Toro Sand Pro 5040, Sand Pro 3040, Infield Pro 5040, Infield Pro 3040 Service Manual

Sand Pro & Infield Pro 3040/5040
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 and Infield Pro 3040/5040.
The Toro Company Attn. Technical Publications 8111 Lyndale Avenue South Minneapolis, MN 55420
The Toro Company reserves the right to change product specifications or this publication without notice.
Part No. 06147SL (Rev. A)
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 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.
The Toro Company – 2006
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Sand Pro & Infield Pro 3040/5040
Table Of Contents
Chapter 1 – Safety
Safety Instructions 1 – 2. . . . . . . . . . . . . . . . . . . . . . . . . .
Jacking Instructions 1 – 4. . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Instruction Decals 1 – 4. . . . . . . . . . . . . . . .
Chapter 2 – Product Records and Maintenance
Product Records 2 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 2 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equivalents and Conversions 2 – 2. . . . . . . . . . . . . . . .
Torque Specifications 2 – 3. . . . . . . . . . . . . . . . . . . . . . .
Chapter 3 – Gasoline Engine
Introduction 3 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 3 – 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information 3 – 4. . . . . . . . . . . . . . . . . . . . . . . .
Service and Repairs 3 – 5. . . . . . . . . . . . . . . . . . . . . . . .
BRIGGS & STRATTON REPAIR MANUAL FOR
4–CYCLE, V–TWIN CYLINDER, OHV HEAD ENGI­NES
Chapter 4 – Hydraulic System
Specifications 4 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information 4 – 3. . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Schematics 4 – 6. . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Flow Diagrams 4 – 10. . . . . . . . . . . . . . . . . . .
Special Tools 4 – 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 4 – 19. . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing 4 – 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service and Repairs 4 – 34. . . . . . . . . . . . . . . . . . . . . . .
PARKER TORQMOTOR TM SERVICE PROCEDURE
(TC, TB, TE, TJ, TF, TG, TH AND TL SERIES)
SAUER–DANFOSS (SUNDSTRAND) 15 SERIES RE-
PAIR MANUAL
SAUER–DANFOSS (SUNDSTRAND) 15 SERIES
SERVICE MANUAL
SAUER–DANFOSS STEERING UNIT TYPE OSPM
SERVICE MANUAL
Chapter 5 – Electrical System
Electrical Schematic and Drawings 5 – 2. . . . . . . . . . .
Special Tools 5 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 5 – 4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical System Quick Checks 5 – 7. . . . . . . . . . . . . .
Component Testing 5 – 8. . . . . . . . . . . . . . . . . . . . . . . . .
Service and Repairs 5 – 14. . . . . . . . . . . . . . . . . . . . . . .
Chapter 6 – Chassis
Specifications 6 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools 6 – 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service and Repairs 6 – 4. . . . . . . . . . . . . . . . . . . . . . . .
Chapter 7 – Electrical Diagrams
Electrical Schematic 7 – 3. . . . . . . . . . . . . . . . . . . . . . . .
Circuit Diagrams 7 – 4. . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Harness Drawings 7 – 6. . . . . . . . . . . . . . . . . . . . .
SafetyProduct Records
and Maintenance
Engine
Gasoline
SystemDiagrams
Hydraulic
System
Electrical
Chassis
Sand Pro & Infield Pro 3040/5040
Electrical
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Sand Pro & Infield Pro 3040/5040
Table of Contents
SAFETY INSTRUCTIONS 2. . . . . . . . . . . . . . . . . . . . . .
Before Operating 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
While Operating 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance and Service 3. . . . . . . . . . . . . . . . . . . .
JACKING INSTRUCTIONS 4. . . . . . . . . . . . . . . . . . . . .
SAFETY AND INSTRUCTION DECALS 4. . . . . . . . . .
Chapter 1
Safety
Safety
Page 1 – 1 SafetySand Pro & Infield Pro 3040/5040
Safety Instructions
The Sand Pro and Infield Pro are designed and tested to offer safe service when operated and maintained properly. Although hazard control and accident preven­tion are partially 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
Before Operating
1. Read and understand the contents of the Operator’s Manual before starting and operating the machine. Be­come familiar with the controls and know how to stop the machine quickly. A replacement Operator’s Manual is available on the Internet at www.Toro.com or by sending the complete model and serial number to:
The Toro Company Attn. Technical Publications 8111 Lyndale Avenue South Bloomington, Minnesota 55420–1196
2. Keep all shields, safety devices and decals in place. If a shield, safety device or decal is defective, illegible or damaged, repair or replace it before operating the machine. Also, tighten any loose nuts, bolts or screws to ensure machine is in safe operating condition.
or death. To reduce the potential for injury or death, comply with the following safety instructions.
WARNING
To reduce the potential for injury or death, comply with the following safety instructions.
4. Ensure that the traction interlock switch is adjusted correctly so the engine cannot be started unless the traction pedal is released and in the neutral position.
5. Since gasoline is highly flammable, handle it careful­ly:
A. Store fuel in containers specifically designed for this purpose.
B. Do not remove machine fuel tank cap while en­gine is hot or running.
C. Do not smoke while handling fuel.
D. Fill fuel tank outdoors and only to within an inch of the top of the tank, not the filler neck. Do not overfill the fuel tank.
3. Wearing safety glasses, safety shoes, long pants and a helmet is advisable and required by some local safety and insurance regulations.
While Operating
1. Operator should be in the operator’s seat when oper­ating the Sand Pro and Infield Pro. Never carry passen­gers.
2. Do not run engine in a confined area without ade­quate ventilation. Exhaust fumes are hazardous and could possibly be deadly.
3. Do not touch engine, muffler or exhaust system while engine is running or soon after it is stopped. These areas could be hot enough to cause burns.
4. If abnormal vibration is detected, stop machine im­mediately and determine source of vibration. Correct problems before resuming the use of the machine.
E. If fuel is spilled, do not start engine. Move the ma­chine away from the area of spillage and allow the gasoline vapors to dissipate. Properly dispose of any spilled fuel.
5. While operating, the machine may exceed noise lev­els of 85 dB(A) at the operator position. Hearing protec­tion is recommended for prolonged exposure to reduce the potential of permanent hearing damage.
6. Before leaving the operator’s position of the ma­chine:
A. Stop movement of the machine.
B. Apply parking brake and lower attachment(s) to the ground. Take precautions to prevent accidental starts, rolling away, etc.
Safety
Page 1 – 2
Sand Pro & Infield Pro 3040/5040
Maintenance and Service
1. Before servicing or making adjustments, position machine on a level surface and apply parking brake to prevent machine from moving.
2. Before servicing or making adjustments, disconnect the spark plug wires from the spark plugs and position the wires away from the spark plugs to ensure that the engine will not start unexpectedly.
3. Make sure machine is in safe operating condition by keeping all nuts, bolts and screws tight.
4. Never store the machine or fuel container inside where there is an open flame, such as near a water heat­er or furnace.
5. Make sure all hydraulic system line connectors are tight and all hydraulic system hoses and lines are in good condition before applying pressure to the hydraulic system.
6. Before disconnecting any hydraulic component or performing any work on the hydraulic system, all pres­sure in hydraulic system must be relieved.
7. 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.
8. Do not overspeed the engine by changing governor setting. To assure safety and accuracy, check maximum engine speed with a tachometer.
9. Shut engine off before checking or adding oil to the engine crankcase.
10.To reduce potential fire hazard, keep engine area free of excessive grease, grass, leaves and dirt.
11. 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 all moving parts. Also, keep bystanders away.
12.When changing tires or performing other service that requires the machine to be raised off the ground, make sure machine is properly supported. If the machine is not properly supported, the machine may move or fall, which may result in personal injury.
13.If major repairs are ever needed or assistance is de­sired, contact an Authorized Toro Distributor.
14.At the time of manufacture, the machine conformed to all applicable safety standards. To assure optimum performance and continued safety certification of the machine, use genuine Toro replacement parts and ac­cessories. Replacement parts and accessories made by other manufacturers may result in non-conformance with the safety standards, and the warranty may be voided.
Safety
Page 1 – 3 SafetySand Pro & Infield Pro 3040/5040
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. Use 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:
Front End Jacking
1. Jack the front of the machine from the bottom of the frame behind the front wheel (Fig. 1). Make sure that jack is positioned directly under frame to prevent dam­age to oil cooler.
1
2
Figure 1
1. Front wheel 2. Front jacking point
1
Rear End Jacking
1. Jack the rear of the machine from below the wheel motor (Fig. 2).
Safety and Instruction Decals
Numerous safety and instruction decals are affixed to the Sand Pro and Infield Pro. If any decal becomes illeg­ible or damaged, install a new decal. Part numbers for replacement decals are listed in your Parts Catalog. Or­der replacement decals from your Authorized Toro Dis­tributor.
2
Figure 2
1. Rear wheel motor 2. Rear jacking point
Safety
Page 1 – 4
Sand Pro & Infield Pro 3040/5040
Page 2 – 1 Product Records and MaintenanceSand Pro & Infield Pro 3040/5040
Chapter 2
Product Records and Maintenance
Table of Contents
PRODUCT RECORDS 1. . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EQUIVALENTS AND CONVERSIONS 2. . . . . . . . . . .
Decimal and Millimeter Equivalents 2. . . . . . . . . . . .
U.S. to Metric Conversions 2. . . . . . . . . . . . . . . . . . .
TORQUE SPECIFICATIONS 3. . . . . . . . . . . . . . . . . . .
Fastener Identification 3. . . . . . . . . . . . . . . . . . . . . . .
Standard Torque for Dry, Zinc Plated and
Steel Fasteners (Inch Series) 4. . . . . . . . . . . . . . .
Standard Torque for Dry, Zinc Plated and
Steel Fasteners (Metric Fasteners) 5. . . . . . . . . .
Other Torque Specifications 6. . . . . . . . . . . . . . . . . .
Conversion Factors 6. . . . . . . . . . . . . . . . . . . . . . . . .
Product Records
Insert a copy of the Operator’s Manual and Parts Cata­log for your Sand Pro or Infield Pro at the end of this chapter. Additionally, if any optional equipment or ac­cessories have been installed to your machine, insert the Installation Instructions, Operator’s Manuals and Parts Catalogs for those options at the end of this chap­ter.
Maintenance
Maintenance procedures and recommended service in­tervals for Sand Pro and Infield Pro machines are cov­ered in the Operator’s Manual. Refer to that publication when performing regular equipment maintenance.
Product Records
and Maintenance
Page 2 – 2
Product Records and Maintenance
Sand Pro & Infield Pro 3040/5040
Equivalents and Conversions
Page 2 – 3 Product Records and MaintenanceSand Pro & Infield Pro 3040/5040
Torque Specifications
Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and spe­cified in this Service Manual.
These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Ser­vice Manual. The following factors shall be considered when applying torque: cleanliness of the fastener, use of a thread sealant (e.g. Loctite), degree of lubrication on the fastener, presence of a prevailing torque feature (e.g. Nylock nut), hardness of the surface underneath the fastener’s head or similar condition which affects the installation.
As noted in the following tables, torque values should be reduced by 25% for lubricated fasteners to achieve the similar stress as a dry fastener. Torque values may also have to be reduced when the fastener is threaded into aluminum or brass. The specific torque value should be determined based on the aluminum or brass material strength, fastener size, length of thread en­gagement, etc.
The standard method of verifying torque shall be per­formed by marking a line on the fastener (head or nut) and mating part, then back off fastener 1/4 of a turn. Measure the torque required to tighten the fastener until the lines match up.
Fastener Identification
Figure 1
Grade 1 Grade 5 Grade 8
Inch Series Bolts and Screws
Figure 2
Class 8.8 Class 10.9
Metric Bolts and Screws
Product Records
and Maintenance
Page 2 – 4
Product Records and Maintenance
Sand Pro & Infield Pro 3040/5040
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series)
Thread Size
Grade 1, 5 &
8 with Thin
Height Nuts
SAE Grade 1 Bolts, Screws, Studs &
Sems with Regular Height Nuts
(SAE J995 Grade 2 or Stronger Nuts)
SAE Grade 5 Bolts, Screws, Studs &
Sems with Regular Height Nuts
(SAE J995 Grade 2 or Stronger Nuts)
SAE Grade 8 Bolts, Screws, Studs &
Sems with Regular Height Nuts
(SAE J995 Grade 5 or Stronger Nuts)
in–lb in–lb N–cm in–lb N–cm in–lb N–cm
# 6 – 32 UNC
15 + 2 169 + 23 23 + 3 262 + 34
# 6 – 40 UNF
10 + 2 13 + 2 147 + 23
17 + 2 192 + 23 25 + 3 282 + 34
# 8 – 32 UNC
29 + 3 328 + 34 41 + 5 463 + 56
# 8 – 36 UNF
13 + 2 25 + 5 282 + 56
31 + 4 350 + 45 43 + 5 486 + 56
# 10 – 24 UNC
42 + 5 475 + 56 60 + 6 678 + 68
# 10 – 32 UNF
18 + 2 30 + 5 339 + 56
48 + 5 542 + 56 68 + 7 768 + 79
1/4 – 20 UNC 48 + 7 53 + 7 599 + 79 100 + 10 1130 + 113 140 + 15 1582 + 169
1/4 – 28 UNF 53 + 7 65 + 10 734 + 113 115 + 12 1299 + 136 160 + 17 1808 + 192
5/16 – 18 UNC 115 + 15 105 + 15 1186 + 169 200 + 25 2260 + 282 300 + 30 3390 + 339
5/16 – 24 UNF 138 + 17 128 + 17 1446 + 192 225 + 25 2542 + 282 325 + 33 3672 + 373
ft–lb ft–lb N–m ft–lb N–m ft–lb N–m
3/8 – 16 UNC 16 + 2 16 + 2 22 + 3 30 + 3 41 + 4 43 + 5 58 + 7
3/8 – 24 UNF 17 + 2 18 + 2 24 + 3 35 + 4 47 + 5 50 + 6 68 + 8
7/16 – 14 UNC 27 + 3 27 + 3 37 + 4 50 + 5 68 + 7 70 + 7 95 + 9
7/16 – 20 UNF 29 + 3 29 + 3 39 + 4 55 + 6 75 + 8 77 + 8 104 + 11
1/2 – 13 UNC 30 + 3 48 + 7 65 + 9 75 + 8 102 + 11 105 + 11 142 + 15
1/2 – 20 UNF 32 + 4 53 + 7 72 + 9 85 + 9 115 + 12 120 + 12 163 + 16
5/8 – 11 UNC 65 + 10 88 + 12 119 + 16 150 + 15 203 + 20 210 + 21 285 + 28
5/8 – 18 UNF 75 + 10 95 + 15 129 + 20 170 + 18 230 + 24 240 + 24 325 + 33
3/4 – 10 UNC 93 + 12 140 + 20 190 + 27 265 + 27 359 + 37 375 + 38 508 + 52
3/4 – 16 UNF 115 + 15 165 + 25 224 + 34 300 + 30 407 + 41 420 + 43 569 + 58
7/8 – 9 UNC 140 + 20 225 + 25 305 + 34 430 + 45 583 + 61 600 + 60 813 + 81
7/8 – 14 UNF 155 + 25 260 + 30 353 + 41 475 + 48 644 + 65 667 + 66 904 + 89
NOTE: Torque values may have to be reduced when installing fasteners into threaded aluminum or brass. The specific torque value should be determined based on the fastener size, the aluminum or base material strength, length of thread engagement, etc.
NOTE: Reduce torque values listed in the table above by 25% for lubricated fasteners. Lubricated fasteners are defined as threads coated with a lubricant such as engine oil or thread sealant such as Loctite.
NOTE: The nominal torque values listed above for Grade 5 and 8 fasteners are based on 75% of the mini­mum proof load specified in SAE J429. The tolerance is approximately +
10% of the nominal torque value. Thin
height nuts include jam nuts.
Page 2 – 5 Product Records and MaintenanceSand Pro & Infield Pro 3040/5040
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Fasteners)
Class 8.8 Bolts, Screws and Studs with
Class 10.9 Bolts, Screws and Studs with
Thread Size Regular Height Nuts
(Class 8 or Stronger Nuts)
Regular Height Nuts
(Class 10 or Stronger Nuts)
M5 X 0.8 57 + 6 in–lb 644 + 68 N–cm 78 + 8 in–lb 881 + 90 N–cm
M6 X 1.0 96 + 10 in–lb 1085 + 113 N–cm 133 + 14 in–lb 1503 + 158 N–cm
M8 X 1.25 19 + 2 ft–lb 26 + 3 N–m 28 + 3 ft–lb 38 + 4 N–m
M10 X 1.5 38 + 4 ft–lb 52 + 5 N–m 54 + 6 ft–lb 73 + 8 N–m
M12 X 1.75 66 + 7 ft–lb 90 + 10 N–m 93 + 10 ft–lb 126 + 14 N–m
M16 X 2.0 166 + 17 ft–lb 225 + 23 N–m 229 + 23 ft–lb 310 + 31 N–m
M20 X 2.5 325 + 33 ft–lb 440 + 45 N–m 450 + 46 ft–lb 610 + 62 N–m
NOTE: Torque values may have to be reduced when installing fasteners into threaded aluminum or brass. The specific torque value should be determined based on the fastener size, the aluminum or base material strength, length of thread engagement, etc.
NOTE: Reduce torque values listed in the table above by 25% for lubricated fasteners. Lubricated fasteners are defined as threads coated with a lubricant such as engine oil or thread sealant such as Loctite.
NOTE: The nominal torque values listed above are based on 75% of the minimum proof load specified in SAE J1199. The tolerance is approximately +
10% of the
nominal torque value.
Product Records
and Maintenance
Page 2 – 6
Product Records and Maintenance
Sand Pro & Infield Pro 3040/5040
Other Torque Specifications
SAE Grade 8 Steel Set Screws
Recommended Torque
Thread Size
Square Head Hex Socket
1/4 – 20 UNC 140 + 20 in–lb 73 + 12 in–lb
5/16 – 18 UNC 215 + 35 in–lb 145 + 20 in–lb
3/8 – 16 UNC 35 + 10 ft–lb 18 + 3 ft–lb
1/2 – 13 UNC 75 + 15 ft–lb 50 + 10 ft–lb
Thread Cutting Screws
(Zinc Plated Steel)
Type 1, Type 23 or Type F
Thread Size Baseline Torque*
No. 6 – 32 UNC 20 + 5 in–lb
No. 8 – 32 UNC 30 + 5 in–lb
No. 10 – 24 UNC 38 + 7 in–lb
1/4 – 20 UNC 85 + 15 in–lb
5/16 – 18 UNC 110 + 20 in–lb
3/8 – 16 UNC 200 + 100 in–lb
Wheel Bolts and Lug Nuts
Thread Size
Recommended Torque**
7/16 – 20 UNF
Grade 5
65 + 10 ft–lb 88 + 14 N–m
1/2 – 20 UNF
Grade 5
80 + 10 ft–lb 108 + 14 N–m
M12 X 1.25
Class 8.8
80 + 10 ft–lb 108 + 14 N–m
M12 X 1.5
Class 8.8
80 + 10 ft–lb 108 + 14 N–m
** For steel wheels and non–lubricated fasteners.
Thread Cutting Screws
(Zinc Plated Steel)
Thread
Threads per Inch
Size
Type A Type B
Baseline Torque*
No. 6 18 20 20 + 5 in–lb
No. 8 15 18 30 + 5 in–lb
No. 10 12 16 38 + 7 in–lb
No. 12 11 14 85 + 15 in–lb
* Hole size, material strength, material thickness & finish must be considered when determining specific torque values. All torque values are based on non–lubricated fasteners.
Conversion Factors
in–lb X 11.2985 = N–cm N–cm X 0.08851 = in–lb
ft–lb X 1.3558 = N–m N–m X 0.7376 = ft–lb
Gasoline EnginePage 3 – 1Sand Pro & Infield Pro 3040/5040
Chapter 3
Gasoline Engine
Table of Contents
INTRODUCTION 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION 4. . . . . . . . . . . . . . . . . . . . .
Fuel Shut–off Valve 4. . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE AND REPAIRS 5. . . . . . . . . . . . . . . . . . . . . .
Cooling System 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Cleaner Assembly 6. . . . . . . . . . . . . . . . . . . . . . . .
Fuel Tank 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Removal 10. . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Installation 12. . . . . . . . . . . . . . . . . . . . . . . .
BRIGGS & STRATTON REPAIR MANUAL FOR
4–CYCLE, V–TWIN CYLINDER, OHV HEAD EN­GINES
Gasoline
Engine
Gasoline Engine Page 3 – 2 Sand Pro & Infield Pro 3040/5040
Introduction
This Chapter gives information about specifications, maintenance, troubleshooting, testing and repair of the Briggs and Stratton gasoline engine used in Sand Pro and Infield Pro machines.
Most repairs and adjustments require tools which are commonly available in many service shops. Special tools are described in the Briggs and Stratton Repair Manual that is included at the end of this Chapter. 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 the Briggs and Stratton en­gine used to power the Sand Pro or Infield Pro are sup­plied through your local Toro distributor or your local Briggs and Stratton dealer or distributor. If no parts list is available, be prepared to provide your distributor with the Toro equipment model and serial numbers as well as the Briggs and Stratton engine model and serial num­bers.
Gasoline EnginePage 3 – 3Sand Pro & Infield Pro 3040/5040
Specifications
Item Description
Engine Make / Designation Briggs and Stratton, 4–cycle, V–Twin Cylinder,
OHV, Air Cooled, Gasoline Engine
Bore x Stroke
Sand Pro & Infield Pro 3040 2.68” x 2.60” (68mm x 66mm) Sand Pro & Infield Pro 5040 2.83” x 2.75” (72mm x 70mm)
Engine Displacement
Sand Pro & Infield Pro 3040 29.3 cu in (480cc) Sand Pro & Infield Pro 5040 34.8 cu in (570cc)
Fuel Unleaded Regular Grade Gasoline
Fuel Capacity 5.0 US gallons (18.9 liters)
Fuel Pump Pulsating Crankcase Vacuum
Carburetor Float Feed, Single Barrel
Governor Mechanical
High Idle Speed (No Load) 3400 + 50 RPM
Low Idle Speed (No Load) 1750 + 100 RPM
Lubrication System Pressure Lubrication
Oil Pump Gear Driven Geroter Type
Crankcase Oil Capacity 1.75 US quarts (1.66 liters) with new filter
Engine Oil See Operator’s Manual
Spark Plugs Champion RC 14YC (or equivalent)
Spark Plug Gap 0.030” (0.76mm)
Starter 12 VDC
Alternator 12 VDC / 15 Amps
Engine Weight (approximate)
Sand Pro & Infield Pro 3040 72 lb (32.7 kg) Sand Pro & Infield Pro 5040 74 lb (33.6 kg)
Gasoline
Engine
Gasoline Engine Page 3 – 4 Sand Pro & Infield Pro 3040/5040
General Information
Fuel Shut Off Valve
The fuel shut off valve located under the fuel tank (Fig.
1) should be closed if the machine is being transported on a trailer or when placing the machine in long term storage. Additionally, close the shut off valve when re­moving the fuel tank or engine from the machine.
Figure 1
1. Fuel shut–off valve
1
Gasoline EnginePage 3 – 5Sand Pro & Infield Pro 3040/5040
Service and Repairs
Cooling System
To ensure proper engine cooling, make sure the rotating screen, cooling fins and other external surfaces of the engine are kept clean at all times.
NOTE: Perform this maintenance procedure at the in­terval specified in the Operator’s Manual.
IMPORTANT: The engine that powers Sand Pro and Infield Pro machines is air–cooled. Operating the engine with dirty or plugged cooling fins, a blocked rotating screen or a plugged or dirty blower housing will result in engine overheating and engine dam­age.
1. Park machine on a level surface, lower attachment, stop engine, apply parking brake and remove key from ignition switch.
CAUTION
The engine and exhaust system may be hot. To avoid possible burns, allow the engine and ex­haust system to cool before working on the en­gine.
IMPORTANT: Never clean engine with pressurized water. Water could enter and contaminate the fuel system.
2. Clean cooling fins on both cylinder heads.
3. Clean rotating screen and blower housing of dirt and debris (Fig. 2).
4. If blower housing removal is necessary for cooling system cleaning, engine needs to be removed from ma­chine (see Engine Removal and Installation in this sec­tion).
IMPORTANT: Never operate engine without the blower housing installed. Overheating and engine damage will result.
5. Make sure rotating screen and blower housing are reinstalled to the engine if removed.
Figure 2
1. Cylinder head
2. Rotating screen
3. Blower housing
2
1
1
3
Gasoline
Engine
Gasoline Engine Page 3 – 6 Sand Pro & Infield Pro 3040/5040
Air Cleaner Assembly
1. Inlet hood
2. Air cleaner assembly
3. Intake elbow
4. Hose clamp
5. Cap screw (2 used)
6. Flat washer (2 used)
7. Mounting bracket
8. Lock nut (2 used)
9. Hose clamp
10. Air hose
11. Flange head screw (4 used)
12. Flat washer (4 used)
13. Gasket (2 used)
14. Intake gasket
Figure 3
FRONT
RIGHT
5
6
7
1
3
8
2
10
4
9
11
12
13
60 to 65 in–lb
(6.8 to 7.3 N–m)
14
Gasoline EnginePage 3 – 7Sand Pro & Infield Pro 3040/5040
Removal (Fig. 3)
NOTE: See Operator’s Manual for air cleaner mainte-
nance procedures and intervals.
1. Park machine on a level surface, lower attachment, stop engine, apply parking brake and remove key from ignition switch.
2. Remove air cleaner components as needed using Figure 3 as a guide.
3. Check air cleaner assembly for damage that could cause possible air leaks (Fig. 4). Make sure that air cleaner cover seals completely to the air cleaner hous­ing.
Installation (Fig. 3)
IMPORTANT: Any leaks in the air filter system will allow dirt into the engine and will cause serious en­gine damage. Make sure that all air cleaner compo­nents are in good condition and are properly secured during assembly.
1. Assemble air cleaner system using Figure 3 as a guide. Make sure that vacuator valve is pointed down af­ter assembly (Fig. 4).
1. Air cleaner housing
2. Pipe plug
3. Filter element
4. Air cleaner cover
5. Vacuator valve
Figure 4
5
4
3
2
1
1. Air hose
2. Breather tube
3. Intake elbow
4. Carburetor
Figure 5
3
1
2
4
Gasoline
Engine
Gasoline Engine Page 3 – 8 Sand Pro & Infield Pro 3040/5040
Fuel Tank
1. Fuel cap
2. Fuel tank
3. Cap screw
4. Clamp
5. Fuel hose
6. Fuel filter
7. Hose clamp
8. Fuel hose
9. Fuel shut off valve
10. Hose clamp
11. Fuel hose
12. Flange bushing
13. Washer
14. Cap screw
15. Lock nut
16. Flat washer
Figure 6
FRONT
RIGHT
30 to 60 in–lb
(3.4 to 6.8 N–m)
13
12
9
11
5
7
8
6
4
3
2
1
10
4
10
14
15
ANTISEIZE
LUBRICANT
16
16
Gasoline EnginePage 3 – 9Sand Pro & Infield Pro 3040/5040
DANGER
Because gasoline is highly flammable, use cau­tion when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while engine is running, hot or when machine is in an enclosed area. Always fill fuel tank outside and clean up any spilled fuel before starting the engine. Store fuel in a clean, safety–approved container and keep fuel cap in place. Use gaso­line for the engine only; not for any other purpose.
Check Fuel Lines and Connections
Check fuel lines and connections periodically as recom­mended in the Operator’s Manual. Check lines for dete­rioration, damage, leaks or loose connections. Replace hoses, clamps and connections as necessary.
Drain and Clean Fuel Tank
IMPORTANT: If fuel tank is to be drained, drain fuel outdoors.
Drain and clean the fuel tank periodically as recom­mended in the Operator’s Manual. Also, drain and clean the fuel tank if the fuel system becomes contaminated or if the machine is to be stored for an extended period.
To clean fuel tank, flush tank and fuel hoses out with clean solvent. Make sure tank is free of contaminates and debris.
Fuel Tank Removal (Fig. 6)
1. Park machine on a level surface, lower attachment, stop engine, apply parking brake and remove key from ignition switch.
2. Close fuel shut off valve (Fig. 7). Disconnect fuel hose from fuel filter inlet.
3. Place disconnected hose in appropriate container and open fuel shut off valve to allow fuel tank to drain completely.
4. Remove three (3) washer head screws that retain dash panel to fuel tank (Fig. 8). Carefully position panel away from fuel tank.
5. Remove fuel tank from machine using Figure 6 as a guide.
6. If fuel in tank was contaminated, carburetor removal and cleaning may be necessary (see Briggs and Strat­ton Repair Manual at the end of this chapter).
Fuel Tank Installation (Fig. 6)
1. If carburetor was removed from engine for cleaning, install carburetor (see Briggs and Stratton Repair Manu­al at the end of this chapter).
2. Install fuel tank to frame using Figure 6 as a guide. Apply antiseize lubricant to cap screw (item 14) that se­cures front of fuel tank to machine. Install and torque cap screw from 30 to 60 in–lb (3.4 to 6.8 N–m).
3. Connect fuel hose to fuel filter inlet. Make sure that fuel hose is secured with hose clamps.
4. Position panel to fuel tank and secure with three (3) washer head screws (Fig. 8).
5. Fill fuel tank (see Operator’s Manual).
6. Open fuel shut off valve and check for any signs of fuel leakage.
1. Fuel shut off valve 2. Fuel filter
Figure 7
1
2
1. Washer head screw
2. Screw
3. Dash panel
4. Choke lever/cable
5. Lock nut
6. Throttle lever/cable
7. Ignition switch
Figure 8
5
7
6
4
3
2
1
1
2
5
Gasoline
Engine
Gasoline Engine Page 3 – 10 Sand Pro & Infield Pro 3040/5040
Engine
Figure 9
1. Muffler shield
2. Negative battery cable
3. Engine
4. Hose clamp (2 used)
5. Engine support
6. Cap screw (4 used)
7. Engine mount (4 used)
8. Front mount bracket (2 used)
9. Flange nut (4 used)
10. Cap screw
11. Flange nut
12. Engine mount
13. Cap screw (4 used)
14. Lock washer
15. Cap screw (4 used)
16. Crankshaft cover
17. Cap screw (2 used)
18. Breather tube
19. Intake gasket
20. Flange head screw (3 used)
21. Flat washer (4 used)
22. Hose
23. Flange head screw (4 used)
24. Washer head screw (4 used)
25. Gasket (2 used)
26. Muffler
27. Intake elbow
28. Tail pipe
29. Flat washer (4 used)
30. Cap screw (3 used)
31. Flange head screw (4 used)
32. Exhaust gasket (2 used)
33. Flat washer (3 used)
34. Flange nut (3 used)
35. Exhaust shield
FRONT
LEFT
170 to 200 in–lb
(19.2 to 22.6 N–m)
60 to 65 in–lb
(6.8 to 7.3 N–m)
35
24
1
26
16
17
11
5
12
29
13
7
8
9
15
3
6
28
11
10
22
20
21
31
32
34
33
30
23
25
27
19
18
11
15
2
11
14
4
Engine Removal (Fig. 9)
1. Park machine on a level surface, lower attachment, stop engine, apply parking brake and remove key from ignition switch.
2. If engine is to be disassembled, it may be easier to drain oil from engine before removing engine from ma­chine (see Operator’s Manual).
3. Chock wheels to prevent the machine from moving.
Gasoline EnginePage 3 – 11Sand Pro & Infield Pro 3040/5040
4. Remove rear attachment from machine.
CAUTION
The engine and exhaust system may be hot. To avoid possible burns, allow the engine and ex­haust system to cool before removing engine from machine.
5. Remove hitch assembly from the rear of the machine (see Hitch Assembly Removal in the Service and Re­pairs section of Chapter 6 – Chassis).
6. Raise operator seat.
CAUTION
When disconnecting the battery cables from the battery, make sure to remove the negative (–) bat­tery cable first and then remove the positive (+) battery cable.
7. Disconnect and remove battery from the machine to prevent the possibility of the engine damaging it during removal (see Battery Service in the Service and Repairs section of Chapter 5 – Electrical Systems).
8. 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.
9. Disconnect machine wire harness from engine as follows (Fig. 10):
A. Disconnect harness violet wire from engine mag­neto terminal.
B. Disconnect harness fusible link from voltage reg­ulator on engine blower housing.
C. Disconnect harness yellow wire from engine fuel solenoid lead.
10.Remove air intake hose from air cleaner assembly and engine intake elbow (see Air Cleaner Assembly Re­moval in this section).
11. Disconnect breather tube from intake elbow.
12.Remove four (4) flange head screws that secure in­take elbow to carburetor. Remove two (2) gaskets and intake manifold. Discard gaskets. Remove and discard intake gasket from between intake elbow and carbure­tor. Make sure that all gasket material is removed from carburetor and intake elbow.
Figure 10
1. Violet wire (magneto)
2. Fusible link (voltage reg.)
3. Voltage regulator
4. Yellow wire
1
2
4
3
1. Throttle control cable
2. Governor control plate
3. Choke cable
4. Choke lever
Figure 11
3
1
2
4
1. Square key
2. Cap screw
3. Set screw
4. Engine hub
5. Coupling spacer
6. Lock nut
7. Drive coupling
8. Coupling
Figure 12
7
8
2
4
3
1
2
5
5
6
6
Loctite #242
Antiseize Lubricant
90 to 110 in–lb
(10.2 to 12.4 N–m)
Gasoline
Engine
Gasoline Engine Page 3 – 12 Sand Pro & Infield Pro 3040/5040
13.Disconnect throttle control cable from the governor control plate and choke control cable from the choke le­ver (Fig. 11).
14.Disconnect red positive cable (solenoid) from the starter motor.
15.Loosen two (2) set screws on the engine hub to allow hub removal from the engine stub shaft (Fig. 12).
16.Remove lock nut and cap screw securing engine and negative battery cable to the engine support. Locate and retrieve lock washer (item 14). Position cable away from engine.
17.Remove remaining three (3) lock nuts and cap screws that secure the engine to the engine support.
IMPORTANT: Make sure not to damage the engine, fuel lines, hydraulic lines, electrical harness or oth­er parts while removing the engine from the ma­chine.
18.Remove engine from machine as follows:
A. Slide engine toward the rear of machine to re­move engine stub shaft from engine hub. Take care not to damage the hydrostat coupling.
B. Once the engine stub shaft is clear of the engine hub, remove engine from the rear of the machine.
C. Locate and retrieve square key from the engine stub shaft.
Engine Installation (Fig. 9)
1. Position machine on a level surface.
2. Make sure that all parts removed from the engine during maintenance or rebuilding are properly installed to the engine.
IMPORTANT: Make sure not to damage the engine, fuel lines, hydraulic lines, electrical harness or oth­er parts while installing the engine.
3. Install engine to machine as follows:
A. Apply antiseize lubricant to bore of engine hub. Place square key into slot on the engine stub shaft.
B. Position engine onto engine support from the rear of the machine.
C. Align engine stub shaft to engine hub. Slide en­gine toward the front of machine until mounting holes in engine align with holes in engine support. Take care not to damage the hydrostat coupling.
D. Install three (3) cap screws and lock nuts to se­cure the engine to the engine support. Do not fully tighten lock nuts.
E. Position lock washer and negative battery cable to the engine. Lock washer should be positioned be­tween engine and ground cable. Install fourth cap screw up through engine support, engine, lock wash­er and ground cable and then install lock nut. Do not fully tighten lock nut.
F. Rotate engine crankshaft by hand and check for deflection of pump couplers that would indicate mis­alignment between engine and hydrostat. Position engine on engine support to best align the coupling assembly.
G. Tighten four (4) cap screws and lock nuts to se­cure engine to machine.
4. Position engine hub on engine stub shaft so that rub­ber pump drive couplings are not distorted. Apply Loctite #242 (or equivalent) to threads of engine hub set screws. Tighten both set screws on the engine hub to secure hub to the engine stub shaft (Fig. 12). Torque set screws from 90 to 110 in–lb (10.2 to 12.4 N–m).
5. Connect throttle control cable to the governor control plate and choke control cable to the choke lever (Fig.
11).
6. Connect positive cable (solenoid) to starter motor.
7. Connect machine wire harness leads to engine as follows (Fig. 10):
A. Connect harness violet wire to the engine mag­neto terminal.
B. Connect harness fusible link to voltage regulator on engine blower housing.
C. Connect harness yellow wire to engine fuel sole­noid lead.
CAUTION
When connecting the battery cables to the bat­tery, make sure to attach the positive (+) battery cable first and then attach the negative (–) bat­tery cable.
8. Install and connect battery to the machine (see Bat­tery Service in the Service and Repairs section of Chap­ter 5 – Electrical Systems).
Gasoline EnginePage 3 – 13Sand Pro & Infield Pro 3040/5040
9. 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.
10.Place new intake gasket on carburetor. Position in­take elbow to top of carburetor. Place two (2) gaskets to top of intake elbow and secure intake elbow with four (4) flange head screws. Torque cap screws from 60 to 65 in–lbs (6.8 to 7.3 N–m).
IMPORTANT: Any leaks in the air filter system will allow dirt into engine and will cause serious engine damage. Make sure that all air cleaner components and breather tube are in good condition and are properly secured during assembly.
11. Secure breather tube to intake elbow. Make sure that hose clamps are properly tightened.
12.Secure air intake hose to air cleaner assembly and engine (see Air Cleaner Assembly Installation in this section). Make sure that hose clamps are properly tight­ened.
13.Install hitch assembly to the rear of the machine (see Hitch Assembly Installation in the Service and Repairs section of Chapter 6 – Chassis).
14.Install attachment to the machine.
15.Lower operator seat.
16.Check and adjust engine oil level (See Operator’s Manual).
17.Check operation of choke and throttle cables. Adjust if necessary (see Operator’s Manual).
Gasoline
Engine
Gasoline Engine Page 3 – 14 Sand Pro & Infield Pro 3040/5040
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Sand Pro & Infield Pro 3040/5040 Page 4 – 1 Hydraulic System
Chapter 4
Hydraulic System
Table of Contents
SPECIFICATIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION 3. . . . . . . . . . . . . . . . . . . . .
Hydraulic Hoses 3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Fitting Installation 3. . . . . . . . . . . . . . . . . .
Towing 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relieving Hydraulic System Pressure 5. . . . . . . . . .
Traction Circuit Component Failure 5. . . . . . . . . . . .
Optional Hydraulic Accessories 5. . . . . . . . . . . . . . .
HYDRAULIC SCHEMATICS 6. . . . . . . . . . . . . . . . . . . .
Sand Pro 3040 and Infield Pro 3040 6. . . . . . . . . . .
Sand Pro 3040 and Infield Pro 3040 (Including
Optional Hydraulic Kits) 7. . . . . . . . . . . . . . . . . . . .
Sand Pro 5040 and Infield Pro 5040 8. . . . . . . . . . .
Sand Pro 5040 and Infield Pro 5040 (Including
Optional Hydraulic Kits) 9. . . . . . . . . . . . . . . . . . . .
HYDRAULIC FLOW DIAGRAMS 10. . . . . . . . . . . . . . .
Traction Circuit 10. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lift Circuit 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Circuit 14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 16. . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 19. . . . . . . . . . . . . . . . . . . . . . . .
TESTING 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charge Pressure and Implement Relief
Valve (R1) Pressure Tests 22. . . . . . . . . . . . . . . . .
Traction Relief Valve (R3) Pressure Test 24. . . . . .
Traction Pump (P1) Flow Test 26. . . . . . . . . . . . . . . .
Wheel Motor Efficiency Test 28. . . . . . . . . . . . . . . . .
Charge Pump (P2) Flow Test 30. . . . . . . . . . . . . . . .
Steering Cylinder Internal Leakage Test
(Sand Pro 5040 and Infield Pro 5040) 32. . . . . . .
SERVICE AND REPAIRS 34. . . . . . . . . . . . . . . . . . . . .
General Precautions for Removing and
Installing Hydraulic System Components 34. . . .
Check Hydraulic Lines and Hoses 34. . . . . . . . . . . .
Flush Hydraulic System 35. . . . . . . . . . . . . . . . . . . . .
Charge Hydraulic System 36. . . . . . . . . . . . . . . . . . .
Hydraulic Tank 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Cooler 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Wheel Motor 42. . . . . . . . . . . . . . . . . . . . . . . . .
Rear Wheel Motor 44. . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Motor Service 46. . . . . . . . . . . . . . . . . . . . . . .
Lift Control Valve 48. . . . . . . . . . . . . . . . . . . . . . . . . . .
Lift Control Valve Service 50. . . . . . . . . . . . . . . . . . . .
Pump Control Assembly 52. . . . . . . . . . . . . . . . . . . .
Hydrostat 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydrostat Service 58. . . . . . . . . . . . . . . . . . . . . . . . . .
Lift Cylinder 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lift Cylinder Service 62. . . . . . . . . . . . . . . . . . . . . . . .
Steering Control Valve (Sand Pro 5040 and
Infield Pro 5040) 64. . . . . . . . . . . . . . . . . . . . . . . . .
Steering Control Valve Service (Sand Pro 5040
and Infield Pro 5040) 66. . . . . . . . . . . . . . . . . . . . . .
Steering Cylinder (Sand Pro 5040 and Infield
Pro 5040) 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Cylinder Service (Sand Pro 5040 and
Infield Pro 5040) 70. . . . . . . . . . . . . . . . . . . . . . . . .
PARKER TORQMOTOR
TM
SERVICE PROCEDURE
(TC, TB, TE, TJ, TF, TG, TH AND TL SERIES)
SAUER–DANFOSS (SUNDSTRAND) 15 SERIES RE-
PAIR MANUAL
SAUER–DANFOSS (SUNDSTRAND) 15 SERIES
SERVICE MANUAL
SAUER–DANFOSS STEERING UNIT TYPE OSPM
SERVICE MANUAL
Hydraulic
System
Page 4 – 2Hydraulic System
Sand Pro & Infield Pro 3040/5040
Specifications
Item Description
Hydrostatic Transmission Sauer–Danfoss (Sundstrand),
Variable displacement piston pump, In–Line type
Axial Piston Design, Model Series 15
Maximum Pump Displacement 0.913 in
3
/rev (15.0 cm3/rev) Maximum Pump Flow Rate (98% efficiency @ 3400 RPM) 13.2 GPM (50.0 LPM) Charge Pump Gerotor Pump in Hydrostat Charge Pump Displacement 0.33 in
3
/rev (5.4 cm3/rev) Charge Pump Flow Rate (60% efficiency @ 3400 RPM) 2.9 GPM (11.0 LPM) Charge Relief Setting 135 PSI (9.3 bar) Implement Relief Setting 1100 PSI (75.9 bar) Traction Relief Setting 3200 PSI (220.7 bar) in Forward Direction
Wheel Motors Orbital rotor motor
Front Wheel Motor Displacement 17.1 in
3
/rev (280 cm3/rev)
Rear Wheel Motor Displacement 8.6 in
3
/rev (141 cm3/rev)
Steering Control Valve (Sand Pro 5040 & Infield Pro 5040) Sauer–Danfoss Steering Unit, Type OSPM
Hydraulic Tank Capacity 5 US gallons (18.9 liters)
Hydraulic Filter 10 Micron (nominal) spin on cartridge type
Hydraulic Oil See Traction Unit Operator’s Manual
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