PART NO. 98957SL, Rev. B Service Manual Sand ProR 2020/3020/5020 Preface The purpose of this publication is to provide the service technician with information for troubleshooting, testing, and repair of major systems and components on the Sand Pro 2020/3020/5020. REFER TO THE OPERATOR’S MANUALS FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. Space is provided in Chapter 2 of this book to insert the Operator’s Manuals and Parts Catalogs for your machine.
Sand Pro 2020/3020/5020
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 1 Jacking Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 4 Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 – 5 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 2 General Information . . . . . . . . . . . . . . . . . . . . . . . . 4 – 3 Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . 4 – 6 Hydraulic Flow Diagrams . . . . . . . . . . . . . . . . . .
Sand Pro 2020/3020/5020
Chapter 1 Safety Safety Table of Contents GENERAL SAFETY INSTRUCTIONS . . . . . . . . . . . . Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service . . . . . . . . . . . . . . . . . . . . 1 1 2 3 JACKING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . SAFETY AND INSTRUCTION DECALS . . . . . . . . . . Sand Pro 2020/3020 . . . . . . . . . . . . . . . . . . . . . . . . Sand Pro 5020 . .
While Operating 11. Exhaust fumes are hazardous and could be deadly, so do not run the engine in a confined area without adequate ventilation. 15. If optional Draw Bar (Part No. 92–2330) or Hitch Kit (Model No. 08833) is installed on machine, vertical load on hitch should not exceed 200 lbs. 12. Sit on seat when operating the machine. Never carry passengers. 16.
20. Before servicing or making adjustments to the machine, stop engine, remove key from the ignition, and pull the spark plug wire off spark plug to prevent accidental starting of the engine. 27. If the engine must be running to perform a maintenance adjustment, keep hands, feet, clothing, and any parts of the body away from the engine and any moving parts. Keep everyone away. 21.
Jacking Instructions CAUTION When changing attachments, tires, or performing other service, use correct blocks, hoists, and jacks. Make sure machine is parked on a solid level floor such as a concrete floor. Prior to raising the machine, remove any attachments that may interfere with the safe and proper raising of the machine. Always chock or block wheels. Used jack stands or solid wood blocks to support the raised machine.
Safety and Instruction Decals Safety The following safety and instruction decals are installed on the Sand Pro 2020/3020. If any become damaged or illegible, replace them. Decal part numbers are listed below and in the parts catalog. Order replacements from your Authorized Toro Distributor. 93–9051 ON NEUTRAL ADJUST MECHANISM (Part No. 93–9051) UNDER SEAT PLATE (Part No. 95–0646) ON VALVE SHROUD (Part No. 95–0647) ON ENGINE SHIELD (Part No. 92–8985) ON ENGINE SHIELD (Part No.
Safety and Instruction Decals The following safety and instruction decals are installed on the Sand Pro 5020. If any become damaged or illegible, replace them. Decal part numbers are listed below and in the parts catalog. Order replacements from your Authorized Toro Distributor. ON BOTH SIDES OF FAN SHROUD (2) (Part No. 93–7272) ON NEUTRAL ADJUST MECHANISM (Part No. 93–9051) ON MUFFLER SHIELD (Part No. 95–0645) ON RIGHT FENDER (Part No. 98–0975) UNDER SEAT PLATE (Part No.
Chapter 2 Product Records and Maintenance PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . 1 2 2 2 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . Capscrew Markings and Torque Values – U.S. . . Capscrew Markings and Torque Values – Metric LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equivalents and Conversions Product Records and Maintenance Page 2 – 2 Sand Pro 2020/3020/5020
Product Records and Maintenance Torque Specifications Sand Pro 2020/3020/5020 Page 2 – 3 Product Records and Maintenance
Lubrication CAUTION Before servicing or making adjustments to the machine, stop engine, set parking brake, and remove key from the ignition switch. Lubricate grease fittings regularly with No. 2 general purpose lithium base grease. Lubricate front wheel bearing and traction control linkage every 25 hours of operation. Lubricate steering shaft and steering shaft sprocket every 100 hours. Figure 1 Sand Pro 2020/3020 (Early Models) The three fittings that must be lubricated are: front wheel bearing (Fig.
Sand Pro 2020/3020/5020 Figure 6 Page 2 – 5 Product Records and Maintenance Product Records and Maintenance Figure 5
Product Records and Maintenance Page 2 – 6 Sand Pro 2020/3020/5020
Product Records and Maintenance EQUIPMENT OPERATION AND SERVICE HISTORY REPORT for Sand ProR 2020/3020/5020 TORO Model and Serial Number: _____________–___________ Engine Numbers: _________________________ Transmission Numbers: _________________________ Date Purchased: _________________________ Purchased From: _________________________ Warranty Expires___________ _________________________ _________________________ Contacts: Parts _________________________ Phone___________________ Service ___
Sand Pro R 2020/3020/5020 Maintenance Schedule Minimum Recommended Maintenance Intervals: Maintenance Procedure Maintenance Interval & Service Every 25hrs Check Battery Fluid Level Check Battery Cable Connections { Change Engine Oil Lubricate Front Wheel Bearing Every 100hrs Every 400hrs Every 800hrs A–Level Service Lubricate Traction Control LInkage Replace Engine Oil Filter Inspect Remote Air Cleaner Element Inspect Engine Air Cleaner Element Lubricate Steering Shaft Grease Fitting Check Steeri
Sand Pro R 2020/3020/5020 Daily Maintenance Checklist Daily Maintenance: (duplicate this page for routine use) Daily Maintenance Check For Week Of ____________ MON n Safety Interlock Operation n Steering Operation n Engine Oil Level n Remote/Engine Air Cleaner Condition TUES WED THURS FRI SAT SUN Product Records and Maintenance Maintenance Check Item b Clean Engine Cooling Fins n Unusual Engine Noises n Unusual Operating Noises n Hydraulic System Oil Level n Hydraulic Hoses for Da
Product Records and Maintenance Page 2 – 10 Sand Pro 2020/3020/5020 R 2020/3020/5020 A B C D Other Service to perform (circle): A – Service required _______________________________ _______________________________ ________________________________ ________________________________ ________________________________ _______________________________ _______________________________ _______________________________ _______________________________ A, B, C, and D – Service Required __________________________
Chapter 3 Engine INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 4 Check Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Fuel Shutoff Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Fill Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . .
Introduction This Chapter gives information about specifications, maintenance, troubleshooting, testing, and repair of the gasoline engines used in the Sand Pro 2020, 3020, and 5020. 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. Most repairs and adjustments require tools which are commonly available in many service shops.
Specifications Item Description Make / Designation Briggs and Stratton Vanguard, 4–Cycle, V–Twin Cylinder, OHV, Air Cooled, Gasoline Engine Horse Power SP 2020/3020 SP 5020 16 HP @ 3600 RPM 18 HP @ 3600 RPM Bore mm (in.) SP 2020/3020 SP 5020 68.0 (2.677) 71.98 (2.834) Total Displacement cc (cu. in.) SP 2020/3020 SP 5020 480 (29.3) 570 (34.8) Unleaded Regular Grade Gasoline Fuel Capacity liters (gallons) SP 2020/3020 SP 5020 16.1 (4.25) 20.8 (5.
General Information Check Engine Oil 2 CAUTION Before servicing or making adjustments to the machine, make sure of the following: stop engine, engage parking brake, lower attachment, and remove key from the switch. IMPORTANT: Check oil level every 8 operating hours or daily. Change oil initially after the first 8 hours of operation. Thereafter, change oil every 25 hours and filter every 100 hours under normal conditions.
Fuel Shutoff Valve This valve should be shut when removing the engine or placing the unit in long term storage. 1 On the SP 2020/3020, the shutoff valve can be accessed from the rear of the machine (Fig. 2). On the SP 5020, the shutoff valve can be accessed by removing the left side panel (Fig. 3). 2 Figure 2 2. Hydraulic oil filter Engine 1. Fuel shutoff valve 1 2 Figure 3 1. Fuel shutoff valve Sand Pro 2020/3020/5020 Page 3 – 5 2.
Fill Fuel Tank IMPORTANT: The Toro Company strongly recommends using fresh, clean, unleaded regular grade gasoline in Toro gasoline powered products. Unleaded gasoline burns cleaner, extends engine life, and promotes good starting by reducing the build– up of combustion chamber deposits. Leaded gasoline can be used if unleaded is not available. IMPORTANT: Never use methanol, gasoline containing methanol, gasoline containing more than 10% ethanol, gasoline additives, premium gasoline, or white gas.
Adjustments Adjust Throttle Control 1. Pivot seat up. On the SP 2020/3020, remove the engine shield. 4 5 1 3 6 2. Loosen cable clamp screw securing the cable to the engine. 3. Move remote throttle control lever forward to the FAST position. 4. Pull firmly on the throttle cable until the back of throttle swivel contacts the throttle stop. 5. Tighten cable clamp screw. Check engine idle setting. 2 Figure 4 1. Cable clamp screw 2. Throttle cable 3. Throttle swivel 4. Throttle stop 5. Cable clamp screw 6.
Service and Repairs Change Engine Oil and Filter Change oil initially after the first 8 hours of operation. Thereafter, change oil every 25 hours and filter every 100 hours. 1. Park machine on a level surface. Turn engine off. 2. Pivot seat up. On the SP 2020/3020, remove the engine shield. 3. Remove drain plug and let oil flow into drain pan. When oil stops, install drain plug. 4. Remove oil filter. Apply a light coat of clean oil to the new filter gasket. 1 2 5.
Service Remote Air Cleaner Inspect air cleaner filter element every 100 hours of operation. Replace every 400 hours or when dirty or damaged 1 2 1. Check air cleaner body and body for damage that could cause possible air leaks. Replace damaged air cleaner body or cover (see Remote Air Cleaner Removal and Installation). 2. Release latches securing air cleaner cover to air cleaner body. Separate cover from the body. Clean inside of the air cleaner cover. ÇÇ ÇÇ ÇÇ 3 4 3.
Throttle and Choke Controls 1 6 4 4 4 9 2 2 3 1 8 1 5 2 7 Figure 10 1. Knob 2. Throttle control 3. Lock nut 4. Cap screw 5. Dash Panel (SP 2020/3020) 6. Right fender (SP 5020) 7. Hex nut 8. Lock Washer 9. Choke control Throttle Control Removal 1 1. Park machine on a level surface, lower attachment, stop engine, engage parking brake, and remove key from the ignition switch. 2. Pivot seat up. On the SP 2020/3020, remove the engine shield. 2 3.
Throttle Control Installation 3 1. Secure throttle control to the dash panel or right fender with both cap screws and lock nuts. Install throttle control knob to the throttle control lever (Fig. 10). 2. Connect throttle cable to the swivel on the engine. Attach cable to engine with clamp. Make sure not to tighten cap screw securing clamp and cable to engine (Fig. 13). 2 3. On the SP 2020/3020, position hood to the dash panel and front shield.
Choke Control Installation 1 1. On the SP 2020/3020 insert choke cable and control through the dash panel. Secure choke control to the panel with lock washer and hex nut (Fig. 10). 4 2. On the SP 5020, secure choke control to the dash panel or right fender with both cap screws and lock nuts. Install knob to the choke control lever (Fig. 10). 3 3. Connect choke cable to the choke pivot lever. Attach cable to engine with clamp. Make sure not to tighten cap screw securing clamp and cable to engine (Fig.
Remote Air Cleaner (SP 2020/3020) Remote Air Cleaner Removal 1 1. Park machine on a level surface, lower attachment, stop the engine, engage parking brake, and remove the key from the ignition switch. 2. Remove three cap screws securing the hood to the front shield (Fig 19). Remove four cap screws securing the dash panel to the hood (Fig. 20). 2 3. Loosen hose clamp. Remove air hose from the air cleaner body (Fig. 21). 5. Unlatch and remove cover from filter body.
Remote Air Cleaner (SP 5020) Remote Air Cleaner Removal 5 1. Park machine on a level surface, lower attachment, stop the engine, engage parking brake, and remove the key from the ignition switch. 4 2. Loosen hose clamp. Remove air cleaner hose from the air cleaner body. 1 3. Remove both lock nuts, flat washers, and cap screws securing the mounting band to the right fender. 3 4. Unlatch and remove cover from air cleaner body. Separate body from the mounting band.
Muffler (SP 5020) Muffler Removal 1. Park machine on a level surface, lower attachment, stop the engine, engage parking brake, and remove the key from the ignition switch. 1 CAUTION 2 The muffler and exhaust pipe may be hot. To avoid possible burns, allow engine and exhaust system to cool before working on the muffler. Figure 23 2. Muffler shield 1 2 3. Remove cap screws securing muffler and both gaskets to the cylinder heads. Pull muffler from the engine (Fig. 24 and 25). Engine 2.
Muffler (SP 2020/3020) Muffler Removal 1 1. Park machine on a level surface, lower attachment, stop the engine, engage parking brake, and remove the key from the ignition switch. 4 2. Chock front wheel to prevent machine from moving with both rear wheels jacked up. Jack up rear wheels enough to allow the muffler to be removed through the bottom of the machine. Block up rear wheels (See Jacking Instructions in Chapter 1 – Safety). CAUTION 2 3 5 Figure 26 The muffler and exhaust pipe may be hot.
Muffler Installation 1 1. Position muffler through the bottom of the machine to the muffler bracket. Insert cap screw with flat washer through the muffler tab and then the muffler bracket. Screw hex nut onto the cap screw, but do not tighten (Fig. 30). 2 2. Attach exhaust tube to the muffler. Attach exhaust tube to the exhaust manifold (Fig. 31). 3. Make sure exhaust tube fits snugly to both the muffler and exhaust manifold. Secure exhaust tube to the exhaust manifold and muffler with muffler clamps (Fig.
Fuel Tank (SP 2020/3020) 1 2 3 4 26 25 5 24 28 23 22 ANTISEIZE LUBRICANT 30 TO 60 IN–LB (35 TO 69 KG–CM) 9 8 6 10 27 31 13 7 14 30 11 23 32 21 12 18 15 20 34 19 33 17 16 29 Figure 32 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Fuel cap Fuel tank Grommet Fuel tank base Lock nut Philips pan head screw Hose clamp Fuel hose Fuel hose clip Wing nut Flat washer Battery clamp Engine 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.
Fuel Tank Removal (Fig. 32) 1 1. Park machine on a level surface, lower attachment, stop the engine, engage parking brake, and remove the key from the ignition switch. 2 2. Pivot seat up. Remove litter box (26) from the frame. 3. Disconnect and remove battery from the machine to prevent possible spillage of fuel on the battery (see Battery Service in Chapter 5 – Electrical Systems). DANGER Figure 33 1. Cap screw & lock washer Fuel Tank installation (Fig. 32) 1. If the fuel tank base (4) was removed, A.
Fuel Tank (SP 5020) 3 4 7 8 9 6 8 10 2 5 1 6 18 16 15 11 17 13 12 11 14 8 7 5 Figure 34 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Fuel tank Fuel cap Steering boot Boot retainer R–clamp Self tapping screw 13. 14. 15. 16. 17. 18. Fuel hose Hose clamp Fuel filter Fuel hose Hose clamp R–clamp Fuel hose Fuel shutoff valve Whiz cap screw Cap screw Flat washer Grommet Fuel Tank Removal (Fig. 34) 2 1.
3. Remove adjustment lever from tilt lock pin by first removing cap screw (Fig. 36). 4. Drain fuel tank as follows: A. Close fuel shutoff valve. 3 B. Remove self tapping screw securing the fuel hose and R–clamp to the frame. C. Disconnect fuel hose leading from the fuel tank at the fuel shutoff valve. Use funnel and hose to drain the fuel into a suitable container for storage. 4 1 5. Remove four cap screws and flat washers securing the fuel tank to the frame. 2 6.
Engine (SP 2020/3020) 23 35 24 9 19 25 22 24 23 34 17 33 36 20 37 32 38 12 14 18 4 1 31 5 30 21 7 40 29 3 8 39 12 16 44 5 2 2 3 6 26 10 41 28 45 3 15 5 5 43 3 27 13 42 2 11 Figure 37 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Muffler Cap screw Flat washer Muffler clamp Hex nut Screen Muffler bracket Fuel hose Pop rivet Flat washer Lock washer Fuel hose Cap screw R–clamp Engine base Engine 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.
Engine Removal (Fig. 37) 6 3 8 1. Park machine on a level surface, lower attachment, stop engine, engage parking brake, and remove key from the ignition switch. 7 2. Pivot seat up. Remove engine cover. Remove move litter box from fuel tank base. 3. Disconnect and remove battery from the machine to prevent the possibility of the engine dropping on it (see Battery Service in Chapter 5 – Electrical Systems).
Engine Installation (Fig. 37) 2 1 CAUTION 3 One person should operate the chain fall or hoist while the other person guides the engine into the frame. 1. Install engine (16) to the engine base (15). A. Attach a hoist or chain fall to the engine. Figure 41 IMPORTANT: Make sure not to damage the engine, fuel and hydraulic lines, electrical harness, or other parts while installing the engine. 1. Cap screw & lock washer 2. Pump mount 3. Engine block 10. Connect harness as follows (Fig. 38): B.
Replace Spark Plugs Replace spark plugs after every 800 operating hours or yearly, which ever occurs first. Recommended air gap is 0.030 inch (0.762 mm). Use a Champion RC 12YC spark plug or equivalent. 0.030 inch 0.762 mm NOTE: A spark plug usually lasts a long time. However, remove. Check spark plugs whenever the engine malfunctions. IMPORTANT: A cracked, fouled, dirty, or otherwise malfunctioning spark plug must be replaced.
Engine (SP 5020) 1 2 3 52 7 4 8 9 10 11 51 6 49 12 48 13 6 47 40 17 46 15 18 14 16 54 19 43 20 45 26 21 44 22 53 28 20 30 24 27 29 25 23 31 32 38 33 55 36 35 37 30 34 Figure 43 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.
Engine Removal (Fig. 43) 1 1. Park machine on a level surface, lower attachment, stop engine, engage, and remove key from the ignition switch. 3 2. Chock wheels to prevent the machine from moving. The brake assembly will be partially disassembled. 4 CAUTION 2 The muffler and exhaust pipe may be hot. To avoid possible burns, allow engine and exhaust system to cool before working near muffler. Figure 44 1. Cotter pin & flat washer 2. Seat rod 3. Lock nut 4. Cap screw & flat washer 3.
10. Disconnect red positive cable cable (solenoid) from the starter (Fig. 47). 11. Remove lock nut and cap screw securing black ground wire and black battery cable (negative) to the engine block. Pull cable and harness clear of the engine (Fig. 47). 1 2 12. Remove remaining three lock nuts and cap screws securing the engine to its base. 5 4 CAUTION 3 Figure 47 Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 – Safety. 1. Positive cable (solenoid) 2. Starter 3.
3. Tighten both set screws on the engine hub to secure hub to the engine shaft (Fig. 46). 6. Install seat base with seat attached to the frame as follows (Fig. 44): 4. Connect throttle control cable to the swivel and choke control cable to the choke lever (see Throttle and Choke Control Installation). A. Position base on machine. Secure base to frame with both spacers, cap screws, flat washers, and lock nuts. 5. Connect wire harness as follows (Fig. 45): B.
Clean Cylinder Head Fins Avoid overheating and possible damage to the engine. Keep cooling fins on cylinder heads clean. 1 1. Park machine on a level surface, lower attachment, stop engine, engage parking brake, and remove key from the ignition switch. 3 2. Gain access to the engine. NOTE: The engines on the SP 2020/3020 and SP 5020 are constructed the same. The SP 2020/3020 engine is shown. 2 Figure 49 3. Remove muffler shield and both air guide covers to gain access to both cylinder heads. 1.
Chapter 4 Hydraulic Systems Table of Contents Sand Pro 2020/3020/5020 Hydrostat (SP 5020) . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flush Hydraulic System . . . . . . . . . . . . . . . . . . . . . . Hydrostat Service . . . . . . . . . . . . . . . . . . . . . . . . . . . Charge Pump Disassembly, Inspection, and Assembly . . . . . . . . . . . . . . .
Specifications Item Description Hydrostatic Transmission Pump Displacement Pump Flow Rate (@ 3150 RPM) Maximum Continuous Rated Speed Maximum Intermittent Rated Speed Maximum Operating Pressure Maximum Intermittent Pressure Charge Pump Displacement Charge Pump Flow Rate (@ 3150 RPM) Charge Relief Setting Maximum Inlet Vacuum Maximum Continuous Case Pressure Maximum (Cold Start) Case Pressure Implement Relief Setting Variable displacement piston pump 0.913 in3/rev (15.0 cm3/rev) 12.5 GPM (47.
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 straight with one and tighten the hose swivel nut onto the fitting with the other. WARNING Before disconnecting or performing any work on hydraulic system, relieve all pressure in system. Stop engine; lower or support box and/or other attachment(s).
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 Traction Unit In case of emergency, the Sand Pro can be towed for a short distance. However, Toro does not recommend this as a standard procedure. IMPORTANT: Do not tow the machine faster than 2 to 3 mph because drive system may be damaged. If machine must be moved a considerable distance, transport it on a truck or trailer. Tires may lock up if machine is towed too fast. If lock up occurs, stop towing the machine.
Hydraulic System OIL COOLER P1 TRACTION PUMP HYDROSTAT TANK P2 CHARGE PUMP FILTER CHARGE CHECK VALVE CHARGE CHECK VALVE CHARGE RELIEF LIFT VALVE ACCELERATION VALVES B * Page 4 – 6 Rev. B LIFT CYLINDER OPTIONAL ORIFICE R2 R1 IMPLEMENT RELIEF A M2 SP 3020 ONLY M3 FRONT RIGHT M1 RH WHEEL MOTOR WITH BLEED OFF FOR OIL COOLING IN FORWARD B 0.915 0.33 7.8 7.8 5.0 – – 15 5.41 127.84 127.84 81.97 – – 12.48 4.5 – – – – – – – – – – 48.3 6.
Sand Pro 2020/3020/5020 Page 4 – 7 OIL COOLER P1 TRACTION PUMP HYDROSTAT TANK P2 CHARGE PUMP FILTER CHARGE CHECK VALVE CHARGE CHECK VALVE R2 R1 M3 FRONT AND RH WHEEL MOTORS HAVE REVERSE TIMED MANIFOLDS RIGHT M1 RH WHEEL MOTOR WITH BLEED OFF FOR OIL COOLING IN FORWARD A B HOT OIL SHUTTLE VALVE FLOW RATE CALCULATED AT 3150 RPM – – – – – 17 – 47.2 Sand Pro 5020 Hydraulic Schematic 6.2 – 90 700 – – R2 R1 – 48.3 17.1 – M3 – 280.22 – 8.6 M2 – 4.5 – – – – – 140.93 8.
Hydraulic Flow Diagrams Traction Forward 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 right wheel motor (M1). These losses are replenished by the charge pump (P2), which is integral to the hydrostat. The engine drives traction pump (P1) directly through a coupling.
Sand Pro 2020/3020/5020 Page 4 – 9 Hydraulic System (Rev.
Traction Reverse The traction circuit operates essentially the same in reverse as it does in forward. However, there are a few differences in operation. When the traction pedal is pressed to the reverse position, the linkage from the pedal positions the swash plate in the traction pump so oil flows out of port A. Oil flow out of port A goes to the wheel motors and turns them in the reverse direction.
Sand Pro 2020/3020/5020 Page 4 – 11 Hydraulic System (Rev.
Retract and Extend Lift Cylinder The hydraulic lift circuits for the SP 2020/3020 and SP 5020 function identically. Each machine has identical charge pumps, lift valves, and lift cylinders. These components are the heart of the lift circuit. In addition to replenishing the closed loop circuit with fluid from the tank, charge pump (P2) flow in excess of replenishment requirements is relieved through the charge relief valve (R2). Fluid returns through the lift valve and back to the tank.
Sand Pro 2020/3020/5020 Page 4 – 13 Hydraulic System (Rev.
Special Tools Order these tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). Some tools may also be available from a local supplier. Hydraulic Pressure Test Kit – TOR47009 Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings. Contains one each: 1000 PSI (70 Bar), 5000 PSI (350 Bar) and 10000 PSI (700 Bar) gauges.
Hydraulic Test Fitting Kit – TOR4079 This kit includes a variety of O–ring Face seal fittings to enable you to connect test gauges into the system. TORO TEST FITTING KIT (NO. TOR4079) The kit includes: tee’s, unions, reducers, plugs, caps, and male test fittings. Figure 10 Hydraulic Test Fittings On the SP 2020/3020, there is tight clearance between the charge pressure test port on the hydrostat and the engine base plate.
Troubleshooting The table 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 test procedures.
Troubleshooting (cont.) Problem Possible Cause System operates in a jerky manner when starting. External control linkage is misadjusted, disconnected, binding, or damaged. Charge valve in hydrostat is defective. Acceleration valves in hydrostat are defective. No traction exists in either direction, or loss of power. Brake is not released. Hydraulic oil is very cold. Oil level in tank is low. External control linkage is misadjusted, disconnected, binding, or damaged.
Troubleshooting (cont.) ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Problem Possible Cause Attachment raises, but will not stay up. Lift cylinders leak internally. Neutral position check valves in lift valve leak.
Testing Before Performing Hydraulic Tests IMPORTANT: All obvious areas such as oil supply, filter, binding linkages, loose fasteners, or improper adjustments must be checked before assuming that a hydraulic component is the source of the problem. Precautions for Hydraulic Testing CAUTION Failure to use gauges with recommended pressure (psi) rating as listed in test procedures could result in damage to the gauge and possible personal injury from leaking hot oil.
TEST NO. 1: Traction Pump Flow (P1) HYDROSTAT FROM WHEEL MOTORS A CHARGE CHECK VALVE IMPLEMENT RELIEF R1 CHARGE PUMP TRACTION PUMP P1 P2 ACCELERATION VALVES R2 CHARGE CHECK VALVE CHARGE RELIEF TO WHEEL MOTORS B FORWARD FROM SHUTTLE VALVE FILTER FROM OIL COOLER TO LIFT VALVE TANK 1 3 2 Figure 12 1. Hydrostat (SP 2020/3020) Hydraulic System (Rev. A) 2. Forward header (SP 2020/3020) Page 4 – 20 3.
5. Operate engine at full speed (3150 + 50 RPM). 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. 2. Make sure machine is parked on a level surface with attachments removed. Make sure engine is off. 3. Read Precautions for Hydraulic Testing. 4. Make sure that traction pedal is adjusted to the neutral and forward positions (see Adjust Traction Pedal for Neutral and Forward).
TEST NO. 2: Charge Relief Valve (R2) and Implement Relief Valve (R1) Pressure HYDROSTAT FROM WHEEL MOTORS A CHARGE CHECK VALVE IMPLEMENT RELIEF R1 CHARGE PUMP TRACTION PUMP P1 P2 ACCELERATION VALVES R2 CHARGE CHECK VALVE CHARGE RELIEF TO WHEEL MOTORS B FORWARD FILTER FROM OIL COOLER FROM SHUTTLE VALVE PRESSURE GAUGE TO LIFT VALVE TANK 1 3 2 Figure 13 1. Charge test port (SP 2020/3020) Hydraulic System (Rev. A) 2. Engine base plate (SP 2020/3020) Page 4 – 22 3.
Procedure for Charge Relief Valve (R2) and Implement Relief Valve (R1) Pressure: 5. Make sure that traction pedal and lift control lever are in neutral and the parking brake is engaged. 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. 6. After installing pressure gauge, start engine and run at low idle speed. Check for hydraulic leakage and correct before proceeding with test. 2.
TEST NO. 3: Charge Pump (P2) Flow HYDROSTAT A CHARGE CHECK VALVE FROM WHEEL MOTORS IMPLEMENT RELIEF R1 CHARGE PUMP TRACTION PUMP P1 P2 ACCELERATION VALVES R2 CHARGE CHECK VALVE CHARGE RELIEF B FORWARD FROM OIL COOLER TO WHEEL MOTORS FILTER FROM SHUTTLE VALVE TANK TO LIFT VALVE 1 3 4 2 Figure 14 1. 2. Lift valve (SP 2020/3020) Hose from pump (SP 2020/3020) Hydraulic System (Rev. A) 3. Lift valve (SP 5020) Page 4 – 24 4.
Procedure for Charge Pump (P2) Flow: 8. Operate engine at full speed (3150 + 50 RPM). 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. 9. Slowly close the flow control valve on the tester until 500 PSI is obtained. 2. Make sure machine is parked on a level surface with the attachments lowered. Make sure engine is off and the parking brake is engaged. 10. Verify pump speed is 3150 + 50 RPM with a phototac. 11.
TEST NO. 4: Wheel Motor Efficiency HYDROSTAT HOT OIL SHUTTLE VALVE A CHARGE PUMP TRACTION PUMP P1 IMPLEMENT RELIEF CHARGE CHECK VALVE B R1 LEFT M2 RIGHT M1 P2 A R2 CHARGE CHECK VALVE CHARGE RELIEF ACCELERATION VALVES B FORWARD FRONT M3 FILTER FROM OIL COOLER TO LIFT VALVE TANK 1 3 2 Figure 15 1. Hydrostat (SP 2020/3020) Hydraulic System (Rev. A) 2. Forward header (SP 2020/3020) Page 4 – 26 3.
Procedure for Wheel Motor Efficiency: 10. Slowly push traction pedal in the forward direction until 1000 PSI is displayed on the tester pressure gauge. 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 11. With all drive wheels locked (not rotating), total internal leakage for all wheel motors will be shown on the flow meter. Flow should be less than 2 GPM (7.6 LPM). Record test results. 12.
Adjustments Adjust Traction Pedal for Neutral If the machine “creeps” when the traction pedal is in the neutral position, the traction cam must be adjusted. 5. Start engine. Rotate adjustment cam in both directions to determine mid position of neutral span. 1. Park the machine on a level surface. Turn the engine off. 6. Tighten lock nut securing the adjustment cam. 7. Stop engine. 2. On the SP 2020/3020, pivot seat upward and remove engine shield.
Adjust Traction Pedal for Forward (SP 5020) If the jam nuts on the control rod are loosened or if the pedal is removed, adjusted traction pedal for forward. 1. Park machine on a level surface and turn engine off. 2 2. Make sure pump is in neutral. 3. Loosen jam nuts on the control rod. 4. Press down on the forward pad of the pedal until the pedal rod contacts the footrest. Tighten jam nuts. 1 Figure 18 Jam nuts 2. Control rod Hydraulic Systems 1.
Adjust Lift Lever (SP 2020/3020) The lift lever should be adjusted if the attachment does not float (follow ground contour) properly during operation. 1. Park machine on a level surface. Turn engine off and engage parking brake. 2. Disconnect attachment from lift cylinder. Extend cylinder part way. 3 3. Loosen capscrews and locknuts securing the lever guide to the valve shroud. 2 4. Move lever guide until the cylinder moves freely when the lift lever is in the detent position. 5.
Service and Repairs Check Hydraulic Lines and Hoses WARNING Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not hands, to search for leaks. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury. If fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type of injury. Gangrene may result from such an injury.
13. After the hydraulic system starts to show signs of fill, actuate lift control lever until the lift cylinder rod moves in and out several times. If the cylinder rod does not move after 10 to 15 seconds, or the pump emits abnormal sounds, shut the engine off immediately and determine cause or problem. Inspect for the following: 17. On the SP 2020/3020, install engine shield and pivot seat down. On the SP 5020, secure panel to right side of machine with cap screws. 18.
Change Hydraulic System Fluid and Filter The hydraulic system filter must be changed initially after the first 8 hours of operation. Thereafter, it must be changed every 400 hours of operation or yearly, whichever comes first. Use a genuine Toro oil filter for replacement. The hydraulic oil must be changed every 400 hours of operation or yearly, whichever comes first. 2 1. Park machine on a level surface and turn the engine off. 1 2. On the SP 2020/3020, pivot seat up.
Lift Valve (SP 2020/3020) 5 21 28 19 7 37 6 24 17 3 27 2 8 25 4 1 26 22 18 10 9 31 23 29 36 30 20 11 34 31 35 33 12 32 38 14 13 15 16 Figure 25 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Control panel decal Lift valve shroud Cap screw 90o hydraulic fitting Knob Lift lever Cap screw Offset link Pivot bracket Lock nut Lock nut Swivel run T–fitting 45o hydraulic fitting Hydraulic System (Rev. A) 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.
Removal (Fig. 25) Installation (Fig. 25) 1. Before removing any parts from the hydraulic system, park machine on a level surface, engage parking brake, lower attachment, and stop engine. 1. Make sure lift valve, hydraulic hoses, fittings, and tubes are cleaned thoroughly. 2. Reinstall O–rings (31) and hydraulic fittings (4 and 13) to the lift valve. Observe match marks when tightening. Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil.
Lift Valve (SP 5020) 5 21 22 20 2 27 12 3 24 7 8 29 26 11 31 32 4 6 25 14 27 28 10 26 9 29 33 28 23 26 34 14 35 1 23 40 14 41 36 16 30 18 15 30 19 17 38 13 30 30 37 39 30 18 30 15 Figure 26 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
Removal (Fig. 26) Installation (Fig. 26) 1. Before removing any parts from the hydraulic system, park machine on a level surface, engage parking brake, lower attachment, and stop engine. 1. Make sure lift valve, hydraulic hoses, fittings, and tubes are cleaned thoroughly. 2. Reinstall O–rings (27 and 28) and hydraulic fittings (2, 8, 9, and 10) to the lift valve. Observe match marks when tightening.
Lift Valve 15 12 14 13 11 10 7 9 8 1 2 3 5 9 7 2 3 4 5 6 1 9 10 11 12 13 14 15 4 6 9 8 Figure 27 1. 2. 3. 4. 5. Plug O–ring Spring Ball Check valve seat 6. 7. 8. 9. 10. Cam pin Body Spool O–ring Spring retainer 11. 12. 13. 14. 15. Spring Spring retainer Spacer float Spool retaining ring Retaining ring 2. Inspect check valve seat for wear and damage of sealing surface. Replace if necessary. Disassembly 1. Wash valve in solvent and dry thoroughly. 2.
Lift Cylinder (SP 2020/3020) Removal 6 1. Before removing any parts from the hydraulic system, park the machine on a level surface, engage the parking brake, lower attachment, and stop the engine. 5 6 1 6 2 4 7 CAUTION 3 1 Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. Controls must be operated with the ignition switch in OFF. Remove key from the ignition switch. 4 6 2. Label all hydraulic connections for reassembly. 8 3.
Lift Cylinder(SP 5020) Removal 1 18 1. Before removing any parts from the hydraulic system, park the machine on a level surface, engage the parking brake, lower the cutting units, and stop the engine. 2 3 4 17 11 12 13 15 14 13 16 9 CAUTION 10 Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. Controls must be operated with the ignition switch in OFF. Remove key from the ignition switch. 5 2.
Lift Cylinder Service ÉÉ 1 3 7 4 14 13 ÉÉ ÉÉ 8 5 9 2 6 10 11 14 2 7 12 15 11 3 5 6 4 10 8 13 15 9 12 11. 12. 13. 14. 15. Dust seal Retaining ring Shaft (w/clevis) Pivot end Clevis O–ring Barrel Nut Uni–ring Piston 6. 7. 8. 9. 10. O–ring Poly–pack O–ring Back–up ring Head Disassembly Reassembly 1. Remove oil from the hydraulic cylinder into a drain pan by slowly pumping the cylinder shaft. Plug both ports and clean the outside of the cylinder. 1.
Hydrostat (SP 2020/3020) 5 34 33 RIGHT 6 7 4 3 15 2 29 9 FRONT 29 26 27 24 28 8 30 20 19 18 32 23 17 21 3 16 16 22 10 31 11 15 25 12 17 13 18 19 14 20 Figure 31 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Not used Shaft cover Lock washer Hydraulic hose Hydraulic hose Cap screw Wire standoff Suction hose Hydrostat Push on hose fitting Hydraulic hose 90o hydraulic fitting 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.
7. Remove three cap screws securing the pump plate to the hydrostat while pulling the pump plate from the hydrostat (Fig. 32). 8. Clean all hydraulic fittings and hydraulic hoses attached to the hydrostat. Label all hydraulic connections for reassembly. 9. Place a suitable container under hydrostat to collect hydraulic oil. 10. Clamp suction hose (8) to prevent draining the hydraulic tank. 11. Remove hydraulic hoses (11 and 14) from 90o hydraulic fittings (13 and 12).
Hydrostat (SP 5020) 15 35 3 31 34 7 2 6 RIGHT FRONT 14 2 1 12 5 2 7 6 7 20 8 15 36 2 13 16 12 11 13 17 14 13 15 18 10 11 13 9 12 12 19 15 11 9 21 33 27 22 23 24 32 22 31 23 24 28 29 30 25 Figure 33 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Hydraulic hose (to front motor) O–ring Hydraulic tube Not used Hydraulic tube 90o hydraulic fitting O–ring Hydrostat Woodruff key Lock nut Set screw Hex nut 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
5. Disconnect air hose from the air cleaner. Remove lower shroud from the cooler mount to prevent damage to the fan when removing the hydrostat. 1 6. Disconnect control rod from pump lever and wires from the neutral switch (Fig. 36). 3 4 7. Loosen both set screws (11) on the pump hub (19) enough to allow the hydrostat shaft to be released. 2 8. Clamp hydraulic hose (35) and hydraulic hose (25) to prevent draining of the tank. Disconnect all six hydraulic hoses from fittings on the hydrostat.
3. Reinstall O–rings and hydraulic fittings to the hydrostat. Observe match marks when tightening. 4. Install woodruff key (9) and fan hub (27) with cooling fan (28) to the hydrostat shaft. Secure hub to shaft with both set screws. 14. Install left fender and seat (see Left Fender (Seat Base) Installation in Chapter 6 – Wheels, Brakes, and Miscellaneous). Install left and right side panels to the machine. Lower seat. 15. Charge hydraulic system (see Charge Hydraulic System). 5.
Flush Hydraulic System IMPORTANT: Flush hydraulic system any time there is a severe component failure or the system is contaminated (oil appears milky or black or contains metal particles). IMPORTANT: Flush hydraulic system when changIng from petroleum base hydraulic fluid. Operate machine under normal operating conditions for at least four (4) hours before draining. 1. Park machine on a level surface. Lower attachments, stop engine, and engage parking. 11. Connect both spark plug leads to spark plugs. 12.
Hydrostat Service 1 2 3 4 5 6 7 8 9 10 11 HYDROSTAT IS ILLUSTRATED FROM BELOW 57 43 44 55 12 54 15 52 13 16 14 17 18 28 53 26 51 25 22 24 9 10 23 50 11 27 10 19 30 20 49 29 21 48 2 47 24 31 46 32 45 33 44 27 35 34 25 26 56 34 43 28 33 41 32 29 40 39 38 37 36 42 2 Figure 40 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.
Charge Pump Disassembly 1. Make sure hydrostat is cleaned thoroughly before disassembly to prevent contamination. 2 2. Match mark charge pump housing and variable housing for reassembly. 7 3 3. Clean shaft to remove all sharp edges, burrs, dirt, and abrasive residue that could damage the lip seal. 5 4. Remove both cap screws securing the pump housing to the variable housing. 6 5. Slide charge pump housing with needle bearing and lip seal carefully off the shaft. Slide gerotor assembly off the shaft.
Shaft Seal Removal NOTE: The hydrostat uses lip seals on the main, control, and trunnion shafts. Replacement of these seals requires no disassembly. 1. When replacing trunnion shaft seals, remove retaining ring and washer from the housing and shaft. 2. Pry lip seal carefully off the shaft. Make sure not to distort the housing or damage the bore or shaft. Discard seal. 3 1 Shaft Seal Installation 2 1. Polish exposed surface of the shaft.
Acceleration Valve Removal (Fig. 43) Charge Check Valve Inspection (Fig. 44) 1. Remove plugs and O–rings from both sides of the end cap. 1. Inspect ball and spring for nicks, cracks, and distortion. Replace parts as necessary. 2. Slide acceleration valve and spring out of one side of the end cap. Slide other valve out the other side. 2. Inspect valve seat in the end cap for damage and foreign material. Remove any foreign material. Acceleration Valve Inspection (Fig.
Traction Pump Disassembly 1. Remove charge pump from variable housing (see Charge Pump Disassembly). 7 6 2. Remove lip seals from shaft and trunnion shafts (see Shaft Seal Removal). 5 1 IMPORTANT: All exposed surfaces are critical. Use caution to avoid damage to exposed surfaces. 2 3 3. Remove four cap screws and washers from the end cap. Loosen cap screws evenly to prevent distortion of parts (Fig. 45). A.
5. Inspect variable housing (Fig. 47). Traction Pump Inspection A. Bearing needles must remain in the cage, roll freely, and not be bent or damaged. Remove and replace bearings as necessary 1. Inspect end cap (Fig. 45). A. Bearing needles must remain in the cage, roll freely, and not be bent or damaged. Remove and replace bearings as necessary. B. Needle bearings should be flush to 1/64 inch (0.40 mm) below the counter bore for the lip seals. B. Journal bearing must be free of damage. C.
Traction Pump Assembly 11 1. Make sure all parts are cleaned thoroughly and free of dirt and debris. 2. Secure ball bearing onto shaft with retaining ring. Press assembly into variable housing. Snap retaining ring into housing to secure bearing and shaft (Fig. 49). 8 5 6 7 1 10 IMPORTANT: Make sure not to damage the face surface on the cavity side of the variable housing. 3. Position variable housing so the large cavity is up. Press needle bearings into each side of the variable housing.
NOTE: When properly installed, a light spring compression can be felt when pushing the cylinder block assembly into the variable housing. 7 9. Position variable housing in a horizontal position. Slide cylinder block assembly over the shaft engaging splines. Make sure pistons and thrust plate remain in place (Fig. 51). 6 5 1 10. Press needle bearing into the end cap. Bearing must protrude 3/32 to 1/8 inch (2.38 to 3.18mm) from face (Fig. 51). 2 3 8 9 11.
Front Wheel Motor 8 9 6 7 11 12 17 15 5 13 16 10 200 to 400 ft–lb 27.7 to 55.3 kg–m 21 20 18 22 14 RIGHT 45 to 55 ft–lb 6.2 to 7.6 kg–m 19 1 FRONT 4 3 2 Figure 53 1. 2. 3. 4. 5. 6. 7. 8. Hydraulic motor 45o hydraulic fitting Hydraulic hose O–ring Set screw Locking collar Cap screw Lock nut 9. 10. 11. 12. 13. 14. 15. Relube flangette Flangette Bearing tab Front wheel fork Socket head screw Lock nut Front wheel 16. 17. 18. 19. 20. 21. 22.
8. Remove both socket head screws and lock nuts securing the hydraulic motor the fork. 3. Secure lug nuts to drive studs. Torque nuts from 45 to 55 ft–lb (6.2 to 7.6 kg–m). 4. Slide flangette and bearing assembly onto the spindle shaft so the locking collar faces the wheel. Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 – Safety. IMPORTANT: Support wheel and motor when jacking up the front fork to prevent dropping and damaging the motor. 5.
Rear Wheel Motors (SP 2020/3020) 29 20 15 32 19 9 RIGHT 22 FRONT 31 28 12 23 25 26 40 to 50 ft–lb 5.5 to 6.9 kg–m 6 30 8 33 10 4 29 3 31 15 32 18 13 11 14 9 21 26 27 2 17 5 16 1 250 to 400 ft–lb 34.6 to 55.3 kg–m 7 Figure 54 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Lug nut Drive stud Wheel Wheel hub Lock nut Left wheel motor Right wheel motor Brake drum Woodruff key Cotter pin Clevis pin Hydraulic System (Rev. A) 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
1. Before removing any parts from the hydraulic system, park the machine on a level surface, lower attachment, and stop the engine. CAUTION Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. Controls must be operated with the ignition switch in OFF. Remove key from the ignition switch. WARNING Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 – Safety. 10. Remove hydraulic fittings and O–rings from the wheel motor.
Rear Wheel Motors (SP 5020) 1 11 12 2 44 9 3 10 6 8 41 39 5 42 36 4 14 43 250 to 400 ft–lb 34.6 to 55.3 kg–m 13 45 30 23 31 40 to 50 ft–lb 5.5 to 6.9 kg–m 32 35 34 16 15 2 1 11 22 37 38 18 21 20 29 40 33 32 17 RIGHT FRONT 19 Figure 57 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
Removal (Fig. 57 or 58) 1. Before removing any parts from the hydraulic system, park the machine on a level surface, lower attachment, and stop the engine. CAUTION 10. Remove hydraulic fittings and O–rings from the wheel motor. Put caps or plugs on disconnected tubes and motor ports to prevent contamination from entering. 11. Remove hex cap screws, spacers, and lock washers securing the brake bracket and wheel motor to the frame. Remove motor from the frame. Installation (Fig.
Wheel Motor Service 12 13 11 10 3 1 4 5 6 7 8 8 9 14 2 15 16 5 17 5 24 5 5 23 22 26 27 21 20 19 28 18 29 30 28 27 25 26 Figure 60 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Dirt & water seal Bearing Housing Back–up washer Seal ring Back–up washer Inner seal Thrust washer Thrust bearing Bearing Hydraulic System (Rev. A) 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Coupling shaft Thrust bearing Drive link Cap screw Commutator seal Commutator Woodruff key Wear plate Rotor Vane Page 4 – 62 21. 22.
Disassembly (Fig. 60) WARNING If the wheel motor is not held firmly in the vise, it could dislodge during service and cause injury. 8. Remove rotor set and wearplate (18) together, and retain the rotor set in its assembled form with the same vane (20) to stator (21) contact surfaces. The drive link (13) may come away from the coupling shaft (11) with the rotor set and wearplate. You may have to shift the rotor set on the wearplate to work the drive link out of the rotor (19) and wearplate (Fig. 63). 1.
9. Remove seal ring (5) that is between the rotor set and wearplate (18). 3. Inspect commutator ring (23) for cracks and burrs. Replace commutator ring as necessary. 10. Remove drive link (13) from the coupling shaft (11) if it was not removed with rotor set and wear plate (18). Remove seal ring (5) from housing (3). 4. Inspect commutator (16) for cracks, burrs, wear, scoring, chipping, and peening. If any of these conditions exist, replace commutator and commutator ring (23) as a matched set. 11.
6. Inspect manifold (22) for cracks, surface scoring, peening, chipping. Replace manifold if any of these conditions exist. A polished pattern on the ground surface from commutator or rotor rotation is normal. NOTE: The rotor set consists of the rotor (19), vanes (20), and stator (21). Rotor set components may become disassembled during service procedures. 7. Inspect rotor set in its assembled form for nicks, scoring, and chipping on any surface. Inspect for broken and worn splines.
14. If the housing (3) has passed inspection to this point, inspect outer bearing (2), inner bearing (10), thrust washers (8), and thrust bearing (9). Bearing rollers must be firmly retained in the bearing cages but must rotate and orbit freely. All rollers and thrust washers must be free of peening and corrosion. If any bearing or thrust washer does not pass inspection, replace the housing (3) as a complete assembly (Fig. 71). Assembly (Fig. 60) 1.
6. Apply masking tape around splines or keyway on coupling shaft (11) to prevent damage to seal. IMPORTANT: The outer bearing (2) is not lubricated by the system’s hydraulic fluid. Make sure it is thoroughly packed with Mobil Mobilith SHC R 460 grease. NOTE: Coupling shaft (11) should be approximately 0.10 inch (2.54 mm) below the housing wear plate surface to allow the assembly of the thrust bearing (12). The coupling shaft must rotate smoothly on the thrust bearing (9) and thrust washer (8) (Fig. 76).
NOTE: The rotor set consists of the rotor (19), vanes (20), and stator (21). Rotor set components may become disassembled during service procedures. Do not service separately. NOTE: It may be necessary to turn one alignment stud out of the housing (3) temporarily to assemble rotor set over the drive link (13). NOTE: The rotor set rotor counterbore side must be down against wear plate for drive link clearance and to maintain the original rotor–drive link spline contact.
E. Grasp the output end of coupling shaft (11) with locking pliers or other appropriate turning device. Rotate coupling shaft, drive link (13), and rotor (19) to seat the rotor and the assembled vanes (20) into the stator (21). This rotation should create the necessary clearance to assemble the seventh or remaining vanes. Use minimum force when assembling the remaining vanes (Fig. 83). 23. Torque both plugs from 9 to 12 ft–lb (1.2 to 1.7 kg–m). 24. Check motor shaft for rotation.
Hydraulic Tank (SP 2020/3020) 27 26 2 22 1 5 20 28 9 10 4 LATE MODELS 29 19 37 18 6 7 15 21 30 33 17 31 14 25 30 to 60 ft–lb 35 to 69 kg–cm 32 13 16 23 31 34 8 35 11 36 3 24 23 12 Figure 86 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Oil cap Shoulder screw Worm clamp Hydraulic tank 45o hydraulic fitting Cap screw Lock washer Filter head Flat washer Cap screw 90o hydraulic fitting Oil fitting Hydraulic fitting 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.
Removal (Fig. 86) Installation (Fig. 86) 1. Before removing any parts from the hydraulic system, park machine on a level surface, set brake, lower attachment, and stop engine. NOTE: Apply antiseize lubricant or to the threads of cap screws prior to installation. 1. If the hydraulic tank (4 or 29) was separated from the tank base (18), secure the base to the tank with three cap screws (17), flat washers (21), and grommets (19). Torque cap screws from 30 to 60 in–lb (35 to 69 kg–cm).
Hydraulic Oil Cooler (SP 2020/3020) 35 7 8 33 34 32 31 30 3 14 17 27 21 4 6 5 24 1 16 22 12 23 29 25 5 41 10 15 10 2 12 28 43 37 42 40 39 44 15 26 45 38 30 11 36 13 20 18 9 20 19 12 Figure 87 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Hood Oil cooler Rubber clamp T–nut 90o hydraulic fitting Valve to cooler tube Operating decal Cover Flat head screw Flat washer Cap screw Lock nut Floor tread Flat head screw Cap screw Hydraulic System (Rev. A) 16. 17. 18. 19. 20.
Removal (Fig. 87) Cleaning and Inspection (Fig. 87) 1. Before removing any parts from the hydraulic system, park machine on a level surface, set brake, lower attachment, and stop engine. 1. Back flush oil cooler with cleaning solvent (bottom opening to top opening). After cooler is clean, make sure all solvent is drained from the cooler. CAUTION CAUTION 2. Pivot seat up. Remove cover (8) from the midsection of the machine. 3. Disconnect air hose attached to the air cleaner on the engine. 4.
Hydraulic Tank and Oil Cooler (SP 5020) 1 2 3 41 4 5 6 10 12 7 14 11 40 8 9 5 7 39 19 23 29 37 35 21 15 8 16 22 7 20 36 5 34 8 13 38 18 11 42 17 23 24 30 to 60 ft–lb 35 to 69 kg–cm 25 26 27 33 30 14 32 29 28 31 Figure 88 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28.
3. Plug both ends of oil cooler. Clean exterior of cooler. Make sure fins are clear of dirt and debris. CAUTION One person should operate the chain fall or jack while the other person guides the engine and hydrostat from the frame. 4. The oil cooler should be free of corrosion, cracked tubes, and excessive pitting of tubes. 2 IMPORTANT: When moving the engine and hydrostat from the frame, make sure not the damage the cooling fan, wires, hoses, and cables. 6.
Oil Cooler Installation (Fig. 88) 1. Make sure both hydraulic openings to the oil cooler are clean. Remove plugs from the cooler openings. 11. Connect air hose to the air cleaner. Remove lower shroud to the cooler mount. Connect control rod to the pump lever (Fig. 89). 2. Reinstall O–rings and 90o hydraulic fittings to the oil cooler. Torque fittings from 36 to 40 ft–lb (5.0 to 5.5 kg–m). 12.
Chapter 5 Electrical Systems Table of Contents 2 2 3 4 5 6 7 7 8 ELECTRICAL SYSTEM QUICK CHECKS . . . . . . . . 9 Battery Test (Open Circuit) . . . . . . . . . . . . . . . . . . . 9 COMPONENT TESTING . . . . . . . . . . . . . . . . . . . . . . 10 Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Starter Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Neutral Switch . . . . . . . . .
Electrical Systems BLACK + – Page 5 – 2 NEUTRAL SWITCH BLACK – GRAY BATTERY + B+L+S START RED A M B S RED STARTER SOLENOID RED BLUE GREEN IGNITION SWITCH RED/WHITE L G BLUE/WHITE OPTIONAL LIGHTS B+L+A RUN WHITE BLACK HOUR METER BLACK BLACK G+M+A TERMINAL CONTINUITY OFF IGNITION SWITCH POSITION SOLENOID DETAIL TO STARTER WHEEL ENGINE RED SP BLUE FUSE (20 AMP) BLACK GRAY TO BATTERY BLUE FL RED GREEN WIRE HARNESS FUEL SOLENOID FUSIBLE LINK SPLICE FL SP
AWG 16 16 16 16 14 14 18 18 16 18 16 18 16 16 TYPE GPT GPT GPT GPT GPT GPT FUSIBLE LINK GPT GPT GPT GPT GPT GPT GPT ROUTE P2–G TO J4 TO J4 TO J8 TO P1–B TO P2–B TO P3–1 TO P2–L TO SP1 TO J3 TO J15 TO P2–M TO P2–S TO J5 TO Sand Pro 2020/3020 J8 J14 J12 J12 J7 P1–A SP1 J3 J16 P4–1 J16 J11 J6 J13 Harness and Wiring Diagram J12 J13 P3 J11 Electrical Systems AB XXX XXX P1 J14 J15 OPTIONAL LIGHTS J2 A W9 W11 W1 G W8 L W12 Sand Pro 2020/3020/5020 Page 5 – 3 IGNITION SWITCH B G S P2 M L J7
Electrical Systems BLACK Page 5 – 4 (+) TO STARTER FRONT OF TRACTOR TO BATTERY GREEN STARTER SOLENOID RED FL GRAY GREEN RED RED/WHITE NEUTRAL SWITCH (CLOSED IN NEUTRAL) FL SP SP FRAME GROUND BLACK SOLENOID DETAIL RED GREY WIRE HARNESS BATTERY (–) STARTER REG. FUEL SOLENOID RED/WHITE REAR OF TRACTOR FRAME GROUND BLACK ENGINE GROUND ALT.
WIRE IDENTIFICATION Sand Pro 5020 SP1 P2–5 SP2 P3–1 J11 J6 P1–A P4–1 J3 J15 J12 J4 J13 J14 P2–4 J7 (B+) START SOLENOID Harness and Wiring Diagram J6 ROUTE J7 TO SP1 TO J2 TO SP2 TO P2–2 TO P2–1 TO P2–3 TO P1–B TO P1–B TO J3 TO J5 TO J8 TO J4 TO J13 TO J8 TO (+) TYPE FUSABLE LINK GPT GPT FUSABLE LINK GPT GPT GPT GPT GPT GPT GPT GPT GPT GPT GPT J5 AWG 18 14 14 18 18 14 14 18 18 18 18 18 18 18 18 (–) COLOR N/A RED RED/WHT N/A BLU GRN ORG WHT/RED WHT/RED WHT/RED GRY BLK BLK BLK BLK SP1 X SP2 HOU
Special Tools Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). Some tools may also be available from a local supplier. Multimeter The meter can test electrical components and circuits for current, resistance, or voltage. NOTE: Toro recommends the use of a DIGITAL Volt– Ohm–Amp multimeter when testing electrical circuits.
Troubleshooting For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and components used on this machine (see Wiring Schematics section of this chapter). CAUTION Remove all jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Disconnect the battery cables unless the test requires battery voltage. 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 start circuitry (see Wiring Schematics) is loose, corroded, or damaged. 10 ampere fuse is missing or open (SP 5020). Ignition switch is faulty. Fuel solenoid is faulty. Spark plugs are faulty. Engine or fuel system is malfunctioning (see Chapter 4 – Briggs & Stratton Vanguard Engine). Engine is out of fuel or may be to cold.
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%) Set multimeter to the DC volts setting. The battery should be at a temperature of 60 to 100_F (16 to 38_C). 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 doing a continuity check). NOTE: For more component testing information, see the Briggs and Stratton Vanguard Service and Repair Manual for 4–Cycle, V–Twin Cylinder, OHV Engines.
Hour Meter IMPORTANT: Make sure to observe polarity on the meter label when testing. Damage to the meter may result from an improper connection. 1. Connect the positive (+) terminal of a 12 VDC source to the positive terminal of the hour meter. 2. Connect the negative (–) terminal of the voltage source to the other terminal of the hour meter. 3. The hour meter should move a 1/10 of an hour in six minutes. SP 2020/3020 4. Disconnect the voltage source from the hour meter.
Starter Solenoid NOTE: Prior to taking small resistance readings with a digital multimeter, short the test leads together. The meter will display a small resistance value (usually 0.5 ohms or less). This resistance is due to the internal resistance of the meter and test leads. Subtract this value from from the measured value of the component you are testing. SOLENOID COIL POSTS TOP VIEW SIDE VIEW MAIN CONTACT POSTS 1. Make sure engine is off. Disconnect solenoid electrical connections. 2.
Service and Repairs NOTE: For more component repair information, see the Briggs and Stratton Vanguard Service and Repair Manual for 4–Cycle, V–Twin Cylinder, OHV Engines. Battery Storage 3. Leave cables disconnected if the battery is stored on the machine. If the machine will be stored for more than 30 days 1. Remove the battery and charge it fully (see Battery Service). 4. Store battery in a cool atmosphere to avoid quick deterioration of the battery charge. 2.
Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be extend. Additionally, battery and electrical component failure can be prevented. CAUTION 1 2 3 5 When working with batteries, use extreme caution to avoid slashing or spilling electrolyte. Electrolyte can destroy clothing and burn skin or eyes. Always wear safety goggles and a face shield when working with batteries.
Inspection, Maintenance, and Testing (Fig. 12) 1. Perform following inspections and maintenance: A. Check for cracks caused by overly tight hold– down clamp. Replace battery if cracked and leaking. MAX. FILL DO NOT OVERFILL B. Check battery terminal posts for corrosion. Use a terminal brush or steel wool to clean corrosion from the battery terminal posts. MIN. FILL IMPORTANT: Before cleaning the battery, tape or block vent holes to the filler caps and make sure the caps are on tightly. TORO C.
E. Connect a battery load tester to the battery terminals following the manufacturer’s instructions. Connect a digital multimeter to the battery terminals. F. Apply a test load of one half the Cranking Performance (see Battery Specifications) rating of the battery for 15 seconds. G. Take a voltage reading at 15 seconds, then remove the load. H. Using the table below, determine the minimum voltage for the cell temperature reading. 6.
2. Determine the charging time and rate using the manufacturer’s battery charger instructions or the following table. Battery Reserve Capacity (Minutes) CAUTION Do not charge a frozen battery because it can explode and cause injury. Let the battery warm to 60_F (15.5_ C) before connecting to a charger. Battery Charge Level (Percent of Fully Charged) Charge the battery in a well–ventilated place to dissipate gases produced from charging.
Optional Lights After market lighting kits are available for the SP 2020/3020 and SP 5020. These kits can be electrically connected to the machine’s electrical system using the proper wiring diagram as a guide (see Sand Pro 2020/3020 or Sand Pro 5020 Harness and Wiring Diagrams). IMPORTANT: Do not exceed a total lighting capacity of 150 watts on a machine. Exceeding this limit will damage the alternator.
Chapter 6 Wheels, Brakes, and Miscellaneous Table of Contents Front Fork and Steering (Newer SP 3020 Models) . . . . . . . . . . . . . . . . . . Upper Steering Disassembly . . . . . . . . . . . . . . . Upper Steering Assembly . . . . . . . . . . . . . . . . . . Lower Steering Disassembly . . . . . . . . . . . . . . . Lower Steering Assembly . . . . . . . . . . . . . . . . . . Front Fork Removal . . . . . . . . . . . . . . . . . . . . . . . Front Fork Installation . . . . . . . . . . . . . . . . . . . . .
Specifications Item Description Front tire pressure 4 to 6 PSI, (0.28 to 0.41 bar) Rear tire pressure 4 to 6 PSI, (0.28 to 0.41 bar) Wheel lug nut torque Wheels, Brakes, and Miscellaneous 45 to 55 ft–lb, (6.2 to 7.
Adjustments Adjust Steering Chain NOTE: Since the chain and sprocket are subjected to sand thrown up by the front tire, inspect them frequently for wear. If either the chain or sprocket is worn beyond acceptable limits, replace both chain and sprocket. NOTE: The steering chains on the SP 2020/3020 (Fig. 1) and SP 5020 (Fig. 2) are adjusted in the same manner. Newer models of the SP 3020 have a chain guide similar to the SP 5020. 2 1. Place front wheel in the straight ahead position. 2.
Adjust Brake (SP 2020/3020) CAUTION Before and after adjusting the brakes, always check the brakes in a wide open area that is flat and free of other persons and obstructions. 5 6 1 1. While driving the machine, pull brake lever. Both wheels should lock equally. 2 2. Park machine on a level surface, turn engine off, and block wheels. 4 3. Loosen jam nut on actuator rod. Remove cotter pin securing actuator rod traverse rod lever. Increase or decrease actuator rod length by rotating rod.
Service and Repairs Seat (SP 2020/3020) 1 5 3 2 2 4 4 12 16 15 6 13 7 14 11 10 8 9 6 Seat Cap screw R–clamp Flat washer Manual tube lock nut 7. 8. 9. 10. 11. Cap screw Seat clamp Service decal Rubber cushion Seat plate 12. 13. 14. 15. 16. Angle bracket Spacer Lock nut Seat base shield Cap screw Removal Installation 1. Park machine on a level surface, engage the parking brake, lower attachment, and stop engine. 1.
Front Wheel (SP 2020) 5 7 6 1 3 12 2 4 5 13 10 9 2 11 1 5 6 7 5 RIGHT 8 FRONT 4 14 3 Figure 6 1. 2. 3. 4. 5. Hex nut Lock washer Carriage bolt Set screw Bearing flange 6. 7. 8. 9. 10. Bearing Locking collar Tire Front axle Front fork 11. 12. 13. 14. Lug nut Drive stud Wheel rim Valve stem Removal (Fig. 6) CAUTION 1. Park machine on a level surface, engage parking brake, lower attachment, and stop the engine.
Installation (Fig. 6) 4. Secure bearing flanges to the front fork with carriage bolts, lock washers, and hex nuts. 1. Position front axle and drive studs through the wheel rim. Secure axle to rim with lug nuts to studs. Torque nuts from 45 to 55 ft–lb (6.2 to 7.6 kg–m). 2. Place bearing between two bearing flanges. Slide assembly onto axle with the locking collar facing away from the wheel. Repeat with remaining bearing and flanges on the other end of the axle. 3. Position wheel to the front fork.
Front Wheel (SP 3020 and SP 5020) 4 5 2 3 7 8 14 12 1 9 13 17 16 6 10 RIGHT 15 FRONT 11 Figure 7 1. 2. 3. 4. 5. 6. Set screw Locking collar Cap screw Lock nut Relube flangette Flangette 7. 8. 9. 10. 11. 12. Bearing tab Front fork Socket head screw Lock nut Hydraulic motor Front wheel NOTE: The front wheel motors and wheels on the SP 3020 and SP 5020 are attached to the front fork in the same manner. Therefore the same procedures can be use for removal and installation. Removal (Fig. 7) 1.
9. If the wheel hub needs replacing, remove hydraulic motor from hydraulic lines, and remove hub from motor (see Front Wheel Removal in Chapter 4 – Hydraulic Systems). 5. Slide flangette and bearing assembly onto the spindle shaft so the locking collar faces the wheel. 6. Position hydraulic motor, wheel, and flangettes to the front fork. Installation (Fig. 7) 1.
Rear Wheels and Brakes 8 22 19 21 18 6 11 13 20 15 16 6 23 9 14 7 4 22 3 24 25 10 12 16 17 2 RIGHT 5 FRONT 1 Figure 8 1. 2. 3. 4. 5. 6. 7. 8. 9. Lug nut Drive stud Wheel Hub Lock nut Motor shaft Brake drum Woodruff key Cotter pin 10. 11. 12. 13. 14. 15. 16. 17. Clevis pin Brake lever Clevis Backing plate Retaining clip Return spring Brake shoe Cam shaft 18. 19. 20. 21. 22. 23. 24. 25. Brake bracket Lock nut Cap screw Hex nut Lock washer Spacer Cap screw Valve stem 3.
ÇÇ ÇÇ ÇÇ ÇÇ NOTE: The brake lever, backing plate, retaining clip, return springs, brake shoes, and cam shaft can be removed as a complete brake assembly. 7. If it is desired to remove the brake assembly from the brake bracket, remove four cap screws and lock nuts securing the assembly to the bracket. 3 7 1 4 8. Disassemble brake assembly as follows (Fig. 9): A. Remove return springs from the brake shoes. Remove brake shoes from the backing plate. B.
Brake Linkages (SP 2020/3020) 1 3 4 5 2 7 6 8 9 10 11 7 RIGHT 19 12 8 13 FRONT 9 14 18 15 7 16 1. 2. 3. 4. 5. 6. 7. Cap screw Lock nut Brake lever Spacer Clevis pin Flat washer Cotter pin 20 8. 9. 10. 11. 12. 13. 14. 21 17 Figure 10 Clevis Jam nut Brake rod Adjusting rod Roll pins Spacer Flat washer 15. 16. 17. 18. 19. 20. 21. Most parking brake linkage parts can be repaired or replaced without removing any interference.
Brake Linkages (SP 5020) 22 23 1 24 2 3 17 21 4 5 20 21 19 18 20 6 17 25 7 416 15 8 9 14 10 13 11/12 26 RIGHT 28 27 29 30 FRONT 31 32 Figure 12 Curved washer Lever bracket Lock nut Lock nut Clevis pin Lock nut Side flange bearing Hex head flange Roll pin Brake arm Left bearing bracket 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
Front Fork and Steering (SP 2020 and Older SP 3020 Models) 24 25 23 1 26 6 27 16 2 29 7 22 3 17 6 4 20 28 5 21 19 27 18 20 14 15 7 17 14 8 16 9 30 13 10 12 11 RIGHT FRONT Figure 13 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Steering wheel Roll pin Upper steering shaft Sleeve bushing Steering post Cap screw Flange bushing Drive–lock pin Sprocket Front fork (SP 2020) 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Front Fork and Steering (Newer SP 3020 Models) 22 20 1 21 15 23 24 16 18 2 35 7 3 6 25 26 6 19 4 17 5 18 9 25 16 13 15 14 7 8 13 33 31 12 32 29 34 11 28 10 27 RIGHT 30 Figure 14 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Steering wheel Roll pin Upper steering shaft Sleeve bushing Steering post Cap screw Flange bushing Drive–lock pin Sprocket Front fork Lock nut Steering adjustment pin Sand Pro 2020/3020/5020 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
Upper Steering Disassembly (Fig. 13 and 14) 6 5 NOTE: The front fork and steering assemblies on the SP 2020 and SP 3020 are almost identical. However, there are differences in the construction of the front fork, chain guide, chain bracket, and the number of steering washers. 7 2 8 4 1. Park machine on a level surface, lower attachment, stop engine, engage parking brake, and remove key from the ignition switch. 2 3 2. Remove hood from the dash panel and machine (see Hood and Dash Panel Removal).
Lower Steering Disassembly (Fig. 13 and 14) NOTE: If disassembly of the steering mechanism below the steering knuckle is required, proceed as follows: 1. Loosen lock nut on the steering adjustment pin enough to loosen the steering chain from the sprocket. Remove chain from sprocket. 2 2. Remove drive–lock pin from the sprocket and lower steering shaft with drift punch (Fig. 17). 1 3. Drive out roll pin securing lower steering shaft to steering knuckle with drift punch. 5.
4. Position fork shaft up through frame. Install bearing cone and bearing washer onto the shaft. If bearing cones were damaged, install new bearing cone onto shaft. 5. Screw slotted nut onto the fork shaft until a slight drag is felt while rotating the fork. Back off nut so nearest slot aligns with cross hole in the shaft. Secure nut to shaft with cotter pin. Wheels, Brakes, and Miscellaneous 6. Install front wheel to the front fork (see Front Wheel Installation). 7.
Seat (SP 5020) 16 3 4 2 1 5 3 10 14 6 11 7 8 19 10 20 9 RIGHT 3 FRONT 18 13 17 15 10 12 Figure 18 R–clamp Lock washer Cap screw Manual tube Seat adjust plate Round head screw Flat washer 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Service decal Lynch pin Lock nut 4–inch seat slider Leveling screw Jam nut Seat slider Flat washer Seat Lock nut Flat washer Cup holder Seat base Removal Installation 1.
Steering (SP 5020) 1 25 2 24 28 3 23 27 4 22 26 5 12 29 6 31 7 30 8 12 9 22 10 21 12 32 11 20 19 35 18 17 33 34 13 16 38 37 13 14 15 36 Figure 19 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Steering wheel Roll pin Cap screw Handle Steering adjust lever Tilt lock pin Upper lock block Retaining ring Flat washer Cap screw Spacer Lock nut Cap screw Wheels, Brakes, and Miscellaneous 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.
Upper Steering Disassembly (Fig. 19) Lower Steering Disassembly (Fig. 13 and 14) NOTE: If disassembly above the steering knuckle is required, use the following procedure. NOTE: If disassembly of the steering mechanism below the steering knuckle is required, precede as follows: 1. Park machine on a level surface, lower attachment, stop engine, engage parking brake, and remove key from the ignition switch. 1.
Front Fork (SP 5020) Removal (Fig. 20) 2 1 5 NOTE: If disassembly of the front fork and its bearings is required, proceed as follows: 4 6 WARNING 6 Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 – Safety. 5 4 1. Jack up front wheel enough to allow removal of the front fork. 3 2. Remove fuel tank from the machine (see Fuel Tank Removal in Chapter 3 – Briggs & Stratton Vanguard Engines). 3. Remove cotter pin securing the slotted nut to the fork shaft.
Hood and Dash Panel (SP 2020/3020) Removal 2 1 1. Park machine on a level surface, lower attachment, stop engine, engage parking brake, and remove key from the ignition switch. 2. Disconnect black (negative) cable from the battery. 5 3. Remove three flange head screws securing the hood to the front shield (Fig. 11). 4. Remove four cap screws securing the dash panel to the hood. Remove hood from the machine (Fig. 12). 3 6. Remove both flange head screws from the dash panel and steering post (Fig. 12).
Fenders (SP 5020) Left Fender(Seat Base )Removal (Fig. 44) 1 1. Park machine on a level surface, lower attachment, stop engine, engage parking brake, and remove key from the ignition switch. 3 2. Pivot seat up. Separate seat rod from the base by removing cotter pin and flat washer. 4 3. Separate base from frame by removing both lock nuts, cap screws, flat washers, and spacers. 2 Seat Base Installation (Fig. 44) 1. Position seat base to the frame.
Commercial Products E The Toro Company – 1998