Form No. 18237SL Rev B Pro Force® Debris Blower Models 44552, 44552TE, 44553 & 44554 © 2020—The Toro® Company 8111 Lyndale Avenue South Bloomington, MN 55420 Original Instructions (EN) Contact us at www.Toro.com.
Revision History Revision Date A 01/2019 Initial Issue B 05/2020 Added rotation gauge, digital hour meter, 2 schematics and 2 wire harness Revision History Description Page 2 Pro Force® Debris Blower 18237SL Rev B
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 e-mail: servicemanuals@toro.
Reader Comments Page 4 Pro Force® Debris Blower 18237SL Rev B
Preface This service manual was written expressly for service technicians. Basic shop safety knowledge and mechanical/electrical skills are assumed. The Toro Company has made every effort to make the information in this manual complete and correct. The purpose of this publication is to provide the service technician with information about troubleshooting, testing, and repairing major systems and components. This manual may also be specified for use on numerous products.
Service Procedure Icons The following icons appear throughout this Service Manual to bring attention to specific important details of a service procedure. Critical Process This icon is used to highlight: • installing safety equipment (shields, guards, seat belts, brakes and R.O.P.S.
Table of Contents Preface ................................................................................................................ 5 Chapter 1: Safety ............................................................................................ 1–1 Safety Instructions ....................................................................................... 1–2 Jacking Instructions ..................................................................................... 1–6 Safety and Instructional Decals .
Additional Reference Materials KOHLER Command Pro CH740 Service Manual Preface Page 8 Pro Force® Debris Blower 18237SL Rev B
Chapter 1 Safety Table of Contents Safety Instructions ................................................................................................................................ 1–2 Think Safety First ............................................................................................................................... 1–3 Jacking Instructions ..............................................................................................................................
Safety Instructions DANGER This safety symbol means danger. When you see this symbol, carefully read the instructions that follow. Failure to obey the instructions could kill or cause serious permanent injury or disability. WARNING This safety symbol means warning. When you see this symbol, carefully read the instructions that follow. Failure to obey the instructions can result in serious injury. CAUTION This safety symbol means caution.
Think Safety First Toro Products are tested and certified for compliance with existing safety standards and specifications. Although hazard control and accident prevention are partially dependent upon the design and configuration of the machine, hazard control and accident prevention are also dependent upon the awareness, concern and proper training of the personnel involved in the operation, transport, maintenance, and storage of the machine.
Think Safety First (continued) • Avoid injury to bystanders… • • • • • • • • • Safety: Safety Instructions Always clear the area of bystanders before starting or testing powered equipment. Avoid injury due to projectiles… Always clear the area of sticks, rocks or any other debris that could be picked up and thrown by the powered equipment. Avoid modifications… Never alter or modify any part unless it is a factory approved procedure.
Think Safety First (continued) Use the proper class of fire extinguisher in case of fire. Ensure fire extinguishers are serviced regularly, and replace any fire extinguishers that are discharged or in use beyond their expiration dates. – Class A fire extinguishers are for ordinary combustible materials such as paper, wood, cardboard, and most plastics. The numerical rating on these types of extinguishers indicates the amount of water it holds and the amount of fire it can extinguish.
Jacking Instructions CAUTION Failing to properly support the machine with appropriate jack stands can cause the machine to move or fall and can result in personal injury. When changing the attachments, tires, or performing other services, do the following steps: • Use correct blocks, hoists, and jacks to raise and support the machine. • Park the machine on a solid level surface, such as a concrete floor.
Chapter 2 Specifications and Maintenance Table of Contents Specifications ....................................................................................................................................... 2–2 Overall Dimensions............................................................................................................................ 2–2 Engine................................................................................................................................................
Specifications Overall Dimensions g274940 Figure 2 Specifications and Maintenance: Specifications Page 2–2 Pro Force® Debris Blower 18237SL Rev B
Engine Item Description Make/Designation Kohler CH740S, 2-cylinder, air cooled, OHV gasoline engine Bore x Stroke 83 x 67 mm (3.27 x 2.64 inches) Total displacement 725 cm3 (44 in3) Compression ratio 9.
Torque Specifications The recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in this Service Manual. These torque specifications for the installation and tightening of the fasteners will apply to all the fasteners which do not have a specific requirement identified in this Service Manual.
Calculating the Torque Values When Using a Drive-Adapter Wrench g205924 Figure 3 Torque Conversion Factor = A / B 1. Torque wrench 3. A (effective length of torque wrench) 2. Drive-adapter wrench (crowsfoot) 4. B (effective length of torque wrench and drive-adapter wrench) Using a drive-adapter wrench (e.g.
Identifying the Fastener g206089 Figure 4 Metric Bolts and Screws 1. Class 8.8 2. Class 10.9 g206088 Figure 5 Inch Series Bolts and Screws 1. Grade 1 2. Grade 5 3. Grade 8 Fasteners with a Locking Feature IMPORTANT If a fastener with a locking feature or previously applied thread locking compound is reused, clean the fastener threads and apply new thread locker to the fastener during installation. Locking features are designed to create friction and prevent a fastener from loosening.
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 - 24 UNC # 10 - 32 UNF Grade 1, 5 and 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs, and Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) in-lb in-lb N∙cm 10 ± 2 13 ± 2 147 ± 23 13 ± 2 25 ± 5 282 ± 56 18 ± 2 30 ± 5 339 ± 56 SAE Grade 5 Bolts, Screws, Studs, and Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts)
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners) Thread Size 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 ± 6 in-lb 644 ± 68 N∙cm 78 ± 8 in-lb 881 ± 90 N∙cm M6 X 1.0 96 ± 10 in-lb 1085 ± 113 N∙cm 133 ± 14 in-lb 1503 ± 158 N∙cm M8 X 1.25 19 ± 2 ft-lb 26 ± 3 N∙m 28 ± 3 ft-lb 38 ± 4 N∙m M10 X 1.
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 ± 3 ft-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 ± 5 in-lb No. 8 - 32 UNC 30 ± 5 in-lb No.
Shop Supplies The procedures found in this Service Manual may recommend the use of commonly used shop supplies (lubricants, sealants, and adhesives). A symbol denoting the use of a shop supply may appear in figures that support a procedure. Always refer to the written procedure for specific information regarding the type and the application of a shop supply. IMPORTANT Always follow manufacturers instructions when using or storing shop supplies.
Shop Supplies (continued) GASKET COMPOUND Used to create a seal between mating parts. Gasket compounds may be used with or without the presence of a pre-formed gasket. Gasket compounds may be solvent or silicone based, and cure when exposed to air or designed to cure in an air-less environment (anaerobic). Most gasket compounds are designed to be applied to clean surfaces free of oil, chemical residue and previously used gaskets or gasket compounds.
Special Tools Multimeter Obtain this tool locally The meter can test the electrical components and circuits for current, resistance, or voltage. Note: Use a digital multimeter when testing the electrical circuits. The high impedance (internal resistance) of a digital meter in the voltage mode ensures that the excess current is not allowed through the meter. This excess current can damage the circuits that are not designed to carry it. Battery Terminal Protector Toro Part No.
Offset Wrench Toro Part No. TOR6006 The offset wrench is used to tighten the nut that secures the blower rotor assembly to the fan shaft. Use with 1/2 inch torque wrench at right angle to the offset wrench handle to ensure that proper torque is applied to the nut. Shaft Alignment Tool Toro Part No. 137–6616 The shaft alignment tool is used to align the engine output shaft with the blower shaft if the engine, blower drive shaft, or blower assembly is removed.
Specifications and Maintenance: Special Tools Page 2–14 Pro Force® Debris Blower 18237SL Rev B
Chapter 3 Troubleshooting Table of Contents GEARS – The Systematic Approach to Defining, Diagnosing and Solving Problems ............................. 3–2 Gather Information ............................................................................................................................. 3–2 Evaluate Potential Causes ................................................................................................................. 3–2 Assess Performance.............................................
GEARS – The Systematic Approach to Defining, Diagnosing and Solving Problems Gather Information •Information reported by the customer •Information observed by you •Establish the what, where and when of the issue Evaluate Potential Causes Consider possible causes of the problem to develop a hypothesis •Narrow down the focus of the problem Assess Performance •Ensure you have all the necessary tools for testing •Test all potential causes of the failure •Reevaluate and create a new hypothesis if necessary Re
Using the Onboard Diagnostic Lamp Machines with wireless hand held remote control (Models 44552, 44552TE, and 44553) have a diagnostic light located on the control tower below the hour meter. The diagnostic light is an output of the Toro Electronic Controller (TEC) that indicates normal machine operation or the presence of active machine faults.
Entering Diagnostic Mode (continued) Note: If there are multiple machine faults active, each fault will flash followed by a long pause. After each active faults has been displayed, the fault sequence will repeat. If no active faults exist, the diagnostic light will flash continuously once per second.
Clearing Active Machine Faults 1. Resolve the active fault(s). 2. While in diagnostic mode (shunt connectors together), set the key switch to the RUN position. 3. Disconnect the diagnostic shunt connectors, then reconnect them. The diagnostic light will flash continuously once per second if all the active faults have been cleared. 4. Set the key switch to the OFF position. Exiting Diagnostic Mode 1. Set the key switch to the OFF position. 2.
Starting Problems Problem The starter solenoid clicks, but the starter does not crank Possible Cause Corrective Action The battery charge is low Charge the battery The battery is discharged or damaged Charge and test the battery Replace the battery if necessary Nothing happens when you attempt to start the engine using the key switch The battery cables are loose or corroded Clean and secure the battery cables The ground connection is loose or corroded Clean and secure the ground connections at th
Starting Problems (continued) Problem Possible Cause Models 44552, 44552TE, and 44553 – Nothing happens when you attempt to start the engine using the wireless remote Corrective Action Attempt to start the engine with the key switch.
General Operation Problems Problem The battery does not charge Possible Cause Corrective Action The battery cables are loose or corroded Clean and secure the battery cables The ground connection is loose or corroded Clean and secure the ground connections at the engine block The battery is discharged or damaged Charge and test the battery Replace the battery if necessary The in-line charging circuit fuse F-5 (30 A) is damaged Test the fuse and replace it if necessary; refer to Fuses in Chapter 5 –
General Operation Problems (continued) Problem The engine shuts off during operation Possible Cause Corrective Action Models 44552, 44552TE, and 44553 – The controller has switched to Power Save Mode after 2.
General Operation Problems (continued) Problem The nozzle does not rotate Possible Cause Corrective Action The drive belt is loose or damaged Adjust the drive belt or replace it as necessary; refer to the machine Operator’s Manual A nozzle relay is damaged Test nozzle relay 1 and nozzle relay 2 and replace them if necessary; refer to Component Testing in Chapter 5 – Electrical System The nozzle rotation motor is damaged Test the nozzle rotation motor and replace it if necessary; refer to Component T
General Operation Problems (continued) Problem The engine speed does not change Possible Cause Corrective Action Models 44552, 44552TE, and 44553 – The wireless remote is not functioning, (nozzle rotation control is not functioning also) Test the wireless remote batteries and replace them if necessary Make sure the batteries are properly installed; refer to Wireless Remote in Chapter 5 – Electrical System Re-establish “associate” remote control-to-base unit communication; refer to the machine Operator’
Troubleshooting: General Operation Problems Page 3–12 Pro Force® Debris Blower 18237SL Rev B
Chapter 4 Engine Table of Contents General Information .............................................................................................................................. 4–2 Operator’s Manual ............................................................................................................................. 4–2 Engine Owner’s Manual..................................................................................................................... 4–2 Engine Service Manual ............
General Information This chapter gives the information about specifications and repair of the Kohler Command Pro CH740 gasoline engine used in the Pro Force debris blower. Described adjustments and repairs require tools that are commonly available in many service shops. Service and repair parts for the engine in your Pro Force debris blower are supplied through your Authorized Toro Distributor. Be prepared to provide your distributor with the Toro Model and Serial Number of your machine to obtain parts.
Kohler Gasoline Engine g278566 Figure 7 1. Pulse style fuel pump 4. Fuel shut-off solenoid 2. Governor control unit (GCU) 5. Oil pressure switch 3. Voltage regulator/rectifier 6. Digital linear actuator (DLA) The engine includes an electronic speed control system. In addition to the necessary linkages, the speed control system includes a Governor Control Unit (GCU) and a Digital Linear Actuator (DLA). Electrical power must be available to the GCU for the engine to start and run.
Adjustments Aligning the Engine and Blower Drive Shafts g280938 Figure 8 1. Engine 3. Shaft alignment tool 2. Blower assembly 4. Collar (2 each) Align the engine output shaft with the blower shaft if the engine, blower drive shaft, or blower assembly is removed. 1. The fasteners securing the engine to the chassis should be installed finger tight. 2. Ensure a woodruff key is installed in the engine shaft and the blower shaft. 3.
Adjusting the Engine Idle Speed Refer to the Kohler Command CH740 Service Manual for additional information.
Service and Repairs Fuel Tank g275247 Figure 9 1. 2. Fuel tank Fuel tank cap 6. 7. Vent/rollover valve Grommet 11. 12. Fuel line – tank to filter Fuel filter 3. Tank strap (2 each) 8. Standpipe 13. Fuel line – filter to carburetor 4. Seal 9. Hose clamp (4 each) 14. Flange nut (4 each) 5. Fuel gauge Engine: Service and Repairs 10.
DANGER Gasoline fuel is highly flammable and explosive. A fire or an explosion from the fuel can burn you, burn other people, and damage property. • Use caution whenever you store or handle gasoline fuel. • Do not smoke while filling the fuel tank. • Do not fill the fuel tank while the engine is running, while the engine is hot, or when the machine is in an enclosed area. • Always fill the fuel tank outside and wipe up any spilled gasoline fuel before starting the engine.
Installing the Fuel Tank (continued) 1. Install any previously removed components on the fuel tank. 2. Position the fuel tank on the machine (fuel cap outward) and install the hold down straps and flange nuts. 3. Remove the covers and plugs from the hoses and fittings, then secure the fuel hoses to the tank fittings with the hose clamps. 4. If the fuel filter (item 12) was removed, ensure that the arrow on the filter body points toward the engine. 5. Fill the fuel tank with clean fuel and start the engine.
Fuel Evaporative Control System g275201 Figure 10 1. Fuel tank 6. Carbon canister 2. Grommet 7. Hose (3 each) 12. Hose clamp (4 each) 3. 4. Vent/rollover valve Hose clamp (8 each) 8. 9. Fresh air filter Hose – fresh air 13. 14. Fuel filter Purge valve 5. Hose – tank to carbon canister Hose – canister to filter 15. Hose – purge valve to manifold 10. 11.
Disassembling the Fuel Evaporative Control System (continued) DANGER Gasoline fuel is highly flammable and explosive. A fire or an explosion from the fuel can burn you, burn other people, and damage property. • Use caution whenever you store or handle gasoline fuel. • Do not smoke while handling gasoline. • Wipe up any spilled fuel before starting the engine. 1. Inspect the carbon canister and attached hoses for damage or obvious leaks. A damaged or leaking canister should be replaced. 2.
Engine g277842 Figure 11 1. Engine Woodruff key 17. Hardened washer (2 each) 2. Flange nut (4 each) 10. Engine shaft hub 18. Muffler mount 3. Top grill 11. Washer 19. Flange-head screw (2 each) 4. Flange nut (4 each) 12. Cap screw 20. Muffler 5. Rubber coupling spacer (4 each) 13. Flange-head screw (4 each) 21. Gasket (2 each) 6. Washer (4 each) 14. Flange nut (4 each) 22. Flange nut (4 each) 7. Cap screw (4 each) 15. Flange-head screw (4 each) 8.
Removing the Engine (continued) 1. Park the machine on a level surface, shut off the engine, and remove the key from the key switch. Block the wheels with chocks to prevent the machine from moving. 2. Remove the top grill. 3. Disconnect the negative battery cable from the battery terminal; refer to Servicing the Battery (page 5–37). CAUTION A hot engine and exhaust system can cause burns. Allow the engine and the exhaust system to cool before removing the engine. 4.
Removing the Engine (continued) g277747 Figure 12 1. Fuel supply hose 5. Multi-pin wire harness connector 2. Fuel pump 6. Flange-head screw 3. Fuel evaporative control hose 7. Lock washer 4. Positive battery cable 8. Negative battery cable 9. 10. Wire harness ground Engine ground 5. Disconnect the fuel evaporative control hose at the intake manifold. Cover or plug the disconnected hose and the intake manifold inlet to prevent fuel evaporative control system contamination. 6.
Removing the Engine (continued) CAUTION Use an appropriate lift and the lifting lugs provided to prevent the engine from falling and causing personal injury or product damage. The weight of the engine is approximately 53 kg (116 lb). 13. Carefully remove the engine from the machine. 14. Remove the muffler, muffler mount, and engine shaft hub if necessary. Installing the Engine Refer to Figure 11 for this procedure. 1. Ensure that all parts that were removed from the engine are properly installed. 2.
Installing the Engine (continued) 9. Secure the drive shaft to the hubs with the bolts, washers, and flange nuts. Tighten the drive shaft mounting fasteners to 34 to 37 N·m (25 to 27.5 ft-lb). 10. Secure the engine ground connector, wire harness ground, and negative battery cable to the engine with the screw and lock washer (Figure 12). Coat the ring terminals with Battery Terminal Protector; refer to Special Tools (page 2–12). 11. Connect the multi-pin wire harness connector to the engine. 12.
Engine: Service and Repairs Page 4–16 Pro Force® Debris Blower 18237SL Rev B
Chapter 5 Electrical System Table of Contents General Information .............................................................................................................................. 5–2 Operator’s Manual ............................................................................................................................. 5–2 Kohler Engine Electrical Components................................................................................................
General Information IMPORTANT Before performing any welding on the machine, turn the key switch to the OFF position. To prevent damage to the machine electrical system, disconnect the ground (-) cable from the engine when welding on the chassis. Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your Pro Force Debris Blower. Refer to the Operator’s Manual for additional information when servicing the machine.
Toro Wireless Modules (TWMs) Wireless controlled Pro Force Debris Blowers (Models 44552, 44552TE, and 44553) use Toro Wireless Modules (TWMs) to allow the operator to control the blower from the tow vehicle without the need for a tethered control box. There are two TWMs used on the machine. The first is a 240005 series RF2CAN (radio frequency to CAN) controller, and the second is a 240006 series wireless handheld remote control. The RF2CAN controller is attached to the machine control tower.
CAN-bus Communications The Toro Electronic Controller (TEC) and the Toro Wireless Modules (TWMs) used on wireless controlled Pro Force Debris Blowers (Models 44552, 44552TE, and 44553) communicate with each other on a Controller Area Network (CAN) bus system. Using this network integrates all the different electrical components of the machine and brings them together as one.
Electrical Schematics and Wire Harness Drawings/Diagrams Refer to the Electrical Schematics and Wire Harness Drawings/Diagrams in Appendix A (page A–1).
Electrical System Quick Checks Testing the Battery (Open Circuit Test) Use a multimeter to measure the voltage between the battery terminals; refer to Battery Test Table (page 5–6). Set the multimeter to the DC volts settings. The battery must be at a temperature of 16°C to 38°C (60°F to 100°F). Ensure that the key is in the OFF position and all the accessories are turned off. Connect the positive (+) multimeter lead to the positive battery post and negative (-) multimeter lead to the negative battery post.
Testing the Charging System (continued) Battery Voltage Table Charging System Performance: at least 0.50 V over the initial battery voltage Pro Force® Debris Blower 18237SL Rev B Initial battery voltage = 12.30 V Battery voltage after 3 minutes charge = 12.85 V Difference = +0.
Testing the Electrical Components For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g., disconnect the key switch connector before doing a continuity check of the switch). IMPORTANT When testing the electrical components for continuity with a multimeter (ohms setting), ensure that you disconnect the power to the circuit.
Fuses The individual control circuits are protected by a variety of fuses (F-1 – F-4) found in the fuse block located on the machine control tower next to the engine (Figure 14). g233941 Figure 14 1. Engine 2. Fuse block cover 3. Fuse block The engine wire harness includes a 30A in-line fuse (F-5) for charging circuit protection. The engine fuse is located near the starter motor (Figure 15). g233945 Figure 15 1. Pro Force® Debris Blower 18237SL Rev B Engine fuse 2.
Identification and Function g234233 Figure 16 1. Fuse F–1 (7.5 A) 3. Fuse F–3 (15 A) 2. Fuse F–2 (7.5 A) 4. Fuse F–4 (2 A) Models 44552, 44552TE, and 44553 • Fuse F–1 (7.5 A) protects the power supply to TEC outputs 1–3 • Fuse F–2 (7.
Can bus The machine controllers communicate with each other on a Controller Area Network (CAN) bus system. Using this network allows full integration of all the different electrical components of the machine, allowing them to operate together as one. Two specially designed, twisted wires form the CAN bus. These wires provide the data pathways between the components on the network. The engineering term for these cables are CAN High and CAN Low.
Toro Electronic Controller (TEC) (Models 44552, 44552TE, and 44553) g233944 Figure 18 1. Engine 4. Gray connector 2. TEC (Toro Electronic Controller) 5. Control tower 3. Green connector Wireless controlled Pro Force Debris Blowers (Models 44552, 44552TE, and 44553) use a Toro Electronic Controller (TEC) to manage machine electrical functions.
Toro Electronic Controller (TEC) (Models 44552, 44552TE, and 44553) (continued) TEC Digital Inputs INPUT NUMBER DESCRIPTION INPUT NUMBER DESCRIPTION DIN 1 Hour Meter and Engine Oil Pressure Switch DIN 6 Not Used DIN 2 Not Used DIN 7 Not Used DIN 3 Not Used DIN 8 Not Used DIN 4 Not Used KEY RUN Key Switch (RUN position) DIN 5 Not Used KEY START Key Switch (START position) OUTPUT NUMBER DESCRIPTION OUTPUT NUMBER DESCRIPTION THROTTLE CONTROL (PWM) Engine Governor Control Unit (GCU)
Toro Electronic Controller (TEC) (Models 44552, 44552TE, and 44553) (continued) g234237 Figure 19 1. Wire harness connectors P01 (gray) and P50 (green) 2. Toro Electronic Controller (TEC) Two color coded 12 pin wire harness connectors are attached to the controller. The connection terminal function for the controller and the wire harness connector pins are shown above. IMPORTANT The TEC wire harness connections are color coded.
Toro Wireless Module (TWM) RF2CAN (Models 44552, 44552TE, and 44553) g278908 Figure 20 1. 2. 3. Control tower RF2CAN module Antenna The RF2CAN module is a solid state electrical device used to convert radio frequency signals to and from the wireless handheld remote to CAN signals to and from the TEC. The RF2CAN module is only active when the key switch is in the RUN or START position. The RF2CAN module is mounted inside the machine control tower.
Toro Wireless Module (TWM) Handheld Remote (Models 44552, 44552TE, and 44553) g278931 Figure 21 1. Remote transmitter 4. Screws (6 each) 2. 3. LED AAA (1.5V) alkaline battery (4 used) 5. 6. Gasket Steel backer The handheld remote is a solid state electrical device that sends and receives radio frequency (RF) signals to and from the RF2CAN module. The handheld remote to RF2CAN module range should be approximately 4.6 m (15 ft).
Key Switch (for Models 44552, 44552TE, and 44553) g279128 Figure 22 1. 2. Control tower POSITION CLOSED CIRCUITS OFF 1 + 6, 4 + 5 RUN 1+3+4+5+6 START 1+2+4+5+6 Key switch The key switch on the machine control tower has three (3) positions − OFF, RUN and START. The key switch is an input used by the TEC and RF2CAN module to manage various machine functions. The key switch is part of the Energize to Run (ETR) circuit.
Testing the Key Switch (continued) 4. Use a multimeter (ohms setting) and the preceding table to determine whether continuity exists between the various terminals for each switch position. 5. Replace the switch if necessary. 6. If the switch tests correctly and a circuit problem still exists, check the wire harnesses; refer to Appendix A (page A–1). 7. Install the switch and connect the wire harness after testing. 8. Connect the battery negative (-) cable at the battery.
Key Switch (for Model 44554) g235608 Figure 23 1. Key switch 2. POSITION CLOSED CIRCUITS OFF NONE RUN B + C + F, D + E START A+B+C Tether control box The key switch on the tether control box has three (3) positions − OFF, RUN and START. Testing the Key Switch 1. Park the machine on a level surface and stop the engine. 2. Disconnect the battery negative (-) cable at the battery. 3. Remove the tether control box cover and disconnect the wire harness connector from the switch.
Hour Meter g233942 Figure 24 1. 2. Control tower Hour meter The hour meter used on the Pro Force Debris Blower records the amount of time that the engine is running. Testing the Hour Meter 1. Park the machine on a level surface and stop the engine. 2. Disconnect the battery negative (-) cable at the battery. 3. Disconnect the wire harness connector from the hour meter and remove the hour meter from the control tower if necessary. 4.
Nozzle Direction Switch (for Model 44554) g235609 Figure 25 1. Nozzle direction switch 2. POSITION CLOSED CIRCUITS RAISE or FORWARD 2 + 3, 5 + 6 OFF NONE LOWER or REVERSE 2 + 1, 5 + 4 Tether control box When the left side of the nozzle direction switch is pressed and held, the nozzle rotates in the counterclockwise direction. When the right side of the nozzle direction switch is pressed and held, the nozzle rotates in the clockwise direction.
Engine Speed Control (for Model 44554) g235611 Figure 26 1. Engine speed control 2. Tether control box The engine speed control is a potentiometer located in the tether control box, and is used to control the engine speed (RPM). Testing the Engine Speed Control 1. Park the machine on a level surface and stop the engine. 2. Disconnect the battery negative (-) cable at the battery. 3. Remove the tether control box cover and disconnect the wire harness connector from the switch.
Testing the Engine Speed Control (continued) B. Measure the resistance between the terminals A and C and then measure the resistance between the terminals A and B. Record these resistances. The total of the 2 measured resistances should be approximately 10,000 ohms. C. Rotate the speed control knob and repeat step B 5. Replace the speed control if necessary. 6. If the speed control tests correctly and a circuit problem still exists, check the wire harness; refer to Appendix A (page A–1). 7.
Relays g234235 Figure 28 Start relay 4. Nozzle relay 2 2. Control tower 5. Nozzle relay 1 3. Main power relay 1. The electrical system of the Pro Force Debris Blower uses 4 identical electrical relays that have 5 terminals. A tag near the relay wire harness connector can be used to identify each relay. The main power relay is used to provide electrical power to the machine. When the key switch is in the RUN or START position, the main power relay is energized.
g235610 Figure 29 1. Relay 2. Tether control box Note: Model 44554 machines have an additional 5 terminal relay located in the tethered control box. This relay is not presently being used. Testing the Relays 1. Park the machine on a level surface and stop the engine. 2. Disconnect the battery negative (-) cable at the battery. 3. Locate the relay to be tested and disconnect the wire harness connector from the relay. Remove the relay from the control tower if necessary.
Testing the Relays (continued) A. Check the coil resistance between the terminals 85 and 86 with a multimeter (ohms setting). The resistance must be approximately 70 to 90 ohms. B. Connect the multimeter leads to the relay terminals 30 and 87. Then ground terminal 85 and apply +12 VDC to terminal 86. The relay should make and break the continuity between terminals 30 and 87 as +12 VDC is applied and removed from terminal 86. C. Connect the multimeter leads to the relay terminals 30 and 87A.
CAN bus Terminator Resistors g223018 Figure 31 1. 2. CAN-bus terminator resistor Keyway The system communication between the electrical components on the Pro Force Debris Blower is accomplished on a CAN bus communication system. The 2 specially designed, twisted cables form the bus for the network are used on the machine. These wires provide the data pathways between the machine components. The engineering term for these cables are CAN High and CAN Low.
Testing the CAN bus Terminator Resistor (continued) 5. If the resistor tests correctly and a circuit problem still exists, check the remainder of the CAN bus; refer toAppendix A (page A–1) or contact an Authorized Toro Distributor for assistance. 6. After testing, ensure that the CAN bus terminator resistor is fully installed into the wire harness connector and secured to the wire harness with cable tie.
Diagnostic Lamp (for Models 44552, 44552TE, and 44553) g279250 Figure 32 Diagnostic Lamp (LED) 4. Hex hut 2. Gasket 5. Red wire (+) 3. Lock washer 6. Black wire (-) 1. Machines with wireless remote control have an LED diagnostic light located on the machine control tower. The TEC controller uses the diagnostic light (output) to notify the operator or the service technician of an issue that may exist with the machine; refer to Using the Onboard Diagnostic Lamp (page 3–3).
Nozzle Motor The motor used to rotate the nozzle is a reversible 12 VDC electric motor with an integrated gear box. The assembly components are not serviceable separately. g279312 Figure 33 1. Nozzle motor assembly 2. Nozzle motor connector Testing the Nozzle Motor 1. Make sure that key switch is in the OFF position. 2. Disconnect the nozzle motor connector from the wire harness. 3. Connect a 12 VDC power source (machine battery) to the nozzle motor terminals.
Service and Repairs Note: Refer to the Kohler Engine Service Manual (included at the end of Engine (page 4–11)) for engine electrical component repair information.
Nozzle Motor g233406 Figure 34 1. Nozzle 10. Nozzle motor 2. Nozzle clamp 11. Bolt (3 each) 20. Locknut 3. V-belt 12. Motor bracket 21. Leaf spring 4. Bolt (6 each) 13. Flange nut (4 each) 22. Shoulder bolt 5. Spacer (8 each) 14. Flange-head screw (2 each) 23. Flat washer (10 each) 6. Nozzle pulley 15. Drive pulley 24. Flat washer (4 each) 7. Nozzle guide (4 each) 16. Locknut 25. Bolt (2 each) 8. Outer housing 17. Belt guard 9. Flange nut (10 each) 18.
Removing the Nozzle Motor (continued) 6. Loosen the 2 flange-head screws (item 14) and 2 flange nuts that secure the nozzle motor bracket to the outer housing. Rotate the bracket and nozzle motor to loosen the V-belt. 7. Loosen the 2 bolts and 2 flange nuts that secure the belt guard (item 17), route V-belt from behind guard and carefully remove the belt from the machine. Note: The nozzle motor shaft is tapered. 8. Use appropriate puller to remove the drive pulley from the nozzle motor. 9.
Installing the Nozzle Motor (continued) 9. Connect the battery negative (-) cable at the battery. 10. Test the nozzle rotation before returning the machine to service.
Caring for the Battery 1. The battery-electrolyte level must be properly maintained. The top of the battery must be kept clean. If the machine is stored in a location where the temperatures are extremely high, the battery will discharge more rapidly than if the machine is stored in a location where the temperatures are cool. WARNING • Wear safety goggles and rubber gloves when working with electrolyte. • Charge battery in a well ventilated place so gasses produced while charging can dissipate.
Storing the Battery If you store the machine for more than 30 days: 1. Remove the battery and charge it fully; refer to Charging the Battery (page 5–42). 2.
Servicing the Battery g279482 Figure 36 1. Battery 4. Battery negative (-) cable 2. Battery positive (+) cable 5. Engine and chassis ground 3. Starter motor Battery Specifications Battery-electrolyte specific gravity Fully Charged: 1.25 to 1.28 at 27°C (80°F) Discharged: less than 1.24 Battery specifications BCI Group 26 540 CCA at -18°C (0°F) Reserve Capacity of 80 minutes at 27°C (80°F) Battery dimensions (including terminal posts and caps) Length 22.4 cm (8.8 inches) Width 16.8 cm (6.
CAUTION Battery-electrolyte is corrosive and can burn skin and eyes and damage clothing. While working with the batteries, use extreme caution to avoid splashing or spilling of the electrolyte. Always wear the safety goggles and a face shield while working with batteries.
Removing and Installing the Battery g234239 Figure 37 Pro Force® Debris Blower 18237SL Rev B 1. Hairpin cotter (2 each) 7. Control tower 2. Battery cover 8. Carriage screw 3. Battery 9. Battery cover bracket 4. Battery positive (+) cable 10. Bolt (2 each) 5. Flange nut 11. Clip (2 each) 6. Battery retainer 12.
Removing and Installing the Battery (continued) IMPORTANT Be careful when removing the battery cables and ensure that you do not damage the terminal posts or cable connectors. 1. Park the machine on a level surface, shut off the engine, and remove the key from the key switch. Block the wheels with chocks to prevent the machine from moving. 2. Remove the battery cover. 3. Loosen and remove the negative (-) cable from the battery. Position the disconnected cable away from the battery. 4.
Inspecting, Maintaining, and Testing the Battery (continued) 1. Inspect the battery as follows: A. Check for cracks. Replace the battery if cracked or leaking. B. Check the battery terminals for corrosion. Use the wire brush to clean corrosion from the posts. IMPORTANT Before cleaning the battery, tape or block the vent holes of the filler caps and ensure that the caps are secure. C.
Inspecting, Maintaining, and Testing the Battery (continued) 3. Do a high-discharge test with an adjustable load tester. This is a very reliable means of testing a battery as it simulates the battery cold-cranking capacity. A commercial battery load tester is required to do this test. CAUTION Follow the manufacturer's instructions when using a battery load tester. A. Check the voltage across the battery terminals before testing the battery. If the voltage is less than 12.
Charging the Battery (continued) Battery Charge Rate Battery Reserve Capacity (Minutes) Battery Charge Level (Percent of Fully Charged) 75% 50% 25% 0% 80 or less 3.8 hrs @ 3 A 7.5 hrs @ 3 A 11.3 hrs @ 3 A 15 hrs @ 3 A 81 to 125 5.3 hrs @ 4 A 10.5 hrs @ 4 A 15.8 hrs @ 4 A 21 hrs @ 4 A 126 to 170 5.5 hrs @ 5 A 11 hrs @ 5 A 16.5 hrs @ 5 A 22 hrs @ 5 A 171 to 250 5.8 hrs @ 6 A 11.5 hrs @ 6 A 17.
Charging the Battery (continued) Note: 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 3 consecutive readings.
Chapter 6 Blower Assembly Table of Contents General Information .............................................................................................................................. 6–2 Service and Repairs ............................................................................................................................. 6–3 Blower Drive Shaft .............................................................................................................................
General Information The Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your Pro Force Debris Blower. Refer to the Operator’s Manual for additional information when servicing the machine.
Service and Repairs CAUTION To ensure that the machine operation does not occur unexpectedly, disconnect the negative battery cable from the battery before performing any machine service; refer to Servicing the Battery (page 5–37).
Blower Drive Shaft g233401 Figure 38 1. 2. 6. 7. Drive Shaft Bolt (2 each) Bolt Coupling spacer (2 each) 11. 12. Fan hub Woodruff key 13. Engine hub and coupling assembly 3. Bolt (2 each) 8. Flange nut (4 each) 4. Washer (4 each) 9. Washer 5. Drive coupling (2 each) 10. Coupling spacer (2 each) Note: The shaft hub and coupling assemblies used between the drive shaft and the engine shaft are comprised of the same components.
Removing the Blower Drive Shaft (continued) 4. Remove the bolts, washers, and flange nuts that secure the drive shaft assembly to the hubs on the engine shaft and blower shaft. 5. Lift the drive shaft assembly from the machine. 6. Disassemble the drive couplings from the drive shaft. For assembly purposes, note the differences in the coupling spacers. 7. Inspect the drive couplings for damage and replace if necessary. 8. If necessary, remove the hubs from the engine shaft or blower shaft as follows: A.
Replacement Blower g280438 Figure 39 1. Replacement blower assembly 11. Rear fan mount 2. Retaining ring 12. Nozzle guide (2 each) 3. Wave washer 13. Spacer (4 each) 4. Front cap 14. Washer (2 each) 5. Weld seam 15. Ball bearing 6. Inlet bell 16. Cap screw 7. Front fan mount 17. Cap screw (3 each) 8. Cap screw (8 each) 18. 3/8–16 eye bolt (lift point) 9. Washer (8 each) 19. Jam nut 10.
Assembling a Replacement Blower Refer to Figure 39 for this procedure. 1. Install the front cap, wave washer, and retaining ring. 2. Locate the weld seam on the blower outer housing. Install the inlet bell and the front fan mount so the fan mount is centered over the weld seam. Move the fan mount all the way to the right in its mounting slots (counterclockwise) and secure all of the inlet bell fasteners. Note: A ball bearing is installed on 1 of the nozzle guide fasteners. 3.
Rotor Assembly g280191 Figure 40 1. Retaining ring 5. Outer tab washer 9. Woodruff key 2. Wave washer 6. Inner tab washer 10. Washer (A/R) 11. Rotor shaft 3. Front cap 7. Spacer 4. Hex nut (left-hand threads) 8. Rotor assembly Removing the Rotor Assembly Refer to Figure 40 for the for this procedure. 1. Remove the blower drive shaft from the machine; refer to Removing the Blower Drive Shaft (page 6–4). 2. Remove the retaining ring (item 1), wave washer, and front cap from the shaft.
Removing the Rotor Assembly (continued) Note: The rotor assembly components are not available separately. If rotor damage occurs, replace the complete rotor assembly. Installing the Rotor Assembly Refer to Figure 40 for the for this procedure. Note: Washers (item 10) are used to prevent the rotor from contacting the rotor housing assembly. Typically, 2 washers are necessary. 1. Install the same number of washers previously removed from the rotor shaft. 2.
Rotor Shaft g280307 Figure 42 1. Flange-head screw (8 each) 5. End cap 9. Nozzle clamp 2. Front bearing cap 6. O-ring 10. Nozzle 3. Retaining ring (4 each) 7. Rear bearing cap 11. Rotor shaft 4. Bearing (2 each) 8. Center plate Note: The rotor shaft and bearings can be serviced without removing the inner housing from the machine. Removing the Rotor Shaft Refer to Figure 42 for this procedure. 1. Remove the rotor assembly; refer to Removing the Rotor Assembly (page 6–8). 2.
Removing the Rotor Shaft (continued) 7. Inspect the rotor shaft, bearing bores of the bearing caps, and bearings for wear or damage, and replace the parts as necessary. Installing the Rotor Shaft Refer to Figure 42 for this procedure. 1. Install the inner retaining rings into the rotor shaft grooves if they were removed. 2. Install the bearings onto the rotor shaft by pressing on the inner race of the bearing. Ensure that the bearings are seated against the inner retaining rings. 3.
Inner Housing Assembly g280705 Figure 43 1. Inner housing assembly 4. Cap screw (8 each) 7. 3/8–16 eye bolt (lift point) 2. Stator vane (24 each) 5. Support fin (4 each) 8. Jam nut 3. Flange-head screw (24 each) 6. Shim – 0.030 inch (as required) Note: The rotor shaft and bearings can be serviced without removing the inner housing from the blower assembly; refer to Rotor Shaft (page 6–10). Removing Inner Housing Components Refer to Figure 43 for this procedure. 1.
Removing Inner Housing Components (continued) 4. Disconnect the nozzle motor from the machine wire harness and remove the fasteners that secure the blower assembly to the machine frame. Remove the blower assembly from the machine. 5. Remove the nozzle motor bracket assembly, nozzle pulley, and rear fan mount from the blower assembly; refer to Removing the Nozzle Assembly (page 6–16). 6. Position the blower assembly on supports with the rotor shaft pointing up. Place 14.
Installing Inner Housing Components (continued) 1. Assemble the inner housing if it was disassembled; refer to Installing the Rotor Shaft (page 6–11). 2. Position the inner housing assembly on supports with the rotor shaft pointing up. Carefully lower the outer housing around inner housing assembly. Place 14.3 mm (9/16 inch) thick spacers between the supports and the outer housing.
Installing Inner Housing Components (continued) 6. Install the rear fan mount, nozzle pulley, and nozzle motor bracket assembly to the blower assembly; refer to Installing the Nozzle Assembly (page 6–17). CAUTION The blower assembly weighs approximately 50 kg (110 lbs). Use an appropriate lifting device when moving the blower assembly. 7. Temporarily install a 3/8–16 eye bolt and jam nut in the blower shaft end for lifting the blower assembly. 8.
Nozzle Assembly g280635 Figure 45 1. Nozzle 7. Cap screw (6 each) 13. Button head screw (4 each) 2. Nozzle clamp 8. Cap screw (2 each) 14. Indicator – red 3. Nozzle pulley 9. Flat washer (4 each) 15. Flange nut (4 each) 4. Nozzle motor bracket assembly 10. Ball bearing (2 each) 16. Indicator – green 5. Cap screw (2 each) 11. Spacer (8 each) 17. Rotation gauge 6. Flange nut (10 each) 12. Nozzle guide (4 each) 18.
Installing the Nozzle Assembly Refer to Figure 45 for this procedure. 1. Assemble the nozzle motor bracket assembly if necessary. Note: When installing the leaf spring assembly, the flat side of the leaf spring should be downward. The bearing on the leaf spring assembly should be centered on the outside of the V-belt. g280657 Figure 46 1. Nozzle motor 9. Belt guard 2. Motor bracket 10. Flat washer (10 each) 3. Flange-head screw (3 each) 11. Shoulder bolt 4. Flange nut (4 each) 12.
Installing the Nozzle Assembly (continued) 5. Use the square hole provided and a 3/8 inch drive torque wrench to pivot the motor bracket assembly to 23 to 25 N∙m (200 to 230 in-lb). Hold the motor bracket in position and tighten the 2 flange-head screws and flange nuts to secure the nozzle motor bracket assembly. Refer to the machine Operator’s Manual for additional information. 6. Check and adjust the belt guard around the V-belt as necessary. 7. Install the nozzle and the nozzle clamp.
Chapter 7 Chassis Table of Contents General Information .............................................................................................................................. 7–2 Service and Repairs ............................................................................................................................. 7–3 Wheels ...............................................................................................................................................
General Information The Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your Pro Force Debris Blower. Refer to the Operator’s Manual for additional information when servicing the machine.
Service and Repairs Wheels g233390 Figure 47 Models 44552, 44552TE, and 44554 shown 1. Main frame 3. Wheel-lug nut (4 each wheel) 5. Wheel hub assembly 2. Fender 4. Wheel and tire assembly 6. Axle mount Removing the Wheel 1. Have the Pro Force Blower attached to a tow vehicle and park the machines on a level surface. Engage the vehicle parking brake, shut off the engine, and remove the key from the key switch. Ensure that the blower engine is shut off.
Installing the Wheel (continued) WARNING Failure to maintain proper torque could result in failure or loss of wheel and may result in personal injury. Maintain the proper torque of the wheel-lug nuts. 3. Lower the machine to the ground and tighten the lug nuts to 95 to 122 N∙m (70 to 90 ft-lb) in a crossing pattern.
Wheel Hubs and Bearings g233391 Figure 48 1. Carriage bolt (3 each per axle) 6. Lug screw (4 each per hub) 11. Dust cap 2. Axle 7. Bearing cup (2 each per axle) 12. Wheel hub 3. Cotter pin 8. Spindle washer 13. Flange nut (3 each per axle) 9. Nut 14. Carriage bolt (4 each) Nut retainer 15. Flange nut (4 each) 4. Oil seal 5. Bearing cone (2 each per axle) 10. Note: Machines with Models 44552, 44552TE, and 44554 use an axle mount that is fastened to the frame.
Assembling the Wheel Hubs and Bearings Refer to Figure 48 for the following procedure. 1. Assemble the wheel hub as follows: A. If the lug screws were removed from the wheel hub, press the lug screws fully into the hub. Ensure that the lug screw flange is pressed fully to the hub surface. B. If the bearing cups were removed from the wheel hub, press the inner and outer cups into the wheel hub until they seat against the wheel hub shoulder. C. Fill the wheel hub approximately 50% full of grease. D.
Guards g233393 Figure 49 1. Muffler mount 4. Bolt (2 each) 2. Tinnerman nut (2 each) 5. Flange nut (4 each) 3. Hardened washer (2 each) 6. Top grill Removing the Guards 1. Park the machine on a level surface, shut off the engine, and remove the key from the key switch. Block the wheels with chocks to prevent the machine from moving. 2. To prevent unexpected machine operation, disconnect the negative battery cable from the battery terminal; refer to Servicing the Battery (page 5–37).
Installing the Guards (continued) 2. Connect the negative battery cable to the negative battery terminal. Tighten the nut that secures the battery cable to 14 to 20 N∙m (10 to 15 ft-lb). Ensure that the battery cover is secured.
Appendix A Foldout Drawings Table of Contents Electrical Drawing Designations.........................................................................................................A–2 Electrical Schematic – Models 44552, 44552TE, and 44553 (serial numbers below 403421000)......................................................................................................................A–3 Electrical Schematic – Models 44552, 44552TE, and 44553 (serial numbers above 403421000)...........................
Electrical Drawing Designations Note: A splice used in a wire harness will be identified on the wire harness diagram by SP. The manufacturing number of the splice is also identified on the wire harness diagram (e.g., SP01 is splice number 1). Wire Color The following abbreviations are used for wire harness colors on the electrical schematics and wire harness drawings in this chapter.
Electrical Schematic – Models 44552, 44552TE, and 44553 (serial numbers below 403421000) g326140 Pro Force Blower - Models 44552, 44552TE and 44553 (serial numbers below 403421000), Drawing 122-0211 Rev B, Sheet 1 of 1 18237SL Rev B Page A–3
Electrical Schematic – Models 44552, 44552TE, and 44553 (serial numbers above 403421000) g279528 Page A–4 18237SL Rev B Pro Force Blower - Models 44552, 44552TE and 44553 (serial numbers above 403421000), Drawing 122-1506 Rev A, Sheet 1 of 1
Electrical Schematic – Model No.
Electrical Schematic – Model No. 44554 (serial numbers above 403421000) g326141 Page A–6 18237SL Rev B Pro Force Blower - Model No.
Engine Electrical Diagram g279585 Pro Force Blower, Drawing Rev , Sheet 1 of 1 18237SL Rev B Page A–7
Wire Harness Drawing – Main (serial numbers below 403421000) g326212 Page A–8 18237SL Rev B Pro Force Blower (serial numbers below 403421000), Drawing 122-0220 Rev E, Sheet 1 of 2
Wire Harness Diagram – Main (serial numbers below 403421000) g326211 ProForce Blower (serial numbers below 403421000), Drawing 122-0220 Rev E, Sheet 2 of 2 18237SL Rev B Page A–9
Wire Harness Drawing – Main (serial numbers 403421000 to 405799999) g279710 Page A–10 18237SL Rev B Pro Force Blower (serial numbers 403421000 to 405799999), Drawing 122-1505 Rev A, Sheet 1 of 2
Wire Harness Diagram – Main (serial numbers 403421000 to 405799999) g279709 Pro Force Blower (serial numbers 403421000 to 405799999), Drawing 122-1505 Rev A, Sheet 2 of 2 18237SL Rev B Page A–11
Wire Harness Drawing – Main (serial numbers above 405799999) g326526 Page A–12 18237SL Rev B Pro Force Blower (serial numbers above 405799999), Drawing 122-1747 Rev A, Sheet 1 of 2
Wire Harness Diagram – Main (serial numbers above 405799999) g326525 Pro Force Blower (serial numbers above 405799999), Drawing 122-1747 Rev A, Sheet 2 of 2 18237SL Rev B Page A–13
Wire Harness-Trailer (Model No.
Wire Harness -Tethered Control Box (Model No. 44554) g235233 Pro Force Blower (Model No.
Wire Harness-Tether Adapter (Model No.
