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