Toro Greensmaster eFlex 1800 User manual

Diagnostics Manual
FormNo.3386-113RevB
Greensmaster®eFlex®1800and
2100TractionUnit
ModelNo.04042—SerialNo.314001001andUp
ModelNo.04043—SerialNo.314001001andUp
G017154
Registeratwww.Toro.com.
OriginalInstructions(EN)*3386-113*B

Introduction
Thepurposeofthispublicationistoprovideaservice
technicianwithinformationfordiagnostictroubleshooting
andtestingoffaultcodesontheGreensmastereFlex1800
andeFlex2100.
RefertotheGreensmaster®eFlex®1800or2100TractionUnit
Operator’sManualforinformationonoperating,maintaining,
andadjustingthemachineanditscomponents.
RefertotheGreensmaster®eFlex®1800/2100ServiceManual
forinformationontroubleshooting,testing,andrepairingthe
machineanditscomponents.
RefertotheToroDIAGUser’sGuideforinformationon
systemoperation,diagnostics,andmachineprogramming.
TheToroCompanyreservestherighttochangeproduct
specicationsorthispublicationwithoutnotice.
Improperuseormaintenancebytheoperatororownercan
resultininjury.Toreducethepotentialforinjury,comply
withallsafetyinstructionsinthismanual,andalwayspay
attentiontothesafetyalertsymbol(Figure1),whichmeans
caution,warning,ordanger(i.e.,personalsafetyinstruction.)
Failuretocomplywiththeinstructionmayresultinpersonal
injuryordeath.
Figure1
SafetyAlertSymbol
©2015—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN554202
Contactusatwww.Toro.com.
PrintedintheUSA
AllRightsReserved

Contents
Safety............................................................................4
MaintenanceandService..........................................4
GeneralInformation.......................................................5
ExternalReferenceMaterial......................................5
ToroDIAGSoftware...............................................5
Abbreviations.........................................................5
Glossary.................................................................5
GeneralElectricalDiagnosticInformation.........................6
ConsumableMaterialsList........................................6
SpecialTools...........................................................6
InstallingtheLi+DiagnosticWireHarness.................8
UninstallingtheLi+DiagnosticWireHarness............10
“WakingUp”theBatteryPack..................................12
InspectingtheWireHarnessesandComponent
ConnectorAssemblies.........................................13
RepairingHarnessWireInsulation............................13
TestingElectricalCircuits........................................14
PreparingtoTesttheComponents............................15
TestingtheComponent...........................................15
InfoCenterDiagnosticsScreenIcons........................16
FrequentlyUsedProcedures............................................17
ConnectingtheBatteryPack....................................17
DisconnectingtheBatteryPack................................17
UsingtheKickstand................................................17
ReadingFaultCodes...............................................18
ClearingFaultCodeswhileUsingtheMachine............19
ClearingtheInfoCenterFaultLog.............................19
TurningontheMachine..........................................19
TurningofftheMachine..........................................19
ReturningtheEquipmenttoService..........................19
ConsoleCover.......................................................19
PowerCenterCover................................................20
Fault01InternalTEC....................................................21
Fault0212VdcSupply...................................................23
Fault035VSupply........................................................35
Fault04Pre-Charge.......................................................41
Fault05Communication................................................57
Fault07MotorOverTemperature....................................70
Fault09InternalMotor..................................................75
Fault10MotorStalled....................................................88
Fault11SoftwareIncompatible.......................................90
Fault12KeyStuckOn....................................................91
Fault13InternalBattery...............................................100
Fault15Software.........................................................110
Fault16ContactorFault...............................................111
AppendixA:WireHarnesses.........................................113
ElectricalSystemHarnessConnector,Pin,and
TerminalIdentication......................................113
AppendixB:ToroElectronicController
Connections.....................................................135
3

Safety
ThemachinehasbeentestedandcertiedbyTorofor
compliancewithexistingsafetystandardsandspecications.
Improperuseormaintenanceofthemachinecan
resultininjuryordeath.Toreducethepotentialfor
injuryordeath,complywiththesafetyinstructionsfound
inthemachineOperator’sManualandthefollowingspecic
service-relatedprecautions:
WARNING
TheeFlexlithium-ionbatterypackcontainshigh
voltage,whichcouldburnorelectrocuteyou.
•Neverattempttoopenthebatterypack.
•Donotplaceanythingintheconnectoronthe
batterypackotherthanaTorowireharness
connectormadefortheproduct.
•Donotallowtoolsorvehiclecomponentsto
completethebatterycircuit.
•Useextremecarewhenhandlingabatterypack
withacrackedcase.
•Removeabatterypackwithacrackedcase
immediately.
•UseonlytheTorobatterychargerdesignedfor
thebatterypack.
MaintenanceandService
•Beforeservicingormakingadjustmentstothemachine,
settheparkingbrake,turnthekeyswitchtotheOFF
position,andremovethekeyfromthekeyswitch.Wait
forallmachinemotiontostop,andthendisconnectthe
batterypacktopreventunintentionalmachineoperation.
RefertoDisconnectingtheBatteryPack(page17).
•Keepallnuts,bolts,screws,andbeltsproperlytightened.
•Toreducepotentialrehazard,keepthebatterypack,
electricalconnectors,cuttingunit,anddrivecomponents
freeofdebris.
•Wearcut-resistantorheavyleatherglovesandusecaution
whencheckingorservicingthecuttingunit.
•Ifyoumustperformmaintenanceormakeanadjustment
withtheelectricmotorrunning,keepyourhands,feet,
clothing,andallpartsofyourbodyawayfromthecutting
unitandallothermovingparts.
Note:Keepbystandersawaywhenrunningtheelectric
motorforthecuttingunit.
•Beforeinstalling,removing,orworkingonthecutting
unit,disconnectthebatterypack.RefertoDisconnecting
theBatteryPack(page17).
•Donotopenoralterthebatterypackinanyway.
Openingthebatterypackmayexposeyoutodangerous
voltage.Thewarrantywillbevoidedifyouattemptto
openthebatterypack.Thebatterypackcontainsnouser
serviceableparts,withtheexceptionofthebatterypack
fuse,fusecover,andlabels.
•IfyoumustshipyoureFlexbatterypack,youwillneed
specialpackagingtocomplywithshippingregulations.
RefertotheOperator’sManualforadditionalbattery
shippinginformation.
•Atthetimeofmanufacture,themachineconformed
toallapplicablesafetystandards.Toensureoptimum
performanceandcontinuedsafetycerticationofthe
machine,useonlygenuineTororeplacementpartsand
accessories.
4

GeneralInformation
ExternalReferenceMaterial
ThismanualreferencesinformationfoundinotherToro
sourcematerial.Youcanaccessthereferencedmanuals
online.
Note:IfyourserviceareadoesnothaveInternetaccess,
downloadtheapplicablemanualsinadvance.
RefertotheGreensmaster®eFlex®1800or2100TractionUnit
Operator’sManualforinformationonoperating,maintaining,
andadjustingthemachineanditscomponents.
RefertotheGreensmaster®eFlex®1800/2100ServiceManual
forinformationontroubleshooting,testing,andrepairingthe
machineanditscomponents.
RefertotheToroDIAGUser’sGuideforinformationon
systemoperation,diagnostics,andmachineprogramming.
•TheGreensmaster®eFlex®1800or2100TractionUnit
Operator’sManualisavailablethroughwww.Toro.com.
(Siteloginisnotrequired.)
•TheLithiumBatteryChargerOperator’sManualisavailable
throughwww.Toro.com.(Siteloginisnotrequired.)
•TheGreensmaster®eFlex®1800/2100ServiceManualis
availablethroughtheToroCompanyServiceLibrary
Gateway.(Siteloginisrequired.)
•TheDistributorOperationsBulletin12-121-TPdocument
includeslinkstoshipping,packaging,andtransportation
information,andtheMaterialSafetyDataSheet(MSDS)
forthelithiumionbatterypack.(Siteloginisrequired.)
ToroDIAGSoftware
ToroDIAGsoftwareisdownloadedfromtheToroDealer
andDistributorPortalandtheninstalledonaPC.This
softwareisintendedtoassistwithtroubleshootingelectrical
issuesonToromachinesthatuseaToroElectronicController
(TEC).
FeaturesandbenetsoftheToroDIAGsoftwareinclude
thefollowing:
•ThesoftwareusesaUSBtoCANconnection.
•Youcanmonitorthecompletemachinecontrollersystem.
•ThesoftwareisaWindows-basedapplication.
•Softwareupdatesaresentautomatically.
•Youcanreviewfaultcodes.
•Youcaneasilyreprogramthemachine.
•Youcanseetheinputsandtheoutputs.
•Youcanseethecontrollerstateofhealth.
TheToroDIAGUser’sGuideisavailablethroughtheToro
DealerandDistributorPortal.(Siteloginisrequired.)
TheToroDIAGsoftwareisavailablefordownloadingthrough
theToroDealerandDistributorPortal.(Siteloginis
required.)
Abbreviations
Acronymdenitions
AcronymDenition
AmpAmpere
CANControllerareanetwork
FETFieldeffecttransistor
Li+,Li-ionLithium-ion(battery)
MSDSMaterialsafetydatasheet
NEGNegative
NC,N.C.Normallyclosed
NO,N.O.Normallyopen
P/NPartnumber
POSPositive
ProxProximity
SWSwitch
TECToroElectronicController
ToroDIAGToroDiagnostics
VdcVoltsdirectcurrent
Glossary
ConnectionTerminology
Pinsarethemetalcontactscontainedinsideaconnector
housing.
Terminalsaretheexposedmetaltabsorpoststhatarenot
containedinsideaconnectorhousing.Terminalsaremost
oftenpartofacomponent.Examplesofterminalsinclude
threadedpostsandsoldercups.Often,crimplugs(e.g.,rings,
hooks,forks,etc.)areattachedtoterminalsbytighteninga
nutorascrew.
Fault
Afaultisintendedtohelpidentifythesourceofproblemsfor
diagnostictroubleshooting.
AnactivefaultisdisplayedontheInfoCenteruntilyouclear
thefaultoryouturnthemachineoff.Allfaultsarestored
inandaccessedfromthenonvolatilememoryoftheToro
electroniccontroller(TEC).
5

GeneralElectrical
DiagnosticInformation
UsetheeFlexServiceManual,Chapter8,FoldoutDrawings,for
electricalschematicsandwireharnessdiagramsrequiredfor
troubleshooting.
TheGreensmastereFlexusesa53Vdcbattery-based
electricalsystem.Actualmeasurementsofbatteryvoltage
willvaryfrom42to64Vdc,dependingonthechargelevel
ofthebattery.
Note:Themachineframeisnotusedasanelectricalground.
Groundisdistributedthroughthemachinewireharnesses.
ConsumableMaterialsList
Important:RefertotheapplicableMSDSwhenusing
chemicals.
ConsumableMaterials
MaterialSpecicationandor
Manufacturer/Supplier
Non-conductiveabrasive
paper(120grit)
Manufacturer/Supplier(3M),
commerciallyavailable
IsopropylalcoholCommerciallyavailable
Blackvinyltape3M™T artan™1710General
UseVinylElectricalInsulating
Tape,commerciallyavailable
CavityplugGT150GT150cavityplug,
manufacturerP/N:15305171
CrocusclothANSIB74.18,commercially
available
DielectricgelToroP/N:107-0342
ElectricalcontactcleanerCommerciallyavailable
Eraser(pinkpearl)Commerciallyavailable
SodiumbicarbonateCommerciallyavailable
Skin-overgreaseToroP/N:TOR50547
WiredryeraerosolCommerciallyavailable
SpecialTools
ToroDIAGDiagnosticSoftware
Note:RefertotheToroDIAGUser’sGuide.
ToroDIAGUSB/CANCable
ToroP/N115-1944
Note:RefertotheToroDIAGUser’sGuide.
Multimeter
Note:Useadigitalmultimeterwhentestingelectrical
circuits.Thehighimpedance(internalresistance)ofadigital
multimeterinthevoltagemodewillensurethatexcesscurrent
isnotallowedthroughthemultimeter.Excesscurrentcan
damageelectricalandelectroniccircuitsnotdesignedtocarry
thecurrent.
Note:Readandunderstandthemanufacturer’soperating
instructionsforthemultimeter.
Li+DiagnosticWireHarness
ToroP/N120-6339
UsetheLi+diagnosticwireharness(Figure2)whenchecking
thefollowing:
•testingthebatteryvoltage
•testingthebatterycontactor
•determiningdamagetothebatterywireharness
TheLi+diagnosticwireharnessisconguredwithextrawire
lengthandhasthecapabilitytoisolateelectricalcircuits.It
alsoprovidesthecapabilityfordirectCANcommunicationto
thebatterypackwhileusingtheToroDIAGinterface,andit
canbeconnecteddirectlytoabatterypackconnectedtothe
machineorabatterypackoffthemachine.
Note:UsetheLi+diagnosticwireharness,aToroDIAG
USB/CANinterfacecable,andaPCwithToroDIAG
softwaretoretrieveCANinformationwhenworkingwitha
ToroServiceRepresentative.
6

Figure2
Li+DiagnosticWireHarnessConnectorIdentication
1.P05moldedcap(forstoringP06andP07)5.P04
2.P346.P01batterypackconnector
3.P07batterywake(ground)7.P03CANbusterminator(120ohm)
4.P06batterywake(signal)8.P02Torodiagnosticconnector
AdditionalInformation
Li+DiagnosticWire
HarnessConnector
DescriptionofUse
P05moldedcapProtectsconnectorsP06andP07whentheyarenotinuse
P06andP07batterywakeConnecttheP06andP07connectorstogethermomentarilyallowthebatterypackto“wake”fromthe
hibernatestatesothatyoucandeterminetheconditionofthebatterypack.
P04machine/charger
connector
ConnectstheLi+diagnosticwireharnesstothebatterywireharnessP04connectoratthesideof
thebatterypack
P01batterydiagnostic
connector
ConnectstheLi+diagnosticwireharnesstothebottomofthebatterypackafteryouraisethebattery
pack
P02ToroDIAGcable
connector
ConnectstheT oroDIAGUSB/CANcabletothebatterypack
7

InstallingtheLi+Diagnostic
WireHarness
Performthefollowing3shortprocedurestoinstalltheLi+
diagnosticwireharness:
PreparetheMachine
1.Parkthemachineonalevelsurfaceandmovethe
tractionlevertotheNEUTRALposition.
2.RotatethekeyswitchtotheOFFpositionandthen
removethekeyfromtheswitch.
3.Disconnectthebatterypack.RefertoDisconnecting
theBatteryPack(page17).
4.DisconnectthemainwireharnessP34connector
(Figure3).
1
g030573
Figure3
1.MainwireharnessP34connector
RaisetheBatteryPackandDisconnect
theP01Connector
1.Removethenutthatsecurestherearofthebattery
platformtothemachineframe(Figure4).
Figure4
1.Nut
2.Loosenthe2pivotboltsahalfturneach(Figure5).
Figure5
RaisedBatteryPackandPlatform
1.Batterypackandplatform3.Lockingholes
2.Pivotboltsandnuts
3.Raisethebackofthebatteryplatformuntilthelocking
holesinthefrontofthebatteryplatformandframe
align(Figure5).
4.Inserta6mm(1/4inch)steelrod(e.g.,screwdriver)
throughthelockingholestoholdthebatteryplatform
intheraisedposition(Figure5).
5.Onthebottomofthebatterypack,disconnectthe
batterywireharnessP01connectorbyrotatingthe
lockingcollarcounterclockwiseapproximatelyhalfa
turn(Figure6).
8

g030574
3
2
1
Figure6
1.BatterywireharnessP01
connector
3.Battery-packconnector
2.Lockingcollar
ConnecttheLi+DiagnosticWire
Harness
1.ConnecttheLi+diagnosticwireharnessP01
connector.
A.AlignthetabsontheinsideoftheP01connector
withtheslotsinthebattery-packconnector
(Figure7).Thenpushtheconnectorintothe
batterypackconnector.
B.RotatethelockingcollarontheP01connector
clockwiseuntilitengageswiththebatterypack
receptacleandbeginstopulltheconnectorin
towardthebatterypack(Figure6).Continue
turningthelockingcollaranother120degrees
(1/3ofaturn)clockwiseuntilitfullyseats.
G017358
Figure7
ConnectorP01AlignmentwiththeBatteryPack
2.Removethesteelrodthatholdsthebatteryplatform
intheraisedposition,andgentlylowerthebattery
platformtothemachineframe.
Important:Donotpinchthewireharness
betweentheframeandthebatteryplatform.
3.ConnecttheLi+diagnosticwireharnessP34connector
tothemainwireharnessP34connector(Figure8).
G017235
1
2
Figure8
1.MainwireharnessP34
connector
2.Li+diagnosticwire
harnessP34connector
4.ConnecttheLi+diagnosticwireharnessP04connector
tothebatteryadapterwireharnessP04connector
(Figure9).
9

Figure9
1.Li+diagnosticwire
harnessP04connector
2.BatterywireharnessP04
connector
UninstallingtheLi+Diagnostic
WireHarness
Performthefollowing4shortprocedurestouninstallthe
Li+diagnosticwireharness:
RaisetheBatteryPackandPlatform
1.Raisethebackofthebatteryplatformuntilthelocking
holesinthefrontofthebatteryplatformandframe
align(Figure10).
Figure10
1.Batterypackandplatform3.Lockingholes
2.Pivotboltsandnuts
2.Inserta6-mm(1/4-inch)steelrod(e.g.,screwdriver)
throughthelockingholestoholdthebatteryplatform
intheraisedposition(Figure10).
DisconnecttheLi+DiagnosticHarness
1.Onthebottomofthebatterypack,disconnecttheLi+
diagnosticwireharnessP01connectorbyrotatingthe
lockingcollarcounter-clockwiseapproximatelyhalfof
aturn(Figure11).
g030574
3
2
1
Figure11
1.BatteryharnessP01
connector
3.Battery-packconnector
2.Lockingcollar
2.DisconnecttheLi+diagnosticwireharnessP34
connectorfromthemainwireharnessP34connector
(Figure12).
10