Toro 20363 Service Manual
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Toro 20363 Service Manual

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Form No. 3429-828 Rev A
60v WPM Service Manual
Published: December 2019
© 2019—The Toro® Company
Original Instructions (EN)
8111 Lyndale Avenue South
Contact us at www.Toro.com.
Bloomington, MN 55420
All Rights Reserved

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  • Page 1 Form No. 3429-828 Rev A 60v WPM Service Manual Published: December 2019 © 2019—The Toro® Company Original Instructions (EN) 8111 Lyndale Avenue South Contact us at www.Toro.com. Bloomington, MN 55420 All Rights Reserved...
  • Page 2 Revision History Revision History Page 2 60v WPM Service Manual 3429-828 Rev A...
  • Page 3 The Toro Company RLC/SWS Customer Care Department 8111 Lyndale Avenue South Bloomington, MN 55420 The Toro Company reserves the right to change product specifications or make changes to this manual without notice. 60v WPM Service Manual Page 3 Preface...
  • Page 4 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. components) that may have been removed •...

  • Page 5: Table Of Contents

    Table of Contents Preface ........................ 3 Chapter 1: Safety .................... 1–1 Safety Instructions ..................1–2 Chapter 2: Specifications and Maintenance ............ 2–1 Specifications ....................2–2 Torque Specifications ................... 2–3 Chapter 3: Troubleshooting ................3–1 General Troubleshooting ................3–3 Error Beep Table ................... 3–4 Chapter 4: Power Head Assembly..............
  • Page 6 Preface Page 6 60v WPM Service Manual 3429-828 Rev A...
  • Page 7 Chapter 1 Safety Table of Contents Safety Instructions ..........................1–2 Think Safety First ..........................1–2 60v WPM Service Manual Page 1–1 Safety 3429-828 Rev A...

  • Page 8: Safety Instructions

    Safety Instructions DANGER This safety symbol means danger. When you see this symbol, carefully read the instructions that follow. Failure to obey the instructions could cause serious permanent injury, disability, or death. WARNING This safety symbol means warning. When you see this symbol, carefully read the instructions that follow.
  • Page 9 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…...
  • Page 10 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.
  • Page 11 Chapter 2 Specifications and Maintenance Table of Contents Specifications ............................2–2 Torque Specifications ........................... 2–3 Equivalents and Conversions......................2–8 U.S. to Metric Conversions ........................ 2–9 60v WPM Service Manual Page 2–1 Specifications and Maintenance 3429-828 Rev A...

  • Page 12: Specifications

    Specifications Product Specifications Model 20363 20366 Motor 60 volt, 2kW motor Battery 6.0Ah battery (1/3 acres of cut) 7.5Ah battery (approx. .4 Acres of cut) Charge Time 2 amp charger, 6.0Ah battery takes 2 amp charger, 7.5 Ah battery takes about...

  • Page 13: Torque Specifications

    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.
  • Page 14 Metric Bolts and Screws g272209 Figure 2 Class 8.8 Class 10.9 Specifications and Maintenance: Torque Specifications Page 2–4 60v WPM Service Manual 3429-828 Rev A...
  • Page 15 Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size Grade 1, SAE Grade 1 Bolts, Screws, SAE Grade 5 Bolts, Screws, SAE Grade 8 Bolts, Screws, 5, & 8 Studes & Sems with Studs & Sems with Regular Studs &...
  • Page 16 Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Series) Thread Size Class 8.8 Bolts, Screws, Studs with Regular Class 10.9 Bolts, Screws, Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Height Nuts (Class 10 or stronger Nuts) in-lb.
  • Page 17 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 ±...
  • Page 18 Equivalents and Conversions Decimal and Millimeter Equivalents Fractions Decimals Fractions Decimals 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...
  • Page 19 U.S. to Metric Conversions To Convert Into Multiply By Miles Kilometers 1.609 Yards Meters 0.9144 Feet Meters 0.3048 Linear Measurement 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 Area Square Inches...
  • Page 20 Specifications and Maintenance: Torque Specifications Page 2–10 60v WPM Service Manual 3429-828 Rev A...
  • Page 21 Chapter 3 Troubleshooting Table of Contents General Troubleshooting ........................3–3 Error Beep Table............................ 3–4 60v WPM Service Manual Page 3–1 Troubleshooting 3429-828 Rev A...
  • Page 22 GEARS The Systematic approach to defining, diagnosing and solving problems. Gather Information • Information reported by the customer • Information observed by you • Establish the what, where and when of the issue Evaluate Potential Causes • Consider possible causes of the problem to develop a hypothesis •...

  • Page 23: General Troubleshooting

    General Troubleshooting Problem Possible Cause Corrective Action The tool will not operate 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.

  • Page 24: Error Beep Table

    Error Beep Table Error Type Number of Beeps Next Step Communication Error Verify motor driver and battery functionality. Replace motor driver and/or battery as necessary. Time Out Error Verify motor driver and battery functionality. Replace motor driver and/or battery as necessary. Motor Driver Error Verify motor driver functionality.
  • Page 25 Table of Contents General Information ..........................4–2 Service and Repairs ..........................4–3 20363 with Personal Pace 22 inch Recycler Power Head Assembly Replacement......4–5 20361 22 inch Recycler Power Head Assembly Replacement ............4–11 60v WPM Service Manual Page 4–1...

  • Page 26: General Information

    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.

  • Page 27: Service And Repairs

    Service and Repairs 20363 with Personal Pace 22 inch Recycler Power Head Assembly g294042 Figure 3 Motor Module Pulley HWH Screw Blade Retainer Belt Cover Blade Belt Guide Blade Support Taptite Screw Blade Bolt 60v WPM Service Manual Page 4–3...
  • Page 28 20361 22 inch Recycler Power Head Assembly g294040 Figure 4 Motor Module Blade HWH Form THD Screw Blade Support Taptite Screw Blade Bolt Power Head Assembly: Service and Repairs Page 4–4 60v WPM Service Manual 3429-828 Rev A...

  • Page 29: 20363 With Personal Pace 22 Inch Recycler Power Head Assembly Replacement

    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.
  • Page 30 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.
  • Page 31 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.
  • Page 32 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.
  • Page 33 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.
  • Page 34 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.

  • Page 35: 20361 22 Inch Recycler Power Head Assembly Replacement

    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.
  • Page 36 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. Power Head Assembly: Service and Repairs Page 4–12 60v WPM Service Manual...
  • Page 37 Chapter 5 Controls Table of Contents General Information ..........................5–2 Service and Repairs ..........................5–3 Starter Switch Replacement....................... 5–5 Safety Bail Switch Replacement ......................5–8 60v WPM Service Manual Page 5–1 Controls 3429-828 Rev A...

  • Page 38: General Information

    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.

  • Page 39: Service And Repairs

    Service and Repairs Starter Switch Assembly g295233 Figure 18 Cable Clamp Starter Switch Asm. 60v WPM Service Manual Page 5–3 Controls: Service and Repairs 3429-828 Rev A...
  • Page 40 Figure 18 (continued) Safety Bail Switch Assembly g295142 Figure 19 Safety Bail Switch Lower Shroud Controls: Service and Repairs Page 5–4 60v WPM Service Manual 3429-828 Rev A...

  • Page 41: Starter Switch Replacement

    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.
  • Page 42 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.
  • Page 43 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.

  • Page 44: Safety Bail Switch Replacement

    Starter Switch Harness Testing (continued) g296543 Figure 26 Wire Color Continuity with Left Side Continuity with Right Side Continuity with Both Side Switch Depressed Switch Depressed 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...
  • Page 45 Safety Bail Switch Testing (continued) g296544 Figure 27 60v WPM Service Manual Page 5–9 Controls: Service and Repairs 3429-828 Rev A...
  • Page 46 Controls: Service and Repairs Page 5–10 60v WPM Service Manual 3429-828 Rev A...
  • Page 47 Chapter 6 Charger and Battery Table of Contents General Information ..........................6–2 Service and Repairs ..........................6–3 Battery..............................6–4 Charger .............................. 6–4 60v WPM Service Manual Page 6–1 Charger and Battery 3429-828 Rev A...

  • Page 48: General Information

    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.

  • Page 49: Service And Repairs

    Service and Repairs Battery and Charger Assembly g295057 Figure 28 Battery Charger 60v WPM Service Manual Page 6–3 Charger and Battery: Service and Repairs 3429-828 Rev A...

  • Page 50: Battery

    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.
  • Page 51 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 ..................7–5 Motor Shroud Replacement ......................7–16 Battery Door Replacement....................... 7–26 60v WPM Service Manual Page 7–1 Shrouds 3429-828 Rev A...

  • Page 52: General Information

    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. Shrouds: General Information Page 7–2 60v WPM Service Manual 3429-828 Rev A...

  • Page 53: Service And Repairs

    Service and Repairs Shroud Assembly g294043 Figure 29 Upper Shroud LH Spring Magnet PPH Screw Flange Screw Hood RH Spring 60v WPM Service Manual Page 7–3 Shrouds: Service and Repairs 3429-828 Rev A...

  • Page 54: Power Head Shroud Upper Replacement

    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.

  • Page 55: Power Head Shroud Lower Replacement

    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.
  • Page 56 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. Shrouds: Service and Repairs Page 7–6 60v WPM Service Manual 3429-828 Rev A...
  • Page 57 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.
  • Page 58 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. Shrouds: Service and Repairs Page 7–8 60v WPM Service Manual 3429-828 Rev A...
  • Page 59 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. 60v WPM Service Manual Page 7–9 Shrouds: Service and Repairs 3429-828 Rev A...
  • Page 60 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.
  • Page 61 Power Head Shroud Lower Installation (continued) g293791 Figure 44 Install the lower shroud to the motor base assembly. g293795 Figure 45 3. Install the motor shroud to the power head assembly. 60v WPM Service Manual Page 7–11 Shrouds: Service and Repairs 3429-828 Rev A...
  • Page 62 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. Shrouds: Service and Repairs Page 7–12 60v WPM Service Manual...
  • Page 63 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.
  • Page 64 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. Shrouds: Service and Repairs Page 7–14 60v WPM Service Manual 3429-828 Rev A...
  • Page 65 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 Negative Positive 11. Install the 4 (T-20) torx screws to the motor fan shroud. Torque screws to 15–20 in-lbs.

  • Page 66: Motor Shroud Replacement

    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.
  • Page 67 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. 60v WPM Service Manual Page 7–17 Shrouds: Service and Repairs...
  • Page 68 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. Shrouds: Service and Repairs Page 7–18 60v WPM Service Manual 3429-828 Rev A...
  • Page 69 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.
  • Page 70 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. Shrouds: Service and Repairs Page 7–20 60v WPM Service Manual 3429-828 Rev A...
  • Page 71 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. 60v WPM Service Manual Page 7–21 Shrouds: Service and Repairs 3429-828 Rev A...
  • Page 72 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. Shrouds: Service and Repairs Page 7–22 60v WPM Service Manual...
  • Page 73 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.
  • Page 74 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. Shrouds: Service and Repairs Page 7–24 60v WPM Service Manual 3429-828 Rev A...
  • Page 75 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.

  • Page 76: Battery Door Replacement

    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.
  • Page 77 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.
  • Page 78 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.
  • Page 79 Chapter 8 Motor Driver Table of Contents General Information ..........................8–2 Service and Repairs ..........................8–3 Motor Driver Replacement ......................... 8–4 60v WPM Service Manual Page 8–1 Motor Driver 3429-828 Rev A...
  • Page 80 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. Motor Driver: General Information Page 8–2 60v WPM Service Manual 3429-828 Rev A...
  • Page 81 Service and Repairs Motor Driver Assembly g294111 Figure 79 Screw Flange Screw Motor Driver Motor Shroud 60v WPM Service Manual Page 8–3 Motor Driver: Service and Repairs 3429-828 Rev A...
  • Page 82 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.

  • Page 83: Chapter 8: 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. 60v WPM Service Manual Page 8–5 Motor Driver: Service and Repairs 3429-828 Rev A...
  • Page 84 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. Verify battery is operational. 2. Verify motor driver is getting voltage (power to motor driver). 3.
  • Page 85 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. 60v WPM Service Manual Page 8–7 Motor Driver: Service and Repairs 3429-828 Rev A...
  • Page 86 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.
  • Page 87 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.
  • Page 88 Motor Driver: Service and Repairs Page 8–10 60v WPM Service Manual 3429-828 Rev A...
  • Page 89 Chapter 9 Battery Terminal Table of Contents General Information ..........................9–2 Service and Repairs ..........................9–3 Battery Terminal Replacement ......................9–4 60v WPM Service Manual Page 9–1 Battery Terminal 3429-828 Rev A...

  • Page 90: General Information

    General Information The battery terminal is a 3 terminal receiver with a positive, negative, and communication probe. Battery Terminal: General Information Page 9–2 60v WPM Service Manual 3429-828 Rev A...

  • Page 91: Service And Repairs

    Service and Repairs Battery Terminal Assembly g294109 Figure 92 Screw Flange Screw Motor Driver Motor Shroud XKW Motor Battery Receiver Asm. Lock Nut Lower Shroud 60v WPM Service Manual Page 9–3 Battery Terminal: Service and Repairs 3429-828 Rev A...
  • Page 92 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.

  • Page 93: Chapter 9: Battery Terminal

    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. 60v WPM Service Manual Page 9–5 Battery Terminal: Service and Repairs 3429-828 Rev A...
  • Page 94 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.
  • Page 95 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.
  • Page 96 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: Service and Repairs Page 9–8 60v WPM Service Manual 3429-828 Rev A...
  • Page 97 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.
  • Page 98 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.
  • Page 99 Battery Terminal Installation (continued) g293756 Figure 107 8. Install the battery to the power head assembly. 60v WPM Service Manual Page 9–11 Battery Terminal: Service and Repairs 3429-828 Rev A...
  • Page 100 Battery Terminal: Service and Repairs Page 9–12 60v WPM Service Manual 3429-828 Rev A...
  • Page 101 Chapter 10 Motor Table of Contents General Information ..........................10–2 Service and Repairs ........................... 10–3 Motor Replacement.......................... 10–4 Bail Switch Replacement ....................... 10–18 60v WPM Service Manual Page 10–1 Motor 3429-828 Rev A...

  • Page 102: General Information

    General Information The motor is a brushless DC motor with cooling fans mounted on top to keep the motor temps down during operation. Motor: General Information Page 10–2 60v WPM Service Manual 3429-828 Rev A...

  • Page 103: Service And Repairs

    Service and Repairs Motor Assembly g294076 Figure 108 Screw Battery Receiver Asm. Motor Driver Lower Shroud Wire Harness Motor Base Asm. Mount Bail Switch Asm. Foam Flange Screw Foam Bracket XKW Motor Plastic Screw Lock Nuts Screw Flange Screw Motor Mount Insert Motor Shroud 60v WPM Service Manual Page 10–3...

  • Page 104: Motor Replacement

    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.

  • Page 105: Service And Repairs

    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. 60v WPM Service Manual Page 10–5 Motor: Service and Repairs 3429-828 Rev A...
  • Page 106 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: Service and Repairs Page 10–6 60v WPM Service Manual...
  • Page 107 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. 60v WPM Service Manual Page 10–7 Motor: Service and Repairs 3429-828 Rev A...
  • Page 108 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: Service and Repairs Page 10–8 60v WPM Service Manual 3429-828 Rev A...
  • Page 109 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. 60v WPM Service Manual Page 10–9 Motor: Service and Repairs 3429-828 Rev A...
  • Page 110 Motor Removal (continued) g293794 Figure 121 g293793 Figure 122 Motor Installation 1. Install the motor to the motor base assembly. Motor: Service and Repairs Page 10–10 60v WPM Service Manual 3429-828 Rev A...
  • Page 111 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). 60v WPM Service Manual Page 10–11 Motor: Service and Repairs 3429-828 Rev A...
  • Page 112 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: Service and Repairs Page 10–12 60v WPM Service Manual 3429-828 Rev A...
  • Page 113 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. 60v WPM Service Manual Page 10–13 Motor: Service and Repairs 3429-828 Rev A...
  • Page 114 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.
  • Page 115 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. 60v WPM Service Manual Page 10–15 Motor: Service and Repairs 3429-828 Rev A...
  • Page 116 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.
  • Page 117 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.

  • Page 118: Bail Switch Replacement

    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.
  • Page 119 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. 60v WPM Service Manual Page 10–19 Motor: Service and Repairs 3429-828 Rev A...
  • Page 120 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.
  • Page 121 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. 60v WPM Service Manual Page 10–21 Motor: Service and Repairs 3429-828 Rev A...
  • Page 122 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. Motor: Service and Repairs Page 10–22 60v WPM Service Manual 3429-828 Rev A...
  • Page 123 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.
  • Page 124 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. g297103 Figure 150 Motor: Service and Repairs Page 10–24 60v WPM Service Manual 3429-828 Rev A...
  • Page 125 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.
  • Page 126 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. Motor: Service and Repairs Page 10–26 60v WPM Service Manual...
  • Page 127 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.
  • Page 128 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. Motor: Service and Repairs Page 10–28 60v WPM Service Manual 3429-828 Rev A...
  • Page 129 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.
  • Page 130 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.
  • Page 131 Appendix A Foldout Drawings Table of Contents Electrical Drawing Abbreviations......................A–2 Electrical Schematic...........................A–3 Electrical Schematic...........................A–4 60v WPM Service Manual Page A–1 Foldout Drawings 3429-828 Rev A...

  • Page 132: Electrical Drawing Abbreviations

    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 Black BR or BM Brown Blue Green Gray Orange Pink R or RD Violet W or WH White Y or YE Yellow...

  • Page 133: Electrical Schematic

    Electrical Schematic g295078 , Drawing Rev A, Sheet 1 3429-828 Rev A Page A–3...
  • Page 134 Electrical Schematic g302253 Page A–4 3429-828 Rev A , Drawing Rev , Sheet...

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