TORO/LAWNBOY BATTERY & ELECTRIC POWERED MOWER SERVICE MANUAL Table Of Contents – Page 1 of 1 INTRODUCTION SPECIFICATIONS 120 VOLT MODELS BATTERY MODELS MOTOR EUROPEAN MODELS METRIC TORQUE AND BLADE TIP SPEED ASSEMBLY REQUIREMENTS SPECIAL TOOLS SAFETY INFORMATION 120 VOLT MODELS BATTERY POWERED MODELS OPERATIONAL TIPS (120 VOLT MODELS) BEFORE STARTING MAINTENANCE OPERATIONAL TIPS (24/36 VOLT MODELS) CHARGING LED CHARGING LIGHTS CHART STORAGE BATTERY POWER STATUS OPERATION KEY STARTING/STOPPING INSTRUCTIONS M
TABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Models Covered In This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . North American Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . International Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS Operational Tips (24/36 Volt Models). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 7 Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 7 LED Charging Lights Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 8 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS Switch Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Switch Testing (battery powered models). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing Safety Key Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Breaker Testing . . . . . . . . . . . .
PREFACE ABOUT THIS MANUAL This manual was written expressly for the Toro and Lawn-Boy brand electric and battery powered mowers. The Toro Company has made every effort to make the information in this manual complete and correct. This manual was written with the service technician in mind. The book contains material covering mowers that operate on 120 volt alternating current (North America only), and battery powered mowers that operate on 24 volt or 36 volt direct current.
1 INTRODUCTION Models Covered In This Manual Model/Serial Number Location North American Models On all battery or electric powered mowers, the model and serial number is engraved in the lower rear of the body or on a metal tag at this location (Figure 1). Models covered by this manual. All are built on the same 18” chassis. The only differences are in the electrical systems. Model No.
SPECIFICATIONS Specifications (120 Volt Models) Item Specification Width of Cut 18” (46 cm) Motor Universal wound 120 volt motor. Motor rated at 12 amps continuous duty. RPM Motor 20,500 with step down belt drive ratio 5.8-1. Blade speed at 20,500 fps is 3,534 rpm. Blade Tip Speed @ 3600 rpm 16,493 fps Weight 38 lbs. net dry. Standard Function The mowers come with mulching capability and a side discharge deflector. Options Side bagging kit. Compliance Conforms to UL #1447, CSA #C22.2 No.
SPECIFICATIONS Motor 24 Volt Models 36 Volt Models Type 24 volt permanent magnet 36 volt permanent magnet Speed 3750 ± 375 rpm 3600 ± 360 rpm Torque 165 oz.-in. @ 3100 rpm 180 oz.-in. @ 2950 rpm Rated Continuous Duty 22 amps 15 amps No Load Amps 8 amps 4.5 amps Blade Tip Speed 17,180 fps @ 3750 rpm 16,473 fps @ 3600 rpm Compliance Conforms to UL #1447, CSA #C22.2 No. 147-M90, ANSI B71.
SPECIFICATIONS Assembly Requirements Item Assembly Information Deck to liner screws 15 - 20 in. lbs. (17.3 - 23.0 kg cm) Wheel bolts 180 - 240 in. lbs. (207 - 276 kg cm) Motor to deck screws 80 - 85 in. lbs. (92 - 97 kg cm) Spindle pulley nut (120 volt) 200 - 300 in. lbs. (230 - 345.5 kg cm) Spindle to deck screws 80 - 85 in. lbs. (92 0 97 kg cm) Blade bolt (battery models) 35 - 40 ft. lbs. (4.8 - 5.5 kg m) Blade bolt (120 volt) 45 - 50 ft. lbs. (6.2 - 6.
2 SAFETY INFORMATION 120 Volt Models 2. The operator of the mower is responsible for keeping everyone, especially children and pets, away from area of operation. The operator is responsible for accidents or hazards occurring to other people or their property. 3. Thoroughly inspect area where mower will be used and remove sticks, stones, wire, and debris that could be picked up and thrown by mower. Watch for foreign objects while mowing.
SAFETY INFORMATION 10. WARNING: To prevent electric shock, use only with an extension cord suitable for outdoor use, such as SW-A, SOW-A, STW-A, STOW-A, SJWA, SJOW-A, SJTW-A, or SJTOW-A. 11. Extension Cord — Make sure your extension cord set is in good condition. When using an extension cord, be sure to use one heavy enough to carry the current your product will draw. Refer to Extension Cord Chart, see page 3 - 1.
SAFETY INFORMATION 11. Always maintain secure footing. Keep a firm grip on the handle and walk; never run. Mow only in daylight or in good artificial light. 24. Don't abuse extension cord. Never pull mower by cord or yank cord to disconnect it from receptacle. Keep cord away from heat, oil, and sharp edges. 12. Mow across the face of slopes; never up and down. Use extreme caution when changing direction on slopes. Do not mow excessively steep slopes. Wear skid resistant shoes on slopes. 25.
SAFETY INFORMATION 7. When not in use, store mower indoors in a dry, locked-up place out of the reach of children. Allow motor to cool before storing in an enclosure. 8. Check optional grass catcher bag frequently for wear or deterioration. Replace with a new bag when worn or damaged for your protection. 9. At the time of manufacture, the mower conformed to the safety standards in effect for rotary mowers.
SAFETY INFORMATION Safety and Instruction Decals any area of potential danger. Replace any decal that is damaged or lost. Safety decals and instructions are easily visible to the operator and are located near ON CONTROL PANEL ON MULCH PLUG ON MULCH PLUG ON MULCH PLUG ON REAR OF MOWER Carefree Mower Service Manual UNDER COVER (Part No.
2 SAFETY INFORMATION Battery Powered Models Safety Introduction IMPORTANT SAFETY INSTRUCTIONS Thank you for purchasing a Toro product. Improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert ! symbol which means CAUTION, WARNING or DANGER — “personal safety instruction.” Failure to comply with the instruction may result in personal injury.
SAFETY INFORMATION 3. 4. 5. 6. 7. 8. Thoroughly inspect area where mower will be used and remove sticks, stones, wire, and debris that could be picked up and thrown by mower. Watch for foreign objects while mowing. Objects struck by the lawn mower blade can cause severe injuries to persons. 4. Use Right Appliance — Do not use mower for any job except that for which it is intended. 5. Stay Alert — Watch what you are doing.
SAFETY INFORMATION 17. Use extreme caution when reversing or pulling the mower toward you. Before and while moving backwards, look behind and down for small children. 4. To prevent electric shock while charging, repair or replace any damaged electrical cords immediately. Note: The extension cord is only needed to recharge the battery. It is not used for mowing with the mower. 18.
SAFETY INFORMATION 15. To reduce fire hazard, keep motor free of excessive grass, leaves, and accumulations of dirt. 16. Check optional grass catcher bag frequently for wear or deterioration. Replace with a new bag when worn or damaged for your protection. 17. When not in use, remove key and store mower indoors in a dry, locked-up place out of the reach of children. Allow motor to cool before storing in an enclosure. 18.
SAFETY INFORMATION Sound Emissions Vibration Level This unit has a maximum airborne noise emission, based on measurement of identical machines: This unit has a maximum vibration level of 2.5 m/s2, based on measurement of identical machines*. Sound Pressure Level - 76dB(A)* Sound Power Level - 88 LwA* *Unit tested under no load condition. * Unit tested under no load condition.
SAFETY INFORMATION Keep dry Low Electrical shock, electrocution High Cutting element height of cut Splash-proof construction C. E.
3 OPERATIONAL TIPS (120 VOLT MODELS) Before Starting Secure Extension Cord Use only a UL listed (CSA certified in Canada) extension cord recommended for outdoor use. Refer to Extension Cord Chart. EXTENSION CORD CHART If length of extension cord is less than or equal to: 100 ft. 150 ft. Assure wire size gauge (A.W.G.) in cord is: 14 12 Note: Use of an extension cord over 150 feet is not recommended. Figure 4 Scan7-a 1. Form a loop in extension cord and secure it in cord lock (Figure 5).
OPERATIONAL TIPS (120 VOLT MODELS) Maintenance WARNING POTENTIAL HAZARD • The electrical cord could be damaged. WARNING WHAT CAN HAPPEN • A damaged electrical cord could cause a shock or fire. HOW TO AVOID THE HAZARD • Thoroughly inspect electrical cord before charging unit. If cord is damaged, do not charge unit. Replace or repair damaged cord immediately. Contact your TORO service dealer for assistance.
OPERATIONAL TIPS (120 VOLT MODELS) After Every Use • • Clean the underside of the mower housing. Be particularly careful to keep the front cavity clear of all debris (Figure 7). Remove dirt and grass clippings with a hardwood scraper. Avoid burrs and sharp edges. Check for any discolored or charred wires or switch contacts. If any are damaged, see your Authorized Toro Service Dealer for repairs. Blade Always mow with a sharp blade.
OPERATIONAL TIPS (120 VOLT MODELS) 3. EXAMINING BLADE - Carefully examine blade for sharpness and wear, especially where flat and curved parts meet. Since sand and abrasive material can wear away the metal that connects the flat and curved parts of the blade, check blade before using the mower. If a slot or wear is noticed replace blade (Figure 10). Refer to step 4. 4. REMOVING BLADE - Grasp end of blade using a rag or thickly padded glove. Remove blade bolt, washer and blade (Figure 11).
OPERATIONAL TIPS (120 VOLT MODELS) 6. Reinstall sharp, balanced blade, washer and blade bolt. Sail part of blade must point toward top of mower housing to ensure correct installation. Washer is curved and must be reinstalled with curve side down as shown in (Figure 13). Tighten blade bolt to 35-40 ft. lbs. (48-54 N·m). Figure 13 Storage Store mower in a cool, clean, dry place. Cover mower to keep it clean and protected. 1. Clean mower housing. See “Cleaning” section on page 3 - 2. 2.
3 OPERATIONAL TIPS (24/36 VOLT MODELS) Charging (battery powered models) 2. If key is in plug receptacle, remove it (Figure 14). Standard with all battery powered models is an automatic charger. This charger will periodically check the charge status of the batteries and charge them as needed. When the batteries are fully charged, the charger turns off. This charger also has the ability to sense when the batteries are too hot or too cold to be charged.
OPERATIONAL TIPS (24/36 VOLT MODELS) 4. The three vertical LED lights on the control panel will indicate the charging status (Figure 16). Refer to the Charging Chart below (Figure 17) for a summary of the LED lights. 5. After a few minutes, the red light will stop flashing and become a steady red. This indicates the battery is charging. 6. When the battery is almost fully charged, the red light will go out and the green light will go on. The red and green light will alternately turn on and off.
OPERATIONAL TIPS (24/36 VOLT MODELS) Storage (battery models) Battery Power Status The best storage for a battery is a cool dry place. In fact, a fully charged battery will withstand temperatures of about -50° F without freezing. (Windchill is not a factor for batteries, this is thermometer temperature.) However, a discharged battery will freeze at +32° F, the freezing point of water.
OPERATIONAL TIPS (24/36 VOLT MODELS) Key 3. The mower will only operate when key is fully seated in plug receptacle (Figure 19). To prevent accidental starting or unauthorized use of mower, always remove key from plug receptacle when leaving mower unattended. The key has a tab with a hole in it to allow key to be hung from a nail, out of the reach of children. Read warning label on key. Pull control bar toward handle while pushing down slide on control (Figure 21). Figure 21 4.
OPERATIONAL TIPS (24/36 VOLT MODELS) To Stop Motor 2. 1. Release control bar. 2. Remove key from plug receptacle if mower will be unattended for any period of time. Hang key in a high place out of reach of children. 3. Always charge battery immediately after each use of mower. If battery is not charged after each use, battery life will be shortened. See “Charging (battery powered models)” on page 3 7.
OPERATIONAL TIPS (24/36 VOLT MODELS) • Height-of-cut setting - If you are experiencing problems with the battery running down too fast, try raising the height-of-cut setting one notch. • Grass grows at different rates at different times of the year. In the heat of summer, it is generally best to cut grass at the 2-1/2", 3" or 3-1/2" height-of-cut settings. Only about 1/3 of the grass blade should be cut off.
OPERATIONAL TIPS (24/36 VOLT MODELS) • Walk at a slower mowing speed if leaves are not being cut up finely enough to be hidden down in the grass. • If you cut up a lot of oak leaves, you might want to add lime to your grass in the spring. Lime reduces the acidity of oak leaves. Adjusting Height-of-Cut The mower has five height-of-cut adjustments: 1-1/2", 2", 2-1/2", 3", and 3-1/2".
OPERATIONAL TIPS (24/36 VOLT MODELS) Cleaning Once A Year Before cleaning mower, stop motor, wait for all moving parts to stop, and disconnect extension cord from mower. • IMPORTANT: Do not clean mower with a garden hose. Moisture can be trapped in mower and may cause corrosion of internal parts. IMPORTANT: Do not use metal objects to clean around battery. If metal objects contact the positive and negative posts at the same time, this could short the battery.
OPERATIONAL TIPS (24/36 VOLT MODELS) 1. 2. Stop motor and wait for all moving parts to stop. Disconnect extension cord from mower. Tip mower on its side (Figure 29). WARNING POTENTIAL HAZARD • A worn or damaged blade could break and a piece of blade could be thrown in operator's or bystander's direction. WHAT CAN HAPPEN • A thrown piece of blade could cause serious personal injury or death to operator or bystanders. HOW TO AVOID THE HAZARD • Inspect blade periodically for wear or damage.
OPERATIONAL TIPS (24/36 VOLT MODELS) 5. SHARPENING BLADE — Using a file, sharpen top side of blade and maintain original cutting angle (Figure 32). The blade will remain balanced if same amount of material is removed from both cutting edges. IMPORTANT: Check balance of blade by putting it on a blade balancer. An inexpensive balancer can be purchased at a hardware store. A balanced blade stays in a horizontal position and an unbalanced blade settles to the heavy side.
4 TESTING ELECTRICAL COMPONENTS 120 Volt Models 120 Electrical System Testing There are four components in the electrical system: Because of the simplicity of the system, there are only two tests that need to be made. A. B. C. D. Motor. 2 wires between the motor and switch. Switch. Wires between the switch and the plug receptacle. Description Specification Motor Input Voltage 108 - 132 VAC Motor Resistance* 0.8 to 1.2 ohms *Measure at motor leads with power disconnected. Safety Information A.
TESTING ELECTRICAL COMPONENTS Battery Powered Models The electrical components in a battery powered model are as follows: A. B. C. D. E. F. G. H. I. Motor. Solenoid. Batteries. Charger — includes indicator lights. Transformer. Switch. Wire harness. Safety key terminals. Circuit breaker. Motor Testing There is one simple test that can be made on the motor. Unplug the motor from the wire harness. Set an ohmmeter on Rx1 and zero the meter.
TESTING ELECTRICAL COMPONENTS This 24 volt solenoid requires a minimum of 18 volts to engage, therefore, it is necessary to use the actual mower batteries to test it (Figure 38). Test the A - A terminals by connecting power and the ohmmeter as shown below.
TESTING ELECTRICAL COMPONENTS Charger Testing Flashing Yellow Charging Indicator This charger’s control system cannot be tested using common testing equipment. However, if the charging lights work, the charger is likely working. A flashing yellow indicator shows that the temperature is either too hot or too cold. When the temperature situation is corrected, the red indicator will illuminate and the charger will resume charging at the rate last determined (Figure 41).
TESTING ELECTRICAL COMPONENTS Flashing Red Charging Indicator Steady Red Charging Indicator A flashing red light indicates that the charger is performing the “Pre-Charge Qualification.” During this stage, the charger sends a trickle charge to the batteries to determine if they will be able to take a charge. The charger also evaluates the ambient temperature to insure that its not too hot or too cold to charge (Figure 42).
TESTING ELECTRICAL COMPONENTS Steady Green Charging Indicator Charge Remaining Indicator Lights A steady green charging indicator shows that the batteries are fully charged. Even once the fully charged level is achieved, the charger still periodically re-evaluates battery condition to determine if they need to be “topped off.” If so, the charger will switch to the charge mode (indicated by the steady red indicator).
TESTING ELECTRICAL COMPONENTS Transformer Testing Test the transformer using a volt/ohmmeter (Figure 47). #3 #1 #2 & #4 Figure 47 0674-008 European, U.K., & Swiss Models US & Canadian Models # Test 24 Volt Models 36 Volt Models 1 Transformer Input Voltage 108 to 132 VAC 108 to 132 VAC 207 - 244 VAC @ 50 hz 2 Transformer Output Voltage* 37.8 to 42.1 VAC* 52.0 to 57.8 VAC* 43.2 VAC* 3 Transformer Primary Resistance 4.5 to 5.3 Ohms 4.6 to 5.
TESTING ELECTRICAL COMPONENTS Testing Safety Key Terminals Switch Testing Switch Testing (battery powered models) The switch used is a two position, three terminal switch. Two tests must be made to assure the switch works properly. An ohmmeter or continuity light will properly test this switch. Continuity must be present as shown in the diagram (Figure 48). Test by checking for 24 or 36 volts between both terminals with the key removed and the control bar in the ON position (Figure 49).
5 BLADE STOPPING SYSTEMS Blade Stopping Systems Battery Mower Systems There are two blade stopping systems in use on the various battery and electric powered mowers — one for the 120 vac models and the other for the battery powered models. Both systems are designed to stop the blade within three seconds of the operator releasing the bail on the handle. The battery powered models use a permanent magnet motor. If you turn the armature of a permanent magnet motor by hand, the motor becomes a generator.
6 DISASSEMBLY & REASSEMBLY Disassembly — Battery Models Battery Replacement All the electrical components are located under the hood. The on/off switch is controlled by a cable that runs alongside the handle. With the hood removed, there is access to the test points of all electrical components. The batteries are held in place by a strap. To remove the strap, remove either of the screws securing the ends of the strap. However, the batteries are resting on double sided tape.
DISASSEMBLY & REASSEMBLY Blade Brake — 120 Volt Models 1. Remove the motor cover retained with four screws. 2. Roll the belt off the large pulley. See ”Belt Replacement" on page 6 - 3. 3. Remove the nut on the large pulley and remove the pulley (Figure 52). NOTE: The blade and spindle shaft may drop down when the pulley is removed. Figure 53 (A) Brake Arm 0663-011 (B) Cable Support Bracket 120 Volt Motor Replacement Figure 52 (A) Nut 4.
DISASSEMBLY & REASSEMBLY Replacing Blade Spindle or Spindle Bearings Cable Adjustment Remove the nut on the large pulley and remove the pulley. Lower the bail to the rest position. The switch should be off. Proper adjustment is achieved when the slack is removed from the cable, but no tension is applied. 1. Remove the motor cover retained with four screws. Belt Replacement — 120 Volt Models 2. Roll the belt off the large pulley. See Belt Replacement on page 6 - 3. 3.
7 HIPOT TESTING Introduction 120 volt mowers should be hipot tested to assure a safe product after any electrical repairs are performed. 4. If still no voltage, the ground is disconnected and you must have the outlet repaired or find a grounded outlet. Hipot Tester Safety Rules Safety Rule #1 • Turn the voltage to the lowest setting (if applicable) and the power switch to OFF when not using the tester. This will prevent inadvertently energizing the test probes.
HIPOT TESTING Step #2: Tape the Power Switch “ON” Step #4: Select the Correct Voltage Prepare the unit to be tested by taping the power switch in the “ON” position (Figure 60). This completes the circuit inside the equipment and helps insure that your hipot test includes ALL wires inside the product. Turn the tester on and set the voltage at recommended test voltage (Figure 62). The “pre” and “post” tests are usually performed at different voltages as indicated below.
HIPOT TESTING Perform a second test between the output shaft and the wiring at the same voltage as below (Figure 65). Figure 63 0669-009-a Testing the Motor Figure 65 If in the process of repair of product you expose the motor, it is a good idea to test the motor itself. The motor should have internal insulation to prevent voltage from reaching the case or output shaft.
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