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Preface
Table of Contents
1 - Safety
2 - Product Records and Maintenance
3 - Kohler Engine
Kohler Engine Service Manual
4 - Hydraulic System
5 - Electrical System
6 - Water System
7 - Wheels, Brakes and Steering
8 - Electrical Diagrams

Part No. 04134SL (Rev. B)

Preface

This publications provides the service technician with

information for troubleshooting, testing, and repair of the

Hydroject.

REFER TO THE HYDROJECT OPERATOR’S MAN-

UAL FOR OPERATING, MAINTENANCE AND AD-

JUSTMENT INSTRUCTIONS. Space is provided in

Chapter 2 of this book to insert the Operator’s Manual

and Parts Catalog for your machine. A replacement

Operator’s Manual is available by sending the complete

Model and Serial Number of the machine to:

The Toro Company

8111 Lyndale Avenue South

Bloomington, MN 55420

The Toro Company reserves the right to change product

specifications or this publication without notice.

Service Manual

Hydroject ® 3010

INSTRUCTION. When you see this symbol,

This safety symbol means DANGER,

WARNING, or CAUTION, PERSONAL SAFETY

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.

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. 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.

Hydroject 3010 Page 1 – 1 Safety

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

gine. Avoid spilling gasoline. Since gasoline is flam-

mable, 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

10. DON’T TAKE AN INJURY RISK! When a person or

pet appears unexpectedly in or near the WORKING

area, STOP AERATING.

11. Keep hands and feet away from nozzle and roller

area. High velocity water jets can penetrate hands and

feet. Penetration by the high velocity water jets can

cause serious personal injury. If accidental penetration

occurs, seek medical attention immediately.

12. Never use chemicals in the water supply system.

13. Do not operate water injection system on concrete

or asphalt because water jets will permanently damage

these surfaces.

14. Start engine with parking brake engaged.

15. Do not run the engine in a confined area without ad-

equate ventilation. Exhaust fumes are hazardous and

could possibly be deadly.

16. Using the machine demands attention, and to pre-

vent loss of control:

Maintenance

21. Disconnect wires from spark plugs to prevent acci-

dental starting of the engine when servicing, adjusting or

storing the machine.

22. 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 bat-

tery.

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 mainte-

nance adjustment, keep hands, feet, clothing and other

parts of the body away from any moving parts.

26. Make sure all hydraulic line connectors are tight, and

all hydraulic hoses and lines are in good condition be-

fore applying pressure to the system.

Safety Hydroject 3010

D. Fill fuel tank outdoors and up to about one

inch (25 mm) from top of the tank, not the

filler neck.

E. Wipe up any spilled gasoline.

9. Check interlock switches daily for proper operation.

If a switch fails, replace it before operating the machine.

The interlock system is for your protection, so do not by-

pass it. Replace all interlock switches every two years.

A. Use only in daylight or when there is good

artificial light.

B. Watch for holes or other hidden hazards.

C. Do not transport machine close to a sand

trap, ditch, creek or other hazard.

17. If the machine starts to vibrate abnormally, shut the

engine off. Remove wires from spark plugs to prevent

possibility of accidental starting. Check machine for

damage and defective parts. Repair any damage before

restarting the engine and operating the machine.

18. Do not touch engine or muffler while engine is run-

ning or soon after it is stopped. These areas could be hot

enough to cause a burn.

19. Before leaving the operator’s position–behind han-

dle–engage parking brake.

20. When leaving the machine unattended, engage

parking brake , shut engine OFF and remove key from

ignition switch.

27. Keep body and hands away from pin hole leaks or

nozzles that eject water or hydraulic fluid under high

pressure. Use paper or cardboard, not hands, to search

for leaks. Hydraulic fluid or water escaping under pres-

sure can have sufficient force to penetrate skin and do

serious damage. If either of these fluids are ejected into

the skin they must be surgically removed within a few

hours by a doctor familiar with this form of injury or gan-

grene may result.

28. Before disconnecting or performing any work on the

hydraulic oil system, all pressure in system must be re-

lieved by stopping engine and opening by–pass valve.

29. Make sure all water line connectors are tight, and all

hoses and lines are in good condition before applying

pressure to the system.

Page 1 – 2

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 accumula-

tor servicing can cause dismemberment or death. Do

not attempt to disassemble a accumulator, have this

work done by a Authorized Toro Distributor.

32. Do not overspeed the engine by changing governor

settings. To be sure of safety and accuracy, have an Au-

thorized T0R0 Distributor check maximum engine

speed with a tachometer.

33. Engine must be shut off before checking oil or add-

ing oil to the crankcase.

34. Allow engine to cool before storing machine in any

enclosure such as a garage or storage shed. Make sure

the fuel tank is empty if machine is to be stored in excess

of 30 days. Do not store machine near any open flame or

where gasoline fumes may be ignited by a spark. Always

store gasoline in a safety approved, red metal container.

35. When storing or transporting machine (trailering),

make sure fuel shut–off valve is closed.

36. Perform only those maintenance instructions de-

scribed in this manual. If major repairs are ever needed

or assistance is desired, contact an Authorized Toro Dis-

tributor. To ensure optimum performance and safety, al-

ways purchase genuine TORO replacement parts and

accessories to keep the Toro all TORO. NEVER USE

“WILL–FIT” REPLACEMENT PARTS AND ACCESSO-

RIES MADE BY OTHER MANUFACTURERS. Look for

the TORO logo to assure genuineness. 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 re-

placement decals from your authorized Toro Distributor.

Safety Page 1 – 4 Hydroject 3010

Chapter 2

Product Records and Maintenance

Table of Contents

PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . 1 Standard Torque for Dry, Zinc Plated and

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Steel Fasteners (Inch Series) . . . . . . . . . . . . . . . 4

EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . 2 Standard Torque for Dry, Zinc Plated and

Decimal and Millimeter Equivalents . . . . . . . . . . . . 2 Steel Fasteners (Metric Fasteners) . . . . . . . . . . 5

U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . 2 Other Torque Specifications . . . . . . . . . . . . . . . . . . 6

TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . 3 Conversion Factors . . . . . . . . . . . . . . . . . . . . . . . . . 6

Fastener Identification . . . . . . . . . . . . . . . . . . . . . . . 3

Product Records

Insert Operator’s Manual and Parts Catalog for your Hy-

droject 3010 at the end of this chapter. Additionally, if

any optional equipment or accessories have been

installed to your Hyroject, insert the Installation Instruc-

tions, Operator’s Manuals and Parts Catalogs for those

options at the end of this chapter.

Maintenance

Maintenance procedures and recommended service in-

tervals for the Hydroject 3010 covered in the Operator’s

Manual. Refer to that publication when performing regu-

lar equipment maintenance. Refer to the Engine Opera-

tor’s Manual for additional engine specific maintenance

procedures.

Hydroject 3010 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

Grade 1

Inch Series Bolts and Screws

Grade 5 Grade 8

Figure 1

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 per-

formed by marking a line on the fastener (head or nut)

and mating part, then back off fastener 1/4 of a turn.

Measure the torque required to tighten the fastener until

the lines match up.

Class 8.8 Class 10.9

Metric Bolts and Screws

Figure 2

Hydroject 3010 Page 2 – 3 Product Records and Maintenance

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

Grade 1, 5 &

8 with Thin

Height Nuts

SAE Grade 1 Bolts, Screws, Studs &

Sems with Regular Height Nuts

(SAE J995 Grade 2 or Stronger Nuts)

SAE Grade 5 Bolts, Screws, Studs &

Sems with Regular Height Nuts

(SAE J995 Grade 2 or Stronger Nuts)

SAE Grade 8 Bolts, Screws, Studs &

Sems with Regular Height Nuts

(SAE J995 Grade 5 or Stronger Nuts)

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

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

# 6 – 40 UNF

10 + 2 13 + 2 147 + 23

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

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

# 8 – 36 UNF

13 + 2 25 + 5 282 + 30

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

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

# 10 – 32 UNF

18 + 2 30 + 5 339 + 56

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

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

ft–lb ft–lb N–m ft–lb N–m ft–lb N–m

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

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

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

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

Thread Size

10 + 2

13 + 2

147+23

13 + 2

25 + 5

282+30

18 + 2

30 + 5

339+56

1125 +

113 115 +

115 + 1186 +

115 +

5/8 – 11 UNC 119 +

115 +

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.

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.

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 + 10% of the nominal torque value. Thin

height nuts include jam nuts.

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)

Regular Height Nuts

(Class 10 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

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

Thread Size

Regular Height Nuts

92 + 125 +

166 +

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.

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.

NOTE: The nominal torque values listed above are

based on 75% of the minimum proof load specified in

SAE J1199. The tolerance is approximately + 10% of the

nominal torque value.

Hydroject 3010 Page 2 – 5 Product Records and Maintenance

Other Torque Specifications

SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts

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 Size

7/16 – 20 UNF

Grade 5

65 + 10 ft–lb 88 + 14 N–m

1/2 – 20 UNF

Grade 5

80 + 10 ft–lb 108 + 14 N–m

M12 X 1.25

Class 8.8

80 + 10 ft–lb 108 + 14 N–m

M12 X 1.5

Class 8.8

80 + 10 ft–lb 108 + 14 N–m

Thread Size

Recommended Torque Recommended Torque**

** For steel wheels and non–lubricated fasteners.

Thread Cutting Screws Thread Cutting Screws

(Zinc Plated Steel) (Zinc Plated Steel)

Thread Size

No. 6 – 32 UNC 20 + 5 in–lb

No. 8 – 32 UNC 30 + 5 in–lb

No. 10 – 24 UNC 38 + 7 in–lb

1/4 – 20 UNC 85 + 15 in–lb

5/16 – 18 UNC 20 in–lb

3/8 – 16 UNC 200 + 100 in–lb

Type 1, Type 23 or Type F

Baseline Torque*

110 +

Thread

Size

Threads per Inch

Size

No. 6 18 20 20 + 5 in–lb

No. 8 15 18 30 + 5 in–lb

No. 10 12 16 38 + 7 in–lb

No. 12 11 14 85 + 15 in–lb

Baseline Torque*

Type A Type B

Baseline Torque*

* Hole size, material strength, material thickness & finish

must be considered when determining specific torque

values. All torque values are based on non–lubricated

fasteners.

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

Product Records and Maintenance Page 2 – 6 Hydroject 3010

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Chapter 4

Hydraulic System

Table of Contents

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. . . . . . . . . 8

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

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

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

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

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

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

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

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

25 micron screw-on type. No by-pass

Wheel Motor Orbit rotor type

Hydraulic Oil

Reservoir (gear case) Approximately 4 - 5 quarts

Sundstrand Series 70, BDP-10L Variable Displacement Pump

Oil filter

See Operator’s Manual

Specifications Page 4 - 2 Hydroject 3010

paper or

with this

Figure 2

Body

Sleeve

Seal

Final

General Information

Hydraulic Hoses

spect the hoses frequently for signs of deterioration or

damage. gine and opening the bypass valve.

Keep body and hands away from pin hole

der high pressure. Use cardboard,

escaping under pressure can have sufficient

hours by a doctor familiar

injury or gangrene may result.

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

replaced any time the connection is opened.

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

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

Nut

and Body Position

Extend Line

Initial

Position

CAUTION

Hydraulic hoses are subject to extreme conditions such

as, pressure differentials during operation and exposure

to weather, sun, chemicals, very warm storage condi-

tions or mishandling during operation or maintenance.

These conditions can cause damage or premature de-

terioration. Some hoses, such as reel motor hoses, are

more susceptible to these conditions than others. In-

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.

Before disconnecting or performing any work

on the hydraulic system, all pressure in the

system must be relieved by stopping the en-

leaks or nozzles that eject hydraulic fluid un-

not hands, to search for leaks. Hydraulic fluid

force to penetrate the skin and do serious

damage. If fluid is injected into the skin, it

must be surgically removed within a few

type of

in the groove. It is recommended that the O-ring be

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

.75

1.00

.75

Mark Nut

Finger Tight After Proper Tightening

16 (1 in.) .75 r .25 Figure 3

Hydroject 3010 Page 4 - 3 General Information

Figure 4

O-Ring

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).

Lock Nut

O-Ring

Back-Up Washer

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. To put the fitting in the desired position, unscrew it by

the required amount, but no more than one full turn Step 1

(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. Step 2

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 Figure 6

12 (3/4 in.) 1.50 r .25

16 (1 in.) 1.50 r .25

Step 3

Step 4

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.

IMPORTANT: Do not push or tow the machine faster

than 5 MPH because the hydraulic pump may be

damaged. If the machine must be moved further

than a few feet, transport it on a trailer or pull with

traction wheel raised and secured to a dolly. When-

ever the machine is pushed or towed, the by-pass

valve must be open. Hook on front of handle is used

for a tie-down only, not a hitch point.

1. Stop the engine and raise the hood.

2. Open the by-pass valve by turning it counterclockwise

(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 by-

pass 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

Charge

Check

Val

Wheel

Motor

Disp. Pump

(Gear Case)

Inlet

Filter

Charge Relief

Val

Cooling

Charge

Pump

Input

(Belt Drive)

ves

By-pass

Variable

Reservoir

Orifice

Figure 8

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)

Outlet

Hose

Flow Meter

Gauge

Inlet Hose

Gauge

Low Pressure

Gauge

Load Valve

High Pressure

Protector Valve

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.

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 sys-

tem is best diagnosed with the use of proper testing

equipment and a thorough understanding of the com-

plete hydraulic system.

A hydraulic system with an excessive increase in heat

or noise is a potential failure. Should either of these

conditions be noticed, immediately stop the machine,

turn off the engine, locate the cause of the trouble, and

correct it before allowing the machine to be used again.

Continued use of an improperly functioning hydraulic

system could lead to extensive internal component

damage.

The charts that follow contain detailed information to

assist in troubleshooting. There may possibly be more

than one cause for a machine malfunction. All causes

should be checked in the order in which they are listed

on the charts.

Refer to the Testing section of this Chapter for precau-

tions and specific test procedures.

Transmission 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.

Inspect charge pump and replace if faulty.

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

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

Troubleshooting 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.)

pressure (psi) rating as listed in the test pro-

oil.

CAUTION

Failure to use gauges with the recommended

cedures could result in damage to the gauge

and possible personal injury from leaking hot

Before Performing Hydraulic Tests

All obvious areas such as oil supply, filter, binding

linkage, loose fasteners, or improper adjustments must

be checked before assuming that a hydraulic compo-

nent is the source of the problem being experienced.

gine and opening the bypass valve.

Keep body and hands away from pin hole

escaping under pressure can have sufficient

doctor familiar with this type of injury or gan-

grene may result.

Before disconnecting or performing any work

on the hydraulic system, all pressure in the

system must be relieved by stopping the en-

leaks or nozzles that eject hydraulic fluid un-

der high pressure. Use paper or cardboard,

not hands, to search for leaks. Hydraulic fluid

force to penetrate skin and do serious dam-

age. If fluid is injected into the skin, it must be

surgically removed within a few hours by a

WARNING

1. Thoroughly clean the machine before disconnecting

or disassembling any hydraulic components. Always

keep in mind the need for cleanliness when working on

hydraulic equipment.

2. Put caps or plugs on any hydraulic lines left open or

exposed during testing or removal of components.

3. The engine must be in good operating condition. Use

a tachometer when making a hydraulic test. Engine

speed can affect the accuracy of the tester readings.

4. To prevent damage to tester or components, the inlet

and the outlet hoses must be properly connected, and

not reversed (tester with pressure and flow capabilities).

5. To minimize the possibility of damaging components,

completely open the load valve by turning it counter-

clockwise (tester with pressure and flow capabilities).

6. Install fittings finger tight, far enough to insure that

they are not cross-threaded, before tightening 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 tem-

perature by operating the machine for approximately 10

minutes.

2. Engage parking brake and stop the engine. Make

sure parking brake is properly adjusted before perform-

ing hydraulic tests.

3. With engine off, disconnect hose from bulkhead fitting

and install tester in series between traction pump and

wheel motor. Make sure tester flow control valve is

OPEN.

IMPORTANT: Make sure that the oil flow indicator

arrow on the flow gauge is showing that oil will flow

from pump, through tester and to wheel motor.

Test A: Charge Pressure

4. Start the engine and move throttle to full engine RPM

(approx. 3500 RPM).

GAUGE READING: 25 to 70 PSI no load.

5. If there is no pressure, or pressure is low, inspect for

restriction in pump intake line and inlet filter. Inspect

charge relief valve and valve seat. Inspect for sheared

charge pump key. Disassemble charge pump and in-

spect for internal damage or worn parts. If charge pump

is in good condition (no scoring, scratches, or excessive

wear), piston pump and motor might be suspected of

wear and inefficiency, thus charge pump is unable to

keep up with internal leakage.

TEST B: Traction Pump Flow

6. Lift the drive wheel off the ground using a jack. Block

front and rear of the other wheels. Make sure the tester

flow control valve is OPEN.

7. Start the engine and release the parking brake.

8. While watching flow and pressure gauges, move

traction handle (up or down) so flow is from the pump,

through the tester, then to the wheel motor. Move trac-

tion handle until 6 GPM is obtained.

9. If pressure is less than 200 to 300 PSI go to step 10.

If pressure is more than 200 to 300 PSI stop the engine

and inspect for binding parking brake. Inspect for restric-

tion in lines to and from motor. If there are no restrictions,

motor should be suspected of having internal damage.

10. While watching flow and pressure gauges, move

traction handle (up or down) to full speed position so

flow is from the pump, through the tester, then to the

wheel motor. Slowly close flow control valve until you

get readings of 7 GPM and 500 PSI.

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.

Figure 10

1. Hose 2. Bulkhead fitting

Wheel

Motor

Variable Displacement Pump

Teste r

Figure 11

Testing Page 4 - 10 Hydroject 3010

Adjustments

Traction Cable Adjustment (Fig. 12)

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

open the hood. Remove lower cover from handle.

2. Adjust pump end of push-pull cable with pump lever

in neutral starting position by adjusting jam nuts so

distance from seal to threads is 1.00 r 0.05 in.

3. Adjust jam nuts at tiller end of push-pull cable so

traction handle is centered on control handle.

Figure 12

1. Jam nuts - pump end 2. Jam nuts - tiller end

Speed Control Adjustment (Fig. 13)

1. Park machine on a level surface, stop the engine and 3. Adjust speed rods (Item 14) so rod end mounting

open the hood. holes in pivot arms (Items 11, 23) are located vertically

in line with pivot pin (Item 22).

2. Adjust speed control cable (Item 26) so speed stop

lever (Item 9) can move to horizontal position.

1 2 3

28 29

11 12

19 20

8 13

28 24 19

Figure 13

Hydroject 3010 Page 4 - 11 Adjustments

Transmission 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.

1 2

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

Traction Pump Belt Adjustment (Fig. 16, 17)

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

open the hood.

2. Check belt tension by depressing belt midway be-

tween pulleys with 3 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.

Figure 16

C. Loose three (3) capscrews securing pulley guard

bracket (Fig. 20, Item 21) to control panel and pump 1. Traction pump belt

support.

D. Use a pry bar 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 17

1. Adjusting nut

2. Pivot nut

Hydroject 3010 Page 4 - 13 Adjustments

Repairs

Traction Pump Belt Replacement (Fig. 18, 19)

1. Park machine on a level surface, engage parking

brake, open hood and disconnect engine spark plug

wires.

2. Remove pulley guard bracket (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.

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).

Figure 19

Figure 18

1. Pump drive belt

2. Drive coupling

3. Valve clutch

4. Valve clutch stops

1. Adjusting nut

2. Pivot nut

Repairs Page 4 - 14 Hydroject 3010

Hydraulic Pump Removal and Installation (Fig. 20)

1. Park machine on a level surface, engage parking

brake, open hood and disconnect engine spark plug

wires.

2. Disconnect wires from neutral and pump switches

(Item 31) on hydraulic pump. Label wires for proper

reinstallation.

3. Remove extension spring (Item 17).

4. Disconnect stroke control cable ball joint (Item 43)

from pump lever (Item 30). Disconnect upper and lower

speed adjustment rods from pump lever (see Fig. 14).

5. Loosen belt tension and remove belt from pump

pulley (see Pump Belt Tension Adjustment).

6. Disconnect hydraulic lines from fittings on pump. Put

caps on open lines and fittings to prevent contamination.

Put labels on hydraulic lines for proper reinstallation.

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

washers (Item 47). Remove locknut (Item 54) and cap-

screw (Item 57).

8. Remove pump assembly from pump support

(Item 55) and put pump on a work bench.

9. Loosen jam nuts (Item 3) and set screws (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.

1 2 3 4 5

27 28 29 30

24 25

6 7 8

34 35 36 37 38 39

11 12

1516 17 18

53 52

Figure 20

Hydroject 3010 Page 4 - 15 Repairs

Pump Shaft Seal Replacement (Fig. 21)

Lip type seals are used on input shaft and displacement

control shaft. These seals can be replaced without major

disassembly of pump.

1. Remove retaining ring from housing (input shaft seal

only).

2. Carefully pull seal out of housing bore. A “hook” type

tool may be used to grasp seal and pull it out, or a slide

hammer type puller may be used to remove seal. Be

careful not to damage housing bore, shaft sealing sur-

face, or bearing. After the seal is removed, it cannot be

used again.

IMPORTANT: When input shaft seal is removed,

pump block spring may push shaft partially out of

housing. Do not attempt to pull shaft out of housing.

Internal parts could move out of alignment or fall

into pump, requiring major disassembly of pump.

3. Inspect sealing area of shaft for rust, wear or contami-

nation. Polish sealing area on shaft if necessary.

4. Lubricate new seal with petroleum jelly.

5. Wrap shaft with thin plastic or use a seal protector to

prevent damage to seal lip during installation.

6. Slide seal over shaft and press it into housing bore.

Be careful not to damage the seal.

7. Install seal retaining ring into housing (input shaft seal

only).

4 1

installed in machine 3

Top of pump when

Figure 21

1. Retaining ring

2. Seal (input shaft)

3. Spacer

4. Seal (displacement control shaft)

Repairs Page 4 - 16 Hydroject 3010

Pump Charge Check Valve Service (Fig. 22)

1. Remove check valve plug with a 1/4 in. internal hex

wrench.

2. Remove valve spring and check ball from pump end

cap.

IMPORTANT: Do not allow check balls to fall into

closed loop passages in end cap.

3. Inspect check balls and mating seats in end cap for

damage or foreign material.

4. Lay pump on its side and reinstall check ball, spring

and plug (with O-ring) into end cap. Make sure check

ball does not fall into closed loop passage inside pump.

Tighten plug to a torque of 15 to 35 ft-lb. Turn pump over

and repeat installation procedure for other check valve.

installed in machine

15 to 35 ft-lb.

Top of pump when

Torque to

Figure 22

1. Check valve plug

2. O-ring

3. Check valve spring

4. Check ball

5. Pump end cap

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. 1

installed in machine

7 to 10 ft-lb. Top of pump whenTorque to

Figure 23

1. Bypass valve

2. Back-up ring

3. O-ring

4. Pump end cap

Hydroject 3010 Page 4 - 17 Repairs

Charge Pump Service (Fig. 24)

1. Use a 5 mm internal hex wrench to remove the two

(2) screws holding charge pump cover to pump end cap.

NOTE: Charge pump rotation is determined by orienta-

tion of charge pump cover on pump end cap. Cast boss

on charge pump cover indicates orientation. Note orien-

tation of cast boss before removing charge pump cover.

2. Remove charge pump cover and O-ring.

3. Remove charge pump gerotor assembly.

4. Remove charge relief valve spring and ball.

5. Inspect gerotor assembly, charge pump cover and

end cap for abnormal wear, damage or foreign material.

Inspect charge relief valve seat in end cap for damage

or foreign material.

6. Before installing charge pump, apply a small amount

of petroleum jelly to inside diameter, outside diameter

and slide faces of gerotor assembly.

7. Install charge relief ball and spring.

8. Install charge pump gerotor assembly.

9. Install charge pump cover and O-ring. Make sure

charge relief spring enters recess in cover.

10. Install charge pump cover screws and tighten to a

torque of 84 to 120 in-lb.

installed in machine

84 to 120 in-lb.

Top of pump when

Torque to

Figure 24

1. Charge pump cover

2. O-ring

3. Gerotor assembly

4. Charge relief ball

5. Charge relief spring

Major Pump Repair (Fig. 25, 26)

The procedures on the following pages are for complete

disassembly and reassembly of the pump.

Cleanliness is a primary means of assuring satisfactory

transmission life, on either new or repair units. Cleaning

parts by using a clean solvent wash and air drying is

usually adequate. As with any precision equipment, all

parts must be kept free of foreign materials and chemi-

cals. Protect all sealing surfaces and open cavities from

damage and foreign material.

During assembly of the pump, all surfaces which have

relative motion between two parts should be coated with

a film of clean hydraulic oil. This will assure that these

surfaces will be lubricated during start-up.

It is recommended that all gaskets, o-rings and seals be

replaced. Lightly lubricate all o-rings with clean petro-

leum jelly before assembly. All gasket sealing surfaces

must be cleaned before installing new gaskets.

Repairs Page 4 - 18 Hydroject 3010

16 18

6 7 8

9 10

35 36 37

13 14

1 2 3

34 33 31 32 30 4321

Figure 25

Disassembly of Hydraulic Pump

1. Before performing major repairs on the pump, remove

external components as described in previous proce-

dures. These include the following:

Shaft Seals

Charge Check Valves

Bypass Valve

Charge Pump

2. Lay pump on its side. Use a 6 mm internal hex wrench

to remove the four (4) screws (Item 30) which retain end

cap to variable pump housing.

3. Internal springs will separate end cap from housing.

Remove end cap (Item 31) from housing (Item 18).

IMPORTANT: Pump cylinder block (Item 7) will stick

to surface of end cap. Be careful to prevent damage

to end cap and cylinder block.

4. Remove gasket (Item 6) and two (2) alignment pins

(Item 15) from housing.

5. Remove cylinder block kit (Item 7) from shaft

(Item 19).

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

(Item 9) from shaft.

7. Remove swashplate assembly (Item 25) from hous-

ing.

8. Remove thrust plate (Item 11) from swashplate. The

bearing guide is pressed into the swashplate and is

usually not removed. The inner thrust washer is retained

by the bearing guide.

9. Remove slot guide block (Item 13) from displacement

control shaft (Item 12).

10. Remove swashplate cradle bearings (Item 14) from

housing.

11. Remove input shaft seal retaining ring (Item 24).

12. Carefully pull input shaft seal (Item 23) out of hous-

ing bore. A hook may be used to pry seal out, or a slide

hammer type puller may be used to remove the seal. Be

careful not to damage housing bore, shaft sealing sur-

face, or bearing. After seal is removed it cannot be used

again.

13. Remove bearing spacer washer (Item 22).

Hydroject 3010 Page 4 - 19 Repairs

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

from housing.

15. Remove outer bearing retaining ring (Item 21) (and

washer, if used). Press shaft out of bearing.

16. If pump block retaining spring retaining ring

(Item 10) requires replacement, remove it from pump

shaft.

17. Remove displacement control shaft from housing.

18. Pry displacement control shaft seal out of housing.

Care must be taken so as not to damage housing bore.

19. If displacement control shaft journal bearing re-

quires replacement, press it out of housing.

Inspection and Replacement of Pump Parts

After disassembly, thoroughly clean all parts in a suit-

able solvent. Replace all o-rings, gaskets and seals.

Inspect all parts for damage, nicks or unusual wear

patterns. Replace all parts having unusual or excessive

wear or discoloration.

Inspect seal surfaces, bearing surfaces and shaft spli-

nes. Polish sealing areas on shafts if necessary. Re-

place any worn or damaged parts.

The pump shaft bushing (Item 5) is pressed into end cap

and is usually not removed.

The running surfaces of cylinder blocks MUST be flat

and free from scratches. If scratches or wear are found

on running surfaces of cylinder blocks or end cap, polish

or replace the parts. When polishing these surfaces, up

to 0.0004 in. may be removed. If this is not sufficient to

obtain a flat surface, free of scratches, the part should

be replaced.

Assembly of Hydraulic Pump

1. Clean and lightly oil parts before assembly. Tighten

all threaded parts to recommended torque value.

IMPORTANT: Most parts have critical, high toler-

ance surfaces. Use caution to prevent damage to

these surfaces during assembly. Protect exposed

surfaces, openings and ports from damage and

foreign material.

2. 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.

NOTE: The position of the bearing in the housing deter-

mines control shaft end play. Do not press bearing

deeper into housing at this time.

3. Install displacement control shaft (Item 12) into hous-

ing.

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.

IMPORTANT: Be careful not to damage shaft sealing

surface.

6. Install pump shaft and bearing assembly into housing.

7. Install bearing spacer washer (Item 22).

8. Wrap shaft with thin plastic or use a seal protector to

prevent damage to seal during installation. Lubricate

new pump shaft seal (Item 23) with petroleum jelly.

9. Slide seal over shaft and press it into housing bore.

Be careful not to damage the seal.

10. 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.

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 pis-

tons must move freely in their bores.

17. With pump swashplate in “neutral” (0 angle) position

and pump housing laying on its side, install pump cylin-

der block kit onto pump shaft in housing.

Repairs Page 4 - 20 Hydroject 3010

18. Check that piston springs are centered in cylinder

block bores, If necessary, move springs into position

with a small screwdriver.

IMPORTANT: Do not damage running surfaces of

cylinder blocks.

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

new gasket (Item 6) onto housing.

20. 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 hous-

ing. Be careful to prevent damage to end cap and

cylinder block sealing surfaces.

21. When end cap is properly installed, the internal

springs will hold it away from the housing approximately

3/8 in.

22. Install the four (4) capscrews which retain end cap

to housing. Tighten screws to a torque of 138 to 180

in-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.

16 18

6 7 8

9 10

35 36 37

13 14

1 2 3

34 33 31 32 30 4321

Figure 26

Hydroject 3010 Page 4 - 21 Repairs

Wheel Motor Removal and Installation (Fig. 27)

1 2 3

9 10

13 14 15 16

250 to 400 ft-lb.

23 24

Torque to

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 re-

moval or installation.

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

Wheel Motor Shaft Seal and/or Shaft Replacement (Fig. 28)

5 6

Figure 28

Disassembly of Shaft and Front Seal Assembly

1. Put motor on a clean, flat surface with shaft facing up.

Clean front end of motor to avoid contaminating internal

parts during procedure.

2. Remove key (Item 11) from shaft.

3. Remove snap ring (Item 14) using a snap ring pliers.

4. Pull shaft (Item 10) out vertically.

IMPORTANT: When pulling shaft vertically, do not

rotate shaft or move motor as this may alter internal

timing.

5. With seal retainer assembly and shaft assembly

removed, remove all parts from shaft and inspect vari-

ous parts of seal assembly (Item 15, 16, 17), shaft

(Item 10) and thrust bearing assembly (Item 19, 20, 21).

Replace any worn or damaged parts. Always replace

seal retainer assembly (Item 15, 16, 17). The shaft

should have smooth polished surfaces in bearing and

seal areas. If the shaft is lightly scratched in these areas,

polish with fine emery paper in a circumferential direc-

tion. However, if the shaft has any pitting or deep

scratches, entire motor should be disassembled for

inspection.

Assembly of Shaft and Front Seal Assembly

1. Assemble thrust washers (Item 19) and thrust bearing

(Item 20) on shaft using the snap ring (Item 21). Snap

ring sharp edges MUST face away from thrust washers

with thrust bearing (Item 20) between washers.

2. Slowly lower spline end of shaft (Item 10) assembly

into motor body using caution not to rotate internal parts

once shaft spline starts to engage.

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

bore.

4. Gently slide oiled seal retainer assembly (Item 15, 16,

17) over shaft, chamfered side first, and press into body

bore. When fully in place, body snap ring groove will be

visible.

5. Install snap ring (Item 14) into its body groove with

snap ring’s sharp edges facing outward and retainer pin

between snap ring lugs. Be sure snap ring is completely

seated in groove.

Hydroject 3010 Page 4 - 23 Repairs

Wheel Motor Repair (Fig. 29)

5 6

Figure 29

IMPORTANT: Before DISASSEMBLING motor, plug

open ports and clean all dirt from outside of motor.

IMPORTANT: Before ASSEMBLING motor, lightly oil

all seals, rollers and threaded bolt ends.

Disassembly of Cover Section of Motor

1. Remove key (Item 11) from shaft.

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

shaft facing down.

3. Remove the eight capscrews (Item 1).

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

square ring seal (Item 4).

5. Remove IGR assembly (Item 5) starting with outer

locating ring, rollers, outer rolls, inner rotor and valve

plate (Item 7). If any of these components are damaged,

entire IGR assembly must be replaced.

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

NOTE: The check balls may fall into body tapered holes

or into body valve ports during disassembly. Be sure that

the check balls are removed.

Disassembly of Shaft Section of Motor

(See Disassembly of Shaft and Front Seal Assembly

under Main Shaft Seal and/or Shaft Replacement.)

Assembly of Complete Motor

1. Before assembly, all parts must be cleaned with a

suitable solvent and free of nicks and burrs.

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

or other holding mechanism.

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

bearings. (See Assembly of Shaft and Front Seal As-

sembly under Main Shaft Seal and/or Shaft Replace-

ment.)

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

vise or other holding fixture.

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

shaped slots on first.

Repairs Page 4 - 24 Hydroject 3010

6. Next put IGR inner member on shaft spline with

semi-circular roll pockets between rotary valve ports.

7. Put contour member of IGR over inner and insert

seven rolls into inner pockets (large diameter rolls).

8. Lightly oil square ring seal (Item 4) and put in body

groove.

9. Put check balls (Item 6) over the two 1/8" inch

diameter holes in body. Be sure the check balls do not

fall into body tapped holes.

10. Put locating ring section (4.5 inch diameter) of IGR

(Item 5) onto body with check ball holes facing down-

ward over balls. Align the eight bolt holes in locating ring

with eight holes in body. The holes align in only one

position.

NOTE: Be sure not to dislodge body square ring seal

while moving locating ring.

11. Install the eight locating ring rollers into their pockets

and oil lightly.

12. Put other lightly oiled square ring seal (Item 4) into

groove in cover and put cover over shaft end and align

bolt holes.

13. Install the eight bolts with lightly oiled thread ends

into bolt holes and tighten diagonally to 30 ft-lb.

NOTE: The shaft may not turn freely after assembly. A

short running period may be required.

Hydroject 3010 Page 4 - 25 Repairs

Repairs Page 4 - 26 Hydroject 3010

Chapter 5

Electrical System

Table of Contents

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

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

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

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

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

Aerator Engage and Disengage Switches . . . . 19

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

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

Brake 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

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

SWITCHES

Oil Pressure Switch

Wheel Position Switch

Accumulator Charge Switch

Aerator Start (Engage) Switch

Aerator Stop (Disengage) Switch

Lift Switch DOWN (Aerate)

Accumulator High Press Switch

Brake Switch

ACTIONS

1. Start X X

2. Run X X

3. Machine Lower (aerate position) X O X

4. Aerate (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

5. Machine Raise (transport position) X X O

Switch Closed Momentarily

Switch Conditon Not Relevent

Start - Key Switch B + L + S

Run - Key Switch B + L + A

Traction Switch 1

Water Pressure Switch

Traction Switch 2

Lift Switch UP (Transport)

ming below)

Controller Timing

Aerate START-UP Sequence

1. Pump clutch engages immediately.

2. Valve clutch engages 5 seconds after pump clutch engages.

Aerate SHUT-DOWN Sequence (Neutral Delay)

1. Pump clutch disengages and green light goes off 4 seconds after transport switch opens (red light goes off).

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

NOTE: Keeping aerate start (engage) switch pushed in (closed) will keep green light on and override neutral delay

shut-down.

Aerate SHUT-DOWN Sequence (Disengage Delay)

1. Pump clutch 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

Contoller Lights

Lights (LEF’s) on the controller indicate when the follow-

ing inputs are made to the contoller:

Red: Traction switch 1 closed (traction bail in neu-

tral).

Green: Aerate start (engage) switch closed. If red

and yellow lights are on, green light will stay on until

either red or yellow goes off.

Yellow: Wheel position switch closed (machine low-

ered to aerate position), water pressure switch

closed (water pressure of more than 30 psi) and

accumulator charge pressure switch closed (nitrogen

pressure more than 1800 psi). 1. Red Light 2. Green Light 3. Yellow Light

Hydroject 3010 Page 5 - 3 Wiring Schematics and Diagrams

Electrical Schematic and Wiring Diagrams

See Chapter 8 - Electrical Diagrams.

Wiring Schematics and Diagrams Page 5 - 4 Hydroject 3010

Special Tools

NOTE: Order special tools from the TORO SPECIAL

TOOLS AND APPLICATIONS GUIDE (COMMERCIAL

PRODUCTS). Some tools may be available from a local

supplier.

Digital Multimeter (Fig. 6)

The meter can test electrical components and circuits

for current, resistance, or voltage drop.

NOTE: Toro recommends the use of a DIGITAL meter

when 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 de-

signed to carry it.

Figure 6

Hydroject 3010 Page 5 - 5 Special Tools

Skin-Over Grease (Fig. 7)

Special non-conductive grease which forms a light pro-

tective skin to help waterproof electrical switches and

contacts.

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

Figure 7

Special Tools Page 5 - 6 Hydroject 3010

________________________________________________________________________________________________________________________________________________________

Troubleshooting

voltage.

CAUTION

Remove all jewelry, especially rings and

watches, before doing any electrical trou-

bleshooting or testing. Disconnect the bat-

tery cables unless the test requires battery

For effective troubleshooting and repairs, you MUST

have a good understanding of the electrical circuits and

components used on this machine. (See Electrical

Schematic.)

Starting Problems

Study the operating characteristics preceding the elec-

trical 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.

If the machine being repaired has any interlock switches

by-passed, they must be reconnected for proper trou-

bleshooting and safety.

Condition Possible Cause Correction

Engine fails to crank, regardless Loose or corroded battery connec- Clean and tighten connections.

of traction bail position. tions.

Low battery charge. Charge battery. Replace battery if

it will not hold a charge (also see

Battery does not charge under

General Run and Transport Prob-

lems).

Circuit breaker open. Reset circuit breaker. Find cause

for open circuit breaker and cor-

rect. Replace circuit breaker if

faulty.

Ignition key switch faulty. Test switch and replace if faulty.

Traction switch 1 faulty. Make sure switch is properly in-

stalled and adjusted. Test switch

and replace if faulty.

Start relay faulty. Test relay and replace if faulty.

Starter solenoid faulty. Test starter solenoid and replace

if faulty.

Starter is faulty. Test starter and repair replace if

faulty.

Engine is seized. Repair engine.

Loose or damaged wiring. Check connections. Repair wiring.

Hydroject 3010 Page 5 - 7 Troubleshooting

________________________________________________________________________________________________________________________________________________________

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 inter- “L” terminal on ignition key switch Connect wire.

lock system. loose.

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

Chapter 3 - Engine).

Engine cranks (but should not) See Safety Interlock System Prob-

with traction bail in neutral. lems.

Engine starts, but shuts down Not electrical - regulate choke dur- Normal condition.

when ignition key switch is re- ing cold start-up.

leased to RUN position. Not electrical - low engine oil pres- Find and correct cause of low en-

sure. gine oil pressure.

Oil pressure switch faulty. Test switch and replace if faulty.

Loose or broken wire in oil pres- Check all wiring and connections

sure switch circuit. and repair as necessary.

Starter does not disengage when Ignition switch faulty. Test ignition key switch and re-

key switch is released to RUN po- place if faulty.

sition. Short in start circuit wiring. Check all wiring and connections

and repair as necessary.

Start relay faulty. Test start relay and replace if nec-

essary.

Starter solenoid faulty. Test starter solenoid and replace

if necessary.

Starter failed (mechanical). Test starter and replace if neces-

sary.

Troubleshooting Page 5 - 8 Hydroject 3010

________________________________________________________________________________________________________________________________________________________

General Run and Transport Problems

Condition Possible Cause Correction

Engine shuts down during trans- Not electrical - low engine oil pres- Find and correct cause of engine

port or when idling (not in Aerate sure, no fuel, etc. shut down.

mode). Oil pressure switch faulty. Test switch and replace if faulty.

Loose or broken wire in oil pres- Check all wiring and connections

sure switch circuit. and repair as necessary.

Engine does not stop when igni- Engine timing or carburetor out of Adjust carburetor or engine tim-

tion key switch is rotated to OFF adjustment. ing.

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

faulty.

Short in ignition circuit wiring. Check all wiring and connections

and repair as necessary.

Battery does not charge. Loose or damaged wire(s) in en- Check wiring and connections

gine electrical system. and repair as necessary.

Regulator or engine charging cir- 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 Check all wiring and connections

circuit. and repair as necessary.

Linear actuator faulty. Test actuator and repair or re-

place if faulty.

Hydroject 3010 Page 5 - 9 Troubleshooting

________________________________________________________________________________________________________________________________________________________

General Run and Transport Problems (continued)

Condition Possible Cause Correction

Machine does not raise (to trans- Lift/Lower switch faulty. Test switch and replace if faulty.

port position). Ignition key switch faulty. Test ignition switch and replace if

faulty.

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

and repair as necessary.

Linear actuator faulty. Test actuator and repair or re-

place if faulty.

Troubleshooting Page 5 - 10 Hydroject 3010

________________________________________________________________________________________________________________________________________________________

Aerate Operation Problems

Condition Possible Cause Correction

Machine continues to aerate (but See Safety Interlock System Prob-

should not) with traction bail in lems.

neutral.

Machine aerates (but should not) See Safety Interlock System Prob-

with with machine raised in trans- lems.

port position.

Machine starts aerating (but Water pressure switch faulty. Test switch and replace if faulty.

should not) with inlet water pres-

sure of less than 20 to 30 PSI, or Water pressure switch wiring faulty. Check for short in pressure

machine does not stop aerating if switch/controller connections and

inlet water pressure drops to wiring and repair as necessary.

10 PSI. Controller faulty. Replace controller.

Machine does not start aerating Problem not electrical (see Chap-

when engage button is pushed in ter 6 - Water System.)

(pump drive belt does NOT ro-

tate). 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 Accumulator high pressure

faulty. switch faulty.T

Pressure gauge switch faulty. Test switch and replace if faulty.

Pump clutch faulty. Test clutch and replace if faulty.

Pump relay faulty. Test relay and replace if faulty.

Aerator stop (disengage) switch Test switch and replace if faulty.

faulty.

Wheel position switch faulty. Make sure switch is installed

properly. Test switch and replace

if faulty.

Aerator start (engage) switch faulty. Test switch and replace if faulty.

Controller faulty. Replace controller.

Hydroject 3010 Page 5 - 11 Troubleshooting

________________________________________________________________________________________________________________________________________________________

Aerate Operation Problems (continued)

Condition Possible Cause Correction

Machine does not start aerating Valve clutch out of adjustment. Check air gap on valve clutch

when engage button is pushed in and adjust if necessary.

(pump belt IS rotating, but gear-

case drive shaft is NOT rotating). Loose or broken wire in valve Check all connections and wiring

clutch / controller circuit. and repair as necessary.

Valve clutch faulty. Test valve clutch and repair or re-

place if faulty.

Valve clutch relay faulty. Test relay and replace if faulty.

Controller faulty. Replace controller.

Machine stops aerating when not It is normal for pump clutch and Educate operator. NOTE: Holding

moving (traction bail in neutral). water clutch to disengage when Aerate start switch in ENGAGE

traction bail is neutral for 3 to 4 sec- position will override neutral de-

onds. lay shut-down.

Machine stops aerating while ma- Problem not electrical (see Trou-

chine is moving (traction bail out bleshooting in Chapter 6 - Water

of neutral). 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 Check all connections and wiring

switch / controller circuit. and repair as necessary.

Also see possible causes in (Water

pump clutch does not engage) and

(Water pump clutch engages, but

water valve clutch does not en-

gage.)

Troubleshooting Page 5 - 12 Hydroject 3010

________________________________________________________________________________________________________________________________________________________

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

necessary.

Machine continues to aerate (but Red light on controller is ON Make sure traction switch 2 is in-

should not) with traction bail in (should be OFF) with traction bail stalled and adjusted properly.

neutral. in neutral. Test switch and replace if faulty.

Check for short in traction switch

2/controller connections and wir-

ing and repair as necessary.

Green light on controller stays ON Test aerate engage (start) switch

(should be OFF) with aerate en- and replace if faulty (make sure

gage switch released. switch action is momentary and

comes comes back out after be-

ing pushed in).

Controller faulty. Replace controller.

Machine aerates (but should not) Yellow light on controller is ON Test wheel position switch and re-

with with machine raised in trans- (should be OFF) with machine place if faulty.

port position. raised in transport position. Check for short in wheel position

switch connections and wiring

and repair as necessary.

Controller faulty. Replace controller.

Hydroject 3010 Page 5 - 13 Troubleshooting

________________________________________________________________________________________________________________________________________________________

Safety Interlock System Problems (continued)

Condition Possible Cause Correction

No lights on controller come on Battery is dead or disconnected. Charge battery. Replace battery if

when troubleshooting interlock it will not hold a charge. Clean

system. and tighten connections.

Circuit breaker open. Reset circuit breaker. Find cause

for open circuit breaker and cor-

rect. Replace circuit breaker if

faulty.

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 Check all connections and wiring

switch/controller circuit. and repair as necessary.

Controller faulty. Replace controller.

Green light on controller glows Normal condition.

faintly when only red light should

be on (traction bail out of neutral

and aerate engage switch re-

leased).

Troubleshooting Page 5 - 14 Hydroject 3010

Testing

It is often to the technician’s advantage to leave the

components intact in the electrical system, and by

studying the electrical troubleshooting charts and sche-

matics, determine which component is at fault. How-

ever, this section will define given components, and the

tests that can be performed on those components, when

those parts are disconnected from the electrical system.

For accurate resistance and/or continuity checks, elec-

trically disconnect the component being tested from the

circuit.

tinuity with a volt-ohm meter or continuity

been disconnected.

CAUTION

When testing electrical components for con-

tester, make sure that power to the circuit has

NOTE: Electrical troubleshooting of any 12 Volt power

connection can also be performed through voltage drop

tests without disconnection of the component.

Verify Safety Interlock System Operation

The safety interlock system prevents the engine from

cranking or starting, unless traction bail is in NEUTRAL

and prevents the water system from engaging if ma-

chine is in the transport (raised) position. It also stops

aeration if traction bail is released while operating or if

machine is raised to the transport position.

protection, so DO NOT disconnect them.

sense!

CAUTION

The interlock switches are for the operator’s

Check operation of switches daily to make

sure interlock system is operating. If a switch

is defective, replace it before operating. Re-

gardless if switches are operating properly or

not, replace interlock switches every two (2)

years to assure maximum safety. Do not rely

entirely on safety switches; use common

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 pres-

sure must be 20 to 30 PSI or more. Start the engine.

Raise machine to transport position (up off of rollers).

Push aerate ENGAGE button. If water pump engages

and machine begins aerating, there is a malfunction in

the interlock system that must be corrected. If machine

does not begin aerating, go to step 4.

4. Lower machine to aerate position (on rollers). Engage

traction bail to start machine moving. Push, then release

aerate ENGAGE button. Water pump should engage

immediately, then machine should begin aerating 5 sec-

onds after pump engages. Release traction bail to neu-

tral position so machine stops moving. The water pump

should 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 aerat-

ing, go to step 5.

5. Engage traction bail to start machine moving, then

push aerate ENGAGE button to begin aerating. Push

aerate DISENGAGE button. The water pump should

disengage immediately, then stop aerating after 3 sec-

onds. If machine does not stop aerating, there is a

malfunction in the interlock system that must be cor-

rected.

Hydroject 3010 Page 5 - 15 Testing

Clutch Engagement / Electronic Control System Test (Fig. 8)

This test can be used to check for proper operation of

the electronic control system and clutches without con-

necting the machine to a water source or operating the

machine.

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

engage the parking brake, open the hood and discon-

nect the engine spark plug wires.

2. Disconnect wiring harness connector from bottom of

water pressure gauge. Install a jumper wire across

terminals of disconnected wire connector. This will elec-

trically by-pass the water pressure switch.

3. Turn ignition key switch to ON position. DO NOT start

the engine.

4. ENGAGE test:

A. Lower machine to aerate position (on rollers).

Yellow light should be ON.

B. Move traction bail out of neutral. Red light should

come ON.

C. With traction bail out of neutral, push, then re-

lease, green aerate ENGAGE button. Green light

should come ON and pump clutch should engage.

After 5 seconds valve clutch should engage.

NOTE: Touch clutches with a metal object, such as

a screw driver, to help check for clutch engagement

(clutch will be magnetized).

5. NEUTRAL shut-down test:

A. Release traction bail. Red light should turn OFF.

B. After 4 seconds, pump clutch should disengage

and green light should go OFF.

C. After another 3 seconds, valve clutch should

disengage.

6. DISENGAGE test:

A. Move traction bail out of neutral and push green

aerate ENGAGE button.

B. After clutches are engaged, push red aerate

DISENGAGE button.

C. Green light should immediately turn OFF and

pump clutch should disengage.

D. After 3 seconds, valve clutch should disengage.

E. System must not restart without pushing green

aerate ENGAGE button.

IMPORTANT: When test is completed, water pres-

sure switch by-pass must be removed to prevent

damage to water system from low inlet water pres-

sure.

7. Remove by-pass jumper wire that was connected in

step 2 and connect wire harness connector to terminals

on bottom of water pressure gauge.

Figure 8A

1. Red light

2. Green light

3. Yellow light

Figure 8B

1. Red light

2. Green light

3. Yellow light

Testing Page 5 - 16 Hydroject 3010

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Controller (Fig. 11)

The controller senses the condition of various switches,

such as the transport switch and aerate start switch and

directs power output to allow certain machine functions,

such as aerate engage, disengage and timing of those

functions.

Because of the solid state circuitry built into the control-

ler, there is no method to test it directly. The controller

may be damaged if an attempt is made to test it with an

electrical test device, such as a volt-ohm meter.

IMPORTANT: Before welding on the machine, dis-

connect both battery cables from the battery, dis-

connect both wire harness plugs from the electronic

control unit and disconnect the terminal connector

from the alternator to prevent damage to the electri-

cal system.

Lights (LED’s) on the controller indicate the condition of

the interlock 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).

Traction Switch 1 and 2 (Fig. 12)

Traction switch 1 is normally open (N.O.) and is closed

when traction bail is neutral. Traction switch 2 is nor-

mally closed (N.C.) and is open when the traction bail is

in neutral.

IMPORTANT: Traction switch 1 and 2 have three (3)

terminals. Traction switch 1 must have the wires

connected to the “COMMON” and “N.O.” terminals.

The Traction switch 2 must have the wires con-

nected 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.

Test the switch by disconnecting the wires from the

switch terminals and connecting a continuity tester

across the two terminals that had wires connected to

them. With the engine turned off, slowly push the trac-

tion bail in a forward and reverse direction while watch-

ing the continuity tester. There should be indications that

the switch is opening and closing. Allow the traction bail

to return to neutral. There should be continuity across

the terminals of traction switch 1 and no continuity

across the terminals of the traction switch 2. (See Trac-

tion Switch 1 and 2 Replacement and Adjustment in the

Repairs section of this chapter for replacement and

adjustment procedures.)

Figure 11

1. Red light

2. Yellow light

3. Green light

Figure 12

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

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

3. Switch tab

Testing Page 5 - 18 Hydroject 3010

Wheel Position Switch (Fig. 13)

leads of the switch.

Wheel Position Switch

Aerate (machine lowered)

CLOSED OPEN

Figure 13

Test the switch by disconnecting the wire connector and

installing a continuity tester or ohm meter across the two

Transport (machine raised)

NOTE: For proper operation, the switch must be

screwed all the way in. A damaged pivot shaft or bush-

ings could cause the switch to not open and close

properly. Debris in the switch could also cause it to not

open and close properly.

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

Lift Switch (Fig. 15)

The lift switch is a three position switch. Switch position

is maintained in center position with no circuits made.

Test the switch by disconnecting the wires from the

switch terminals and connecting a continuity tester or

ohm meter across the terminals.

Terminals 2-3 and 5-6 should have continuity in UP.

Terminals 2-1 and 5-4 should have continuity in DOWN.

Figure 15

1. Lift switch

Linear Actuator (Fig. 16)

The linear actuator has a bi-directional electric motor

which engages a clutch and screw mechanism to ex-

tend or retract a rod and raise or lower the transport

wheels.

To test the actuator:

1. Disconnect the wiring connector.

2. Connect a 12 volt battery so the negative (–) terminal

is connected to the red wire of the actuator connector.

When the positive (+) battery terminal is connected to

the yellow wire the actuator motor should operate to

extend the actuator cylinder, raising the wheels to aer-

ate position. Figure 16

3. Connect a 12 volt battery so the negative (–) terminal 1. Linear actuator 2. Wiring connector

is connected to the yellow wire of the actuator connec-

tor. When the positive (+) battery terminal is connected

to the red wire the actuator motor should operate to

retract the actuator cylinder, lowering the wheels to

transport position.

Rod end play 0.070 max.

Current draw 26 amps max.

12 VDC

Speed 3/4 in. per second at maximum

load

Linear Actuator Specifications

Voltage

Testing Page 5 - 20 Hydroject 3010

Brake Switch (Fig. 17)

The brake switch is a normally open (N.O.) switch that

closes when the brake is engaged.

To test the brake switch disconnect the wires from the

switch terminals and connect a continuity tester or ohm

meter across the terminals of the switch. With the brake

disengaged, the switch should show no continuity. With

the brake engaged, the switch should show continuity.

Figure 17

1. Brake switch

Pressure Gauge/Switch (Fig. 18)

The pressure gauge switch is normally open and closes

when inlet water pressure goes above 20 to 30 PSI. The

switch opens when inlet water pressure goes below

approximately 10 PSI.

To test the pressure switch, disconnect the wire connec-

tor and connect a continuity tester or ohm meter across

the terminals of the switch connector. The switch should

show continuity when inlet water pressure reaches 20

to 30 PSI on gauge. The switch should break continuity

as water pressure goes below 10 PSI.

Figure 18

1. Pressure gauge/switch

Accumulator Charge and High Pressure Limit Switches (Fig. 18a)

The accumulator charge switch is normally open and

closes when accumulator charge pressure is greater

than 1800 PSI. The switch opens when accumulator

charge pressure goes below 1400 PSI.

The high pressure limit switch opens at 5500 PSI (rising

pressure) and closes at 5350 PSI (falling pressure).

DANGER

The accumulator contains nitrogen gas under

high pressure. DO NOT attempt to remove or Figure 18a

replace these switches without first opening

the high pressure water bleed valve and then 1. High pressure limit switch 2. Accumulator charge switch

releasing pressurized gas from the accumu-

lator (see Accumulator Service in Chapter 6 -

Water System).

Hydroject 3010 Page 5 - 21 Testing

Relays (Fig. 19, 20)

To test a relay, disconnect the relay wire connector and

install a continuity tester between the relay terminals

(terminals 30 and 87). The relay should make and break

continuity at terminals 30 and 87 as 12 V.D.C. is con-

nected and disconnected to terminal 85 with terminal 86

connected to ground.

Resistance specifications:

Terminals 85 and 86 = 80 to 90 Ohms

Terminals 30 and 87a (normally closed) = continuity

Terminals 30 and 87 (normally open) = continuity when 12V

DC is applied to terminals 85 and 86

Figure 19

Figure 20

Battery

Use a hydrometer to test the battery. Charge the battery

if necessary (see Battery Service).

Electrolyte Specific Gravity

Fully charged: 1.250 - 1.280

Discharged: less than 1.240

Testing Page 5 - 22 Hydroject 3010

Pump Clutch (Fig. 21)

To test the pump clutch, disconnect the wire connector

and connect a continuity tester or ohm meter across the

terminals of the clutch wire connector. There should be

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 20oC (68o F) Figure 21

1. Pump clutch

Valve Clutch (Fig. 22)

To test the valve clutch, disconnect the wire connector

and connect a continuity tester or ohm meter across the

terminals of the clutch wire connector. There should be

continuity across the terminals of the clutch connector.

Resistance measured through the clutch coil should be

approximately 3 ohms.

The clutch can also be tested by connecting a 12 VDC

battery across the clutch connector terminals. The

clutch should engage as 12 VDC is connected to the

clutch connector terminals.

Clutch coil resistance:

3.5 Ohms + 5% at 20oC (68o F) Figure 22

1. Valve clutch

Circuit Breaker and Fusible Link (Fig. 23)

The electrical system is protected by a 20 AMP circuit

breaker with reset button and a fusible link.

To test the circuit breaker, check for continuity between

the two terminals.

The fusible link is located in the control panel wiring

harness between the circuit breaker and and starter B+

terminal. To test the fusible link, check for continuity

between terminals J22 and J23 of the control panel

wiring harness (see Schematic and Control Panel Wir-

ing Harness in Chapter 8 - Electrical Diagrams).

Figure 23

1. Circuit breaker

Hydroject 3010 Page 5 - 23 Testing

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.

warm to 60o F (15.5o

tery posts.

CAUTION

Do not charge a frozen battery because it can

explode and cause injury. Let the battery

C) before connecting to

a charger.

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 bat-

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 0o F (–17 o C)

110 min. Reserve Capacity at 80o F (27 o C)

Figure 24

1. Positive (+) terminal

2. Negative (–) terminal

Figure 25

Repairs Page 5 - 24 Hydroject 3010

Traction Switch 1 and 2 Replacement and Adjustment (Fig. 26)

1. Disconnect wires from switch terminals.

2. Have a helper push traction bail down into either

FORWARD or REVERSE position or disconnect exten-

sion spring; this will take switch arm tension off of switch.

Loosen two (2) screws and remove switch.

3. Have a helper push traction bail down and Install new

switch. DO NOT over-tighten screws as the switch case

could break.

4. Reconnect wires to new switch. Make sure one wire

is connected to “COMMON” terminal, and one wire is

connected to N.O. terminal (traction switch 1) or N.C.

terminal (traction switch 2). Figure 26

IMPORTANT: Traction switch 1 and 2 have three (3) 1. Traction switch 1 – N.O. (gray & black wires)

terminals. If the two (2) wires are not connected to 2. Traction switch 2 – N.C. (orange & yellow wires)

3. Switch tab

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.

traction bail in forward or reverse.

CAUTION

If the wires are not correctly installed to trac-

tion switch 1, the engine could start with the

5. Coat switch terminals and wires with skin-over

grease.

6. Loosen two (2) screws and adjust switch tab so

switches are actuated, but not bottomed out, when

pump control is in neutral.

Hydroject 3010 Page 5 - 25 Repairs

Controller Replacement (Fig. 27)

IMPORTANT: Before welding on the machine, dis-

connect both battery cables from the battery, dis-

connect both wire harness plugs from the controller

and disconnect the terminal connector from the

alternator to prevent damage to the electrical sys-

tem.

1. Stop the engine and disconnect battery cables from

battery.

2. Disconnect wiring harness connectors from control-

ler.

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

remove controller.

4. Install new controller and secure to frame with nuts 1. Controller

removed in step 3.

5. Connect wiring harness connectors to controller.

6. Connect battery cables.

Figure 27

Repairs Page 5 - 26 Hydroject 3010

Linear Actuator Replacement (Fig. 28)

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

2. Put the machine on a level 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.

Figure 28

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

1. Linear actuator 3. Extension spring

2. Wire connector 4. Capscrew & nut

Hydroject 3010 Page 5 - 27 Repairs

Repairs Page 5 - 28 Hydroject 3010

Chapter 6

Water System

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

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

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

Specifications

Water Pump Clutch: Electromagnetic, dual groove belt

drive for water pump and driveshaft flange brake/clutch

for main valve gearbox.

Air gap 0.018 in.

Pre Filter – Spin down type with washable cartridge in

clear plastic housing and plastic ball valve for flushing.

Supply Filter – Replaceable 5 micron cartridge in plas-

tic housing with air bleed button.

Water Filter Cartridge: Toro part no. 86–8630

Water Pressure Switch – Senses for water pressure

after filter.

Switch closes when pressure is over 20–28 PSI and

opens when pressure drops below 7–13 PSI.

Pump – Toro exclusive design with cast stainless steel

head and 3 piston plungers. Vee packing seals and Ke-

vlar guides. Forged crankshaft with plasma sprayed ce-

ramic on stainless steel plungers and cast iron

connecting rods.

Nominal performance is 4 GPM at 5000 PSI with

1400 RPM input.

Accumulator – Toro exclusive design with low charge

pressure sensor.

Charged with nitrogen gas charged to 2500 PSI

maximum pressure.

Low charge pressure limit switch:

Closes at 1800 PSI

Opens at 1400 PSI

High operating pressure limit switch:

Closes at 5500 PSI (rising pressure)

Opens at 5350 PSI (falling pressure)

Cam and Gearbox – Reduction gear drive for cam that

actuates main water valve. Roller cam follower rides on

cam specifically designed (patent pending) to control

water injection at 5.3 cycles per second (320 rpm) and

store energy in accumulator between injections. Cast

iron case also serves as 4 quart hydraulic reservoir.

Valve – Cast stainless steel valve body functions as

mounting base for accumulator, gearbox and manifold

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 +0.002 –0.04 inch (with new cam)

Rollers – Pivoting aluminum rollers uniformly smooth

the turf and provide protection from the nozzle dis-

charge. Adjustable flow (0 – 3 GPM) spray wash system

with 6 flood tip nozzles maintain clean rollers.

Pressure Relief Valve – Poppet–type valve with corro-

sion resistant stainless and brass materials.

5000 + 300 PSI relief valve pressure.

Manifold and Nozzles – Extruded stainless steel man-

ifold with11 flanged nozzle extensions containing check

valves and hardened stainless discharge orifice. Check

valves may be reversed in housing to block unused

nozzles.

Aeration Width: 33 inches with 11 nozzles on 3 inch

centers.

Aeration Depth: 4 to 6 inches depending on turf condi-

tions and nozzle configuration.

Hole Pattern: Variable from 1.5” to 6” spacing in the di-

rection of travel, and 3 or 6” increments in width.

Water Pump Case Oil – See Operator’s Manual.

Water Supply – Recommend a source with 7–8 gallons

per minute. A minimum pressure of 30 psi at the ma-

chine is required for the pump to engage. Maximum al-

lowable pressure of 200 psi. Although irrigation water

pumped from ponds or effluent holding pools can be

used, not all conditions can be handled by the machines

filtration system, additional or alternative filtration may

be required.

DO NOT USE CHEMICALS – Concern for environ-

mental issues and corrosive affects on machine

components.

Specifications Page 6 – 2 Hydroject 3010

Rev. B

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.

Part No. Approx.

Depth

Drill Size Decimal Size

(inch)

Metric Size

(mm)

Quantity of Nozzles

Open Blocked **

86–8130 #56 .0465 1.181 * * *

86–8131 #53 .0595 0 4–6”

86–8133 #46 .0810 2.057 6 5 6–8”

* Use only with varied size configurations

NOZZLE SIZE AND APPROXIMATE DEPTH CHART

1.511 11

Aluminum Washer is required with any nozzle change:

Part no. 86–8150

Part No. Approx.

Depth

Drill Size Decimal Size

(inch)

Metric Size

(mm)

Quantity of Nozzles

Open Blocked **

86–8130 #56 .0465 1.181 6 and 0** 3–4”

86–8133 #46 .0810 2.057 5 0** 6–8”

OPTIONAL STAGGERED SIZE NOZZLE CONFIGURATION

Aluminum Washer is required with any nozzle change:

(S/N 29999 & Below) Part no. 80–6680

Part no. 86–8150

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

Hydroject 3010 Page 6 – 2.1 Specifications

Rev. B

CLOSED (BLOCKED) NOZZLEOPEN NOZZLE

Spring

70 – 80 ft–lb

Aluminum washer (P/N 86–8150)

is required with any nozzle change.

Check Valve Ball

Specifications Page 6 – 2.2 Hydroject 3010

Rev. B

Water System Schematic

QUICK COUPLER

ENGINE

ELECTRIC

CLUTCH

PUMP

ELECTRIC

BRAKE CLUTCH

PRESSURE

SWITCH

20 PSI – ON

10 PSI – OFF

PRESSURE GAUGE

2500 PSI

NITROGEN PRE–CHARGE

5000 PSI

GEARBOX CAM

HIGH PRESSURE

NOZZLES

PRESSURE REDUCING

WATER SUPPLY

WATER

SPRAY WASH

VALVE

ACCUMULATOR

WATER

VALVE

RELIEF VALVE

AERATION NOZZLES

ROLLER WASH

PRE–FILTER

FILTER

VALVE

Hydroject 3010 Page 6 – 3 Water System Schematic

Special Tools

The following special tools are required for servicing the Order special tools from the

TORO SPECIAL TOOLS

HydroJect 3010.

AND APPLICATIONS GUIDE (COMMERCIAL

PRODUCTS)

Accumulator Charging Valve and Pressure Gauge - 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 Com-

pressed Gas Association No. 677 tank connection. 5

Figure 2

1. Accumulator connector 4. Inlet valve

2. Pressure gauge 5. Relief valve

3. Outlet valve with diffuser 6. Nitrogen tank connector

Accumulator Seal Installation Tool - TOR4002 (Fig. 3)

Used for installing piston seal during accumulator

rebuilding.

Figure 3

Special Tools Page 6 - 4 HydroJect 3010

Accumulator Cap Wrench - TOR4003 (Fig. 4)

After discharging accumulator, use this special wrench

to remove accumulator cap for accumulator rebuilding.

Figure 4

Water System Pressure Gauge - TOR4005 (Fig. 5)

The Water System Pressure Gauge and Adapter is

temporarily connected into the high pressure water

system for measuring water pressure available to the

water valve.

Figure 5

Flow Meter - 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

Valve Lift Indicator - TOR4007 (Fig. 7)

A special dial indicator and adaptor is temporarily in-

stalled into the inspection port on the side of the high

pressure manifold to measure water valve lift. This

indicator is also used to measures cam wear and deter-

mines correct shim size to get proper valve lift.

Figure 7

Valve Spring Compressor - 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 8

Special Tools Page 6 - 6 HydroJect 3010

Seal Installation Tools (Fig. 9)

Water Valve Seal Installation Guide - TOR4009

The Water Valve Installation Guide (small) is needed to

properly install the water valve seal into the water valve

body. Use Insertion Mandril with this seal guide.

Pump Seal Installation Guide - TOR4010

The Pump Seal Installation Guide (large) is needed to

properly install the pump displacement rod seal into the

pump head. Use Insertion Mandril with this seal guide.)

Seal Installation Mandril - TOR4011

Use Insertion Mandril with both seal guides. Seal Inser-

tion Mandril is necessary to properly install seals in the

water valve and pump head.

Filter Body Wrench - TOR4012 (Fig. 10)

Special spanner wrench use for servicing the inlet water

filter.

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

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.

Figure 11

Pump Wear Sleeve Driver - TOR4015 (Fig. 12)

Driver used for removal and installation of plunger

guides in pump crankcase.

Figure 12

Special Tools Page 6 - 8 HydroJect 3010

___________________________________________________________________________________________

________________________________________________________________________________________________________________________________________________________

Troubleshooting

The cause of an improperly functioning water system is

best diagnosed with the use of proper testing equipment

and a thorough understanding of the complete system.

The charts that follow contain detailed information to

assist in troubleshooting. There may possibly be more

than one cause for a machine malfunction.

ALL POSSIBLE CAUSES SHOULD BE CHECKED IN

THE ORDER IN WHICH THEY ARE LISTED ON THE

CHARTS.

Troubleshooting Water System Problems

Refer to the Testing section of this Chapter for precau-

tions and specific test procedures.

NOTE: The water aeration system operates under very

high pressures and severe duty cycles. Performance of

the water system will be gradually reduced over a period

of time due to normal wear in the pump, valve and

accumulator. If you perform water system tests to isolate

a possible problem, such as reduced hole depth, it is

recommended that ALL tests be performed in the order

listed even if the apparent problem has been isolated,

such as low accumulator pre-charge pressure. This will

verify that all components are operating properly.

El l l

cl i

when fi i ion.

li l

ti i

Condition Possible Cause Correction

Mach ne does not start aerating

when engage button is pushed in

(pump belt does NOT rotate).

Transport wheels not fully raised

(unit lowered to aerate mode).

Low inlet water pressure.

Sheared pump c utch key.

ectrical problem.

Check to make sure transport

wheel arms are fully raised (unit

in aerate mode).

Check that water pressure gauge

reads 20 to 30 PSI or more. If

pressure is low, obtain proper

water supply source.

Repair.

See Troubleshooting in

Chapter 5 - E ectrical System

Mach ne does not start aerating

when engage button is pushed in

(pump belt IS rotat ng but gear-

case drive shaft is NOT rotat ng.).

ectric brake c utch (valve c utch)

out of adjustment.

Sheared valve c utch key.

ectrical problem.

Check air gap at electr c brake

utch and adjust f necessary.

Repair.

See Troubleshooting in

Chapter 5 - E ectrical System

Mach ne makes unusual noise

rst start ng aerat

Air in system. NOTE: Re ef va ve

may “squeal” for a short per od of

me during init al startup due to air

in the system.

Damaged component.

With engine OFF and water supp-

ly connected, open high pressure

bleed valve and bleed air out of

system. Repeat procedure if

noise continues.

Check for damaged components

and repair or replace as neces-

sary.

HydroJect 3010 Page 6 - 9 Troubleshooting

__________________________________________________________________________________________

________________________________________________________________________________________________________________________________________________________

i i ing.

Pl i

l i l

ion

i i

initi

Pl l l

l i

les

ing

Leak i

zl l

i i

zle Si

l i

Condition Possible Cause Correction

Mach ne stops aerating (pump

shuts down during aeration).

Mach ne not mov

Inadequate water supply.

ugged inlet water f lter.

ectrical problem.

Norma condition of nter ock sys-

tem. Operator must hold engage

button in to aerate with tract

bail in neutral.

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

when pump is engaged. If pres-

sure drops to less than 15 PSI,

but was ally higher, replace

water f lter.

See Troubleshooting in

Chapter 5 - E ectrical System

Water system engages (pump

belt and gear case drive shaft

rotate), but no aerat on holes are

produced or aeration hole depth

is shallow or incons stent.

Air in system.

Soil density or mo sture content.

ugged nozz es, worn nozz es or

improper nozz e conf guration.

NOTE: Check operation of nozz

by aerating over a piece of

cardboard, then inspect

cardboard.

Gear or cam damage in gear case.

n high pressure water sys-

tem.

With engine OFF and water supp-

ly connected, open high pressure

bleed valve and bleed air out of

system.

If hole depth was sat sfactory

before in another area, different

nozz e configuration may be re-

quired.

Stop engine, open high pressure

bleed valve, then inspect noz-

es. Check for plugged nozz es.

Ver fy s ze and quantity (see Noz-

ze and Approximate Depth

Chart). Nozz es that are too large

will cause loss in pressure and

could cause damage to the ac-

cumulator and other water sys-

tem components.

Inspect gear case for gear or

cam damage and repair as neces-

sary.

Check for eaks w th water sys-

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-

ing from shim area below gear-

case indicates valve wear or

damage. Do water system tests

and make repairs as necessary.

Troubleshooting Page 6 - 10 HydroJect 3010

___________________________________________________________________________________________

________________________________________________________________________________________________________________________________________________________

Condition Possible Cause Correction

Machine aerates, but aeration Low accumulator pre-charge or Charge accumulator with dry Ni-

hole depth is shallow or inconsis- damaged accumulator - TEST trogen. Rebuild or replace accu-

tent (continued). NO. 1. mulator if necessary.

Low water system pressure AND Rebuild pump.

flow - TEST NO. 2.

Low water system pressure (flow is NOTE: When testing, make sure

OK) - TEST NO. 2. cam is not holding water valve

open - rotate gear so cam is off of

valve lifter.

If water is exiting relief valve out-

let hose, replace relief valve. DO

NOT attempt to adjust.

Rebuild water valve.

Low water system flow (pressure is Check engine speed and correct

OK) - TEST NO. 2. if necessary.

Rebuild pump.

Improper water valve lift - TEST Perform valve lift adjustment. Re-

NO. 3. pair valve or replace cam if nec-

essary.

Worn or damaged water valve - Rebuild water valve.

TEST NO. 2.

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) pressure seal or cracked ceramic sleeves.

plunger.

Engine dies when water system Low engine RPM. Throttle must be in FAST posi-

is engaged. tion. Adjust carburetor fast setting

to 3450 to 3550 RPM - no load.

Relief pressure too high - TEST Replace relief valve. DO NOT at-

NO. 2. tempt to adjust.

Low engine power. 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 gear- Inspect components and repair

case. as necessary.

Hydroject 3010 Page 6 - 11 Troubleshooting

Testing

Before Performing Water System Tests

1. The water aeration system operates under very high

pressures and severe duty cycles. Performance of the

water system will be gradually reduced over a period of

time due to normal wear in the pump, valve and ac-

cumulator. If you perform water system tests to isolate

a possible problem, such as reduced hole depth, it is

recommended that ALL tests be performed in the order

listed even if the apparent problem has been isolated,

such as low accumulator pre-charge pressure. This will

verify that all components are operating properly.

High pressure water system components can

cause personal in ury if disassembled incor-

rectly. Discharge water pressure at bleed

valve before attempting any water system

servicing. Open bleed valve slowly and avoid

contact with high velocity water stream.

WARNING

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

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 Figure 14

of the water system.

1. High pressure bleed valve

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 15

1. Protective cover 2. Valve cap

in a

Charged accumulators contain high pressure

nitrogen. Nitrogen is the only gas to use for

accumulator charging. Installing IMPROPER

gases in an accumulator can cause an EX-

PLOSION AND DEATH. Charging requires

special tools and precautions. Charge ac-

cumulators 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, DIS-

MEMBERMENT OR DEATH.

Charged accumulators cannot be shipped via

air freight.

DANGER

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

Rev. A

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 de-

pressurize tool by slowly opening outlet valve on right

hand side of pressure gauge.

9. Disconnect charging tool from accumulator. Reinstall

the yellow protective cap and valve protector bracket.

Adding Dry Nitrogen to Accumulator

10. With charging tool connected to accumulator, attach

a charged tank of dry Nitrogen to high pressure tube on

charging tool. Tighten tank fitting by turning hose fitting

counterclockwise.

11. The accumulator tool, attached to the accumulator,

has a pressurized manifold. Open inlet valve on left

hand slide of charging tool to pressurize supply tube.

While watching pressure gauge on tool, slowly open

supply tank valve. Pressure reading on gauge will start

to rise. Close supply tank valve when gauge pressure

reaches 2500 PSI Wait a few minutes to make sure

system pressure has equalized then add additional

Nitrogen if necessary for 2500 PSI pre-charge.

12. Close accumulator valve by turning lower nut clock-

wise.

13. Slowly open knob on right hand side of charging tool

de-pressurize the tool, then remove tool from ac-

cumulator. Reinstall yellow protective cap and valve

protector bracket.

NOTE: After completion, install a tag on accumulator

indentifying the charging pressure and charging date.

14. Do Test No. 2: Water Pump Pressure and Flow.

Figure 16

Figure 17

Testing Page 6 - 14 HydroJect 3010

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

1. The engine must be in good operating condition. Use

a tachometer to verify that the engine is operating at

specified full governed RPM (3450 to 3550 RPM no

load). Engine speed will affect accuracy of flow meter

reading.

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

the hood.

High pressure water system components can

cause personal in ury if disassembled incor-

rectly. Discharge water pressure at bleed

valve before attempting any water system

servicing. Open bleed valve slowly and avoid

contact with high velocity water stream.

WARNING

Figure 18

1. High pressure bleed valve

3. Slowly open the high pressure bleed valve allowing

any pressurized water to escape.

4. Install Water System Pressure Gauge (TOR4005)

into port in water valve housing as shown.

Figure 19

1. Water system pressure gauge (TOR4005)

5. Disconnect wire harness connection for water valve

clutch to prevent the water valve from operating during

the test.

Figure 20

1. Water valve clutch

HydroJect 3010 Page 6 - 15 Testing

Rev. A

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 Figure 21

observes pressure gauge and flow meter readings.

1. Water supply quick connector

PRESSURE should be 5000 ± 300 PSI and

FLOW more than 3.4 GPM.

If pressure is too high, replace relief valve.

If pressure AND flow is low, disconnect small tube

running from bottom side of valve housing to water

pump inlet by backing out small 1/16" NPT fitting

(Fig. 39, Item 31). Plug open port with a 1/16" NPT

plug. Do this test procedure again beginning with

step 1. If pressure AND flow is still low, rebuild pump.

After rebuilding pump, do this test procedure again

beginning with step 1, to verify that valve is sealing

properly in closed position. A large quantity of water

exiting valve side of tube indicates a leaking valve Figure 22

ceramic sleeve or seal. Reconnect small tube.

If pressure is low, but flow is OK, make sure cam is

not on roller follower, keeping valve in open position.

If water is exiting outlet fitting on relief valve, replace

relief valve. If water is not exiting outlet fitting on relief

valve, rebuild water valve. After replacing relief valve

or rebuilding water valve, do this test procedure

again, beginning with step 1, to verify that pump has

adequate flow at specified operating pressure.

If pressure is OK, but flow is low, rebuild pump.

10. Perform Test No. 3: Water Valve Lift.

11. Do steps 2 - 4 and 6 - 8 of this pressure and flow test

again, with valve clutch connected to wire harness. Figure 23

/1. Flow meter pressure gauge (TOR4006)

Pressure gauge needle will go rapidly to the relief 1. Relief valve 2. Hose

setting (5000 ± 300 PSI) for 3 to 4 seconds, then

begin to fluctuate rapidly when the unit begins aerat

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.

HydroJect 3010 Testing Page 6 - 16

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.

High pressure water system components can

cause personal in ury if disassembled incor-

rectly. Discharge water pressure at bleed

valve before attempting any water system

servicing. Open bleed valve slowly and avoid

contact with high velocity water stream.

WARNING

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.

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.

Dial indicator should move 0.090 to 0.102. There

should be no movement of dial indicator gauge on

lead-in or lead-out portion of cam.

7. If indicator moves more than 0.102, cam lobe is

probably contacting follower on lead-in portion of cam

and must be adjusted (see Valve Lift Adjustment). If

indicator moves less than 0.090, remove gear case

cover and inspect cam for wear. Use your hand to rotate

coupling to position working cam on top. Visually inspect

top of cam lobe for wear. There is a thin area on this

replaceable cam that does not contact the cam follower.

If cam is worn, a ridge will develop between tip of cam

and unused surface. If the ridge is deep enough to catch

a fingernail, replace the cam (see Gear Case Service).

If cam is not worn, adjust valve lift.

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

Pressure and Flow.

iLead- n to lead-out is

two (2) rev. of pinion.

Lead-out

Cam lobe Lead-in portion

Figure 24

1. Coupling 2. Cam 3. Follower

Figure 25

1. Valve lift indicator (TOR 4007)

HydroJect 3010 Page 6 - 17 Testing

Adjustments

Electric Brake Clutch Adjustment (Fig. 26)

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

engage the parking brake, open the hood and discon-

nect engine spark plug wires.

2. Adjust air gap to .018" by inserting a thickness gauge

into the clutch openings. Evenly tighten the three lock

nuts on clutch to reduce the air gap. Failure to maintain

the correct air gap could result in clutch not engaging

even though it is electrically energized.

NOTE: It may be necessary to remove clutch retainer to

allow clutch rotation for access to all three (3) adjust-

ment nuts.

Figure 26

1. Locknut (3)

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

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

engage the parking brake, open the hood and discon-

nect the engine spark plug wires.

High pressure water system components can

cause personal in ury if disassembled incor-

rectly. Discharge water pressure at bleed

valve before attempting any water system

servicing. Open bleed valve slowly and avoid

contact with high velocity water stream.

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, position-

ing working cam on top. Visually inspect top of cam lobe

for wear. There is a thin area on this replaceable cam

that does not contact the cam follower. If cam is worn,

a ridge will develop between tip of cam and unused

surface. If the ridge is deep enough to catch a fingernail,

replace the cam lobe. Do not measure valve lift using a

worn cam lobe. Rotate cam to make sure cam lobe is

not contacting follower.

i l is

Lead- n to ead-out

two (2) rev. of pin on.

Lead-out

Cam lobe Lead-in portion

Figure 27

1. Coupling 2. Cam 3. Follower

Adjustments Page 6 - 18 HydroJect 3010

5. Remove test cap from manifold feeder and install

Valve Lift Indicator (TOR4007) into this opening. Make

sure dial indicator contacts top of water valve, then zero

out dial indicator.

6. Rotate coupling, moving cam toward cam follower.

Continue to rotate until cam follower is on lead-in portion

of cam, approximately one inch (slightly less than 1/2

turn of coupler) from cam lobe. If dial indicator shows

no lifting of valve, loosen four (4) capscrews holding

gear case to valve body. Remove one shim from both

front and rear, then tighten capscrews. Repeat this

procedure until some opening of valve occurs on lead-in

portion to make sure cam follower touches cam.

7. Zero dial indicator again with cam follower completely

off the cam. 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.

8. Add shims, equal to or greater by 0.002 inch, to

amount measured. For example, if 0.015 is measured

while follower is on lead-in portion of cam, add a 0.015

shim. If 0.009 is measured, add 0.010 shim (two 0.005

shims) and retighten capscrews.

NOTE: If more than a multiple of 0.005 shims are

required, it is recommended that procedure be done in

two steps - for example if 0.023 is indicated, add 0.02

shim (four 0.005 shims) first, then repeat procedure.

IMPORTANT: Clearances greater than 0.002 in. will

cause high contact stresses and rapid cam wear.

9. Check proper function of cam by again zeroing dial

indicator with cam away from cam follower. Rotate

coupling, moving cam toward cam follower and continue

to rotate until cam follower is on lead-in portion of cam,

approximately one inch from cam lobe. There should be

no movement of dial indicator on lead-in portion of cam.

Continue to rotate over cam lobe. Lift should measure

0.10 +0.002/–0.004 in. (with new cam). Continue to rotate

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

for entire lead-out portion.

Figure 28

1. Valve lift indicator (TOR4007)

Gear case

Shims

Cam follower

(on lead-in portion of cam)

Cam

Shims

Water valve

housing

Cam lobe

Water (4000 - 5000 PSI

operating pressure)

Figure 29

HydroJect 3010 Page 6 - 19 Adjustments

Hydroject 3010

Page 6 – 20

Repairs Rev. B

Repairs

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

1. Park the machine on a level surface, engage the park-

ing brake, open the hood and disconnect the engine

spark plug wires. Remove guard (Item 38).

2. To remove coupling shaft, remove four capscrews

connecting the rubber couplers (Item 11, 12) to clutch

(Item 8) and adapter hub (Item 16), then lift shaft away

from machine.

3. Clutch (Item 8), pulley (Item 3) and clutch (Item 2) can

now be removed by removing bolt (Item 26) and washer

(Item 27). A puller tool may be required.

4. Apply “Never–Seez“ or equivalent to engine shaft and

pulley shafts. Make sure keys (Item 1 and 4) are properly

installed, then align keyways in clutches and pulley with

keys. Make sure clutch (Item 8) is installed so clutch

angle (Item 7), clutch stops (Item 5, 33) and clutch

bumpers (Item 6) will prevent clutch rotation. The clutch

bumper gap should be 0.22 + .03 in.

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 gear-

box input shaft. When installing hub, be sure to use spe-

cial hardened washer (Item18), apply Loctite 271 or 680

to threads of capscrew (Item14) and tighten to a torque

of to 15 ft–lbs.

6. Install all bolts and spacers in drive coupling using il-

lustration below. Position flat of spacer (Item10) toward

welded flange of drive shaft (Item 24). Tighten caps-

crews until shoulder of spacer is seated, then tighten to

a torque of 15 ft–lb more than prevailing torque required

to turn locknut on threads.

1234567

18 19

131415

Clutch bumper gap

0.19 – 0.25 in.

Never–seez

Loctite 271 or 680

25 – 30 ft–lb

Loctite 271 or 680

25 – 30 ft–lb

on engine shaft

Figure 30

Pump Drive Belt Replacement (Fig. 31, 32)

1. Park the machine on a level surface, engage the

parking brake, open the hood and disconnect the engine

spark plug wires.

2. Remove the drive coupling (see Drive Coupling

Removal and Installation).

3. Disconnect electrical connectors for both clutches.

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

retainer bracket (Fig. 30, Item 39).

5. Loosen hydraulic pump belt tension and remove

small belt from hydraulic pump pulley (see Pump Drive

Belt Adjustment in Chapter 4 - Hydraulic System). Figure 31

6. Loosen water pump idler pulley and work belt off of 1. Water pump belt

large pulley. Carefully pull this belt out from under the

electric clutches.

7. Reverse steps 2 - 6 to install the belt. Adjust hydraulic

pump belt tension (see Pump Drive Belt Adjustment in

Chapter 4 - Hydraulic System).

Figure 32

1. Hydraulic pump belt

HydroJect 3010 Page 6 - 21 Repairs

Water Filter Replacement (Fig. 33, 34)

When pump inlet pressure decreases or the water sys-

tem shuts down, it usually means the water filter is

restricted and must be replaced.

IMPORTANT: Never operate the machine without a

water filter. Operating without a water filter can

cause severe damage to the water system.

1. Put the machine on a level surface, engage the

parking brake, stop the engine and disconnect the en-

gine spark plug wires.

2. Locate the water filter assembly, which is mounted

below the fuel tank.

NOTE: Be careful when removing filter body. Filter body

is full of water and will be heavy.

3. Unscrew the filter body counterclockwise (as viewed

from top). Remove filter and discard.

4. Rinse out filter body and insert a new filter.

5. Clean filter head to prevent contamination of water

system. Thread body with filter onto filter head. Hand

tighten.

6. Bleed water system with engine OFF and water

supply connected and turned on:

A. Push button on top of filter head to purge air from

filter body until water comes out around button.

B. Open high pressure bleed valve below ac-

cumulator to bleed air from water system. Close high

pressure bleed valve.

NOTE: The quality and micron rating of this filter is very

important. Do not use any substitutes. This filter has a

5 micron rating. For easier filter removal, use Filter

Wrench (TOR4012).

Figure 33

Figure 34

1. Filter body

2. Filter

3. Filter head

4. Bleed button

Repairs Page 6 - 22 HydroJect 3010

Water Pump Removal and Installation (Fig. 35)

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

engage the parking brake, open the hood and discon-

nect the engine spark plug wires.

High pressure water system components can

cause personal in ury if disassembled incor-

rectly. Discharge water pressure at bleed

valve before attempting any water system

servicing. Open bleed valve slowly and avoid

contact with high velocity water stream.

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.

11 12

14 15

Torque to 25 - 33 ft-lb.

(Eight locations)

Figure 35

HydroJect 3010 Page 6 - 23 Repairs

Water Pump Head Service (Fig. 36)

The three major wear components in the high pressure

pump that require maintenance include: the check val-

ves, plunger sleeves, and plunger seals. These com-

ponents will require maintenance after approx. 500

pump operating hours (approx 750 engine hours).

High pressure water system components can

cause personal in ury if disassembled incor-

rectly. Discharge water pressure at bleed

valve before attempting any water system

servicing. Open bleed valve slowly and avoid

contact with high velocity water stream.

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.

l i

ily i ll

Fi i

l l

i l

i l wi l l

l l

PLUNGER SEAL REMOVAL - Step 1:

Fill out et port of pump head w th water and

use two capscrews, to temporar nsta

Pump Seal Out et Cover (TOR4014) onto

the out et port of the pump head.

PLUNGER SEAL REMOVAL - Step 2:

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

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

assemb y and brass retainer shou d move about

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. Use Loctite 242 or equivalent

Torque to 205 - 235 ft-lb.

(Six locations)

Torque to 25 - 33 ft-lb.

(Eight locations)

Figure 36

Repairs Page 6 - 24 HydroJect 3010

Rev. B

Plunger Seal Replacement

(See illustration on previous page)

NOTE: Check valves must be in good condition for this

procedure to work correctly.

1. Fill pump head outlet cavity with water, then use two

capscrews to temporarily install Pump Seal Outlet Cov-

er (TOR4014) onto outlet port of pump head. Check

valves must 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 Ex-

traction Tool (TOR4013) into each water filled cavity.

WEAR SAFETY GLASSES. Quickly, strike the extrac-

tion tool with a large hammer or mallet. The seal assem-

bly and brass retainer should move about 1/4” out of the

cylinder head. If seal does not move, add more water

and try again. NOTE: If seal does not move after a few

attempts, try using heavy oil or grease instead of water.

4. Remove all seals from pump head and remove outlet

cover tool. Discard back–up ring (Item 6), packing vee

(Item 5) and seal support (Item 4). Inspect brass seal re-

tainer (Item 2) for wear and replace if worn. If brass seal

retainer can be reused, remove and replace U–cup seal

(Item 3) and O–ring seal (Item1).

NOTE: Apply clean grease to each seal before installing

in steps 5 – 9.

5. Insert back–up ring (Item 6), flat side first, into each

pump head cavity.

6. Insert packing vee (Item 5) into Installation Guide

(TOR4010) making sure that “V“ will mate with back–up

ring (Item6).

7. Insert Installation Guide into cylinder head cavity and

use Insertion Mandril (TOR4011) to completely install

the seal.

8. Insert seal support (Item 4) into Installation Guide

(TOR4010) making sure “V“ groove will mate with high

pressure seal. Insert Installation Guide into cylinder

head 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.

Plunger Sleeve Replacement (Model 09800)

(see Figure 38 on next page)

The plunger sleeves are installed on, and sealed to

stainless steel plunger rods. This assembly is inserted

through a special high pressure seal in the pump head.

During pump servicing, a complete repair kit should be

installed.

1. Remove plunger sleeves (Item 26) from crankcase

plunger rods (Item 9) by loosening and removing plung-

er bolt assemblies (Item 30). The plunger sleeves can

be gently pulled forward for inspection or replacement.

Remove large washer (Item 25) from rear of plunger rod.

2. Remove O–Ring (Item 29) and PTFE seal (Item 28)

on plunger bolt assembly (Item 30). Install new greased

O–ring (Item 28) next to head on bolt, then install PTFE

ring (Item 28).

3. Install new large washer (Item 25), then new plungers

(Item26), onto plunger rods.

4. Apply Loctite 271 or equivalent to threads of plunger

bolts, then install assemblies onto plunger rods. Torque

plunger bolts to 10 ft–lbs.

Pump Head Installation (Fig. 37)

1. Apply grease to ceramic plunger sleeves. Carefully

install pump head onto pump crankcase studs and

plungers. While installing, tap evenly on pump head

while turning pump crankshaft.

2. Install eight (8) nuts onto studs and evenly torque

locknuts to 25 – 33 ft–lbs.

3. Install water pump assembly into frame (see Water

Pump Removal and Installation).

Figure 37

Hydroject 3010 Page 6 – 25 Repairs

Repairs Page 6 – 26 Hydroject 3010

Rev. B

Water Pump Crankcase Service (Fig. 38)

56 7 8

22 10

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 gall-

ing or wear.

7. Pull connecting rods (Item 12) out through crankcase.

Check for wear on plunger (12) and plunger guides

(Item 28). If plunger guides are worn, use Wear Sleeve

Tool (TOR4015) to drive guides out through crankcase.

Also use this tool for plunger guide installation.

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.

Rev. B

Crankcase Bearing Installation and Shimming

(Model 09801)

1. Remove crankshaft bearing end caps.

2. Remove existing shims from both end caps.

3. Install one yellow (.020) shim and one pink (.015)

shim onto input shaft bearing housing if required.

4. Install three yellow (.020), three blue (.005) and two

red (.002) shims onto the end cap bearing housing.

5. Install input shaft end cap over crankshaft input shaft

and secure to water pump housing. Tighten fasteners to

a torque of 18 – 20 ft–lb.

6. Install end cap bearing housing over output shaft and

secure with fasteners, but do not tighten.

7. Measure the crankshaft end play and remove shims

from end cap as required to get .006 + .001 INTERFER-

ENCE FIT (see chart).

8. Tighten fasteners (Item 10) to a torque of 18 – 20 ft–lb.

Crankshaft end play

from dial indicator

Shim thickness removed

to get .006 + .001

.010 .016

.009 .015

,008 .014

.007 .014

.006 .012

.005 .012

.004 .010

.003 .009

.002 .008

.001 .007

.000 .006

Hydroject 3010Repairs Page 6 – 27

This page is intentionally blank.

Repairs Page 6 - 28 HydroJect 3010

Rev. B

Water Valve Service (Fig. 39, 40)

The water valve controls the release of high pressure

water. The water valve is opened when a cam contacts

and moves a roller follower. The follower moves the

valve stem against spring pressure, which opens the

water valve. After discharge, the valve spring closes the

water valve, diverting pump flow into the accumulator for

storage. The valve stem is installed completely through

the water valve body and guided through a replaceable

bushing and two sealing assemblies.

The water valve consists of a tapered valve stem sealing

against a captured valve seat. The valve seat is sealed

on both sides. One valve seat seal contacts the water

valve body and the other seal contacts the manifold

feeder. When the manifold feeder is installed on the wa-

ter valve, the seals are compressed, locking in and

maintaining correct alignment of the water valve and

also preventing blow by.

Any abrasives in the water will rapidly erode the valve

surfaces. The valve and valve seat can be ground and

lapped to renew their working surfaces. After grinding,

adjust the valve lift by measuring the lift and adjusting

the shim stack thickness. The shim stack is located be-

tween the water valve body and gear case flange.

If the high pressure seal leaks for extended periods of

time, water may be forced past the oil seal and into the

gearbox. If the gearbox oil looks milky or brown, flush the

system immediately, replacing oil, filter, and fluids in hy-

drostatic transmission and wheel motor.

The water valve assembly is similar to the pump head.

It uses the same ceramic sleeve and seals. Since the

water valve is the junction point for all high pressure liq-

uid movement and is fairly difficult to access, complete

rebuilding is recommended when this assembly is re-

moved.

Seal Replacement

There are two major seals in the water valve that will re-

quire regular maintenance or replacement. One seal

keeps high pressure water in the high pressure water

system and the other seal keeps the gear case oil within

the gear case.

The high pressure water seal is identical to the pump

head displacement rod seal. The major difference is the

different brass insert.

If the oil seal leaks, oil will leak down and through the

gear case shims. If low pressure water seal fails water

will leak out between shims. If low pressure water seal

and oil seal fail water will leak into the gear case.

Water Valve Disassembly

1. Park machine on a level surface, stop the engine, en-

gage the parking brake, open the hood and disconnect

the engine spark plug wires.

WARNING: High pressure water system compo-

nents can cause personal injury if disassembled in-

correctly. Discharge water pressure at bleed valve

before attempting any water system servicing.

Open bleed valve slowly and avoid contact with

high velocity water stream.

2. Open High Pressure bleed valve. Remove accumula-

tor (see Accumulator Replacement). Remove manifold,

manifold feeder and manifold support as an assembly

from water valve body.

3. Disconnect drive coupler from gear case hub adapter

(see Drive Coupling and Clutch Removal and Installa-

tion).

4. Drain oil from gearcase. Disconnect hydraulic lines

from gearcase. Remove four (4) capscrews securing

gear case to water valve and carefully pull gear case off

of gear box pilot on water valve.

5. Disconnect valve seal drain tube by unscrewing small

fitting at pump inlet. Remove two (2) locknuts from studs

securing water valve to frame. Remove four (4) caps-

crews connecting water valve to water pump head. Re-

move water valve and put it on a clean work bench.

6. Install valve spring tool studs through the Valve Spring

Compressor (TOR4008) and into threaded holes of wa-

ter valve.

7. Tighten nuts to compress tool until retaining ring

(Item14) can be removed from valve spool. Remove re-

taining ring, then carefully loosen nuts on special tool re-

leasing valve spring compression.

8. Remove spring retainer (Item 15) and spring (Item16)

from water valve stem. Remove screws (Item13) from

gear case pilot. Remove gear case pilot (Item18) from

water valve.

9. Use a wrench to keep spool valve (Item1) stationary

and use a deep wall socket to loosen jam nut (Item 22)

on valve spool.

10. Remove jam nut (Item 22) and large washer (Item

23), then gently push valve spool through valve body.

Valve seat (Item 2) will come out with the valve.

Hydroject 3010 Page 6 – 29 Repairs

Hydroject 3010

Page 6 – 30

Repairs Rev. B

11. Inspect sealing surfaces of valve spool and valve

seat. If surfaces appear worn, replace or regrind. Both

angles are 30 degrees.

12. Remove and inspect sleeve (Item 7) and remove

backup (Item 6) and O–ring seals (Item 5).

13. Remove seal assembly (Items 25–30) by pressing

a socket wrench through the casting. Discard all seal

components.

14. Remove snap ring (Item 21) from gear box pilot

(Item18). Insert a shaft into the outboard side of the gear

box pilot to push out sleeve bushing (Item17), seal

back–up (Item 20) and oil seal (Item 19).

Torque to 14 – 18 ft–lb

(Six locations)

10 ft–lb

Apply Loctite 271

to threads of spool

Apply grease to

O.D. of sleeve

before installing

Figure 39

Water Valve Assembly

1. Press a new sleeve bushing (Item17) into gear case

pilot until bushing is flush with recessed (oil side) sur-

face.

2. Use a shaft to install oil seal (Item 19) and seal back–

up (Item 20) into gear box pilot. Install retaining ring

(Item 21).

3. Grease O–ring (Item 5) and back–up ring (Item 6),

then install onto valve spool (Item1). Rubber O–ring is

furthest away from threads.

4. Install black back–up ring (Item 30) into valve cavity,

flat side first.

5. Use Valve Seal Installer (TOR4009) and Seal Inser-

tion Mandrel (TOR4011) to properly install packing seal

(Item 29) and seal/plunger support (Item 28) into valve

body. Remove installers.

6. Insert valve guide (Item 27) into valve body. Install O–

ring (Item 24) and U–cup seal (Item 26) to seal retainer

(Item 25), then install into valve cavity.

7. Apply grease to outside of sleeve (Item 7). Use valve

spool inserted through sleeve to gently drive sleeve into

seals, inserting it from the “spring“ side.

8. Insert valve spool (Item1) through valve seat (Item 2)

and install O–ring (Item 3) on inboard side of valve seat.

. B

9. Hold spool and seat in place so O–ring does not fall

out of place, then carefully slide valve spool, new sleeve

seals, and valve seat, through ceramic sleeve.

10. Install flat washer (Item 23) onto valve spool. Apply

Loctite 271 or equivalent to threads and install jam nut

(Item 22). Tighten to a torque 10 ft–lbs.

11. Fill snap ring groove in valve spool (Item 1) with wax

to prevent damage to seal. Install gear case pilot

(Item18) making sure the drain hole is pointing down.

Holes in pilot allow only one method of installation.

Tighten screws (Item13) to a torque of 14 – 18 ft–lb.

12. Install compression spring (Item16) onto valve

spool.

13. Install valve spring studs through Valve Spring Com-

pressor (TOR4008) and into threaded holes of water

valve. Put spring retainer (Item 15) over spring and un-

der spring compressor. Tighten nuts to compress

spring, and install and retaining ring (Item14). Remove

special tool.

NOTE: The manifold feeder keeps the valve seat sta-

tionary. The spring force of the water valve positions the

valve seat prior to Feeder Manifold installation. Make

sure cam lobe does not contact cam follower during

feeder manifold installation (Fig. 29).

6 7 13 14

23 18

25 21

24 20

272829

30 36

Figure 40

Hydroject 3010 Page 6 – 31 Rev Repairs

Gear Case Service (Fig. 41)

The gear case is a pinion and gear reduction drive that

actuates the water valve. The pinion (Item 12) is con-

nected to the electric brake clutch with a drive coupler.

The gear (Item 22) moves the cam over the roller

follower, actuating the water valve to control water in-

jection at 5.3 cycles per second (at 320 RPM).

The gear case also serves as the hydraulic oil reservoir.

If the gear case is disassembled for repair, make sure

the taper roller bearings have a light rolling resistance

after reassembly by adjusting shim thicknesses

(Item 16 and 20). Bearing pre-load is 0 to 0.002 in.

There is a replaceable cam (Item 23) and weight block

(Item 27) on the gear. Only the cam contacts the roller

cam follower. The weight block is for balance. Make sure

you inspect the cam and not the weight block, when

checking for wear. DO NOT INSTALL TWO CAMS

ONTO THE GEAR.

The cam (Item 23) can be replaced without removing or

disassembling the gear case. Evenly torque capscrews

securing cam to 22 - 28 ft-lb.

NOTE: If there is wear on the teeth of the gear (Item 22),

interchange the locations of the cam (Item 22) and

weight block (Item 27) so higher gear teeth load occurs

in a new location.

After replacing the cam or repairing or replacing the gear

case, adjust water valve lift (see Water Valve Lift in the

Adjustments section).

14 15

16 17

Torque both capscrews

evenly to 22 - 28 ft-lb.

Figure 41

Repairs Page 6 - 32 HydroJect 3010

Rev. B

Nozzle Service and Replacement

NOTE: See Specifications section of this chapter for

more information.

1. Park machine on a level surface, stop the engine, en-

gage the parking brake, open the hood and disconnect

the spark plug wires from the engine.

2. Inspect nozzle configuration and diameter. Nozzles

are stamped with numbers indicating the drill size of the

orifice. Nozzle orifice can be inspected by inserting

shank end of drill bit matching size stamped on orifice.

If drill bit fit is loose, the nozzle is worn. If nozzles are

worn or incorrect, replace with new nozzles in correct

configuration.

3. The nozzle check valves and seats are located in the

nozzle drops and are easily replaced if they wear. Occa-

sionally inspect the springs especially if one nozzle

leaks water after the machine is shut down.

4. For normal operation, install nozzle springs with the

narrow spiral pointing up and the check ball on top of the

spring. To block the flow for different nozzle configura-

tions, install the narrow spiral pointing down with the

check ball below the spring.

NOTE: Nozzles are stamped with numbers indicating

drill size of orifice. Standard configuration is 11 nozzles,

which will produce depths of approximately 4 to 6 inch-

es, depending on soil conditions. Blocked nozzle loca-

tions are obtained by reversing nozzle check valve and

spring.

CLOSED (BLOCKED) NOZZLEOPEN NOZZLE

Spring

70 – 80 ft–lb

Check Valve Ball

Tighten nut to

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

Hydroject 3010 Page 6 – 33 Repairs

Accumulator Replacement (Fig. 43)

1. Stop the engine, engage the parking brake, open the

hood and disconnect the engine spark plug wires.

in a

Charged accumulators contain high pressure

nitrogen. Nitrogen is the only gas to use for

accumulator charging. Installing IMPROPER

gases in an accumulator can cause an EX-

PLOSION AND DEATH. Charging requires

special tools and precautions. Charge ac-

cumulators 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, DIS-

MEMBERMENT OR DEATH.

Charged accumulators cannot be shipped via

air freight.

DANGER

2. Slowly open the high pressure bleed valve allowing

any pressurized water to escape

3. Remove splash shield from manifold to get access to

capscrews securing accumulator. Use a socket wrench

with long extension to remove four (4) capscrews

(Item 14) securing accumulator (Item 47) to valve hous-

ing (Item 11). Remove the accumulator. Discard O-ring

(Item 26).

4. Install new O-ring seal (Item 26) into groove on top of

valve housing. Carefully install accumulator onto top of

valve housing. Make sure decals (Items 47:2, 47:1)

are facing forward and securely attached to accumulator.

6. Install four (4) NEW special bolts (Item 14) through

valve body and into base of accumulator. Tighten to a

torque of 40 ft-lb.

7. Charge accumulator with dry Nitrogen (see TEST

NO. 3: Accumulator Pre-Charge Pressure and Adding

Dry Nitrogen in the Testing section).

Repairs Page 6 - 34 (Rev. A) HydroJect 3010

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Rev. A

in a

DANGER

Charged accumulators contain high pressure

nitrogen. Nitrogen is the only gas to use for

accumulator charging. Installing IMPROPER

gases in an accumulator can cause an EX-

PLOSION AND DEATH. Charging requires

special tools and precautions. Charge ac-

cumulators 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, DIS-

MEMBERMENT OR DEATH.

Charged accumulators cannot be shipped via

air freight.

Accumulator Service (Fig. 44, 45, 46)

The accumulator piston seals will wear over a period of

time. As seals wear, the accumulator will require more

frequent recharging and eventually, it will not hold gas.

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

engage the parking brake and open the hood.

Figure 44

1. Protective cover 2. Valve cap (yellow)

Figure 45

2. Slowly open the high pressure bleed valve allowing

any pressurized water to escape.

3. Remove protective cover from top of accumulator.

4. Attach and gently tighten special fitting of Charging

Tool (TOR4001) to inlet on top of accumulator.

5. Close both valves on charging tool to prevent loss of

pressurized Nitrogen from accumulator.

6. Rotate the jam nut (not the fitting) of the accumulator

valve two (2) turns counterclockwise as viewed from the

top. This opens the valve and pressurizes the tool and

gauge.

7. Slowly open outlet valve on right hand side of charg-

ing tool to release pressurized gas from accumulator.

When gas stops escaping, disconnect the charging tool.

Repairs Page 6 - 36 HydroJect 3010

8. Remove gas valve (Item 4) from top of accumulator.

9. Remove accumulator from top of water valve housing

(see Accumulator Replacement).

10. Insert Accumulator Cap Wrench (TOR4003) into the

top cap (Item 12) of the accumulator. Hold the ac-

cumulator cylinder (Item 6) stationary using a strap or

chain wrench and remove the top cap (Item 12) and

bottom cap (Item 9) of the accumulator.

11. Use a brass or aluminum shaft to force the piston

(Item 8) out of top side of accumulator and discard the

piston.

Accumulator Service Evaluation

Inspect bore of accumulator cylinder for score marks or

wear. If barrel of accumulator is not scratched or scored,

it can be reused. If bore is scored or damaged, it will

require resurfacing and nickel plating. If cylinder bore is

damaged, it may be more cost effective to replace the

complete accumulator than to continue this repair.

Accumulator Assembly and Seal Installation

12. If bore not damaged or worn, use solvent to

thoroughly clean accumulator cylinder.

13. Apply clean hydraulic oil to new end seal and back-

up ring (Item 4). Install end seal and back-up ring in

groove of bottom end cap (Item 9) so O-ring is toward

the piston. Apply “Never-Seez” or equivalent to threads

of end cap. Carefully install end cap and tighten to a

torque of 125 ft-lbs.

14. Special grease is supplied with a new piston. Apply

coating of special grease to piston. Make sure spaces

between seals on piston are filled with special grease.

Put a light coating of special grease on accumulator

bore and installation tool.

15. Use Accumulator Seal Installation tool (TOR4002)

to prevent seal damage during piston installation.

CAREFULLY insert this tool into top side of cylinder.

SLOWLY insert piston (large cross facing down) through

the tool and into the cylinder bore.

16. Move piston to bottom of accumulator cylinder. Add

11 oz. of Mobil DTE 26 hydraulic oil to completely fill cup

in piston and cover top edges of piston.

17. Apply clean hydraulic oil to new end seal and back-

up ring (Item 4). Install end seal and back-up ring in

groove of top end cap (Item 12) so O-ring is toward the

piston. Apply “Never-Seez” or equivalent to threads of

end cap. Carefully install end cap and tighten to a torque

of 125 ft-lbs.

18. Install gas valve (Item 3) using a new O-ring (Item 4).

19. Install accumulator onto water valve housing (see

Accumulator Replacement).

20. Charge accumulator gas chamber with dry Nitrogen

(see TEST NO. 1: Accumulator Pre-Charge Pressure

Test / Adding Dry Nitrogen).

Apply special

grease to piston

and cylinder bore

Apply Never-Seez

Torque to 125 ft-lb.

Apply Never-Seez

Torque to 125 ft-lb.

Figure 46

HydroJect 3010 Page 6 - 37 (Rev. A) Repairs

Rev. B

General Information

Storage

It is very important that the water system be drained

to avoid freezing and damaging the components.

Drain system as follows:

1. Stop engine, remove key from ignition switch and

remove wires from spark plugs.

2. Remove (2) screws securing drive shield to frame

and remove shield.

3. With the engine ”OFF” and key removed from igni-

tion, rotate the drive coupling by hand until resistance is

felt. Continue to rotate the coupling about 1/4 revolution,

opening the cycling valve.

4. Using the appropriate reducers (National Pipe

thread), connect a source of compressed air (maximum

pressure 150 psi – minimum pressure 90 psi) to the wa-

ter inlets on either side of machine.

DANGER: Compressed air can penetrate the skin

and cause physical harm. Use extreme caution and

wear protective goggles and gloves when working

with high pressure air. Get prompt medical attention

if an injury occurs.

5. Let compressed air flow through the machine for 3

minutes. While compressed air is flowing, temporarily

open the spray wash and high pressure drain valve,

purging water from the spray wash and high pressure

system.

6. Disconnect compressed air and reducers. Reinstall

the drive shield previously removed and tighten the re-

lief valve tube.

7. Remove and drain the water filter container. Install

new filter and replace the filter container.

Engine

1. Drain the engine oil from the oil pan and replace the

drain cap.

2. Remove and discard the oil filter. Install a new filter.

3. Refill the engine with 3 qts. of recommended SAE

30 wt. motor oil.

4. Start the engine and run at idle speed for two min-

utes. DO NOT RUN LONGER THAN TWO MINUTES.

5. Stop the engine; remove the spark plugs.

6. Pour one ounce of clean engine oil into spark plug

holes.

7. With the spark plugs removed, crank the engine

with the starter for a least 12 revolutions to distribute oil

in the cylinders.

8. Reinstall spark plugs.

9. Drain the gasoline from the fuel tank and fuel lines.

Reinstall all lines and secure all connections.

10. Thoroughly clean and service the air cleaner.

11. Check the oil filler cap and fuel tank cap to ensure

they securely in place.

Traction Unit

1. Thoroughly clean machine.

2. Grease or oil all fittings or pivot points.

3. Check to make sure all tires are over inflated to 20 –

30 p.s.i.

4. Lightly sand and use touch up paint on all areas that

are scratched, chipped or rusted.

5. Drain and replace hydraulic oil and filter on cam

gear case.

6. Drain and replace oil in water pump case.

7. Clean the battery, terminals and posts with a wire

brush and baking soda solution. Coat cable terminals

and battery posts with skin over grease or petroleum jel-

ly. Recharge battery.

General Information Page 6 – 38 Hydroject 3010

Chapter 7

Wheels, Brakes and Steering

Table of Contents

ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 2 Brake Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Wheel Bearing Service . . . . . . . . . . . . . . . . . . . . 4

Hydroject 3010 Page 7 - 1 Table of Contents

Adjustments

Brake Adjustment (Fig. 1)

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

2. Remove screws securing cover to under side of tiller

handle. Remove cover.

3. Loosen upper jam nut securing brake cable to

bracket.

4. Tighten lower jam nut until 25 to 30 pounds of force

are required to actuate brake lever. Tighten jam nut.

5. Install lower cover.

Figure 1

1. Brake cable

Adjustments Page 7 - 2 Hydroject 3010

Repairs

Brake Service (Fig. 2)

1 2 3

13 14 15

Torque to

250 to 400 ft-lb.

23 24

Figure 2

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

engage the parking brake. Open the hood and discon-

nect engine spark plug wires. Lift drive wheel off the

ground using a jack. Block front and rear of other

wheels.

2. Remove wheel nuts (Item 23) and remove wheel.

Remove spindle nut (Item 22) from wheel hub.

3. Mount a wheel puller to wheel mount studs and

remove wheel hub (Item 19) and brake drum (Item 18).

Remove key (Item 7) from wheel motor shaft.

IMPORTANT: To prevent damage to wheel motor,

DO NOT hit wheel hub with a hammer during re-

moval or installation.

4. Remove brake shoe springs (Item 16) and brake

shoes (Item 17).

5. Repair or replace parts as necessary.

6. After installing brake shoes, install brake shoe springs

(Item 17) into holes on each brake shoe plate from the

outside. Springs should be installed in opposite direc-

tion of each other.

7. Mount key (Item 7) in wheel motor shaft so top of key

is in line with taper in shaft, then install wheel hub and

brake drum.

8. Install spindle nut (item 13) and tighten to a torque of

250 - 400 ft-lb.

9. Install wheel and secure with wheel nuts. Tighten

wheel nuts evenly in a crossing pattern to a torque of

40 to 50 ft-lb.

10. Adjust and check brakes.

Hydroject 3010 Page 7 - 3 Repairs

Wheel Bearing Service (Fig. 3)

1. Park machine on a level surface and raise wheels to

aerate position. Engage parking brake, open hood and

disconnect engine spark plug wires.

2. Remove dust cap (Item 28) from end of wheel spindle.

3. Remove cotter pin (Item 27), slotted nut (Item 29) and

washer (Item 30). Slide wheel and hub off of spindle

shaft.

4. Pull seal (Item 34) out of wheel hub (Item 23).

5. Remove bearings (Item 32) from both sides of wheel

hub. Clean bearings in solvent. Make sure the bearings

are in good operating condition. Clean inside of wheel

hub. Check bearing cups (Item 33) for wear, pitting or

other noticeable damage. Replace worn or damaged

parts.

6. If bearing cups were removed from wheel hub, press

them into hub until they seat against the shoulder.

7. Pack both bearings with grease. Use No. 2 general

purpose lithium base grease containing E.P. additive.

Install one bearing into cup on inboard side of wheel

hub. Lubricate inside of new lip seal and press it into

wheel hub.

IMPORTANT: The lip seal (Item 34) must be pressed

in so it is flush with end of hub. Lip of seal must be

toward the bearing.

8. Pack inside of wheel hub with some grease (not full).

Install remaining bearing into bearing cup.

9. Slide hub onto spindle shaft and secure it in place

with flat washer and slotted nut. DO NOT tighten nut or

install cotter pin.

10. Adjust pre-load on wheel bearings by rotating wheel

by hand and tightening slotted nut until bearing binds

SLIGHTLY. Then, loosen nut until nearest slot and hole

in spindle line up. Install cotter pin. Correct end play of

adjusted assembly is 0.002 to 0.005 inches.

11. Put a coating of grease on inside of dust cap and

install dust cap on end of wheel spindle.

26 27

24 25

28 29 30

Figure 3

Repairs Page 7 - 4 Hydroject 3010

Chapter 8

Electrical Diagrams

Table of Contents

Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Main Harness Drawing . . . . . . . . . . . . . . . . . . . . . . . . . 4

Main Harness Wiring Diagram . . . . . . . . . . . . . . . . . . 5

Control Panel Harness Drawing . . . . . . . . . . . . . . . . . 6

Control Panel Wiring Diagram . . . . . . . . . . . . . . . . . . . 7

Tiller Harness Drawing and Wiring Diagram . . . . . . . 8

Hydroject 3010 Page 8 – 1 Electrical Diagrams

Electrical

Diagrams

This page is intentionally blank.

Electrical Diagrams Page 8 – 2 Hydroject 3010

Page 8 – 3

Electrical Schematic

Hydroject 3010

Main Harness

Page 8 – 4

Page 8 – 5

Main Wiring Diagram

Hydroject 3010

Control Panel Harness

Page 8 – 6

Hydroject 3010

Tiller Wire Harness and Diagram

Page 8 – 7

BT 3010 Corel Ventura HJPREF.CHP User Manual To The Af744bf1 060e 4843 A7df 66d9b2648f55

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