UNC 200 + 100 in–lb

110 +

Conversion Factors

in–lb X 11.2985 = N–cm N–cm X 0.08851 = in–lb

ft–lb X 1.3558 = N–m N–m X 0.7376 = ft–lb

No. 10 12 16 38 + 7 in–lb

No. 12 11 14 85 + 15 in–lb

* Hole size, material strength, material thickness & finish must be considered when determining specific torque values. All torque values are based on non–lubricated fasteners.

Product Records and Maintenance

Page 2 – 6

Hydroject 3010

Page 15

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Page 19

Table of Contents

Chapter 4

Hydraulic System

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . 3

Hydraulic Hose and Fitting Information . . . . . . . . 3

Pushing or Towing . . . . . . . . . . . . . . . . . . . . . . . . 5

HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . 6

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Hydraulic Tester. . . . . . . . . . . . . . . . . . . . . . . . . . 7

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 8

Transmission Operates in One Direction Only . . 8

System Operates Hot, Looses Power or

Will Not Operate in Either Direction

TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Hydraulic Tests . . . . . . . . . . . . . . . . . . . . . . . . . 10

ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Traction Cable Adjustment . . . . . . . . . . . . . . . . . 11

. . . . . . . . . 8

Speed Control Adjustment. . . . . . . . . . . . . . . . . 11

Transmission Neutral Adjustment . . . . . . . . . . . 12

Aeration Speed Adjustment . . . . . . . . . . . . . . . . 12

Pump Drive Belt Adjustment . . . . . . . . . . . . . . . 13

REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Pump Drive Belt Replacement . . . . . . . . . . . . . 14

Hydraulic Pump Removal and Installation. . . . . 15

Pump Shaft Seal Replacement . . . . . . . . . . . . 16

Pump Charge Check Valve Service . . . . . . . . . 17

Pump Bypass Valve Service . . . . . . . . . . . . . . . 17

Charge Pump Service . . . . . . . . . . . . . . . . . . . . 18

Major Pump Repair . . . . . . . . . . . . . . . . . . . . . . 18

Wheel Motor Removal and Installation . . . . . . . 22

Wheel Motor Repair. . . . . . . . . . . . . . . . . . . . . . 23

Hydroject 3010 Page 4 - 1 Table of Contents

Page 20

Specifications

Item Description

__________________________________________________________________________________________

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

________________________________________________________________________________________________________________________________________________________

Wheel Motor Orbit rotor type

________________________________________________________________________________________________________________________________________________________

Hydraulic Oil

________________________________________________________________________________________________________________________________________________________

Reservoir (gear case) Approximately 4 - 5 quarts

Sundstrand Series 70, BDP-10L Variable Displacement Pump

25 micron screw-on type. No by-pass

See Operator’s Manual

Specifications Page 4 - 2 Hydroject 3010

Page 21

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 conditions or mishandling during operation or maintenance. These conditions can cause damage or premature deterioration. Some hoses, such as reel motor hoses, are more susceptible to these conditions than others. Inspect 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.

CAUTION

Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved by stopping the engine and opening the bypass valve.

Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use 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 injury or gangrene may result.

paper or

with this

type of

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 recommended that the O-ring be replaced any time the connection is opened.

3. Lubricate the O-ring with a light coating of oil.

4. Put the tube and nut squarely into position on the face seal end of the fitting and tighten the nut until finger tight.

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 on the nut and fitting body will verify that the connection has been tightened.

Size F.F.F.T.

4 (1/4 in. nominal hose or tubing) .75 r .25

6 (3/8 in.) r .25

8 (1/2 in.) .75 r .25

10 (5/8 in.) r .25

12 (3/4 in.) r .25

16 (1 in.) .75 r .25

.75

1.00 .75

Nut

Sleeve

Seal

Body

Figure 2

Mark Nut and Body

Finger Tight After Proper Tightening

Final Position

Extend Line

Initial Position

Figure 3

Hydroject 3010 Page 4 - 3 General Information

Page 22

SAE Straight Thread O-Ring Port - Non-adjustable (Fig. 4)

1. Make sure both threads and sealing surfaces are free of burrs, nicks, scratches, or any foreign material.

2. Always replace the O-ring seal when this type of fitting shows signs of leakage.

3. Lubricate the O-ring with a light coating of oil.

4. Install the fitting into the port and tighten it down full length until finger tight.

5. Tighten the fitting to the correct flats from finger tight (F.F.F.T.).

Size F.F.F.T.

4 (1/4 in. nominal hose or tubing) 1.00 r .25 6 (3/8 in.) 1.50 r .25 8 (1/2 in.) 1.50 r .25 10 (5/8 in.) 1.50 r .25 12 (3/4 in.) 1.50 r .25 16 (1 in.) 1.50 r .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).

O-Ring

Figure 4

Lock Nut

Back-Up Washer O-Ring

5. Install the fitting into the port and tighten finger tight

Figure 5

until the washer contacts the face of the port (Step 2).

6. T o put the fitting in the desired position, unscrew it by the required amount, but no more than one full turn

Step 1

Step 3

(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 finger tight (F.F.F.T.) (Step 4)

Size F.F.F.T.

4 (1/4 in. nominal hose or tubing) 1.00 r .25 6 (3/8 in.) 1.50 r .25 8 (1/2 in.) 1.50 r .25 10 (5/8 in.) 1.50 r .25 12 (3/4 in.) 1.50 r .25 16 (1 in.) 1.50 r .25

Step 2

Step 4

Figure 6

General Information Page 4 - 4 Hydroject 3010

Page 23

Pushing or Towing (Fig. 7)

The machine can be pushed or towed for very short distances with the engine off, if necessary.

IMPORT ANT: Do not push or tow the machine faster than 5 MPH because the hydraulic pump may be damaged. If the machine must be moved further than a few feet, transport it on a trailer or pull with traction wheel raised and secured to a dolly . Whenever the machine is pushed or towed, the by-pass valve must be open. Hook on front of handle is used for a tie-down only, not a hitch point.

1. Stop the engine and raise the hood.

2. Open the by-pass valve by turning it counterclockwise (2 turns maximum).

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 bypass valve open will cause improper operation and overheating of the hydraulic system.

Figure 7

1. By-pass valve

Hydroject 3010 Page 4 - 5 General Information

Page 24

Hydraulic Diagram

Cooling Orifice

Input (Belt Drive)

Variable Disp. Pump

Inlet Filter

Charge Pump

Reservoir (Gear Case)

Charge Relief Val

Figure 8

Charge Check

ves

Val

By-pass

Val

Wheel Motor

Hydraulic Diagram Page 4 - 6 Hydroject 3010

Page 25

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)

Load Valve

Low Pressure Gauge

Outlet Hose

Gauge Protector Valve

Inlet Hose

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.

Flow Meter

High Pressure Gauge

4. HIGH PRESSURE GAUGE: High range gauge to accommodate pressure beyond the capacity 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.

Hydroject 3010 Page 4 - 7 Special Tools

Page 26

Troubleshooting

The cause of an improperly functioning hydraulic system is best diagnosed with the use of proper testing

system could lead to extensive internal component

damage. equipment and a thorough understanding of the complete hydraulic system.

The charts that follow contain detailed information to

assist in troubleshooting. There may possibly be more 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,

than one cause for a machine malfunction. All causes

should be checked in the order in which they are listed

on the charts. 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

Refer to the Testing section of this Chapter for precau-

tions and specific test procedures.

Tr ansmission Operates in One Direction Only

Cause Correction

__________________________________________________________________________________________

Faulty traction control linkage. Repair linkage

________________________________________________________________________________________________________________________________________________________

Transmission charge check valve defective. Inspect and clean or replace charge/check.

System Operates Hot, Looses Power or Will Not Operate in Either Direction

Cause Correction

__________________________________________________________________________________________

Faulty control linkage. 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.

________________________________________________________________________________________________________________________________________________________

Low traction pump flow/pressure - Test B. Repair or replace pump.

________________________________________________________________________________________________________________________________________________________

Inspect charge pump and replace if faulty.

Low traction motor efficiency - Test C. Repair or replace traction motor.

Troubleshooting Page 4 - 8 Hydroject 3010

Page 27

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.)

CAUTION

Failure to use gauges with the recommended pressure (psi) rating as listed in the test procedures 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 component is the source of the problem being experienced.

W ARNING

Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved by stopping the engine and opening the bypass valve.

Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under 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 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.

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. T o 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. T o minimize the possibility of damaging components, completely open the load valve by turning it counterclockwise (tester with pressure and flow capabilities).

6. Install fittings finger tight, far enough to insure that they are not cross-threaded, before tightening with 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.

Hydroject 3010 Page 4 - 9 Testing

Page 28

Hydraulic Tests (Fig. 10, 11)

1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes.

2. Engage parking brake and stop the engine. Make sure parking brake is properly adjusted before performing hydraulic tests.

3. With engine off, 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.

T est 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 inspect for internal damage or worn parts. If charge pump is in good condition (no scoring, scratches, or excessive wear), piston pump and motor might be suspected of wear and inefficiency, thus charge pump is unable to keep up with internal leakage.

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 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.

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 traction 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 inspect for binding parking brake. Inspect for restriction 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.

Figure 10

1. Hose 2. Bulkhead fitting

Variable Displacement Pump

Tes ter

Figure 11

Wheel Motor

Testing Page 4 - 10 Hydroject 3010

Page 29

Adjustments

Tr action Cable Adjustment (Fig. 12)

1. Park machine on a level surface, stop the engine and open the hood. Remove lower cover from handle.

2. Adjust pump end of push-pull cable with pump lever in neutral starting position by adjusting jam nuts so distance from seal to threads is 1.00 r 0.05 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

Page 30

Tr ansmission Neutral Adjustment (Fig. 14)

If machine moves when lever is released, transmission neutral adjustment is needed.

1. Park machine on a level surface, stop the engine and open the hood.

2. Lift drive wheel off the ground using a jack. Block front and rear of other wheels.

3. Start engine and release parking brake.

4. Slightly loosen locknut on top of neutral adjustment cam and rotate cam hex until traction wheel stops rotating. Tighten the locknut.

5. Move traction bail completely up and down. Release handle and check for wheel rotation. If wheel continues rotating, repeat step 4.

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.

Figure 14

1. Neutral adjustment cam

2. Locknut

3. Switch tab

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.

6. Operate engine at full speed.

7. Move traction handle UP to full speed position.

8. Loosen jam nuts and adjust LOWER speed rod until traction wheel rotates at 20-22 RPM. Tighten jam nuts.

9. Move traction handle DOWN to full speed position.

10. Adjust UPPER speed rod until traction wheel rotates at 20-22 RPM. Tighten jam nuts.

Figure 15

1. Speed control lever

2. Lower speed rod

3. Upper speed rod

Adjustments Page 4 - 12 Hydroject 3010

Page 31

Tr action Pump Belt Adjustment (Fig. 16, 17)

1. Park machine on a level surface, stop the engine and open the hood.

2. Check belt tension by depressing belt midway between pulleys with 3 lb. of force. Belt should deflect 1/4 in.

3. If adjustment is necessary: A. Loosen pivot nut securing pump mount to pump

support. B. Loosen adjusting nut securing pump and pump

mount to slotted pump support. C. Loose three (3) capscrews securing pulley guard

bracket (Fig. 20, Item 21) to control panel and pump support.

D. Use a pry bar in hole on pump bracket to pull pump 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 16

1. Traction pump belt

Figure 17

1. Adjusting nut

2. Pivot nut

Hydroject 3010 Page 4 - 13 Adjustments

Page 32

Repairs

Tr action Pump Belt Replacement (Fig. 18, 19)

1. Park machine on a level surface, engage parking brake, open hood and disconnect engine spark plug wires.

2. Remove pulley guard bracket (Fig. 20, Item 21).

3. Remove drive coupling (see Drive Coupling Removal and Installation in Chapter 6 - 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 to slotted pump support.

8. Push pump towards inside of machine to loosen belt tension and remove the belt.

9. Reverse steps 2 - 8 to install new belt.

10. Adjust belt tension (see Traction Pump Belt Adjustment).

1. Pump drive belt

2. Drive coupling

3. Valve clutch

4. Valve clutch stops

Figure 19

1. Adjusting nut

2. Pivot nut

Repairs Page 4 - 14 Hydroject 3010

Page 33

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.

19 20

19 13

7. Remove locknut (Item 46), capscrew (Item 5) and washers (Item 47). Remove locknut (Item 54) and capscrew (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 (Item 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.

40 41

33 32

Figure 20

Hydroject 3010 Page 4 - 15 Repairs

Page 34

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 surface, 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 or contamination. Polish sealing area on shaft if necessary.

4. Lubricate new seal with petroleum jelly.

Top of pump when installed in machine

Figure 21

1. Retaining ring

2. Seal (input shaft)

3. Spacer

4. Seal (displacement control shaft)

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 Page 4 - 16 Hydroject 3010

Page 35

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. T urn pump over and repeat installation procedure for other check valve.

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 15 to 35 ft-lb.

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 into end cap. Tighten to a

torque of 7 to 10 ft-lb.

7 to 10 ft-lb.

Top of pump whenTorque to 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

Page 36

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 orientation of charge pump cover on pump end cap. Cast boss on charge pump cover indicates orientation. Note orientation 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.

Top of pump when installed in machine

Torque to 84 to 120 in-lb.

Figure 24

1. Charge pump cover

2. O-ring

3. Gerotor assembly

4. Charge relief ball

5. Charge relief 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 torque 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 chemicals. Protect all sealing surfaces and open cavities from damage and foreign material.

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 petroleum jelly before assembly. All gasket sealing surfaces must be cleaned before installing new gaskets.

Repairs Page 4 - 18 Hydroject 3010

Page 37

33 31 32

Figure 25

Disassembly of Hydraulic Pump

1. Before performing major repairs on the pump, remove

external components as described in previous procedures. These include the following:

Shaft Seals Charge Check Valves Bypass Valve Charge Pump

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).

IMPORT ANT: 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).

6. Remove cylinder block spring (Item 8) and washer (Item 9) from shaft.

7. Remove swashplate assembly (Item 25) from housing.

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 housing 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 surface, or bearing. After seal is removed it cannot be used again.

13. Remove bearing spacer washer (Item 22).

Hydroject 3010 Page 4 - 19 Repairs

Page 38

14. Remove pump shaft (Item 19) and bearing assembly from housing.

3. Install displacement control shaft (Item 12) into housing.

15. Remove outer bearing retaining ring (Item 21) (and washer, if used). Press shaft out of bearing.

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 requires replacement, press it out of housing.

Inspection and Replacement of Pump Parts

After disassembly, thoroughly clean all parts in a suitable 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 splines. Polish sealing areas on shafts if necessary. Replace any worn or damaged parts.

4. If 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.

IMPORT ANT : 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. Install retaining ring (Item 24).

11. Install swashplate cradle bearings (Item 14) into housing, making sure they are located on cast-in pins in housing.

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. Tighten all threaded parts to recommended torque value.

IMPORTANT: Most parts have critical, high tolerance surfaces. Use caution to prevent damage to these surfaces during assembly. Protect exposed surfaces, openings and ports from damage and foreign material.

2. If 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.

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 (Item 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 pistons must move freely in their bores.

17. With pump swashplate in “neutral” (0 angle) position and pump housing laying on its side, install pump cylinder block kit onto pump shaft in housing.

NOTE: The position of the bearing in the housing determines control shaft end play. Do not press bearing deeper into housing at this time.

Repairs Page 4 - 20 Hydroject 3010

Page 39

18. Check that piston springs are centered in cylinder

block bores, If necessary, move springs into position with a small screwdriver.

21. When end cap is properly installed, the internal springs will hold it away from the housing approximately 3/8 in.

IMPORTANT: Do not damage running surfaces of cylinder blocks.

19. Install two (2) alignment pins (Item 15) and install a

new gasket (Item 6) onto housing.

20. Lubricate 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 housing. Be careful to prevent damage to end cap and cylinder block sealing surfaces.

22. Install the four (4) capscrews which retain end cap to housing. Tighten screws to a torque of 138 to 180 in-lb.

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.

33 31 32

Figure 26

Hydroject 3010 Page 4 - 21 Repairs

Page 40

Wheel Motor Removal and Installation (Fig. 27)

37 36

Torque to 250 to 400 ft-lb.

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 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 removal or installation.

23 24

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 (Item 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.

Repairs Page 4 - 22 Hydroject 3010

Page 41

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.

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.

4. Pull shaft (Item 10) out vertically.

2. Slowly lower spline end of shaft (Item 10) assembly into motor body using caution not to rotate internal parts

IMPORTANT: When pulling shaft vertically, do not

once shaft spline starts to engage.

rotate shaft or move motor as this may alter internal timing.

3. Put lightly oiled o-ring (Item 12) into groove in body bore.

5. With seal retainer assembly and shaft assembly

removed, remove all parts from shaft and inspect various 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

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. seal retainer assembly (Item 15, 16, 17). The shaft should have smooth polished surfaces in bearing and seal areas. If the shaft is lightly scratched in these areas, polish with fine emery paper in a circumferential direction. However, if the shaft has any pitting or deep

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.

Hydroject 3010 Page 4 - 23 Repairs

Page 42

Wheel Motor Repair (Fig. 29)

Figure 29

IMPORTANT: Before DISASSEMBLING motor, plug open ports and clean all dirt from outside of motor .

IMPORT ANT : Before ASSEMBLING motor , lightly oil all seals, rollers and threaded bolt ends.

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

Disassembly of Cover Section of Motor

(See Disassembly of Shaft and Front Seal Assembly under Main Shaft Seal and/or Shaft Replacement.)

1. Remove key (Item 11) from shaft.

Assembly of Complete Motor

2. Mount motor in a vice or other holding device with shaft facing down.

1. Before assembly, all parts must be cleaned with a suitable solvent and free of nicks and burrs.

3. Remove the eight capscrews (Item 1).

2. Mount body with pilot and bearing facing up in a vise

4. Remove cover & bearing assembly (Item 2) and

or other holding mechanism.

square ring seal (Item 4).

3. Insert shaft (Item 10) and install seals and thrust

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,

bearings. (See Assembly of Shaft and Front Seal Assembly under Main Shaft Seal and/or Shaft Replacement.)

entire IGR assembly must be replaced.

4. Mount body with pilot and bearing facing down in a

6. Remove the two check balls (Item 6).

vise or other holding fixture.

5. Put rotary valve (Item 7) on shaft spline with “T” shaped slots on first.

Repairs Page 4 - 24 Hydroject 3010

Page 43

6. Next put IGR inner member on shaft spline with semi-circular roll pockets between rotary valve ports.

NOTE: Be sure not to dislodge body square ring seal

while moving locating ring.

7. Put contour member of IGR over inner and insert seven rolls into inner pockets (large diameter rolls).

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 downward over balls. Align the eight bolt holes in locating ring with eight holes in body. The holes align in only one position.

1 1. 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.

Hydroject 3010 Page 4 - 25 Repairs

Page 44

Repairs Page 4 - 26 Hydroject 3010

Page 45

Table of Contents

Chapter 5

Electrical System

WIRING SCHEMATICS AND DIAGRAMS . . . . . . . . 2

Logic Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Controller lights . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 7

Starting Problems . . . . . . . . . . . . . . . . . . . . . . . . 7

General Run and Transport Problems. . . . . . . . . 9

Aerate Operation Problems. . . . . . . . . . . . . . . . . 11

Safety Interlock System Problems . . . . . . . . . . 13

TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Verify Safety Interlock System Operation . . . . . 15

Clutch Engagement /

Electronic Control System Test

Ignition Key Switch . . . . . . . . . . . . . . . . . . . . . . 17

Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Traction Switch 1 and 2 . . . . . . . . . . . . . . . . . . . 18

Wheel Position Switch. . . . . . . . . . . . . . . . . . . . 19

Aerator Engage and Disengage Switches . . . . 19

. . . . . . . . . . . . . 16

Lift Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Linear Actuator . . . . . . . . . . . . . . . . . . . . . . . . . 20

Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Pressure Gauge/Switch. . . . . . . . . . . . . . . . . . . 21

Accumulator Charge and High Press. Switches 21

Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Pump Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Valve Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Circuit Breaker and Fusible Link . . . . . . . . . . . . 23

REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . 24

Traction Switch 1 and 2

Replacement and Adjustment . . . . . . . . . . . . 25

Controller Replacement. . . . . . . . . . . . . . . . . . . 26

Linear Actuator Replacement . . . . . . . . . . . . . . 27

Hydroject 3010 Page 5 - 1 Table of Contents

Page 46

Wiring Schematics and Diagrams

Logic Chart

Each line on the Logic Chart shows the combination of switch conditions that must be made for the listed action to occur. Example - START, under ACTIONS: For the engine to start the Key Switch must be moved to Start (making terminals B + L + S) and the hydraulic pump must be in Neutral (Traction Switch 1 CLOSED).

KEY

Switch Closed

Switch Open



Switch Closed Momentarily Switch Conditon Not Relevent

SWITCHES

Start - Key Switch B + L + S

Run - Key Switch B + L + A

ACTIONS

1. Start X X

2. Run X X

3. Machine Lower (aerate position) X O X

4. Aerate

5. Machine Raise (transport position) X X O

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.

(see Controller Ti

Machine Moving (out of neutral) X X X X X  X O Machine Stationary (neutral) X X X X X X O

ming below)

Oil Pressure Switch

Traction Switch 1

Water Pressure Switch

Wheel Position Switch

Accumulator Charge Switch

Aerator Start (Engage) Switch

Traction Switch 2

Aerator Stop (Disengage) Switch

Lift Switch DOWN (Aerate)

Lift Switch UP (Transport)

Accumulator High Press Switch

Brake Switch

Aerate SHUT-DOWN Sequence (Disengage Delay)

1. Pump clutch disengages and green light goes off immediately when stop (disengage) switch is pushed in (opens) or if pump start limit switch or water pressure switch opens (yellow light goes off).

2. After another 3 seconds, valve clutch will disengage.

Wiring Schematics and Diagrams Page 5 - 2 Hydroject 3010

Page 47

Contoller Lights

Lights (LEF’s) on the controller indicate when the following inputs are made to the contoller:

Red: Traction switch 1 closed (traction bail in neutral).

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 lowered 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

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Page 48

Electrical Schematic and Wiring Diagrams

See Chapter 8 - Electrical Diagrams.

Wiring Schematics and Diagrams Page 5 - 4 Hydroject 3010

Page 49

Special Tools

NOTE: Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). Some tools may be available from a local

supplier.

Digital Multimeter (Fig. 6)

The meter can test electrical components and circuits for current, resistance, or voltage drop.

NOTE: Toro recommends the use of a DIGITAL meter when testing electrical circuits. The high impedance (internal resistance) of a digital meter will ensure that excess current is not allowed through the meter. Excess current can cuase damage to a circuit that is not designed to carry it.

Figure 6

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Page 50

Skin-Over Grease (Fig. 7)

Special non-conductive grease which forms a light protective skin to help waterproof electrical switches and contacts.

Toro P/N 505-47 8 oz. (.24 L) can

Figure 7

Special Tools Page 5 - 6 Hydroject 3010

Page 51

Troubleshooting

CAUTION

Remove all jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Disconnect the battery cables unless the test requires battery voltage.

Study the operating characteristics preceding the electrical failure to help identify the area of difficulty. Try to isolate the failure to a specific functional system; then check that area, repairing one component at a time. Attempting to repair more than one system at one time will lead to confusion.

Possible Causes and Corrections in the troubleshooting charts should be checked in the order in which they are listed.

For effective troubleshooting and repairs, you MUST have a good understanding of the electrical circuits and components used on this machine. (See Electrical Schematic.)

If the machine being repaired has any interlock switches by-passed, they must be reconnected for proper troubleshooting and safety.

Starting Problems

Condition Possible Cause Correction

________________________________________________________________________________________________________________________________________________________

Engine fails to crank, regardless Loose or corroded battery connecof traction bail position. tions.

Low battery charge.

Circuit breaker open.

Clean and tighten connections.

Charge battery. Replace battery if it will not hold a charge (also see Battery does not charge under General Run and Transport Problems).

Reset circuit breaker. Find cause for open circuit breaker and correct. Replace circuit breaker if

faulty. Ignition key switch faulty. Traction switch 1 faulty.

Start relay faulty. Starter solenoid faulty.

Starter is faulty.

Engine is seized. Loose or damaged wiring.

Hydroject 3010 Page 5 - 7 Troubleshooting

Test switch and replace if faulty.

Make sure switch is properly in-

stalled and adjusted. Test switch

and replace if faulty.

Test relay and replace if faulty.

Test starter solenoid and replace

if faulty.

Test starter and repair replace if

faulty.

Repair engine.

Check connections. Repair wiring.

Page 52

Starting Problems (continued)

Condition Possible Cause Correction

________________________________________________________________________________________________________________________________________________________

Engine cranks, but does not start.

Engine wire harness loose. Connect wires. NOTE: If engine cranks, cause of problem is UNRELATED to interlock system.

“L” terminal on ignition key switch Connect wire.

loose.

Engine problem, or no fuel. Find problem and correct (see

________________________________________________________________________________________________________________________________________________________

Chapter 3 - Engine).

Engine cranks (but should not) See Safety Interlock System Probwith traction bail in neutral.

________________________________________________________________________________________________________________________________________________________

Engine starts, but shuts down Not electrical - regulate choke durwhen ignition key switch is re-

lems.

Normal condition.

ing cold start-up. leased to RUN position.

Not electrical - low engine oil pres-

sure.

Oil pressure switch faulty.

Loose or broken wire in oil pres-

________________________________________________________________________________________________________________________________________________________

sure switch circuit.

Starter does not disengage when Ignition switch faulty. key switch is released to RUN po-

Find and correct cause of low engine oil pressure.

Test switch and replace if faulty. Check all wiring and connections

and repair as necessary.

Test ignition key switch and replace if faulty.

sition.

Short in start circuit wiring.

Check all wiring and connections and repair as necessary.

Start relay faulty.

Starter solenoid faulty.

Starter failed (mechanical).

Test start relay and replace if necessary.

Test starter solenoid and replace if necessary.

Test starter and replace if necessary.

Troubleshooting Page 5 - 8 Hydroject 3010

Page 53

General Run and Tr ansport Problems

Condition Possible Cause Correction

________________________________________________________________________________________________________________________________________________________

Engine shuts down during trans- Not electrical - low engine oil presport or when idling (not in Aerate sure, no fuel, etc.

Find and correct cause of engine shut down.

mode).

Oil pressure switch faulty. Loose or broken wire in oil pres-

________________________________________________________________________________________________________________________________________________________

sure switch circuit.

Test switch and replace if faulty. Check all wiring and connections

and repair as necessary.

Engine does not stop when igni- Engine timing or carburetor out of Adjust carburetor or engine timtion key switch is rotated to OFF

adjustment. ing.

position.

Ignition switch faulty.

Test ignition switch and replace if faulty.

Short in ignition circuit wiring.

________________________________________________________________________________________________________________________________________________________

Battery does not charge. Loose or damaged wire(s) in en-

gine electrical system. Regulator or engine charging cir-

Check all wiring and connections and repair as necessary.

Check wiring and connections and repair as necessary.

Repair engine charging circuit.

cuit faulty.

________________________________________________________________________________________________________________________________________________________

Battery faulty. Test battery and replace if faulty.

Machine does not lower (to aer- Lift/lower switch faulty. Test switch and replace if faulty. ate position).

Ignition key switch faulty. Test ignition switch and replace if

faulty.

Loose or broken wire in lift down circuit.

Linear actuator faulty.

Check all wiring and connections and repair as necessary.

Test actuator and repair or replace if faulty.

Hydroject 3010 Page 5 - 9 Troubleshooting

Page 54

General Run and Tr ansport Problems (continued)

Condition Possible Cause Correction

________________________________________________________________________________________________________________________________________________________

Machine does not raise (to trans- Lift/Lower switch faulty. port position).

Ignition key switch faulty.

Lose or broken wire in lift up circuit. Check all wiring and connections

Linear actuator faulty.

Test switch and replace if faulty. Test ignition switch and replace if

faulty.

and repair as necessary. Test actuator and repair or re-

place if faulty.

Troubleshooting Page 5 - 10 Hydroject 3010

Page 55

Aerate Operation Problems

Condition Possible Cause Correction

________________________________________________________________________________________________________________________________________________________

Machine continues to aerate (but should not) with traction bail in neutral.

________________________________________________________________________________________________________________________________________________________

Machine aerates (but should not) with with machine raised in transport position.

________________________________________________________________________________________________________________________________________________________

Machine starts aerating (but

See Safety Interlock System Problems.

Water pressure switch faulty. Test switch and replace if faulty. should not) with inlet water pressure of less than 20 to 30 PSI, or machine does not stop aerating if inlet water pressure drops to

Water pressure switch wiring faulty. Check for short in pressure

switch/controller connections and wiring and repair as necessary.

10 PSI.

________________________________________________________________________________________________________________________________________________________

Machine does not start aerating when engage button is pushed in

Controller faulty.

Problem not electrical (see Chap-

ter 6 - Water System.)

Replace controller.

(pump drive belt does NOT rotate).

Loose or broken wire.

Check all connections and wiring and repair as necessary.

Accumulator charge switch faulty.

Test switch and replace if 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.

Controller 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

Page 56

Aerate Operation Problems (continued)

Condition Possible Cause Correction

________________________________________________________________________________________________________________________________________________________

Machine does not start aerating when engage button is pushed in

Valve clutch out of adjustment. Check air gap on valve clutch

and adjust if necessary. (pump belt IS rotating, but gearcase drive shaft is NOT rotating). Loose or broken wire in valve

clutch / controller circuit. Valve clutch faulty.

Check all connections and wiring

and repair as necessary.

Test valve clutch and repair or re-

place if faulty.

Valve clutch relay faulty.

________________________________________________________________________________________________________________________________________________________

Controller faulty. Replace controller.

Machine stops aerating when not It is normal for pump clutch and moving (traction bail in neutral).

water clutch to disengage when traction bail is neutral for 3 to 4 sec-

________________________________________________________________________________________________________________________________________________________

onds.

Test relay and replace if faulty.

Educate operator. NOTE: Holding

Aerate start switch in ENGAGE

position will override neutral de-

lay shut-down.

Machine stops aerating while ma- Problem not electrical (see Trouchine is moving (traction bail out of neutral).

bleshooting in Chapter 6 - Water System.)

Traction switch 2 faulty.

Make sure switch is installed and

adjusted properly . Test switch

and replace if 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 engage.)

Check all connections and wiring

and repair as necessary.

Troubleshooting Page 5 - 12 Hydroject 3010

Page 57

Safety Interlock System Problems

Condition Possible Cause Correction

________________________________________________________________________________________________________________________________________________________

Engine cranks (but should not) Traction switch 1 faulty. Make sure switch is installed and with traction bail in neutral. adjusted properly . Test neutral

switch and replace if faulty.

Traction switch 1 wiring faulty.

Check for short in switch wiring and connections and repair as

________________________________________________________________________________________________________________________________________________________

Machine continues to aerate (but Red light on controller is ON should not) with traction bail in neutral.

(should be OFF) with traction bail in neutral.

necessary.

Make sure traction switch 2 is installed and adjusted properly. Test switch and replace if faulty.

Check for short in traction switch 2/controller connections and wiring and repair as necessary.

Green light on controller stays ON (should be OFF) with aerate engage switch released.

Test aerate engage (start) switch and replace if faulty (make sure switch action is momentary and comes comes back out after being pushed in).

________________________________________________________________________________________________________________________________________________________

Controller faulty.

Machine aerates (but should not) Yellow light on controller is ON with with machine raised in transport position.

(should be OFF) with machine raised in transport position.

Replace controller.

Test wheel position switch and replace if faulty.

Check for short in wheel position switch connections and wiring and repair as necessary.

Controller faulty.

Replace controller.

Hydroject 3010 Page 5 - 13 Troubleshooting

Page 58

Safety Interlock System Problems (continued)

Condition Possible Cause Correction

________________________________________________________________________________________________________________________________________________________

No lights on controller come on Battery is dead or disconnected. when troubleshooting interlock system.

Circuit breaker open.

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.

Faulty controller ground.

Check controller ground connec-

tion and wiring and repair as nec-

essary.

Ignition key switch faulty.

Test ignition switch and replace if

faulty.

Loose or damaged wiring in key switch/controller circuit.

________________________________________________________________________________________________________________________________________________________

Green light on controller glows

Controller faulty.

Normal condition.

Check all connections and wiring

and repair as necessary.

Replace controller.

faintly when only red light should be on (traction bail out of neutral and aerate engage switch released).

Troubleshooting Page 5 - 14 Hydroject 3010

Page 59

Testing

It is often to the technician’s advantage to leave the components intact in the electrical system, and by studying the electrical troubleshooting charts and schematics, determine which component is at fault. However, this section will define given components, and the tests that can be performed on those components, when those parts are disconnected from the electrical system.

For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit.

Verify Safety Interlock System Operation

CAUTION

When testing electrical components for continuity 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.

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 machine 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.

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. Regardless 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!

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.

3. Connect water supply to machine. Turn on water supply and bleed all air out of the system. Water pressure 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 seconds after pump engages. Release traction bail to neutral position so machine stops moving. The water pump should disengage 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 aerating, 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 seconds. If machine does not stop aerating, there is a malfunction in the interlock system that must be corrected.

Hydroject 3010 Page 5 - 15 Testing

Page 60

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 connecting 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 disconnect 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 electrically 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.

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 pressure switch by-pass must be removed to prevent damage to water system from low inlet water pressure.

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.

C. With traction bail out of neutral, push, then release, 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.

Figure 8A

1. Red light

2. Green light

3. Yellow light

Figure 8B

1. Red light

2. Green light

3. Yellow light

Testing Page 5 - 16 Hydroject 3010

Page 61

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Page 62

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 controller, 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, disconnect both battery cables from the battery, disconnect both wire harness plugs from the electronic control unit and disconnect the terminal connector from the alternator to prevent damage to the electrical system.

Lights (LED’s) on the controller indicate the condition of the interlock switches. 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 or the controller (see Wiring Schematics and Diagrams).

Tr action 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 normally 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 “N.O.” terminals. The Traction switch 2 must have the wires connected to the “COMMON” and “N.C.” terminals. If the wires are not connected to the correct terminals, on each switch the safety interlock circuit will not function properly.

Figure 11

1. Red light

2. Yellow light

3. Green light

Test the switch by disconnecting the wires from the

Figure 12

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 traction bail in a forward and reverse direction while watch-

1. Traction switch 1 –– N.O. (gray & black wires)

2. Traction switch 2 –– N.C. (orange & yellow wires)

3. Switch tab

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 Traction Switch 1 and 2 Replacement and Adjustment in the Repairs section of this chapter for replacement and adjustment procedures.)

Testing Page 5 - 18 Hydroject 3010

Page 63

Wheel Position Switch (Fig. 13)

T est 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) CLOSED OPEN

Transport (machine raised)

NOTE: For proper operation, the switch must be screwed all the way in. A damaged pivot shaft or bushings 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.

Figure 14

1. Aeration start (engage) switch (pink & orange wires)

2. Aeration stop (disengage) switch (gray & white wires)

Hydroject 3010 Page 5 - 19 Testing

Page 64

Lift Switch (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. T erminals 2-1 and 5-4 should have continuity in DOWN.

Linear Actuator (Fig. 16)

The linear actuator has a bi-directional electric motor which engages a clutch and screw mechanism to extend or retract a rod and raise or lower the transport wheels.

Figure 15

1. Lift switch

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 aerate position.

3. Connect a 12 volt battery so the negative (–) terminal is connected to the yellow wire of the actuator connector. 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 Speed 3/4 in. per second at maximum

12 VDC

load

Figure 16

1. Linear actuator 2. Wiring connector

Testing Page 5 - 20 Hydroject 3010

Page 65

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.

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.

T o test the pressure switch, disconnect the wire connector 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 17

1. Brake switch

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).

DANGER

The accumulator contains nitrogen gas under high pressure. DO NOT attempt to remove or replace these switches without first opening the high pressure water bleed valve and then releasing pressurized gas from the accumulator (see Accumulator Service in Chapter 6 Water System).

1. High pressure limit switch 2. Accumulator charge switch

Figure 18a

Hydroject 3010 Page 5 - 21 Testing

Page 66

Relays (Fig. 19, 20)

To test a relay, disconnect the relay wire connector and install a continuity tester between the relay terminals (terminals 30 and 87). The relay should make and break continuity at terminals 30 and 87 as 12 V.D.C. is connected and disconnected to terminal 85 with terminal 86 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

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

Figure 20

Testing Page 5 - 22 Hydroject 3010

Page 67

Pump Clutch (Fig. 21)

To test the pump clutch, disconnect the wire connector and connect a continuity tester or ohm meter across the terminals of the clutch wire connector. There should be continuity across the terminals of the clutch connector. Resistance measured through the clutch coil should be approximately 3 ohms.

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 (68o 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.

Figure 21

1. Pump clutch

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

C (68o 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 Wiring Harness in Chapter 8 - Electrical Diagrams).

Figure 22

1. Valve clutch

Figure 23

1. Circuit breaker

Hydroject 3010 Page 5 - 23 Testing

Page 68

Repairs

Battery Service (Fig. 24, 25)

IMPORTANT: To prevent damage to the electrical components, do not operate the engine with the battery cables disconnected.

Keep the terminals and entire battery case clean. To clean the battery, wash the entire case with a solution of baking soda and water. Rinse with clear water . Do not get the soda solution into the battery because damage to the battery will result. Coat the battery posts and cable connectors with skin-over grease, or petroleum jelly to prevent corrosion.

Check for loose battery hold-downs. A loose 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.

CAUTION

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.

Electrolyte Specific Gravity Fully charged: 1.250 - 1.280

Discharged: less than 1.240 Battery Specifications BCI Group 28 Battery:

535 Amp Cranking Performance at 0 110 min. Reserve Capacity at 80

Figure 24

1. Positive (+) terminal

2. Negative (–) terminal

F (–17 o C)

F (27 o C)

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 from the electrical outlet before connecting or disconnecting the charger leads from the battery posts.

Figure 25

Repairs Page 5 - 24 Hydroject 3010

Page 69

Tr action Switch 1 and 2 Replacement and Adjustment (Fig. 26)

1. Disconnect wires from switch terminals.

2. Have a helper push traction bail down into either FORWARD or REVERSE position or disconnect extension spring; this will take switch arm tension off of switch. Loosen two (2) screws and remove 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).

IMPORTANT: Traction switch 1 and 2 have three (3) terminals. If the two (2) wires are not connected to the “COMMON” and “N.O.” terminals on traction switch 1 and “COMMON” and “N.C.” terminals on traction switch 2, the safety interlock circuit will not function properly.

CAUTION

If the wires are not correctly installed to traction switch 1, the engine could start with the traction bail in forward or reverse.

5. Coat switch terminals and wires with skin-over grease.

Figure 26

1. Traction switch 1 – N.O. (gray & black wires)

2. Traction switch 2 – N.C. (orange & yellow wires)

3. Switch tab

6. Loosen two (2) screws and adjust switch tab so switches are actuated, but not bottomed out, when pump control is in neutral.

Hydroject 3010 Page 5 - 25 Repairs

Page 70

Controller Replacement (Fig. 27)

IMPORTANT: Before welding on the machine, disconnect both battery cables from the battery, disconnect both wire harness plugs from the controller and disconnect the terminal connector from the alternator to prevent damage to the electrical system.

1. Stop the engine and disconnect battery cables from battery.

2. Disconnect wiring harness connectors from controller.

3. Remove two (2) nuts securing controller to frame and remove controller.

Figure 27

4. Install new controller and secure to frame with nuts removed in step 3.

5. Connect wiring harness connectors to controller.

6. Connect battery cables.

1. Controller

Repairs Page 5 - 26 Hydroject 3010

Page 71

Linear Actuator Replacement (Fig. 28)

1. Put wheels in transport position (machine raised).

2. Put the machine on a level surface, stop the engine, engage the parking brake and disconnect engine spark plug wires.

3. Open the hood.

4. Disconnect linear actuator wire connector.

5. Disconnect extension springs.

6. Remove capscrew and nut securing each end of linear actuator.

7. Reverse steps 3 - 6 to install the linear actuator.

Figure 28

1. Linear actuator 3. Extension spring

2. Wire connector 4. Capscrew & nut

Hydroject 3010 Page 5 - 27 Repairs

Page 72

Repairs Page 5 - 28 Hydroject 3010

Page 73

Table of Contents

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Nozzle Size and Approximate Depth Chart . . . . . 2

WATER SYSTEM SCHEMATIC . . . . . . . . . . . . . . . . 3

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Accumulator Charging Valve

and Pressure Gauge

Accumulator Seal Installation Tool . . . . . . . . . . . 4

Accumulator Cap Wrench . . . . . . . . . . . . . . . . . . 5

Water System Pressure Gauge . . . . . . . . . . . . . . 5

Flow Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Valve Lift Indicator . . . . . . . . . . . . . . . . . . . . . . . . 6

Valve Spring Compressor . . . . . . . . . . . . . . . . . . 6

Water Valve Seal Installation Guide . . . . . . . . . . 7

Pump Seal Installation Guide . . . . . . . . . . . . . . . 7

Seal Installation Mandril . . . . . . . . . . . . . . . . . . . 7

Filter Body Wrench . . . . . . . . . . . . . . . . . . . . . . . 7

Pump Seal Extraction Tool . . . . . . . . . . . . . . . . . 8

Pump Seal Outlet Cover . . . . . . . . . . . . . . . . . . . 8

Pump Wear Sleeve Driver . . . . . . . . . . . . . . . . . . 8

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 9

Troubleshooting Water System Problems . . . . . . 9

. . . . . . . . . . . . . . . . . . . . 4

Chapter 6

Water System

TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Before Performing Water System Tests . . . . . . 12

TEST NO. 1: Accumulator Pre-Charge Pressure

and Adding Dry; Nitrogen . . . . . . . . . . . . . . . . 13

TEST NO. 2: Water System Pressure and Flow 15

TEST NO. 3: Water Valve Lift . . . . . . . . . . . . . . 17

ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Electric Clutch Adjustment . . . . . . . . . . . . . . . . . 18

Water Valve Lift . . . . . . . . . . . . . . . . . . . . . . . . . 18

REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

HydroJect 3010 Page 6 - 1 Table of Contents

Page 74

Specifications

Water Pump Clutch: Electromagnetic, dual groove belt

drive for water pump and driveshaft flange brake/clutch for main valve gearbox.

Air gap 0.018 in.

Pre Filter – Spin down type with washable cartridge in clear plastic housing and plastic ball valve for flushing.

Supply Filter – Replaceable 5 micron cartridge in plastic housing with air bleed button.

Water Filter Cartridge: Toro part no. 86–8630

Water Pressure Switch – Senses for water pressure after filter.

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 ceramic on stainless steel plungers and cast iron connecting rods.

outlet. All high pressure water flows in and out through the valve body. Pressure balanced valve spool with floating (patent pending), hardened stainless seat aligns during assembly. Bleed valve in base allows for bleed–off of high pressure and drain down for cold weather storage. Bolted flanges and polyurethane O– rings mate all components to valve body.

Valve lift: 0.100

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 corrosion resistant stainless and brass materials.

5000 + 300 PSI relief valve pressure.

Manifold and Nozzles – Extruded stainless steel manifold with11 flanged nozzle extensions containing check valves and hardened stainless discharge orifice. Check valves may be reversed in housing to block unused nozzles.

+0.002

inch (with new cam)

–0.04

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

Aeration Width: 33 inches with 11 nozzles on 3 inch centers.

Aeration Depth: 4 to 6 inches depending on turf conditions and nozzle configuration.

Hole Pattern: Variable from 1.5” to 6” spacing in the direction 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 allowable pressure of 200 psi. Although irrigation water pumped from ponds or effluent holding pools can be used, not all conditions can be handled by the machines filtration system, additional or alternative filtration may be required.

DO NOT USE CHEMICALS – Concern for environmental issues and corrosive affects on machine components.

Specifications

Page 6 – 2

Hydroject 3010

Page 75

Depths and Nozzle Configurations: All nozzles are identified with numbers indicating the drill size of the orifice. The standard configuration is 11 nozzles producing depths of 4 to 6 inches depending on turf conditions. Blocked nozzle locations are obtained by reversing the nozzle check valve ball and spring. See nozzle size chart and illustrations be low:

IMPORTANT: Use only nozzle configurations shown or damage to the machine may occur.

NOZZLE SIZE AND APPROXIMATE DEPTH CHART

Part No. Approx.

Drill Size Decimal Size

(inch)

Metric Size

(mm)

Quantity of Nozzles

Open

Blocked **

Depth

86–8130 #56 .0465 1.181 * * * 86–8131 #53 .0595 0 4–6”

1.511 11 86–8133 #46 .0810 2.057 6 5 6–8” *

Use only with varied size configurations

Aluminum Washer is required with any nozzle change:

Part no. 86–8150

OPTIONAL STAGGERED SIZE NOZZLE CONFIGURATION

Part No. Approx.

86–8130 #56 .0465 1.181 6 and 0** 3–4” 86–8133 #46 .0810 2.057 5 0** 6–8”

Aluminum Washer is required with any nozzle change:

(S/N 29999 & Below) Part no. 80–6680 Part no. 86–8150

Drill Size Decimal Size

(inch)

Metric Size

(mm)

Quantity of Nozzles

Open

Blocked **

Depth

**Additional nozzles may be blocked to compensate for pump wear.

Hydroject 3010

Page 6 – 2.1

Rev. B

Specifications

Page 76

Check Valve Ball

Spring

Check Valve Ball

70 – 80 ft–lb

CLOSED (BLOCKED) NOZZLEOPEN NOZZLE

Aluminum washer (P/N 86–8150) is required with any nozzle change.

Specifications

Page 6 – 2.2

Rev. B

Hydroject 3010

Page 77

Water System Schematic

ENGINE

ELECTRIC

CLUTCH

FILTER

ACCUMULATOR

2500 PSI

NITROGEN PRE–CHARGE

WATER

PUMP

ELECTRIC

BRAKE CLUTCH

PRESSURE

SWITCH

20 PSI – ON

10 PSI – OFF

PRESSURE GAUGE

SPRAY WASH

VALV E

PRESSURE REDUCING

VALV E

RELIEF VALVE

5000 PSI

WATER

VALV E

GEARBOX CAM

PRE–FILTER

ROLLER WASH

NOZZLES

AERATION NOZZLES

QUICK COUPLER

HIGH PRESSURE

WATER SUPPLY

ROLLER WASH

NOZZLES

Hydroject 3010

Page 6 – 3

Rev. B

Water System Schematic

Page 78

Special Tools

The following special tools are required for servicing the Order special tools from the HydroJect 3010.

AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS)

Accumulator Charging Valve and Pressure Gauge - TOR4001 (Fig. 2)

The charging valve connects the accumulator to a high pressure (3000-3500 or 6000 PSIG) Nitrogen tank for pre-charging the accumulator. 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 Compressed Gas Association No. 677 tank connection.

TORO SPECIAL TOOLS

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 installing piston seal during accumulator rebuilding.

Figure 2

Figure 3

Special Tools Page 6 - 4 HydroJect 3010

Page 79

Accumulator Cap Wrench - TOR4003 (Fig. 4)

After discharging accumulator, use this special wrench to remove accumulator cap for accumulator rebuilding.

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 4

Figure 5

Flow Meter - TOR4006 (Fig. 6)

The in-line flow meter with a battery-powered electronic digital display is installed in the water supply line 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 Page 6 - 5 Special Tools

Page 80

Valve Lift Indicator - TOR4007 (Fig. 7)

A special dial indicator and adaptor is temporarily installed into the inspection port on the side of the high pressure manifold to measure water valve lift. This indicator is also used to measures cam wear and deter mines correct shim size to get proper valve lift.

Valve Spring Compressor - TOR4008 (Fig. 8)

The valve spring compressor and hardware is used for compressing the water valve spring allowing removal and installation of the valve spring retainer. The spring retainer must be remove before servicing the water valve, water valve seals, and water valve seat.

Figure 7

Figure 8

Special Tools Page 6 - 6 HydroJect 3010

Page 81

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 Insertion 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.

Figure 9

1. Water Valve Seal Installation Guide

2. Pump Seal Installation Guide

3. Seal Installation Mandril

Figure 10

HydroJect 3010 Page 6 - 7 Special Tools

Page 82

Pump Seal Extraction Tools (Fig. 11)

Pump Seal Extraction Tool - TOR4013

Rod used to hydraulically extract pump seals from the pump cylinder head. Use with Pump Seal Outlet Cover and heavy mallet or hammer.

Pump Seal Outlet Cover - TOR4014

Cover plate with O-ring used with Seal Extraction Tool to hydraulically extract pump seals from pump head.

Pump Wear Sleeve Driver - TOR4015 (Fig. 12)

Driver used for removal and installation of plunger guides in pump crankcase.

Figure 11

Figure 12

Special Tools Page 6 - 8 HydroJect 3010

Page 83

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.

Refer to the Testing section of this Chapter for precautions 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.

Troubleshooting Water System Problems

Condition Possible Cause Correction

___________________________________________________________________________________________

Mach ne does not start aerating

i when engage button is pushed in (pump belt does NOT rotate).

Transport wheels not fully raised (unit lowered to aerate mode).

Check to make sure transport wheel arms are fully raised (unit in aerate mode).

Low inlet water pressure.

Sheared pump c utch key.

ectrical problem.

________________________________________________________________________________________________________________________________________________________

Mach ne does not start aerating

i when engage button is pushed in (pump belt IS rotat ng but gearcase drive shaft is NOT rotat ng.).

________________________________________________________________________________________________________________________________________________________

Mach ne makes unusual noise

i when fi i ion.

rst start ng aerat

ectric brake c utch (valve c utch)

El l l out of adjustment.

Sheared valve c utch key.

ectrical problem.

Air in system. NOTE: Re ef va ve may “squeal” for a short per od of

me during init al startup due to air

ti i in the system.

li l

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 - E ectrical System

Check air gap at electr c brake

utch and adjust f necessary.

cl i

Repair.

See Troubleshooting in Chapter 5 - E ectrical System

With engine OFF and water supply connected, open high pressure bleed valve and bleed air out of system. Repeat procedure if noise continues.

Damaged component.

HydroJect 3010 Page 6 - 9 Troubleshooting

Check for damaged components and repair or replace as necessary.

Page 84

Condition Possible Cause Correction

__________________________________________________________________________________________

Mach ne stops aerating (pump

i i ing.

Mach ne not mov

shuts down during aeration).

l i l

Norma condition of nter ock system. Operator must hold engage button in to aerate with tract

ion

bail in neutral.

Inadequate water supply.

Pl i

ugged inlet water f lter.

Check for k nked water supply hose, restr ction in line or part ally open va ve at water source.

Check water pressure at gauge

i i

when pump is engaged. If pressure drops to less than 15 PSI, but was ally higher, replace water f lter.

ectrical problem.

________________________________________________________________________________________________________________________________________________________

Water system engages (pump

Air in system. belt and gear case drive shaft rotate), but no aerat on holes are

i produced or aeration hole depth is shallow or incons stent.

Soil density or mo sture content.

See Troubleshooting in Chapter 5 - E ectrical System

With engine OFF and water supply connected, open high pressure bleed valve and bleed air out of system.

If hole depth was sat sfactory

initi

i before in another area, different nozz e configuration may be re-

quired.

ugged nozz es, worn nozz es or

Pl l l improper nozz e conf guration. NOTE: Check operation of nozz

l i

les by aerating over a piece of cardboard, then inspect

ing

cardboard.

Gear or cam damage in gear case.

n high pressure water sys-

Leak i tem.

Stop engine, open high pressure bleed valve, then inspect noz-

es. Check for plugged nozz es.

zl l Ver fy s ze and quantity (see Noz-

i i

ze and Approximate Depth

zle Si Chart). Nozz es that are too large

l will cause loss in pressure and could cause damage to the accumulator and other water system components.

Inspect gear case for gear or cam damage and repair as necessary.

Check for eaks w th water sys-

l i tem engaged. Stop engine, open high pressure bleed valve and repair eaks as necessary.

NOTE: Excessive water exiting between pump head and crankcase ndicates pump wear or damage. Excess ve water exit-

i ing from shim area below gearcase indicates valve wear or damage. Do water system tests and make repairs as necessary.

Troubleshooting Page 6 - 10 HydroJect 3010

Page 85

Condition Possible Cause Correction

___________________________________________________________________________________________

Machine aerates, but aeration Low accumulator pre-charge or hole depth is shallow or inconsistent (continued).

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.

Charge accumulator with dry Nitrogen. Rebuild or replace accumulator 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 outlet 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 necessary.

Worn or damaged water valve -

________________________________________________________________________________________________________________________________________________________

TEST NO. 2.

Rebuild water valve.

Water in gear case Worn or damaged water valve low Rebuild water valve. (milky or brown color in oil) pressure water seal and oil seal.

________________________________________________________________________________________________________________________________________________________

Oil leaking from below gear case Worn or damaged water valve oil Rebuild water valve. shim area. seal.

________________________________________________________________________________________________________________________________________________________

Water in pump crankcase Worn or damaged water pump low Rebuild pump head and plunger (milky or brown color in oil)

________________________________________________________________________________________________________________________________________________________

Engine dies when water system Low engine RPM. is engaged.

pressure seal or cracked ceramic sleeves. plunger.

Throttle must be in FAST position. Adjust carburetor fast setting to 3450 to 3550 RPM - no load.

Relief pressure too high - TEST NO. 2.

Low engine power.

Replace relief valve. DO NOT attempt to adjust.

Check for contaminated fuel, plugged fuel filter or fuel line, plugged air cleaner, bad spark plug. (see Chapter 3 - Engine).

Jammed or siezed pump or gearcase.

Inspect components and repair as necessary.

Hydroject 3010 Page 6 - 11 Troubleshooting

Page 86

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 isolated, such as low accumulator pre-charge pressure. This will verify that all components are operating properly.

WARNING

High pressure water system components can cause personal in ury if disassembled incorrectly. 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. 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.

Figure 13

1. High pressure bleed valve

Testing Page 6 - 12 HydroJect 3010

Page 87

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 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.

Figure 14

1. High pressure bleed valve

DANGER

Charged accumulators contain high pressure nitrogen. Nitrogen is the only gas to use for accumulator charging. Installing IMPROPER gases in an accumulator can cause an EXPLOSION AND DEATH. Charging requires special tools and precautions. Charge accumulators well ventilated area. It is recommended that the accumulator checked and charged by an Authorized TORO Distributor.

Wear eye protection. Keep hands and face away from gas valve.

Slowly open high pressure water bleed valve before servicing any component connected to high pressure water system. 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 in ury, DISMEMBERMENT OR DEATH.

in a

Figure 15

1. Protective cover 2. Valve cap

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 Testing

Page 88

4. Attach and gently tighten special fitting of Charging Tool (TOR4001) to inlet on top of accumulator.

5. Close outlet valve on right hand side of charging tool to prevent loss of pressurized Nitrogen from 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 depressurize tool by slowly opening outlet valve on right hand side of pressure gauge.

Figure 16

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. 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 clockwise.

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.

Figure 17

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 HydroJect 3010

Rev. A

Page 89

TEST NO. 2: Water System Pressure and Flow (Fig. 18, 19, 20, 21, 22, 23)

1. The engine must be in good operating condition. Use a tachometer to verify that the engine is operating at specified full governed RPM (3450 to 3550 RPM no load). Engine speed will affect accuracy of flow meter reading.

2. Stop the engine, engage the parking brake and open the hood.

WARNING

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 18

1. High pressure bleed valve

Figure 19

1. Water system pressure gauge (TOR4005)

5. Disconnect wire harness connection for water valve clutch to prevent the water valve from operating during the test.

Figure 20

1. Water valve clutch

HydroJect 3010 Page 6 - 15 Testing

Page 90

6. Install Flow Meter (TOR4006) between water supply hose and hose adapter. Connect hose adapter to quick connector on side of machine.

7. Turn on water supply. Open high pressure bleed valve until all air is out of the system. Close high pressure bleed valve for pump testing. NOTE: Air in system will cause improper test readings.

8. Disconnect hose from relief valve fitting.

9. THIS IS A TWO (2) PERSON OPERATION. Start engine and operate at full speed. WEAR SAFETY GLASSES! Have one person press and HOLD engage button while other person stands to side of machine and observes pressure gauge and flow meter readings.

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 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 ceramic sleeve or seal. Reconnect small tube.

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.

Figure 21

1. Water supply quick connector

Figure 22

/1. Flow meter pressure gauge (TOR4006)

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 again, with valve clutch connected to wire harness.

Pressure gauge needle will go rapidly to the relief setting (5000 ± 300 PSI) for 3 to 4 seconds, then begin to fluctuate rapidly when the unit begins aerat

ing. Note the highest pressure. If highest pressure is 4000 to 4500 PSI, plan to rebuild the valve. If pres

sure is less than 4000 PSI, rebuild the valve.

12. After testing is completed, open high pressure bleed valve, then remove water system pressure gauge. Reinstall plug in open port of water valve housing. Connect relief valve hose. Remove flow meter.

Rev. A

Figure 23

1. Relief valve 2. Hose

HydroJect 3010 Testing Page 6 - 16

Page 91

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.

WARNING

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 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.

IMPORTANT: A reading of 0.090 to 0.102 does not guarantee a properly adjusted cam. When in doubt, inspect cam. A worn cam which has been adjusted to 0.090 to 0.102 will not perform properly. A worn cam can cause opening of valve on lead-in portion of cam in this range.

Cam lobe Lead-in portion

Lead-out

iLead- n to lead-out is

two (2) rev. of pinion.

Figure 24

1. Coupling 2. Cam 3. Follower

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.

1. Valve lift indicator (TOR 4007)

Figure 25

8. Go to step 11 under TEST NO. 2 - Water System Pressure and Flow.

HydroJect 3010 Page 6 - 17 Testing

Page 92

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.

Water Valve Lift Adjustment (Fig. 27, 28, 29)

Figure 26

1. Locknut (3)

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.

WARNING

2. Slowly open high pressure bleed valve allowing any pressurized water to escape.

3. Remove belt guard to expose drive shaft. Remove gear case cover.

4. Use your hand to rotate coupling assembly, positioning 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 a worn cam lobe. Rotate cam to make sure cam lobe is not contacting follower.

Cam lobe Lead-in portion

Lead-out

i l is

Lead- n to ead-out two (2) rev. of pin on.

Figure 27

1. Coupling 2. Cam 3. Follower

Adjustments Page 6 - 18 HydroJect 3010

Page 93

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. 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. 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.

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

+0.002

0.10

in. (with new cam). Continue to rotate

–0.004

on lead-out portion. The dial indicator should read zero for entire lead-out portion.

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

Water (4000 - 5000 PSI operating pressure)

Wate r valve housing

Shims

Figure 28

1. Valve lift indicator (TOR4007)

Gear case

Cam lobe

Cam follower (on lead-in portion of cam)

Shims

Cam

Figure 29

HydroJect 3010 Page 6 - 19 Adjustments

Page 94

Repairs

Drive Coupling and Clutch Removal and Installation (Fig. 30)

1. Park the machine on a level surface, engage the parking brake, open the hood and disconnect the engine spark plug wires. Remove guard (Item 38).

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 +

Never–seez

on engine shaft

1234567

.03 in.

5. Apply Loctite 271 or 680 to threads of bolt (item 26). Use special washer (Item 27) and install bolt. Remove engine air cleaner feed hose to access teeth of flywheel. Hold flywheel and tighten bolt to a torque of 25 – 30 ft–lb.

NOTE: A tapered hub (Item 16) is attached to cam gearbox input shaft. When installing hub, be sure to use special 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 illustration below. Position flat of spacer (Item10) toward welded flange of drive shaft (Item 24). Tighten capscrews 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

18 19

Never–seez

Repairs

33 34

Figure 30

Page 6 – 20

Clutch bumper gap

0.19 – 0.25 in.

Rev. B

Loctite 271 or 680 25 – 30 ft–lb

Hydroject 3010

Page 95

Pump Drive Belt Replacement (Fig. 31, 32)

1. Park the machine on a level surface, engage the parking brake, open the hood and disconnect the engine spark plug wires.

2. Remove the drive coupling (see Drive Coupling Removal and Installation).

3. Disconnect electrical connectors for both clutches.

4. Remove clutch stops (Fig. 30, Item 5) and clutch retainer bracket (Fig. 30, Item 39).

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

Figure 31

6. Loosen water pump idler pulley and work belt off of large pulley. Carefully pull this belt out from under the electric clutches.

7. Reverse steps 2 - 6 to install the belt. Adjust hydraulic pump belt tension (see Pump Drive Belt Adjustment in Chapter 4 - Hydraulic System).

1. Water pump belt

Figure 32

1. Hydraulic pump belt

HydroJect 3010 Page 6 - 21 Repairs

Page 96

Water Filter Replacement (Fig. 33, 34)

When pump inlet pressure decreases or the water system shuts down, it usually means the water filter is restricted and must be replaced.

IMPORTANT: Never operate the machine without a water filter. Operating without a water filter can cause severe damage to the water system.

1. Put the machine on a level surface, engage the parking brake, stop the engine and disconnect the 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.

Figure 33

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 accumulator to bleed air from water system. Close high pressure bleed valve.

NOTE: The quality and micron rating of this filter is very important. Do not use any substitutes. This filter has a 5 micron rating. For easier filter removal, use Filter Wrench (TOR4012).

Figure 34

1. Filter body

2. Filter

3. Filter head

4. Bleed button

Repairs Page 6 - 22 HydroJect 3010

Page 97

Water Pump Removal and Installation (Fig. 35)

1. Park machine on a level surface, stop the engine, engage the parking brake, open the hood and discon nect the engine spark plug wires.

WARNING

2. Slowly open the high pressure bleed valve allowing any pressurized water to escape.

3. Remove lower plug and let oil drain out of pump crankcase into a container. Install drain plug.

4. Remove drive belt from driven pulley.

5. Remove four (4) water valve inlet bolts (Inset Item 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.

7. Reverse steps 3 - 6 to install pump. After installing pump, fill crankcase with 30 oz. of Mobil DTE Extra Heavy hydraulic oil or equivalent.

Torque to 25 - 33 ft-lb. (Eight locations)

14 15

Figure 35

HydroJect 3010 Page 6 - 23 Repairs

Page 98

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 components will require maintenance after approx. 500 pump operating hours (approx 750 engine hours).

WARNING

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 (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:

ll the three (3) plunger openings w th water.

Fi i Insert Pump Sea Extraction Too (TOR4013) into each water filled cav ty. Quick y, strike the extract on too th a heavy ead mallet. Sea

i l wi l l

assemby and brass retainer shou d move about

l l 1/4 in. out of the cylinder head. If sea 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 nstead of water.

l l

i l

PLUNGER SEAL REMOVAL - Step 1:

Fill out et port of pump head w th water and

l i use two capscrews, to temporar nsta Pump Seal Out et Cover (TOR4014) onto the out et port of the pump head.

Use Loctite 242 or equivalent Torque to 205 - 235 ft-lb. (Six locations)

ily i ll

Torque to 25 - 33 ft-lb. (Eight locations)

Figure 36

Repairs Page 6 - 24 HydroJect 3010

Page 99

Plunger Seal Replacement

(See illustration on previous page)

Plunger Sleeve Replacement

(see Figure 38 on next page)

(Model 09800)

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 be installed.

2. Position pump head on a SOLID workbench or in a vise keeping displacement rod openings pointing up wards.

3. Fill plunger openings with water. Insert Pump Seal Extraction Tool (TOR4013) into each water filled cavity. WEAR SAFETY GLASSES. Quickly, strike the extrac tion tool with a large hammer or mallet. The seal assembly 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.

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 install pump head onto pump crankcase studs and plungers. While installing, tap evenly on pump head while turning pump crankshaft.

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 cavity 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.

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).

Figure 37

Hydroject 3010

Page 6 – 25

Rev. B

Repairs

Page 100

Water Pump Crankcase Service (Fig. 38)

18 – 20 ft–lb

56 7 8

Apply grease to O.D. of plunger

before installing pump head

18 – 20 ft–lb

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 galling 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.

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 and 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–lb.

13. Install pulley with tapered hub onto pump drive shaft.

Repairs

Page 6 – 26 Hydroject 3010

Rev. B

Toro 3010 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Preface

Table Of Contents