Service Manual
Sand ProR 2020/3020/5020
Preface
E The Toro Company - 1998, 2003
Sand Pro 2020/3020/5020
Table Of Contents
Chapter 1 - Safety
Engine Product Records Safety and Manuals
Chapter 2 - Product Records and Manuals
Sand Pro 2020/3020/5020
Safety
Table of Contents
General Safety Instructions
Chapter
While Operating
Safety
Page 1
Sand Pro 2020/3020/5020
Maintenance and Service
Safety
Safety
Sand Pro 2020/3020/5020
Jacking Instructions
Safety
Jacking the Front End
Jacking the Rear End
Safety and Instruction Decals
ON NEUTRAL ADJUST MECHANISM
Safety
Safety
Safety and Instruction Decals
ON NEUTRAL ADJUST
ON LEFT FENDER Part No ON CENTER PANEL Part No Safety
ON BATTERY
Product Records and Maintenance
Product Records
Table of Contents
Product Records and Maintenance
Equivalents and Conversions
Product Records and Maintenance
Page 2
Sand Pro 2020/3020/5020
Torque Specifications
Product Records and Maintenance
Product Records and Maintenance
Sand Pro 2020/3020/5020
Lubrication
Product Records and Maintenance
Sand Pro 2020/3020 Early Models
Sand Pro 2020/3020 Late Models
Product Records and Maintenance
Product Records and Maintenance
Sand Pro 2020/3020/5020
Page 2
Product Records and Maintenance
Page 2
Sand Pro 2020/3020/5020
EQUIPMENT OPERATION AND SERVICE HISTORY REPORT for
Sand ProR 2020/3020/5020
Sand Pro R 2020/3020/5020 Maintenance Schedule
Minimum Recommended Maintenance Intervals
Maintenance Procedure
Maintenance Interval & Service
Sand Pro R 2020/3020/5020 Daily Maintenance Checklist
Daily Maintenance duplicate this page for routine use
Maintenance
Daily Maintenance Check For Week Of
A- Service every 25 hours
B - Service every 100 hours
C - Service every 400 hours
D - Service every 800 houurs
Engine
Table of Contents
Chapter
Engine
Introduction
Engine
Page 3
Sand Pro 2020/3020/5020
Specifications
Engine
Sand Pro 2020/3020/5020
Page 3
General Information
Check Engine Oil
Engine
Page 3
Fuel Shutoff Valve
Engine
Sand Pro 2020/3020/5020
Page 3
DANGER
Fill Fuel Tank
Engine
Page 3
Adjustments
Adjust Throttle Control
Adjust Choke Control
Engine
Service and Repairs
Service Engine Air Cleaner
Change Engine Oil and Filter
Engine
Service Remote Air Cleaner
Use eye protection such as goggles when using compressed air
Engine
Sand Pro 2020/3020/5020
Throttle and Choke Controls
Throttle Control Removal
Engine
Page 3
Throttle Control Installation
Choke Control Removal
Engine
Sand Pro 2020/3020/5020
Replace Fuel Filter
Choke Control Installation
sure not to damage carburetor gasket while instal- ling base Fig
Engine
Remote Air Cleaner SP 2020/3020
Remote Air Cleaner Removal
Remote Air Cleaner Installation
Sand Pro 2020/3020/5020
Remote Air Cleaner SP
Remote Air Cleaner Removal
Remote Air Cleaner Installation
Engine
Muffler SP
Muffler Installation
Muffler Removal
Engine
Muffler SP 2020/3020
Muffler Removal
Engine
Page 3
Muffler Installation
Engine
Sand Pro 2020/3020/5020
Page 3
Fuel Tank SP 2020/3020
Engine
Page 3
Sand Pro 2020/3020/5020
Fuel Tank installation Fig
DANGER
Fuel Tank Removal Fig
Engine
Fuel Tank SP
DANGER
Fuel Tank Removal Fig
Engine
Fuel Tank installation Fig
Engine
Sand Pro 2020/3020/5020
Page 3
Engine SP 2020/3020
Wire harness Ground wire
Engine
Page 3
Engine Removal Fig
Engine
Sand Pro 2020/3020/5020
Page 3
Engine Installation Fig
1. Install engine 16 to the engine base
Engine
Page 3
Replace Spark Plugs
0.030 inch 0.762 mm
Sand Pro 2020/3020/5020
Page 3
Engine SP
Engine
Page 3
Sand Pro 2020/3020/5020
Engine Removal Fig
Engine
Sand Pro 2020/3020/5020
Page 3
Engine Installation Fig
Engine
Page 3
Sand Pro 2020/3020/5020
Engine
Sand Pro 2020/3020/5020
Page 3
Engine
Clean Cylinder Head Fins
Use eye protection such as goggles when using compressed air
Engine
Page 3
Hydraulic Systems
Table of Contents
Chapter
Hydraulic
Specifications
Hydraulic System
Page 4 - 2 Rev. B
Sand Pro 2020/3020/5020
Hydraulic Fitting Installation
Hydraulic Hoses
General Information
O-Ring Face Seal
SAE Straight Thread O-Ring Port - Non-adjustable
SAE Straight Thread O-Ring Port - Adjustable
Hydraulic System Rev. A
Page 4
Towing Traction Unit
Check Hydraulic System Fluid
NOT OVERFILL
ISO type 46/68 anti-wear hydraulic fluid
Hydraulic
Hydraulic Schematic
Page
Hydraulic Schematic
Rev. A
Hydraulic Systems
Page 4
Hydraulic Flow Diagrams
Traction Forward
Hydraulic System Rev. A
Page 4
Page 4 Hydraulic System Rev. A
Traction Forward
Hydraulic Systems
Traction Reverse
Hydraulic System Rev. A
Page 4
Sand Pro 2020/3020/5020
Hydraulic System Rev. A
Traction Reverse
Hydraulic Systems
Page
Retract and Extend Lift Cylinder
Hydraulic System Rev. A
Page 4
Sand Pro 2020/3020/5020
Page 4 Hydraulic System Rev. A
Extend and Retract lift Cylinder
Hydraulic Systems
EXTEND LIFT CYLINDER
Special Tools
Hydraulic Pressure Test Kit - TOR47009
Hydraulic Tester Pressure and Flow - TOR214678
Hydraulic System Rev. A
Hydraulic Test Fitting Kit - TOR4079
Hydraulic Test Fittings
TORO TEST FITTING KIT NO. TOR4079
Hydraulic
Troubleshooting
Problem
Hydraulic System
Page 4 - 16 Rev. B
Troubleshooting cont
Problem
Sand Pro 2020/3020/5020
Page 4
Troubleshooting cont
Problem
Hydraulic System Rev. A
Page 4 - 18 Rev. B
Testing
Precautions for Hydraulic Testing
Before Performing Hydraulic Tests
Hydraulic
TEST NO. 1 Traction Pump Flow P1
Hydraulic System Rev. A
Page 4
Sand Pro 2020/3020/5020
Procedure for Traction Pump Flow P1 Fig.12
Hydraulic
Systems
Sand Pro 2020/3020/5020
Hydraulic System Rev. A
Page 4
Sand Pro 2020/3020/5020
1. Charge test port SP 2020/3020
Hydraulic
Systems
Page 4 - 23 Rev. B
Hydraulic System Rev. A
TEST NO. 3 Charge Pump P2 Flow
Hydraulic System Rev. A
Page 4
Sand Pro 2020/3020/5020
Procedure for Charge Pump P2 Flow
Hydraulic
Systems
Sand Pro 2020/3020/5020
TEST NO. 4 Wheel Motor Efficiency
Hydraulic System Rev. A
Page 4
Sand Pro 2020/3020/5020
Procedure for Wheel Motor Efficiency
Make sure the tester flow control valve is fully open
Hydraulic
Systems
Adjust Traction Pedal for Neutral
Adjust Traction Pedal for Forward SP 2020/3020
Adjustments
Hydraulic System Rev. A
Adjust Traction Pedal for Forward SP
Hydraulic
Systems
Sand Pro 2020/3020/5020
Adjust Lift Lever SP 2020/3020
Adjust Lift Lever SP
Hydraulic System Rev. A
Page 4
Check Hydraulic Lines and Hoses
Charge Hydraulic System
Service and Repairs
Hydraulic
A. Loose filter or suction lines
Hydraulic System Rev. A
Page 4
Sand Pro 2020/3020/5020
Change Hydraulic System Fluid and Filter
Sand Pro 2020/3020/5020
Page 4
Hydraulic System Rev. A
Lift Valve SP 2020/3020
Hydraulic System Rev. A
Page 4
Sand Pro 2020/3020/5020
Installation Fig
Removal Fig
Hydraulic
Systems
Lift Valve SP
Hydraulic System Rev. A
Page 4
Sand Pro 2020/3020/5020
Installation Fig
Removal Fig
Hydraulic
Systems
Lift Valve
Disassembly
Reassembly
Inspection
Lift Cylinder SP 2020/3020
Installation
Removal
Hydraulic
Lift CylinderSP
Installation
Removal
Hydraulic System Rev. A
Lift Cylinder Service
Disassembly
Reassembly
Hydraulic
Hydrostat SP 2020/3020
Removal Fig
Hydraulic System Rev. A
Page 4
Installation Fig
Hydraulic
Systems
Sand Pro 2020/3020/5020
Hydrostat SP
Removal Fig
Hydraulic System Rev. A
Page 4
Installation Fig
Hydraulic
Systems
Sand Pro 2020/3020/5020
6. Reinstall engine and hydrostat as follows
Hydraulic System Rev. A
Page 4
Sand Pro 2020/3020/5020
Flush Hydraulic System
Hydraulic
Systems
Sand Pro 2020/3020/5020
Hydrostat Service
HYDROSTAT IS ILLUSTRATED FROM BELOW
Hydraulic System Rev. A
Page 4 - 48 Rev. B
Charge Pump Disassembly
Charge Pump Assembly
Charge Pump Inspection
Hydraulic
Shaft Seal Installation
Shaft Seal Removal
Hydraulic System Rev. A
Page 4
Acceleration Valve Assembly Fig
Relief Valve Disassembly Fig
Relief Valve Assembly Fig
Charge Check Valve Disassembly Fig
Traction Pump Disassembly
6. Position variable housing so the large cavity faces up Fig
Hydraulic System Rev. A
Page 4
Traction Pump Inspection
Hydraulic
Systems
Sand Pro 2020/3020/5020
Traction Pump Assembly
1. Make sure all parts are cleaned thoroughly and free
Hydraulic System Rev. A
Page 4
Hydraulic
Systems
Sand Pro 2020/3020/5020
Page 4
Front Wheel Motor
Removal Fig
Hydraulic System Rev. A
Page 4
Installation Fig
Hydraulic
Systems
Sand Pro 2020/3020/5020
Rear Wheel Motors SP 2020/3020
Hydraulic System Rev. A
Page 4
Sand Pro 2020/3020/5020
Installation Fig. 57 or
Removal Fig. 57 or
Hydraulic
Systems
Rear Wheel Motors SP
Adjustment clevis
Hydraulic System Rev. A
Page 4
Installation Fig. 57 or
Removal Fig. 57 or
Hydraulic
Systems
Wheel Motor Service
End cover assembly Front & LH
Hydraulic System Rev. A
Page 4
Disassembly Fig
Use eye protection such as goggles when using compressed air
Hydraulic
Systems
Use eye protection such as goggles when using compressed air
Inspection Fig
Hydraulic System Rev. A
Page 4
Hydraulic
Systems
Sand Pro 2020/3020/5020
Page 4
Assembly Fig
Use eye protection such as goggles when using compressed air
Hydraulic System Rev. A
Hydraulic
Systems
Sand Pro 2020/3020/5020
Page 4
Hydraulic System Rev. A
Hydraulic
Systems
Sand Pro 2020/3020/5020
Page 4
Hydraulic Tank SP 2020/3020
30 to 60 ft-lb
35 to 69 kg-cm
Hydraulic System Rev. A
Installation Fig
Removal Fig
Inspection Fig
Hydraulic
Hydraulic Oil Cooler SP 2020/3020
Hydraulic System Rev. A
Page 4
Sand Pro 2020/3020/5020
Cleaning and Inspection Fig
Use eye protection such as goggles when using compressed air
Installation Fig
Removal Fig
Hydraulic Tank and Oil Cooler SP
Oil Cooler Removal Fig
Hydraulic System Rev. A
Page 4
Use eye protection such as goggles when using compressed air
Oil Cooler Inspection Fig
Hydraulic
Systems
Oil Cooler Installation Fig
Hydraulic Tank Installation Fig
Hydraulic Tank Removal Fig
Hydraulic Tank Inspection Fig
Electrical Systems
Table of Contents
Chapter
Electrical
Electrical Schematics and
Diagrams
Sand Pro 2020/3020
Electrical Schematic
Harness and Wiring Diagram
Sand Pro 2020/3020
Electrical
Systems
Sand Pro
Electrical Schematic
Electrical Systems Page 5
BLACK
Harness and Wiring Diagram
Sand Pro
Electrical
Systems
Multimeter
Skin-Over Grease
Special Tools
Electrical Systems
Starting Problems
Troubleshooting
Problem
Possible Causes
Starting Problems continued
General Run and Transport Problems
Problem
Problem
Battery Test Open Circuit Test
Electrical System Quick Checks
Battery Charge Level
Voltage Measured
Component Testing
Ignition Switch
Electrical Systems
Page 5
Hour Meter
0 0 0 0
SP 2020/3020
Electrical
Neutral Switch
Starter Solenoid
3.1 ohms
Electrical Systems
Battery Storage
Battery Care
Service and Repairs
Electrical
Battery Service
Removal Fig. 10 and
Electrical Systems
Page 5
Inspection, Maintenance, and Testing Fig
Follow the manufacturer’s instructions when us- ing a battery tester
Electrical
Systems
Battery Electrolyte
Installation Fig. 10 and
Follow the manufacturer’s instructions when us- ing a battery charger
Battery Charge
Check Interlock System
manufacturer’s battery charger instructions or the following table
Battery
Battery Charge Level
Optional Lights
Electrical Systems
Page 5
Sand Pro 2020/3020/5020
Wheels, Brakes, and Miscellaneous
Table of Contents
Chapter
Sand Pro 2020/3020/5020
Specifications
Wheels, Brakes, and Miscellaneous
Page 6
Sand Pro 2020/3020/5020
Adjust Steering Chain
Adjustments
Sand Pro 2020/3020/5020
Page 6
Adjust Brake SP 2020/3020
Adjust Brake SP
Wheels, Brakes, and Miscellaneous
Page 6
Seat SP 2020/3020
Service and Repairs
Installation
Removal
Front Wheel SP
Removal Fig
Wheels, Brakes, and Miscellaneous
Page 6
Installation Fig
7. Lower front wheel to ground
Sand Pro 2020/3020/5020
Page 6
Front Wheel SP 3020 and SP
Removal Fig
Wheels, Brakes, and Miscellaneous
Page 6
Installation Fig
Sand Pro 2020/3020/5020
Page 6
Wheels, Brakes,and Miscellaneous
Rear Wheels and Brakes
Removal Fig
Wheels, Brakes, and Miscellaneous
Page 6
8. Disassemble brake assembly as follows Fig
Installation Fig
Sand Pro 2020/3020/5020
Page 6
Brake Linkages SP 2020/3020
RIGHT
FRONT
Wheels, Brakes, and Miscellaneous
Brake Linkages SP
RIGHT
FRONT
Sand Pro 2020/3020/5020
Front Fork and Steering SP 2020 and Older SP 3020 Models
Wheels, Brakes, and Miscellaneous
Page 6
Sand Pro 2020/3020/5020
Front Fork and Steering Newer SP 3020 Models
Sand Pro 2020/3020/5020
Page 6
Wheels, Brakes,and Miscellaneous
Upper Steering Disassembly Fig. 13 and
Upper Steering Assembly Fig. 13 and
Wheels, Brakes, and Miscellaneous
Page 6
Lower Steering Disassembly Fig. 13 and
Lower Steering Assembly Fig. 13 and
Front Fork Installation Fig. 13 and
Front Fork Removal Fig. 13 and
6. Install front wheel to the front fork see Front Wheel Installation
Wheels, Brakes, and Miscellaneous
Page 6
Sand Pro 2020/3020/5020
Seat SP
Installation
Removal
Sand Pro 2020/3020/5020
Steering SP
Wheels, Brakes, and Miscellaneous
Page 6
Sand Pro 2020/3020/5020
Upper Steering Disassembly Fig
Upper Steering Assembly Fig
Lower Steering Disassembly Fig. 13 and
Lower Steering Assembly Fig. 13 and
Front Fork SP
Installation Fig
Removal Fig
Wheels, Brakes, and Miscellaneous
Hood and Dash Panel SP 2020/3020
Installation
Removal
Sand Pro 2020/3020/5020
Fenders SP
Seat Base Installation Fig
Right Fender Installation Fig. 25 and
Left FenderSeat Base Removal Fig
Page
Commercial Products
E The Toro Company