Page 1 Form No. 20251SL Rev A Sand Pro ® 3040 and 5040 (Models 08743 and 08745) © 2021—The Toro® Company Original Instructions (EN) 8111 Lyndale Avenue South Contact us at www.Toro.com. Bloomington, MN 55420 All Rights Reserved...
Page 2 Revision History Revision Date Description Initial release 04/2021 Revision History Page 2 Sand Pro ® 3040 and 5040 20251SL Rev A...
Page 3 Reader Comments The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we encourage user feedback. Please comment on the completeness, accuracy, organization, usability, and readability of this manual by an e-mail servicemanuals@toro.com...
Page 4 Reader Comments Page 4 Sand Pro ® 3040 and 5040 20251SL Rev A...
Page 5 This manual may also be specified for use on numerous products. Refer to the Table of Contents for a list of the systems and the related topics covered in this manual. The Toro Company has made every effort to make the information in this manual complete and correct.
Page 6 Service Procedure Icons The following icons appear throughout this Service Manual to bring attention to specific important details of a service procedure. Critical Process This icon is used to highlight: • installing safety equipment (shields, guards, seat belts, brakes and R.O.P.S. components) that may have been removed •...
Page 7: Table Of Contents
Hydraulic Schematic – Sand Pro 3040 ............A–3 Hydraulic Schematic – Sand Pro 5040 ............A–4 Electrical Schematic – Sand Pro 3040/5040..........A–5 Wire Harness Drawing – Sand Pro 3040/5040 ..........A–6 Wire Harness Diagram – Sand Pro 3040/5040..........A–7 Wire Harness – Rear Remote Hydraulics (Optional)........A–8 Wire Harness –...
Page 8: Preface
Danfoss DDC20 Axial Piston Pump Service Manual Parker Torqmotor™ Service Procedure (TF, TG, TH, and TL Series) Danfoss OSPM Steering Unit Service Manual Parker PGP/PGM 500 Series Service Manual Preface Page 8 Sand Pro ® 3040 and 5040 20251SL Rev A...
Page 9 Chapter 1 Safety Table of Contents Safety Instructions ..........................1–2 Think Safety First ..........................1–3 Jacking Instructions ..........................1–6 Safety and Instructional Decals ......................1–7 Sand Pro ® 3040 and 5040 Page 1–1 Safety 20251SL Rev A...
Page 10: Safety Instructions
Safety Instructions DANGER This safety symbol means danger. When you see this symbol, carefully read the instructions that follow. Failure to obey the instructions could cause serious permanent injury, disability, or death. WARNING This safety symbol means warning. When you see this symbol, carefully read the instructions that follow.
Page 11: Think Safety First
Think Safety First Toro Products are evaluated for compliance with existing safety standards and specifications. Although hazard control and accident prevention are partially dependent upon the design and configuration of the machine, hazard control and accident prevention are also dependent upon the awareness, concern and proper training of the personnel involved in the operation, transport, maintenance, and storage of the machine.
Page 12 Think Safety First (continued) Use only original equipment parts to ensure that important safety criteria are met. • Avoid injury to bystanders… Always clear the area of bystanders before starting or testing powered equipment. • Avoid injury due to projectiles… Always clear the area of any debris that could be picked up and thrown by the powered equipment.
Page 13 Think Safety First (continued) – Ensure that chock blocks are used on equipment that can move. – Use lifts or jacks and jack stands that are rated to support the total weight of the machine and any attachments. – Do not rely on jacks to support the machine. –...
Page 14: Jacking Instructions
Jacking Instructions DANGER Mechanical or hydraulic jacks may fail to support the machine and cause a serious injury. • Use jack stands to support the raised machine. • Use only mechanical or hydraulic jacks to lift the machine. • Do not use the attachment or implement as a jacking point. 1.
Page 15: Safety And Instructional Decals
Safety and Instructional Decals Numerous safety and instruction decals are affixed to the traction unit and attachments of the Sand Pro 3040/5040. If any decal becomes illegible or damaged, replace it with a new decal. Part numbers are listed in the Parts Catalogs, Operator’s Manuals and Installation Instructions for the traction unit or...
Page 16 Safety: Safety and Instructional Decals Page 1–8 Sand Pro ® 3040 and 5040 20251SL Rev A...
Page 17 Chapter 2 Specifications and Maintenance Table of Contents Specifications ............................2–2 Overall Dimensions..........................2–2 Engine Specifications (Model 08743)....................2–2 Engine Specifications (Model 08745)....................2–3 Hydraulic System Specifications ......................2–3 Chassis Specifications ........................2–4 Torque Specifications ........................... 2–5 Calculating the Torque Values When Using a Drive-Adapter Wrench ..........2–6 Identifying the Fastener........................
Page 18: Specifications
Specifications Overall Dimensions g340648 Figure 2 Engine Specifications (Model 08743) Item Description Make/Designation Briggs and Stratton Model 305447, 4–cycle, V–Twin Cylinder, OHV, Air Cooled, Gasoline Engine Bore 68 mm (2.68 inch) Stroke 66 mm (2.60 inch) Total displacement 480 cm (29.3 inch Fuel Refer to the traction unit Operator’s Manual...
Page 19: Engine Specifications (Model 08745)
Engine Specifications (Model 08745) Item Description Make/Designation Briggs and Stratton Model 356447, 4–cycle, V–Twin Cylinder, OHV, Air Cooled, Gasoline Engine Bore 72 mm (2.83 inch) Stroke 70 mm (2.76 inch) Total displacement 570 cm (34.8 inch Fuel Refer to the traction unit Operator’s Manual Fuel tank capacity 18.9L (5 US gallons) Fuel pump...
Page 20: Chassis Specifications
Hydraulic System Specifications (continued) Item Description Lift circuit relief pressure 5171 kPa (750 psi) Hydraulic filter 10 Micron spin-on cartridge type Hydraulic fluid Refer to the Traction Unit Operator's Manual Hydraulic reservoir capacity Standard machine – 18.9 L (5 US gallons) with optional Rear Remote Hydraulics or Switch Kit –...
Page 21: Torque Specifications
Torque Specifications The recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in this Service Manual.
Page 22: Calculating The Torque Values When Using A Drive-Adapter Wrench
Calculating the Torque Values When Using a Drive-Adapter Wrench g205924 Figure 3 Torque Conversion Factor = A / B Torque wrench A (effective length of torque wrench) Drive-adapter wrench (crowsfoot) B (effective length of torque wrench and drive-adapter wrench) Using a drive-adapter wrench (e.g., crowfoot wrench) in any position other than 90°...
Page 23: Identifying The Fastener
Toro recommends replacing fasteners with a locking feature once they have been removed because the effectiveness of the locking feature diminishes with each reuse. If it is necessary to reuse a fastener with a locking feature; apply a thread locking compound (Loctite for example) to the fastener during installation.
Page 24: Standard Torque For Dry, Zinc Plated, And Steel Fasteners (Inch)
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch) Thread Size Grade 1, 5 and 8 with SAE Grade 1 Bolts, SAE Grade 5 Bolts, SAE Grade 8 Bolts, Thin Height Nuts Screws, Studs, and Screws, Studs, and Screws, Studs, and Sems with Regular Sems with Regular Sems with Regular...
Page 25 Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch) (continued) Note: The torque values must be reduced when installing the fasteners into threaded aluminum or brass. The specified torque value should be determined based on the aluminum or base material strength, fastener size, length of thread engagement, etc.
Page 26: 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 Class 10.9 Bolts, Screws, and Studs Thread Size with Regular Height Nuts (Class 8 with Regular Height Nuts (Class 10 or Stronger Nuts) or Stronger Nuts) M5 X 0.8 6 to 7 N·m (51 to 63 in-lb)
Page 27: Other Torque Specifications
Other Torque Specifications SAE Grade 8 Steel Set Screws Recommended Torque Thread Size Square Head Hex Socket 1/4 - 20 UNC 14 to 18 N·m (120 to 160 in-lb) 7 to 9 N·m (61 to 85 in-lb) 5/16 - 18 UNC 20 to 28 N·m (180 to 250 in-lb) 14 to 18 N·m (125 to 165 in-lb) 3/8 - 16 UNC...
Page 28: Shop Supplies
Shop Supplies The procedures found in this Service Manual may recommend the use of commonly used shop supplies (lubricants, sealants, and adhesives). A symbol denoting the use of a shop supply may appear in figures that support a procedure. Always refer to the written procedure for specific information regarding the type and the application of a shop supply.
Page 29 Shop Supplies (continued) GASKET COMPOUND Used to create a seal between mating parts. Gasket compounds may be used with or without the presence of a pre-formed gasket. Gasket compounds may be solvent or silicone based, and cure when exposed to air or designed to cure in an air-less environment (anaerobic). Most gasket compounds are designed to be applied to clean surfaces free of oil, chemical residue and previously used gaskets or gasket compounds.
Page 30: Special Tools
Special Tools You can order these special tools from your Toro Distributor. Some tools may also be available from a local tool supplier. Hydraulic Pressure Testing Kit K–Line Part No. TOR47009 Use this kit to take various pressure readings for diagnostic tests. Quick...
Page 31 Hydraulic O-Ring Kit Toro Part No. 117-2727 This kit includes O-rings in a variety of sizes for the face seal and port seal hydraulic connections. To help prevent a hydraulic leak, replace the O-rings when you open the hydraulic connection.
Page 32 Hydraulic Test Fitting Kit K–Line Part No. TOR4079 This kit includes a variety of O-ring face seal fittings to let you connect the test gauges into the system. FITTING TYPE SIZE PART NUMBER 4 ORFS (9/16–18) TOR4079–3 6 ORFS (11/16–16) TOR4079–12 8 ORFS (13–16–16) TOR4079–4...
Page 33 Note: This kit does not include the hydraulic hoses; refer to Hydraulic Hose Kit (page 2–15). Note: The replacement filter element is Toro Part No. TOR6012. The filter element canister tightening torque is 34 N∙m (25 ft-lb). Multimeter Obtain this tool locally...
Page 34 Dielectric Gel Toro Part No. 107-0342 Use the dielectric gel to prevent corrosion of unsealed connection terminals. To ensure that the terminals are completely coated, liberally apply the gel to the component and wire harness connector, plug the connector into the component, unplug the...
Page 35 Chapter 3 Troubleshooting Table of Contents GEARS – The Systematic Approach to Defining, Diagnosing and Solving Problems ......3–2 Troubleshooting – Hydraulic ........................3–3 General Hydraulic System Problems ..................... 3–4 Traction System Problems........................3–6 Steering System Problems (Model 08745 Only) ..................3–8 Attachment Lift/Lower Problems......................
Page 36: Gears - The Systematic Approach To Defining, Diagnosing And Solving Problems
GEARS – The Systematic Approach to Defining, Diagnosing and Solving Problems 1. Gather Information • Information reported by the customer • Information observed by you • Establish the what, where and when of the issue 2. Evaluate Potential Causes • Consider possible causes of the problem to develop a hypothesis •...
Page 37: Troubleshooting - Hydraulic
Troubleshooting – Hydraulic The following tables contain suggestions that can be used to solve performance issues specific to the hydraulic system. The suggestions are not all-inclusive. There can be more than 1 cause for a machine malfunction. Review the hydraulic schematic found in Appendix A (page A–1) and information on the hydraulic system operation in the...
Page 38: General Hydraulic System Problems
General Hydraulic System Problems Problem Possible Cause Corrective Action Hydraulic fluid is leaking from the The fitting(s), hose(s), or tube(s) are Secure or replace loose or damaged system. loose or damaged. hydraulic connections. The O-ring(s) or seal(s) are missing or Install a new O-ring(s) or seal(s).
Page 39 General Hydraulic System Problems (continued) Problem Possible Cause Corrective Action The hydraulic system operates hot The hydraulic fluid level in the hydraulic Adjust the hydraulic fluid level. (exceeds 95° C (203° F). tank is low. The hydraulic fluid is contaminated or Replace the hydraulic fluid.
Page 40: Traction System Problems
Traction System Problems Problem Possible Cause Corrective Action The traction response is sluggish. The hydraulic fluid is very cold. Allow the hydraulic fluid to warm by safely operating the machine at rest. The hydraulic fluid level in the hydraulic Adjust the hydraulic fluid level. tank is low.
Page 41 Traction System Problems (continued) Problem Possible Cause Corrective Action No traction exists in either direction. The parking brake is engaged. Disengage the parking brake. The hydraulic fluid level in the hydraulic Adjust the hydraulic fluid level. tank is low (other hydraulic circuit performance is affected as well).
Page 42: Steering System Problems (Model 08745 Only)
Steering System Problems (Model 08745 Only) Problem Possible Cause Corrective Action Steering is sluggish, operates poorly or Steering components (e.g. ball joint, Inspect steering components and repair or replace if necessary. is inoperative. steering cylinder) are worn or binding. The charge pressure is low (traction Verify charge pressure;...
Page 43: Attachment Lift/Lower Problems
Attachment Lift/Lower Problems Problem Possible Cause Corrective Action Lift cylinders will not raise or raise Engine speed is too low. Increase engine speed. slowly. Lift arms are binding, worn or damaged. Inspect lift components and repair or replace if necessary. The hydraulic fluid level in the hydraulic Adjust the hydraulic fluid level.
Page 44: Attachment Hydraulic Problems
Attachment Hydraulic Problems Problem Possible Cause Corrective Action The front or rear attachment hydraulic The Operator is not in the seat when Sit in the seat before engaging the PTO motor will not engage. the traction pedal is depressed. switch. A mechanical problem exists with the Inspect the attachment assembly for attachment.
Page 45: Troubleshooting - Electrical
Troubleshooting – Electrical CAUTION Remove all the jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Disconnect the battery cables unless the test requires battery voltage. Sand Pro ® 3040 and 5040 Page 3–11 Troubleshooting: Attachment Hydraulic Problems 20251SL Rev A...
Page 46: Starting Problems
Starting Problems Problem Possible Cause Corrective Action Nothing happens when you attempt to The traction pedal is not in the N Move the traction pedal to the neutral EUTRAL start the engine. position, out of adjustment, or faulty. position. Check the neutral switch adjustment. Test the neutral switch.
Page 47 Starting Problems (continued) Problem Possible Cause Corrective Action The engine cranks, but does not start. The fuel shut-off valve is closed. Open the fuel shut-off valve. The fuel tank is empty. Fill the fuel tank. The engine and/or fuel can be too cold. Move the machine to a heated environment and allow the engine and fuel to warm.
Page 48: General Run Problems
General Run Problems Problem Possible Cause Corrective Action The engine shuts off when the traction The Operator is not in the seat or the Sit in the seat before depressing the pedal is depressed. seat switch is faulty. traction pedal. The seat switch is faulty.
Page 49: Attachment Electrical Problems
Attachment Electrical Problems Problem Possible Cause Corrective Action The front or rear attachment hydraulic The Operator is not in the seat when Sit in the seat before engaging the PTO motor will not engage. the traction pedal is depressed. switch. The fuse F4 (10 A) is damaged.
Page 50 Troubleshooting: Attachment Electrical Problems Page 3–16 Sand Pro ® 3040 and 5040 20251SL Rev A...
Page 51 Chapter 4 Engine Table of Contents General Information ..........................4–2 Traction Unit Operator’s Manual ......................4–2 Briggs & Stratton Service Manual ...................... 4–2 Fuel Shut-Off Valve ..........................4–3 Adjustments ............................4–4 Adjusting the Engine Controls ......................4–4 Service and Repairs ..........................4–7 Cooling System..........................
Page 52: General Information
Service and repair parts for the Briggs & Stratton engines are supplied through your Authorized Toro Distributor. If the parts list is not available, provide your distributor with the Toro model and serial number of your machine as well as the Briggs & Stratton engine model and serial numbers.
Page 53: Fuel Shut-Off Valve
Fuel Shut-Off Valve The fuel shut-off valve is located under the fuel tank and 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 servicing the fuel filter, fuel impulse pump, or fuel lines, and when removing the fuel tank or engine from the machine.
Page 54: Chapter 4: Engine
Adjustments Adjusting the Engine Controls 1. Park the machine on a level surface, lower any attachments, apply the parking brake, and set the key switch to the O position. 2. Pivot the seat upward. 3. Set the throttle control to full F (high idle).
Page 55 Adjusting the Engine Controls (continued) 10. Start the engine and let it run at half throttle for approximately 5 minutes to warm up. 11. Set the throttle control to the S (low idle) position and verify the engine RPM. 12. Adjust the low idle setting if necessary: A.
Page 56 Adjusting the Engine Controls (continued) 14. Adjust the high idle setting if necessary by bending the high-speed spring anchor tang to attain the specified high idle speed. g350735 Figure 10 High-speed spring anchor tang Adjustment tool (shown for reference) Engine: Adjustments Page 4–6 Sand Pro ®...
Page 57: 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. Perform this maintenance procedure at the interval specified in the Operator’s Manual. IMPORTANT The engine that powers Sand Pro machines is air–cooled.
Page 58 Cooling System (continued) g340591 Figure 11 (shown with seat and seat base removed) Blower housing Cylinder head Rotation screen 3. Clean the rotating screen and the blower housing of dirt and debris. If blower housing removal is necessary for cooling system cleaning, the engine needs to be removed from machine;...
Page 59: Air Cleaner Assembly
Air Cleaner Assembly g340344 Figure 12 Air cleaner cover Hose clamp Hose clamp Intake hose Lock nut (2 each) Air cleaner housing Vacutator valve Hose clamp Mounting bracket Cap screw (2 each) Filter element Plug Removing the Air Cleaner Assembly Refer to Figure 12 for this procedure.
Page 60 Installing the Air Cleaner Assembly (continued) IMPORTANT Any leaks in the air cleaner system will allow the dirt into the engine and will cause serious engine damage. Ensure that all air cleaner components are in good condition and are properly secured during assembly.
Page 61: Fuel System
Fuel System g340716 Figure 13 Fuel tank Flat washer (2 used) R-clamp Fuel cap Cap nut Hose clamp (4 used) Grommet Fresh air filter Fuel filter Valve, rollover Fuel hose, fresh air filter Fuel hose, filter Flat washer (2 used) Carbon canister Shut-off valve Cap screw (2 used)
Page 62 The fuel system includes a fuel tank with a mechanical fuel shut-off valve, an in-line fuel filter, and a vacuum pulse fuel pump mounted on the engine. The fuel system also includes an fuel evaporative control system designed to collect and store evaporative emissions from the fuel tank;...
Page 63 Removing and Installing the Fuel Tank (continued) 5. Cover or plug the fuel hoses or fitting openings to prevent contamination from entering the fuel system. 6. Remove the cap screw (item 32) from under the front of the fuel tank. 7.
Page 64 Evaporative Control System (continued) vacuum unseats the check valve which then allows vapors from the canister to flow to the engine purge port. These vapors are then consumed by the engine. When the engine is not running, evaporative vapors remain in the fuel tank and carbon canister.
Page 65: Engine
Engine g341964 Figure 15 Spacer (2 used) Lock nut (8 used) Exhaust gasket (2 used) Exhaust shield Engine Support Engine assembly Wire harness connections Lock nut (4 used) Cap screw (2 used) Starter motor power cable Lock washer Muffler guard Cap screw (4 used) Ground cable Breather tube...
Page 66 Removing the Engine (continued) CAUTION The engine and exhaust system may be hot. To avoid possible burns, allow the engine and exhaust system to cool before removing engine from machine. 4. Remove the hitch assembly from the rear of the machine; refer to Removing and Installing the Hitch Assembly (page 7–22).
Page 67 Removing the Engine (continued) • Fusible link at the voltage regulator • Red wire at the engine fuel solenoid lead 12. Disconnect the red power cable at the starter motor. 13. Remove the cap screw securing the right front corner of the engine to the engine support and disconnect the ground cable from the engine crankcase.
Page 68 Installing the Engine (continued) g341647 Figure 17 Drive hub Set screw (short) Set screw (long) Rubber drive coupler 3. Place the square key into the slot on the engine stub shaft. CAUTION Use a hoist or lift to remove the engine once the engine is clear of the machine frame.
Page 69 Installing the Engine (continued) 9. Connect the machine wire harness at the left side of the engine: • Violet wire at the engine magneto lead • Fusible link at the voltage regulator • Red wire at the engine fuel solenoid lead 10.
Page 70 Engine: Service and Repairs Page 4–20 Sand Pro ® 3040 and 5040 20251SL Rev A...
Page 71 Chapter 5 Hydraulic System Table of Contents General Information ..........................5–3 Traction Unit Operator’s Manual and Accessory Installation Instructions..........5–3 Relieving Pressure from the Hydraulic System .................. 5–3 Towing the Traction Unit........................5–4 Traction Circuit Component Failure....................5–5 Hydraulic Hoses..........................5–6 Installing Hydraulic Hoses and Tubes (O-Ring Face Seal Fitting)............
Page 72 Servicing the Rear Lift Cylinder......................5–96 Steering Control Valve (Model 08745)....................5–99 Servicing the Steering Control Valve (Model 08745) ..............5–101 Steering Cylinder (Model 08745)....................5–102 Servicing the Steering Cylinder (Model 08745) ................5–104 Front Lift Cylinder (Optional) ......................5–107 Servicing the Front Lift Cylinder (Optional)..................
Page 73: General Information
General Information Traction Unit Operator’s Manual and Accessory Installation Instructions The traction unit Operator’s Manual and accessory Installation Instructions provide information regarding the operation, general maintenance and maintenance intervals for the machine and its accessories. Refer to the traction unit Operator’s Manual and accessory Installation Instructions for additional information.
Page 74: Towing The Traction Unit
Towing the Traction Unit IMPORTANT If towing limits are exceeded, severe damage to the hydraulic pump may occur. If it becomes necessary to tow or push the machine, the traction pump must be set to bypass hydraulic fluid. Move the machine at a speed below 4.8 kph (3 mph), and for a very short distance.
Page 75: Traction Circuit Component Failure
Note: If traction circuit contamination exists, the traction pump case drain could allow contaminates to enter the hydraulic tank. The alternative to using the Toro high flow hydraulic filter kit after a traction circuit component failure would be to disassemble, drain and thoroughly clean all the components, the hydraulic tank, and the hydraulic tubes and hoses in the traction circuit.
Page 76: Hydraulic Hoses
Note: If the hose has an elbow at one end, tighten the swivel nut on the elbow end before you tighten the nut on the straight end of the hose. For more hydraulic hose information, refer to the Toro Basics Series Training Book Hydraulic Hose Servicing (Part No. 94813SL).
Page 77: Installing Hydraulic Hoses And Tubes (O-Ring Face Seal Fitting)
Installing Hydraulic Hoses and Tubes (O-Ring Face Seal Fitting) g212099 Figure 19 Tube or hose Swivel nut O-ring Fitting body 1. Ensure that all the threads, the sealing surfaces of the hose/tube, and the fitting are free of burrs, nicks, scratches, or unwanted material. 2.
Page 78 Installing Hydraulic Hoses and Tubes (O-Ring Face Seal Fitting) (continued) Hose/Tube Installation Torque Table (continued) Hose/Tube Side Thread Size Fitting Dash Size Installation Torque (inch)—threads per inch) 1–3/16—12 116 to 142 N∙m (85 to 105 ft-lb) 1–7/16—12 150 to 184 N∙m (110 to 136 ft-lb) 1–11/16—12 190 to 233 N∙m (140 to 172 ft-lb) Flats From Wrench Resistance Table...
Page 79: Installing The Hydraulic Fittings (Sae Straight Thread O-Ring Fittings)
Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings) Installing a Non-Adjustable Fitting g212226 Figure 21 Fitting O-ring 1. Ensure that all the threads, the sealing surfaces of fitting, and the component port are free of burrs, nicks, scratches, or unwanted material. 2.
Page 80 Installing an Adjustable Fitting g212224 Figure 22 Locknut Back-up washer O-ring g212225 Figure 23 Step 1: clearance the lock nut Step 3: align the fitting Step 2: seat the back-up washer Step 4: tighten the lock nut 1. Ensure that all the threads, the sealing surfaces of fitting, and the component port are free of burrs, nicks, scratches, or unwanted material.
Page 81 Installing an Adjustable Fitting (continued) A. Hold the fitting in the correct alignment with a wrench and use a torque wrench and tighten the lock nut to the recommended torque value within the specified range of torque values; refer to the Fitting Installation Torque Table (page 5–11).
Page 82: Hydraulic Schematics
Hydraulic Schematics The hydraulic schematics for the Sand Pro 3040/5040 machines and optional hydraulic accessories are located in Appendix A (page A–1). Hydraulic System: Hydraulic Schematics Page 5–12 Sand Pro ® 3040 and 5040 20251SL Rev A...
Page 83: Hydraulic Flow Diagrams
Hydraulic Flow Diagrams Traction Circuit g343423 Figure 24 Traction Circuit Diagram (Forward) Sand Pro ® 3040 and 5040 Page 5–13 Hydraulic System: Hydraulic Flow Diagrams 20251SL Rev A...
Page 84 The hydraulic traction circuit is a closed loop system consisting of a variable displacement piston (traction) pump, three wheel motors, and a remote mounted relief valve. The traction pump is driven by the engine directly through a rubber drive coupling. The traction pump swash plate and trunnion shaft is moved by the traction pedal through a neutral detent linkage assembly.
Page 85 Reverse Direction (continued) motor. Fluid by-passes the front wheel motor in the reverse direction because of the check valve inside the front motor. The front wheel does not provide traction in the reverse direction. Hydraulic fluid is continuously pumped through the closed loop traction circuit as long as the traction pedal is pressed rearward.
Page 86: Steering Circuit (Model 08745)
Steering Circuit (Model 08745) g343421 Figure 25 Steering Circuit Diagram Hydraulic System: Hydraulic Flow Diagrams Page 5–16 Sand Pro ® 3040 and 5040 20251SL Rev A...
Page 87 The implement/charge pump (P2) is a fixed displacement gerotor pump that is part of the traction pump. The implement/charge pump supplies oil flow for the steering circuit on model 08745 machines. The implement/charge pump also supplies fluid flow for the lift circuit and the charge circuit of the closed loop traction system for both model 08743 and 08745 machines.
Page 88 Left Turn (continued) the rotary meter and is directed out the L port. Pressure retracts the steering cylinder for a left turn. The rotary meter ensures that the oil flow to the cylinder is proportional to the amount of the rotation of the steering wheel. Fluid leaving the steering cylinder flows back through the spool valve, then out the T port of the steering valve and returns to the hydraulic tank.
Page 89: Lift Circuit
Lift Circuit g343420 Figure 27 Lift Circuit Diagram (model 08745 shown) Sand Pro ® 3040 and 5040 Page 5–19 Hydraulic System: Hydraulic Flow Diagrams 20251SL Rev A...
Page 90 The implement/charge pump (P2) is a fixed displacement gerotor pump that is part of the traction pump. The implement/charge pump also supplies fluid flow for the lift circuit and the charge circuit of the closed loop traction system for both model 08743 and 08745 machines.
Page 91: Rear Remote Hydraulic Circuit (Optional)
Figure 28 Rear Remote Hydraulic Circuit Diagram A remote rear hydraulics kit (model 08781) is available for both Sand Pro 3040 and 5040 machines to support the hydraulic needs of various rear attachments. The kit includes its own fixed displacement gear type hydraulic pump (P3) and a separate hydraulic manifold.
Page 92: Switch Kit Hydraulic Circuit (Optional)
Switch Kit Hydraulic Circuit (Optional) g349334 Figure 29 Switch Kit Hydraulic Circuit Diagram (rear attachment selected) A hydraulics switch kit (model 08783) is available for Sand Pro 5040 machines to support the hydraulic needs of various front and rear attachments. The kit includes its own fixed displacement gear type hydraulic pump (P3) and a separate hydraulic manifold.
Page 93: Testing The Hydraulic System
Testing the Hydraulic System The most effective procedure to isolate the problems in the hydraulic system is to use hydraulic test equipment, such as pressure gauges and flow meters in the circuits during different operational checks; refer to Special Tools (page 2–14).
Page 94 IMPORTANT Use 2 people to perform all the tests, with 1 person in the seat and the other to read and record the test results. 1. Use the following resources to assist with hydraulic system troubleshooting. • The Hydraulic Schematic in Appendix A (page A–1) •...
Page 95 12. Record the results of all hydraulic tests performed. Sand Pro ® 3040 and 5040 Page 5–25 Hydraulic System: Testing the Hydraulic System 20251SL Rev A...
Page 96: Hydraulic Test Selection
Hydraulic Test Selection Before beginning any hydraulic test, identify if the problem is related to the traction circuit, steering circuit (model 08745 only), lift circuit, or attachment circuit. Once the faulty system has been identified, perform tests that relate to that circuit. If a traction circuit problem exists, consider performing one or more of the following tests: Charge Pressure Test, Wheel Motor Efficiency Test, and/or Traction Pump (P1) Flow and Relief Valve Test.
Page 97: Testing The Traction Circuit - Charge Pressure
Testing the Traction Circuit – Charge Pressure g354956 Figure 30 Traction Circuit – Charge Pressure Test The charge pressure test is the first in a series of tests recommended to determine traction circuit performance. A charge pressure drop of more than 20% when a moderate load is placed on the piston (traction) pump indicates an internal leak in the piston (traction) pump.
Page 98 excessive heat, cause damage to seals and other components in the hydraulic system, and affect overall machine performance. Special Equipment Required: • Pressure Gauge (accurate below 300 psi) • Flow meter with pressure gauge that has at least a 57 liters/minute (15 gallons/minute) capacity •...
Page 99 Test Procedure (continued) g354951 Figure 32 Hydraulic fluid cooler Hydraulic tube Hydraulic hose Hydraulic hose 8. Disconnect the hose from the fitting at the fluid cooler, then install a tee fitting with the pressure gauge between the fitting and disconnected hose. 9.
Page 100 Test Procedure (continued) A. The piston (traction) pump charge relief valve is damaged. Replace or repair the pump charge relief valve; refer to Servicing the Piston (traction) Pump (page 5–74). B. The in-line check valve/fitting (near the piston pump suction port) is faulty. C.
Page 101: Testing The Traction Circuit - Wheel Motor Efficiency
Testing the Traction Circuit – Wheel Motor Efficiency g355180 Figure 33 Traction Circuit – Wheel Motor Efficiency Tests Wheel motor efficiency is the second in a series of tests recommended to determine traction circuit performance. Too much hydraulic fluid flow through a single stationary wheel motor under load indicates an internal leak in the wheel motor.
Page 102 position, the test results will be higher should not be used to determine wheel motor efficiency. Test the wheel motors in three (3) different wheel positions to obtain accurate test results. Record test readings for all three (3) wheel positions and use the average for the final test result.
Page 103 Test Procedure (continued) g355127 Figure 34 Hydraulic tube Hydraulic hose B. Disconnect the hydraulic hose at the hydraulic tube above the front wheel motor. Use an additional hydraulic hose to install the tester to the exposed fittings. Make sure the tester is installed in the correct flow direction (toward the front wheel motor) and the tester flow control valve is fully open.
Page 104 Test Procedure (continued) A. Isolate the front wheel motor from the traction circuit by disconnecting both of the hydraulic hoses from the hydraulic tubes above the front wheel motor. Cap the hydraulic tubes and connect the hydraulic tester to the 2 disconnected hoses.
Page 105 Test Procedure (continued) K. Release the traction pedal, shut off the engine, and rotate the connected wheel motor 180°. Test again and record the flow meter reading. L. Use the average of the 3 flow meter readings to judge the wheel motor performance.
Page 106: Testing The Traction Circuit - Traction Pump (P1) Flow And Relief Pressure
Testing the Traction Circuit – Traction Pump (P1) Flow and Relief Pressure g355126 Figure 36 Traction Circuit – Piston (traction) Pump (P1) Flow and Relief Pressure Test The hydraulic pump (P1) flow test is the third in a series of tests recommended to determine the traction circuit performance.
Page 107 Load with fluid flow Under Load. A drop in flow under load of more than 12% indicates an internal leak or malfunctioning relief valve in the hydraulic pump. The final traction circuit test is verifying the hydraulic pump forward direction relief valve operation.
Page 108 Test Procedure (continued) g355127 Figure 37 Hydraulic tube Hydraulic hose 7. Disconnect the hydraulic hose at the hydraulic tube above the front wheel motor. Use an additional hydraulic hose to install the tester to the exposed fittings. Make sure the tester is installed in the correct flow direction (toward the front wheel motor) and the tester flow control valve is fully open.
Page 109 Test Procedure (continued) Note: The relief valve setting is 22,050 kPa (3,200 psi). An additional 690 kPa (100 psi) is necessary to overcome system charge pressure before the relief valve opens. D. Release the traction pedal, open the flow control valve fully, move the throttle to low speed, and set the key switch to the O position.
Page 110: Testing The Lift And Steering Circuit - Implement/Charge Pump (P2) Flow And Circuit Relief
Testing the Lift and Steering Circuit – Implement/Charge Pump (P2) Flow and Circuit Relief g355217 Figure 38 Implement/Charge Pump (P2) Flow and Circuit Relief Test Hydraulic System: Testing the Hydraulic System Page 5–40 Sand Pro ® 3040 and 5040 20251SL Rev A...
Page 111 The implement/charge pump (P2) is part of the piston (traction) pump assembly. The implement/charge pump is designed to satisfy the needs of the lift cylinder (and steering cylinder on model 08745 machines) simultaneously at full speed throttle. The Implement/Charge Pump (P2) Flow and Circuit Relief Test compares fluid flow at No Load with fluid flow Under Load.
Page 112 Test Procedure (continued) correct flow direction (away from the pump) and the tester flow control valve is fully open. 6. Start the engine and run it at low-idle speed. Correct any hydraulic fluid leaks at the test connections before continuing the test. 7.
Page 113 Test Procedure (continued) 12. Move the throttle to low speed position and set the key switch to the O position. 13. The under load test flow reading (step 10) should not drop more than 20% (3.8 LPM (1 GPM)) when compared to the no load test flow reading (step 9). A difference in flow of more than 20% (Under Load >...
Page 114: Testing The Steering Circuit (Model 08745 Only) - Steering Cylinder Internal Leakage
Testing the Steering Circuit (Model 08745 only) – Steering Cylinder Internal Leakage g355311 Figure 40 Steering Circuit (Model 08745 only) – Steering Cylinder Internal Leakage Test Unit steering performance will be affected by incorrect front tire pressure, binding in the hydraulic steering cylinder, extra weight on the vehicle, and/or binding of the steering linkage or front fork.
Page 115 Test Procedure (continued) A. Park the machine on a level surface, lower any attachments, and engage the parking brake. B. With the engine running, turn the steering wheel to the right (clockwise) until the steering cylinder rod is fully extended and set the key switch to the O position.
Page 116: Testing The Lift Circuit - Lift Cylinder Internal Leakage
Testing the Lift Circuit – Lift Cylinder Internal Leakage g355399 Figure 42 Lift Circuit – Lift Cylinder Internal Leakage Test Perform the lift cylinder internal leakage test if you identify an attachment lift or lower problem. This test determines if the lift cylinder being tested is damaged. When performing the lift cylinder internal leakage test, the attachment should be attached to the hitch assembly.
Page 117 Test Procedure (continued) g355401 Figure 43 Elbow fitting at lift cylinder rod end – Hydraulic hose – plugged capped 4. Cap the disconnected fitting and plug the disconnected hose. 5. Remove the block or jack stand supporting the attachment, then lower and remove the jack.
Page 118: Testing The Optional Attachment Circuit - Attachment Pump (P3) Flow And Circuit Relief
Figure 44 Optional Attachment Circuit – Attachment Pump (P3) Flow and Circuit Relief A remote rear hydraulics kit (model 08781) is available for both Sand Pro 3040 and 5040 machines to support the hydraulic needs of various rear attachments. A hydraulics switch kit (model 08783) is available for Sand Pro 5040 machines to support the hydraulic needs of various front and rear attachments.
Page 119 Test Procedure (continued) 2. Read and adhere to the information provided in Testing the Hydraulic System (page 5–23). 3. Disconnect the attachment from the kit quick-disconnect fittings or remove the covers and plugs from the quick-disconnect fittings. 4. Use 2 hydraulic test hoses to install the tester to the kit quick-disconnect fittings.
Page 120 Test Procedure (continued) A. Monitor the tester pressure gauge carefully while slowly closing the flow control valve B. The system pressure should reach approximately 17,235 kPa (2,500 psi) before the relief valve opens. Record the tester pressure reading. C. Open the flow control valve fully, move the throttle to low speed, and set the key switch to the O position.
Page 121: Adjustments
Adjustments Sand Pro ® 3040 and 5040 Page 5–51 Hydraulic System: Adjustments 20251SL Rev A...
Page 122: Adjusting The Traction System For Neutral
Adjusting the Traction System for Neutral The traction pedal must return to the N position when released from either EUTRAL the forward or reverse position. The machine must not creep in either direction on level ground when in the traction pedal is in the N position.
Page 123 Adjusting the Traction System for Neutral (continued) B. Turn the adjustment cam slowly in the opposite direction until the wheel begins to rotate in the reverse direction (position R). C. Turn the adjustment cam to the mid point between position F and R. The wheels should not rotate in either direction.
Page 124: Service And Repairs
Service and Repairs General Precautions for Removing and Installing the Hydraulic System Components Before Repairing or Replacing the Components 1. Before removing any parts from the hydraulic system, park the machine on a level surface, lower any attachments, engage the parking brake, set the key switch to the O position and remove the key from the switch.
Page 125 After Repairing or Replacing the Components (continued) Fitting) (page 5–7) Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings) (page 5–9). 5. After you complete the repairs, check the control linkages or cables for proper adjustment, binding, or broken parts. 6.
Page 126: Checking The Hydraulic Lines And Hoses
Checking the Hydraulic Lines and Hoses WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury. • Ensure that all hydraulic-fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to the hydraulic system. •...
Page 127: Flushing The Hydraulic System
Flushing the Hydraulic System IMPORTANT If a component failure occurs in the traction circuit; refer to Filtering the Closed-loop Traction Circuit (page 5–59) for additional information. IMPORTANT Flush the hydraulic system whenever there is a severe component failure or the system is contaminated (for example, the fluid appears milky, black, or contains metal particles).
Page 128 Flushing the Hydraulic System (continued) 8. Fill the hydraulic tank with the correct type and quantity of new hydraulic fluid; refer to the traction unit Operator’s Manual. 9. Prime the hydraulic pumps; refer to Priming the Hydraulic Pumps (page 5–63). 10.
Page 129: Filtering The Closed-Loop Traction Circuit
To effectively remove contamination from the closed−loop traction circuit, use of a Toro bidirectional high flow hydraulic filter and hydraulic hose kit is recommended; refer to...
Page 130 Filtering the Closed-loop Traction Circuit (continued) g349443 Figure 47 Traction (piston) Pump Hydraulic tube Hydraulic hose C. If rear wheel motor was replaced, remove the wheel at the new wheel motor; refer to Removing and Installing the Rear Wheels (page 7–5).
Page 131 5. Connect the Toro high flow hydraulic filter in series between the disconnected fittings and tube or hose. Use the hydraulic hose kit to connect the filter to the machine if necessary;...
Page 132 IMPORTANT If you are using a filter that is not the Toro high flow filter that is bi-directional, do not press the traction pedal in the opposite direction.
Page 133: Priming The Hydraulic Pumps
Priming the Hydraulic Pumps Whenever hydraulic fluid has been drained from the pumps (system drain, flush, or pump removal/installation) it is important to properly prime the hydraulic pumps. Priming the hydraulic pumps ensures that the gear pumps and piston (traction) pump have sufficient fluid while charging the hydraulic system. IMPORTANT If the traction (piston) pump was rebuilt or replaced, make sure the pump housing is at least half full of clean hydraulic fluid after...
Page 134: Charging The Hydraulic System
Charging the Hydraulic System IMPORTANT Air must be purged from the hydraulic system to reduce the chance of component damage. When initially starting the hydraulic system with new or rebuilt components such as wheel motors, pumps, or cylinders, it is important that the hydraulic system is charged properly to remove air from the system.
Page 135 Charging the Hydraulic System (continued) 9. For model 08745 machines, turn the steering wheel in both directions so that the steering cylinder moves in and out several times. 10. Operate the traction pedal in the forward and reverse directions. Make sure the wheels are turning in the proper direction.
Page 136: Hydraulic Tank
Hydraulic Tank g349634 Figure 49 Cap screw (3 each) Check valve Flat washer (3 each) Dipstick Filter bracket Clamp Hydraulic tank Cap screw (2 each) Clamp (2 each) Elbow fitting (2 each) Barb fitting Lock nut (3 each) Hose clamp (4 each) Barb fitting Plug w/O-ring Hose –...
Page 137 Removing the Hydraulic Tank (continued) 5. Remove the left rear wheel from the machine; refer to Removing and Installing the Rear Wheels (page 7–5). 6. Read and adhere to the information provided in General Precautions for Removing and Installing the Hydraulic System Components (page 5–54).
Page 138: Hydraulic Fluid Cooler
Hydraulic Fluid Cooler g349636 Figure 50 Center Shroud Elbow fitting Rubber clamp (2 each) Dash Shroud Elbow fitting (model 08743) Fan shroud Rear fuel tank clamp (2 each) Tee fitting (model 08745) Cooler panel Dash Panel Hydraulic fluid cooler Removing and Installing the Hydraulic Fluid Cooler Refer to Figure 50 for this procedure.
Page 139 Removing and Installing the Hydraulic Fluid Cooler (continued) 4. Remove the fasteners at the bottom of the dash shroud and remove the dash shroud from the machine. 5. Read and adhere to the information provided in General Precautions for Removing and Installing the Hydraulic System Components (page 5–54).
Page 140: Piston (Traction) Pump
Piston (traction) Pump g350536 Figure 51 Damper Cap screw (2 each) Cap screw Set screw (2 each) Cap screw (2 each) Hydraulic hose – filter Lock nut (2 each) Piston (traction) pump assembly Hose clamp Washer – hardened (2 each) Hydraulic fluid filter assembly Removing the Piston (traction) Pump Refer...
Page 141 Removing the Piston (traction) Pump (continued) 9. Clean the hydraulic pump and all hydraulic connections to prevent hydraulic system contamination. 10. Remove the suction hose between the hydraulic fluid filter and the pump. 11. For assembly purposes, label all the hydraulic connections. Record the location of cable ties and routing of the hydraulic hoses for assembly purposes.
Page 142 Removing the Piston (traction) Pump (continued) g350535 Figure 52 Piston (traction) pump Harness retainer Check valve Cap screw Elbow fitting Tee fitting Straight fitting Hose clamp (2 each) Tee fitting Suction hose Tee fitting Elbow fitting Straight fitting Elbow fitting Elbow fitting 23.
Page 143 Installing the Piston (traction) Pump (continued) 3. If previously removed, install the fan. The fan must bottom against the end of the pump shaft. Tighten the cap screw securing the fan to the pump shaft from 3.0 to 3.5 N·m (28 to 32 in-lb). 4.
Page 144: Servicing The Piston (Traction) Pump
Servicing the Piston (traction) Pump g350860 Figure 53 Swashplate Shaft-Drive Bypass Valve Asm Bearing-Ball Plate - Valve CCW Plug Asm (2 each) Cylinder Block Kit Ring-Retaining Spring (2 each) Gasket-Cap, End Ring-Retaining (2 each) Relief Valve (2 each) Plate-Thrust Seal-Lip, Shaft Pin-Slotted Bearing-Needle Plug Asm (5 each)
Page 145 Servicing the Piston (traction) Pump (continued) Note: For the piston (traction) pump repair information; refer to the Danfoss DDC20 Axial Piston Pump Service Manual. IMPORTANT If a piston (traction) pump failure occurs, refer to Filtering the Closed-loop Traction Circuit (page 5–59) for information regarding the importance of removing contamination from the traction circuit.
Page 146: Wheel Motors
Wheel Motors Front Wheel Motor g349934 Figure 54 Lock nut Elbow fitting (2 each) Woodruff key Wheel hub Front wheel motor Drive stud (4 each) Removing the Front Wheel Motor Refer to Figure 54 for this procedure. 1. Remove the front wheel; refer to Removing the Front Wheel (page 7–3).
Page 147 Front Wheel Motor (continued) 10. If the hydraulic fittings are to be removed from the wheel motor, mark the fitting orientation for assembly purposes. Remove the fittings from the wheel motor and discard the O-rings from the fittings. Installing the Front Wheel Motor IMPORTANT Because of the internal differences in the wheel motors, do not interchange the wheel motors on the machine (e.g., do not put a rear...
Page 148 Rear Wheel Motor g350200 Figure 55 Hydraulic tube assembly Drive stud (4 each) Lock washer (4 each Rear wheel motor Wheel hub Elbow fitting (2 each) Woodruff key Wheel hub nut Elbow fitting Parking brake bracket Hydraulic hose assembly Cap screw (4 each) Removing the Rear Wheel Motor Refer toFigure 55...
Page 149 Rear Wheel Motor (continued) 8. Use a hub puller to loosen the wheel hub from the wheel motor; refer to Wheel Hub Puller (page 2–18). 9. Remove the lock nut, hub, and woodruff key from the motor shaft. 10. Support the wheel motor to prevent it from falling. Remove the 4 fasteners that secure the motor to the frame.
Page 150 Rear Wheel Motor (continued) 8. Charge the hydraulic system; refer to Charging the Hydraulic System (page 5–64). Hydraulic System: Service and Repairs Page 5–80 Sand Pro ® 3040 and 5040 20251SL Rev A...
Page 151: Servicing The Wheel Motors
Servicing the Wheel Motors g350211 Figure 56 (Front Wheel Motor Shown) Dirt and water seal Cap screw (7 each) Commutator ring Housing Plug Commutator Back-up washer O-Ring Manifold Back-up ring Spring Stator Shaft seal Ball Wear plate Coupling shaft End cover Rotor Thrust bearing Body seal (5 each)
Page 152 Servicing the Wheel Motors (continued) For the wheel motor repair procedures; refer to the Parker Torqmotor™ Service Procedure (TF, TG, TH, and TL Series). IMPORTANT If a wheel motor fails, refer to Traction Circuit Component Failure (page 5–5) for information regarding the importance of removing contamination from the traction circuit.
Page 153: Traction Relief Manifold
Traction Relief Manifold g352482 Figure 57 (view from under machine) Traction relief manifold Hydraulic hose (2 each) Manifold bracket For cartridge valve service procedures, refer to Servicing a Hydraulic Cartridge Valve (page 5–87). Removing and Installing the Traction Relief Manifold The traction relief manifold is located near the left rear wheel and is best accessed from under the machine.
Page 154 Removing and Installing the Traction Relief Manifold (continued) 7. If the hydraulic fittings are to be removed from the manifold, mark the fitting orientation for assembly purposes and remove the fittings from the manifold. Discard the O-rings from the fittings. 8.
Page 155: Rear Lift Relief Manifold (Model 08743)
Rear Lift Relief Manifold (Model 08743) g352503 Figure 58 Hydraulic hose Hydraulic tube Rear lift relief manifold For cartridge valve service procedures, refer to Servicing a Hydraulic Cartridge Valve (page 5–87). Removing and Installing the Rear Lift Relief Manifold The rear lift relief manifold is located near the rear lift valve, and is supported by the lift valve plumbing (hydraulic tube).
Page 156 Removing and Installing the Rear Lift Relief Manifold (continued) 8. Remove the caps and plugs then connect the hydraulic lines to the manifold fittings; refer to Installing Hydraulic Hoses and Tubes (O-Ring Face Seal Fitting) (page 5–7). 9. Charge the hydraulic system; refer to Charging the Hydraulic System (page 5–64).
Page 157: Servicing A Hydraulic Cartridge Valve
Servicing a Hydraulic Cartridge Valve Remove the following manifolds from the machine before removing the cartridge valves; refer to Traction Relief Manifold (page 5–83), Rear Lift Relief Manifold (Model 08743) (page 5–85), or Hydraulic Switch Kit Manifold (Optional) (page 5–117). The optional Rear Remote Hydraulics Manifold is difficult to remove;...
Page 158 Servicing a Hydraulic Cartridge Valve (continued) While energized, flush out any contamination with a nonflammable aerosol brake cleaner. De-energize the solenoid. Repeat the flush while energized procedure 5 or 6 times. Remove the solenoid from the cartridge. 6. Install the cartridge valve: A.
Page 159: Lift Control Valve
Lift Control Valve g352024 Figure 59 (standard rear lift valve shown) Cap screw (2 each) Cap screw (2 each) Flat washer (2 each) Lock nut (3 each) Lever guide plate Right side wheel shroud Roll pin Lift control valve Lift lever Cap screw (4 each) Curved washer Cap screw (3 each)
Page 160 Removing the Lift Control Valves (continued) 5. Remove the fasteners that secure the lift lever pivot (item 7) to the lift control valve and the pivot bracket. Remove the lift lever assembly from the machine. 6. Read and adhere to the information provided in General Precautions for Removing and Installing the Hydraulic System Components (page 5–54).
Page 161 Installing the Lift Control Valves (continued) 5. Install the lift lever pivot (item 7) to the lift control valve and the pivot bracket with the previously removed fasteners. 6. Install the lever guide plate with the previously removed fasteners. 7. Install the right side wheel shroud. 8.
Page 162: Servicing The Lift Control Valve
Servicing the Lift Control Valve g351917 Figure 61 Spool Plug (2 each) O-ring (2 each) Spring retainer, inner Valve body Spring Pin (2 each) Spring retainer, outer Seat – valve (2 each) Spacer Ball (2 each) Retaining ring, spool Spring (2 each) Retaining ring O-ring (2 each) The same valve is used for the standard rear lift valve and the optional front lift...
Page 163 Disassembling the Lift Valve (continued) 7. Carefully push and twist the spool from the valve body. 8. Being careful not to scratch the valve bore finish, remove the O-rings (spool seals) from the inside bore of the valve body. 9. Inspect all the components for wear, paying special attention to the spool. Signs of wear on one side of the spool may indicate a bent spool.
Page 164: Rear Lift Cylinder
Rear Lift Cylinder g351871 Figure 62 (view from under machine) Cap screw Rear hitch Cap screw Lift cylinder Flat washer Removing the Rear Lift Cylinder Refer to Figure 62 for this procedure. The rear lift cylinder is located on the left side of the machine.
Page 165 Installing the Rear Lift Cylinder Refer to Figure 62 for this procedure. 1. If the hydraulic fittings were removed from the cylinder, lubricate new O-rings with clean hydraulic fluid, position the O-rings to the fittings, and install the fittings in the marked orientation; refer to Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings) (page 5–9).
Page 166: Servicing The Rear Lift Cylinder
Servicing the Rear Lift Cylinder g351441 Figure 63 Barrel Rod seal Retaining ring Lock nut Head O-ring Cylinder rod Piston wear ring Head back-up ring Grease fitting Piston Cylinder head Rod wiper Rod O-ring If items other than the cylinder seals are worn or damaged, the cylinder must be replaced as a complete assembly.
Page 167 Disassembling the Rear Lift Cylinder (continued) IMPORTANT Do not clamp the vise jaws against the shaft surface. Clamp on the clevis ONLY. 5. Mount the shaft securely in a vise by clamping on the clevis of the shaft. Remove the lock nut and piston from the shaft. Carefully slide the head off the shaft.
Page 168 Assembling the Rear Lift Cylinder (continued) A. Using a spanner wrench, rotate the head until the retaining ring hole appears in the barrel opening. B. Insert the retaining ring hook through the barrel opening and into the hole in the head. C.
Page 169: Steering Control Valve (Model 08745)
Steering Control Valve (Model 08745) g351051 Figure 64 Steering control valve Hydraulic tube Hydraulic hose Cap screw (4 each) Hydraulic hose Hydraulic tube Lock nut (4 each) Hydraulic hose Removing the Steering Control Valve 1. Park the machine on a level surface, lower any attachments, engage the parking brake, set the key switch to the O position and remove the key from the switch.
Page 170 Installing the Steering Control Valve (continued) g351039 Figure 65 Hose from piston (taction) pump – Port P Hose to steering cylinder barrel end – Port Tube to oil cooler Tee fitting – Port T Hose to steering cylinder rod end – Port L Tube to lift control Tee fitting –...
Page 171: Servicing The Steering Control Valve (Model 08745)
Servicing the Steering Control Valve (Model 08745) g350902 Figure 66 Sleeve Housing Inner gearwheel Dust seal ring Cross pin Outer gearwheel Ring End cover Relief valve (2 each) Spool Relief valve spring (2 each) O–ring (5 each) Bearing assembly Cardan shaft Screw/fitting (ports L, R, T) Shaft seal Spacer...
Page 172: Steering Cylinder (Model 08745)
Steering Cylinder (Model 08745) g351128 Figure 67 Retaining ring Spacer (2 each) Elbow fitting (2 each) Washer (2 each) Bushing (2 each) Ball joint Yoke Grease fitting Jam nut (2 each) Cap screw (2 each) Retaining ring Washer (2 each) Steering cylinder Removing the Steering Cylinder Refer to...
Page 173 Removing the Steering Cylinder (continued) 8. Remove the retaining ring and washers from the yoke shaft and remove the yoke from the machine if necessary. 9. Inspect the cylinder ball joint boot and replace the ball joint if necessary. 10. If the hydraulic fittings are to be removed from the cylinder, mark the fitting orientation for assembly purposes and remove the fittings from the cylinder.
Page 174: Servicing The Steering Cylinder (Model 08745)
Servicing the Steering Cylinder (Model 08745) g351311 Figure 68 Barrel Rod O-ring Retaining ring Lock nut Rod seal Rod wiper Piston wear ring Head O-ring Cylinder rod Piston Head back-up ring Piston seal Head If items other than the cylinder seals are worn or damaged, the cylinder must be replaced as a complete assembly.
Page 175 Disassembling the Steering Cylinder (continued) IMPORTANT Do not clamp the vise jaws against the shaft surface. Clamp on the clevis ONLY. 5. Mount the shaft securely in a vise by clamping on the clevis of the shaft. Remove the lock nut and piston from the shaft. Carefully slide the head off the shaft.
Page 176 Assembling the Steering Cylinder (continued) A. Using a spanner wrench, rotate the head until the retaining ring hole appears in the barrel opening. B. Insert the retaining ring hook through the barrel opening and into the hole in the head. C.
Page 177: Front Lift Cylinder (Optional)
Front Lift Cylinder (Optional) g351815 Figure 69 Retaining ring Elbow fitting Lift cylinder Elbow fitting Retaining ring (2 each) Hydraulic hose assemblies Cylinder pin Removing and Installing the Optional Front Lift Cylinder Refer to Figure 69 for this procedure. 1. Park the machine on a level surface, lower any attachments, engage the parking brake, set the key switch to the O position and remove the key from the switch.
Page 178 Removing and Installing the Optional Front Lift Cylinder (continued) 9. Remove the caps and plugs then connect the hydraulic hoses to the cylinder fittings; refer to Installing Hydraulic Hoses and Tubes (O-Ring Face Seal Fitting) (page 5–7). 10. Charge the hydraulic system; refer to Charging the Hydraulic System (page 5–64).
Page 179: Servicing The Front Lift Cylinder (Optional)
Servicing the Front Lift Cylinder (Optional) g351446 Figure 70 Barrel Rod O-ring Retaining ring Lock nut Rod seal Rod wiper Piston wear ring Head O-ring Cylinder rod Piston Head back-up ring Piston seal Head If items other than the cylinder seals are worn or damaged, the cylinder must be replaced as a complete assembly.
Page 180 Disassembling the Optional Front Lift Cylinder (continued) IMPORTANT Do not clamp the vise jaws against the shaft surface. Clamp on the clevis ONLY. 5. Mount the shaft securely in a vise by clamping on the clevis of the shaft. Remove the lock nut and piston from the shaft. Carefully slide the head off the shaft.
Page 181 Assembling the Optional Front Lift Cylinder (continued) A. Using a spanner wrench, rotate the head until the retaining ring hole appears in the barrel opening. B. Insert the retaining ring hook through the barrel opening and into the hole in the head. C.
Page 182: Rear Remote Hydraulics (Optional) Or Switch Kit (Optional) Hydraulic Pump
Rear Remote Hydraulics (Optional) or Switch Kit (Optional) Hydraulic Pump g353005 Figure 71 (rear remote hydraulics kit shown with hitch removed) Square key Barb fitting – suction Cap screw (2 each) Rubber bushing Hose clamp Washer (2 each) Bracket Coupler Cap screw (2 each) Set screw (4 each) Hydraulic pump...
Page 183 Removing the Optional Hydraulic Pump (continued) 7. Loosen the set screws securing the optional hydraulic pump to the coupler and remove the pump assembly from the machine. Retrieve the pump shaft key. 8. If necessary, remove the fasteners securing the hydraulic pump to the torque plate and remove the torque plate.
Page 184: Servicing The Optional Rear Remote Hydraulics Or Optional Switch Kit Hydraulic Pump
Servicing the Optional Rear Remote Hydraulics or Optional Switch Kit Hydraulic Pump g352961 Figure 72 Front cover Rear cover Thrust block (2 each) Seal- O-ring (2 each) Cap screw (4 each) Driven gear Dowel pin (2 each) Washer (4 each) Shaft seal Body Back–up seal (2 each)
Page 185: Rear Remote Hydraulics Manifold (Optional)
Rear Remote Hydraulics Manifold (Optional) g352948 Figure 73 (view from under machine) Rear remote hydraulics manifold assembly 3. Traction relief manifold assembly Hydraulic tube (3 each) The rear remote hydraulics manifold is located near the left rear wheel. For cartridge valve service procedures, refer to Servicing a Hydraulic Cartridge Valve (page 5–87).
Page 186 Removing the Optional Rear Remote Hydraulics Manifold Refer to Figure 73 for this procedure. 1. If the hydraulic fittings were removed from the manifold, lubricate new O-rings with clean hydraulic fluid, position the O-rings to the fittings, and install the fittings in the marked orientation;...
Page 187: Hydraulic Switch Kit Manifold (Optional)
Hydraulic Switch Kit Manifold (Optional) g352652 Figure 74 Flat plain (3 each) Cap screw (2 each) Hydraulic tank clamp Cap screw Clamp Lock nut Cap screw (2 each) Hydraulic manifold assembly Coupler panel Manifold bracket Removing the Hydraulic Switch Kit Manifold Refer to Figure 74 for this procedure.
Page 188 Installing the Hydraulic Switch Kit Manifold Refer to Figure 74 for this procedure. 1. If the hydraulic fittings were removed from the manifold, lubricate new O-rings with clean hydraulic fluid, position the O-rings to the fittings, and install the fittings in the marked orientation; refer to Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings) (page 5–9).
Page 189: Servicing The Optional Hydraulic Switch Kit Manifold
Servicing the Optional Hydraulic Switch Kit Manifold g352574 Figure 76 Manifold block Coil nut (2 each) #4 zero-leak plug with O-ring (5 each) Solenoid valve – S3 Coil nut Solenoid valve – S2 Solenoid coil (3 each) Solenoid valve – S1 Relief valve –...
Page 190 Hydraulic System: Service and Repairs Page 5–120 Sand Pro ® 3040 and 5040 20251SL Rev A...
Page 191 Chapter 6 Electrical System Table of Contents General Information ..........................6–2 Traction Unit Operator’s Manual and Accessory Installation Instructions..........6–2 Electrical Schematics and Wire Harness Drawings/Diagrams ............... 6–3 Electrical System Quick Checks ......................6–4 Testing the Charging System ......................6–4 Checking the Operation of the Safety Interlock Switches ..............
Page 192: General Information
General Information Traction Unit Operator’s Manual and Accessory Installation Instructions The traction unit Operator’s Manual and accessory Installation Instructions provide information regarding the operation, general maintenance and maintenance intervals for the machine and its accessories. Refer to the traction unit Operator’s Manual and accessory Installation Instructions for additional information.
Page 193: Electrical Schematics And Wire Harness Drawings/Diagrams
Electrical Schematics and Wire Harness Drawings/Diagrams The electrical schematics and wire harness drawings for the Sand Pro 3040/5040 machine are located in Appendix A (page A–1). Sand Pro ® 3040 and 5040 Page 6–3 Electrical System: Electrical Schematics and Wire...
Page 194: Electrical System Quick Checks
Electrical System Quick Checks Testing the Charging System The Sand Pro 3040/5040 machines use a single 12 Volt maintenance free battery mounted behind the right side rear wheel. The battery is charged by a 15 Amp 12 volt alternator with separate voltage regulator supplied by the engine manufacturer.
Page 195: Checking The Operation Of The Safety Interlock Switches
Checking the Operation of the Safety Interlock Switches CAUTION Do not disconnect safety interlock switches. They are for the operator’s protection. Check the operation of the safety interlock switches daily for proper operation. Replace any malfunctioning switches before operating the machine. The machine interlock components include: •...
Page 196: Testing The Electrical Components
Testing the Electrical Components For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g., unplug the key switch connector before doing a continuity check of the switch). Always check the item being tested and the harness connector for damage or corrosion and clean or repair if necessary.
Page 197: Fusible Links
Fusible Links The Sand Pro 3040/5040 machines use 2 fusible links for circuit protection. The fusible links are located in the machine wire harness. One fusible link connects the starter solenoid B+ terminal to the fuse block at pin 2. The other fusible link connects the voltage regulator to the fuse block at pin 1.
Page 198 Testing the Fusible Links (continued) and cable connectors before installing the boot; refer to Battery Terminal Protector (page 2–17). 7. Connect the positive battery cable to the battery terminal and then connect the negative cable to the battery; refer to Removing and Installing the Battery (page 6–31).
Page 199: Fuses
Fuses g353097 Figure 78 (shown with seat raised) Fuse block Fuse F3 (10 Amp) Fuse F1 (20 Amp) Fuse F4 (open slot or optional 10 Amp) Fuse F2 (10 Amp) The individual control circuits are protected by a variety of fuses found in the main fuse block located under the operator’s seat.
Page 200 Testing the Fuses (continued) 5. If the fuse tests correctly and a circuit problem still exists, check the wire harness(es); refer to Appendix A (page A–1). Electrical System: Testing the Electrical Components Page 6–10 Sand Pro ® 3040 and 5040 20251SL Rev A...
Page 201: Key Switch
Key Switch POSITION CLOSED CIRCUITS G + M + A B + L + A START B + L + S The key switch is located on the operator’s console and has 3 positions: O , and S TART Testing the Key Switch 1.
Page 202: Starter Solenoid
Starter Solenoid g354011 Figure 79 Starter solenoid Stand-off nut – contact post Hex nut – coil post (2 each) Hex nut – contact post (2 each) Positive (+) battery cable Starter cable Wire harness Wire harness The starter solenoid is located on the right side frame rail under the operator seat. Testing the Starter Solenoid Refer to Figure 79...
Page 203 Testing the Starter Solenoid (continued) 8. Replace the starter solenoid if necessary. 9. If the starter solenoid tests correctly and a circuit problem still exists, check the wire harnesses; refer to Appendix A (page A–1). 10. Reconnect the wires and cables to the starter solenoid. Tighten the nuts on the coil posts from 1.7 to 2.3 N·m (15 to 20 in-lb), and the nuts on the main contact posts from 5.7 to 6.8 N·m (50 to 60 in-lb).
Page 204: Hour Meter
Hour Meter g354009 Figure 80 Hour meter Operators console The hour meter is located on the dash panel of the operator’s console. Testing the Hour Meter Refer to Figure 80 for this procedure. 1. Park the machine on a level surface, lower any attachments, engage the parking brake, set the key switch to the O position and remove the key from the switch.
Page 205: Seat Switch
Seat Switch g354064 Figure 81 Seat switch The seat switch is normally open and closes when the operator is on the seat. The seat switch is part of the safety interlock system. The seat switch is located directly under the seat cushion. Testing the switch can be done without removing the seat by disconnecting the seat switch wire harness from the machine wire harness.
Page 206: Traction Neutral Switch
Traction Neutral Switch g349907 Figure 82 Pump plate Cap screw (target) Neutral switch The traction neutral switch is a normally open proximity switch that closes when the traction pedal is in the neutral position. The switch is mounted to a plate on the right side of the traction (piston) pump.
Page 207 Adjusting the Traction Neutral Switch (continued) g349780 Figure 83 Neutral switch Cap screw (target) Pump plate Lock nut Neutral lever 3. If the clearance is incorrect, loosen the lock nut that secure car screw (target) to the neutral laver and adjust the cap screw. Tighten the lock nut and re-check the switch to cap screw clearance.
Page 208 Testing the Traction Neutral Switch (continued) 6. There should be continuity across the switch terminals when the traction pedal is in the N position. EUTRAL 7. Slowly push the traction pedal in the forward or reverse direction while watching the multimeter. There should be no continuity across the switch terminals in either the forward or reverse position.
Page 209: Relays With 5 Terminals
Relay – start Optional relay – seat switch The Sand Pro 3040/5040 machines use up to 4 relays that have 5 terminals. The standard relays are located along the frame crossmember under the operator’s seat. A tag near each wire harness relay connector can be used to identify each relay.
Page 210 Testing Relays with 5 Terminals (continued) g256780 Figure 85 Relay with 5 terminals Note: Prior to taking small resistance readings with a digital multimeter, short the meter test leads together. The meter will display a small resistance value (usually 0.5 ohms or less). This resistance is due to the internal resistance of the meter and test leads.
Page 211: Diode Assemblies
Diode Assemblies g354337 Figure 86 Starter solenoid Main wire harness diode D2 Optional rear remote hydraulics wire harness diode D1 Main wire harness diode D1 Optional rear remote hydraulics kit relay Two diodes plug into the main wire harness below the right side frame rail near the starter solenoid.
Page 212 Testing the Diode Assemblies (continued) Multimeter Multimeter Resistance Red (+) Lead Black (-) Lead DIODE DIODE VERY LOW TERMINAL A TERMINAL B DIODE DIODE VERY HIGH TERMINAL B TERMINAL A 4. If testing determines the diode is faulty, replace the diode. 5.
Page 213: Hydraulic Solenoid Valve Coils (Optional)
Hydraulic Solenoid Valve Coils (Optional) g354354 Figure 87 Rear remote hydraulics kit manifold 4. hydraulics switch kit manifold Valve SV3 coil (rear attachment) Valve coil (rear attachment) Valve SV1 coil (tank) Coil nut Valve SV2 coil (front attachment) Electric coil actuated hydraulic valves are used on the optional rear remote hydraulics kit manifold and the optional hydraulics switch kit manifold.
Page 214 Testing the Hydraulic Solenoid Valve Coils (continued) D. Install the coil and the nut onto the valve and tighten nut to 7 N∙m (60 in-lb). 4. If the solenoid coil resistance is correct and a circuit problem still exists, check the wire harness; refer to Appendix A (page A–1).
Page 215: Pto Switch (Optional)
PTO Switch (Optional) POSITION CLOSED CIRCUITS COM B + NC B (DOWN) COM C+ NC C ON (UP) COM B + NO B COM C+ NO C The power take off (PTO) switch is located on the dash panel of the operator’s console.
Page 216: Mode Select Switch (Optional)
Mode Select Switch (Optional) POSITION CLOSED CIRCUITS 2 + 1, 5 + 4 ENGAGE FRONT ATTACHMENT NONE ENGAGE 2 + 3, 5 + 6 REAR ATTACHMENT The mode select switch is a 3 position switch located on the dash panel of the operator’s console.
Page 217: Light Switch (Optional)
Light Switch (Optional) POSITION CLOSED CIRCUITS 2 + 1, 5 + 4 2 + 3, 5 + 6 The light switch is located on the dash panel near the steering wheel. Testing the Light Switch 1. Park the machine on a level surface, lower any attachments, engage the parking brake, set the key switch to the O position and remove the key from the switch.
Page 218: Service And Repairs
Service and Repairs Note: For engine component repair information, see the Briggs & Stratton V-Twin Engine Service Manual. Caring for the Battery WARNING • Wear safety goggles and rubber gloves when working with electrolyte. • Charge battery in a well ventilated place so gasses produced while charging can dissipate.
Page 219: Storing The Battery
Caring for the Battery (continued) 6. If corrosion occurs at the battery terminals, disconnect the battery cables. Always disconnect the negative (-) cable first. Clean the cable clamps and terminals separately. Connect the battery cables. Always connect the positive (+) cable first. Apply a coating of battery terminal protector or a light coat of petroleum jelly to the terminals to reduce corrosion after you make the connections;...
Page 220: Servicing The Battery
Servicing the Battery The battery is the heart of the electrical system. With the regular and correct service, the battery life can be extended. Additionally, the battery and electrical component failure can be prevented. CAUTION Battery-electrolyte is corrosive and can burn skin and eyes and damage clothing.
Page 221 Removing and Installing the Battery g353094 Figure 88 Positive (+) cable Hold-down post (2 each) Hex nut (2 each) Battery tray Negative (-) cable Wire harness ground connection Hold-down rod Cap screw (2 each) Battery IMPORTANT Be careful when removing the battery cables and ensure that you do not damage the terminal posts or cable connectors.
Page 222 Removing and Installing the Battery (continued) IMPORTANT To prevent possible electrical problems, install only a fully charged battery. A. Connect the positive (+) cable connector onto the positive (+) battery terminal. B. Connect a digital multimeter (set to A) between the negative (-) battery post and the negative (-) cable connector.
Page 223 Inspecting, Maintaining, and Testing the Battery (continued) B. Check the battery terminals for corrosion. Use the wire brush to clean corrosion from the posts. IMPORTANT Before cleaning the battery, tape or block the vent holes of the filler caps and ensure that the caps are secure. C.
Page 224 Inspecting, Maintaining, and Testing the Battery (continued) CAUTION Follow the manufacturer's instructions when using a battery load tester. A. Check the voltage across the battery terminals before testing the battery. If the voltage is less than 12.0 VDC, charge the battery before continuing the test.
Page 225 Charging the Battery (continued) To minimize damage to the battery and allow the battery to charge fully, use the following slow charging procedure. You can accomplish this charging procedure with a constant current battery charger that is available locally. IMPORTANT Follow the manufacturer's instructions when using a battery charger.
Page 226 Electrical System: Service and Repairs Page 6–36 Sand Pro ® 3040 and 5040 20251SL Rev A...
Page 227 Chapter 7 Chassis Table of Contents General Information ..........................7–2 Traction Unit Operator’s Manual and Accessory Installation Instructions..........7–2 Service and Repairs ..........................7–3 Wheels ............................... 7–3 Parking Brake ............................ 7–7 Traction Pedal and Control Assembly ....................7–10 Steering Wheel ..........................7–13 Steering Gear Box (Model 08743)....................
Page 228: General Information
General Information Traction Unit Operator’s Manual and Accessory Installation Instructions The traction unit Operator’s Manual and accessory Installation Instructions provide information regarding the operation, general maintenance and maintenance intervals for the machine and its accessories. Refer to the traction unit Operator’s Manual and accessory Installation Instructions for additional information.
Page 229: Service And Repairs
Service and Repairs Wheels Removing the Front Wheel g350145 Figure 89 Front fork Wheel and tire Set screw Lock nut (2 each) Lug nut (2 or 4 each) Flange nut (3 each) Hydraulic tube Bearing tab Wheel weight adapter (2 each) Tube clamp assembly Flangette –...
Page 230 Removing the Front Wheel (continued) 4. Loosen the set screw on the bearing locking collar. 5. Remove the fasteners securing the bearing assembly and bearing tab to the front fork. 6. Remove the fasteners securing the hydraulic motor to the fork. IMPORTANT Support the wheel and motor assembly when raising the front of the machine to prevent hydraulic tube damage.
Page 231 Installing the Front Wheel (continued) C. Carefully slide the wheel weight onto the studs and secure the weight to the wheel with the 2 thrust washers and lock nuts previously removed. 4. Assemble the flangettes and bearing then slide the bearing assembly onto the spindle shaft so the bearing locking collar faces the wheel.
Page 232 Removing and Installing the Rear Wheels (continued) IMPORTANT Before lifting the machine with a jack, review and follow Jacking Instructions (page 1–6). 2. Raise the machine so the rear wheel is off ground. 3. Remove the 4 lug nuts and remove the rear wheel. 4.
Page 233: Parking Brake
Parking Brake g354526 Figure 92 Retaining ring Spring washer (2 each) Retaining ring (2 each) Brake cable Hair pin (4 each) Spacer Cap screw (2 each) Latch bar (2 each) Woodruff key Brake lever Latch link (2 each) Locknut Brake lever bracket Compression spring (2 each) Wheel hub Lock washer (4 each)
Page 234 Disassembling and Assembling the Parking Brakes (continued) 1. Remove the rear wheels; refer to Removing and Installing the Rear Wheels (page 7–5). CAUTION Be careful when removing extension spring from parking brake bellcrank. The spring is under heavy load and may cause personal injury.
Page 235 Replacing the Parking Brake Cable (continued) 1. Park the machine on a level surface, lower any attachments, set the key switch to the Off position and remove the key from the switch. Ensure that the parking brake is not engaged. 2.
Page 236: Traction Pedal And Control Assembly
Traction Pedal and Control Assembly g349747 Figure 93 Forward pedal Traction neutral switch Flat washer (2 each) Pad – forward Adjustment pin Traction pedal assembly Neutral arm Pump plate Cotter pin Thrust washer Cap screw (3 each) Flange lock nut (2 each) Bearing Shoulder bolt Pedal stop...
Page 237 Removing Traction Pedal and Control Components (continued) CAUTION The extension spring is under tension. Use caution when removing the spring to avoid personal injury. 5. Loosen the adjustment pin lock nut to allow the extension spring to relax. Unhook the spring from the neutral arm. 6.
Page 238 Installing Traction Pedal and Control Components (continued) 4. If the rod end was removed from the traction rod, install the rod end so that the distance from the center of one rod end to the other is 35.8 cm (14.11 inch). 5.
Page 239: Steering Wheel
Steering Wheel g354677 Figure 95 (model 08745 shown) Steering wheel cover Steering wheel Lock nut Foam collar Flat washer Steering shaft Removing and Installing the Steering Wheel 1. Carefully remove the steering wheel cover from the steering wheel. 2. Remove the locknut and flat washer that secure the steering wheel to the steering control valve or steering shaft.
Page 240: Steering Gear Box (Model 08743)
Steering Gear Box (Model 08743) g354690 Figure 96 Cap screw Slotted hex nut Lock nut Woodruff key Bearing set screw Steering gear box Steering wheel and shaft assembly Flange nut Cotter pin Removing the Steering Gear Box 1. Park the machine on a level surface, lower any attachments, engage the parking brake, set the key switch to the O position and remove the key from the switch.
Page 241 Removing the Steering Gear Box (continued) Note: The steering box sector gear and castor fork shaft have tapered shafts that must be loosened before steering box can be separated from castor fork. 8. Separate the gear box from the front fork shaft using one of the following procedures: A.
Page 242: Servicing The Steering Gear Box (Model 08743)
Servicing the Steering Gear Box (Model 08743) g354537 Figure 97 Retaining ring Pinion gear Shim (as required) Retaining ring Gear box cover Gasket Ball bearing (2 each) Bushing (2 each) Gear box plate Spacer Sector gear Cap screw (8 each) Disassembling the Steering Gear Box 1.
Page 243 Assembling the Steering Gear Box 1. If removed, install the bushings into the gear box cover and the gear box plate. Make sure that the bushing flange is fully seated. 2. Apply Molilgrease XHP high temperature grease (or equivalent) to the bearing surfaces of the flange bushings.
Page 244: Front Fork
Front Fork Removing the Front Fork (Model 08743) g354744 Figure 98 Front fork Washer Hose guide Flange nut (2 each) Bearing cone (2 each) Spacer Slotted nut Bearing cup (2 each) Cotter pin Cap screw (2 each) 1. Remove the steering gear box; refer to Removing the Steering Gear Box (page 7–14).
Page 245 Installing the Front Fork (Model 08743) Refer to Figure 98 for this procedure. 1. If the bearing cups were removed from the frame, press new bearing cups into the frame making sure that they fully contact the shoulder in the frame. 2.
Page 246 Removing the Front Fork (Model 08745) g354776 Figure 99 (model 08745) Cap screw Steering sleeve Set screw Steering pivot Bearing cone (2 each) Lock nut Front fork Bearing cup (2 each) Steering nut Flat washer (4 each) Cap screw (2 each) Jam nut (2 each) Cap screw (4 each) Hose guide...
Page 247 Removing the Front Fork (Model 08745) (continued) B. Loosen the set screw in the steering nut. C. Remove the steering nut and the lower bearing cone. D. Remove the steering sleeve and the upper bearing cone. E. Clean and inspect the bearing cups and cones for wear or damage and replace the bearings if necessary.
Page 248: Hitch Assembly
Hitch Assembly g354858 Figure 100 (shown with rear left wheel removed) Rear cover and manual tube assembly Hitch adapter cap screw (3 each) Pivot pin (2 each) Lift cylinder Clevis pin Pivot pin Grease fitting Pivot hub (2 each) Bushing (2 each) Flat washer (4 each) Roller tube Cap screw (4 each)
Page 249 Removing and Installing the Hitch Assembly (continued) 3. Remove the rear cover and manual tube assembly. 4. Remove the hitch adapter from the machine: A. Support the hitch adapter to prevent it from falling during removal. B. Remove the 2 lower hitch adapter pivot pins. C.
Page 250: Operator's Console
Operator’s Console g351974 Figure 101 Operator’s console Knob Flat washer (7 each) Dash panel assembly Cap screw (7 each) Carbon canister Lock washer (3 each) Lock nut (4 each) Flat washer (4 each) Console support plate Cap screw (4 each) Carbon canister bracket Removing and Installing the Operator’s Console Refer to...
Page 251: Operator Seat
Operator Seat g354857 Figure 102 Seat back cover Seat switch Seat cushion cover Flange nut (4 each) Track assembly Receptacle – rubber Seat base Centering post – rubber Slic pin (2 each) Spacer Wire harness connector Bumper – rubber (2 each) Switch actuator cap Removing and Installing the Operator Seat 1.
Page 252 Chassis: Service and Repairs Page 7–26 Sand Pro ® 3040 and 5040 20251SL Rev A...
Page 253 Hydraulic Schematic – Sand Pro 3040....................A–3 Hydraulic Schematic – Sand Pro 5040....................A–4 Electrical Schematic – Sand Pro 3040/5040 ..................A–5 Wire Harness Drawing – Sand Pro 3040/5040 ...................A–6 Wire Harness Diagram – Sand Pro 3040/5040...................A–7 Wire Harness – Rear Remote Hydraulics (Optional) ................A–8 Wire Harness –...
Page 254: Electrical Drawing Designations
Y or YE YELLOW Numerous harness wires used on the Toro machines 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., R/BK is a red wire with a black line, OR_BK is an orange wire with a black line).
Page 255: Hydraulic Schematic - Sand Pro 3040
Hydraulic Schematic – Sand Pro 3040 g349192 Model 08743, Drawing 140-0311 Rev D, Sheet 1 of 1 20251SL Rev A Page A–3...
Page 256: Hydraulic Schematic - Sand Pro 5040
Hydraulic Schematic – Sand Pro 5040 g349193 Page A–4 20251SL Rev A Model 08745, Drawing 140-0308/140-0309 Rev A/A, Sheet 1 of 1...
Page 257: Electrical Schematic - Sand Pro 3040/5040
Electrical Schematic – Sand Pro 3040/5040 g339987 Model 08743 and 08745, Drawing 122-1402 Rev B, Sheet 1 of 1 20251SL Rev A Page A–5...
Page 258: Wire Harness Drawing - Sand Pro 3040/5040
Wire Harness Drawing – Sand Pro 3040/5040 g339989 Page A–6 20251SL Rev A Model 08743 and 08745, Drawing 122-1403 Rev B, Sheet 1 of 1...
Page 259: Wire Harness Diagram - Sand Pro 3040/5040
Wire Harness Diagram – Sand Pro 3040/5040 g339988 Model 08743 and 08745, Drawing 122-1403 Rev B, Sheet 1 of 1 20251SL Rev A Page A–7...
Page 260: Wire Harness - Rear Remote Hydraulics (Optional
Wire Harness – Rear Remote Hydraulics (Optional) g339990 Page A–8 20251SL Rev A Model 08781, Drawing 122-1432 Rev A, Sheet 1 of 1...
Page 261: Wire Harness - Switch Kit (Optional
Wire Harness – Switch Kit (Optional) g339991 Model 08783, Drawing 122-1465 Rev A, Sheet 1 of 2 20251SL Rev A Page A–9...

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Toro Sand Pro 3040 Service Manual

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General Information/Service and Repairs

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