Toro Sand Pro 2020, Sand Pro 3020, Sand Pro 5020 User Manual

Sand ProR 2020/3020/5020

Preface

The purpose of this publication is to provide the service technician with information for troubleshooting, testing, and repair of major systems and components on the Sand Pro 2020/3020/5020.

REFER TO THE OPERATOR’S MANUALS FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. Space is provided in Chapter 2 of this book to insert the Operator’s Manuals and Parts Catalogs for your machine. Replacement Operator’s Manuals are available by sending complete Model and Serial Number to:

The Toro Company 8111 Lyndale Avenue South Bloomington, MN 55420–1196

The Toro Company reserves the right to change product specifications or this publication without notice.

PART NO. 98957SL, Rev. B

Service Manual

This safety symbol means DANGER, WARNING, or CAUTION, PERSONAL SAFETY INSTRUCTION. When you see this symbol, carefully read the instructions that follow. Failure to obey the instructions may result in personal injury.

NOTE: A NOTE will give general information about the

correct operation, maintenance, service, testing, or re pair of the machine.

IMPORTANT: The IMPORTANT notice will give important instructions which must be followed to prevent damage to systems or components on the machine.

E The Toro Company – 1998, 2003, 2006

Sand Pro 2020/3020/5020

Chapter 1 – Safety

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 1

Jacking Instructions Safety and Instruction Decals

Chapter 2 – Product Records and Manuals

Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 1

Equivalents and Conversions Torque Specifications Lubrication Operation and Service History Reports

Chapter 3 – Engine

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 2

Specifications General Information Adjustments Service and Repairs Briggs & Stratton Vanguard Service and Repair Manual

for 4–Cycle V–Twin Cylinder OHV Engines

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 4

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 7

. . . . . . . . . . . . . . . . . . . . . . . . . 1 – 4

. . . . . . . . . . . . . . . . 1 – 5

. . . . . . . . . . . . . . . . 2 – 2

. . . . . . . . . . . . . . . . . . . . . . . 2 – 3

. . . . . . . . 2 – 7

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 3

. . . . . . . . . . . . . . . . . . . . . . . . 3 – 4

. . . . . . . . . . . . . . . . . . . . . . . . 3 – 8

Chapter 4 – Hydraulic Systems

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 2

General Information Hydraulic Schematics Hydraulic Flow Diagrams Special Tools Trouble Shooting Testing Adjustments Service and Repairs

Chapter 5 – Electrical Systems

Electrical Schematics and Diagrams . . . . . . . . . . 5 – 2

Special Tools Troubleshooting Electrical System Quick Checks Component Testing Service and Repairs

Chapter 6 – Wheels, Brakes, and Miscellaneous

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 2

Adjustments Service and Repairs

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 19

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 14

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 28

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 6

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 3

. . . . . . . . . . . . . . . . . . . . . . . . 4 – 3

. . . . . . . . . . . . . . . . . . . . . . . 4 – 6

. . . . . . . . . . . . . . . . . . . . 4 – 8

. . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 16

. . . . . . . . . . . . . . . . . . . . . . . 4 – 31

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 7

. . . . . . . . . . . . . . 5 – 9

. . . . . . . . . . . . . . . . . . . . . . . . 5 – 10

. . . . . . . . . . . . . . . . . . . . . . . 5 – 13

. . . . . . . . . . . . . . . . . . . . . . . . 6 – 5

SafetyProduct Records

and Manuals

Engine

Systems

Hydraulic

Systems

Electrical

Wheels, Brakes

and Miscellaneous

Sandpro 2020/3020/5020

Sand Pro 2020/3020/5020

Chapter 1

Safety

GENERAL SAFETY INSTRUCTIONS . . . . . . . . . . . . 1

Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Maintenance and Service . . . . . . . . . . . . . . . . . . . . 3

General Safety Instructions

The Sand Pro 2020/3020/5020 were tested and certified by TORO for compliance with the B71.4–1984 specifica tions of the American National Standards Institute. Although hazard control and accident prevention partially are dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern, and proper training of the person nel involved in the operation, transport, maintenance, and storage of the machine. Improper use or mainte nance of the machine can result in injury or death.

Before Operating

1. Operate machine only after reading and understanding the contents of this manual. A replacement manual is available by sending complete model and se rial number to:

The Toro Company 8111 Lyndale Avenue South Minneapolis, Minnesota 55420–1196

JACKING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . 4

SAFETY AND INSTRUCTION DECALS . . . . . . . . . . 5

Sand Pro 2020/3020 Sand Pro 5020

To reduce the potential for injury or death, comply with the following safety instructions.

7. Ensure traction interlock switch is adjusted correctly so engine cannot be started unless traction pedal is re leased and in neutral position.

8. Keep everyone, especially children and pets away from the areas of operation.

9. Gasoline is highly flammable; handle it carefully.

. . . . . . . . . . . . . . . . . . . . . . . . 5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

WARNING

Safety

2. Never allow children to operate the machine or adults to operate it without proper instructions.

3. Become familiar with the controls and know how to stop the engine quickly.

4. Keep all shields, safety devices and decals in place. If a shield, safety device or decal is malfunctioning, illeg ible, or damaged, repair or replace it before operating the machine.

5. Always wear substantial shoes. Do not operate machine while wearing sandals, tennis shoes or sneakers. Do not wear loose fitting clothing which could get caught in moving parts and cause personal injury.

6. Wearing safety glasses, safety shoes, long pants and a helmet is advisable and required by some local safety and insurance regulations.

Sand Pro 2020/3020/5020

Page 1 – 1

A. Use an approved gasoline container. B. Do not remove cap from fuel tank when engine is

hot or running. C. Do not smoke while handling gasoline. D. Fill fuel tank outdoors to about one inch below

top of tank, (bottom of filler neck). Do not overfill. E. Wipe up any spilled gasoline.

10. Check the safety interlock system daily for proper operation (see Check Interlock System in Chapter 5 – Electrical Systems). If the switch should malfunction, re place switch before operating machine. (After every two years, replace interlock switch in the safety system, whether it is working properly or not.)

Safety

While Operating

1 1. Exhaust fumes are hazardous and could be deadly, so do not run the engine in a confined area without ade quate ventilation.

12. Sit on seat when operating the machine. Never carry passengers.

13. When starting the engine: A. Make sure traction pedal is released. B. After the engine is started, keep foot off traction

pedal. Machine must not move. If movement is evi dent, the neutral return mechanism is adjusted incorrectly; therefore, shut engine off and readjust mechanism so machine does not move when in neutral position. If engine does not start, check in terlock switch connections.

14. Using the machine demands attention. To prevent

tipping or loss of control:

A. Use care when entering and leaving sand traps. Use extreme caution around ditches, creeks or oth er hazards.

15. If optional Draw Bar (Part No. 92–2330) or Hitch Kit (Model No. 08833) is installed on machine, vertical load on hitch should not exceed 200 lbs.

16. Do not touch engine, muffler or exhaust pipe while engine is running or soon after it has stopped because these areas are hot enough to cause burns.

17. If the machine ever vibrates abnormally, stop immediately , turn engine off, wait for all motion to stop and inspect for damage. Repair all damage before com mencing operation.

18. Before getting off the seat: A. Stop movement of the machine. B. Set parking brake and lower attachments to the

ground. Take precautions to prevent accidental starts, rolling away, etc.

19. Whenever machine is left unattended, be sure en-

gine is stopped, parking brake is set, attachments are lowered to the ground, and key is removed from ignition.

B. Watch for holes or other hidden hazards. C. Use caution when operating machine on a steep

slope. Reduce speed when making sharp turns or when turning on hillsides.

D. Avoid sudden stops and starts. Do not go from reverse to full forward without first coming to a com plete stop.

E. Before backing up, look to the rear and assure no one is behind the machine.

F . Watch out for traf fic when near of crossing roads. Always yield the right of way.

Safety

Page 1 – 2

Sand Pro 2020/3020/5020

Maintenance and Service

20. Before servicing or making adjustments to the machine, stop engine, remove key from the ignition, and pull the spark plug wire off spark plug to prevent acci dental starting of the engine.

21. Make sure all hydraulic line connectors are tight,and all hydraulic hoses and lines are in good condition be fore applying pressure to the system.

22. Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not hands, to search for leaks. Hydraulic fluid escaping under pressure can have suffi cient force to penetrate skin and do serious damage. If fluid is injected into the skin it must be surgically re moved within a few hours by a doctor familiar with this form of injury or gangrene may result.

23. Before disconnecting or performing any work on the hydraulic system, all pressure in system must be re lieved by stopping engine, engaging parking brake and lowering attachments to the ground.

24. To make sure entire machine is in good condition, keep all nuts, bolts and screws properly tightened.

25. If major repairs are ever needed or assistance is required, contact an Authorized TORO Distributor.

26. To reduce potential fire hazard, keep the engine area free of excessive grease, grass, leaves and accu mulation of dirt.

27. If the engine must be running to perform a maintenance adjustment, keep hands, feet, clothing, and any parts of the body away from the engine and any moving

parts. Keep everyone away.

28. Do not overspeed engine by changing governor settings. Maximum engine speed is 3200 rpm. To assure

safety and accuracy , have an Authorized Toro Distribu tor check maximum engine speed with a tachometer.

29. Engine must be shut off before checking oil or adding oil to the crankcase.

30. To be sure of optimum performance and safety, always purchase genuine TORO replacement parts and

accessories. Replacement parts and accessories made

by other manufacturers could be dangerous. Such use could void the product warranty of The Toro Company.

31. When changing attachments, tires, or performing

other service, use correct blocks, hoists, and jacks.

Make sure machine is parked on a solid level floor such as a concrete floor. Prior to raising the machine, remove any attachments that may interfere with the safe and proper raising of the machine. Always chock or block wheels. Used jack stands or solid wood blocks to sup port the raised machine. If the machine is not properly supported by blocks or jack stands, the machine may move or fall, which may result in personal injury.

Safety

Sand Pro 2020/3020/5020

Page 1 – 3

Safety

Jacking Instructions

CAUTION

When changing attachments, tires, or performing other service, use correct blocks, hoists, and jacks. Make sure machine is parked on a solid level floor such as a concrete floor. Prior to raising the machine, remove any attachments that may interfere with the safe and proper raising of the machine. Always chock or block wheels. Used jack stands or solid wood blocks to support the raised machine. If the machine is not properly supported by blocks or jack stands, the machine may move or fall, which may result in personal injury.

Use the following positions when jacking up the machine:

Jacking the Front End

Figure 1

1. On the SP 2020/3020, jack from below the front cross support that is above the retaining strip for the rub ber shield (Fig. 1).

2. On the SP 5020, jack from below the front cross support tube on the bottom of the frame (Fig. 2).

Jacking the Rear End

1. On the SP 2020/3020, jack from below the square tube of the frame (Fig. 3).

2. On the SP 5020, jack from below the square tube of the frame (Fig. 3).

Figure 2

Figure 3

Safety

Page 1 – 4

Figure 4

Sand Pro 2020/3020/5020

Safety and Instruction Decals

The following safety and instruction decals are installed on the Sand Pro 2020/3020. If any become damaged or illegible, replace them. Decal part numbers are listed below and in the parts catalog. Order replacements from your Authorized Toro Distributor.

93–9051

ON NEUTRAL ADJUST

MECHANISM

(Part No. 93–9051)

Safety

UNDER SEA T PLATE

(Part No. 95–0646)

ON ENGINE SHIELD

(Part No. 92–8985)

ON VALVE SHROUD

(Part No. 95–0647)

ON ENGINE SHIELD

(Part No. 95–0645)

Sand Pro 2020/3020/5020

ON DASH P ANEL

(Part No. 95–0648)

Page 1 – 5

Safety

Safety and Instruction Decals

The following safety and instruction decals are installed on the Sand Pro 5020. If any become damaged or illegible, replace them. Decal part numbers are listed below and in the parts catalog. Order replacements from your Authorized Toro Distributor.

ON BOTH SIDES OF FAN SHROUD (2)

(Part No. 93–7272)

UNDER SEA T PLATE

(Part No. 98–0977)

ON NEUTRAL ADJUST

MECHANISM

(Part No. 93–9051)

ON RIGHT FENDER

(Part No. 98–0975)

ON FRAME & BOTH SIDES

OF CENTER PANEL (3)

(Part No. 93–9052)

ON MUFFLER SHIELD

(Part No. 95–0645)

Safety

ON LEFT FENDER (Part No. 93–9053)

ON CENTER P ANEL

(Part No. 93–9050)

ON RIGHT FENDER

(Part No. 93–7442)

Page 1 – 6

ON BATTERY

(Part No. 93–7276)

UNDER BA TTERY

(Part No. 93–6668)

Sand Pro 2020/3020/5020

Product Records and Maintenance

Chapter 2

PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . 1

EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . 2

Decimal and Millimeter Equivalents . . . . . . . . . . . . 2

U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . 2

Product Records

Record maintenance and repair information about your Sand Pro 2020/3020/5020 on the OPERATION AND SERVICE HISTORY REPORT form. Use this informa tion when referring to your machine.

TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . 3

Capscrew Markings and Torque Values – U.S. . . 3

Capscrew Markings and Torque Values – Metric 3

LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

OPERATION & SERVICE HISTORY REPORTS . . . 7

Insert Operator’s Manuals and Parts Catalogs for your Sand Pro 2020/3020/5020 at the end of this section.

Product Records

and Maintenance

Sand Pro 2020/3020/5020

Page 2 – 1

Product Records and Maintenance

Equivalents and Conversions

Product Records and Maintenance

Page 2 – 2

Sand Pro 2020/3020/5020

Torque Specifications

Product Records

and Maintenance

Sand Pro 2020/3020/5020

Page 2 – 3

Product Records and Maintenance

Lubrication

CAUTION

Before servicing or making adjustments to the machine, stop engine, set parking brake, and remove key from the ignition switch.

Lubricate grease fittings regularly with No. 2 general purpose lithium base grease. Lubricate front wheel bearing and traction control linkage every 25 hours of operation. Lubricate steering shaft and steering shaft sprocket every 100 hours.

Sand Pro 2020/3020 (Early Models)

The three fittings that must be lubricated are: front wheel bearing (Fig. 1), traction control linkage (Fig. 3) and steering shaft (Fig. 4).

Sand Pro 2020/3020 (Late Models)

The four fittings to lubricated are: front wheel bearing (Fig. 1), traction control linkage (Fig. 3) and steering shaft and steering chain sprocket shaft(Fig. 5).

Figure 1

Sand Pro 5020

The four fittings to lubricate are: front wheel bearing (Fig. 2), traction control linkage (Fig. 3), and both the steering shaft and steering chain sprocket shaft (Fig. 6).

NOTE: On the Sand Pro 5020, gain access to the grease fitting on the traction control linkage (Fig. 3) by removing the right side panel.

1. Wipe grease fitting clean so foreign matter cannot be forced into the bearing or bushing.

2. Pump grease into the bearing or bushing. Wipe up excess grease.

NOTE: Do not lubricate steering chain unless it becomes stiff from rust. If the chain rusts, it may be lubricated lightly with a dry type lubricant.

Figure 2

Figure 3

Product Records and Maintenance

Page 2 – 4

Figure 4

Sand Pro 2020/3020/5020

Figure 5

Figure 6

Product Records

and Maintenance

Sand Pro 2020/3020/5020

Page 2 – 5

Product Records and Maintenance

Page 2 – 6

Sand Pro 2020/3020/5020

EQUIPMENT OPERATION AND SERVICE HISTORY REPORT

for

Sand ProR 2020/3020/5020

TORO Model and Serial Number: _____________–___________ Engine Numbers: _________________________ Transmission Numbers: _________________________ Date Purchased: _________________________ Warranty Expires___________ Purchased From: _________________________

_________________________ _________________________

Product Records

and Maintenance

Contacts: Parts Phone___________________

Service Phone___________________ Sales Phone___________________

_________________________ _________________________ _________________________

See your TORO Distributor for other Publications, Manuals, and Videos from the TORO company.

Sand Pro 2020/3020/5020

Page 2 – 7

Product Records and Maintenance

Sand Pro R 2020/3020/5020 Maintenance Schedule

Minimum Recommended Maintenance Intervals:

Maintenance Procedure Maintenance Interval & Service

Check Battery Fluid Level Check Battery Cable Connections

{ Change Engine Oil

Lubricate Front Wheel Bearing Lubricate Traction Control LInkage

Replace Engine Oil Filter Inspect Remote Air Cleaner Element Inspect Engine Air Cleaner Element Lubricate Steering Shaft Grease Fitting Check Steering Chain Adjustment

{

Torque Wheel Lug Nuts Change Hydraulic Oil

{ Replace Hydraulic Oil Filter

Replace Remote Air Cleaner Element Replace Engine Air Cleaner Element

Replace Spark Plugs Replace Fuel Filter Decarbonize Combustion Chamber Adjust Valves and Torque Head Bolts Check Engine RPM (idle and full throttle) Drain and Clean Fuel Tank

Every 25hrs

A–Level

Service

Every

100hrs

B–Level

Service

Every

400hrs

C–Level

Service

Every

800hrs

D–Level

Service

{ Initial break in at 8 hours

Replace Moving Hoses Replace Traction Interlock (Safety) Switch

(See proper section of Operator’s and Service Manuals for procedures and fluid specifications.)

Product Records and Maintenance

Items listed are recommended every 1,500 hours

Page 2 – 8

Annual Recommendations:

or 2 years, whichever comes first.

Sand Pro 2020/3020/5020

Sand Pro R 2020/3020/5020 Daily Maintenance Checklist

Daily Maintenance: (duplicate this page for routine use)

Maintenance Check Item b

n Safety Interlock Operation n Steering Operation n Engine Oil Level n Remote/Engine Air Cleaner Condition

Clean Engine Cooling Fins

n Unusual Engine Noises n Unusual Operating Noises n Hydraulic System Oil Level n Hydraulic Hoses for Damage n Fluid Leaks n Fuel Level n Tire Pressure n Instrument Operation

Touch–up Damaged Paint

Daily Maintenance Check For Week Of ____________

MON TUES WED THURS FRI SAT SUN

Notation for areas of concern: Inspection performed by:__________________

Item Date Information

Product Records

and Maintenance

1 2 3 4 5 6 7 8

(Check proper section of Operator’s and Service Manuals for procedures and fluid specifications.)

Sand Pro 2020/3020/5020

Page 2 – 9

Product Records and Maintenance

Date: ________________

_______________________________

Remarks:

Change Hydraulic Oil

Replace Hydraulic Oil Filter

Replace Remote Air Cleaner Element

Replace Engine Air Cleaner Element

C – Service (every 400 hours)

A and B – Sevice required

_______________________________

Maintenance Supervisor Work Order

A B C D Other

__________________–__________________

Sand Pro 2020/3020/5020

TORO I.D. #:

Unit Designation:

(Duplicate this page for routine use.)

Service to perform (circle):

Hours:

Technician:

Replace Engine Oil Filter

Inspect Remote Air Cleaner Element

Check Battery Fluid Level

A– Service (every 25 hours) B – Service (every 100 hours)

Check Battery Cable Connections

Lubricate Steering Shaft Grease Fitting

Inspect Engine Air Cleaner Element

Change Engine Oil

Check Steering Chain Adjustment

Lubricate Traction Control Linkage

Lubricate Front Wheel Bearing

A – Service required

Torque Wheel Lug Nuts

________________________________

_______________________________

________________________________

_______________________________

Replace Moving Hoses

A, B, C, and D – Service Required

Replace Traction Interlock (Safety) Switch

_______________________________

_______________________________ _______________________________

Other – Annual Service and Specials

________________________________

Replace Spark Plugs

Replace Fuel Filter

Adjust Valves and Torque Head Bolts

Decarbonize Combustion Chamber

Drain and Clean Fuel Tank

Check Engine RPM (idle and full throttle)

A, B, and C – Sevice required

D – Service (every 800 houurs)

_______________________________

________________________________

(See Operator’s and Service Manual for specifications and procedures.)

Product Records and Maintenance

Page 2 – 10

Sand Pro 2020/3020/5020

Chapter 3

Engine

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

SPECIFICA TIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 4

Check Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Fuel Shutoff Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Fill Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Adjust Throttle Control . . . . . . . . . . . . . . . . . . . . . . . 7

Adjust Choke Control . . . . . . . . . . . . . . . . . . . . . . . . 7

SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 8

Change Engine Oil and Filter . . . . . . . . . . . . . . . . . 8

Service Engine Air Cleaner . . . . . . . . . . . . . . . . . . . 8

Service Remote Air Cleaner . . . . . . . . . . . . . . . . . . 9

Throttle and Choke Controls . . . . . . . . . . . . . . . . . 10

Throttle Control Removal Throttle Control Installation Choke Control Removal

Choke Control Installation

Replace Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . 12

Remote Air Cleaner (SP 2020/3020) Remote Air Cleaner (SP 5020)

. . . . . . . . . . . . . . . . . . 10

. . . . . . . . . . . . . . . . . 11

. . . . . . . . . . . . . . . . . . . . 11

. . . . . . . . . . . . . . . . . 12

. . . . . . . . . . 13

. . . . . . . . . . . . . . . 14

Muffler (SP 5020) . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Muffler (SP 2020/3020) . . . . . . . . . . . . . . . . . . . . . 16

Muffler Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Muffler Installation . . . . . . . . . . . . . . . . . . . . . . . . 17

Fuel Tank (SP 2020/3020) . . . . . . . . . . . . . . . . . . . 18

Fuel Tank Removal . . . . . . . . . . . . . . . . . . . . . . . 19

Fuel Tank Installation . . . . . . . . . . . . . . . . . . . . . . 19

Fuel Tank (SP 5020) . . . . . . . . . . . . . . . . . . . . . . . . 20

Fuel Tank Removal . . . . . . . . . . . . . . . . . . . . . . . 20

Fuel Tank Installation . . . . . . . . . . . . . . . . . . . . . . 21

Engine (SP 2020/3020) . . . . . . . . . . . . . . . . . . . . . 22

Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . 24

Replace Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . 25

Engine (SP 5020) . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . 28

Clean Cylinder Head Fins . . . . . . . . . . . . . . . . . . . 30

BRIGGS & STRATTON VANGUARD SERVICE AND

REPAIR MANUAL FOR 4–CYCLE V–TWIN CYLINDER OHV ENGINES

Engine

Sand Pro 2020/3020/5020 Page 3 – 1 Engine

Introduction

This Chapter gives information about specifications, maintenance, troubleshooting, testing, and repair of the gasoline engines used in the Sand Pro 2020, 3020, and

5020. Most repairs and adjustments require tools which are

commonly available in many service shops. Special tools are described in the Briggs and Stratton V anguard Repair and Service Manual for 4–Cycle V–Twin Cylin der OHV Engines. The use of some specialized test

equipment is explained. However, the cost of the test equipment and the specialized nature of some repairs may dictate that the work be done at an engine repair fa cility .

Service and repair parts for Briggs and Stratton Vanguard engines are supplied through your local Briggs and Stratton dealer or distributor. If no parts list is avail able, be sure to provide your distributor with the Toro model and serial number.

Engine

Page 3 – 2

Sand Pro 2020/3020/5020

Specifications

Item Description

Make / Designation Briggs and Stratton Vanguard, 4–Cycle, V–Twin Cylinder, OHV,

Air Cooled, Gasoline Engine

Horse Power

SP 2020/3020 16 HP @ 3600 RPM SP 5020 18 HP @ 3600 RPM

Bore mm (in.)

SP 2020/3020 68.0 (2.677) SP 5020 71.98 (2.834)

Total Displacement cc (cu. in.)

SP 2020/3020 480 (29.3) SP 5020 570 (34.8)

Fuel Unleaded Regular Grade Gasoline

Fuel Capacity liters (gallons)

SP 2020/3020 16.1 (4.25) SP 5020 20.8 (5.50)

Fuel Pump Pulsating Crankcase Vacuum

Governor Mechanical

Low Idle (no load) 1750 + 50 RPM

Engine

High Idle (no load) 3150 + 50 RPM

Intake and Exhaust Valve Seat Angle 45_

Intake and Exhaust Valve Clearance (Cold) mm (in.) 0.10 to 0.15 (0.004 to 0.006)

Carburetor Single Barrel, Float Feed with Suppress Afterfire Solenoid

Engine Oil SAE 30 SE, SF, or SG

Oil Pump Internal Gear Driven Gerotor Type

Crankcase Oil Capacity liters (U.S. qt.) 1.66 (1.75) with filter

Starter 12 VDC

Alternator/Regulator 12 VDC 16 AMP

Spark Plug Champion RC12YC or NGK BKR4E or Equivalent

Spark Plug Gap mm (in.) 0.76 (0.030)

Sand Pro 2020/3020/5020 Page 3 – 3 Engine

General Information

Check Engine Oil

CAUTION

Before servicing or making adjustments to the machine, make sure of the following: stop engine, engage parking brake, lower attachment, and remove key from the switch.

IMPORTANT: Check oil level every 8 operating hours or daily. Change oil initially after the first 8 hours of operation. Thereafter, change oil every 25 hours and filter every 100 hours under normal con ditions. Change oil more frequently when the engine is operated in extremely dusty or dirty conditions.

The engine is shipped with 1–3/4 quarts (w/ filter) of oil in the crankcase; however, oil level must be checked be fore and after the engine is first started.

1. Position machine on a level surface.

2. Unscrew dipstick and wipe it with a clean rag. Screw dipstick into the tube, and make sure it is seated fully. Unscrew dipstick out of the tube. Check oil level. If oil level is low, remove filler cap from the valve cover (next to dipstick), and add enough oil to raise the level to the FULL mark on the dipstick.

Figure 1

1. Dipstick 2. Filler cap

3. The engine uses any high-quality detergent oil having the American Petroleum Institute -API- “service classification” SE, SF or SG. Recommended viscosity (weight) is SAE 30.

IMPORTANT: Dipstick must be fully seated in tube to provide proper sealing of engine crankcase. Fail ure to seal crankcase may result in engine damage.

4. Install dipstick firmly into the tube.

Engine

Page 3 – 4

Sand Pro 2020/3020/5020

Fuel Shutoff Valve

This valve should be shut when removing the engine or placing the unit in long term storage.

On the SP 2020/3020, the shutoff valve can be accessed from the rear of the machine (Fig. 2).

On the SP 5020, the shutoff valve can be accessed by removing the left side panel (Fig. 3).

Figure 2

1. Fuel shutoff valve 2. Hydraulic oil filter

Engine

Figure 3

1. Fuel shutoff valve 2. Hydraulic oil tank

Sand Pro 2020/3020/5020 Page 3 – 5 Engine

Fill Fuel Tank

IMPORTANT: The Toro Company strongly recommends using fresh, clean, unleaded gasoline in Toro gasoline powered products. Un leaded gasoline burns cleaner, extends engine life, and promotes good starting by reducing the build– up of combustion chamber deposits. Leaded gaso line can be used if unleaded is not available.

IMPORTANT: Never use methanol, gasoline containing methanol, gasoline containing more than 10% ethanol, gasoline additives, premium gasoline, or white gas. Damage may result to engine fuel sys tem.

NOTE: Fuel tank capacity is about 4.25 gallons for the

SP 2020/3020 and 5.5 gallons for the SP 5020.

1. Clean area around fuel tank cap.

2. Remove fuel tank cap.

3. Fill tank about one inch below top of the tank, (bottom of filler neck). DO NOT OVERFILL. Then install cap.

4. Prevent a fire hazard. Wipe up any spilled fuel.

regular grade

Gasoline is flammable; use caution when storing

or handling it. Do not fill fuel tank while the engine is running, hot, or when machine is in an enclosed area. V apors may build up, and can be ignited by a spark or flame source many feet away . Prevent the possibility of an explosion. DO NOT SMOKE while filling the fuel tank. Always fill fuel tank outside. Wipe up any spilled gasoline before starting the engine. Use a funnel or spout to prevent spilling gasoline. Fill tank no higher than one inch below top of tank, (bottom of filler neck). DO NOT OVER FILL. Store gasoline in a clean safety approved container and keep the cap on the container. Keep gasoline in a cool, well–ventilated place; never store in an enclosed area such as a hot storage shed. To assure volatility, do not buy more than a 30 day supply of gasoline. Gasoline is a fuel for internal combustion engines; do not use it for any other purpose. Many children like the smell of gas, so keep it out of their reach. Gas fumes are explosive and dangerous to inhale.

DANGER

Engine

Page 3 – 6

Sand Pro 2020/3020/5020

Adjustments

Adjust Throttle Control

Proper throttle operation is dependent upon the proper adjustment of the throttle control. Before adjusting the carburetor, assure throttle control is operating properly.

1. Pivot seat up. On the SP 2020/3020, remove the engine shield.

2. Loosen cable clamp screw securing the cable to the engine.

3. Move remote throttle control lever forward to the FAST position.

4. Pull firmly on the throttle cable until the back of throttle swivel contacts the throttle stop.

5. Tighten cable clamp screw. Check engine idle setting.

A. High Idle: 3150 50 B. Low Idle: 1750 50

Adjust Choke Control

Figure 4

1. Cable clamp screw 4. Throttle stop

2. Throttle cable 5. Cable clamp screw

3. Throttle swivel 6. Choke cable

Engine

1. Pivot seat up. On the SP 2020/3020, remove the engine shield.

2. Remove air cleaner cover, cover plate, and air cleaner filter element from the air cleaner base (See Service Engine Air Cleaner).

3. Loosen cable clamp screw securing the choke cable to engine

(Fig. 4).

4. Pull choke control knob out completely from dash panel (SP 2020/3020). Shift choke lever to the choke position (SP 5020).

NOTE: Newer engine models will have a different carburetor shield that has five hex head flange screws securing the shield and air cleaner base to the carburetor.

5. Pull firmly on the choke cable until the choke butterfly is completely closed. Make sure choke control knob is still pulled out completely or the choke lever is shifted

to choke, then tighten cable clamp screw

(Fig. 4).

6. Reinstall air cleaner filter element, cover plate, and air cleaner cover to the air cleaner base

(See Service

Engine Air Cleaner).

Figure 5

1. Carburetor shield 4. Carburetor shield (newe

2. Air cleaner base

3. Choke butterfly

models)

Sand Pro 2020/3020/5020 Page 3 – 7 Engine

Service and Repairs

Change Engine Oil and Filter

Change oil initially after the first 8 hours of operation. Thereafter, change oil every 25 hours and filter every 100 hours.

1. Park machine on a level surface. Turn engine off.

2. Pivot seat up. On the SP 2020/3020, remove the engine shield.

3. Remove drain plug and let oil flow into drain pan. When oil stops, install drain plug.

4. Remove oil filter. Apply a light coat of clean oil to the new filter gasket.

5. Screw filter on by hand until gasket contacts filter adapter, then tighten 1/2 to 3/4 turn further. DO NOT OVER–TIGHTEN.

6. Add oil to crankcase (see Check Engine Oil). Dispose of oil properly.

Figure 6

1. Drain plug 2. Oil filter

Service Engine Air Cleaner

Inspect paper element every 100 hours of operation. Replace element every 400 hours or when dirty or damaged. Do not wash paper element or do not clean with compressed air as damage will occur.

1. Park machine on a level surface. Turn engine off.

2. Pivot seat up. On the SP 2020/3020, remove the engine shield.

3. Remove knobs and air cleaner cover.

4. Remove filter element and cover plate. Inspect filter for cleanliness, ruptures, holes, and tears. Replace defective filter element.

5. With air cleaner disassembled, check air cleaner components for damage. Replace if necessary.

A. Make sure rubber breather tube in base plate is securely in place or severe engine damage may occur.

B. Make sure carburetor breather hose is routed out through engine vents.

1. Knob

2. Cover

3. Knob

Figure 7

4. Cover plate

5. Filter element

6. Air cleaner base

6. Reinstall filter element. Secure element with cover plate and knob. Reinstall air cleaner cover and secure with knobs.

Engine

Page 3 – 8

Sand Pro 2020/3020/5020

Service Remote Air Cleaner

Inspect air cleaner filter element every 100 hours of operation. Replace every 400 hours or when dirty or damaged

1. Check air cleaner body and body for damage that could cause possible air leaks. Replace damaged air cleaner body or cover (see Remote Air Cleaner Remov al and Installation).

2. Release latches securing air cleaner cover to air cleaner body. Separate cover from the body. Clean in side of the air cleaner cover.

3. Wash filter element with soap and water as follows: A. Prepare a solution of filter cleaner and water.

Soak filter element about 15 minutes. See filter cleaner carton for detailed instructions.

B. After soaking filter for 15 minutes, rinse it with clear water. Maximum water pressure must not ex ceed 40 psi to prevent damage to the filter element. Rinse filter element from clean side to dirty to side.

C. Dry filter element using warm, flowing air not ex ceeding 160_F, or allow element to air–dry. Do not use a light bulb to dry the filter element because damage may result.

ÇÇ

Figure 8

1. Latch 3. Body

2. Cover 4. Filter element

Engine

CAUTION

Use eye protection such as goggles when using compressed air.

4. Clean filter element with compressed air as follows: A. Blow compressed air from the inside to the out-

side of the dry filter element. Do not exceed 100 psi to prevent damage to the element.

B. Keep air hose nozzle at least 2 inches from the filter. Move nozzle up and down while rotating the filter element. Inspect for holes and tears by looking through the filter toward a bright light.

5. Inspect new filter element for shipping damage.

Check sealing end of element. Do not install a damaged filter element.

6. Insert new filter element properly into the air cleaner

body . Make sure element is sealed properly by applying pressure to outer rim of filter when installing. Do not press on flexible center of filter.

Figure 9

1. Latch

2. Cover 4. Air inlet hood

3. Body

7. Reinstall cover and secure latches. Make sure cov-

er is positioned with TOP side up. Sand Pro 2020/3020/5020 Page 3 – 9 Engine

Throttle and Choke Controls

Figure 10

1. Knob 4. Cap screw 7. Hex nut

2. Throttle control 5. Dash Panel (SP 2020/3020) 8. Lock Washer

3. Lock nut 6. Right fender (SP 5020) 9. Choke control

Throttle Control Removal

1. Park machine on a level surface, lower attachment, stop engine, engage parking brake, and remove key from the ignition switch.

2. Pivot seat up. On the SP 2020/3020, remove the engine shield.

3. On the SP 2020/3020 remove three hex flange head screws securing the hood to the front shield (Fig. 11). Remove four cap screws securing the dash panel to the hood (Fig. 12). Remove hood from the machine.

4. Release throttle cable from clamp securing it to the engine. Disconnect throttle cable from the swivel on the engine (Fig. 13).

5. Remove throttle knob from the throttle control. Remove both lock nuts and cap screws securing the throttle control to the dash panel or right fender. Remove throttle control from the machine (Fig. 10).

Figure 11

1. Hex flange head screw 3. Front shield

2. Hood

Engine

1. Cap screws 3. Hood

2. Dash panel

Page 3 – 10

Figure 12

Sand Pro 2020/3020/5020

Throttle Control Installation

1. Secure throttle control to the dash panel or right

fender with both cap screws and lock nuts. Install throttle control knob to the throttle control lever (Fig. 10).

2. Connect throttle cable to the swivel on the engine.

Attach cable to engine with clamp. Make sure not to tighten cap screw securing clamp and cable to engine (Fig. 13).

3. On the SP 2020/3020, position hood to the dash

panel and front shield. Secure hood to front shield with three hex flange head screws (Fig. 11). Secure dash panel to hood with four cap screws (Fig. 12).

4. Adjust throttle control (see Adjust Throttle Control).

Install cover over the engine.

Choke Control Removal

1. Park machine on a level surface, lower attachment,

stop engine, engage parking brake, and remove key from the ignition switch.

2. Pivot seat up. On the SP 2020/3020, remove the en-

gine shield.

3. On the SP 2020/3020 remove three hex flange head

screws securing the hood to the front shield (Fig. 11). Remove four cap screws securing the dash panel to the hood (Fig. 12). Remove hood from the machine.

Figure 13

1. Throttle cable 3. Swivel

2. Clamp 4. Air cleaner

3 1

6 7

Engine

4. Remove air hose from air cleaner cover. Remove air

cleaner cover. Remove cover plate and air cleaner ele ment from the air cleaner base (Fig. 14).

NOTE: Newer engine models will have a different carburetor shield that has five hex head flange screws securing the shield and air cleaner base to the carburetor.

5. Remove two cap screws and three hex head flange

screws securing air cleaner base to the carburetor. Re move base carefully from carburetor. Make sure not to damage carburetor gasket. Cover carburetor to prevent dirt and debris from entering (Fig. 15).

6. Release choke cable from clamp securing it to the

engine. Disconnect choke cable from the choke pivot le ver on the engine (Fig. 16).

7. On the SP 2020/3020 remove hex nut and lock

washer securing the choke control to the dash panel. Pull choke control and cable from dash panel (Fig. 10).

8. On the SP 5020, remove choke knob from the

choke control. Remove both lock nuts and cap screws securing the choke control to the right fender. Remove choke control from the machine (Fig. 10).

1. Hose clamp 5. Air cleaner knob

2. Air hose 6. Cover plate

3. Air cleaner cover 7. Air cleaner element

4. Air cleaner knob 8. Air cleaner base

Figure 14

Figure 15

1. Cap screw 4. Air cleaner base

2. Carburetor shield 5. Carburetor shield (newe

3. Hex head flange screw models)

Sand Pro 2020/3020/5020 Page 3 – 11 Engine

Choke Control Installation

1. On the SP 2020/3020 insert choke cable and control through the dash panel. Secure choke control to the panel with lock washer and hex nut (Fig. 10).

2. On the SP 5020, secure choke control to the dash panel or right fender with both cap screws and lock nuts. Install knob to the choke control lever (Fig. 10).

3. Connect choke cable to the choke pivot lever. Attach cable to engine with clamp. Make sure not to tighten cap screw securing clamp and cable to engine (Fig. 16).

4. Remove any covering protecting the carburetor inlet. Install air cleaner base carefully to carburetor. Make

sure not to damage carburetor gasket while instal ling base (Fig. 15).

NOTE: Newer engine models will have a different car-

buretor shield that has five hex head flange screws securing the shield and air cleaner base to the carburetor.

5. Secure air cleaner base and carburetor shield to the carburetor with two cap screws and three hex head flange screws (Fig. 15).

Replace Fuel Filter

Figure 16

1. Carburetor 3. Clamp

2. Choke cable 4. Choke pivot lever

6. Install air cleaner element and cover plate to the air

cleaner base. Secure air cleaner cover to air cleaner. Secure air hose to air cleaner cover. (Fig. 14).

7. Position hood to the dash panel and front shield. Secure hood to front shield with three hex flange head screws (Fig. 11). Secure dash panel to hood with four cap screws (Fig. 12).

8. Adjust choke control (see Adjust Choke Control). Install cover over the engine.

The fuel filter on the SP 2020/3020 can be accessed from the rear of the machine. It is located just left of the hydrostat (Fig. 17).The fuel filter on the SP 5020 can be accessed by pivoting up the seat up. It is located just for ward and right of the engine (Fig. 18).

An in–line filter is incorporated into the fuel line. Change filter every 800 hours. Use the following procedure when replacement becomes necessary:

1. Close fuel shutoff valve.

CAUTION

Since gasoline is highly flammable, drain it outdoors and make sure engine is cool to prevent a potential fire hazard. Wipe up any gasoline that may have spilled. Do not drain gasoline near any open flame or where gasoline fumes may be ignited by a spark. Do not smoke a cigar, cigarette, or a pipe when handling gasoline.

2. Clamp both fuel hoses connected to the fuel filter so gasoline cannot drain when hoses are removed. Loosen hose clamps. Pull fuel hoses off the filter.

Figure 17

1. Fuel hose 3. Fuel filter

2. Hose clamp

3. Secure new filter to hoses with hose clamps. Make sure arrow on the side of filter points toward the carbure tor. Remove clamps that were used to prevent drainage.

Engine

Page 3 – 12

1. Fuel hose 3. Fuel filter

2. Hose clamp

Sand Pro 2020/3020/5020

Figure 18

Remote Air Cleaner (SP 2020/3020)

Remote Air Cleaner Removal

1. Park machine on a level surface, lower attachment,

stop the engine, engage parking brake, and remove the key from the ignition switch.

2. Remove three cap screws securing the hood to the

front shield (Fig 19). Remove four cap screws securing the dash panel to the hood (Fig. 20).

3. Loosen hose clamp. Remove air hose from the air

cleaner body (Fig. 21).

4. Remove both lock nuts, flat washers, and cap

screws securing the mounting band to the front shield (Fig. 21).

5. Unlatch and remove cover from filter body. Sepa-

rate filter body from the mounting band. Make sure not to drop the filter element (Fig. 21).

Remote Air Cleaner Installation

1. Insert filter body through the mounting band. Install

and latch cover to the filter body (Fig. 21).

Figure 19

1. Hex flange head screw 3. Front shield

2. Hood

Engine

2. Secure mounting band and air cleaner to the front

shield with both cap screws, flat washers, and lock nuts (Fig. 21).

3. Secure air hose to the air cleaner with hose clamp

(Fig. 21).

4. Position hood to the front shield. Potion dash panel

to the hood. Secure dash panel to the hood with four cap screws (Fig. 20). Secure hood to the front shield with three cap screws (Fig 19).

Figure 20

1. Cap screws 3. Hood

2. Dash panel

Figure 21

1. Hose clamp 4. Lock nut & flat washer

2. Air hose 5. Mounting band

3. Air cleaner body 6. Cover

Sand Pro 2020/3020/5020 Page 3 – 13 Engine

Remote Air Cleaner (SP 5020)

Remote Air Cleaner Removal

1. Park machine on a level surface, lower attachment, stop the engine, engage parking brake, and remove the key from the ignition switch.

2. Loosen hose clamp. Remove air cleaner hose from the air cleaner body.

3. Remove both lock nuts, flat washers, and cap screws securing the mounting band to the right fender.

4. Unlatch and remove cover from air cleaner body. Separate body from the mounting band. Make sure not to drop the filter element.

Remote Air Cleaner Installation

1. Insert air cleaner body through the mounting band. Make sure filter element is inside the body. Install and latch cover to the air cleaner body.

2. Secure mounting band and air cleaner to the front shield with both cap screws, flat washers, and lock nuts.

3. Secure air hose to the air cleaner with hose clamp.

Figure 22

1. Body 4. Latch

2. Cap screw & flat washer 5. Cover

3. Mounting band

Engine

Page 3 – 14

Sand Pro 2020/3020/5020

Muffler (SP 5020)

Muffler Removal

1. Park machine on a level surface, lower attachment,

stop the engine, engage parking brake, and remove the key from the ignition switch.

CAUTION

The muffler and exhaust pipe may be hot. To avoid possible burns, allow engine and exhaust system to cool before working on the muffler.

2. Access muffler from the rear of the machine. Re-

move muffler shield from the engine by removing three cap screws and lock washers securing it to the engine (Fig. 23 and 24).

3. Remove cap screws securing muffler and both gas-

kets to the cylinder heads. Pull muffler from the engine (Fig. 24 and 25).

Muffler Installation

1. Replace gaskets if torn or damaged. Replace ex-

haust detector if worn or damaged.

Figure 23

1. Cap screw & lock washer 2. Muffler shield

Engine

2. Secure gaskets and muffler to cylinder heads with

cap screws (Fig. 24 and 25).

3. Secure muffler shield to the engine with three cap

screws and lock washers (Fig. 23 and 24).

Figure 24

1. Cap screw 5. Muffler

2. Lock washer 6. Gasket

3. Muffler shield 7. Screw

4. Cap screw 8. Exhaust deflector

Figure 25

1. Muffler 2. Cylinder head

Sand Pro 2020/3020/5020 Page 3 – 15 Engine

Muffler (SP 2020/3020)

Muffler Removal

1. Park machine on a level surface, lower attachment, stop the engine, engage parking brake, and remove the key from the ignition switch.

2. Chock front wheel to prevent machine from moving with both rear wheels jacked up. Jack up rear wheels enough to allow the muffler to be removed through the bottom of the machine. Block up rear wheels (See Jack ing Instructions in Chapter 1 – Safety).

CAUTION

The muffler and exhaust pipe may be hot. To avoid possible burns, allow the engine and exhaust system to cool before working on the muffler.

3. Remove knob from the lift lever . Remove both lock nuts and cap screws securing the lift valve shroud, lift le ver guide, and lift lever latch (Fig. 26).

4. Remove bottom front cap screw securing the lift valve shroud to the frame. Pull shroud from the frame (Fig. 26).

Figure 26

1. Knob 4. Lift lever guide & latch

2. Lock nut & cap screw 5. Cap screw

3. Lift valve shroud

5. Remove cotter pins from both adjusting rods. Separate adjusting rods from both brake arms (Fig. 27).

6. Remove cotter pin from the brake rod. Separate brake rod from the traverse rod lever (Fig. 28).

7. Loosen both hex flange head screws and lock nuts on each side flange bearing. Lower traverse rod from the frame (Fig. 28).

8. Remove three cap screws and star washers securing the muffler shield, R–clamp, and fuel hose to the engine (Fig. 29).

9. Remove hex nut, cap screw, flat washer securing the muffler tab to the muffler bracket (Fig. 30).

10. Remove both muffler clamps securing the exhaust tube to the muffler and exhaust manifold (Fig. 31).

11. Separate exhaust tube from the exhaust manifold. Separate exhaust tube from the muffler . Remove muffler through the bottom of the machine (Fig. 31).

Figure 27

1. Cotter pin 3. Brake arm

2. Adjusting rod

Figure 28

1. Cotter pin 4. Lock nut

2. Brake rod 5. Flange bearing

3. Traverse rod lever

Engine

Page 3 – 16

Sand Pro 2020/3020/5020

Muffler Installation

1. Position muffler through the bottom of the machine

to the muffler bracket. Insert cap screw with flat washer through the muffler tab and then the muffler bracket. Screw hex nut onto the cap screw, but do not tighten (Fig. 30).

2. Attach exhaust tube to the muffler. Attach exhaust

tube to the exhaust manifold (Fig. 31).

3. Make sure exhaust tube fits snugly to both the muf-

fler and exhaust manifold. Secure exhaust tube to the exhaust manifold and muffler with muffler clamps (Fig.

31).

4. Tighten cap screw and hex nut securing the muffler

to the muffler bracket (Fig. 30).

Figure 29

1. Cap screw & star washer 2. Muffler shield

5. Secure R–clamp and muffler shield to the engine

with three cap screws and star washers (Fig. 29).

6. Position traverse rod to the frame. Make sure each

side flange bearing is on the inside of the frame. Secure bearings to the frame by tightening both hex flange head screws on each bearing (Fig. 28).

7. Connect brake rod to the traverse rod lever. Secure

brake rod with cotter pin (Fig. 28).

8. Connect adjusting rods to both brake arms. Secure

both adjusting rods with a cotter pin (Fig. 27).

9. Secure top of lift valve shroud, lift lever guide, and

lift lever latch to the frame with both cap screws and lock nuts. Make sure nylon lift lever guide is placed on top of metal lift lever latch (Fig. 26).

10. Secure bottom of shroud to frame with cap screw.

Screw knob onto lift lever (Fig. 26).

11. Lower rear wheels to the ground after removing

blocks.

Figure 30

1. Lock nut & cap screw 3. Muffler bracket

2. Muffler

Engine

Figure 31

1. Muffler clamps 3. Muffler

2. Exhaust tube

Sand Pro 2020/3020/5020 Page 3 – 17 Engine

Fuel Tank (SP 2020/3020)

ANTISEIZE LUBRICANT

30 TO 60 IN–LB (35 TO 69 KG–CM)

1. Fuel cap

2. Fuel tank

3. Grommet

4. Fuel tank base

5. Lock nut

6. Philips pan head screw

7. Hose clamp

8. Fuel hose

9. Fuel hose clip

10. Wing nut

11. Flat washer

12. Battery clamp

Engine

13. Cap screw

14. Flat washer

15. Battery

16. Battery bolt

17. Lock nut

18. Cap screw

19. Lock nut

20. R–clamp

21. Socket button head screw

22. Fuel hose

23. Hose clamp

Page 3 – 18

Figure 32

24. Fuel shutoff valve

25. Grommet

26. Litter box

27. Battery wire (ground)

28. Flat washer

29. Battery decal

30. Danger decal

31. Fuel filter

32. Fuel hose

33. Terminal boot

34. Battery wire (start solenoid)

Sand Pro 2020/3020/5020

Fuel Tank Removal (Fig. 32)

1. Park machine on a level surface, lower attachment,

stop the engine, engage parking brake, and remove the key from the ignition switch.

2. Pivot seat up. Remove litter box (26) from the frame.

3. Disconnect and remove battery from the machine to

prevent possible spillage of fuel on the battery (see Bat tery Service in Chapter 5 – Electrical Systems).

DANGER

Gasoline is flammable. Use caution when storing or handling it. Do not drain fuel tank while the engine is running, or when the machine is in an enclosed area. Vapors may build up and be ignited by a spark or flame source many feet away. DO NOT SMOKE while draining the fuel tank to prevent the possibility of an explosion. Always drain fuel tank outside. Wipe up any spilled gasoline. Store gasoline in a clean, safety–approved container, and secure cap on the container. Keep gasoline in a cool, well ventilated place and never in an enclosed area such as a hot storage shed. Since many children like the smell of gas, keep it out of their reach because the fumes are explosive and dangerous to inhale.

4. Drain fuel tank (2) as follows: A. Close fuel shutoff valve (24). B. Disconnect fuel hose (22) from the fuel filter (31).

Use funnel and hose to drain the fuel into a suitable container for storage.

C. Drain fuel tank completely by opening the fuel shutoff valve. Close fuel shutoff valve when tank is drained.

5. Loosen hose clamp (7) and disconnect fuel hose (8)

from the bottom of the fuel tank (2).

Figure 33

1. Cap screw & lock washer 2. Filter head

Fuel Tank installation (Fig. 32)

1. If the fuel tank base (4) was removed, A. Secure fuel tank base (4) to the frame with three

cap screws (13), flat washers (14), lock nuts (5). B. Securing filter head to the base with both cap

screws and lock washers (Fig. 33).

2. Position fuel tank (2) to the fuel tank base (4). A. Apply antiseize lubricant to the threads of the

four philips pan head screws (6). B. Make sure grommets (3) are in place. Secure

fuel tank to the base with four flat washers (4) and pan head screws.

C. Torque cap screws from 30 to 60 in–lb (35 to 69 kg–cm).

3. Connect and secure fuel hose (8) to the fuel tank (2)

with hose clamp (7).

4. Connect and secure fuel hose (22) to the fuel filter

(31) with hose clamp (23).

5. Open fuel shutoff valve (9) below the fuel tank.

Engine

6. Remove four philips pan head screws (6) and flat washers (28) securing the fuel tank (2) to the fuel tank base (4).

7. Lift fuel tank (2) from fuel tank base (4). Make sure not to lose grommets (3).

8. If the fuel tank base (4) is to be removed, A. Remove both cap screws and lock washers se-

curing the filter head to the base (Fig. 33). B. Remove three lock nuts, cap screws, and flat

washers securing the base to the frame.

Sand Pro 2020/3020/5020 Page 3 – 19 Engine

6. Install and connect battery to the machine (see Battery Service in Chapter 5 – Electrical Systems).

7. Install litter box (26) to the frame. Pivot seat down.

8. Fill fuel tank with fuel (see Fill fuel T ank). Check fuel lines and tank for leaks.

Fuel Tank (SP 5020)

1. Fuel tank

2. Fuel cap

3. Steering boot

4. Boot retainer

5. R–clamp

6. Self tapping screw

7. Fuel hose

8. Hose clamp

9. Fuel filter

10. Fuel hose

11. Hose clamp

12. R–clamp

Figure 34

89 8

814111213

13. Fuel hose

14. Fuel shutoff valve

15. Whiz cap screw

16. Cap screw

17. Flat washer

18. Grommet

Fuel Tank Removal (Fig. 34)

1. Park machine on a level surface, lower attachment, stop the engine, engage parking brake, and remove the key from the ignition switch.

DANGER

Figure 35

1. Roll pin

2. Steering wheel

3. Upper steering shaft

2. Remove roll pin from the steering wheel and upper steering shaft with a drift punch. Remove steering wheel from the upper steering shaft (Fig. 35).

Engine

Page 3 – 20

Sand Pro 2020/3020/5020

3. Remove adjustment lever from tilt lock pin by first re-

moving cap screw (Fig. 36).

4. Drain fuel tank as follows: A. Close fuel shutoff valve. B. Remove self tapping screw securing the fuel

hose and R–clamp to the frame. C. Disconnect fuel hose leading from the fuel tank

at the fuel shutoff valve. Use funnel and hose to drain the fuel into a suitable container for storage.

5. Remove four cap screws and flat washers securing

the fuel tank to the frame.

6. Make sure not to tear the steering boot while care-

fully pulling the top of the boot over the tilt pin.

7. Lift fuel tank from frame. Make sure not to lose

grommets.

Fuel Tank installation (Fig. 34)

1. Position fuel tank to the frame making sure not to

tear the steering boot while carefully lowering the top of the boot over the tilt pin.

A. Apply antiseize lubricant to the threads of the four cap screws.

Figure 36

1. Adjustment lever 3. Cap screw

2. Tilt lock pin 4. Steering boot

Engine

B. Make sure grommets are in place. Secure fuel tank to the fame with four flat washers and cap screws.

C. Torque cap screws from 30 to 60 in–lb (35 to 69 kg–cm).

2. Route fuel hose from the tank to the fuel shutoff

valve. Connect and secure fuel hose to the shutoff valve with the hose clamp.

3. Secure R–clamp and fuel hose to the frame with self

tapping screw.

4. Secure adjustment lever to tilt lock pin with cap

screw (Fig. 36).

5. Install steering wheel onto the upper steering shaft.

Secure steering wheel to upper steering shaft with the roll pin using a drift punch (Fig. 35).

6. Open fuel shutoff valve.

7. Fill fuel tank with fuel (see Fill fuel T ank). Check fuel

lines and tank for leaks.

Sand Pro 2020/3020/5020 Page 3 – 21 Engine

Engine (SP 2020/3020)

20 32

23 24

1. Muffler

2. Cap screw

3. Flat washer

4. Muffler clamp

5. Hex nut

6. Screen

7. Muffler bracket

8. Fuel hose

9. Pop rivet

10. Flat washer

11. Lock washer

12. Fuel hose

13. Cap screw

14. R–clamp

15. Engine base

Figure 37

16. Engine

17. Exhaust tube

18. Exhaust manifold

19. Air cleaner cover

20. Ring gasket

21. Air cleaner base

22. Muffler shield

23. Cap screw

24. Lock washer

25. Hot surface plate

26. Battery cable (Ground)

27. Red cable (Starter solenoid)

28. Hose clamp

29. Carburetor inlet shield

30. Screw

31. Air cleaner element

32. Cover plate

33. Air hose

34. Hose clamp

35. Air cleaner knob

36. Air cleaner knob

37. Washer face screw

38. Screw

39. Carburetor gasket

40. Manifold gasket

41. Screw

42. Boot

43. Wire harness (Ground wire)

44. Cable tie

45. Bumper

Engine

Page 3 – 22

Sand Pro 2020/3020/5020

Engine Removal (Fig. 37)

1. Park machine on a level surface, lower attachment,

stop engine, engage parking brake, and remove key from the ignition switch.

2. Pivot seat up. Remove engine cover. Remove move

litter box from fuel tank base.

3. Disconnect and remove battery from the machine to

prevent the possibility of the engine dropping on it (see Battery Service in Chapter 5 – Electrical Systems).

NOTE: Do not disconnect brake linkages or remove traverse rod when disconnecting the exhaust tube (17) and muffler (1) from the engine (16).

4. Separate exhaust tube (17) and muffler (1) from the

exhaust manifold (see Muffler Removal).

5. Close fuel shutoff located below the fuel tank.

Clamp fuel hose (12) near engine (16) to prevent fuel spillage. Loosen hose clamp (28) and remove fuel hose (12) from the engine.

6. Remove cable tie from the starter and wire harness.

Disconnect harness as follows (Fig. 38):

A. Disconnect blue wire from magneto terminal. B. Disconnect blue wire with fusible link from volt-

age regulator.

Figure 38

1. Cable on starter 5. Fusible link

2. Blue wire 6. Voltage regulator

3. Magneto terminal 7. Red/white wire

4. Blue wire 8. Red (+) battery cable

Engine

C. Disconnect red/white wire from fuel solenoid. D. Disconnect red (+) cable from starter.

7. Remove air hose (33) from air cleaner cover (19).

8. Disconnect throttle control cable from the swivel

and choke control cable from the choke lever (see Throttle and Choke Control Removal).

9. Remove cotter pin from the pump control rod. Sepa-

rate rod from the pump lever (Fig. 39).

10. Loosen both set screws on the engine hub to re-

move hub from the pump shaft (Fig. 40). 1 1. Remove four cap screws and lock washers securing

the pump mount to the engine block. Pull pump and mount from the engine and secure to frame. Remove square key from engine shaft (Fig. 41).

12. Remove hex nut (5), lock washer (11), and cap

screw (13) securing the black (–) battery cable (26) and wire harness (43) ground wire to the engine block. Pull cable and harness clear of the engine (16).

Figure 39

1. Cotter pin 3. Pump lever

2. Pump control rod

Figure 40

1. Engine hub 2. Set screw (pump hub)

IMPORTANT: Make sure not to damage wires, wire harness, hoses, and cables are while lifting the en gine from the machine.

13. Remove three hex nuts (5), flat washers (3), and

cap screws (13) securing the engine (16) to its base

14. Connect hoist or chain fall to the engine. Slowly remove engine from the machine.

(15).

Sand Pro 2020/3020/5020 Page 3 – 23 Engine

Engine Installation (Fig. 37)

CAUTION

One person should operate the chain fall or hoist while the other person guides the engine into the frame.

1. Install engine (16) to the engine base (15). A. Attach a hoist or chain fall to the engine.

IMPORTANT: Make sure not to damage the engine, fuel and hydraulic lines, electrical harness, or other parts while installing the engine.

B. Lower engine slowly onto the engine base. C. Insert cap screw (13) through engine base and

engine block. Install lock washer (11) onto cap screw with battery cable (26) and wire harness (43). Screw hex nut (5) onto the cap screw.

D. Insert cap screws (13) through engine base and engine block. Install flat washers (3) and screw hex nuts (5) onto the cap screws. Do not tighten fasten ers at this time.

Figure 41

1. Cap screw & lock washer 3. Engine block

2. Pump mount

10. Connect harness as follows (Fig. 38): A. Connect blue wire to magneto terminal. B. Connect blue wire with fusible link to voltage reg-

ulator. C. Connect red/white wire to fuel solenoid. D. Connect red (+) cable to starter.

E. Secure wire harness with cable tie to the starter .

E. Tighten all four fasteners securing the engine to its base.

2. Place square key on the engine shaft.

3. Position pump and pump mount to the engine. Make sure engine hub slides onto the engine shaft and square key (Fig. 40). Secure pump mount to the engine block with four cap screws and lock washers (Fig. 41).

4. Tighten both set screws securing the engine hub to the engine shaft (Fig. 40).

5. Insert end of pump control rod into the pump lever . Secure rod with cotter pin (Fig. 39).

6. Connect throttle control cable to the swivel and choke control cable to the choke lever (see Throttle and Choke Control Installation).

7. Install air hose (33) to air cleaner cover (19). Secure hose with hose clamp (34).

8. Secure fuel hose (12) to the engine (16) with hose clamp (28). Remove clamp used to prevent drainage from fuel hose (12). Open fuel shutoff located below the fuel tank.

1 1. Install and connect battery to the machine (see Battery Service in Chapter 5 – Electrical Systems).

12. Install litter box to the fuel tank base.

13. Install engine cover. Pivot seat down.

9. Connect exhaust tube and muffler to the exhaust manifold (see Muffler Installation).

Engine

Page 3 – 24

Sand Pro 2020/3020/5020

Replace Spark Plugs

Replace spark plugs after every 800 operating hours or yearly , which ever occurs first. Recommended air gap is

0.030 inch (0.762 mm). Use a Champion RC 12YC spark plug or equivalent.

NOTE: A spark plug usually lasts a long time. However, remove. Check spark plugs whenever the engine mal functions.

IMPORTANT: A cracked, fouled, dirty, or otherwise malfunctioning spark plug must be replaced. Do not sand blast, scrape, or clean electrodes by using a wire brush because grit may be released from the plug and fall into the cylinder. The result is usually a damaged engine.

0.030 inch

0.762 mm

1. Clean area around spark plugs so foreign matter cannot fall into cylinder when spark plug is removed.

2. Pull spark plug wires off spark plugs. Remove plugs from cylinder head.

3. Check condition of side electrode, center electrode, and center electrode insulator. Make sure there is no damage.

Figure 42

4. Set air gap between the center and side of the electrodes at 0.030 inch (0.762 mm). Install correctly gapped spark plug with gasket seal. Tighten spark plug to 200 in–lb (230 kg–cm). If torque wrench is not used, tighten plug firmly.

Engine

Sand Pro 2020/3020/5020 Page 3 – 25 Engine

Engine (SP 5020)

49 48 47

1. Air cleaner knob

2. Air cleaner cover

3. Cover seal

4. Air cleaner knob

5. Not used

6. Hex flange head screw

7. Cap screw

8. Lock washer

9. Pop rivet

10. Hot surface plate

11. Muffler shield

12. Screw

13. Exhaust deflector

14. Muffler

15. Screw

16. Exhaust gasket

17. Hose clamp

18. Rubber guard

19. Fuel hose

Figure 43

20. Lock nut

21. Battery cable (negative)

22. Cable cover

23. Cable tie

24. Lock washer

25. Positive cable (from starter solenoid))

26. Ground wire (to frame)

27. Stub shaft

28. Lock nut

29. Cap screw

30. Flat washer

31. Engine mount

32. Lock nut

33. Engine support

34. Cap screw

35. Cap screw

36. Cap screw

37. Cap screw

30 34

38. Engine base

39. Not used

40. Carburetor gasket

41. Not used

42. Not used

43. Cap screw

44. Cap screw

45. Screen/spacer

46. Engine

47. Fuel hose

48. Air cleaner base

49. Carburetor inlet shield

50. Not used

51. Filter element

52. Cover plate

53. Cover

54. Cap screw

55. Cap screw

Engine

Page 3 – 26

Sand Pro 2020/3020/5020

Engine Removal (Fig. 43)

1. Park machine on a level surface, lower attachment, stop engine, engage, and remove key from the ignition switch.

2. Chock wheels to prevent the machine from moving. The brake assembly will be partially disassembled.

CAUTION

The muffler and exhaust pipe may be hot. To avoid possible burns, allow engine and exhaust system to cool before working near muffler.

3. Remove attachment from the rear of the machine to gain access to the engine.

4. Pivot seat up. Remove seat base with seat attached as follows (Fig. 44):

A. Separate seat rod from the base by removing cotter pin and flat washer.

B. Separate base from frame by removing both lock nuts, cap screws, flat washers, and spacers.

5. Disconnect and remove battery from the machine to prevent the possibility of the engine damaging it during removal (see Battery Service in Chapter 5 – Electrical Systems).

6. Close fuel shutoff valve. Clamp fuel hose near engine to prevent fuel spillage. Loosen hose clamp at fuel pump and remove fuel hose from the pump.

Figure 44

1. Cotter pin & flat washer 3. Lock nut

2. Seat rod 4. Cap screw & flat washer

Engine

Figure 45

1. Blue wire (magneto) 3. Voltage regulator

2. Blue wire (voltage reg.) 4. Red/white wire

7. Disconnect wire harness as follows (Fig. 45):

A. Disconnect blue wire from magneto terminal. B. Disconnect blue wire with fusible link from volt-

age regulator. C. Disconnect red/white wire from fuel solenoid.

IMPORTANT: Keep air cleaner base removed from the carburetor after disconnecting the choke cable from the choke lever. This is necessary to remove the engine from the machine.

1. Set screw 2. Engine hub

Figure 46

8. Disconnect throttle control cable from the swivel and choke control cable from the choke lever (see Throttle and Choke Control Removal).

9. Loosen both set screws on the engine hub to remove hub from the engine shaft (Fig. 46).

Sand Pro 2020/3020/5020 Page 3 – 27 Engine

10. Disconnect red positive cable cable (solenoid) from the starter (Fig. 47).

11. Remove lock nut and cap screw securing black ground wire and black battery cable (negative) to the en gine block. Pull cable and harness clear of the engine (Fig. 47).

12. Remove remaining three lock nuts and cap screws securing the engine to its base.

CAUTION

Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 – Safety.

One person should operate the jack while the other person guides the engine from the frame and engine base.

IMPORTANT: Make sure not to damage wires, wire harness, hoses, and cables while removing the en gine from the machine.

13. Remove engine as follows (Fig. 43 and 48): A. Position a jack under the rear of the engine base.

Figure 47

1. Positive cable (solenoid) 4. Battery cable (negative)

2. Starter 5. Ground wire (frame)

3. Lock nut and cap screw

B. Support engine with a jack, then remove cap screws and flat washers securing the engine sup port to the frame.

IMPORTANT: When the rear of the engine base is lowered, the base will pivot at the front engine mounts. Lower base about 1 inch (2.5 cm), which is enough to allow the top of the engine to clear the tra verse rod. Avoid damaging the cooling fan and oil cooler as the hydrostat pivots up. The engine should then slide off the base. Do not allow engine to drop.

C. Lower rear of the engine base. Remove engine from the engine hub and base. Remove square key from the engine shaft.

14. Secure engine base and hydrostat to prevent the

cooling fan from damaging the oil cooler.

Engine Installation (Fig. 43)

CAUTION

One person should operate the jack while the other person guides the engine into the frame.

Figure 48

1. Cap screw & flat washer 3. Traverse rod

2. Engine support 4. Engine base

1. Install engine to its base as follows (Fig. 43 and 48): A. Attach a jack to the rear of the engine base. B. Make sure square key is placed on the shaft.

Position engine onto the engine base. Slide engine shaft into the engine hub

C. Insert three cap screws through engine base and engine block. Install lock nuts to the cap screws. Do not tighten fasteners at this time.

D. Insert cap screw through engine base and engine block. Connect black ground wire and black battery cable (negative) to the cap screw. Screw lock nut onto the cap screw (Fig. 47).

E. Tighten all four fasteners securing the engine to its base.

F. Jack up engine base enough to secure the engine support to the frame. Secure engine support to the frame cap screws and flat washer.

IMPORTANT: Make sure not to damage the engine, fuel and hydraulic lines, electrical harness, or other parts while installing the engine.

Engine

Page 3 – 28

2. Connect red positive cable cable (solenoid) to the

starter (Fig. 47).

Sand Pro 2020/3020/5020

3. Tighten both set screws on the engine hub to secure hub to the engine shaft (Fig. 46).

6. Install seat base with seat attached to the frame as follows (Fig. 44):

4. Connect throttle control cable to the swivel and choke control cable to the choke lever (see Throttle and Choke Control Installation).

5. Connect wire harness as follows (Fig. 45): A. Connect blue wire to the magneto terminal. B. Connect blue wire with fusible link to voltage reg-

ulator. C. Connect red/white wire to fuel solenoid.

A. Position base on machine. Secure base to frame with both spacers, cap screws, flat washers, and lock nuts.

B. Secure seat rod to the base with flat washer and cotter pin.

7. Install and connect battery to the machine (see Battery Service in Chapter 5 – Electrical Systems).

8. Secure fuel hose to the fuel pump with hose clamp. Remove clamp from fuel hose that was used to prevent fuel spillage. Open fuel shutoff valve.

Engine

Sand Pro 2020/3020/5020 Page 3 – 29 Engine

Clean Cylinder Head Fins

Avoid overheating and possible damage to the engine. Keep cooling fins on cylinder heads clean.

1. Park machine on a level surface, lower attachment, stop engine, engage parking brake, and remove key from the ignition switch.

2. Gain access to the engine. NOTE: The engines on the SP 2020/3020 and SP 5020

are constructed the same. The SP 2020/3020 engine is shown.

3. Remove muffler shield and both air guide covers to gain access to both cylinder heads.

CAUTION

Use eye protection such as goggles when using compressed air.

Blow dirt and debris from between the cooling fins

and away from the engine.

5. Use nylon bristle brush and hot soapy water to remove any encrusted mud or other debris on and between the cooling fins. Rinse fins with clear water after cleaning.

Figure 49

1. Muffler shield 3. Cylinder head (LH)

2. Air guide cover (LH)

Figure 50

1. Muffler shield 3. Cylinder head (RH)

2. Air guide cover (RH)

6. Secure both air guide covers and muffler shield to the engine.

7. Install engine cover to the machine.

Engine

Page 3 – 30

Sand Pro 2020/3020/5020

Chapter 4

Hydraulic Systems

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3

Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Hydraulic Fitting Installation . . . . . . . . . . . . . . . . . . . 3

Towing Traction Unit . . . . . . . . . . . . . . . . . . . . . . . . . 5

Check Hydraulic System Fluid . . . . . . . . . . . . . . . . . 5

HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . . . . . . . 6

Sand Pro 2020/3020 . . . . . . . . . . . . . . . . . . . . . . . . . 6

Sand Pro 5020 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

HYDRAULIC FLOW DIAGRAMS . . . . . . . . . . . . . . . . 8

Traction Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Traction Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Retract and Extend Lift Cylinder

SPECIAL TOOLS

Hydraulic Pressure Test Kit Hydraulic Tester – Pressure and Flow

Hydraulic Test Fittings TROUBLESHOOTING

TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Precautions for Hydrostatic Testing

TEST NO. 1: Traction Pump Flow (P1)

TEST NO. 2: Charge Relief Valve (R2)

and Implement Relief Valve (R1) . . . . . . . . . . . . 22

TEST NO. 3: Charge Pump (P2) Flow TEST NO. 4: Wheel Motor Efficiency

ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Adjust Traction Pedal for Neutral Adjust Traction Pedal for Forward

(SP 2020/3020) . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Adjust Traction Pedal for Forward (SP 5020) . . . 29 Adjust LIft Lever (SP 2020/3020) Adjust LIft Lever (SP 5020)

SERVICE AND REPAIRS

Check Hydraulic Lines and Hoses Charge Hydraulic System Change Hydraulic System Fluid and Filter Lift Valve (SP 2020/3020)

Removal and Installation

Lift Valve (SP 5020)

Removal and Installation . . . . . . . . . . . . . . . . . . . . 37

Lift Valve Service Lift Cylinder (SP 2020/3020) Lift Cylinder (SP 5020) Lift Cylinder Service Hydrostat (SP 2020/3020)

Removal

Installation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

. . . . . . . . . . . . . . . . . . . . . . . 15

. . . . . . . . . . . . . . . . . . . . . . . . 16

. . . . . . . . . . . . . . . . . . . . . 31

. . . . . . . . . . . . . . . . . . . . . . . . . 36

. . . . . . . . . . . . . . . . . . . . . . . . . . . 38

. . . . . . . . . . . . . . . . . . . . . . 40

. . . . . . . . . . . . . . . . . . . . . . . . . 41

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

. . . . . . . . . . . . . . 12

. . . . . . . . . . . . . . . . . . . 14

. . . . . . . . . 14

. . . . . . . . . . . . 19

. . . . . . . . 20

. . . . . . . . . 24

. . . . . . . . . . 26

. . . . . . . . . . . . . . 28

. . . . . . . . . . . . . 30

. . . . . . . . . . . . . . . . . . . 30

. . . . . . . . . . . . . 31

. . . . . . . . . . . . . . . . . . . . 31

. . . . . . 32

. . . . . . . . . . . . . . . . . . . . 34

. . . . . . . . . . . . . . . . . . . . 35

. . . . . . . . . . . . . . . . . 39

. . . . . . . . . . . . . . . . . . . 42

Hydrostat (SP 5020) . . . . . . . . . . . . . . . . . . . . . . . . 44

Removal

Installation

Flush Hydraulic System . . . . . . . . . . . . . . . . . . . . . . 47

Hydrostat Service

Charge Pump Disassembly, Inspection,

and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Shaft Seal Removal and Installation Acceleration Valve Disassembly, Inspection,

and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Charge and Implement Relief Valve

Disassembly, Inspection, and Assembly Charge Check Valve Disassembly,

Inspection, and Assembly . . . . . . . . . . . . . . . . . 51

Traction Pump Disassembly Traction Pump Inspection Traction Pump Assembly

Front Wheel Motor

Removal Installation

Rear Wheel Motors (SP 2020/3020)

Removal and Installation

Rear Wheel Motors (SP 5020)

Removal and Installation

Wheel Motor Service

Disassembly Inspection Assembly

Hydraulic Tank (SP 2020/3020)

Removal, Inspection, and Installation

Hydraulic Oil Cooler (SP 2020/3020)

Removal, Inspection, and Installation

Hydraulic Tank and Oil Cooler (SP 5020) . . . . . . 74

Oil Cooler Removal Oil Cooler Inspection Oil Cooler Installation Hydraulic Tank Removal,

Inspection, and Installation . . . . . . . . . . . . . . . . 76

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

. . . . . . . . . . . . . . . . . . . . . . . . . . . 48

. . . . . . . . . . 50

. . . . . 51

. . . . . . . . . . . . . . . . . 52

. . . . . . . . . . . . . . . . . . . 53

. . . . . . . . . . . . . . . . . . . . 54

. . . . . . . . . . . . . . . . . . . . . . . . . . 56

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

. . . . . . . . . . . 58

. . . . . . . . . . . . . . . . . . . . 59

. . . . . . . . . . . . . . . . 60

. . . . . . . . . . . . . . . . . . . . 61

. . . . . . . . . . . . . . . . . . . . . . . . 62

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

. . . . . . . . . . . . . . . 70

. . . . . . . . . 71

. . . . . . . . . . 72

. . . . . . . . . 73

. . . . . . . . . . . . . . . . . . . . . . . . 74

. . . . . . . . . . . . . . . . . . . . . . . 75

. . . . . . . . . . . . . . . . . . . . . . . 76

Systems

Hydraulic

Sand Pro 2020/3020/5020 Page 4 – 1 Hydraulic System (Rev. A)

Specifications

Item Description

Hydrostatic Transmission Variable displacement piston pump

Pump Displacement 0.913 in Pump Flow Rate (@ 3150 RPM) 12.5 GPM (47.2 LPM) Maximum Continuous Rated Speed 4000 RPM Maximum Intermittent Rated Speed 4200 RPM Maximum Operating Pressure 2500 PSI (175 bar) Maximum Intermittent Pressure 4500 PSI (310 bar) Charge Pump Displacement 0.33 in Charge Pump Flow Rate (@ 3150 RPM) 4.5 GPM (17.0 LPM) Charge Relief Setting 90 to 180 PSI (4.8 to 10.4 bar) Maximum Inlet Vacuum 5 inch Hg Maximum Continuous Case Pressure 10 PSI (0.7 bar) Maximum (Cold Start) Case Pressure 25 PSI (1.7 bar) Implement Relief Setting 700 to 800 PSI (48.3 to 55.2 bar)

Right Wheel Motors (SP 2020/SP 3020) Orbital rotor vane with shuttle valve

Motor Displacement 7.8 in Maximum Operating Pressure 2000 PSI (138 bar) Maximum Intermittent Pressure 3000 PSI (207 bar) Maximum Flow 20 GPM (76 LPM) Rated Speed @ Maximum Flow 583 RPM

Right Wheel Motors (SP 5020) Orbital rotor vane with reverse timed manifold and shuttle valve

Motor Displacement 8.6 in Maximum Operating Pressure 2000 PSI (138 bar) Maximum Intermittent Pressure 3000 PSI (207 bar) Maximum Flow 20 GPM (76 LPM) Rated Speed @ Maximum Flow 530 RPM

Left Wheel Motors (SP 2020/SP 3020) Orbital rotor vane

Motor Displacement 7.8 in Maximum Operating Pressure 2000 PSI (138 bar) Maximum Intermittent Pressure 3000 PSI (207 bar) Maximum Flow 20 GPM (76 LPM) Rated Speed @ Maximum Operating Pressure and Rated Flow 583 RPM

/rev (15.0 cm3/rev)

/rev (5.4 cm3/rev)

/rev (127.8 cm3/rev)

/rev (140.1 cm3/rev)

/rev (127.8 cm3/rev)

Left Wheel Motors (SP 5020) Orbital rotor vane

Motor Displacement 8.6 in Maximum Operating Pressure 2000 PSI (138 bar) Maximum Intermittent Pressure 3000 PSI (207 bar) Maximum Flow 20 GPM (76 LPM) Rated Speed @ Maximum Flow 530 RPM

Front Wheel Motor (SP 3020) Orbital rotor motor

Motor Displacement 5.0 in Maximum Operating Pressure 3000 PSI (207 bar) Maximum Intermittent Pressure 4000 PSI (276 bar) Maximum Flow 12 GPM (45 LPM) Rated Speed @ Maximum Flow 693 RPM

Front Wheel Motor (SP 5020) Orbital rotor vane with reverse timed manifold

Motor Displacement 17.1 in Maximum Operating Pressure 2000 PSI (138 bar) Maximum Intermittent Pressure 3000 PSI (207 bar) Maximum Flow 25 GPM (95 LPM) Rated Speed @ Maximum Flow 334 RPM

Hydraulic Filter 25 Micron spin on cartridge type

Hydraulic Oil See Check Hydraulic System Fluid in General section

Hydraulic Tank Tank capacity 3.0 gal. U.S. (20.8 L)

/rev (140.9 cm3/rev)

/rev (81.9 cm3/rev)

/rev (280.3 cm3/rev)

Rev. B

Sand Pro 2020/3020/5020Hydraulic System Page 4 – 2

General Information

Hydraulic Hoses

Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather, sun, chemicals, very warm storage condi tions, or mishandling during operation or maintenance. These conditions can cause damage or premature dete rioration. Some hoses are more susceptible to these conditions than others. Inspect the hoses frequently for signs of deterioration or damage.

Before disconnecting or performing any work on hydraulic system, relieve all pressure in

WARNING

system. Stop engine; lower or support box and/or other attachment(s).

When replacing a hydraulic hose, be sure that the hose is straight (not twisted) before tightening the fittings. This can be done by observing the imprint on the hose. Use two wrenches; hold the hose straight with one and tighten the hose swivel nut onto the fitting with the other.

Hydraulic Fitting Installation

O–Ring Face Seal

1. Make sure both threads and sealing surfaces are free of burrs, nicks, scratches, or any foreign material.

2. Make sure the O–ring is installed and properly seated in the groove. It is recommended that the O–ring be replaced any time the connection is opened.

3. Lubricate the O–ring with a light coating of oil.

Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not hands, to search for leaks. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury. If fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type of injury. Gangrene may result from such an injury.

Nut

Sleeve

Seal

Body

Systems

Hydraulic

4. Put the tube and nut squarely into position on the face seal end of the fitting and tighten the nut until finger tight.

Figure 1

5. Mark the nut and fitting body. Hold the body with a wrench. Use another wrench to tighten the nut to the cor

rect flats from finger tight (F.F.F.T.). The markings on the nut and fitting body will verify that the connection has been tightened.

Size F.F.F.T.

4 (1/4 in. nominal hose or tubing) 0.75 + 6 (3/8 in.) 0.75 + 0.25 8 (1/2 in.) 0.75 + 0.25 10 (5/8 in.) 1.00 + 12 (3/4 in.) 0.75 + 0.25 16 (1 in.) 0.75 +

0.25

Finger Tight After Proper Tightening

Final Position

Mark Nut and Body

Extend Line

Figure 2

Initial Position

Sand Pro 2020/3020/5020 Page 4 – 3 Hydraulic System (Rev. A)

SAE Straight Thread O–Ring Port – Non–adjustable

1. Make sure both threads and sealing surfaces are free of burrs, nicks, scratches, or any foreign material.

2. Always replace the O–ring seal when this type of fitting shows signs of leakage.

3. Lubricate the O–ring with a light coating of oil.

O–Ring

4. Install the fitting into the port and tighten it down full length until finger tight.

5. Tighten the fitting to the correct flats from finger tight (F.F.F.T.).

Size F.F.F.T.

4 (1/4 in. nominal hose or tubing) 1.00 + 6 (3/8 in.) 1.50 + 0.25 8 (1/2 in.) 1.50 + 0.25 10 (5/8 in.) 1.50 + 0.25 12 (3/4 in.) 1.50 + 16 (1 in.) 1.50 +

0.25

SAE Straight Thread O–Ring Port – Adjustable

1. Make sure both threads and sealing surfaces are free of burrs, nicks, scratches, or any foreign material.

2. Always replace the O–ring seal when this type of fitting shows signs of leakage.

3. Lubricate the O–ring with a light coating of oil.

4. Turn back the jam nut as far as possible. Make sure the back up washer is not loose and is pushed up as far as possible (Step 1).

Figure 3

Lock Nut

Back–up Washer

O–Ring

5. Install the fitting into the port and tighten finger tight until the washer contacts the face of the port (Step 2).

Figure 4

6. To put the fitting in the desired position, unscrew it by the required amount, but no more than one full turn (Step 3).

Step 1

Step 3

7. Hold the fitting in the desired position with a wrench and turn the jam nut with another wrench to the correct flats from finger tight (F.F.F.T.) (Step 4).

Size F.F.F.T.

4 (1/4 in. nominal hose or tubing) 1.00 + 6 (3/8 in.) 1.50 + 0.25 8 (1/2 in.) 1.50 + 0.25 10 (5/8 in.) 1.50 + 12 (3/4 in.) 1.50 + 0.25 16 (1 in.) 1.50 +

0.25

Step 2

Step 4

Figure 5

Hydraulic System (Rev. A) Page 4 – 4 Sand Pro 2020/3020/5020

Towing Traction Unit

In case of emergency, the Sand Pro can be towed for a short distance. However, Toro does not recommend this as a standard procedure.

Check Hydraulic System Fluid

The hydraulic system is designed to operate on Mobil 424 hydraulic oil. The machine’s 3 gallon tank is filled at the factory with oil. However, check oil level before the engine is first started and daily thereafter.

1. Remove cap from the hydraulic oil tank.

2. Check oil level in the tank. Oil level should be up to the top of the cone point on tank screen.

IMPORTANT: To prevent system contamination, clean top of hydraulic oil containers before punctur ing. Assure pour spout and funnel are clean.

3. If fluid level is low, slowly fill tank with appropriate hydraulic fluid until level reaches bottom of screen. DO

NOT OVERFILL.

NOTE: The fluids within this group are interchange-

able.

IMPORTANT: Do not tow the machine faster than 2 to 3 mph because drive system may be damaged. If machine must be moved a considerable distance, transport it on a truck or trailer. Tires may lock up if machine is towed too fast. If lock up occurs, stop towing the machine. Wait for the traction circuit pressure to stabilize before resuming towing at a slower speed.

Figure 6

1. Cap 2. Tank (SP 2020/3020)

Systems

Hydraulic

Group 1 Hydraulic Fluid (Recommended for ambient

temperatures consistently below 100

F.):

ISO type 46/68 anti–wear hydraulic fluid

Mobil Amoc International Harvester Texaco Shell Union OIl Chevron BP Oil Boron OIl Exxon Conoco Kendall Phillips

Hydraulic/Tractor Fluid Tractor Hydraulic Fluid

Mobil Fluid 424

Amoco 1000

Hy–Tran

TDH

Donax TD

BP HYD TF

Eldoran UTH

Torque Fluid

Power–Tran 3

Hyken 052

HG Fluid

4. Install tank cap.

Figure 7

1. Cap 2. Tank (SP 5020)

Sand Pro 2020/3020/5020 Page 4 – 5 Hydraulic System (Rev. A)

Hydraulic Schematics

*FLOW RATE

GPM LPM

47.2

12.48

4.5

–––

–

HOT OIL

SHUTTLE

VALVE

BARS

–––––

RIGHT

FRONT

LEFT

SP 3020 ONLY

ACCELERATION

VALVES

RH WHEEL MOTOR

WITH BLEED OFF

FOR OIL COOLING

IN FORWARD

FORWARD

lbs/in

DISPLACEMENT PRESSURE

in /rev cm /rev

DISPLACEMENT, FLOW RATE, AND PRESSURE CHART

COMPONENT

–––––

5.41

127.84

0.915

0.33

7.8

P2M1M2

48.3

6.2

700

––

7.8 127.84

––

5.0 81.97

LIFT VALVE

Hydraulic Schematic

Sand Pro 2020/3020

FLOW RATE CALCULATED AT 3150 RPM

CHARGE

IMPLEMENT

RELIEF

CHARGE

CHECK

VALVE

CHARGE

PUMP

TRACTION

PUMP

HYDROSTAT

CHARGE

RELIEF

CHECK

VALVE

FILTER

Rev. B

TANK

OIL COOLER

Sand Pro 2020/3020/5020Hydraulic System Page 4 – 6

ORIFICE

OPTIONAL

LIFT CYLINDER

HOT OIL

VALV E

SHUTTLE

–

48.3

–

6.2

Hydraulic Schematic

Sand Pro 5020

–––

47.2

–––

12.48

4.5

GPM LPM

*FLOW RATE

WITH BLEED OFF

RH WHEEL MOTOR

FOR OIL COOLING

IN FORWARD

BARS

–

–––

RIGHT

LEFT

TIMED MANIFOLDS

FRONT AND RH WHEEL

MOTORS HAVE REVERSE

FRONT

FORWARD

lbs/in

DISPLACEMENT PRESSURE

in /rev cm /rev

DISPLACEMENT, FLOW RATE, AND PRESSURE CHART

COMPONENT

–

5.41

0.915

0.33

P2M1M2

–––

140.93

8.6 140.93

8.6

700

– –

17.1 280.22

– –

FLOW RATE CALCULATED AT 3150 RPM

** *

LIFT VALVE

Systems

Hydraulic

IMPLEMENT

RELIEF

ACCELERATION

VALVES

CHARGE

RELIEF

LIFT CYLINDER

VALV E

CHARGE

CHECK

CHARGE

PUMP

TRACTION

PUMP

HYDROSTAT

VALV E

CHARGE

CHECK

Sand Pro 2020/3020/5020 Page 4 – 7

FILTER

TANK

OIL COOLER

Hydraulic System (Rev. A)

Hydraulic Flow Diagrams

Traction Forward

The traction circuit of the hydraulic system consists of a hydrostat connected in a closed loop circuit to three or bital vane wheel motors. Hydraulic fluid losses are designed to occur from case drain leakage of the traction pump (P1) and bleed off from the right wheel motor (M1). These losses are replenished by the charge pump (P2), which is integral to the hydrostat.

The engine drives traction pump (P1) directly through a coupling. The traction pump is a variable displacement piston pump. The traction pedal connects through a link age to the trunnion shaft and swash plate of the pump. With the engine running and the traction pedal in the neutral position, P2 supplies no flow to the wheel mo tors. When the traction pedal is pressed to the forward position, the linkage from the pedal positions the swash plate in the traction pump so oil flows out port B. Oil flow out of port B goes to the wheel motors and turns them in the forward direction. On the SP 5020, the oil flow goes through the front motor first and then through the left and right rear wheel motors. Oil flowing out of the wheel motors returns to port A of the hydrostat and is continuously pumped out of port B.

The hydrostat uses a small amount of hydraulic fluid for internal lubrication. Fluid is designed to leak across pump parts into the case drain. This leakage results in the loss of hydraulic fluid from the closed loop circuit that must be replenished.

The charge pump (P2) is a fixed displacement gerotor pump. It is driven directly off the traction pump. The pump replenishes the closed loop circuit with fluid from the tank. The charge relief valve (R2) supplies sufficient head so that charge pump flow is guided to the low pres sure side of the traction circuit through one of two check valves. Pump flow in excess of replenishment require ments is relieved through the charge relief valve back to the tank.

The right wheel motor bleeds off a small amount of hydraulic fluid for cooling of the closed loop circuit. This bleed off happens in the forward direction only. The high pressure side of the motor forces a shuttle spool to shift against a spring. The pressure drop across the motor causes a small amount of fluid to bleed off through a fixed orifice on the low pressure side of the motor and then through the shuttle spool. This bleed off returns to the tank through the oil cooler.

The acceleration valves reduce the rate of change in acceleration (jerkiness) when hydrostat output is increased by the action of the operator. An increase of pressure on the output side of the hydrostat will by–pass some pump flow to the low pressure side of the pump. The valve on the high pressure side closes at a predeter mined rate as pressure increases. This gives the hydrostat a smooth acceleration rate when the swashplate is stroked rapidly.

Hydraulic System (Rev. A) Page 4 – 8 Sand Pro 2020/3020/5020

SHUTTLE

HOT OIL

VALV E

SP 5020

RH WHEEL MOTOR

FOR OIL COOLING

WITH BLEED OFF

IN FORWARD

WITH BLEED OFF

RH WHEEL MOTOR

FOR OIL COOLING

IN FORWARD

RIGHT

FRONT

SP 3020 ONLY

LEFT

IMPLEMENT

RELIEF

ACCELERATION

VALVES

CHARGE

RELIEF

FORWARD

LEFT

RIGHT

LIFT VALVE

FORWARD

FRONT

FRONT AND RH WHEEL

MOTORS HAVE REVERSE

TIMED MANIFOLDS

TO LIFT VALVE

LIFT CYLINDER

Systems

Hydraulic

VALV E

CHARGE

CHECK

CHARGE

PUMP

TRACTION

PUMP

HYDROSTAT

VALV E

CHARGE

CHECK

FILTER

Sand Pro 2020/3020/5020 Page 4 – 9

TANK

High Pressure

Low Pressure (Charge)

Return or Suction

OIL COOLER

Traction Forward

Sand Pro 2020/3020/5020

Flow

Hydraulic System (Rev. A)

Traction Reverse

The traction circuit operates essentially the same in reverse as it does in forward. However, there are a few differences in operation.

When the traction pedal is pressed to the reverse position, the linkage from the pedal positions the swash plate in the traction pump so oil flows out of port A. Oil flow out of port A goes to the wheel motors and turns them in the reverse direction. On the SP 5020, the oil flow goes through the left and right rear wheel motors first and then through the front wheel motor. Oil flowing out of the wheel motors returns to port B of the hydrostat and is continuously pumped out of port A.

The right wheel motor does not bleed off any hydraulic fluid for cooling of the closed loop circuit in the reverse direction.

Hydraulic System (Rev. A) Page 4 – 10 Sand Pro 2020/3020/5020

SHUTTLE

HOT OIL

VALV E

SP 5020

WITH BLEED OFF

RH WHEEL MOTOR

FOR OIL COOLING

IN FORWARD

WITH BLEED OFF

RH WHEEL MOTOR

FOR OIL COOLING

IN FORWARD

REVERSE

IMPLEMENT

RELIEF

FRONT

LEFT

RIGHT

FORWARD

LEFT

SP 3020 ONLY

FRONT

LIFT VALVE

ACCELERATION

VALVES

CHARGE

RELIEF

FRONT AND RH WHEEL

MOTORS HAVE REVERSE

TIMED MANIFOLDS

TO LIFT VALVE

LIFT CYLINDER

Systems

Hydraulic

CHARGE

CHECK

VALV E

HYDROSTAT

Sand Pro 2020/3020/5020

CHARGE

PUMP

TRACTION

PUMP

CHARGE

CHECK

VALV E

FILTER

TANK

Hydraulic System (Rev. A) Page 4 – 11

High Pressure

Low Pressure (Charge)

OIL COOLER

Traction Reverse

Sand Pro 2020/3020/5020

Return or Suction

Flow

Retract and Extend Lift Cylinder

The hydraulic lift circuits for the SP 2020/3020 and SP 5020 function identically. Each machine has identical

charge pumps, lift valves, and lift cylinders. These com ponents are the heart of the lift circuit.

In addition to replenishing the closed loop circuit with fluid from the tank, charge pump (P2) flow in excess of replenishment requirements is relieved through the charge relief valve (R2). Fluid returns through the lift valve and back to the tank. This excess flow is used to operate the lift cylinder.

The charge pump is a fixed displacement gerotor pump that is driven directly off the traction pump (P1). It has sufficient output to handle intermittent operation of the lift cylinder under load. The implement relief valve (R1) in the charge circuit allows high enough pressure to op erate the lift cylinder with attachments, and protects the charge pump.

When the lift lever to the lift valve is in the neutral position, fluid flow from the charge pump is bypassed around the lift cylinder through the lift valve. Fluid returns to the tank as a normal part of the charge and bleed off circuits.

Moving the lift lever to the lift position allows the lift valve to direct fluid flow from the charge pump into the rod side of the piston. The piston moves into the cylinder pushing fluid out the piston end of the cylinder and to the tank. As the cylinder rod retracts, the attachment is raised. When the lift lever is released, the lift valve returns to the neu tral position. The attachment is held in its present position.

Moving the lift lever to the lower position allows the lift valve to direct fluid flow from the charge pump into the piston side of the cylinder. The piston moves out of the cylinder pushing fluid out the rod end of the cylinder and to the tank. As the cylinder rod extends, the attachment is lowered. When the lift lever is released, the lift valve returns to the neutral position. The attachment is held in its present position.

Excessive load on the lift cylinder causes circuit pressure to increase and the implement relief valve (R1) to dump directly to the tank. This condition happens in both the lift and lower modes.

Hydraulic System (Rev. A) Page 4 – 12 Sand Pro 2020/3020/5020

SHUTTLE

HOT OIL

VALV E

WITH BLEED OFF

RH WHEEL MOTOR

FOR OIL COOLING

IN FORWARD

RIGHT

NEUTRAL

POSITION

LIFT VALVE

RETRACT LIFT CYLINDER

FRONT

SP 3020 ONLY

LEFT

FORWARD

ACCELERATION

VALVES

FROM CHARGE RELIEF (R2)

COOLER

TO OIL

LIFT VALVE

Systems

Hydraulic

LIFT CYLINDER LIFT CYLINDER

IMPLEMENT

RELIEF

CHARGE

RELIEF

NEUTRAL

POSITION

EXTEND LIFT CYLINDER

CHARGE

CHECK

RELIEF

CHARGE

PUMP

TRACTION

PUMP

HYDROSTAT

CHARGE

CHECK

RELIEF

FILTER

TANK

High Pressure

Low Pressure (Charge)

OIL COOLER

Extend and Retract lift Cylinder

Sand Pro 2020/3020

Return or Suction

Flow

Sand Pro 2020/3020/5020 Page 4 – 13

Hydraulic System (Rev. A)

Special Tools

Order these tools from the TORO SPECIAL TOOLS Some tools may also be available from a local supplier. AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS).

Hydraulic Pressure Test Kit – TOR47009

Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings. Contains one each: 1000 PSI (70 Bar), 5000 PSI (350 Bar) and 10000 PSI (700 Bar) gauges. Use gauges as recommended in Testing section of this chapter.

Figure 8

Hydraulic Tester (Pressure and Flow) – TOR214678

Figure 9

This tester requires O–ring face seal (ORFS) adapter fittings for use on this machine.

1. INLET HOSE: Hose connected from the system circuit to the inlet side of the hydraulic tester.

2. LOAD VALVE: A simulated working load is created in the circuit by turning the valve to restrict flow.

3. LOW PRESSURE GAUGE: Low range gauge to provide accurate reading at low pressure, 0 to 1000 PSI.

A protector valve cuts out when pressure is about to exceed the normal range for the gauge. The cutout pressure is adjustable.

4. HIGH PRESSURE GAUGE: High range gauge which accommodates pressures beyond the capacity of the low pressure gauge, 0 to 5,000 PSI.

5. FLOW METER: This meter measures actual oil flow in the operating circuit with a gauge rated at 15 GPM.

6. OUTLET HOSE: A hose from the outlet side of the hydraulic tester connects to the hydraulic system circuit.

Hydraulic System (Rev. A) Page 4 – 14 Sand Pro 2020/3020/5020

Hydraulic Test Fitting Kit – TOR4079

This kit includes a variety of O–ring Face seal fittings to enable you to connect test gauges into the system.

The kit includes: tee’s, unions, reducers, plugs, caps, and male test fittings.

Hydraulic Test Fittings

On the SP 2020/3020, there is tight clearance between the charge pressure test port on the hydrostat and the engine base plate. It might be helpful to first attach a male pipe (swivel) adapter to the test port and then a street elbow before connecting a test gauge.

TORO TEST FITTING KIT (NO. TOR4079)

Figure 10

Both fittings carry the following Parker Hannifin part numbers:

Male Pipe Adapter 0107–2–2

Street Elbow 1/8 CD

Figure 11

1. Swivel Adapter 2. Street elbow

Systems

Hydraulic

Sand Pro 2020/3020/5020 Page 4 – 15 Hydraulic System (Rev. A)

Troubleshooting

The table that follows contains information to assist in troubleshooting. There may possibly be more than one cause for a machine malfunction.

Problem

Hydraulic oil leaks from the system.

БББББББББББ

Hydraulic fluid foams.

БББББББББББ

Hydraulic system operates hot.

БББББББББББ

Unit operates in one direction only.

БББББББББББ

Neutral is difficult to find.

БББББББББББ

Wheel motor will not turn.

БББББББББББ

Possible Cause Fitting(s), hose(s), or tube(s) are loose or damaged.

ББББББББББББББББББББ

O–ring(s) or seal(s) are missing or damaged. Oil level in tank is low.

ББББББББББББББББББББ

Hydraulic system has wrong type of oil.

ББББББББББББББББББББ

One of the pump suction lines has an air leak. Oil level in tank is low.

ББББББББББББББББББББ

Oil is contaminated or too light.

ББББББББББББББББББББ

Heat exchanger is damaged or plugged.

ББББББББББББББББББББ

Accelerator valves leak from high pressure to low pressure side.

ББББББББББББББББББББ

Charge pressure is low due to the following possible causes:

ББББББББББББББББББББ

Oil filter is clogged.

ББББББББББББББББББББ

Charge relief valve is defective.

ББББББББББББББББББББ

Implement relief valve is defective.

ББББББББББББББББББББ

Charge pump is defective.

ББББББББББББББББББББ

Traction pump outlet pressure is high due to the following possible

ББББББББББББББББББББ

causes:

ББББББББББББББББББББ

Wheel load is to high or brakes are applied.

ББББББББББББББББББББ

Traction pump is worn or damaged.

ББББББББББББББББББББ

Shuttle valve in RH rear wheel motor is stuck or faulty.

ББББББББББББББББББББ

Wheel motor(s) are worn or damaged. External control linkage is misadjusted, disconnected, binding, or

ББББББББББББББББББББ

damaged.

ББББББББББББББББББББ

Charge check valve in hydrostat is defective.

ББББББББББББББББББББ

Acceleration valves in hydrostat are defective.

ББББББББББББББББББББ

External control linkage is misadjusted, disconnected, binding, or damaged.

ББББББББББББББББББББ

Internal parts in wheel motor are damaged.

ББББББББББББББББББББ

Brakes are binding.

ББББББББББББББББББББ

Key on wheel motor shaft is sheared or missing.

Refer to the Testing section of this Chapter for precautions and specific test procedures.

Rev. B

Sand Pro 2020/3020/5020Hydraulic System (Rev. A) Page 4 – 16

Troubleshooting (cont.)

Problem Possible Cause

System operates in a jerky manner when starting.

No traction exists in either direction, or loss of power.

External control linkage is misadjusted, disconnected, binding, or damaged.

Charge valve in hydrostat is defective.

Acceleration valves in hydrostat are defective.

Brake is not released.

Hydraulic oil is very cold.

Oil level in tank is low.

External control linkage is misadjusted, disconnected, binding, or damaged.

Charge pressure is low due to the following possible causes:

Oil filter is clogged.

Charge relief valve is defective.

Implement relief valve is defective.

Charge pump is defective.

Traction pump outlet pressure is low due to the following possible causes:

Systems

Hydraulic

Accelerator valves are defective.

Charge check valves are defective.

Traction pump is worn or defective.

Wheel motor(s) are worn or damaged.

Wheel motor will not hold load in neutral.

Attachment will not lift or lifts slowly. Engine speed is too low.

Make up fluid from charge pump is not available.

Charge check valves are damaged.

Charge pump is damaged.

Lift cylinder linkage is binding or broken.

Lift cylinder bushings bind.

Tank oil level is low.

Charge pump pressure or flow is insufficient.

Implement relief valve is stuck open.

Lift cylinders leak internally.

Sand Pro 2020/3020/5020 Hydraulic System (Rev. A)Page 4 -- 17

Troubleshooting (cont.)

Problem

Attachment raises, but will not stay

БББББББББББ

up.

БББББББББББ

Difficult to make slight changes when raising and lowering the at-

БББББББББББ

tachment (Sand Pro 2020 and

БББББББББББ

3020).

Possible Cause Lift cylinders leak internally.

ББББББББББББББББББББ

Neutral position check valves in lift valve leak.

ББББББББББББББББББББ

Optional orifice fitting (85–9720) for lift control outlet is available that will improve sensitivity of lift control valve. This fitting is stan-

ББББББББББББББББББББ

dard on the Sand Pro 5020.

ББББББББББББББББББББ

Rev. B

Sand Pro 2020/3020/5020Hydraulic System (Rev. A) Page 4 – 18

Testing

The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks (See the Special Tools section in this Chapter).

Before Performing Hydraulic Tests

IMPORTANT: All obvious areas such as oil supply, filter, binding linkages, loose fasteners, or improper adjustments must be checked before assuming that a hydraulic component is the source of the problem.

Precautions for Hydraulic Testing

CAUTION

Failure to use gauges with recommended pressure (psi) rating as listed in test procedures could result in damage to the gauge and possible personal injury from leaking hot oil.

All testing should be performed by two (2) people. One person should be in the seat to operate the machine, and the other should read and record test results.

CAUTION

Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. Controls must be operated with the ignition switch in OFF. Remove key from the ignition switch.

WARNING

Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Do not use hands to search for leaks; use paper or cardboard. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury. If fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type of injury. Gangrene may result from such an injury.

1. Clean machine thoroughly before disconnecting or disassembling any hydraulic components. Always keep in mind the need for cleanliness when working on hy draulic equipment. Contamination will cause excessive wear of components.

2. Put metal caps or plugs on any hydraulic lines left open or exposed during testing or removal of compo nents.

3. The engine must be in good operating condition. Use a phototac when performing a hydraulic test. En gine speed can affect the accuracy of the tester readings.

4. The inlet and the outlet hoses must be properly connected and not reversed (tester with pressure and flow capabilities) to prevent damage to the hydraulic tester or components.

5. When using tester with pressure and flow capabilities, open load valve completely in the hydraulic tester to minimize the possibility of damaging components.

Systems

Hydraulic

6. Install fittings finger tight and far enough to make

WARNING

Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved. Stop engine; Lower or support attachments.

Sand Pro 2020/3020/5020 Page 4 – 19 Hydraulic System (Rev. A)

sure that they are not cross–threaded before tightening them with a wrench.

7. Position tester hoses to prevent rotating machine parts from contacting and damaging the hoses or tester.

8. Check oil level in the tank. After connecting test equipment, make sure tank is full.

9. Check the traction pedal linkage for improper adjustment, binding or broken parts.

10. All hydraulic tests should be made with the hydraulic oil at normal operating temperature.

TEST NO. 1: Traction Pump Flow (P1)

HYDROSTAT

CHARGE CHECK VALV E

TRACTION PUMP

CHARGE PUMP

IMPLEMENT RELIEF

FROM

WHEEL MOTORS

ACCELERATION VALVES

TO LIFT VALV E

FORWARD

FROM SHUTTLE VALV E

TO WHEEL MOTORS

FROM OIL COOLER

TANK

FILTER

CHARGE CHECK VALV E

CHARGE RELIEF

Figure 12

1. Hydrostat (SP 2020/3020) 2. Forward header (SP 2020/3020) 3. Wheel motor connector (SP 5020)

Hydraulic System (Rev. A) Page 4 – 20 Sand Pro 2020/3020/5020

Procedure for Traction Pump Flow (P1)

1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes.

(Fig.12):

5. Operate engine at full speed (3150 +

CAUTION

50 RPM).

2. Make sure machine is parked on a level surface with attachments removed. Make sure engine is off.

3. Read Precautions for Hydraulic Testing.

4. Make sure that traction pedal is adjusted to the neutral and forward positions (see Adjust Traction Pedal for Neutral and Forward).

WARNING

Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 – Safety.

1. Jack up machine as follows to allow the drive wheels to spin freely and to allow hydraulic flow through the traction circuit:

A. On the SP 2020, jack up both rear wheels. Sup- port machine with blocks or jack stands so that both rear wheels are off the ground.

B. On the SP 3020 and SP 5020, jack up both rear wheels and the front wheel. Support machine with blocks or jack stands so that all three wheels are off the ground.

2. Disconnect hydraulic connections to install hydraulic tester (flow meter).

A. On the SP 2020/3020, disconnect left hose at the forward header.

Use extreme caution when taking gauge readings. The tires off the ground will be spinning.

6. Slowly push traction pedal into the fully forward position.

7. Slowly close flow control valve on tester until pressure gauge on the hydraulic tester reads 1700 PSI. As flow control valve is being closed, engine speed will de crease to approximately 2200 RPM (verify engine speed with a phototac).

8. Observe flow gauge. Tester reading should be minimum flow of 7.5 GPM (28.4 LPM). Record test results.

9. Release traction pedal, open flow control valve on tester, and turn off machine.

10. If 1700 PSI (tester pressure), 2200 RPM (engine speed), or 7.5 GPM flow cannot be achieved, consider the following:

A. The traction pedal and traction speed may need adjustment (see Adjust Traction Pedal for Neutral and Forward).

B. If the engine speed drops excessively (below 2200 RPM) as the traction pump load is applied, en gine performance should be evaluated (see Chapter 3 – Briggs & Stratton Vanguard Engines).

C. If engine speed does not drop and pressure and flow specifications are not met, the hydrostat needs to be repaired or replaced as necessary.

Systems

Hydraulic

B. On the SP 5020, disconnect bottom hose at the front wheel motor.

3. Install hydraulic tester (flow meter). Make sure the

flow control valve is fully open.

A. On the SP 2020/3020, make sure the flow arrow points out of the hydrostat and into the forward header.

B. On the SP 5020, make sure the flow arrow points from the hose and into the bottom port of the front wheel motor.

4. After installing hydraulic tester, start engine and run at idle speed. Check for hydraulic leakage and correct before proceeding with test.

Sand Pro 2020/3020/5020 Page 4 – 21 Hydraulic System (Rev. A)

11. If specifications are met and traction circuit problem exists, check wheel motor efficiency (see TEST NO. 4: Wheel Motor Efficiency in this section).

12. If testing is complete, lower wheels to the ground. Remove hydraulic tester and reconnect hydraulic hose.

13. Make sure hydraulic tank is full (see Check Hydraulic System Fluid).

TEST NO. 2: Charge Relief Valve (R2) and Implement Relief Valve (R1) Pressure

HYDROSTAT

FROM WHEEL MOTORS

TRACTION PUMP

CHARGE PUMP

CHARGE CHECK VALV E

IMPLEMENT RELIEF

ACCELERATION VALVES

TO LIFT VALV E

FORWARD

FROM SHUTTLE VALV E

TO WHEEL MOTORS

FROM OIL COOLER

TANK

FILTER

CHARGE CHECK VALV E

PRESSURE GAUGE

CHARGE RELIEF

Figure 13

1. Charge test port (SP 2020/3020) 2. Engine base plate (SP 2020/3020) 3. Charge test port (SP 5020)

Hydraulic System (Rev. A) Page 4 – 22 Sand Pro 2020/3020/5020

Procedure for Charge Relief Valve (R2) and Imple-

ment Relief Valve (R1) Pressure:

5. Make sure that traction pedal and lift control lever are in neutral and the parking brake is engaged.

1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes.

2. Park machine on a level surface with the attachments lowered. Make sure engine is off. Make sure the parking brake is engaged.

CAUTION

An attachment must be installed to the lift cylinder for the performance of this test to prevent personal injury and damage to the machine.

3. Read Precautions for Hydraulic Testing. NOTE: On the SP 2020/3020, special hydraulic fittings

are required to fit the test gauge into the hydrostat test port because of the engine base plate (see Hydraulic Test Fittings in the Special Tools section of this Chapter).

4. Remove plug and install pressure gauge to the hydrostat charge test port.

NOTE: If only implement relief valve (R1) pressure is to be measured, an alternate pressure gauge location is to install a T–connector with pressure gauge in series with the hose from the pump and the T–fitting on the lift valve (Figure 14).

6. After installing pressure gauge, start engine and run at low idle speed. Check for hydraulic leakage and correct before proceeding with test.

7. Operate engine at full speed (3150 + Verify pump hub speed with a phototac.

8. The pressure gauge will display system charge pressure and should read from 170 to 380 PSI. Record test results.

9. If the specification is not met, replace charge relief valve (R2) (see Hydrostat Service in this Chapter).

10. With the engine still running at full speed (3150 + RPM), lower attachment. Hold lift lever in the lower position to allow the implement relief valve to activate. Pressure gauge should read from 700 to 1000 PSI. Record test results.

11. If specification is not met, replace implement relief valve (R1) (see Hydrostat Service in this Chapter).

12. Shut off engine.

13. Disconnect gauge and fittings from the hydrostat charge test port. Install and tighten plug to test port.

14. Make sure hydraulic tank is full (see Check Hydraulic System Fluid).

50 RPM).

Systems

Hydraulic

Sand Pro 2020/3020/5020 Hydraulic System (Rev. A)Page 4 – 23

Rev. B

TEST NO. 3: Charge Pump (P2) Flow

HYDROSTAT

CHARGE CHECK VALV E

TRACTION PUMP

CHARGE PUMP

IMPLEMENT RELIEF

FROM

WHEEL MOTORS

FROM OIL COOLER

TANK

FILTER

CHARGE CHECK VALV E

CHARGE RELIEF

ACCELERATION VALVES

TO LIFT VALV E

FORWARD

FROM SHUTTLE VALV E

TO WHEEL MOTORS

Figure 14

1. Lift valve (SP 2020/3020) 3. Lift valve (SP 5020) 4. Hose from pump (SP 5020)

2. Hose from pump (SP 2020/3020)

Hydraulic System (Rev. A) Page 4 – 24 Sand Pro 2020/3020/5020

Procedure for Charge Pump (P2) Flow

8. Operate engine at full speed (3150 +

50 RPM).

1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes.

2. Make sure machine is parked on a level surface with the attachments lowered. Make sure engine is off and the parking brake is engaged.

3. Read Precautions for Hydraulic Testing.

4. Disconnect hose from the T–fitting on the lift valve.

5. Install hydraulic tester (flow meter) in series with the hose from the pump and the T–fitting on the lift valve. Make sure the flow arrow points toward the lift valve and the flow control valve on the tester is fully open.

6. Make sure that traction pedal and lift control lever are in neutral and the parking brake is engaged.

7. After installing hydraulic tester, start engine and run at low idle speed. Check for hydraulic leakage and cor rect before proceeding with test.

9. Slowly close the flow control valve on the tester until 500 PSI is obtained.

10. Verify pump speed is 3150 + tac.

11. Flow indication on tester should be a minimum of 1 GPM (3.8 LPM). Record test results.

12. Open the flow control valve on the tester and shut off engine.

13. If flow is less than 1 GPM or 500 PSI can not be obtained, check for restrictions in the pump circuit. If pump circuit is not restricted, repair or replace charge pump (see Hydrostat Service in this Chapter).

14. Disconnect tester from the hose and T–fitting. Reconnect hose to T–fitting.

15. Make sure hydraulic tank is full (see Check Hydrau-

lic System Fluid).

50 RPM with a photo

Systems

Hydraulic

Sand Pro 2020/3020/5020 Page 4 – 25 Hydraulic System (Rev. A)

TEST NO. 4: Wheel Motor Efficiency

HYDROSTAT

TRACTION PUMP

FROM OIL COOLER

TANK

CHARGE PUMP

CHARGE CHECK VALV E

FILTER

IMPLEMENT RELIEF

CHARGE RELIEF

ACCELERATION VALVES

TO LIFT VALV E

FORWARD

HOT OIL SHUTTLE

LEFT

FRONT

RIGHT

VALV E

Figure 15

1. Hydrostat (SP 2020/3020) 2. Forward header (SP 2020/3020) 3. Wheel motor connector (SP 5020)

Hydraulic System (Rev. A) Page 4 – 26 Sand Pro 2020/3020/5020

Procedure for Wheel Motor Efficiency

Note: Over a period of time, a wheel motor can wear

internally. A worn motor may by–pass oil causing the motor to be less efficient. Eventually, enough oil loss will cause the wheel motor to stall under heavy load condi tions. Continued operation with a worn, inefficient motor can generate excessive heat, cause damage to seals and other components in the hydraulic system, and af fect overall machine performance.

1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full.

2. Park machine on a level surface with the attachments lowered. Make sure engine is off and the parking brake is engaged.

3. Read Precautions for Hydraulic Testing.

4. Make sure that traction pedal is adjusted to the neutral position (see Adjust Traction Drive for Neutral in the Adjustments Section).

5. Attach a heavy chain between the rear of the machine frame and an immovable object to prevent the machine from moving during testing.

6. Install hydraulic tester (flow meter) using the same tester connections as TEST NO. 1: Traction Pump Flow.

Make sure the tester flow control valve is fully open.

7. Make sure parking brake is engaged. On machines with 3 wheel drive, chock the front wheel to prevent front wheel rotation.

8. After installing hydraulic tester, start engine and run at low idle speed. Check for hydraulic leakage and cor rect before proceeding with test.

10. Slowly push traction pedal in the forward direction until 1000 PSI is displayed on the tester pressure gauge.

11. With all drive wheels locked (not rotating), total internal leakage for all wheel motors will be shown on the

flow meter. Flow should be less than 2 GPM (7.6 LPM). Record test results.

12. Release traction pedal and shut engine off.

13. If specification is not met, individual wheel motors need to be removed from the traction circuit to deter mine which motor(s) is leaking excessively.

A. For SP2020/3020 machines, a wheel motor can be removed from the traction circuit by disconnect ing and capping the two hydraulic lines at the motor.

B. For SP5020 machines, the front motor can be removed from the traction circuit by disconnecting the two hydraulic lines at the motor and then connecting the hoses together to allow flow to the rear wheels. A rear motor on a SP5020 can be removed from the traction circuit by disconnecting and capping the two hydraulic lines at the motor.

14. After removing a motor from the circuit, retest using steps 6 through 10 making sure that the remaining drive wheels are locked (not rotating) during testing. When a worn motor is removed from the traction circuit, the test results should show a decrease in leakage flow from the system. Any wheel motor that has leakage greater than

.7 GPM needs to be repaired or replaced.

Example: consider a SP5020 that has a total internal

leakage of 3.5 GPM. When the right, rear wheel motor is disconnected, the system leakage decreases to 1 GPM. The leakage for the disconnected motor is 2.5

GPM which indicates the need to repair or replace the right, rear wheel motor.

Systems

Hydraulic

Multiple wheel motors may be worn, so efficiency testing

CAUTION

Use extreme caution when performing test. The drive wheels will be trying to move the machine.

9. Move throttle to full speed (3150 + 50 RPM).

Sand Pro 2020/3020/5020 Page 4 – 27 Hydraulic System (Rev. A)

of all wheel motors may be required. After an individual motor is tested, reconnect that motor before proceeding to test another motor.

15. After testing is completed, disconnect tester from machine and reconnect all hose connections.

Adjustments

Adjust Traction Pedal for Neutral

If the machine “creeps” when the traction pedal is in the neutral position, the traction cam must be adjusted.

1. Park the machine on a level surface. Turn the engine off.

2. On the SP 2020/3020, pivot seat upward and re- move engine shield. On the SP 5020, remove three cap screws securing side panel to the right side of machine and remove panel.

WARNING

Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 – Safety.

3. Raise one rear wheel off floor and place support blocks under frame.

4. Loosen locknut on the adjustment cam.

WARNING

5. Start engine. Rotate adjustment cam in both directions to determine mid position of neutral span.

6. Tighten lock nut securing the adjustment cam.

7. Stop engine.

8. Remove support blocks and lower the machine. Test drive machine to make sure it does not creep.

9. On the SP 2020/3020, install engine shield and pivot seat down. On the SP 5020, secure side panel to the right side of machine with three cap screws.

The engine must be running to perform the final adjustment of the traction adjustment cam. Guard against possible personal injury. Keep hands, feet, face, and other parts of the body away from rotating parts and hot engine parts such as the muffler.

1. Lock nut 2. Adjustment cam

Adjust Traction Pedal for Forward (SP 2020/3020)

The pedal must be adjusted for forward if the jam nuts on the control rod are loosened or if the pedal is re moved.

1. If the jam nuts on the control rod are loosened or the pedal is removed, adjust pedal for forward.

2. Make sure pump is in neutral.

3. Loosen jam nuts on the control rod.

4. Press down on the rear of the pedal until the pedal contacts the footrest.

5. Adjust jam nuts to allow for full stroke of the pump lever in the reverse direction. The control rod must deflect slightly when the pedal is at full stroke.

1. Jam nuts 3. Pedal

2. Control rod

Figure 16

Figure 17

Hydraulic System (Rev. A) Page 4 – 28 Sand Pro 2020/3020/5020

Adjust Traction Pedal for Forward (SP 5020)

If the jam nuts on the control rod are loosened or if the pedal is removed, adjusted traction pedal for forward.

1. Park machine on a level surface and turn engine off.

2. Make sure pump is in neutral.

3. Loosen jam nuts on the control rod.

4. Press down on the forward pad of the pedal until the pedal rod contacts the footrest. Tighten jam nuts.

Figure 18

1. Jam nuts 2. Control rod

Systems

Hydraulic

Sand Pro 2020/3020/5020 Page 4 – 29 Hydraulic System (Rev. A)

Adjust Lift Lever (SP 2020/3020)

The lift lever should be adjusted if the attachment does not float (follow ground contour) properly during operation.

1. Park machine on a level surface. Turn engine off and engage parking brake.

2. Disconnect attachment from lift cylinder. Extend cylinder part way.

3. Loosen capscrews and locknuts securing the lever guide to the valve shroud.

4. Move lever guide until the cylinder moves freely when the lift lever is in the detent position.

5. Tighten capscrews and locknuts to lock in adjustment.

Adjust Lift Lever (SP 5020)

The lift lever detent plate should be adjusted if the attachment does not float (follow ground contour) properly during operation.

1. Park the machine on a level surface, turn engine off, set parking brake, and block wheels.

2. Loosen both capscrews securing lift lever detent plate to the fender and frame.

1. Cap screws

2. Lever guide

Figure 19

3. Lift lever

4. Detent position

3. Insert a 3/16–inch hex key through the access hole of the front fender and into the jacking screw of the lift lever detent plate.

WARNING

The engine must be running so final adjustment of the lift lever detent plate can be performed. To guard against possible personal injury, keep hands, feet, face and other parts of the body away from the muffler, other hot parts of the engine and other rotating parts.

4. Start engine.

5. With engine running and lift lever in the FLOAT position, rotate jacking screw until the lift cylinder can be extended and retracted by hand.

6. Tighten both lift lever detent plate cap screws to secure adjustment.

1. Cap screws

2. Detent plate

Figure 20

3. Access hole

4. Jacking screw

Sand Pro 2020/3020/5020Hydraulic System (Rev. A) Page 4 – 30

Service and Repairs

Check Hydraulic Lines and Hoses

WARNING

Charge Hydraulic System

Check hydraulic lines and hoses daily for leaks, kinked lines, loose mounting supports, wear, loose fittings, weather deterioration and chemical deterioration. Make all necessary repairs before operating.

NOTE: When initially starting the hydraulic system with new or rebuilt components such as motors, pumps, or lift cylinders, it is important that the hydraulic system be charged properly. Air must be purged from the system and its components to reduce the chance of damage.

IMPORTANT: Change hydraulic oil filter whenever hydraulic components are repaired or replaced.

1. Park machine on a level surface, and turn the engine off.

2. Make sure all hydraulic connections, lines, and components are secured tightly.

3. If component failure was severe or the system is contaminated, flush and refill hydraulic system and tank (see Flush Hydraulic System).

4. Make sure hydraulic tank is full. Add correct oil if necessary (see Check Hydraulic System Fluid).

5. Disconnect spark plug leads to prevent the engine from starting.

6. Check control linkage to the hydrostat for proper adjustment, binding, or broken parts.

10. Loosen lock nut on spring adjusting pin until bearing moves freely from cam. The pump shaft must be free to rotate during start–up.

WARNING

Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 – Safety.

11. Raise one rear wheel off the floor, and place support blocks under frame. Chock remaining wheels to prevent movement of the machine.

12. Make sure traction pedal and lift control lever are in neutral. Start engine and run it at low idle of 1800 rpm. The charge pump should pick up oil and fill the hydraulic system. If there is no indication of fill in 30 seconds, stop the engine and determine the cause.

Systems

Hydraulic

7. Make sure traction pedal and the lift control lever are in the neutral position. Turn ignition key switch; engage starter for fifteen (15) seconds to prime the traction and charge pumps.

8. Reconnect spark plug leads.

9. On the SP 2020/3020, pivot seat upward and re- move engine shield. On the SP 5020, remove cap screws that secure side panel to right side of machine.

Sand Pro 2020/3020/5020 Page 4 – 31 Hydraulic System (Rev. A)

Figure 21

1. Spring adjusting pin 3. Cam

2. Bearing

13. After the hydraulic system starts to show signs of fill, actuate lift control lever until the lift cylinder rod moves in and out several times. If the cylinder rod does not move after 10 to 15 seconds, or the pump emits abnor mal sounds, shut the engine off immediately and determine cause or problem. Inspect for the following:

A. Loose filter or suction lines.

B. Loose or faulty coupler on the pump.

17. On the SP 2020/3020, install engine shield and pivot seat down. On the SP 5020, secure panel to right side of machine with cap screws.

18. Check operation of the traction interlock switch (see Check Interlock System in Chapter – 5, Electrical Sys tems).

19. Remove block from wheels and lower machine. Remove chocks from remaining wheels.

C. Blocked suction line.

D. Faulty charge relief valve.

E. Faulty charge pump.

14. If cylinder moves in 10 to 15 seconds, proceed to step 15.

15. Operate the traction pedal in the forward and reverse directions. The wheel off the floor should rotate in the proper direction.

A. If the wheel rotates in the wrong direction, stop engine, remove lines from rear of pump, and re verse the connections.

B. If the wheel rotates in the proper direction, stop engine and adjust the spring adjusting pin lock nut.

16. Adjust traction pedal to the neutral position (see Adjust Traction Pedal for Neutral).

20. If the traction pump or a wheel motor was replaced or rebuilt, run the traction unit so all wheels turn slowly for 10 minutes.

21. Operate traction unit by gradually increasing its work load to full over a 10 minute period.

22. Stop the machine. Check tank and fill if necessary. Check hydraulic components for leaks and tighten any loose connections.

Hydraulic System (Rev. A) Page 4 – 32 Sand Pro 2020/3020/5020

Change Hydraulic System Fluid and Filter

The hydraulic system filter must be changed initially after the first 8 hours of operation. Thereafter, it must be changed every 400 hours of operation or yearly, which ever comes first. Use a genuine Toro oil filter for replacement. The hydraulic oil must be changed every 400 hours of operation or yearly, whichever comes first.

1. Park machine on a level surface and turn the engine off.

2. On the SP 2020/3020, pivot seat up. On the SP 5020, remove three cap screws securing the right side panel to the machine and remove panel.

3. On the SP 2020/3020, disconnect tube from the bottom fitting of the hydraulic tank. Let oil flow into a drain pan. Reinstall and tighten tube connection when oil stops draining.

4. On the SP 5020, place a funnel under the tank drain plug to direct oil into a drain pan. Remove drain plug and allow oil to drain into pan. Reinstall and tighten drain plug when the oil stops draining (Fig. 22).

Figure 22

1. Tank (SP 5020) 2. Drain plug

5. Clean area around the hydraulic oil filter. Remove filter from the filter head. Allow oil to flow into a drain pan. Dispose of the oil filter properly (Fig 23 or 24).

6. Apply a film of clean hydraulic oil on the filter gasket. Install filter by hand until gasket contacts filter head, then tighten filter an additional three–fourths of a turn.

7. Fill tank to the proper level (see Check Hydraulic System Fluid).

8. Make sure traction pedal and lift lever are in the neutral position. Start engine. Run engine at lowest possible RPM to purge the system of air.

9. Run engine until the lift cylinder can be extended and retracted and wheel motion in the forward and re verse direction is achieved.

10. Stop engine and check oil level in the tank. Add oil if necessary.

11. Check all hydraulic connections for leaks.

12. On the SP 2020/3020, pivot seat down. On the SP 5020, install right side panel and secure with three cap screws.

13. Dispose of oil properly.

Systems

Hydraulic

Figure 23

1. Filter (SP 2020/3020) 2. Filter head

Figure 24

1. Filter (SP 5020) 2. Filter head

Sand Pro 2020/3020/5020 Page 4 – 33 Hydraulic System (Rev. A)

Lift Valve (SP 2020/3020)

26 22

1. Control panel decal

2. Lift valve shroud

3. Cap screw

4. 90

hydraulic fitting

5. Knob

6. Lift lever

7. Cap screw

8. Offset link

9. Pivot bracket

10. Lock nut

11. Lock nut

12. Swivel run T–fitting

13. 45

hydraulic fitting

Figure 25

14. Lift valve

15. Cap screw

16. Self tapping screw

17. Seat support spacer

18. Pivot

19. Spring pin

20. Valve lever latch

21. Brake lever

22. Clevis

23. Hex nut

24. Clevis pin

25. Cotter pin

26. Flat washer

27. Lock nut

28. Cap screw

29. O–ring

30. Hydraulic hose

31. O–ring

32. Hydraulic hose

33. Shuttle valve tube

34. Hydraulic tube

35. Brake rod

36. Lift lever guide

37. Wave washer

38. Lock nut

Sand Pro 2020/3020/5020Hydraulic System (Rev. A) Page 4 – 34

Removal (Fig. 25)

Installation (Fig. 25)

1. Before removing any parts from the hydraulic system, park machine on a level surface, engage parking brake, lower attachment, and stop engine.

CAUTION

2. Remove cover from the midsection of the machine. Pivot seat up. Unscrew knob (5) from lift lever (6).

3. Remove lift valve shroud (2) as follows:

A. Remove self tapping screw (16) from the shroud and frame.

B. Remove both cap screws (3) and lock nuts (38) securing the shroud, lift lever guide (36), and valve lever latch (20) to the frame.

C. Lift shroud from the frame.

1. Make sure lift valve, hydraulic hoses, fittings, and tubes are cleaned thoroughly.

2. Reinstall O–rings (31) and hydraulic fittings (4 and

13) to the lift valve. Observe match marks when tighten ing.

3. Position lift valve (14) to the frame. Insert four cap screws (15) through the frame and lift valve. Screw lock nuts (11) to the bottom two cap screws (15).

4. Position lift lever (6) through the frame and attached pivot bracket (9) and other attached parts onto the top two cap screws (15). Screw lock nuts (11) to the top two cap screws (15). Tighten all four lock nuts.

5. Secure pivot (18) to the lift valve stem with cap screw (7) and lock nut (10). Tighten fasteners.

6. Remove caps and plugs from the disconnected hoses, tubes, and fittings

7. Reconnect hydraulic tube (34) to the 90 fitting (4). Reconnect swivel run T–fitting (12) to the 45 hydraulic fitting (13). Reconnect both hydraulic hoses (30) with O–rings (29) to the lift valve. Tighten all connections.

hydraulic

4. Clean lift valve (14) and all hydraulic fittings, tubes, and hoses attached to it thoroughly.

5. Label all hydraulic connections for reassembly.

6. Disconnect both hydraulic hoses (30) from the lift valve. Disconnect swivel run T–fitting (12) from the 45 hydraulic fitting (13). Disconnect hydraulic tube (34) from the 90 fittings to drain into a suitable container.

7. Put caps or plugs on disconnected hoses, tubes, and fittings to prevent contamination.

8. Remove cap screw (7) and lock nut (10) securing the pivot (18) to the lift valve stem.

9. Remove four cap screws (15) and lock nuts (11) securing the pivot bracket (9) to the lift valve and the lift valve to the frame. Separate lift valve from the frame. Do

not further disassemble parts assembled to the lift lever.

IMPORTANT: Match mark positions of hydraulic fittings (4 and 13) relative to their ports on the lift valve.

10. Remove remaining hydraulic fittings (4 and 13) and O–rings (31) from the lift valve.

hydraulic fitting (4). Allow hoses, tubes, and

8. Attach lift valve shroud (2) as follows:

A. Position valve lever latch (20) and lift lever guide (36) over the lift lever and onto the frame.

B. Insert both cap screws (3) to the shroud.

C. Lower shroud around lift lever (6) and onto frame. Make sure cap screws go through lift lever guide (36) and valve lever latch (20).

D. Attach lock nuts (38) to cap screws. Do not

tighten fasteners.

E. Reinstall self tapping screw (16) to the shroud and frame. Tighten screw.

9. Screw knob (5) onto the lift lever (6). Hand tighten.

10. Charge hydraulic system (see Charge Hydraulic System).

11. Run machine and check lift valve, hydraulic hoses, tubes, and fittings for leaks. Tighten as necessary.

12. Adjust lift lever (6) (see Adjust Lift Lever).

13. Reinstall cover to the midsection of the machine.

Systems

Hydraulic

Sand Pro 2020/3020/5020 Page 4 – 35 Hydraulic System (Rev. A)

Lift Valve (SP 5020)

829

1. Lock nut

2. 90

hydraulic fitting

3. Cap screw

4. Lock nut

5. Lever knob

6. Pivot bracket

7. Cap screw

8. Hydraulic orifice fitting

9. Hydraulic straight fitting

10. Hydraulic T–fitting

11. LIft valve

12. Offset link

13. Bulkhead bracket

14. Self tapping screw

15. Hydraulic T–fitting

16. Bulkhead nut

17. Spacer

18. Washer

19. Grommet

20. Lift lever

21. Welded pivot

22. Spring pin

23. R–clamp

24. Lock washer

25. Curved washer

26. O–ring

27. O–ring

28. O–ring

Figure 26

29. O–ring

30. O–ring

31. Hydraulic tube

32. Hydraulic hose

33. Hydraulic hose

34. Hydraulic hose

35. Hydraulic tube

36. Hydraulic tube

37. Hydraulic tube

38. Hydraulic tube

39. Hydraulic tube

40. Hydraulic tube

41. Hydraulic tube

Sand Pro 2020/3020/5020Hydraulic System (Rev. A) Page 4 – 36

Removal (Fig. 26)

Installation (Fig. 26)

1. Before removing any parts from the hydraulic system, park machine on a level surface, engage parking brake, lower attachment, and stop engine.

CAUTION

2. Remove cover from the midsection of the machine. Unscrew knob (5) from lift lever (20).

3. Remove control panel (right fender) to gain access to the lift valve (see Control Panel Removal in Chapter 6 – Wheels, Brakes, and Miscellaneous).

4. Clean lift valve assembly (11) and all hydraulic fittings, tubes, and hoses attached to it thoroughly.

5. Label all hydraulic connections for reassembly.

6. Disconnect both hydraulic hoses (32 and 33) and O–rings (29) from hydraulic fittings (8 and 9). Allow hoses and fittings to drain into a suitable container.

1. Make sure lift valve, hydraulic hoses, fittings, and tubes are cleaned thoroughly.

2. Reinstall O–rings (27 and 28) and hydraulic fittings (2, 8, 9, and 10) to the lift valve. Observe match marks when tightening.

3. Position lift valve to the frame. Insert two cap screws (7) through the bottom two holes of frame bracket frame and lift valve. Screw lock nuts (1) to the bottom two cap screws (7).

4. Position lift lever to the lift valve. Insert two cap screws (7) through flat washer (24), pivot bracket (6), and top two holes of lift valve and frame bracket. Screw lock nut (1) to the top cap screw (7). Tighten all three lock nuts and four cap screws.

5. Secure welded pivot (21) to the lift valve stem with cap screw (3) and lock nut (4). Tighten fasteners.

6. Remove caps and plugs from the disconnected hoses, tubes, and fittings

7. Reconnect hydraulic tube (31) and O–ring (26) to

hydraulic fitting (2).

8. Reconnect hydraulic hose (34), hydraulic tube (35), and O–rings (26) to hydraulic T–fitting (10).

7. Disconnect hydraulic hose (34), hydraulic tube (35), and O–rings (26) from hydraulic T–fitting (10). Allow hose, tube, and fitting to drain into a suitable container.

8. Disconnect hydraulic tube (31) and O–ring (26) from

hydraulic fitting (2). Allow tube and fitting to drain

90 into a suitable container.

9. Put caps or plugs on disconnected hoses, tubes, and fittings to prevent contamination.

10. Remove cap screw (3) and lock nut (14) securing the welded pivot (21) to the lift valve stem.

11. Remove four cap screws (7), lock washer (24) and lock nuts (1) securing the pivot bracket (6) to the lift valve and the lift valve to the frame. Separate lift valve from the frame. Do not further disassemble parts assembled

to the lift lever.

IMPORTANT: Match mark positions of hydraulic fittings (2,8,9 and 10) relative to their ports on the lift valve.

12. Remove remaining hydraulic fittings (2, 8, 9, and 10) and O–rings (27 and 28) from the lift valve.

9. Reconnect both hydraulic hoses (32 and 33) and O– rings (29) to hydraulic fittings (8 and 9).

10. Reinstall control panel (see Control Panel Installation in Chapter 6 – Wheels, Brakes, and Miscellaneous).

11. Charge hydraulic system (see Charge Hydraulic System).

12. Run machine and check lift valve, hydraulic hoses, tubes, and fittings for leaks. Tighten as necessary.

13. Adjust lift lever (20) (see Adjust Lift Lever).

Systems

Hydraulic

Sand Pro 2020/3020/5020 Page 4 – 37 Hydraulic System (Rev. A)

Lift Valve

1. Plug

2. O–ring

3. Spring

4. Ball

5. Check valve seat

1 2

9 10

11 12 13 14 15

3 5

Figure 27

6. Cam pin

7. Body

8. Spool

9. O–ring

10. Spring retainer

11. Spring

12. Spring retainer

13. Spacer float

14. Spool retaining ring

15. Retaining ring

Disassembly

1. Wash valve in solvent and dry thoroughly.

2. Mount valve carefully in a vise so that the retaining ring is facing up and the mounting pads are against the jaws of the vise.

3. Remove plug and O–ring from the valve body. Remove spring, ball, and cam pin.

4. Remove spool retaining ring from the spool. Push and twist spool carefully out of the body.

5. Remove spacer float from the spring retainer.

6. Remove retaining ring from the body. Remove spring retainer, spring, and spring retainer from the body.

7. Use hooked scribe to remove both O–rings from the body. Be careful not to scratch bore finish.

Inspection

1. Inspect spool for wear and flatness. Wear on one side of the spool may indicate a bent spool. Replace spool if necessary.

2. Inspect check valve seat for wear and damage of sealing surface. Replace if necessary.

3. Inspect ball for wear, damage, and flat spots. Replace if necessary.

Reassembly

1. Clean and dry all parts thoroughly. Coat all O–rings with clean hydraulic fluid.

2. Use hooked scribe to install both O–rings into the grooves of the body bore.

3. Install spring retainer, spring, and spring retainer into the body. Secure with retaining ring.

4. Install spacer float into the spring retainer.

5. Coat spool with clean hydraulic oil. Push and twist spool carefully into the body. Secure spool with spool re taining ring.

6. Install cam pin, ball, and spring into the body. Install O–ring and plug into the body. Tighten plug.

Hydraulic System (Rev. A) Page 4 – 38 Sand Pro 2020/3020/5020

Lift Cylinder (SP 2020/3020)

Removal

1. Before removing any parts from the hydraulic system, park the machine on a level surface, engage the parking brake, lower attachment, and stop the engine.

CAUTION

2. Label all hydraulic connections for reassembly.

3. Disconnect hydraulic hoses and O–rings from the hydraulic fittings. Allow hoses to drain into a suitable container.

4. Put caps or plugs on disconnected hoses and fittings to prevent contamination.

5. Remove cotter pin from the clevis pin. Pull clevis pin from the hydraulic cylinder and lift arm.

6. Support hydraulic cylinder to prevent it from dropping.

A. Remove a cotter pin from the cylinder pin.

Figure 28

1. Hydraulic hose

2. 90o Hydraulic fitting

3. 45

Hydraulic fitting 7. Cylinder pin (clevis)

4. O–ring 8. Cylinder pin

5. Hydraulic cylinder

6. Cotter pin

Systems

Hydraulic

B. Pull cylinder pin from the hydraulic cylinder and frame.

C. Remove hydraulic cylinder from the frame.

Installation

1. Position hydraulic cylinder tho the frame. Insert cylinder pin through the frame bracket and cylinder. Secure pin with cotter pins.

2. Position clevis of the hydraulic cylinder to the lift arm. Insert clevis pin through the cylinder clevis and se

cure with cotter pins.

3. Remove caps or plugs from the disconnected hose and fittings. Connect hydraulic hoses and O–rings to the hydraulic fittings. Tighten hose connections.

4. Charge hydraulic system (see Charge Hydraulic System).

Sand Pro 2020/3020/5020 Page 4 – 39 Hydraulic System (Rev. A)

Lift Cylinder(SP 5020)

Removal

1. Before removing any parts from the hydraulic system, park the machine on a level surface, engage the parking brake, lower the cutting units, and stop the en gine.

CAUTION

2. Label all hydraulic connections for reassembly.

3. Disconnect hydraulic hoses and O–rings from the hydraulic fittings. Allow hoses to drain into a suitable container.

4. Put caps or plugs on disconnected hoses and fittings to prevent contamination.

5. Remove both hair pins from the cylinder pin. Pull cylinder pin from the lift cylinder, spacer, and lift arm.

Figure 29

1. Spacer

2. Hydraulic cylinder

3. Cap screw

4. Cylinder pin

5. Hydraulic hose

6. Cylinder support

7. Not used

8. Not used

9. Cable tie

10. Protective sleeve

11. Cap screw

12. Washer

13. 90

hydraulic fitting

14. Hydraulic hose

15. O–ring

16. O–ring

17. Lock nut

18. Hair pin

6. Support lift cylinder to prevent it from dropping.

A. Remove cap screw and flat washer from the cylinder support.

B. Remove lift cylinder from the support.

Installation

1. Position lift cylinder to the frame. Install lift cylinder to to the cylinder support. Secure cylinder to the support with flat washer and cap screw.

2. Position clevis of the lift cylinder to the lift arm and spacer. Insert cylinder pin through the cylinder clevis, lift arm, and spacer. Secure cylinder pin with both hair pins.

3. Remove caps or plugs from the disconnected hoses and fittings. Connect hydraulic hoses and O–rings to the hydraulic fittings. Tighten hose connections.

4. Charge hydraulic system (see Charge Hydraulic System).

Hydraulic System (Rev. A) Page 4 – 40 Sand Pro 2020/3020/5020

Lift Cylinder Service

1. O–ring

2. Barrel

3. Nut

4. Uni–ring

5. Piston

ÉÉ

Figure 30

6. O–ring

7. Poly–pack

8. O–ring

9. Back–up ring

10. Head

11. Dust seal

12. Retaining ring

13. Shaft (w/clevis)

14. Pivot end

15. Clevis

Disassembly

1. Remove oil from the hydraulic cylinder into a drain pan by slowly pumping the cylinder shaft. Plug both ports and clean the outside of the cylinder.

IMPORTANT: Prevent damage when clamping the hydraulic cylinder into a vise; clamp on pivot end only. Do not close vise enough to distort the barrel.

2. Mount hydraulic cylinder in a vice. Remove dust seal and retaining ring.

3. Extract shaft, head, and piston by carefully twisting and pulling on the shaft.

IMPORTANT: Do not clamp vise jaws against the shaft surface. Protect shaft surface before mount ing in a vice.

4. Mount shaft securely in a vise by clamping on the clevis of the shaft. Remove lock nut and piston from the shaft. Slide head off the shaft.

5. Remove Uni–ring and O–ring from the piston. Remove poly–pack, O–ring, and back–up ring from the head.

Reassembly

1. Make sure all parts are clean before reassembly.

2. Coat new O–rings, Uni–rings, poly–pack, back–up ring, and dust seal with with clean hydraulic oil. Install Uni–ring and O–ring to the piston. Install poly–pack, O– ring, and back–up ring to the head.

IMPORTANT: Do not clamp vise jaws against the shaft surface. Protect shaft surface before mount ing in a vice.

3. Mount shaft securely in a vise by clamping on the clevis of the shaft. Slide head onto the onto the shaft. Install piston and lock nut onto the shaft. Tighten lock nut. Remove shaft from the vise.

IMPORTANT: Prevent damage when clamping the hydraulic cylinder into a vise; clamp on pivot end only. Do not close vise enough to distort the barrel.

4. Mount barrel in a vice.

5. Coat all internal parts with a light coat of clean hydraulic oil. Slide piston, shaft, and head assembly into the barrel being careful not to damage the seals.

Systems

Hydraulic

6. Secure head in the barrel with the retaining ring.

Sand Pro 2020/3020/5020 Page 4 – 41 Hydraulic System (Rev. A)

Hydrostat (SP 2020/3020)

RIGHT

FRONT

Figure 31

1. Not used 13. 90o hydraulic fitting

2. Shaft cover 14. Hydraulic hose

3. Lock washer 15. Cap screw

4. Hydraulic hose 16. Lock nut

5. Hydraulic hose 17. Flat washer

6. Cap screw 18. Coupling spacer

7. Wire standoff 19. Cap screw

8. Suction hose 20. Set screw

9. Hydrostat 21. Engine hub

10. Push on hose fitting 22. Square key

11. Hydraulic hose 23. Rubber coupling

12. 90

hydraulic fitting

Removal (Fig. 31)

1. Before removing any parts from the hydraulic system, park machine on a level surface, set brake, lower attachment, and stop engine.

24. Pump hub

25. Pump mount

26. Woodruff key

27. Hex nut

28. Lock washer

29. O–ring

30. Hose clamp

31. O–ring

32. O–ring

33. Cable tie

34. Hydraulic hose

CAUTION

The muffler and exhaust pipe may be hot. Avoid possible burns. Allow engine and exhaust system to cool before working near the muffler.

CAUTION

3. Remove muffler shield from the engine by first removing three cap screws and lock washers securing the

Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy

draulic oil. Controls must be operated with the ignition switch in OFF. Remove key from the ignition switch.

2. Pivot seat up. Remove cover from the midsection of the machine.

shield.

4. Remove cotter pin and flat washer securing the pump control rod to the pump lever. Pull control rod from the pump lever (Fig. 32).

5. Label electrical wires. Disconnect wires from the neutral switch (Fig. 32).

6. Remove cap screw and lock nut securing the pump lever to the hydrostat trunnion (Fig. 32).

Hydraulic System (Rev. A) Page 4 – 42 Sand Pro 2020/3020/5020

7. Remove three cap screws securing the pump plate to the hydrostat while pulling the pump plate from the hy drostat (Fig. 32).

8. Clean all hydraulic fittings and hydraulic hoses attached to the hydrostat. Label all hydraulic connections for reassembly.

9. Place a suitable container under hydrostat to collect hydraulic oil.

10. Clamp suction hose (8) to prevent draining the hydraulic tank.

11. Remove hydraulic hoses (11 and 14) from 90

hydraulic fittings (13 and 12). Allow fluid to drain from the hoses into the container.

12. Remove suction hose (8) from push on fitting (10). Allow fluid to drain from the hose into the container.

13. Remove hydraulic hoses (4 and 5) and O–rings (29) from the hydrostat. Allow fluid to drain from the hoses into the container.

6. Remove caps and plugs from disconnected hoses

and fittings.

7. Reinstall hydraulic hoses (11 and 14) to 90 lic fittings (13 and 12).

8. Reinstall hose clamp (30) and suction hose (8) to push on fitting (10). Tighten hose clamp.

9. Remove clamp used to prevent draining the hydraulic tank from suction hose (8).

10. Reinstall hydraulic hoses (4 and 5) and O–rings (29) to hydrostat (9).

11. Secure pump plate to the hydrostat with three cap screws. Tighten cap screws while attaching the pump plate to the hydrostat (Fig. 32).

12. Align pump lever to the hydrostat trunnion. Secure pump lever to the hydrostat trunnion with cap screw and lock nut (Fig. 32).

13. Reconnect wires to the neutral switch (Fig. 32).

hydrau-

14. Put caps or plugs on disconnected hoses and fittings to prevent contamination.

15. Loosen both set screws (20) from hydrostat shaft.

16. Support hydrostat to prevent dropping during removal. Remove both hex nuts (27), lock washers (28), cap screws (6) from the hydrostat (9) and pump mount (25). Pull hydrostat from mount and machine.

17. Remove woodruff key (26) from hydrostat shaft.

18. Match mark position of hydraulic fittings on the hydrostat. Remove remaining fittings (10, 12, and 13) and O–rings (31 and 32) from the hydrostat. insert caps or plugs into open ports of the hydrostat.

Installation (Fig. 31)

1. Make sure lift valve, hydraulic hoses, fittings, and tubes are cleaned thoroughly.

2. Reinstall O–rings (32) and hydraulic fittings (12 and

13) to the hydrostat. Observe match marks when tight ening.

3. Remove caps or plugs from the hydrostat.

4. Install woodruff key (26) to hydrostat shaft. Support hydrostat (9) while positioning onto pump mount (25). Make sure woodruff key (26) stays in place when the shaft is inserted into the pump hub (24).

14. Insert control rod into the pump lever. Secure pump control rod to the pump lever with flat washer and cotter pin (Fig. 32).

15. Secure muffler shield to the engine with three cap screws and lock star washers securing. Make sure R– clamp and fuel hose a secured to the muffler shield by cap screw and lock star washer.

16. Secure cover to the midsection of the machine and pivot seat down.

17. Charge hydraulic system (see Charge Hydraulic System).

Figure 32

1. Control rod 4. Neutral switch

2. Pump lever 5. Pump plate

3. Wires

Systems

Hydraulic

5. Secure hydrostat to mount with both cap screws (6), lock washers (28), hex nuts (27). Tighten set screw (20) to hydrostat shaft.

Sand Pro 2020/3020/5020 Page 4 – 43 Hydraulic System (Rev. A)

Hydrostat (SP 5020)

RIGHT

FRONT

6 7

Figure 33

1. Hydraulic hose (to front motor)

2. O–ring

3. Hydraulic tube

4. Not used

5. Hydraulic tube

6. 90

hydraulic fitting

7. O–ring

8. Hydrostat

9. Woodruff key

10. Lock nut

11. Set screw

12. Hex nut

13. Coupler spacer

14. Rubber coupler

15. Cap screw

16. Coupling

17. Square key

18. Engine hub

19. Pump hub

20. Socket head screw

21. Hydraulic hose (To lift valve)

22. O–ring

23. 90

hydraulic fitting

24. O–ring

Removal (Fig. 33)

1. Before removing any parts from the hydraulic system, park machine on a level surface, set brake, lower attachment, and stop engine.

CAUTION

2. Pivot seat up. Remove left and right side panels from the machine. Remove left fender and seat (see Left Fender (Seat Base) Removal in Chapter 6 – Wheels, Brakes, and Miscellaneous).

25. Hydraulic hose (from oil cooler)

26. Not used

27. Fan hub

28. Cooling fan

29. Cap screw

30. Hydraulic hose (from oil filter)

31. Hose clamp

32. 90

hydraulic fitting

33. O–ring

34. 45

hydraulic fitting

35. Hydraulic hose (to tank)

36. Hydraulic hose (from rear motors)

CAUTION

The muffler and exhaust pipe may be hot. To avoid possible burns, allow engine and exhaust system to cool before working near the muffler.

3. Disconnect wire harness as follows: disconnect blue wire from magneto terminal, disconnect blue wire from voltage regulator, disconnect red/white wire from fuel solenoid (Fig. 45).

4. Disconnect red positive cable cable (solenoid) from the starter. Remove lock nut and cap screw securing black ground wire and black battery cable (negative) to the engine block. Pull cable and harness clear of the engine (Fig. 47).

Sand Pro 2020/3020/5020Hydraulic System (Rev. A) Page 4 – 44

5. Disconnect air hose from the air cleaner. Remove lower shroud from the cooler mount to prevent damage to the fan when removing the hydrostat.

6. Disconnect control rod from pump lever and wires from the neutral switch (Fig. 36).

7. Loosen both set screws (11) on the pump hub (19) enough to allow the hydrostat shaft to be released.

8. Clamp hydraulic hose (35) and hydraulic hose (25) to prevent draining of the tank. Disconnect all six hy draulic hoses from fittings on the hydrostat. Allow hoses to drain into a suitable container.

9. Remove self tapping screw securing R–clamp and fuel hose to the frame (Fig. 37)

CAUTION

One person should operate the chain fall or hoist while the other person guides the engine from the frame.

IMPORTANT: When moving the engine and hydrostat from the frame, make sure not the damage the cooling fan, wires, hoses, and cables.

10. Reposition hydrostat and engine as follows:

A. Position a jack or chain fall to the engine base (Fig. 39).

Figure 34

1. Blue wire (magneto) 3. Voltage regulator

2. Blue wire (voltage reg.) 4. Red/white wire

Figure 35

1. Positive cable (solenoid) 4. Battery cable (negative)

2. Starter 5. Ground wire (frame)

3. Lock nut and cap screw

Systems

Hydraulic

B. Remove lock nuts, flat washers, and cap screws securing both front engine mounts to the frame (Fig. 38).

C. Remove cap screws and flat washers securing the engine support the the frame (Fig. 39).

D. Lower and pull back hydrostat and engine from the cooler mount so the cooling fan is clear of the mount.

11. Separate hydrostat from the engine base by removing both lock nuts and socket head screws.

12. Remove fan hub (27) with cooling fan (28) and woodruff key (9) from the hydrostat shaft.

13. Match mark position of all hydraulic fittings on the hydrostat. Remove all hydraulic fittings and O–rings from the hydrostat. Plug or cap all ports to prevent con

tamination.

14. Remove cap screw and lock nut securing the pump lever to the hydrostat trunnion. Remove three cap screws securing the pump plate to the hydrostat while pulling the pump plate from the hydrostat (Fig. 36).

Figure 36

1. Control rod 4. Neutral switch

2. Pump lever 5. Pump plate

3. Wires

Installation (Fig. 33)

1. Make sure hydraulic hoses, fittings, and tubes are cleaned thoroughly.

2. Securing pump plate to the hydrostat with three cap screws. Secure pump lever to the hydrostat trunnion with cap screw and lock nut (Fig. 36).

Sand Pro 2020/3020/5020 Page 4 – 45 Hydraulic System (Rev. A)

3. Reinstall O–rings and hydraulic fittings to the hydrostat. Observe match marks when tightening.

4. Install woodruff key (9) and fan hub (27) with cooling fan (28) to the hydrostat shaft. Secure hub to shaft with both set screws.

5. Secure hydrostat (8) to engine base with both socket head screws (20) and lock nuts (10).

6. Reinstall engine and hydrostat as follows:

14. Install left fender and seat (see Left Fender (Seat Base) Installation in Chapter 6 – Wheels, Brakes, and Miscellaneous). Install left and right side panels to the machine. Lower seat.

15. Charge hydraulic system (see Charge Hydraulic System).

CAUTION

One person should operate the chain fall or jack while the other person guides the engine to the frame.

IMPORTANT: When repositioning the engine and hydrostat to the frame, make sure not the damage the cooling fan, wires, hoses, and cables.

A. Use jack or chain fall to position the front engine mounts and engine support to the frame (Fig. 38 and 39).

B. Secure engine mount to the frame with four cap screws and flat washers (Fig. 39).

C. Secure front engine mounts to the frame with both cap screws, flat washers, and lock nuts (Fig.

38).

D. Remove jack or chain fall from the engine base.

7. Secure R–clamp and fuel hose to the frame with self tapping screw (Fig. 37).

8. Connect all six hydraulic hoses to fittings on the hydrostat. Remove clamps from hydraulic hoses (25 and

35) that prevented draining of the tank.

Figure 37

1. R–clamp 2. Fuel hose

Figure 38

1. Lock nut 3. Cap screw

2. Flat washer 4. Engine mount

9. Tighten both set screws (11) on pump hub (19) enough to secure the hub to the shaft.

10. Connect air hose to the air cleaner. Install lower shroud to the cooler mount. Connect control rod to the pump lever (Fig. 36).

11. Secure black ground wire and black battery cable (negative) to the engine block with cap screw and lock nut (Fig. 47).

Figure 39

12. Connect red positive cable cable (solenoid) to the starter (Fig. 47).

1. Cap screw & flat washer 3. Engine base

2. Engine support

13. Connect wire harness as follows: connect blue wire to the magneto terminal, connect blue wire to the volt

age regulator, and connect red/white wire to the fuel solenoid (Fig. 45).

Hydraulic System (Rev. A) Page 4 – 46 Sand Pro 2020/3020/5020

Flush Hydraulic System

IMPORTANT: Flush hydraulic system any time there is a severe component failure or the system is contaminated (oil appears milky or black or con tains metal particles).

IMPORTANT: Flush hydraulic system when changIng from petroleum base hydraulic fluid. Operate machine under normal operating conditions for at least four (4) hours before draining.

1. Park machine on a level surface. Lower attachments, stop engine, and engage parking.

CAUTION

IMPORTANT: Make sure to clean around any hydraulic connections that will be disconnected for draining.

11. Connect both spark plug leads to spark plugs.

12. Start engine and let it idle at low speed (1750 + RPM) for a minimum 2 minutes. Increase engine speed to high idle (3150 + 50 RPM) for minimum of 1 minute under no load.

13. Raise and lower attachments several times.

14. Shut off engine and check for hydraulic oil leaks. Check oil level in hydraulic tank and add correct oil if necessary.

15. Operate the machine for 2 hours under normal operating conditions.

16. Check condition of hydraulic oil. If the new fluid shows any signs of contamination, or if you are changing to biodegradable fluid, repeat steps 1 through 16 again.

17. Assume normal operation and follow recommended maintenance intervals.

2. Drain hydraulic tank (see Hydraulic Tank Removal).

3. Make sure lift cylinder, lift valve, hydrostat, oil cooler, wheel motors, hoses, and tube lines are drained into a suitable container while the system is warm.

4. Remove oil filter and drain into a suitable container. Discard filter (see Change Hydraulic System Fluid and Filter).

5. Inspect and clean tank (see Hydraulic Tank Inspection).

6. Install new oil filter and drain into a suitable contain- er. Discard filter (see Change Hydraulic System Fluid and Filter).

NOTE: Use only hydraulic fluids (including biodegradable) specified in Checking Hydraulic System Fluid. Other fluids may cause system damage.

7. Reconnect all hydraulic hoses, lines, and components that were disconnected prior to draining.

8. Fill hydraulic tank with new hydraulic fluid (see Change Hydraulic System Fluid and Filter).

Systems

Hydraulic

9. Disconnect both spark plug leads from spark plugs.

10. Turn ignition key switch; engage starter for 10 seconds to the prime hydrostat. Repeat this step again.

Sand Pro 2020/3020/5020 Page 4 – 47 Hydraulic System (Rev. A)

Hydrostat Service

12 34 5 678 910

HYDROSTAT IS ILLUSTRATED FROM BELOW

Figure 40

1. Plug

2. O–ring

3. Spring

4. Ball

5. Plug

6. O–ring

7. End cap

8. Acceleration valve spring

9. Acceleration valve

10. O–ring

11. Plug

12. O–ring

13. Locating pin

14. End cap gasket

15. Valve plate

16. Cylinder block

17. Spider

18. Piston assembly

19. Woodruff key

20. Ball bearing

21. Retaining ring

22. Plug

23. Pipe plug (2 used)

24. Journal bearing

25. Lip seal

26. Washer

27. Control shaft (SP 2020/3020)

28. Retaining ring

29. Plug

30. Implement relief shim kit

31. Implement relief spring

32. Poppet

33. Plug

34. O–ring

35. Charge pump housing

36. Lip seal

37. Needle bearing

38. Cap screw (4 used)

Note: The hydrostat used on the Sand Pro 2020,

3020, and 5020 are very similar. Due to different pump attachment to the engine, the location of the control shaft is different. On the Sand Pro 2020 and 3020, the control shaft is on the implement relief valve (30 and 31) side of the hydrostat. On the Sand Pro 5020, the control shaft is on the charge relief valve (41 and 42) side.

39. Gerotor assembly

40. O–ring

41. Charge relief shim kit

42. Charge relief spring

43. Trunnion shaft (SP 2020/3020)

44. Needle bearing

45. Variable housing

46. Retaining ring

47. Shaft

48. Swashplate

49. Spring pin

50. Thrust plate

51. Shaft bearing

52. Cylinder block assembly

53. Lip seal

54. Washer (4 used)

55. Cap screw (4 used)

56. Control shaft/bearing (SP 5020)

57. Trunnion shaft/bearing (SP 5020)

Rev. B

Sand Pro 2020/3020/5020Hydraulic System (Rev. A) Page 4 – 48

Charge Pump Disassembly

1. Make sure hydrostat is cleaned thoroughly before disassembly to prevent contamination.

2. Match mark charge pump housing and variable housing for reassembly.

3. Clean shaft to remove all sharp edges, burrs, dirt, and abrasive residue that could damage the lip seal.

4. Remove both cap screws securing the pump housing to the variable housing.

5. Slide charge pump housing with needle bearing and lip seal carefully off the shaft. Slide gerotor assembly off the shaft.

6. Remove O–ring from the charge pump housing and discard.

Charge Pump Inspection

1. Inspect wear surfaces of inner and outer gear of the gerotor assembly for excessive scratching and heavy wear patterns. Replace entire gerotor assembly if either part needs replacing.

Figure 41

1. Charge pump housing 5. Cap screw (4 used)

2. Variable housing 6. Needle bearing

3. Shaft 7. Gerotor assembly

4. Lip seal 8. O–ring

2. Inspect needle bearing for visible signs of wear. Replace bearing if needles do not turn freely or do not remain in cage. Replace bearing as necessary.

3. Inspect lip seal for tears and damage that will reduce the sealing properties of the seal. Replace as necessary.

4. Inspect gerotor pocket inside the charge pump housing of excessive scoring. Replace as necessary.

Charge Pump Assembly

1. Coat both sides of gerotor assembly and pump housing face with clean hydraulic oil.

2. Slide gerotor assembly onto the shaft. Make sure inner gear splines mesh with the splines on the shaft.

3. Coat O–ring with clean hydraulic oil and place into charge pump housing.

4. Coat shaft with clean hydraulic oil. Slide charge pump housing onto shaft being careful not to damage lip seal.

Systems

Hydraulic

5. Align match marks. Secure charge pump housing to variable housing with both cap screws.

Sand Pro 2020/3020/5020 Page 4 – 49 Hydraulic System (Rev. A)

Shaft Seal Removal

NOTE: The hydrostat uses lip seals on the main, con-

trol, and trunnion shafts. Replacement of these seals requires no disassembly.

1. When replacing trunnion shaft seals, remove retaining ring and washer from the housing and shaft.

2. Pry lip seal carefully off the shaft. Make sure not to distort the housing or damage the bore or shaft. Discard seal.

Shaft Seal Installation

1. Polish exposed surface of the shaft. Remove all sharp edges, burrs, dirt, and abrasive residue that could damage the lip seal during installation.

NOTE: The outside diameter of the lip seal may be coated with Loctite High Performance Sealant 5923 or equivalent. This aids the prevention of leaks caused by seal bore damage.

2. Lubricate shaft with clean hydraulic oil. Slide lip seal over shaft carefully. Make sure not to damage lip seal. Press seal into housing bore.

3. Replace washer if it is noticeably bent or distorted.

4. After replacing trunnion shaft seals, reinstall washer and retaining ring to the shaft and housing.

Figure 42

1. Retaining ring 3. Lip seal

2. Washer

4. Lip seal

Hydraulic System (Rev. A) Page 4 – 50 Sand Pro 2020/3020/5020

Toro Sand Pro 2020, Sand Pro 3020, Sand Pro 5020 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Preface

Table Of Contents

Table of Contents

General Safety Instructions

Before Operating

While Operating

Maintenance and Service

Jacking Instructions

Safety and Instruction Decals

Table of Contents

Product Records

Lubrication

Sand Pro R 2020/3020/5020 Maintenance Schedule

Table of Contents

Introduction

Specifications

General Information

Check Engine Oil

Fuel Shutoff Valve

Fill Fuel Tank

Adjustments

Service and Repairs

Change Engine Oil and Filter

Throttle and Choke Controls

Replace Fuel Filter

Remote Air Cleaner (SP 2020/3020)

Remote Air Cleaner (SP 5020)

Muffler (SP 5020)

Muffler (SP 2020/3020)

Fuel Tank (SP 2020/3020)

Fuel Tank (SP 5020)

Engine (SP 2020/3020)

Replace Spark Plugs

Engine (SP 5020)

Clean Cylinder Head Fins

Table of Contents

Specifications

General Information

Hydraulic Hoses

Hydraulic Fitting Installation

Towing Traction Unit

Check Hydraulic System Fluid

Hydraulic Schematics

Hydraulic Flow Diagrams

Traction Forward

Traction Reverse

Retract and Extend Lift Cylinder

Special Tools

Hydraulic Test Fittings

Troubleshooting

Testing

Before Performing Hydraulic Tests

TEST NO. 1: Traction Pump Flow (P1)

TEST NO. 2: Charge Relief Valve (R2) and Implement Relief Valve (R1) Pressure

TEST NO. 3: Charge Pump (P2) Flow

TEST NO. 4: Wheel Motor Efficiency

Adjustments

Adjust Traction Pedal for Neutral

Adjust Traction Pedal for Forward (SP 2020/3020)

Adjust Traction Pedal for Forward (SP 5020)

Adjust Lift Lever (SP 2020/3020)

Adjust Lift Lever (SP 5020)

Service and Repairs

Check Hydraulic Lines and Hoses

Charge Hydraulic System

Change Hydraulic System Fluid and Filter

Lift Valve (SP 2020/3020)

Lift Valve (SP 5020)

Lift Valve

Lift Cylinder (SP 2020/3020)

Lift Cylinder(SP 5020)

Lift Cylinder Service

Hydrostat (SP 2020/3020)

Hydrostat (SP 5020)

Flush Hydraulic System

Hydrostat Service