Toro 1 Amp 60V MAX* Flex-Force Power System Charger 81801 User manual

Brand: Toro

Model: 1 Amp 60V MAX* Flex-Force Power System Charger 81801

Type: User manual

FormNo.3439-480RevA

60vBatteryServiceManual

Published:January2021

8111LyndaleAvenueSouth

Bloomington,MN55420

OriginalInstructions(EN)

Contactusatwww.Toro.com.

AllRightsReserved

RevisionHistory

RevisionHistoryPage2

60vBatteryServiceManual

3439-480RevA

Preface

ThisservicemanualwaswrittenexpresslyforToroservicetechnicians.TheT oroCompanyhasmade

everyefforttomaketheinformationinthismanualcompleteandcorrect.

Basicshopsafetyknowledgeandmechanical/electricalskillsareassumed.TheT ableofContentslists

thesystemsandtherelatedtopicscoveredinthismanual.

Wearehopefulthatyouwillndthismanualavaluableadditiontoyourserviceshop.Ifyouhaveany

questionsorcommentsregardingthismanual,pleasecontactusatthefollowingaddress:

TheToroCompany

RLC/SWSCustomerCareDepartment

8111LyndaleAvenueSouth

Bloomington,MN55420

TheToroCompanyreservestherighttochangeproductspecicationsormakechangestothismanual

withoutnotice.

60vBatteryServiceManual

Page3

Preface

3439-480RevA

ServiceProcedureIcons

ThefollowingiconsappearthroughoutthisServiceManualtobringattentionto

specicimportantdetailsofaserviceprocedure.

CriticalProcess

Thisiconisusedtohighlight:

•Installingsafetyequipment(shields,guards,seatbelts,brakes,andR.O.P .S.

components)thatmayhavebeenremoved

•Dimensionsorsettingsthatmustbemaintainedforpropermachineoperation

•Aspecicfastenertighteningsequence

•Componentorientationthatmaynotbeobvious

CriticalTorque

Thisiconisusedtohighlightanassemblytorquerequirementthatisdifferent

thanwhatisrecommendedintheStandardT orqueT ables.

FluidSpecications

Thisiconisusedtohighlightuidspecicationsandcapacitiesthatareless

common,andmaynotappearonthemachineservicedecalorinthemachine

Operator’sManual.

Note:RefertotheservicedecalonthemachineandthemachineOperator’s

Manualforcommonlyuseduidspecicationsandcapacities.

Preface

Page4

60vBatteryServiceManual

3439-480RevA

TableofContents

Preface................................................................................................................3

Chapter1:Safety............................................................................................1–1

SafetyInstructions.......................................................................................1–2

Chapter2:SpecicationsandMaintenance....................................................2–1

Specications...............................................................................................2–2

TorqueSpecications...................................................................................2–3

Chapter3:Troubleshooting.............................................................................3–1

GeneralTroubleshooting..............................................................................3–3

BatteryOperatedProductsTroubleshootingGuide.......................................3–4

Chapter4:TheoryofOperation.......................................................................4–1

GeneralInformation.....................................................................................4–2

ServiceandRepairs.....................................................................................4–3

Chapter5:UseExpectations...........................................................................5–1

GeneralInformation.....................................................................................5–2

ServiceandRepairs.....................................................................................5–3

Chapter6:Testing...........................................................................................6–1

GeneralInformation.....................................................................................6–2

ServiceandRepairs.....................................................................................6–3

60vBatteryServiceManual

Page5

Preface

3439-480RevA

Preface

Page6

60vBatteryServiceManual

3439-480RevA

Chapter1

Safety

TableofContents

SafetyInstructions................................................................................................................................1–2

ThinkSafetyFirst...............................................................................................................................1–2

60vBatteryServiceManual

Page1–1

Safety

3439-480RevA

SafetyInstructions

DANGER

Thissafetysymbolmeansdanger.Whenyouseethissymbol,

carefullyreadtheinstructionsthatfollow.Failuretoobeythe

instructionscouldcauseseriouspermanentinjury,disability,or

death.

WARNING

Thissafetysymbolmeanswarning.Whenyouseethissymbol,

carefullyreadtheinstructionsthatfollow.Failuretoobeythe

instructionscanresultinseriousinjury.

CAUTION

Thissafetysymbolmeanscaution.Whenyouseethissymbol,

carefullyreadtheinstructionsthatfollow.Failuretoobeythe

instructionscanresultinminortomoderateinjuryand/ordamage

topropertyorequipment.

ThinkSafetyFirst

Avoidunexpectedstartingofengine…

Alwaysturnofftheengine,removetheignitionkeyanddisconnectthesparkplug

wire(s)beforecleaning,adjusting,orrepair.

Avoidlacerationsandamputations…

Stayclearofallmovingpartswhenevertheengineisrunning.Treatallnormally

movingpartsasiftheyweremovingwhenevertheengineisrunningorhas

thepotentialtostart.

Avoidburns…

Donottouchtheengine,mufer,orothercomponents,whichmaybehotduring

operation,whiletheunitisrunningorshortlyafterithasbeenrunning.

Avoidresandexplosions…

Useextremecareinhandlingfuel.Itisammableanditsvaporsareexplosive.

Extinguishallcigarettes,cigars,pipes,andothersourcesofignition.Avoid

spillingfuelandneversmokewhileworkingwithanytypeoffuelorlubricant.

Wipeupanyspilledfueloroilimmediately.Neverremovethefuelcaporadd

fuelwhentheengineisrunning.Alwaysuseapproved,labeledcontainersfor

storingortransportingfuelandlubricants.Donotaddordrainfuelinanenclosed

space.Donotstorethemachineorfuelcontainerwherethereisanopename,

spark,orpilotlight,suchasonawaterheaterorotherappliance.

Avoidasphyxiation…

Donotoperateanengineinaconnedareawithoutproperventilation.

Avoidinjuryfrombatteries…

Safety:SafetyInstructions

Page1–2

60vBatteryServiceManual

3439-480RevA

ThinkSafetyFirst(continued)

Batteryacidispoisonousandcancauseburns.Avoidcontactwithskin,eyes

andclothing.Batterygasescanexplode.Keepcigarettes,sparksandames

awayfromthebattery.

Avoidinjuryfromlithium-ionbatteries…

Ifanysmokeisobserved,callthelocalemergencyservicesimmediately.

Alwaysservicelithium-ionbatterieswiththemachineparkednearaservicedoor

largeenoughtomovetheproductorbatteryoutsideincaseofanemergency

andkeepareblanketnearby.Alwaysdisconnectthebatterieswhenservicing

productswithlithium-ionbatteries.Donotuseareextinguisheronthebatteries.

Keepaplasticbucketfullofcleanwaternearbythatcancompletelysubmerge

thehandheldbatteryandnottipover.Immediatelysubmergehandheldbatteries

ifsmokeappears.

UseonlyToro-speciedlithium-ionbatterypacksdesignedforyourmachine.

DonotmixbatteriesofanybrandortypeinToroproducts.Useonlythe

Toro-speciedlithium-ionchargerdesignedtochargeyourmachine.Donot

attempttouseanyotherbatterycharger.Donotheat,puncture,over-chargeor

over-dischargethebatteries.

Immediatelydiscontinueuseofthebatteryif,whileusing,charging,orstoringthe

battery,itemitsanunusualsmell,feelshot,changescolororshape,orappears

abnormalinanyotherway.Ifthishappens,movetheproductorbatterytoa

safeoutdoorareaawayfromanybuilding,vehicle,orcombustiblematerial.

Observethebatteryforatleast1hourtoensurethatanyreactionhasstopped.

Ifthereactioncontinues,orifanysmokeisobserved,callyourlocalemergency

servicesimmediately.

Avoidinjuryduetoinferiorparts…

Useonlyoriginalequipmentpartstoensurethatimportantsafetycriteriaaremet.

Avoidinjurytobystanders…

Alwayscleartheareaofbystandersbeforestartingortestingpowered

equipment.

Avoidinjuryduetoprojectiles…

Alwayscleartheareaofsticks,rocksoranyotherdebristhatcouldbepickedup

andthrownbythepoweredequipment.

Avoidmodications…

Neveralterormodifyanypartunlessitisafactoryapprovedprocedure.

Avoidunsafeoperation…

Alwaystestthesafetyinterlocksystemaftermakingadjustmentsorrepairson

themachine.RefertotheElectricalsectioninthismanualformoreinformation.

Avoidelectricalshock…

Nevertouchelectricalwiresorcomponentswhiletheengineisrunning.They

canbesourcesofshock.De-energizethesystemifyouarehavingtodorepairs.

Iftestingelectricalcomponentsensureyouareworkinginadryenvironment.

HydraulicSystem...

Releaseallpressureinthehydraulicsystembeforeperforminganyworkon

thesystem.Keepyourbodyandhandsawayfrompin-holeleaksornozzles

thatejecthydraulicuidunderhighpressure.Donotuseyourhandstosearch

forleaks.Hydraulicuidescapingunderpressurecanhavesufcientforceto

60vBatteryServiceManual

Page1–3

Safety:SafetyInstructions

3439-480RevA

ThinkSafetyFirst(continued)

penetratetheskinandcauseseriousinjury.Seekmedicalattentionrightawayif

hydraulicuidgetsintheskin.

PersonalProtectiveEquipment…

Tiebacklonghair,anddonotwearlooseclothingorjewelry.Useappropriate

personalprotectiveequipment(PPE)forprotectingyourselffrompotential

hazardsintheenvironmentinwhichyouwillwork.Eachprocessoutlinedinthis

manualmayneeddifferentPPEtoprotecttheserviceperson.Usetheproper

PPEforthetaskathand.

Tools…

Alltoolsshouldbeinproperworkingorder.Donotusetoolsthatarebrokenorin

disrepair.Usethepropertoolfortheproperapplication.

Lifts,Hoists,andJacks…

Alllifts,hoists,andjacksshouldbeusedinaccordancewiththemanufacturer

information.Inspectlifts,hoists,andjackspriortouse.Donotoverloadlifts,

hoists,andjacks.Donotworkunderasuspendedload.Ensurechockblocks

areusedonequipmentthatcanmove.Useliftsorjacksandjackstandsthat

areratedtosupportthetotalweightofthemachineandanyattachments.Do

notrelyonjackstosupportthemachine.Ifyouareunsureoftheoperationof

anylifts,hoists,andjacksdonotuse.

FireExtinguishers…

Theproperclassofreextinguishershouldbeusedincaseofre.

ClassAextinguishersareforordinarycombustiblematerialssuchaspaper,

wood,cardboard,andmostplastics.Thenumericalratingonthesetypesof

extinguishersindicatestheamountofwateritholdsandtheamountofreitcan

extinguish.Geometricsymbol(greentriangle).

ClassBresinvolveammableorcombustibleliquidssuchasgasoline,

kerosene,greaseandoil.ThenumericalratingforclassBextinguishers

indicatestheapproximatenumberofsquarefeetofreitcanextinguish.

Geometricsymbol(redsquare).

ClassCresinvolveelectricalequipment,suchasappliances,wiring,circuit

breakersandoutlets.NeverusewatertoextinguishclassCres-theriskof

electricalshockisfartoogreat!ClassCextinguishersdonothaveanumerical

rating.TheCclassicationmeanstheextinguishingagentisnon-conductive.

Geometricsymbol(bluecircle).

ABCreextinguishersareadrychemicaltypeusedformultiplepurposes.See

aboveinformationfordescription.

Ensurereextinguishersareserviceableandreplaceanythataredischargedor

outofinspectiondates.

Safety:SafetyInstructions

Page1–4

60vBatteryServiceManual

3439-480RevA

Chapter2

SpecicationsandMaintenance

TableofContents

Specications.......................................................................................................................................2–2

TorqueSpecications...........................................................................................................................2–3

EquivalentsandConversions.............................................................................................................2–8

U.S.toMetricConversions................................................................................................................2–9

60vBatteryServiceManual

Page2–1

SpecicationsandMaintenance

3439-480RevA

Specications

Model8862088625886408866088675

Battery2.0AhBattery2.5AhBattery4.0AhBattery6.0AhBattery7.5AhBattery

BatterySize

(WxHxL)

15.11x20.32x10.41cm(5.95x8.0x4.1inches)

Weight

1.65kg(3.65lb)2.33kg(5.15lb)2.94kg(6.5lb)3.15kg(6.95lb)

SpecicationsandMaintenance:Specications

Page2–2

60vBatteryServiceManual

3439-480RevA

TorqueSpecications

Therecommendedfastenertorquevaluesarelistedinthefollowingtables.For

criticalapplications,asdeterminedbyToro,eithertherecommendedtorqueora

torquethatisuniquetotheapplicationisclearlyidentiedandspeciedinthe

servicemanual.

Thesetorquespecicationsfortheinstallationandtighteningoffastenersshall

applyforallfastenerswhichdonothaveaspecicrequirementidentiedin

theservicemanual.Thefollowingfactorsshallbeconsideredwhenapplying

torque:cleanlinessofthefastener,useofathreadsealant(Loctite),degreeof

lubricationonthefastener,presenceofaprevailingtorquefeature,hardness

ofthesurfaceunderneathofthefastener’shead,orsimilarconditionwhich

affectstheinstallation.

Asnotedinthefollowingtables,torquevaluesshouldbereducedby25%for

lubricatedfastenerstoachievethesimilarstressasadryfastener.Torquevalues

mayalsohavetobereducedwhenthefasteneristhreadedintoaluminumor

brass.Thespecictorquevalueshouldbedeterminedbasedonthealuminum

orbrassmaterialstrength,fastenersize,lengthofthreadengagement,etc.

Thestandardmethodofverifyingtorqueshallbeperformedbymarkingalineon

thefastener(headornut)andmatingpart,thenbackofffastener1/4ofaturn.

Measurethetorquerequiredtotightenthefasteneruntilthelinesmatchup.

FastenerIdentication

InchSeriesBoltsandScrews

g272208

Figure1

1.Grade13.Grade8

2.Grade5

60vBatteryServiceManual

Page2–3

SpecicationsandMaintenance:TorqueSpecications

3439-480RevA

MetricBoltsandScrews

g272209

Figure2

1.Class8.82.Class10.9

SpecicationsandMaintenance:TorqueSpecications

Page2–4

60vBatteryServiceManual

3439-480RevA

StandardTorqueforDry,ZincPlated,andSteelFasteners(InchSeries)

ThreadSizeGrade1,

5,&8

Fasteners

withThin

HeightNuts

SAEGrade1Bolts,Screws,

Studes&Semswith

RegularHeightNuts(SAE

Grade2orBetterNut)

SAEGrade5Bolts,Screws,

Studs&SemswithRegular

HeightNuts(SAEGrade

5orBetterNut)

SAEGrade8Bolts,Screws,

Studs&SemswithRegular

HeightNuts(SAEGrade

8orBetterNut)

in-lbin-lbN•cmin-lbN•cmin-lbN•cm

#6-32UNC

15±2169±2323±3260±34

#6-40UNF

10±213±2147±23

17±2192±2325±3282±34

#8-32UNC

29±3328±3441±5463±56

#8-36UNF

13±225±5282±30

31±4350±4543±5486±56

#10-24UNC

42±5475±5660±6678±68

#10-32UNF

18±230±5339±56

48±5542±5668±7768±79

1/4-20UNC

48±753±7599±79100±101130±113140±151582±169

1/4-28UNF

53±765±10734±113115±121299±136160±171808±192

5/16-18UNC

115±15105±151186±169200±252260±282300±303390±339

5/16-24UNF

138±17128±171446±192225±252542±282325±333672±373

ft-lbft-lb

N•m

ft-lb

N•m

ft-lb

N•m

3/8-16UNC

16±216±222±330±341±443±558±7

3/8-24UNF

17±218±224±335±447±550±668±8

7/16-14UNC

27±327±337±450±568±770±795±9

7/16-20UNF

29±329±339±455±675±877±8104±11

1/2-13UNC

30±348±765±975±8102±11105±11142±15

1/2-20UNF

32±453±772±985±9115±12120±12163±16

5/8-11UNC

65±1088±12119±16150±15203±20210±21285±28

5/8-18UNF

75±1095±15129±20170±18230±24240±24325±33

3/4-10UNC

93±12140±20190±27265±27359±37375±38508±52

3/4-16UNF

115±15165±25224±34300±30407±41420±43569±58

7/8-9UNC

140±20225±25305±34430±45583±61600±60813±81

7/8-14UNF

155±25260±30353±41475±48644±65667±66904±89

Note:Reducetorquevalueslistedinthetableaboveby25%forlubricatedfasteners.Lubricated

fastenersaredenedasthreadscoatedwithalubricantsuchasoil,graphite,orthreadsealantsuch

asLoctite.

Torquevaluesmyhavetobereducedwheninstallingfastenersintothreadedaluminumorbrass.The

specictorquevalueshouldbedeterminedbasedonthefastenersize,thealuminumorbasematerial

strength,lengthofthreadengagement,etc.

ThenominaltorquevalueslistedaboveforGrade5and8fastenersarebasedon75%oftheminimum

proofloadspeciedinSAEJ429.Thetoleranceisapproximately±10%ofthenominaltorquevalue.

Thinnutsincludejamnuts.

60vBatteryServiceManual

Page2–5

SpecicationsandMaintenance:TorqueSpecications

3439-480RevA

StandardTorqueforDry,ZincPlated,andSteelFasteners(MetricSeries)

Class8.8Bolts,Screws,StudswithRegular

HeightNuts(Class8orStrongerNuts)

Class10.9Bolts,Screws,StudswithRegular

HeightNuts(Class10orstrongerNuts)

ThreadSize

in-lbN•cmin-lbN•cm

M5X0.857±6644±6878±8881±90

M6X1.096±101085±113133±141503±158

ft-lb

N•m

ft-lb

N•m

M8X1.2519±226±328±338±4

M10X1.538±452±554±673±8

M12X1.7566±790±1093±10126±14

M16X2.0166±17255±23229±23310±31

M20X2.5325±33440±45450±46610±62

Note:Reducetorquevalueslistedinthetableaboveby25%forlubricatedfasteners.Lubricated

fastenersaredenedasthreadscoatedwithalubricantsuchasoil,graphite,orthreadsealantsuch

asLoctite.

Torquevaluesmayhavetobereducedwheninstallingfastenersintothreadedaluminumorbrass.The

specictorquevalueshouldbedeterminedbasedonthefastenersize,thealuminumorbasematerial

strength,lengthofthreadengagement,etc.

Thenominaltorquevalueslistedabovearebasedon75%oftheminimumproofloadspeciedinSAE

J1199.Thetoleranceisapproximately±10%ofthenominaltorquevalue.Thinheightnutsincludejam

nuts.

SpecicationsandMaintenance:TorqueSpecications

Page2–6

60vBatteryServiceManual

3439-480RevA

SAEGrade8SteelSetScrews

RecommendedTorque

ThreadSize

SquareHeadHexSocket

1/4-20UNC

140±20in-lb73±12in-lb

5/16-18UNC

215±35in-lb145±20in-lb

1/2-13UNC75±15ft-lb50±10ft-lb

3/8-16UNC35±10ft-lb18±3ft-lb

WheelBoltsandLugNuts

ThreadSizeRecommendedTorque**

7/16-20UNFGrade565±10ft-lb

88±14N•m

1/2-20UNFGrade580±10ft-lb

108±14N•m

M12X1.25Class8.880±10ft-lb

108±14N•m

M12X1.5Class8.880±10ft-lb

108±14N•m

**Forsteelwheelsandnon-lubricatedfasteners.

ThreadCuttingScrews(ZincPlatedSteel)

Type1,Type23,orTypeF

ThreadSizeBaselineTorque*

No.6-32UNC

20±5in-lb

No.8-32UNC

30±5in-lb

No.10-24UNC

38±7in-lb

1/4-20UNC

85±15in-lb

5/16-18UNC

110±20in-lb

3/8-16UNC

200±100in-lb

*Holesize,materialstrength,materialthicknessandnishmustbeconsideredwhendetermining

specictorquevalues.Alltorquevaluesarebasedonnon-lubricatedfasteners.

ConversionFactors

in-lbX11.2985=N•cm

ft-lbX1.3558=N•m

N•cmX0.08851=in-lb

N•cmX0.73776=ft-lb

ThreadCuttingScrews(ZincPlatedSteel)

ThreadsperInch

ThreadsSize

TypeATypeB

BaselineTorque*

No.6182020±5in-lb

No.8151830±5in-lb

No.10121638±7in-lb

No.12111485±15in-lb

*Holesize,materialstrength,materialthicknessandnishmustbeconsideredwhendetermining

specictorquevalues.Alltorquevaluesarebasedonnon-lubricatedfasteners.

60vBatteryServiceManual

Page2–7

SpecicationsandMaintenance:TorqueSpecications

3439-480RevA

EquivalentsandConversions

DecimalandMillimeterEquivalents

FractionsDecimals

1/64

0.0156250.397

33/64

0.51562513.097

1/32

0.031250.794

16/32

0.5312513.484

3/64

0.0468751.191

35/64

0.54687513.891

1/16

0.06251.588

9/16

0.562514.288

5/64

0.0781251.984

37/64

0.57812514.684

3/32

0.93752.381

19/32

0.5937515.081

1/8

0.12503.175

5/8

0.625015.875

9/64

0.1406253.572

41/64

0.64062516.272

5/32

0.156253.969

21/32

0.6562516.669

11/64

0.1718754.366

43/64

0.67187517.066

3/16

0.18754.762

11/64

0.687517.462

13/64

0.2031255.159

45/64

0.70312517.859

7/32

0.218755.556

23/32

0.7187518.256

15/64

0.2343755.953

47/64

0.73437518.653

1/4

0.25006.350

3/4

0.750019.050

17/64

0.2656256.747

49/64

0.76562519.447

9/32

0.281257.144

25/32

0.7812519.844

19/64

0.2968757.541

51/64

0.79687520.241

5/16

0.31257.541

13/16

0.812520.638

21/64

0.3281258.334

53/64

0.82812521.034

11/32

0.343758.731

27/32

0.8437521.431

23/64

0.3593759.128

55/64

0.85937521.828

3/8

0.37509.525

7/8

0.875022.225

25/64

0.3906259.922

57/64

0.89062522.622

13/32

0.4062510.319

29/32

0.9062523.019

27/64

0.42187510.716

59/64

0.92187523.416

7/16

0.437511.112

15/16

0.937523.812

29/64

0.45312511.509

61/64

0.95312524.209

15/32

0.4687511.906

31/32

0.9687524.606

31/64

0.48437512.303

63/64

0.98437525.003

1/2

0.500012.70011.00025.400

1mm=0.03937in.0.001in.=0.0254mm

SpecicationsandMaintenance:TorqueSpecications

Page2–8

60vBatteryServiceManual

3439-480RevA

U.S.toMetricConversions

ToConvert

IntoMultiplyBy

MilesKilometers1.609

YardsMeters0.9144

FeetMeters0.3048

Feet

Centimeters

30.48

InchesMeters0.0254

Inches

Centimeters

2.54

LinearMeasurement

InchesMillimeters25.4

SquareMilesSquareKilometers

2.59

SquareFeetSquareMeters

0.0929

SquareInchesSquareCentimeters

6.452

Area

AcreHectare0.4047

CubicYardsCubicMeters

0.7646

CubicFeetCubicMeters

0.02832

Volume

CubicInchesCubicCentimeters

16.39

Tons(Short)

MetricT ons0.9078

PoundsKilograms0.4536 Weight

OuncesGrams

28.3495

Pressure

Pounds/SquareInch

Kilopascal6.895

Foot-PoundsNewton-Meters1.356

Foot-PoundsKilogram-Meters0.1383

Work

Inch-Pounds

Kilogram-Centimeters

1.152144

Quarts

Liters0.9463

LiquidVolume

Gallons

Liters3.785

LiquidFlows

Gallons/MinuteLiters/Minute

3.785

1.Subtractby32°

TemperatureFahrenheit

Celsius

2.Multiplyby5/9

60vBatteryServiceManual

Page2–9

SpecicationsandMaintenance:TorqueSpecications

3439-480RevA

SpecicationsandMaintenance:TorqueSpecications

Page2–10

60vBatteryServiceManual

3439-480RevA

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Toro 1 Amp 60V MAX* Flex-Force Power System Charger 81801 User manual

Toro 1 Amp 60V MAX* Flex-Force Power System Charger 81801 User manual

Toro 1 Amp 60V MAX* Flex-Force Power System Charger 81801 User manual

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