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Toro service manual Sand Pro 2020/3020/5020

Models: 3020 2020 5020

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Sand Pro 2020/3020/5020

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Toro service manual Sand Pro 2020/3020/5020

Contents

Service Manual Sand ProR 2020/3020/5020Preface E The Toro Company - 1998, 2003Sand Pro 2020/3020/5020 Table Of Contents Chapter 1 - SafetyEngine Product Records Safety and Manuals Chapter 2 - Product Records and ManualsSand Pro 2020/3020/5020 Safety Table of ContentsGeneral Safety Instructions ChapterWhile Operating SafetyPage 1 Sand Pro 2020/3020/5020Maintenance and Service SafetySafety Sand Pro 2020/3020/5020Jacking Instructions SafetyJacking the Front End Jacking the Rear EndSafety and Instruction Decals ON NEUTRAL ADJUST MECHANISMSafety SafetySafety and Instruction Decals ON NEUTRAL ADJUSTON LEFT FENDER Part No ON CENTER PANEL Part No Safety ON BATTERYProduct Records and Maintenance Product RecordsTable of Contents Product Records and MaintenanceEquivalents and Conversions Product Records and MaintenancePage 2 Sand Pro 2020/3020/5020Torque Specifications Product Records and MaintenanceProduct Records and Maintenance Sand Pro 2020/3020/5020Lubrication Product Records and MaintenanceSand 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 EQUIPMENT OPERATION AND SERVICE HISTORY REPORT for Sand ProR 2020/3020/5020Sand Pro R 2020/3020/5020 Maintenance Schedule Minimum Recommended Maintenance IntervalsMaintenance Procedure Maintenance Interval & ServiceSand Pro R 2020/3020/5020 Daily Maintenance Checklist Daily Maintenance duplicate this page for routine useMaintenance Daily Maintenance Check For Week OfA- Service every 25 hours B - Service every 100 hoursC - Service every 400 hours D - Service every 800 houursEngine Table of ContentsChapter EngineIntroduction EnginePage 3 Sand Pro 2020/3020/5020Specifications EngineSand Pro 2020/3020/5020 Page 3General Information Check Engine OilEngine Page 3Fuel Shutoff Valve EngineSand Pro 2020/3020/5020 Page 3DANGER Fill Fuel TankEngine Page 3Adjustments Adjust Throttle ControlAdjust Choke Control EngineService and Repairs Service Engine Air CleanerChange Engine Oil and Filter EngineService Remote Air Cleaner Use eye protection such as goggles when using compressed airEngine Sand Pro 2020/3020/5020Throttle and Choke Controls Throttle Control RemovalEngine Page 3Throttle Control Installation Choke Control RemovalEngine Sand Pro 2020/3020/5020Replace Fuel Filter Choke Control Installationsure not to damage carburetor gasket while instal- ling base Fig EngineRemote Air Cleaner SP 2020/3020 Remote Air Cleaner RemovalRemote Air Cleaner Installation Sand Pro 2020/3020/5020Remote Air Cleaner SP Remote Air Cleaner RemovalRemote Air Cleaner Installation EngineMuffler SP Muffler InstallationMuffler Removal EngineMuffler SP 2020/3020 Muffler RemovalEngine Page 3Muffler Installation EngineSand Pro 2020/3020/5020 Page 3Fuel Tank SP 2020/3020 EnginePage 3 Sand Pro 2020/3020/5020Fuel Tank installation Fig DANGERFuel Tank Removal Fig EngineFuel Tank SP DANGERFuel Tank Removal Fig EngineFuel Tank installation Fig EngineSand Pro 2020/3020/5020 Page 3Engine SP 2020/3020 Wire harness Ground wireEngine Page 3Engine Removal Fig EngineSand Pro 2020/3020/5020 Page 3Engine Installation Fig 1. Install engine 16 to the engine baseEngine Page 3Replace Spark Plugs 0.030 inch 0.762 mmSand Pro 2020/3020/5020 Page 3Engine SP EnginePage 3 Sand Pro 2020/3020/5020Engine Removal Fig EngineSand Pro 2020/3020/5020 Page 3Engine Installation Fig EnginePage 3 Sand Pro 2020/3020/5020Engine Sand Pro 2020/3020/5020Page 3 EngineClean Cylinder Head Fins Use eye protection such as goggles when using compressed airEngine Page 3Hydraulic Systems Table of ContentsChapter HydraulicSpecifications Hydraulic SystemPage 4 - 2 Rev. B Sand Pro 2020/3020/5020Hydraulic Fitting Installation Hydraulic HosesGeneral Information O-Ring Face SealSAE Straight Thread O-Ring Port - Non-adjustable SAE Straight Thread O-Ring Port - AdjustableHydraulic System Rev. A Page 4Towing Traction Unit Check Hydraulic System FluidNOT OVERFILL ISO type 46/68 anti-wear hydraulic fluidHydraulic Schematic HydraulicPage Hydraulic Schematic Rev. AHydraulic Systems Page 4Hydraulic Flow Diagrams Traction ForwardHydraulic System Rev. A Page 4Traction Forward Page 4 Hydraulic System Rev. AHydraulic Systems Traction Reverse Hydraulic System Rev. APage 4 Sand Pro 2020/3020/5020Hydraulic System Rev. A Traction ReverseHydraulic Systems PageRetract and Extend Lift Cylinder Hydraulic System Rev. APage 4 Sand Pro 2020/3020/5020Page 4 Hydraulic System Rev. A Extend and Retract lift CylinderHydraulic Systems EXTEND LIFT CYLINDERSpecial Tools Hydraulic Pressure Test Kit - TOR47009Hydraulic Tester Pressure and Flow - TOR214678 Hydraulic System Rev. AHydraulic Test Fitting Kit - TOR4079 Hydraulic Test FittingsTORO TEST FITTING KIT NO. TOR4079 HydraulicTroubleshooting ProblemHydraulic System Page 4 - 16 Rev. BTroubleshooting cont ProblemSand Pro 2020/3020/5020 Page 4Troubleshooting cont ProblemHydraulic System Rev. A Page 4 - 18 Rev. BTesting Precautions for Hydraulic TestingBefore Performing Hydraulic Tests HydraulicTEST NO. 1 Traction Pump Flow P1 Hydraulic System Rev. APage 4 Sand Pro 2020/3020/5020Procedure for Traction Pump Flow P1 Fig.12 HydraulicSystems Sand Pro 2020/3020/5020Hydraulic System Rev. A Page 4Sand Pro 2020/3020/5020 1. Charge test port SP 2020/3020Hydraulic SystemsPage 4 - 23 Rev. B Hydraulic System Rev. ATEST NO. 3 Charge Pump P2 Flow Hydraulic System Rev. APage 4 Sand Pro 2020/3020/5020Procedure for Charge Pump P2 Flow HydraulicSystems Sand Pro 2020/3020/5020TEST NO. 4 Wheel Motor Efficiency Hydraulic System Rev. APage 4 Sand Pro 2020/3020/5020Procedure for Wheel Motor Efficiency Make sure the tester flow control valve is fully openHydraulic SystemsAdjust Traction Pedal for Neutral Adjust Traction Pedal for Forward SP 2020/3020Adjustments Hydraulic System Rev. AAdjust Traction Pedal for Forward SP HydraulicSystems Sand Pro 2020/3020/5020Adjust Lift Lever SP 2020/3020 Adjust Lift Lever SPHydraulic System Rev. A Page 4Check Hydraulic Lines and Hoses Charge Hydraulic SystemService and Repairs HydraulicA. Loose filter or suction lines Hydraulic System Rev. APage 4 Sand Pro 2020/3020/5020Change Hydraulic System Fluid and Filter Sand Pro 2020/3020/5020Page 4 Hydraulic System Rev. ALift Valve SP 2020/3020 Hydraulic System Rev. APage 4 Sand Pro 2020/3020/5020Installation Fig Removal FigHydraulic SystemsLift Valve SP Hydraulic System Rev. APage 4 Sand Pro 2020/3020/5020Installation Fig Removal FigHydraulic SystemsLift Valve DisassemblyReassembly InspectionLift Cylinder SP 2020/3020 InstallationRemoval HydraulicLift CylinderSP InstallationRemoval Hydraulic System Rev. ALift Cylinder Service DisassemblyReassembly HydraulicHydrostat SP 2020/3020 Removal FigHydraulic System Rev. A Page 4Installation Fig HydraulicSystems Sand Pro 2020/3020/5020Hydrostat SP Removal FigHydraulic System Rev. A Page 4Installation Fig HydraulicSystems Sand Pro 2020/3020/50206. Reinstall engine and hydrostat as follows Hydraulic System Rev. APage 4 Sand Pro 2020/3020/5020Flush Hydraulic System HydraulicSystems Sand Pro 2020/3020/5020Hydrostat Service HYDROSTAT IS ILLUSTRATED FROM BELOWHydraulic System Rev. A Page 4 - 48 Rev. BCharge Pump Disassembly Charge Pump AssemblyCharge Pump Inspection HydraulicShaft Seal Installation Shaft Seal RemovalHydraulic System Rev. A Page 4Acceleration Valve Assembly Fig Relief Valve Disassembly FigRelief Valve Assembly Fig Charge Check Valve Disassembly FigTraction Pump Disassembly 6. Position variable housing so the large cavity faces up FigHydraulic System Rev. A Page 4Traction Pump Inspection HydraulicSystems Sand Pro 2020/3020/5020Traction Pump Assembly 1. Make sure all parts are cleaned thoroughly and freeHydraulic System Rev. A Page 4Hydraulic SystemsSand Pro 2020/3020/5020 Page 4Front Wheel Motor Removal FigHydraulic System Rev. A Page 4Installation Fig HydraulicSystems Sand Pro 2020/3020/5020Rear Wheel Motors SP 2020/3020 Hydraulic System Rev. APage 4 Sand Pro 2020/3020/5020Installation Fig. 57 or Removal Fig. 57 orHydraulic SystemsRear Wheel Motors SP Adjustment clevisHydraulic System Rev. A Page 4Installation Fig. 57 or Removal Fig. 57 orHydraulic SystemsWheel Motor Service End cover assembly Front & LHHydraulic System Rev. A Page 4Disassembly Fig Use eye protection such as goggles when using compressed airHydraulic SystemsUse eye protection such as goggles when using compressed air Inspection FigHydraulic System Rev. A Page 4Hydraulic SystemsSand Pro 2020/3020/5020 Page 4Use eye protection such as goggles when using compressed air Assembly FigHydraulic System Rev. A Hydraulic SystemsSand Pro 2020/3020/5020 Page 4Hydraulic System Rev. A Hydraulic SystemsSand Pro 2020/3020/5020 Page 4Hydraulic Tank SP 2020/3020 30 to 60 ft-lb35 to 69 kg-cm Hydraulic System Rev. AInstallation Fig Removal FigInspection Fig HydraulicHydraulic Oil Cooler SP 2020/3020 Hydraulic System Rev. APage 4 Sand Pro 2020/3020/5020Cleaning and Inspection Fig Use eye protection such as goggles when using compressed airInstallation Fig Removal FigHydraulic Tank and Oil Cooler SP Oil Cooler Removal FigHydraulic System Rev. A Page 4Use eye protection such as goggles when using compressed air Oil Cooler Inspection FigHydraulic SystemsOil Cooler Installation Fig Hydraulic Tank Installation FigHydraulic Tank Removal Fig Hydraulic Tank Inspection FigElectrical Systems Table of ContentsChapter ElectricalElectrical Schematics and DiagramsSand Pro 2020/3020 Electrical SchematicHarness and Wiring Diagram Sand Pro 2020/3020Electrical SystemsSand Pro Electrical SchematicElectrical Systems Page 5 BLACKHarness and Wiring Diagram Sand ProElectrical SystemsMultimeter Skin-Over GreaseSpecial Tools Electrical SystemsStarting Problems TroubleshootingProblem Possible CausesStarting Problems continued General Run and Transport ProblemsProblem ProblemBattery Test Open Circuit Test Electrical System Quick ChecksBattery Charge Level Voltage MeasuredComponent Testing Ignition SwitchElectrical Systems Page 5Hour Meter 0 0 0 0SP 2020/3020 ElectricalNeutral Switch Starter Solenoid3.1 ohms Electrical SystemsBattery Storage Battery CareService and Repairs ElectricalBattery Service Removal Fig. 10 andElectrical Systems Page 5Inspection, Maintenance, and Testing Fig Follow the manufacturer’s instructions when us- ing a battery testerElectrical SystemsBattery Electrolyte Installation Fig. 10 andFollow the manufacturer’s instructions when us- ing a battery charger Battery ChargeCheck Interlock System manufacturer’s battery charger instructions or the following tableBattery Battery Charge LevelOptional Lights Electrical SystemsPage 5 Sand Pro 2020/3020/5020Wheels, Brakes, and Miscellaneous Table of ContentsChapter Sand Pro 2020/3020/5020Specifications Wheels, Brakes, and MiscellaneousPage 6 Sand Pro 2020/3020/5020Adjust Steering Chain AdjustmentsSand Pro 2020/3020/5020 Page 6Adjust Brake SP 2020/3020 Adjust Brake SPWheels, Brakes, and Miscellaneous Page 6Seat SP 2020/3020 Service and RepairsInstallation RemovalFront Wheel SP Removal FigWheels, Brakes, and Miscellaneous Page 6Installation Fig 7. Lower front wheel to groundSand Pro 2020/3020/5020 Page 6Front Wheel SP 3020 and SP Removal FigWheels, Brakes, and Miscellaneous Page 6Installation Fig Sand Pro 2020/3020/5020Page 6 Wheels, Brakes,and MiscellaneousRear Wheels and Brakes Removal FigWheels, Brakes, and Miscellaneous Page 68. Disassemble brake assembly as follows Fig Installation FigSand Pro 2020/3020/5020 Page 6Brake Linkages SP 2020/3020 RIGHTFRONT Wheels, Brakes, and MiscellaneousBrake Linkages SP RIGHTFRONT Sand Pro 2020/3020/5020Front Fork and Steering SP 2020 and Older SP 3020 Models Wheels, Brakes, and MiscellaneousPage 6 Sand Pro 2020/3020/5020Front Fork and Steering Newer SP 3020 Models Sand Pro 2020/3020/5020Page 6 Wheels, Brakes,and MiscellaneousUpper Steering Disassembly Fig. 13 and Upper Steering Assembly Fig. 13 andWheels, Brakes, and Miscellaneous Page 6Lower Steering Disassembly Fig. 13 and Lower Steering Assembly Fig. 13 andFront Fork Installation Fig. 13 and Front Fork Removal Fig. 13 and6. Install front wheel to the front fork see Front Wheel Installation Wheels, Brakes, and MiscellaneousPage 6 Sand Pro 2020/3020/5020Seat SP InstallationRemoval Sand Pro 2020/3020/5020Steering SP Wheels, Brakes, and MiscellaneousPage 6 Sand Pro 2020/3020/5020Upper Steering Disassembly Fig Upper Steering Assembly FigLower Steering Disassembly Fig. 13 and Lower Steering Assembly Fig. 13 andFront Fork SP Installation FigRemoval Fig Wheels, Brakes, and MiscellaneousHood and Dash Panel SP 2020/3020 InstallationRemoval Sand Pro 2020/3020/5020Fenders SP Seat Base Installation FigRight Fender Installation Fig. 25 and Left FenderSeat Base Removal FigPage Commercial Products E The Toro Company