Toro ProForce 44538, ProForce 44539 Service Manual

Page 1

ProForceRDebris Blower

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 OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. Space is provided in Chapter 2 of this book to insert the Operator’s Manuals and Parts Catalogs for your machine. Additional copies of the Operator’s 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. C)

Service Manual

This safety symbol means DANGER, WARNING, or CAUTION, PERSONAL SAFETY INSTRUCTION. When you see this symbol, carefully read the instructions that follow. Failure to obey the instructions may result in personal injury.

NOTE: A NOTE will give general information about the

correct operation, maintenance, service, testing or repair of the machine.

IMPORTANT: The IMPORTANT notice will give im portant instructions which must be followed to prevent damage to systems or components on the machine.

E The Toro Company -- 2008, 2009, 2011, 2014

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ProForce Debris Blower

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Table Of Contents

Chapter 1 - Safety

Safety Instructions 1 - 2..........................

Securing ProForce Debris Blower to Tow Vehicle 1 - 5

Jacking 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 COMMAND 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 - 20.......................

Chapter 5 - Blower Assembly

General Information 5 - 2........................

Special Tools 5 - 3..............................

Service and Repairs 5 - 4........................

Chapter 6 - Chassis

Specifications 6 - 2..............................

General Information 6 - 3........................

Service and Repairs 6 - 4........................

Chapter 7 - Electrical Diagrams

Electrical Schematics 7 - 3.......................

Engine Electrical Diagrams 7 - 6..................

Circuit Drawings 7 - 8............................

Wire Harness Drawings 7 - 14....................

SafetyProduct Records

and Maintenance

EngineElectricalBlower

System

ProForce Debris Blower

Rev. C

Chassis

Electrical

Assembly

Diagrams

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ProForce Debris Blower

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Chapter 1

Safety

Table of Contents

SAFETY INSTRUCTIONS 2......................

Before Operating 2............................

While Operating 3.............................

Maintenance and Service 4....................

SECURING PROFORCE DEBRIS BLOWER TO

TOW VEHICLE 5..............................

JACKING INSTRUCTIONS 5.....................

SAFETY AND INSTRUCTION DECALS 6..........

Safety

ProForce Debris Blower Page 1 -- 1 Safety

Page 6

Safety Instructions

The ProForce Debris Blower is designed and tested to offer safe service when operated and maintained properly. Although hazard control and accident prevention partially are dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern and proper training of the personnel involved in the operation, transport, maintenance 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

WARNING

To reduce the potential for injury or death, comply with the following safety instructions.

1. Read and understand the contents of the Operator’s Manual before starting and operating the ProForce Debris Blower. Become familiar with the controls and know how to stop the machine quickly.Additional copies of the Operator’s Manual are available on the 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.

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 vehicle operation.

5. Tighten any loose nuts, bolts, screws or other fasteners to ensure machine is in safe operating condition.

6. Make sure that the ProForce Debris Blower is properly attached to tow vehicle.

Rev. A

ProForce Debris BlowerPage 1 -- 2Safety

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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 procedures.

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 while the Debris 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.

7. While operating, the combination of the tow vehicle and the ProForce Debris Blower may exceed noise levels of 85dB(A) at the operator position. Hearing protection is recommended for prolonged exposure to reduce the potential of permanent hearing damage.

8. Before leaving the operator’s position of the tow vehicle:

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

ProForce Debris Blower Page 1 -- 3 Safety

Page 8

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 attached to tow vehicle, apply tow vehicle parking brake, stop engine and remove key from the ignition switch. Also, turn blower ignition switch OFF and remove key from switch.

2. To prevent unexpected machine operation, disconnect battery before performing any Debris Blower service. Disconnect negative battery cable first and positive cable last. If battery voltage is required for troubleshooting or test procedures, temporarily connect the battery. Reconnect positive battery cable first and negative 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. T oassure safety and accuracy, check maximum engine speed with a tachometer.

9. Shut Debris Blower engine off before checking or adding oil to the crankcase.

10.Battery acid is poisonous and can cause burns. Avoid contact with skin, eyes and clothing. Protect your face, eyes and clothing when working with a battery.

1 1.Battery gases can explode. Keep 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 machine is parked on a solid level surface such as a concrete floor . Always chock or block wheels. Use suitable jack stands to support the raised machine. If the machine is not properly supported by suitable jack stands, the machine may move or fall, which may result in personal injury (see Jacking Instructions in this chapter).

14.If welding on the machine is necessary, disconnect the negative battery cable and the wire harness connector from the wireless control module to prevent electrical system damage.

15.If major repairs are ever needed or assistance is desired, contact an Authorized Toro Distributor.

16.Engine oil, engine and remote batteries are pollutants to the environment. Dispose of these according to your state and local regulations.

17.At the time of manufacture, the machine conformed to all applicable safety standards. T o assure optimum performance and continued safety certification of the machine, use genuine Toro replacement parts and accessories. Replacement parts and accessories made by other manufacturers may result in non-conformance with the safety standards, and the warranty may be voided.

Rev. C

ProForce Debris BlowerPage 1 -- 4Safety

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Securing ProForce Debris Blower to Tow Vehicle

While operating or servicing the ProForce Debris Blower, make sure that blower is properly secured to tow vehicle (Fig. 1). Refer to your Operator’s Manual for the correct procedure for attaching blower to tow vehicle.

1. Tow vehicle hitch

2. Hitch pin

Figure 1

3. Hairpin clip

Jacking Instructions

Safety

CAUTION

When changing tires or performing other service, use suitable hoists and jacks to support the ProForce Debris Blower. Make sure machine is parked on a solid level surface such as a concrete floor. Always chock or block wheels. Use suitable jack stands to support the raised machine. If the machine is not properly supported by jack stands, the machine may move or fall, which may result in personal injury.

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 moving.

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.

Figure 2

1. Wheel 2. Frame jacking point

ProForce Debris Blower Page 1 -- 5 Safety

Page 10

Safety and Instruction Decals

Numerous safety and instruction decals are affixed to the ProForce Debris Blower. If any decal becomes illegible or damaged, install a new decal. Part numbers for replacement decals are listed in your Parts Catalog. Order replacement decals from your Authorized Toro Distributor.

ProForce Debris BlowerPage 1 -- 6Safety

Page 11

Product Records and Maintenance

Table of Contents

PRODUCT RECORDS 1.........................

MAINTENANCE 1...............................

EQUIVALENTS AND CONVERSIONS 2...........

Decimal and Millimeter Equivalents 2............

U.S. to Metric Conversions 2...................

TORQUE SPECIFICATIONS 3....................

Fastener Identification 3.......................

Standard Torque for Dry, Zinc Plated and

Steel Fasteners (Inch Series) 4...............

Standard Torque for Dry, Zinc Plated and

Steel Fasteners (Metric Fasteners) 5...........

Other Torque Specifications 6..................

Conversion Factors 6..........................

Product Records

Chapter 2

Product Records

and Maintenance

Insert Operator’s Manual and Parts Catalog for your ProForce Debris Blower at the end of this chapter. Additionally, if any optional equipment or accessories have been installed to your blower, insert the Installation Instructions, Operator’s Manuals and Parts Catalogs for those options at the end of this chapter.

Maintenance

Maintenance procedures and recommended service intervals 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

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Equivalents and Conversions

0.09375

ProForce Debris BlowerPage 2 -- 2Product Records and Maintenance

Page 13

Torque Specifications

Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in this Service Manual.

These Torque Specifications for the installation and tightening of fasteners s hall apply to all fasteners which do not have a specific requirement identified in this Service 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

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 engagement, etc.

The standard method of verifying torque shall be performed 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.

Product Records

and Maintenance

Grade 1 Grade 5 Grade 8

Inch Series Bolts and Screws

Figure 1

Class 8.8 Class 10.9

Metric Bolts and Screws

Figure 2

ProForce Debris Blower Page 2 -- 3 Product Records and Maintenance

Page 14

Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series)

Thread Size

# 6 -- 32 UNC

# 6 -- 40 UNF

# 8 -- 32 UNC

# 8 -- 36 UNF

#10--24UNC

#10--32UNF

1/4 -- 20 UNC 48 + 7 53 + 7 599 + 79 100 + 10 1125 + 100 140 + 15 1580 + 170

1/4 -- 28 UNF 53 + 7 65 + 10 734 + 11 3 11 5 + 10 1300 + 100 160 + 15 1800 + 170

5/16 -- 18 UNC 115 + 15 105 + 17 1186 + 169 200 + 25 2250 + 280 300 + 30 3390 + 340

5/16 -- 24 UNF 138 + 17 128 + 17 1446 + 192 225 + 25 2540 + 280 325 + 30 3670 + 340

3/8 -- 16 UNC 16 + 2 16 + 2 22 + 3 30 + 3 41 + 4 43 + 4 58 + 5

Grade 1, 5 &

8withThin

Height Nuts

in--lb in--lb N--cm in-- lb N--cm in-- lb N--cm

10 + 2 13 + 2 147 + 23

13 + 2 25 + 5 282 + 30

18 + 2 30 + 5 339 + 56

ft--lb ft--lb N--m ft--lb N--m ft--lb N--m

SAE Grade 1 Bolts, Screws, Studs &

Sems with Regular Height Nuts

(SAE J995 Grade 2 or Stronger Nuts)

SAE Grade 5 Bolts, Screws, Studs &

Sems with Regular Height Nuts

(SAE J995 Grade 2 or Stronger Nuts)

15 + 2 170 + 20 23 + 2 260 + 20

17 + 2 190 + 20 25 + 2 280 + 20

29 + 3 330 + 30 41 + 4 460 + 45

31 + 3 350 + 30 43 + 4 485 + 45

42 + 4 475 + 45 60 + 6 675 + 70

48 + 4 540 + 45 68 + 6 765 + 70

SAE Grade 8 Bolts, Screws, Studs &

Sems with Regular Height Nuts

(SAE J995 Grade 5 or Stronger Nuts)

3/8 -- 24 UNF 17 + 2 18 + 2 24 + 3 35 + 3 47 + 4 50 + 4 68 + 5

7/16 -- 14 UNC 27 + 3 27 + 3 37 + 4 50 + 5 68 + 7 70 + 7 95 + 9

7/16 -- 20 UNF 29 + 3 29 + 3 39 + 4 55 + 5 75 + 7 77 + 7 104 + 9

1/2 -- 13 UNC 30 + 3 48 + 7 65 + 9 75 + 8 102 + 11 105 + 10 142 + 14

1/2 -- 20 UNF 32 + 3 53 + 7 72 + 9 85 + 8 11 5 + 11 120 + 10 163 + 14

5/8 -- 11 UNC 65 + 10 88 + 12 119 + 16 150 + 15 203 + 20 210 + 20 285 + 27

5/8 -- 18 UNF 75 + 10 95 + 15 129 + 20 170 + 15 230 + 20 240 + 20 325 + 27

3/4 -- 10 UNC 93 + 12 140 + 20 190 + 27 265 + 25 359 + 34 375 + 35 508 + 47

3/4 -- 16 UNF 115 + 15 165 + 25 224 + 34 300 + 25 407 + 34 420 + 35 569 + 47

7/8 -- 9 UNC 140 + 20 225 + 25 305 + 34 430 + 45 583 + 61 600 + 60 813 + 81

7/8 -- 14 UNF 155 + 25 260 + 30 353 + 41 475 + 45 644 + 61 660 + 60 895 + 81

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: The nominal torque values listed above for Grade 5 and 8 fasteners are based on 75% of the minimum proof load specified in SAE J429. The tolerance is approximately +

10% of the nominal torque value. Thin

height nuts include jam nuts.

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 BlowerPage 2 -- 4Product Records and Maintenance

Page 15

Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Fasteners)

Class 8.8 Bolts, Screws and Studs with

Thread Size Regular Height Nuts

(Class 8 or Stronger Nuts)

Class 10.9 Bolts, Screws and Studs with

Regular Height Nuts

(Class 10 or Stronger Nuts)

M5 X 0.8 57 + 5in--lb 640 + 60 N--cm 78 + 7in--lb 885 + 80 N--cm

M6 X 1.0 96 + 9in--lb 1018 + 100 N--cm 133 + 13 in--lb 1500 + 150 N --cm

M8 X 1.25 19 + 2ft--lb 26 + 3N--m 27 + 2ft--lb 36 + 3N--m

M10 X 1.5 38 + 4ft--lb 52 + 5N--m 53 + 5ft--lb 72 + 7N--m

M12 X 1.75 66 + 7ft--lb 90 + 10 N--m 92 + 9ft--lb 125 + 12 N--m

M16 X 2.0 166 + 15 ft--lb 225 + 20 N--m 229 + 22 ft--lb 310 + 30 N--m

M20 X 2.5 325 + 33 ft--lb 440 + 45 N--m 450 + 37 ft--lb 610 + 50 N--m

NOTE: The nominal torque values listed above are based on 75% of the minimum proof load specified in SAE J1199. The tolerance is approximately + nominal torque value.

10% ofthe

Product Records

and Maintenance

ProForce Debris Blower Page 2 -- 5 Product Records and Maintenance

Page 16

Other Torque Specifications

SAE Grade 8 Steel Set Screws

Recommended Torque

Thread Size

Square Head Hex Socket

1/4 -- 20 UNC 140 + 20 in--lb 73 + 12 in--lb

5/16 -- 18 UNC 215 + 35 in--lb 145 + 20 in--lb

3/8 -- 16 UNC 35 + 10 ft--lb 18 + 3ft--lb

1/2 -- 13 UNC 75 + 15 ft--lb 50 + 10 ft--lb

Thread Cutting Screws

(Zinc Plated Steel)

Type 1, Type 23 or Type F

Thread Size Baseline Torque*

No. 6 -- 32 UNC 20 + 5in--lb

Wheel Bolts and Lug Nuts

Thread Size

7/16 -- 20 UNF

Grade 5

1/2 -- 20 UNF

Grade 5

M12 X 1.25

Class 8.8

M12 X 1.5

Class 8.8

** For steel wheels and non--lubricated fasteners.

Thread Cutting Screws

(Zinc Plated Steel)

Thread

Size

No. 6 18 20 20 + 5in--lb

Threads per Inch

Type A Typ e B

Recommended Torque**

65 + 10 ft--lb 88 + 14 N--m

80 + 10 ft--lb 108 + 14 N--m

Baseline Torque

No. 8 -- 32 UNC 30 + 5in--lb

No. 10 -- 24 UNC 38 + 7in--lb

1/4 -- 20 UNC 85 + 15 in--lb

5/16 -- 18 UNC 110 + 20 in--lb

3/8 -- 16 UNC 200 + 100 in--lb

Conversion Factors

in--lb X 11.2985 = N--cm N--cm X 0.08851 = in --lb

ft--lb X 1.3558 = N--m N--m X 0.7376 = ft --lb

No. 8 15 18 30 + 5in--lb

No. 10 12 16 38 + 7in--lb

No. 12 11 14 85 + 15 in--lb

* Hole size, material strength, material thickness & finish must be considered when determining specific torque values. All torque values are based on non--lubricated fasteners.

ProForce Debris BlowerPage 2 -- 6Product Records and Maintenance

Page 17

Table of Contents

SPECIFICATIONS 2............................

GENERAL INFORMATION 3.....................

Operator’s Manual 3..........................

Electrical Power 3.............................

SERVICE AND REPAIRS 5......................

Engine Cooling System 5......................

Fuel Tank 6..................................

Engine 8.....................................

Engine Removal 9...........................

Engine Installation 10........................

Fuel Evaporative Control System (Serial Number

Above 310000000) 12.......................

KOHLER COMMAND ENGINE SERVICE MANUAL

Chapter 3

Engine

ProForce Debris Blower Page 3 - 1 Engine

Rev. C

Page 18

Specifications

Item Description

Make / Designation Kohler, 4--cycle, V--Twin cylinder,

Bore x Stroke 3.27 in x 2.64 in (83 mm x 67 mm)

Total Displacement 44 in3(725 cc)

Compression Ratio 9.0:1

Governor Electronic

Low Idle Speed (no load) 1800 + 100 RPM

High Idle Speed (no load) 3450 + 100 RPM

Carburetor Float feed, fixed main jet, solenoid fuel shut-- off

Fuel Unleaded, regular grade gasoline

Fuel Pump Mechanical

Fuel Tank Capacity 5 U.S. gal (18.9 l)

Air Cleaner Dual element

Lubrication System Pressure lubrication with oil cooler

OHV, air cooled, Model CH740S

Crankcase Oil Capacity 2.0U.S.qt(1.9l)

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 lbs (43 kg)

ProForce Debris BlowerPage 3 -- 2Engine

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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 COMMAND ENGINE SERVICE MANUAL that is included at the end of this Chapter. The use of some specialized test equip-

Operator’s Manual

The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your ProForce Debris Blower machine. Refer to the Operator’s Manual for additional information when servicing the machine.

Electrical Power

Electrical power to ProForce Debris Blower components is controlled by the Remote Control Module. To make sure that machine operation does not occur unexpectedly, 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).

ment is explained. However, the cost of the test equipment and the specialized nature of some repairs may dictate that the work be done at an engine repair facility.

Service and repair parts f or Kohler engines are supplied through your local Toro distributor. Be prepared to provide your distributor with the Toro model and serial number.

Engine

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 Engine

Rev. C

Page 20

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ProForce Debris BlowerPage 3 -- 4Engine

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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 plugged cooling fins or a plugged or dirty blower housing will result in engine overheating 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, 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.

CAUTION

The engine may be hot. Allow engine to cool before 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.

1. Cylinder head

2. Grass screen

Figure 1

3. Blower housing

Engine

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--lb (14 to 20 N--m). Make sure that battery cover is secured.

ProForce Debris Blower Page 3 -- 5 Engine

Page 22

Fuel Tank

RIGHT

FRONT

SERIAL NUMBER BELOW 310000000 SHOWN

1. Frame

2. Foam strip (2 used)

3. Fuel tank

DANGER

Because gasoline is highly flammable, use caution 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 container and keep cap in place. Use gasoline for the engine only; not for any other purpose.

Figure 2

4. Felt strip (2 used)

5. Flange nut (4 used)

6. Tank strap (2 used)

7. Fuel cap and gauge

8. Worm clamp

9. Fuel hose

Check Fuel Lines and Connections

Check fuel lines and connections periodically as recommended in the Operator’s Manual. Check fuel lines for deterioration, damage or leaking connections. Replace hoses, clamps and connections as necessary.

Drain and Clean Fuel Tank

Drain and clean the fuel tank periodically as recommended in the Operator’s Manual. Also, drain and clean the fuel tank if the fuel system becomes contaminated or if the machine is to be stored for an extended period.

To clean fuel tank, flush tank out with clean solvent. Make sure tank is free of all contaminates and debris.

Rev. B

ProForce Debris BlowerPage 3 -- 6Engine

Page 23

Fuel Tank Removal (Figs. 2 and 4)

1. Park machine on alevel surface with the engineOFF. Chock wheels to prevent machine from moving.

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 4 as 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--lb (14 to 20 N--m). Make sure that battery cover is secured.

Figure 3

1. Engine blower housing

2. Fuel filter

SERIAL NUMBER ABOVE

310000000 SHOWN

Figure 4

1. Fuel tank assembly

2. Flange nut (4 used)

SERIAL

NUMBER

ABOVE

310000000

3. Fuel filter inlet

3. Tank strap (2 used)

Engine

ProForce Debris Blower Page 3 -- 7 Engine

1. Fuel tank

2. Fuel tank cap

3. Grommet

4. Fuel gauge

Rev. B

Figure 5

5. Rollover valve

6. Standpipe

7. Grommet

8. Bushing

Page 24

Engine

RIGHT

FRONT

270 to 330 in-- lb

(31to37N--m)

1. Frame

2. Engine

Figure 6

3. Fuel tank

4. Flange nut (4 used)

5. Flange head screw (4 used)

6. Blower coupler assembly

ProForce Debris BlowerPage 3 -- 8Engine

Page 25

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.

IMPORTANT: Make sure to not damage the engine, fuel hoses, electrical harness or other parts while removing the engine.

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 machine.

4. Label and disconnect wire harness connectors from engine.

A. Disconnect positive battery cable and fusible link from the starter motor B+ stud.

CAUTION

To prevent personal injury,make surethat engine is properly supported as it is removed from the machine. Engine weighs approximately 94 pounds (43 kg).

9. Carefully remove the engine from machine.

10.Remove engine parts and attachments as necessary to repair the engine.

Engine

B. Disconnect wire harness blue wire from starter motor terminal.

C. Loosen and remove flange bolts that secure negative battery cable and wire harness ground connector to engine. Note that there is a lock washer on the

1. Fuel filter 2. Fuel filter inlet

Figure 7

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 crankshaft (see Drive Shaft Removal in the Service and Repairs section of Chapter 5 -- Blower Assembly).

8. Remove four (4) flange head screws and flange nuts that secure engine to machine.

1. Screw

2. Washer

3. Flange nut

ProForce Debris Blower Page 3 -- 9 Engine

Rev. B

Figure 8

4. Top grill

5. Side grill

Page 26

Engine Installation (Fig. 6)

9. Connect wire harness connectors to engine.

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 section of Chapter 5 -- Blower Assembly).

6. Move engine on frame as necessary to align the blower driveshaft assembly between the blowerand engine shafts.

7. Fully tighten the engine mounting fasteners. Torque fasteners from 270 to 330 in--lb (31 to 37 N--m).

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 remaining engine wires.

10.Remove plug installed in fuel hose during engine removal 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.

8. Install top grill and side grill (see Guards Installation in the Service and Repairs section of Chapter 6 -- Chassis).

Rev. B

ProForce Debris BlowerPage 3 -- 10Engine

Page 27

This page is intentionally blank.

Engine

ProForce Debris Blower Page 3 -- 11 Engine

Rev. C

Page 28

Fuel Evaporative Control System (Serial Number Above 310000000)

FUEL TAN K

CARBON

CANISTER

FRESH AIR

FILTER

Figure 11

CHECK VALVE

ENGINE

TO ENGINE

FITTING

ProForce blowers with serial number above 310000000 are equipped with a fuel evaporative control system (EVAP) designed to collect and store evaporative emissions from the fuel tank. The EVAPuses a carbon canister to collect these evaporative emissions. Fuel vapors from the fuel tank are vented to the canister where they are stored. Vapors from the canister are consumed when the engine is running which purges the canister.

The fuel tank o n these ProForce machines uses a non-vented fuel cap. To connect the tank to the evaporative control system, a fuel vent valve is positioned in the top of the tank that allows tank venting through the carbon canister.

NOTE: If there is restriction in the fresh air filter, the carbon canister or the fuel vent valve, the fuel tank may distort due to venting issues. I f the fuel tank returns to it’s normal shape when the fuel cap is removed, restriction in the evaporative control system is likely.

Machines with a carbon canister include a single engine connection to the engine intake system that is used to connect the evaporative system to the engine. These machines use an inline check valve and fuel filter between the carbon canister and the engine fitting. Evaporative control system components for ProForce blowers are shown in Figure 11.

Rev. C

ProForce Debris BlowerPage 3 -- 1 2Engine

Page 29

Disassembly

DANGER

Gasoline is flammable. Use caution when storing or handling it. Wipe up any spilled fuel before starting the engine.

1. Inspect carbon canister and attachedhoses for damage or obvious leaks. A damaged or leaking canister should be replaced.

2. Remove components as needed using Figures 12 and 13 as guides.

A. If check valve (item 7 in Fig. 13) is removed, note direction of arrow on valve body for assembly purposes.

B. If filter (item 5 in Fig. 13) is removed, note direction of arrow on filter body for assembly purposes.

Assembly

1. Install all removed components using Figures 12 and 13 as guides.

A. If check valve (item 7 in Fig. 13) was removed, make sure that arrow on valve body points toward engine.

1. Carbon canister

2. Fuel hose

3. Fuel hose

Figure 12

4. Fresh air filter

5. Fuel hose

Engine

B. If filter (item 5 in Fig. 13) was removed, make sure that arrow on filter body points toward engine.

C. Make sure that evaporative system fuel hoses are not kinked after installation. Also, secure all hoses with hose clamps.

1. Hose clamp

2. Barb fitting

3. Hose clamp

4. Fuel hose

5. Filter

Figure 13

6. Fuel hose

7. Check valve

8. Fuel hose

9. Fuel hose

ProForce Debris Blower Page 3 -- 13 Engine

Rev. C

Page 30

This page is intentionally blank.

Rev. C

ProForce Debris BlowerPage 3 -- 1 4Engine

Page 31

Table of Contents

GENERAL INFORMATION 2.....................

Operator’s Manual 2..........................

Electrical Power 2............................

ELECTRICAL DIAGRAMS 2.....................

SPECIAL TOOLS 3.............................

TROUBLESHOOTING 5.........................

Starting Problems 5...........................

General Run Problems 7......................

ELECTRICAL SYSTEM QUICK CHECKS 8........

Battery Test (Open Circuit Test) 8...............

Charging System Test 8.......................

COMPONENT TESTING 9.......................

Ignition Switch 9..............................

Hour Meter 10................................

Fuse 11......................................

Fusible Link (Serial Number Below 310000000) 12

Relays 13....................................

Remote Transmitter (Machines with Single

Channel Controller) 14.......................

Remote Transmitter (Machines with Multi

Channel Controller) 15.......................

Wireless Control Module (Machines with Single

Channel Controller) 16.......................

Wireless Control Module (Machines with Multi

Channel Controller) 17.......................

Diode Assembly (Serial Number Below

310000000) 18.............................

SERVICE AND REPAIRS 20.....................

Nozzle Motor 20..............................

Battery Storage 22............................

Battery Care 22...............................

Battery Service 23............................

Chapter 4

Electrical System

Electrical

System

ProForce Debris Blower Page 4 -- 1 Electrical System

Rev. C

Page 32

General Information

This Chapter gives information about troubleshooting, testing and repair of the electrical system used in the ProForce Debris Blower.

Operator’s Manual

Electrical Power

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).

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

Page 33

Special Tools

Order special tools from your Toro Distributor. Some tools may also be available from a local supplier.

Multimeter

The multimeter can test electrical components and circuits 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 highimpedance (internal resistance) of a digital meter in the voltage mode will make sure that excess current is not allowed through the meter. This excess current can cause damage to circuits not designed to carry it.

Figure 1

Skin--Over Grease

Special non--conductive grease which forms a light protective 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

Figure 2

System

Electrical

ProForce Debris Blower Page 4 -- 3 Electrical System

Figure 3

Rev. B

Page 34

Battery Hydrometer

Use the battery hydrometer when measuring s pecific gravity of battery electrolyte. Obtain this tool locally.

Figure 4

Electrical System

Page 4 -- 4

ProForce Debris Blower

Page 35

Troubleshooting

For effective troubleshooting and repairs, there must be

CAUTION

Remove all jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Disconnect the battery cables unless the test requires battery voltage.

Starting Problems

Problem Possible Causes

Starter solenoid clicks, but starter will not crank. Battery is discharged.

a good understanding of the electrical circuits (see Chapter 7 -- Electrical Diagrams) and components used on this machine.

Battery cables are loose or corroded.

Wire harness ground cable is loose or c orroded.

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).

Battery cables are loose or corroded.

Wire harness ground cable is loose or c orroded.

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.

System

Electrical

ProForce Debris Blower Page 4 -- 5 Electrical System

Page 36

Starting Problems (Continued)

Problem Possible Causes

Engine cranks, but does not start. Ignition switch is faulty.

Magneto relay or circuit wiring is faulty.

Fuel relay or circuit wiring is faulty.

Diode is faulty.

Operator remote control or remote control module is faulty.

Engine or fuel system is malfunctioning (see Chapter 3

-- Engine).

Engine and fuel may be too cold.

Electrical System

Page 4 -- 6

ProForce Debris Blower

Page 37

General Run Problems

Problem Possible Causes

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.

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.

System

Electrical

ProForce Debris Blower Page 4 -- 7 Electrical System

Page 38

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 C). The ignition switch should be in the OFFposition and all accessories turned off. Connect the positive (+) multimeter lead to the positive battery post and the negative (--) multimeter lead to the negative battery post. Record the battery voltage.

NOTE: This testprovides a relative condition of the battery. Load testing of the battery will provide additional and more accurate information (see Battery Service in the Service and Repairs section).

to 100oF(16oto 38

Charging System Test

This is a simple test used to determine if a charging system 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 battery post. Keep the test leads connected to the battery posts and record the battery voltage.

Voltage Measured

12.68 volts Fully charged (100%)

Start the engine and run at high idle (3450 RPM). Allow the battery to charge for at least 3 minutes. Record the battery voltage.

After running the engine for at least 3 minutes, battery voltage shouldbe at least 0.50 volthigher than initial battery voltage.

An example of a charging system that is functioning:

12.45 volts 75% charged

12.24 volts 50% charged

12.06 volts 25% charged

11.89 volts 0% charged

Battery Charge Level

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.

At least 0.50 volt over initial battery voltage.

Initial Battery Voltage = 12.30 v

Battery Voltage after 3 Minute Charge = 12.85 v

Difference = +0.55 v

Electrical System

Page 4 -- 8

ProForce Debris Blower

Page 39

Component Testing

For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g. unplug the switch connector before doing a continuity check on switch).

Ignition Switch

CAUTION

When testing electrical components for continuity with a multimeter (ohms setting), make sure that power to the circuit has been disconnected.

The ignition (key) switch used on the ProForce Debris Blower has three positions (OFF, RUN and START) .

On ProForce blowers with s erial 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, disconnect 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. On blowers with serial numbers below 310000000, remove engine blower housing to gain access to ignition switch (see the KohlerEngine Service Manual at theend of Chapter 3 -- Engine).

OFF

RUN

START

Figure 5

POSITION CIRCUITS

OFF G+M+A

RUN B+A+R

START B+S

Figure 6

RUN

OFF

START

System

Electrical

4. Unplug wire harness connectors from switch.

5. With the use of a multimeter (ohms setting), test ignition switch by verifying continuity between switch terminals 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 Engine 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--lb (14 to 20 N--m). Make sure that battery cover is secured.

ProForce Debris Blower Page 4 -- 9 Electrical System

FRONT VIEW

REAR VIEW

Figure 7

POSITION CIRCUITS

OFF NONE

RUN B+C+F, D+E

START A+B+C

Figure 8

Rev. B

Page 40

Hour Meter

The hour meter used on the ProForce Debris Blower records the amount of time that the engine is running.

Testing

1. Make sure that ignition switch is OFF.

3. Locate wire harness connector at rear of hour meter. Unplug harness connector from hour meter.

4. Connect the 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.

Hobbs

QUARTZ

0000

HOURS

FRONT

BACK

Figure 7

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--lb (14 to 20 N--m). Make sure that battery cover is secured.

Electrical System

Page 4 -- 10

ProForce Debris Blower

Page 41

Fuse

The ProForce Debris Blower uses a 15 amp fuse for circuit 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 circuit protection. The engine fuse is located near the starter motor (Fig. 9).

Testing

1. Make sure that ignition switch is OFF.

3. Press latch that retains fuse holder cover and raise cover to access fuse.

4. With the use of a multimeter (ohmssetting), 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--lb (14 to 20 N--m). Make sure that battery cover is secured.

1. Wire harness

2. Fuse

Figure 8

3. Fuse cover

System

Electrical

Figure 9

1. Engine fuse

2. Starter motor

ProForce Debris Blower Page 4 -- 11 Electrical System

Page 42

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.

3. Locate and unplug fusible link connector from machine wire harness.

4. Use a multimeter to make sure that continuity exists between the disconnected fusible link connector andthe link terminal at the starter motor (Fig. 13). If the fusible link is open (no continuity), replace the fusible link harness.

5. After testing is complete, make sure that fusible link connectors are securely attached to starter and machine wire harness.

6. 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.

Figure 12

1. Fusible link

2. Starter B+ terminal

FUSIBLE LINK HARNESS

P1 J1

Figure 13

BATTERY B+HARNESS

Electrical System

Page 4 -- 12

Rev. B

ProForce Debris Blower

Page 43

Relays

The electrical system on all P roForce Debris Blowers includes a fuel relay that is used t o energize the engine carburetor fuel solenoid. When the ignition switch is in the RUN or START position, the fuel relay is energized by the Wireless Control Module.

ProForce blowers with serial numbers below 310000000 include a second relay. The power relay on these machines is used to provide machine electrical power when it is energized by the Remote Control Module.

ProForce blower models 44538 and 44539 with serial numbers above 312000000 include an additional three (3) relays: a start relay and two (2) relays for energizing the chute rotation motor. These relays are energized by the Wireless Control Module when a remote transmitter input is entered for engine starting or chute rotation.

The relays are secured to the control tower bracket next to the engine. The relays can be identified by the wire colors at the wire harness connector (see Wire Harness Drawings in Chapter 7 -- Electrical Diagrams).

Test i n g

4. Using a multimeter (ohms setting), measure coil resistance between terminals 85 and 86 (Fig. 14). Resistance should be between 70 and 90 ohms.

5. Connect multimeter (ohms setting) leads to relay terminals 30 and 87. Ground terminal 86 and apply +12 VDC to terminal 85. The relay should have continuity between terminals 30 and 87 as + 12 VDC is applied to terminal 85. The relay should not have continuity between terminals 30 and 87 as +12 VDC is removed from terminal 85.

6. Disconnect voltage and multimeter leads from the relay terminals.

7. Connect multimeter (ohms setting) leads to relay terminals 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 terminal 85.

8. Disconnect voltage and multimeter leads from the relay terminals.

1. Make sure that ignition switch is OFF.

3. Locate relay and disconnect the machine wire harness connector from the relay. Remove relay from machine 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 value from the measured value of the component you are testing.

9. Secure relay to machine and connect machine wire harness connector to relay.

10.Connect negative battery cable to n egative b attery 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.

868587A 87

Figure 14

Electrical

System

ProForce Debris Blower Page 4 -- 13 Electrical System

Rev. C

Page 44

Remote Transmitter (Machines with Single Channel Controller)

NOTE: Machines with a single channel controller can

be identified by the external antenna on the control module (Fig. 15).

The remote transmitter is a solid state electrical device that sends radio frequency (RF) signal inputs to the machine control module for control of machine electrical operation (Fig. 15). The remote transmitter has sufficient range to send an RF signal to the control module from the tow vehicle operator position.

Whenabuttonontheremotetransmitter is pressed, the LED on the remote should flicker (Fig. 16). If the machine control module is energized (control module Time Out andPower 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 button functions are as follows:

Pressing the Engine Start button initiates a starting sequence to start the engine. This sequence (see Operator’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.

Remote Transmitter Battery Replacement

1. Remove six (6) screws t hat secure the rear cover to the remote transmitter.

2. Lift rear cover from remote transmitter.

3. Remove batteries from remote transmitter and replace with three (3) new AAA alkaline batteries.

4. Place rear cover on remote transmitter and secure with six (6) screws.

Figure 15

1. Remote transmitter

2. Control module

3. External antenna

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 blower nozzle to rotate to the right.

Pressing the LH Nozzle Rotate button causes the blower nozzle to rotate to the left.

Pressing the engine Stop button causes the engine to stop running.

NOTE: Whentheenginestopbuttonontheremote transmitter is pressed, there will be a one (1) second delay before the engine stop LED on the control module illuminates. Also, for approximately five (5) seconds after the stop button is pressed, the control module engine stop LED will remain illuminated and no o ther remote transmitter operationscanbeperformed.

The remote transmitter is powered by three (3) AAA alkaline batteries. If the range of the transmitter has diminished or the transmitter LED does not flicker when a button is pressed, the batteries should be replaced.

Electrical System

Page 4 -- 14

1. Speed increase

2. Speed decrease

3. RH nozzle rotate

4. LH nozzle rotate

Rev. C

Figure 16

5. Engine stop

6. Engine start

7. Remote control LED

ProForce Debris Blower

Page 45

Remote Transmitter (Machines with Multi Channel Controller)

NOTE: Machines with a multi channel controller can be

identified by the lack of an external antenna on the control module (Fig. 17).

NOTE: Additional information regarding the remote transmitter is included in the Operator’s Manual.

The remote transmitter is a solid state electrical device that sends radio frequency (RF) signal inputs to the machine control module for control of machine electrical operation (Fig. 17). The remote transmitter has sufficient range to send an RF signal to the control module from the tow vehicle operator position.

When a button on the remote transmitter is pressed, the TX LED on the remote should illuminate and then blink (Fig. 18). If the machine control module is energized (control module health LED is illuminated) and a remote transmitter button is pressed, the control module TX/RX LED should blink.

If the control module is energized(control module health LED is illuminated), remote transmitter button functions are as follows:

Pressing the Engine Start button initiates a starting sequence to start the engine. This sequence (see Operator’s Manual) is necessary to prevent accidental engine starting. If any transmitter buttons are pressed out of order during the starting sequence, the sequence will be aborted.

The remote transmitter is powered by three (3) AAA alkaline batteries. If the range of the transmitter has diminished or the transmitter TX LED does not illuminate when a button is pressed, the transmitter batteries should be replaced.

Figure 17

1. Remote transmitter

2. Control module

Electrical

System

Pressing the LH Nozzle Rotate button causes the blower nozzle to rotate to the left.

Pressing the RH Nozzle Rotate button causes the blower nozzle to rotate to the right.

Pressing the Speed Decrease (turtle) button when the engine is running causes the engine speed to decrease.

Pressing the Speed Increase (rabbit) button when the engine is running causes the engine speed to increase.

NOTE: Pressing the speed increase and speed decrease buttons simultaneously will return the engine to low idle speed.

Pressing the Engine Stop button causes the engine to stop running.

1. LH nozzle rotate

2. RH nozzle rotate

3. Speed decrease

4. Speed increase

5. Engine start

Figure 18

6. Engine stop

7. TX LED

8. RX LED

9. Link LED

ProForce Debris Blower Page 4 -- 15 Electrical System

Rev. C

Page 46

Wireless Control Module (Machines with Single Channel Controller)

NOTE: Machines with a single channel controller can

be identified by the external antenna on the control module (Fig. 15).

The wireless control module is a solid state electrical device that receives signal inputs from the remote transmitter and uses those inputs to control machine electrical operation. The control module is attached to the frame next to the battery (Fig. 19).

Inputs from the ignition switch and the remote transmitter are monitored by the control module. Output to the magneto relay, fuel relay, power relay, engine starter motor solenoid, engine throttle control module and nozzle rotation motor are controlled based on the inputs received by the control module.

To start b lower 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 Power LED’s should both be illuminated during blower operation (Fig. 20).

When a remote transmitter button is pressed, the corresponding control module LED should illuminate and the control m odule RF activity LED should flicker (Fig. 20).

NOTE: Because of the normal RF activity in the environment, 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: Whentheenginestopbuttonontheremote transmitter is pressed, there will be a one (1) second delay before the control module engine stop LED illuminates. Also, the control module engine stop LED will remain illuminated and no other remote transmitter operations can be performed for about five (5) seconds.

The control module includes a time--out feature to allow machine operation for a time period after the last control input (e.g. key switch turned off or remote transmitter button pressed). If no inputs are provided to the control module during this time period, the control module will shut off all machine electrical power including turning off the engine, if running. When the engine is turned off with either the key switch or the remote transmitter, the control module Time Out and Power LED’s will both be illuminated 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--programmed and does not record any fault data. The machine wire harness does include a communication port with loopback connector that should remain connected.

Because of the solid state circuitry built into the control module, thereis no reliablemethod to testit. The module maybedamagedifanattemptismadetotestitwithan electrical test device, such as a digital multimeter.

IMPORTANT: Before performing any welding on the machine, disconnect the negative battery cable from the battery and the wire harness connector from the wireless control module to prevent damage to the electrical system.

Figure 19

1. Remote transmitter

2. Control module

3. External antenna

Model: 44538

Test ed t o C ompl y

With FCC Standar ds

FORHOMEOROFFICEUSE

Canada 3575APFB1

N1625

Mad e in U .S . A.

Figure 20

1. Speed increase LED

2. Speed decrease LED

3. RH nozzle rotate LED

4. LH nozzle rotate LED

5. Engine stop LED

6. Engine start LED

7. Time out LED

8. Power LED

9. RF activity LED

Electrical System

Page 4 -- 16

Rev. C

ProForce Debris Blower

Page 47

Wireless Control Module (Machines with Multi Channel Controller)

NOTE: Machines with a multi channel controller can be

identified by the lack of an external antenna on the control module (Fig. 21).

Inputs from the machine ignition switch and the remote transmitter are monitored by the control module. Output to the fuel relay, start relay, engine starter motor solenoid, engine throttle control module and nozzle rotation relays are controlled based on the inputs received by the control module.

To start blower operation, rotation of the ignition switch totheSTARTpositionisusedtoturnonor“wakeup”the control module. The control module Health LED should be illuminated green during normal blower operation (Fig. 22). If the Health LED is illuminated either yellow or red, a problem exists with the controller.

When a remote transmitter button is pressed, the control module TX/RX LED should flicker (Fig. 22). The TX/RX LED will be green when the module is receiving a signal from the remote and will be red when the module is transmitting.

Figure 21

1. Remote transmitter

2. Control module

Electrical

System

NOTE: Because of the normal RF activity in the envi-

ronment, the control module TX/RX LED may flicker or be illuminated at any time during machine operation. Machine operation will only be controlled by the remote transmitter that is associated to the control module.

The control module includes a power save mode if the module is active for more than 2.5 hours without communication from the remote transmitter. Once in the power save mode, the control module will not communicate with the remote transmitter, will not activate any machine outputs and will not function normally. All machine electrical power will be shut--off including turning off the engine, if running. Refer to your Operator’s Manual for additional details on the power save mode.

The control module does not connect to an external computer or hand held device, can not be re--programmed and does not record any fault data. Because of the solid state circuitry built into the control module, there is no reliable method to test it. The module may be damaged if an attempt is made to test it with an electrical test device, such as a digital multimeter.

1. Health LED

Figure 22

2. TX/RX LED

ProForce Debris Blower Page 4 -- 17 Electrical System

Rev. C

Page 48

Diode Assembly (Serial Number Below 310000000)

ProForce Debris Blowers with a serial number below 310000000 use a diode assembly in the wire harness (Fig. 23) (see wire harness drawings in Chapter 7 -Electrical Diagrams). The diode allows the initial current flow to energize or “wake up” the remote control module.

Testing

1. Make sure that ignition switch is OFF.

3. Locate diode assembly and remove cable tie that secures diode to machine wire harness.

4. Unplug the diode from the wire harness for testing.

5. The diode (Fig. 24) can be tested using a digital multimeter (diode test or ohms setting) and the table in the right column.

6. After testing is complete, make sure that diode is fully installed into machine wire harness connector and secured 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--lb (14 to 20 N--m). Make sure that battery cover is secured.

Figure 23

1. Machine wire harness 2. Diode assembly

Figure 24

1. Diode

2. Male terminal

Multimeter

Red Lead (+)

on Terminal

Multimeter

Black Lead (--)

on Terminal

3. Female terminal

Continuity

Female Male YES

Male Female NO

Electrical System

Page 4 -- 18

Rev. B

ProForce Debris Blower

Page 49

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Electrical

System

ProForce Debris Blower Page 4 -- 19 Electrical System

Page 50

Service and Repairs

NOTE: See the Kohler Engine Service Manual (in-

cluded at the end of Chapter 3 -- Engine) for engine electrical component repair information.

Nozzle Motor

FRONT

RIGHT

1. Nozzle

2. Nozzle clamp

3. V belt

4. Housing assembly

5. Flat washer (10 used)

6. R--clamp

7. Nozzle motor

8. Motor bracket

9. Cap screw (3 used)

NOTE: If nozzle motor wear or damage occurs, motor

replacement is necessary. Individual components for the nozzle motor are not available.

Electrical System

Figure 25

10. Drive pulley

11. Lock nut

12. Cap screw (2 used)

13. Belt guard

14. Flange head screw (2 used)

15. Flat washer

16. Cap screw

17. Flange nut (2 used)

18. Flange nut

Page 4 -- 20

19. Leaf spring

20. Bearing

21. Cap screw (2 used)

22. Flange nut (2 used)

23. Shoulder bolt

24. Lock nut

25. Nozzle pulley

26. Nozzle guide

ProForce Debris Blower

Page 51

Removal (Fig. 25)

1. Position machine on a firm, level surface. Make sure engine is stopped and remove key from the ignition switch. Chock wheels to prevent machine from moving.

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.

3. Unplug wire harness connector from nozzle motor.

4. Loosen, but do not fully remove, flange nut that secures drive pulley to nozzle motor shaft. Loosen flange nut at least two turns.

5. Remove two (2) cap screws(item 21) andflange nuts (item 22) that secure leaf spring to motor bracket. Remove 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.

5. With a 3/8 in. drive torque wrench, pivot the motor bracket from 200 to 230 in--lb (23 to 25 N--m) to set v-- belt tension (Fig. 26). Do not over tension belt. Hold bracket with the torque wrench and tighten two (2) flange head screws and flange nuts to secure belt adjustment and nozzle motor bracket.

6. Center belt guard around v--belt. Tighten cap screws andflangenutstosecurebeltguardtomachine.

7. Position leaf spring with bearing and flat washers (item 5) to bracket. Make sure that five (5) washers are placed between spring and bracket at each mounting hole. The bearing on the leaf spring should be centered on the outside of the v--belt. Secure leaf spring to motor bracket with two (2) cap screws (item 21) and flange nuts (item 22).

8. Connect wire harness to nozzle motor.

9. Connect negative battery cable to negative battery terminal. Tighten nut that secures battery cable from 10 to 15 ft--lb (14 to 20 N--m). Make sure that battery cover is secured.

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 motor shaft.

10.Support nozzle motor to prevent it from falling. Remove three (3) cap screws that secure nozzle motor to bracket. Remove nozzle motor from machine.

Installation (Fig. 25)

1. Position nozzle motor to bracket and secure with three (3) cap screws.

2. Thoroughly clean tapered surfaces of motor shaft and drive pulley.

1. Drive pulley

2. Leaf spring

Figure 26

3. Flange head screw

4. Torque wrench access

System

Electrical

ProForce Debris Blower Page 4 -- 21 Electrical System

Page 52

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 maintained. The top of the battery must be kept clean. lf the machine is stored in a location where temperatures are extremely high, the battery will discharge more rapidly than if the machine is stored in a location where temperatures are cool.

CAUTION

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. Unplug charger from electrical outlet before connecting or disconnecting charger leads to or from battery posts.

IMPORTANT: Do not remove battery fill caps while cleaning.

2. Check battery condition weekly or after every 50 hours of operation. Keep terminals and entire battery case clean because a dirty battery will discharge slowly.

4. Store battery in a cool atmosphere to avoid quick deterioration of the battery charge.

5. To help 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).

CAUTION

Connecting battery cables to the wrong battery post could result in personal injury a nd/or damage to the electrical system.

4. If corrosion occurs at battery terminals, disconnect cables. Always disconnect negative (--) cable first. Clean clamps and terminals separately. Reconnect cables to battery with positive (+) cable first. Coat battery 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 m achine is in storage.

6. Maintain battery cell level with distilled water. Do not fill battery cells above the fill line.

A. Clean battery by washing entire case with a solution of baking soda and water. Rinse with clear water.

B. Coat battery posts and cable connectors with Battery Terminal Protector (Toro Part No. 107--0392) or petroleum jelly to prevent corrosion.

Electrical System

Page 4 -- 22

ProForce Debris Blower

Page 53

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 canbeprevented.

CAUTION

When working with batteries, use extreme caution 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.

RIGHT

FRONT

Electrolyte Specific Gravity

Fully charged: 1.265 corrected to 80 Discharged: less than 1.240

Battery Specifications

BCI Group Size 28 535 CCA at 0 Reserve Capacity of 110 minutes at 80

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)

F(--18oC)

F(26.7oC)

F(27oC)

Battery Removal and Installation (Fig. 27)

1. Make sure that ignition switch is in the OFF position and that none of the LED’s on Remote Control Module are illuminated. Loosen strap and remove battery box cover.

2. Loosen and remove negative cable from battery. After negative cable has been removed, loosen and remove positive cable.

3. Carefully remove battery from machine.

4. Install battery in reverse order making sure to connect and tighten positive cable to battery before connecting negative cable. Tighten nuts that secure battery cables from 10 to 15 ft--lb (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 negative (ground) cable connector. The reading should be less than 0.1 amp. If the 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.

Figure 27

1. Strap

2. Battery box cover

3. Battery

4. Battery box

5. Positive cable

6. Negative cable

7. Flange nut

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 disconnect negative (--) cable first. Clean cable clamps and battery terminals separately. Reconnect cables with positive (+) cable first. Coat battery posts and cable connectors 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 battery with a solution of baking soda and water, then rinse it with clean water.

4. Check that the cover seal is not broken away. Replace 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 e lectrolyte.

Electrical

System

ProForce Debris Blower Page 4 -- 23 Electrical System

Page 54

Battery Testing

1. Conduct a hydrometer test of the battery electrolyte.

IMPORTANT: Make sure the area around the cells is clean before opening the battery caps.

B. If the battery has recently been charged, remove the battery surface charge before performing the load test. Disconnect the engine fuel stop solenoid to prevent the engine from starting. Engage the starter motor for 10 seconds to remove battery surface charge. Reconnect the fuel stop solenoid.

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-upthehydrometer.Atthesametimetakethetemperature of the cell.

B. Temperature correct each cell reading. For each

F(5.5oC) above 80oF(26.7oC) add 0.004 to the

specific gravity reading. For each 10

low 80

F(26.7oC) subtract 0.004 from the specific

F(5.5oC) be-

gravity reading.

Example: Cell Temperature 100oF

Cell Gravity 1.245

F minus 80oF equals 20oF

100

C minus 26.7oC equals 1 1.0oC)

(37.7

F multiply by 0.004/10oF equals 0.008

C multiply by 0.004/5.5oC equals 0.008)

(11 ADD (conversion above) 0.008 Correction to 80oF(26.7oC) 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 lessthan 1.225, chargethe battery. Charge at the recommended rate and time given 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 isone of themost reliable means of testing a battery as it simulates the cold--cranking test. A commercialbattery load tester is required to perform this test.

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 terminals following the load tester manufacturer’s in- structions. Connect a digital multimeter to the battery terminals.

F. Apply a testload of 270 amps (one half the Cranking Performance rating of the battery) for 15 seconds.

G. Take a voltage reading after 15 seconds, then remove the load.

H. Using the table below, determine the minimum voltage for the cell temperature reading:

Minimum

Voltage

Battery Electrolyte

Temperature

9.6 70oF(andup) 21.1oC(andup)

9.5 60oF 15.6oC

9.4 50oF 10.0oC

9.3 40oF 4.4oC

9.1 30oF -- 1 . 1oC

8.9 20oF -- 6 . 7oC

8.7 10oF -- 1 2 . 2oC

8.5 0oF -- 1 7 . 8oC

I. If the test voltage is below the minimum, replace the battery. If the test voltage is at or above the minimum, return the battery to service.

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.

Electrical System

Page 4 -- 24

ProForce Debris Blower

Page 55

Battery Charging

To minimize possible damage to the battery and allow the battery to be fully charged, the slow charging method is presented here. This charging method can be accomplished with a constant current battery charger which is commonly available.

CAUTION

Follow the battery charger manufacturer’s instructions when using a battery charger.

NOTE: Using specific gravity of the battery cells is the

most accurate method of determining battery condition.

1. Determine the battery charge level from either its specific gravity or open circuit voltage.

Battery Charge

Level

100% 1.265 12.68

75% 1.225 12.45

50% 1.190 12.24

25% 1.155 12.06

0% 1.120 11.89

2. Determine the charging time and rate using the bat- tery charger manufacturer’s instructions or the following table:

Specific

Gravity

Open Circuit

Volt a g e

CAUTION

Do not charge a frozen battery because it can explode and cause injury. Let the battery warm to

F (15.5oC) 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 electrical spark away from the battery. Do not smoke. Nausea may result if the gases are inhaled. Unplug the charger from the electrical outlet before connecting or disconnecting the charger leads from the battery posts.

3. Following the battery charger manufacturer’s instructions, connect the charger cables to the battery.

Make sure a good connection is made.

4. Charge the battery following the battery charger manufacturer’s instructions.

5. Occasionally check t he temperature of the battery electrolyte. If the temperature exceeds 125 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, measure 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.

F(51.6oC)

Electrical

System

Battery

Reserve

Capacity

(Minutes)

80 or less 3.8 hrs

81 to 125 5.3 hrs

126 to

170

171 to

250

above

250

ProForce Debris Blower Page 4 -- 25 Electrical System

75% 50% 25% 0%

3amps

4amps

5.5 hrs

5amps

5.8 hrs

6amps

6hrs

10 amps

Battery Charge Level

(Percent of Fully Charged)

7.5 hrs @

3amps

10.5 hrs @

4amps

11 hrs

5amps

11. 5 hrs @

6amps

12 hrs

10 amps

11.3 hrs @

3amps

15.8 hrs @

4amps

16.5 hrs @

5amps

17.3 hrs @

6amps

18 hrs

10 amps

15 hrs

3amps

21 hrs

4amps

22 hrs

5amps

23 hrs

6amps

24 hrs

10 amps

Page 56

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Electrical System

Page 4 -- 26

ProForce Debris Blower

Page 57

Table of Contents

GENERAL INFORMATION 2.....................

Operators Manual 2...........................

Electrical Power 2............................

SPECIAL TOOLS 3.............................

SERVICE AND REPAIRS 4......................

Blower Drive Shaft 4..........................

Rotor Assembly 6.............................

Rotor Shaft (Serial Number Below 313000000) 8.

Rotor Shaft (Serial Number Above 313000000) 10

Nozzle Assembly 12..........................

Inner Housing Assembly 14....................

Chapter 5

Blower Assembly

ProForce Debris Blower Page 5 -- 1 Blower Assembly

Rev. C

Blower

Assembly

Page 58

General Information

Operator’s Manual

Electrical Power

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 BlowerPage 5 -- 2Blower Assembly

Page 59

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 properly tighten the rotor assembly nuts.

Toro Part Number: TOR6006

Figure 1

ProForce Debris Blower Page 5 -- 3 Blower Assembly

Blower

Assembly

Page 60

Service and Repairs

Blower Drive Shaft

RIGHT

FRONT

300 to 330 in-- lb

(34to37N--m)

Loctite #242

300 to 330 in-- lb

(34to37N--m)

1. Flange nut

2. Fan hub

3. Cap screw

4. Spacer

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) andengine shaft iscomposed of the same components (Fig. 3).

Figure 2

6. Flat washer

7. Cap screw

8. Drive coupling

9. Flat washer

10. Cap screw

11. Woodruff key

12. Drive shaft

13. Engine hub and coupling assembly

ProForce Debris BlowerPage 5 -- 4Blower Assembly

Page 61

Removal (Fig. 2)

2. Place coupling spacers into rubber coupling.

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.

3. Remove top grill to allow access to blower drive shaft (see Guards Removal in the Service and Repairs section of Chapter 6 -- Chassis).

4. Remove cap screws, flat washers and lock nuts that secure drive shaft assembly to hubs on engine shaft and blower shaft.

5. Lift drive shaft assembly from machine.

6. Disassemble drive couplings from drive shaft using Figures 2 and 3 as guides. Note differences in coupling spacer flange thickness for assembly purposes.

7. Inspect drive couplings for damage and replace if necessary.

8. If necessary, remove hubs from engine shaft and blower shaft:

A. Remove cap screw and flat washer that secure hub to shaft.

NOTE: Hub has a taperedID and will require apuller 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 used to secure hub to shaft.Secure hub to shaft with cap screw and flat washer.

3. Secure drive couplings to driveshaft 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 -- Chassis).

7. 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.

Loctite #242

300 to 330 in-- lb

(34to37N--m)

Figure 3

1. Cap screw

2. Flat washer

3. Cap screw

4. Spacer

5. Cap screw

6. Woodruff key

7. Shaft hub

8. Flat washer

9. Flange nut

10. Spacer

11. Drive coupling

12. Fan hub/coupling

Blower

Assembly

ProForce Debris Blower Page 5 -- 5 Blower Assembly

Rev. B

Page 62

Rotor Assembly

SERIAL NUMBER BELOW 310000000

See text for

tightening procedure

Loctite #242

RIGHT

FRONT

1. Inlet bell

2. Retaining ring

3. Wave washer (up to 3 used)

4. Front cap

5. Nut (LH threads)

6. Spacer

7. Rotor assembly

8. Woodruff key

9. Rotor shaft

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.

Figure 4

10. Outer housing

11. Flange nut (8 used)

12. Washer (as needed)

13. Cap screw (8 used)

3. Remove top grill to allow access to blower assembly (see Guards Removal in the Service and Repairs section of Chapter 6 -- Chassis).

4. Remove blower drive shaft from machine (see Blower 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 assembly to rotor shaft, use a 1 1/4” wrench in flats on shaft to prevent the shaft from turning.

IMPORTANT: The nuts used to secure the rotor assembly to the rotor shaft have left hand threads. Loosen these nuts by rotating clockwise.

Rev. B

ProForce Debris BlowerPage 5 -- 6Blower Assembly

Page 63

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 offset wrench (see Special Tools) to loosen nuts from rotor shaft.

B. On machines with serial numbers above 310000000 (Fig. 5), straighten inner tab washer to allow removal of nut. Remove nut from rotor shaft by rotating nut in a clockwise direction. Remove two (2) tab washers from rotor shaft.

NOTE: Washers (item 12) are used to prevent rotor from contacting rotor housing assembly. Typically, two (2) washers are required.

7. Slide spacer (item 6), rotor assembly and washer(s) (item 12) from shaft. Locate and retrieve woodruff key.

8. Remove rotor assembly from rotor shaft.

NOTE: Component parts for the rotor assembly are not available. If rotor damage exists, replace complete rotor assembly.

SERIAL NUMBER ABOVE 310000000

190 to 210 ft-- lb

(258 to 284 N-- m)

Figure 5

1. Retaining ring

2. Wave washer

3. Front cap

4. Nut (LH threads)

5. Inner tab washer

6. Outer tab washer

7. Spacer

8. Rotor assembly

9. Washer (as needed)

10. Woodruff key

11. Rotor shaft

D. Apply Loctite #242 (or equivalent) to exposed threads of rotor shaft.

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 sure that rotordoes not contact rotor housing. If necessary, add additional washer(s) to allow proper clearance.

IMPORTANT: The nuts used to secure the rotor assembly to the rotor shaft have left hand threads. Tighten these nuts by rotating counter--clockwise.

NOTE: When installing nuts that secures rotor assem-

blytoshaft,usea11/4”wrenchinflatsonshafttoprevent the shaft from turning.

2. On machines with serial numbers below 310000000 (Fig. 4), secure rotor assembly to rotor shaft as follows:

A. Clean rotor shaft threads withbrake 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 completely.

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--lb (68 to 81 N--m) to secure rotor assembly on 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 N--m).

3. On machines 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--lb (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 -- Chassis).

7. 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.

Blower

Assembly

ProForce Debris Blower Page 5 -- 7 Blower Assembly

Rev. B

Page 64

Rotor Shaft (Serial Number Below 313000000)

180 to 200 in --lb

(21 to 23 N-- m)

180 to 200 in--lb

(21to23N--m)

Product 641

Loctite

SERIAL NUMBER BELOW 310000000

SERIAL NUMBER FROM 310000000

TO 313000000

1. Cap screw (4 used)

2. Bearing holder

3. Rotor shaft

4. Retaining ring

5. Bearing (2 used)

6. Front bearing cap

7. Flange head screw (4 used)

8. Inner housing

NOTE: The rotor shaft and bearings can be serviced

without removing inner housing from machine.

NOTE: Several changes were made to the rotor shaft assembly above machine serial number 310000000. Figure 6 shows both the earlier and later illustration for the inner housing assembly used on machines with serial number below 313000000.

NOTE: If inner housing has been replaced by a later housing version, use appropriate illustration and service procedures. Rotorshaft for machineswith serial number above 313000000 is described later in this section.

Figure 6

9. Front bearing cap (2 used)

10. Flange nut (4 used)

11. O- -ring

Removal (Fig. 6)

1. Position machine on a firm, level surf ace. Make sure engine is stopped and remove key from the ignition switch. Chock wheels to prevent machine from moving.

3. Remove nozzle and nozzle pulley from rear of outer housing (see Nozzle Assembly Removal in this section).

Rev. C

ProForce Debris BlowerPage 5 -- 8Blower Assembl y

Page 65

4. Remove top grill to allow access to blower assembly (see Guards Removal in the Service and Repairs section of Chapter 6 -- Chassis).

5. Remove blower drive shaft from machine (see Blower Drive Shaft Removal in this section).

6. Remove rotor assembly (see Rotor Assembly Removal 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.

IMPORTANT: To prevent the bearings from rotating in the inner housing or bearing holder on machines with serial numbers below 310000000, Loctite Primer N (or equivalent) and Loctite Product 641 (or equivalent) must be used during assembly.

2. On machines 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.

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 inner 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 secure front bearing cap to bearing holder. Remove bearing holder from rotor shaft assembly.

11. Using Figure 6 as a guide, remove bearings, retaining rings and front bearing cap from rotor shaft as necessary.

12.On machines with serial numbers above 310000000, remove and discard O--ring (item 11) from inner housing.

13.Inspect rotor shaft and bearing bores of bearing holder and inner housing for wear or damage. Replace parts as necessary.

Installation (Fig. 6)

1. Install bearings onto rotor shaft:

A. Install inner retaining rings into shaft grooves if they were removed.

B. Make sure that front bearing cap (item 6) is placed on rotor shaft between bearing locations.

C. Install bearings onto shaft by pressing on inner race. Make sure that bearings are s eated against inner retaining ring.

D. If equipped, install outer retaining rings.

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 andsecurewithfour(4)flangeheadscrews(item7).

4. On machines with serial numbers above 310000000, install new O--ring (item 11) into inner housing.

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 assembly.

5. Install rotor shaft assembly into inner housing. Make sure to align marker line made during disassembly and that bearingis 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--lb (21 to 23 N--m). After tighten- ing screws, make sure that rotor shaft rotates freely.

7. Install rotor assembly (see Rotor Assembly Installation 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 -- Chassis).

10.Install nozzle pulley and nozzle to rear of outer housing (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--lb (14 to 20 N--m). Make sure that battery cover is secured.

Blower

Assembly

ProForce Debris Blower Page 5 -- 9 Blower Assembly

Rev. C

Page 66

Rotor Shaft (Serial Number Above 313000000)

Loctite #242

90 to 100 in-- lb

(10.2 to 11.3 N--m)

1. Inner housing

2. Rotor shaft

3. Flange head screw (8 used)

4. Bearing cap

5. End cap

6. Retaining ring (4 used)

NOTE: The rotor shaft and bearings can be serviced

without removing inner housing from machine.

NOTE: Rotor shaft for machines with serial number below 313000000 is described earlier in this section. If inner housing has been replaced by a later housing version, use appropriate illustration and service procedures.

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.

3. Remove nozzle and nozzle pulley from rear of outer housing (see NozzleAssembly Removal in this section).

4. Remove top grill to allow access to blower assembly (see Guards Removal in the Service and Repairs section of Chapter 6 -- Chassis).

Figure 7

7. Bearing (2 used)

8. Rear cap

9. O-- ring

Loctite #242

90 to 100 in--lb

(10.2 to 11.3 N--m)

5. Remove blower drive shaft from machine (see Blower Drive Shaft Removal in this section).

6. Remove rotor assembly (see Rotor Assembly Removal in this section).

7. Remove four (4) flange h ead screws that secure bearing cap (item 4) to inner housing.

8. Carefully slide rotor shaft assembly from inner housing. Note slot in inner housing that locates tab on end cap (item 5) for assembly purposes. Rear cap will remain in inner housing.

9. Using Figure 6 as a guide, remove bearing cap (item

4), end cap (item 5), retaining rings (item 6) and bearings (item 7) from rotor shaft as necessary.

10.Remove and discard O--ring (item 9) from rear cap.

11. If necessary, remove rear cap (item 8) from inner housing.

12.Inspect rotor shaft and bearing bores of bearing cap and rear cap for wear or damage. Replace parts as necessary.

Rev. C

ProForce Debris BlowerPage 5 -- 10Blower Assembly

Page 67

Installation (Fig. 6)

1. If removed, install bearings onto rotor shaft:

A. Install inner retaining rings into shaft grooves if they were removed.

B. Install bearings onto shaft by pressing on inner race. Make sure that bearings are s eated against inner retaining ring.

C. Install outer retaining rings to secure bearings onto shaft.

2. If rear cap was removed from inner housing, install rear cap:

A. Slide rear cap (item 8) into housing.

B. Apply Loctite #242 (or equivalent) to threads of flange head screws (item 4).

C. Secure rear cap to inner housing with flange head screws (item 4). Torque screws from 90 to 100 in--lb (10.2 to 11.3 N--m).

3. Install new O--ring (item 9) into inner housing. After O--ring installation, clean O--ring to remove all oil, grease or other material.

7. Install rotor assembly (see Rotor Assembly Installation 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 -- Chassis).

10.Install nozzle pulley and nozzle to rear of outer housing (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--lb (14 to 20 N--m). Make sure that battery cover is secured.

4. Position end cap (item 5) between bearings on rotor shaft.

5. Install rotor shaft assembly into inner housing. Align tab on end cap (item 5) and slot in inner housing as rotor shaft assembly is being inserted into inner housing. Make sure that end cap and bearing are fully seated in housing bearing bore. Also, align holes in end cap with threaded holes in inner housing.

6. Install bearing cap (item 4) into inner housing (Fig.

8):

A. Slide bearing cap (item 4) into inner housing. Make sure that cap is fully installed onto rotor shaft bearing.

B. Apply Loctite #242 (or equivalent) to threads of flange head screws (item 4).

C. Secure bearing cap to inner housing with flange head screws (item 7). Torque screws from 90 to 100 in--lb (10.2 to 11.3 N--m).

D. After tightening screws, make sure that rotor shaft rotates freely.

1. Inner housing

2. Rotor shaft assembly

3. End cap

Figure 8

4. Bearing cap

5. Flange head screw

Blower

Assembly

ProForce Debris Blower Page 5 -- 11 Blower Assembly

Rev. C

Page 68

Nozzle Assembly

FRONT

RIGHT

45 to 50 in-- lb

(5.1 to 5.6 N-- m)

1. Nozzle

2. Nozzle clamp

3. V belt

4. Housing assembly

5. Flat washer (10 used)

6. R--clamp

7. Nozzle motor

8. Motor bracket

9. Cap screw (3 used)

10. Drive pulley

Figure 9

11. Lock nut

12. Cap screw (2 used)

13. Belt guard

14. Flange head screw (2 used)

15. Flat washer (2 used per bearing)

16. Cap screw

17. Flange nut (2 used)

18. Flange nut

19. Leaf spring

20. Bearing

21. Cap screw (2 used)

22. Flange nut (2 used)

23. Shoulder bolt

24. Lock nut

25. Nozzle pulley

26. Nozzle guide (4 used)

27. Lock nut

28. Socket head screw

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.

3. Loosen socket head screw and lock nut that secures ends of nozzle clamp. Remove clamp from nozzle and nozzle pulley.

4. Remove nozzle from outer housing.

5. Remove two (2) cap screws (item 21) andflange nuts (item 22) that secure leaf spring to motor bracket. Remove 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 BlowerPage 5 -- 12Blower Assembly

Page 69

7. Loosen cap screws and flange nuts that secure belt guard (item 13), route v--belt from behind guard and carefully remove belt from machine.

8. If necessary, remove nozzle guides, pulley bearings and nozzle pulley from 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. Place v--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 bracket from 200 to 230 in--lb (23 to 25 N--m) to set v-- belt tension (Fig. 10). Do not over tension belt. Hold bracket with the torque wrench and tighten two (2) flange head screws and flange nuts to secure belt adjustment and nozzle motor bracket.

4. Center belt guard around v--belt. Tighten cap screws and flange nuts to secure belt guard to machine.

5. If bearing was removed from leaf spring (Fig. 11), position bearing to leaf spring and secure with shoulder bolt and lock nut.

NOTE: When installing the leaf spring assembly, the leaf spring bearing mounting loops should be orientated up.

6. Position leaf spring assembly and flat washers (item

5) to bracket. Make sure that five (5) washers are placed between spring and bracket at each mounting hole. The bearing on the leaf spring should be centered on the outside of the v--belt. Secure leaf spring to motor bracket with two (2) cap screws (item 21) and flange nuts (item

22).

1. Drive pulley

2. Leaf spring assembly

1. Leaf spring

2. Lock nut

Figure 10

3. Flange head screw

4. Torque wrench access

Figure 11

3. Shoulder bolt

4. Bearing

Blower

Assembly

7. Fit nozzle and nozzle clamp to pulley. Tighten socket head screw and lock nut to secure nozzle to pulley. Torque fasteners from 45 to 50 in--lb (5.1 to 5.6 N--m).

8. 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 Page 5 -- 13 Blower Assembly

1. Outer housing

2. Nozzle pulley

3. Cap screw

Figure 12

4. Nozzle guide (4 used)

5. Flange nut

6. Spacer

Page 70

Inner Housing Assembly

SERIAL NUMBER BELOW 310000000 SHOWN

RIGHT

FRONT

Loctite #242

See text for

tightening

procedure

90 to 100 in-- lb

10 to 20 in-- lb

(10.2 to 11.2 N--m)

(1.2 to 2.2 N--m)

1. Inlet bell

2. Retaining ring

3. Wave washer (up to 3 used)

4. Front cap

5. Nut (LH thread)

6. Spacer

7. Rotor assembly

8. Washer (as needed)

Figure 13

9. Woodruff key

10. Stator vane (24 used)

11. Carriage screw (2 used)

12. Outer housing

13. Flange head screw (24 used)

14. Cap screw (8 used)

15. Flange head screw (8 used)

16. Nozzle pulley

17. Cap screw (2 used per guide)

18. Nozzle guide (4 used)

19. Flange nut (16 used)

20. Fan housing mount (2 used)

21. Carriage screw (2 used)

22. Flange nut (4 used)

23. Inner housing assembly

24. Spacer (2 used per guide)

NOTE: The rotor shaft and bearings can be serviced

without removing inner housing (item 23) from machine (see Rotor Shaft in this section). For replacement of the inner housing, stator vanes (item 10) or outer housing (item 12), the following procedure is necessary.

NOTE: ProForce Blowers have used three (3) methods of securing the inner and outer housings. On machines with serial number below 310000000 (Fig. 13), the inner housing is attached directly to the outer housing. Onmachines with serial number from 310000000 to 313000000, a fin spacer and possibly additional thin spacers exist between the inner housing flanges and the outer housing (Fig. 14). Machines with serial number above 313000000 use four (4) fin mounts with fin spacers and possibly additional thin spacers that are secured between inner housing and outer housing (Fig.

15). Refer to correct illustration when removing and installing inner and outer housings.

Rev. C

ProForce Debris BlowerPage 5 -- 14Blower Assembly

Page 71

Removal (Fig. 13)

1. Position machine on a firm, level surface. Make sure engine is stopped and remove key from the ignition switch. Chock wheels to prevent machine from moving.

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 section of Chapter 6 -- Chassis).

5. Remove blower drive shaft from machine (see Blower Drive Shaft Removal in this section).

6. Remove rotor assembly (see Rotor Assembly Removal in this section).

7. Remove cap screws and flange nuts that secure outer housing to fan housing mounts (item 20).

CAUTION

Figure 14

1. Inner housing assembly

2. Stator vane (24 used)

3. Fin spacer (4 used)

4. Thin spacer (as needed)

SERIAL NUMBER FROM 310000000

TO 313000000

5. Flange screw (8 used)

6. Flange screw (24 used)

7. Outer housing

Loctite #242

To prevent personal injury, make sure that fan housing assembly is properly supported as it is removed from the machine. Assembly weighs approximately 70 pounds (31.8 kg).

8. Lift fan housing assembly from machine and set on workbench with rotor shaft pointing straight up (Fig. 17).

9. Place inner housing on two (2) supports (2” x 4” or equivalent). Then, place 9/16” (14.3 mm) thick support between supports and outer housing (Fig. 16). This process will support f an housing assembly to prevent unexpected shifting of any components during disassembly.

10.Loosen, but do not remove, eight (8) screws (item

15) that secure inner housing to outer housing.

1 1. Remove flange head screw (item 13) that secures each stator vane (item 10) to outer housing. Carefully tilt vane to free vane lugs from inner housing and remove vane from assembly. Repeat for all twenty four (24) vanes. Inspect each vane to make sure that mounting lugs and screw threads are in good condition. Replace any vane that shows signs of damage or wear.

1. Inner housing

2. Outer housing

3. Fin spacer (4 used)

Figure 15

SERIAL NUMBER

ABOVE 313000000

4. Thin spacer (as needed)

5. Fin mount (4 used)

6. Cap screw (8 used)

Blower

Assembly

12.Fully remove screws (item 15) that secure inner housing to outer housing.

ProForce Debris Blower Page 5 -- 15 Blower Assembly

1. Support

2. 9/16” support

Rev. C

Figure 16

3. Outer housing

4. Mounting holes

Page 72

13.If equipped (machines with serial numbers above

310000000), locate and retrieve fin mounts, fin spacers and thin spacers from between inner housing and outer housing (Fig. 14 or 15). Note location of these components for assembly purposes.

14.Lift inner housing assembly out of the outer housing.

15.If necessary, disassemble inner housing assembly (see Rotor Shaft in this section).

Installation (Fig. 13)

1. Assemble inner housing if it was disassembled (see Rotor Shaft in this section).

2. Place inner housing assembly with the rotor shaft pointing upwards onto two (2) supports (2” x 4” or equivalent). Carefully lower outer housing around inner housing assembly. Then, place 9/16” (14.3 mm) thick support between supports and outer housing (Fig. 16). This process should allow alignment of mounting holes in inner housing flanges to outer housing.

3. On machines with serial numbers above 310000000, install fin mounts, fin spacers and thin spacers (if equipped) between inner housing and outer housing (Fig. 14 or 15).

NOTE: When assembling inner and outer housings, do not fully tighten any screws until all screws are installed to inner housing flanges and stator vanes. Also, use hand tools rather than air impact tools during assembly.

4. On machines with serial numbers above 313000000 (Fig. 15), apply Loctite #242 (or equivalent) to threads of screws used to secure inner and outer housings.

5. Make sure that holes in inner housing flanges align with outer housing holes. Install and finger tighten eight (8) screws (item 15) into threads of inner housing flanges. Do not fully tighten screws at this time.

6. Install stator vanes to inner and outer housing:

A. Position avane between inner and outer housing. Make sure that rounded end of vane is orientated toward rotor shaft (Fig. 17).

B. Tilt vane and engage vane lugs to inner housing holes. While keeping vane lugs in inner housing holes, rotate vane to align threaded hole of vane with outer housing hole.

C. Install and finger tighten flange head screw (item

12) into threads of vane. Do not fully tighten screw at this time.

ROUNDED

END

INTAKE

END

DISCHARGE

END

Figure 17

1. Outer housing

2. Inner housing assembly

3. Stator vane (24 used)

4. Flange head screw

5. Flange head screw

7. Tighten fasteners in the following order to secure assembly:

A. Use nutdriver to hand tighten the eight (8) screws (item 15) that secure inner housing flanges to outer housing. Use a crossing pattern while tightening the screws.

B. Use nutdriver to hand tighten the flange head screws (item 12) that secure the twenty-- four (24) stator vanes to outer housing. Use a crossing pattern while tightening the screws.

C. Torque flange head screws (item 15) that secure inner housing flanges to outer housing from 90 to 100 in--lb (10.2 to 11.2 N--m). Use a crossing pattern while torquing the screws.

IMPORTANT: DO NOT overtighten screws that secure stator vanes to outer housing. If screws are overtightened, threads in vanes could be damaged.

D. Torque screws (item 12) that secure stator vanes to outer housing from 10 to 20 in--lb (1.2 to 2.2 N--m). Use a c rossing pattern while torquing the screws.

D. Repeat process for all twenty--four (24) vanes.

Rev. C

ProForce Debris BlowerPage 5 -- 16Blower Assembly

Page 73

CAUTION

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).

10.Install blower drive shaft (see Blower Drive Shaft Installation in this section).

11. Install top grill to machine(see Guards Installation in the Service and Repairs section of Chapter 6 -- Chassis).

12.Install nozzle pulley and nozzle to rear of outer housing (see Nozzle Assembly Installation in this section).

8. Position outer housing assembly to machine. Secure outer housing to fan housing mounts with cap screws and flange nuts.

9. Install rotor assembly (see Rotor Assembly Installation in this section).

13.Connect negative battery cable to n egative b attery 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 Page 5 -- 17 Blower Assembly

Rev. C

Blower

Assembly

Page 74

This page is intentionally blank.

ProForce Debris BlowerPage 5 -- 18Blower Assembly

Page 75

Table of Contents

SPECIFICATIONS 2.............................

GENERAL INFORMATION 3.....................

Operator’s Manual 3..........................

Securing ProForce Debris Blower to Tow Vehicle 3

Electrical Power 3.............................

SERVICE AND REPAIRS 4......................

Wheels 4....................................

Wheel Hubs and Bearings 6....................

Guards 10...................................

Chapter 6

Chassis

ProForce Debris Blower Page 6 -- 1 Chassis

Chassis

Rev. B

Page 76

Specifications

Item Description

Tire s

Size 20 x 10 -- 8, 4 Ply, Tubeless Pressure 14 PSI (96.5 kPa)

Wheel Lug Nut Torque 70 to 90 ft--lb (95 to 122 N--m)

Rev. B

ProForce Debris BlowerPage 6 -- 2Chassis

Page 77

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 servicing 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

1. Tow vehicle hitch

2. Hitch pin

Figure 1

3. Hairpin clip

Chassis

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 6 -- 3 Chassis

Page 78

Service and Repairs

Wheels

RIGHT

FRONT

70 to 90 ft-- lb

(95 to 122 N-- m)

1. Main frame

2. Engine

Figure 2

3. Wheel hub assembly

4. Wheel and tire assembly

5. Lug nut (4 used per wheel)

Rev. B

ProForce Debris BlowerPage 6 -- 4Chassis

Page 79

Wheel Removal (Fig. 2)

Wheel Installation (Fig. 2)

1. Have ProForce Debris Blower attached to tow vehicle and park machines on a level surface. Engage vehicle 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. To prevent unexpected 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 secure wheel to be removed.

4. Jack or hoist ProForce blower from ground and support 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.

1. Position wheel to wheel hub on raised machine.

2. Secure wheel to ProForce blower with four (4) lug nuts.

WARNING

Failure to maintain proper lug nut torque could result in failure or loss of wheel and may result in 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--lb (14 to 20 N--m). Make sure that battery cover is secured.

ProForce Debris Blower Page 6 -- 5 Chassis

Chassis

Rev. B

Page 80

Wheel Hubs and Bearings

SERIAL NUMBER BELOW 310000000 SHOWN

See text for

tightening procedure

RIGHT

FRONT

27 to 33 ft-- lb

(37to44N--m)

1. Axle (2 used)

2. Grease seal

3. Bearing cone (2 used per axle)

4. Bearing cup (2 used per axle)

5. Wheel hub

6. Lug screw (4 used per hub)

7. Tab washer

8. Nut retainer

9. Flange nut (3 used per axle)

NOTE: Machines with serial number above 310000000

either use an axle mount that is fastened to the frame (Fig. 4) or have a suspension axle for road ready machines (Fig. 5). Wheel hub and bearing service is the same for all axle types.

Figure 3

10. Cotter pin

11. Jam nut

12. Dust cap

13. Carriage screw (3 used per axle)

Disassembly (Fig. 3)

1. Have ProCore Processor attached to tow vehicle and park machines on a level surface. Engage vehicle 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.

Rev. B

ProForce Debris BlowerPage 6 -- 6Chassis

Page 81

3. Jack or hoist blower from ground and support with jack stands (see Operator’s Manual and Jacking Instructions 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.

D. Lubricate the inside of new greaseseal and press it into the wheel hub.

E. If lug screws were removed from hub, press screws fully into hub.Make sure that lug screwflange is pressed fully to hub surface.

SERIAL NUMBER ABOVE 310000000 SHOWN

7. Remove nutretainer, jam nut and tabwasher that secure wheel hub tospindle. Slide wheel hub withbearings from spindle.

8. Disassemble wheel hub:

A. Remove grease seal from the wheel hub taking care to not damage the hub bore. Discard seal.

B. Remove bearing cones from both sides of wheel hub. Clean bearings in solvent. Clean inside of hub.

C. If necessary, remove bearing cups from hub.

D. Inspect wheelbearings. Check the bearing cones and bearing cups for wear, pitting or other damage. Replace worn or damaged parts.

E. If necessary, press lug screws from hub.

9. Inspect axle spindle for wear or damage. Replace axle if necessary. Refer to appropriate axle illustration for fastener torque values.

Assembly (Fig. 3)

27 to 33 ft-- lb

(37to44N--m)

1. Frame

2. Carriage screw

3. Axle

4. Flange nut

SUSPENSION AXLE SHOWN

Figure 4

27 to 33 ft-- lb

(37to44N--m)

5. Hub assembly

6. Lock nut

7. Carriage screw

8. Axle mount

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 Page 6 -- 7 Chassis

67 to 83 ft-- lb

(91 to 112 N--m)

1. Frame

2. Carriage screw

3. Axle

Rev. B

Figure 5

4. Lock nut

5. Hub assembly

Chassis

Page 82

3. Install the wheel hub onto the axle spindle taking care to not damage grease seal in hub.

7. Install wheel assembly (see Wheel Installation in this section).

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-lb (8.5 to 20.3 N--m) to seat bear- ings. Loosen nut until it is away from tab washer and hub has end play. Finally, while rotating hub, tighten jam nut from 15 to 20 in--lbs (1.7 to 2.3 N--m).

6. Install nut retainer and cotter pin to secure jam nut. Install dust cap to hub.

WARNING

Failure to maintain proper lug nut torque could result in failure or loss of wheel and may result in personal injury.

8. Carefully lower machine to ground. Make sure to properly torque wheel lug nuts from 70 to 90 ft--lb (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--lb (14 to 20 N--m). Make sure that battery cover is secured.

Rev. B

ProForce Debris BlowerPage 6 -- 8Chassis

Page 83

This page is intentionally blank.

Chassis

ProForce Debris Blower Page 6 -- 9 Chassis

Rev. B

Page 84

Guards

SERIAL NUMBER BELOW 311000000 SHOWN

RIGHT

FRONT

1. Cap screw (2 used)

2. Washer (2 used)

Figure 6

3. Flange nut (2 used)

4. Top grill

Rev. B

5. Side grill

6. Flange head screw (2 used)

ProForce Debris BlowerPage 6 -- 10Chassis

Page 85

Removal

1. Park machine on a level surface. Make sure engine is OFF. Chock wheels to prevent machine from moving.

SERIAL NUMBER ABOVE 311000000 SHOWN

CAUTION

The engine may be hot. Allow engine to cool before 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 machines requires removal of the blower driveshaft or engine.

Installation

1. Install removed guards from machine using Figs. 6 or 7 as a guide.

1. Cap screw (2 used)

2. Washer (2 used)

3. Flange screw (2 used)

4. Flange nut (2 used)

Figure 7

5. Muffler mount

6. Top grill

7. Tinnerman nut (2 used)

ProForce Debris Blower Page 6 -- 11 Chassis

Chassis

Rev. B

Page 86

This page is intentionally blank.

Rev. B

ProForce Debris BlowerPage 6 -- 12Chassis

Page 87

Table of Contents

ELECTRICAL SCHEMATICS

Model 44538 with Serial Number Below

310000000 3...............................

Models 44538 and 44539 with Serial Number

From 310000000 to 311999999 & Model 44542

(all Serial Numbers) 4.......................

Models 44538 and 44539 with Serial Number

Above 312000000 5.........................

ENGINE ELECTRICAL DIAGRAMS

Serial Number Below 310000000 6.............

Serial Number Above 310000000 7.............

CIRCUIT DRAWINGS

Control Module Wake Up 8.....................

Crank Circuits 9..............................

Run Circuits 10...............................

Engine Speed Increase Circuits 11...............

Nozzle Rotation Circuits 12....................

WIRE HARNESS DRAWINGS

Model 44538 with Serial Number Below

310000000 14..............................

Models 44538 and 44539 with Serial Number

From 310000000 to 311999999 & Model 44542

(all Serial Numbers) 16......................

Models 44538 and 44539 with Serial Number

Above 312000000 18........................

Chapter 7

Electrical Diagrams

ProForce Debris Blower Electrical DiagramsPage 7 -- 1

Rev. C

Electrical

Diagrams

Page 88

This page is intentionally blank.

ProForce Debris BlowerElectrical Diagrams Page 7 -- 2

Page 89

Rev. C

Page 7 -- 3

GRAY

YELLOW

GREEN

BLUE

FUSIBLE

RED/YELLOW

WHITE

PINK

GREEN

RED

BLACK

RED/WHITE

RED

GREEN

RED/YELLOW

RED

GREEN

GREEN/BLACK

BLACK

ORANGE/BLACK

BLACK

BLUE

GREEN

PINK

BLACK

GRAY

YELLOW/BLACK

GRAY

RED/WHITE

ENGINE

THROTTLE CONTROL

OIL PRESSURE SWITCH (GREEN)

ENGINE KILL (WHITE)

B+

START

FUEL SOLENOID OUT (RED)

FUEL SOLENOID (RED/WHITE)

GRAY

COIL POWER

GRAY

BATTERY

LINK

NOZZLE

INLINE FUSE (15A)

Electrical Schematic

All ground wires are black.

Below 310000000

Model 44538 with Serial Number

ProForce Debris Blower

Page 90

Rev. C

Page 7 -- 4

Electrical Schematic

All ground wires are black.

Model 44542 (all Serial Numbers)

From 310000000 to 311999999

Models 44538 and 44539 with Serial Number

ProForce Debris Blower

GREEN

BLUE

RED/YELLOW

WHITE

RED/WHITE

RED

GREEN

RED/YELLOW

RED/WHITE

GREEN/BLACK

BLACK

ORANGE/BLACK

GRAY

GREEN

PINK

BLUE

RED

YELLOW

GRAY

WHITE

GREEN

YELLOW

BROWN

WHITE

YELLOW

BROWN

BLUE GREEN PINK BLACK

GRAY

YELLOW/BLACK

Page 91

Rev. C

Page 7 -- 5

Electrical Schematic

All ground wires are black.

Above 312000000

Models 44538 and 44539 with Serial Number

ProForce Debris Blower

RED/WHITE

PINK

RED/YELLOW

GREEN

YELLOW

BROWN

WHITE

YELLOW

BROWN

WHITE

BROWN

BROWN WHITE

TAN

YELLOWRED

RED/YELLOW

GREEN

RED

BLUE

ORANGE

GREEN

WHITE

BLACK

GREEN

YELLOW

BLACK

PINK

BLACK

PINK

YELLOW

BLACK

RED/WHITE

PINK

GRAY

PINK

TAN

BLUE

TAN GREEN PINK BLACK GRAY

Page 92

Rev. C

Page 7 -- 6

Engine Electrical Diagram

Serial Numbers Below 310000000

All ground wires are black.

DLA2B (pinB DLA) DLA2A(pinCDLA) TX Diag Lamp Driver

GCU Power +12V

RX GROUND Speed Input Shutdown

GROUND

DLA1A(pinADLA)

DLA1B (pinD DLA)

1 2 3 4 5

6 7

8 9

10 11

12 13 14

A B

C D

A B

C D

WHITE

RED/YELLOW

RED

BLACK (GRD)

PINK

BROWN

GRAY

ORANGE

DIGITAL

RED/YELLOW

(30A)

RED/WHITE

GREEN

GRAY

RED

MACHINE

WIRE

HARNESS

LINEAR

ACTUATOR

(DLA)

GOVERNOR

CONTROL

UNIT

(GCU)

NOTE: THE OIL PRESSURE SWITCH IS NO RMALLYO PEN AND CLOSES WHEN ENGINE OIL PRESSURE EXISTS

ProForce Debris Blower

Page 93

Rev. C

Page 7 -- 7

Engine Electrical Diagram

Serial Numbers Above 310000000

All ground wires are black.

ProForce Debris Blower

DLA2B (pinB DLA)

DLA2A(pinCDLA) TX Diag Lamp Driver

GCU Power +12V

RX GROUND Speed Input Shutdown

GROUND

DLA1A(pinADLA)

DLA1B (pinD DLA)

1 2

3 4 5

6 7

8 9

10 11

12 13 14

A B

C D

A B

C D

WHITE

RED/YELLOW

RED

BLACK (GRD)

PINK

BROWN

GRAY

ORANGE

DIGITAL

MACHINE

WIRE

HARNESS

LINEAR

ACTUATOR

(DLA)

GOVERNOR

CONTROL

UNIT

(GCU)

NOTE: THE OIL PRESSURE SWITCH IS NO RMALLYO PEN AND CLOSES WHEN ENGINE OIL PRESSURE EXISTS

(30A)

123456

RED/YELLOW

RED/WHITE

GREEN

BLUE

RED

Page 94

Rev. C

Page 7 -- 8

GRAY

YELLOW

GREEN

BLUE

FUSIBLE

RED/YELLOW

WHITE

PINK

GREEN

RED

BLACK

RED/WHITE

RED

GREEN

RED/YELLOW

RED

GREEN

GREEN/BLACK

BLACK

ORANGE/BLACK

BLACK

BLUE

GREEN

PINK

BLACK

GRAY

YELLOW/BLACK

GRAY

RED/WHITE

ENGINE

THROTTLE CONTROL

OIL PRESSURE SWITCH (GREEN)

ENGINE KILL (WHITE)

B+

START

FUEL SOLENOID OUT (RED)

FUEL SOLENOID (RED/WHITE)

GRAY

COIL POWER

GRAY

BATTERY

LINK

RUN

START

OFF

Control Module Wake Up

Power Current Control Current Indicator/Gauge Cur rent

ProForce Debris Blower

Ignition Switch Turnedto START

IGNITION SWITCH

(ON ENGINE)

TURNED TO START

No Control Module LED’s Illuminated

Teste dt o Compl y

WithFCC Standar ds

FORHOMEOROFFICEUSE

Canada 3575APFB1

Model: 44538

N1625

Made in U.S .A.

NO BUTTONS PRESSED

CONTROL MODULE

REMOTE TRANSMITTER

LED’s

ILLUMINATED

No Remote Transmit ter Buttons Pressed

NOZZLE

INLINE FUSE (15A)

NOTE: THE DRAWING ON THIS PAGE USES THE ELECTRICAL SCHEMATICF ROM A MACHINE WITH A SERIAL NUMBER BELOW 310000000 TOSHOW THE

OPERATIONAL CIRCUITS.

Page 95

Rev. C

Page 7 -- 9

GRAY

YELLOW

GREEN

BLUE

FUSIBLE

RED/YELLOW

WHITE

PINK

GREEN

RED

BLACK

RED/WHITE

RED

GREEN

RED/YELLOW

RED

GREEN

GREEN/BLACK

BLACK

ORANGE/BLACK

BLACK

BLUE

GREEN

PINK

BLACK

GRAY

YELLOW/BLACK

GRAY

RED/WHITE

ENGINE

THROTTLE CONTROL

OIL PRESSURE SWITCH (GREEN)

ENGINE KILL (WHITE)

B+

START

FUEL SOLENOID OUT (RED)

FUEL SOLENOID (RED/WHITE)

GRAY

COIL POWER

GRAY

BATTERY

LINK

START

RUN

OFF

IGNITION SWITCH

(ON ENGINE)

IN RUN POSITION

Crank Circuits

Power Current Control Current Indicator/Gauge Cur rent

ProForce Debris Blower

Ignition Switch in RUN Position

Control Module LED’s Illuminated

Remote Transmitter ENGINE START Sequence Pr essed

ENGINE START

SEQUENCE

PRESSED

Teste dt o Compl y

WithFCCStandar ds

FORHOMEOROFFICEUSE

Canada 3575APFB1

Model: 44538

N1625

Made in U.S .A.

CONTROL MODULE

LED’S

ILLUMINATED

ENERGIZED

REMOTE TRANSMITTER

NOZZLE

INLINE FUSE (15A)

NOTE: THE DRAWING ON THIS PAGE USES THE ELECTRICAL SCHEMATICF ROM A MACHINE WITH A SERIAL NUMBER BELOW 310000000 TOSHOW THE OPERATIONAL CIRCUITS.

Page 96

Rev. C

Page 7 -- 10

GRAY

YELLOW

GREEN

BLUE

FUSIBLE

RED/YELLOW

WHITE

PINK

GREEN

RED

BLACK

RED/WHITE

RED

GREEN

RED/YELLOW

RED

GREEN

GREEN/BLACK

BLACK

ORANGE/BLACK

BLACK

BLUE

GREEN

PINK

BLACK

GRAY

YELLOW/BLACK

GRAY

RED/WHITE

ENGINE

THROTTLE CONTROL

OIL PRESSURE SWITCH (GREEN)

ENGINE KILL (WHITE)

B+

START

FUEL SOLENOID OUT (RED)

FUEL SOLENOID (RED/WHITE)

GRAY

COIL POWER

GRAY

BATTERY

LINK

START

RUN

OFF

IGNITION SWITCH

(ON ENGINE)

IN RUN POSITION

Run Circuits

Power Current Control Current Indicator/Gauge Cur rent

ProForce Debris Blower

Ignition Switch in RUN Position and Engine Running

Control Module LED’s Illuminated

No Remote Transmitter Buttons Being Pressed

NO BUTTONS PRESSED

Teste dt o Compl y

With FCCStanda r ds

FORHOMEOROFFICEUSE

Canada 3575APFB1

Model: 44538

N1625

Made in U.S .A.

CONTROL MODULE

LED’S

ILLUMINATED

ENERGIZED

REMOTE TRANSMITTER

NOZZLE

INLINE FUSE (15A)

NOTE: THE DRAWING ON THIS PAGE USES THE ELECTRICAL SCHEMATICF ROM A MACHINE WITH A SERIAL NUMBER BELOW 310000000 TOSHOW THE

OPERATIONAL CIRCUITS.

Page 97

Rev. C

Page 7 -- 11

GRAY

YELLOW

GREEN

BLUE

FUSIBLE

RED/YELLOW

WHITE

PINK

GREEN

RED

BLACK

RED/WHITE

RED

GREEN

RED/YELLOW

RED

GREEN

GREEN/BLACK

BLACK

ORANGE/BLACK

BLACK

BLUE

GREEN

PINK

BLACK

GRAY

YELLOW/BLACK

GRAY

RED/WHITE

ENGINE

THROTTLE CONTROL

OIL PRESSURE SWITCH (GREEN)

ENGINE KILL (WHITE)

B+

START

FUEL SOLENOID OUT (RED)

FUEL SOLENOID (RED/WHITE)

GRAY

COIL POWER

GRAY

BATTERY

LINK

START

RUN

OFF

IGNITION SWITCH

(ON ENGINE)

IN RUN POSITION

Engine Speed Increase Circuits

Power Current Control Current Indicator/Gauge Cur rent

ProForce Debris Blower

Ignition Switch in RUN Position and Engine Running

Control Module LED’s Illuminated

Remote Speed Increase Button Being Pressed

SPEED

BUTTON

PRESSED

Teste dt o Compl y

WithFCCStandar ds

FORHOMEOROFFICEUSE

Canada 3575APFB1

Model: 44538

N1625

Made in U.S .A.

CONTROL MODULE

ILLUMINATED

ENERGIZED

REMOTE TRANSMITTER

LED’S

INCREASE

PRESSED

NOZZLE

INLINE FUSE (15A)

NOTE: THE DRAWING ON THIS PAGE USES THE ELECTRICAL SCHEMATICF ROM A MACHINE WITH A SERIAL NUMBER BELOW 310000000 TOSHOW THE

OPERATIONAL CIRCUITS.

Page 98

Rev. C

Page 7 -- 12

GRAY

YELLOW

GREEN

BLUE

FUSIBLE

RED/YELLOW

WHITE

PINK

GREEN

RED

BLACK

RED/WHITE

RED

GREEN

RED/YELLOW

RED

GREEN

GREEN/BLACK

BLACK

ORANGE/BLACK

BLACK

BLUE

GREEN

PINK

BLACK

GRAY

YELLOW/BLACK

GRAY

RED/WHITE

ENGINE

THROTTLE CONTROL

OIL PRESSURE SWITCH (GREEN)

ENGINE KILL (WHITE)

B+

START

FUEL SOLENOID OUT (RED)

FUEL SOLENOID (RED/WHITE)

GRAY

COIL POWER

GRAY

BATTERY

LINK

START

RUN

OFF

IGNITION SWITCH

(ON ENGINE)

IN RUN POSITION

Nozzle Rotation Circuits

Power Current Control Current Indicator/Gauge Cur rent

ProForce Debris Blower

Ignition Switch in RUN Position and Engine Running

Control Module LED’s Illuminated

Remote Nozzle Rotate Button Pr essed

NOZZLE

BUTTON

PRESSED

Teste dt o Compl y

With FCCStanda r ds

FORHOMEOROFFICEUSE

Canada 3575APFB1

Model: 44538

N1625

Made in U.S .A.

CONTROL MODULE

ILLUMINATED

ENERGIZED

REMOTE TRANSMITTER

LED’S

ROTATE

PRESSED

NOZZLE

INLINE FUSE (15A)

NOTE: THE DRAWING ON THIS PAGE USES THE ELECTRICAL SCHEMATICF ROM A MACHINE WITH A SERIAL NUMBER BELOW 310000000 TOSHOW THE OPERATIONAL CIRCUITS.

Page 99

Rev. C

Page 7 -- 13

This page is intentionally blank.

Page 100

Rev. C

Page 7 -- 14

Wire Harness Drawing

NOZZLE

ROTATION

MOTOR

ProForce Debris Blower

Below 310000000

Model 44538 with Serial Number