Toro Sand Pro 2020 User manual

PART NO. 98957SL, Rev. B
Service Manual
Sand ProR2020/3020/5020
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 OP-
ERATING, MAINTENANCE AND ADJUSTMENT
INSTRUCTIONS. Space is provided in Chapter 2 of this
book to insert the Operator’s Manuals and Parts Cata-
logs for your machine. Replacement Operator’s Manu-
als are available by sending complete Model and Serial
Number to:
The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420–1196
The Toro Company reserves the right to change product
specifications or this publication without notice.
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 personal injury.
NOTE: A NOTE will give general information about the
correct operation, maintenance, service, testing, or re-
pair of the machine.
IMPORTANT: The IMPORTANT notice will give im-
portant instructions which must be followed to pre-
vent damage to systems or components on the
machine.
EThe Toro Company – 1998, 2003, 2006

Sand Pro 2020/3020/5020

Table Of Contents
Chapter 1 – Safety
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 1
Jacking Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 4
Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 – 5
Chapter 2 – Product Records and Manuals
Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 1
Equivalents and Conversions . . . . . . . . . . . . . . . . 2 – 2
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . 2 – 3
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 4
Operation and Service History Reports . . . . . . . . 2 – 7
Chapter 3 – Engine
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 3
General Information . . . . . . . . . . . . . . . . . . . . . . . . 3 – 4
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 7
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 3 – 8
Briggs & Stratton Vanguard Service and Repair Manual
for 4–Cycle V–Twin Cylinder OHV Engines
Chapter 4 – Hydraulic Systems
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 2
General Information . . . . . . . . . . . . . . . . . . . . . . . . 4 – 3
Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . 4 – 6
Hydraulic Flow Diagrams . . . . . . . . . . . . . . . . . . . . 4 – 8
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 14
Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 16
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 19
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 28
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 4 – 31
Chapter 5 – Electrical Systems
Electrical Schematics and Diagrams . . . . . . . . . . 5 – 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 7
Electrical System Quick Checks . . . . . . . . . . . . . . 5 – 9
Component Testing . . . . . . . . . . . . . . . . . . . . . . . . 5 – 10
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 5 – 13
Chapter 6 – Wheels, Brakes, and Miscellaneous
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 2
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 3
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 6 – 5
SafetyProduct Records
and Manuals
Engine
Hydraulic
Systems
Electrical
Systems
Wheels, Brakes
and Miscellaneous
Sandpro 2020/3020/5020

Sand Pro 2020/3020/5020

Chapter 1
Safety
Table of Contents
GENERAL SAFETY INSTRUCTIONS . . . . . . . . . . . . 1
Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Maintenance and Service . . . . . . . . . . . . . . . . . . . . 3
General Safety Instructions
TheSandPro2020/3020/5020weretestedandcertified
byTOROforcompliancewiththeB71.4–1984specifica-
tions of the American National Standards Institute. Al-
though hazard control and accident prevention partially
aredependentuponthedesignandconfigurationofthe
machine, these factors are also dependent upon the
awareness, concern, and proper training of the person-
nel involved in the operation, transport, maintenance,
and storage of the machine. Improper use or mainte-
nance of the machine can result in injury or death.
JACKING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . 4
SAFETY AND INSTRUCTION DECALS . . . . . . . . . . 5
Sand Pro 2020/3020 . . . . . . . . . . . . . . . . . . . . . . . . 5
Sand Pro 5020 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
comply with the following safety instructions.
WARNING
To reduce the potential for injury or death,
Safety
Before Operating
1. Operate machine only after reading and under-
standing the contents of this manual. A replacement
manualis available by sending complete model and se-
rial number to:
The Toro Company
8111 Lyndale Avenue South
Minneapolis, Minnesota 55420–1196
2. Never allow children to operate the machine or
adults to operate it without proper instructions.
3. Become familiar with the controls and know how to
stop the engine quickly.
4. Keepallshields,safetydevicesanddecalsinplace.
Ifashield,safetydeviceordecalismalfunctioning,illeg-
ible, or damaged, repair or replace it before operating
the machine.
5. Alwayswearsubstantial shoes.Donotoperate ma-
chine while wearing sandals, tennis shoes or sneakers.
Donotwearloosefittingclothingwhichcouldgetcaught
in moving parts and cause personal injury.
6. Wearing safety glasses, safety shoes, long pants
and a helmet is advisable and required by some local
safety and insurance regulations.
7. Ensuretractioninterlockswitchisadjustedcorrectly
so engine cannot be started unless traction pedal is re-
leased and in neutral position.
8. Keep everyone, especially children and pets away
from the areas of operation.
9. Gasoline is highly flammable; handle it carefully.
A. Use an approved gasoline container.
B. Donotremovecapfromfueltankwhenengineis
hot or running.
C. Do not smoke while handling gasoline.
D. Fill fuel tank outdoors to about one inch below
top of tank, (bottom of filler neck). Do not overfill.
E. Wipe up any spilled gasoline.
10. Check the safety interlock system daily for proper
operation (see Check Interlock System in Chapter 5 –
ElectricalSystems).Iftheswitchshouldmalfunction,re-
placeswitchbeforeoperatingmachine.(Aftereverytwo
years, replace interlock switch in the safety system,
whether it is working properly or not.)
Sand Pro 2020/3020/5020 Page 1 – 1 Safety

While Operating
11. Exhaust fumes are hazardous and could be deadly,
so do not run the engine in a confined area without ade-
quate ventilation.
12. Sit on seat when operating the machine. Never
carry passengers.
13. When starting the engine:
A. Make sure traction pedal is released.
B. After the engine is started, keep foot off traction
pedal. Machine must not move. If movement is evi-
dent, the neutral return mechanism is adjusted in-
correctly; therefore, shut engine off and readjust
mechanism so machine does not move when in
neutral position. If engine does not start, check in-
terlock switch connections.
14. Using the machine demands attention. To prevent
tipping or loss of control:
A. Use care when entering and leaving sand traps.
Use extreme caution around ditches, creeks or oth-
er hazards.
B. Watch for holes or other hidden hazards.
C. Usecautionwhenoperatingmachine onasteep
slope. Reduce speed when making sharp turns or
when turning on hillsides.
D. Avoid sudden stops and starts. Do not go from
reversetofullforwardwithout first coming toacom-
plete stop.
E. Before backing up, look to the rear and assure
no one is behind the machine.
F. Watchoutfortrafficwhennearofcrossingroads.
Always yield the right of way.
15. If optional Draw Bar (Part No. 92–2330) or Hitch Kit
(ModelNo. 08833) is installed on machine, vertical load
on hitch should not exceed 200 lbs.
16. Do not touch engine, muffler or exhaust pipe while
engine is running or soon after it has stopped because
these areas are hot enough to cause burns.
17. If the machine ever vibrates abnormally, stop im-
mediately, turn engine off, wait for all motion to stop and
inspect for damage. Repair all damage before com-
mencing operation.
18. Before getting off the seat:
A. Stop movement of the machine.
B. Set parking brake and lower attachments to the
ground. Take precautions to prevent accidental
starts, rolling away, etc.
19. Whenever machine is left unattended, be sure en-
gine is stopped, parking brake is set, attachments are
loweredtotheground,andkeyisremovedfromignition.
Safety Page 1 – 2 Sand Pro 2020/3020/5020

Maintenance and Service
20. Before servicing or making adjustments to the ma-
chine, stop engine, remove key from the ignition, and
pull the spark plug wire off spark plug to prevent acci-
dental starting of the engine.
21. Makesureallhydrauliclineconnectorsaretight,and
all hydraulic hoses and lines are in good condition be-
fore applying pressure to the system.
22. Keep body and hands away from pin hole leaks or
nozzles that eject hydraulic fluid under high pressure.
Use paper or cardboard, not hands, to search for leaks.
Hydraulic fluid escaping under pressure can have suffi-
cient force to penetrate skin and do serious damage. If
fluid is injected into the skin it must be surgically re-
moved within a few hours by a doctor familiar with this
form of injury or gangrene may result.
23. Beforedisconnectingorperforminganyworkonthe
hydraulic system, all pressure in system must be re-
lieved by stopping engine, engaging parking brake and
lowering attachments to the ground.
24. To make sure entire machine is in good condition,
keep all nuts, bolts and screws properly tightened.
25. Ifmajorrepairsareever needed or assistanceisre-
quired, contact an Authorized TORO Distributor.
26. To reduce 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. Donotoverspeedenginebychanginggovernorset-
tings. Maximum engine speed is 3200 rpm. To assure
safety and accuracy, have an Authorized Toro Distribu-
tor check maximum engine speed with a tachometer.
29. Engine must be shut off before checking oil or ad-
ding oil to the crankcase.
30. To be sure of optimum performance and safety, al-
ways purchase genuine TORO replacement parts and
accessories.Replacementpartsandaccessoriesmade
by other manufacturers could be dangerous. Such use
could void the product warranty of The Toro Company.
31. When changing attachments, tires, or performing
other service, use correct blocks, hoists, and jacks.
Make sure machine is parked on a solid level floor such
asaconcrete floor.Priortoraisingthemachine,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 sup-
port the raised machine. If the machine is not properly
supported by blocks or jack stands, the machine may
move or fall, which may result in personal injury.
Safety
Sand Pro 2020/3020/5020 Page 1 – 3 Safety

Jacking Instructions
Figure 1
Use the following positions when jacking up the ma-
chine:
Jacking the Front End
1. On the SP 2020/3020, jack from below the front
crosssupportthatisabovetheretainingstripfortherub-
ber shield (Fig. 1).
2. On the SP 5020, jack from below the front cross Figure 2
support tube on the bottom of the frame (Fig. 2).
CAUTION
forming other service, use correct blocks,
hoists, and jacks. Make sure machine is
parkedonasolidlevel floorsuchasaconcrete
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 themachineisnotproperlysupported
by blocks or jack stands, the machine may
moveorfall, whichmayresult in personalinju-
When changing attachments, tires, or per-
floor. Prior to raising the machine, remove any
ry.
Jacking the Rear End
1. On the SP 2020/3020, jack from below the square
tube of the frame (Fig. 3).
2. OntheSP 5020,jackfrombelow the square tube of
the frame (Fig. 3).
Figure 3
Figure 4
Safety Page 1 – 4 Sand Pro 2020/3020/5020

Safety and Instruction Decals
The following safety and instruction decals are installed on the Sand Pro 2020/3020. If any become damaged
or illegible, replace them. Decal part numbers are listed below and in the parts catalog. Order replacements
from your Authorized Toro Distributor.
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

Safety and Instruction Decals
The following safety and instruction decals are installed on the Sand Pro 5020. If any become damaged or
illegible,replacethem.Decalpartnumbersarelistedbelowandinthepartscatalog.Orderreplacementsfrom
your Authorized 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) (Part No. 93–6668)
Safety Page 1 – 6 Sand Pro 2020/3020/5020