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08158SL

1. OIL PRESSURE SWITCH GREEN GREEN REEN 5 Y Y Y _86 GRAY THROTTLE CONTROL RED YELLOW 4 COILPOWER 4 GRAY ENGINE NOZZLE ROTATION MOTOR 2 2 GREEN 4 8 aMOTOR OUT 4 ENGINE START BLUE FUEL 8 IGNITION SWITCH WHITE GREEN Ws MOTOR OUT 2 VBB ON ENGINE PINK Bee p MOTOR OUT 1 GROUND p BLACK DIAG GND RELAY ENABLE 1 RUN PSP 6 GRAY t 47 g_pDIAG Rx LEARN ENABLE VELLOW BLACK DIAG Tx START RED YELLOW 8 H HROTTLE CONTROL INS REMOTE CONTROL MODULE TURNED TO START A REMOTE TRANSMITTER GREEN BLACK B BLACK e GRAY ED ORANGE BLACK E a F COMMUNICATION PORT NO BUTTONS BLACK PRESSED POWER RELAY _ 2 o 872 INLINE FUSE 15A 4 o 82 i BATTERY FUSIBLE YELLOW E RINK LINK GRAY 22S YY Y186 pBrack _ _ E HOUR METER ProForce Debris Blower C Control Module Wake Up GREEN No Control Module LED s Illuminated NOTE THE DRAWING ON THIS PAGE USES THE No Remote Transmitter Buttons Pressed ELECTRICAL SCHEMATIC FROM A MACHINE WITH Ignition Switch Turned to START A SERIAL NUMBER BELOW 310000000 TO SHOW THE Power Current OPERATIONAL
2. z ORANGE s DLA 2B pin B DLA 1 GRAY gt DLA 2A DLA 2 a TX 3 Diag Lamp Driver 4 5 Eis BROWN DLA 1A pin A DLA 6 B DLA1B pnDDLA 7 GROUND 8 9 GCU Power 12V 10 RED RX 11 BLACK GRD GROUND RED YELLOW peed Inpu Shutdown 14 WHITE GOVERNOR CONTROL UNIT GCU GRD RED WHI TE CARB SOLENOID INTAKE MANIFOLD SCREW e O T P ai SOLENOID STUD STARTER SOLENOID TANG ProForce Debris Blower Serial Numbers Below 310000000 Engine Electrical Diagram All ground wires are black P ES ALTERNATE IGNI TION PULSE SIGNAL STARTER ASS Y NOTE THE OIL PRESSURE SWITCH IS NORMALLY OPEN AND CLOSES WHEN ENGINE OIL PRESSURE EXISTS GREEN vA S OIL PRESSURE SWITCH BLACK GROUND INTAKE MANIFOLD SCREW ye i EASI 7E DSAI POWER dep c ACCESSORY TERM po ASE WHITE Mer WHITE E DSAI KILL REGULATOR REC
3. cm 1622 mec n ar NOTE Reduce torque values listed 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 2 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 10 of the nominal torque value Thin height nuts include jam nuts ProForce Debris Blower Standard Torque 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 M10 X 1 5 38 4 ft lb M12 X 1 75 66 7 ft lb M16 X 2 0 166 15 ft lb M20 X 2 5 325
4. 16 SERVICE AND REPAIRS 18 Nozzle Motor 18 Battery Storage 20 Battery 20 Battery Service 21 ProForce Debris Blower 4 1 Rev B 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 the 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 tool
5. A ProForce Debris Blower Serial Number Above 310000000 Wire Harness Drawing Page 7 14 Rev B CHUTE HOUR METER FUEL RELAY ROTATION P08 PIO PII z 30 85 81 87 86 2 3 2 3 4 5 A B gt E lt I XX 5 t co o Oo GREEN WHITE 0 5 01 S A BLUE BLACK B 8 ORANGE BLACK IGNITION GREEN BLACK 6 SWITCH PF f X RED YELLOW y t Em AF REMOTE CONTROL SP02 BLUE mnm GREEN B __ PINK OIL PRESSURE BLACK gt Poe MAGNETO 2 GRAY STARTER ue a BLUE YELLOW BLACK F FUEL SOL 4 WIRE IN TUBING i COIL POWER REDMHITE THROTTLE s POWER li INPUT ENGINE TONER GROUND fey ug gt ra lt gt o A B D E F A B D E F P06 P04 P05 FUSE COMM PORT LOOP BACK CONNECTOR ProForce Debris Blower Serial Number Above 310000000 Wire Harness Diagram Page 7 15 Rev B
6. 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 if the 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 Removal Figs 2 and 4 1 Park machine ona level surface with the engine OFF Chock wheels to prevent machine from moving 2 To prevent unexpected machine operation discon
7. 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 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 Product Records and Maintenance 2 2 ProForce Debris Blower Torque Specifications Recommended fastener torque values are listed in the followi
8. 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 2 5 27 2 ft lb 36 3 N m NOTE The nominal torque values listed above are based on 7596 of the minimum proof load specified in SAE J1199 Thetolerance is approximately 1096 ofthe nominal torque value Product Records and Maintenance Product Records 5 8 E Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Thread Size Square Head Hex Socket 716 200 65 10 ft lb 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 lb M12 X 1 25 80 10 ft lb 108 14 N m Class 8 8 1 2 13 UNC 75 15 ft lb 50 10 ft Ib M12 X 1 5 80 10 ft lb 108 14 Class 8 8 For steel wheels non lubricated fasteners Thread Cutting Screws Thread Cutting Screws
9. 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 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 lb 258 to 284 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 nut and torque with offset wrench see Special Tools from 190 to 210 ft Ib 258 to 284 N m C Bend inner tab washer over flat of nut 4 Install front cap 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 secur
10. Preface The purpose of this publication is to provide the service technician with information for troubleshooting testing and repair of major systems and components on the ProForce Debris Blower REFER TO THE OPERATOR S MANUALS FOR OP ERATING MAINTENANCE AND ADJUSTMENT INSTRUCTIONS Space is provided in Chapter 2 of this book to insert the Operator s Manuals and Parts Cata logs for your machine Additional copies of the Opera tors Manual are available on the Internet at www Toro com The Toro Company reserves the right to change product specifications or this publication without notice Part No 08158SL Rev B 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 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 The Toro Company 2008 2009 2011 This page is intentionally blank ProForce Debris Blower Table Of Contents Chapter 1 Safety Safety 1 2 Securing ProForce Debris Blower to Tow Vehicle 1 5 Jacki
11. 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 Check the electrolyte level in 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 Battery Testing 1 Conduct 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 10 F 5 5
12. 3 Remove top 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 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 roto
13. C above 80 F 26 7 C add 0 004 to the specific gravity reading For each 10 F 5 5 C be low 80 F 26 7 C subtract 0 004 from the specific gravity reading Example Cell Temperature 100 F Cell Gravity 1 245 100 F minus 80 F equals 20 F 37 7 C minus 26 7 C equals 11 0 C 20 F multiply by 0 004 10 F equals 0 008 11 C multiply by 0 004 5 5 C equals 0 008 ADD conversion above 0 008 Correction to 80 F 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 the 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 A commercial bat tery load tester is required to perform this test AX 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 surf
14. Class 8 8 Class 10 9 Metric Bolts and Screws Figure 2 Product Records and Maintenance 7 o oc m 5 5 and Maintenance Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series SAE Grade 8 Bolts Screws Studs amp Sems with Regular Height Nuts SAE Grade 5 Bolts Screws Studs amp 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 inte 100 10 1125 100 140 15 1580 170 obo omo 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 29 3 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 25 224 34 7 8 9 UNC 140 20 225 25 305 34 7 8 14 UNF 155 25 260 30 353 41 Spe aee EEE wame
15. Flange nut 4 used SERIAL NUMBER ABOVE 310000000 Fuel tank Fuel tank cap Grommet Fuel gauge Page3 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 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 A CAUTION The exhaust system may be hot Avoid possible burns allow exhaust to 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 and 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 ba
16. 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 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 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 TORO Engine Table of Contents SPECIFICATIONS 2 GENERAL INFORMATION 3 Operator s Manual 3 Electrical 3 SERVICE AND REPAIRS 5 Engine Cooling System 5 Fuel Tank 6 Enigiie oet ED dU Ed 8 Engine Removal 9 Engine Installation 10 KOHLER ENGINE SERVICE MANUAL ProForce Debris Blower Page 3 1 Engine Specifications Item Description Make Designation Kohler 4 cycle V Twin cylinder OHV air cooled Model CH740S Bore x Stroke 3 27 in x 2 64 in 83 mm x
17. bearing onthe 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 Assembly 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 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 Figure 12 1 Outer housing 4 Nozzle guide 4 used 2 Nozzle pulley 5 Flange nut 3 Cap screw 6 Spacer ProForce Debris Blower Page 5 11 Blower Assembly Inner Housing Assembly N Pd Loctite 242 See text for tightening procedure 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 11 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 g
18. 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 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 during assembly ProForce Debris Blower 5 9 Rev B 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 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 mark
19. 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 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 ProForce 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
20. 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 Drive 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 10 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 Removetwo 2 cap screws item 21 andflange 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 flan
21. 67 mm Total Displacement 44 in 725 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 require tools which are commonly available in many service shops Special tools are described in the KOHLER ENGINE SERVICE MANUAL that is included at the end of this Chapter The use of some specialized test equipment is explained Operator s Manual The Operator s Manual provides information regarding the operation general
22. CIRCUITS Control Current Indicator Gauge Current Page7 7 Rev B 2 2 CONTROL MODULE SOLENOID SHIFT STARTER Se START L BE SS SS SS SS SS SS SS SS SS SS SS SSS SS M Q qqocqqq 7 Canada 3575APFBL Made in U S A FUEL SOLENOID OUT RED FUEL SOLENOID RED WHITE ENGINE KILL WHITE OIL PRESSURE SWITCH GREEN RED WHITE LED S FUEL RELAY ILLUMINATED o 87a o DET RED WHITE GREEN THROTTLE CONTROL REDYELLOW GRAY COIL POWER ENGINE NOZZLE ROTATION MOTOR M GREEN 8 OTOR OUT 4 ENGINE START L BLUE L o WHITE g g CIO 2 Us s GREEN a g cMOTOR OUT 2 _ PINK 1 g_ _MOTOR OUT 1 GROUND p BLACK 3_pDIAG CND RELAY ENABLE START g pP AG Rx LEARN ENABLE VELLOW BLACK DIAG Tx RED YELLOW g LI HROTILE CONTROL REMOTE TRANSMITTER IGNITION SWITCH ON ENGINE IN RUN POSITION REMOTE CONTROL MODULE GREEN BLACK B BLACK E ORANGE BLACK E
23. Maintenance Electrical Chassis Blower Assembly 0 oO 6 9 6 ua This page is intentionally blank ProForce Debris Blower Chapter 1 Safety Table of Contents SAFETY INSTRUCTIONS 2 Before Operating 2 While 3 Maintenance and Service 4 SECURING PROFORCE DEBRIS BLOWER TO TOW VEHICLE 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 Op
24. OFF 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 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 terminal of a 12 VDC source to the positive 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 tor Figure 7 ProForce Debris Blower Fuse The ProForce Debris Blower uses a 15 amp fuse for cir cuit 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 nect the nega
25. 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 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 f
26. 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 move three 3 cap screws that secure nozzle motor to bracket Remove nozzle motor from machine Installation Fig 20 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 19 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 21 Do not over tension belt Hold bracket with the torque wrench and tighten two 2 flange head screws and flange nuts to secure b
27. 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 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 surface SERIAL NUMBER ABOVE 310000000 SHOWN 4 271033ft b 7 37 to 44 N m 27 to 33 ft Ib 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 91 112 N m Axle 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 greas
28. gine starter motor solenoid engine throttle control mod ule 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 21 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 21 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 nates Also the control module engine stop LED will re main illuminated and no other remote transmitter operations can be performed for approximately 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 s
29. machine on a level surface Make sure engine is OFF 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 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 2 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 2 used 7 nneiman 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 6 12 Rev B ProForce Debris Blower Chapter 7 TORO Electrical Diagrams Table of Contents ELECTRICAL SCHEMATICS Electrical Schematic Serial Number Below 310000000 3 Engine Electrical Diagram Serial Number Below 310000000 4 Electrical Schematic Serial Number
30. 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 lt 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 4 Blowers with serial numbers above 310000000 use one 1 nut Fig 5 Removal Fig 4 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 Page5 6 Rev B 10 Outer housing 11 Flange nut 8 used 12 Washer as needed 13 Cap screw 8 used
31. 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 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 21 Figure 22 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
32. to 38 C The ignition switch should be in the OFF position and all accessories turned off Connect the positive multi meter lead to the positive battery post and the negative multimeter lead to the negative battery post Record the battery voltage NOTE This test provides a relative condition of the 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 temperature the battery voltage will increase at different rates as the battery charges Electrical System Page 4 8 Voltage Measured Battery Charge Level 12 68 volts Fully charged 100 12 45 volts 75 charged 12 24 volts 50 charged 12 06 volts 25 charged 11 89 volts 0 charged Start the engine and run at high idle 3450 RPM Allow the battery
33. to charge for at least 3 minutes Record the battery voltage After running the engine for at least 3 minutes battery voltage should be at least 0 50 volt higher than 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 30 Battery Voltage after 3 Minute Charge 12 85 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 Figure 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 nect the 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 ter
34. while the De bris Blower engine is running or 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 ke
35. 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 5 4 ProForce Debris Blower Removal Fig 2 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 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 top grill to 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 as
36. AY ILLUMINATED Uae ua Ay tae sd 87a ENGINE KILL WHITE RED ENS EXCEL dt RED WHITE OIL PRESSURE SWITCH GREEN c 8556 Hes r GREEN 28 1 1 1 2 G THROTTLE CONTROL 7 RED YELLOW 7 ENERGIZED GRAY M ENGINE NOZZLE ROTATION MOTOR 2 i GREEN s 4 0 TOR OUT 4 ENGINE START BLUE o OTOR OUT 3 FUEL WHITE 8 8 6 8 GREEN g MOTOR our 2 PINK MOTOR OUT 1 GROUND 5 BLACK RELAY ENABLE g pDIAG GND 6 GRAY g Rx LEARN ENABLE p YELLOW BLACK THROTTLE CONTROL REMOTE TRANSMITTER IGNITION SWITCH ON ENGINE IN RUN POSITION REMOTE CONTROL MODULE GREEN BLACK B BLACK ORANGE BLACK E SPEED INCREASE BUTTON PRESSED COMMUNICATION PORT Mago 87 INLINE FUSE 15 RE 7 x X YELLOW PINK BATTERY FUSIBLE ProF D is LINK L GRAY See TY BLACK Lt a roForce Debris Blower Engine Speed Increase Circuits Ignition Switch in RUN Position and Engine Running Control Module LED s Illuminated Remote Speed Increase Button Be
37. Above 310000000 5 Engine Electrical Diagram Serial Number Above 310000000 6 CIRCUIT DRAWINGS Control Module Wake 7 Grank GIrCuits 202522820046 bien 8 Rum CIrGUils zie 9 Engine Speed Increase Circuits 10 Nozzle Rotation Circuits 11 WIRE HARNESS DRAWINGS Wire Harness Drawing Serial Number Below 310000000 12 Wire Harness Diagram Serial Number Below 310000000 13 Wire Harness Drawing Serial Number Above 310000000 14 Wire Harness Diagram Serial Number Above 310000000 15 o 3e oD 95 ProForce Debris Blower 7 1 Rev B Electrical Diagrams This page is intentionally blank Electrical Diagrams Page 7 2 ProForce Debris Blower SOLENOID SHIFT STARTER B START BLUE FUEL SOLENOID OUT RED RED WHITE FUEL SOLENOID RED WHITE RED FUEL RELAY 7 ENGINE KILL WHITE RED 30 or RUE i gt REDMHITE OIL PRESSURE SWITCH GREEN GREEN GREEN 22 Y Y _86
38. ENGINE START SEQUENCE PRESSED COMMUNICATION PORT RE TQUE 87 INLINE FUSE 15 28 BATTERY FUSIBLE YELLOW Pk LINK L NMa GRAY LA BLACK ProForce Debris Blower 1 leso ENERGIZED Crank Circuits 4 Ignition Switch in RUN Position METER Control Module LED s Illuminated Remote Transmitter ENGINE START Sequence 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 5 E CONTROL MODULE SOLENOID SHIFT STARTER B START BLUE Canada 3575 Made U S A FUEL SOLENOID OUT RED RED WHITE LED S FUEL SOLENOID RED WHITE RED 222 24210 ELS NM ILLUMINATED 87a ENGINE KILL WHITE RED uer i RED WHITE OIL PRESSURE SWITCH GREEN GREEN 4 am LY YY Lge m GREEN eS 6G THROTTLE CONTROL RED YELLOW ENERGIZED POWER GRAY ENGINE NOZZLE ROTATION MOTOR _ i GREEN 8 aMOTOR OUT 4 ENGINE START amp B
39. GRAY THROTTLE CONTROL RED YELLOW 4 pac ORE COIL POWER GRAY ENGINE NOZZLE ROTATION MOTOR 2 z GREEN s AVOTOR OUT 4 ENGINE START 64 BLUE a WHITE re agus e 8 GREEN Ws _ g MOTOR OUT 2 c g_pMOTOR OUT 1 GROUND 5 BLACK GND RELAY ENABLE JE GRAY g pP AG Rx LEARN ENABLE p YELLOW BLACK cDiAG Tx RED YELLOW HROTTLE CONTROL REMOTE CONTROL MODULE GREEN BLACK 8 BLACK gt EM GRAY ORANGE BLACK E AN F COMMUNICATION PORT GRAY BLACK POWER RELAY Peer ON 87 INLINE FUSE 15A RED 2 BATTERY p o YELLOW GRAY T Y Tl se OMNI iss See SS SS Ce METER GREEN ProForce Debris Blower Serial Number Below 310000000 Electrical Schematic All ground wires are black Page7 3 Rev B BLUE RED WIRES RED WIRE RED WIRE WHITE WIRES YELLOW WIRES KEY SWITCH CONNECTOR LAYOUT POS e BATTERY STARTER KEY SWITCH GRD BLACK R RECTIFIER GRD STARTER B BATTERY A ACCESSORY KEY SWITCH M MAGNETO CONNECTOR DIGITAL LINEAR ACTUATOR DLA UU oov cw uet RED RED WHITE GRAY MACHINE WIRE GREEN HARNESS
40. Housing Assembly 12 gt 5 7 4 ProForce Debris Blower Page 5 1 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 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 lb 14 20 N m Blower Assembly 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 5 4 ProForce Debris Blower Page
41. J05 P03 J01 FUEL m o o gt m o o HOUR METER FUEL RELAY SOLENOID FUEL THROTTLE NOZZLE OUT SOLENOID DIODE CONTROL ROTATION PIO 4 30 85 87 87 86 J02 J03 P33 107 Pl or 23 4 5 A B A B C f o x E W tr I a tr tr a 9 a m GREEN WHITE BLACK ORANGE BLACK GREEN BLACK 4 RED YELLOW BLUE BLUE skue GREEN ace WTE iis i 6 OF WIRE HIDDEN UNDER TUBING m J RED BLACK TE gt a 05 x 18 2 0 en a A c D F A BC DE F 2 3 4 5 A B P05 P04 A i5 LOOP BACK COMM PORT CONNECTOR OIL PRESSURE POWER RELAY FUSE ProForce Debris Blower REMOTE CONTROL Serial Number Below 310000000 Wire Harness Diagram Page 7 13 Rev B g P03 IGNITION SW ITCH P10 FUEL RELAY P08 HOUR METER Ule POS LOOP BACK CONNEC TOR POT COMM PORT 101 ENGINE GROUND P11 CHUTE ROTATION 01 REMOTE H CONTROL G P02 REMOTE CONTROL B C D
42. Kohler Engine Service Manual in cluded atthe end of Chapter 3 Engine for engine elec trical component repair information Nozzle Motor Figure 20 1 Nozzle 10 Drive pulley 2 Nozzle clamp 11 Lock nut 3 V belt 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 18 Leaf spring Bearing Cap screw 2 used Flange nut 2 used Shoulder bolt Lock nut Nozzle pulley Nozzle guide ProForce Debris Blower Removal Fig 20 1 Position machine 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
43. LUE LL WHITE gg TOR BUTS 1M GREEN MOTOR OUT 2 VBB PINK 1 g_pMOTOR OUT 1 GROUND 5 BLACK g_pDIAG GND RELAY ENABLE 1 g pP AG Rx LEARN ENABLE e YELLOW BLACK g DIAG Tx RED YELLOW a HI HROTTLE CONTROL IGNITION SWITCH ON ENGINE IN RUN POSITION REMOTE CONTROL MODULE 7 REMOTE TRANSMITTER GREEN BLACK BLACK ORANGE BLACK E NO BUTTONS PRESSED COMMUNICATION PORT INLINE FUSE 15 YELLOW 9 Pk BATTERY FUSIBLE LINK E GRAY 2U Las _ BLACK Doi ProForce Debris Blower l c Run Circuits 1 HOUR METER Ignition Switch in RUN Position and Engine Running 7 Control Module LED s Illuminated NOTE THE DRAWING ON THIS PAGE USES THE O GREEN i No Remote Transmitter Buttons 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 Page7 9 Rev B E 4 CONTROL MODULE SOLENOID SHIFT STARTER B START BLUE Canada 3575 Made U S A FUEL SOLENOID OUT RED RED WHITE LED S FUEL SOLENOID RED WHITE 229000 a FUEL REL
44. NOZZLE ROTATE BUTTON PRESSED COMMUNICATION PORT 87 INLINE FUSE 15 5 gt RE 7 a YELLOW 4 PINK BATTERY FUSIBLE LINK L GRAY 2U Las _ BLACK ProForce Debris Blower c Nozzle Rotation Circuits 1 HOUR METER Ignition Switch in RUN Position and Engine Running 22 Control Module LED s Illuminated NOTE THE DRAWING ON THIS PAGE USES THE Se Sota eee ore ase elena ee ede wee misse os GREEN 2 Remote Nozzle Rotate Button 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 B P07 87 POWER 3 c 30 8 86 P05 0 5 PIN OUT J07 THROTTLE POL P05 CONTROL J06 COMM PORT LOOP BACK J02 OIL CONNECTOR FUEL PRESSURE SOLENOID 03 10 FUEL RELAY P01 REMOTE CONTROL 108 STARTER P02 REMOTE CONTROL J01 ENGINE GROUND ProForce Debris Blower Serial Number Below 310000000 Wire Harness Drawing Page 7 12 Rev B J05 COIL POWER P11 NOZZLE ROTATION MOTOR STARTER COIL POWER POWER INPUT ENGINE GROUND J04
45. OUT 2 c PK START A B C gp MOTOR OUT 1 GROUND _p BK g gP AG GND RUN POWER amp c GY g_pDIAG Rx LEARN ENABLE Y BK A Be Ce D Tx R Y g H HROTTLE CONTROL RUN START WIRELESS CONTROL MODULE R y e PK INLINE FUSE 15A oA BU 2 AN NL A D of GN BK 8 E COMMUNICATION ee eee GY PORT GNITION SWITCH OR BK OPTIONAL TRAILER LIGHT KIT Y LEFT TAIL LIGHT BN TRAILER LIGHT Pn BN LICENSE PLATE ProForce Debris Blower Y Serial Number Above 310000000 CN Electrical Schematic BN RIGHT TAIL LIGHT i Page7 5 Rev B E g8 8 ORANGE 9 c LINEAR 7 DLA2B pinBDLA 1 d a MACHINE ACTUATOR DLA 2A pin C DLA 2 WIRE DLA TX 3 HARNESS Diag Lamp Driver 4 A A S 3 3 B B 6 5 4 3 2 1 BROWN DARD PINK BEM AD 6 6 5 4 3 2 1 D D DLA 1B pin D DLA 7 GROUND 8 9 NOTE THE OIL PRESSURE RED SWITCH IS NORMALLY OPEN OSU FOWO 2 10 AND CLOSES WHEN ENGINE BLACK GRD C CUNS 11 OIL PRESSURE EXISTS L 12 RED YELLOW Speed Input 13 WHITE Shutdown 14 GOVERNOR G CONTROL TL INTAKE MANIFOLD UNIT NEED jai SCREW GCU RED WHITE GREEN I b Ol OIL PRESSU
46. RE CARB SOLENO D N SWITCH WHITE BLACK GROUND INTAKE MANIFOLD SCREW Ne RED WHITE EE POS NEG BATTERY EC BLACK GROUND RED B WHITE 5 1 KILL BLUE P ane STARTER FLYWHEEL SOLENOID STATOR aa STUD ASS Y pm ee DSA MODULE CYLINDER 1 DSAI MODULE a RED CYLINDER 42 Ko STARTER SOLENOID VODENE A TANG BLACK I GROUND WHITE RED REGULATOR B LA RECTIFIER J WHITE STARTER ASS Y DSAI KILL ACHB Ey CONNECTOR SPARK PLUG ProForce Debris Blower SPARK PLUG Serial Numbers Above 310000000 afr FUSE Engine Electrical Diagram ka SPARK PLUG 30A VIOLET B LEAD EU E 1 CYLINDER mud i 4 WHITE m pem All ground wires are black 25 518 3 CHARGING LEADS Page 7 6 Rev B E CONTROL MODULE SOLENOID SHIFT Model 44538 STARTER BLUE Canada 3575 Made U S A FUEL SOLENOID OUT RED RED WHITE FUEL SOLENOID RED WHITE RED FUEL RELAY earn es A ENGINE KILL WHITE 30 LED s eeu ILLUMINATED m I
47. TIFIER O ACH B CONNECTOR m BLACK RED GROUND Renee B Page 7 4 Rev B pe B LEAD 20916 34 DSA MODULE CYLINDER 2 WHITE CHARGING LEADS FLYWHEEL STATOR ASSAY WHITE DSAI E eS p DSA MODULE CYLINDER 1 MODULE SCREW BLACK GROUND RED B WHITE DSAI KILL RED WHITE SPARK PLUG 2 CYLINDER SPARK PLUG 1 CYLINDER BATTERY GY SOLENOID sour METER SHIFT 53 STARTER B4 START BU R ENGINE IGNITION RED 4 FUEL SOLENOID RED W R W Eo E ENGINE KILL WHITE ey OIL SWITCH GREEN GN GN e SA GY 1 THROTTLE CONTROL RED Y R Y FUEL RELAY ENGINE CHUTE ROTATION GN g MOTOR OUT 4 ENGINE START BU 4 W g_gMOTOR OUT 3 FUEL 6g CN zr ieu M MOTOR
48. ace 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 Connect a 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 Applyatestload of 270 amps one halfthe 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 minimum voltage for the cell temperature reading Minimum Battery Electrolyte Voltage Temperature 96 70 F 21 19 and up 60 F 15 69 89 20 F 6 79 l 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 22 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
49. al 85 The relay should not have continuity between terminals 30 and 87 as 12 VDC is removed from termi nal 85 6 Disconnect voltage and multimeter leads from the relay terminals Electrical System Page 4 14 Rev B 7 Connect multimeter 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 Make sure that battery cover is secured Figure 16 2 Battery 3 Relay location 860 87A 87 30 86 85 87 87 p Figure 17 ProForce Debris Blower Remote Transmitter 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 18 The remote transmitter has suffi cient range to send an signal to the control module from the tow vehicle operator position When a button on t
50. 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 15 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 cured to harness with cable tie 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 Figure 14 1 Machine wire harness 2 Diode assembly Figure 15 1 Diode 3 Female terminal 2 Male terminal Multimeter Multimeter Red Lead Black Lead Continuity on Terminal on Terminal ProForce Debris Blower Page 4 13 Rev B Electrical System Fuel and Power Relays The ProForce Debris Blower electrical system includes a fuel relay that is used to energize the engine carbure tor fuel solenoid When the ignition switch is in the RUN or START position the fuel relay is energized by the Re mote Control Module ProForce blowers with serial numbers bel
51. 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 Voltage 2 Determine the charging time and rate using the bat tery charger manufacturer s instructions or the fol lowing table Battery Charge Level Gravity 100 1 265 75 1 225 50 1 190 25 1 155 0 1 120 Specific Battery Battery Charge Level Reserve Percent of Fully Charged Capacity tne 80 or less 3 8hrs 7 5hrs 11 3 hrs 15 hrs 3 amps 3 amps 3 amps 3 amps 5 3 hrs 10 5 hrs 15 8 hrs 21 hrs 4 amps 4 amps 4 amps 4 amps 126 to 5 5 hrs 11 hrs 16 5hrs 22 hrs 170 5 amps 5 amps 5 amps 5 amps 171 to 5 8hrs 11 5 hrs 17 3 hrs 23 hrs 250 6 amps 6 amps 6 amps 6 amps above 6 hrs 12 hrs 18 hrs 24 hrs 250 10 amps 10 amps 10 amps 10 amps ProForce Debris Blower Page 4 23 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 out
52. battery terminals disconnect cables Always disconnect negative cable first Clean clamps and terminals separately Reconnect cables to battery with positive 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 extended 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 22 1 Make sure that ignition
53. cable from the battery terminal see Battery Service in the Service and Repairs section 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 link terminal at the starter motor Fig 13 If the fusible link is open no continuity replace the fusible link har ness 1 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 4 12 Rev B ProForce Debris Blower Diode Assembly Serial Number Below 310000000 Ni ProForce Debris Blowers with a serial number below 310000000 use a diode assembly in the wire harness Fig 14 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 nect the negative
54. ce and Repairs sec tion of Chapter 6 Chassis ProForce Debris Blower 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 below 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
55. 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 explosive keep open flames and electrical sparks away from the battery do not smoke Nausea may result if the gases are inhaled Un plug charger from electrical outlet before con necting 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 tion 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 20 4 Store battery in a cool atmosphere to avoid quick de terioration of the battery charge 5 Tohelp prevent the 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 lb 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
56. d thin spacers if equipped from between inner housing flanges and outer housing Fig 13 Note location of spacers for assembly purposes 14 Lift inner housing assembly out of the outer housing 15 If necessary disassemble inner housing assembly see Rotor Shaft Removal in this section ProForce Debris Blower Page 5 13 Rev B 1 Wood plank 2 9 16 support 3 Outer housing 4 Mounting holes Figure 13 Inner housing assembly Stator vane 24 used Fin spacer 4 used Thin spacer as needed 5 Flange screw 8 used 6 Flange screw 24 used 7 Outer housing Installation Fig 11 1 If rotor shaft was removed from inner housing as semble inner housing see Rotor Shaft Installation in this section 2 Place inner housing assembly with the rotor shaft pointing upwards onto two 2 wood planks 2 x 4 or equivalent Carefully lower outer housing around inner housing assembly Then place 9 16 14 3 mm thick support between planks and outer housing Fig 12 This process should allow alignment of mounting holes in inner housing flanges to outer housing Blower Assembly gt 5 lt 3 On machines with serial numbers above 310000000 install fin spacers and thin spacers if equipped between inner housing flanges and outer housing Fig 13 NOTE When assembling inner and outer housings do not fully tighten any screws until all screws are installed
57. e 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 lb 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 lb 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 Page 6 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 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 Jack or hoist ProForce blower from ground and sup p
58. e 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 cover is secured ProForce Debris Blower This page is intentionally blank ProForce Debris Blower 6 9 Rev B Chassis Guards SERIAL NUMBER BELOW 311000000 SHOWN Yan Ios MT UAR pr E 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
59. ed Blower Assembly gt lt Rotor Shaft 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 ABOVE 310000000 Figure 6 Cap screw 4 used Bearing holder Rotor shaft Retaining ring BON 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 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 Blower Assembly Bearing 2 used Front bearing cap Flange head screw 4 used Inner housing 5 8 Rev B 9 Front bearing cap 2 used 10 Flange nut 4 used 11 O ring 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 Removal in this section 4 Remove top grill to allow access to blower assembly see Guards Removal in the Servi
60. ed eho ProForce Debris Blower Chapter 6 TORO Chassis Table of Contents SPECIFICATIONS 2 GENERAL INFORMATION 3 Operator s Manual 3 Securing ProForce Debris Blower to Tow Vehicle 3 Electrical 3 SERVICE AND REPAIRS 4 Wheels iki ke evan 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 6 2 Rev B ProForce Debris Blower General Information Operator s Manual The Operator s Manual provides information regarding the operation general maintenance and 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 machin
61. edure 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 Page1 5 Safety Safety and Instruction Decals Numerous safety and instruction decals are affixed to the ProForce Debris Blower If any decal becomes illeg ible or damaged install a new decal Part numbers for replacement decals are listed in your Parts Catalog Or der replacement decals from your Authorized Toro Dis trib
62. eep cigarettes sparks and flames away from 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 If welding on the machine is necessary disconnect the negative battery cable to prevent electrical system damage 15 If major repairs are ever needed or assistance is de sired contact an Authorized Toro Distributor 16 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 operating 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 proc
63. elt 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 ofthe 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 Figure 21 1 Drive pulley 2 Leaf spring 3 Flange head screw 4 Torque wrench access Electrical System lt 2 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 ifthe machine is stored in a location where temper atures are
64. er 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 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 Blower Assembly gt 5 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
65. erator s Manual are available on the internet 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 Page 1 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 Do not touch engine or exhaust system
66. g 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 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 Remove nut retainer jam nut and tab washer that se 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 If necessary remove bearing cups from hub D Inspect wheel bearings Check the bearing cones and bearing cups for wear pitting or other damage Replace worn or damaged parts E If necessary press lug screws
67. ge 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 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 belt in 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 Figure 10 bracket from 200 to 230 in Ib 23 to 25 N m to set v 1 Drive pulley 3 Flange head screw belt tension Fig 10 Do not over tension belt Hold 2 Leaf spring assembly 4 Torque wrench access 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 Figure 11 up 1 Leaf spring 3 Shoulder bolt 2 Locknut 4 Bearing 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
68. he remote transmitter is pressed the LED on the remote should flicker Fig 19 If the ma chine control module is energized control module Time Out and 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 5 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 second
69. hut 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 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 The ma chine wire harness does include a communication port with loopback connector that should remain connected Electrical System Page 4 16 Rev 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 to prevent damage to the electrical system Figure 20 1 Remote transmitter 2 Control module Figure 21 1 Speed increase LED 6 Engine start LED 2 Speed decrease LED 7 Time out LED 3 RH nozzle rotate LED 8 Power LED 4 LHnozzle rotate LED 9 RF activity LED 5 Engine stop LED ProForce Debris Blower This page is intentionally blank T o ProForce Debris Blower Page 4 17 Electrical System Service and Repairs NOTE See the
70. ing Pressed CEDE 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 B 5 E CONTROL MODULE SOLENOID SHIFT STARTER B START BLUE Canada 3575 Made U S A FUEL SOLENOID OUT RED RED WHITE LED S FUEL SOLENOID RED WHITE ILLUMINATED ENGINE KILL WHITE RED RED WHITE OIL PRESSURE SWITCH GREEN GREEN 4 am LY YY Lge m GREEN eS 6G THROTTLE CONTROL RED YELLOW ENERGIZED POWER GRAY ENGINE NOZZLE ROTATION MOTOR 2 GREEN OUT 4 ENGINE START amp BLUE OTOR OUT 3 FUEL WHITE 8 5 GREEN MOTOR OUT 2 VBB g p MOTOR OUT 1 GROUND _p BLACK RELAY ENABLE g_pDIAG GND GRAY Rx LEARN ENABLE p YELLOW BLACK a cDIAG Tx THROTTLE CONTROL RED YELLOW 8 H IGNITION SWITCH REMOTE TRANSMITTER ON ENGINE IN RUN POSITION REMOTE CONTROL MODULE GREEN BLACK B BLACK ORANGE BLACK z
71. let 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 69C 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 specific gravity for three consecutive readings Electrical System T 2 This page is intentionally blank Electrical System Page 4 24 ProForce Debris Blower Chapter 5 TORO Blower Assembly Table of Contents GENERAL INFORMATION 2 Operators 2 Electrical 2 SPECIAL TOOLS 3 SERVICE AND REPAIRS 4 Blower Drive Shaft 4 Rotor Assembly 6 Rotor Shaft aa p das 8 Nozzle 10 Inner
72. 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 lb 14 to 20 N m ProForce Debris Blower Page 3 3 However the cost of the test equipment and the special ized 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 external 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
73. minal 3 On blowers with serial numbers below 310000000 remove engine blower housing to gain access to ignition switch see the Kohler Engine Service Manual at the 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 Figure 6 FRONT VIEW REAR VIEW Figure 7 POSITION CIRCUITS B C F D E START Figure 8 Electrical System 5 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
74. n 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 Connect blower drive shaft to 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 the Service and Repairs section of Chapter 6 Chas sis Engine 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 ground 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
75. ng Instructions 1 5 Safety and Instruction Decals 1 6 Chapter 2 Product Records and Maintenance Product Records 2 1 Maintenance 2 1 Equivalents and Conversions 2 2 Torque Specifications 2 3 Chapter 3 Engine Specifications 3 2 General Information 3 3 Service and Repairs 3 5 KOHLER ENGINE SERVICE MANUAL Chapter 4 Electrical System General Information 4 2 Electrical Diagrams 4 2 Special Tools 4 3 Troubleshooting 4 5 Electrical System Quick Checks 4 8 Component Testing 4 9 Service and Repairs 4 18 ProForce Debris Blower Rev B Chapter 5 Blower Assembly General Information Special TOONS secco e Eee Service and Repairs Chapter 6 Chassis Specifications General Information Service and Repairs Chapter 7 Electrical Diagrams Electrical Schematic Circuit 6 Wire Harness Drawings Product Records and
76. ng tables For critical applications as determined by Toro either the recommended torque or a torque that is unique to the application is clearly identified and 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 on the fastener presence of a prevailing torque feature hardness of the 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 in the 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 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
77. ort raised machine with jack stands see Operator s Manual and Jacking Instructions in Chapter 1 Safety 5 Remove lug nuts 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 in failure or loss of wheel and may resultin personal injury 3 Lower machine to ground Alternately torque lug nuts from 70 to 90 ft lb 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 lb 37 to 44 N m Figure 3 1 Axle 2 used 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 bearin
78. ow 310000000 include a second relay The power relay on these machines is used to provide machine electrical power when itis energized by the Remote Control Mod ule The fuel relay and power relay if equipped are secured to a frame bracket between the battery and the engine Fig 16 Testing 1 Make sure that ignition switch is OFF 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 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 meter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal resistance of the meter and test leads Subtract this val ue from the measured value of the component you are testing 4 Using a multimeter ohms setting measure coil re sistance between terminals 85 and 86 Fig 17 Resist ance should be between 70 and 90 ohms 5 Connect multimeter 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 min
79. 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 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 E E E 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 15 ft Ib 14 to 20 N m Make sure that battery cover is secured ProForce Debris Blower Page 3 5 Engine Fuel Tank Pd SERIAL NUMBER BELOW 310000000 SHOWN
80. r 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 follows 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 SERIAL NUMBER ABOVE 310000000 190 to 210 ft Ib 9 258 to 284 N m
81. 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 lb 14 to 20 N m Make sure that battery cover is secured ProForce Debris Blower Chapter 4 TORO Electrical System Table of Contents GENERAL INFORMATION 2 Operator s Manual 2 Electrical 2 ELECTRICAL DIAGRAMS 2 SPECIALE TOOLS eos 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 Hour Meter 10 FUSE UR geet Goudy ER A RS 11 Fusible Link Serial Number Below 310000000 12 Diode Assembly Serial Number Below 310000000 13 9 Fuel and Power Relays 14 5 Remote Transmitter 15 Control Module
82. s 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 The remote transmitter is powered by three 3 AAA al kaline batteries If the range of the remote transmitter has diminished or the transmitter LED does not flicker when a button is pressed the batteries should be re placed To replace the remote batteries 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 1 ProForce Debris Blower Page 4 15 Figure 18 Remote transmitter 2 Control module Figure 19 Speed increase 5 Engine stop Speed decrease 6 Engine start RH nozzle rotate 7 Remote control LED LH nozzle rotate Electrical System Control Module The control module is a solid state electrical device that receives signal inputs from the remote transmitter and uses those inputs to control machine electrical opera tion The control module is attached to the frame next to the battery Fig 20 Inputs from the engine mounted ignition switch and the remote transmitter are monitored by the control module Output to the magneto relay fuel relay power relay en
83. s and Conversions Fractions Decimals mm Fractions Decimals mm 1 64 0 015625 0 397 33 64 0 515625 13 097 1 32 0 03125 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 64 0 203125 5 159 45 64 0 703125 17 859 7 82 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 16 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 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
84. s 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 2 A RA Prodes 112X Figure 2 FLEXIBLE NON TACK PROoTECT 2 14 Electrical System Battery Hydrometer Use the battery hydrometer when measuring specific gravity of battery electrolyte Obtain this tool locally Figure 4 Electrical System 4 4 ProForce Debris Blower Troubleshooting For effective troubleshooting and repairs there must be
85. sembly 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 usedto secure hub to shaft Secure hub to shaft with cap screw and flat washer ProForce Debris Blower 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
86. sing assembly is properly supported as it is removed from the machine Assembly weighs approximately 70 pounds 31 8 kg 8 Liftfan housing assembly from machine Setassem bly on workbench with rotor shaft pointing straight up Fig 14 9 Place inner housing on two 2 wood planks 2 x 4 or equivalent Then place 9 16 14 3 mm thick sup port between planks and outer housing Fig 12 This process will support fan housing assembly to prevent unexpected shifting of any components during disas sembly 10 Loosen but do not remove eight 8 flange head screws item 14 that secure inner housing flanges to outer housing 11 Remove flange head screw item 12 that secures each stator vane item 9 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 NOTE Machines with serial numbers above 310000000 have a fin spacer and possibly additional thin spacers between inner housing flanges and outer housing Fig 13 Take note of location of spacers when removing flange head screws that secure inner housing 12 Fully remove flange head screws item 14 that se cure inner housing flanges to outer housing 13 0n machines with serial numbers above 310000000 locate and retrieve fin spacers an
87. tive 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 With the 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 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 cable 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 nect the negative battery
88. to inner housing flanges and stator vanes Also use hand tools rather than air impact tools during assembly 4 Make sure that holes in inner housing flanges align with outer housing holes Install and finger tighten eight 8 flange head screws item 15 into threads of inner housing flanges Do not fully tighten screws at this time 5 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 14 B Tilt vane and engage vane lugs to inner housing holes C While keeping vane lugs in inner housing holes rotate vane to align threaded hole of vane with outer housing hole D Install and finger tighten flange head screw item 12 into threads of vane Do not fully tighten screw at this time E Repeat process for all twenty four 24 vanes 6 Tighten fasteners in the following order to secure as sembly A Use nutdriver to hand tighten the eight 8 flange head 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 2 to 11 2 N m Use a crossing pa
89. ttern 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 Blower Assembly 5 14 Rev B 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 7 Position outer housing assembly to machine Secure outer housing to fan housing mounts with cap screws and flange nuts 8 Install rotor assembly see Rotor Assembly Installa tion in this section 9 Install blower drive shaft see Blower Drive Shaft Installation in this section 10 Install top grill to machine see Guards Installation in the Service and Repairs section of Chapter 6 Chas sis 11 Install nozzle pulley and nozzle to rear of outer hous ing see Nozzle Assembly Installation in this section 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 ROUNDED END INTAKE END j A oe DISCHARGE END Figure 14 4 Flange head screw 5 Flange head screw Outer housing Inner housing assembly Stator vane 24 us
90. ttery 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 sure that 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 engine Figure 7 1 Fuel filter 2 Fuel filter inlet Figure 8 1 Screw 4 grill 2 Washer 5 Side grill 3 Flange nut Engine Engine Installatio
91. uel may be too cold Electrical System 4 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 motor is faulty Operator remote control or remote control module is faulty ProForce Debris Blower Page 4 7 Electrical System Electrical System Quick 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 100 F 16
92. uide NOTE Theillustration in Figure 11 is fora machine with serial number below 310000000 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 of the inner housing stator vanes item 10 or outer housing item 12 the following procedure is necessary Removal Fig 11 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 Blower Assembly 5 12 Rev B 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 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 ProForce Debris Blower 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 cap screws and flange nuts that secure out er housing to fan housing mounts item 20 To prevent personal injury make sure that fan hou
93. utor Safety Page 1 6 ProForce Debris Blower Chapter 2 TORO Product Records and Maintenance Table of Contents PRODUCT 1 1 ae EQUIVALENTS AND CONVERSIONS 2 59 Decimal and Millimeter Equivalents 2 S U S to Metric Conversions 2 TORQUE 3 5 3 Fastener Identification 3 EE Standard Torque for Dry Zinc Plated and 5 Steel Fasteners Inch Series 4 Standard Torque for Dry Zinc Plated and Steel Fasteners Metric Fasteners 5 Other Torque Specifications 6 Conversion 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 maintenance ProForce Debris Blower Page 2 1 Product Records and Maintenance Decimal and Millimeter Equivalents Equivalent
94. y from switch 2 To prevent unexpected machine 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 Safety Page1 4 9 Shut Debris Blower engine off before checking or adding oil to the crankcase 10 Battery acid is poisonous and can cause burns Awoid contact with skin eyes and clothing Protect your face eyes and clothing when working with a battery 11 Battery gases can explode K

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