Toro 3010 User Manual

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.

Hydroject 3010

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

Hydroject 3000/4000

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

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.

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

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

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

Equivalents and Conversions

Product Records and Maintenance

Page 2 – 2

Hydroject 3010

Torque Specifications

Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and 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

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

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

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

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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

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

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

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

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

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

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

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

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

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

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

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

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Toro 3010 User Manual

Preface

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