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  3. Flex-Force Power System 60V MAX 22in Recycler Lawn Mower
Flex-Force Power System 60V MAX 22in Recycler Lawn Mower

Toro Flex-Force Power System 60V MAX 22in Recycler Lawn Mower User manual

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FormNo.3439-480RevA
60vBatteryServiceManual
Published:January2021
©2020—TheToro®Company
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
mm
FractionsDecimals
mm
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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