Toro Sand Pro 2040Z Service Manual
Toro Sand Pro 2040Z Service Manual

Toro Sand Pro 2040Z Service Manual

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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 2040Z.
REFER TO THE OPERATOR'S MANUAL FOR OPER-
ATING,
MAINTENANCE
INSTRUCTIONS. For reference, insert a copy of the
Operator's Manual and Parts Catalog for your machine
into Chapter 2 of this service manual. Additional copies
of the Operator's Manual and Parts Catalog are avail-
able on the internet at www.Toro.com.
The Toro Company reserves the right to change product
specifications or this publication without notice.
AND
ADJUSTMENT
E The Toro Company - 2014

Service Manual

Sand Pro 2040Z
This safety symbol means DANGER, WARNING,
or CAUTION, PERSONAL SAFETY INSTRUC-
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.
Part No. 14210SL

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Table of Contents
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Summary of Contents for Toro Sand Pro 2040Z

  • Page 1: Service Manual

    NOTE: A NOTE will give general information about the correct operation, maintenance, service, testing or re- The Toro Company reserves the right to change product pair of the machine. specifications or this publication without notice.
  • Page 2 This page is intentionally blank. Sand Pro 2040Z...
  • Page 3: Table Of Contents

    4 - 19 Service and Repairs ..... . . 4 - 26 MODEL TZT13 TUFF TORQ TRANSAXLE SERVICE MANUAL Sand Pro 2040Z...
  • Page 4 This page is intentionally blank. Sand Pro 2040Z...
  • Page 5 ..... SAFETY AND INSTRUCTION DECALS ..Sand Pro 2040Z Page 1 - 1 Safety...
  • Page 6: Safety Instructions

    Safety Instructions The Sand Pro 2040Z is tested and certified by Toro for compliance with existing safety standards and speci- WARNING fications. Although hazard control and accident preven- tion partially are dependent upon the design and To reduce the potential for injury or death, com- configuration of the machine, these factors are also de- ply with the following safety instructions.
  • Page 7: While Operating

    7. Keep body and hands away from pin hole leaks or machine, use genuine Toro replacement parts and ac- nozzles that eject hydraulic fluid under high pressure. cessories. Replacement parts and accessories made Use paper or cardboard, not hands, to search for leaks.
  • Page 8: Jacking Instructions

    Sand Pro. If any decal becomes illegible or dam- aged, install a new decal. Part numbers for replacement decals are listed in your Parts Catalog. Order replace- ment decals from your Authorized Toro Distributor. Page 1 - 4 Sand Pro 2040Z...
  • Page 9: Product Records

    Maintenance Maintenance procedures and recommended service in- tervals for Sand Pro machines are covered in the Opera- tor’s Manual. Refer to that publication when performing regular equipment maintenance. Sand Pro 2040Z Page 2 - 1 Product Records and Maintenance...
  • Page 10: Equivalents And Conversions

    Equivalents and Conversions 0.09375 Page 2 - 2 Sand Pro 2040Z Product Records and Maintenance...
  • Page 11: Torque Specifications

    For critical applications, as determined reduced by 25% for lubricated fasteners to achieve by Toro, either the recommended torque or a torque that the similar stress as a dry fastener. Torque values may is unique to the application is clearly identified and spe- also have to be reduced when the fastener is threaded cified in this Service Manual.
  • Page 12 The specific torque value should be determined based on the fastener size, the aluminum or base material strength, length of thread engagement, etc. Page 2 - 4 Sand Pro 2040Z Product Records and Maintenance...
  • Page 13 The specific torque value should be determined based on the fastener size, the aluminum or base material strength, length of thread engagement, etc. Sand Pro 2040Z Page 2 - 5 Product Records and Maintenance...
  • Page 14: Other Torque Specifications

    Conversion Factors in- lb X 11.2985 = N- cm N- cm X 0.08851 = in- lb ft- lb X 1.3558 = N- m N- m X 0.7376 = ft- lb Page 2 - 6 Sand Pro 2040Z Product Records and Maintenance...
  • Page 15 ......Fuel Evaporative Control System Service ..KAWASAKI FX481V SERVICE MANUAL Sand Pro 2040Z Page 3 - 1 Gasoline Engine...
  • Page 16: Specifications

    NGK BPR4ES (or equivalent) Spark Plug Gap 0.028” to 0.030” (0.7 to 0.8 mm) Starter 12 VDC Alternator 12 VDC / 20 Amps @ 3600 RPM Engine Weight (approximate) 90 lb (41 kg) Gasoline Engine Page 3 - 2 Sand Pro 2040Z...
  • Page 17: General Information

    Most repairs and adjustments require tools which are commonly available in many service shops. Special Operator’s Manuals The Sand Pro 2040Z Operator’s Manual and the Kawa- saki Engine Owner’s Manual provides information re- garding the operation, general maintenance and maintenance intervals for the Kawasaki engine that powers your Sand Pro machine.
  • Page 18: Fuel Evaporative Control System

    Vapors from the canister are consumed when the engine is running. The fuel tank on Sand Pro 2040Z machines uses a non- vented fuel cap. A vacuum control valve located above the fuel tank is used to control evaporative emission flow through the system.
  • Page 19: Service And Repairs

    IMPORTANT: Never operate engine without the blower housing installed. Overheating and engine damage will result. 6. Make sure rotating screen, blower housing and screen guard are reinstalled to the engine if removed. Sand Pro 2040Z Page 3 - 5 Gasoline Engine...
  • Page 20: Fuel Tank

    Operator’s Manual. Also, empty and other purpose. clean the fuel tank if the fuel system becomes contami- nated or if the machine is to be stored for an extended period. Gasoline Engine Page 3 - 6 Sand Pro 2040Z...
  • Page 21 3. Carefully slide fuel tank into position on machine frame. Make sure that fuel tank pockets engage both bumpers at rear of tank mount bracket. Sand Pro 2040Z Page 3 - 7 Gasoline Engine...
  • Page 22: Exhaust System

    5. Washer head screw (2 used) NOTE: Muffler shield (item 2) and muffler (item 9) can be removed with engine attached to the Sand Pro 2040Z frame. If it is necessary to remove exhaust manifold (item 10), engine removal is necessary.
  • Page 23 (items 3, 4 and 5). Position muffler 0.850” to 0.970” shield so that muffler tailpipe is centered in shield hole. (21.6 to 24.6 mm) Figure 8 1. Frame 2. Muffler Sand Pro 2040Z Page 3 - 9 Gasoline Engine...
  • Page 24: Engine

    C. Remove flange head screw that secures wire 9. Belleville washer (4) 19. Lock nut (2) harness ground (black wire) and negative battery 10. Carriage bolt cable to engine beneath the starter motor. Gasoline Engine Page 3 - 10 Sand Pro 2040Z...
  • Page 25: Engine Installation

    1. Cap screw 2. Belleville washer new exhaust gaskets between engine and exhaust manifold. When securing exhaust manifold to engine, torque nuts from 17 to 21 ft- lb (24 to 28 N- m). Sand Pro 2040Z Page 3 - 11 Gasoline Engine...
  • Page 26 8. Connect two (2) EVAP hoses to fittings on engine in- take manifold and air intake tube (Fig. 10). 9. Connect machine wire harness connections to cor- rect engine components. Gasoline Engine Page 3 - 12 Sand Pro 2040Z...
  • Page 27 This page is intentionally blank. Sand Pro 2040Z Page 3 - 13 Gasoline Engine...
  • Page 28: Fuel Evaporative Control System Service

    1. If necessary to access fuel evaporative control sys- tem components, remove seat support plate with at- tached operator seat from machine (see Operator Seat in the Service and Repairs section of Chapter 6 - Figure 15 Chassis). Gasoline Engine Page 3 - 14 Sand Pro 2040Z...
  • Page 29 Figure 18 1. Muffler 4. EVAP manifold hose 2. Washer head screw 5. EVAP intake hose 3. R- clamp Sand Pro 2040Z Page 3 - 15 Gasoline Engine...
  • Page 30 This page is intentionally blank. Gasoline Engine Page 3 - 16 Sand Pro 2040Z...
  • Page 31 Groomer (Rear Attachment) Lift Cylinder Internal Leakage Test ......Sand Pro 2040Z Page 4 - 1 Hydraulic System...
  • Page 32: Specifications

    Right Side of Machine 2.1 US quarts (2.0 liters) Left Side of Machine 2.0 US quarts (1.9 liters) Hydraulic Filters Transmission Mounted (each transmission) Cartridge type Control Manifold Mounted Spin on cartridge type Sand Pro 2040Z Hydraulic System Page 4 - 2...
  • Page 33: General Information

    General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Sand Pro 2040Z machine. Refer to that publication for additional information when servicing the machine. Check Hydraulic Fluid The Sand Pro 2040Z hydraulic system is designed to operate on anti- wear hydraulic fluid.
  • Page 34: Relieving Hydraulic System Pressure

    Rotate the bypass- valve levers so that they point in- ward, toward the center of the machine. This allows the hydraulic oil to bypass the internal transmission motors, enabling the machine wheels to turn freely. Sand Pro 2040Z Hydraulic System Page 4 - 4...
  • Page 35: Hydraulic Hoses

    If the hose has an elbow at one end, tighten the swivel nut on that end before tightening the nut on the straight end of the hose. For additional hydraulic hose information, refer to Toro Service Training Book, Hydraulic Hose Servicing (Part Number 94813SL).
  • Page 36: Hydraulic Hose And Tube Installation

    85 to 105 ft- lb (116 to 142 N- m) 1 7/16 - 12 110 to 136 ft- lb (150 to 184 N- m) 1 11/16 - 12 140 to 172 ft- lb (190 to 233 N- m) Figure 6 Sand Pro 2040Z Hydraulic System Page 4 - 6...
  • Page 37: Hydraulic Fitting Installation

    121 to 149 ft- lb (165 to 202 N- m) 1 5/8 - 12 247 to 303 ft- lb (335 to 410 N- m) 149 to 183 ft- lb (202 to 248 N- m) Figure 8 Sand Pro 2040Z Page 4 - 7 Hydraulic System...
  • Page 38 1.00 + 0.25 6 (3/8 in.) 1.50 + 0.25 8 (1/2 in.) 1.50 + 0.25 10 (5/8 in.) 1.50 + 0.25 12 (3/4 in.) 1.50 + 0.25 16 (1 in.) 1.50 + 0.25 Sand Pro 2040Z Hydraulic System Page 4 - 8...
  • Page 39: Hydraulic Schematic

    Hydraulic Schematic Sand Pro 2040Z Page 4 - 9 Hydraulic System...
  • Page 40: Hydraulic Flow Diagrams

    Hydraulic Flow Diagrams Sand Pro 2040Z Hydraulic System Page 4 - 10...
  • Page 41: Traction Circuit

    2. Traction lever 4. Bypass valve the transmission case drain. This leakage results in the loss of hydraulic fluid from the closed loop traction cir- cuits that must be replenished. Sand Pro 2040Z Page 4 - 11 Hydraulic System...
  • Page 42 Sand Pro 2040Z Hydraulic System Page 4 - 12...
  • Page 43: Groomer Lift Circuit

    (rear at- retract to cause the rear attachment to lower. As circuit tachment) lift circuit on Sand Pro 2040Z machines. Lift pressure increases, a manifold sensing line unseats the circuit pressure is limited to 650 PSI (45 bar) by the im-...
  • Page 44: Special Tools

    Special Tools Order special tools from your Toro Distributor. Hydraulic Pressure Test Kit Toro Part Number: 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.
  • Page 45: Measuring Container

    Hydraulic Test Fitting Kit Toro Part Number: TOR4079 TORO TEST FITTING KIT (TOR4079) The test fitting kit includes a variety of O- ring Face Seal fittings to enable the connection of test gauges into the system. The kit includes: tee’s, unions, reducers, plugs, caps and male test fittings.
  • Page 46 Transmission Pulley Puller Toro Part Number: TOR6031 The transmission pulley puller allows safe removal of the pulley from the input shaft of the transmissions used on the Sand Pro 2040Z. Figure 19 Wheel Hub Puller Toro Part Number: TOR4097 The wheel hub puller allows safe removal of the wheel hub from the transmission output shaft.
  • Page 47: Troubleshooting

    The chart that follows contains information to assist in Refer to the Testing section of this Chapter for precau- troubleshooting the Sand Pro 2040Z hydraulic system. tions and specific hydraulic test procedures. There may possibly be more than one cause for a ma- chine malfunction.
  • Page 48 Rear attachment raises, but will not Groomer (rear attachment) lift cylinder leaks internally. stay in the raised position. Check valve in hydraulic control manifold leaks. Sand Pro 2040Z Hydraulic System Page 4 - 18...
  • Page 49: Testing

    All testing should be performed by two (2) people. One person should be in the seat to oper- ate the machine, and the second person should read test instruments and record test results. Sand Pro 2040Z Page 4 - 19 Hydraulic System...
  • Page 50: Implement (Lift) Relief Valve Pressure Test

    Implement (Lift) Relief Valve Pressure Test TESTER Figure 21 Sand Pro 2040Z Hydraulic System Page 4 - 20...
  • Page 51 581 to 725 PSI (40 to 50 bar). After noting relief pressure, return lift switch to neutral position. Sand Pro 2040Z Page 4 - 21 Hydraulic System...
  • Page 52: Rh Transmission Gear Pump Flow Test

    RH Transmission Gear Pump Flow Test TESTER Figure 23 Sand Pro 2040Z Hydraulic System Page 4 - 22...
  • Page 53 11. Once flow has been determined, open flow control valve on tester, reduce engine speed and turn engine Figure 24 off. Record test results. 1. RH transmission 3. Hose to port P 2. Control manifold Sand Pro 2040Z Page 4 - 23 Hydraulic System...
  • Page 54: Groomer (Rear Attachment) Lift Cylinder Internal Leakage Test

    Groomer (Rear Attachment) Lift Cylinder Internal Leakage Test STEEL PLUG LOOK FOR LEAKAGE GROOMER LIFT CYLINDER (FULLY EXTENDED) Figure 25 Sand Pro 2040Z Hydraulic System Page 4 - 24...
  • Page 55 Use paper or cardboard, not hands, to search for leaks. Hydraulic fluid es- caping under pressure can have sufficient force to penetrate the skin and cause serious injury. Sand Pro 2040Z Page 4 - 25 Hydraulic System...
  • Page 56: Service And Repairs

    5. Note the position of hydraulic fittings (especially el- bow fittings) on hydraulic components before removal. Mark parts if necessary to make sure they will be aligned properly when reinstalling hydraulic fittings and lines. Sand Pro 2040Z Hydraulic System Page 4 - 26...
  • Page 57: Check Hydraulic Lines And Hoses

    If fluid is in- jected into the skin, it must be surgically re- moved within a few hours by a doctor familiar with this type of injury. Gangrene may result from such an injury. Sand Pro 2040Z Page 4 - 27 Hydraulic System...
  • Page 58: Flush Hydraulic System

    NOTE: Left and right transmissions are not connected 9. Disconnect and ground engine spark plug wires to to each other on the Sand Pro 2040Z. If a transmission prevent the engine from starting. Make sure that motion issue arises with one of the transmissions that requires control handles and lift control switch are in the neutral flushing, both transmissions do not have to be flushed.
  • Page 59: Charge Hydraulic System

    Check hydraulic components for leaks. CAUTION Tighten any loose connections. Drive (rear) wheels will be off the ground. Make sure machine is supported so it will not move and accidentally fall to prevent injury. Sand Pro 2040Z Page 4 - 29 Hydraulic System...
  • Page 60: Hydraulic Reservoirs

    3. Place drain pan under transmission for reservoir that nation. is to be serviced. Make sure that drain pan is large enough to hold contents of transmission and hydraulic reservoir (see Specifications in this Chapter). Sand Pro 2040Z Hydraulic System Page 4 - 30...
  • Page 61 2. LH gear side drain 6. RH gear side drain 3. LH transmission filter 7. RH transmission filter 4. LH pump side drain 8. RH pump side drain 2. Position hydraulic reservoir to reservoir bracket. Sand Pro 2040Z Page 4 - 31 Hydraulic System...
  • Page 62: Hydraulic Control Manifold

    8. Hydraulic fitting (3 used) 13. Hydraulic hose 4. Cap screw (2 used) 9. O- ring 14. Hydraulic hose 5. Flange nut (2 used) 10. O- ring 15. RH hydraulic reservoir Sand Pro 2040Z Hydraulic System Page 4 - 32...
  • Page 63 6. Remove control manifold from the frame using Fig- ure 29 as a guide. 7. If necessary, remove fittings from manifold and dis- card O- rings. Sand Pro 2040Z Page 4 - 33 Hydraulic System...
  • Page 64: Hydraulic Control Manifold Service

    PC is the check valve loc- ation (see Hydraulic Schematic in this Chapter to identi- fy the function of the hydraulic lines and cartridge valves at each manifold port). Sand Pro 2040Z Hydraulic System Page 4 - 34...
  • Page 65 B. If valve sealing surfaces appear pitted or dam- and clean again or replace cartridge valve. aged, the hydraulic system may be overheating or there may be water in the system. Sand Pro 2040Z Page 4 - 35 Hydraulic System...
  • Page 66: Groomer (Rear Attachment) Lift Cylinder

    10. Lift cylinder 16. O- ring 5. Pivot sleeve (2 used) 11. Groomer lift frame 17. Grease fitting (2 used) 6. Flange bushing (4 used) 12. 90 hydraulic fitting (2 used) Sand Pro 2040Z Hydraulic System Page 4 - 36...
  • Page 67 8. Remove lift cylinder from machine. 9. If hydraulic fittings are to be removed from lift cylin- der, mark fitting orientation to allow correct assembly. Remove fittings from lift cylinder and discard O- rings. Sand Pro 2040Z Page 4 - 37 Hydraulic System...
  • Page 68: Groomer (Rear Attachment) Lift Cylinder Service

    6. Taking care to not scratch or damage the piston, re- 3. Using a spanner wrench, remove internal collar from move piston seal and O- ring from the piston. barrel. Sand Pro 2040Z Hydraulic System Page 4 - 38...
  • Page 69 A. Carefully install new piston seal and O- ring to the piston. B. Carefully install new rod seal, back- up ring, O- ring and dust seal to the head. Sand Pro 2040Z Page 4 - 39 Hydraulic System...
  • Page 70: Transmission Control Assembly

    1. Motion control handle 3. Screw (4 used) B. If motion control handle (item 16) is removed, 2. Control cover note orientation of spring washers for assembly pur- poses (shown in Fig. 35). Sand Pro 2040Z Hydraulic System Page 4 - 40...
  • Page 71 1. Motion control assy 3. Jam nuts 2. Rear pump linkage prevents engine starting and operation when motion control handles are not in the neutral locked position. Sand Pro 2040Z Page 4 - 41 Hydraulic System...
  • Page 72: Transmission Drive Belt

    17. Flange head screw (4 used) 5. Cap screw (4 used) 12. LH transmission assembly 18. Socket head screw (2 used) 6. V- belt 13. Lock nut (2 used) 19. Square key 7. Engine drive pulley Sand Pro 2040Z Hydraulic System Page 4 - 42...
  • Page 73 Figure 39. Take care to not damage the transmission cooling fans during belt installation. 2. Make sure that extension spring is attached to an- chor points on frame and pump idler assembly. Sand Pro 2040Z Page 4 - 43 Hydraulic System...
  • Page 74: Transmission Idler Assembly

    17. Flange head screw (4 used) 5. Cap screw (4 used) 12. LH transmission assembly 18. Socket head screw (2 used) 6. V- belt 13. Lock nut (2 used) 19. Square key 7. Pulley Sand Pro 2040Z Hydraulic System Page 4 - 44...
  • Page 75 2. Slide idler assembly onto carriage screw (item 2) and secure to the machine with flange nut (item 11). 3. Lubricate grease fitting on pump idler assembly. 4. Install transmission drive belt (see Transmission Drive Belt in this section). Sand Pro 2040Z Page 4 - 45 Hydraulic System...
  • Page 76: Transmissions

    2. Read the General Precautions for Removing and burns. Allow the machine components to cool Installing Hydraulic System Components at the begin- completely before removing the transmission ning of the this section. from the machine. Sand Pro 2040Z Hydraulic System Page 4 - 46...
  • Page 77 10.Disconnect brake lever from transmission brake 3. Hydraulic hose (2 used) 7. O- ring 4. Hose clamp 8. Flange screw lever (Fig. 45). 11. Disconnect rear pump linkage from transmission traction lever (Fig. 46). Sand Pro 2040Z Page 4 - 47 Hydraulic System...
  • Page 78 (item 17). Take care when installing screws to prevent damaging threads in transmission. D. Secure transmission by tightening eight (8) cap screws from 27 to 33 ft- lb (37 to 44 N- m). Sand Pro 2040Z Hydraulic System Page 4 - 48...
  • Page 79 (pump side and gear drive side) are properly tightened (Fig. 43). IMPORTANT: Use only hydraulic fluids specified in Operator’s Manual. Other fluids could cause system damage. 10.Fill hydraulic reservoir and transmission with new hy- draulic oil to proper level. Sand Pro 2040Z Page 4 - 49 Hydraulic System...
  • Page 80: Transmission Service

    Transmission Service RIGHT SIDE TRANSMISSION SHOWN Figure 47 Sand Pro 2040Z Hydraulic System Page 4 - 50...
  • Page 81 Figure 47 because individual parts are not available component will not be damaged during removal separately. Refer to your parts catalog for part numbers (see Special Tools in this chapter). for transmission component groups. Sand Pro 2040Z Page 4 - 51 Hydraulic System...
  • Page 82 This page is intentionally blank. Sand Pro 2040Z Hydraulic System Page 4 - 52...
  • Page 83 ......Battery Service ......Sand Pro 2040Z Page 5 - 1 Electrical System...
  • Page 84: General Information

    General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Sand Pro 2040Z machine. Refer to that publication for additional information when servicing the machine. Engine Electrical Components When servicing or troubleshooting the engine electrical...
  • Page 85: Special Tools

    The multimeter can test electrical components and cir- cuits for current (amps), resistance (ohms) or voltage. Obtain this tool locally. NOTE: Toro recommends the use of a DIGITAL Volt- Ohm- Amp multimeter when testing electrical circuits. 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.
  • Page 86 Spark Tester The spark tester can be used to test magneto ignitions on gasoline engines. The spark tester determines if igni- tion is present. Toro Part Number: TOR4036 Figure 4 Battery Hydrometer Use the Battery Hydrometer when measuring specific gravity of battery electrolyte. Obtain this tool locally.
  • Page 87: Troubleshooting

    Ground connection to frame is loose or corroded. Start relay is faulty. Fuse block is faulty. Ignition switch is faulty. Starter solenoid (attached to starter motor) is faulty. Starter motor is faulty. Sand Pro 2040Z Page 5 - 5 Electrical System...
  • Page 88 - Gasoline Engine and/or Kawasaki FX481V Service Manual). Engine cranks slowly. Battery is discharged or faulty. Engine is too cold. Battery cables are loose or corroded. Engine is malfunctioning (see Kawasaki FX481V Service Manual). Page 5 - 6 Sand Pro 2040Z Electrical System...
  • Page 89: General Run Problems

    Rear attachment switch is faulty. Hydraulic control manifold solenoid coils or circuit wiring are faulty. A hydraulic problem in the attachment lift/lower circuit exists (see Troubleshooting section of Chapter 4 - Hydraulic System). Sand Pro 2040Z Page 5 - 7 Electrical System...
  • Page 90: Electrical System Quick Checks

    NOTE: Upon starting the engine, the battery voltage will drop and then should increase once the engine is Battery Voltage after 3 Minute Charge = 12.85 v running. Difference = +0.55 v Page 5 - 8 Sand Pro 2040Z Electrical System...
  • Page 91: Check Operation Of Interlock Switches

    Do not disconnect safety switches. They are for the operator’s protection. Check the operation of the interlock switches daily for proper operation. Replace any malfunctioning switches before op- erating the machine. Sand Pro 2040Z Page 5 - 9 Electrical System...
  • Page 92: Component Testing

    Reconnect the har- Figure 6 ness connector to the switch after testing. POSITION CIRCUIT G + M + A B + L + A START B + L + S Figure 7 Page 5 - 10 Sand Pro 2040Z Electrical System...
  • Page 93: Fuses

    If necessary, make sure that ignition switch is OFF and key is removed from switch. Remove fuse from fuse block and check that fuse has continuity across the fuse terminals. Sand Pro 2040Z Page 5 - 11 Electrical System...
  • Page 94: Hour Meter Module

    Hour Meter Module The hour meter module used on the Sand Pro 2040Z mounts to the console and is used to display the amount of time that the ignition switch has been in the ON posi- tion. The hour meter should move 1/10 of an hour in six (6) minutes.
  • Page 95: Parking Brake Switch

    7. If testing determines that parking brake switch is 0000.0 faulty, replace parking brake switch. 8. Connect wire harness connector to parking brake switch after testing is complete. Figure 12 1. Hour meter module 2. Parking brake indicator Sand Pro 2040Z Page 5 - 13 Electrical System...
  • Page 96: Rear Attachment Switch

    4. Rear attachment switch wires are attached to the switch terminals as shown in Figure 14. The upper switch terminal should have the red wire connected to it for proper lift operation. Page 5 - 14 Sand Pro 2040Z Electrical System...
  • Page 97: Seat Switch

    1. Hour meter module 2. Operator seat indicator 10.Secure seat support plate with attached operator seat to machine (see Operator Seat in the Service and Repairs section of Chapter 6 - Chassis). Sand Pro 2040Z Page 5 - 15 Electrical System...
  • Page 98: Traction Neutral Switches

    Traction Neutral Switches The Sand Pro 2040Z use two (2), identical traction neut- ral switches. These switches are normally open and close when the motion control handles are in the neutral locked position. The neutral switches are attached to the motion control bracket at the lower end of the motion control handle assembly (Fig.
  • Page 99: Start And Charge Relays

    30 and 87A. Apply +12 VDC to terminal 85. The Figure 21 relay should make and break continuity between termi- nals 30 and 87A as +12 VDC is applied and removed from terminal 85. Sand Pro 2040Z Page 5 - 17 Electrical System...
  • Page 100: Hydraulic Manifold Solenoid Coils

    1. Hydraulic manifold 4. Solenoid coil (raise) solenoid valve coil. The correct resistance for the Sand 2. Cartridge valve 5. Nut Pro solenoid coils is 8.8 ohms. 3. Solenoid coil (lower) Page 5 - 18 Sand Pro 2040Z Electrical System...
  • Page 101: Service And Repairs

    B. Coat battery posts and cable connectors with bat- chine is stored in a location where temperatures are ex- tery terminal protector (Toro Part No. 107- 0392) or tremely high, the battery will discharge more rapidly petroleum jelly to prevent corrosion.
  • Page 102: Battery Service

    6. Hold down post (2 used) Always connect the positive (red) battery cable 3. Positive (+) cable 7. Battery tray 4. Wing nut and washer before connecting the negative (black) cable. Page 5 - 20 Sand Pro 2040Z Electrical System...
  • Page 103 Also, check battery case for dirt and oil. Clean the bat- tery with a solution of baking soda and water, then rinse it with clean water. Sand Pro 2040Z Page 5 - 21 Electrical System...
  • Page 104 G. Using the table below, determine the minimum voltage for the electrolyte temperature reading: Minimum Battery Electrolyte Voltage Temperature F (and up) C (and up) - 12 - 17 Page 5 - 22 Sand Pro 2040Z Electrical System...
  • Page 105 0.003 change in specific gravity for three (3) consecu- lowing table. tive readings. NOTE: The reserve capacity of the battery used in Sand Pro 2040Z machines is 28 minutes. Battery Battery Charge Level Reserve (Percent of Fully Charged)
  • Page 106 This page is intentionally blank. Page 5 - 24 Sand Pro 2040Z Electrical System...
  • Page 107 ..... Operator Seat ......Page 6 - 1 Chassis Sand Pro 2040Z...
  • Page 108: Specifications

    Specifications Item Description Tire Pressure Front Tire 7 PSI (48 kPa) Rear Tire 7 PSI (48 kPa) Rear Wheel Lug Nut Torque 70 to 90 ft- lb (95 to 122 N- m) Chassis Page 6 - 2 Sand Pro 2040Z...
  • Page 109: General Information

    General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Sand Pro 2040Z machine. Refer to that publication for additional information when servicing the machine. Page 6 - 3 Chassis Sand Pro 2040Z...
  • Page 110: Service And Repairs

    (95 to 122 N- m) Figure 1 1. Rear wheel assembly 3. Drive stud (4 used per rear wheel) 5. Front castor fork 2. Lug nut (4 used per rear wheel) 4. Front wheel assembly Chassis Page 6 - 4 Sand Pro 2040Z...
  • Page 111 Using a jack or hoist, raise machine so rear wheel is off ground. Support machine with jack stands (see Jacking Instructions in Chapter 1 - Safety). 3. Remove four (4) lug nuts and remove rear wheel. Page 6 - 5 Chassis Sand Pro 2040Z...
  • Page 112: Front Wheel

    5. Oil seal (2 used) 8. Grease fitting 2. Castor bolt 6. Bearing cone (2 used) 9. Castor fork 3. Front wheel assembly 7. Bearing cup (2 used) 10. Rear wheel assembly 4. Spacer (2 used) Chassis Page 6 - 6 Sand Pro 2040Z...
  • Page 113 13.7 mm) after installation. 3. Pack new bearing cones with general purpose lithi- um grease. 4. Install greased bearing cones into the wheel rim hub. Press new oil seals into the hub. Page 6 - 7 Chassis Sand Pro 2040Z...
  • Page 114: Front Castor Fork

    9. Bearing cone (2 used) 2. Castor bolt 6. Grease cap 10. Seal 3. Spacer (2 used) 7. Lock nut 11. Bearing cup (2 used) 4. Front wheel assembly 8. Belleville washer (3 used) 12. Plug Chassis Page 6 - 8 Sand Pro 2040Z...
  • Page 115 Place upper bearing cone and three (3) belleville washers onto castor fork shaft. Make sure that belleville washers are properly orientated (Fig. 5). Page 6 - 9 Chassis Sand Pro 2040Z...
  • Page 116: Parking Brake Linkage

    9. Rubber bumper 20. Brake shaft 31. Hex nut (2 used) 10. Cap screw (2 used) 21. Flange nut (2 used) 32. Balljoint (2 used) 11. Brake rod (2 used) 22. Parking brake switch Chassis Page 6 - 10 Sand Pro 2040Z...
  • Page 117 2. Hex nut SPRING COMPRESSION WITH BRAKE ENGAGED 1.875” to 2.125” (47.7 to 53.9 mm) Figure 9 1. Brake rod 4. Compression spring 2. Lock nut 5. Brake shaft bracket 3. Flat washer Page 6 - 11 Chassis Sand Pro 2040Z...
  • Page 118: Groomer Lift Assembly

    (2 used) 3. Washer head screw (2 used) 8. Pivot pin 13. Hydraulic hose 4. Pivot pin 9. Cap screw (2 used) 14. Hydraulic hose 5. Pivot sleeve (2 used) 10. Lift cylinder Chassis Page 6 - 12 Sand Pro 2040Z...
  • Page 119 (item 1) and flat washers (item 2) that secure lift 5. Install rear attachment to machine. frame to machine. C. Remove lift frame from machine. 5. If required, remove pivot sleeves and flange bush- ings from groomer lift frame. Page 6 - 13 Chassis Sand Pro 2040Z...
  • Page 120: Operator Seat

    Figure 11 1. Operator seat 4. Flat washer (4 used) 6. Flange nut 2. Seat support plate 5. Clip nut (4 used) 7. Harness seat switch connection 3. Flange head screw (4 used) Chassis Page 6 - 14 Sand Pro 2040Z...
  • Page 121 1. Arm rest cushion 5. Hex nut 2. Flat washer (2 used) 6. Arm rest bracket 3. Cap screw 7. Cap screw (4 used) 4. Arm rest channel 8. Lock nut (2 used) Page 6 - 15 Chassis Sand Pro 2040Z...
  • Page 122 This page is intentionally blank. Chassis Page 6 - 16 Sand Pro 2040Z...
  • Page 123: Electrical Drawing Designations

    Wire Harness Diagram ..... . . Rear Attachment Switch Wire Harness Drawing Sand Pro 2040Z Page 7 - 1 Electrical Drawings...
  • Page 124 WHITE Y or YE YELLOW Numerous harness wires used on Sand Pro 2040Z ma- chines include a line with an alternate color. These wires are identified with the wire color and line color with either a / or _ separating the color abbreviations listed above (e.g.
  • Page 125 Sand Pro 2040Z Electrical Schematic All relays and solenoids are shown as de- energized. All ground wires are black. Page 7 - 3...
  • Page 126: Crank Circuits

    Sand Pro 2040Z Crank Circuits Power Current Control Current Indication Current Page 7 - 4...
  • Page 127: Run Circuits

    Sand Pro 2040Z Run Circuits Power Current Control Current Indication Current Page 7 - 5...
  • Page 128: Wire Harness Drawings

    Sand Pro 2040Z Wire Harness Drawing Page 7 - 6...
  • Page 129: Wire Harness Diagram

    Sand Pro 2040Z Wire Harness Diagram Page 7 - 7...
  • Page 130: Rear Attachment Switch Wire Harness Drawing

    Sand Pro 2040Z Rear Attachment Switch Wire Harness Drawing Page 7 - 8...

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