Toro Greensmaster TriFlex 3300 User manual

FormNo.16229SLRevA
Greensmaster®TriFlex™3300,
3320,3400,and3420Diagnostic
FaultCodeManual
ModelNo.04510,04520,04530,and04540
Registeratwww.Toro.com.
OriginalInstructions(EN)*16229SL*

Introduction
Thepurposeofthispublicationistoprovidetheservicetechnicianwithinformationfordiagnostictroubleshooting
andtestingonallfourmodelsoftheGreensmasterTriFlexgreensmowers:3300,3320,3400,and3420.
TheT oroCompanyreservestherighttochangeproductspecicationsorthispublicationwithoutnotice.
Improperuseormaintenancebytheoperatororownercanresultininjury.Toreducethepotentialforinjury,
complywiththesesafetyinstructionsandalwayspayattentiontothesafetyalertsymbol(Figure1),whichis
integratedintothepersonalsafetyinstructionsymbolsforCaution,Warning,andDanger.Failuretocomplywith
theinstructionmayresultinpersonalinjuryordeath.
g000502
Figure1
SafetyAlertSymbol
ThismachinemeetsorexceedsCENstandardEN836:1997,ISOstandard5395:1990,andANSIB71.4-2004
specicationsineffectatthetimeofproduction.
ReaderComments
TheT oroCompanyTechnicalAssistanceCentermaintainsacontinualefforttoimprovethequalityand
usefulnessofitspublications.Todothiseffectively,weencourageuserfeedback.Pleasecomment
onthecompleteness,accuracy,organization,usability,andreadabilityofthismanualviaemailto
[email protected]
ormailto:
TechnicalPublicationManager,Commercial
TheToroCompany
8111LyndaleAvenueSouth
Bloomington,MN55420-1196
Phone:[phone]
©2017—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420Registeratwww.T oro.com.
OriginalInstructions(EN)
PrintedintheUSA
AllRightsReserved*16229SL*

RevisionHistory
RevisionDateDescription
A09/2020Initialissue
3

Contents
ReaderComments.........................................................................................................................................2
RevisionHistory.............................................................................................................................................3
Safety...................................................................................................................................................................7
MaintenanceandService...............................................................................................................................7
GeneralInformation...............................................................................................................................................8
ExternalReferenceMaterial...........................................................................................................................8
ToroDIAGSoftware.......................................................................................................................................8
Acronyms.......................................................................................................................................................9
Glossary.........................................................................................................................................................9
GeneralElectricalDiagnosticInformation............................................................................................................10
ConsumableMaterialsList...........................................................................................................................10
SpecialTools................................................................................................................................................10
InspectingtheHarnessandComponentConnectorAssemblies..................................................................10
RepairingtheWireInsulation.......................................................................................................................11
TestingtheElectricalCircuits........................................................................................................................11
InfoCenterDiagnostics.................................................................................................................................12
InfoCenterIcons...........................................................................................................................................13
InfoCenterScreenMap................................................................................................................................15
TroubleshootingIntermittentElectricalFaults...............................................................................................16
FrequentlyUsedProcedures...............................................................................................................................17
ConnectingandDisconnectingthe12VBattery...........................................................................................17
ConnectingandDisconnectingthe48VPowertotheCuttingReelMotors...................................................18
ReadingFaults.............................................................................................................................................18
ClearingFaultsfromtheInfoCenter..............................................................................................................19
PreparingforTroubleshootingand/orTesting...............................................................................................20
ReturningtheMachinetoService.................................................................................................................21
ToroDIAG–QuickStart.................................................................................................................................22
ReplacingaT oroElectronicController(TEC)...............................................................................................23
Fault12:48VContactorOpen............................................................................................................................26
Fault13:HighTemperatureWarning–ReelMotor1...........................................................................................32
Fault14:HighTemperatureWarning–ReelMotor2...........................................................................................35
Fault15:HighTemperatureWarning–ReelMotor3...........................................................................................38
Fault16:HighT emperatureWarning–Starter/Generator...................................................................................41
Fault17:MotorSpeedStall–CuttingUnit1........................................................................................................44
Fault18:MotorSpeedStall–CuttingUnit2........................................................................................................47
Fault19:MotorSpeedStall–CuttingUnit3........................................................................................................50
Fault21:ModelNumberUnknown......................................................................................................................53
Fault22:48VoltDevicesOfine..........................................................................................................................55
Fault23:CANBusFault–ReelMotor1..............................................................................................................65
Fault24:CANBusFault–ReelMotor2..............................................................................................................73
Fault25:CANBusFault–ReelMotor3..............................................................................................................81
Fault26:CANBusFault–Starter/Generator......................................................................................................89
Fault29:MasterBoardInternalError..................................................................................................................95
Fault31:EngineCoolantTemperatureSenderOutOfRange.............................................................................96
Fault32:EngineCoolantT emperatureHigh–EngineKill.................................................................................102
Fault33:48VoltKeyswitchUndervolt–ReelMotor1........................................................................................106
Fault34:48VoltKeyswitchUndervolt–ReelMotor2........................................................................................114
Fault35:48VoltKeyswitchUndervolt–ReelMotor3........................................................................................122
Fault36:48VoltKeyswitchUndervolt–Starter/Generator................................................................................130
Fault37:FanRelay-CurrentT ooHigh............................................................................................................132
Fault39:MasterTECInternalError...................................................................................................................134
Fault41:48VoltPrechargeCircuitFault...........................................................................................................136
Fault43:HydraulicOilT emperatureSensor–Overtemp...................................................................................138
Fault44:48VoltBattery–Undervolt.................................................................................................................140
Fault45:48VoltBus–Overvoltage..................................................................................................................142
Fault46:48VoltKeyswitch–Overvoltage........................................................................................................144
4

Fault47:OvertempBulb–CurrentTooHigh.....................................................................................................147
Fault49:FaultLatch–PhaseOvercurrent........................................................................................................150
Fault51:AlternatorFailure................................................................................................................................152
Fault52:ChargingSystemHighVoltage...........................................................................................................154
Fault57:GlowRelay/LeakDetectorAlarm–CurrentT ooHigh..........................................................................156
Fault59:LineContactorClosed........................................................................................................................160
Fault63:IDModuleFault..................................................................................................................................166
Fault64:MainPowerRelayFailure...................................................................................................................169
Fault66:SoftwareVersionIncompatibility.........................................................................................................172
Fault67:S1Enable–CurrentT ooHigh............................................................................................................173
Fault69:LineContactor–Overcurrent.............................................................................................................178
Fault71:S2Lower–CurrentTooHigh..............................................................................................................180
Fault74:S3–CurrentTooHigh........................................................................................................................185
Fault76:S4–CurrentTooHigh........................................................................................................................190
Fault78:SRVCoil-Overcurrent.......................................................................................................................195
Fault81:StartRelay–Overcurrent...................................................................................................................200
Fault83:MasterContentionFault.....................................................................................................................205
Fault84:ElectronicReelMotorEnable–CurrentHigh......................................................................................206
Fault86:48VBusOvervoltage–ReelMotor1.................................................................................................210
Fault87:48VBusOvervoltage–ReelMotor2.................................................................................................214
Fault88:48VBusOvervoltage–ReelMotor3.................................................................................................218
Fault89:48VBusOvervolt–Starter/Generator...............................................................................................222
Fault94:48VBusLowVoltage–ReelMotor1.................................................................................................226
Fault95:48VBusLowVoltage–ReelMotor2.................................................................................................230
Fault96:48VBusLowVoltage–ReelMotor3.................................................................................................234
Fault97:48VBusLowVoltage–Starter/Generator.........................................................................................238
Fault98:48VKeySwitchOvervolt–ReelMotor1............................................................................................241
Fault99:48VKeySwitchOvervolt–ReelMotor2............................................................................................246
Fault101:48VKeySwitchOvervolt–ReelMotor3..........................................................................................251
Fault102:48VKeySwitchOvervolt–Starter/Generator..................................................................................256
Fault103:Starter/GeneratorT emperatureSensorFailure................................................................................259
Fault104:OvercurrentDisable–ReelMotor1..................................................................................................260
Fault105:OvercurrentDisable–ReelMotor2..................................................................................................262
Fault106:OvercurrentDisable–ReelMotor3..................................................................................................264
Fault111:InternalRegulatorOvervolt–Starter/Generator................................................................................266
Fault112:InternalRegulatorLowVoltage–ReelMotor1.................................................................................268
Fault113:InternalRegulatorLowVoltage–ReelMotor2.................................................................................274
Fault114:InternalRegulatorLowVoltage–ReelMotor3.................................................................................280
Fault121:InvalidHallState–ReelMotor1.......................................................................................................286
Fault122:InvalidHallState–ReelMotor2.......................................................................................................288
Fault123:InvalidHallState–ReelMotor3.......................................................................................................290
Fault124:InvalidHallState–Starter/Generator...............................................................................................292
Fault125:ShortDetected–ReelMotor1..........................................................................................................294
Fault126:ShortDetected–ReelMotor2..........................................................................................................296
Fault127:ShortDetected–ReelMotor3..........................................................................................................298
Fault128:ShortDetected–UnknownReelMotor.............................................................................................300
Fault129:Starter/GeneratorCurrentSensorFault............................................................................................304
Fault131:InternalTECControllerFault............................................................................................................306
Fault132:InternalTECControllerFault............................................................................................................307
Fault133:InternalTECControllerFault............................................................................................................308
Fault134:InternalTECControllerFault............................................................................................................309
Fault135:InternalTECControllerFault............................................................................................................310
Fault136:InternalTECControllerFault............................................................................................................311
Fault137:JoystickBroken................................................................................................................................312
Fault141:SoftwareIncompatible–ReelMotor1..............................................................................................319
Fault142:SoftwareIncompatible–ReelMotor2..............................................................................................320
Fault143:SoftwareIncompatible–ReelMotor3..............................................................................................321
Fault144:SoftwareIncompatible–Starter/Generator......................................................................................322
5

Fault145:SoftwareIncompatible–InfoCenter..................................................................................................323
Fault146:CANBusFault–InfoCenter.............................................................................................................328
Fault147:TractionPotentiometerFailure.........................................................................................................333
6

Safety
ThemachinehasbeentestedandcertiedbyToroforcompliancewithexistingsafetystandardsand
specications.Improperuseormaintenanceofthemachinecanresultininjuryordeath.Toreducethe
potentialforinjuryordeath,complywithallofthesafetyinstructionsfoundintheGreensmaster3300/3320
TriFlexTractionUnitOperator’sManualorGreensmaster3400/3420TriFlexTractionUnitOperator’sManual,
andGreensmasterTriFlex3300/3400ServiceManual,andthefollowingspecicservice-relatedprecautions.
MaintenanceandService
•Beforeservicingormakinganyadjustmentstothemachine,settheparkingbrake,turnthekeytotheOFF
position,andremovethekeyfromthekeyswitch.Waitforallofthemachinemotiontostop.Referto
theoperator’smanualforyourmachine.
•Keepallnuts,bolts,screws,andbeltsproperlytightened.
•Toreduceanypotentialrehazard,keepallelectricalconnectors,cuttingunits,anddrivecomponents
freeofdebris.
•Wearcut-resistantorheavyleatherglovesandusecautionwhencheckingorservicingthecuttingunits.
•Ifyoumustperformmaintenanceormakeanadjustmentwiththeenginerunning,keepyourhands,feet,
clothing,andallpartsofyourbodyawayfromthecuttingunitsandallothermovingparts.
•Atthetimeofmanufacture,themachineconformedtoallapplicablesafetystandards.T oensureoptimum
performanceandcontinuedsafetycerticationofthemachine,useonlygenuineTororeplacementparts
andaccessories.
7

GeneralInformation
ExternalReferenceMaterial
ThismanualreferstoinformationlocatedinotherT orosourcematerial.Youcanaccessthereferencedmanuals
online.
IfyourserviceareadoesnothaveInternetaccess,downloadtheapplicablemanualsinadvance.
Refertotheapplicableoperator’smanualforinformationonoperating,maintaining,andadjustingthemachine
anditscomponents.Forsomefaults,thisdiagnosticsmanualreferstotheoperator’smanualforspecic
installationandadjustmentprocedures.
Refertotheapplicableservicemanualforinformationontroubleshooting,testing,andrepairingthemachine
anditscomponents.Formanyfaults,thisdiagnosticsmanualreferstotheservicemanualforspecictest
andrepairprocedures.
RefertotheToroDIAGUser’sGuideforinformationonsystemoperation,diagnostics,andmachine
programming.Formanyfaults,thisdiagnosticsmanualreferstotheToroDIAGguideforspecictestand
repairprocedures.
TherearemultiplecuttingunitsavailablefortheTriFlex.Thecuttingunitoperator’smanualsareavailable
throughwww.Toro.com.(Siteloginisnotrequired.)
•8-BladeDPACuttingUnit
Searchformodelnumber04651
•11-BladeDPACuttingUnit
Searchformodelnumber04653
•14-BladeDPACuttingUnit
Searchformodelnumber04655
HowtoObtainReferenceMaterials
1.GototheToroGatewaysiteandloginwithyourusernameandpassword.
2.OnthePublicationSearchpage,typethemodelnumberofyourmachineandthenclickGo.
TheModelListtableappears.
3.Usetheserialnumberofyourmachinetodeterminetheproperrowinthetableforyourmachine.
4.ClicktheLinkedPublicationsbuttoninthetablerowforyourmachine.
5.Linkstooperator’smanuals,servicemanuals,hydraulicandelectricalschematics,partscatalogs,and
otherdocumentswillbedisplayed.
ToroDIAGSoftware
DownloadtheToroDIAGsoftwarefromtheToroDealerandDistributorPortalandtheninstallthesoftwareona
computer.ThissoftwareisintendedtoassistyouwithtroubleshootingelectricalissuesonT oromachinesthat
useaT oroelectroniccontroller(TEC).
ThefeaturesandbenetsoftheT oroDIAGsoftwareincludethefollowing:
•ThesoftwareusesaUSBtoCANconnectionviaaT oroDIAGUSB/CANCable(T oroPartNo.115-1944).
•Youcanmonitorthecontrollersystemintheentiremachine.
•ThesoftwareisaWindows-basedapplication.
•SoftwareupdatestoToroDIAGaresentautomatically.
•Youcanreviewfaultcodesandtheirdescriptions.
•Youcanseemachinecountersandtimers.
•YoucandownloadamachinecountersandtimersleforuploadingintoareplacementTEC-5001controller.
•Youcaneasilyreprogramthemachine.
8

•Youcanseetheinputsandtheoutputs.
•Youcanseethecurrentstatusofeachofthevariouscontrollers.
TheToroDIAGSoftwareGuide(PartNo.12194SL)isavailablethroughT oroConnect.com(Siteloginis
required)andtheT oroCompanyServiceLibraryGateway(siteloginisrequired).
TheT oroDIAGsoftwareisavailabletodownloadthroughT oroConnect.com(siteloginisrequired.)
Acronyms
AcronymDenition
AGMAbsorbedglassmat(battery)
yCANControllerareanetwork
CRMCuttingreelmotor(themotorthatdrivesthecuttingreel)
CUCuttingunit
DPADualpointadjust
ECTEnginecoolanttemperature
FETField-effecttransistor
IPEInputpull-upenable
M/GMotor/generator
psipounds/squareinch
yS/GStarter/generator
ySV(SV1,SV2,SV3)Solenoidvalve
ySVRV(SV4)Solenoidvalve,reliefvalve
yTECToroelectroniccontroller
Glossary
ConnectionTerminology
Pinsarethemetalcontactscontainedinsideaconnectorhousing.
Terminalsaretheexposedmetaltabsorpoststhatarenotcontainedinsideaconnectorhousing.T erminals
aremostoftenapartofacomponent.Examplesofterminalsincludethreadedpostsandsoldercups.Often,
crimplugs(e.g.,rings,hooks,forks,etc.)areattachedtoterminalsbytighteninganutorascrew.
Fault
Afaultiscomposedofanumericcode(faultcode)andadescription.
Afaultisintendedtohelpidentifythesourceofproblemsfordiagnostictroubleshooting.
AnactivefaultisdisplayedontheInfoCenterwhilethefaultconditionispresentuntilyouclearthefaultor
youturnthemachineoff.AllfaultsarearchivedinandaccessiblefromthenonvolatilememoryoftheToro
electroniccontroller(TEC).
9

GeneralElectricalDiagnosticInformation
Machineelectricalschematicsandwireharnessdiagramsarenecessaryfortroubleshootingmachine
circuits.TheschematicsanddiagramsareavailableintheGreensmasterTriFlex3300/3320or3400/3420
ServiceManual.
ConsumableMaterialsList
Important:Refertotheapplicablematerialsafetydatasheets(MSDS)whenusingchemicals.
ConsumableMaterials
MaterialSpecicationandorManufacturer/Supplier
BatteryterminalprotectorToroPartNo.107-0392
Blackvinyltape3M™Tartan™1710GeneralUseVinylElectricalInsulatingTape,commerciallyavailable
CrocusclothANSIB74.18,commerciallyavailable
DielectricgelToroPartNo.107-0342
ElectricalcontactcleanerCommerciallyavailable
Eraser(pinkpearl)Commerciallyavailable
IsopropylalcoholCommerciallyavailable
Non-conductiveabrasivepaper(120grit)Manufacturer/Supplier(3M),commerciallyavailable
WiredryeraerosolCommerciallyavailable
SpecialTools
Multimeter
Useadigitalmultimeterwhentestingelectricalcircuits.
Readandunderstandthemanufacturer’soperatinginstructionsforthemultimeter.
ToroDIAGUSB/CANCable
TheToroDIAGsoftwareusesaUSBtoCANconnection,viaaT oroDIAGUSB/CANcable(ToroPartNo.
115-1944).
InspectingtheHarnessandComponentConnector
Assemblies
Thewireharnessesandelectricalcomponentsincludethefollowing:
•Electricalconnectors
•Connectorpins
•Electricalterminals
•Insulatedwire
Whileyouaretroubleshooting,inspectthepartsforwear,damage,andcorrosion.
Commonelectricalproblemsinclude:
•Open,shorted,orburnedwires
Note:Debris,suchaswetgrassclippings,canactasaconductor.
•Corrodedterminalsorpins
•Waterintheconnector
10

•Connectorpinsthatareloose,bent,orrecessed
•Connectorsthatarenotfullyseated
•Wiresthatarepinched,frayed,oraremissinginsulation
•Damagedconnectorlocks,clips,orhousings
•Missingorinadequatedielectricgrease
Note:Dielectricgreaseisusedinallunsealedwireharnessconnectors.
RepairingtheWireInsulation
Ifdamageextendsthroughtheinsulationandstrandsofthewirearebroken,repairorreplacethewireharness.
Ifthereisdamagetotheouterinsulationonly,orifthedamagetotheshieldingisabrasionordeformationonly
withnobrokenstrands,repairthewireharnessasfollows:
1.Cleanthedamagedareaofthepartwithisopropylalcohol.
2.Drythepartwithacleanlint-freecloth.
3.Wrapthedamagedareawith2layersofall-weatherelectricaltapeoranequivalent.
Note:Ensurethatthetapeextendspastthedamagebyaminimumof1.3cm(1/2inch).
Note:Heatshrinktapethatisproperlyinstalledwiththesameprecautionaselectricaltapeisacceptable.
Installtheheatshrinktapeaccordingtothemanufacturer’sinstructions.
AttachingtheWireHarnesses
Properlyattachingthewireharnessestothemachinehelpskeeptheconnectorsfromlooseningandprotects
theharnessesfromaccidentaldamagecausedbyvibration.
•Ensurethatnodeviceusedtoattachawireharnesstothemachinecanrotateorslidefreelyonthewire
harness.
•Forwiresnotcontainedinconvolutedtubingorprotectivesleeving,securethewireswithelectricaltape
oracabletieevery10to15cm(4to6inches).
•Forsplit-loom,convolutedtubing,ensurethatthetapeorcabletiesare1.3cm(1/2inch)awayfromany
connectorsorlabels.
TestingtheElectricalCircuits
TestingforaShortCircuit
Ashortcircuitisanabnormalelectricalconnectionbetween2electricalcircuits.Youcandiagnoseashortcircuit
byperformingvoltagechecksand/orcontinuitytests.
•Ashortcircuittogroundbeforeanelectricalcomponentusuallycausesthefuseforthecircuittoopen.
•Ashortcircuittogroundafteranelectricalcomponentusuallycausestheelectricalcomponenttostay
onaslongasthereispowertothecomponent.
Useamultimetertotestbetweentheidentiedwireharnessconnectorpinsorcomponentterminalsand
thesuspectedpointsoffailure.
Foraccurateresistanceand/orcontinuitychecks,electricallyisolatethecomponentbeingtestedby
disconnectingallwiringorremovingitfromthecircuit.
TestingtheVoltageofaCircuit
1.Measurethevoltagebetweentheidentiedwireharnessconnectorpinsorcomponentterminalsand
thesuspectedpointsoffailure.
2.Ifthevoltagethatyoumeasureishigherorlowerthanthespeciedvoltage,cleanandinspecttheterminal
connectionsalongthecircuitpaththatyouaretesting.
11

CleaningtheElectronicComponentsandConnections
Note:Useelectrical-contactcleaneronly.Donotusebrakecleaner,asitmaypermanentlydamageelectrical
connectorbodiesandotherplasticcomponentsofthemachine.Avoidusingmineralsolvents,astheymay
damageconnectors,seals,andwireinsulation.
WARNING
Cleaningchemicalsandtoolscancauseinjuryifusedimproperly.
RefertotheapplicableMSDSforappropriatepersonalprotectivegear,suchasgloves,
respirators,andsafetyglasses.
1.Markthewiresforproperinstallationaftercleaningiscompleted.Removepinsfromconnectorswiththe
properextractiontool.
2.Cleantheterminalsortheconnectorpinsusinganeraser,mildabrasivepaper,oranylonorberbristle
brush.Donotusemetalormetaloxides.
3.Finishthecleaningwithaberbristlebrushdippedinisopropylalcohol.
4.Gentlywipeoffthecleanpins,terminals,andcomponentswithalint-freeclothdampenedwithisopropyl
alcohol.
5.Whenavailable,drythecomponentswithdry,oil-freecompressedairwithapressurenomorethan
138kPa(20psi).
6.Ensurethatallconnectorsandcomponentsarecleananddrypriortoreassemblyandtesting.
InfoCenterDiagnostics
TheInfoCenterDiagnosticsscreendisplaysthecurrentstatusofvariousmachineelectricalcomponentsand
batteryvoltages(Figure2).UsetheDIAGNOSTICSscreentotestmachineswitchesandcontrolswhen
possible.
g020650
Figure2
1.Indicatorlight3.Middlebutton—pressittoscrolldownthemenusordigits
forPINcode.
2.Rightbutton—pressittoopenamenuwhenarightarrow
indicatesadditionalcontent.
4.Leftbutton(menuaccess/backbutton)—pressittoaccess
theInfoCentermenus.Alsouseittobackoutofanymenu
thatyouarecurrentlyusing.
TondadditionalinformationonnavigatingtheInfoCentermenuitems,refertotheInfoCenterDisplaysectionin
yourmachine’sservicemanual,ortoyourmachine’soperator’smanual.SeetheExternalReferenceMaterial
(page8)sectioninthismanualforhelpobtainingthecorrectmanualsforyourmachine.
12

InfoCenterIcons
IconDenition
Hourmeter
Infoicon
Fast
Slow
Fuellevel
Glowplugsareactive
Raisecuttingunits
Lowercuttingunits
Operatormustsitinseat
Parkingbrakeindicator—indicateswhentheparkingbrakeisON
IdentiestherangeasHigh(Transport)
Neutral
IdentiestherangeasLow(Mow)
CoolantT emperature—indicatestheenginecoolanttemperatureineither°Cor°F
Temperature(hot)
PTOisengaged
Deniedornotallowed
Enginestart
Stoporshutdown
Engine
Ignitionswitch
Battery
13

IconDenition
Starter/generator(notcharging)
Starter/generator(charging)
Reelenable
Electriccuttingreelmotorinacuttingunit
Frontbacklap
Rearbacklap
Indicateswhenthecuttingunitsarebeinglowered
Indicateswhenthecuttingunitsarebeingraised
PINpasscode
CANbus
InfoCenter
Badorfailed
Bulb
OutputofTEC-5002orcontrolwireinwiringharness
Switch
Operatormustreleaseswitch
Operatorshouldchangetoindicatedstate
Checkmark
Current(electrical)
Symbolsareoftencombinedtoformsentences.Someexamplesareshownbelow
Enginestartdenied
Engineshutdown
Enginecoolanttoohot
14

InfoCenterScreenMap
Thevariousscreenscanbeaccessedbymanipulatingthedirectionalarrows.Thescreensavailableonthe
TriFlex3320/3420arearrangedasseeninFigure3.
g294925
Figure3
15

TroubleshootingIntermittentElectricalFaults
AttempttoDuplicatetheFault
1.Operatethemachinebasedontheinformationprovidedbytheoperator.
2.Observethemachineduringnormaloperation.Payattentiontohowthemachineisbeingoperated.
3.Worktowardbeingabletoduplicatethefaultpredictably.
4.Makenotesasyouproceedthroughyourdiagnosis.Documentyourstepsandanytestresultsforfuture
reference.
CompletetheBasicMaintenanceChecks
ChecktheConditionofthe12VBattery
1.Inspectforanycorroded,loose,ordamagedwiresandconnections,includingallchassisgroundpoints.
•Loosen,clean,andtightenthebatteryconnections(cables,posts,etc.).
•Loosen,clean,andtightenthechassisgroundpoints.
2.Loadtestthebatterytoensureitmeetstheoutputspecication.
TesttheChargingSystem
Testthechargingsystemtoensureitmeetstheoutputspecication.
InspectFusesandFusibleLinks
1.Verifyallfusesareofthecorrectratingandthatthecontactsarecleanandsecurelyseated.
2.Verifyallfusiblelinksareofthecorrectratingandthattheconnectorsarecleanandsecurelyseated.
Note:Openfusesarenotnecessarilythecauseofafailure.
CircuitWiringandConnectors
Commonissuestolookforare:
•Damagedwiringinsulation
•Corrosion
•Brokenwirestrands
•Incorrectwiringcircuitorharnessrouting
•Looseconnectionsbetweenconnectors
•Loose,bent,orbackedoutconnectorterminals
•Connectorhousinglocksthatarebrokenornotengagingfully
•Improperorweakcrimps,splices,andsolderedjoints
•Discoloredorburnedconnectors
CANCircuitsandCommunicationCapture
Iftheintermittentissueremainsafterthebasicdiagnosticprocessesarecomplete,usethecontroller-specic
diagnostictoolsandfunctionsavailabletomonitororcapturedataasthemalfunctionoccurs.Theseinclude:
•ToroDIAGSavefunction(seetheToroDIAGSoftwareGuide)
•ToroCANCapture(seetheToroDIAGSoftwareGuide)
•ToroScopeRecordfunction(seetheToroDIAGSoftwareGuide)
16

FrequentlyUsedProcedures
ConnectingandDisconnectingthe12VBattery
CAUTION
Beforeinstalling,removing,orservicingcomponentsinthe12Vsystem(e.g.,starter,
alternator,controlarmcomponents,etc.),disconnectthe12Vbattery.Thisprevents
unexpectedoperationof12Vsystemcomponents.
g226400
Figure4
1.Operator’sseat4.Negativepost/cable
2.12Vbattery5.Engine
3.Positivepost/cable
1.Disconnectingthe12VBattery
A.Parkthemachineonalevelsurfaceandlowerthecuttingunits.
B.Shutofftheengine,applytheparkingbrake,andremovethekeyfromthekeyswitch.
C.Attheleftsideofthemachine,locatethe12Vbattery(Figure4).
D.Disconnectthenegativecablefromthebattery(Figure4).
E.Disconnectthepositivecablefromthebattery(Figure4).
2.Connectingthe12VBattery
A.Afterservicingthe12Vsystem,coatthebatterypostsandthecableconnectorswithbatteryterminal
protector(ToroPartNo.107-0392)orpetroleumjellytopreventcorrosion.
B.Connectandtightenthepositivecabletothebattery(beforeconnectingthenegativecable)(Figure4).
C.Installtherubberbootontothepositivebatterycable(Figure4).
D.Connectandtightenthenegativecabletothebattery(Figure4).
17

ConnectingandDisconnectingthe48VPowertothe
CuttingReelMotors
CAUTION
Beforeinstalling,removing,orservicingthecuttingunits,disconnectthecuttingunitsfromthe
48Vpowersystembyseparatingthecuttingunitpowerconnectors.Thispreventsunexpected
operationofcuttingunits.
1.Parkthemachineonalevelsurfaceandlowerthecuttingunits.
2.Shutofftheengine,applytheparkingbrake,andremovethekeyfromtheignitionswitch.
3.Locatethecuttingunitpowerconnectors,whichareattachedtotheleftframerailneartheoperator’s
seat(Figure5).
g222909
Figure5
1.Cuttingunitpowerconnectors(48V)2.Operator’sseat
4.Separatethetwoconnectors.
5.Afterworkingonthecuttingunits,applyacoatofdielectricgreasetothepinsinthecuttingunitpower
connectors.
6.Reattachthetwoconnectors.
ReadingFaults
TheInfoCenterdisplayshowsinformationaboutyourmachine,suchasfaults,thechargelevelofthe12V
batteryandthe48Vbatterypack,andvariousdiagnosticmessagesandiconsthatprovidecurrentinformation
aboutthemachine.
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Youcanreadfaults2ways:ontheInfoCenterdisplay(Figure6)oronaPCusingToroDIAGSoftware(page
8).ThissectionfocusesontheInfoCenterdisplay.
g020650
Figure6
1.Indicatorlight3.Middlebutton:pressittoscrolldownthemenusordigitsfor
thePINcode.
2.Rightbutton:pressittoopenamenuwhenarightarrow
indicatesadditionalcontent.
4.Leftbutton(menuaccess/backbutton):pressittoaccess
theInfoCentermenus.Alsouseittobackoutofanymenu
thatyouarecurrentlyusing.
Ifanelectricalfaultoccurs,theInfoCenterfaultindicatorlightashesandafaultcodenumberappearson
thedisplay.
•Faultsthatarecurrentlyhappeningarecalledactivefaults.Assoonasafaultoccurs,thefaultnumberis
displayedontheInfoCenter.Faultsremainactiveonthescreenuntilyouclearthemoruntilthecondition
thatcreatedthefaultnolongerexists.
•UsetheInfoCenterFaultsscreentoseealistoffaultsthatoccurredbeforethemostrecentstartingofthe
machine.TheFaultsscreenlistsallofthemachinefaultsthathaveoccurredsincetheInfoCenterfaultlog
waslastcleared.
ClearingFaultsfromtheInfoCenter
Note:YoucanclearsystemfaultsfromtheInfoCenterifyouhavethePINnumbertoaccessthepropermenu
item.ThecompletefaulthistoryisretainedintheTEC-5001memoryandcanbeviewedviaToroDIAGsoftware.
EnteringthePINcode
1.PresstheleftbuttonasneededtodisplaytheMainMenu.
2.FromtheMainMenu,pressthemiddlebuttonasneededtohighlightSettings.
3.PresstherightbuttontodisplaytheSettingsmenu.
4.PressthemiddlebuttonasneededtohighlightProtectedMenus.
5.Presstherightbutton.TheEnterPINscreenappears.
6.Pressthemiddlebuttontochangethenumericvalues,andtherightbuttontoselecteachdigit.
7.WhenthePINentryiscomplete,presstherightbuttontoenterthecode.
8.Ifthecodeiscorrect,acheck-markiconappearsatthebottom/centeroftheInfoCenterdisplayscreen.
9.PressthemiddlebuttononcetoreturntotheSettingsmenu.IfthecorrectPINwasentered,the
InfoCenterscreendisplays“PIN”intheupperrightcornerofthescreen.
Note:ThePINstaysactiveuntilthekeyisturnedOFF.IfyouneedtoaccesstheProtectedMenusagain
afterthemachinehasbeenturnedoff,youwillneedtoreenterthePIN.
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ClearingfaultsafterenteringthePIN
1.Presstheleftbutton.TheMainMenuappears.
Note:Ifnofaultshaveoccurredsincethelasttimethefaultswerecleared,aNoFaultsLoggedmenu
itemwillbedisplayedinsteadoftheFaultsmenuitem.PresstheleftbuttonasneededtoexittheMain
Menu.
2.PressthemiddlebuttonasneededtohighlightFaults,andthenpresstherightbutton.TheFaults
screenappears.
3.PressthemiddlebuttontoscrolldownthroughthefaultsuntilClearSystemFaultsishighlighted.
4.Presstherightbutton.Aconrmationscreenappears.
5.PressthemiddlebuttontoconrmclearingtheInfoCenterfaultlog.An“Allfaultscleared”message
appears.
6.Presstheleftbuttonasneededtoreturntoanoperatorinformationscreen.
Note:Somefaultsclearwhenyouturntheengineoffandthenstarttheengine.Afterthefaultclears,youcan
resumenormaloperationofthemachine.
Ifafaultrepeatseachtimeyoustarttheengine,conductdiagnostictroubleshootingoftheaffectedsystem
andrelatedcomponents.
PreparingforTroubleshootingand/orTesting
CAUTION
Rings,watches,bracelets,necklaces,andotherjewelrycancauseanelectricalshockor
becomeentangledwiththemachine.
Removealljewelry,especiallyringsandwatches,beforedoinganytroubleshootingortesting.
Beforeperformingtroubleshootingand/ortestingproceduresonthemachine,dothefollowingsteps:
1.Parkthemachineonalevelsurface.
2.EnsurethatthetractionpedalisintheNEUTRALposition.
3.Engagetheparkingbrake.
4.MovetheenginespeedswitchtotheLOWIDLEpositionandwaitfortheenginetoslowtolowidlespeed.
5.Shutofftheengineandremovethekeyfromtheignitionswitch.
CAUTION
Performingcontinuitytestingonelectricalcomponentswiththe12Vand/or48Vpower
connectedcanleadtosevereelectricalshock.
Disconnectpowerfromthemachinebeforetestingelectricalcomponents.
6.Disconnectthe12Vbatterybeforeservicingthemachine,unlessitisneededfortroubleshootingor
testing.RefertoConnectingandDisconnectingthe12VBattery(page17).
7.Beforeinstalling,removing,orworkingonthe48Vsystem,isolatethecomponents(i.e.,cuttingreel
motors)byunpluggingthe48Vbatteryconnector.RefertoConnectingandDisconnectingthe48VPower
totheCuttingReelMotors(page18).
Themachineisnowreadyfortestinganddiagnosticworktotakeplace.
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