Toro 5020 manual

P ART NO. 98957SL, Rev . B Service Manual Sand Pro R 2020/3020/5020 Preface The purpose of this publication is to provide the service technician with information for troubleshooting, testing, and repair of major systems and components on the Sand Pro 2020/3020/5020. REFER TO THE OPERA TOR’S MANUALS FOR OP- ERA TING, MAINTENANCE AND ADJUSTMENT INS[...]

Sand Pro 2020/3020/5020[...]

T able Of Contents Chapter 1 – Safety Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 1 Jacking Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 4 Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 – 5 Chapter 2 – Product Records and Manuals Product Records . . . . . . . . . . . .[...]

Sand Pro 2020/3020/5020[...]

Chapter 1 Safety T able of Contents GENERAL SAFETY INSTRUCTIONS . . . . . . . . . . . . 1 Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Maintenance and Service . . . . . . . . . . . . . . . . . . . . 3 General Safety Instructions The Sand Pro 2020[...]

While Operating 1 1. Exhaust fumes are hazardous and could be deadly , so do not run the engine in a confined area without ade - quate ventilation. 12. Sit on seat when operating the machine. Never carry passengers. 13. When starting the engine: A. Make sure traction pedal is released. B. After the engine is started, keep foot of f traction pedal. [...]

Maintenance and Service 20. Before servicing or making adjustments to the ma- chine, stop engine, remove key from the ignition, and pull the spark plug wire off spark plug to prevent acci - dental starting of the engine. 21. Make sure all hydraulic line connectors are tight,and all hydraulic hoses and lines are in good condition be - fore applying [...]

Jacking Instructions Figure 1 Use the following positions when jacking up the ma- chine: Jacking the Front End 1. On the SP 2020/3020 , jack from below the front cross support that is above the retaining strip for the rub - ber shield (Fig. 1). 2. On the SP 5020 , jack from below the front cross Figure 2 support tube on the bottom of the frame (Fig[...]

Safety and Instruction Decals The following safety and instruction decals are installed on the Sand Pro 2020/3020. If any become damaged or illegible, replace them. Decal part numbers are listed below and in the parts catalog. Order replacements from your Authorized T oro Distributor . ON ENGINE SHIELD (Part No. 95–0647) (Part No. 95–0646) ON N[...]

Safety and Instruction Decals The following safety and instruction decals are installed on the Sand Pro 5020. If any become damaged or illegible, replace them. Decal part numbers are listed below and in the parts catalog. Order replacements from your Authorized T oro Distributor . ON NEUTRAL ADJUST MECHANISM ON BOTH SIDES OF F AN SHROUD (2) (Part N[...]

Chapter 2 Product Records and Maintenance T able of Contents PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . 1 EQUIV ALENTS AND CONVERSIONS . . . . . . . . . . . 2 Decimal and Millimeter Equivalents . . . . . . . . . . . . 2 U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . 2 Product Records Record maintenance and r[...]

Equivalents and Conversions Product Records and Maintenance Page 2 – 2 Sand Pro 2020/3020/5020[...]

Product Records and Maintenance Sand Pro 2020/3020/5020 Page 2 – 3 Product Records and Maintenance T orque Specifications[...]

Sand Pro 2020/3020/5020 Page 2 – 4 Product Records and Maintenance Lubrication CAUTION Before servicing or making adjustments to the machine, stop engine, set parking brake, and re- move key from the ignition switch. Lubricate grease fittings regularly with No. 2 general purpose lithium base grease. Lubricate front wheel bearing and traction cont[...]

Sand Pro 2020/3020/5020 Page 2 – 5 Product Records and Maintenance Figure 5 Figure 6 Product Records and Maintenance[...]

Product Records and Maintenance Page 2 – 6 Sand Pro 2020/3020/5020[...]

_________________________ _________________________ _________________________ _________________________ _________________________ EQUIPMENT OPERA TION AND SERVICE HIST OR Y REPORT for Sand Pro R 2020/3020/5020 TORO Model and Serial Number: _____________–___________ Engine Numbers: _________________________ T ransmission Numbers: _________________[...]

Sand Pro R 2020/3020/5020 Maintenance Schedule Minimum Recommended Maintenance Intervals: Check Battery Fluid Level Check Battery Cable Connections { Change Engine Oil Lubricate Front Wheel Bearing Every 25hrs Every 100hrs Annual Recommendations: Items listed are recommended every 1,500 hours or 2 years, whichever comes first. Every 400hrs Replace [...]

Sand Pro R 2020/3020/5020 Daily Maintenance Checklist Daily Maintenance: (duplicate this page for routine use) Maintenance Check Item b Daily Maintenance Check For Week Of ____________ MON TUES WED THURS FRI SA T SUN n Safety Interlock Operation n Steering Operation n Engine Oil Level n Remote/Engine Air Cleaner Condition Clean Engine Cooling Fins [...]

________________________________ ________________________________ ________________________________ ________________________________ _______________________________ _______________________________ ________________________________ ________________________________ _______________________________ _______________________________ ________________________[...]

Chapter 3 Engine T able of Contents INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIFICA TIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GENERAL INFORMA TION . . . . . . . . . . . . . . . . . . . . . 4 Check Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Fuel Shutoff V alve . . . .[...]

Introduction This Chapter gives information about specifications, maintenance, troubleshooting, testing, and repair of the gasoline engines used in the Sand Pro 2020, 3020, and 5020. Most repairs and adjustments require tools which are commonly available in many service shops. Special tools are described in the Briggs and Stratton V anguard Repair [...]

Specifications Item Description Make / Designation Briggs and Stratton V anguard, 4–Cycle, V–T win Cylinder , OHV , Air Cooled, Gasoline Engine Horse Power SP 2020/3020 16 HP @ 3600 RPM SP 5020 18 HP @ 3600 RPM Bore mm (in.) SP 2020/3020 68.0 (2.677) SP 5020 71.98 (2.834) T otal Displacement cc (cu. in.) SP 2020/3020 480 (29.3) SP 5020 570 (34.[...]

General Information Check Engine Oil CAUTION Before servicing or making adjustments to the machine, make sure of the following: stop en- gine, engage parking brake, lower attachment, and remove key from the switch. IMPORT ANT : Check oil level every 8 operating hours or daily . Change oil initially after the first 8 hours of operation. Thereafter ,[...]

Fuel Shutoff V alve This valve should be shut when removing the engine or placing the unit in long term storage. On the SP 2020/3020 , the shutof f valve can be ac- cessed from the rear of the machine (Fig. 2). On the SP 5020 , the shutoff valve can be accessed by removing the left side panel (Fig. 3). 2 1 Figure 2 1. Fuel shutoff valve 2. Hydrauli[...]

Fill Fuel T ank IMPORT ANT : The T oro Company strongly recom- mends using fresh, clean, unleaded regular grade gasoline in T oro gasoline powered products. Un - leaded gasoline burns cleaner , extends engine life, and promotes good starting by reducing the build– up of combustion chamber deposits. Leaded gaso - line can be used if unleaded is no[...]

Adjustments Adjust Throttle Control Proper throttle operation is dependent upon the proper adjustment of the throttle control. Before adjusting the carburetor , assure throttle control is operating properly . 1. Pivot seat up. On the SP 2020/3020 , remove the en- gine shield. 2. Loosen cable clamp screw securing the cable to the engine. 3. Move rem[...]

Sand Pro 2020/3020/5020 Page 3 – 8 Engine Service and Repairs Change Engine Oil and Filter Change oil initially after the first 8 hours of operation. Thereafter , change oil every 25 hours and filter every 100 hours. 1. Park machine on a level surface. T urn engine off. 2. Pivot seat up. On the SP 2020/3020 , remove the en- gine shield. 3. Remove[...]

Service Remote Air Cleaner Inspect air cleaner filter element every 100 hours of op- eration. Replace every 400 hours or when dirty or dam- aged 1. Check air cleaner body and body for damage that could cause possible air leaks. Replace damaged air cleaner body or cover (see Remote Air Cleaner Remov - al and Installation). 2. Release latches securin[...]

Throttle and Choke Controls 1 9 3 7 2 8 1 1 4 4 4 6 5 2 2 Figure 10 1. Knob 4. Cap screw 7. Hex nut 2. Throttle control 5. Dash Panel (SP 2020/3020) 8. Lock Washer 3. Lock nut 6. Right fender (SP 5020) 9. Choke control Throttle Control Removal 1. Park machine on a level surface, lower attachment, stop engine, engage parking brake, and remove key fr[...]

Throttle Control Installation 1. Secure throttle control to the dash panel or right fender with both cap screws and lock nuts. Install throttle control knob to the throttle control lever (Fig. 10). 2. Connect throttle cable to the swivel on the engine. Attach cable to engine with clamp. Make sure not to tighten cap screw securing clamp and cable to[...]

Choke Control Installation 1. On the SP 2020/3020 insert choke cable and control through the dash panel. Secure choke control to the panel with lock washer and hex nut (Fig. 10). 2. On the SP 5020 , secure choke control to the dash panel or right fender with both cap screws and lock nuts. Install knob to the choke control lever (Fig. 10). 3. Connec[...]

Remote Air Cleaner (SP 2020/3020) Remote Air Cleaner Removal 1. Park machine on a level surface, lower attachment, stop the engine, engage parking brake, and remove the key from the ignition switch. 2. Remove three cap screws securing the hood to the front shield (Fig 19). Remove four cap screws securing the dash panel to the hood (Fig. 20). 3. Loo[...]

Remote Air Cleaner (SP 5020) Remote Air Cleaner Removal 1. Park machine on a level surface, lower attachment, stop the engine, engage parking brake, and remove the key from the ignition switch. 2. Loosen hose clamp. Remove air cleaner hose from the air cleaner body . 3. Remove both lock nuts, flat washers, and cap screws securing the mounting band [...]

Muffler (SP 5020) Muffler Removal 1. Park machine on a level surface, lower attachment, stop the engine, engage parking brake, and remove the key from the ignition switch. CAUTION avoid possible burns, allow engine and exhaust The muffler and exhaust pipe may be hot. T o system to cool before working on the muffler . 2. Access muffler from the rear[...]

Muffler (SP 2020/3020) Muffler Removal 1. Park machine on a level surface, lower attachment, stop the engine, engage parking brake, and remove the key from the ignition switch. 2. Chock front wheel to prevent machine from moving with both rear wheels jacked up. Jack up rear wheels enough to allow the muffler to be removed through the bottom of the [...]

Muffler Installation 1. Position muf fler through the bottom of the machine to the muffler bracket. Insert cap screw with flat washer through the muffler tab and then the muf fler bracket. Screw hex nut onto the cap screw , but do not tighten (Fig. 30). 2. Attach exhaust tube to the muffler . Attach exhaust tube to the exhaust manifold (Fig. 31). 3[...]

Sand Pro 2020/3020/5020 Page 3 – 18 Engine Fuel T ank (SP 2020/3020) Figure 32 1. Fuel cap 2. Fuel tank 3. Grommet 4. Fuel tank base 5. Lock nut 6. Philips pan head screw 7. Hose clamp 8. Fuel hose 9. Fuel hose clip 10. Wing nut 1 1. Flat washer 12. Battery clamp 13. Cap screw 14. Flat washer 15. Battery 16. Battery bolt 17. Lock nut 18. Cap scre[...]

Fuel T ank Removal (Fig. 32) 1. Park machine on a level surface, lower attachment, stop the engine, engage parking brake, and remove the key from the ignition switch. 2. Pivot seat up. Remove litter box (26) from the frame. 3. Disconnect and remove battery from the machine to prevent possible spillage of fuel on the battery (see Bat - tery Service [...]

Sand Pro 2020/3020/5020 Page 3 – 20 Engine Fuel T ank (SP 5020) Figure 34 1. Fuel tank 2. Fuel cap 3. Steering boot 4. Boot retainer 5. R–clamp 6. Self tapping screw 7. Fuel hose 8. Hose clamp 9. Fuel filter 10. Fuel hose 1 1. Hose clamp 12. R–clamp 13. Fuel hose 14. Fuel shutoff valve 15. Whiz cap screw 16. Cap screw 17. Flat washer 18. Grom[...]

3. Remove adjustment lever from tilt lock pin by first re- moving cap screw (Fig. 36). 4. Drain fuel tank as follows: A. Close fuel shutoff valve. B. Remove self tapping screw securing the fuel hose and R–clamp to the frame. C. Disconnect fuel hose leading from the fuel tank at the fuel shutoff valve. Use funnel and hose to drain the fuel into a [...]

Sand Pro 2020/3020/5020 Page 3 – 22 Engine Engine (SP 2020/3020) Figure 37 1. Muffler 2. Cap screw 3. Flat washer 4. Muffler clamp 5. Hex nut 6. Screen 7. Muffler bracket 8. Fuel hose 9. Pop rivet 10. Flat washer 1 1. Lock washer 12. Fuel hose 13. Cap screw 14. R–clamp 15. Engine base 16. Engine 17. Exhaust tube 18. Exhaust manifold 19. Air cle[...]

Engine Removal (Fig. 37) 1. Park machine on a level surface, lower attachment, stop engine, engage parking brake, and remove key from the ignition switch. 2. Pivot seat up. Remove engine cover . Remove move litter box from fuel tank base. 3. Disconnect and remove battery from the machine to prevent the possibility of the engine dropping on it (see [...]

Engine Installation (Fig. 37) CAUTION One person should operate the chain fall or hoist while the other person guides the engine into the frame. 1. Install engine (16) to the engine base (15). A. Attach a hoist or chain fall to the engine. IMPORT ANT : Make sure not to damage the engine, fuel and hydraulic lines, electrical harness, or other parts [...]

Replace Spark Plugs Replace spark plugs after every 800 operating hours or yearly , which ever occurs first. Recommended air gap is 0.030 inch (0.762 mm). Use a Champion RC 12YC spark plug or equivalent. NOTE: A spark plug usually lasts a long time. However , remove. Check spark plugs whenever the engine mal - functions. IMPORT ANT : A cracked, fou[...]

Sand Pro 2020/3020/5020 Page 3 – 26 Engine Engine (SP 5020) Figure 43 1. Air cleaner knob 2. Air cleaner cover 3. Cover seal 4. Air cleaner knob 5. Not used 6. Hex flange head screw 7. Cap screw 8. Lock washer 9. Pop rivet 10. Hot surface plate 1 1. Muffler shield 12. Screw 13. Exhaust deflector 14. Muffler 15. Screw 16. Exhaust gasket 17. Hose c[...]

Engine Removal (Fig. 43) 1. Park machine on a level surface, lower attachment, stop engine, engage, and remove key from the ignition switch. 2. Chock wheels to prevent the machine from moving. The brake assembly will be partially disassembled. CAUTION avoid possible burns, allow engine and exhaust The muffler and exhaust pipe may be hot. T o system[...]

10. Disconnect red positive cable cable (solenoid) from the starter (Fig. 47). 1 1. Remove lock nut and cap screw securing black ground wire and black battery cable (negative) to the en - gine block. Pull cable and harness clear of the engine (Fig. 47). 12. Remove remaining three lock nuts and cap screws securing the engine to its base. CAUTION One[...]

3. T ighten both set screws on the engine hub to secure 6. Install seat base with seat attached to the frame as hub to the engine shaft (Fig. 46). follows (Fig. 44): 4. Connect throttle control cable to the swivel and choke control cable to the choke lever (see Throttle and Choke Control Installation). A. Position base on machine. Secure base to fr[...]

Clean Cylinder Head Fins Avoid overheating and possible damage to the engine. Keep cooling fins on cylinder heads clean. 1. Park machine on a level surface, lower attachment, stop engine, engage parking brake, and remove key from the ignition switch. 2. Gain access to the engine. NOTE: The engines on the SP 2020/3020 and SP 5020 are constructed the[...]

Chapter 4 Hydraulic Systems T able of Contents SPECIFICA TIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMA TION . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic Fitting Installation . . . . . . . . . . . . . . . . . . . 3 T owing T raction[...]

Rev . B Sand Pro 2020/3020/5020 Hydraulic System Page 4 – 2 Specifications Item Description Hydrostatic T ransmission V ariable displacement piston pump Pump Displacement 0.913 in 3 /rev (15.0 cm 3 /rev) Pump Flow Rate (@ 3150 RPM) 12.5 GPM (47.2 LPM) Maximum Continuous Rated Speed 4000 RPM Maximum Intermittent Rated Speed 4200 RPM Maximum Operat[...]

General Information Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials du ring 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 dete - rioration. Some hoses are more suscept[...]

SAE Straight Thread O–Ring Port – Non–adjustable 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 fit- ting shows signs of leakage. 3. Lubricate the O–ring with a light coating of oil. 4. Install t he fitting i nto the port and [...]

T owing T raction Unit In case of emergency , the Sand Pro can be towed for a short dis t ance. However , T oro does not recommend this as a standard procedure. IMPORT ANT : Do not tow the machine faster than 2 to 3 mph because drive system may be damaged. If machine must be moved a considerable distance, transport it on a truck or trailer . Tires [...]

Rev . B Sand Pro 2020/3020/5020 Hydraulic System Page 4 – 6 Hydraulic Schematics LIFT CYLINDER LIFT V AL VE OIL COOLER FIL TER M2 RIGHT A B A RH WHEEL MOTOR WITH BLEED OFF FOR OIL COOLING LEFT M1 IN FORW ARD P1 B P2 R2 R1 HYDROST A T 0.915 0.33 7.8 15 5.41 127.84 BARS 7.8 127.84 DISPLACEMENT PRESSURE COMPONENT P1 DISPLACEMENT , FLOW RA TE, AND PR[...]

LIFT V AL VE Sand Pro 5020 Hydraulic Schematic LIFT CYLINDER Sand Pro 2020/3020/5020 Page 4 – 7 M3 M2 RIGHT B A A WITH BLEED OFF FRONT LEFT M1 P1 B P2 R2 R1 0.915 0.33 8.6 15 5.41 140.93 BARS 8.6 140.93 DISPLACEMENT PRESSURE COMPONENT P1 P2 M1 M2 M3 17.1 280.22 in /rev cm /rev lbs/in 2 3 3 GPM LPM 12.48 4.5 47.2 17 – – – – – – – –[...]

Hydraulic Flow Diagrams T raction Forward The traction circuit of the hydraulic system consists of a hydrostat connected in a closed loop circuit to three or - bital vane wheel motors. Hydraulic fluid losses are de- signed to occur from case drain leakage of the traction pump (P1) and bleed of f from the right wheel motor (M1). These losses are rep[...]

Sand Pro 2020/3020/5020 Page 4 – 9 M2 RIGHT A B A WITH BLEED OFF LEFT M1 P1 B P2 R2 R1 M3 FRONT High Pressure Low Pressure (Charge) Return or Suction Flow Sand Pro 2020/3020/5020 M3 M2 RIGHT B A WITH BLEED OFF FRONT LEFT M1 TIMED MANIFOLDS B A SHUTTLE CHARGE CHECK CHARGE CHECK CHARGE PUMP TRACTION PUMP IMPLEMENT RELIEF CHARGE RELIEF Hydraulic Sys[...]

T raction Reverse The traction circuit operates essentially the same in re- verse as it does in forward. However , there are a few dif- ferences in operation. When the traction pedal is pressed to the reverse posi- tion, the linkage from the pedal positions the swash plate in the traction pump so oil flows out of port A. Oil flow out of port A goes[...]

Sand Pro 2020/3020/5020 M2 RIGHT A B A WITH BLEED OFF LEFT M1 P1 B P2 R2 R1 M3 FRONT REVERSE High Pressure Low Pressure (Charge) Return or Suction Flow Sand Pro 2020/3020/5020 M3 M2 RIGHT B A WITH BLEED OFF FRONT LEFT M1 TIMED MANIFOLDS B A SHUTTLE CHARGE CHECK CHARGE CHECK CHARGE PUMP TRACTION PUMP IMPLEMENT RELIEF CHARGE RELIEF Hydraulic Systems [...]

Retract and Extend Lift Cylinder The hydraulic lift circuits for the SP 2020/3020 and SP 5020 function identically . Each machine has identical charge pumps, lift valves, and lift cylinders. These com - ponents are the heart of the lift circuit. In addition to replenishing the closed loop circuit with fluid from the tank, charge pump (P2) flow in e[...]

Sand Pro 2020/3020/5020 Page 4 – 13 M2 RIGHT A B A WITH BLEED OFF LEFT M1 P1 B P2 R2 R1 M3 FRONT Extend and Retract lift Cylinder High Pressure Low Pressure (Charge) Sand Pro 2020/3020 FROM CHARGE RELIEF (R2) COOLER EXTEND LIFT CYLINDER RETRACT LIFT CYLINDER SHUTTLE IMPLEMENT RELIEF CHARGE RELIEF CHARGE CHECK RELIEF CHARGE CHECK RELIEF CHARGE PUM[...]

Special T ools Order these tools from the TORO SPECIAL T OOLS Some tools may also be available from a local supplier . AND APPLICA TIONS GUIDE (COMMERCIAL PROD- UCTS) . Hydraulic Pressure T est Kit – TOR47009 Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machin[...]

Hydraulic T est Fitting Kit – TOR4079 This kit includes a variety of O–ring Face seal fittings to enable you to connect test gauges into the system. The kit includes: tee’s, unions, reducers, plugs, caps, and male test fittings. Figure 10 TORO TEST FITTING KIT (NO. T OR4079) Hydraulic T est Fittings On the SP 2020/3020 , there is tight cleara[...]

Rev . B Sand Pro 2020/3020/5020 Hydraulic System (Rev . A) Page 4 – 16 T roubleshooting The table that follows contains information to assist in troubleshooting. There may possibly be more than one cause for a machine malfunction. Refer to the T esting section of this Chapter for precau- tions and specific test procedures. Problem Possible Cause [...]

Sand Pro 2020/3020/5020 Hydraulic System (Rev . A) Page 4 - - 17 T roubleshooting (cont.) Problem Possible Cause System operates in a jerky manner when starting. External control linkage is misadjusted, disconnected, binding, or damaged. Charge valve in hydrostat is defective. Acceleration valves in hydrostat are defective. No traction exists in ei[...]

Rev . B Sand Pro 2020/3020/5020 Hydraulic System (Rev . A) Page 4 – 18 T roubleshooting (cont.) Problem Possible Cause Attachment raises, but will not stay up. Lift cylinders leak internally . Neutral position check valves in lift valve leak. Difficult to make slight changes when raising and lowering the at- tachment (Sand Pro 2020 and 3020). Opt[...]

T esting 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 T ools section in this Chapter). Before Performing Hydraulic T ests IMPORT ANT : All obvious areas such as oil supply , filt[...]

TEST NO. 1: T raction Pump Flow (P1) A P1 B P2 R2 R1 IMPLEMENT RELIEF CHARGE RELIEF CHARGE CHECK CHARGE CHECK CHARGE PUMP TRACTION PUMP TO WHEEL FROM WHEEL FROM SHUTTLE TO LIFT FROM OIL COOLER 3 1 2 HYDROST A T FORW ARD ACCELERA TION V ALVES VA LV E VA LV E MOTORS MOTORS VA LV E VA LV E FIL TER T ANK Figure 12 1. Hydrostat (SP 2020/3020) 2. Forward[...]

Procedure for T raction Pump Flow (P1) (Fig.12): 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. 2. M a ke sure machine is parked on a level surface with attachments removed. Make sure engine is off. 3. Read Precautions for Hydraulic T esting. 4. M ak e sure that traction pedal [...]

TEST NO. 2: Charge Relief V alve (R2) and Implement Relief V alve (R1) Pressure A P1 B P2 R2 R1 IMPLEMENT RELIEF CHARGE RELIEF CHARGE CHECK CHARGE CHECK CHARGE PUMP TRACTION PUMP FROM SHUTTLE TO LIFT FROM OIL COOLER PRESSURE GAUGE HYDROST A T FORW ARD ACCELERA TION V ALVES VA LV E VA LV E VA LV E VA LV E FIL TER T ANK FROM WHEEL MOTORS TO WHEEL MOT[...]

Rev . B Sand Pro 2020/3020/5020 Hydraulic System (Rev . A) Page 4 – 23 Procedure for Charge Relief V alve (R2) and Imple- ment Relief V alve (R1) Pressure : 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. 2. Park machine on a level surface with the attach- ments lowered. Make [...]

TEST NO. 3: Charge Pump (P2) Flow A P1 B P2 R2 R1 IMPLEMENT RELIEF CHARGE RELIEF CHARGE CHECK CHARGE CHECK CHARGE PUMP TRACTION PUMP TO WHEEL FROM WHEEL FROM SHUTTLE TO LIFT FROM OIL COOLER 1 2 3 4 HYDROST A T FORW ARD ACCELERA TION V ALVES VA LV E VA LV E MOTORS MOTORS VA LV E VA LV E FIL TER T ANK Figure 14 1. Lift valve (SP 2020/3020) 3. Lift va[...]

Procedure for Charge Pump (P2) Flow : 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. 2. M a ke sure machine is parked on a level surface with the attachments lowered. Make sure engine is off and the parking brake is engaged. 3. Read Precautions for Hydraulic T esting. 4. Discon[...]

TEST NO. 4: Wheel Motor Efficiency 3 1 2 M3 M2 RIGHT B A A FRONT LEFT M1 P1 B P2 R2 R1 IMPLEMENT RELIEF CHARGE RELIEF CHARGE CHECK CHARGE CHECK CHARGE PUMP TRACTION PUMP SHUTTLE FROM OIL COOLER TO LIFT FIL TER HYDROST A T FORW ARD ACCELERA TION V ALVES T ANK VA LV E VA LV E HOT OIL VA LV E VA LV E Figure 15 1. Hydrostat (SP 2020/3020) 2. Forward he[...]

Procedure for Wheel Motor Efficiency : Note: Over a period of time, a wheel motor can wear internally . A worn motor may by–pass oil causing the motor t o b e l ess ef ficient. Eventually , enough oil loss will cause the wheel motor to stall under heavy load condi - tions. Continued operation with a worn, inef ficient motor can generate excessive[...]

Adjustments Adjust T raction Pedal for Neutral If the machine “creeps” when the traction pedal is in the neutral position, the traction cam must be adjusted. 1. Park the machine on a level surface. Turn the en- gine off. 2. On the SP 2020/3020 , pivot seat upward and re- mov e engine shield. On the SP 5020 , remove three cap screws securing sid[...]

Adjust T raction Pedal for Forward (SP 5020) If the jam nuts on the control rod are loosened or if the pedal is removed, adjusted traction pedal for forward. 1. Park machine on a level surface and turn engine of f. 2. Make sure pump is in neutral. 3. Loosen jam nuts on the control rod. 4. Press down on the forward pad of the pedal until the pedal r[...]

Sand Pro 2020/3020/5020 Hydraulic System (Rev . A) Page 4 – 30 Adjust Lift Lever (SP 2020/3020) The lift lever should be adjusted if the attachment does not float (follow ground contour) properly during opera- tion. 1. Park machine on a level surface. T urn engine off and engage parking brake. 2. Disconnect at t achment from lift cylinder . Exten[...]

Service and Repairs Check Hydraulic Lines and Hoses nozzles that eject hydraulic fluid under high pres- sure. Use paper or cardboard, not hands, to within a few hours by a doctor familiar with this W ARNING Keep body and hands away from pin hole leaks or search for leaks. Hydraulic fluid escaping under pressure can have sufficient force to penetrat[...]

13. After the hydraulic system starts to show signs of fill, actuate lift control lever until the lift cylinder rod moves in and out several times. If the cylinder rod does not move after 10 to 15 seconds, or the pump emits abnor - mal sounds, shut the engine off immediately and deter- mine cause or problem. Inspect for the following: A. Loose filt[...]

Change Hydraulic System Fluid and Filter The hydraulic system filter must be changed initially af- ter the first 8 hours of operation. Thereafter , it must be changed every 400 hours of operation or yearly , which - ever comes first. Use a genuine T o ro oil filter for replace- ment. The hydraulic oil must be changed every 400 hours of operation or[...]

Sand Pro 2020/3020/5020 Hydraulic System (Rev . A) Page 4 – 34 Lift V alve (SP 2020/3020) 1. Control panel decal 2. Lift valve shroud 3. Cap screw 4. 90 o hydraulic fitting 5. Knob 6. Lift lever 7. Cap screw 8. Offset link 9. Pivot bracket 10. Lock nut 1 1. Lock nut 12. Swivel run T–fitting 13. 45 o hydraulic fitting 14. Lift valve 15. Cap scre[...]

Removal (Fig. 25) 1. Before removing any parts from the hydraulic sys- tem, park machine on a level surface, engage parking brake, lower attachment, and stop engine. CAUTION draulic oil. Controls must be operated with the tion switch. Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy- ignition switch in [...]

Sand Pro 2020/3020/5020 Hydraulic System (Rev . A) Page 4 – 36 Lift V alve (SP 5020) 1. Lock nut 2. 90 o hydraulic fitting 3. Cap screw 4. Lock nut 5. Lever knob 6. Pivot bracket 7. Cap screw 8. Hydraulic orifice fitting 9. Hydraulic straight fitting 10. Hydraulic T–fitting 1 1. LIft valve 12. Offset link 13. Bulkhead bracket 14. Self tapping s[...]

Removal (Fig. 26) 1. Before removing any parts from the hydraulic sys- tem, park machine on a level surface, engage parking brake, lower attachment, and stop engine. CAUTION draulic oil. Controls must be operated with the tion switch. Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy- ignition switch in [...]

Lift V alve 1 2 3 4 5 6 7 12 15 14 1 2 8 9 9 10 4 11 12 13 14 15 3 5 6 9 8 7 9 10 11 13 Figure 27 1. Plug 6. Cam pin 1 1. Spring 2. O–ring 7. Body 12. Spring retainer 3. Spring 8. Spool 13. Spacer float 4. Ball 9. O–ring 14. Spool retaining ring 5. Check valve seat 10. Spring retainer 15. Retaining ring Disassembly 1. W ash valve in solvent and[...]

Lift Cylinder (SP 2020/3020) Removal 6 1. Before removing any parts from the hydraulic sys- tem, park the machine on a level surface, engage the parking brake, lower attachment, and stop the engine. 1 2 6 5 8 3 6 6 4 4 1 7 CAUTION draulic oil. Controls must be operated with the tion switch. Operate all hydraulic controls to relieve system pressure [...]

Lift Cylinder(SP 5020) Removal 1. Before removing any parts from the hydraulic sys- tem, park the machine on a level surface, engage the parking brake, lower the cutting units, and stop the en - gine. CAUTION draulic oil. Controls must be operated with the tion switch. Operate all hydraulic controls to relieve system pressure and avoid injury from [...]

Lift Cylinder Service 1 14 2 3 4 5 7 8 9 10 11 12 6 2 7 3 5 4 6 10 11 13 14 13 15 15 8 9 12 Figure 30 1. O–ring 6. O–ring 2. Barrel 7. Poly–pack 3. Nut 8. O–ring 4. Uni–ring 9. Back–up ring 5. Piston 10. Head Disassembly 1. Remove oil from the hydraulic cylinder into a drain pan by slowly pumping the cylinder shaft. Plug both ports and [...]

22 Hydrostat (SP 2020/3020) 27 28 30 15 2 4 5 6 7 12 14 15 16 17 18 20 21 23 24 25 26 8 9 10 11 13 3 3 16 17 18 19 19 20 31 32 29 33 34 29 FRONT RIGHT Figure 31 1. Not used 13. 90 o hydraulic fitting 24. Pump hub 2. Shaft cover 14. Hydraulic hose 25. Pump mount 3. Lock washer 15. Cap screw 26. Woodruff key 4. Hydraulic hose 16. Lock nut 27. Hex nut[...]

7. Remov e three cap screws securing the pump plate to the hydrostat while pulling the pump plate from the h y - drostat (Fig. 32). 8. Clean all hydraulic fittings and hydraulic hoses at- tached to t he hydrostat. Label all hydraulic connections for reassembly . 9. Place a suitable container under hydrostat to collect hydraulic oil. 10. Clamp sucti[...]

Sand Pro 2020/3020/5020 Hydraulic System (Rev . A) Page 4 – 44 Hydrostat (SP 5020) 1. Hydraulic hose (to front motor) 2. O–ring 3. Hydraulic tube 4. Not used 5. Hydraulic tube 6. 90 o hydraulic fitting 7. O–ring 8. Hydrostat 9. Woodruff key 10. Lock nut 1 1. Set screw 12. Hex nut 13. Coupler spacer 14. Rubber coupler 15. Cap screw 16. Couplin[...]

5. Disconnect air hose from the air cleaner . Remove lower shroud from the cooler mount to prevent damage to the fan when removing the hydrostat. 6. Disconnect control rod from pump lever and wires from the neutral switch (Fig. 36). 7. Loosen both set screws (1 1) on the pump hub (19) enough to allow the hydrostat shaft to be released. 8. Clamp hyd[...]

3. Reinstall O–rings and hydraulic fittings to the hy- drostat. Observe match marks when tightening. 4. Install woodruff key (9) and fan hub ( 27) with cooling fan (28) to the hydrostat shaft. Secure hub to shaft with both set screws. 5. Secure hydrostat (8) to engine base with both sock- et head screws (20) and lock nuts (10). 6. Reinstall engin[...]

Flush Hydraulic System IMPORT ANT : Flush hydraulic system any time there is a severe component failure or the system is contaminated (oil appears milky or black or con - tains metal particles). IMPORT ANT : Flush hydraulic system when chang- Ing from petroleum base hydraulic fluid. Operate machine under normal operating conditions for at least fou[...]

Rev . B Sand Pro 2020/3020/5020 Hydraulic System (Rev . A) Page 4 – 48 Hydrostat Service 1. Plug 2. O–ring 3. Spring 4. Ball 5. Plug 6. O–ring 7. End cap 8. Acceleration valve spring 9. Acceleration valve 10. O–ring 1 1. Plug 12. O–ring 13. Locating pin 14. End cap gasket 15. V alve plate 16. Cylinder block 17. Spider 18. Piston assembly [...]

Charge Pump Disassembly 1. Make sure hydrostat is cleaned thoroughly before disassembly to prevent contamination. 2. Match mark charge pump housing and variable housing for reassembly . 3. Clean shaft to remove all sharp edges, burrs, dirt, and abrasive residue that could damage the lip seal. 4. Remov e both cap screws securing the pump hous- ing t[...]

Shaft Seal Removal NOTE: The hydrostat uses lip seals on the main, con- trol, and trunnion shafts. Replacement of these seals re- quires no disassembly . 1. Wh en replacing trunnion shaft seals, remove retain- ing ring and washer from the housing and shaft. 2. Pry lip seal carefully off the shaft. Make sure not to distort the housing or damage the [...]

Acceleration V alve Removal (Fig. 43) 1. Remove plugs and O–rings from both sides of the end cap. 2. Slide acceleration valve and spring out of one side of the end cap. Slide other valve out the other side. Acceleration V alve Inspection (Fig. 43) 1. Inspect valves for cracks, bending, and plugged holes. Clean out plugged holes; be careful not to[...]

T raction Pump Disassembly 1. Remove charge pump from variable housing (see Charge Pump Disassembly). 2. Remove lip seals from shaft and trunnion shafts (see Shaft Seal Removal). IMPORT ANT : All exposed surfaces are critical. Use caution to avoid damage to exposed surfaces. 3. R em ov e four cap screws and washers from the end cap. Loosen cap scre[...]

T raction Pump Inspection 1. Inspect end cap (Fig. 45). A. Bearing needles must remain in the cage, roll freely , and not be bent or damaged. Remove and re - place bearings as necessary . B. Journal bearing must be free of damage. C. Needle and journal bearings should protrude be- yond face from 3/32 to 1/8 inch (2.38 to 3.18 mm). 2. Inspect valve [...]

11 T raction Pump Assembly 1. Ma ke sure all parts are cleaned thoroughly and free of dirt and debris. 2. Secure ball bearing onto shaft with retaining ring. Press assembly into variable housing. Snap retaining ring into housing to secure bearing and shaft (Fig. 49). IMPORT ANT : Make s u re n ot to damage the face sur- face on the cavity side of t[...]

NOTE: Wh en properly installed, a light spring compres- sion can be felt when pushing the cylinder block assem- bly into the variable housing. 9. Position variable housing in a horizontal position. Slide cylinder block assembly over the shaft engaging splines. Make sure pistons and thrust plate remain in place (Fig. 51). 10. Press needle bearing in[...]

Front Wheel Motor 15 12 11 8 18 21 16 20 14 22 1 4 6 9 5 10 7 17 2 3 19 FRONT RIGHT 45 to 55 ft–lb 6.2 to 7.6 kg–m 200 to 400 ft–lb 27.7 to 55.3 kg–m Figure 53 1. Hydraulic motor 9. Relube flangette 16. Spindle 2. 45 o hydraulic fitting 10. Flangette 17. Bearing 3. Hydraulic hose 1 1. Bearing tab 18. Lug nut 4. O–ring 12. Front wheel fork[...]

8. R em ov e both socket head screws and lock nuts se- curing the hydraulic motor the fork. W ARNING Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 – Safety . IMPORT ANT : Support wheel and motor when jack- ing up the front fork to prevent dropping and dam- aging the motor . 9. Jack up fork slowly until the hyd[...]

Sand Pro 2020/3020/5020 Hydraulic System (Rev . A) Page 4 – 58 Rear Wheel Motors (SP 2020/3020) 1. Lug nut 2. Drive stud 3. Wheel 4. Wheel hub 5. Lock nut 6. Left wheel motor 7. Right wheel motor 8. Brake drum 9. Woodruff key 10. Cotter pin 1 1. Clevis pin 12. Brake lever 13. Clevis 14. 45 o hydraulic fitting 15. 90 o hydraulic fitting 16. Shuttl[...]

Removal (Fig. 57 or 55) 1. Before removing any parts from the hydraulic sys- tem, park the machine on a level surface, lower attach- ment, and stop the engine. CAUTION draulic oil. Controls must be operated with the tion switch. Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy- ignition switch in OFF . [...]

Sand Pro 2020/3020/5020 Hydraulic System (Rev . A) Page 4 – 60 Rear Wheel Motors (SP 5020) 1. O–ring 2. O–ring 3. O–ring 4. O–ring 5. Woodruff key 6. Brake lever 7. Not used 8. Left wheel motor 9. Hydraulic tube 10. Hydraulic tube 1 1. Hydraulic straight fitting 12. Right wheel motor 13. Hydraulic straight fitting 14. Hydraulic tube 15. T[...]

Removal (Fig. 57 or 58) 1. Before removing any parts from the hydraulic sys- tem, park the machine on a level surface, lower attach- ment, and stop the engine. CAUTION draulic oil. Controls must be operated with the tion switch. Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy- ignition switch in OFF . [...]

Sand Pro 2020/3020/5020 Hydraulic System (Rev . A) Page 4 – 62 Wheel Motor Service 1. Dirt & water seal 2. Bearing 3. Housing 4. Back–up washer 5. Seal ring 6. Back–up washer 7. Inner seal 8. Thrust washer 9. Thrust bearing 10. Bearin g 1 1. Coupling shaft 12. Thrust bearing 13. Drive link 14. Cap screw 15. Commutator seal 16. Commutator [...]

Disassembly (Fig. 60) it could dislodge during service and cause in- W ARNING If the wheel motor is not held firmly in the vise, jury . 1. Place wheel motor in a soft jawed vice with the cou- pling shaft (1 1) point ed down and the vise jaws clamping firmly on the sides of the housing (3). 2. Scribe an alignment mark down and across the wheel motor[...]

9. Remove seal ring (5) that is between the rotor set and wearplate (18). 10. Remove drive link (13) from the coupling shaft (1 1) if it was not removed with rotor set and wear plate (18). Remove seal ring (5) from housing (3). 1 1. Rem ov e thrust bearing (12) from the top of the cou- pling shaft (1 1). 12. Check exposed portion of coupling shaft [...]

6. Inspect manifold (22) for cracks, surface scoring, peening, chipping. Replace manifold if any of these conditions exist. A polished pattern on the ground sur - face from commutator or rotor rotation is normal. NOTE: The rotor set consists of the rotor (19), vanes (20), and stator (21). Rotor set components may be - come disassembled during servi[...]

14. If the housing (3) has passed inspection to this point, inspect outer bearing (2), inner bearing (10), thrust washers (8), and thrust bearing (9). Bearing roll - ers m ust be firmly retained in the bearing cages but must rotate and orbit freely . All rollers and thrust washers must be free of peening and corrosion. If any bearing or thrust wash[...]

6. Apply masking tape around splines or keyway on coupling shaft (1 1) to prevent damage to seal. IMPORT ANT : The outer bearing (2) is not lubricated by the system’s hydraulic fluid. Make sure it is thor - oughly packed with Mobil Mobilith SHC R 460 grease. NOTE: Coupling shaft (1 1) should be approximately 0.10 inch (2.54 mm) below the housing [...]

NOTE: The rotor set consists of the rotor (19), vanes (20), and stator (21). Rotor set components may be - come disassembled during service procedures. Do not service separately . NOTE: It may be necessary to turn one alignment stud out of the housing (3) temporarily to assemble rotor set over the drive link (13). NOTE: The rotor set rotor counterb[...]

E. Grasp the output end of coupling shaft (1 1) with 23. T orque both plugs from 9 to 12 ft–lb (1.2 to 1.7 locking pliers or other appropriate turning device. kg–m). Rotate coupling shaft, drive link (13), and rotor (19) to seat the rotor and the assembled vanes (20) into 24. Check m otor shaft for rotation. T orque require to ro - the stator ([...]

Sand Pro 2020/3020/5020 Hydraulic System (Rev . A) Page 4 – 70 Hydraulic T ank (SP 2020/3020) 1. Oil cap 2. Shoulder screw 3. Worm clamp 4. Hydraulic tank 5. 45 o hydraulic fitting 6. Cap screw 7. Lock washer 8. Filter head 9. Flat washer 10. Cap screw 1 1. 90 o hydraulic fitting 12. Oil fitting 13. Hydraulic fitting 14. Hydraulic hose 15. Lock n[...]

Removal (Fig. 86) 1. Before removing any parts from the hydraulic sys- tem, park machine on a level surface, set brake, lower attachment, and stop engine. CAUTION draulic oil. Controls must be operated with the tion switch. Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy- ignition switch in OFF . Remov[...]

Sand Pro 2020/3020/5020 Hydraulic System (Rev . A) Page 4 – 72 Hydraulic Oil Cooler (SP 2020/3020) 1. Hood 2. Oil cooler 3. Rubber clamp 4. T–nut 5. 90 o hydraulic fitting 6. V alve to cooler tube 7. Operating decal 8. Cover 9. Flat head screw 10. Flat washer 1 1. Cap screw 12. Lock nut 13. Floor tread 14. Flat head screw 15. Cap screw 16. Spac[...]

Removal (Fig. 87) 1. Before removing any parts from the hydraulic sys- tem, park machine on a level surface, set brake, lower attachment, and stop engine. CAUTION draulic oil. Controls must be operated with the tion switch. Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy- ignition switch in OFF . Remov[...]

Sand Pro 2020/3020/5020 Hydraulic System (Rev . A) Page 4 – 74 Hydraulic T ank and Oil Cooler (SP 5020) 1. T ether retainer 2. T ether 3. T ank cap 4. Filler screen 5. O–ring 6. 90 o Hydraulic fitting 7. Hose clamp 8. O–ring 9. 90 o hydraulic fitting 10. 90 o hydraulic fitting 1 1. Hydraulic hose 12. Hose clamp 13. Lock washer 14. Cap screw 1[...]

2 CAUTION drostat from the frame. One person should operate the chain fall or jack while the other person guides the engine and hy- 3. Plug both ends of oil cooler . Clean exterior of cooler . Make sure fins are clear of dirt and debris. 4. The oil cooler should be free of corrosion, cracked tubes, and excessive pitting of tubes. IMPORT ANT : When [...]

Oil Cooler Installation (Fig. 88) 1. Make sure both hydraulic openings to the oil cooler are clean. Remove plugs from the cooler openings. 2. Reinstall O–r i ngs and 90 o hydraulic fittings to the oil cooler . T orque fittings from 36 to 40 ft–lb (5.0 to 5.5 kg–m). 3. Secure oil cooler to cooler mount (25) with rubber clamps (35), socket head[...]

Chapter 5 Electrical Systems T able of Contents ELECTRICAL SCHEMA TICS AND DIAGRAMS . . . 2 ELECTRICAL SYSTEM QUICK CHECKS . . . . . . . . 9 Sand Pro 2020/3020 Electrical Schematic . . . . . . 2 Battery T est (Open Circuit) . . . . . . . . . . . . . . . . . . . 9 Sand Pro 2020/3020 COMPONENT TESTING . . . . . . . . . . . . . . . . . . . . . . 10 Ha[...]

BLACK Sand Pro 2020/3020/5020 Page 5 – 2 Electrical Systems OPTIONAL LIGHTS BLUE/WHITE BLACK BLACK BLACK BLACK RED/WHITE BLUE BLUE GREEN RED BLACK – + NEUTRAL SWITCH FUSE (20 AMP) RED RED WHITE RED SOLENOID HOUR METER IGNITION SWITCH BLUE + – ENGINE FUEL REG. GROUND SOLENOID M B L A S G OFF RUN B+L+A B+L+S IGNITION SWITCH POSITION TERMINAL CO[...]

HOUR ST ART METER SOLENOID GROUND FUSE ENGINE J3 J4 J5 J6 J7 J8 P1 P3 P4 J1 1 1 1 1 1 1 1 A B 1 1 1 W8 W10 W2 W3 W14 W13 W5 W6 W5 W7 W10 W12 W1 W4 W4 1 W3 J12 NEUTRAL SWITCH W14 1 W6 J13 W8 W1 W9 B S W13 IGNITION W12 M P2 SWITCH L G SP1 W9 W7 J2 A W1 1 W1 1 W2 1 1 J15 J14 HOUR OPTIONAL METER LIGHTS J3 J4 XXX SOLENOID J6 P1 FUSE J5 J7 LIGHTS AB XXX [...]

OPTIONAL (–) (+) HR SP SPLICE FUSIBLE LINK FL ENGINE FUEL REG. SP FL FUSE 10 A S L B A M G FL SP (–) (+) FRAME FRAME NEUTRAL (CLOSED IN NEUTRAL) OFF RUN G+M+A B+L+A B+L+S IGNITION SWITCH POSITION TERMINAL CONTINUITY Electrical Schematic Sand Pro 5020 All relays and solenoids are shown as de–energized. All ground wires are black. SOLENOID GROU[...]

ENGINE METER SOLENOID GROUND AL T FUEL MAGNETO HOUR STAR T FRAME FUSE J3 J4 J6 J5 J7 J8 P1 P3 P4 J1 1 WIRE IDENTIFICA TION LABEL COLOR A WG TYPE W1 N/A 18 FUSABLE LINK ROUTE J7 TO SP1 Sand Pro 5020 W2 RED 14 GPT W3 RED/WHT 14 GPT SP1 TO J2 TO P2–5 SP2 Harness and Wiring Diagram W4 N/A 18 FUSABLE LINK SP2 TO P3–1 W5 BLU 18 GPT P2–2 T O J1 1 W6[...]

Special T ools Order special tools from the TORO SPECIAL TOOLS Some tools may also be available from a local supplier . AND APPLICA TIONS GUIDE (COMMERCIAL PROD- UCTS) . Multimeter The meter can test electrical components and circuits for current, resistance, or voltage. NOTE: T oro recommends the use of a DIGIT AL V olt– Ohm–Amp multimeter whe[...]

T roubleshooting CAUTION Remove all especially rings and watches, before doing any electrical trouble- cables unless the test requires battery voltage. jewelry , shooting or testing. Disconnect the battery For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and components used on this machine (se[...]

Starting Problems (continued) Problem Possible Causes Engine cranks, but does not start. Wiring to start circuitry (see Wiring Schematics) is loose, corroded, or damaged. 10 ampere fuse is missing or open (SP 5020). Ignition switch is faulty . Fuel solenoid is faulty . Spark plugs are faulty . Engine or fuel system is malfunctioning (see Chapter 4 [...]

Electrical System Quick Checks Battery T est (Open Circuit T est) Use a multimeter to measure the voltage between the battery terminals. Set multimeter to the DC volts setting. The battery should be at a temperature of 60 to 100 _ F (16 to 38 _ C). The ignition key should be off and all accessories turned off. Connect the positive (+) meter lead to[...]

Component T esting For accurate resistance and/or continuity checks, elec- trically disconnect the component being tested from the circuit (e.g. unplug the ignition switch connector before doing a continuity check). NOTE: For more component testing information, see the Briggs and Stratton V anguard Service and Repair Manual for 4–Cycle, V–T win[...]

Hour Meter IMPORT ANT : Make sure to observe polarity on the meter label when testing. Damage to the meter may result from an improper connection. 1. Connect the positive (+) terminal of a 12 VDC source to the positive terminal of the hour meter . 2. Connect the negative (–) terminal of the voltage source to the other terminal of the hour meter .[...]

Starter Solenoid NOTE: Prior to taking small resistance readings with a digital multimeter , short the test leads together . The me - ter will display a small resistance value (usually 0.5 ohms or less). This resistance is due to the internal re - sistance of the meter and test leads. Subtract this value from from the measured value of the componen[...]

Service and Repairs NOTE: For more component repair information, see the Briggs and Stratton V anguard Service and Repair Manual for 4–Cycle, V–T win Cylinder , OHV Engines. Battery Storage If the machine will be stored for more than 30 days 1. Remove the battery and charge it fully (see Battery Service). 2. Either store battery on a shelf or o[...]

Sand Pro 2020/3020/5020 Page 5 – 14 Electrical Systems Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be extend. Additionally , battery and electrical component failure can be prevented. CAUTION When working with batteries, use extreme cau- tion to avoid slashing or spilling el[...]

Inspection, Maintenance, and T esting (Fig. 12) 1. Perform following inspections and maintenance: A. Check for cracks caused by overly tight hold– down clamp. Replace battery if cracked and leak - ing. B. Check battery terminal posts for corrosion. Use a terminal brush or steel wool to clean corrosion from the battery terminal posts. IMPORT ANT :[...]

E. Connect a battery load tester to the battery ter- minals following the manufacturer ’ s instruc- tion s. Connect a digital multimeter to the battery terminals. F . Apply a test load of one half the Cranking Perfor- mance (see Battery Specifications) rating of the bat- tery for 15 seconds. G. T ake a voltage reading at 15 seconds, then re- move[...]

2. Determine the charging time and rate using the manufacturer ’ s battery charger instructions or the following table. Battery Battery Charge Level Reserve (Percent of Fully Charged) Capacity Capacity (Minutes) 75% 50% 25% 0% 80 or less 3.8 hrs 7.5 hrs 1 1.3 hrs 15 hrs @ @ @ @ 3 amps 3 amps 3 amps 3 amps 81 to 125 5.3 hrs 10.5 hrs 15.8 hrs 21 hr[...]

Optional Lights After market lighting kits are available for the SP 2020/3020 and SP 5020 . These kits can be electrically connected to the machine’s electrical system using the proper wiring diagram as a guide (see Sand Pro 2020/3020 or Sand Pro 5020 Harness and Wiring Dia - grams). IMPORT ANT : Do not exceed a total lighting capacity of 150 wat[...]

Chapter 6 Wheels, Brakes, and Miscellaneous T able of Contents SPECIFICA TIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Adjust Steering Chain . . . . . . . . . . . . . . . . . . . . . . . 3 Adjust Brake (SP 2020/3020) . . . . . . . . . . . . . . . . . 4 Adjus[...]

Specifications Item Description Front tire pressure 4 to 6 PSI, (0.28 to 0.41 bar) Rear tire pressure 4 to 6 PSI, (0.28 to 0.41 bar) Wheel lug nut torque 45 to 55 ft–lb, (6.2 to 7.6 kg–m) Wheels, Brakes, and Miscellaneous Page 6 – 2 Sand Pro 2020/3020/5020[...]

Sand Pro 2020/3020/5020 Page 6 – 3 Wheels, Brakes,and Miscellaneous Adjustments Adjust Steering Chain NOTE: Since the chain and sprocket are subjected to sand thrown up by the front tire, inspect them frequently for wear . If either the chain or sprocket is worn beyond acceptable limits, replace both chain and sprocket. NOTE: The steering chains [...]

Adjust Brake (SP 2020/3020) CAUTION check the brakes in a wide open area that is flat and free of other persons and obstructions. Before and after adjusting the brakes, always 1. While driving the machine, pull brake lever . Both wheels should lock equally . 2. Park machine on a level surface, turn engine off, and block wheels. 3. Loosen jam nut on[...]

Service and Repairs Seat (SP 2020/3020) 1 5 3 4 2 9 10 11 2 4 6 12 7 8 6 13 14 15 16 Figure 5 1. Seat 7. Cap screw 12. Angle bracket 2. Cap screw 8. Seat clamp 13. Spacer 3. R–clamp 9. Service decal 14. Lock nut 4. Flat washer 10. Rubber cushion 15. Seat base shield 5. Manual tube 1 1. Seat plate 16. Cap screw 6. lock nut Removal Installation 1. [...]

Front Wheel (SP 2020) 10 6 2 1 11 5 5 4 7 13 5 7 6 3 12 5 9 4 8 2 1 FRONT RIGHT 14 3 Figure 6 1. Hex nut 6. Bearing 1 1. Lug nut 2. Lock washer 7. Locking collar 12. Drive stud 3. Carriage bolt 8. Tire 13. Wheel rim 4. Set screw 9. Front axle 14. V alve stem 5. Bearing flange 10. Front fork Removal (Fig. 6) 1. Park machine on a level surface, engag[...]

Installation (Fig. 6) 4. Secure bearing flanges to the front fork with car - 1. Position front axle and drive studs through the wheel rim. Secure axle to rim with lug nuts to studs. T orque nuts from 45 to 55 ft–lb (6.2 to 7.6 kg–m). 2. Place bearing between two bearing flanges. Slide assembly onto axle with the locking collar facing away from [...]

Front Wheel (SP 3020 and SP 5020) FRONT RIGHT 9 12 8 7 4 15 16 13 2 5 1 6 3 14 10 11 17 Figure 7 1. Set screw 7. Bearing tab 13. Spindle 2. Locking collar 8. Front fork 14. Bearing 3. Cap screw 9. Socket head screw 15. Lug nut 4. Lock nut 10. Lock nut 16. Drive stud 5. Relube flangette 1 1. Hydraulic motor 17. Wheel hub 6. Flangette 12. Front wheel[...]

9. If the wheel hub needs replacing, remove hydraulic motor from hydraulic lines, and remove hub from motor (see Front Wheel Removal in Chapter 4 – Hydraulic Systems). Installation (Fig. 7) 1. If the wheel hub was removed from the hydraulic motor , install hub to motor , and install hydraulic motor to hydraulic lines (see Front Wheel Installation[...]

Sand Pro 2020/3020/5020 Page 6 – 10 Wheels, Brakes, and Miscellaneous Rear Wheels and Brakes 1. Lug nut 2. Drive stud 3. Wheel 4. Hub 5. Lock nut 6. Motor shaft 7. Brake drum 8. Woodruff key 9. Cotter pin 10. Clevis pin 1 1. Brake lever 12. Clevis 13. Backing plate 14. Retaining clip 15. Return spring 16. Brake shoe 17. Cam shaft 18. Brake bracke[...]

NOTE: The brake lever , backing plate, retaining clip, return springs, brake shoes, and cam shaft can be re - moved as a complete brake assembly . 7. If it is desired to remove the brake assembly from the brake bracket, remove four cap screws and lock nuts securing the assembly to the bracket. 8. Disassemble brake assembly as follows (Fig. 9): A. R[...]

Brake Linkages (SP 2020/3020) 5 7 12 11 10 15 13 14 16 7 17 4 3 7 2 1 9 18 8 20 19 6 8 9 21 RIGHT FRONT Figure 10 1. Cap screw 8. Clevis 15. Side flange bearing 2. Lock nut 9. Jam nut 16. Cap screw 3. Brake lever 10. Brake rod 17. Brake arm 4. Spacer 1 1. Adjusting rod 18. Adjusting rod 5. Clevis pin 12. Roll pins 19. Cotter pin 6. Flat washer 13. [...]

Brake Linkages (SP 5020) 30 29 31 28 26 27 1 2 3 4 5 6 7 8 9 10 16 17 18 19 20 21 22 23 24 13 14 15 20 21 17 4 25 32 1 1/12 RIGHT FRONT Figure 12 1. Curved washer 12. Right bearing bracket 23. Cap screw 2. Lever bracket 13. W asher head screw 24. Spacer 3. Lock nut 14. Flat washer 25. Hourmeter bracket 4. Lock nut 15. Cotter pin 26. Cotter pin 5. C[...]

Sand Pro 2020/3020/5020 Page 6 – 14 Wheels, Brakes, and Miscellaneous Front Fork and Steering (SP 2020 and Older SP 3020 Models) 1. Steering wheel 2. Roll pin 3. Upper steering shaft 4. Sleeve bushing 5. Steering post 6. Cap screw 7. Flange bushing 8. Drive–lock pin 9. Sprocket 10. Front fork (SP 2020) 1 1. Front fork (SP 3020 older models) 12.[...]

Sand Pro 2020/3020/5020 Page 6 – 15 Wheels, Brakes,and Miscellaneous Front Fork and Steering (Newer SP 3020 Models) 1. Steering wheel 2. Roll pin 3. Upper steering shaft 4. Sleeve bushing 5. Steering post 6. Cap screw 7. Flange bushing 8. Drive–lock pin 9. Sprocket 10. Front fork 1 1. Lock nut 12. Steering adjustment pin 13. Connecting link 14.[...]

Upper Steering Disassembly (Fig. 13 and 14) NOTE: The front fork and steering assemblies on the SP 2020 and SP 3020 are almost identical. However , there are differences in the construction of the front fork, chain guide, chain bracket, and the number of steering washers. 1. Park machine on a level surface, lower attachment, stop engine, engage par[...]

Lower Steering Disassembly (Fig. 13 and 14) NOTE: If disassembly of the steering mechanism be- low the steering knuckle is required, proceed as follows: 1. Loosen lock nut on the steering adjustment pin enough to loosen the steering chain from the sprocket. Remove chain from sprocket. 2. Remove drive–lock pin from the sprocket and lower steering [...]

4. Position fork shaft up through frame. Install bearing cone and bearing washer onto the shaft. If bearing con - es were damaged, install new bearing cone onto shaft. 5. Screw slotted nut onto the fork shaft until a slight drag is felt while rotating the fork. Back off nut so nearest slot aligns with cross hole in the shaft. Secure nut to shaft wi[...]

Sand Pro 2020/3020/5020 Page 6 – 19 Wheels, Brakes,and Miscellaneous Seat (SP 5020) 1. R–clamp 2. Lock washer 3. Cap screw 4. Manual tube 5. Seat adjust plate 6. Round head screw 7. Flat washer 8. Service decal 9. L ynch pin 10. Lock nut 1 1. 4–inch seat slider 12. Leveling screw 13. Jam nut 14. Seat slider 15. Flat washer 16. Seat 17. Lock n[...]

Sand Pro 2020/3020/5020 Page 6 – 20 Wheels, Brakes, and Miscellaneous Steering (SP 5020) 1. Steering wheel 2. Roll pin 3. Cap screw 4. Handle 5. Steering adjust lever 6. Tilt lock pin 7. Upper lock block 8. Retaining ring 9. Flat washer 10. Cap screw 1 1. Spacer 12. Lock nut 13. Cap screw 14. Fuel tank bracket 15. Spacer 16. Lock nut 17. Adjustme[...]

Upper Steering Disassembly (Fig. 19) NOTE: If disassembly above the steering knuckle is re- quired, use the following procedure. 1. Park machine on a level surface, lower attachment, stop engine, engage parking brake, and remove key from the ignition switch. NOTE: The fuel tank must be removed from the frame to allow separation of the upper steerin[...]

Front Fork (SP 5020) Removal (Fig. 20) NOTE: If disassembly of the front fork and its bearings is required, proceed as follows: W ARNING Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 – Safety . 1. Jack up front wheel enough to allow removal of the front fork. 2. Remove fuel tank from the machine (see Fuel T an[...]

Hood and Dash Panel (SP 2020/3020) Removal 1. Park machine on a level surface, lower attachment, stop engine, engage parking brake, and remove key from the ignition switch. 2. Disconnect black (negative) cable from the battery . 3. Remove three flange head screws securing the hood to the front shield (Fig. 1 1). 4. Remove four cap screws securing t[...]

Fenders (SP 5020) Left Fender(Seat Base )Removal (Fig. 44) 1. Park machine on a level surface, lower attachment, stop engine, engage parking brake, and remove key from the ignition switch. 2. Pivot seat up. Separate seat rod from the base by removing cotter pin and flat washer . 3. Separate base from frame by removing both lock nuts, cap screws, fl[...]

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Commercial Products E The T oro Company – 1998[...]