Form No.
Revision History Revision Date Description -- 2008 Initial Issue. A 2009 Updated Engine chapter. B 2011 Updated Electrical chapter. C 2014 Updated Engine chapter. D 02/2018 Added revision history. © THE TORO COMPANY 2018 This document and all information contained herein is the sole property of The Toro Company (and/or its affiliated companies). No intellectual property rights are granted by the delivery of this document or the disclosure of its content.
Reader Comments The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we encourage user feedback. Please comment on the completeness, accuracy, organization, usability, and readability of this manual by an e-mail to servicemanuals@toro.
NOTES _
Part No. 08158SL (Rev. D) Service Manual ProForceR Debris 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.
This page is intentionally blank.
Table Of Contents Chapter 2 - Product Records and Maintenance Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equivalents and Conversions . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . 2222- 1 1 2 3 Chapter 3 - Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2 General Information . . . . . . . . . . . . . . . . . . . .
This page is intentionally blank.
Chapter 1 Safety Safety Table of Contents SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service . . . . . . . . . . . . . . . . . . . . SECURING PROFORCE DEBRIS BLOWER TO TOW VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JACKING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . .
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.
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. 7.
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.
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. 2 Safety 1 3 Figure 1 1. Tow vehicle hitch 2. Hitch pin 3. Hairpin clip Jacking Instructions CAUTION When changing tires or performing other service, use suitable hoists and jacks to support the ProForce Debris Blower.
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.
Chapter 2 Product Records and Maintenance Table of Contents 1 1 2 2 2 3 3 Product Records and Maintenance PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . Fastener Identification . .
Equivalents and Conversions 0.
Torque Specifications These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Service Manual. The following factors shall be considered when applying torque: cleanliness of the fastener, use of a thread sealant (e.g.
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series) Thread Size # 6 -- 32 UNC Grade 1, 5 & 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) in--lb in--lb N--cm 10 + 2 13 + 2 147 + 23 # 6 -- 40 UNF # 8 -- 32 UNC 13 + 2 25 + 5 282 + 30 # 8 -- 36 UNF # 10 -- 24 UNC 18 + 2 30 + 5 339 + 56 # 10 -- 32 UNF SAE Grade 5 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger N
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Fasteners) Class 8.8 Bolts, Screws and Studs with 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 + 5 in--lb 640 + 60 N--cm 78 + 7 in--lb 885 + 80 N--cm M6 X 1.0 96 + 9 in--lb 1018 + 100 N--cm 133 + 13 in--lb 1500 + 150 N--cm M8 X 1.25 19 + 2 ft--lb 26 + 3 N--m 27 + 2 ft--lb 36 + 3 N--m M10 X 1.
Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Thread Size 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 + 3 ft--lb 1/2 -- 13 UNC 75 + 15 ft--lb 50 + 10 ft--lb Recommended Torque** 7/16 -- 20 UNF Grade 5 65 + 10 ft--lb 88 + 14 N--m 1/2 -- 20 UNF Grade 5 80 + 10 ft--lb 108 + 14 N--m M12 X 1.25 Class 8.
Chapter 3 Engine Table of Contents ProForce Debris Blower Page 3 - 1 Rev. C Engine SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Electrical Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 5 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . .
Specifications Item Description Make / Designation Kohler, 4--cycle, V--Twin cylinder, OHV, air cooled, Model CH740S Bore x Stroke 3.27 in x 2.64 in (83 mm x 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.
General Information This Chapter gives information about specifications, maintenance, troubleshooting, testing and repair of the gasoline engine used in the ProForce Debris Blower. 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. Most repairs and adjustments require tools which are commonly available in many service shops.
This page is intentionally blank.
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. 1 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 1. Park machine on a level surface. Make sure engine is OFF.
Fuel Tank 6 RIGHT FRONT 7 5 4 SERIAL NUMBER BELOW 310000000 SHOWN 8 3 9 2 1 Figure 2 1. Frame 2. Foam strip (2 used) 3. Fuel tank 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 DANGER Because gasoline is highly flammable, use caution when storing or handling it. Do not smoke while filling the fuel tank.
Fuel Tank Removal (Figs. 2 and 4) 1. Park machine on a level surface with the engine 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. 2 3 3. Remove fuel from the fuel tank and into a suitable container. 5.
Engine RIGHT 6 FRONT 2 270 to 330 in--lb (31 to 37 N--m) 3 4 1 5 Figure 6 1. Frame 2. Engine Engine 3. Fuel tank 4. Flange nut (4 used) Page 3 -- 8 5. Flange head screw (4 used) 6.
Engine Removal (Fig. 6) 1. Park machine on a level surface with the engine not running and the ignition key removed from the key switch. Chock wheels to prevent machine from moving. 2. To prevent unexpected machine operation, 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.
9. Connect wire harness connectors to engine. Engine Installation (Fig. 6) 1. Position machine on a level surface. 2. Make sure that all parts removed from the engine during maintenance or rebuilding are properly installed to the engine. IMPORTANT: Take care to not damage the engine, fuel hoses, electrical harness or other parts while installing the engine. 3. Carefully position engine on machine frame. 4. Install four (4) flange head screws up through the frame and engine mounting holes.
Engine This page is intentionally blank. ProForce Debris Blower Page 3 -- 11 Rev.
Fuel Evaporative Control System (Serial Number Above 310000000) CHECK VALVE FUEL TANK TO ENGINE FITTING CARBON CANISTER FRESH AIR FILTER ENGINE Figure 11 ProForce blowers with serial number above 310000000 are equipped with a fuel evaporative control system (EVAP) designed to collect and store evaporative emissions from the fuel tank. The EVAP uses a carbon canister to collect these evaporative emissions. Fuel vapors from the fuel tank are vented to the canister where they are stored.
Disassembly DANGER Gasoline is flammable. Use caution when storing or handling it. Wipe up any spilled fuel before starting the engine. 2 1 4 1. Inspect carbon canister and attached hoses for damage or obvious leaks. A damaged or leaking canister should be replaced. 3 2. Remove components as needed using Figures 12 and 13 as guides. 5 A. If check valve (item 7 in Fig. 13) is removed, note direction of arrow on valve body for assembly purposes. Assembly Figure 12 1. Carbon canister 2. Fuel hose 3.
This page is intentionally blank. Engine Page 3 -- 14 Rev.
Chapter 4 Electrical System Table of Contents ProForce Debris Blower Page 4 -- 1 Rev. C Electrical System GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Electrical Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . 2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TROUBLESHOOTING . . . . . . . . . . . . . . . . . .
General Information This Chapter gives information about troubleshooting, testing and repair of the electrical system used in the ProForce Debris Blower. Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your ProForce Debris Blower machine. Refer to the Operator’s Manual for additional information when servicing the machine.
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.
Battery Hydrometer Use the battery hydrometer when measuring specific gravity of battery electrolyte. Obtain this tool locally.
Troubleshooting 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. For effective troubleshooting and repairs, there must be a good understanding of the electrical circuits (see Chapter 7 -- Electrical Diagrams) and components used on this machine. Starting Problems Problem Possible Causes Starter solenoid clicks, but starter will not crank. Battery is discharged.
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.
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.
Electrical System Quick Checks Battery Test (Open Circuit Test) Use a digital multimeter to measure the battery voltage. Voltage Measured Battery Charge Level Set the multimeter to the DC volts setting. The battery should be at a temperature of 60o to 100o F (16o to 38o C). The ignition switch should be in the OFF position 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.
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). CAUTION When testing electrical components for continuity with a multimeter (ohms setting), make sure that power to the circuit has been disconnected. Ignition Switch The ignition (key) switch used on the ProForce Debris Blower has three positions (OFF, RUN and START) .
Hour Meter The hour meter used on the ProForce Debris Blower records the amount of time that the engine is running. 00001 1. Make sure that ignition switch is OFF. HOURS 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. + Hobbs QUARTZ Testing 1 10 FRONT BACK Figure 7 3.
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). 3 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 2 1. Make sure that ignition switch is OFF. 2.
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. 2 Testing 1 1.
Relays 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.
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.
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 powered by three (3) AAA alkaline batteries.
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).
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). 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 engine.
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. 2.
Electrical System This page is intentionally blank.
Service and Repairs NOTE: See the Kohler Engine Service Manual (included at the end of Chapter 3 -- Engine) for engine electrical component repair information. Nozzle Motor 26 25 FRONT 18 3 RIGHT 4 1 20 2 16 20 16 21 19 24 15 23 15 13 14 6 20 5 17 12 7 9 11 10 22 8 Figure 25 1. 2. 3. 4. 5. 6. 7. 8. 9. Nozzle Nozzle clamp V belt Housing assembly Flat washer (10 used) R--clamp Nozzle motor Motor bracket Cap screw (3 used) 10. 11. 12. 13. 14. 15. 16. 17. 18.
1. Position machine on a firm, level surface. Make sure engine is stopped and remove key from the ignition switch. Chock wheels to prevent machine from moving. 2. To prevent unexpected machine operation, 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. Unplug wire harness connector from nozzle motor. 4.
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. 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. Leave battery cables disconnected if the battery is stored on the machine. Battery Care 1.
Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be extended. Additionally, battery and electrical component failure can be prevented. 1 RIGHT 2 FRONT 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. Electrolyte Specific Gravity Fully charged: 1.
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. Battery Testing 1. Conduct a hydrometer test of the battery electrolyte. IMPORTANT: Make sure the area around the cells is clean before opening the battery caps. A.
Battery Charging 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 Specific Gravity Open Circuit Voltage 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.
This page is intentionally blank.
Chapter 5 Blower Assembly Table of Contents Blower Assembly GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2 Operators Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Electrical Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4 Blower Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Rotor Assembly . . . . .
General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your ProForce Debris Blower machine. 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.
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.
Service and Repairs Blower Drive Shaft RIGHT FRONT Loctite #242 300 to 330 in--lb (34 to 37 N--m) 1 4 11 1 2 5 8 9 1 10 5 3 7 6 13 4 1 9 9 10 3 12 11 300 to 330 in--lb (34 to 37 N--m) Figure 2 1. 2. 3. 4. 5. Flange nut Fan hub Cap screw Spacer Spacer 6. 7. 8. 9. Flat washer Cap screw Drive coupling Flat washer 10. 11. 12. 13.
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. Secure drive couplings to drive shaft with cap screws and lock nuts using Figures 2 and 3 as guides. 2.
Rotor Assembly SERIAL NUMBER BELOW 310000000 10 9 See text for tightening procedure Loctite #242 8 7 6 5 2 3 4 11 1 12 RIGHT 13 FRONT Figure 4 1. 2. 3. 4. 5. Inlet bell Retaining ring Wave washer (up to 3 used) Front cap Nut (LH threads) 6. 7. 8. 9. Spacer Rotor assembly Woodruff key 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).
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. SERIAL NUMBER ABOVE 310000000 3 NOTE: Component parts for the rotor assembly are not available. If rotor damage exists, replace complete rotor assembly. Installation (Fig. 4) 1. Position woodruff key in slot in rotor shaft.
Rotor Shaft (Serial Number Below 313000000) 180 to 200 in--lb (21 to 23 N--m) 3 2 7 6 4 5 4 5 1 Loctite Product 641 8 SERIAL NUMBER BELOW 310000000 8 180 to 200 in--lb (21 to 23 N--m) 9 5 2 10 5 7 3 1 9 4 11 4 SERIAL NUMBER FROM 310000000 TO 313000000 Figure 6 1. 2. 3. 4. Cap screw (4 used) Bearing holder Rotor shaft Retaining ring 5. 6. 7. 8.
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. 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.
Rotor Shaft (Serial Number Above 313000000) Loctite #242 90 to 100 in--lb (10.2 to 11.3 N--m) 1 9 8 7 3 4 6 5 2 3 6 6 Loctite #242 90 to 100 in--lb (10.2 to 11.3 N--m) 7 Figure 7 1. Inner housing 2. Rotor shaft 3. Flange head screw (8 used) 4. Bearing cap 5. End cap 6. Retaining ring (4 used) 7. Bearing (2 used) 8. Rear cap 9. O--ring NOTE: The rotor shaft and bearings can be serviced without removing inner housing from machine. 5.
7. Install rotor assembly (see Rotor Assembly Installation in this section). 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 seated 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.
Nozzle Assembly FRONT 26 45 to 50 in--lb (5.1 to 5.6 N--m) RIGHT 25 18 3 4 2 20 28 1 16 27 20 15 23 15 16 13 21 19 24 14 6 20 5 17 12 7 9 8 11 10 22 Figure 9 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Nozzle Nozzle clamp V belt Housing assembly Flat washer (10 used) R--clamp Nozzle motor Motor bracket Cap screw (3 used) Drive pulley 11. 12. 13. 14. 15. 16. 17. 18. 19.
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. 1 8. If necessary, remove nozzle guides, pulley bearings and nozzle pulley from outer housing using Figures 9 and 12 as guides. 3 Installation (Fig. 9) 1. If removed, install nozzle pulley, pulley bearings and nozzle guides using Figures 9 and 12 as guides. 3. With a 3/8 in.
Inner Housing Assembly SERIAL NUMBER BELOW 310000000 SHOWN RIGHT 90 to 100 in--lb (10.2 to 11.2 N--m) 10 to 20 in--lb (1.2 to 2.2 N--m) FRONT 15 13 24 17 12 11 Loctite #242 10 9 See text for tightening procedure 18 8 7 6 19 5 20 4 2 16 3 21 23 1 22 14 Figure 13 1. 2. 3. 4. 5. 6. 7. 8. Inlet bell Retaining ring Wave washer (up to 3 used) Front cap Nut (LH thread) Spacer Rotor assembly Washer (as needed) 9. 10. 11. 12. 13. 14. 15. 16.
Removal (Fig. 13) 1. Position machine on a firm, level surface. Make sure engine is stopped and remove key from the ignition switch. Chock wheels to prevent machine from moving. 2. To prevent unexpected machine operation, 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. 6 5 7 4 3 2 1 3.
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. ROUNDED END 2 3 14.Lift inner housing assembly out of the outer housing. 15.If necessary, disassemble inner housing assembly (see Rotor Shaft in this section). INTAKE END Installation (Fig. 13) 1.
10.Install blower drive shaft (see Blower Drive Shaft Installation in this section). 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). 8. Position outer housing assembly to machine. Secure outer housing to fan housing mounts with cap screws and flange nuts. 12.Install nozzle pulley and nozzle to rear of outer housing (see Nozzle Assembly Installation in this section). 13.
This page is intentionally blank.
Chapter 6 Chassis Table of Contents Chassis 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications Item Description Tires Size Pressure 20 x 10 -- 8, 4 Ply, Tubeless 14 PSI (96.5 kPa) Wheel Lug Nut Torque Chassis 70 to 90 ft--lb (95 to 122 N--m) Page 6 -- 2 Rev.
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).
Service and Repairs Wheels RIGHT FRONT 2 70 to 90 ft--lb (95 to 122 N--m) 1 5 3 4 Figure 2 1. Main frame 2. Engine Chassis 3. Wheel hub assembly 4. Wheel and tire assembly Page 6 -- 4 Rev. B 5.
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. 1. Position wheel to wheel hub on raised machine. 2.
Wheel Hubs and Bearings SERIAL NUMBER BELOW 310000000 SHOWN See text for tightening procedure 13 1 6 5 9 RIGHT 3 11 FRONT 10 12 2 27 to 33 ft--lb (37 to 44 N--m) 3 4 7 8 Figure 3 1. 2. 3. 4. 5. Axle (2 used) Grease seal Bearing cone (2 used per axle) Bearing cup (2 used per axle) Wheel hub 6. 7. 8. 9. Lug screw (4 used per hub) Tab washer Nut retainer 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.
D. Lubricate the inside of new grease seal and press it into the wheel hub. 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. Jack or hoist blower from ground and support with jack stands (see Operator’s Manual and Jacking Instructions in Chapter 1 -- Safety). E.
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. 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). 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 bearings.
Chassis This page is intentionally blank. ProForce Debris Blower Page 6 -- 9 Rev.
Guards SERIAL NUMBER BELOW 311000000 SHOWN RIGHT FRONT 4 6 1 3 2 2 6 1 5 3 Figure 6 1. Cap screw (2 used) 2. Washer (2 used) Chassis 3. Flange nut (2 used) 4. Top grill Page 6 -- 10 Rev. B 5. Side grill 6.
Removal SERIAL NUMBER ABOVE 311000000 SHOWN 1. Park machine on a level surface. Make sure engine is OFF. Chock wheels to prevent machine from moving. 6 1 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 7 2 4 3 4 5 The engine may be hot.
This page is intentionally blank. Chassis Page 6 -- 12 Rev.
Chapter 7 Electrical Diagrams Table of Contents Electrical Diagrams 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 . . . . . . . . . . . . . . . . . . . . . . . . .
This page is intentionally blank.
B+ START BLUE FUEL SOLENOID OUT (RED) RED/WHITE FUEL SOLENOID (RED/WHITE) RED ENGINE KILL (WHITE) RED OIL PRESSURE SWITCH (GREEN) RED/WHITE GREEN COIL POWER GRAY GREEN RED/YELLOW THROTTLE CONTROL GRAY ENGINE NOZZLE BLUE GREEN GREEN WHITE PINK BLACK GRAY YELLOW/BLACK RED/YELLOW GREEN/BLACK BLACK GRAY ORANGE/BLACK GRAY BLACK RED BATTERY FUSIBLE LINK GRAY INLINE FUSE (15A) YELLOW PINK BLACK GREEN ProForce Debris Blower Model 44538 with Serial Number Below 310000000 Electrical S
GRAY BLUE RED RED/WHITE RED/WHITE GRAY GREEN GREEN GRAY RED/YELLOW GREEN WHITE BLUE GREEN PINK BLACK GRAY YELLOW/BLACK RED/YELLOW RED PINK YELLOW BLUE GREEN/BLACK BLACK GRAY ORANGE/BLACK ProForce Debris Blower Models 44538 and 44539 with Serial Number From 310000000 to 311999999 Model 44542 (all Serial Numbers) Electrical Schematic All ground wires are black. Page 7 -- 4 Rev.
BLACK BLUE BLUE RED BLACK PINK TAN RED/WHITE RED/WHITE GREEN BLACK PINK GREEN RED/YELLOW GREEN PINK GRAY YELLOW BLACK BLACK PINK WHITE BLACK YELLOW ORANGE TAN GREEN PINK BLACK GRAY RED/YELLOW RED YELLOW PINK TAN YELLOW BROWN WHITE WHITE BROWN BROWN YELLOW GREEN BROWN WHITE ProForce Debris Blower Models 44538 and 44539 with Serial Number Above 312000000 Electrical Schematic All ground wires are black. Page 7 -- 5 Rev.
A B C D A B C D BLACK (GRD) BROWN PINK 6 7 8 9 GCU Power +12V RX GROUND Speed Input Shutdown 10 11 12 13 14 GOVERNOR CONTROL UNIT (GCU) (30 A) ProForce Debris Blower Serial Numbers Below 310000000 Engine Electrical Diagram All ground wires are black. Page 7 -- 6 Rev.
A B A B C D C D BROWN PINK DLA 1A (pin A DLA) DLA 1B (pin D DLA) GROUND GCU Power +12V BLACK (GRD) RX GROUND Speed Input Shutdown 3 4 5 6 7 BLUE 1 2 GREEN DLA 2A (pin C DLA) TX Diag Lamp Driver RED DLA 2B (pin B DLA) RED/WHITE GRAY RED/YELLOW ORANGE DIGITAL LINEAR ACTUATOR (DLA) MACHINE WIRE HARNESS 6 5 4 3 2 1 6 5 4 3 2 1 8 9 10 11 12 13 14 RED NOTE: THE OIL PRESSURE SWITCH IS NORMALLY OPEN AND CLOSES WHEN ENGINE OIL PRESSURE EXISTS RED/YELLOW WHITE GOVERNOR CONTROL UNI
CONTROL MODULE Model: 44538 Tested to Compl y With FCC Standar ds FO R HOME OR O FFICE U S E B+ START BLUE FUEL SOLENOID OUT (RED) N 16 2 5 Canada 3575APFB1 Made in U.S .A.
CONTROL MODULE Model: 44538 Tested to Compl y With FCC Standar ds FO R HOME OR O FFICE U S E B+ START N 16 2 5 BLUE FUEL SOLENOID OUT (RED) Canada 3575APFB1 RED/WHITE FUEL SOLENOID (RED/WHITE) LED’S ILLUMINATED RED ENGINE KILL (WHITE) RED OIL PRESSURE SWITCH (GREEN) RED/WHITE GREEN COIL POWER GRAY GREEN RED/YELLOW THROTTLE CONTROL Made in U.S .A.
CONTROL MODULE Model: 44538 Tested to Compl y With FCC Standar ds FO R HOME OR O FFICE U S E B+ START N 16 2 5 BLUE FUEL SOLENOID OUT (RED) Canada 3575APFB1 RED/WHITE FUEL SOLENOID (RED/WHITE) LED’S ILLUMINATED RED ENGINE KILL (WHITE) RED OIL PRESSURE SWITCH (GREEN) RED/WHITE GREEN COIL POWER GRAY GREEN RED/YELLOW THROTTLE CONTROL ON ENERGIZED GRAY ENGINE ON NOZZLE BLUE GREEN OFF Made in U.S .A.
CONTROL MODULE Model: 44538 ON Tested to Compl y With FCC Standar ds FO R HOME OR O FFICE U S E B+ START N 16 2 5 BLUE FUEL SOLENOID OUT (RED) Canada 3575APFB1 RED/WHITE FUEL SOLENOID (RED/WHITE) LED’S ILLUMINATED RED ENGINE KILL (WHITE) RED OIL PRESSURE SWITCH (GREEN) RED/WHITE GREEN COIL POWER GRAY GREEN RED/YELLOW THROTTLE CONTROL ON ENERGIZED GRAY ENGINE ON NOZZLE BLUE GREEN OFF Made in U.S .A.
CONTROL MODULE Model: 44538 Tested to Compl y With FCC Standar ds FO R HOME OR O FFICE U S E B+ START N 16 2 5 BLUE FUEL SOLENOID OUT (RED) Canada 3575APFB1 ON RED/WHITE FUEL SOLENOID (RED/WHITE) RED ENGINE KILL (WHITE) RED OIL PRESSURE SWITCH (GREEN) COIL POWER GRAY GREEN RED/YELLOW ON ENERGIZED GRAY ENGINE ON NOZZLE BLUE GREEN OFF LED’S ILLUMINATED RED/WHITE GREEN THROTTLE CONTROL Made in U.S .A.
This page is intentionally blank. Page 7 -- 13 Rev.
NOZZLE ROTATION MOTOR ProForce Debris Blower Model 44538 with Serial Number Below 310000000 Wire Harness Drawing Page 7 -- 14 Rev.
BLUE PINK RED/WHITE GRAY RED GREEN GREEN PINK NOZZLE ROTATION MOTOR GREEN WHITE BLACK ORANGE/BLACK GREEN/BLACK RED/YELLOW BLUE BLUE GREEN PINK BLACK GRAY WHITE YELLOW/BLACK RED GRAY PINK BLACK YELLOW GRAY GREEN BLACK ProForce Debris Blower Model 44538 with Serial Number Below 310000000 Wire Harness Diagram Page 7 -- 15 Rev.
ProForce Debris Blower Models 44538 and 44539 with Serial Number From 310000000 to 311999999 Model 44542 (all Serial Numbers) Wire Harness Drawing Page 7 -- 16 Rev.
GRAY GRAY RED/WHITE GREEN GRAY GREEN WHITE BLUE BLACK ORANGE/BLACK GREEN/BLACK RED/YELLOW BLUE GREEN PINK BLACK GRAY YELLOW/BLACK BLUE GRAY RED YELLOW RED/WHITE ProForce Debris Blower Models 44538 and 44539 with Serial Number From 310000000 to 311999999 Model 44542 (all Serial Numbers) Wire Harness Diagram Page 7 -- 17 Rev.
ProForce Debris Blower Models 44538 and 44539 with Serial Number Above 312000000 Wire Harness Drawing Page 7 -- 18 Rev.
GREEN WHITE PINK BLACK BLACK PINK BLACK BLACK GRAY PINK RED/WHITE BLACK TAN PINK GREEN GRAY TAN PINK PINK RED/YELLOW YELLOW ORANGE GREEN GRAY PINK TAN BLACK BLUE RED/WHITE RED YELLOW BLACK ProForce Debris Blower Models 44538 and 44539 with Serial Number Above 312000000 Wire Harness Diagram Page 7 -- 19 Rev.
