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ProForceR Debris Blower

1. 2 BATTERY GRAY GA SOLENOID FIR our METER SHIFT 65 STARTER B4 START BLUE RED ENGINE IGNITION RED yp fe FUEL SOLENOID RED W BE J o 87a EIA RED WHITE dii e 8L GRAY ENGINE KILL WHITE qe I am 1 85 86 OIL SWITCH GREEN GREEN GREEN ios ke ter E GRAY RED Y FUEL RELAY THROTTLE CONTROL RED YELLOW ENGINE CHUTE ROTATION GREEN g a MOTOR OUT 4 ENGINE START 6 A BLUE WHITE gg MOTOR OUT 3 FUEL 6 8 GREEN ae SCR Pe Bus g c MOTOR OUT 2 VBB c PINK START A B C g pMOTOR OUT 1 GROUND 5 BLACK PAC GND RUN POWER c GRAY gpDIAG Rx LEARN ENABLES py YELLOW BLACK A B Cc D E g_PIAG Tx RED YELLOW gU HROTILE CONTROL ore RUN START WIRELESS CONTROL MODULE B e e RED YELLOW J Jj PINK INLINE FUSE 15A lt oA BLUE A D L E B GREEN BLACK o BLACK x GRAY GNITION SWITCH ME T o ORANGE BLACK E COMMUNICATION PORT OPTIONAL TRAILER LIGHT KIT YELLOW BROWN gt LEFT TAIL LIGHT ProForce Debris Blower WHITE Models 44538 and 44539 with Serial Number WHITE TRAILER LIGHT lt BROWN BROWN 5 gt LICENSE PLATE From 310000000 to 311999999 CONNECTOR Model 44542 all Serial Numbers T YELLOW Electr
2. GREEN 8 4 N WHITE g rub P F 8 8 GREEN 8 IGNITION SWITCH pan 3 ON ENGINE ime um cp OFF 8 D ll e BLAC g c 6 GND RELAY ENABEE de RUN GRAY a PDIAG Rx LEARN ENABLE YELLOW BLACK a D AC Tx pr x START RED YELLOW Be MOTER er REMOTE CONTROL MODULE TURNED TO START REMOTE TRANSMITTER GREEN BLACK B BLACK c i GRAY ORANGE BLACK E COMMUNICATION PORT NO BUTTONS BLACK PRESSED POWER RELAY a _ e o Bla INLINE FUSE 15A o CQ E y i BATTERY FUSIBLE r YELLOW PINK LINK GRAY 35 f Y Y Y 1 86 BLACK HOUR METER e ProForce Debris Blower AR Control Module Wake Up z No Control Module LED s Illuminated GREEN No Remote Transmitter Buttons Pressed NOTE THE DRAWING ON THIS PAGE USES THE Ignition Switch Turned to START ELECTRICAL SCHEMATIC FROM A MACHINE WITH A SERIAL NUMBER BELOW 310000000 TO SHOW THE OPERATIONAL CIRCUITS Power Current Control Current Indicator Gauge Current s CONTROL MODULE SOLENOID SHIFT STARTER Fa START L BL ES SS SS SS SS ES SS R SS M Wa Wa E SS A E E SS SS A E qo 7 Canada 3575APFBL Made in U S A FUEL SOLENOID OUT RED FUEL SOLENOID RED WHITE ENGINE
3. HOUR METER START RELAY FUEL RELAY CHUTE RELAYS ROTATION P08 PI4 PIO PI PI3 PII E 30 85 81A 81 86 30 85 87A 87 86 30 85 81A 81 86 30 85 81A 81 86 2 3 22 03 de 5 e 3 45 2 3 4 5 2 43 E S Ab O i gt z xz x I x x X X ox sx x x W zt O zx 00 2 002 uz o E a E 3 E 345 3535 EU 5 a Tm em om ica ra 20 SPO S A TAN SP02 B B IGNITION p53 PINK PINK SWITCH xp RED YELLOW 2 YE YELLOW 3 A F ORANGE 4 AA GREEN 5 N GRAY 1 REMOTE E 1 CONTROL POWER J04 ps PINK 8 TAN i OIL PRESSURE 10 MAGNETO 2 SP03 T STARTER BLUE BLACK 2 FUEL SOL 4 COIL POWER 5 _ RED WHITE THROTTLE 6 POWER 2 TO INPUT LJ ENGINE ED GROUND JOI ur BLACK z O aa Ww ul T gt ProForce Debris Blower A B Models 44538 and 44539 with Serial Number am Above 312000000 FUSE Wire Harness Diagram Page 7 19 Rev C
4. FRONT VIEW REAR VIEW Figure 7 POSITION CIRCUITS B C F D E START Figure 8 Electrical System T O E o D uu Hour Meter The hour meter used on the ProForce Debris Blower re cords the amount of time that the engine is running Testing 1 Make sure that ignition switch is OFF 2 To prevent unexpected machine operation discon nectthe negative battery cable from the battery terminal see Battery Service in the Service and Repairs section of this chapter Position disconnected negative cable away from the negative battery terminal 3 Locate wire harness connector at rear of hour meter Unplug harness connector from hour meter 4 Connectthe positive 4 terminal ofa 12 VDC source to the positive 4 terminal of the hour meter 5 Connect the negative terminal of the voltage source to the other terminal of the hour meter 6 The hour meter should move 1 10 of an hour in six minutes 7 Disconnect the voltage source from the hour meter 8 Replace the hour meter if necessary 9 Connect wire harness connector to hour meter 10 Connect negative battery cable to negative battery terminal Tighten nut that secures battery cable from 10 to 15 ft Ib 14 to 20 N m Make sure that battery cover is secured Electrical System Page 4 10 lor pac tor Figure 7 ProForce Debris Blower Fuse The ProForce Debris Blower uses a 15 amp fuse for cir c
5. START BLUE FUEL SOLENOID OUT RED RED WHITE FUEL SOLENOID RED WHITE RED FUEL RELAY PA TED ENGINE KILL WHITE pep Bees feri 0 RED WHITE OIL PRESSURE SWITCH GREEN GREEN GREEN 9 86 GRAY THROTTLE CONTROL RED YELLOW 4 fete ka ERE COIL POWER GRAY ENGINE NOZZLE ROTATION MOTOR M e s ES GREEN s AVOTOR OUT 4 ENGINE START amp BLUE l WHITE tgp TOR OUTS ii GREEN Ws _ MOTOR OUT 2 VBBg _ PINK D gp OTOR OUT 1 GROUND p BLACK a DIAS GND RELAY NE GRAY A a pDIAG Rx LEARN ENABLE YELLOW BLACK a DIAG Tx RED YELLOW g UI HROTILE CONTROL REMOTE CONTROL MODULE A GREEN BLACK z BLACK C 5 GRAY ORANGE BLACK E COMMUNICATION PORT GRAY BLACK Pa POWER RELAY ES rr a 87a INLINE FUSE 15A 30 5 ie 5 Sp LUE c YELLOW PINK BATTERY FUSIBLE i LINK GRAY 85 Y Y Y 86 BLACK js om rae re Men zl HOUR METER e GREEN ProForce Debris Blower Model 44538 with Serial Number Below 310000000 Electrical Schematic All ground wires are black Page 7 3 Rev C
6. Figure 2 FLEXIBLE NON TACK PROTECT a coATIN 5 20 T Electrical System Battery Hydrometer Use the battery hydrometer when measuring specific gravity of battery electrolyte Obtain this tool locally Figure 4 Electrical System Page4 4 ProForce Debris Blower Troubleshooting For effective troubleshooting and repairs there must be a good understanding of the electrical circuits see Chapter 7 Electrical Diagrams and components used on this machine Remove all jewelry especially rings and watches before doing any electrical trouble shooting or testing Disconnect the battery cables unless the test requires battery voltage Starting Problems Starter solenoid clicks but starter will not crank Battery is discharged Battery cables are loose or corroded Wire harness ground cable is loose or corroded Wiring at starter is faulty Starter solenoid is faulty Starter is faulty Nothing happens when start attempt is made Battery is discharged Wiring to the start circuit components is loose corroded or damaged see Electrical Schematic in Chapter 7 Electrical Diagrams Electrical Battery cables are loose or corroded Wire harness ground cable is loose or corroded Main fuse 15 amp is loose or faulty Fusible link is faulty Ignition switch is faulty Starter solenoid is faulty Operator remote control or remote control module is faulty ProForce Debris Blower Pag
7. REGULATOR RECTIFIER ai ia BLACK GROUND INTAKE MANIFOLD SCREW fo FLYWHEEL STATOR ASS DSAI MODULE CYLINDER 2 Ns e S BLACK BLACK GROUND RED B WHITE DSAI au di HH DSAI MODULE CYLINDER 1 RED MODULE SCREW BLACK GROUND WHITE RED B WHITE DSAI KILL SPARK PLUG 2 CYLINDER ef FUSE 30 A NS B LEAD 25 ola 34 WHITE AC CHARGING LEADS dE SPARK PLUG 1 CYLINDER Lj ProForce Debris Blower Serial Numbers Above 310000000 Engine Electrical Diagram All ground wires are black Page 7 7 Rev C E CONTROL MODULE SOLENOID SHIFT Model 44538 STARTER FOR HOME Ce v BLUE Canada 3575APFBL Made in U S A FUEL SOLENOID OUT RED RED WHITE FUEL SOLENOID RED WHITE RED FUEL RELAY TA moe 870 ENGINE KILL WHITE RED 30 LED s ILLUMINATED I 957 RED WHITE GREEN OIL PRESSURE SWITCH GREEN GREEN 82 Y Y Y 86 GRAY RED YELLOW G PM E THROTTLE CONTROL COIL POWER GRAY ENGINE NOZZLE ROTATION MOTOR a e te OTOR OUT 4 ENGINE START 6 A BLUE
8. Product Records and Maintenance Page 2 2 ProForce Debris Blower Torgue Specifications Recommended fastener torgue values are listed in the following tables For critical applications as determined by Toro either the recommended torque or atorque that is unique to the application is clearly identified and spe cified in this Service Manual These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Ser vice Manual The following factors shall be considered when applying torque cleanliness of the fastener use of a thread sealant e g Loctite degree of lubrication onthe fastener presence of a prevailing torque feature hardness ofthe surface underneath the fastener s head or similar condition which affects the installation Fastener Identification Grade 5 Grade 1 Inch Series Bolts and Screws Figure 1 ProForce Debris Blower Page 2 3 As noted inthe following tables torque values should be reduced by 25 for lubricated fasteners to achieve the similar stress as a dry fastener Torque values may also have to be reduced when the fastener is threaded into aluminum or brass The specific torque value should be determined based on the aluminum or brass material strength fastener size length of thread en gagement etc The standard method of verifying torque shall be per formed by marking a line on the
9. 9 525 7 8 0 8750 22 225 25 64 0 390625 9 922 57 64 0 890625 22 622 13 32 0 40625 10 319 29 32 0 90625 23 019 27 64 0 421875 10 716 59 64 0 921875 23 416 7 16 0 4375 11 112 15 16 0 9375 23 812 29 64 0 453125 11 509 61 64 0 953125 24 209 15 32 0 46875 11 906 31 32 0 96875 24 606 31 64 0 484375 12 303 63 64 0 984375 25 003 1 2 0 5000 12 700 1 1 000 25 400 1 mm 0 03937 in 0 001 in 0 0254 mm U S to Metric Conversions To Convert Into Multiply By Linear Miles Kilometers 1 609 Measurement Yards Meters 0 9144 Feet Meters 0 3048 Feet Centimeters 30 48 Inches Meters 0 0254 Inches Centimeters 2 54 Inches Millimeters 25 4 Area Square Miles Square Kilometers 2 59 Square Feet Square Meters 0 0929 Square Inches Square Centimeters 6 452 Acre Hectare 0 4047 Volume Cubic Yards Cubic Meters 0 7646 Cubic Feet Cubic Meters 0 02832 Cubic Inches Cubic Centimeters 16 39 Weight Tons Short Metric Tons 0 9078 Pounds Kilograms 0 4536 Ounces Avdp Grams 28 3495 Pressure Pounds Sq In Kilopascal 6 895 Pounds Sq In Bar 0 069 Work Foot pounds Newton Meters 1 356 Foot pounds Kilogram Meters 0 1383 Inch pounds Kilogram Centimeters 1 152144 Liquid Volume Quarts Liters 0 9463 Gallons Liters 3 785 Liquid Flow Gallons Minute Liters Minute 3 785 Temperature Fahrenheit Celsius 1 Subract 32 2 Multiply by 5 9
10. PINK C OIL PRESSURE l BLACK D poz MAGNETO 2 GRAY E STARTER pp 3 BLUE YELLOW BLACK 1 FUEL SOL 4 WIRE IN TUBING poo COIL POWER 5 RED WHITE THROTTLE 6 Ww ENGINE YA GROUND Int z 89 gt tg E gt 5 A B A Dori D E F A B D E F P06 P04 P05 FUSE COMM PORT LOOP BACK CONNECTOR ProForce Debris Blower Models 44538 and 44539 with Serial Number From 310000000 to 311999999 Model 44542 all Serial Numbers Wire Harness Diagram Page 7 17 Rev C J02 POWER INPUT POT OIL PRESSURE MAGNETO 01 STARTER CONTROL FUEL SOL COIL POWER THROTTLE J01 ENGINE GROUND P08 HOUR METER JOL TETHER POWER P03 IGNITION SW ITCH j m Tr rx rara ra ra Pi CHUTE ROTATION P14 START RELAY P13 CHUTE RELAY b Es Y gt D o8 S m P10 FUEL RELAY X CHUTE RELAY B5 E 87 PA a o A halt oF E e 30 408 Pig 1 ia 5 ProForce Debris Blower Models 44538 and 44539 with Serial Number Above 312000000 Wire Harness Drawing Page 7 18 Rev C CHUTE
11. Shoulder bolt Lock nut Nozzle pulley Nozzle guide ProForce Debris Blower Removal Fig 25 1 Position machine on a firm level surface Make sure engine is stopped and remove key from the ignition switch Chock wheels to prevent machine from moving 2 To prevent unexpected machine operation discon nectthe negative battery cable from the battery terminal see Battery Service in the Service and Repairs section of this chapter Position disconnected negative cable away from the negative battery terminal 3 Unplug wire harness connector from nozzle motor 4 Loosen but do not fully remove flange nut that se cures drive pulley to nozzle motor shaft Loosen flange nut at least two turns 5 Removetwo 2 cap screws item 21 and flange nuts item 22 that secure leaf spring to motor bracket Re move leaf spring with bearing and flat washers item 5 from bracket 6 Loosen two 2 flange head screws item 14 and flange nuts that secure nozzle motor bracket to outer housing Rotate bracket and nozzle motor to loosen v belt 7 Loosen cap screws and flange nuts that secure belt guard item 13 route v belt from behind guard and carefully remove belt from machine NOTE The shaft of the nozzle motor is tapered 8 Use appropriate puller to loosen drive pulley from nozzle motor 9 Remove flange nut and drive pulley from nozzle mo tor shaft 10 Support nozzle motor to prevent it from falling Re mo
12. Figure 26 1 Drive pulley 2 Leaf spring 3 Flange head screw 4 Torque wrench access Electrical System T uz E o 2 wi Battery Storage If the machine will be stored for more than 30 days 1 Remove the battery from the machine and charge it fully see Battery Service 2 Either store battery on a shelf or on the machine 3 Leave battery cables disconnected if the battery is stored on the machine Battery Care 1 Battery electrolyte level must be properly main tained The top of the battery must be kept clean If the machine is stored in a location where temperatures are extremely high the battery will discharge more rapidly than if the machine is stored in a location where temper atures are cool Wear safety goggles and rubber gloves when working with electrolyte Charge battery in a well ventilated place so gasses produced while charging can dissipate Since the gases are ex plosive keep open flames and electrical sparks away from the battery do not smoke Nausea may result if the gases are inhaled Unplug char ger from electrical outlet before connecting or disconnecting charger leads to or from battery posts IMPORTANT Do not remove battery fill caps while cleaning 2 Check battery condition weekly or after every 50 hours of operation Keep terminals and entire battery case clean because a dirty battery will discharge slowly A Clean battery by washing entire case with a solu tio
13. Preface The purpose ofthis publication is to provide the service technician with information for troubleshooting testing and repair of major systems and components on the ProForce Debris Blower REFER TO THE OPERATOR S MANUALS FOR OP ERATING MAINTENANCE AND ADJUSTMENT INSTRUCTIONS Space is provided in Chapter 2 ofthis book to insert the Operator s Manuals and Parts Cata logs for your machine Additional copies of the Opera tors Manual are available on the Internet at www Toro com The Toro Company reserves the rightto change product specifications or this publication without notice Part No 08158SL Rev C Service Manual ProForce Debris Blower 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 O The Toro Company 2008 2009 2011 2014 This page is intentionally blank ProForce Debris Blower Table Of Contents Chapter 1 Safety Chapter 5 Blower Assembly Safety Instructions 1 2 General Information Se
14. 4 Blowers with serial numbers above 310000000 use one 1 nut Fig 5 Removal Fig 4 1 Position machine on afirm level surface Make sure engine is stopped and remove key from the ignition switch Chock wheels to prevent machine from moving 2 To prevent unexpected machine operation discon nectthe negative battery cable from the battery terminal see Battery Service in the Service and Repairs section of Chapter 4 Electrical System Position discon nected negative cable away from the negative battery terminal Blower Assembly Page5 6 Rev B 10 Outer housing 11 Flange nut 8 used 12 Washer as needed 13 Cap screw 8 used 3 Removetop grill to allow access to blower assembly see Guards Removal in the Service and Repairs sec tion of Chapter 6 Chassis 4 Remove blower drive shaft from machine see Blow er Drive Shaft Removal in this section 5 Remove retaining ring item 2 wave washer s item 3 and front cap item 4 from shaft NOTE When loosening nuts that secure rotor assem bly to rotor shaft use a 1 1 4 wrench in flats on shaftto prevent the shaft from turning IMPORTANT The nuts used to secure the rotor as sembly to the rotor shaft have left hand threads Loosen these nuts by rotating clockwise ProForce Debris Blower 6 Remove nut s that secures rotor assembly A On machines with serial numbers below 310000000 Fig 4 remove outer nut from rotor shaft by rotating nut
15. CYLINDER 1 MODULE SCREW BLACK GROUND RED B WHITE DSAI KILL NON RED WHITE pM B LEAD 25 518 34 WHITE AC CHARGING LEADS SPARK PLUG 2 CYLINDER SPARK PLUG 1 CYLINDER Ja RED WHITE E g 8 ORANGE 9 E i 3 H RINE E DLA2B pinBDLA 1 J E 2 t MACHINE ACTUATOR DLA2A pinC DLA 2 a A WIRE DLA TX 3 m i HARNESS Diag Lamp Driver 4 5 ES A 6 5 4 3 2 1 33 B B BROWN PED c e PINK PL MABINA DERE 6 6 5 4 3 2 1 D D DLA 1B pnD DLA 7 GROUND 3 9 NOTE THE OIL PRESSURE RED SWITCH IS NORMALLY OPEN GCU POWEL TIEN 19 M AND CLOSES WHEN ENGINE BLACK GRD RX T OIL PRESSURE EXISTS a GROUND 12 RED YELLOW pa Speed Input 13 WHITE Shutdown 14 GOVERNOR CONTROL INTAKE MANIFOLD UNIT e d SCREW GCU GREEN yi CARB e OIL PRESSURE SWITCH SOLENOID xO O G d p POS NEG N v RED WHITE BATTERY E STARTER SOLENOID EY STUD STARTER SOLENOID TANG CONNECTOR REGULATOR STARTER ASS Y
16. cure wheel hub to spindle Slide wheel hub with bearings from spindle 8 Disassemble wheel hub A Remove grease seal from the wheel hub taking care to not damage the hub bore Discard seal B Remove bearing cones from both sides of wheel hub Clean bearings in solvent Clean inside of hub C If necessary remove bearing cups from hub D Inspectwheel bearings Checkthe bearing cones and bearing cups for wear pitting or other damage Replace worn or damaged parts E If necessary press lug screws from hub 9 Inspect axle spindle for wear or damage Replace axle if necessary Refer to appropriate axle illustration for fastener torque values Assembly Fig 3 1 Thoroughly clean all wheel hub components before assembly 2 Assemble wheel hub A If bearing cups were removed from the wheel hub press inner and outer cups into the hub until they seat against the hub shoulder B Fill hub approximately 50 full of grease C Pack both bearing cones with grease Install greased inner bearing cone into the cup on inboard side of the wheel hub IMPORTANT The grease seal must be pressed in so it is flush with the end of the hub The lip of the seal must face the inner bearing ProForce Debris Blower on Pon D Lubricate the inside of new grease seal and press it into the wheel hub E If lug screws were removed from hub press screws fully into hub Make sure thatlug screwflange is pressed fully to hub
17. cured to harness with cable tie 7 Connect negative battery cable to negative battery terminal Tighten nut that secures battery cable from 10 to 15ft Ib 14 to 20 N m Make sure that battery cover is secured Electrical System Page 4 18 Rev B ui A gt Figure 23 1 Machine wire harness 2 Diode assembly Figure 24 1 Diode 3 Female terminal 2 Male terminal Multimeter Black Lead on Terminal Multimeter Red Lead on Terminal Continuity Female Mae YES Male Femae no ProForce Debris Blower T E o 2 wi This page is intentionally blank ProForce Debris Blower Page 4 19 Electrical System Service and Repairs NOTE See the Kohler Engine Service Manual in cluded atthe end of Chapter 3 Engine for engine elec trical component repair information Nozzle Motor Figure 25 1 Nozzle 10 Drive pulley 2 Nozzle clamp 11 Lock nut 3 Vbelt 12 Cap screw 2 used 4 Housing assembly 13 Belt guard 5 Flat washer 10 used 14 Flange head screw 2 used 6 R clamp 15 Flat washer 7 Nozzle motor 16 Cap screw 8 Motor bracket 17 Flange nut 2 used 9 Cap screw 3 used 18 Flange nut NOTE If nozzle motor wear or damage occurs motor replacement is necessary Individual components for the nozzle motor are not available Electrical System Page 4 20 Leaf spring Bearing Cap screw 2 used Flange nut 2 used
18. seconds Pressing the Speed Increase rabbit button when the engine is running causes the engine speed to increase Pressing the Speed Decrease turtle button when the engine is running causes the engine speed to decrease Pressing the RH Nozzle Rotate button causes the blow er nozzle to rotate to the right Pressing the LH Nozzle Rotate button causes the blow er nozzle to rotate to the left Pressing the engine Stop button causes the engine to stop running NOTE When the engine stop button on the remote transmitter is pressed there will be a one 1 second delay before the engine stop LED on the control module illuminates Also for approximately five 5 seconds af ter the stop button is pressed the control module engine stop LED will remain illuminated and no other remote transmitter operations can be performed Remote Transmitter Battery Replacement 1 Remove six 6 screws that secure the rear cover to the remote transmitter 2 Lift rear cover from remote transmitter 3 Remove batteries from remote transmitter and re place with three 3 new AAA alkaline batteries 4 Place rear cover on remote transmitter and secure with six 6 screws Figure 15 1 Remote transmitter 3 External antenna 2 Control module EA E ON NE A e Ia Figure 16 The remote transmitter is powered by three 3 AAA al a spaan picea e Ede sti i 1 7 imin pee ecrease ngine star ka
19. KILL WHITE OIL PRESSURE SWITCH GREEN RED WHITE l l RED o REA ILLUMINATED o 87a RED l GREEN THROTTLE CONTROL RED YELLOW GRAY l L Ln COIL POWER ENGINE NOZZLE ROTATION MOTOR EM B E GREEN s AVOTOR OUT 4 ENGINE START amp Ah m BLUE L OTOR OUT 3 FUEL a WHITE 8 B 6 3 GREEN 9 _ MOTOR OUT 2 VBB 5 PINK g p MOTOR OUT 1 GROUND p BLAC RELAY ENABLE g pP AC GND E GRAY a DIAG Rx LEARN ENABLE p YELLOW BLACK DIAG Tx RED YELLOW g UI HROTTLE CONTROL REMOTE TRANSMITTER IGNITION SWITCH ON ENGINE IN RUN POSITION REMOTE CONTROL MODULE GREEN BLACK BLACK c ORANGE BLACK E ENGINE START SEQUENCE PRESSED COMMUNICATION PORT e ao o Bla INLINE FUSE 15A BATTERY FUSIBLE Mp ES ENS LINK L GRAY UY Y Y LLLI BLACK p l 4 ProForce Debris Blower ENERGIZED HOUR METER Z Crank Circuits FR Ignition Switch in RUN Position Control Module LED s Illuminated NOTE THE DRAWING ON THIS PAGE USES THE GREEN Remote Transmitter ENGINE START Sequence Pressed ELECTRICAL SCHEMATIC FROM A MACHINE WITH A SERIAL NUMBER BELOW 310000000 TO SHOW THE Power Current OPERATIONAL CIRCU
20. Machines with Single 2 Channel Controller 14 3 Remote Transmitter Machines with Multi Channel Controller 15 Wireless Control Module Machines with Single Channel Controller 16 Wireless Control Module Machines with Multi Channel Controller 17 Diode Assembly Serial Number Below 310000000 18 SERVICE AND REPAIRS 20 Nozzle Motor oer me mes 20 Battery Storage 22 Battery Care 22 Battery Service 23 ProForce Debris Blower Page 4 1 Rev C Electrical System General Information This Chapter gives information about troubleshooting testing and repair of the electrical system used in the ProForce Debris Blower Operator s Manual The Operator s Manual provides information regarding the operation general maintenance and maintenance intervals for your ProForce Debris Blower machine Re fer to the Operator s Manual for additional information when servicing the machine Electrical Power Electrical power to ProForce Debris Blower compo nents is controlled by the Remote Control Module To make sure that machine operation does not occur unex pectedly disconnect the negative battery cable from the battery before performing any machine service Reattach the disconnected negative battery cable as th
21. The reading should be less than 0 1 amp Ifthe reading is 0 1 amp or more the machine s electrical system should be tested for short circuits or faulty components and repaired 5 Install battery box cover and secure with strap ProForce Debris Blower Page 4 23 Figure 27 1 Strap 5 Positive cable 2 Battery box cover 6 Negative cable 3 Battery 7 Flange nut 4 Battery box Battery Inspection and Maintenance 1 Check battery case for cracks Replace battery if cracked or leaking 2 Check battery terminals for corrosion If corrosion occurs at terminals disconnect cables Always discon nect negative cable first Clean cable clamps and battery terminals separately Reconnect cables with positive cable first Coat battery posts and cable con nectors with Battery Terminal Protector Toro Part No 107 0392 or petroleum jelly to prevent corrosion IMPORTANT Before cleaning the battery tape or block vent holes to the filler caps and make sure the caps are on tightly 3 Check for signs of wetness or leakage on the top of the battery which might indicate a loose or missing filler cap overcharging loose terminal post or overfilling Also check battery case for dirt and oil Clean the bat tery with a solution of baking soda and water then rinse it with clean water 4 Check that the cover seal is not broken away Re place the battery if the seal is broken or leaking 5 Checkthe electrolyte level in
22. during assembly 2 Onmachines with serial numbers below 310000000 A Clean bearing bores of bearing holder and inner housing with brake parts cleaner or similar non oily cleaner After cleaner dries completely apply Loctite Primer N or equivalent to bearing bores Allow Primer to dry completely B Thoroughly clean OD of bearings on rotor shaft Apply Loctite Product 641 or equivalent to OD of both bearings 3 Slide bearing holder onto bearing on rotor shaft Position front bearing cap item 6 or 9 to bearing holder and secure with four 4 flange head screws item 7 4 On machines with serial numbers above 310000000 install new O ring item 11 into inner hous ing NOTE Later production bearing holder item 2 has a groove that locates onto tab on inner housing item 8 If equipped make sure that these items align during as sembly 5 Install rotor shaft assembly into inner housing Make sure to align marker line made during disassembly and that bearing is fully seated in housing bearing bore Also make sure that bearing holder slides fully into inner housing 6 Install four 4 cap screws to secure bearing holder to inner housing Tighten screws in three 3 equal steps and in a crossing pattern Final torque on screws should be from 180 to 200 in Ib 21 to 23 N m After tighten ing screws make sure that rotor shaft rotates freely 7 Install rotor assembly see Rotor Assembly Installa tion in this s
23. each cell If the level is below the tops of the plates in any cell fill all cells with distilled water between the minimum and maximum fill lines Charge at 15 to 25 amps for 15 minutes to allow sufficient mixing of the electrolyte Electrical System T O o 9 LLI Battery Testing 1 Conduct a hydrometer test of the battery electrolyte IMPORTANT Make sure the area around the cells is clean before opening the battery caps A Measure the specific gravity of each cell with a hydrometer Draw electrolyte in and out of the hydrometer barrel prior to taking a reading to warm up the hydrometer At the same time take the tem perature of the cell B Temperature correct each cell reading For each 109F 5 59C above 809F 26 79C add 0 004 to the specific gravity reading For each 109F 5 59C be low 809F 26 79C subtract 0 004 from the specific gravity reading Example Cell Temperature 1009F Cell Gravity 1 245 1009F minus 809F equals 209F 37 7 C minus 26 7 C equals 11 09C 209F multiply by 0 004 109F equals 0 008 11 C multiply by 0 004 5 5 C equals 0 008 ADD conversion above 0 008 Correction to 809F 26 79C 1 253 C If the difference between the highest and lowest cell specific gravity is 0 050 or greater or the lowest cell specific gravity is less than 1 225 charge the bat tery Charge at the recommended rate and time giv en in Charging or until specific gravity of all cells is 1 225 or greater with t
24. engine Figure 7 1 Fuel filter 2 Fuel filter inlet Figure 8 1 Screw 4 Top grill 2 Washer 5 Side grill 3 Flange nut Engine Engine Installation Fig 6 1 Position machine on a level surface 2 Make sure that all parts removed from the engine during maintenance or rebuilding are properly installed to the engine IMPORTANT Take care to not damage the engine fuel hoses electrical harness or other parts while installing the engine 3 Carefully position engine on machine frame 4 Install four 4 flange head screws up through the frame and engine mounting holes Install flange nuts on screws Do not fully tighten nuts at this time 5 Connectblower drive shaftto engine crankshaft see Drive Shaft Installation in the Service and Repairs sec tion of Chapter 5 Blower Assembly 6 Move engine on frame as necessary to align the blower drive shaft assembly between the blower and en gine shafts 7 Fully tighten the engine mounting fasteners Torque fasteners from 270 to 330 in Ib 31 to 37 N m 8 Install top grill and side grill see Guards Installation in the Service and Repairs section of Chapter 6 Chas sis Engine Page 3 10 Rev B 9 Connect wire harness connectors to engine A Connect positive battery cable and fusible link to the starter motor B stud B Connect wire harness blue wire to starter motor terminal C Secure negative battery cable and wire harness grou
25. fastener head or nut and mating part then back off fastener 1 4 of a turn Measure the torque required to tighten the fastener until the lines match up Class 8 8 Class 10 9 Metric Bolts and Screws Figure 2 Product Records and Maintenance 7 o e o o oc m O E o e A and Maintenance Standard Torgue for Dry Zinc Plated and Steel Fasteners Inch Series SAE Grade 8 Bolts Screws Studs 8 Sems with Regular Height Nuts SAE Grade 5 Bolts Screws Studs 8 Sems with Regular Height Nuts SAE J995 Grade 2 or Stronger Nuts Grade 1 5 amp 8 with Thin Height Nuts SAE Grade 1 Bolts Screws Studs amp Sems with Regular Height Nuts SAE J995 Grade 2 or Stronger Nuts SAE J995 Grade 5 or Stronger Nuts ovem omo im 100 10 1125 100 140 15 1580 170 obo wm omo on Thread Size 6 32 UNC 147 23 6 40 UNF 8 32 UNC 8 36 UNF 10 24 UNC 339 56 10 32 UNF 1 4 20 UNC 48 7 599 79 1 4 28 UNF 65 10 734 113 5 16 18 UNC 115 15 105 17 1186 169 5 16 24 UNF 138 17 128 17 1446 192 3 8 16 UNC 16 2 3 8 24 UNF 7 16 14 UNC 27 3 7 16 20 UNF 2943 39 4 430 45 583 61 600 60 813 81 475 45 644 61 660 60 895 81 1 2 13 UNC 30 3 65 9 1 2 20 UNF 72 9 5 8 11 UNC 65 10 88 12 119 16 5 8 18 UNF 75 10 95 15 129 20 3 4 10 UNC 93 12 140 20 190 27 3 4 16 UNF 115 15 165 2
26. hrs 11 hrs 170 Samps 5 amps 171 to 5 8 hrs 11 5 hrs 17 3 hrs 23 hrs 250 o o 6 amps 6 amps 6 amps 6 amps above 6 hrs 12 hrs 18 hrs 24 hrs 250 o 10 amps 10 amps 10 amps 10 amps ProForce Debris Blower Page 4 25 Do not charge a frozen battery because it can ex plode and cause injury Let the battery warm to 60 F 15 5 C before connecting to a charger Charge the battery in a well ventilated place to dissipate gases produced from charging These gases are explosive keep open flame and elec trical spark away from the battery Do not smoke Nausea may result if the gases are inhaled Un plug the charger from the electrical outlet before connecting or disconnecting the charger leads from the battery posts 3 Following the battery charger manufacturer s instructions connect the charger cables to the battery Make sure a good connection is made 4 Charge the battery following the battery charger manufacturer s instructions 5 Occasionally check the temperature of the battery electrolyte If the temperature exceeds 125 F 51 6 C or the electrolyte is violently gassing or spewing the charging rate must be lowered or temporarily stopped 6 Three hours prior to the end of the charging mea sure the specific gravity of a battery cell once per hour The battery is fully charged when the cells are gassing freely at a low charging rate and there is less than a 0 003 change in speci
27. 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 Safety Page1 6 ProForce Debris Blower Chapter 2 TORO Product Records and Maintenance Table of Contents PRODUCTRECORDS 1 MAINTENANCE 1 aas EQUIVALENTS AND CONVERSIONS 2 Be Decimal and Millimeter Equivalents 2 g S U S to Metric Conversions 2 L 2 TORQUE SPECIFICATIONS 3 8 3 Fastener Identification 3 EE Standard Torque for Dry Zinc Plated and as Steel Fasteners Inch Series 4 Standard Torque for Dry Zinc Plated and Steel Fasteners Metric Fasteners 5 Other Torque Specifications 6 Conversion Factors 6 Product Records Insert Operator s Manual and Parts Catalog for your ProForce Debris Blower atthe end of this chapter Addi tionally if any optional equipment or accessories have been installed to your blower insert the Installation In structions Operator s Manuals and Parts Catalogs for those options at the end of this chapter Maintenance Maintenance procedures and recommended service in tervals for the ProForce Debris Blower are covered in the Operator s Manual Refer to that publication when performing regular equipment m
28. in a clockwise direction Then remove inner nut by rotating nut clockwise Use off set wrench see Special Tools to loosen nuts from rotor shaft B On machines with serial numbers above 310000000 Fig 5 straighten inner tab washer to allow removal of nut Remove nut from rotor shaft by rotating nut in a clockwise direction Remove two 2 tab washers from rotor shaft NOTE Washers item 12 are used to prevent rotor from contacting rotor housing assembly Typically two 2 washers are required 7 Slide spacer item 6 rotor assembly and washer s item 12 from shaft Locate and retrieve woodruff key 8 Remove rotor assembly from rotor shaft NOTE Component parts for the rotor assembly are not available If rotor damage exists replace complete rotor assembly Installation Fig 4 1 Position woodruff key in slot in rotor shaft Slide washer s item 12 rotor assembly and then spacer item 6 onto shaft Make surethat rotor does not contact rotor housing If necessary add additional washer s to allow proper clearance IMPORTANT The nuts used to secure the rotor as sembly to the rotor shaft have left hand threads Tighten these nuts by rotating counter clockwise NOTE When installing nuts that secures rotor assem bly to shaft use a 1 1 4 wrench in flats on shaft to pre vent the shaft from turning 2 Onmachines with serial numbers below 310000000 Fig 4 secure rotor assembly to rotor shaft as follo
29. key from the ignition switch Make sure that blower engine is off Chock wheels to prevent movement of either machine 2 Topreventunexpected blower operation disconnect the negative battery cable from the battery terminal see Battery Service in the Service and Repairs section of Chapter 4 Electrical System Position disconnected negative cable away from the negative battery terminal 3 Loosen but do not remove four 4 lug nuts that se cure wheel to be removed 4 Jackor hoist ProForce blower from ground and sup port raised machine with jack stands see Operator s Manual and Jacking Instructions in Chapter 1 Safety 5 Removelugnuts and pull wheel from machine wheel hub ProForce Debris Blower Page 6 5 Rev B Wheel Installation Fig 2 1 Position wheel to wheel hub on raised machine 2 Secure wheel to ProForce blower with four 4 lug nuts Failure to maintain proper lug nut torque could result infailure or loss of wheel and may result in personal injury 3 Lower machine to ground Alternately torque lug nuts from 70 to 90 ft Ib 95 to 122 N m 4 Connect negative battery cable to negative battery terminal Tighten nut that secures battery cable from 10 to 15 ft Ib 14 to 20 N m Make sure that battery cover is secured Chassis Wheel Hubs and Bearings SERIAL NUMBER BELOW 310000000 SHOWN See text for tightening procedure 27 to 33 ft Ib 37 to 44 N m Figure 3 1 Axle 2 used
30. m WHITE LEFT TAIL LIGHT TRAILER LIGHT BROWN CONNECTOR S YELLOW BROWN LICENSE PLATE GREEN 74 BROWN Y WHITE RIGHT TAIL LIGHT ProForce Debris Blower Models 44538 and 44539 with Serial Number Above 312000000 Electrical Schematic All ground wires are black Page7 5 Rev C BLUE RED WIRES RED WIRE WHITE WIRES YELLOW WIRES KEY SWITCH CONNECTOR LAYOUT RED WIRE RED WHITE RED GRAY MACHINE WIRE HARNESS PR 3 ORANGE 9 DIGITAL DLA 2B pin B DLA 1 LINEAR GRAY gt ACTUATOR DLA 2A pin C DLA 2 DLA TX 3 W Diag Lamp Driver 4 i KEY SWITCH GRD 5 BLACK A A GRD B B dd a C BROWN D AiA BnADLA 6 STARTER D E PINK F D D DLA1B pnDDLA 7 D B BATTERY GROUND 8 9 A ACCESSORY GCU Power 12V 10 RED KEY SWITCH RX 11 BLACK GRD GROUND E 12 RED YELLOW R RECTIFIER S
31. of the inner housing stator vanes item 10 or outer housing item 12 the following procedure is necessary Blower Assembly Page 5 14 Rev C NOTE ProForce Blowers have used three 3 methods of securing the inner and outer housings On machines with serial number below 310000000 Fig 13 the inner housing is attached directly to the outer housing On ma chines with serial number from 310000000 to 313000000 a fin spacer and possibly additional thin spacers exist between the inner housing flanges and the outer housing Fig 14 Machines with serial number above 313000000 use four 4 fin mounts with fin spacers and possibly additional thin spacers that are se cured between inner housing and outer housing Fig 15 Refer to correct illustration when removing and in stalling inner and outer housings ProForce Debris Blower Removal Fig 13 1 Position machine on a firm level surface Make sure engine is stopped and remove key from the ignition switch Chock wheels to prevent machine from moving 2 To prevent unexpected machine operation discon nect the negative battery cable from the battery terminal see Battery Service in the Service and Repairs section of Chapter 4 Electrical System Position discon nected negative cable away from the negative battery terminal 3 Remove nozzle and nozzle pulley from rear of outer J A SERIAL NUMBER housing see Nozzle Assembly Removal in this section UN VPN FROM 31000
32. prevent accidental engine starting If any transmitter buttons are pressed out of or der during the starting sequence the sequence will be aborted Pressing the LH Nozzle Rotate button causes the blow er nozzle to rotate to the left Pressing the RH Nozzle Rotate button causes the blow er nozzle to rotate to the right Pressing the Speed Decrease turtle button when the engine is running causes the engine speed to decrease Pressing the Speed Increase rabbit button when the engine is running causes the engine speed to increase NOTE Pressing the speed increase and speed de crease buttons simultaneously will return the engine to low idle speed Pressing the Engine Stop button causes the engine to stop running ProForce Debris Blower Page 4 15 The remote transmitter is powered by three 3 AAA al kaline batteries If the range ofthe transmitter has dimin ished or the transmitter TX LED does not illuminate when a button is pressed the transmitter batteries should be replaced Figure 17 1 Remote transmitter 2 Control module Figure 18 1 LH nozzle rotate 6 Engine stop 2 RH nozzle rotate 7 TXLED 3 Speed decrease 8 RXLED 4 Speed increase 9 Link LED 5 Engine start Rev C Electrical System T E E o 2 wi Wireless Control Module Machines with Single Channel Controller NOTE Machines with a single channel controller can be identified by the extern
33. soon after it is stopped These areas could be hot enough to cause burns 6 If abnormal vibration is detected shut off blower and stop tow vehicle immediately Determine source of vibration and correct problem s before resuming the use of blower ProForce Debris Blower Page 1 3 7 While operating the combination of the tow vehicle and the ProForce Debris Blower may exceed noise lev els of 85dB A at the operator position Hearing protec tion is recommended for prolonged exposure to reduce the potential of permanent hearing damage 8 Before leaving the operator s position of the tow ve hicle A Park on level surface and stop ProForce Debris Blower engine Make sure that all machine motion has stopped B Ensure that tow vehicle transmission or traction lever is in neutral set parking brake stop engine and remove key from ignition switch C Wait for all moving parts to stop before leaving the tow vehicle D If blower use is complete turn ProForce Debris Blower ignition switch OFF and remove key from Switch Safety Maintenance and Service 1 Before servicing or making adjustments to ProForce Debris Blower position ProForce Debris Blower on a level surface and stop blower engine If blower is at tached to tow vehicle apply tow vehicle parking brake stop engine and remove key from the ignition switch Also turn blower ignition switch OFF and remove key from switch 2 To prevent unexpected mach
34. the battery 12 After servicing the ProForce Debris Blower be sure that all guards and covers are properly installed 13 When changing tires or performing other service use correct supports hoists and jacks Make sure ma chine is parked on a solid level surface such as a con crete floor Always chock or block wheels Use suitable jack stands to support the raised machine If the ma chine is not properly supported by suitable jack stands the machine may move or fall which may result in per sonal injury see Jacking Instructions in this chapter 14 1f welding on the machine is necessary disconnect the negative battery cable and the wire harness con nector from the wireless control module to prevent elec trical system damage 15 If major repairs are ever needed or assistance is de sired contact an Authorized Toro Distributor 16 Engine oil engine and remote batteries are pollut ants to the environment Dispose of these according to your state and local regulations 17 At the time of manufacture the machine conformed to all applicable safety standards To assure optimum performance and continued safety certification of the machine use genuine Toro replacement parts and ac cessories Replacement parts and accessories made by other manufacturers may result in non conformance with the safety standards and the warranty may be voided ProForce Debris Blower Securing ProForce Debris Blower to Tow Vehicle While operat
35. 0000 j TO 313000000 4 Remove top grill to allow access to blower assembly see Guards Removal in the Service and Repairs sec Figure 14 tion of Chapter 6 Chassis 1 Inner housing assembly 5 Flange screw 8 used 2 Stator vane 24 used 6 Flange screw 24 used 5 Remove blower drive shaft from machine see Blow 3 Fin spacer 4 used 7 Outer housing 4 Thin spacer as needed er Drive Shaft Removal in this section 6 Remove rotor assembly see Rotor Assembly Re moval in this section Loctite 242 7 Remove cap screws and flange nuts that secure out er housing to fan housing mounts item 20 To prevent personal injury make sure that fan housing assembly is properly supported as it is removed from the machine Assembly weighs A ABOVE 31 gt approximately 70 pounds 31 8 kg OVE 212009009 2 Figure 15 Q 8 Lift fan housing assembly from machine and set on 1 Inner housing 4 Thin spacer as needed 2 workbench with rotor shaft pointing straight up Fig 17 2 Outer housing 5 Fin mount 4 used 3 Fin spacer 4 used 6 Cap screw 8 used 9 Place inner housing on two 2 supports 2 x 4 or equivalent Then place 9 16 14 3 mm thick support between supports and outer housing Fig 16 This pro cess will support fan housing assembly to prevent unex pected shifting of any components during disassembly 10 Loosen but do not remove eight 8 screws item 15 that secure inner housi
36. 10 X 1 5 38 4 ft lb M12X 1 75 66 7 ft lb M16 X 2 0 166 15 ft lb M20 X 2 5 325 33 ft lb NOTE Reduce torque values listed in the table above by 25 for lubricated fasteners Lubricated fasteners are defined as threads coated with a lubricant such as oil graphite or thread sealant such as Loctite NOTE Torque values may have to be reduced when installing fasteners into threaded aluminum or brass The specific torque value should be determined based on the fastener size the aluminum or base material strength length of thread engagement etc ProForce Debris Blower 26 3N m 52 5N m 90 10 N m 225 20 N m 440 45 N m Page 2 5 27 2 ft lb 36 3 N m NOTE The nominal torque values listed above are based on 75 of the minimum proof load specified in SAE J1199 The tolerance is approximately 10 ofthe nominal torque value Product Records and Maintenance Product Records o 5 a c 7 2 E E E Other Torgue Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Thread Size Square Head Hex Socket 7 116 20UNE 65 10ft Ib 88 14 N m Grade 5 5 16 18 UNC 215 35 in Ib 145 20 in Ib Grade 5 1 2 20 UNF 80 10 ft lb 108 14 N m 3 8 16 UNC 35 10 ft lb 18 3 ft Ib M12X 1 25 80 10 ft lb 108 14 N m Class 8 8 1 2 13 UNC 75 15 ft lb 50 10 ft lb M12 X 1 5 80 10 ft lb 108 14 N m Class 8 8 For steel wheels and
37. 15 ft Ib 14 to 20 N m Make sure that battery cover is secured ProForce Debris Blower Page 3 5 Engine Fuel Tank ss Pd SERIAL NUMBER BELOW 310000000 SHOWN Figure 2 1 Frame 4 Felt strip 2 used 7 Fuel cap and gauge 2 Foam strip 2 used 5 Flange nut 4 used 8 Worm clamp 3 Fuel tank 6 Tank strap 2 used 9 Fuel hose Check Fuel Lines and Connections Check fuel lines and connections periodically as recom mended in the Operator s Manual Check fuel lines for deterioration damage or leaking connections Replace Because gasoline is highly flammable use cau i hoses clamps and connections as necessary tion when storing or handling it Do not smoke while filling the fuel tank Do not fill fuel tank while engine is running hot or when machine is in an enclosed area Always fill fuel tank outside and wipe up any spilled fuel before starting the engine Store fuel in a clean safety approved mended inthe Operator s Manual Also drain and clean container and keep cap in place Use gasoline for the fuel tank if the fuel system becomes contaminated the engine only not for any other purpose or ifthe machine is to be stored for an extended period Drain and Clean Fuel Tank Drain and clean the fuel tank periodically as recom To clean fuel tank flush tank out with clean solvent Make sure tank is free of all contaminates and debris Engine Page3 6 Rev B ProForce Debris Blower Fuel Tank Re
38. 5 224 34 7 8 9 UNC 140 20 225 25 305 34 7 8 14 UNF 155 25 260 30 353 41 Spe aee EEE mee e wame ar 9 mema oar me oe 1euno 1622 0 2 acr rea exe maya i 2 mema ws n acne we ar acer i ie NOTE Reduce torque values listed in the table above by 25 for lubricated fasteners Lubricated fasteners are defined as threads coated with a lubricant such as oil graphite or thread sealant such as Loctite NOTE Torque values may have to be reduced when installing fasteners into threaded aluminum or brass The specific torque value should be determined based on the fastener size the aluminum or base material strength length of thread engagement etc Product Records and Maintenance Page2 4 NOTE The nominal torque values listed above for Grade 5 and 8 fasteners are based on 75 of the mini mum proof load specified in SAE J429 The tolerance is approximately 1096 of the nominal torque value Thin height nuts include jam nuts ProForce Debris Blower Standard Torgue for Dry Zinc Plated and Steel Fasteners Metric Fasteners Regular Height Nuts Thread Size M5 X 0 8 57 5 in Ib 96 9 in Ib Class 8 8 Bolts Screws and Studs with Class 8 or Stronger Nuts 640 60 N cm 1018 100 N cm Class 10 9 Bolts Screws and Studs with Regular Height Nuts Class 10 or Stronger Nuts 133 13 in Ib 1500 150 N cm M6 X 1 0 M8 X 1 25 19 2 ft lb M
39. 6 Lug screw 4 used per hub 10 Cotter pin 2 Grease seal 7 Tab washer 11 Jam nut 3 Bearing cone 2 used per axle 8 Nutretainer 12 Dust cap 4 Bearing cup 2 used per axle 9 Flange nut 3 used per axle 13 Carriage screw 3 used per axle 5 Wheel hub NOTE Machines with serial number above 310000000 Disassembly Fig 3 either use an axle mount that is fastened to the frame Fig 4 or have a suspension axle for road ready ma 1 Have ProCore Processor attached to tow vehicle chines Fig 5 Wheel hub and bearing service is the and park machines on a level surface Engage vehicle same for all axle types parking brake stop engine and remove key from the ignition switch Make sure that Processor engine is off Chock wheels to prevent movement of either machine Chassis Page 6 6 Rev B ProForce Debris Blower 2 Topreventunexpected blower operation disconnect the negative battery cable from the battery terminal see Battery Service in the Service and Repairs section of Chapter 4 Electrical System Position disconnected negative cable away from the negative battery terminal 3 Jack or hoist blower from ground and support with jack stands see Operator s Manual and Jacking In structions in Chapter 1 Safety 4 Remove wheel assembly see Wheel Removal in this section 5 Carefully pry dust cap from wheel hub 6 Straighten cotter pin and remove from axle spindle 7 Removenutretainer jam nut and tab washer that se
40. ITS Control Current Indicator Gauge Current Page 7 9 Rev C I CONTROL MODULE SOLENOID SHIFT STARTER B START BLUE Canada 3575APFB1 Made in U S A FUEL SOLENOID OUT RED RED WHITE LED S FUEL SOLENOID RED WHITE RED SL ES cra ILLUMINATED 87a ENGINE KILL WHITE RED o RED WHITE OIL PRESSURE SWITCH GREEN GREEN uu c RR F GREEN LIT M G THROTTLE CONTROL RED YELLOW ENERGIZED COIL POWER L GRAY i AAA E EEE ee E ENGINE NOZZLE ROTATION MOTOR M E GREEN e aVOTOR OUT 4 ENGINE START BLUE OTOR OUT 3 FUEL WHITE 6 8 pc GREEN g MOTOR OUT 2 VBB 6 PINK g D MOTOR OUT 1 GROUND p BLAC RELAY ENABLE g LDIAG GND reed GRAY a pDIAG Rx LEARN ENABLE YELLOW BLACK DIAG Tx RED YELLOW g H HROTTLE CONTROL IGNITION SWITCH ON ENGINE IN RUN POSITION REMOTE CONTROL MODULE REMOTE TRANSMITTER GREEN BLACK B BLACK g ORANGE BLACK a NO BUTTONS PRESSED COMMUNICATION PORT POWER RELAY POS o Bla INLINE FUSE 15A e Aa o e YELLOW T PINK BATTERY FUSIBLE a LINK L GRAY WU YY Lee B
41. LACK 1 LI ProForce Debris Blower Pie area E ii z Run Circuits i Ignition Switch in RUN Position and Engine Running 1 Control Module LED s Illuminated E I No Remote Transmitter Buttons Being Pressed GREEN NOTE THE DRAWING ON THIS PAGE USES THE ELECTRICAL SCHEMATIC FROM A MACHINE WITH Power Current A SERIAL NUMBER BELOW 310000000 TO SHOW THE Control Current OPERATIONAL CIRCUITS Indicator Gauge Current Page 7 10 Rev C CONTROL MODULE SOLENOID SHIFT STARTER B START BLUE Canada 3575APFB1 Made in U S A FUEL SOLENOID OUT RED 5 5 RED WHITE FUEL SOLENOID RED WHITE ES FUEL RELAY ILLUMINATED PT PRIUS PT 87a ENGINE KILL WHITE RED Cp d ees aa ua OIL PRESSURE SWITCH GREEN GREEN E adis mi un EDS 2399 5 CEN RAY a A ER GREEN H 11128 G THROTTLE CONTROL RED YELLOW ENERGIZED COIL POWER GRAY l AZ eo eg er ENGINE I I I LI lo I lo NOZZLE l ROTATION MOTOR 7 E i GREEN s AVOTOR OUT 4 ENGINE START amp BLUE _ OTOR OUT 3 FUEL WHITE 8 8 6 5 GREEN 1 gc MOTOR OUT 2 VBBs c PINK I g p MOTOR OUT 1 GROUND p BLAC RELAY ENABLE 3 cDIAG GND ra GRAY i a pDIAG R
42. LACK SP03 z trc gt Wa 9 x 9 O xX cod 3 zZ 9 c a a A CD F Bo C 0 EP 2 3 4 5 A B P05 P04 30 85 87A 81 86 iE P0 LOOP BACK COMM PORT CONNECTOR OIL PRESSURE POWER RELAY FUSE ProForce Debris Blower Model 44538 with Serial Number Below 310000000 Wire Harness Diagram REMOTE CONTROL Page 7 15 Rev C P03 IGNITION SW ITCH P08 HOUR METER P07 LOOP BACK CONNEC TOR ENGINE POL COMM PORT J01 ENGINE GROUND P01 REMOTE H CONTROL G P02 REMOTE CONTROL Page 7 16 Rev C P11 CHUTE ROTATION ProForce Debris Blower Models 44538 and 44539 with Serial Number From 310000000 to 311999999 Model 44542 all Serial Numbers Wire Harness Drawing CHUTE HOUR METER FUEL RELAY ROTATION P08 PIO PII m E 30 85 81A 87 86 2 3 2 3 4 5 A B E gt 0 6 5 66 GREEN E WHITE B C D BLUE S BLACK E Pol B 8 ORANGE BLACK 4 F IGNITION ES 11e GREEN BLACK SWITCH yo RED YELLOW 4 Y E AF REMOTE CONTROL SP02 BLUE A GREEN B
43. POWER E lop RELAY 85 L 87 2 4 Pe 15 gt DAR 30 HE BY e PQS orate 45 PIN QUT J07 THROTTLE POL POS ifs CONTROL J06 LOOP BACK OIL COMM PORT CONNEC TOR PRESSURE 105 COIL POWER FUEL SOLENOID J03 P10 FUEL RELAY P01 REMOTE CONTROL JOL STARTER P11 NOZZLE ROTATION gt MOTOR A E as Bae I aj B P02 REMOTE CONTROL J01 ENGINE GROUND ProForce Debris Blower Model 44538 with Serial Number Below 310000000 Wire Harness Drawing Page 7 14 Rev C FUEL HOUR METER FUEL RELAY SOLENOID FUEL THROTTLE NOZZLE T ROTATION YA OUT SOLENOID DIODE CONTROL OTATIO 4 P08 7 30 85 87A 87 86 J02 J03 P33 J07 PII GC p om Gm ES A B A B C gt w ux gt f a a lt E 323Z a Li TH 5 oo o o m GREEN WHITE C D BLACK 5 ORANGE BLACK F GREEN BLACK 4 5 RED YELLOW 4 STARTER Joa BLUE 7 BLUE 4 A GREEN 8 SPO PINK c BLACK 0 Po2 COIL POWER Jos WHITE Pi GRAY t YELLOW BLACK F 6 OF WIRE HIDDEN UNDER TUBING POWER ms E RED INPUT ENGINE go J 1 GROUND B
44. YELLOW ENERGIZED COIL POWER L GRAY ENGINE NOZZLE ROTATION MOTOR i i f f i GREEN g MOTOR OUT 4 ENGINE START _ BLUE WHITE g 9 MOTOR OUT 3 p MEER g_ MOTOR OUT 2 V8B o PINE 1 g_ MOTOR OUT 1 GROUND p BLAC 6 gcP AG GND RELAY ENABLE a GRAV gc ue Ra LEARN ENABLES VELLOW BLACK yg DIAG Tx RED YELLOW g HTHROTTLE CONTROL REMOTE TRANSMITTER IGNITION SWITCH ON ENGINE IN RUN POSITION REMOTE CONTROL MODULE GREEN BLACK B BLACK g ORANGE BLACK a NOZZLE ROTATE BUTTON PRESSED COMMUNICATION PORT POS o Bla INLINE FUSE 15A o Dml BATTERY FUSIBLE MEA PINIS LINK L GRAY WU YY Lee BLACK 1 LI ProForce Debris Blower f a n Nozzle Rotation Circuits Ignition Switch in RUN Position and Engine Running 1 Control Module LED s Illuminated E I Remote Nozzle Rotate Button Pressed Lia a a a ee E ee eS A ee GREEN NOTE THE DRAWING ON THIS PAGE USES THE ELECTRICAL SCHEMATIC FROM A MACHINE WITH Power Current A SERIAL NUMBER BELOW 310000000 TO SHOW THE Control Current OPERATIONAL CIRCUITS Indicator Gauge Current Page 7 12 Rev C This page is intentionally blank Page 7 13 Rev C B P07 87A
45. a fuel vent valve is positioned in the top of the tank that allows tank venting through the carbon canister Engine Page 3 12 Rev C NOTE Ifthereis restriction in the fresh air filter the car bon canister or the fuel vent valve the fuel tank may dis tort due to venting issues If the fuel tank returns to it s normal shape when the fuel cap is removed restriction in the evaporative control system is likely Machines with a carbon canister include a single engine connection to the engine intake system that is used to connect the evaporative system to the engine These machines use an inline check valve and fuel filter between the carbon canister and the engine fitting Evaporative control system components for ProForce blowers are shown in Figure 11 ProForce Debris Blower Disassembly Gasoline is flammable Use caution when storing or handling it Wipe up any spilled fuel before starting the engine 1 Inspect carbon canister and attached hoses for dam age or obvious leaks A damaged or leaking canister should be replaced 2 Remove components as needed using Figures 12 and 13 as guides A If check valve item 7 in Fig 13 is removed note direction of arrow on valve body for assembly pur poses z AN Figure 12 B If filter item 5 in Fig 13 is removed note direc 1 Carbon canister A Freshair titer tion of arrow on filter body for assembly purposes 2 Fuel hose 5 Fuel hose 3 Fuel hose Assembl
46. aintenance ProForce Debris Blower Page 2 1 Product Records and Maintenance Decimal and Millimeter Eguivalents Eguivalents and Conversions Fractions Decimals mm Fractions Decimals mm 1 64 0 015625 0 397 33 64 0 515625 13 097 1 32 0 08125 0 794 17 32 0 53125 13 494 3 64 0 046875 1 191 35 64 0 546875 13 891 1 6 0 0625 1 588 9 16 0 5625 14 288 5 64 0 078125 1 984 37 64 0 578125 14 684 3 32 0 09375 2 381 19 32 0 59375 15 081 7 64 0 109275 2 778 39 64 0 609375 15 478 1 8 0 1250 8 175 5 8 0 6250 15 875 9 64 0 140625 3 572 41 64 0 640625 16 272 5 32 0 15625 3 969 21 32 0 65625 16 669 11 64 0 171875 4 366 43 64 0 671875 17 066 3 16 0 1875 4 762 11 16 0 6875 17 462 13 04 0 203125 5 159 45 64 0 703125 17 859 7 32 0 21875 5 556 23 32 0 71875 18 256 15 64 0 234375 5 953 47 64 0 734375 18 653 1 4 0 2500 6 350 3 4 0 7500 19 050 17 64 0 265625 6 747 49 64 0 765625 19 447 9 32 0 28125 7 144 25 32 0 78125 19 844 19 64 0 296875 7 541 51 64 0 796875 20 241 5 6 0 3125 7 938 13 16 0 8125 20 638 21 64 0 328125 8 334 53 64 0 828125 21 034 11 32 0 34375 8 731 27 32 0 84375 21 431 23 64 0 359375 9 128 55 64 0 859375 21 828 3 8 0 3750
47. al antenna on the control mod ule Fig 15 The wireless control module is a solid state electrical de vice that receives signal inputs from the remote trans mitter and uses those inputs to control machine electrical operation The control module is attached to the frame next to the battery Fig 19 Inputs from the ignition switch and the remote transmit ter are monitored by the control module Output to the magneto relay fuel relay power relay engine starter motor solenoid engine throttle control module and nozzle rotation motor are controlled based on the inputs received by the control module To start blower operation rotation of the ignition switch to the START position is used to turn on or wake up the control module The control module Time Out and Pow er LED s should both be illuminated during blower op eration Fig 20 When a remote transmitter button is pressed the corre sponding control module LED should illuminate and the control module RF activity LED should flicker Fig 20 NOTE Because of the normal RF activity in the envi ronment the control module RF activity LED may flicker or be illuminated at any time during machine operation Machine operation will only be controlled by the remote transmitter that is recognized by the control module NOTE When the engine stop button on the remote transmitter is pressed there will be a one 1 second delay before the control module engine stop LED illumi n
48. an nut 2 used or 7 as a guide 4 Flange nut 2 used ProForce Debris Blower Page 6 11 Rev B Chassis This page is intentionally blank Chassis Page6 12 Rev B ProForce Debris Blower Chapter 7 Electrical Diagrams Table of Contents ELECTRICAL SCHEMATICS Model 44538 with Serial Number Below 310000000 iii es 3 Models 44538 and 44539 with Serial Number From 310000000 to 311999999 8 Model 44542 all Serial Numbers 4 Models 44538 and 44539 with Serial Number Above 312000000 5 ENGINE ELECTRICAL DIAGRAMS Serial Number Below 310000000 6 Serial Number Above 310000000 7 CIRCUIT DRAWINGS Control Module Wake Up 8 Crank Circuits ii ipe a ended 9 Run Circuits llle 10 Engine Speed Increase Circuits 11 Nozzle Rotation Circuits 12 WIRE HARNESS DRAWINGS Model 44538 with Serial Number Below 310000000 14 Models 44538 and 44539 with Serial Number From 310000000 to 311999999 amp Model 44542 all Serial Numbers 16 Models 44538 and 44539 with Serial Number Above 312000000 18 B SE ES o O 2 amp wo ProForce Debris Blower Page 7 1 Rev C Electrical Diagrams This page is intentionally blank Electrical Diagrams Page 7 2 ProForce Debris Blower SOLENOID SHIFT STARTER B
49. arburetor fuel solenoid When the ignition switch is in the RUN or START position the fuel relay is energized by the Wireless Control Module ProForce blowers with serial numbers below 310000000 include a second relay The power relay on these machines is used to provide machine electrical power when it is energized by the Remote Control Mod ule ProForce blower models 44538 and 44539 with serial numbers above 312000000 include an additional three 3 relays a start relay and two 2 relays for energizing the chute rotation motor These relays are energized by the Wireless Control Module when a remote transmitter input is entered for engine starting or chute rotation The relays are secured to the control tower bracket next to the engine The relays can be identified by the wire colors at the wire harness connector see Wire Harness Drawings in Chapter 7 Electrical Diagrams Testing 1 Make sure that ignition switch is OFF 2 To prevent unexpected machine operation discon nectthe negative battery cable from the battery terminal see Battery Service in the Service and Repairs section of this chapter Position disconnected negative cable away from the negative battery terminal 3 Locate relay and disconnect the machine wire har ness connector from the relay Remove relay from ma chine for easier testing NOTE Prior to taking small resistance readings with a digital multimeter short the meter test leads together The met
50. ates Also the control module engine stop LED will re main illuminated and no other remote transmitter operations can be performed for about five 5 seconds The control module includes a time out feature to allow machine operation for a time period after the last control input e g key switch turned off or remote transmitter button pressed If no inputs are provided to the control module during this time period the control module will shut off all machine electrical power including turning off the engine if running When the engine is turned off with either the key switch or the remote transmitter the con trol module Time Out and Power LED s will both be illu minated for this time period Refer to your Operator s Manual for additional details on the time out feature Because of the solid state circuitry built into the control module there is no reliable method to test it The module may be damaged if an attempt is made to test it with an electrical test device such as a digital multimeter IMPORTANT Before performing any welding on the machine disconnect the negative battery cable from the battery and the wire harness connector from the wireless control module to prevent dam age to the electrical system Figure 19 1 Remote transmitter 3 External antenna 2 Control module Model 44538 Tested to C Figure 20 The control module does not connect to an external 1 Speed increase LED 6 Engine start LED compute
51. ative battery cable to negative battery terminal Tighten nut that secures battery cable from 10 to 15 ft Ib 14 to 20 N m Make sure that battery cover is secured 1 Drive pulley Figure 10 3 Flange head screw 2 Leaf spring assembly 4 Torque wrench access 1 Leaf spring 2 Locknut 1 Outer housing 2 Nozzle pulley 3 Cap screw ProForce Debris Blower Page 5 13 Figure 11 3 Shoulder bolt 4 Bearing Figure 12 4 Nozzle guide 4 used 5 Flange nut 6 Spacer Blower Assembly Assembly Inner Housing Assembly N a Loctite 242 See text for tightening procedure pa SERIAL NUMBER BELOW 310000000 SHOWN 90 to 100 in Ib 10 2 to 11 2 N m 10 to 20 in Ib 1 2 to 2 2 N m Figure 13 1 Inlet bell 9 Woodruff key 17 Cap screw 2 used per guide 2 Retaining ring 10 Stator vane 24 used 18 Nozzle guide 4 used 3 Wave washer up to 3 used 11 Carriage screw 2 used 19 Flange nut 16 used 4 Front cap 12 Outer housing 20 Fan housing mount 2 used 5 Nut LH thread 13 Flange head screw 24 used 21 Carriage screw 2 used 6 Spacer 14 Cap screw 8 used 22 Flange nut 4 used 7 Rotor assembly 15 Flange head screw 8 used 23 Inner housing assembly 8 Washer as needed 16 Nozzle pulley 24 Spacer 2 used per guide NOTE The rotor shaft and bearings can be serviced without removing inner housing item 23 from machine see Rotor Shaft in this section For replacement
52. curing ProForce Debris Blower to Tow Vehicle 1 5 Special Tools Jacking Instructions 1 5 Service and Repairs Safety and Instruction Decals 1 6 Chapter 6 Chassis Chapter 2 Product Records and Maintenance Specifications Product Records 2 1 General Information 4 3 Maintenance ui AE kaaa 2 1 Service and Repairs g 8 Eguivalents and Conversions 2 2 c2 Torque Specifications 2 3 Chapter 7 Electrical Diagrams El E Lo Chapter 3 Engine Electrical Schematics E Engine Electrical Diagrams Specifications 3 2 Circuit Drawings General Information 3 3 Wire Harness Drawings Service and Repairs 3 5 KOHLER COMMAND ENGINE SERVICE MANUAL Chapter 4 Electrical System General Information 4 2 Electrical Diagrams 4 2 Special Tools 4 3 8 Troubleshooting 4 5 5 Electrical System Quick Checks 4 8 T Component Testing 4 9 Service and Repairs 4 20 Chassis Blower Asse
53. d fusible link from the starter motor B stud B Disconnect wire harness blue wire from starter motor terminal C Loosen and remove flange bolts that secure neg ative battery cable and wire harness ground connec tor to engine Note that there is a lock washer on the bolt that secures the negative battery cable D Disconnect wire harness connectors from re maining engine wires 5 Loosen hose clamp that secures fuel hose to fuel fil ter inlet Fig 7 Remove fuel hose from fuel filter Plug fuel hose to prevent leakage and contamination Make sure to clean up any spilled fuel Position disconnected fuel hose away from engine 6 Remove top grill and side grill from machine see Guards Removal in the Service and Repairs section of Chapter 6 Chassis 7 Disconnect blower drive shaft from engine crank shaft see Drive Shaft Removal in the Service and Re pairs section of Chapter 5 Blower Assembly 8 Remove four 4 flange head screws and flange nuts that secure engine to machine ProForce Debris Blower Page 3 9 Rev B IMPORTANT Make sure to not damage the engine fuel hoses electrical harness or other parts while removing the engine To prevent personal injury make surethat engine is properly supported as it is removed from the machine Engine weighs approximately 94 pounds 43 kg 9 Carefully remove the engine from machine 10 Remove engine parts and attachments as neces sary to repair the
54. e Fig 12 If the link should fail current to the machine will cease Refer to electrical schematic and wire harness drawings in Chapter 7 Electrical Diagrams for additional fusible link information Testing 1 Make sure that ignition switch is OFF 2 To prevent unexpected machine operation discon nectthe negative battery cable from the battery terminal see Battery Service in the Service and Repairs section f of this chapter Position disconnected negative cable Figure 12 away from the negative battery terminal 1 Fusible link 2 Starter B terminal 3 Locate and unplug fusible link connector from ma chine wire harness FUSIBLE LINK HARNESS 4 Useamultimeter to make sure that continuity exists betweenthe disconnectedfusible link connector andthe I sO link terminal at the starter motor Fig 13 If the fusible B link is open no continuity replace the fusible link har ness P1 Ji HARNESS BATTERY B Figure 13 5 After testing is complete make sure that fusible link connectors are securely attached to starter and ma chine wire harness 6 Connect negative battery cable to negative battery terminal Tighten nut that secures battery cable from 10 to 15 ft Ib 14 to 20 N m Make sure that battery cover is secured Electrical System Page 4 12 Rev B ProForce Debris Blower Relays The electrical system on all ProForce Debris Blowers in cludes a fuel relay that is used to energize the engine c
55. e 4 5 Electrical System Starting Problems Continued Engine cranks but does not start Ignition switch is faulty Magneto relay or circuit wiring is faulty Fuel relay or circuit wiring is faulty Diode is faulty Operator remote control or remote control module is faulty Engine or fuel system is malfunctioning see Chapter 3 Engine Engine and fuel may be too cold Electrical System Page4 6 ProForce Debris Blower General Run Problems Battery does not charge Wiring to charging circuit components is loose corroded or damaged see Electrical Schematic in Chapter 7 Electrical Diagrams Voltage regulator is not properly grounded to engine Voltage regulator is faulty Ignition switch is faulty Battery is faulty Alternator stator or engine flywheel is faulty Engine stops during operation Operator remote control button was inadvertently pressed Ignition switch is faulty Fuse or fusible link is faulty Fuel magneto and or power relay is are faulty Wiring to the run circuit components is broken or disconnected see Electrical Schematic in Chapter 7 Electrical Diagrams Operator remote control or remote control module is faulty Electrical Engine or fuel system is malfunctioning see Chapter 3 Engine Nozzle rotation motor does not operate Wiring to the nozzle rotation motor is broken or disconnected see Electrical Schematic in Chapter 7 Electrical Diagrams Nozzle rotation mot
56. e Debris Blower 1 2 1 2 1 2 3 4 Fuel filter SERIAL NUMBER ABOVE Ss Figure 3 Engine blower housing 3 310000000 SHOWN Fuel tank assembly Flange nut 4 used SERIAL NUMBER ABOVE 310000000 Fuel tank Fuel tank cap Grommet Fuel gauge Page 3 7 Rev B Figure 4 Fuel filter inlet 3 Tank strap 2 used Rollover valve Standpipe Grommet Bushing Engine Engine 270 to 330 in Ib 31 to 37 N m Figure 6 1 Frame 3 Fuel tank 5 Flange head screw 4 used 2 Engine 4 Flange nut 4 used 6 Blower coupler assembly Engine Page 3 8 ProForce Debris Blower Engine Removal Fig 6 1 Park machine on a level surface with the engine not running and the ignition key removed from the key switch Chock wheels to prevent machine from moving 2 To prevent unexpected machine operation discon nectthe negative battery cable from the battery terminal see Battery Service in the Service and Repairs section of Chapter 4 Electrical System Position discon nected negative cable away from the negative battery terminal A CAUTION The exhaust system may be hot Avoid possible burns allow exhaustto cool before removing the engine 3 If engine is to be disassembled it may be easier to drain oil from engine before removing engine from ma chine 4 Label and disconnect wire harness connectors from engine A Disconnect positive battery cable an
57. e last step in any repair Secure cable with flange nut Torque nut from 10 to 15 ft Ib 14 to 20 N m Electrical Diagrams The electrical schematic and wire harness drawings for the ProForce Debris Blower are located in Chapter 7 Electrical Diagrams Electrical System Page 4 2 ProForce Debris Blower Special Tools Order special tools from your Toro Distributor Some tools may also be available from a local supplier Multimeter 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 This excess current can cause damage to circuits not designed to carry it Skin Over Grease Special non conductive grease which forms a light pro tective skin to help waterproof electrical switches and contacts Toro Part Number TOR50547 Battery Terminal Protector Aerosol spray that should be used on battery terminals to reduce corrosion problems Apply battery terminal protector after the battery cable has been secured to the battery terminal Toro Part Number 107 0392 ProForce Debris Blower Page 4 3 Rev B Figure 1 T o D wi P R RA li Prodes o 112X 1015600
58. e shaft see Blower Drive Shaft Installation in this section 11 Install top grill to machine see Guards Installation in the Service and Repairs section of Chapter 6 Chas sis 12 Install nozzle pulley and nozzle to rear of outer hous ing see Nozzle Assembly Installation in this section 13 Connect negative battery cable to negative battery terminal Tighten nut that secures battery cable from 10 to 15 ft Ib 14 to 20 N m Make sure that battery cover is secured Blower Assembly 2 Ko o 7 7 lt This page is intentionally blank Blower Assembly Page 5 18 ProForce Debris Blower Chapter 6 TORO Chassis Table of Contents SPECIFICATIONS wi ia 2 GENERAL INFORMATION 3 Operator s Manual 3 Securing ProForce Debris Blower to Tow Vehicle 3 Electrical Power 3 SERVICE AND REPAIRS 4 Wheels iki evan a ra 4 Wheel Hubs and Bearings 6 Guards ius tante Aat eru hA IE YR EDS 10 ProForce Debris Blower Page 6 1 Rev B Chassis Specifications Item Description Tires Size 20 x 10 8 4 Ply Tubeless Pressure 14 PSI 96 5 kPa Wheel Lug Nut Torque 70 to 90 ft Ib 95 to 122 N m Chassis Page 6 2 Rev B ProForce Debris Blower General Information Operator s Manual The Operator s Manual provides information regarding the operation general maintenance a
59. e sure that battery cover is secured 860 87A EC a 85 O Figure 14 Electrical System T uz E o 2 wi Remote Transmitter Machines with Single Channel Controller NOTE Machines with a single channel controller can be identified by the external antenna on the control mod ule Fig 15 The remote transmitter is a solid state electrical device that sends radio frequency RF signal inputs to the ma chine control module for control of machine electrical operation Fig 15 The remote transmitter has suffi cient range to send an RF signal to the control module from the tow vehicle operator position When a button on the remote transmitter is pressed the LED on the remote should flicker Fig 16 If the ma chine control module is energized control module Time Outand Power LED s are both illuminated and a remote transmitter button is pressed the corresponding control module LED should illuminate and the control module RF activity LED should flicker If the control module is energized control module Time Out and Power LED s are both illuminated remote but ton functions are as follows Pressing the Engine Start button initiates a starting se quence to start the engine This sequence see Opera tor s Manual is necessary to prevent accidental engine starting After pressing the Engine Start button the RH Nozzle and LH Nozzle Rotate buttons are inactive for five b
60. ead screw 1 Outer housing 2 Inner housing assembly 3 Stator vane 24 used 7 Tighten fasteners in the following order to secure as sembly A Usenutdriver to hand tighten the eight 8 screws item 15 that secure inner housing flanges to outer housing Use a crossing pattern while tightening the Screws B Use nutdriver to hand tighten the flange head screws item 12 that secure the twenty four 24 stator vanes to outer housing Use a crossing pattern while tightening the screws C Torque flange head screws item 15 that secure inner housing flanges to outer housing from 90 to 100 in Ib 10 2to 11 2 N m Usea crossing pattern while torquing the screws IMPORTANT DO NOT overtighten screws that secure stator vanes to outer housing If screws are overtightened threads in vanes could be damaged D Torque screws item 12 that secure stator vanes to outer housing from 10 to 20 in Ib 1 2 to 2 2 N m Use a crossing pattern while torquing the Screws ProForce Debris Blower To prevent personal injury make sure that outer housing assembly is properly supported as it is positioned to machine Assembly weighs approximately 70 pounds 31 8 kg 8 Position outer housing assembly to machine Secure outer housing to fan housing mounts with cap screws and flange nuts 9 Install rotor assembly see Rotor Assembly Installa tion in this section ProForce Debris Blower Page5 17 Rev C 10 Install blower driv
61. ection 8 Install blower drive shaft see Blower Drive Shaft Installation in this section 9 Install top grill to machine see Guards Installation in the Service and Repairs section of Chapter 6 Chas sis 10 Install nozzle pulley and nozzle to rear of outer hous ing see Nozzle Assembly Installation in this section 11 Connect negative battery cable to negative battery terminal Tighten nut that secures battery cable from 10 to 15 ft Ib 14 to 20 N m Make sure that battery cover is secured Blower Assembly 2 o 0 0 lt Rotor Shaft Serial Number Above 313000000 Loctite 242 90 to 100 in Ib 10 2 to 11 3 N m Loctite 242 90 to 100 in Ib 10 2 to 11 3 N m Figure 7 4 Bearing cap 5 Endcap 1 Inner housing 2 Rotor shaft 3 Flange head screw 8 used NOTE The rotor shaft and bearings can be serviced without removing inner housing from machine NOTE Rotor shaft for machines with serial number be low 313000000 is described earlier in this section If in ner housing has been replaced by a later housing version use appropriate illustration and service proced ures Removal Fig 6 1 Position machine on a firm level surface Make sure engine is stopped and remove key from the ignition switch Chock wheels to prevent machine from moving 2 To prevent unexpected machine operation discon nectthe negative battery cable from the battery terminal see Battery Service in t
62. elow 310000000 bearings are secured with Loctite Product 641 medium strength bearing mount Heating of the in ner housing and bearing holder in the bearing area may be required during disassembly 9 Slide rotor shaft and bearing holder assembly from inner housing 10 Remove four 4 flange head screws item 7 that se cure front bearing cap to bearing holder Remove bear ing holder from rotor shaft assembly 11 Using Figure 6 as a guide remove bearings retain ing rings and front bearing cap from rotor shaft as neces sary 12 0n machines with serial numbers above 310000000 remove and discard O ring item 11 from inner housing 13 Inspect rotor shaft and bearing bores of bearing holder and inner housing for wear or damage Replace parts as necessary Installation Fig 6 1 Install bearings onto rotor shaft A Install inner retaining rings into shaft grooves if they were removed B Make sure that front bearing cap item 6 is placed on rotor shaft between bearing locations C Install bearings onto shaft by pressing on inner race Make sure that bearings are seated against in ner retaining ring D If equipped install outer retaining rings ProForce Debris Blower Page 5 9 Rev C IMPORTANT To prevent the bearings from rotating in the inner housing or bearing holder on machines with serial numbers below 310000000 Loctite Prim er N or equivalent and Loctite Product 641 or equivalent must be used
63. em Description Make Designation Kohler 4 cycle V Twin cylinder OHV air cooled Model CH740S Bore x Stroke 3 27 in x 2 64 in 88 mm x 67 mm Total Displacement 44 in 725 cc Compression Ratio 9 0 1 Governor Electronic Low Idle Speed no load 1800 100 RPM High Idle Speed no load 3450 100 RPM Carburetor Float feed fixed main jet solenoid fuel shut off Fuel Unleaded regular grade gasoline Fuel Pump Mechanical Fuel Tank Capacity 5 U S gal 18 9 I Air Cleaner Dual element Lubrication System Pressure lubrication with oil cooler Crankcase Oil Capacity 2 0 US qt 1 9 I Engine Oil See Operator s Manual Ignition System Flywheel magneto twin electronic armatures with ignition advance Spark Plug Champion RC12YC resister style Spark Plug Gap 0 030 in 0 76 mm Starter 12 VDC solenoid shift Alternator 12 VDC 15 Amps Dry Weight 94 Ibs 43 kg Engine Page 3 2 ProForce Debris Blower General Information This Chapter gives information about specifications maintenance troubleshooting testing and repair of the gasoline engine used in the ProForce Debris Blower Most repairs and adjustments reguire tools which are commonly available in many service shops Special tools are described in the KOHLER COMMAND EN GINE SERVICE MANUAL that is included at the end of this Cha
64. engine is stopped and remove key from the ignition switch Chock wheels to prevent machine from moving 2 To prevent unexpected machine operation discon nectthe negative battery cable from the battery terminal see Battery Service in the Service and Repairs section of Chapter 4 Electrical System Position discon nected negative cable away from the negative battery terminal 3 Removetop grillto allow access to blower drive shaft see Guards Removal in the Service and Repairs sec tion of Chapter 6 Chassis 4 Remove cap screws flat washers and lock nuts that secure drive shaft assembly to hubs on engine shaft and blower shaft 5 Lift drive shaft assembly from machine 6 Disassemble drive couplings from drive shaft using Figures 2 and 3 as guides Note differences in coupling spacer flange thickness for assembly purposes 7 Inspect drive couplings for damage and replace if necessary 8 If necessary remove hubs from engine shaft and blower shaft A Remove cap screw and flat washer that secure hub to shaft NOTE Hubhasatapered ID and will require a puller to remove it from shaft B Use appropriate puller to remove hub from shaft C Remove woodruff key from shaft slot Installation Fig 2 1 If hub was removed from engine shaft or blower shaft thoroughly clean tapers of shaft s and hub s Fit woodruff key to shaft slot and place hub on shaft Apply Loctite 242 or equivalent to threads of cap screw
65. er is secured ProForce Debris Blower This page is intentionally blank ProForce Debris Blower Page6 9 Rev B Chassis Guards SERIAL NUMBER BELOW 311000000 SHOWN DD ef DAR MT UAR Wea al Mery Meer yarn pr A1 LP E YA Figure 6 1 Cap screw 2 used 3 Flange nut 2 used 5 Side grill 2 Washer 2 used 4 Top grill 6 Flange head screw 2 used Chassis Page 6 10 Rev B ProForce Debris Blower Removal SERIAL NUMBER ABOVE 311000000 SHOWN 1 Park machine on a level surface Make sure engine is OFF Chock wheels to prevent machine from moving 2 To prevent unexpected machine operation discon nectthe negative battery cable from the battery terminal see Battery Service in the Service and Repairs section of Chapter 4 Electrical System Position discon nected negative cable away from the negative battery terminal A CAUTION The engine may be hot Allow engine to cool be fore removing guards from machine 3 Remove guards from machine as needed using Fig 6 or 7 as a guide NOTE Machines with serial number above 311000000 use a muffler mount to support the front of the top grill Fig 7 Removal of the muffler mount on these ma chines requires removal of the blower driveshaft or en gine E Figure 7 Installation gure 1 Cap screw 2 used 5 Muffler mount j j i 2 Washer 2 used 6 Top grill 1 Install removed guards from machine using Figs 6 3 Flange screw C used 7 nneim
66. er 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 Subtract this val ue from the measured value of the component you are testing ProForce Debris Blower Page4 13 Rev C 4 Using a multimeter ohms setting measure coil re sistance between terminals 85 and 86 Fig 14 Resist ance should be between 70 and 90 ohms 5 Connectmultimeter ohms setting leads to relay ter minals 30 and 87 Ground terminal 86 and apply 12 VDC to terminal 85 The relay should have continuity be tween terminals 30 and 87 as 12 VDC is applied to ter minal 85 The relay should not have continuity between terminals 30 and 87 as 412 VDC is removed from termi nal 85 6 Disconnect voltage and multimeter leads from the relay terminals 7 Connectmultimeter ohms setting leads to relay ter minals 30 and 87A Ground terminal 86 and apply 12 VDC to terminal 85 The relay should not have continuity between terminals 30 and 87A as 12 VDC is applied to terminal 85 The relay should have continuity between terminals 30 and 87A as 12 VDC is removed from ter minal 85 8 Disconnect voltage and multimeter leads from the relay terminals 9 Secure relay to machine and connect machine wire harness connector to relay 10 Connect negative battery cable to negative battery terminal Tighten nut that secures battery cable from 10 to 15 ft Ib 14 to 20 N m Mak
67. et at www Toro com 2 Keep all shields safety devices and decals in place If a shield safety device or decal is defective illegible or damaged repair or replace it before operating the machine Safety Page1 2 Rev A To reduce the potential for injury or death com ply with the following safety instructions 3 Make sure that the tow vehicle is carefully selected to assure the best performance and safe operation of the ProForce Debris Blower 4 Make sure that operator is familiar with safe tow ve hicle operation 5 Tighten any loose nuts bolts screws or other fasten ers to ensure machine is in safe operating condition 6 Make sure that the ProForce Debris Blower is prop erly attached to tow vehicle ProForce Debris Blower While Operating 1 Operator should be on the tow vehicle when starting the engine and when operating the ProForce Debris Blower Stay away from the blower when it is engaged 2 Before starting the engine on the tow vehicle refer to tow vehicle Operator s Manual for safe starting proce dures 3 Do not run engine of ProForce Debris Blower or tow vehicle in a confined area without adequate ventilation Exhaust fumes are hazardous and could possibly be deadly 4 Be aware of the blower nozzle direction and do not point it at anyone Keep away from the nozzle opening during machine operation 5 Donottouch engine or exhaust system while the De bris Blower engine is running or
68. fic gravity for three consecutive readings Electrical System T E o 2 wi This page is intentionally blank Electrical System Page 4 26 ProForce Debris Blower Chapter 5 Blower Assembly Table of Contents GENERAL INFORMATION 2 Operators Manual 2 Electrical Power 2 SPEGIAL TOOLS WA 3 SERVICE AND REPAIRS 4 Blower Drive Shaft 4 Rotor Assembly 6 Rotor Shaft Serial Number Below 313000000 8 Rotor Shaft Serial Number Above 313000000 10 Nozzle Assembly 12 Inner Housing Assembly 14 2 Ko o 7 7 lt ProForce Debris Blower Page 5 1 Rev C Blower Assembly General Information Operator s Manual The Operator s Manual provides information regarding the operation general maintenance and maintenance intervals for your ProForce Debris Blower machine Re fer to the Operator s Manual for additional information when servicing the machine Electrical Power Electrical power to ProForce Debris Blower compo nents is controlled by the Remote Control Module To make sure that machine operation does not occur unex pectedly disconnect the negative battery cable from the battery before performing any machine service see Battery Service in the Service and Repairs section of Chapter 4 Electr
69. he Service and Repairs section of Chapter 4 Electrical System Position discon nected negative cable away from the negative battery terminal 3 Remove nozzle and nozzle pulley from rear of outer housing see Nozzle Assembly Removal in this section 4 Remove top grill to allow access to blower assembly see Guards Removal in the Service and Repairs sec tion of Chapter 6 Chassis Blower Assembly 6 Retaining ring 4 used Page5 10 Rev C 7 Bearing 2 used 8 Rear cap 9 O ring 5 Remove blower drive shaft from machine see Blow er Drive Shaft Removal in this section 6 Remove rotor assembly see Rotor Assembly Re moval in this section 7 Remove four 4 flange head screws that secure bearing cap item 4 to inner housing 8 Carefully slide rotor shaft assembly from inner hous ing Note slot in inner housing that locates tab on end cap item 5 for assembly purposes Rear cap will re main in inner housing 9 Using Figure 6 as a guide remove bearing cap item 4 end cap item 5 retaining rings item 6 and bear ings item 7 from rotor shaft as necessary 10 Remove and discard O ring item 9 from rear cap 11 1f necessary remove rear cap item 8 from inner housing 12 Inspect rotor shaft and bearing bores of bearing cap and rear cap for wear or damage Replace parts as nec essary ProForce Debris Blower Installation Fig 6 1 Ifremoved install bearings onto rotor shaft A Ins
70. he difference in specific gravity between the highest and lowest cell less than 0 050 If these charging conditions can not be met replace the battery 2 Perform a high discharge test with an adjustable load tester This is one ofthe most reliable means of testing a battery as it simulates the cold cranking test Acommercial bat tery load tester is required to perform this test A CAUTION Follow the battery load tester manufacturer s instructions when using a battery load tester A Check the voltage across the battery terminals prior to load testing the battery If the voltage is less than 12 4 VDC recharge the battery B Ifthe battery has recently been charged remove the battery surface charge before performing the load test Disconnect the engine fuel stop solenoid to prevent the engine from starting Engage the starter motor for 10 seconds to remove battery surface charge Reconnect the fuel stop solenoid C Make sure battery terminals are free of corrosion D Measure the temperature of the center battery cell E Connecta battery load tester to the battery termi nals following the load tester manufacturer s in structions Connect a digital multimeter to the battery terminals F Apply atest load of 270 amps one half the Crank ing Performance rating of the battery for 15 se conds G Take a voltage reading after 15 seconds then re move the load H Using the table below determine the minim
71. ical Schematic GREEN BROWN RIGHT TAIL LIGHT All ground wires are black WHITE Page7 4 Rev C BLACK 4 ENGINE BLOCK X HOUR METER INTERNAL ENGINE CHARGE REGULATOR J START RELAY B4 ry H o J START BLUE BLUE Lo is RED BLACK Y 117 55 TAN SOLO OID ENGINE IGNITION RED uc reru 1 SHIFT FUEL SOLENOID RED W RED WHITE STARTER perse e ee lt KIA Na AA REDWHITE 0 i PINK OIL SWITCH GREEN GREEN icio a BLACK THROTTLE CONTROL GREEN 0872 PINK r GREEN 85 TY Y se GRAY RED YELLOW i porcine 4 CHUTE BLACK SYM YELLOW FUEL RELAY ROTATION CHUTE RELAYS RAE giai _ WHITE Lo rd ie Lt YELLOW 3 MOTOR OUT ENGINE START 9 TAN RUN AA BLACK lie ORANGE MOTOR OUT ve s C GREEN START A B C A VBB PINK wo GROUND gt BLACK LL ag NC RUN POWER amp GRAY L 1 N C A B C D E F RED YELLOW 2 THROTTLE CONTROL E OFF RUN START INLINE FUSE 15A WIRELESS CONTROL MODULE RED YELLOW e PINK EA GER oA TAN M oe OPTIONAL TRAILER LIGHT KIT YELLOW BROWN WHITE A
72. ical System Reattach the disconnected negative battery cable as the last step in any repair Secure cable with flange nut Torque nut from 10 to 15 ft Ib 14 to 20 N m Blower Assembly Page 5 2 ProForce Debris Blower Special Tools Offset Wrench The offset wrench is used to properly tighten the nuts that secure the rotor assembly to the rotor shaft Use with 1 2 torque wrench at right angle to offset wrench handle to ensure that proper torque is applied to nut NOTE Two 2 offset wrenches are required to proper ly tighten the rotor assembly nuts Toro Part Number TOR6006 Figure 1 gt 2 o o o lt ProForce Debris Blower Page 5 3 Blower Assembly Service and Repairs Blower Drive Shaft N Pd Loctite 242 300 to 330 in Ib 34 to 37 N m N M N 300 to 330 in Ib 34 to 37 N m Figure 2 1 Flange nut 6 Flat washer 10 Cap screw 2 Fan hub 7 Capscrew 11 Woodruff key 3 Cap screw 8 Drive coupling 12 Drive shaft 4 Spacer 9 Flat washer 13 Engine hub and coupling assembly 5 Spacer NOTE The coupling assembly between the blower shaft and drive shaft item 12 is illustrated in Figure 2 The coupling assembly item 13 used between the drive shaft item 12 and engine shaftis composed ofthe same components Fig 3 Blower Assembly Page 5 4 ProForce Debris Blower Removal Fig 2 1 Position machine on a firm level surface Make sure
73. igure 7 and switch circuits are shown in Figure 8 Testing 1 Make sure that ignition switch is OFF 2 To prevent unexpected machine operation discon nectthe negative battery cable from the battery terminal see Battery Service in the Service and Repairs section of this chapter Position disconnected negative cable away from the negative battery terminal 3 On blowers with serial numbers below 310000000 remove engine blower housing to gain access to ignition switch seethe Kohler Engine Service Manual atthe end of Chapter 3 Engine 4 Unplug wire harness connectors from switch 5 With the use of a multimeter ohms setting test igni tion switch by verifying continuity between switch termi nals for each switch position 6 Connect the harness connectors to the switch after testing 7 On blowers with serial numbers below 310000000 install blower housing onto engine see the Kohler En gine Service Manual at the end of Chapter 3 Engine 8 Connect negative battery cable to negative battery terminal Tighten nut that secures battery cable from 10 to 15 ft Ib 14 to 20 N m Make sure that battery cover is secured ProForce Debris Blower Page 4 9 Rev B When testing electrical components for continu ity with a multimeter ohms setting make sure that power to the circuit has been disconnected Figure 5 or RN 85A Figure 6
74. ine operation discon nect battery before performing any Debris Blower ser vice Disconnect negative battery cable first and positive cable last If battery voltage is required for trou bleshooting or test procedures temporarily connect the battery Reconnect positive battery cable first and nega tive cable last 3 Make sure machine is in safe operating condition by keeping all nuts bolts screws and other fasteners tight 4 Use care when checking or servicing the blower wear gloves and use caution 5 Before disconnecting ProForce Debris Blower from tow vehicle park blower on a hard level surface and chock blower wheels to prevent machine movement 6 To reduce potential fire hazard keep engine area free of excessive grease grass leaves and dirt 7 If engine must be running to perform maintenance or to make an adjustment keep hands feet clothing and other parts of the body away from moving parts on the Debris Blower Keep bystanders away 8 Do not overspeed the engine by changing governor setting To assure safety and accuracy check maximum engine speed with a tachometer 9 Shut Debris Blower engine off before checking or adding oil to the crankcase Safety Page1 4 Rev C 10 Battery acid is poisonous and can cause burns Avoid contact with skin eyes and clothing Protect your face eyes and clothing when working with a battery 11 Battery gases can explode Keep cigarettes sparks and flames away from
75. ing or servicing the ProForce Debris Blow er make sure that blower is properly secured to tow ve hicle Fig 1 Refer to your Operator s Manual for the correct procedure for attaching blower to tow vehicle Figure 1 1 Tow vehicle hitch 3 Hairpin clip 2 Hitch pin Jacking Instructions When changing tires or performing other ser vice use suitable hoists and jacks to support the ProForce Debris Blower Make sure ma chine is parked on a solid level surface such as aconcrete floor Always chock or block wheels Use suitable jack stands to support the raised machine If the machine is not properly sup ported by jack stands the machine may move or fall which may result in personal injury Figure 2 1 Wheel 2 Frame jacking point 1 Position ProForce Debris Blower on a level surface with blower attached to tow vehicle Engage tow vehicle parking brake stop engine and remove key from the ignition switch Make sure that blower engine is off Chock blower wheels to prevent the machine from mo ving 2 Position jack securely under the main frame of the blower Fig 2 Do not use the axle as a jacking point 3 Carefully jack machine off the ground 4 Position jack stands under the main frame to support the ProForce Debris Blower ProForce Debris Blower Page 1 5 Safety Safety and Instruction Decals Numerous safety and instruction decals are affiked to the ProForce Debris Blower If any decal becomes illeg
76. lding on the machine disconnect the negative battery cable from the battery and the wire harness connector from the wireless control module to prevent dam age to the electrical system Figure 21 1 Remote transmitter 2 Control module Figure 22 2 TX RX LED 1 Health LED Electrical System T lt E o 2 wi Diode Assembly Serial Number Below 310000000 NY O V perit ProForce Debris Blowers with a serial number below 310000000 use a diode assembly in the wire harness Fig 23 see wire harness drawings in Chapter 7 Electrical Diagrams The diode allows the initial current flow to energize or wake up the remote control module Testing 1 Make sure that ignition switch is OFF 2 To prevent unexpected machine operation discon nectthe negative battery cable from the battery terminal see Battery Service in the Service and Repairs section of this chapter Position disconnected negative cable away from the negative battery terminal 3 Locate diode assembly and remove cable tie that se cures diode to machine wire harness 4 Unplug the diode from the wire harness for testing 5 The diode Fig 24 can be tested using a digital multimeter diode test or ohms setting and the table in the right column 6 After testing is complete make sure that diode is fully installed into machine wire harness connector and se
77. line batteries Ifthe range ofthetransmitter has dimin 5 RH nozzle rotate 7 Remote control LED ished or the transmitter LED does not flicker when a 4 LH nozzle rotate button is pressed the batteries should be replaced Electrical System Page4 14 Rev C ProForce Debris Blower Remote Transmitter Machines with Multi Channel Controller NOTE Machines with a multi channel controller can be identified by the lack of an external antenna on the con trol module Fig 17 NOTE Additional information regarding the remote transmitter is included in the Operator s Manual The remote transmitter is a solid state electrical device that sends radio frequency RF signal inputs to the ma chine control module for control of machine electrical operation Fig 17 The remote transmitter has suffi cient range to send an RF signal to the control module from the tow vehicle operator position When a button on the remote transmitter is pressed the TX LED on the remote should illuminate and then blink Fig 18 If the machine control module is energized control module health LED is illuminated and a remote transmitter button is pressed the control module TX RX LED should blink Ifthe control module is energized control module health LED is illuminated remote transmitter button functions are as follows Pressing the Engine Start button initiates a starting se quence to start the engine This sequence see Opera tor s Manual is necessary to
78. mbly 7 oO gE 5 8 S EE o 2 S Ww a ProForce Debris Blower Rev C This page is intentionally blank ProForce Debris Blower Chapter 1 Safety Table of Contents SAFETY INSTRUCTIONS 2 Before Operating 2 While Operating 3 Maintenance and Service 4 SECURING PROFORCE DEBRIS BLOWER TO TOW VEHICLE AAA pekR 5 JACKING INSTRUCTIONS 5 SAFETY AND INSTRUCTION DECALS 6 ProForce Debris Blower Page 1 1 Safety Safety Instructions The ProForce Debris Blower is designed and tested to offer safe service when operated and maintained prop erly Although hazard control and accident prevention partially are dependent upon the design and configura tion of the machine these factors are also dependent upon the awareness concern and proper training of the personnel involved in the operation transport mainte nance and storage of the machine Improper use or maintenance of the machine can result in injury or death To reduce the potential for injury or death comply with the following safety instructions Before Operating 1 Read and understand the contents of the Operator s Manual before starting and operating the ProForce De bris Blower Become familiar with the controls and know how to stop the machine quickly Additional copies of the Operator s Manual are available on the intern
79. moval Figs 2 and 4 1 Parkmachine on a level surface with the engine OFF Chock wheels to prevent machine from moving 2 To prevent unexpected machine operation discon nectthe negative battery cable from the battery terminal see Battery Service in the Service and Repairs section of Chapter 4 Electrical System Position discon nected negative cable away from the negative battery terminal 3 Remove fuel from the fuel tank and into a suitable container 4 Note routing of fuel hoses for installation purposes Disconnect fuel hoses from fuel tank fittings Plug fuel hoses to prevent leakage or contaminant entry 5 Remove fuel tank from machine using Figure 2 or 4 as a guide Make sure to clean up any spilled fuel 6 On machine with serial number above 310000000 remove components from fuel tank as needed using Figure 5 as a guide Fuel Tank Installation Figs 2 and 4 1 On machine with serial number above 310000000 install all removed components to fuel tank using Figure 5 as a guide 2 Install fuel tank to machine using Figure 2 or 4as a guide 3 Remove plugs placed in fuel hoses during fuel tank removal Connect fuel hoses to tank fittings and secure with hose clamps 4 Add fuel to tank and check for any fuel leaks 5 Connect negative battery cable to negative battery terminal Tighten nut that secures battery cable from 10 to 15 ft Ib 14 to 20 N m Make sure that battery cover is secured ProForc
80. n Ib 10 2 to 11 3 N m D After tightening screws make sure that rotor shaft rotates freely ProForce Debris Blower Page5 11 Rev C 7 Install rotor assembly see Rotor Assembly Installa tion in this section 8 Install blower drive shaft see Blower Drive Shaft Installation in this section 9 Install top grill to machine see Guards Installation in the Service and Repairs section of Chapter 6 Chas sis 10 Install nozzle pulley and nozzle to rear of outer hous ing see Nozzle Assembly Installation in this section 11 Connect negative battery cable to negative battery terminal Tighten nut that secures battery cable from 10 to 15 ft Ib 14 to 20 N m Make sure that battery cover is secured Figure 8 1 Inner housing 2 Rotor shaft assembly 3 Endcap 4 Bearing cap 5 Flange head screw Blower Assembly 2 2 o o Qo lt Nozzle Assembly 45 to 50 in Ib 5 1 to 5 6 N m Figure 9 1 Nozzle 11 Lock nut 20 Bearing 2 Nozzle clamp 12 Cap screw 2 used 21 Cap screw 2 used 3 V belt 13 Belt guard 22 Flange nut 2 used 4 Housing assembly 14 Flange head screw 2 used 23 Shoulder bolt 5 Flat washer 10 used 15 Flat washer 2 used per bearing 24 Lock nut 6 R clamp 16 Cap screw 25 Nozzle pulley 7 Nozzle motor 17 Flange nut 2 used 26 Nozzle guide 4 used 8 Motor bracket 18 Flange nut 27 Lock nut 9 Cap screw 3 used 19 Leaf spring 28 Socket head screw 10 D
81. n of baking soda and water Rinse with clear water B Coat battery posts and cable connectors with Battery Terminal Protector Toro Part No 107 0392 or petroleum jelly to prevent corrosion Electrical System Page 4 22 4 Store battery in a cool atmosphere to avoid quick de terioration of the battery charge 5 Tohelp preventthe battery from freezing make sure it is fully charged see Battery Service 3 Battery cables must be tight on terminals to provide good electrical contact Tighten nuts that secure battery cables from 10 to 15 ft Ib 14 to 20 N m Connecting battery cables to the wrong bat tery post could result in personal injury and or damage to the electrical system 4 If corrosion occurs at battery terminals disconnect cables Always disconnect negative cable first Clean clamps and terminals separately Reconnect cables to battery with positive 4 cable first Coat bat tery posts and cable connectors with Battery Terminal Protector Toro Part No 107 0392 or petroleum jelly to prevent corrosion 5 Periodically at least every 50 operating hours check battery electrolyte level Check electrolyte level every 30 days if machine is in storage 6 Maintain battery cell level with distilled water Do not fill battery cells above the fill line ProForce Debris Blower Battery Service The battery is the heart of the electrical system With regular and proper service battery life can be e
82. nal surfaces of the engine are kept clean at all times IMPORTANT The engine that powers the ProForce Debris Blower is air cooled Operating the engine with dirty or plugged cooling fins or a plugged or dirty blower housing will result in engine overheat ing and damage 1 Park machine on a level surface Make sure engine is OFF Chock wheels to prevent machine from moving 2 To prevent unexpected machine operation discon nectthe negative battery cable from the battery terminal see Battery Service in the Service and Repairs section of Chapter 4 Electrical System Position discon nected negative cable away from the negative battery i 6 ndrhead d IBloweroudina terminal 2 Grass screen Figure 1 The engine may be hot Allow engine to cool be fore cleaning the engine cooling fins IMPORTANT Never clean engine with pressurized water Water could enter and contaminate the fuel system 3 Clean cooling fins on both cylinder heads 4 Clean grass screen and blower housing of dirt and debris Fig 1 5 If necessary remove blower housing from engine for more thorough engine cleaning IMPORTANT Never operate engine without the blower housing installed Overheating and engine damage will result 6 Make sure blower housing and or engine cylinder shrouds are installed to the engine if removed 7 Connect negative battery cable to negative battery terminal Tighten nut that secures battery cable from 10 to
83. nch see Special Tools from 190 to 210 ft Ib 258 to 284 N m C Bend inner tab washer over flat of nut 4 Installfrontcap item 4 wave washer s item 3 and retaining ring item 2 onto shaft Up to three 3 wave washers might be necessary to secure front cap 5 Install blower drive shaft see Blower Drive Shaft Installation in this section 6 Install top grill to machine see Guards Installation in the Service and Repairs section of Chapter 6 Chas sis 7 Connect negative battery cable to negative battery terminal Tighten nut that secures battery cable from 10 to 15 ft Ib 14 to 20 N m Make sure that battery cover is secured Blower Assembly gt 2 Iz 7 7 4 Rotor Shaft Serial Number Below 313000000 180 to 200 in Ib 21 to 23 N m 180 to 200 in Ib 21 to 23 N m Loctite Product 641 SERIAL NUMBER BELOW 310000000 SERIAL NUMBER FROM 310000000 TO 313000000 Figure 6 Cap screw 4 used Bearing holder Rotor shaft Retaining ring Bearing 2 used Front bearing cap pon PN Inner housing NOTE The rotor shaft and bearings can be serviced without removing inner housing from machine NOTE Several changes were made to the rotor shaft assembly above machine serial number 310000000 Figure 6 shows both the earlier and later illustration for the inner housing assembly used on machines with seri al number below 313000000 NOTE If inner housing has been replaced by a la
84. nd connector to engine with flange bolts Note that there is a lock washer on the bolt that secures the negative battery cable D Connect wire harness connectors to remaining engine wires 10 Remove plug installed in fuel hose during engine re moval process Connect fuel hose to the fuel filter inlet and secure with hose clamp Fig 7 11 Check and adjust engine oil level as needed 12 Connect negative battery cable to negative battery terminal Tighten nut that secures battery cable from 10 to 15 ft Ib 14 to 20 N m Make sure that battery cover is secured ProForce Debris Blower This page is intentionally blank ProForce Debris Blower Page3 11 Rev C Engine Fuel Evaporative Control System Serial Number Above 310000000 i PT EN i CARBON I i CANISTER FRESH AIR FILTER TO ENGINE FITTING ENGINE Figure 11 ProForce blowers with serial number above 310000000 are equipped with a fuel evaporative control system EVAP designed to collect and store evaporative emis sions from the fuel tank The EVAP uses a carbon canis ter to collect these evaporative emissions Fuel vapors from the fuel tank are vented to the canister where they are stored Vapors from the canister are consumed when the engine is running which purges the canister The fuel tank on these ProForce machines uses a non vented fuel cap To connect the tank to the evaporative control system
85. nd maintenance intervals for your ProForce Debris Blower Refer to the Operator s Manual for additional information when ser vicing the machine Securing ProForce Debris Blower to Tow Vehicle While operating or servicing the ProForce blower make sure that hitch pin is properly positioned in tow vehicle hitch and blower tongue Hitch pin should be secured with hairpin clip Fig 1 Electrical Power Electrical power to ProForce Debris Blower compo nents is controlled by the Remote Control Module To make sure that machine operation does not occur unex pectedly disconnect the negative battery cable from the battery before performing any machine service see Battery Service in the Service and Repairs section of Chapter 4 Electrical System Reattach the disconnected negative battery cable as the last step in any repair Secure cable with flange nut Torque nut from 10 to 15 ft Ib 14 to 20 N m 1 Tow vehicle hitch 2 Hitch pin ProForce Debris Blower Page 6 3 Figure 1 3 Hairpin clip Chassis Service and Repairs Wheels 70 to 90 ft Ib 95 to 122 N m Figure 2 1 Main frame 3 Wheel hub assembly 5 Lug nut 4 used per wheel 2 Engine 4 Wheel and tire assembly Chassis Page6 4 Rev B ProForce Debris Blower Wheel Removal Fig 2 1 Have ProForce Debris Blower attached to tow ve hicle and park machines on a level surface Engage ve hicle parking brake stop engine and remove
86. ng to outer housing 11 Remove flange head screw item 13 that secures each stator vane item 10 to outer housing Carefully tilt vane to free vane lugs from inner housing and remove vane from assembly Repeat for all twenty four 24 vanes Inspect each vane to make sure that mounting lugs and screw threads are in good condition Replace any vane that shows signs of damage or wear Mar v 12 Fully remove screws item 15 that secure inner Figure 16 housing to outer housing 1 Support 3 Outer housing 2 9 16 support 4 Mounting holes ProForce Debris Blower Page 5 15 Rev C Blower Assembly 13 If equipped machines with serial numbers above 310000000 locate and retrieve fin mounts fin spacers and thin spacers from between inner housing and outer housing Fig 14 or 15 Note location of these compon ents for assembly purposes 14 Lift inner housing assembly out of the outer housing 15 If necessary disassemble inner housing assembly see Rotor Shaft in this section Installation Fig 13 1 Assemble inner housing if it was disassembled see Rotor Shaft in this section 2 Place inner housing assembly with the rotor shaft pointing upwards onto two 2 supports 2 x 4 or equiv alent Carefully lower outer housing around inner hous ing assembly Then place 9 16 14 3 mm thick support between supports and outer housing Fig 16 This pro cess should allow alignment of mounting holes in inner housing flanges
87. non lubricated fasteners Thread Cutting Screws Thread Cutting Screws Zinc Plated Steel Zinc Plated Steel Type 1 Type 23 or Type F Thread Size Baseline Torque No 6 32 UNC 20 5 in Ib No 8 32 UNC 30 5 in Ib Baseline Torque Type A Type B No 10 24 UNC 38 7 in Ib 1 4 20 UNC 85 15 in Ib 5 16 18 UNC 110 20 in Ib Hole size material strength material thickness amp finish must be considered when determining specific torque 3 8 16 UNC 200 100 in Ib values All torque values are based on non lubricated 85 15 in Ib 0 5in 16 7 in fasteners Conversion Factors in lb X 11 2985 N cm N cm X 0 08851 in Ib ft lb X 1 3558 N m N m X 0 7376 ft lb Product Records and Maintenance Page2 6 ProForce Debris Blower Chapter 3 Engine Table of Contents SPECIFICATIONS 2 GENERAL INFORMATION 3 Operator s Manual 3 Electrical Power 3 SERVICE AND REPAIRS 5 Engine Cooling System 5 Fuel Tank us ems ctas ce tret eres exa 6 Engine serbe psa 8 Engine Removal 9 Engine Installation 10 Fuel Evaporative Control System Serial Number Above 310000000 12 KOHLER COMMAND ENGINE SERVICE MANUAL ProForce Debris Blower Page3 1 Rev C Engine Specifications It
88. or is faulty Operator remote control or remote control module is faulty ProForce Debris Blower Page 4 7 Electrical System Electrical System Guick Checks Battery Test Open Circuit Test Use a digital multimeter to measure the battery voltage Set the multimeter to the DC volts setting The battery should be at a temperature of 60 to 1009 F 16 to 38 C The ignition switch should be inthe OFF position and all accessories turned off Connectthe positive 4 multi meter lead to the positive battery post and the negative multimeter lead to the negative battery post Record the battery voltage NOTE Thistest provides a relative condition ofthe bat tery Load testing of the battery will provide additional and more accurate information see Battery Service in the Service and Repairs section Charging System Test This is a simple test used to determine if a charging sys tem is functioning It will tell you if the charging system has an output but not its capacity Use a digital multimeter set to DC volts Connect the positive multimeter lead to the positive battery post and the negative multimeter lead to the negative bat tery post Keep the test leads connected to the battery posts and record the battery voltage NOTE Upon starting the engine the battery voltage will drop and then should increase once the engine is running NOTE Depending upon the condition of the battery charge and battery tempe
89. outer housing using Figures 9 and 12 as guides Installation Fig 9 1 If removed install nozzle pulley pulley bearings and nozzle guides using Figures 9 and 12 as guides 2 Placev beltin nozzle pulley route behind belt guard item 13 and install belt on motor pulley 3 With a 3 8 in drive torque wrench pivot the motor bracket from 200 to 230 in Ib 23 to 25 N m to set v belt tension Fig 10 Do not over tension belt Hold bracket with the torque wrench and tighten two 2 flange head screws and flange nuts to secure belt ad justment and nozzle motor bracket 4 Center belt guard around v belt Tighten cap screws and flange nuts to secure belt guard to machine 5 If bearing was removed from leaf spring Fig 11 position bearing to leaf spring and secure with shoulder bolt and lock nut NOTE When installing the leaf spring assembly the leaf spring bearing mounting loops should be orientated up 6 Position leaf spring assembly and flat washers item 5 to bracket Make sure that five 5 washers are placed between spring and bracket at each mounting hole The bearing on the leaf spring should be centered on the out side of the v belt Secure leaf spring to motor bracket with two 2 cap screws item 21 and flange nuts item 22 7 Fitnozzle and nozzle clamp to pulley Tighten socket head screw and lock nut to secure nozzle to pulley Torque fasteners from 45 to 50 in Ib 5 1 to 5 6 N m 8 Connect neg
90. peed Input 1 WHITE M MAGNETO Shutdown 14 L_ CONNECTOR ONT UNIT GCU YELLOW BLACK GRD L KO INTAKE MANIFOLD ELS SCREW LU RED WHITE i RED l J k i 1 CARB are SOLENO1D KO e i je i RED N X 7 Lae neo cU y ASS Y 2 RED DSA POWER d di YELLOW jaa Ka TERM puts POS BATTERY NEG CHI BLUE STARTER SOLENOID SE 0 STARTER SOLENOID TANG ProForce Debris Blower Serial Numbers Below 310000000 Engine Electrical Diagram All ground wires are black Page 7 6 Rev C NOTE THE OIL PRESSURE SWITCH IS NORMALLY OPEN AND CLOSES WHEN ENGINE OIL PRESSURE EXISTS YA i PRESSURE SWITCH BLACK INTAKE MANIFOLD SCREW GROUND P on ALTERNATE IGNITIO PULSE N SIGNAL STARTER ASS Y WHITE DSAI KILL CONNECTOR MF REGULATOR RECTIFIER ACH B HAC o o o O DSAI MODULE CYLINDER 2 BLACK GROUND RED B WHITE DSAI D d A E DSAI MODULE
91. pter The use of some specialized test equip Operator s Manual The Operator s Manual provides information regarding the operation general maintenance and maintenance intervals for your ProForce Debris Blower machine Re fer to the Operator s Manual for additional information when servicing the machine Electrical Power Electrical power to ProForce Debris Blower compo nents is controlled by the Remote Control Module To make sure that machine operation does not occur unex pectedly disconnect the negative battery cable from the battery before performing any machine service see Battery Service in the Service and Repairs section of Chapter 4 Electrical System Reattach the disconnected negative battery cable as the last step in any repair Secure cable with flange nut Torque nut from 10 to 15 ft Ib 14 to 20 N m ProForce Debris Blower Page3 3 Rev C ment is explained However the cost of the test equip ment and the specialized nature of some repairs may dictate that the work be done at an engine repair facility Service and repair parts for Kohler engines are supplied through your local Toro distributor Be prepared to pro vide your distributor with the Toro model and serial num ber Engine This page is intentionally blank Engine Page 3 4 ProForce Debris Blower Service and Repairs Engine Cooling System To ensure proper engine cooling make sure the grass screen cooling fins and other exter
92. r or hand held device can not be re pro 2 Speed decrease LED 7 Time out LED d dd t d fault data The ma 3 RH nozzle rotate LED 8 Power LED gramme an oes no siet any Tau al n e 4 LH nozzle rotate LED 9 RFactivity LED chine wire harness does include a communication port 5 Engine stop LED with loopback connector that should remain connected Electrical System Page4 16 Rev C ProForce Debris Blower Wireless Control Module Machines with Multi Channel Controller NOTE Machines with a multi channel controller can be identified by the lack of an external antenna on the con trol module Fig 21 The wireless control module is a solid state electrical de vice that receives signal inputs from the remote trans mitter and uses those inputs to control machine electrical operation The control module is attached to the frame next to the engine Inputs from the machine ignition switch and the remote transmitter are monitored by the control module Output to the fuel relay start relay engine starter motor sole noid engine throttle control module and nozzle rotation relays are controlled based on the inputs received by the control module To start blower operation rotation of the ignition switch to the START position is used to turn on or wake up the control module The control module Health LED should be illuminated green during normal blower operation Fig 22 If the Health LED is illuminated either yellow or red a problem exists
93. rature the battery voltage will increase at different rates as the battery charges Electrical System Page4 8 Voltage Measured Battery Charge Level 12 68 volts Fully charged 10096 12 45 volts 7596 charged 12 24 volts 5096 charged 12 06 volts 2596 charged 11 89 volts 096 charged Start the engine and run at high idle 3450 RPM Allow the battery to charge for at least 3 minutes Record the battery voltage After running the engine for at least 3 minutes battery voltage should be atleast 0 50 volthigherthan initial bat tery voltage An example of a charging system that is functioning At least 0 50 volt over initial battery voltage Initial Battery Voltage 12 30v Battery Voltage after 3 Minute Charge 12 85 v ProForce Debris Blower Component Testing For accurate resistance and or continuity checks elec trically disconnect the component being tested from the circuit e g unplug the switch connector before doing a continuity check on switch Ignition Switch The ignition key switch used on the ProForce Debris Blower has three positions OFF RUN and START On ProForce blowers with serial numbers below 310000000 the ignition switch is mounted to the engine blower housing This switch is shown in Figure 5 and switch circuits are shown in Figure 6 ProForce blowers with serial numbers above 310000000 have the ignition switch mounted to the frame panel above the battery This switch is shown in F
94. rive pulley NOTE For service information on the nozzle motor item 7 refer to the Service and Repairs section of Chapter 4 Electrical System Removal Fig 9 1 Position machine on a firm level surface Make sure engine is stopped and remove key from the ignition switch Chock wheels to prevent machine from moving 2 To prevent unexpected machine operation discon nectthe negative battery cable from the battery terminal see Battery Service in the Service and Repairs section of Chapter 4 Electrical System Position discon nected negative cable away from the negative battery terminal Blower Assembly Page 5 12 3 Loosen socket head screw and lock nut that secures ends of nozzle clamp Remove clamp from nozzle and nozzle pulley 4 Remove nozzle from outer housing 5 Remove two 2 cap screws item 21 and flange nuts item 22 that secure leaf spring to motor bracket Re move leaf spring assembly and flat washers item 5 from bracket If necessary remove bearing from leaf spring Fig 11 6 Loosen two 2 flange head screws item 14 and flange nuts that secure nozzle motor bracket to outer housing Fig 10 Rotate bracket and nozzle motor to loosen v belt ProForce Debris Blower 7 Loosen cap screws and flange nuts that secure belt guard item 13 route v belt from behind guard and carefully remove belt from machine 8 If necessary remove nozzle guides pulley bearings and nozzle pulley from
95. surface SERIAL NUMBER ABOVE 310000000 SHOWN 4 27 10 38 ft lb 37 to 44 N m 27 to 33 ft lb 37 to 44 N m Figure 4 Frame 5 Hub assembly Carriage screw 6 Lock nut Axle 7 Carriage screw Flange nut 8 Axle mount SUSPENSION AXLE SHOWN 7 67 to 83 ft lb 3 4 91 to 112 N m Frame Axle Page 6 7 Rev B Carriage screw Figure 5 4 Lock nut 5 Hub assembly Chassis 3 Install the wheel hub onto the axle spindle taking care to not damage grease seal in hub 4 Install greased outer bearing cone tab washer and jam nut onto spindle shaft 5 While rotating the wheel hub by hand torque the jam nut from 75 to 180 in Ib 8 5 to 20 3 N m to seat bear ings Loosen nut until itis away from tab washer and hub has end play Finally while rotating hub tighten jam nut from 15 to 20 in Ibs 1 7 to 2 3 N m 6 Install nut retainer and cotter pin to secure jam nut Install dust cap to hub Failure to maintain proper lug nut torque could result in failure or loss of wheel and may result in personal injury Chassis Page6 8 Rev B 7 Install wheel assembly see Wheel Installation in this section 8 Carefully lower machine to ground Make sure to properly torque wheel lug nuts from 70 to 90 ft Ib 95 to 122 N m 9 Connect negative battery cable to negative battery terminal Tighten nut that secures battery cable from 10 to 15 ft Ib 14 to 20 N m Make sure that battery cov
96. tall inner retaining rings into shaft grooves if they were removed B Install bearings onto shaft by pressing on inner race Make sure that bearings are seated against in ner retaining ring C Install outer retaining rings to secure bearings onto shaft 2 If rear cap was removed from inner housing install rear cap A Slide rear cap item 8 into housing B Apply Loctite 2242 or equivalent to threads of flange head screws item 4 C Secure rear capto inner housing with flange head screws item 4 Torque screws from 90 to 100 in Ib 10 2 to 11 3 N m 3 Install new O ring item 9 into inner housing After O ring installation clean O ring to remove all oil grease or other material 4 Position end cap item 5 between bearings on rotor shaft 5 Install rotor shaft assembly into inner housing Align tab on end cap item 5 and slot in inner housing as rotor shaft assembly is being inserted into inner housing Make sure that end cap and bearing are fully seated in housing bearing bore Also align holes in end cap with threaded holes in inner housing 6 Install bearing cap item 4 into inner housing Fig 8 A Slide bearing cap item 4 into inner housing Make sure that cap is fully installed onto rotor shaft bearing B Apply Loctite 2242 or equivalent to threads of flange head screws item 4 C Secure bearing cap to inner housing with flange head screws item 7 Torque screws from 90 to 100 i
97. ter housing version use appropriate illustration and service procedures Rotor shaft for machines with serial number above 313000000 is described later in this section 9 Front bearing cap 2 used 10 Flange nut 4 used Flange head screw 4 used 11 O ring Removal Fig 6 1 Position machine on a firm level surface Make sure engine is stopped and remove key from the ignition switch Chock wheels to prevent machine from moving 2 To prevent unexpected machine operation discon nect the negative battery cable from the battery terminal see Battery Service in the Service and Repairs section of Chapter 4 Electrical System Position discon nected negative cable away from the negative battery terminal 3 Remove nozzle and nozzle pulley from rear of outer housing see Nozzle Assembly Removalin this section Blower Assembly Page5 8 Rev C ProForce Debris Blower 4 Remove top grill to allow access to blower assembly see Guards Removal in the Service and Repairs sec tion of Chapter 6 Chassis 5 Remove blower drive shaft from machine see Blow er Drive Shaft Removal in this section 6 Remove rotor assembly see Rotor Assembly Re moval in this section 7 For assembly purposes use a marker to make a line across the bearing holder item 2 and inner housing item 8 to show proper alignment 8 Remove four 4 cap screws that secure bearing holder to inner housing NOTE On machines with serial numbers b
98. to outer housing 3 On machines with serial numbers above 310000000 install fin mounts fin spacers and thin spacers if equipped between inner housing and outer housing Fig 14 or 15 NOTE When assembling inner and outer housings do not fully tighten any screws until all screws are installed to inner housing flanges and stator vanes Also use hand tools rather than air impact tools during assembly 4 Onmachines with serial numbers above 313000000 Fig 15 apply Loctite 2242 or equivalent to threads of screws used to secure inner and outer housings 5 Make sure that holes in inner housing flanges align with outer housing holes Install and finger tighten eight 8 screws item 15 into threads of inner housing flanges Do not fully tighten screws at this time 6 Install stator vanes to inner and outer housing A Position a vane between inner and outer housing Make sure that rounded end of vane is orientated to ward rotor shaft Fig 17 B Tilt vane and engage vane lugs to inner housing holes While keeping vane lugs in inner housing holes rotate vane to align threaded hole of vane with outer housing hole C Install and finger tighten flange head screw item 12 into threads of vane Do not fully tighten screw at this time D Repeat process for all twenty four 24 vanes Blower Assembly Page5 16 Rev C ROUNDED END DISCHARGE END Figure 17 4 Flange head screw 5 Flange h
99. uit protection The fuse holder for this fuse is located next to the engine Fig 8 The engine wire harness includes a 30 amp fuse for cir cuit protection The engine fuse is located near the start er motor Fig 9 Testing 1 Make sure that ignition switch is OFF 2 To prevent unexpected machine operation discon nectthe negative battery cable from the battery terminal see Battery Service in the Service and Repairs section of this chapter Position disconnected negative cable away from the negative battery terminal 3 Press latch that retains fuse holder cover and raise cover to access fuse 4 Withthe use of a multimeter ohms setting check for continuity between fuse terminals by using test ports at top of fuse Fuse should have continuity between fuse terminals 5 If necessary remove and replace fuse 6 Connect negative battery cable to negative battery terminal Tighten nut that secures battery cable from 10 to 15 ft Ib 14 to 20 N m Make sure that battery cover is secured Figure 8 1 Wire harness 3 Fuse cover 2 Fuse T o uw Figure 9 1 Engine fuse 2 Starter motor ProForce Debris Blower Page 4 11 Electrical System Fusible Link Serial Number Below 310000000 ProForce Debris Blowers with a serial number below 310000000 use a fusible link for circuit protection This fusible link connects the main wire harness to the starter B terminal and positive battery cabl
100. um voltage for the cell temperature reading Minimum Battery Electrolyte Voltage Temperature 98 70 F andup 21 1 C and up 1220 Ifthe test voltage is below the minimum replace the battery If the test voltage is at or above the mini mum return the battery to service Electrical System Page 4 24 ProForce Debris Blower Battery Charging 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 complished with a constant current battery charger which is commonly available Follow the battery charger manufacturer s instructions when using a battery charger NOTE Using specific gravity of the battery cells is the most accurate method of determining battery condition 1 Determine the battery charge level from either its specific gravity or open circuit voltage Battery Charge Level Gravity 100 75 50 257 d 2 Determine the charging time and rate using the bat tery charger manufacturer s instructions or the fol lowing table Open Circuit Voltage 12 68 12 45 12 24 12 06 11 89 Battery Battery Charge Level Reserve Percent of Fully Charged Capacity ines 80 or less 3 8 hrs 7 5 hrs 11 3hrs 15hrs o o o o 3amps 3 amps 3 amps 3 amps 5 3 hrs 10 5 hrs 15 8 hrs 21 hrs 4 amps 4amps 4amps 4 amps 16 5 hrs 22 hrs o o o amps 5amps o 126 to 5 5
101. usedto secure hub to shaft Secure hub to shaft with cap screw and flat washer ProForce Debris Blower Page 5 5 Rev B 2 Place coupling spacers into rubber coupling 3 Secure drive couplings to drive shaft with cap screws and lock nuts using Figures 2 and 3 as guides 4 Position drive shaft assembly to engine shaft and blower shaft 5 Secure drive shaft assembly to hubs on engine shaft and blower shaft with cap screws flat washers and lock nuts 6 Install top grill to machine see Guards Installation in the Service and Repairs section of Chapter 6 Chas sis 7 Connect negative battery cable to negative battery terminal Tighten nut that secures battery cable from 10 to 15 ft Ib 14 to 20 N m Make sure that battery cover is secured 300 to 330 in Ib 34 to 37 N m Loctite 242 Figure 3 1 Cap screw 7 Shaft hub 2 Flat washer 8 Flat washer 3 Cap screw 9 Flange nut 4 Spacer 10 Spacer 5 Cap screw 11 Drive coupling 6 Woodruff key 12 Fan hub coupling Blower Assembly gt 2 Iz o 7 7 4 Rotor Assembly SERIAL NUMBER BELOW 310000000 Loctite 242 See text for tightening procedure Figure 4 1 Inlet bell 6 Spacer 2 Retaining ring 7 Rotor assembly 3 Wave washer up to 3 used 8 Woodruff key 4 Front cap 9 Rotor shaft 5 Nut LH threads NOTE ProForce blowers with a serial number below 310000000 use two 2 nuts to secure rotor assembly to rotor shaft Fig
102. ve three 3 cap screws that secure nozzle motor to bracket Remove nozzle motor from machine Installation Fig 25 1 Position nozzle motor to bracket and secure with three 3 cap screws 2 Thoroughly clean tapered surfaces of motor shaft and drive pulley ProForce Debris Blower Page 4 21 3 Slide drive pulley onto motor shaft and secure with flange nut 4 Place v belt in nozzle pulley route behind belt guard item 13 and install belt on motor pulley 5 With a 3 8 in drive torque wrench pivot the motor bracket from 200 to 230 in Ib 23 to 25 N m to set v belt tension Fig 26 Do not over tension belt Hold bracket with the torque wrench and tighten two 2 flange head screws and flange nuts to secure belt ad justment and nozzle motor bracket 6 Center belt guard around v belt Tighten cap screws and flange nuts to secure belt guard to machine 7 Position leaf spring with bearing and flat washers item 5 to bracket Make sure that five 5 washers are placed between spring and bracket at each mounting hole The bearing on the leaf spring should be centered on the outside of the v belt Secure leaf spring to motor bracket with two 2 cap screws item 21 and flange nuts item 22 8 Connect wire harness to nozzle motor 9 Connect negative battery cable to negative battery terminal Tighten nut that secures battery cable from 10 to 15 ft Ib 14 to 20 N m Make sure that battery cover is secured
103. with the controller When aremote transmitter button is pressed the control module TX RX LED should flicker Fig 22 The TX RX LED will be green when the module is receiving a signal from the remote and will be red when the module is transmitting NOTE Because of the normal RF activity in the envi ronment the control module TX RX LED may flicker or be illuminated at any time during machine operation Machine operation will only be controlled by the remote transmitter that is associated to the control module The control module includes a power save mode if the module is active for more than 2 5 hours without com munication from the remote transmitter Once in the power save mode the control module will not commu nicate with the remote transmitter will not activate any machine outputs and will not function normally All ma chine electrical power will be shut off including turning off the engine if running Refer to your Operator s Manual for additional details on the power save mode The control module does not connect to an external computer or hand held device can not be re pro grammed and does not record any fault data Because of the solid state circuitry built into the control module there is no reliable method to test it The module may be damaged if an attempt is made to test it with an electrical test device such as a digital multimeter ProForce Debris Blower Page4 17 Rev C IMPORTANT Before performing any we
104. ws A Cleanrotor shaftthreads with brake parts cleaner or similar non oily cleaner and allow to dry After cleaner dries completely apply Loctite Primer N or equivalent to shaft threads Allow primer to dry com pletely B Apply Loctite 242 or equivalent to threads of rotor shaft C While holding rotor shaft with a 1 1 4 wrench in flats on shaft to prevent the shaft from turning install inner nut and torque with offset wrench see Special Tools from 50 to 60 ft Ib 68 to 81 N m to secure rotor assembly on shaft ProForce Debris Blower Page5 7 Rev B SERIAL NUMBER ABOVE 310000000 190 to 210 ft Ib 9 258 to 284 N m A Figure 5 Retaining ring 7 Spacer Wave washer 8 Rotor assembly Front cap 9 Washer as needed Nut LH threads Inner tab washer Outer tab washer 10 Woodruff key 11 Rotor shaft DAIAPON A D Apply Loctite 242 or equivalent to exposed threads of rotor shaft E While holding inner nut with offset wrench see Special Tools to prevent it from turning install and torque outer nut with second offset wrench from 190 to 210 ft Ib 258 to 284 N m 3 Onmachines with serial numbers above 310000000 Fig 5 secure rotor assembly to rotor shaft as follows A Slide inner tab washer larger OD and then outer tab washer onto rotor shaft B While holding rotor shaft with a 1 1 4 wrench in flats on shaft to prevent the shaft from turning install nutand torque with offset wre
105. x LEARN ENABLE _p YELLOW BLACK I I THROTTLE CONTROL IGNITION SWITCH ON ENGINE IN RUN POSITION REMOTE CONTROL MODULE REMOTE TRANSMITTER GREEN BLACK B BLACK ORANGE BLACK 5 SPEED INCREASE BUTTON PRESSED COMMUNICATION PORT zi HORE on o Bla INLINE FUSE 15A E x e c BATTERY FUSIBLE O cimo VBMR FINIS L GRAY YY LA BLACK E ProForce Debris Blower Engine Speed Increase Circuits 1 Ignition Switch in RUN Position and Engine Running Control Module LED s Illuminated NOTE THE DRAWING ON THIS PAGE USES THE UU IE EIU E MISES GREEN 4 Remote Speed Increase Button Being Pressed ELECTRICAL SCHEMATIC FROM A MACHINE WITH A SERIAL NUMBER BELOW 310000000 TO SHOW THE _ Power Current OPERATIONAL CIRCUITS Control Current Indicator Gauge Current Page 7 11 Rev C I CONTROL MODULE SOLENOID SHIFT STARTER B START BLUE Canada 3575APFB1 Made in U S A FUEL SOLENOID OUT RED RED WHITE LED S FUEL SOLENOID RED WHITE RED SL oe ILLUMINATED ENGINE KILL WHITE RED pea RED WHITE OIL PRESSURE SWITCH GREEN GREEN 1 i i uu c RR F GREEN LIT M G THROTTLE CONTROL RED
106. xtended Additionally battery and electrical component failure can be prevented When working with batteries use extreme cau tion to avoid splashing or spilling electrolyte Electrolyte can destroy clothing and burn skin and eyes Always wear safety goggles and a face shield when working with batteries Electrolyte Specific Gravity Fully charged 1 265 corrected to 80 F 26 7 C Discharged less than 1 240 Battery Specifications BCI Group Size 28 535 CCA at 0 F 18 C Reserve Capacity of 110 minutes at 80 F 27 C Dimensions including terminal posts Length 10 3 inches 26 2 cm Width 6 8 inches 17 3 cm Height 9 5 inches 24 1 cm Battery Removal and Installation Fig 27 1 Make sure that ignition switch is in the OFF position and that none of the LED s on Remote Control Module are illuminated Loosen strap and remove battery box cover 2 Loosen and remove negative cable from battery Af ter negative cable has been removed loosen and re move positive cable 3 Carefully remove battery from machine 4 Install battery in reverse order making sure to con nect and tighten positive cable to battery before con necting negative cable Tighten nuts that secure battery cables from 10 to 15 ft Ib 14 to 20 N m NOTE Before connecting the negative ground cable to the battery connect a digital multimeter set to DC Amps between the negative battery post and the nega tive ground cable connector
107. y 1 Install all removed components using Figures 12 and 13 as guides A If check valve item 7 in Fig 13 was removed make sure that arrow on valve body points toward engine B Iffilter item 5 in Fig 13 was removed make sure that arrow on filter body points toward engine C Make sure that evaporative system fuel hoses are not kinked after installation Also secure all hoses with hose clamps Figure 13 1 Hose clamp 6 Fuel hose 2 Barb fitting 7 Check valve 3 Hose clamp 8 Fuel hose 4 Fuel hose 9 Fuel hose 5 Filter ProForce Debris Blower Page3 13 Rev C Engine This page is intentionally blank Engine Page3 14 Rev C ProForce Debris Blower Chapter 4 Electrical System Table of Contents GENERAL INFORMATION 2 Operator s Manual 2 Electrical Power iiec 2 ELECTRICAL DIAGRAMS 2 SPECIAL TOOLS 3 TROUBLESHOOTING 5 Starting Problems 5 General Run Problems 7 ELECTRICAL SYSTEM QUICK CHECKS 8 Battery Test Open Circuit Test 8 Charging System Test 8 COMPONENT TESTING 9 Ignition Switch 9 Four Meter ocio bi ci A MERI 10 PUSE tas 11 Fusible Link Serial Number Below 310000000 12 Helays ii o ttle ted 13 5 Remote Transmitter

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