Toro Sand Pro 5020 Service Manual Download Page 127

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Chapter 5

Electrical Systems

Table of Contents

ELECTRICAL SCHEMATICS AND DIAGRAMS . . . 2

ELECTRICAL SYSTEM QUICK CHECKS . . . . . . . . 9

Sand Pro 2020/3020 Electrical Schematic . . . . . . 2

Battery Test (Open Circuit) . . . . . . . . . . . . . . . . . . . 9

Sand Pro 2020/3020

COMPONENT TESTING . . . . . . . . . . . . . . . . . . . . . . 10

Harness and Wiring Diagram . . . . . . . . . . . . . . . 3

Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Sand Pro 5020 Electrical Schematic . . . . . . . . . . . 4

Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Sand Pro 5020

Starter Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Harness and Wiring Diagram . . . . . . . . . . . . . . . 5

Neutral Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 13

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 7

Battery Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Starting Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Battery Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

General Run & Transport Problems . . . . . . . . . . . . 8

Battery Service  . . . . . . . . . . . . . . . . . . . . . . . . . . . .  14
Check Interlock System  . . . . . . . . . . . . . . . . . . . . .  17
Optional Lights  . . . . . . . . . . . . . . . . . . . . . . . . . . . .  18

Sand Pro 2020/3020/5020

Page 5 – 1

Electrical Systems

Electrical

Systems

Summary of Contents for Sand Pro 5020

Page 1: ...lete Model and Serial Number to The Toro Company 8111 Lyndale Avenue South Bloomington MN 55420 1196 The Toro Company reserves the right to change product specifications or this publication without notice or CAUTION PERSONAL SAFETY INSTRUC This safety symbol means DANGER WARNING TION When you see this symbol carefully read the instructions that follow Failure to obey the instructions may result in...

Page 2: ...Sand Pro 2020 3020 5020 ...

Page 3: ... V Twin Cylinder OHV Engines Chapter 4 Hydraulic Systems Specifications 4 2 General Information 4 3 Hydraulic Schematics 4 6 Hydraulic Flow Diagrams 4 8 Special Tools 4 14 Trouble Shooting 4 16 Testing 4 19 Adjustments 4 28 Service and Repairs 4 31 Chapter 5 Electrical Systems Electrical Schematics and Diagrams 5 2 Special Tools 5 6 Troubleshooting 5 7 Electrical System Quick Checks 5 9 Component ...

Page 4: ...Sand Pro 2020 3020 5020 ...

Page 5: ...h the controls and know how to stop the engine quickly 4 Keep all shields safety devices and decals in place If a shield safety device or decal is malfunctioning illeg ible or damaged repair or replace it before operating the machine 5 Always wear substantial shoes Do not operate ma chine while wearing sandals tennis shoes or sneakers Do not wear loose fitting clothing which could get caught in mo...

Page 6: ...on hillsides D Avoid sudden stops and starts Do not go from reverse to full forward without first coming to a com plete stop E Before backing up look to the rear and assure no one is behind the machine F Watch out for traffic when near of crossing roads Always yield the right of way 15 If optional Draw Bar Part No 92 2330 or Hitch Kit Model No 08833 is installed on machine vertical load on hitch s...

Page 7: ...potential fire hazard keep the engine area free of excessive grease grass leaves and accu mulation of dirt 27 If the engine must be running to perform a mainte nance adjustment keep hands feet clothing and any parts of the body away from the engine and any moving parts Keep everyone away 28 Do not overspeed engine by changing governor set tings Maximum engine speed is 3200 rpm To assure safety and...

Page 8: ...level floor such as a concrete 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 ma chine If the machine is not properly supported by blocks or jack stands the machine may move or fall which may result in personal inju When changing attachments tires or per floor Prior to raising t...

Page 9: ...art numbers are listed below and in the parts catalog Order replacements from your Authorized Toro Distributor ON ENGINE SHIELD Part No 95 0647 Part No 95 0646 ON NEUTRAL ADJUST MECHANISM Part No 93 9051 93 9051 ON VALVE SHROUD UNDER SEAT PLATE Part No 92 8985 ON ENGINE SHIELD Part No 95 0645 Safety ON DASH PANEL Part No 95 0648 Sand Pro 2020 3020 5020 Page 1 5 Safety ...

Page 10: ...zed Toro Distributor ON NEUTRAL ADJUST MECHANISM ON BOTH SIDES OF FAN SHROUD 2 Part No 93 7272 Part No 93 9051 ON MUFFLER SHIELD Part No 95 0645 ON RIGHT FENDER Part No 98 0975 UNDER SEAT PLATE Part No 98 0977 ON FRAME BOTH SIDES OF CENTER PANEL 3 Part No 93 9052 ON LEFT FENDER Part No 93 9053 ON BATTERY Part No 93 7276 ON CENTER PANEL Part No 93 9050 ON RIGHT FENDER UNDER BATTERY Part No 93 7442 ...

Page 11: ...0 on the OPERATION AND SERVICE HISTORY REPORT form Use this informa tion when referring to your machine TORQUE SPECIFICATIONS 3 Capscrew Markings and Torque Values U S 3 Capscrew Markings and Torque Values Metric 3 LUBRICATION 4 OPERATION SERVICE HISTORY REPORTS 7 Insert Operator s Manuals and Parts Catalogs for your Sand Pro 2020 3020 5020 at the end of this section Product Records and Maintenanc...

Page 12: ...Equivalents and Conversions Product Records and Maintenance Page 2 2 Sand Pro 2020 3020 5020 ...

Page 13: ...Product Records and Maintenance Sand Pro 2020 3020 5020 Page 2 3 Product Records and Maintenance Torque Specifications ...

Page 14: ...o 2020 3020 Late Models The four fittings to lubricated are front wheel bearing Fig 1 traction control linkage Fig 3 and steering shaft and steering chain sprocket shaft Fig 5 Sand Pro 5020 The four fittings to lubricate are front wheel bearing Fig 2 traction control linkage Fig 3 and both the steering shaft and steering chain sprocket shaft Fig 6 NOTE On the Sand Pro 5020 gain access to the greas...

Page 15: ...Sand Pro 2020 3020 5020 Page 2 5 Product Records and Maintenance Figure 5 Figure 6 Product Records and Maintenance ...

Page 16: ...Product Records and Maintenance Page 2 6 Sand Pro 2020 3020 5020 ...

Page 17: ...s _________________________ Transmission Numbers _________________________ Date Purchased _________________________ Warranty Expires___________ Purchased From _________________________ Contacts Parts Phone___________________ Service Phone___________________ Sales Phone___________________ Product Records and Maintenance See your TORO Distributor for other Publications Manuals and Videos from the TO...

Page 18: ...Oil Filter Replace Remote Air Cleaner Element Replace Engine Air Cleaner Element A Level Service B Level Service C Level Service Every 800hrs D Level Service Replace Engine Oil Filter Inspect Remote Air Cleaner Element Inspect Engine Air Cleaner Element Lubricate Steering Shaft Grease Fitting Check Steering Chain Adjustment Replace Moving Hoses Lubricate Traction Control LInkage Maintenance Proced...

Page 19: ...ean Engine Cooling Fins n Unusual Engine Noises n Unusual Operating Noises n Hydraulic System Oil Level n Hydraulic Hoses for Damage n Fluid Leaks n Fuel Level n Tire Pressure n Instrument Operation Touch up Damaged Paint Notation for areas of concern Inspection performed by __________________ Item Date Information 1 2 3 4 5 6 7 8 Check proper section of Operator s and Service Manuals for procedur...

Page 20: ...r Cleaner Element Replace Engine Air Cleaner Element A and B Sevice required Sand Pro 2020 3020 5020 R Unit Designation Hours __________________ __________________ Service to perform circle A B C D Other Remarks A Service every 25 hours B Service every 100 hours D Service every 800 houurs Check Battery Fluid Level Check Battery Cable Connections Change Engine Oil Replace Engine Oil Filter Replace ...

Page 21: ...trol Installation 12 Replace Fuel Filter 12 Remote Air Cleaner SP 2020 3020 13 Remote Air Cleaner SP 5020 14 Muffler SP 5020 15 Muffler SP 2020 3020 16 Muffler Removal 16 Muffler Installation 17 Fuel Tank SP 2020 3020 18 Fuel Tank Removal 19 Fuel Tank Installation 19 Fuel Tank SP 5020 20 Fuel Tank Removal 20 Fuel Tank Installation 21 Engine SP 2020 3020 22 Engine Removal 23 Engine Installation 24 ...

Page 22: ...d Service Manual for 4 Cycle V Twin Cylin der OHV Engines The use of some specialized test equipment is explained However the cost of the test equipment and the specialized nature of some repairs may dictate that the work be done at an engine repair fa cility Service and repair parts for Briggs and Stratton Van guard engines are supplied through your local Briggs and Stratton dealer or distributor...

Page 23: ...8 5 50 Fuel Pump Pulsating Crankcase Vacuum Governor Mechanical Low Idle no load 1750 50 RPM High Idle no load 3150 50 RPM Intake and Exhaust Valve Seat Angle 45_ Intake and Exhaust Valve Clearance Cold mm in 0 10 to 0 15 0 004 to 0 006 Carburetor Single Barrel Float Feed with Suppress Afterfire Solenoid Engine Oil SAE 30 SE SF or SG Oil Pump Internal Gear Driven Gerotor Type Crankcase Oil Capacit...

Page 24: ...fore and after the engine is first started 1 Position machine on a level surface 2 Unscrew dipstick and wipe it with a clean rag Screw dipstick into the tube and make sure it is seated fully Unscrew dipstick out of the tube Check oil level If oil level is low remove filler cap from the valve cover next to dipstick and add enough oil to raise the level to the FULL mark on the dipstick 2 1 Figure 1 ...

Page 25: ...020 3020 the shutoff valve can be ac cessed from the rear of the machine Fig 2 On the SP 5020 the shutoff valve can be accessed by removing the left side panel Fig 3 2 1 Figure 2 1 Fuel shutoff valve 2 Hydraulic oil filter 1 2 Figure 3 1 Fuel shutoff valve 2 Hydraulic oil tank Sand Pro 2020 3020 5020 Page 3 5 Engine Engine ...

Page 26: ...soline is flammable use caution when storing or handling it Do not fill fuel tank while the en gine is running hot or when machine is in an en Prevent the possibility of an explosion DO NOT starting the engine Use a funnel or spout to pre vent spilling gasoline Fill tank no higher than one inch below top of tank bottom of filler neck DO NOT OVER FILL Store gasoline in a clean safety approved conta...

Page 27: ...ne shield 2 Remove air cleaner cover cover plate and air cleaner filter element from the air cleaner base See Service Engine Air Cleaner 3 Loosen cable clamp screw securing the choke cable to engine Fig 4 4 Pull choke control knob out completely from dash panel SP 2020 3020 Shift choke lever to the choke position SP 5020 1 2 3 4 NOTE Newer engine models will have a different car Figure 5 buretor s...

Page 28: ...pect paper element every 100 hours of operation Replace element every 400 hours or when dirty or dam aged Do not wash paper element or do not clean with compressed air as damage will occur 1 Park machine on a level surface Turn engine off 2 Pivot seat up On the SP 2020 3020 remove the en gine shield 3 Remove knobs and air cleaner cover 4 Remove filter element and cover plate Inspect filter for cle...

Page 29: ...er element using warm flowing air not ex ceeding 160_F or allow element to air dry Do not use a light bulb to dry the filter element because damage may result 1 2 4 3 Engine CAUTION Use eye protection such as goggles when using compressed air 4 Clean filter element with compressed air as follows 1 Latch Figure 9 3 Body 2 Cover 4 Air inlet hood A Blow compressed air from the inside to the out side ...

Page 30: ...three hex flange head screws securing the hood to the front shield Fig 11 Remove four cap screws securing the dash panel to the hood Fig 12 Remove hood from the machine Figure 11 1 3 2 1 Hex flange head screw 3 Front shield 4 Release throttle cable from clamp securing it to the 2 Hood engine Disconnect throttle cable from the swivel on the engine Fig 13 5 Remove throttle knob from the throttle con...

Page 31: ...leaner ele ment from the air cleaner base Fig 14 NOTE Newer engine models will have a different car buretor shield that has five hex head flange screws se curing the shield and air cleaner base to the carburetor 5 Remove two cap screws and three hex head flange screws securing air cleaner base to the carburetor Re move base carefully from carburetor Make sure not to damage carburetor gasket Cover ...

Page 32: ...d to front shield with three hex flange head screws Fig 11 Secure dash panel to hood with four cap screws Fig 12 8 Adjust choke control see Adjust Choke Control Install cover over the engine Replace Fuel Filter The fuel filter on the SP 2020 3020 can be accessed from the rear of the machine It is located just left of the hydrostat Fig 17 The fuel filter on the SP 5020 can be accessed by pivoting u...

Page 33: ...re not to drop the filter element Fig 21 Remote Air Cleaner Installation 1 Insert filter body through the mounting band Install and latch cover to the filter body Fig 21 2 Secure mounting band and air cleaner to the front shield with both cap screws flat washers and lock nuts Fig 21 3 Secure air hose to the air cleaner with hose clamp Fig 21 4 Position hood to the front shield Potion dash panel to...

Page 34: ...emove cover from air cleaner body Separate body from the mounting band Make sure not 1 5 2 4 3 Figure 22 to drop the filter element 1 Body 4 Latch 2 Cap screw flat washer 5 Cover Remote Air Cleaner Installation 3 Mounting band 1 Insert air cleaner body through the mounting band Make sure filter element is inside the body Install and latch cover to the air cleaner body 2 Secure mounting band and ai...

Page 35: ...nd 24 3 Remove cap screws securing muffler and both gas kets to the cylinder heads Pull muffler from the engine Fig 24 and 25 Muffler Installation 1 Replace gaskets if torn or damaged Replace ex haust detector if worn or damaged 2 Secure gaskets and muffler to cylinder heads with cap screws Fig 24 and 25 3 Secure muffler shield to the engine with three cap screws and lock washers Fig 23 and 24 1 2...

Page 36: ... from both adjusting rods Sepa rate adjusting rods from both brake arms Fig 27 6 Remove cotter pin from the brake rod Separate brake rod from the traverse rod lever Fig 28 7 Loosen both hex flange head screws and lock nuts on each side flange bearing Lower traverse rod from the frame Fig 28 8 Remove three cap screws and star washers secur ing the muffler shield R clamp and fuel hose to the en gine...

Page 37: ...r washers Fig 29 6 Position traverse rod to the frame Make sure each side flange bearing is on the inside of the frame Secure bearings to the frame by tightening both hex flange head screws on each bearing Fig 28 7 Connect brake rod to the traverse rod lever Secure brake rod with cotter pin Fig 28 8 Connect adjusting rods to both brake arms Secure both adjusting rods with a cotter pin Fig 27 Figur...

Page 38: ...er 15 Battery 16 Battery bolt 17 Lock nut 18 Cap screw 19 Lock nut 20 R clamp 21 Socket button head screw 22 Fuel hose 23 Hose clamp 24 Fuel shutoff valve 25 Grommet 26 Litter box 27 Battery wire ground 28 Flat washer 29 Battery decal 30 Danger decal 31 Fuel filter 32 Fuel hose 33 Terminal boot 34 Battery wire start solenoid 1 2 3 4 5 6 7 8 9 10 16 17 22 23 24 25 26 27 28 33 11 12 13 14 15 34 29 1...

Page 39: ... is drained 5 Loosen hose clamp 7 and disconnect fuel hose 8 from the bottom of the fuel tank 2 6 Remove four philips pan head screws 6 and flat washers 28 securing the fuel tank 2 to the fuel tank base 4 7 Lift fuel tank 2 from fuel tank base 4 Make sure not to lose grommets 3 8 If the fuel tank base 4 is to be removed A Remove both cap screws and lock washers se curing the filter head to the bas...

Page 40: ... tank while the en gine is running or when the machine is in an en closed area Vapors may build up and be ignited by a spark or flame source many feet away DO NOT SMOKE while draining the fuel tank to pre vent the possibility of an explosion Always drain fuel tank outside Wipe up any spilled gasoline Store gasoline in a clean safety approved con tainer and secure cap on the container Keep gasoline...

Page 41: ...Position fuel tank to the frame making sure not to tear the steering boot while carefully lowering the top of the boot over the tilt pin A Apply antiseize lubricant to the threads of the four cap screws B Make sure grommets are in place Secure fuel tank to the fame with four flat washers and cap screws C Torque cap screws from 30 to 60 in lb 35 to 69 kg cm 2 Route fuel hose from the tank to the fu...

Page 42: ...se 22 Muffler shield 23 Cap screw 24 Lock washer 25 Hot surface plate 26 Battery cable Ground 27 Red cable Starter solenoid 28 Hose clamp 29 Carburetor inlet shield 30 Screw 31 Air cleaner element 32 Cover plate 33 Air hose 34 Hose clamp 35 Air cleaner knob 36 Air cleaner knob 37 Washer face screw 38 Screw 39 Carburetor gasket 40 Manifold gasket 41 Screw 42 Boot 43 Wire harness Ground wire 44 Cabl...

Page 43: ...19 8 Disconnect throttle control cable from the swivel and choke control cable from the choke lever see Throttle and Choke Control Removal 9 Remove cotter pin from the pump control rod Sepa rate rod from the pump lever Fig 39 10 Loosen both set screws on the engine hub to re move hub from the pump shaft Fig 40 11 Remove four cap screws and lock washers securing the pump mount to the engine block P...

Page 44: ...cap screws and lock washers Fig 41 4 Tighten both set screws securing the engine hub to the engine shaft Fig 40 5 Insert end of pump control rod into the pump lever Secure rod with cotter pin Fig 39 6 Connect throttle control cable to the swivel and choke control cable to the choke lever see Throttle and Choke Control Installation 7 Install air hose 33 to air cleaner cover 19 Secure hose with hose...

Page 45: ...e released from the plug and fall into the cylinder The result is usually a damaged engine 1 Clean area around spark plugs so foreign matter cannot fall into cylinder when spark plug is removed 2 Pull spark plug wires off spark plugs Remove plugs from cylinder head 3 Check condition of side electrode center electrode and center electrode insulator Make sure there is no damage 0 030 inch 0 762 mm F...

Page 46: ...asher 25 Positive cable from starter solenoid 26 Ground wire to frame 27 Stub shaft 28 Lock nut 29 Cap screw 30 Flat washer 31 Engine mount 32 Lock nut 33 Engine support 34 Cap screw 35 Cap screw 36 Cap screw 37 Cap screw 38 Engine base 39 Not used 40 Carburetor gasket 41 Not used 42 Not used 43 Cap screw 44 Cap screw 45 Screen spacer 46 Engine 47 Fuel hose 48 Air cleaner base 49 Carburetor inlet ...

Page 47: ...lectrical Systems 6 Close fuel shutoff valve Clamp fuel hose near engi ne to prevent fuel spillage Loosen hose clamp at fuel pump and remove fuel hose from the pump 7 Disconnect wire harness as follows Fig 45 A Disconnect blue wire from magneto terminal B Disconnect blue wire with fusible link from volt age regulator C Disconnect red white wire from fuel solenoid IMPORTANT Keep air cleaner base re...

Page 48: ...hub and base Remove square key from the engine shaft 14 Secure engine base and hydrostat to prevent the cooling fan from damaging the oil cooler Engine Installation Fig 43 CAUTION One person should operate the jack while the other person guides the engine into the frame IMPORTANT Make sure not to damage the engine fuel and hydraulic lines electrical harness or other parts while installing the engi...

Page 49: ...s flat washers and lock nuts 5 Connect wire harness as follows Fig 45 B Secure seat rod to the base with flat washer and cotter pin A Connect blue wire to the magneto terminal 7 Install and connect battery to the machine see Bat B Connect blue wire with fusible link to voltage reg tery Service in Chapter 5 Electrical Systems ulator 8 Secure fuel hose to the fuel pump with hose clamp C Connect red ...

Page 50: ...ide covers to 1 Muffler shield 3 Cylinder head LH 2 Air guide cover LH gain access to both cylinder heads CAUTION Use eye protection such as goggles when using 4 and away from the engine 5 Use nylon bristle brush and hot soapy water to re 1 3 2 compressed air Blow dirt and debris from between the cooling fins move any encrusted mud or other debris on and be Figure 50 tween the cooling fins Rinse f...

Page 51: ...ation 35 Lift Valve SP 5020 36 Removal and Installation 37 Lift Valve Service 38 Lift Cylinder SP 2020 3020 39 Lift Cylinder SP 5020 40 Lift Cylinder Service 41 Hydrostat SP 2020 3020 42 Removal 42 Installation 43 Hydrostat SP 5020 44 Removal 44 Installation 45 Flush Hydraulic System 47 Hydrostat Service 48 Charge Pump Disassembly Inspection and Assembly 49 Shaft Seal Removal and Installation 50 A...

Page 52: ...v Maximum Operating Pressure 2000 PSI 138 bar Maximum Intermittent Pressure 3000 PSI 207 bar Maximum Flow 20 GPM 76 LPM Rated Speed Maximum Flow 530 RPM Left Wheel Motors SP 2020 SP 3020 Orbital rotor vane Motor Displacement 7 8 in3 rev 127 8 cm3 rev Maximum Operating Pressure 2000 PSI 138 bar Maximum Intermittent Pressure 3000 PSI 207 bar Maximum Flow 20 GPM 76 LPM Rated Speed Maximum Operating P...

Page 53: ...aks or nozzles that eject hydraulic fluid under high penetrate the skin and cause serious injury If fluid is injected into the skin it must be surgi familiar with this type of injury Gangrene may result from such an injury Hydraulic Fitting Installation O Ring Face Seal 1 Make sure both threads and sealing surfaces are free of burrs nicks scratches or any foreign material 2 Make sure the O ring is...

Page 54: ...eign material 2 Always replace the O ring seal when this type of fit ting shows signs of leakage 3 Lubricate the O ring with a light coating of oil 4 Turn back the jam nut as far as possible Make sure O Ring Lock Nut Back up Washer the back up washer is not loose and is pushed up as far as possible Step 1 5 Install the fitting into the port and tighten finger tight Figure 4 until the washer contac...

Page 55: ...nk 2 Check oil level in the tank Oil level should be up to the top of the cone point on tank screen IMPORTANT To prevent system contamination clean top of hydraulic oil containers before punctur ing Assure pour spout and funnel are clean 3 If fluid level is low slowly fill tank with appropriate hy draulic fluid until level reaches bottom of screen DO NOT OVERFILL NOTE The fluids within this group ...

Page 56: ...RS 7 8 127 84 DISPLACEMENT PRESSURE COMPONENT P1 DISPLACEMENT FLOW RATE AND PRESSURE CHART P2 M1 M2 M3 5 0 81 97 in rev cm rev lbs in 2 3 3 FLOW RATE GPM LPM 12 48 4 5 47 2 17 FLOW RATE CALCULATED AT 3150 RPM R1 R2 700 90 48 3 6 2 Hydraulic Schematic Sand Pro 2020 3020 M3 FRONT FORWARD SP 3020 ONLY CHARGE CHECK VALVE CHARGE CHECK VALVE IMPLEMENT RELIEF CHARGE RELIEF ACCELERATION VALVES TANK HOT OI...

Page 57: ...m rev lbs in 2 3 3 GPM LPM 12 48 4 5 47 2 17 R1 R2 700 90 48 3 6 2 TIMED MANIFOLDS IMPLEMENT RELIEF CHARGE RELIEF CHARGE CHECK CHARGE CHECK CHARGE PUMP TRACTION PUMP SHUTTLE Hydraulic System Rev A OIL COOLER FILTER RH WHEEL MOTOR FOR OIL COOLING IN FORWARD HYDROSTAT DISPLACEMENT FLOW RATE AND PRESSURE CHART FLOW RATE FLOW RATE CALCULATED AT 3150 RPM FORWARD FRONT AND RH WHEEL MOTORS HAVE REVERSE A...

Page 58: ...rain This leakage results in the loss of hydraulic fluid from the closed loop circuit that must be replenished The charge pump P2 is a fixed displacement gerotor pump It is driven directly off the traction pump The pump replenishes the closed loop circuit with fluid from the tank The charge relief valve R2 supplies sufficient head so that charge pump flow is guided to the low pres sure side of the...

Page 59: ...LDS B A SHUTTLE CHARGE CHECK CHARGE CHECK CHARGE PUMP TRACTION PUMP IMPLEMENT RELIEF CHARGE RELIEF Hydraulic Systems Hydraulic System Rev A LIFT CYLINDER LIFT VALVE OIL COOLER FILTER RH WHEEL MOTOR FOR OIL COOLING IN FORWARD HYDROSTAT FORWARD SP 3020 ONLY Traction Forward RH WHEEL MOTOR FOR OIL COOLING IN FORWARD FORWARD FRONT AND RH WHEEL MOTORS HAVE REVERSE TO LIFT VALVE SP 5020 TANK HOT OIL VAL...

Page 60: ...rt A Oil flow out of port A goes to the wheel motors and turns them in the reverse direction On the SP 5020 the oil flow goes through the left and right rear wheel motors first and then through the front wheel motor Oil flowing out of the wheel motors returns to port B of the hydrostat and is continuously pumped out of port A The right wheel motor does not bleed off any hydraulic fluid for cooling...

Page 61: ...S B A SHUTTLE CHARGE CHECK CHARGE CHECK CHARGE PUMP TRACTION PUMP IMPLEMENT RELIEF CHARGE RELIEF Hydraulic Systems Hydraulic System Rev A Page 4 11 LIFT CYLINDER LIFT VALVE OIL COOLER FILTER RH WHEEL MOTOR FOR OIL COOLING IN FORWARD HYDROSTAT SP 3020 ONLY Traction Reverse RH WHEEL MOTOR FOR OIL COOLING IN FORWARD FORWARD FRONT AND RH WHEEL MOTORS HAVE REVERSE TO LIFT VALVE SP 5020 TANK HOT OIL VAL...

Page 62: ...t cylinder through the lift valve Fluid returns to the tank as a normal part of the charge and bleed off circuits Moving the lift lever to the lift position allows the lift valve to direct fluid flow from the charge pump into the rod side of the piston The piston moves into the cylinder pushing fluid out the piston end of the cylinder and to the tank As the cylinder rod retracts the attachment is ...

Page 63: ...T CYLINDER RETRACT LIFT CYLINDER SHUTTLE IMPLEMENT RELIEF CHARGE RELIEF CHARGE CHECK RELIEF CHARGE CHECK RELIEF CHARGE PUMP TRACTION PUMP NEUTRAL POSITION NEUTRAL POSITION Hydraulic System Rev A LIFT VALVE OIL COOLER FILTER RH WHEEL MOTOR FOR OIL COOLING IN FORWARD HYDROSTAT FORWARD SP 3020 ONLY TANK LIFT VALVE TO OIL HOT OIL VALVE ACCELERATION VALVES Return or Suction Flow LIFT CYLINDER LIFT CYLI...

Page 64: ...RFS adapter fit tings for use on this machine 1 INLET HOSE Hose connected from the system cir cuit to the inlet side of the hydraulic tester 2 LOAD VALVE A simulated working load is created in the circuit by turning the valve to restrict flow 3 LOW PRESSURE GAUGE Low range gauge to provide accurate reading at low pressure 0 to 1000 PSI A protector valve cuts out when pressure is about to exceed th...

Page 65: ... the SP 2020 3020 there is tight clearance between the charge pressure test port on the hydrostat and the engine base plate It might be helpful to first attach a male pipe swivel adapter to the test port and then a street elbow before connecting a test gauge Both fittings carry the following Parker Hannifin part numbers Male Pipe Adapter 0107 2 2 Street Elbow 1 8 CD 2 1 Figure 11 1 Swivel Adapter ...

Page 67: ...auses Oil filter is clogged Charge relief valve is defective Implement relief valve is defective Charge pump is defective Traction pump outlet pressure is low due to the following possible causes Accelerator valves are defective Charge check valves are defective Traction pump is worn or defective Wheel motor s are worn or damaged Wheel motor will not hold load in neutral Make up fluid from charge ...

Page 69: ...nds to search for leaks use paper or cardboard Hydraulic fluid 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 Gan grene may result from such an injury 1 Clean machine thoroughly before disconnecting or disassembling any hydraulic components Always keep in mind the need for cleanliness when working on hy draul...

Page 70: ...TRACTION PUMP TO WHEEL FROM WHEEL FROM SHUTTLE TO LIFT FROM OIL COOLER 3 1 2 HYDROSTAT FORWARD ACCELERATION VALVES VALVE VALVE MOTORS MOTORS VALVE VALVE FILTER TANK Figure 12 1 Hydrostat SP 2020 3020 2 Forward header SP 2020 3020 3 Wheel motor connector SP 5020 Hydraulic System Rev A Page 4 20 Sand Pro 2020 3020 5020 ...

Page 71: ...ydraulic tester start engine and run at idle speed Check for hydraulic leakage and correct before proceeding with test 5 Operate engine at full speed 3150 50 RPM CAUTION Use extreme caution when taking gauge read ings The tires off the ground will be spinning 6 Slowly push traction pedal into the fully forward position 7 Slowly close flow control valve on tester until pres sure gauge on the hydrau...

Page 72: ...ARGE PUMP TRACTION PUMP FROM SHUTTLE TO LIFT FROM OIL COOLER PRESSURE GAUGE HYDROSTAT FORWARD ACCELERATION VALVES VALVE VALVE VALVE VALVE FILTER TANK FROM WHEEL MOTORS TO WHEEL MOTORS 1 2 3 Figure 13 1 Charge test port SP 2020 3020 2 Engine base plate SP 2020 3020 3 Charge test port SP 5020 Hydraulic System Rev A Page 4 22 Sand Pro 2020 3020 5020 ...

Page 73: ...tor with pressure gauge in series with the hose from the pump and the T fitting on the lift valve Figure 14 5 Make sure that traction pedal and lift control lever are in neutral and the parking brake is engaged 6 After installing pressure gauge start engine and run at low idle speed Check for hydraulic leakage and cor rect before proceeding with test 7 Operate engine at full speed 3150 50 RPM Veri...

Page 74: ...PUMP TO WHEEL FROM WHEEL FROM SHUTTLE TO LIFT FROM OIL COOLER 1 2 3 4 HYDROSTAT FORWARD ACCELERATION VALVES VALVE VALVE MOTORS MOTORS VALVE VALVE FILTER TANK Figure 14 1 Lift valve SP 2020 3020 3 Lift valve SP 5020 4 Hose from pump SP 5020 2 Hose from pump SP 2020 3020 Hydraulic System Rev A Page 4 24 Sand Pro 2020 3020 5020 ...

Page 75: ...ged 7 After installing hydraulic tester start engine and run at low idle speed Check for hydraulic leakage and cor rect before proceeding with test 8 Operate engine at full speed 3150 50 RPM 9 Slowly close the flow control valve on the tester until 500 PSI is obtained 10 Verify pump speed is 3150 50 RPM with a photo tac 11 Flow indication on tester should be a minimum of 1 GPM 3 8 LPM Record test ...

Page 76: ...HARGE CHECK CHARGE CHECK CHARGE PUMP TRACTION PUMP SHUTTLE FROM OIL COOLER TO LIFT FILTER HYDROSTAT FORWARD ACCELERATION VALVES TANK VALVE VALVE HOT OIL VALVE VALVE Figure 15 1 Hydrostat SP 2020 3020 2 Forward header SP 2020 3020 3 Wheel motor connector SP 5020 Hydraulic System Rev A Page 4 26 Sand Pro 2020 3020 5020 ...

Page 77: ...er pressure gauge 11 With all drive wheels locked not rotating total in ternal leakage for all wheel motors will be shown on the flow meter Flow should be less than 2 GPM 7 6 LPM Record test results 12 Release traction pedal and shut engine off 13 If specification is not met individual wheel motors need to be removed from the traction circuit to deter mine which motor s is leaking excessively A Fo...

Page 78: ... in both direc tions to determine mid position of neutral span 6 Tighten lock nut securing the adjustment cam 7 Stop engine 8 Remove support blocks and lower the machine Test drive machine to make sure it does not creep 9 On the SP 2020 3020 install engine shield and piv ot seat down On the SP 5020 secure side panel to the right side of machine with three cap screws 1 2 Figure 16 1 Lock nut 2 Adju...

Page 79: ...forward 1 Park machine on a level surface and turn engine off 2 Make sure pump is in neutral 3 Loosen jam nuts on the control rod 4 Press down on the forward pad of the pedal until the pedal rod contacts the footrest Tighten jam nuts 1 2 Figure 18 1 Jam nuts 2 Control rod Sand Pro 2020 3020 5020 Page 4 29 Hydraulic System Rev A Hydraulic Systems ...

Page 80: ...t does not float follow ground contour properly during operation 1 Park the machine on a level surface turn engine off set parking brake and block wheels 2 Loosen both capscrews securing lift lever detent plate to the fender and frame 3 Insert a 3 16 inch hex key through the access hole of the front fender and into the jacking screw of the lift lever detent plate WARNING The engine must be running...

Page 81: ... system is contaminated flush and refill hydraulic system and tank see Flush Hydraulic System 4 Make sure hydraulic tank is full Add correct oil if necessary see Check Hydraulic System Fluid 5 Disconnect spark plug leads to prevent the engine from starting 6 Check control linkage to the hydrostat for proper ad justment binding or broken parts 7 Make sure traction pedaland the lift control lever ar...

Page 82: ...nd re verse the connections B If the wheel rotates in the proper direction stop engine and adjust the spring adjusting pin lock nut 16 Adjust traction pedal to the neutral position see Ad just Traction Pedal for Neutral 17 On the SP 2020 3020 install engine shield and piv ot seat down On the SP 5020 secure panel to right side of machine with cap screws 18 Check operation of the traction interlock ...

Page 83: ...2 5 Clean area around the hydraulic oil filter Remove filter from the filter head Allow oil to flow into a drain pan Dispose of the oil filter properly Fig 23 or 24 6 Apply a film of clean hydraulic oil on the filter gasket Install filter by hand until gasket contacts filter head then tighten filter an additional three fourths of a turn 7 Fill tank to the proper level see Check Hydraulic System Fl...

Page 84: ... 14 Lift valve 15 Cap screw 16 Self tapping screw 17 Seat support spacer 18 Pivot 19 Spring pin 20 Valve lever latch 21 Brake lever 22 Clevis 23 Hex nut 24 Clevis pin 25 Cotter pin 26 Flat washer 27 Lock nut 28 Cap screw 29 O ring 30 Hydraulic hose 31 O ring 32 Hydraulic hose 33 Shuttle valve tube 34 Hydraulic tube 35 Brake rod 36 Lift lever guide 37 Wave washer 38 Lock nut Figure 25 1 2 3 4 5 7 9...

Page 85: ...hydraulic fittings 4 and 13 and O rings 31 from the lift valve Installation Fig 25 1 Make sure lift valve hydraulic hoses fittings and tubes are cleaned thoroughly 2 Reinstall O rings 31 and hydraulic fittings 4 and 13 to the lift valve Observe match marks when tighten ing 3 Position lift valve 14 to the frame Insert four cap screws 15 through the frame and lift valve Screw lock nuts 11 to the bot...

Page 86: ...16 Bulkhead nut 17 Spacer 18 Washer 19 Grommet 20 Lift lever 21 Welded pivot 22 Spring pin 23 R clamp 24 Lock washer 25 Curved washer 26 O ring 27 O ring 28 O ring 29 O ring 30 O ring 31 Hydraulic tube 32 Hydraulic hose 33 Hydraulic hose 34 Hydraulic hose 35 Hydraulic tube 36 Hydraulic tube 37 Hydraulic tube 38 Hydraulic tube 39 Hydraulic tube 40 Hydraulic tube 41 Hydraulic tube Figure 26 25 1 2 3...

Page 87: ...from the frame Do not further disassemble parts assembled to the lift lever IMPORTANT Match mark positions of hydraulic fit tings 2 8 9 and 10 relative to their ports on the lift valve 12 Remove remaining hydraulic fittings 2 8 9 and 10 and O rings 27 and 28 from the lift valve Installation Fig 26 1 Make sure lift valve hydraulic hoses fittings and tubes are cleaned thoroughly 2 Reinstall O rings ...

Page 88: ... the body 7 Use hooked scribe to remove both O rings from the body Be careful not to scratch bore finish Inspection 1 Inspect spool for wear and flatness Wear on one side of the spool may indicate a bent spool Replace spool if necessary 2 Inspect check valve seat for wear and damage of sealing surface Replace if necessary 3 Inspect ball for wear damage and flat spots Re place if necessary Reassemb...

Page 89: ...lic cylinder and lift arm 6 Support hydraulic cylinder to prevent it from drop ping A Remove a cotter pin from the cylinder pin B Pull cylinder pin from the hydraulic cylinder and frame C Remove hydraulic cylinder from the frame Installation 1 Position hydraulic cylinder tho the frame Insert cyl inder pin through the frame bracket and cylinder Secure pin with cotter pins 2 Position clevis of the h...

Page 90: ... Remove cap screw and flat washer from the cyl inder support B Remove lift cylinder from the support Installation 1 Position lift cylinder to the frame Install lift cylinder to to the cylinder support Secure cylinder to the support with flat washer and cap screw 2 Position clevis of the lift cylinder to the lift arm and spacer Insert cylinder pin through the cylinder clevis lift arm and spacer Sec...

Page 91: ...the piston Re move poly pack O ring and back up ring from the head 11 Dust seal 12 Retaining ring 13 Shaft w clevis 14 Pivot end 15 Clevis Reassembly 1 Make sure all parts are clean before reassembly 2 Coat new O rings Uni rings poly pack back up ring and dust seal with with clean hydraulic oil Install Uni ring and O ring to the piston Install poly pack O ring and back up ring to the head IMPORTAN...

Page 92: ...k machine on a level surface set brake lower attachment and stop engine CAUTION possible burns Allow engine and exhaust sys The muffler and exhaust pipe may be hot Avoid tem to cool before working near the muffler CAUTION 3 Remove muffler shield from the engine by first re moving three cap screws and lock washers securing the Operate all hydraulic controls to relieve system shield pressure and avo...

Page 93: ...drostat Observe match marks when tight ening 3 Remove caps or plugs from the hydrostat 4 Install woodruff key 26 to hydrostat shaft Support hydrostat 9 while positioning onto pump mount 25 Make sure woodruff key 26 stays in place when the shaft is inserted into the pump hub 24 5 Secure hydrostat to mount with both cap screws 6 lock washers 28 hex nuts 27 Tighten set screw 20 to hydrostat shaft 6 R...

Page 94: ...T RIGHT Removal Fig 33 1 Before removing any parts from the hydraulic sys tem park machine on a level surface set brake lower attachment and stop engine CAUTION Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy draulic oil Controls must be operated with the ignition switch in OFF Remove key from the igni tion switch 2 Pivot seat up Remove left and right...

Page 95: ...port the the frame Fig 39 D Lower and pull back hydrostat and engine from the cooler mount so the cooling fan is clear of the mount 11 Separate hydrostat from the engine base by remov ing both lock nuts and socket head screws 12 Remove fan hub 27 with cooling fan 28 and woodruff key 9 from the hydrostat shaft 13 Match mark position of all hydraulic fittings on the hydrostat Remove all hydraulic fi...

Page 96: ...crew Fig 37 8 Connect all six hydraulic hoses to fittings on the hy drostat Remove clamps from hydraulic hoses 25 and 35 that prevented draining of the tank 9 Tighten both set screws 11 on pump hub 19 enough to secure the hub to the shaft 10 Connect air hose to the air cleaner Install lower shroud to the cooler mount Connect control rod to the pump lever Fig 36 11 Secure black ground wire and blac...

Page 97: ... oil filter and drain into a suitable contain er Discard filter see Change Hydraulic System Fluid and Filter NOTE Use only hydraulic fluids including biodegrad able specified in Checking Hydraulic System Fluid Other fluids may cause system damage 7 Reconnect all hydraulic hoses lines and compo nents that were disconnected prior to draining 8 Fill hydraulic tank with new hydraulic fluid see Change ...

Page 98: ...g 43 Trunnion shaft SP 2020 3020 44 Needle bearing 45 Variable housing 46 Retaining ring 47 Shaft 48 Swashplate 49 Spring pin 50 Thrust plate 51 Shaft bearing 52 Cylinder block assembly 53 Lip seal 54 Washer 4 used 55 Cap screw 4 used 56 Control shaft bearing SP 5020 57 Trunnion shaft bearing SP 5020 Figure 40 30 31 32 33 34 35 36 37 38 39 40 32 42 29 43 44 45 46 47 48 49 50 51 9 1 2 3 4 5 6 7 8 9...

Page 99: ...ing if needles do not turn freely or do not re main in cage Replace bearing as necessary 3 Inspect lip seal for tears and damage that will re duce the sealing properties of the seal Replace as nec essary 4 Inspect gerotor pocket inside the charge pump housing of excessive scoring Replace as necessary Charge Pump Assembly 1 Coat both sides of gerotor assembly and pump housing face with clean hydrau...

Page 100: ...d abrasive residue that could Figure 42 damage the lip seal during installation 2 3 1 1 Retaining ring 3 Lip seal 4 Lip seal NOTE The outside diameter of the lip seal may be 2 Washer coated with Loctite High Performance Sealant 5923 or equivalent This aids the prevention of leaks caused by seal bore damage 2 Lubricate shaft with clean hydraulic oil Slide lip seal over shaft carefully Make sure not...

Page 101: ...ring and poppet out of the housing Relief Valve Inspection Fig 44 1 Inspect poppet and spring for nicks cracks and dis tortion Replace parts as necessary 2 Inspect valve seat in the housing for damage and foreign material Remove any foreign material Relief Valve Assembly Fig 44 1 Insert poppet spring and shim kit into housing 2 Install O rings and plugs into housing Tighten plugs Charge Check Valv...

Page 102: ...ounterbore in the face of the swashplate Fig 46 IMPORTANT Make sure not to damage the face sur face on the cavity side of the variable housing 6 Position variable housing so the large cavity faces up Fig 47 NOTE The variable housing has a cast recess that al lows the spring pins to be driven free of the trunnion shaft and control shaft 7 Drive spring pin out of the trunnion shaft and control shaft...

Page 103: ...ck surface that makes contact with the valve plate should be smooth and free of deep scratches Do not lap cylinder block C The bore areas of the cylinder block should be free of scoring and contamination Pistons should move freely in the bore areas D Examine the mutual contact surfaces on the spi der and spider pivot both contact areas should be smooth and free of wear E Replace entire cylinder bl...

Page 104: ...l linkage Fig 49 4 A Insert control and trunnion shafts through the housing into the swash plate bores B Make sure holes in the swashplate and shafts are aligned properly 6 Insert new spring pins through the swashplate and into the control and trunnion shafts Fig 50 5 1 1 1 4 INCH 6 4 mm 7 3 6 A Install first pin until the second pin can be started Figure 50 5 Variable housing B Drive both pins in...

Page 105: ...inst the end cap face The two V notches must face away from the end cap 14 Insert locating pin into the end cap Lubricate slotted side of valve plate Slip plate over pin and protruding bearing Fig 52 IMPORTANT Make sure valve plate gasket and O rings stay in position when securing the end cap to the variable housing 15 Mate four cap screws to the variable housing Fig 52 A Tighten cap screws in an ...

Page 106: ... must be operated with the tion switch Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy ignition switch in OFF Remove key from the igni 21 Lock nut 22 Woodruff key 2 Clean hydraulic wheel motor 45o hydraulic fittings and hydraulic hose connections thoroughly 3 Label all hydraulic connections for reassembly Dis connect hydraulic hoses from 45o hydraulic...

Page 107: ...nd drive studs through wheel Make sure valve stem and hydraulic motor are on the opposite sides of the wheel 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 5 Position hydraulic motor wheel and flangettes to the front fork 6 Lower front fork slowly making sure flange...

Page 108: ...ve hydraulic tube 17 Right motor rear hydraulic tube 18 Right motor front hydraulic tube 19 Left motor front hydraulic tube 20 Left motor rear hydraulic tube 21 O ring 22 Brake bracket 23 Backing plate 24 Anchor pin 25 Return spring 26 Brake shoe 27 Cam shaft 28 Hex nut 29 Lock washer 30 Spacer 31 Cap screw 32 O ring 33 Retaining clip Figure 54 25 26 3 27 26 2 1 5 4 31 29 28 8 23 11 10 33 22 30 12...

Page 109: ...caps or plugs on disconnected tubes and motor ports to prevent contamination from entering NOTE On the SP 2020 3020 two hex nuts are used with the top two cap screws when securing the wheel motor to the frame 11 Remove hex nuts cap screws spacers and lock washers securing the brake bracket and wheel motor to the frame Remove motor from the frame Installation Fig 57 or 56 NOTE On the SP 2020 3020 t...

Page 110: ...ap screw 21 Lock washer 22 Hydraulic tube 23 Hydraulic tube 24 Not used 25 Not used 26 Not used 27 Not used 28 Not used 29 Retainer 30 Cam shaft 31 Extension spring 32 Brake shoe 33 Backing plate 34 Brake drum 35 Cap screw 36 Lock nut 37 Spacer 38 Brake bracket 39 Rod adjustment 40 Brake lever 41 Jam nut 42 Adjustment clevis 43 Clevis pin 44 Cotter pin 45 Cotter pin Figure 57 21 37 13 10 12 14 23 ...

Page 111: ... drain into a suitable con tainer 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 wash ers securing the brake bracket and wheel motor to the frame Remove motor from the frame Installation Fig 57 or 59 1 Position wheel motor to the frame Secure motor...

Page 112: ...ng 11 Coupling shaft 12 Thrust bearing 13 Drive link 14 Cap screw 15 Commutator seal 16 Commutator 17 Woodruff key 18 Wear plate 19 Rotor 20 Vane 21 Stator 22 Manifold 23 Commutator ring 24 End cover assembly Front LH 25 End cover assembly RH 26 Plug 27 O ring RH 28 Spring RH 29 Shuttle valve RH 30 Ball RH Figure 60 1 2 3 4 5 6 7 8 9 10 16 17 18 19 20 21 22 23 24 11 12 13 14 15 8 25 27 26 29 30 28...

Page 113: ...emove commutator 16 and commutator seal 15 Remove commutator seal from the commutator using an air hose to blow air into the ring groove until the commutator seal is lifted out Fig 62 NOTE The manifold 22 is constructed of plates bonded together to form an integral component not sub ject to further disassembly for service Compare config uration of both sides of the manifold to make sure that Figur...

Page 114: ...huttle valve 29 and ball 30 Remove remaining plug and O ring Inspection Fig 60 1 Inspect bolts 14 for damaged threads and sealing rings under the bolt head Replace if damaged Fig 65 NOTE A polished pattern not scratches on the end cover 24 or 25 from rotation of the commutator 16 is normal Discoloration would indicate excess fluid tem perature thermal shock or excess speed and require system inves...

Page 115: ...Inspect drive link 13 for cracks and worn or dam Figure 68 aged splines No perceptible backlash play should be noted between mating spline parts of the rotor 19 or coupling shaft 11 Replace as necessary Fig 68 11 Inspect thrust bearing 12 for wear peening corro sion and a full complement of retained rollers Replace as necessary 12 Inspect coupling shaft 11 internal and external splines and keyway ...

Page 116: ...s a new dirt and water seal 1 into the housing 3 outer bearing counterbore Press seal in with the lip facing out and until the seal is 0 020 inch 0 51 mm be low the end of housing 4 Place housing 3 into a soft jawed vise with the cou pling shaft bore down clamp against the mounting flange IMPORTANT Early model wheel motors that do not have back up washer 6 assemble with a new back up washer 4 new ...

Page 117: ... 3 seal ring groove NOTE One or two alignment studs screwed finger tight into housing 3 bolt holes approximately 180 degrees apart will facilitate the assembly and alignment of com Figure 76 ponents as required in the following procedures The studs can be made by cutting off the heads of 3 8 24 UNF 2A bolts so they are 0 5 inch 12 7 mm or longer than cap screw 14 NOTE Use any alignment marks put o...

Page 118: ...led by hand assemble with the following procedures A Place stator 21 onto wear plate 18 with seal ring 5 side down Be sure the seal ring is in place Fig 80 Figure 80 B If assembly alignment studs are not being uti lized align stator 21 bolt holes with wear plate 18 and housing 3 bolt holes Screw two cap screws 14 finger tight into bolt holes approximately 180 degrees apart to retain stator and wea...

Page 119: ...over the alignment studs and drive link 13 and onto the rotor set Be sure the correct manifold surface is against the rotor set 17 Apply clean petroleum jelly to a new seal ring 5 and insert it in the seal ring groove exposed on the man ifold 22 18 Assemble the commutator ring 6 over alignment studs onto the manifold 22 Fig 84 Figure 84 19 Assemble a new commutator seal 15 flat side up into commut...

Page 120: ...n 21 Flat washer 22 O ring 23 O ring 24 Hydraulic hose 25 O ring 26 Tether retainer 27 Oil cap tether 28 Hydraulic hose 29 Hydraulic tank 30 Return hose 31 Hose clamp 32 Push on hose fitting 33 Barb fitting 34 Hose clamp 35 Suction hose 36 90o degree hydraulic fitting 37 O ring Figure 86 1 2 4 5 6 8 9 10 16 17 18 19 20 21 22 23 11 12 13 14 15 3 23 24 25 26 27 28 7 29 31 36 35 34 33 32 30 31 37 LAT...

Page 121: ... cap screws 17 fit tightly into the tank If loose remove and reinstall cap screws with antiseize lubricant on the threads Torque cap screws from 30 to 60 in lb 35 to 69 kg cm 5 Make sure hydraulic fittings are tight and do not leak Installation Fig 86 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 bas...

Page 122: ...0 Rubber shield 21 Hose clamp 22 Air hose 23 Air cleaner 24 Mounting band 25 Floor tread 26 Front shield 27 Sand Pro decal 28 CE mark decal 29 O ring 30 Pop rivet 31 Semitubular rivet 32 Rubber pad 33 Latch handle 34 Bracket RH 35 Bracket LH 36 Keeper 37 Wire tie 38 Wear strip 39 Convoluted tube 40 Wire harness 41 Wire assembly 42 Wire assembly 43 Hydraulic hose 44 Rubber snubber 45 Front motor tu...

Page 123: ...rubber clamps 3 and T nuts 4 12 Pull the oil cooler 2 from the machine 13 Remove 90o hydraulic fittings 5 and O rings 29 from the oil cooler 2 Cleaning and Inspection Fig 87 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 Use eye protection such as goggles when using compressed air 2 Dry insi...

Page 124: ...5 6 12 8 10 7 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 11 13 14 15 7 7 11 8 8 9 14 42 5 23 29 5 30 to 60 ft lb 35 to 69 kg cm Oil Cooler Removal Fig 88 1 Before removing any parts from the hydraulic sys tem park machine on a level surface set brake lower attachment and stop engine CAUTION Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy draulic oil...

Page 125: ...rews 21 and flat washers 20 se curing the hydraulic tank 40 to the cooler mount 25 9 Remove three self tapping screws 26 securing the lower portion of the cooler mount 25 to the frame 10 Remove both lock nuts 23 and cap screws 42 se curing the upper front portion of the cooler mount 25 to the frame Lower mount and cooler from the machine 11 Separate oil cooler 40 from the cooler mount 25 by removi...

Page 126: ... tube 37 10 Make sure hydraulic fittings 36 on the oil cooler 30 are clean Connect hydraulic tube 37 and hose 28 to the cooler 11 Connect air hose to the air cleaner Remove lower shroud to the cooler mount Connect control rod to the pump lever Fig 89 12 Install left fender and seat see Left Fender Seat Base Installation in Chapter 6 Wheels Brakes and Miscellaneous Install left and right side panel...

Page 127: ...ing Diagram 3 Ignition Switch 10 Sand Pro 5020 Electrical Schematic 4 Hour Meter 11 Sand Pro 5020 Starter Solenoid 12 Harness and Wiring Diagram 5 Neutral Switch 12 SPECIAL TOOLS 6 SERVICE AND REPAIRS 13 TROUBLESHOOTING 7 Battery Storage 13 Starting Problems 7 Battery Care 13 General Run Transport Problems 8 Battery Service 14 Check Interlock System 17 Optional Lights 18 Sand Pro 2020 3020 5020 Pa...

Page 128: ...UE ENGINE FUEL REG GROUND SOLENOID M B L A S G OFF RUN B L A B L S IGNITION SWITCH POSITION TERMINAL CONTINUITY G M A Electrical Schematic Sand Pro 2020 3020 All relays and solenoids are shown as de energized All ground wires are black SOLENOID SP SPLICE FUSIBLE LINK FL FL SP RED GREEN ENGINE WIRE HARNESS Electrical Schematics and Diagrams GRAY BATTERY STARTER STARTER ALT MAGNETO S START DETAIL GR...

Page 129: ...GINE WIRE IDENTIFICATION LABEL COLOR AWG TYPE W1 BLK 16 GPT W2 BLK 16 GPT ROUTE P2 G TO J4 TO J8 J14 Harness and Wiring Diagram Sand Pro 2020 3020 W3 BLK 16 GPT J4 TO J12 W4 BLK 16 GPT J8 TO J12 W5 RED 14 GPT P1 B TO J7 W6 RED 14 GPT P2 B TO P1 A W7 BLU 18 FUSIBLE LINK P3 1 TO SP1 W8 WHT 18 GPT P2 L TO J3 W9 BLU 16 GPT SP1 TO J16 W10 RED WHT 18 GPT J3 TO P4 1 W11 BLU 16 GPT J15 TO J16 W12 BLU 18 G...

Page 130: ...lays and solenoids are shown as de energized All ground wires are black SOLENOID GROUND GROUND SOLENOID SWITCH GROUND LIGHTS ORANGE BLUE RED WHITE BLACK RED WHITE BLACK BLUE RED WHITE RED WHITE RED WHITE RED BLACK GREEN RED RED BLACK BLACK REAR OF TRACTOR FRONT OF TRACTOR TO RED GREEN TO GREY WIRE HARNESS STARTER ALT MAGNETO S BATTERY STARTER START GRAY STARTER BATTERY Electrical Systems Page 5 4 ...

Page 131: ... 18 GPT P1 B TO J3 START W10 WHT RED 18 GPT J3 TO J15 W11 GRY 18 GPT J5 TO J12 W12 BLK 18 GPT J8 TO J4 J5 J6 J7 W13 BLK 18 GPT J4 TO J13 W14 BLK 18 GPT J13 TO J14 B W15 BLK 18 GPT J8 TO P2 4 Sand Pro 2020 3020 5020 Page 5 5 Electrical Systems 2 3 4 P2 5 4 XXX FUEL X SP2 2 IGNITION SWITCH 3 1 NEUTRAL SWITCH J12 J13 P3 P4 ENGINE P1 FUSE J2 HOUR METER J14 J15 LIGHTS A B XXX J8 GROUND MAG J3 J4 X A B ...

Page 132: ...lt Ohm Amp multimeter when testing electrical circuits The high impedance internal resistance of a digital me ter in the voltage mode will make sure that excess cur rent is not allowed through the meter This excess current can cause damage to circuits not designed to carry it Figure 1 Skin Over Grease Special non conductive grease Toro Part No 505 47 which forms a light protective skin which helps...

Page 133: ...rlock system Battery charge is low Battery cables are loose or corroded Battery ground to frame is loose or corroded Wiring at starter is faulty Starter solenoid is faulty Starter mounting bolts are loose or not supplying a sufficient ground for solenoid Starter is faulty and causing an incomplete circuit for the solenoid Nothing happens when start attempt is made Battery is dead Wiring to the sta...

Page 134: ...el system is malfunctioning see Chapter 4 Briggs Stratton Vanguard Engine Engine is out of fuel or may be to cold General Run and Transport Problems Problem Possible Causes Battery does not charge Wiring to the charging circuit see Wiring Schematics components is loose corroded or damaged Voltage regulator alternator is faulty 20 ampere fuse is missing or open SP 2020 3020 Fusible link is open Ign...

Page 135: ...rned off Connect the positive meter lead to the positive battery post and the negative meter lead the the neg ative battery post NOTE This test provides a relative condition of the bat tery Load testing of the battery will provide additional and more accurate information Voltage Measured Battery Charge Level 12 68 V or higher Fully charged 100 12 45 V 75 charged 12 24 V 50 charged 12 06 V 25 charg...

Page 136: ...tting make sure that power to the circuit has been disconnected Ignition Switch The ignition key switch has three positions OFF RUN and START The terminals are marked as shown The circuitry of the ignition switch is shown in the chart With the use of a multimeter ohms setting the switch func tions may be tested to determine whether continuity ex ists between the various terminals for each position...

Page 137: ...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 Figure 6 WINDOW 1 10 WHEEL WHITE W BLACK NUMBERS HOUR WHEELS BLACK W WHITE NUMBERS 1 10 HOURS 0 0 0 0 0 RUNNING INDICATOR QUARTZ SP 5020 Figure 7 Sand Pro 2020 3020 5020 Page 5 11...

Page 138: ...W Neutral Switch NOTE Prior to taking small resistance readings with a digital multimeter short the test leads together The me NEUTRAL SWITCH ter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal re sistance of the meter and test leads Subtract this value from from the measured value of the component you are testing This switch is closed when the...

Page 139: ...g can dissipate Since the gases are explosive keep open flames and electrical plug charger from electrical outlet before con from battery posts WARNING Wear safety goggles and rubber gloves when sparks away from the battery do not smoke Nausea may result if the gases are inhaled Un necting or disconnecting charger leads to or 2 Keep top of battery clean by washing periodically with a brush dipped ...

Page 140: ...10 and 11 IMPORTANT Be careful not to damage terminal posts or cable connectors when removing the bat tery cables 1 Remove wing nuts washers and battery clamp or hold down from battery hold down rod 2 Remove lock nut and cap screw from ground cable post first and remove cable from battery This should prevent short circuiting the battery other components or the operators hands 3 Remove lock nut and...

Page 141: ...ch 10_F 5 5_C above 80_F 26 7_C add 0 004 to the specific gravity reading For each 10_F 5 5_C be low 80_F 26 7_C subtract 0 004 from the specific gravity reading Example Cell Temperature 100_F Cell Gravity 1 245 100_F minus 80_F equals 20_F 37 7_C minus 26 7_C equals 11 0_C 20_F multiply by 0 004 10_F equals 0 008 11_C multiply by 0 004 5 5_C equals 0 008 ADD conversion above 0 008 Correction to 8...

Page 142: ... battery post Tighten cap screw and lock nut with two wrenches 5 Secure battery clamp or hold down to the battery and hold down rod with the washer and wing nut Do not overtighten to prevent cracking or distorting the battery case 6 Apply a light coat of grease on all battery posts and cable connectors to reduce corrosion after connections are made 7 Connect a digital multimeter set to amps betwee...

Page 143: ... of the battery electrolyte If the temperature exceeds 125_F 51 6_C or the electrolyte is violently gassing or spewing the charging rate must be lowered or temporarily stopped 6 Three hours prior to the end of the charging mea sure the specific gravity of a battery cell once per hour The battery is fully charged when the cells are gassing freely at a low charging rate and there is less than a 0 00...

Page 144: ...cted 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 Dia grams IMPORTANT Do not exceed a total lighting capacity of 150 watts on a machine Exceeding this limit will damage the alternator Electrical Systems Page 5 18 Sand Pro 2020 3020 5020 ...

Page 145: ...3020 12 Brake Linkages SP 5020 13 Front Fork and Steering SP 2020 and Older SP 3020 Models 14 Front Fork and Steering Newer SP 3020 Models 15 Upper Steering Disassembly 16 Upper Steering Assembly 16 Lower Steering Disassembly 17 Lower Steering Assembly 17 Front Fork Removal 17 Front Fork Installation 17 Seat SP 5020 19 Steering SP 5020 20 Front Fork SP 5020 22 Hood and Dash Panel SP 2020 3020 23 F...

Page 146: ...escription 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 45 to 55 ft lb 6 2 to 7 6 kg m Wheels Brakes and Miscellaneous Page 6 2 Sand Pro 2020 3020 5020 ...

Page 147: ...chains on the SP 2020 3020 Fig 1 and SP 5020 Fig 2 are adjusted in the same man ner Newer models of the SP 3020 have a chain guide similar to the SP 5020 1 Place front wheel in the straight ahead position 2 Adjust locknuts until the chain is snug on both sides of the sprocket 3 Turn the steering wheel full left and full right to be sure the chain does not bind or hang up in either direc tion Readj...

Page 148: ...ke lever 3 Cotter pin 5 Drive the machine and pull brake lever Both wheels should lock equally Readjust brake if necessary Adjust Brake SP 5020 CAUTION check the brakes in a wide open area that is flat and free of other persons and obstructions Before and after adjusting the brakes always 1 While driving the machine pull brake lever Both wheels should lock equally 2 Park machine an a level surface...

Page 149: ...ne brackets and seat clamps with cap screws flat washers and lock nuts Secure manual tube and R clamps to 2 Lift seat up Remove four cap screws from seat angle bracket with cap screws flat washers and lock plate and seat Separate seat from plate Make sure not nuts to lose four spacers 2 Position seat and spacers to seat plate Insert cap 3 Remove seat plate from frame by removing lock screws throug...

Page 150: ...WARNING Before jacking up the machine review and follow Jacking Instructions in Chapter 1 Safety Support wheel and shaft when removing car flanges to prevent personal injury 6 Slide bearing flanges and bearings off the front axle 2 Jack up front fork enough to allow the bearing flanges and front axle to drop free of the fork 7 Separate bearing flanges from the bearings 3 Loosen set screws on both ...

Page 151: ...front fork Make sure bearing flanges are placed inside the fork riage bolts lock washers and hex nuts 5 Rotate both bearing lock collars in the direction of normal forward wheel rotation Place drift punch into the blind whole of the locking collar Strike punch sharply with a hammer in the direction of shaft rotation to lock the collar Repeat with other collar 6 Apply Loctite 242 or equivalent to b...

Page 152: ... hydraulic motor and brake lower attachment and stop the engine flangettes can be removed from the fork Remove flan gettes spindle wheel and motor from the fork 2 Loosen both set screws on the locking collar 6 Slide flangettes and bearing assembly from the 3 Support front of the machine Remove three cap spindle Separate flangettes from the bearing screws and lock nuts securing the flangettes and b...

Page 153: ...nuts from 45 to 55 ft lb 6 2 to 7 6 kg m 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 7 Lower front fork slowly Make sure flangettes and front wheel motor fit snugly into the fork A Secure flangettes to the fork with cap screws bearing tab and locknuts B Secure hydraulic motor t...

Page 154: ... on a level surface lower attachment and stop engine WARNING Before jacking up the machine review and follow Jacking Instructions in Chapter 1 Safety 2 Jack up rear wheel and use wood blocks to keep the rear tire off the floor 3 Remove lug nuts from drive studs Pull wheel from drive studs and wheel hub NOTE The installation torque of the locknut is from 200 to 400 ft lb 27 7 to 55 3 kg cm Use impa...

Page 155: ...ft with retaining clip D Position both brake shoes on the backing plate so that the concave heels attach to the anchor pin E Insert both return springs into the holes of both brake shoes Make sure shoes fit snuggly against the anchor pin and cam ÇÇ ÇÇ ÇÇ ÇÇ 1 6 6 4 5 7 2 3 8 Figure 9 1 Return spring 5 Retaining clip 2 Brake shoe toe end 6 Cam shaft 3 Brake shoe heel end 7 Anchor pin 4 Backing plat...

Page 156: ...ffler 1 Remove knob from the lift lever Remove both lock nuts and cap screws securing the lift valve shroud lift le ver guide and lift lever latch Fig 26 2 Remove bottom front cap screw securing the lift valve shroud to the frame Pull shroud from the frame Fig 26 IMPORTANT When removing the clevis from either the brake rod or brake lever or the brake lever from the cam shaft on the brake assembly ...

Page 157: ...ure to matchmark both parts placed without removing any interference However the when removing the clevis from either the brake rod right fender must be removed to work on the parking or brake lever or removing the brake lever from the brake lever cam shaft on the brake assembly Marking both CAUTION possible burns allow engine and exhaust sys The muffler and exhaust pipe may be hot Avoid tem to co...

Page 158: ...onnecting link 15 Steering chain 16 Steering washer 17 Bearing cone 18 Grease fitting see NOTE 19 Extension tube see NOTE 20 Bearing cup 21 Frame 22 Cotter pin 23 Slotted nut 24 Roll pin 25 Steering knuckle 26 Lower steering shaft 27 Lock nut 28 R clamp 29 Washer 30 Grease fitting see NOTE Figure 13 26 1 2 3 4 5 27 7 8 9 12 13 14 16 17 18 19 20 21 14 15 20 17 16 22 23 24 25 7 6 6 27 28 10 11 FRONT...

Page 159: ...ting link 14 Steering chain 15 Steering washer 16 Bearing cone 17 Grease fitting 18 Bearing cup 19 Frame 20 Cotter pin 21 Slotted nut 22 Roll pins 23 Steering knuckle 24 Lower steering shaft 25 Lock nut 26 R clamp 27 Cap screw 28 Lock washer 29 Chain bracket 30 Hex nut 31 Cap screw 32 Fork stop plate 33 Grease fitting 34 Chain guide 35 Washer Figure 14 13 1 2 3 4 25 16 18 31 8 7 17 19 18 16 20 15 ...

Page 160: ...pper steering shaft from steering post and steering knuckle If desired pull steering knuckle from the lower steering shaft 8 Remove both hex flange head screws securing the dash panel to the steering post Fig 16 9 Remove four lock nuts and cap screws securing both R clamps and steering post to the frame Fig 15 10 Pull dash panel up and back Slide steering post from dash panel Upper Steering Assemb...

Page 161: ...ings is required proceed as follows WARNING Before jacking up the machine review and follow Jacking Instructions in Chapter 1 Safety 1 Jack up front wheel enough to allow removal of the front fork 2 Remove cotter pin securing the slotted nut to the fork shaft Unscrew slotted nut from the shaft Remove steering washer from the shaft 2 1 Figure 17 1 Sprocket 2 Drive lock pin 3 Pull fork from the fram...

Page 162: ...rotating the fork Back off nut so nearest slot aligns with cross hole in the shaft Secure nut to shaft with cotter pin 6 Install front wheel to the front fork see Front Wheel Installation 7 Position steering chain around the sprocket and chain guide Secure chain to chain bracket with steering adjustment pins and lock nuts Adjust steering chain see Adjust Steering Chain Wheels Brakes and Miscellane...

Page 163: ... seat all the way back Remove both cap screws and lock nuts securing the rear of the seat adjust plate to the seat sliders 4 Remove seat and seat adjust plate from the seat sliders Remove four cap screws securing the seat ad just plate to the seat 5 Lift seat base Remove lock nuts and flat washers securing seat sliders to the seat base Installation 1 Lift seat base Secure seat sliders to the seat ...

Page 164: ...k nut 17 Adjustment bolt 18 Connecting link 19 Chain 20 Drive lock pin 21 Sprocket 22 Flange bushing 23 Lower steering shaft 24 Roll pin 25 Steering knuckle 26 Steering column 27 Sleeve bushing 28 Upper steering shaft 29 Flat head socket screw 30 Dowel 31 Lower lock block 32 Grease fitting 33 Chain guide 34 Chain bracket 35 Cap screw 36 Hex nut 37 Lock washer 38 Chain stay plate Figure 19 1 2 3 4 ...

Page 165: ...ne on a level surface lower attachment stop engine engage parking brake and remove key from the ignition switch NOTE The fuel tank must be removed from the frame to allow separation of the lower steering shafts from the steering knuckle 2 Remove fuel tank from the machine see Fuel Tank Removal in Chapter 3 Briggs Stratton Vanguard En gines 3 Loosen lock nut on the steering adjustment bolt enough t...

Page 166: ...necessary Installation Fig 20 1 Secure chain guide and fork stay plate to the front fork with cap screws spacers and hex nuts 2 Secure chain bracket to the chain guide with cap screws and lock washers 1 5 6 4 4 5 6 2 7 3 Figure 20 1 Cotter pin 5 Bearing cone 2 Slotted nut 6 Bearing cup 3 Front fork 7 Grease fitting 4 Steering washers 3 If bearing cones or cups were damaged press new bearing cups i...

Page 167: ...nstallation 1 Position dash panel over the steering post and to the machine Fig 12 2 Connect choke and throttle control cables to the en gine see Throttle Control and Choke Control Installa tion in Chapter 3 Briggs Stratton Vanguard Engines 3 Secure dash panel to steering post with both flange head screws Fig 12 4 Connect electrical connections to the fuse holder hourmeter and ignition switch Fig ...

Page 168: ...ve hex nut and lock washer securing the igni tion switch to the right fender Pull switch clear of the Figure 25 fender 1 Knob 5 Ignition switch 2 Throttle control 6 Hex flange head screw 3 Choke control 7 Lift lever 5 Unscrew knob from the lift lever Remove both hex 4 Cap screw lock nut 8 Carriage bolt lock nut flange head screws from the fender Remove both car riage bolts and lock nuts securing t...

Page 169: ......

Page 170: ...Commercial Products E The Toro Company 1998 ...

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Toro Sand Pro 5020, Service Manual

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