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

0 (0)

PART NO. 98957SL, Rev. B

Service 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.

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 repair 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

Table Of Contents

Chapter 1 – Safety

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

Jacking Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 4

Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 – 5

Chapter 2 – Product Records and Manuals

Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 1 Equivalents and Conversions . . . . . . . . . . . . . . . . 2 – 2 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . 2 – 3 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 4 Operation and Service History Reports . . . . . . . . 2 – 7

Chapter 3 – Engine

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

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 3

General Information . . . . . . . . . . . . . . . . . . . . . . . . 3 – 4

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

Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 3 – 8

Briggs & Stratton Vanguard Service and Repair Manual

for 4–Cycle V–Twin Cylinder OHV Engines

Chapter 4 – Hydraulic Systems

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

General Information . . . . . . . . . . . . . . . . . . . . . . . . 4 – 3

Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . 4 – 6

Hydraulic Flow Diagrams . . . . . . . . . . . . . . . . . . . . 4 – 8

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 14

Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 16

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

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

Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 4 – 31

Chapter 5 – Electrical Systems

Electrical Schematics and Diagrams . . . . . . . . . . 5 – 2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 7 Electrical System Quick Checks . . . . . . . . . . . . . . 5 – 9 Component Testing . . . . . . . . . . . . . . . . . . . . . . . . 5 – 10 Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 5 – 13

Chapter 6 – Wheels, Brakes, and Miscellaneous

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

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

Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 6 – 5

Engine Product Records Safety and Manuals

Hydraulic

Systems

 

 

Electrical

Systems

 

 

 

 

Wheels, Brakes

and Miscellaneous

 

 

Sandpro 2020/3020/5020

Sand Pro 2020/3020/5020

Chapter 1

Safety

Table of Contents

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 specifications 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 personnel involved in the operation, transport, maintenance, and storage of the machine. Improper use or maintenance of the machine can result in injury or death.

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

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

Sand Pro 2020/3020 . . . . . . . . . . . . . . . . . . . . . . . . 5

Sand Pro 5020 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

WARNING

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

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 serial number to:

The Toro Company

8111 Lyndale Avenue South Minneapolis, Minnesota 55420–1196

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, illegible, 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.

7.Ensure traction interlock switch is adjusted correctly so engine cannot be started unless traction pedal is released 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.

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, replace switch before operating machine. (After every two years, replace interlock switch in the safety system, whether it is working properly or not.)

Sand Pro 2020/3020/5020

Page 1 – 1

Safety

Safety

While Operating

11.Exhaust fumes are hazardous and could be deadly, so do not run the engine in a confined area without adequate 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 evident, 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 interlock 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 other hazards.

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 complete stop.

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

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

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

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 accidental starting of the engine.

21.Make sure all hydraulic line connectors are tight,and all hydraulic hoses and lines are in good condition before 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 sufficient force to penetrate skin and do serious damage. If fluid is injected into the skin it must be surgically removed 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 relieved 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 accumulation 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 Distributor 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 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.

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

1.On the SP 2020/3020, jack from below the front cross support that is above the retaining strip for the rubber 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 1

Figure 2

Figure 3

 

 

Figure 4

Safety

Page 1 – 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.

Safety

93–9051

ON NEUTRAL ADJUST

MECHANISM

(Part No. 93–9051)

UNDER SEAT PLATE

(Part No. 95–0646)

ON VALVE SHROUD

(Part No. 95–0647)

ON ENGINE SHIELD

(Part No. 92–8985) ON ENGINE SHIELD

(Part No. 95–0645)

ON DASH PANEL

(Part No. 95–0648)

Sand Pro 2020/3020/5020

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)

ON NEUTRAL ADJUST

 

MECHANISM

ON MUFFLER SHIELD

(Part No. 93–7272)

(Part No. 93–9051)

 

 

(Part No. 95–0645)

UNDER SEAT PLATE

(Part No. 98–0977)

ON LEFT FENDER

(Part No. 93–9053)

ON CENTER PANEL

(Part No. 93–9050)

Safety

ON RIGHT FENDER

(Part No. 98–0975)

ON FRAME & BOTH SIDES OF CENTER PANEL (3)

(Part No. 93–9052)

ON BATTERY

(Part No. 93–7276)

ON RIGHT FENDER

UNDER BATTERY

(Part No. 93–7442)

(Part No. 93–6668)

Page 1 – 6

Sand Pro 2020/3020/5020

Chapter 2

Product Records and Maintenance

Table of Contents

PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . 1 EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . 2 Decimal and Millimeter Equivalents . . . . . . . . . . . . 2 U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . 2

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

Product Records

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

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

Product Records and Maintenance

Page 2 – 2

Sand Pro 2020/3020/5020

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

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).

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 1

Figure 2

Figure 3

 

 

Figure 4

Product Records and Maintenance

Page 2 – 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

Product Records and Maintenance

Page 2 – 6

Sand Pro 2020/3020/5020

Product Records and Maintenance

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:

 

_________________________

 

 

 

_________________________

 

 

 

_________________________

 

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

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Every

 

 

 

 

 

 

 

Every

Every

 

 

 

 

 

 

800hrs

 

 

 

 

 

Check Battery Fluid Level

Every

400hrs

 

 

 

 

 

100hrs

 

 

 

 

 

 

 

Check Battery Cable Connections

25hrs

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

{ Change Engine Oil

 

 

 

 

 

 

 

 

 

 

Lubricate Front Wheel Bearing

A–Level

 

 

 

 

 

 

 

 

 

Lubricate Traction Control LInkage

 

 

 

 

 

 

 

 

 

Service

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Replace Engine Oil Filter

 

 

 

 

 

 

 

 

 

 

Inspect Remote Air Cleaner Element

 

 

 

 

 

 

 

 

 

 

Inspect Engine Air Cleaner Element

 

 

 

 

 

 

 

 

 

 

Lubricate Steering Shaft Grease Fitting

 

 

 

 

 

 

 

 

 

 

Check Steering Chain Adjustment

 

B–Level

 

 

 

 

 

 

 

 

{ Torque Wheel Lug Nuts

 

Service

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Change Hydraulic Oil

 

 

 

 

 

 

 

 

 

 

{ Replace Hydraulic Oil Filter

 

 

 

 

 

 

 

 

 

 

Replace Remote Air Cleaner Element

 

 

C–Level

 

 

 

 

 

 

 

Replace Engine Air Cleaner Element

 

 

Service

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Replace Spark Plugs

 

 

 

 

 

 

 

 

 

 

Replace Fuel Filter

 

 

 

 

 

 

 

 

 

 

Decarbonize Combustion Chamber

 

 

 

 

 

 

 

 

 

 

Adjust Valves and Torque Head Bolts

 

 

 

D–Level

 

 

 

 

 

Check Engine RPM (idle and full throttle)

 

 

 

 

 

 

 

 

Drain and Clean Fuel Tank

 

 

 

Service

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

{ Initial break in at 8 hours

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Replace Moving Hoses

Annual Recommendations:

 

 

 

 

 

 

 

Replace Traction Interlock (Safety) Switch

Items listed are recommended every 1,500 hours

 

 

 

 

 

 

 

or 2 years, whichever comes first.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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

Product Records and Maintenance

Page 2 – 8

Sand Pro 2020/3020/5020

Sand Pro R 2020/3020/5020 Daily Maintenance Checklist

Daily Maintenance: (duplicate this page for routine use)

Maintenance

Daily Maintenance Check For Week Of ____________

Check Item b

 

 

 

 

 

 

MON TUES WED THURS FRI

SAT

SUN

nSafety Interlock Operation

nSteering Operation

nEngine Oil Level

nRemote/Engine Air Cleaner Condition Clean Engine Cooling Fins

nUnusual Engine Noises

nUnusual Operating Noises

nHydraulic System Oil Level

nHydraulic Hoses for Damage

nFluid Leaks

nFuel Level

nTire Pressure

nInstrument Operation Touch–up Damaged Paint

Notation for areas of concern: Inspection performed by:__________________

Item Date Information

1

2

3

4

5

6

7

8

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

Product Records and Maintenance

Sand Pro 2020/3020/5020

Page 2 – 9

Product Records and Maintenance

Maintenance and Records Product

10 – 2 Page

2020/3020/5020 Pro Sand

 

Sand Pro

R 2020/3020/5020

Maintenance Supervisor Work Order

 

 

 

Date: ________________

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(Duplicate this page for routine use.)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Unit Designation:

 

TORO I.D. #:

 

 

 

 

Remarks:

 

 

 

 

 

 

__________________–__________________

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Hours:

 

Service to perform (circle):

 

 

 

 

 

 

 

 

 

 

 

 

 

 

A B C D Other

 

 

 

 

 

 

 

Technician:

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

A– Service (every 25 hours)

 

 

 

B – Service (every 100 hours)

 

 

 

 

C – Service (every 400 hours)

 

Check Battery Fluid Level

 

 

 

Replace Engine Oil Filter

 

 

 

 

Change Hydraulic Oil

 

Check Battery Cable Connections

 

 

 

Inspect Remote Air Cleaner Element

 

 

 

 

Replace Hydraulic Oil Filter

 

Change Engine Oil

 

 

 

Inspect Engine Air Cleaner Element

 

 

 

 

Replace Remote Air Cleaner Element

 

Lubricate Front Wheel Bearing

 

 

 

Lubricate Steering Shaft Grease Fitting

 

 

 

 

Replace Engine Air Cleaner Element

 

Lubricate Traction Control Linkage

 

 

 

Check Steering Chain Adjustment

 

 

 

 

A and B – Sevice required

________________________________

 

 

 

Torque Wheel Lug Nuts

 

 

_______________________________

 

 

 

 

 

________________________________

 

 

 

A – Service required

 

 

_______________________________

 

 

 

 

 

________________________________

 

 

 

_______________________________

 

 

 

 

_______________________________

 

 

 

 

 

 

________________________________

 

 

 

_______________________________

 

 

 

 

_______________________________

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

D – Service (every 800 houurs)

 

Other – Annual Service and Specials

 

 

 

 

 

 

Replace Spark Plugs

 

 

 

Replace Moving Hoses

 

 

_______________________________

 

Replace Fuel Filter

 

 

 

Replace Traction Interlock (Safety) Switch

 

 

_______________________________

 

Decarbonize Combustion Chamber

 

 

 

A, B, C, and D – Service Required

 

 

_______________________________

 

Adjust Valves and Torque Head Bolts

 

_______________________________

 

 

 

 

_______________________________

 

 

 

 

 

 

Check Engine RPM (idle and full throttle)

 

_______________________________

 

 

 

 

_______________________________

 

 

 

 

 

 

Drain and Clean Fuel Tank

 

_______________________________

 

 

 

 

_______________________________

 

 

 

 

 

 

A, B, and C – Sevice required

 

_______________________________

 

 

 

 

_______________________________

 

 

 

 

 

________________________________

 

 

 

_______________________________

 

 

 

 

_______________________________

 

 

 

 

 

________________________________

 

 

 

_______________________________

 

 

 

 

_______________________________

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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

 

 

 

Chapter 3

 

 

 

Engine

 

 

 

 

 

Table of Contents

 

 

 

 

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

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

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

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

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

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

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . .

4

Muffler Removal . . . . . . . . . . . . .

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

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

4

Muffler Installation . . . . . . . . . . .

. . . . . . . . . . . . . 17

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

5

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

. . . . . . . . . . . . . 18

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

6

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

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

ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

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

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

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

7

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

. . . . . . . . . . . . . 20

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

7

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

. . . . . . . . . . . . . 20

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

8

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

. . . . . . . . . . . . . 21

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

8

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

. . . . . . . . . . . . . 22

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

8

Engine Removal . . . . . . . . . . . . .

. . . . . . . . . . . . . 23

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

9

Engine Installation . . . . . . . . . . .

. . . . . . . . . . . . . 24

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

10

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

. . . . . . . . . . . . . 25

Throttle Control Removal . . . . . . . . . . . . . . . . . .

10

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

. . . . . . . . . . . . . 26

Throttle Control Installation . . . . . . . . . . . . . . . . .

11

Engine Removal . . . . . . . . . . . . .

. . . . . . . . . . . . . 27

Choke Control Removal . . . . . . . . . . . . . . . . . . . .

11

Engine Installation . . . . . . . . . . .

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

Choke Control Installation . . . . . . . . . . . . . . . . .

12

Clean Cylinder Head Fins . . . . . .

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

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

12

BRIGGS & STRATTON VANGUARD SERVICE AND

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

13

REPAIR MANUAL FOR 4–CYCLE V–TWIN CYL-

Remote Air Cleaner (SP 5020) . . . . . . . . . . . . . . .

14

INDER 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 Vanguard Repair and Service Manual for 4–Cycle V–Twin Cylinder 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 facility.

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 available, 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

 

 

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)

 

 

Engine

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 conditions. 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 before 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.

2

1

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. Failure 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.

1

 

On the SP 2020/3020, the shutoff valve can be ac-

 

cessed 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).

2

Figure 2

1. Fuel shutoff valve

2. Hydraulic oil filter

1

2

Figure 3

1. Fuel shutoff valve

2. Hydraulic oil tank

Engine

Sand Pro 2020/3020/5020

Page 3 – 5

Engine

Fill Fuel Tank

IMPORTANT: The Toro Company strongly recommends using fresh, clean, unleaded regular grade gasoline in Toro gasoline powered products. Unleaded gasoline burns cleaner, extends engine life, and promotes good starting by reducing the build– up of combustion chamber deposits. Leaded gasoline 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 system.

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.

DANGER

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. Vapors 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–ven- tilated 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.

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

4

5

1

3

6

2

Figure 4

1.

Cable clamp screw

4.

Throttle stop

2.

Throttle cable

5.

Cable clamp screw

3.

Throttle swivel

6.

Choke cable

Adjust Choke Control

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).

4

1

2

 

 

3

 

 

Figure 5

1.

Carburetor shield

4. Carburetor shield (newer

2.

Air cleaner base

models)

3.

Choke butterfly

 

Engine

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.

1

2

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.

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

1

2

3

4

5

 

 

 

6

 

 

Figure 7

 

1.

Knob

4.

Cover plate

2.

Cover

5.

Filter element

3.

Knob

6.

Air cleaner base

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 Removal and Installation).

2.Release latches securing air cleaner cover to air cleaner body. Separate cover from the body. Clean inside 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 exceed 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 exceeding 160_F, or allow element to air–dry. Do not use a light bulb to dry the filter element because damage may result.

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 outside 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.

7.Reinstall cover and secure latches. Make sure cover is positioned with TOP side up.

1

2

3

4

Figure 8

1.

Latch

3.

Body

2.

Cover

4.

Filter element

4

1

 

 

 

3

 

 

2

 

 

 

Figure 9

 

1.

Latch

3.

Body

2.

Cover

4.

Air inlet hood

Sand Pro 2020/3020/5020

Page 3 – 9

Engine

Engine

Throttle and Choke Controls

1

 

 

 

 

 

 

6

 

4

 

9

4

4

 

 

 

 

 

 

 

 

 

 

 

 

2

 

 

3

 

 

 

 

2

 

 

 

 

 

 

 

 

8

5

1

 

1

 

 

7

 

 

 

 

2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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).

1

2

3

Figure 11

1.

Hex flange head screw

3. Front shield

2.

Hood

 

3

1

2

1

 

 

Figure 12

1.

Cap screws

3. Hood

2.

Dash panel

 

Engine

Page 3 – 10

Sand Pro 2020/3020/5020

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