Toro HydroJect 3010 User manual

Part No. 04134SL (Rev. B)
Preface
This publications provides the service technician with
informationfortroubleshooting,testing,andrepairofthe
Hydroject.
REFER TO THE HYDROJECT OPERATOR’S MAN-
UAL FOR OPERATING, MAINTENANCE AND AD-
JUSTMENT INSTRUCTIONS. Space is provided in
Chapter 2 of this book to insert the Operator’s Manual
and Parts Catalog for your machine. A replacement
Operator’s Manual is availableby sending the complete
Model and Serial Number of the machine to:
The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420
TheToroCompanyreserves therightto changeproduct
specifications or this publication without notice.
Service Manual
Hydroject ®3010
INSTRUCTION. When you see this symbol,
This safety symbol means DANGER,
WARNING, orCAUTION,PERSONALSAFETY
carefully read the instructions that follow.
Failure to obey the instructions may result in
personal injury.
NOTE: A NOTE will give general information about the
correct operation, maintenance, service, testing or re-
pair of the machine.
IMPORTANT: The IMPORTANT notice will give im-
portant instructions which must be followed to pre-
vent damage to systems or components on the
machine.
©The Toro Company 2005, 2006, 2007

Hydroject 3010

Table Of Contents
Chapter 1 - Safety
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1
Chapter 2 - Product Records and Manuals
Product Records. . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1
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 . . . . . . . . . . . . . . . . . . . . . . . 4 - 3
Hydraulic Diagram . . . . . . . . . . . . . . . . . . . . . . . . 4 - 6
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 7
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 8
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 9
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 11
Repairs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 14
Chapter 5 - Electrical System
Wiring Schematics and Diagrams. . . . . . . . . . . . . 5 - 2
Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 7
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 15
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 24
Chapter 6 - Water System
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 2
Water System Schematic . . . . . . . . . . . . . . . . . . . 6 - 3
Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 9
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 12
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 18
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 . . . . . . . . . . . . . . . . . . . . . . 8 - 5
Control Panel Harness . . . . . . . . . . . . . . . . . . . . . 8 - 6
Control Panel Wiring Diagram . . . . . . . . . . . . . . . 8 - 7
Tiller Harness and Wiring Diagram. . . . . . . . . . . . 8 - 8
Hydroject 3010

Hydroject 3000/4000

Chapter 1
Safety
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 inter-
fere with operation. Keep all bystanders away from the
work area.
6. Keep all shields and safety devices in place. If a
shield, safety device or decal is defective or damaged,
repair or replace it before operation is commenced. Also
tighten any loose nuts, bolts and screws to assure ma-
chine is in safe operating condition.
7. Do not operate machine while wearing sandals, ten-
nis shoes, sneakers or shorts. Also, do not wear loose
fitting clothing which could get caught in moving parts.
Always wear long pants and substantial shoes. Wearing
safety glasses, safety shoes, ear protection and a hel-
met is advisable and required by some local ordinances
and insurance regulations.
Table of Contents
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 1
Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety Instructions
Although hazard control and accident prevention par-
tially are dependent upon the design and configuration
of the machine, these factors are also dependent upon
the awareness, concern, and proper training of the per-
sonnel involved in the operation, transport, mainte-
nance, and storage of the machine. Improper use or
maintenance of the machine can result in injury or
death. T
o 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.
Hydroject 3010 Page 1 – 1 Safety