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

G017235
1
2
Figure12
1.MainwireharnessP34
connector
2.Li+diagnosticwire
harnessP34connector
3.DisconnecttheLi+diagnosticwireharnessP04
connectorfromthebatteryadapterharnessP04
connector(Figure13).
Figure13
1.Li+diagnosticwire
harnessP04connector
2.BatterywireharnessP04
connector
4.MovetheLi+diagnosticwireharnessawayfromthe
machine.
ConnecttheWireHarnessConnectors
1.ConnectthebatterywireharnessP01connector.
A.AlignthetabsontheinsideoftheP01connector
withtheslotsinthebattery-packconnector
(Figure14).Then,pushtheconnectorintothe
batterypackconnector.
G017358
Figure14
B.RotatethelockingcollarontheP01connector
clockwiseuntilitengageswiththebatterypack
connectorandbeginstopulltheconnectorin
towardthebatterypack(Figure15).Continue
turningthelockingcollaranother120degrees
(1/3ofaturn)clockwiseuntilitlocksinplace.
g030574
3
2
1
Figure15
1.BatterywireharnessP01
connector
3.Battery-packconnector
2.Lockingcollar
2.ConnecttheLi+diagnosticwireharnessP34connector
tothemainwireharnessP34connector(Figure16).
11

G017235
1
2
Figure16
1.MainwireharnessP34
connector
2.Li+diagnosticwire
harnessP34connector
SecuretheBatteryPackandPlatform
1.Removethesteelrodthatisholdingthebattery
platformintheraisedposition,andgentlylowerthe
batteryplatformtothemachineframe(Figure17).
Figure17
1.Batterypackandplatform3.Lockingholes
2.Pivotboltsandnuts
Important:Donotpinchthewireharness
betweentheframeandthebatteryplatform.
2.Installthenut(Figure18).
Figure18
1.Nut
3.Tightenthepivotboltsandnuts(Figure17).
4.Connectthebatterypack.RefertoConnectingthe
BatteryPack(page17).
“WakingUp”theBatteryPack
Innormaloperation,turningthekeytotheSTARTposition
“wakesup”thebatterypack.Thisprovidespowertothe
TEC-2401,whichsendsperiodic“keepalive”messages
throughtheCANbustothebatterycontrollertokeepthe
batterypackpoweredup.TheLi+diagnosticwireharness
allowsthebatterypacktopowerupmomentarilysothatyou
canperformdiagnosticprocedures.Thebatterypackremains
ononlymomentarilybecausenoCANmessageissent.
To“wakeup”thebatterypack,performthefollowingsteps:
1.InstalltheLi+diagnosticwireharness.Referto
InstallingtheLi+DiagnosticWireHarness(page8).
2.DisconnecttheP06andP07connectorsfromP05(the
moldedstoragecap).
3.ConnecttheP06andP07connectorstogether.
4.Listenforanaudible“clunk”fromthebatteryinternal
contactor.Forthenext2to3seconds,thebatterypack
willsupplypowertoitsoutputterminals.
12

InspectingtheWireHarnesses
andComponentConnector
Assemblies
Figure19showsthethreewireharnesses.
g030844
2
3
1
Figure19
1.Mainharness3.Batteryharness
2.Batteryadapterharness
Thewireharnessesandelectricalcomponentsincludethe
following:
•Electricalconnectors
•Connectorpins
•Electricalterminals
•Insulatedwire
Whileyouaretroubleshooting,inspectthepartsforwear
anddamage.
Commonelectricalproblemsinclude:
•Open,shorted,orburnedwires
Note:Debris,suchaswetgrassclippings,canactasa
conductor.
•Corrodedterminalsorpins
•Waterintheconnector
•Connectorpinsthatareloose,bent,ormispositioned
•Connectorsthatarenotfullyseated
•Wiresthatarepinched,frayed,oraremissinginsulation
•Damagedconnectorlocks,clips,orhousings
•Missingorinadequatedielectricgrease
Note:Dielectricgreaseisusedinallunsealedwire
harnessconnectors.
RepairingHarnessWire
Insulation
Ifdamageextendsthroughtheinsulationandstrandsofthe
wirearebroken,repairorreplacethewireharness.Contact
yourToroServiceRepresentativeforguidancewhenrepairing
wires,terminals,pins,and/orconnectors.
Ifthereisdamagetotheouterinsulationonly,orifthe
damagetotheshieldingisabrasionordeformationonlywith
nobrokenstrands,repairthewireharnessasfollows:
1.Cleanthedamagedareaofthepartwithisopropyl
alcohol.
2.Drythepartwithacleanlint-freecloth.
3.Wrapthedamagedareawith2layersofall-weather
electricaltapeoranequivalent.
Note:Ensurethatthetapeextendspastthedamagebya
minimumof1.3cm(1/2inch).
Note:Heatshrinktapeproperlyinstalledinthesamemanner
aselectricaltapeisacceptable.Installtheheatshrinktape
accordingtothemanufacturer’sinstructions.
AttachingWireHarnesses
Properlyattachingthewireharnessestothemachinehelps
keeptheconnectorsfrombecominglooseandprotectsthe
harnessesfromaccidentaldamagecausedbyvibration.
•Ensurethatnodeviceusedtoattachawireharnesstothe
machinecanrotateorslidefreelyonthewireharness.
•Forwiresnotcontainedinconvolutedtubing,securethe
wireswithelectricaltapeoracabletieevery10to15cm
(4to6inches).
•Forsplit-loom,convolutedtubing,ensurethatthetapeor
cabletiesare1.3cm(1/2inch)awayfromanyconnectors
orlabels.
13

TestingElectricalCircuits
GroundingOptionforTesting
WARNING
TheeFlexlithium-ionbatterypackcontainshigh
voltage,whichcouldburnorelectrocuteyou.
•Neverattempttoopenthebatterypack.
•Donotplaceanythingintheconnectoronthe
batterypackotherthanaTorowireharness
connectormadefortheproduct.
•Donotallowtoolsorvehiclecomponentsto
completethebatterycircuit.
•Useextremecarewhenhandlingabatterypack
withacrackedcase.
•Removeabatterypackwithacrackedcase
immediately.
•UseonlytheTorobatterychargerdesignedfor
thebatterypack.
Important:Themachineframeisnotusedforany
groundconnections.
Usetheworklightsconnectorforagroundconnection
(Figure20)fortestingasfollows:
1.LocatethemainwireharnessP04connector(forthe
optionalworklights)ontheleftsideoftheupper
handle.
2.Ifthemachineisequippedwiththeoptionalwork
lights,unplugconnectorP04fromtheworklight.
3.UseconnectorP04,pinB(blackwire)astheground
duringcontinuityandvoltagetesting.
B
Ag030839
P04
Figure20
MainWireHarnessWorkLightP04Connector
PinIdenticationDescriptionWireColor
A42to64VdcViolet(VIO)
BGround(harnesssupplied)Black(BK)
TestingforaShortCircuit
Ashortcircuitisanabnormalelectricalconnectionbetween
2electricalcircuits,andcanbediagnosedbyvoltagechecks
and/orcontinuitytests.
•Ashortcircuittogroundbeforeanelectricalcomponent
usuallycausesthefuseforthecircuittoopen.
•Ashortcircuittogroundafteranelectricalcomponent
usuallycausestheelectricalcomponenttostayonaslong
asthereispower.
Useamultimetertotestbetweentheidentiedwireharness
connectorpinsorcomponentterminalsandthesuspected
pointsoffailure.
TestingtheVoltageofaCircuit
1.Measurethevoltagebetweentheidentiedwire
harnessconnectorpinsorcomponentterminalsand
thesuspectedpointsoffailure.
2.Ifthevoltagethatyoumeasureishigherorlowerthan
thespeciedvoltage,cleanandinspecttheterminal
connectionsalongthecircuitpaththatyouaretesting.
CleaningElectronicComponentsand
Connections
Note:Useelectrical-contactcleaneronly.Donotusebrake
cleaner,asitmaypermanentlydamageelectricalconnector
bodiesandotherplasticcomponentsofthemachine.Avoid
usingmineralsolvents,astheymaydamageconnectors,seals,
andwireinsulation.
WARNING
Cleaningchemicalsandtoolscancauseinjuryif
usedimproperly.
RefertotheapplicableMSDSforappropriate
personalprotectivegear,suchasgloves,respirators,
andsafetyglasses.
1.Markthewiresforproperinstallationaftercleaningis
completed.Extractconnectorpinswiththeproper
extractiontool.
2.Cleantheterminalsortheconnectorpinsusingan
eraser,mildabrasivepaper,oranylonorberbristle
brush.Donotusemetalormetaloxides,including
aluminum.
14

3.Finishthecleaningwithaberbristlebrushdipped
inisopropylalcohol.
4.Gentlywipeoffthecleanpins,terminals,and
componentswithalint-freeclothdampenedwith
isopropylalcohol.
5.Whenavailable,drythecomponentswithdry,oil-free
compressedair(maximumairpressure20psig/137.895
kPa).
6.Ensureallconnectorsandcomponentsarecleanand
drypriortoreassemblyandtesting.
PreparingtoTestthe
Components
1.Parkthemachineonalevelsurface.
2.MovethetractionlevertotheNEUTRALposition.
3.MovethekickstandintotheJACKSTANDposition.
RefertoUsingtheKickstand(page17).
TestingtheComponent
CAUTION
Performingcontinuitytestingonelectrical
componentswiththebatterypackconnectedcan
leadtosevereelectricalshock.
Disconnectthebatterypackfromthemachine
beforetestingelectricalcomponents.Referto
DisconnectingtheBatteryPack(page17).
CAUTION
Wearingjewelrywhiletroubleshootingortesting
themachinecanbedangerous.Jewelrycancausea
shortcircuitorgetcaughtonthemachine,causing
seriousinjury.
Removealljewelry,especiallyringsandwatches,
beforedoinganyelectricaltroubleshootingor
testing.
Important:TheGreensmastereFlexusesa53-Vdc
battery-basedelectricalsystem.Actualmeasurements
ofvoltagewillvaryfrom42to64Vdc,dependingonthe
chargelevelofthebatterypack.
Important:Themachineframeisnotusedasan
electricalground.Groundisdistributedthroughthe
machinewireharnesses.
SomecomponentscanbetestedthroughtheInfoCenter
display.RefertotheeFlexServiceManual,Chapter4,
DiagnosticsScreen.
IfdiagnosisusingtheInfoCenterisnotpossible,remove
powerfromthemachinebyturningthekeyswitchto
theOFFposition,removingthekeyfromtheswitch,and
disconnectingthebatterypack.RefertoDisconnectingthe
BatteryPack(page17).
Foraccurateresistanceand/orcontinuitychecks,electrically
isolatethecomponentbeingtestedbydisconnectingallwiring
orremovingitfromthecircuit).
Note:RefertotheeFlexServiceManualChapter4,Electrical
System.
ComponentsCoveredintheComponent
TestingProceduresintheeFlexService
Manual
ComponentDetail
FuseblockFuseF1-1(30amp/80volt),fuseF1-2(3
amp/80volt),fuseF1-3(3amp/80volt)
Lithiumbattery
packfuse
58Vfusereplacement
KeyswitchKeyswitchtesting
Parkingbrake
latchswitch
Parkingbrakelatchswitchoperation,
testing,andremoval/installation
TractionswitchTractionswitchoperation,testing,and
removal/installation
Reel-engage
switch
Reel-engageswitchoperation,testing,and
removal/installation
EZ-TurnswitchEZ-Turnswitchtesting
EZ-TurnsensorEZ-Turnsensortesting
Speed-control
potentiometer
Speed-controlpotentiometeroperationand
testing
MaincontactorMaincontactortesting
ToroElectronic
Controller
(TEC-2401)
ToroElectronicControllerinformation
CAN-Bus
termination
resistor
CAN-Busterminationresistorandresistor
testing
15

InfoCenterDiagnosticsScreenIcons
TheInfoCenterdiagnosticsscreendisplaysthecurrentstatusofvariousmachineelectricalcomponentsandpowersupply
voltages.Usethediagnosticsscreentochecktheoperationofthemachineswitchesandcontrolswhenpossible.
TondadditionalinformationonnavigatingtheInfoCentermenuitems,refertotheeFlexServiceManualChapter4,Electrical
System,InfoCenterDiagnosticsScreensection.
DiagnosticsiconDescriptionDisplaystatePossiblestatesNotes
Thekeyisin
theONpositionONONOFFisnotdisplayed,asthepowerisnot
available.
Thekeyis
ontheSTART
position
OFFON/OFFMomentarykeyswitchposition
Parkingbrake
latchONON/OFFON=open
OFF=grounded
EZ-TurnOFFON/OFF
TractionFWDFWD/OFF
ReelenableONON/OFF
Throttle0Vto5V
Throttlerotatedfullybackward=0to1
Volts.Throttlerotatedfullyforward=4to
5Volts
Targetspeed
(rpm)
rpm(numeric
value)Thedemandedtargetrpm1
Motorspeed
(rpm)
rpm(numeric
value)Theactualmotorrpm1
12VdcsupplyVolts(numeric
value)
Voltagereadingforthe12Vdcpower
supply.Agoodreadingis10.5to13.8
Vdc.
5VdcsupplyVolts(numeric
value)
Voltagereadingforthe5Vdcpower
supply.Agoodreadingis4.91to5.09
volts.
CANbusNormalIndicatesthestatusofthemachine
communicationbus
1:Examiningthetargetspeed(rpm)versustheactualspeed(rpm)aidsinndingpossibleexcessivemachineloadsinternally
(adjustment,wear,ordamage)andorexternallyappliedloads(debrisorterrain).
16

FrequentlyUsed
Procedures
ConnectingtheBatteryPack
1.VerifythatthekeyswitchisintheOFFposition.
2.Removethekeyfromthekeyswitch.
3.ConnectthebatteryadapterwireharnessP04T-handle
connectortothebatterywireharnessP04connector
(Figure21).
DisconnectingtheBattery
Pack
CAUTION
Unintentionaloperationofthemachinewhile
servicingitcaninjureyou.
Beforeservicingthemachine,disconnectthe
batterypack.
WARNING
TheeFlexlithium-ionbatterypackcontainshigh
voltage,whichcouldburnorelectrocuteyou.
•Neverattempttoopenthebatterypack.
•Donotplaceanythingintheconnectoronthe
batterypackotherthanaTorowireharness
connectormadefortheproduct.
•Donotallowtoolsorvehiclecomponentsto
completethebatterycircuit.
•Useextremecarewhenhandlingabatterypack
withacrackedcase.
•Removeabatterypackwithacrackedcase
immediately.
•UseonlytheTorobatterychargerdesignedfor
thebatterypack.
1.RotatethekeyswitchtotheOFFpositionandthen
removethekey.
2.Wait10to15minutesforthemotorcapacitorsto
discharge.
3.DisconnecttheT-handleconnectorfromthebattery
wireharnessP04connector(Figure21).
G017237
12
Figure21
1.Batteryadapterwire
harnessP04T-handle
connector
2.BatterywireharnessP04
connector
UsingtheKickstand
Thekickstand,mountedontherearofthemachine,keeps
themachinefromfallingbackwardontothehandlewhen
youremovethereelfromthefrontofthemachine.The
kickstandalsoraisestherearofthemachineduringtheuse
oftheInfoCenterDisplayDiagnosticsscreen.Thekickstand
has3positions:STORAGE,SERVICE,andJACKSTAND.
•Tousethekickstandwhenremovingthereel,lowerthe
kickstandfromtheSTORAGEpositionintotheSERVICE
position.Thenpushinthelockingpintolockthe
kickstandintheSERVICEposition(Figure22).
17

G017356
1
2
3
Figure22
1.Kickstand—STORAGE
position
3.Kickstand—SERVICE
position
2.Lockingpin
•TousethekickstandduringtheuseoftheInfoCenter
DisplayDiagnosticsscreen,lowerthekickstandtothe
groundandstepdownonthekickstandloopwhile
pullingupandbackonthelowercentermachinehandle
(Figure23).
Important:Putonlyfootpressuredownonthe
kickstandloop,anduseonlythelowercenter
machinehandletoraisethemachine.Attemptingto
raisethemachineontothekickstandbyanyother
meanscancauseinjury.
g018793
Figure23
1.Lowercentermachine
handle
2.Kickstandloop
Figure24showsthekickstandintheJACKSTAND
position.
G017246
1
2
Figure24
1.Kickstand2.Kickstandloop
ReadingFaultCodes
Youcanreadfaultcodes2differentways:onthemachine
InfoCenterdisplayoronaPCusingToroDIAGSoftware
(page5).ThissectionfocusesontheInfoCenterdisplay.
TheInfoCenterLCDdisplayshowsinformationaboutyour
machine,suchasfaultcodes,thechargelevelofthebattery
pack,andvariousdiagnosticmessagesandiconsthatprovide
currentinformationaboutthemachineandthebatterypack
(Figure25).
1
3
654
2
G030436
Figure25
TheInfoCenterLCDdisplay
1.Faultindicatorlight4.Rightbutton
2.Batterychargeindicator5.Downbutton
3.Speed-controlsetting6.Menuaccess/backbutton
Ifanelectricalfaultoccurs,theInfoCenterfaultindicator
lightashesandatextmessageappearsimmediatelytonotify
youaboutthefault.
•Faultsthatarecurrentlyhappeningarecalledactivefaults.
Assoonasafaultoccurs,informationaboutthatfaultis
displayedontheInfoCenter.Faultsremainactiveuntil
18

youclearthemortheconditionthatcreatedthefaultno
longerexists.
•Toseealistoffaultsthatoccurredbeforethemostrecent
startingofthemachine,usetheInfoCenterFaultsscreen.
TheFaultsscreenlistsallthemachinefaultsthathave
occurredsincetheInfoCenterfaultlogwaslastcleared.
ClearingFaultCodeswhile
UsingtheMachine
Ifafaultoccurswhileyouareoperatingthemachine,attempt
toclearthefaultbyperformingthefollowing:
1.MovethetractionlevertotheNEUTRALposition.
2.RotatethekeyswitchtotheOFFposition.
3.Allowallmachinefunctionstostop.
4.Startthemachineandtestittoseeifoperationhas
returnedtonormal.
ClearingtheInfoCenterFault
Log
YoucanclearthefaultsfromtheInfoCenterfaultlog;
however,thefaulthistorywillberetainedintheTEC-2401
memory.
Note:RefertoFigure25forhelpusingthisprocedure.
1.PresstheMenuAccess/Backbutton.
TheMainMenuappears.
2.VerifythattheFaultsmenuitemisselected,andthen
presstheRightbutton.
TheFaultsscreenappears.
3.PresstheDownbuttontoscrolldownthroughthe
faultsuntilClearSystemFaultsisselected.
4.PresstheRightarrow.
Aconrmationscreenappears.
5.PresstheDownbuttontoconrmclearingthe
InfoCenterfaultlog.
An“ Allfaultscleared”messageappears.
6.PresstheMenuAccess/Backbutton3timestoreturn
totheMainMenuscreen.
Note:Somefaultsclearwhenyoustartthemachine.After
thefaultclears,youcanresumenormaloperationofthe
machine.
Ifafaultrepeatseachtimeyoustartthemachine,conduct
diagnostictroubleshootingoftheaffectedsystemandrelated
components.
TurningontheMachine
1.EnsurethattheT-handleconnectoronthebattery
adapterwireharnessisconnectedtothebatterywire
harnessconnector.
2.Ensurethatthetractionandreeldriveleversareinthe
NEUTRALposition.
3.RotatethekeyswitchtotheSTARTpositionandholdit
thereuntiltheInfoCenterLCDdisplaylightsup,then
releasethekeytotheONposition.
TurningofftheMachine
1.Disengagethetractionandreel-drivecontrols.
2.RotatethekeyswitchtotheOFFpositionandremove
thekey.
ReturningtheEquipmentto
Service
Toensureoptimumperformanceandcontinuedsafety,
performthefollowingstepsaftercompletingalldiagnostic,
maintenance,and/orrepairactivities:
1.Removeanydiagnosticequipmentortoolsattached
tothemachineforthepurposeoftroubleshootingor
repair.
2.Fullyassemblethemachine.Thisincludesallcovers,
cableties,andpartsthatyouloosenedorremoved.
3.Makesurethatallnuts,bolts,screws,andbeltsare
properlytightened.
4.Verifythatallsystemsfunctionsafelyandareas
speciedintheeFlexOperator’sManualandtheeFlex
ServiceManual.
5.Returnthemachinetoservice.
ConsoleCover
Theconsolecovermustberemovedtoaccesssomeofthe
connectorsonthemainwireharness.RefertoFigure26.
Theconsolecoverissecuredwith4screws.
1
2 2
g030840
Figure26
1.Consolecover2.1/4x20,1/2-inchscrews
19

PowerCenterCover
Youmustremovethepowercentercovertoaccesssomeof
theconnectorsonthemainwireharness,thebatterywire
harness,andthebatteryadapterwireharness.RefertoFigure
27.
Thepowercentercoverissecuredwith4screws.
g030841
1
2
2
Figure27
1.Powercentercover2.Screws(4used)
20