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