Form No.
Revision History Revision Date Description -- 2006 Initial Issue. A 2006 Updated Engine chapter. B 2018 Added revision history. C 4/2020 Update elec. schematic, wire harness, add kit wire harnesses © THE TORO COMPANY 2020 This document and all information contained herein is the sole property of The Toro Company (and/or its affiliated companies). No intellectual property rights are granted by the delivery of this document or the disclosure of its content.
Reader Comments The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we encourage user feedback. Please comment on the completeness, accuracy, organization, usability, and readability of this manual by an e-mail to servicemanuals@toro.
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Part No. 06147SL (Rev. C) 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. 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.
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Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equivalents and Conversions . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . 2–1 2–1 2–2 2–3 Chapter 3 – Gasoline Engine Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 3 General Information . . . . .
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Safety Table of Contents SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service . . . . . . . . . . . . . . . . . . . . JACKING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . SAFETY AND INSTRUCTION DECALS . . . . . . . . . .
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 or death.
1. Before servicing or making adjustments, position machine on a level surface and apply parking brake to prevent machine from moving. 8. Do not overspeed the engine by changing governor setting. To assure safety and accuracy, check maximum engine speed with a tachometer. 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. 9.
Jacking Instructions CAUTION 1 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.
Chapter 2 Product Records and Maintenance PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . Fastener Identification . . . . . . . . . . . . . . . . . . . . . . .
Equivalents and Conversions Product Records and Maintenance Page 2 – 2 Sand Pro & Infield Pro 3040/5040
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.
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series) Thread Size # 6 – 32 UNC 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) in–lb in–lb N–cm 10 + 2 13 + 2 147 + 23 # 6 – 40 UNF # 8 – 32 UNC 13 + 2 25 + 5 282 + 56 # 8 – 36 UNF # 10 – 24 UNC 18 + 2 30 + 5 339 + 56 # 10 – 32 UNF SAE Grade 5 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) SAE
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Fasteners) Class 8.8 Bolts, Screws and Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws and Studs with 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.
Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size 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 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.
Chapter 3 Gasoline Engine Table of Contents Sand Pro & Infield Pro 3040/5040 Page 3 – 1 Gasoline Engine INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 4 Fuel Shut–off Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 5 Cooling System . . . . . . . . . . . . . . . . . .
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.
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 Sand Pro & Infield Pro 5040 2.68” x 2.60” (68mm x 66mm) 2.83” x 2.75” (72mm x 70mm) Engine Displacement Sand Pro & Infield Pro 3040 Sand Pro & Infield Pro 5040 29.3 cu in (480cc) 34.8 cu in (570cc) Fuel Unleaded Regular Grade Gasoline 5.0 US gallons (18.
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. 1 Figure 1 1.
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. 1 1 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. 3 1.
Air Cleaner Assembly 7 1 5 60 to 65 in–lb (6.8 to 7.3 N–m) 2 6 11 8 3 12 4 13 10 9 14 RIGHT FRONT Figure 3 1. 2. 3. 4. 5. Inlet hood Air cleaner assembly Intake elbow Hose clamp Cap screw (2 used) Gasoline Engine 6. 7. 8. 9. 10. Flat washer (2 used) Mounting bracket Lock nut (2 used) Hose clamp Air hose Page 3 – 6 11. 12. 13. 14.
Removal (Fig. 3) NOTE: See Operator’s Manual for air cleaner maintenance procedures and intervals. 3 1. Park machine on a level surface, lower attachment, stop engine, apply parking brake and remove key from ignition switch. 2 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. 1 Installation (Fig.
Fuel Tank 1 2 4 16 3 16 5 4 6 7 8 10 11 10 9 12 13 ANTISEIZE LUBRICANT 14 RIGHT FRONT 15 30 to 60 in–lb (3.4 to 6.8 N–m) Figure 6 1. 2. 3. 4. 5. 6. Fuel cap Fuel tank Cap screw Clamp Fuel hose Fuel filter Gasoline Engine 7. 8. 9. 10. 11. Hose clamp Fuel hose Fuel shut off valve Hose clamp Fuel hose Page 3 – 8 12. 13. 14. 15. 16.
Fuel Tank Installation (Fig. 6) 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.
Engine 23 21 25 60 to 65 in–lb (6.8 to 7.3 N–m) 3 20 30 22 1 27 2 11 19 35 18 14 4 33 6 34 17 11 16 7 26 9 28 11 11 32 15 15 24 31 5 170 to 200 in–lb (19.2 to 22.6 N–m) 8 10 FRONT 12 LEFT 29 13 Figure 9 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Muffler shield Negative battery cable Engine Hose clamp (2 used) Engine support Cap screw (4 used) Engine mount (4 used) Front mount bracket (2 used) Flange nut (4 used) Cap screw Flange nut Engine mount 13. 14. 15. 16. 17. 18. 19.
4. Remove rear attachment from machine. 3 1 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). 2 4 Figure 10 1. Violet wire (magneto) 2. Fusible link (voltage reg.) 3. Voltage regulator 4. Yellow wire 6. Raise operator seat.
13.Disconnect throttle control cable from the governor control plate and choke control cable from the choke lever (Fig. 11). D. Install three (3) cap screws and lock nuts to secure the engine to the engine support. Do not fully tighten lock nuts. 14.Disconnect red positive cable (solenoid) from the starter motor. E. Position lock washer and negative battery cable to the engine. Lock washer should be positioned between engine and ground cable.
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.
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Chapter 4 Hydraulic System SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic Fitting Installation . . . . . . . . . . . . . . . . . . 3 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Relieving Hydraulic System Pressure . . . . . . . . . . 5 Traction Circuit Component Failure . . . . . . . . . . . .
Specifications Item Description Hydrostatic Transmission Sauer–Danfoss (Sundstrand), Variable displacement piston pump, In–Line type Axial Piston Design, Model Series 15 0.913 in3/rev (15.0 cm3/rev) 13.2 GPM (50.0 LPM) Gerotor Pump in Hydrostat 0.33 in3/rev (5.4 cm3/rev) 2.9 GPM (11.0 LPM) 135 PSI (9.3 bar) 1100 PSI (75.9 bar) 3200 PSI (220.
General Information Hydraulic Hoses 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 in position with one wrench and tighten the hose swivel nut onto the fitting with the second wrench. WARNING Before disconnecting or performing any work on hydraulic system, relieve all pressure in system (see Relieving Hydraulic System Pressure).
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. O–Ring 3. Lubricate the o–ring with a light coating of oil. 4. Install the fitting into the port and tighten it down full length until finger tight. Figure 3 5. Tighten the fitting to the correct flats from finger tight (F.F.F.T.). Size 4 (1/4 in.
Towing If it becomes necessary to tow (or push) the machine, tow (or push) at a speed below 1 mph (1.6 kph), and for a very short distance. If machine needs to be moved a considerable distance, machine should be transported on a trailer. Refer to Traction Unit Operator’s Manual for Towing Procedures. IMPORTANT: If towing limits are exceeded, severe damage to the transmission may occur. Also, if machine is towed too fast, wheels may lock up. If wheel lock up occurs, stop towing the machine.
Hydraulic System Page 4 – 6 Sand Pro 3040 & Infield Pro 3040 Hydraulic Schematic THIS SYMBOL INDICATES THAT CHECK VALVE IS OPENED BY SPOOL CAM PIN Hydraulic Schematics Sand Pro & Infield Pro 3040/5040
Sand Pro & Infield Pro 3040/5040 Page 4 – 7 Hydraulic System Sand Pro 3040 & Infield Pro 3040 (Including Optional Hydraulics Kits) Hydraulic Schematic Hydraulic System THIS SYMBOL INDICATES THAT CHECK VALVE IS OPENED BY SPOOL CAM PIN
Hydraulic System Page 4 – 8 Sand Pro & Infield Pro 3040/5040 Sand Pro 5040 & Infield Pro 5040 Hydraulic Schematic THIS SYMBOL INDICATES THAT CHECK VALVE IS OPENED BY SPOOL CAM PIN
Sand Pro & Infield Pro 3040/5040 Page 4 – 9 Hydraulic System Sand Pro 5040 & Infield Pro 5040 (Including Optional Hydraulic Kits) Hydraulic Schematic Hydraulic System THIS SYMBOL INDICATES THAT CHECK VALVE IS OPENED BY SPOOL CAM PIN
THIS SYMBOL INDICATES THAT CHECK VALVE IS OPENED BY SPOOL CAM PIN Hydraulic System Page 4 – 10 Working Pressure Low Pressure (Charge) Return or Suction Flow Traction Circuit (Forward Shown) (Sand Pro/Infield Pro 5040 Schematic Shown) Hydraulic Flow Diagrams Sand Pro & Infield Pro 3040/5040
Traction Circuit The traction circuit of the hydraulic system consists of a hydrostat connected in a closed loop circuit to three orbital vane wheel motors. Hydraulic fluid losses are designed to occur from case drain leakage of the traction pump (P1) and bleed off from the left rear 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.
Hydraulic System Page 4 – 12 Sand Pro & Infield Pro 3040/5040 REAR LIFT CYLINDER (RETRACTING) THIS SYMBOL INDICATES THAT CHECK VALVE IS OPENED BY SPOOL CAM PIN LIFT VALVE (RAISE POSITION) Working Pressure Low Pressure (Charge) Return or Suction Flow Lift Circuit (Raise Shown) (Sand Pro/Infield Pro 5040 Schematic Shown)
Lift Circuit The charge pump (P2) 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 (1100 PSI / 75.9 bar) to operate the lift cylinder with attachments, and protects the charge pump while using the lift circuit to raise or lower the attachment.
Hydraulic System Page 4 – 14 Sand Pro & Infield Pro 3040/5040 THIS SYMBOL INDICATES THAT CHECK VALVE IS OPENED BY SPOOL CAM PIN (NEUTRAL POSITION) Working Pressure Low Pressure (Charge) Return or Suction Flow Steering Circuit (Right Turn Shown) Sand Pro/Infield Pro 5040 (EXTENDING)
The charge pump in the hydrostat on Sand Pro 5040 and Infield Pro 5040 machines supplies flow for the steering circuit and for the implement lift circuit. Pump output flows to the steering control valve before reaching the lift control valve so the steering circuit has priority. Steering circuit pressure is limited to 1100 PSI (75.9 bar) by the implement relief valve (R1) located in the hydrostat. P port passes through the rotary meter and is directed out port R.
Specifications Item Description Tire Pressure Front Tire Rear Tire Chassis 8 to 10 PSI (0.5 to 0.7 Bar) 8 to 10 PSI (0.5 to 0.
Hydraulic Test Fitting Kit Part Number: TOR4079 TORO TEST FITTING KIT (TOR4079) The test fitting kit includes a variety of O–ring Face Seal fittings to enable the connection of test gauges into the system. The kit includes: tee’s, unions, reducers, plugs, caps and male test fittings. Figure 10 Measuring Container Part Number: TOR4077 Hydraulic System Use this graduated container for doing hydraulic motor efficiency testing (motors with case drain lines only).
O–Ring Kit Part Number: 16–3799 The o–ring kit includes o–rings in a variety of sizes for face seal and port seal hydraulic connections. It is recommended that o–rings be replaced whenever a hydraulic connection is loosened. Figure 13 Wheel Hub Puller Part Number: TOR4097 The wheel hub puller allows safe removal of the wheel hub from the shaft of hydraulic wheel motors.
Troubleshooting The chart that follows contains information to assist in troubleshooting. There may possibly be more than one cause for a machine malfunction. Refer to the Testing section of this Chapter for precautions and specific hydraulic test procedures.
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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). 3. Before testing, check all control linkages for improper adjustment, binding or broken parts. 4. All hydraulic tests should be made with the hydraulic oil at normal operating temperature.
Hydraulic System Page 4 – 22 THIS SYMBOL INDICATES THAT CHECK VALVE IS OPENED BY SPOOL CAM PIN PRESSURE GAUGE (SAND PRO/INFIELD PRO 5040) PRESSURE GAUGE (SAND PRO/INFIELD PRO 3040) NOTE: SAND PRO/INFIELD PRO 5040 SCHEMATIC SHOWN Charge Pressure and Implement Relief Valve (R1) Pressure Tests Figure 16 Sand Pro & Infield Pro 3040/5040
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 attachment lowered. Make sure engine is off and that the parking brake is applied. 3. Read and follow Precautions for Hydraulic Testing. IMPORTANT: Make sure to thoroughly clean around all hydraulic connections that will be disassembled. 4. Install pressure gauge to machine: A.
THIS SYMBOL INDICATES THAT CHECK VALVE IS OPENED BY SPOOL CAM PIN PRESSURE GAUGE NOTE: SAND PRO/INFIELD PRO 5040 SCHEMATIC SHOWN Traction Relief Valve (R3) Pressure Test Figure 19 Hydraulic System Page 4 – 24 Sand Pro & Infield Pro 3040/5040
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 attachment removed. Make sure engine is off and that the parking brake is applied. 3. Read and follow Precautions for Hydraulic Testing. 4. Make sure that traction pedal is adjusted to the neutral position (see Operator’s Manual). IMPORTANT: Make sure to thoroughly clean around all hydraulic connections that will be disassembled. 5.
Hydraulic System THIS SYMBOL INDICATES THAT CHECK VALVE IS OPENED BY SPOOL CAM PIN NOTE: SAND PRO/INFIELD PRO 5040 SCHEMATIC SHOWN TESTER Traction Pump (P1) Flow Test Figure 21 Page 4 – 26 Sand Pro & Infield Pro 3040/5040
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 attachment removed. Make sure engine is off. 3. Read and follow Precautions for Hydraulic Testing. 4. Make sure that traction pedal is adjusted to the neutral position and that traction pedal allows full stroke of the pump lever (see Operator’s Manual). WARNING 11.
THIS SYMBOL INDICATES THAT CHECK VALVE IS OPENED BY SPOOL CAM PIN TESTER NOTE: SAND PRO/INFIELD PRO 5040 SCHEMATIC SHOWN Wheel Motor Efficiency Test Figure 23 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 condiHydraulic System tions.
A. The front motor can be removed from the traction circuit by disconnecting the hydraulic hose from the hydraulic tube leading to the front wheel motor upper port. Disconnect tester hose from hydraulic tube leading to the front wheel motor lower port. Then, to allow flow to the rear wheels, connect the flow meter hose to the disconnected hydraulic hose. Procedure for Wheel Motor Efficiency Test: 1.
THIS SYMBOL INDICATES THAT CHECK VALVE IS OPENED BY SPOOL CAM PIN TESTER NOTE: SAND PRO/INFIELD PRO 5040 SCHEMATIC SHOWN Charge Pump (P2) Flow Test Figure 25 Hydraulic System Page 4 – 30 Sand Pro & Infield Pro 3040/5040
Procedure for Charge Pump (P2) Flow Test: SP/IP 3040 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 attachment lowered. Make sure engine is off and that the parking brake is applied. 1 3 3. Read and follow Precautions for Hydraulic Testing. 4. Make sure that traction pedal is adjusted to the neutral position (see Operator’s Manual).
Steering Cylinder Internal Leakage Test (Sand Pro 5040 and Infield Pro 5040) LOOK FOR LEAKAGE PLUG STEERING CYLINDER (FULLY EXTENDED) STEERING WHEEL TURNED FOR RIGHT TURN Figure 28 Hydraulic System Page 4 – 32 Sand Pro & Infield Pro 3040/5040
Procedure for Steering Cylinder Internal Leakage Test (Sand Pro 5040 and Infield Pro 5040): 1 NOTE: Steering on Sand Pro 5040 and Infield Pro 5040 machines will be affected by incorrect front tire pressure, binding in the hydraulic steering cylinder, excessive weight on the vehicle and/or binding of the castor fork assembly. Make sure that these items are checked before proceeding with any hydraulic testing, disassembly or repairs. 2 1.
Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components After Repair or Replacement of Components 1. Before removing any parts from the hydraulic system, park machine on a level surface, apply parking brake, lower attachment and stop engine. Remove key from ignition switch. 1. Check oil level in the hydraulic tank and add correct oil if necessary.
Flush Hydraulic System IMPORTANT: Flush hydraulic system when changIng from petroleum base hydraulic fluid to a biodegradable fluid such as Toro Biodegradable Hydraulic Fluid. IMPORTANT: If a failure occurs in the traction circuit, traction circuit component disassembly and thorough cleaning may be required to remove contaminates from the traction circuit.
Charge Hydraulic System 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. 10.Make sure traction pedal and lift control lever are in neutral. Start engine and run at low idle speed (1750 RPM). The charge pump should pick up oil and fill the hydraulic system.
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Hydraulic Tank 13 9 2 1 22 24 6 11 8 10 7 2 3 27 4 6 5 21 12 23 11 22 11 22 16 12 17 14 25 15 5 RIGHT FRONT 26 21 25 18 25 19 28 5 20 Figure 30 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Cap O–ring Dipstick Hydraulic tank O–ring O–ring Bushing Vent fitting Hose Tank clamp 11. 12. 13. 14. 15. 16. 17. 18. 19. Flat washer Tank clamp Plug Washer head screw (2 used) Filter bracket Cap screw (2 used) Lock washer (2 used) Hydraulic fitting Oil filter head Removal (Fig. 30) 1.
5. Remove left rear wheel from machine (see Rear Wheel Removal in the Service and Repairs section of Chapter 6 – Chassis). 2 1 3 6. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 7. Thoroughly clean hydraulic hose ends and fittings on hydraulic tank to prevent hydraulic system contamination. 8. Label all hydraulic connections on hydraulic tank for assembly purposes. 9.
Oil Cooler 3 4 8 2 16 15 15 6 14 12 11 13 5 1 9 7 14 RIGHT 10 SAND PRO/INFIELD PRO 5040 SHOWN FRONT Figure 32 1. 2. 3. 4. 5. 6. Cap screw (4 used) Flange nut (4 used) Lift control valve Steering control valve Fan shroud Tee fitting 7. 8. 9. 10. 11. 90o hydraulic fitting Hydraulic tube Oil cooler Rubber clamp (2 used) Flat washer (2 used) Removal (Figs. 32 and 34) 1. Park machine on a level surface, lower attachment, stop engine, apply parking brake and remove key from ignition switch.
5. Put caps or plugs on disconnected lines and fittings to prevent contamination. 2 1 3 6. Remove four (4) cap screws and flange nuts that secure fan shroud to frame. 7. Carefully remove oil cooler and fan shroud from machine taking care not to damage fan on hydrostat. 8. Remove two (2) cap screws, flat washers and rubber clamps that secure oil cooler to fan shroud. Separate oil cooler from fan shroud. 9.
Front Wheel Motor 90 to 120 in–lb (10.2 to 13.6 N–m) Loctite #242 31 45 to 55 ft–lb (61 to 75 N–m) 8 32 10 2 33 30 11 9 8 7 24 29 28 23 22 27 22 26 13 12 14 15 25 20 16 22 21 5 6 18 19 2 45 to 55 ft–lb (61 to 75 N–m) RIGHT 17 4 22 3 1 FRONT 25 200 to 400 ft–lb (271 to 542 N–m) 16 Figure 35 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Wheel motor Lock nut (2 used) Wheel hub Lock nut Spindle Front wheel Lug nut Cap screw Flangette Flangette Bearing 12. 13. 14. 15. 16. 17. 18. 19. 20.
5. Put caps or plugs on disconnected lines and fittings to prevent contamination. 6. Remove front wheel from machine (see Front Wheel Removal in the Service and Repairs section of Chapter 6 – Chassis). Separate wheel motor and wheel hub from front wheel and spindle. 7. Secure wheel hub in a vise. Loosen but do not remove lock nut that secures wheel hub to wheel motor. IMPORTANT: DO NOT hit wheel hub, wheel hub puller or wheel motor with a hammer during wheel hub removal or installation.
Rear Wheel Motor 14 12 6 13 3 7 5 8 1 4 12 11 RIGHT 2 10 9 FRONT 200 to 400 ft–lb (271 to 542 N–m) 45 to 55 ft–lb (61 to 75 N–m) Figure 36 1. 2. 3. 4. 5. Rear wheel assembly Lug nut (4 used per wheel) Wheel hub Lock nut Cap screw (4 used per motor) 6. 7. 8. 9. 10. Drive stud (4 used per wheel) Brake bracket Lock washer (4 used per motor) Roll pin Brake bar Removal (Fig. 36) 1.
7. Loosen but do not remove lock nut that secures wheel hub to wheel motor. SAND PRO/INFIELD PRO 3040 3 IMPORTANT: DO NOT hit wheel hub, wheel hub puller or wheel motor with a hammer during wheel hub removal or installation. Hammering may cause damage to the wheel motor. 2 1 4 5 8. Using hub puller (see Special Tools), loosen wheel hub from wheel motor. 9. Remove lock nut and wheel hub from motor shaft. Locate and retrieve woodruff key. 10.Support wheel motor to prevent it from falling.
Wheel Motor Service 8 7 10 6 5 4 2 3 11 1 9 19 23 13 12 14 15 17 16 18 16 20 16 21 16 16 FRONT WHEEL MOTOR SHOWN 24 22 Figure 39 1. 2. 3. 4. 5. 6. 7. 8. Dirt seal Housing assembly Back–up washer Seal ring Shaft seal Coupling shaft Thrust bearing Drive link 9. 10. 11. 12. 13. 14. 15. 16. NOTE: The wheel motors used on Sand Pro and Infield Pro machines have the same basic construction. The motors do however have internal differences. The front wheel motor (shown in Fig.
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Lift Control Valve 7 17 RIGHT 20 FRONT 9 18 16 12 8 15 19 23 SAND PRO/INFIELD PRO 5040 14 11 13 5 13 22 24 25 23 1 2 28 10 4 4 26 21 13 3 4 27 6 90 to 110 in–lb (10.2 to 12.4 N–m) SAND PRO/INFIELD PRO 3040 Figure 40 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Hydraulic hose Hydraulic hose Hydraulic tube O–ring Guide plate Lock nut (3 used) Knob Lever Lock nut (2 used) Lift control valve 11. 12. 13. 14. 15. 16. 17. 18. 19.
5. Label all hydraulic connections for assembly purposes. 3. Secure lift lever pivot to lift control valve spool with cap screw and lock nut (Fig. 41). 4. Remove caps or plugs from disconnected hydraulic lines and fittings. Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved. See Relieving Hydraulic System Pressure in the General Information section. 6. Disconnect hydraulic lines from fittings on lift control valve.
Lift Control Valve Service Disassembly (Fig. 42) 1. Wash lift valve in solvent and dry thoroughly. 2. Carefully mount lift valve in a vise so that mounting pads are against jaws of vise. Lift valve spool retaining ring (item 14) should be facing up. 3. Remove two (2) hex cap plugs (item 1) from side of valve body. Inside valve body, behind each hex cap plug, there is a spring (item 3), check ball (item 4) and cam pin (item 6); remove these parts.
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Pump Control Assembly 23 2 24 1 3 26 4 5 25 6 6 7 10 8 9 13 15 21 16 22 17 11 19 20 RIGHT 18 14 FRONT 12 Figure 43 1. 2. 3. 4. 5. 6. 7. 8. 9. Pump lever Cap screw Cap screw Ball bearing Bearing spacer Flange nut Traction stud Thrust washer Neutral arm 10. 11. 12. 13. 14. 15. 16. 17. 18. Extension spring Adjustment pin Lock nut Washer head screw (3 used) Pump plate Carriage screw Switch plate Neutral switch Lock nut Disassembly (Fig. 43) 1.
B. Start engine and depress traction pedal fully in the reverse direction. Using a phototac, check that rear wheel speed is from 135 to 180 RPM. 5. Disassemble remaining pump control components as needed using Figure 43 as a guide. Assembly (Fig. 43) C. If necessary, adjust ball joint on traction rod to provide rear wheel speed from 135 to 180 RPM. 1. Assemble pump control components as needed using Figure 43 as a guide. D.
Hydrostat Antiseize Lubricant RIGHT 5 8 23 19 FRONT 13 4 22 28 27 24 16 27 30 5 18 9 5 6 14 8 30 Antiseize Lubricant 14 3 7 10 9 8 7 11 38 21 2 1 15 15 5 30 31 29 8 36 34 26 34 37 Loctite #242 90 to 110 in–lb (10.2 to 12.4 N–m) 33 21 12 14 17 35 20 32 Loctite #242 90 to 110 in–lb (10.2 to 12.4 N–m) 25 Figure 47 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Removal (Fig. 47) 2 1. Park machine on a level surface, lower attachment, stop engine, apply parking brake and remove key from ignition switch. 1 3 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 3. Remove two (2) cap screws and flat washers that secure center shroud to machine (Fig. 48). Lift center shroud from frame. 4. Place drain pan under hydraulic oil filter.
17.If hydraulic fittings are to be removed from hydrostat, mark fitting location and orientation to allow correct assembly. Remove fittings from hydrostat. Installation (Fig. 47) 1. If fittings were removed from hydrostat, install fittings with new o–rings to hydrostat using marks made during the removal process to properly orientate fittings. 2. If fan was removed from hydrostat, apply antiseize lubricant to bore of fan hub. Position key in hydrostat shaft slot and slide fan hub fully onto shaft.
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Hydrostat Service 36 HYDROSTAT IS ILLUSTRATED FROM BELOW 35 42 37 38 33 34 32 39 27 30 40 24 31 21 32 33 29 13 18 26 25 43 10 7 17 FRONT RIGHT 19 15 25 23 12 20 22 28 11 10 12 13 14 16 8 8 6 3 41 5 4 9 2 1 Figure 50 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
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Lift Cylinder 10 34 RIGHT 28 29 31 6 7 FRONT 18 27 8 12 26 14 30 9 10 32 11 2 4 3 33 15 1 7 5 13 16 21 20 22 24 23 25 17 12 19 26 Figure 51 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. O–ring 90o hydraulic fitting (2 used) O–ring Hydraulic hose Hydraulic hose Clevis pin Cotter pin Hitch adapter Pin (2 used) Washer head screw Cap screw (2 used) Lock washer (4 used) Hydraulic System 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.
Removal (Fig. 51) 1. Park machine on a level surface, lower attachment, stop engine, apply parking brake and remove key from ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 3. Thoroughly clean hydraulic hose ends and fittings on lift cylinder to prevent hydraulic system contamination. 4. Label all hydraulic connections on lift cylinder for assembly purposes. 9.
Lift Cylinder Service 3 5 6 7 1 8 9 2 10 11 12 4 1 5 2 10 6 3 4 7 8 11 9 12 Figure 52 1. 2. 3. 4. Barrel Nut Seal Piston 5. 6. 7. 8. O–ring Rod seal O–ring Backup seal Disassembly (Fig. 52) 1. Remove oil from lift 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 lift cylinder into a vise; clamp on the clevis end of the barrel ONLY. Hydraulic System 9. 10. 11. 12.
3. Mount shaft securely in a vise by clamping on the clevis of the shaft. A. Coat shaft with clean hydraulic oil. IMPORTANT: Do not clamp vise jaws against the shaft surface. Clamp on the clevis ONLY. B. Slide head onto the shaft. 5. Mount shaft securely in a vise by clamping on the clevis of the shaft. Remove lock nut and piston from the shaft. Carefully slide head off the shaft. 6. Taking care to not scratch or damage the piston, remove seal and o–ring from the piston. 7.
Steering Control Valve (Sand Pro 5040 and Infield Pro 5040) 14 1 13 15 2 20 to 26 ft–lb (27 to 35 N–m) 12 3 11 4 10 9 8 5 7 6 RIGHT 2 FRONT 4 Figure 53 1. 2. 3. 4. 5. Steering control valve Hydraulic hose Hydraulic hose Hydraulic hose Steering pivot 6. 7. 8. 9. 10. Castor fork Steering cylinder Cap screw (4 used) Foam collar Hydraulic tube Removal (Fig. 53) 1. Park machine on a level surface, lower attachment, stop engine, apply parking brake and remove key from ignition switch. 2.
7. Put caps or plugs on disconnected hoses, tubes and fittings to prevent contamination. 8. Remove steering wheel from machine: A. Remove cover from steering wheel. B. Loosen and remove nut that secures steering wheel to steering control valve. Remove flat washer from control valve shaft. C. Slide steering wheel and foam collar from steering control valve. 9. Support steering control valve to prevent it from falling during removal. Figure 54 10.
Steering Control Valve Service (Sand Pro 5040 and Infield Pro 5040) 12 11 9 10 8 7 6 5 4 2 3 1 13 14 24 15 16 17 23 15 22 18 15 20 to 24 ft–lb (27 to 33 N–m) 19 20 21 Figure 56 1. 2. 3. 4. 5. 6. 7. 8. Sleeve Cross pin Ring Spool Bearing assembly Shaft seal Ball stop Ball 9. 10. 11. 12. 13. 14. 15. 16. Housing Dust seal ring Relief valve (2 used) Relief valve spring (2 used) Cardan shaft Spacer O–ring Distribution plate 17. 18. 19. 20. 21. 22. 23. 24.
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Steering Cylinder (Sand Pro 5040 and Infield Pro 5040) 1 2 4 3 12 11 5 10 9 7 8 20 19 15 16 9 17 10 6 18 11 12 4 13 16 14 17 2 18 RIGHT 65 to 80 ft–lb (88 to 108 N–m) FRONT Figure 57 1. 2. 3. 4. 5. 6. 7. Steering control valve Hydraulic hose Retaining ring Hydraulic hose Steering pivot Castor fork Flat washer Hydraulic System 8. 9. 10. 11. 12. 13. 14. Yoke Bushing Spacer Flat washer Cap screw Ball joint Jam nut Page 4 – 68 15. 16. 17. 18. 19. 20.
Removal (Fig. 57) Installation (Fig. 57) 1. Park machine on a level surface, lower attachment, stop engine, apply parking brake and remove key from ignition switch. 1. Coat new o–rings lightly with clean hydraulic oil. 2. Thoroughly clean hydraulic hose ends and fittings on steering cylinder to prevent hydraulic system contamination. 3. Label all hydraulic connections for assembly purposes. 2.
Steering Cylinder Service (Sand Pro 5040 and Infield Pro 5040) 1 3 5 6 7 8 9 2 12 13 4 30 to 35 ft–lb (41 to 47 N–m) 10 11 Figure 58 1. 2. 3. 4. 5. Barrel Lock nut Wear ring Piston Seal 6. 7. 8. 9. O–ring Rod seal O–ring Back–up ring Disassembly (Fig. 58) 1. Remove oil from steering cylinder into a drain pan by slowly pumping the cylinder shaft. Plug both ports and clean the outside of the cylinder. 2. Secure steering cylinder in a vise by lightly clamping on the mounting collar on the barrel.
2. Coat new o–rings, back–up ring and other seals with clean hydraulic oil. 4. Mount barrel securely in a vise by lightly clamping on the mounting collar on the barrel. A. Carefully install wear ring, seal and o–ring to the piston. 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. B. Carefully install rod seal, o–ring, back–up ring and wiper to the head.
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Chapter 5 Electrical System Table of Contents Electrical System Engine ELECTRICAL SCHEMATIC AND DRAWINGS . . . . 2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 4 Starting Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 General Run Problems . . . . . . . . . . . . . . . . . . . . . . 5 ELECTRICAL SYSTEM QUICK CHECKS . . . . . . . . 7 Battery Test (Open Circuit Test) . . . . . . . . . . . . . .
Electrical Schematic and Drawings The electrical schematic, circuit diagrams and wire harness drawings for the Sand Pro and Infield Pro are located in Chapter 7 – Electrical Diagrams. Special Tools Multimeter The multimeter can test electrical components and circuits for current (amps), resistance (ohms) or voltage. Obtain this tool locally. NOTE: Toro recommends the use of a DIGITAL Volt– Ohm–Amp multimeter when testing electrical circuits.
Battery Terminal Protector Part Number: 107–0392 Battery Terminal Protector is an aerosol spray that should be used on battery terminals to reduce corrosion problems. Apply terminal protector after battery cable has been secured to battery terminal. Engine Figure 3 Battery Hydrometer Use the Battery Hydrometer when measuring specific gravity of battery electrolyte. Obtain this tool locally.
Troubleshooting NOTE: See the Briggs and Stratton Repair Manual at the end of Chapter 3 – Engine for troubleshooting of engine electrical components. CAUTION Remove all jewelry, especially rings and watches, before doing any electrical testing or troubleshooting. If the machine has any interlock switches by–passed, they must be reconnected for proper troubleshooting and safety.
Starting Problems (continued) Problem Possible Causes Engine cranks, but does not start. Wiring to interlock components is loose, corroded or damaged (see Circuit Diagrams in Chapter 7 – Electrical Diagrams). Diode D2 is faulty. Interlock relay is faulty. Engine is out of fuel or may be too cold. Ignition switch is faulty. Spark plugs are faulty. Engine or fuel system is malfunctioning (see Chapter 3 – Gasoline Engine). Engine cranks slowly. Engine Engine fuel solenoid is faulty.
General Run Problems (Continued) Problem Possible Causes Battery does not charge. Wiring to charging circuit components is loose, corroded or damaged (see Wiring Schematics in Chapter 7 – Electrical Diagrams). Voltage regulator is not grounded or is faulty. Alternator stator is faulty. Fuse F1 (15 amp) is open, loose or missing. Charge relay is faulty. Fusible link to starter solenoid is open. Ignition switch is faulty. Battery is discharged or faulty.
Electrical System Quick Checks Battery Test (Open Circuit Test) Use a multimeter to measure the voltage between the battery terminals. Voltage Measured Battery Charge Level 12.68 V (or higher) Fully charged (100%) Tool required: Digital multimeter set to DC volts. 12.45 V 75% charged Test instructions: The battery should be at a temperature of 60o to 100oF (16o to 38oC). The ignition key should be off and all accessories turned off.
Component Testing For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g. unplug the ignition switch connector before checking continuity between switch terminals). Ignition Switch The ignition (key) switch has three positions (OFF, RUN, and START) (Fig. 6). The switch terminals are identified as shown in Figure 7. OFF 45 o RUN Testing 45 o The circuitry of the ignition switch is shown in the chart below.
Starter Solenoid The engine starter solenoid is attached to a bracket above the battery. When energized, the starter solenoid allows current flow from the battery to the engine starter motor. 1 6 5 Testing 4 1. Park machine on a level surface, lower attachment, stop engine, apply parking brake and remove key from ignition switch. 2. Tilt operator seat up to gain access to starter solenoid. 2 4. Disconnect wires from starter solenoid (Fig. 8). Engine 3.
Hour Meter The hour meter used on the machine records the amount of time that the ignition switch is in the ON position. 6 1 7 2 5 Testing 1. Remove knob from lift lever. 4 2. Remove four (4) screws and flat washers that secure control panel to console (Fig. 10). Lift control panel, unplug wire harness connector from hour meter and remove control panel from machine. 3. Connect the positive (+) terminal of a 12 VDC source to the positive (+) terminal of the hour meter. 3 4.
Charge, Start and Interlock Relays Three (3) relays are used on the machine: start relay, charge relay and interlock relay. The relays are attached to a bracket under the seat (Fig. 13). The relays are identical and are identified by a tag on the wire harness relay connector. 1 The start relay is used in the starting circuit. When energized, the start relay provides current to energize the starter solenoid.
Seat Switch The seat switch is normally open and closes when the operator is occupying the seat. The seat switch is located directly under the seat. If the operator leaves the seat, the engine will stop unless the traction pedal is in the neutral position. The closed seat switch (seat occupied) and diode D1 keep the interlock relay energized and the engine running when the traction pedal is depressed. 1 2 Testing 1.
Traction Neutral Switch The traction neutral switch is a normally open proximity switch that closes when the traction pedal is in the neutral position. The switch is attached to the hydrostat pump plate (Fig. 16). A cap screw located on the neutral arm acts as the sensing plate for the switch. 3 Testing 1 1. Park machine on a level surface, lower attachment, stop engine, apply parking brake and remove key from ignition switch. 5 2. Remove center shroud to allow access to traction neutral switch (Fig.
Service and Repairs Battery Storage If the machine will be stored for more than 30 days: 1. Remove the battery and charge it fully (see Battery Service). 2. Either store battery on a shelf or on the machine. 4. Store battery in a cool atmosphere to avoid quick deterioration of the battery charge. 5. To help prevent the battery from freezing, make sure it is fully charged before storing the battery/machine (see Battery Service). 3. Leave cables disconnected if the battery is stored on the machine.
Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be extended. Additionally, battery and electrical component failure can be prevented. 1 7 1 3 2 2 7 10 CAUTION 11 When working with batteries, use extreme caution to avoid splashing or spilling electrolyte. Electrolyte can destroy clothing and burn skin or eyes. Always wear safety goggles and a face shield when working with batteries.
Testing 1. To properly test a battery, perform a high–discharge test using an adjustable load tester. This is one of the most reliable means of testing a battery as it simulates the cold–cranking test. A commercial battery load tester is required to perform this test. CAUTION Follow the manufacturer’s instructions when using a battery load tester or a battery charger. A. Check the voltage across the battery terminals prior to testing the battery. If the battery voltage is less than 12.
Charging CAUTION Follow the battery charger manufacturer’s instructions when using a battery charger. NOTE: Using specific gravity of the battery cells is the most accurate method of determining battery condition. 1. Determine the battery charge level from either its specific gravity or open circuit voltage. Battery Charge Level Specific Gravity Open Circuit Voltage 100% 1.265 12.68 75% 1.225 12.45 50% 1.190 12.24 25% 1.155 12.06 0% 1.120 11.
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Chapter 6 Chassis Table of Contents Chassis SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4 Front Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Rear Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Parking Brake . .
Specifications Item Description Tire Pressure Front Tire Rear Tire Chassis 8 to 10 PSI (0.5 to 0.7 Bar) 8 to 10 PSI (0.5 to 0.
Special Tools Wheel Hub Puller Part Number: TOR4097 The wheel hub puller allows safe removal of the wheel hub from the shaft of wheel motors.
Service and Repairs Front Wheel 90 to 120 in–lb (10.2 to 13.6 N–m) Loctite #242 31 45 to 55 ft–lb (61 to 75 N–m) 8 2 32 33 10 11 30 9 8 7 24 29 23 28 22 27 22 26 13 12 14 18 19 2 15 45 to 55 ft–lb (61 to 75 N–m) RIGHT 17 25 20 16 22 21 5 6 4 22 3 1 FRONT 25 16 Figure 2 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Wheel motor Lock nut Wheel hub Lock nut Spindle Front wheel Lug nut Cap screw Flangette Flangette Bearing 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
5. Remove both socket head screws and lock nuts securing the hydraulic motor to the fork. IMPORTANT: Support wheel and wheel motor when jacking up the front of the machine to prevent hydraulic tube damage. WARNING Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 – Safety. 6. Jack up front of machine slowly until the hydraulic motor and flangettes can be removed from the fork. Remove flangettes, spindle, wheel and motor from the fork. Installation (Fig. 2) 1.
6. Slide flangette and bearing assembly onto the spindle shaft so the bearing locking collar faces the wheel. 7. Position hydraulic motor, wheel and flangettes to the front fork. IMPORTANT: When securing wheel motor and flangettes to fork, tighten wheel motor fasteners before tightening flangette fasteners. 8. Carefully lower machine to align wheel motor and flangettes to fork. Make sure flangettes and wheel motor fit snugly to the fork. 9. Lower machine completely to the ground.
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Rear Wheel 3 1 2 6 28 4 7 9 13 8 11 5 14 17 28 9 12 22 25 21 26 27 19 200 to 400 ft–lb (271 to 542 N–m) 20 29 28 26 45 to 55 ft–lb (61 to 75 N–m) 25 10 30 34 18 35 17 24 19 22 15 32 31 RIGHT 16 33 14 17 FRONT 23 Figure 4 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Cap screw Flat washer Retaining ring Brake lever Pivot bushing Brake lever bracket Flange nut Cap screw Flat washer Wheel and tire assembly Grip RH wheel motor Chassis 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.
Removal (Fig. 4) Installation (Fig. 4) 1. Park machine on a level surface, lower attachment, stop engine, apply parking brake and remove key from ignition switch. 1. Install rear wheel and secure with four (4) lug nuts. 2. Lower machine to ground. 3. Torque lug nuts evenly in a crossing pattern from 45 to 55 ft–lb (61 to 75 N–m). CAUTION When changing attachments, tires or performing other service, use correct blocks, hoists and jacks.
Console 6 7 6 2 RIGHT FRONT 8 8 7 8 5 3 6 4 7 8 6 10 1 9 10 Figure 5 1. 2. 3. 4. Frame Console RH wheel shroud Console support plate Chassis 5. Lock nut (4 used) 6. Cap screw (6 used) 7. Lock washer (3 used) Page 6 – 10 8. Flat washer (6 used) 9. LH wheel shroud 10.
Removal (Fig. 5) 1. Park machine on a level surface, lower attachment, stop engine, apply parking brake and remove key from ignition switch. 7 1 2 6 2. Remove knob from lift lever. 5 3. Remove four (4) screws and flat washers that secure control panel to console (Fig. 6). Lift control panel, unplug wire harness connector from hour meter and remove control panel from machine. 4 NOTE: Console support plate (item 4) is fastened to console. 4.
Parking Brake 3 1 2 6 28 4 7 9 13 8 11 5 14 17 28 9 12 22 25 21 26 27 19 200 to 400 ft–lb (271 to 542 N–m) 20 29 28 26 45 to 55 ft–lb (61 to 75 N–m) 25 10 34 35 16 15 18 30 31 24 32 33 RIGHT 19 22 14 17 FRONT 23 Figure 7 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Cap screw Flat washer Retaining ring Brake lever Pivot bushing Brake lever bracket Flange nut Cap screw Flat washer Wheel and tire assembly Grip RH wheel motor Chassis 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
Installation (Fig. 7) Removal (Fig. 7) 1. Park machine on a level surface, lower attachment, stop engine and remove key from ignition switch. CAUTION 2. Make sure parking brake is disengaged. 3. Block front wheel. Jack or hoist rear of machine from ground and support machine with blocking or jack stands (see Operator’s Manual and Jacking Instructions in Chapter 1 – Safety). 4. Remove rear wheel assembly (see Rear Wheel Removal in this section).
Parking Brake Cable 1 2 3 4 8 7 RIGHT FRONT 6 5 9 10 Figure 9 1. 2. 3. 4. Brake lever Retaining ring Brake cable Retaining ring Chassis 5. Flange nut 6. Spacer 7. Brake clevis Page 6 – 14 8. Shoulder bolt 9. Bellcrank 10.
Removal (Fig. 9) Installation (Fig. 9) 1. Park machine on a level surface, lower attachment, stop engine and remove key from ignition switch. 1. Position new parking brake cable to machine noting original routing. 2. Make sure parking brake is disengaged. 2. Secure brake cable to parking brake bellcrank on rear cross tube of frame: 3. Remove console from machine (see Console Removal in this section). 4. Loosen jam nuts that secure parking brake cable to brake lever bracket. 5.
Hitch Assembly 1 10 2 3 4 5 RIGHT 28 29 31 6 7 FRONT 18 27 8 12 26 14 30 9 10 32 11 33 15 7 13 16 24 21 20 22 25 23 17 12 19 26 Figure 10 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Cap screw (2 used) R–clamp (2 used) Rear cover Housing cap Manual housing Clevis pin Cotter pin Hitch adapter Pin (2 used) Washer head screw Cap screw (2 used) Chassis 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
Removal (Fig 10) 4 1. Park machine on a level surface, lower attachment, stop engine, apply parking brake and remove key from ignition switch. 2. Remove attachment from machine. 3. Remove three (3) washer head screws that secure rear cover to machine. Remove rear cover. 2 3 1 4. Remove hitch adapter from machine: A. Support hitch adapter to prevent it from falling during removal. 1 B. Remove two (2) washer head screws (item 10) that secure pins (item 9) to hitch adapter.
Steering Box (Sand Pro 3040 and Infield Pro 3040) 2 90 to 120 in–lb (10.2 to 13.6 N–m) Loctite #242 21 23 7 3 50 to 60 ft–lb (68 to 81 N–m) 9 5 1 8 10 4 6 11 20 19 20 to 26 ft–lb (27 to 35 N–m) 12 19 13 15 18 14 16 15 17 14 RIGHT 22 FRONT Figure 12 1. 2. 3. 4. 5. 6. 7. 8. Lock nut Flat washer Grommet Steering wheel Foam collar Steering tube Steering shaft Bearing (extended race) Chassis 9. 10. 11. 12. 13. 14. 15. 16.
Removal (Fig. 12) Installation (Fig. 12) 1. Park machine on a level surface, lower attachment, stop engine, apply parking brake and remove key from ignition switch. 1. If steering box was disassembled to separate steering box from castor fork shaft, assemble steering box (see Steering Box Service in this section). 2. Remove fuel tank from machine (see Fuel Tank Removal in the Service and Repairs section of Chapter 3 – Engine). 2.
Steering Box Service (Sand Pro 3040 and Infield Pro 3040) 4 2 1 3 6 5 7 8 9 10 7 11 175 to 225 in–lb (19.8 to 25.4 N–m) 12 Figure 13 1. 2. 3. 4. Retaining ring Retaining ring Ball bearing Spacer Chassis 5. 6. 7. 8. Pinion gear Steering cover Bushing Sector gear Page 6 – 20 9. 10. 11. 12.
2. If bearings were removed from pinion gear shaft: Disassembly (Fig. 13) 1. Remove retaining ring that secures pinion gear assembly in steering cover. Pull pinion gear and bearings from steering box. 2. Remove eight (8) cap screws that secure steering plate to steering cover. 3. Remove steering plate, gasket, shim(s) and sector gear from steering cover. 4. If necessary, remove bearings from pinion gear: A. Press first bearing onto shaft by applying pressure equally to the inner and outer bearing race. B.
Front Castor Fork (Sand Pro 3040 and Infield Pro 3040) 90 to 120 in–lb (10.2 to 13.6 N–m) Loctite #242 2 21 23 7 3 50 to 60 ft–lb (68 to 81 N–m) 9 5 1 8 10 4 6 11 20 19 20 to 26 ft–lb (27 to 35 N–m) 12 See Text For Tightening Procedure 19 13 15 18 14 15 17 14 16 RIGHT 22 FRONT Figure 14 1. 2. 3. 4. 5. 6. 7. 8. Lock nut Flat washer Grommet Steering wheel Foam collar Steering tube Steering shaft Bearing (extended race) Chassis 9. 10. 11. 12. 13. 14. 15. 16.
Removal (Fig. 14) Installation (Fig. 14) 1. Park machine on a level surface, lower attachment, stop engine, apply parking brake and remove key from ignition switch. 1. If bearing cups were removed from frame, press new bearing cups into frame making sure that cups are pressed fully to the shoulder in the frame. 2. Remove fuel tank from machine (see Fuel Tank Removal in the Service and Repairs section of Chapter 3 – Engine). 2. Pack bearing cones with grease. 3.
Front Castor Fork (Sand Pro 5040 and Infield Pro 5040) 17 6 1 18 16 19 20 5 7 150 to 200 ft–lb (203 to 271 N–m) 8 21 2 13 10 9 22 11 12 14 60 to 90 in–lb (6.8 to 10.2 N–m) 4 3 RIGHT 90 to 120 in–lb (10.2 to 13.6 N–m) Loctite #242 FRONT 15 65 to 85 ft–lb (88 to 115 N–m) 23 Figure 15 1. 2. 3. 4. 5. 6. 7. 8. Steering control valve Steering cylinder Jam nut Ball joint Steering sleeve Steering wheel cover Cap screw Steering pivot Chassis 9. 10. 11. 12. 13. 14. 15. 16.
Removal (Fig. 14) Installation (Fig. 14) 1. Park machine on a level surface, lower attachment, stop engine, apply parking brake and remove key from ignition switch. 1. If removed, install steering pivot, steering sleeve and bearings to machine: 3. Remove front wheel (see Front Wheel Removal in this section). 4. Remove hose guide from castor fork. Carefully position hydraulic hoses away from fork taking care to not damage hydraulic lines. 5.
Operator Seat 1 21 2 20 3 19 4 18 17 16 5 6 2 12 7 13 8 9 10 11 15 14 RIGHT FRONT Figure 16 1. 2. 3. 4. 5. 6. 7. Operator seat Flange nut (8 used) LH seat adjuster Carriage screw (4 used) Seat shroud Receptacle Rivet 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. Screw Holding post Bumper (2 used) Jam nut (4 used) Clevis pin (2 used) Hair pin (2 used) Lock nut Spacer Cap screw (4 used) Lock washer (4 used) Flat washer (4 used) RH seat adjuster Seat base Seat switch Removal (Fig.
Chapter 7 Electrical Diagrams Table of Contents Electrical Diagrams CIRCUIT DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Crank Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Run Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Electrical Schematic (machine serial number before 400000000) . . . . .
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(NOT GROUNDED) (ENERGIZED) (ENERGIZED) OPTIONAL LIGHT KIT OPTIONAL AUX.
(NOT GROUNDED) (ENERGIZED) (ENERGIZED) OPTIONAL LIGHT KIT OPTIONAL AUX.
Drawing No. 108- 7902 Rev B OPTIONAL LIGHT KIT OPTIONAL REAR REMOTE HYDRAULIC KIT All relays and solenoids are shown as de–energized. All ground wires are black.
Drawing No. 122- 0837 Rev B OPTIONAL LIGHT KIT OPTIONAL REAR REMOTE HYDRAULIC KIT All relays and solenoids are shown as de–energized. All ground wires are black.
Drawing No. 122- 1402 Rev A OPTIONAL LIGHT KIT OPTIONAL REAR REMOTE HYDRAULIC KIT OPTIONAL HYDRAULIC SWITCH KIT All relays and solenoids are shown as de–energized. All ground wires are black.
Drawing No. 112- 1446 Rev D J1 BATTERY GROUND J2 BATTERY GROUND P12 OPTIONAL AUX. DRIVE P13 AUX.
FUEL SOLENOID REGULATOR J3 P01 P02 J1 J2 1 1 1 1 1 BLACK BLACK BATTERY GROUND OPTIONAL LIGHT KIT SEAT SWITCH P15 P03 P05 A 1 A B YELLOW BLACK 2 YELLOW SP1 WHITE 5 VIOLET 6 8 BLACK SP4 BLACK SP5 VIOLET FUSIBLE LINK SP2 GREEN J6 1 4 87 5 86 1 30 2 85 3 87A 4 87 5 86 A RED STARTER SOLENOID 87A START P06 RELAY P07 INTERLOCK RELAY YELLOW 1 BLACK WHITE GREEN WHITE PINK SP3 J4 85 3 GRAY 7 CONTACT B+ 30 2 PINK P11 1 RED ORANGE FUSE BLOCK
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DIODE GROUND A B C D START RELAY COIL NEUTRAL SWITCH P01 KEY POWER Drawing No.
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