Form No. 3439-480 Rev A 60v Battery Service Manual Published: January 2021 © 2020—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 Battery Service Manual 3439-480 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 Battery Service Manual 3439-480 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.
Think Safety First (continued) 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 from lithium-ion batteries… If any smoke is observed, call the local emergency services immediately. Always service lithium-ion batteries with the machine parked near a service door large enough to move the product or battery outside in case of an emergency and keep a fire blanket nearby.
Think Safety First (continued) penetrate the skin and cause serious injury. Seek medical attention right away if hydraulic fluid gets in the skin. Personal Protective Equipment… Tie back long hair, and do not wear loose clothing or jewelry. Use appropriate personal protective equipment (PPE) for protecting yourself from potential hazards in the environment in which you will work. Each process outlined in this manual may need different PPE to protect the service person.
Chapter 2 Specifications and Maintenance Table of Contents Specifications ....................................................................................................................................... 2–2 Torque Specifications ........................................................................................................................... 2–3 Equivalents and Conversions............................................................................................................. 2–8 U.S.
Specifications Model 88620 88625 88640 88660 88675 Battery 2.0 Ah Battery 2.5 Ah Battery 4.0 Ah Battery 6.0 Ah Battery 7.5 Ah Battery Battery Size (W x H x L) Weight 15.11 x 20.32 x 10.41 cm (5.95 x 8.0 x 4.1 inches) 1.65 kg (3.65 lb) Specifications and Maintenance: Specifications 2.33 kg (5.15 lb) Page 2–2 2.94 kg (6.5 lb) 3.15 kg (6.
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 N • cm 10 ± 2 13 ± 2 147 ± 23 13 ± 2 25 ± 5 282 ± 30 18 ± 2 30 ± 5 339 ± 56 1/4-20 UNC 48 ± 7 53 ± 7 1/4-28 UNF 53 ± 7 5/16-18 UNC 5/16-24 UNF SAE Grade 5 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE Grade 5 or Better Nut) SAE Grade 8 Bolt
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-lb N • m ft-lb 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 N •m 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 Battery Service Manual 3439-480 Rev A
Chapter 3 Troubleshooting Table of Contents General Troubleshooting ....................................................................................................................... 3–3 Battery Operated Products Troubleshooting Guide ...............................................................................
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.
Battery Operated Products Troubleshooting Guide g340220 Figure 3 Troubleshooting: General Troubleshooting Page 3–4 60v Battery Service Manual 3439-480 Rev A
Chapter 4 Theory of Operation Table of Contents General Information .............................................................................................................................. 4–2 Service and Repairs ............................................................................................................................. 4–3 Battery Architecture ...........................................................................................................................
General Information Theory of Operation: General Information Page 4–2 60v Battery Service Manual 3439-480 Rev A
Service and Repairs Battery and Charger Assembly 1 g295057 Figure 4 1. Battery 60v Battery Service Manual 3439-480 Rev A 2.
Battery and Charger Assembly 2 g336766 Figure 5 1.
See Operator’s Manual for additional information. Battery Architecture Inside the battery pack are the cell/power pack and BMS (Battery Management System) combined to ensure the battery in the tool works the way it’s supposed to. Cell/Power Pack The first component of the battery pack is the cell pack. Cell packs come in a variety of formats, different shapes and sizes, for different applications.
Features Managed by Product Features managed by the product include tool operations and power usage control. The BMS does not tell the tool what to do and it does not dictate how much power is being used, the tool does. Battery Configuration When thinking about battery configuration, the 3 key terms are: voltage, amp hours, and watt hours. Individual cylindrical cells are configured in parallel and series to form a battery pack.
Chapter 5 Use Expectations Table of Contents General Information .............................................................................................................................. 5–2 Service and Repairs ............................................................................................................................. 5–3 60 Volt Run Time................................................................................................................................
General Information Use Expectations: General Information Page 5–2 60v Battery Service Manual 3439-480 Rev A
Service and Repairs 60 Volt Run Time Tool 2.5 Ah Battery 4.0 Ah Battery 6.0 Ah Battery 7.
Use Expectations: Service and Repairs Page 5–4 60v Battery Service Manual 3439-480 Rev A
Chapter 6 Testing Table of Contents General Information .............................................................................................................................. 6–2 Service and Repairs .............................................................................................................................
General Information Testing: General Information Page 6–2 60v Battery Service Manual 3439-480 Rev A
Service and Repairs Battery and Charger g336764 Figure 6 At 60 VDC the charger will indicate a full battery. If left on the charger, the battery will continue to charge for a period of time bringing the battery voltage up to 62 VDC. A battery with a reading of under 40 VDC has been over discharged and will likely not recover requiring replacement. The 60v batteries have 4 terminals. To test the battery voltage, place a multimeter on the DC voltage auto range.
