Toro Sand Pro 5040 Service Manual
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Toro Sand Pro 5040 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 and Infield Pro 3040/5040.
REFER TO THE OPERATOR'S MANUALS FOR OP-
ERATING,
MAINTENANCE
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 on the internet at www.toro.com or by
sending complete Model and Serial Number to:
The Toro Company
Attn. Technical Publications
8111 Lyndale Avenue South
Minneapolis, MN 55420
The Toro Company reserves the right to change product
specifications or this publication without notice.
Sand Pro & Infield Pro 3040/5040
AND
ADJUSTMENT
E The Toro Company – 2006

Service Manual

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. 06147SL (Rev. A)

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  • Page 1: Service Manual

    Operator’s Manuals and Parts Cata- logs for your machine. Replacement Operator’s Manu- als are available on the internet at www.toro.com or by sending complete Model and Serial Number to: NOTE: A NOTE will give general information about the...
  • Page 2 This page is intentionally blank. Sand Pro & Infield Pro 3040/5040...

  • Page 3: Table Of Contents

    Table Of Contents Chapter 1 – Safety Chapter 5 – Electrical System Safety Instructions ......1 –...
  • Page 4 This page is intentionally blank. Sand Pro & Infield Pro 3040/5040...
  • Page 5 Chapter 1 Safety Table of Contents SAFETY INSTRUCTIONS ..... . Before Operating ......While Operating .

  • Page 6: Safety Instructions

    A replacement Operator’s Manual is 5. Since gasoline is highly flammable, handle it careful- available on the Internet at www.Toro.com or by sending the complete model and serial number to: A. Store fuel in containers specifically designed for The Toro Company this purpose.

  • Page 7: Maintenance And Service

    Use paper or cardboard, not hands, to search for leaks. machine, use genuine Toro replacement parts and ac- Hydraulic fluid escaping under pressure can have suffi- cessories. Replacement parts and accessories made cient force to penetrate skin and do serious damage.

  • Page 8: Jacking Instructions

    Sand Pro and Infield Pro. If any decal becomes illeg- ible or damaged, install a new decal. Part numbers for replacement decals are listed in your Parts Catalog. Or- der replacement decals from your Authorized Toro Dis- tributor. Page 1 – 4 Sand Pro &...

  • Page 9: Product Records

    Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS ......Standard Torque for Dry, Zinc Plated and MAINTENANCE .

  • Page 10: Equivalents And Conversions

    Equivalents and Conversions Page 2 – 2 Sand Pro & Infield Pro 3040/5040 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 Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series) Grade 1, 5 & SAE Grade 1 Bolts, Screws, Studs & SAE Grade 5 Bolts, Screws, Studs & SAE Grade 8 Bolts, Screws, Studs & Thread Size 8 with Thin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts...

  • Page 13: Standard Torque For Dry, Zinc Plated And Steel Fasteners (Metric Fasteners)

    Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Fasteners) Class 8.8 Bolts, Screws and Studs with Class 10.9 Bolts, Screws and Studs with Thread Size Thread Size Regular Height Nuts Regular Height Nuts Regular Height Nuts Regular Height Nuts (Class 8 or Stronger Nuts) (Class 10 or Stronger Nuts) M5 X 0.8...

  • Page 14: Other Torque Specifications

    Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Recommended Torque** Thread Size Thread Size Square Head Hex Socket 7/16 – 20 UNF 65 + 10 ft–lb 88 + 14 N–m Grade 5 1/4 –...
  • Page 15 Chapter 3 Gasoline Engine Table of Contents INTRODUCTION ......SPECIFICATIONS ......GENERAL INFORMATION .

  • Page 16: Introduction

    Most repairs and adjustments require tools which are the Toro equipment model and serial numbers as well as commonly available in many service shops. Special the Briggs and Stratton engine model and serial num- tools are described in the Briggs and Stratton Repair bers.

  • Page 17: Specifications

    Specifications Item Description Engine Make / Designation Briggs and Stratton, 4–cycle, V–Twin Cylinder, OHV, Air Cooled, Gasoline Engine Bore x Stroke Sand Pro & Infield Pro 3040 2.68” x 2.60” (68mm x 66mm) Sand Pro & Infield Pro 5040 2.83” x 2.75” (72mm x 70mm) Engine Displacement Sand Pro &...

  • Page 18: General Information

    General Information Fuel Shut Off Valve The fuel shut off valve located under the fuel tank (Fig. 1) should be closed if the machine is being transported on a trailer or when placing the machine in long term storage. Additionally, close the shut off valve when re- moving the fuel tank or engine from the machine.

  • Page 19: Service And Repairs

    Service and Repairs Cooling System To ensure proper engine cooling, make sure the rotating screen, cooling fins and other external surfaces of the engine are kept clean at all times. NOTE: Perform this maintenance procedure at the in- terval specified in the Operator’s Manual. IMPORTANT: The engine that powers Sand Pro and Infield Pro machines is air–cooled.

  • Page 20: Air Cleaner Assembly

    Air Cleaner Assembly 60 to 65 in–lb (6.8 to 7.3 N–m) RIGHT FRONT Figure 3 1. Inlet hood 6. Flat washer (2 used) 11. Flange head screw (4 used) 2. Air cleaner assembly 7. Mounting bracket 12. Flat washer (4 used) 3.
  • Page 21 Removal (Fig. 3) NOTE: See Operator’s Manual for air cleaner mainte- nance procedures and intervals. 1. Park machine on a level surface, lower attachment, stop engine, apply parking brake and remove key from ignition switch. 2. Remove air cleaner components as needed using Figure 3 as a guide.

  • Page 22: Fuel Tank

    Fuel Tank ANTISEIZE LUBRICANT RIGHT FRONT 30 to 60 in–lb (3.4 to 6.8 N–m) Figure 6 1. Fuel cap 7. Hose clamp 12. Flange bushing 2. Fuel tank 8. Fuel hose 13. Washer 3. Cap screw 9. Fuel shut off valve 14.
  • Page 23 Fuel Tank Installation (Fig. 6) DANGER 1. If carburetor was removed from engine for cleaning, install carburetor (see Briggs and Stratton Repair Manu- al at the end of this chapter). Because gasoline is highly flammable, use cau- tion when storing or handling it. Do not smoke 2.

  • Page 24: Engine

    Engine 60 to 65 in–lb (6.8 to 7.3 N–m) 170 to 200 in–lb (19.2 to 22.6 N–m) FRONT LEFT Figure 9 1. Muffler shield 13. Cap screw (4 used) 25. Gasket (2 used) 2. Negative battery cable 14. Lock washer 26.
  • Page 25 4. Remove rear attachment from machine. CAUTION The engine and exhaust system may be hot. To avoid possible burns, allow the engine and ex- haust system to cool before removing engine from machine. 5. Remove hitch assembly from the rear of the machine Figure 10 (see Hitch Assembly Removal in the Service and Re- 1.

  • Page 26: Engine Installation

    13.Disconnect throttle control cable from the governor D. Install three (3) cap screws and lock nuts to se- control plate and choke control cable from the choke le- cure the engine to the engine support. Do not fully ver (Fig. 11). tighten lock nuts.
  • Page 27 9. Secure fuel hose to the fuel pump with hose clamp. 12.Secure air intake hose to air cleaner assembly and Remove clamp from fuel hose that was used to prevent engine (see Air Cleaner Assembly Installation in this fuel spillage. Open fuel shutoff valve. section).
  • Page 28 This page is intentionally blank. Gasoline Engine Page 3 – 14 Sand Pro & Infield Pro 3040/5040...
  • Page 29 Hydrostat Service ......Sand Pro 5040 and Infield Pro 5040 (Including Lift Cylinder .......

  • Page 30: Specifications

    /rev) Rear Wheel Motor Displacement 8.6 in /rev (141 cm /rev) Steering Control Valve (Sand Pro 5040 & Infield Pro 5040) Sauer–Danfoss Steering Unit, Type OSPM Hydraulic Tank Capacity 5 US gallons (18.9 liters) Hydraulic Filter 10 Micron (nominal) spin on cartridge type Hydraulic Oil See Traction Unit Operator’s Manual...

  • Page 31: Hydraulic Hoses

    General Information Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure WARNING to weather, sun, chemicals, very warm storage condi- tions or mishandling during operation or maintenance. Before disconnecting or performing any work These conditions can cause damage or premature dete- on hydraulic system, relieve all pressure in rioration.
  • Page 32 SAE Straight Thread O–Ring Port – Non–Adjustable 1. Make sure both threads and sealing surfaces are free of burrs, nicks, scratches or any foreign material. 2. Always replace the o–ring seal when this type of fit- ting shows signs of leakage. O–Ring 3.

  • Page 33: Towing

    Park machine on a level surface, lower relieve hydraulic pressure in lift circuit, move lift lever to attachment, turn key switch to OFF and allow engine to lower. To relieve hydraulic pressure in Sand Pro 5040 stop. and Infield Pro 5040 steering circuit, rotate steering wheel in both directions.

  • Page 34: Hydraulic Schematics

    Hydraulic Schematics Sand Pro & Infield Pro 3040/5040 Hydraulic System Page 4 – 6...
  • Page 35 Sand Pro & Infield Pro 3040/5040 Page 4 – 7 Hydraulic System...
  • Page 36 Sand Pro & Infield Pro 3040/5040 Hydraulic System Page 4 – 8...
  • Page 37 Sand Pro & Infield Pro 3040/5040 Page 4 – 9 Hydraulic System...

  • Page 38: Hydraulic Flow Diagrams

    Hydraulic Flow Diagrams Sand Pro & Infield Pro 3040/5040 Hydraulic System Page 4 – 10...

  • Page 39: Traction Circuit

    Traction Circuit Forward The left rear wheel motor bleeds off a small amount of hydraulic fluid for cooling of the closed loop traction cir- The traction circuit of the hydraulic system consists of a cuit. This bleed off happens in the forward direction only. hydrostat connected in a closed loop circuit to three or- The high pressure side of the motor forces a shuttle bital vane wheel motors.
  • Page 40 Sand Pro & Infield Pro 3040/5040 Hydraulic System Page 4 – 12...

  • Page 41: Lift Circuit

    The piston moves into the circuit on Sand Pro 5040 and Infield Pro 5040 machines. cylinder pushing fluid out the piston end of the cylinder Lift and steering circuit pressure is limited to 1100 PSI and to the tank.
  • Page 42 Sand Pro & Infield Pro 3040/5040 Hydraulic System Page 4 – 14...

  • Page 43: Steering Circuit

    Steering Circuit (Sand Pro 5040 and Infield Pro 5040) The charge pump in the hydrostat on Sand Pro 5040 and P port passes through the rotary meter and is directed Infield Pro 5040 machines supplies flow for the steering out port R. Pressure extends the steering cylinder for a circuit and for the implement lift circuit.

  • Page 44: Special Tools

    Special Tools Order these tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). Hydraulic Pressure Test Kit 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 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 O–Ring Kit Part Number: 16–3799 The o–ring kit includes o–rings in a variety of sizes for face seal and port seal hydraulic connections. It is rec- ommended that o–rings be replaced whenever a hy- draulic connection is loosened. Figure 13 Wheel Hub Puller Part Number: TOR4097 The wheel hub puller allows safe removal of the wheel...

  • Page 47: Troubleshooting

    Service Manual and Sauer–Danfoss Steering Unit Type cause for a machine malfunction. OSPM Service Manual (Sand Pro 5040 and Infield Pro 5040) at the end of this chapter for additional trouble- Refer to the Testing section of this Chapter for precau- shooting information regarding the hydraulic system.
  • Page 48 Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Problem Possible Cause Á Á Á Á Á Á Á Á Á Á Á Á Á Á...

  • Page 49: Testing

    Traction Pump (P1) Flow, Charge Pump (P2) Flow and/or Wheel Motor Efficiency Tests. 1. Clean machine thoroughly before disconnecting or 13.If a lift or steering (Sand Pro 5040 and Infield Pro disassembling any hydraulic components. Always keep 5040) circuit problem exists, consider performing one or...

  • Page 50: Charge Pressure And Implement Relief Valve (R1) Pressure Tests

    Charge Pressure and Implement Relief Valve (R1) Pressure Tests Figure 16 Sand Pro & Infield Pro 3040/5040 Hydraulic System Page 4 – 22...
  • Page 51 Pro 3040 machines, install and tighten hydrostat chines, remove plug from one of the hydrostat test port plug. On Sand Pro 5040 and Infield Pro 5040 charge test ports (Fig. 17). Install pressure gauge to machines, reconnect hydraulic hose to hydrostat tee fit- test port.

  • Page 52: Traction Relief Valve (R3) Pressure Test

    Traction Relief Valve (R3) Pressure Test Figure 19 Sand Pro & Infield Pro 3040/5040 Hydraulic System Page 4 – 24...
  • Page 53 Procedure for Traction Relief Valve (R3) Pressure 11. Pressure gauge reading should be at least 3200 PSI Test: (220.7 bar) higher than charge pressure. Record test results. 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 Example: Consider a machine that has a charge pres- minutes.

  • Page 54: Traction Pump (P1) Flow Test

    Traction Pump (P1) Flow Test Figure 21 Sand Pro & Infield Pro 3040/5040 Hydraulic System Page 4 – 26...
  • Page 55 Procedure for Traction Pump (P1) Flow Test: 11. While holding the traction pedal in full forward, slowly close flow control valve on tester until pressure gauge 1. Make sure hydraulic oil is at normal operating tem- on tester reads 1300 PSI (89.6 bar). As the flow control perature by operating the machine for approximately 10 valve is being closed, engine speed should decrease to minutes.

  • Page 56: Wheel Motor Efficiency Test

    Wheel Motor Efficiency Test Figure 23 NOTE: Over a period of time, a wheel motor can wear tions. Continued operation with a worn, inefficient motor internally. A worn motor may by–pass oil causing the can generate excessive heat, cause damage to seals motor to be less efficient.
  • Page 57 Procedure for Wheel Motor Efficiency Test: A. The front motor can be removed from the traction circuit by disconnecting the hydraulic hose from the 1. Make sure hydraulic oil is at normal operating tem- hydraulic tube leading to the front wheel motor upper perature by operating the machine for approximately 10 port.

  • Page 58: Charge Pump (P2) Flow Test

    Charge Pump (P2) Flow Test Figure 25 Sand Pro & Infield Pro 3040/5040 Hydraulic System Page 4 – 30...
  • Page 59 Procedure for Charge Pump (P2) Flow Test: SP/IP 3040 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. 2. Park machine on a level surface with the attachment lowered. Make sure engine is off and that the parking brake is applied.

  • Page 60: Steering Cylinder Internal Leakage Test (Sand Pro 5040 And Infield Pro 5040)

    Steering Cylinder Internal Leakage Test (Sand Pro 5040 and Infield Pro 5040) LOOK FOR LEAKAGE PLUG STEERING CYLINDER (FULLY EXTENDED) STEERING WHEEL TURNED FOR RIGHT TURN Figure 28 Sand Pro & Infield Pro 3040/5040 Hydraulic System Page 4 – 32...
  • Page 61 Procedure for Steering Cylinder Internal Leakage Test (Sand Pro 5040 and Infield Pro 5040): NOTE: Steering on Sand Pro 5040 and Infield Pro 5040 machines will be affected by incorrect front tire pressure, binding in the hydraulic steering cylinder, excessive weight on the vehicle and/or binding of the castor fork assembly.

  • Page 62: Service And Repairs

    Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components After Repair or Replacement of Components 1. Before removing any parts from the hydraulic sys- 1. Check oil level in the hydraulic tank and add correct tem, park machine on a level surface, apply parking oil if necessary.

  • Page 63: Flush Hydraulic System

    NOTE: Use only hydraulic fluids specified in Operator’s Ing from petroleum base hydraulic fluid to a biode- Manual. Other fluids may cause system damage. gradable fluid such as Toro Biodegradable Hydraulic Fluid. 8. Fill hydraulic tank with new hydraulic fluid (see Oper- ator’s Manual).

  • Page 64: Charge Hydraulic System

    Charge Hydraulic System NOTE: When initially starting the hydraulic system with 10.Make sure traction pedal and lift control lever are in new or rebuilt components such as motors, pumps or lift neutral. Start engine and run at low idle speed (1750 cylinders, it is important that the hydraulic system be RPM).
  • Page 65 This page is intentionally blank. Sand Pro & Infield Pro 3040/5040 Page 4 – 37 Hydraulic System...

  • Page 66: Hydraulic Tank

    Hydraulic Tank RIGHT FRONT Figure 30 1. Cap 11. Flat washer 20. Oil filter 2. O–ring 12. Tank clamp 21. Hydraulic 90 fitting 3. Dipstick 13. Plug 22. Cap screw 4. Hydraulic tank 14. Washer head screw (2 used) 23. Flange nut 5.
  • Page 67 5. Remove left rear wheel from machine (see Rear Wheel Removal in the Service and Repairs section of Chapter 6 – Chassis). 6. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repairs section of this chapter. 7.

  • Page 68: Oil Cooler

    Oil Cooler RIGHT SAND PRO/INFIELD PRO 5040 SHOWN FRONT Figure 32 1. Cap screw (4 used) 7. 90 hydraulic fitting 12. Cap screw (2 used) 2. Flange nut (4 used) 8. Hydraulic tube 13. Hydraulic hose 3. Lift control valve 9.
  • Page 69 5. Put caps or plugs on disconnected lines and fittings to prevent contamination. 6. Remove four (4) cap screws and flange nuts that se- cure fan shroud to frame. 7. Carefully remove oil cooler and fan shroud from ma- chine taking care not to damage fan on hydrostat. 8.

  • Page 70: Front Wheel Motor

    Front Wheel Motor 90 to 120 in–lb (10.2 to 13.6 N–m) Loctite #242 45 to 55 ft–lb (61 to 75 N–m) 45 to 55 ft–lb (61 to 75 N–m) RIGHT FRONT 200 to 400 ft–lb (271 to 542 N–m) Figure 35 1.
  • Page 71 4. Disconnect hydraulic lines from fittings on front Installation (Fig. 35) wheel motor. Allow hoses to drain into a suitable con- 1. If fittings were removed from wheel motor, install fit- tainer. tings with new o–rings to motor using marks made dur- 5.

  • Page 72: Rear Wheel Motor

    Rear Wheel Motor RIGHT FRONT 200 to 400 ft–lb 45 to 55 ft–lb (271 to 542 N–m) (61 to 75 N–m) Figure 36 1. Rear wheel assembly 6. Drive stud (4 used per wheel) 11. Hair pin 2. Lug nut (4 used per wheel) 7.
  • Page 73 7. Loosen but do not remove lock nut that secures SAND PRO/INFIELD wheel hub to wheel motor. PRO 3040 IMPORTANT: DO NOT hit wheel hub, wheel hub puller or wheel motor with a hammer during wheel hub removal or installation. Hammering may cause damage to the wheel motor.

  • Page 74: Wheel Motor Service

    Wheel Motor Service FRONT WHEEL MOTOR SHOWN Figure 39 1. Dirt seal 9. Woodruff key 17. Commutator seal 2. Housing assembly 10. Cap screw (7 used) 18. Commutator ring 3. Back–up washer 11. Plug 19. Commutator 4. Seal ring 12. O–ring 20.
  • Page 75 This page is intentionally blank. Sand Pro & Infield Pro 3040/5040 Page 4 – 47 Hydraulic System...

  • Page 76: Lift Control Valve

    Lift Control Valve RIGHT SAND PRO/INFIELD FRONT PRO 5040 90 to 110 in–lb SAND PRO/INFIELD (10.2 to 12.4 N–m) PRO 3040 Figure 40 1. Hydraulic hose 11. Pivot bracket 20. Flange head screw (2 used) 2. Hydraulic hose 12. Offset link assembly 21.
  • Page 77 5. Label all hydraulic connections for assembly pur- 3. Secure lift lever pivot to lift control valve spool with poses. cap screw and lock nut (Fig. 41). 4. Remove caps or plugs from disconnected hydraulic WARNING lines and fittings. 5. Position new o–rings and connect hydraulic lines to Before disconnecting or performing any work fittings on lift control valve.

  • Page 78: Lift Control Valve Service

    Lift Control Valve Service Disassembly (Fig. 42) 1. Wash lift valve in solvent and dry thoroughly. 2. Carefully mount lift valve in a vise so that mounting pads are against jaws of vise. Lift valve spool retaining ring (item 14) should be facing up. 3.
  • Page 79 This page is intentionally blank. Sand Pro & Infield Pro 3040/5040 Page 4 – 51 Hydraulic System...

  • Page 80: Pump Control Assembly

    Pump Control Assembly RIGHT FRONT Figure 43 1. Pump lever 10. Extension spring 19. Cap screw 2. Cap screw 11. Adjustment pin 20. Hex nut 3. Cap screw 12. Lock nut 21. Bushing (2 used) 4. Ball bearing 13. Washer head screw (3 used) 22.
  • Page 81 5. Disassemble remaining pump control components B. Start engine and depress traction pedal fully in as needed using Figure 43 as a guide. the reverse direction. Using a phototac, check that rear wheel speed is from 135 to 180 RPM. Assembly (Fig.

  • Page 82: Hydrostat

    38. Suction hose 13. O–ring 26. Hydraulic fitting NOTE: Fittings and hose connections on the bottom of the hydrostat for Sand Pro 5040 and Infield Pro 5040 machines are shown in Figure 49. Sand Pro & Infield Pro 3040/5040 Hydraulic System...
  • Page 83 Removal (Fig. 47) 1. Park machine on a level surface, lower attachment, stop engine, apply parking brake and remove key from ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repairs section of this chapter. 3.
  • Page 84 17.If hydraulic fittings are to be removed from hydrostat, 4. Remove plugs and caps placed in hoses and fittings mark fitting location and orientation to allow correct as- during hydrostat removal. sembly. Remove fittings from hydrostat. 5. Position new o–rings and correctly connect hydraulic Installation (Fig.
  • Page 85 This page is intentionally blank. Sand Pro & Infield Pro 3040/5040 Page 4 – 57 Hydraulic System...

  • Page 86: Hydrostat Service

    Hydrostat Service HYDROSTAT IS ILLUSTRATED FROM BELOW 38 39 FRONT RIGHT Figure 50 1. Seal 16. Ball bearing 30. O–ring (2 used) 2. Needle bearing 17. Retaining ring 31. Cap screw (4 used) 3. Cap screw (4 used) 18. Plug with o–ring 32.
  • Page 87 This page is intentionally blank. Sand Pro & Infield Pro 3040/5040 Page 4 – 59 Hydraulic System...

  • Page 88: Lift Cylinder

    Lift Cylinder RIGHT FRONT Figure 51 1. O–ring 13. Hitch frame 24. Cap screw 2. 90 hydraulic fitting (2 used) 14. Cap screw (4 used) 25. Flat washer 3. O–ring 15. Hitch tube 26. Flange nut 4. Hydraulic hose 16. Cylinder pin 27.
  • Page 89 Removal (Fig. 51) 8. Remove cap screw (item 24) and washer (item 25) that secure lift cylinder to frame. 1. Park machine on a level surface, lower attachment, stop engine, apply parking brake and remove key from 9. Remove lift cylinder from machine. ignition switch.

  • Page 90: Lift Cylinder Service

    Lift Cylinder Service Figure 52 1. Barrel 5. O–ring 9. Head 2. Nut 6. Rod seal 10. Dust seal 3. Seal 7. O–ring 11. Retaining ring 4. Piston 8. Backup seal 12. Shaft Disassembly (Fig. 52) 2. Mount lift cylinder securely in a vise by clamping on the clevis end of the barrel.
  • Page 91 4. Remove plugs from ports. Extract shaft, head and 3. Mount shaft securely in a vise by clamping on the cle- piston by carefully twisting and pulling on the shaft. vis of the shaft. IMPORTANT: Do not clamp vise jaws against the A.

  • Page 92: Steering Control Valve (Sand Pro 5040 And Infield Pro 5040)

    Steering Control Valve (Sand Pro 5040 and Infield Pro 5040) 20 to 26 ft–lb (27 to 35 N–m) RIGHT FRONT Figure 53 1. Steering control valve 6. Castor fork 11. Hydraulic tube 2. Hydraulic hose 7. Steering cylinder 12. Lock nut 3.
  • Page 93 7. Put caps or plugs on disconnected hoses, tubes and fittings to prevent contamination. 8. Remove steering wheel from machine: A. Remove cover from steering wheel. B. Loosen and remove nut that secures steering wheel to steering control valve. Remove flat washer from control valve shaft.

  • Page 94: Steering Control Valve Service (Sand Pro 5040 And Infield Pro 5040)

    Steering Control Valve Service (Sand Pro 5040 and Infield Pro 5040) 20 to 24 ft–lb (27 to 33 N–m) Figure 56 1. Sleeve 9. Housing 17. Inner gearwheel 2. Cross pin 10. Dust seal ring 18. Outer gearwheel 3. Ring 11.
  • Page 95 This page is intentionally blank. Sand Pro & Infield Pro 3040/5040 Page 4 – 67 Hydraulic System...

  • Page 96: Steering Cylinder (Sand Pro 5040 And Infield Pro 5040)

    Steering Cylinder (Sand Pro 5040 and Infield Pro 5040) RIGHT 65 to 80 ft–lb FRONT (88 to 108 N–m) Figure 57 1. Steering control valve 8. Yoke 15. Steering cylinder 2. Hydraulic hose 9. Bushing 16. O–ring 3. Retaining ring 10.
  • Page 97 Removal (Fig. 57) Installation (Fig. 57) 1. Park machine on a level surface, lower attachment, 1. Coat new o–rings lightly with clean hydraulic oil. stop engine, apply parking brake and remove key from 2. If fittings were removed from steering cylinder, install ignition switch.

  • Page 98: Steering Cylinder Service (Sand Pro 5040 And Infield Pro 5040)

    Steering Cylinder Service (Sand Pro 5040 and Infield Pro 5040) 30 to 35 ft–lb (41 to 47 N–m) Figure 58 1. Barrel 6. O–ring 10. Head 2. Lock nut 7. Rod seal 11. Retaining ring 3. Wear ring 8. O–ring 12.
  • Page 99 2. Coat new o–rings, back–up ring and other seals with 4. Mount barrel securely in a vise by lightly clamping on clean hydraulic oil. the mounting collar on the barrel. A. Carefully install wear ring, seal and o–ring to the 5.
  • Page 100 This page is intentionally blank. Sand Pro & Infield Pro 3040/5040 Hydraulic System Page 4 – 72...
  • Page 101 Chapter 5 Electrical System Table of Contents ELECTRICAL SCHEMATIC AND DRAWINGS ..SPECIAL TOOLS ......TROUBLESHOOTING .

  • Page 102: Electrical Schematic And Drawings

    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 103 Battery Terminal Protector Part Number: 107–0392 Battery Terminal Protector is an aerosol spray that should be used on battery terminals to reduce corrosion problems. Apply terminal protector after battery cable has been secured to battery terminal. Figure 3 Battery Hydrometer Use the Battery Hydrometer when measuring specific gravity of battery electrolyte.

  • Page 104: Troubleshooting

    Troubleshooting NOTE: See the Briggs and Stratton Repair Manual at the end of Chapter 3 – Engine for troubleshooting of en- CAUTION gine electrical components. If the machine has any interlock switches by–passed, Remove all jewelry, especially rings and watches, before doing any electrical testing or they must be reconnected for proper troubleshooting troubleshooting.

  • Page 105: General Run Problems

    Starting Problems (continued) Problem Possible Causes Engine cranks, but does not start. Wiring to interlock components is loose, corroded or damaged (see Circuit Diagrams in Chapter 7 – Electrical Diagrams). Diode D2 is faulty. Interlock relay is faulty. Engine is out of fuel or may be too cold. Ignition switch is faulty.
  • Page 106 General Run Problems (Continued) Problem Possible Causes Battery does not charge. Wiring to charging circuit components is loose, corroded or damaged (see Wiring Schematics in Chapter 7 – Electrical Diagrams). Voltage regulator is not grounded or is faulty. Alternator stator is faulty. Fuse F1 (15 amp) is open, loose or missing.

  • Page 107: Electrical System Quick Checks

    Electrical System Quick Checks Battery Test (Open Circuit Test) Use a multimeter to measure the voltage between the Voltage Measured Battery Charge Level battery terminals. 12.68 V (or higher) Fully charged (100%) Tool required: Digital multimeter set to DC volts. 12.45 V 75% charged 12.24 V...

  • Page 108: Component Testing

    Component Testing For accurate resistance and/or continuity checks, elec- trically disconnect the component being tested from the circuit (e.g. unplug the ignition switch connector before checking continuity between switch terminals). Ignition Switch The ignition (key) switch has three positions (OFF, RUN, and START) (Fig.

  • Page 109: Starter Solenoid

    Starter Solenoid The engine starter solenoid is attached to a bracket above the battery. When energized, the starter solenoid allows current flow from the battery to the engine starter motor. Testing 1. Park machine on a level surface, lower attachment, stop engine, apply parking brake and remove key from ignition switch.

  • Page 110: Hour Meter

    Hour Meter The hour meter used on the machine records the amount of time that the ignition switch is in the ON posi- tion. Testing 1. Remove knob from lift lever. 2. Remove four (4) screws and flat washers that secure control panel to console (Fig.

  • Page 111: Charge, Start And Interlock Relays

    Charge, Start and Interlock Relays Three (3) relays are used on the machine: start relay, charge relay and interlock relay. The relays are attached to a bracket under the seat (Fig. 13). The relays are iden- tical and are identified by a tag on the wire harness relay connector.

  • Page 112: Seat Switch

    Seat Switch The seat switch is normally open and closes when the operator is occupying the seat. The seat switch is lo- cated directly under the seat. If the operator leaves the seat, the engine will stop unless the traction pedal is in the neutral position.

  • Page 113: Traction Neutral Switch

    Traction Neutral Switch The traction neutral switch is a normally open proximity switch that closes when the traction pedal is in the neu- tral position. The switch is attached to the hydrostat pump plate (Fig. 16). A cap screw located on the neutral arm acts as the sensing plate for the switch.

  • Page 114: Service And Repairs

    Coat battery posts and cable connectors with smoke. Nausea may result if the gases are in- Battery Terminal Protector (Toro Part No. 107–0392) or haled. Unplug battery charger from electrical petroleum jelly to prevent corrosion.

  • Page 115: Battery Service

    Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be extended. Additionally, battery and electrical component failure can be prevented. CAUTION When working with batteries, use extreme cau- tion to avoid splashing or spilling electrolyte. Electrolyte can destroy clothing and burn skin or eyes.
  • Page 116 Testing H. If the test voltage is below the minimum voltage, charge the battery and perform load test again. If test 1. To properly test a battery, perform a high–discharge voltage still is below minimum voltage, replace the test using an adjustable load tester. This is one of the battery.
  • Page 117 Charging CAUTION To minimize possible damage to the battery and allow the battery to be fully charged, the slow charging meth- od is presented here. This charging method can be ac- Do not charge a frozen battery because it can ex- complished with a constant current battery charger plode and cause injury.
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  • Page 119 Infield Pro 3040) ......Front Castor Fork (Sand Pro 5040 and Infield Pro 5040) ......

  • Page 120: Specifications

    Specifications Item Description Tire Pressure Front Tire 4 to 6 PSI (0.3 to 0.4 Bar) Rear Tire 4 to 6 PSI (0.3 to 0.4 Bar) Chassis Page 6 – 2 Sand Pro & Infield Pro 3040/5040...

  • Page 121: Special Tools

    Special Tools Wheel Hub Puller Part Number: TOR4097 The wheel hub puller allows safe removal of the wheel hub from the shaft of wheel motors. Figure 1 Page 6 – 3 Chassis Sand Pro & Infield Pro 3040/5040...

  • Page 122: Service And Repairs

    Service and Repairs Front Wheel 90 to 120 in–lb (10.2 to 13.6 N–m) Loctite #242 45 to 55 ft–lb (61 to 75 N–m) 45 to 55 ft–lb (61 to 75 N–m) RIGHT FRONT Figure 2 1. Wheel motor 12. Flange nut (3 used) 23.
  • Page 123 Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 – Safety. 4. For Sand Pro 5040 and Infield Pro 5040 machines, secure front wheel as follows: 6. Jack up front of machine slowly until the hydraulic motor and flangettes can be removed from the fork.
  • Page 124 6. Slide flangette and bearing assembly onto the 9. Lower machine completely to the ground. Make sure spindle shaft so the bearing locking collar faces the flangettes and hydraulic motor are positioned correctly wheel. into the fork. Tighten fasteners to secure wheel to front fork.
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  • Page 126: Rear Wheel

    Rear Wheel 200 to 400 ft–lb (271 to 542 N–m) 45 to 55 ft–lb (61 to 75 N–m) RIGHT FRONT Figure 4 1. Cap screw 13. Brake cable 25. Retaining ring 2. Flat washer 14. Brake rod 26. Bushing 3. Retaining ring 15.
  • Page 127 Removal (Fig. 4) Installation (Fig. 4) 1. Park machine on a level surface, lower attachment, 1. Install rear wheel and secure with four (4) lug nuts. stop engine, apply parking brake and remove key from 2. Lower machine to ground. ignition switch.

  • Page 128: Console

    Console RIGHT FRONT Figure 5 1. Frame 5. Lock nut (4 used) 8. Flat washer (6 used) 2. Console 6. Cap screw (6 used) 9. LH wheel shroud 3. RH wheel shroud 7. Lock washer (3 used) 10. Washer head screw (8 used) 4.
  • Page 129 Removal (Fig. 5) 1. Park machine on a level surface, lower attachment, stop engine, apply parking brake and remove key from ignition switch. 2. Remove knob from lift lever. 3. Remove four (4) screws and flat washers that secure control panel to console (Fig. 6). Lift control panel, un- plug wire harness connector from hour meter and re- move control panel from machine.

  • Page 130: Parking Brake

    Parking Brake 200 to 400 ft–lb (271 to 542 N–m) 45 to 55 ft–lb (61 to 75 N–m) RIGHT FRONT Figure 7 1. Cap screw 13. Brake cable 25. Retaining ring 2. Flat washer 14. Brake rod 26. Bushing 3. Retaining ring 15.
  • Page 131 Removal (Fig. 7) Installation (Fig. 7) 1. Park machine on a level surface, lower attachment, stop engine and remove key from ignition switch. CAUTION 2. Make sure parking brake is disengaged. Be careful when installing extension spring to 3. Block front wheel. Jack or hoist rear of machine from parking latch pivot.

  • Page 132: Parking Brake Cable

    Parking Brake Cable RIGHT FRONT Figure 9 1. Brake lever 5. Flange nut 8. Shoulder bolt 2. Retaining ring 6. Spacer 9. Bellcrank 3. Brake cable 7. Brake clevis 10. Extension spring 4. Retaining ring Chassis Page 6 – 14 Sand Pro &...
  • Page 133 Removal (Fig. 9) Installation (Fig. 9) 1. Park machine on a level surface, lower attachment, 1. Position new parking brake cable to machine noting stop engine and remove key from ignition switch. original routing. 2. Make sure parking brake is disengaged. 2.

  • Page 134: Hitch Assembly

    Hitch Assembly RIGHT FRONT Figure 10 1. Cap screw (2 used) 12. Lock washer (4 used) 23. Flange bushing (2 used) 2. R–clamp (2 used) 13. Hitch frame 24. Cap screw 3. Rear cover 14. Cap screw (4 used) 25. Flat washer 4.
  • Page 135 Removal (Fig 10) 1. Park machine on a level surface, lower attachment, stop engine, apply parking brake and remove key from ignition switch. 2. Remove attachment from machine. 3. Remove three (3) washer head screws that secure rear cover to machine. Remove rear cover. 4.

  • Page 136: Steering Box (Sand Pro 3040 And Infield Pro 3040)

    Steering Box (Sand Pro 3040 and Infield Pro 3040) 90 to 120 in–lb (10.2 to 13.6 N–m) Loctite #242 50 to 60 ft–lb (68 to 81 N–m) 20 to 26 ft–lb (27 to 35 N–m) RIGHT FRONT Figure 12 1. Lock nut 9.
  • Page 137 Removal (Fig. 12) Installation (Fig. 12) 1. Park machine on a level surface, lower attachment, 1. If steering box was disassembled to separate steer- stop engine, apply parking brake and remove key from ing box from castor fork shaft, assemble steering box ignition switch.

  • Page 138: Steering Box Service (Sand Pro 3040 And Infield Pro 3040)

    Steering Box Service (Sand Pro 3040 and Infield Pro 3040) 175 to 225 in–lb (19.8 to 25.4 N–m) Figure 13 1. Retaining ring 5. Pinion gear 9. Shim (as required) 2. Retaining ring 6. Steering cover 10. Gasket 3. Ball bearing 7.
  • Page 139 Disassembly (Fig. 13) 2. If bearings were removed from pinion gear shaft: 1. Remove retaining ring that secures pinion gear as- A. Press first bearing onto shaft by applying pres- sembly in steering cover. Pull pinion gear and bearings sure equally to the inner and outer bearing race. from steering box.

  • Page 140: Front Castor Fork (Sand Pro 3040 And Infield Pro 3040)

    Front Castor Fork (Sand Pro 3040 and Infield Pro 3040) 90 to 120 in–lb (10.2 to 13.6 N–m) Loctite #242 50 to 60 ft–lb (68 to 81 N–m) 20 to 26 ft–lb (27 to 35 N–m) See Text For Tightening Procedure RIGHT FRONT...
  • Page 141 Removal (Fig. 14) Installation (Fig. 14) 1. Park machine on a level surface, lower attachment, 1. If bearing cups were removed from frame, press new stop engine, apply parking brake and remove key from bearing cups into frame making sure that cups are ignition switch.

  • Page 142: Front Castor Fork (Sand Pro 5040 And Infield Pro 5040)

    Front Castor Fork (Sand Pro 5040 and Infield Pro 5040) 150 to 200 ft–lb (203 to 271 N–m) 60 to 90 in–lb (6.8 to 10.2 N–m) RIGHT 90 to 120 in–lb (10.2 to 13.6 N–m) Loctite #242 FRONT 65 to 85 ft–lb (88 to 115 N–m)
  • Page 143 Removal (Fig. 14) Installation (Fig. 14) 1. Park machine on a level surface, lower attachment, 1. If removed, install steering pivot, steering sleeve and stop engine, apply parking brake and remove key from bearings to machine: ignition switch. A. If bearing cups were removed from frame, press 2.

  • Page 144: Operator Seat

    Operator Seat RIGHT FRONT Figure 16 1. Operator seat 8. Screw 15. Spacer 2. Flange nut (8 used) 9. Holding post 16. Cap screw (4 used) 3. LH seat adjuster 10. Bumper (2 used) 17. Lock washer (4 used) 4. Carriage screw (4 used) 11.
  • Page 145 Chapter 7 Electrical Diagrams Table of Contents ELECTRICAL SCHEMATIC ....Electrical Schematic ......CIRCUIT DIAGRAMS .
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  • Page 147: Electrical Schematic

    OPTIONAL LIGHT KIT OPTIONAL AUX. DRIVE KIT (SEAT NOT OCCUPIED) (NOT IN NEUTRAL) Sand Pro & Infield Pro 3040/5040 Electrical Schematic All relays and solenoids are shown as de–energized. All ground wires are black. Page 7 – 3...

  • Page 148: Crank Circuits

    (NOT GROUNDED) (ENERGIZED) (ENERGIZED) OPTIONAL LIGHT KIT OPTIONAL AUX. DRIVE KIT (ENERGIZED) (ENERGIZED) (SEAT NOT OCCUPIED) (ENERGIZED) (IN NEUTRAL) Sand Pro & Infield Pro 3040/5040 Crank Circuits Power Current Control Current Indication Current Page 7 – 4...

  • Page 149: Run Circuits

    (NOT GROUNDED) (ENERGIZED) (ENERGIZED) OPTIONAL LIGHT KIT OPTIONAL AUX. DRIVE KIT (NOT ENERGIZED) (NOT ENERGIZED) (SEAT OCCUPIED) (ENERGIZED) (NOT IN NEUTRAL) Sand Pro & Infield Pro 3040/5040 Run Circuits Power Current Control Current Indication Current Page 7 – 5...

  • Page 150: Wire Harness Drawing

    BATTERY GROUND BATTERY GROUND OPTIONAL AUX. CAP AUX. DRIVE HOUR DIODE METER CONTACT DIODE STARTER SOLENOID COIL NEUTRAL OPTIONAL SWITCH LIGHT KIT FUSE BLOCK IGNITION SWITCH INTERLOCK RELAY START RELAY CHARGE RELAY SEAT SWITCH REGULATOR Sand Pro & Infield Pro 3040/5040 MAGNETO Wire Harness Drawing FUEL...

  • Page 151: Wire Harness Diagram

    OPTIONAL NEUTRAL SWITCH MAGNETO FUEL SOLENOID REGULATOR BATTERY GROUND LIGHT KIT SEAT SWITCH YELLOW YELLOW START YELLOW RELAY PINK BLACK YELLOW WHITE FUSE BLOCK VIOLET GRAY BLACK BLACK INTERLOCK VIOLET RELAY WHITE BLACK CONTACT FUSIBLE LINK DIODE D1 STARTER GREEN SOLENOID BLACK COIL...
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