Form No. 3429-828 Rev A 60v WPM Service Manual Published: December 2019 © 2019—The Toro® Company 8111 Lyndale Avenue South Bloomington, MN 55420 Original Instructions (EN) Contact us at www.Toro.com.
Revision History Revision History Page 2 60v WPM Service Manual 3429-828 Rev A
Preface This service manual was written expressly for Toro service technicians. The Toro Company has made every effort to make the information in this manual complete and correct. Basic shop safety knowledge and mechanical/electrical skills are assumed. The Table of Contents lists the systems and the related topics covered in this manual. We are hopeful that you will find this manual a valuable addition to your service shop.
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 ................................................................................................................ 3 Chapter 1: Safety ............................................................................................ 1–1 Safety Instructions ....................................................................................... 1–2 Chapter 2: Specifications and Maintenance .................................................... 2–1 Specifications ..............................
Preface Page 6 60v WPM Service Manual 3429-828 Rev A
Chapter 1 Safety Table of Contents Safety Instructions ................................................................................................................................ 1–2 Think Safety First ...............................................................................................................................
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 cause serious permanent injury, disability, or death. 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.
Battery acid is poisonous and can cause burns. Avoid contact with skin, eyes and clothing. Battery gases can explode. Keep cigarettes, sparks and flames away from the battery. Avoid injury due to inferior parts… Use only original equipment parts to ensure that important safety criteria are met. Avoid injury to bystanders… Always clear the area of bystanders before starting or testing powered equipment.
extinguishers indicates the amount of water it holds and the amount of fire it can extinguish. Geometric symbol (green triangle). Class B fires involve flammable or combustible liquids such as gasoline, kerosene, grease and oil. The numerical rating for class B extinguishers indicates the approximate number of square feet of fire it can extinguish. Geometric symbol (red square). Class C fires involve electrical equipment, such as appliances, wiring, circuit breakers and outlets.
Chapter 2 Specifications and Maintenance Table of Contents Specifications ....................................................................................................................................... 2–2 Torque Specifications ........................................................................................................................... 2–3 Equivalents and Conversions............................................................................................................. 2–8 U.S.
Specifications Product Specifications Model 20363 Motor Battery Charge Time 20366 60 volt, 2kW motor 6.0Ah battery (1/3 acres of cut) 7.5Ah battery (approx. .4 Acres of cut) 2 amp charger, 6.0Ah battery takes about 3 hours to charge 2 amp charger, 7.
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 the service manual. These torque specifications for the installation and tightening of fasteners shall apply for all fasteners which do not have a specific requirement identified in the service manual.
Metric Bolts and Screws g272209 Figure 2 1. Class 8.8 Specifications and Maintenance: Torque Specifications 2. Page 2–4 Class 10.
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size Grade 1, 5, & 8 Fasteners with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studes & Sems with Regular Height Nuts (SAE Grade 2 or Better Nut) In-lb. In-lb.
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Series) Thread Size Class 8.8 Bolts, Screws, Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws, Studs with Regular Height Nuts (Class 10 or stronger Nuts) in-lb. N-cm in-lb. N-cm M5 X 0.8 57 ± 6 644 ± 68 78 ± 8 881 ± 90 M6 X 1.0 96 ± 10 1085 ± 113 133 ± 14 1503 ± 158 ft-lbs. N-m ft-lbs. N-m M8 X 1.25 19 ± 2 26 ± 3 28 ± 3 38 ± 4 M10 X 1.5 38 ± 4 52 ± 5 54 ± 6 73 ± 8 M12 X 1.
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. 1/2 - 13 UNC 75 ± 15 ft-lb. 50 ± 10 ft-lb. 3/8 - 16 UNC 35 ± 10 ft-lb. 18 ± 3 ft-lb. Wheel Bolts and Lug Nuts Thread Size Recommended Torque** 7/16 - 20 UNF Grade 5 65 ± 10 ft-lb. 88 ± 14 N-m 1/2 - 20 UNF Grade 5 80 ± 10 ft-lb. 108 ± 14 N-m M12 X 1.25 Class 8.8 80 ± 10 ft-lb. 108 ± 14 Nm M12 X 1.5 Class 8.
Equivalents and Conversions Decimal and Millimeter Equivalents Fractions Decimals mm Fractions Decimals mm 1/64 0.015625 0.397 33/64 0.515625 13.097 1/32 0.03125 0.794 16/32 0.53125 13.484 3/64 0.046875 1.191 35/64 0.546875 13.891 1/16 0.0625 1.588 9/16 0.5625 14.288 5/64 0.078125 1.984 37/64 0.578125 14.684 3/32 0.9375 2.381 19/32 0.59375 15.081 1/8 0.1250 3.175 5/8 0.6250 15.875 9/64 0.140625 3.572 41/64 0.640625 16.272 5/32 0.15625 3.969 21/32 0.
U.S. to Metric Conversions To Convert Into Multiply By Miles Kilometers 1.609 Yards Meters 0.9144 Feet Meters 0.3048 Feet Centimeters 30.48 Inches Meters 0.0254 Inches Centimeters 2.54 Inches Millimeters 25.4 Square Miles Square Kilometers 2.59 Square Feet Square Meters 0.0929 Square Inches Square Centimeters 6.452 Acre Hectare 0.4047 Cubic Yards Cubic Meters 0.7646 Cubic Feet Cubic Meters 0.02832 Cubic Inches Cubic Centimeters 16.39 Tons (Short) Metric Tons 0.
Specifications and Maintenance: Torque Specifications Page 2–10 60v WPM Service Manual 3429-828 Rev A
Chapter 3 Troubleshooting Table of Contents General Troubleshooting ....................................................................................................................... 3–3 Error Beep Table....................................................................................................................................
GEARS The Systematic approach to defining, diagnosing and solving problems.
General Troubleshooting Problem The tool will not operate Possible Cause Corrective Action The charger is not charging the battery. 1. Is the charger physically damaged? If yes, replace the charger. 2. Check if LEDs light up on the battery. If the LEDs do not light up when the battery State of Charge (SOC) button is pressed, replace the battery. 3.
Error Beep Table Error Type Number of Beeps Communication Error 2 Time Out Error 3 Motor Driver Error Motor Driver Error Hall Sensor Error Motor Driver Error Communication Low Error from Battery, Low Power Motor Driver Block Error Internal Error Code Communication High Error from Battery Communication Motor Error 4 5 6 7 8 9 10 11 12 Current Error 13 Precharge Error 14 Gryoscope Error 15 Temp Error 16 Calibration Error 18 Troubleshooting: General Troubleshooting Page 3–4 Next Ste
Chapter 4 Power Head Assembly Table of Contents General Information .............................................................................................................................. 4–2 Service and Repairs ............................................................................................................................. 4–3 20363 with Personal Pace 22 inch Recycler Power Head Assembly Replacement.............................
General Information Both models 20363/20361 power head assemblies are secured to the mower chassis by 3 mounting bolts. The 20363 model (Personal Pace unit) has an added belt driver, belt guide, and belt cover. In addition, the model has traction/drive cable for transmission engagement.
Service and Repairs 20363 with Personal Pace 22 inch Recycler Power Head Assembly g294042 Figure 3 1. Motor Module 6. Pulley 2. 3. 4. HWH Screw Belt Cover Belt Guide 7. 8. 9. Blade Retainer Blade Blade Support 5. Taptite Screw 10.
20361 22 inch Recycler Power Head Assembly g294040 Figure 4 1. 2. Motor Module HWH Form THD Screw 4. 5. Blade Blade Support 3. Taptite Screw 6.
20363 with Personal Pace 22 inch Recycler Power Head Assembly Replacement 20363 with Personal Pace 22 inch Recycler Power Head Assembly Removal 1. Park the machine on a level surface and set the parking brake. Stop the motor, wait for all moving parts to stop and remove the key. 2. Remove the brake cable from the bail. 3. Disconnect the brake cable from the power head. g297088 Figure 5 4. Remove the harness from the power head by squeezing the tabs on the side of the connector and pull downward.
20363 with Personal Pace 22 inch Recycler Power Head Assembly Removal (continued) 6. Remove the blade and blade bolt from the machine. See the operator’s manual. 7. Remove the keyed blade driver from the power head shaft. g295229 Figure 7 8. Remove the 2 (3/8 inch) screws securing the top side of chassis to the belt cover. g296514 Figure 8 9. Squeeze and hold down on the belt cover and remove from the chassis.
20363 with Personal Pace 22 inch Recycler Power Head Assembly Removal (continued) g296525 Figure 9 10. Remove the 2 (1/2 inch) motor mounting bolts securing the belt guide to the chassis. g296526 Figure 10 11. Remove the belt from the pulley driver.
20363 with Personal Pace 22 inch Recycler Power Head Assembly Removal (continued) g296528 Figure 11 12. Remove the pulley driver from the motor shaft. g295231 Figure 12 13. Using an appropriate lifting device, support the motor and remove the last (1/2 inch) motor mount bolt from the chassis. 20363 with Personal Pace 22 inch Recycler Power Head Assembly Installation 1. Using an appropriate lifting device, support the motor. Install the 1 (1/2 inch) motor mount bolts securing the motor to the chassis.
20363 with Personal Pace 22 inch Recycler Power Head Assembly Installation (continued) g295231 Figure 13 3. Install the belt to the pulley driver. g296528 Figure 14 4. Install the 2 (1/2 inch) motor mounting bolts securing the belt guide to the chassis. Torque motor mount bolts to 450 in-lbs. (50.8 Nm).
20363 with Personal Pace 22 inch Recycler Power Head Assembly Installation (continued) g296526 Figure 15 5. Install the belt cover to the chassis. 6. Install the 2 (3/8 inch) screws securing the top side of the chassis to the belt cover. Torque screws to 30 in-lbs. (3.39 Nm). g296514 Figure 16 7. Install the keyed blade driver to the power head shaft.
20363 with Personal Pace 22 inch Recycler Power Head Assembly Installation (continued) g295229 Figure 17 8. Install the blade to the machine. Secure with the blade bolt. Torque blade bolt to 50 ft-lbs. (68 Nm). 9. Install the harness anchor onto the power head. 10. Install the harness to the power head. 11. Connect the brake cable to the power head. 12. Install the brake cable to the bail and power head assembly.
20361 22 inch Recycler Power Head Assembly Installation (continued) 3. Install the blade to the machine. Secure with the blade bolt. Torque blade bolt to 50 ft-lbs. (68 Nm). 4. Connect the brake cable to the power head. 5. Install the brake cable to the bail and power head assembly.
Chapter 5 Controls Table of Contents General Information .............................................................................................................................. 5–2 Service and Repairs ............................................................................................................................. 5–3 Starter Switch Replacement...............................................................................................................
General Information Unit has 2 controls for operation; starter switch and safety bail. Both controls are normally open circuits and needed for machine operation. When the starter switch has the key present and blue button pushed, depressing both internal switches, the circuits are then closed. When the bail is pulled, closing the circuit, the motor/driver is signaled to turn on. The starter switch returns to an open state after being pushed.
Service and Repairs Starter Switch Assembly g295233 Figure 18 1. Cable Clamp 60v WPM Service Manual 3429-828 Rev A 2. Page 5–3 Starter Switch Asm.
Figure 18 (continued) Safety Bail Switch Assembly g295142 Figure 19 1. Safety Bail Switch Controls: Service and Repairs 2.
Starter Switch Replacement Starter Switch Removal 1. Remove the ½ inch nut securing the start switch handle assembly. g296539 Figure 20 2. Remove the starter switch from the machine. 3. Remove the harness and connector. g296540 Figure 21 4. Remove the zip tie from the power head securing the harness. Unplug the harness from the power head by pressing the tabs on the outside of the plug and pulling downward.
Starter Switch Removal (continued) g296541 Figure 22 Starter Switch Harness Testing Continuity testing with the battery disconnected from or removed from the mower. 1. Remove the 3 Philip head screws securing the starter switch to the power head. g296686 Figure 23 2. Split the starter housing apart to expose the circuit board.
Starter Switch Harness Testing (continued) g296663 Figure 24 3. Visually inspect the small switches on the circuit board, looking for any damage or stuck switches. If damaged, replace the switch assembly. 4. Using a digital multi-meter, check the continuity between the board and to the power head plug. Note: Remove the outer plug case for easy determination of the pin/wire. Note: Left switch is the switch furthest away from the board wiring, right side is closest to the board wiring.
Starter Switch Harness Testing (continued) g296543 Figure 26 Wire Color Continuity with Left Side Switch Depressed Continuity with Right Side Switch Depressed Continuity with Both Side Switches Depressed Red Only Red/Black Red/White/Black Black Black/White Black/Red Red/White/Black Yellow Yellow Only Yellow Only Yellow Only White White/Black White Only Red/White/Black Red Starter Switch Installation 1. Install the starter switch to the machine. 2.
Safety Bail Switch Testing (continued) g296544 Figure 27 60v WPM Service Manual 3429-828 Rev A Page 5–9 Controls: Service and Repairs
Controls: Service and Repairs Page 5–10 60v WPM Service Manual 3429-828 Rev A
Chapter 6 Charger and Battery Table of Contents General Information .............................................................................................................................. 6–2 Service and Repairs ............................................................................................................................. 6–3 Battery................................................................................................................................................
General Information Battery The battery has an internal fuse for protection and is not serviceable. Replacement of the battery is required to fix a blown fuse. To verify there is a blown fuse, test the circuit on the battery between the positive and negative circuits. The LED status bar on the battery will shows the current charge level. When the button is pressed, the lights should first cycle through all lights, then end on the light showing the amount of charge.
Service and Repairs Battery and Charger Assembly g295057 Figure 28 1. Battery 60v WPM Service Manual 3429-828 Rev A 2.
Battery Battery Test When probing the battery to check for voltage with a voltmeter probe, do not force the probe into the battery. The battery terminal can be damaged if spread too far. 1. Place a voltmeter probe between the positive and negative terminals on the battery. 2. Battery voltage should be between 43-62 volts. A battery that is reading voltage under 40 volts is over discharged and will most likely not recover.
Chapter 7 Shrouds Table of Contents General Information .............................................................................................................................. 7–2 Service and Repairs ............................................................................................................................. 7–3 Power Head Shroud Upper Replacement .......................................................................................... 7–4 Power Head Shroud Lower Replacement .......
General Information The power head assembly consists of 3 pieces; power head shroud, upper shroud, and lower shroud. All the mounting screws for the upper and lower shroud are the same length, 10 in total.
Service and Repairs Shroud Assembly g294043 Figure 29 1. Upper Shroud 2. Magnet 6. PPH Screw 3. Flange Screw 7. Hood 4. RH Spring 60v WPM Service Manual 3429-828 Rev A 5.
Power Head Shroud Upper Replacement Power Head Shroud Upper Removal 1. Remove the battery from the power head assembly. 2. Remove the 8 (6 top-around the battery cavity and 2 on the bottom rear) (1/4 x 1.0 inch) flange screws securing the power head upper shroud to the lower shroud. Remove the power head upper shroud. g293756 Figure 30 Power Head Shroud Upper Installation Install the power head upper shroud to the lower shroud. Secure with 8 (6 top-around the battery cavity and 2 on the bottom rear).
Power Head Shroud Lower Replacement Power Head Shroud Lower Removal 1. Remove the battery from the power head assembly. 2. Remove the 8 (6 top-around the battery cavity and 2 on the bottom rear) (1/4 x 1.0 inch) flange screws securing the power head upper shroud to the lower shroud. Remove the power head upper shroud. g293756 Figure 32 3. Remove the 4 (T-20) torx screws from the motor fan shroud. g293757 Figure 33 4. Disconnect the 2 connectors from the battery receiver assembly to the motor driver.
Power Head Shroud Lower Removal (continued) g293758 Figure 34 5. Disconnect the harness from the motor driver to the start stop switch and bail switch connectors. g293759 Figure 35 6. Disconnect the motor to the motor driver harness connector.
Power Head Shroud Lower Removal (continued) g293761 Figure 36 7. Disconnect the motor driver to the motor power connection. Remove the motor driver. g293760 Figure 37 8. Remove the 2 (1/4 x 1.0 inch) flange screws at the base of the battery receiver assembly.
Power Head Shroud Lower Removal (continued) g293765 Figure 38 9. Remove the battery receiver assembly from the power head assembly. g293766 Figure 39 10. Remove the remaining 2 (1/4 x 1.0 inch) flange screws from the motor shroud.
Power Head Shroud Lower Removal (continued) g295055 Figure 40 11. Remove the motor shroud from the power head assembly. g293768 Figure 41 12. Separate the lower shroud from the motor base assembly.
Power Head Shroud Lower Removal (continued) g293795 Figure 42 13. Disconnect the harness from the bail switch. Remove the switch and harness from the lower shroud. Note: If harness anchor is damaged, replace. g293791 Figure 43 Power Head Shroud Lower Installation 1. Install the switch and harness to the lower shroud. Connect the harness to the bail switch.
Power Head Shroud Lower Installation (continued) g293791 Figure 44 2. Install the lower shroud to the motor base assembly. g293795 Figure 45 3. Install the motor shroud to the power head assembly.
Power Head Shroud Lower Installation (continued) g293768 Figure 46 4. Install the 2 (1/4 x 1.0 inch) flange screws to the motor shroud. Torque screws to 30 in-lbs. (3.39 Nm). g295055 Figure 47 5. Install the battery receiver assembly to the power head assembly.
Power Head Shroud Lower Installation (continued) g293766 Figure 48 6. Install the 2 (1/4 x 1.0 inch) flange screws at the base of the battery receiver assembly. Torque screws to 30 ± 3 in-lbs. (3.39 Nm). g293765 Figure 49 7. Install the motor driver. Connect the motor driver to the motor power connection.
Power Head Shroud Lower Installation (continued) g296707 Figure 50 8. Connect the motor to the motor driver harness connector. g293761 Figure 51 9. Connect the harness from the motor driver to the start stop switch and bail switch connectors.
Power Head Shroud Lower Installation (continued) g293759 Figure 52 10. Connect the 2 connectors from the battery receiver assembly to the motor driver. Connect the negative first, then the positive. g296708 Figure 53 1. Negative 2. Positive 11. Install the 4 (T-20) torx screws to the motor fan shroud. Torque screws to 15–20 in-lbs. (1.7–2.26 Nm).
Power Head Shroud Lower Installation (continued) g293757 Figure 54 12. Install the power head upper shroud. Secure with 8 (6 top-around the battery cavity and 2 on the bottom rear) (1/4 x 1.0 inch) flange screws securing the power head upper shroud to the lower shroud. Torque screws to 30 ± 3 in-lbs. (3.39 Nm). g293756 Figure 55 Motor Shroud Replacement Motor Shroud Removal 1. Remove the 8 (6 top-around the battery cavity and 2 on the bottom rear) (1/4 x 1.
Motor Shroud Removal (continued) g293756 Figure 56 2. Remove the 4 (T-20) torx screws from the motor fan shroud. g293757 Figure 57 3. Disconnect the 2 connectors from the battery receiver assembly to the motor driver. Disconnect the positive first, then the negative.
Motor Shroud Removal (continued) g293758 Figure 58 4. Disconnect the harness from the motor driver to the start stop switch and bail switch connectors. g293759 Figure 59 5. Disconnect the motor to the motor driver harness connector.
Motor Shroud Removal (continued) g293761 Figure 60 6. Disconnect the motor driver to the motor power connection. Remove the motor driver. g293760 Figure 61 7. Remove the 2 (1/4 x 1.0 inch) flange screws at the base of the battery receiver assembly.
Motor Shroud Removal (continued) g293765 Figure 62 8. Remove the battery receiver assembly from the power head assembly. g293766 Figure 63 9. Remove the remaining 2 (1/4 x 1.0 inch) flange screws from the motor shroud.
Motor Shroud Removal (continued) g295055 Figure 64 10. Remove the motor shroud from the power head assembly. g293768 Figure 65 Motor Shroud Installation 1. Install the motor shroud to the power head assembly.
Motor Shroud Installation (continued) g293768 Figure 66 2. Install the 2 of 4 (1/4 x 1.0 inch) flange screws securing motor shroud to lower shroud. Torque screws to 30 ± 3 in-lbs. (3.39 Nm). g295055 Figure 67 3. Install the battery receiver assembly to the power head assembly.
Motor Shroud Installation (continued) g293766 Figure 68 4. Install the 2 (1/4 x 1.0 inch) flange screws at the base of the battery receiver assembly. Torque screws to 30 ± 3 in-lbs. (3.39 Nm). g293765 Figure 69 5. Install the motor driver. Connect the motor driver to the motor power connection.
Motor Shroud Installation (continued) g296707 Figure 70 6. Connect the motor to the motor driver harness connector. g293761 Figure 71 7. Connect the harness from the motor driver to the start stop switch and bail switch connectors.
Motor Shroud Installation (continued) g293759 Figure 72 8. Connect the 2 connectors from the battery receiver assembly to the motor driver. Connect the negative first, then the positive. g296708 Figure 73 9. Install the 4 (T-20) torx screws to the motor fan shroud. Torque screws to 15–20 in-lbs. (1.7–2.26 Nm).
Motor Shroud Installation (continued) g293757 Figure 74 10. Install the power head upper shroud. Secure with 8 (6 top-around the battery cavity and 2 on the bottom rear) (1/4 x 1.0 inch) flange screws securing the power head upper shroud to the lower shroud. Torque screws to 30 ± 3 in-lbs. (3.39 Nm). g293756 Figure 75 Battery Door Replacement Battery Door Removal 1. Remove the upper shroud from the power head assembly. 2. Turn the upper shroud upside down.
Battery Door Removal (continued) 3. Remove the battery door by spreading apart, allowing the springs to fall into upper shroud. 4. Remove the springs from the upper shroud assembly. g295226 Figure 76 Battery Door Installation 1. Insert the battery door back into the upper shroud assembly. g295227 Figure 77 2. Insert a spring at a time, ensure the correct spring is for the correct side. Long tail of the spring should be toward the inside of the shroud assembly.
Battery Door Installation (continued) g295178 Figure 78 3. Using a small blade type screw driver, push the long tail of the spring into the molded slot on the upper shroud assembly. Repeat for opposite side. Note: This will preload the spring and put tension on the spring to return the door when opened. 4. Install the upper shroud assembly to the power head assembly.
Chapter 8 Motor Driver Table of Contents General Information .............................................................................................................................. 8–2 Service and Repairs ............................................................................................................................. 8–3 Motor Driver Replacement .................................................................................................................
General Information The motor driver measures and controls the battery and motor. It limits battery temperature and controls overheating by shutting down the motor for over temperature. The motor driver limits the amp draw to 35 amps.
Service and Repairs Motor Driver Assembly g294111 Figure 79 1. Screw 3. Flange Screw 2. Motor Driver 4.
Motor Driver Replacement Motor Driver Removal 1. Remove the battery from the power head assembly. 2. Remove the 8 (6 top-around the battery cavity and 2 on the bottom rear) (1/4 x 1.0 inch) flange screws securing the power head upper shroud to the lower shroud. Remove the power head upper shroud. g293756 Figure 80 3. Remove the 4 (T-20) torx screws from the motor fan shroud. g293757 Figure 81 4. Disconnect the 2 connectors from the battery receiver assembly to the motor driver.
Motor Driver Removal (continued) g293758 Figure 82 5. Disconnect the harness from the motor driver to the start stop switch and bail switch connectors. g293759 Figure 83 6. Disconnect the motor to the motor driver harness connector.
Motor Driver Removal (continued) g293761 Figure 84 7. Disconnect the motor driver to the motor power connection. Remove the motor driver. g293760 Figure 85 Motor Driver Test 1. 2. 3. 4. Verify battery is operational. Verify motor driver is getting voltage (power to motor driver). Verify motor is operational. If battery and motor are operational, replace the motor driver. Motor Driver Installation 1. Install the motor driver. Connect the motor driver to the motor power connection.
Motor Driver Installation (continued) g296707 Figure 86 2. Connect the motor to the motor driver harness connector. g293761 Figure 87 3. Connect the harness from the motor driver to the start stop switch and bail switch connectors.
Motor Driver Installation (continued) g293759 Figure 88 4. Connect the 2 connectors from the battery receiver assembly to the motor driver. Connect the negative first, then the positive. g296708 Figure 89 5. Install the 4 (T-20) torx screws to the motor fan shroud. Torque screws to 15–20 in-lbs. (1.7–2.26 Nm).
Motor Driver Installation (continued) g293757 Figure 90 6. Install the power head upper shroud. Secure with 8 (6 top-around the battery cavity and 2 on the bottom rear) (1/4 x 1.0 inch) flange screws securing the power head upper shroud to the lower shroud. Torque screws to 30 ± 3 in-lbs. (3.39 Nm). g293756 Figure 91 7. Install the battery to the power head assembly.
Motor Driver: Service and Repairs Page 8–10 60v WPM Service Manual 3429-828 Rev A
Chapter 9 Battery Terminal Table of Contents General Information .............................................................................................................................. 9–2 Service and Repairs ............................................................................................................................. 9–3 Battery Terminal Replacement ...........................................................................................................
General Information The battery terminal is a 3 terminal receiver with a positive, negative, and communication probe.
Service and Repairs Battery Terminal Assembly g294109 Figure 92 1. Screw 5. Flange Screw 2. 3. Motor Driver XKW Motor 6. 7. Motor Shroud Battery Receiver Asm. 4. Lock Nut 8.
Battery Terminal Replacement Battery Terminal Removal 1. Remove the battery from the power head assembly. 2. Remove the 8 (6 top-around the battery cavity and 2 on the bottom rear) (1/4 x 1.0 inch) flange screws securing the power head upper shroud to the lower shroud. Remove the power head upper shroud. g293756 Figure 93 3. Remove the 4 (T-20) torx screws from the motor fan shroud. g293757 Figure 94 4. Disconnect the 2 connectors from the battery receiver assembly to the motor driver.
Battery Terminal Removal (continued) g293758 Figure 95 5. Disconnect the harness from the motor driver to the start stop switch and bail switch connectors. g293759 Figure 96 6. Disconnect the motor to the motor driver harness connector.
Battery Terminal Removal (continued) g293761 Figure 97 7. Disconnect the motor driver to the motor power connection. Remove the motor driver. g293760 Figure 98 8. Remove the 2 (1/4 x 1.0 inch) flange screws at the base of the battery receiver assembly.
Battery Terminal Removal (continued) g293765 Figure 99 9. Remove the battery receiver assembly from the power head assembly. g293766 Figure 100 Battery Terminal Installation 1. Install the 2 (1/4 x 1.0 inch) flange screws at the base of the battery receiver assembly. Torque screws to 30 ± 3 in-lbs. (3.39 Nm).
Battery Terminal Installation (continued) g293765 Figure 101 2. Install the motor driver. Connect the motor driver to the motor power connection. g296707 Figure 102 3. Connect the motor to the motor driver harness connector.
Battery Terminal Installation (continued) g293761 Figure 103 4. Connect the harness from the motor driver to the start stop switch and bail switch connectors. g293759 Figure 104 5. Connect the 2 connectors from the battery receiver assembly to the motor driver. Connect the negative first, then the positive.
Battery Terminal Installation (continued) g296708 Figure 105 6. Install the 4 (T-20) torx screws to the motor fan shroud. Torque screws to 15–20 in-lbs. (1.7–2.26 Nm). g293757 Figure 106 7. Install the power head upper shroud. Secure with 8 (6 top-around the battery cavity and 2 on the bottom rear) (1/4 x 1.0 inch) flange screws securing the power head upper shroud to the lower shroud. Torque screws to 30 ± 3 in-lbs. (3.39 Nm).
Battery Terminal Installation (continued) g293756 Figure 107 8. Install the battery to the power head assembly.
Battery Terminal: Service and Repairs Page 9–12 60v WPM Service Manual 3429-828 Rev A
Chapter 10 Motor Table of Contents General Information ............................................................................................................................ 10–2 Service and Repairs ........................................................................................................................... 10–3 Motor Replacement.......................................................................................................................... 10–4 Bail Switch Replacement ........
General Information The motor is a brushless DC motor with cooling fans mounted on top to keep the motor temps down during operation.
Service and Repairs Motor Assembly g294076 Figure 108 1. Screw 10. Battery Receiver Asm. 2. 3. 4. 5. Motor Driver Wire Harness Bail Switch Asm. Flange Screw 11. 12. 13. 14. Lower Shroud Motor Base Asm. Mount Foam Foam Bracket 6. 7. 8. XKW Motor Lock Nuts Flange Screw 15. 16. 17. Plastic Screw Screw Motor Mount Insert 9.
Motor Replacement Motor Removal 1. Remove the battery from the power head assembly. 2. Remove the 8 (6 top-around the battery cavity and 2 on the bottom rear) (1/4 x 1.0 inch) flange screws securing the power head upper shroud to the lower shroud. Remove the power head upper shroud. g293756 Figure 109 3. Remove the 4 (T-20) torx screws from the motor fan shroud. g293757 Figure 110 4. Disconnect the 2 connectors from the battery receiver assembly to the motor driver.
Motor Removal (continued) g293758 Figure 111 5. Disconnect the harness from the motor driver to the start stop switch and bail switch connectors. g293759 Figure 112 6. Disconnect the motor to the motor driver harness connector.
Motor Removal (continued) g293761 Figure 113 7. Disconnect the motor driver to the motor power connection. Remove the motor driver. g293760 Figure 114 8. Remove the 2 (1/4 x 1.0 inch) flange screws at the base of the battery receiver assembly.
Motor Removal (continued) g293765 Figure 115 9. Remove the battery receiver assembly from the power head assembly. g293766 Figure 116 10. Remove the remaining 2 (1/4 x 1.0 inch) flange screws from the motor shroud.
Motor Removal (continued) g295055 Figure 117 11. Remove the motor shroud from the power head assembly. g293768 Figure 118 12. Separate the lower shroud from the motor base assembly.
Motor Removal (continued) g293795 Figure 119 13. Remove the 4 (10 mm) nuts from the motor to the motor base assembly. g293792 Figure 120 14. Separate the motor from the motor base assembly.
Motor Removal (continued) g293794 Figure 121 g293793 Figure 122 Motor Installation 1. Install the motor to the motor base assembly.
Motor Installation (continued) g293794 Figure 123 g293793 Figure 124 2. Install the 4 (10 mm) nuts to the from the motor to the motor base assembly. Torque nuts to 10 ft-lbs. (14 Nm).
Motor Installation (continued) g293792 Figure 125 3. Install the lower shroud to the motor base assembly. g293795 Figure 126 4. Install the motor shroud to the power head assembly.
Motor Installation (continued) g293768 Figure 127 5. Install the 2 (10 mm) screws to the motor shroud. Torque screws to 30 in-lbs. (3.39 Nm). g295055 Figure 128 6. Install the battery receiver assembly to the power head assembly.
Motor Installation (continued) g293766 Figure 129 7. Install the 2 (1/4 x 1.0 inch) flange screws at the base of the battery receiver assembly. Torque screws to 30 ± 3 in-lbs. (3.39 Nm). g293765 Figure 130 8. Install the motor driver. Connect the motor driver to the motor power connection.
Motor Installation (continued) g296707 Figure 131 9. Connect the motor to the motor driver harness connector. g293761 Figure 132 10. Connect the harness from the motor driver to the start stop switch and bail switch connectors.
Motor Installation (continued) g293759 Figure 133 11. Connect the 2 connectors from the battery receiver assembly to the motor driver. Connect the negative first, then the positive. g296708 Figure 134 12. Install the 4 (T-20) torx screws to the motor fan shroud. Torque screws to 15–20 in-lbs. (1.7–2.26 Nm).
Motor Installation (continued) g293757 Figure 135 13. Install the power head upper shroud. Secure with 8 (6 top-around the battery cavity and 2 on the bottom rear) (1/4 x 1.0 inch) flange screws securing the power head upper shroud to the lower shroud. Torque screws to 30 ± 3 in-lbs. (3.39 Nm). g293756 Figure 136 14. Install the battery to the power head assembly. Motor Testing The motor should turn relatively easy with a pulsing motion.
Bail Switch Replacement Bail Switch Removal The shoulder bolt is critical if ever removed, replacement part only sold as assembly. 1. Remove the battery from the power head assembly. 2. Remove the 8 (6 top-around the battery cavity and 2 on the bottom rear) (1/4 x 1.0 inch) flange screws securing the power head upper shroud to the lower shroud. Remove the power head upper shroud. g293756 Figure 137 3. Remove the 4 (T-20) torx screws from the motor fan shroud. g293757 Figure 138 4.
Bail Switch Removal (continued) g293758 Figure 139 5. Disconnect the harness from the motor driver to the start stop switch and bail switch connectors. g293759 Figure 140 6. Disconnect the motor to the motor driver harness connector.
Bail Switch Removal (continued) g293761 Figure 141 7. Disconnect the motor driver to the motor power connection. Remove the motor driver. g293760 Figure 142 8. Remove the 2 (1/4 x 1.0 inch) flange screws at the base of the battery receiver assembly.
Bail Switch Removal (continued) g293765 Figure 143 9. Remove the battery receiver assembly from the power head assembly. g293766 Figure 144 10. Remove the remaining 2 (1/4 x 1.0 inch) flange screws from the motor shroud.
Bail Switch Removal (continued) g295055 Figure 145 11. Remove the motor shroud from the power head assembly. g293768 Figure 146 12. Separate the lower shroud from the motor base assembly.
Bail Switch Removal (continued) g293795 Figure 147 13. Remove the 2 (1/4 x 1.0 inch) flange screws securing the bail switch to the lower motor shroud. g297102 Figure 148 14. Disconnect the harness from the bail switch. Remove the switch and harness from the lower shroud. Note: If harness anchor is damaged, replace.
Bail Switch Removal (continued) g297103 Figure 149 Bail Switch Installation 1. Install the switch and harness to the lower shroud. Connect the harness to the bail switch.
Bail Switch Installation (continued) 2. Install the 2 (1/4 x 1.0 inch) flange screws securing the bail switch to the lower motor shroud. Torque screws to 30 ± 3 in-lbs. (3.39 Nm). g297102 Figure 151 3. Install the lower shroud to the motor base assembly. g293795 Figure 152 4. Install the motor shroud to the power head assembly.
Bail Switch Installation (continued) g293768 Figure 153 5. Install the 2 (1/4 x 1.0 inch) flange screws to the motor shroud. Torque screws to 30 in-lbs. (3.39 Nm). g295055 Figure 154 6. Install the battery receiver assembly to the power head assembly.
Bail Switch Installation (continued) g293766 Figure 155 7. Install the 2 (1/4 x 1.0 inch) flange screws at the base of the battery receiver assembly. Torque screws to 30 ± 3 in-lbs. (3.39 Nm). g293765 Figure 156 8. Install the motor driver. Connect the motor driver to the motor power connection.
Bail Switch Installation (continued) g296707 Figure 157 9. Connect the motor to the motor driver harness connector. g293761 Figure 158 10. Connect the harness from the motor driver to the start stop switch and bail switch connectors.
Bail Switch Installation (continued) g293759 Figure 159 11. Connect the 2 connectors from the battery receiver assembly to the motor driver. Connect the negative first, then the positive. g296708 Figure 160 12. Install the 4 (T-20) torx screws to the motor fan shroud. Torque screws to 15–20 in-lbs. (1.7–2.26 Nm).
Bail Switch Installation (continued) g293757 Figure 161 13. Install the power head upper shroud. Secure with 8 (6 top-around the battery cavity and 2 on the bottom rear) (1/4 x 1.0 inch) flange screws securing the power head upper shroud to the lower shroud. Torque screws to 30 ± 3 in-lbs. (3.39 Nm). g293756 Figure 162 14. Install the battery to the power head assembly.
Appendix A Foldout Drawings Table of Contents Electrical Drawing Abbreviations........................................................................................................A–2 Electrical Schematic...........................................................................................................................A–3 Electrical Schematic...........................................................................................................................
Electrical Drawing Abbreviations The following abbreviations are used for wire harness colors on the electrical schematics and wire harness drawings in this chapter. Abbreviation Color BK Black BR or BM Brown BU Blue GN Green GY Gray OR Orange PK Pink R or RD Red T Tan VIO Violet W or WH White Y or YE Yellow Numerous harness wires include a line with an alternate color. These wires are identified with the wire color followed by a / or _ and then the line color (e.
Electrical Schematic g295078 , Drawing Rev A, Sheet 1 3429-828 Rev A Page A–3
Electrical Schematic g302253 Page A–4 3429-828 Rev A , Drawing Rev , Sheet
