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Toro 2020, 5020, 3020 service manual

Models: 3020 2020 5020

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Contents

Sand ProR 2020/3020/5020 Service ManualPreface E The Toro Company - 1998, 2003Sand Pro 2020/3020/5020 Chapter 1 - Safety Table Of ContentsEngine Product Records Safety and Manuals Chapter 2 - Product Records and ManualsSand Pro 2020/3020/5020 Table of Contents SafetyGeneral Safety Instructions ChapterSafety While OperatingPage 1 Sand Pro 2020/3020/5020Safety Maintenance and ServiceSafety Sand Pro 2020/3020/5020Safety Jacking InstructionsJacking the Front End Jacking the Rear EndON NEUTRAL ADJUST MECHANISM Safety and Instruction DecalsSafety SafetyON NEUTRAL ADJUST Safety and Instruction DecalsON LEFT FENDER Part No ON CENTER PANEL Part No Safety ON BATTERYProduct Records Product Records and MaintenanceTable of Contents Product Records and MaintenanceProduct Records and Maintenance Equivalents and ConversionsPage 2 Sand Pro 2020/3020/5020Product Records and Maintenance Torque SpecificationsProduct Records and Maintenance Sand Pro 2020/3020/5020Product Records and Maintenance LubricationSand Pro 2020/3020 Early Models Sand Pro 2020/3020 Late ModelsProduct Records and Maintenance Product Records and MaintenanceSand Pro 2020/3020/5020 Page 2Page 2 Product Records and MaintenanceSand Pro 2020/3020/5020 Sand ProR 2020/3020/5020 EQUIPMENT OPERATION AND SERVICE HISTORY REPORT forMinimum Recommended Maintenance Intervals Sand Pro R 2020/3020/5020 Maintenance ScheduleMaintenance Procedure Maintenance Interval & ServiceDaily Maintenance duplicate this page for routine use Sand Pro R 2020/3020/5020 Daily Maintenance ChecklistMaintenance Daily Maintenance Check For Week OfB - Service every 100 hours A- Service every 25 hoursC - Service every 400 hours D - Service every 800 houursTable of Contents EngineChapter EngineEngine IntroductionPage 3 Sand Pro 2020/3020/5020Engine SpecificationsSand Pro 2020/3020/5020 Page 3Check Engine Oil General InformationEngine Page 3Engine Fuel Shutoff ValveSand Pro 2020/3020/5020 Page 3Fill Fuel Tank DANGEREngine Page 3Adjust Throttle Control AdjustmentsAdjust Choke Control EngineService Engine Air Cleaner Service and RepairsChange Engine Oil and Filter EngineUse eye protection such as goggles when using compressed air Service Remote Air CleanerEngine Sand Pro 2020/3020/5020Throttle Control Removal Throttle and Choke ControlsEngine Page 3Choke Control Removal Throttle Control InstallationEngine Sand Pro 2020/3020/5020Choke Control Installation Replace Fuel Filtersure not to damage carburetor gasket while instal- ling base Fig EngineRemote Air Cleaner Removal Remote Air Cleaner SP 2020/3020Remote Air Cleaner Installation Sand Pro 2020/3020/5020Remote Air Cleaner Removal Remote Air Cleaner SPRemote Air Cleaner Installation EngineMuffler Installation Muffler SPMuffler Removal EngineMuffler Removal Muffler SP 2020/3020Engine Page 3Engine Muffler InstallationSand Pro 2020/3020/5020 Page 3Engine Fuel Tank SP 2020/3020Page 3 Sand Pro 2020/3020/5020DANGER Fuel Tank installation FigFuel Tank Removal Fig EngineDANGER Fuel Tank SPFuel Tank Removal Fig EngineEngine Fuel Tank installation FigSand Pro 2020/3020/5020 Page 3Wire harness Ground wire Engine SP 2020/3020Engine Page 3Engine Engine Removal FigSand Pro 2020/3020/5020 Page 31. Install engine 16 to the engine base Engine Installation FigEngine Page 30.030 inch 0.762 mm Replace Spark PlugsSand Pro 2020/3020/5020 Page 3Engine Engine SPPage 3 Sand Pro 2020/3020/5020Engine Engine Removal FigSand Pro 2020/3020/5020 Page 3Engine Engine Installation FigPage 3 Sand Pro 2020/3020/5020Sand Pro 2020/3020/5020 EnginePage 3 EngineUse eye protection such as goggles when using compressed air Clean Cylinder Head FinsEngine Page 3Table of Contents Hydraulic SystemsChapter HydraulicHydraulic System SpecificationsPage 4 - 2 Rev. B Sand Pro 2020/3020/5020Hydraulic Hoses Hydraulic Fitting InstallationGeneral Information O-Ring Face SealSAE Straight Thread O-Ring Port - Adjustable SAE Straight Thread O-Ring Port - Non-adjustableHydraulic System Rev. A Page 4Check Hydraulic System Fluid Towing Traction UnitNOT OVERFILL ISO type 46/68 anti-wear hydraulic fluidHydraulic Schematic HydraulicPage Rev. A Hydraulic SchematicHydraulic Systems Page 4Traction Forward Hydraulic Flow DiagramsHydraulic System Rev. A Page 4Traction Forward Page 4 Hydraulic System Rev. AHydraulic Systems Hydraulic System Rev. A Traction ReversePage 4 Sand Pro 2020/3020/5020Traction Reverse Hydraulic System Rev. AHydraulic Systems PageHydraulic System Rev. A Retract and Extend Lift CylinderPage 4 Sand Pro 2020/3020/5020Extend and Retract lift Cylinder Page 4 Hydraulic System Rev. AHydraulic Systems EXTEND LIFT CYLINDERHydraulic Pressure Test Kit - TOR47009 Special ToolsHydraulic Tester Pressure and Flow - TOR214678 Hydraulic System Rev. AHydraulic Test Fittings Hydraulic Test Fitting Kit - TOR4079TORO TEST FITTING KIT NO. TOR4079 HydraulicProblem TroubleshootingHydraulic System Page 4 - 16 Rev. BProblem Troubleshooting contSand Pro 2020/3020/5020 Page 4Problem Troubleshooting contHydraulic System Rev. A Page 4 - 18 Rev. BPrecautions for Hydraulic Testing TestingBefore Performing Hydraulic Tests HydraulicHydraulic System Rev. A TEST NO. 1 Traction Pump Flow P1Page 4 Sand Pro 2020/3020/5020Hydraulic Procedure for Traction Pump Flow P1 Fig.12Systems Sand Pro 2020/3020/5020Page 4 Hydraulic System Rev. ASand Pro 2020/3020/5020 1. Charge test port SP 2020/3020Systems HydraulicPage 4 - 23 Rev. B Hydraulic System Rev. AHydraulic System Rev. A TEST NO. 3 Charge Pump P2 FlowPage 4 Sand Pro 2020/3020/5020Hydraulic Procedure for Charge Pump P2 FlowSystems Sand Pro 2020/3020/5020Hydraulic System Rev. A TEST NO. 4 Wheel Motor EfficiencyPage 4 Sand Pro 2020/3020/5020Make sure the tester flow control valve is fully open Procedure for Wheel Motor EfficiencyHydraulic SystemsAdjust Traction Pedal for Forward SP 2020/3020 Adjust Traction Pedal for NeutralAdjustments Hydraulic System Rev. AHydraulic Adjust Traction Pedal for Forward SPSystems Sand Pro 2020/3020/5020Adjust Lift Lever SP Adjust Lift Lever SP 2020/3020Hydraulic System Rev. A Page 4Charge Hydraulic System Check Hydraulic Lines and HosesService and Repairs HydraulicHydraulic System Rev. A A. Loose filter or suction linesPage 4 Sand Pro 2020/3020/5020Sand Pro 2020/3020/5020 Change Hydraulic System Fluid and FilterPage 4 Hydraulic System Rev. AHydraulic System Rev. A Lift Valve SP 2020/3020Page 4 Sand Pro 2020/3020/5020Removal Fig Installation FigHydraulic SystemsHydraulic System Rev. A Lift Valve SPPage 4 Sand Pro 2020/3020/5020Removal Fig Installation FigHydraulic SystemsDisassembly Lift ValveReassembly InspectionInstallation Lift Cylinder SP 2020/3020Removal HydraulicInstallation Lift CylinderSPRemoval Hydraulic System Rev. ADisassembly Lift Cylinder ServiceReassembly HydraulicRemoval Fig Hydrostat SP 2020/3020Hydraulic System Rev. A Page 4Hydraulic Installation FigSystems Sand Pro 2020/3020/5020Removal Fig Hydrostat SPHydraulic System Rev. A Page 4Hydraulic Installation FigSystems Sand Pro 2020/3020/5020Hydraulic System Rev. A 6. Reinstall engine and hydrostat as followsPage 4 Sand Pro 2020/3020/5020Hydraulic Flush Hydraulic SystemSystems Sand Pro 2020/3020/5020HYDROSTAT IS ILLUSTRATED FROM BELOW Hydrostat ServiceHydraulic System Rev. A Page 4 - 48 Rev. BCharge Pump Assembly Charge Pump DisassemblyCharge Pump Inspection HydraulicShaft Seal Removal Shaft Seal InstallationHydraulic System Rev. A Page 4Relief Valve Disassembly Fig Acceleration Valve Assembly FigRelief Valve Assembly Fig Charge Check Valve Disassembly Fig6. Position variable housing so the large cavity faces up Fig Traction Pump DisassemblyHydraulic System Rev. A Page 4Hydraulic Traction Pump InspectionSystems Sand Pro 2020/3020/50201. Make sure all parts are cleaned thoroughly and free Traction Pump AssemblyHydraulic System Rev. A Page 4Systems HydraulicSand Pro 2020/3020/5020 Page 4Removal Fig Front Wheel MotorHydraulic System Rev. A Page 4Hydraulic Installation FigSystems Sand Pro 2020/3020/5020Hydraulic System Rev. A Rear Wheel Motors SP 2020/3020Page 4 Sand Pro 2020/3020/5020Removal Fig. 57 or Installation Fig. 57 orHydraulic SystemsAdjustment clevis Rear Wheel Motors SPHydraulic System Rev. A Page 4Removal Fig. 57 or Installation Fig. 57 orHydraulic SystemsEnd cover assembly Front & LH Wheel Motor ServiceHydraulic System Rev. A Page 4Use eye protection such as goggles when using compressed air Disassembly FigHydraulic SystemsInspection Fig Use eye protection such as goggles when using compressed airHydraulic System Rev. A Page 4Systems HydraulicSand Pro 2020/3020/5020 Page 4Use eye protection such as goggles when using compressed air Assembly FigHydraulic System Rev. A Systems HydraulicSand Pro 2020/3020/5020 Page 4Hydraulic System Rev. A Systems HydraulicSand Pro 2020/3020/5020 Page 430 to 60 ft-lb Hydraulic Tank SP 2020/302035 to 69 kg-cm Hydraulic System Rev. ARemoval Fig Installation FigInspection Fig HydraulicHydraulic System Rev. A Hydraulic Oil Cooler SP 2020/3020Page 4 Sand Pro 2020/3020/5020Use eye protection such as goggles when using compressed air Cleaning and Inspection FigInstallation Fig Removal FigOil Cooler Removal Fig Hydraulic Tank and Oil Cooler SPHydraulic System Rev. A Page 4Oil Cooler Inspection Fig Use eye protection such as goggles when using compressed airHydraulic SystemsHydraulic Tank Installation Fig Oil Cooler Installation FigHydraulic Tank Removal Fig Hydraulic Tank Inspection FigTable of Contents Electrical SystemsChapter ElectricalDiagrams Electrical Schematics andSand Pro 2020/3020 Electrical SchematicSand Pro 2020/3020 Harness and Wiring DiagramElectrical SystemsElectrical Schematic Sand ProElectrical Systems Page 5 BLACKSand Pro Harness and Wiring DiagramElectrical SystemsSkin-Over Grease MultimeterSpecial Tools Electrical SystemsTroubleshooting Starting ProblemsProblem Possible CausesGeneral Run and Transport Problems Starting Problems continuedProblem ProblemElectrical System Quick Checks Battery Test Open Circuit TestBattery Charge Level Voltage MeasuredIgnition Switch Component TestingElectrical Systems Page 50 0 0 0 Hour MeterSP 2020/3020 ElectricalStarter Solenoid Neutral Switch3.1 ohms Electrical SystemsBattery Care Battery StorageService and Repairs ElectricalRemoval Fig. 10 and Battery ServiceElectrical Systems Page 5Follow the manufacturer’s instructions when us- ing a battery tester Inspection, Maintenance, and Testing FigElectrical SystemsInstallation Fig. 10 and Battery ElectrolyteFollow the manufacturer’s instructions when us- ing a battery charger Battery Chargemanufacturer’s battery charger instructions or the following table Check Interlock SystemBattery Battery Charge LevelElectrical Systems Optional LightsPage 5 Sand Pro 2020/3020/5020Table of Contents Wheels, Brakes, and MiscellaneousChapter Sand Pro 2020/3020/5020Wheels, Brakes, and Miscellaneous SpecificationsPage 6 Sand Pro 2020/3020/5020Adjustments Adjust Steering ChainSand Pro 2020/3020/5020 Page 6Adjust Brake SP Adjust Brake SP 2020/3020Wheels, Brakes, and Miscellaneous Page 6Service and Repairs Seat SP 2020/3020Installation RemovalRemoval Fig Front Wheel SPWheels, Brakes, and Miscellaneous Page 67. Lower front wheel to ground Installation FigSand Pro 2020/3020/5020 Page 6Removal Fig Front Wheel SP 3020 and SPWheels, Brakes, and Miscellaneous Page 6Sand Pro 2020/3020/5020 Installation FigPage 6 Wheels, Brakes,and MiscellaneousRemoval Fig Rear Wheels and BrakesWheels, Brakes, and Miscellaneous Page 6Installation Fig 8. Disassemble brake assembly as follows FigSand Pro 2020/3020/5020 Page 6RIGHT Brake Linkages SP 2020/3020FRONT Wheels, Brakes, and MiscellaneousRIGHT Brake Linkages SPFRONT Sand Pro 2020/3020/5020Wheels, Brakes, and Miscellaneous Front Fork and Steering SP 2020 and Older SP 3020 ModelsPage 6 Sand Pro 2020/3020/5020Sand Pro 2020/3020/5020 Front Fork and Steering Newer SP 3020 ModelsPage 6 Wheels, Brakes,and MiscellaneousUpper Steering Assembly Fig. 13 and Upper Steering Disassembly Fig. 13 andWheels, Brakes, and Miscellaneous Page 6Lower Steering Assembly Fig. 13 and Lower Steering Disassembly Fig. 13 andFront Fork Installation Fig. 13 and Front Fork Removal Fig. 13 andWheels, Brakes, and Miscellaneous 6. Install front wheel to the front fork see Front Wheel InstallationPage 6 Sand Pro 2020/3020/5020Installation Seat SPRemoval Sand Pro 2020/3020/5020Wheels, Brakes, and Miscellaneous Steering SPPage 6 Sand Pro 2020/3020/5020Upper Steering Assembly Fig Upper Steering Disassembly FigLower Steering Disassembly Fig. 13 and Lower Steering Assembly Fig. 13 andInstallation Fig Front Fork SPRemoval Fig Wheels, Brakes, and MiscellaneousInstallation Hood and Dash Panel SP 2020/3020Removal Sand Pro 2020/3020/5020Seat Base Installation Fig Fenders SPRight Fender Installation Fig. 25 and Left FenderSeat Base Removal FigPage E The Toro Company Commercial Products