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Toro 3020, 5020, 2020 service manual Commercial Products, E The Toro Company

Models: 3020 2020 5020

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Commercial Products

EThe Toro Company – 1998

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Toro 3020, 5020, 2020 service manual Commercial Products, E The Toro Company

Contents

Preface Service ManualSand ProR 2020/3020/5020 E The Toro Company - 1998, 2003Sand Pro 2020/3020/5020 Engine Product Records Safety and Manuals Table Of ContentsChapter 1 - Safety Chapter 2 - Product Records and ManualsSand Pro 2020/3020/5020 General Safety Instructions SafetyTable of Contents ChapterPage 1 While OperatingSafety Sand Pro 2020/3020/5020Safety Maintenance and ServiceSafety Sand Pro 2020/3020/5020Jacking the Front End Jacking InstructionsSafety Jacking the Rear EndSafety Safety and Instruction DecalsON NEUTRAL ADJUST MECHANISM SafetyON LEFT FENDER Part No ON CENTER PANEL Part No Safety Safety and Instruction DecalsON NEUTRAL ADJUST ON BATTERYTable of Contents Product Records and MaintenanceProduct Records Product Records and MaintenancePage 2 Equivalents and ConversionsProduct Records and Maintenance Sand Pro 2020/3020/5020Product Records and Maintenance Torque SpecificationsProduct Records and Maintenance Sand Pro 2020/3020/5020Sand Pro 2020/3020 Early Models LubricationProduct Records and Maintenance Sand Pro 2020/3020 Late ModelsSand Pro 2020/3020/5020 Product Records and MaintenanceProduct Records and Maintenance Page 2Sand Pro 2020/3020/5020 Product Records and MaintenancePage 2 EQUIPMENT OPERATION AND SERVICE HISTORY REPORT for Sand ProR 2020/3020/5020Maintenance Procedure Sand Pro R 2020/3020/5020 Maintenance ScheduleMinimum Recommended Maintenance Intervals Maintenance Interval & ServiceMaintenance Sand Pro R 2020/3020/5020 Daily Maintenance ChecklistDaily Maintenance duplicate this page for routine use Daily Maintenance Check For Week OfC - Service every 400 hours A- Service every 25 hoursB - Service every 100 hours D - Service every 800 houursChapter EngineTable of Contents EnginePage 3 IntroductionEngine Sand Pro 2020/3020/5020Sand Pro 2020/3020/5020 SpecificationsEngine Page 3Engine General InformationCheck Engine Oil Page 3Sand Pro 2020/3020/5020 Fuel Shutoff ValveEngine Page 3Engine DANGERFill Fuel Tank Page 3Adjust Choke Control AdjustmentsAdjust Throttle Control EngineChange Engine Oil and Filter Service and RepairsService Engine Air Cleaner EngineEngine Service Remote Air CleanerUse eye protection such as goggles when using compressed air Sand Pro 2020/3020/5020Engine Throttle and Choke ControlsThrottle Control Removal Page 3Engine Throttle Control InstallationChoke Control Removal Sand Pro 2020/3020/5020sure not to damage carburetor gasket while instal- ling base Fig Replace Fuel FilterChoke Control Installation EngineRemote Air Cleaner Installation Remote Air Cleaner SP 2020/3020Remote Air Cleaner Removal Sand Pro 2020/3020/5020Remote Air Cleaner Installation Remote Air Cleaner SPRemote Air Cleaner Removal EngineMuffler Removal Muffler SPMuffler Installation EngineEngine Muffler SP 2020/3020Muffler Removal Page 3Sand Pro 2020/3020/5020 Muffler InstallationEngine Page 3Page 3 Fuel Tank SP 2020/3020Engine Sand Pro 2020/3020/5020Fuel Tank Removal Fig Fuel Tank installation FigDANGER EngineFuel Tank Removal Fig Fuel Tank SPDANGER EngineSand Pro 2020/3020/5020 Fuel Tank installation FigEngine Page 3Engine Engine SP 2020/3020Wire harness Ground wire Page 3Sand Pro 2020/3020/5020 Engine Removal FigEngine Page 3Engine Engine Installation Fig1. Install engine 16 to the engine base Page 3Sand Pro 2020/3020/5020 Replace Spark Plugs0.030 inch 0.762 mm Page 3Page 3 Engine SPEngine Sand Pro 2020/3020/5020Sand Pro 2020/3020/5020 Engine Removal FigEngine Page 3Page 3 Engine Installation FigEngine Sand Pro 2020/3020/5020Page 3 EngineSand Pro 2020/3020/5020 EngineEngine Clean Cylinder Head FinsUse eye protection such as goggles when using compressed air Page 3Chapter Hydraulic SystemsTable of Contents HydraulicPage 4 - 2 Rev. B SpecificationsHydraulic System Sand Pro 2020/3020/5020General Information Hydraulic Fitting InstallationHydraulic Hoses O-Ring Face SealHydraulic System Rev. A SAE Straight Thread O-Ring Port - Non-adjustableSAE Straight Thread O-Ring Port - Adjustable Page 4NOT OVERFILL Towing Traction UnitCheck Hydraulic System Fluid ISO type 46/68 anti-wear hydraulic fluidPage HydraulicHydraulic Schematic Hydraulic Systems Hydraulic SchematicRev. A Page 4Hydraulic System Rev. A Hydraulic Flow DiagramsTraction Forward Page 4Hydraulic Systems Page 4 Hydraulic System Rev. ATraction Forward Page 4 Traction ReverseHydraulic System Rev. A Sand Pro 2020/3020/5020Hydraulic Systems Hydraulic System Rev. ATraction Reverse PagePage 4 Retract and Extend Lift CylinderHydraulic System Rev. A Sand Pro 2020/3020/5020Hydraulic Systems Page 4 Hydraulic System Rev. AExtend and Retract lift Cylinder EXTEND LIFT CYLINDERHydraulic Tester Pressure and Flow - TOR214678 Special ToolsHydraulic Pressure Test Kit - TOR47009 Hydraulic System Rev. ATORO TEST FITTING KIT NO. TOR4079 Hydraulic Test Fitting Kit - TOR4079Hydraulic Test Fittings HydraulicHydraulic System TroubleshootingProblem Page 4 - 16 Rev. BSand Pro 2020/3020/5020 Troubleshooting contProblem Page 4Hydraulic System Rev. A Troubleshooting contProblem Page 4 - 18 Rev. BBefore Performing Hydraulic Tests TestingPrecautions for Hydraulic Testing HydraulicPage 4 TEST NO. 1 Traction Pump Flow P1Hydraulic System Rev. A Sand Pro 2020/3020/5020Systems Procedure for Traction Pump Flow P1 Fig.12Hydraulic Sand Pro 2020/3020/5020Sand Pro 2020/3020/5020 Hydraulic System Rev. APage 4 1. Charge test port SP 2020/3020Page 4 - 23 Rev. B HydraulicSystems Hydraulic System Rev. APage 4 TEST NO. 3 Charge Pump P2 FlowHydraulic System Rev. A Sand Pro 2020/3020/5020Systems Procedure for Charge Pump P2 FlowHydraulic Sand Pro 2020/3020/5020Page 4 TEST NO. 4 Wheel Motor EfficiencyHydraulic System Rev. A Sand Pro 2020/3020/5020Hydraulic Procedure for Wheel Motor EfficiencyMake sure the tester flow control valve is fully open SystemsAdjustments Adjust Traction Pedal for NeutralAdjust Traction Pedal for Forward SP 2020/3020 Hydraulic System Rev. ASystems Adjust Traction Pedal for Forward SPHydraulic Sand Pro 2020/3020/5020Hydraulic System Rev. A Adjust Lift Lever SP 2020/3020Adjust Lift Lever SP Page 4Service and Repairs Check Hydraulic Lines and HosesCharge Hydraulic System HydraulicPage 4 A. Loose filter or suction linesHydraulic System Rev. A Sand Pro 2020/3020/5020Page 4 Change Hydraulic System Fluid and FilterSand Pro 2020/3020/5020 Hydraulic System Rev. APage 4 Lift Valve SP 2020/3020Hydraulic System Rev. A Sand Pro 2020/3020/5020Hydraulic Installation FigRemoval Fig SystemsPage 4 Lift Valve SPHydraulic System Rev. A Sand Pro 2020/3020/5020Hydraulic Installation FigRemoval Fig SystemsReassembly Lift ValveDisassembly InspectionRemoval Lift Cylinder SP 2020/3020Installation HydraulicRemoval Lift CylinderSPInstallation Hydraulic System Rev. AReassembly Lift Cylinder ServiceDisassembly HydraulicHydraulic System Rev. A Hydrostat SP 2020/3020Removal Fig Page 4Systems Installation FigHydraulic Sand Pro 2020/3020/5020Hydraulic System Rev. A Hydrostat SPRemoval Fig Page 4Systems Installation FigHydraulic Sand Pro 2020/3020/5020Page 4 6. Reinstall engine and hydrostat as followsHydraulic System Rev. A Sand Pro 2020/3020/5020Systems Flush Hydraulic SystemHydraulic Sand Pro 2020/3020/5020Hydraulic System Rev. A Hydrostat ServiceHYDROSTAT IS ILLUSTRATED FROM BELOW Page 4 - 48 Rev. BCharge Pump Inspection Charge Pump DisassemblyCharge Pump Assembly HydraulicHydraulic System Rev. A Shaft Seal InstallationShaft Seal Removal Page 4Relief Valve Assembly Fig Acceleration Valve Assembly FigRelief Valve Disassembly Fig Charge Check Valve Disassembly FigHydraulic System Rev. A Traction Pump Disassembly6. Position variable housing so the large cavity faces up Fig Page 4Systems Traction Pump InspectionHydraulic Sand Pro 2020/3020/5020Hydraulic System Rev. A Traction Pump Assembly1. Make sure all parts are cleaned thoroughly and free Page 4Sand Pro 2020/3020/5020 HydraulicSystems Page 4Hydraulic System Rev. A Front Wheel MotorRemoval Fig Page 4Systems Installation FigHydraulic Sand Pro 2020/3020/5020Page 4 Rear Wheel Motors SP 2020/3020Hydraulic System Rev. A Sand Pro 2020/3020/5020Hydraulic Installation Fig. 57 orRemoval Fig. 57 or SystemsHydraulic System Rev. A Rear Wheel Motors SPAdjustment clevis Page 4Hydraulic Installation Fig. 57 orRemoval Fig. 57 or SystemsHydraulic System Rev. A Wheel Motor ServiceEnd cover assembly Front & LH Page 4Hydraulic Disassembly FigUse eye protection such as goggles when using compressed air SystemsHydraulic System Rev. A Use eye protection such as goggles when using compressed airInspection Fig Page 4Sand Pro 2020/3020/5020 HydraulicSystems Page 4Hydraulic System Rev. A Assembly FigUse eye protection such as goggles when using compressed air Sand Pro 2020/3020/5020 HydraulicSystems Page 4Hydraulic System Rev. A Sand Pro 2020/3020/5020 HydraulicSystems Page 435 to 69 kg-cm Hydraulic Tank SP 2020/302030 to 60 ft-lb Hydraulic System Rev. AInspection Fig Installation FigRemoval Fig HydraulicPage 4 Hydraulic Oil Cooler SP 2020/3020Hydraulic System Rev. A Sand Pro 2020/3020/5020Installation Fig Cleaning and Inspection FigUse eye protection such as goggles when using compressed air Removal FigHydraulic System Rev. A Hydraulic Tank and Oil Cooler SPOil Cooler Removal Fig Page 4Hydraulic Use eye protection such as goggles when using compressed airOil Cooler Inspection Fig SystemsHydraulic Tank Removal Fig Oil Cooler Installation FigHydraulic Tank Installation Fig Hydraulic Tank Inspection FigChapter Electrical SystemsTable of Contents ElectricalSand Pro 2020/3020 Electrical Schematics andDiagrams Electrical SchematicElectrical Harness and Wiring DiagramSand Pro 2020/3020 SystemsElectrical Systems Page 5 Sand ProElectrical Schematic BLACKElectrical Harness and Wiring DiagramSand Pro SystemsSpecial Tools MultimeterSkin-Over Grease Electrical SystemsProblem Starting ProblemsTroubleshooting Possible CausesProblem Starting Problems continuedGeneral Run and Transport Problems ProblemBattery Charge Level Battery Test Open Circuit TestElectrical System Quick Checks Voltage MeasuredElectrical Systems Component TestingIgnition Switch Page 5SP 2020/3020 Hour Meter0 0 0 0 Electrical3.1 ohms Neutral SwitchStarter Solenoid Electrical SystemsService and Repairs Battery StorageBattery Care ElectricalElectrical Systems Battery ServiceRemoval Fig. 10 and Page 5Electrical Inspection, Maintenance, and Testing FigFollow the manufacturer’s instructions when us- ing a battery tester SystemsFollow the manufacturer’s instructions when us- ing a battery charger Battery ElectrolyteInstallation Fig. 10 and Battery ChargeBattery Check Interlock Systemmanufacturer’s battery charger instructions or the following table Battery Charge LevelPage 5 Optional LightsElectrical Systems Sand Pro 2020/3020/5020Chapter Wheels, Brakes, and MiscellaneousTable of Contents Sand Pro 2020/3020/5020Page 6 SpecificationsWheels, Brakes, and Miscellaneous Sand Pro 2020/3020/5020Sand Pro 2020/3020/5020 Adjust Steering ChainAdjustments Page 6Wheels, Brakes, and Miscellaneous Adjust Brake SP 2020/3020Adjust Brake SP Page 6Installation Seat SP 2020/3020Service and Repairs RemovalWheels, Brakes, and Miscellaneous Front Wheel SPRemoval Fig Page 6Sand Pro 2020/3020/5020 Installation Fig7. Lower front wheel to ground Page 6Wheels, Brakes, and Miscellaneous Front Wheel SP 3020 and SPRemoval Fig Page 6Page 6 Installation FigSand Pro 2020/3020/5020 Wheels, Brakes,and MiscellaneousWheels, Brakes, and Miscellaneous Rear Wheels and BrakesRemoval Fig Page 6Sand Pro 2020/3020/5020 8. Disassemble brake assembly as follows FigInstallation Fig Page 6FRONT Brake Linkages SP 2020/3020RIGHT Wheels, Brakes, and MiscellaneousFRONT Brake Linkages SPRIGHT Sand Pro 2020/3020/5020Page 6 Front Fork and Steering SP 2020 and Older SP 3020 ModelsWheels, Brakes, and Miscellaneous Sand Pro 2020/3020/5020Page 6 Front Fork and Steering Newer SP 3020 ModelsSand Pro 2020/3020/5020 Wheels, Brakes,and MiscellaneousWheels, Brakes, and Miscellaneous Upper Steering Disassembly Fig. 13 andUpper Steering Assembly Fig. 13 and Page 6Front Fork Installation Fig. 13 and Lower Steering Disassembly Fig. 13 andLower Steering Assembly Fig. 13 and Front Fork Removal Fig. 13 andPage 6 6. Install front wheel to the front fork see Front Wheel InstallationWheels, Brakes, and Miscellaneous Sand Pro 2020/3020/5020Removal Seat SPInstallation Sand Pro 2020/3020/5020Page 6 Steering SPWheels, Brakes, and Miscellaneous Sand Pro 2020/3020/5020Lower Steering Disassembly Fig. 13 and Upper Steering Disassembly FigUpper Steering Assembly Fig Lower Steering Assembly Fig. 13 andRemoval Fig Front Fork SPInstallation Fig Wheels, Brakes, and MiscellaneousRemoval Hood and Dash Panel SP 2020/3020Installation Sand Pro 2020/3020/5020Right Fender Installation Fig. 25 and Fenders SPSeat Base Installation Fig Left FenderSeat Base Removal FigPage Commercial Products E The Toro Company