Toro 04042, Diagnostic Manual

Page 1: ...orm No 3386 113 Rev B Greensmaster eFlex 1800 and 2100 Traction Unit Model No 04042 Serial No 314001001 and Up Model No 04043 Serial No 314001001 and Up G017154 Register at www Toro com Original Instructions EN 3386 113 B ...

Page 2: ...DIAG User s Guide for information on system operation diagnostics and machine programming The Toro Company reserves the right to change product specifications or this publication without notice Improper use or maintenance by the operator or owner can result in injury To reduce the potential for injury comply with all safety instructions in this manual and always pay attention to the safety alert s...

Page 3: ...ing the Battery Pack 17 Disconnecting the Battery Pack 17 Using the Kickstand 17 Reading Fault Codes 18 Clearing Fault Codes while Using the Machine 19 Clearing the InfoCenter Fault Log 19 Turning on the Machine 19 Turning off the Machine 19 Returning the Equipment to Service 19 Console Cover 19 Power Center Cover 20 Fault 01 Internal TEC 21 Fault 02 12 Vdc Supply 23 Fault 03 5 V Supply 35 Fault 0...

Page 4: ...tery Pack page 17 Keep all nuts bolts screws and belts properly tightened To reduce potential fire hazard keep the battery pack electrical connectors cutting unit and drive components free of debris Wear cut resistant or heavy leather gloves and use caution when checking or servicing the cutting unit If you must perform maintenance or make an adjustment with the electric motor running keep your ha...

Page 5: ...ller TEC Features and benefits of the Toro DIAG software include the following The software uses a USB to CAN connection You can monitor the complete machine controller system The software is a Windows based application Software updates are sent automatically You can review fault codes You can easily reprogram the machine You can see the inputs and the outputs You can see the controller state of h...

Page 6: ...Wire dryer aerosol Commercially available Special Tools Toro DIAG Diagnostic Software Note Refer to the Toro DIAG User s Guide Toro DIAG USB CAN Cable Toro P N 115 1944 Note Refer to the Toro DIAG User s Guide Multimeter Note Use a digital multimeter when testing electrical circuits The high impedance internal resistance of a digital multimeter in the voltage mode will ensure that excess current i...

Page 7: ...n they are not in use P06 and P07 battery wake Connect the P06 and P07 connectors together momentarily allow the battery pack to wake from the hibernate state so that you can determine the condition of the battery pack P04 machine charger connector Connects the Li diagnostic wire harness to the battery wire harness P04 connector at the side of the battery pack P01 battery diagnostic connector Conn...

Page 8: ... Disconnect the P01 Connector 1 Remove the nut that secures the rear of the battery platform to the machine frame Figure 4 Figure 4 1 Nut 2 Loosen the 2 pivot bolts a half turn each Figure 5 Figure 5 Raised Battery Pack and Platform 1 Battery pack and platform 3 Locking holes 2 Pivot bolts and nuts 3 Raise the back of the battery platform until the locking holes in the front of the battery platfor...

Page 9: ...tery pack Figure 6 Continue turning the locking collar another 120 degrees 1 3 of a turn clockwise until it fully seats G017358 Figure 7 Connector P01 Alignment with the Battery Pack 2 Remove the steel rod that holds the battery platform in the raised position and gently lower the battery platform to the machine frame Important Do not pinch the wire harness between the frame and the battery platfo...

Page 10: ...platform 3 Locking holes 2 Pivot bolts and nuts 2 Insert a 6 mm 1 4 inch steel rod e g screwdriver through the locking holes to hold the battery platform in the raised position Figure 10 Disconnect the Li Diagnostic Harness 1 On the bottom of the battery pack disconnect the Li diagnostic wire harness P01 connector by rotating the locking collar counter clockwise approximately half of a turn Figure...

Page 11: ... tabs on the inside of the P01 connector with the slots in the battery pack connector Figure 14 Then push the connector into the battery pack connector G017358 Figure 14 B Rotate the locking collar on the P01 connector clockwise until it engages with the battery pack connector and begins to pull the connector in toward the battery pack Figure 15 Continue turning the locking collar another 120 degr...

Page 12: ...on turning the key to the START position wakes up the battery pack This provides power to the TEC 2401 which sends periodic keep alive messages through the CAN bus to the battery controller to keep the battery pack powered up The Li diagnostic wire harness allows the battery pack to power up momentarily so that you can perform diagnostic procedures The battery pack remains on only momentarily beca...

Page 13: ...sentative for guidance when repairing wires terminals pins and or connectors If there is damage to the outer insulation only or if the damage to the shielding is abrasion or deformation only with no broken strands repair the wire harness as follows 1 Clean the damaged area of the part with isopropyl alcohol 2 Dry the part with a clean lint free cloth 3 Wrap the damaged area with 2 layers of all we...

Page 14: ...sed by voltage checks and or continuity tests A short circuit to ground before an electrical component usually causes the fuse for the circuit to open A short circuit to ground after an electrical component usually causes the electrical component to stay on as long as there is power Use a multimeter to test between the identified wire harness connector pins or component terminals and the suspected...

Page 15: ...machine frame is not used as an electrical ground Ground is distributed through the machine wire harnesses Some components can be tested through the InfoCenter display Refer to the eFlex Service Manual Chapter 4 Diagnostics Screen If diagnosis using the InfoCenter is not possible remove power from the machine by turning the key switch to the OFF position removing the key from the switch and discon...

Page 16: ... switch position Parking brake latch ON ON OFF ON open OFF grounded EZ Turn OFF ON OFF Traction FWD FWD OFF Reel enable ON ON OFF Throttle 0V to 5V Throttle rotated fully backward 0 to 1 Volts Throttle rotated fully forward 4 to 5 Volts Target speed rpm rpm numeric value The demanded target rpm1 Motor speed rpm rpm numeric value The actual motor rpm1 12 Vdc supply Volts numeric value Voltage readi...

Page 17: ... cracked case Remove a battery pack with a cracked case immediately Use only the Toro battery charger designed for the battery pack 1 Rotate the key switch to the OFF position and then remove the key 2 Wait 10 to 15 minutes for the motor capacitors to discharge 3 Disconnect the T handle connector from the battery wire harness P04 connector Figure 21 G017237 1 2 Figure 21 1 Battery adapter wire har...

Page 18: ...des You can read fault codes 2 different ways on the machine InfoCenter display or on a PC using Toro DIAG Software page 5 This section focuses on the InfoCenter display The InfoCenter LCD display shows information about your machine such as fault codes the charge level of the battery pack and various diagnostic messages and icons that provide current information about the machine and the battery ...

Page 19: ...hen you start the machine After the fault clears you can resume normal operation of the machine If a fault repeats each time you start the machine conduct diagnostic troubleshooting of the affected system and related components Turning on the Machine 1 Ensure that the T handle connector on the battery adapter wire harness is connected to the battery wire harness connector 2 Ensure that the tractio...

Page 20: ...over to access some of the connectors on the main wire harness the battery wire harness and the battery adapter wire harness Refer to Figure 27 The power center cover is secured with 4 screws g030841 1 2 2 Figure 27 1 Power center cover 2 Screws 4 used 20 ...

Page 21: ...ot repeat Go to Returning the Equipment to Service page 19 and follow the steps listed Note If the fault does not repeat a false detect event may have occurred Fail The fault repeated Go to step 2 Step 2 Check the charge level of the battery Check the InfoCenter LCD screen to ensure that the charge level is adequate If the battery indicator does not show at least 1 full block connect the battery c...

Page 22: ...1 Refer to Figure 28 After you have replaced the TEC 2401 go to Returning the Equipment to Service page 19 and follow the steps listed 1 2 3 4 5 6 7 8 g030800 Figure 28 Location of the TEC 2401 Item 5 1 InfoCenter 5 TEC 2401 2 Speed control potentiometer 6 Fuse block 3 EZ Turn Slow in Turn switch 7 Main contactor 4 Light switch optional 8 Battery wire harness P01 connector 22 ...

Page 23: ... operate the machine Refer to the eFlex Operator s Manual Pass The fault did not repeat Go to Returning the Equipment to Service page 19 and follow the steps listed Note If the fault does not repeat a false detect event may have occurred Fail The fault repeated Go to step 2 Step 2 Check the charge level of the battery Check the InfoCenter LCD screen to ensure that the charge level is adequate If t...

Page 24: ... Rotate the key switch to the START position and hold it there until the InfoCenter LCD display lights up then release the key switch to the RUN position 3 Measure the voltage between the main wire harness P17 connector pin 2 and the main wire harness P04 connector pin B Figure 30 The range for a good reading is 10 5 to 13 8 Vdc 4 Rotate the key switch to the OFF position and then connect the main...

Page 25: ...r meter Test the wireless hour meter wire harness P43 connector Figure 31 by performing the following 1 Rotate the key switch to the OFF position 2 If the optional wireless hour meter is installed disconnect the main wire harness P43 connector from the wireless hour meter 3 Rotate the key switch to the START position and hold it there until the InfoCenter LCD display lights up then release the key...

Page 26: ...rn proximity sensor Test for 12 Vdc on the wire harness connector for the EZ Turn proximity sensor Figure 32 by performing the following 1 Rotate the key switch to the OFF position and then disconnect the main wire harness P23 connector at the EZ Turn proximity sensor 2 Rotate the key switch to the START position and hold it there until the InfoCenter LCD display lights up then release the key swi...

Page 27: ...wire harness while checking the items in the following steps Refer to Inspecting the Wire Harnesses and Component Connector Assemblies page 13 Note Troubleshoot 1 circuit or component at a time Disconnect or isolate each component or wire harness section from the system before testing Disconnect the battery pack Refer to Disconnecting the Battery Pack page 17 Step 4 4 1 Check the wire harness for ...

Page 28: ...Location Harness Connector Pin Connector Graphic 1 Main Figure 33 P01 5 1 12 7 6 2 Main Figure 33 P02 7 or 8 1 12 7 6 Figure 33 1 Main wire harness P02 connector 3 TEC 2401 controller 2 Main wire harness P01 connector Note The wire harness diagram uses P01 and P02 for referencing these connectors while the electrical schematic uses P1 and P2 28 ...

Page 29: ...are identified at the listed locations Go to step 4 4 2 and follow the steps listed Fail For those items that failed repair or replace worn or damaged parts as required Go to Returning the Equipment to Service page 19 and follow the steps listed Step 4 4 2 Verify that there are no short conditions for the optional wireless hour meter Verify that a short does not exist between the following pairs o...

Page 30: ... BK Pass No shorts are identified at the listed locations Go to step 4 4 3 and follow the steps listed Fail For those items that failed repair or replace worn or damaged parts as required Go to Returning the Equipment to Service page 19 and follow the steps listed Step 4 4 3 Check the wire harness for continuity and verify no short condition for the EZ Turn proximity sensor Note Refer to the eFlex...

Page 31: ...Connector Pin Connector Graphic 1 Main P01 Figure 33 5 1 12 7 6 2 Main P23 Figure 36 A A B C 1 Main P23 Figure 36 B A B C 2 Main P06 Figure 37 2 3 2 1 8 6 5 4 7 1 Main P23 Figure 36 C A B C 2 Main P04 Figure 30 B B A 31 ...

Page 32: ...tor Graphic 1 Main P01 Figure 33 5 1 12 7 6 2 Main P23 Figure 36 C A B C Figure 36 Main Harness P23 Connector and EZ Turn Slow in Turn Sensor Pin Identification Main Harness P23 Connector Pin Identification Description Wire Color A 12 Vdc In Pink PK B Signal Voltage Out call to ground Orange OR C Ground Black BK 32 ...

Page 33: ...hose items that failed repair or replace worn or damaged parts as required Go to Returning the Equipment to Service page 19 and follow the steps listed Electrical Diagram Figure 38 InfoCenter The TEC 2401 P01 connector pin 5 provides 12 Vdc to the InfoCenter through the main wire harness P17 connector pin 2 The TEC 2401 P02 connector pin 7 provides harness ground to the InfoCenter through the main...

Page 34: ...r meter through the main wire harness P43 connector pin 3 Figure 40 EZ Turn Slow in Turn Proximity Sensor The EZ Turn Slow in Turn functionality consists of 2 circuits 1 of the circuits is for the operation of the proximity sensor which indicates the position of the reel either in the air while turning or on the ground while mowing The other circuit is to reduce the speed of the mower with the ree...

Page 35: ...al Pass The fault did not repeat Go to Returning the Equipment to Service page 19 and follow the steps listed Note If the fault does not repeat a false detect event may have occurred Fail The fault repeated Go to step 2 Step 2 Check the charge level of the battery Check the InfoCenter LCD screen to ensure that the charge level is adequate If the battery indicator does not show at least 1 full bloc...

Page 36: ...tion 3 Measure the voltage between the main wire harness connector P05 pin C and the main wire harness P04 connector pin B Figure 43 The normal voltage range is 4 91 to 5 09 Vdc 4 Rotate the key switch to the OFF position and then connect the main wire harness P05 connector at the speed control position sensor potentiometer 1 2 3 4 5 6 7 8 g030800 Figure 41 Component Locations of the Speed Control...

Page 37: ... wire harness for continuity and verify that there are no short conditions of the speed control potentiometer Note Inspect the wire harnesses for damage and wear while checking the items in the following steps Refer to Inspecting the Wire Harnesses and Component Connector Assemblies page 13 Disconnect the battery pack Refer to Disconnecting the Battery Pack page 17 Note Troubleshoot 1 circuit or c...

Page 38: ...D E F B 2 Main P02 Figure 44 5 1 12 7 6 1 Main P04 Figure 43 B B A 2 Main P05 Figure 42 B A C D E F B 2 Verify that a short does not exist between the following pairs of locations Location Harness Connector Pin Connector Graphic 1 Main P01 Figure 44 4 1 12 7 6 38 ...

Page 39: ...rness diagram uses P01 and P02 for referencing these connectors while the electrical schematic uses P1 and P2 Pass Circuit continuity tested good and no shorts are identified at the listed locations Go to Returning the Equipment to Service page 19 and follow the steps listed Fail For those items that failed repair or replace worn or damaged parts as required Go to Returning the Equipment to Servic...

Page 40: ...Electrical Diagram Figure 45 40 ...

Page 41: ... and prevent the pre charge process from succeeding within the specified time 1 Clear the InfoCenter fault log Refer to Clearing the InfoCenter Fault Log page 19 2 Disconnect the battery pack for 30 seconds Refer to Disconnecting the Battery Pack page 17 3 Connect the battery pack Refer to Connecting the Battery Pack page 17 4 Start and operate the machine Refer to the eFlex Operator s Manual Pass...

Page 42: ...r Assemblies page 13 1 Rotate the key switch to the OFF position 2 Rotate the key switch to the START position and hold it there until the InfoCenter LCD display lights up then release the key switch to the RUN position 3 Check for a continuous 42 to 64 Vdc as follows Measure between the main wire harness P04 connector pin B Figure 46 and the main contactor terminal J02 J05 Figure 47 Measure betwe...

Page 43: ...e circuit failure Go to step 5 Step 5 Use a multimeter to check the wire harness for continuity and measure coil resistance Note You will find additional wire harness and connector information in Appendix A Wire Harnesses page 113 and Appendix B Toro Electronic Controller Connections page 135 Note Inspect the wire harnesses for damage and wear while checking the items in the following steps Refer ...

Page 44: ... 1 Main Figure 48 P13 E A B C D E F 2 Main Figure 47 Main contactor J03 J02 J05 J03 J01 J04 1 Main Figure 48 P13 E A B C D E F 2 Main Figure 49 P01 6 1 12 7 6 1 Main Figure 47 Main contactor J04 J02 J05 J03 J01 J04 2 Main Figure 49 P02 1 1 12 7 6 44 ...

Page 45: ...BK C 12 Vdc Key Run Violet VIO D 48 to 64 Vdc Logic Power White W E 48 to 64 Vdc Pre Charge Logic Power Tan T F Not used Not used Figure 49 Main Harness P01 and P02 Connector Pin Identification 1 Main wire harness P01 connector 3 TEC 2401 controller 2 Main wire harness P02 connector Note The wire harness diagram uses P01 and P02 for referencing these connectors while the electrical schematic uses ...

Page 46: ... coil circuit Repair and or replace malfunctioning parts Go to Returning the Equipment to Service page 19 and follow the steps listed Step 6 Use a multimeter to check the wire harness for continuity and verify that there are no short conditions of the optional work light circuit Note You will find additional wire harness and connector information in Appendix A Wire Harnesses page 113 and Appendix ...

Page 47: ...n the following pairs of locations Location Harness Connector Pin Connector Graphic 1 Main Figure 51 P19 3 3 2 1 8 6 5 4 7 2 Main Figure 46 P04 A B A 1 Main Figure 51 P19 2 3 2 1 8 6 5 4 7 2 Main Figure 52 P03 6 1 2 3 4 5 6 7 8 47 ...

Page 48: ...olor 1 Not used Not used 2 48 to 64 Vdc In Yellow Y 3 48 to 64 Vdc Out Violet VIO 4 through 8 Not used Not used Figure 52 Main Harness P03 Fuse Block Pin Identification Main Harness P03 Fuse Block Pins Pin Identification Description Wire Color 1 Battery Power In Red R 2 Battery Power Out fused battery power out Red R 3 Battery Power Out White W 48 ...

Page 49: ...sted good Go to Returning the Equipment to Service page 19 and follow the steps listed Fail The test found an open in the circuit Repair and or replace malfunctioning parts Go to Returning the Equipment to Service page 19 and follow the steps listed Step 7 Use a multimeter to perform voltage and continuity checks and verify that there are no short conditions Note You will find additional wire harn...

Page 50: ...ain wire harness for continuity and verify that there are no short conditions 1 Check fuse F1 1 Figure 50 for continuity and ensure it is properly installed 2 Check for continuity between the following pairs of locations Location Harness Connector Pin Connector Graphic 1 Main Figure 53 P42 1 1 2 2 Main Figure 47 Main contactor J02 J05 J02 J05 J03 J01 J04 1 Main Figure 47 Main contactor J01 J02 J05...

Page 51: ...Location Harness Connector Pin Connector Graphic 1 Main Figure 52 P03 2 1 2 3 4 5 6 7 8 2 Main Figure 54 P26 A A B 1 Main Figure 53 P42 2 1 2 2 Main Figure 54 P26 B A B 51 ...

Page 52: ...entification Description Wire Color Main 1 Logic Power Tan T 2 Not used Not used 3 CAN High Red White R W 4 CAN Low Black White BK W Main Harness P42 Connector Pin Identification Description Wire Color 1 48 to 64 Vdc Power Red R 2 Ground Black BK Figure 54 Main Harness P26 Connector Pin Identification 52 ...

Page 53: ...6 Connector Pass Circuit continuity tested good and no shorts are identified at the listed locations Go to Step 7 2 and follow the steps listed Fail For those items that failed repair or replace worn or damaged parts as required Go to Returning the Equipment to Service page 19 and follow the steps listed Step 7 2 Check the battery wire harness for continuity and verify that there are no short cond...

Page 54: ...ic 1 Battery Figure 56 P04 POS POS NEG _ P1 P2 S1 S2 2 Battery Figure 56 P01 3 1 2 3 5 6 4 1 Battery Figure 56 P04 NEG POS NEG _ P1 P2 S1 S2 2 Battery Figure 56 P01 4 1 2 3 5 6 4 Figure 56 Battery Harness P01 and P04 Connector Pin Identification 54 ...

Page 55: ... Not used NEG Ground Black BK 3 Verify that a short does not exist between the following pair of locations Location Harness Connector Pin Connector Graphic 1 Battery Figure 56 P01 3 1 2 3 5 6 4 2 Battery Figure 56 P01 4 1 2 3 5 6 4 Pass Circuit continuity tested good and no shorts are identified at the listed locations Go to Returning the Equipment to Service page 19 and follow the steps listed Fa...

Page 56: ...y The main contactor connects the battery pack and the electric motor The TEC 2401 circuitry monitors the voltage at several locations to ensure that the contactor is working properly and that the voltage is correct at all components for operation 56 ...

Page 57: ... an historical event viewable via Toro DIAG Recommended Service Actions Step 1 Verify that the fault repeats 1 Clear the InfoCenter fault log Refer to Clearing the InfoCenter Fault Log page 19 2 Disconnect the battery pack for 30 seconds Refer to Disconnecting the Battery Pack page 17 3 Connect the battery pack Refer to Connecting the Battery Pack page 17 4 Start and operate the machine Refer to t...

Page 58: ... resistance reading was good Go to Step 5 Fail The resistance reading was not good If the reading was between 108 and 132 ohms go to Step 4 1 For all other readings go to Step 5 Step 4 1 Test the main wire harness CAN terminator and wiring 1 Disconnect the CAN terminator from the main wire harness P14 connector Figure 59 Figure 59 Main Harness P14 Connector Pin Identification 58 ...

Page 59: ...e listed locations Connect the main wire harness CAN terminator to the main wire harness P14 connector Go to Step 4 2 Fail The continuity readings are not good Repair or replace worn or damaged parts as required Go to Returning the Equipment to Service page 19 and follow the steps listed Step 4 2 Test the battery wire harness CAN terminator and wiring 1 Disconnect the CAN terminator from the batte...

Page 60: ...tor at connector P03 may already be disconnected This step requires that you disconnect both 120 ohm terminators Step 5 1 Disconnect 4 devices and both terminators Figure 62 shows the locations of the devices and the terminators that need to be disconnected InfoCenter Disconnect the main wire harness P17 connector Main wire harness CAN terminator Disconnect the terminator from the main wire harnes...

Page 61: ... to Figure 58 Note If the reading is not infinite open verify that all 6 items listed in Step 5 1 are disconnected Any 1 of them being connected will cause the reading in this step to be wrong Pass The reading was good Go to Step 5 3 Fail The reading was not good Repair or replace worn or damaged parts as required Go to Returning the Equipment to Service page 19 and follow the steps listed 61 ...

Page 62: ...to 2700 Pass The reading was good Disconnect the main wire harness P17 connector and then go to Step 5 4 Fail The reading was not good Go to Step 5 3 1 Step 5 3 1 Test the InfoCenter wiring 1 Disconnect the main wire harness P17 connector Figure 63 2 Check for continuity between the following pairs of locations Location Harness Connector Pin Connector Graphic 1 Main Figure 58 P37 A B C A 2 Main Fi...

Page 63: ... parts as required Go to Returning the Equipment to Service page 19 and follow the steps listed Step 5 4 Test the motor and associated wiring 1 Connect the main wire harness P41 connector Figure 64 to the motor 2 Use a multimeter to measure the resistance between the main wire harness P37 connector pins A and B Figure 58 The reading should be 139 k to 170 k ohms 139 000 to 170 000 Pass The reading...

Page 64: ... 1 3 2 1 Main Figure 58 P37 B B C A 2 Main Figure 64 P41 4 4 1 3 2 Figure 64 Main Harness P41 Connector Pin Identification P41 Main Harness Motor Controller Connector Pin Identification Description Wire Color 1 Logic Power Tan T 2 Not used Not used 3 CAN High Red White R W 4 CAN Low Black White BK W 64 ...

Page 65: ...e the resistance between the main wire harness P37 connector pins A and B Figure 58 The reading should be 2 2 k to 2 7 k ohms 2200 to 2700 Pass The reading is good Disconnect connector P34 and go to Step 5 6 Fail The reading is not good Go to Step 5 5 1 Step 5 5 1 Test the battery pack wiring 1 Disconnect the battery wire harness P01 connector Refer to Raise the Battery Pack and Disconnect the P01...

Page 66: ... CAN High Red White R W E Not used Not used F CAN Low Black White BK W Pass The continuity readings are good Replace the battery pack Go to Returning the Equipment to Service page 19 and follow the steps listed Fail The continuity readings are not good Repair or replace worn or damaged parts as required Note Refer to the eFlex Service Manual for this step In the Electrical System chapter go to the...

Page 67: ...e resistance reading was not good go to Step 5 6 1 Step 5 6 1 Test the TEC 2401 wiring 1 Disconnect the main wire harness P01 connector from the TEC 2401 Figure 66 2 Check for continuity between the following pairs of locations Location Harness Connector Pin Connector Graphic 1 Main Figure 58 P37 A B C A 2 Main Figure 66 P01 11 1 12 7 6 1 Main Figure 58 P37 B B C A 2 Main Figure 66 P01 12 1 12 7 6...

Page 68: ... 4 devices and both terminators Refer to Figure 62 InfoCenter Connect the main wire harness P17 connector Main wire harness CAN terminator Connect the terminator to the main wire harness P14 connector Battery pack Connect the main wire harness P34 connector to the battery wire wire harness P34 connector Battery wire harness CAN terminator Connect the terminator to the battery wire harness P03 conn...

Page 69: ...Electrical Diagram Figure 67 CAN Bus Electrical Diagram 69 ...

Page 70: ...t and operate the machine Refer to the eFlex Operator s Manual Pass The fault did not repeat Go to Returning the Equipment to Service page 19 and follow the steps listed Note If the fault does not repeat a false detect event may have occurred Fail The fault repeated Go to step 2 Step 2 Check the charge level of the battery Check the InfoCenter LCD screen to ensure that the charge level is adequate...

Page 71: ...sted Fail The fault repeated Go to step 5 Step 5 Remove 2 access covers to aid troubleshooting Performing these steps provides access to connectors on the wire harnesses 1 Remove the console cover Refer to Console Cover page 19 2 Remove the power center cover Refer to Power Center Cover page 20 Step 6 Use a multimeter to check for ground to the motor Note You will find additional wire harness and ...

Page 72: ...B A B 2 Battery Figure 70 P04 NEG POS NEG _ P1 P2 S1 S2 1 Battery Figure 70 P04 NEG POS NEG _ P1 P2 S1 S2 2 Battery Figure 70 P01 4 1 2 3 5 6 4 Figure 68 Main Harness P41 4 pin and P42 2 pin Connector Pin Identification 72 ...

Page 73: ... 64 Vdc Power Red R 2 Ground Black BK Figure 69 Main Harness P26 Connector Pin Identification Main Harness P26 Connector Pin Identification Description Wire Color A 48 to 64 Vdc Power Red R B Ground Black BK Figure 70 Battery Harness P01 and P04 Connector Pin Identification 73 ...

Page 74: ...ed R P1 CAN High Red White R W P2 CAN Low Black White BK W S1 Battery Pack Wake up Blue BU S2 Not used Not used NEG Ground Black BK Note Ensure that the battery wire harness P01 connector is properly seated when reinstalled Pass The continuity checks are good Go to Returning the Equipment to Service page 19 and follow the steps listed Fail For those items that failed repair or replace as required ...

Page 75: ...e 17 4 Start and operate the machine Refer to the eFlex Operator s Manual Pass The fault did not repeat Go to Returning the Equipment to Service page 19 and follow the steps listed Note If the fault does not repeat a false detect event may have occurred Fail The fault repeated Go to step 2 Step 2 Check the charge level of the battery Check the InfoCenter LCD screen to ensure that the charge level ...

Page 76: ...tactor Connector Pin Identification Description Wire Color J01 42 to 64 Vdc from the battery pack Red R J02 42 to 64 Vdc to the motor Red R J03 42 to 64 Vdc from the key switch Tan T J04 Ground from TEC 2401 P2 1 Violet VIO J05 Pre charge sense Brown BN Figure 72 Main Harness P04 Connector Pin Identification 76 ...

Page 77: ...ading was good Go to Returning the Equipment to Service page 19 and follow the steps listed Fail The voltage reading was not good Could be a wrong reading or a reading that gradually decreases Go to step 5 Step 5 Check the wire harness for continuity and test the resistance of the main contactor coil Disconnect the battery pack Refer to Disconnecting the Battery Pack page 17 1 Check for continuity...

Page 78: ...BK C 12 Vdc Key Run Violet VIO D 48 to 64 Vdc Logic Power White W E 48 to 64 Vdc Pre Charge Logic Power Tan T F Not used Not used Figure 74 Main Harness P01 and P02 Connector Pin Identification 1 Main wire harness P01 connector 3 TEC 2401 controller 2 Main wire harness P02 connector Note The wire harness diagram uses P01 and P02 for referencing these connectors while the electrical schematic uses ...

Page 79: ...ter returning the equipment to service then replace the TEC 2401 Go to Returning the Equipment to Service page 19 and follow the steps listed Step 7 Use a multimeter to check for 42 to 64 Vdc at the motor controller Note You will find additional wire harness and connector information in Appendix A Wire Harnesses page 113 and Appendix B Toro Electronic Controller Connections page 135 1 Rotate the k...

Page 80: ...or pin E Figure 73 and the main wire harness P04 connector pin B Figure 72 3 Rotate the key switch to the OFF position and then connect the main wire harness P13 connector Figure 73 Pass Voltage reading was good Go to Returning the Equipment to Service page 19 and follow the steps listed Fail Voltage reading was not good Go to step 9 Step 9 Use a multimeter to check the motor input voltage Note Yo...

Page 81: ...or information in Appendix A Wire Harnesses page 113 and Appendix B Toro Electronic Controller Connections page 135 Note Inspect the wire harness while checking the items in the following steps Refer to Inspecting the Wire Harnesses and Component Connector Assemblies page 13 Note Troubleshoot 1 circuit or component at a time Disconnect or isolate each component or wire harness section from the sys...

Page 82: ...re 71 Main contactor J02 J05 J02 J05 J03 J01 J04 1 Main Figure 71 Main contactor J01 J02 J05 J03 J01 J04 2 Main Figure 78 P03 2 1 2 3 4 5 6 7 8 1 Main Figure 78 P03 2 1 2 3 4 5 6 7 8 2 Main Figure 79 P26 A A B 82 ...

Page 83: ...ck Pins Pin Identification Description Wire Color 1 Battery Power In Red R 2 Battery Power Out common BUS with pin 4 Red R 3 Battery Power Out White W 4 Battery Power In common BUS with pin 2 Not used 5 Main Contactor Power In Brown BN 6 Main Contactor Power Out fused work light power Yellow Y 7 Not used Not used 8 Not used Not used 83 ...

Page 84: ...n Figure 76 P42 2 1 2 Pass Circuit continuity tested good and no shorts are identified at the listed locations Go to Step 10 2 and follow the steps listed Fail For those items that failed repair or replace worn or damaged parts as required Go to Returning the Equipment to Service page 19 and follow the steps listed Step 10 2 Check the battery wire harness for continuity and or a short condition 1 ...

Page 85: ...ic 1 Battery Figure 80 P04 POS POS NEG _ P1 P2 S1 S2 2 Battery Figure 80 P01 3 1 2 3 5 6 4 1 Battery Figure 80 P04 NEG POS NEG _ P1 P2 S1 S2 2 Battery Figure 80 P01 4 1 2 3 5 6 4 Figure 80 P01 and P04 Battery Harness Connector Pin Identification 85 ...

Page 86: ...ness Connector Pin Connector Graphic 1 Battery Figure 80 P01 3 2 Battery Figure 80 P01 4 1 2 3 5 6 4 Pass Circuit continuity tested good and no shorts are identified at the listed locations Go to Returning the Equipment to Service page 19 and follow the steps listed Fail For those items that failed repair or replace worn or damaged parts as required Go to Returning the Equipment to Service page 19...

Page 87: ...Electrical Diagram Figure 81 87 ...

Page 88: ...een to ensure that the charge level is adequate If the battery indicator does not show at least 1 full block connect the battery charger to the battery pack and charge the battery pack to at least 40 capacity Step 3 Check for physical obstructions of the reel and the traction drum Physical obstructions can be twine rope wire debris tree branch etc 1 Disconnect the battery pack Refer to Disconnecti...

Page 89: ...ssed install the motor Go to Returning the Equipment to Service page 19 and follow the steps listed Note If the fault does not repeat a false detect event may have occurred Fail For those items that failed adjust repair or replace worn or damaged parts as required Go to Returning the Equipment to Service page 19 and follow the steps listed Note Do not replace the motor unless the fault repeats 89 ...

Page 90: ...ctions Step 1 Connect Toro Diagnostics Refer to Toro DIAG User s Guide external link System Operation Diagnostics and Programming Part No 12194SL Step 2 Reprogram the Machine Reprogram in accordance with Toro DIAG User s Guide external link System Operation Diagnostics and Programming Manual Part No 12194SL Pass Go to Returning the Equipment to Service page 19 and follow the steps listed Fail Atte...

Page 91: ...il The fault repeated Go to step 2 Step 2 Check the charge level of the battery Check the InfoCenter LCD screen to ensure that the charge level is adequate If the battery indicator does not show at least 1 full block connect the battery charger to the battery pack and charge the battery pack to at least 40 capacity Step 3 Check the operation of the key switch Use a multimeter to test the key switc...

Page 92: ...l and can dislodge dirt and dust particles that can enter your eyes or be inhaled Wear safety glasses to protect your eyes from airborne debris Wear a dust mask to avoid inhaling dirt and dust particles Note Ensure the cavity plugs in the battery adapter harness P04 connector Figure 82 are not removed during the compressed air cleaning process 4 Connect the battery pack Refer to Connecting the Bat...

Page 93: ...ed Perform continuity and short condition checks in step 6 2 Fail The machine did not start Go to step 6 1 2 Step 6 1 2 Check the battery pack voltage 1 Attach a multimeter to the Li diagnostic wire harness P04 connector POS and NEG pins Note After you connect the P06 and P07 connectors together in step 2A the voltage will only be present for approximately 2 to 3 seconds to accomplish step 2B 2 Pe...

Page 94: ...ss Connector Pin Connector Graphic 1 Battery Figure 83 P04 POS POS NEG _ P1 P2 S1 S2 2 Battery Figure 83 P01 3 1 2 3 5 6 4 1 Battery Figure 83 P04 NEG POS NEG _ P1 P2 S1 S2 2 Battery Figure 83 P01 4 1 2 3 5 6 4 1 Battery Figure 83 P04 S1 POS NEG _ P1 P2 S1 S2 2 Battery Figure 83 P01 5 1 2 3 5 6 4 94 ...

Page 95: ...Battery Harness P01 Connector Pin Identification Description Wire Color 1 CAN High Red White R W 2 CAN Low Black White BK W 3 42 to 64 Vdc Power Red R 4 Ground Black BK 5 Battery Pack Wake Up Blue BU 6 Not used Not used Battery Harness P04 Connector Pin Identification Description Wire Color POS 42 to 64 Vdc Power Red R P1 CAN High Red White R W 95 ...

Page 96: ...d D CAN High Red White R W E Not used Not used F CAN Low Black White BK W Pass Circuit continuity tested good at the listed locations Go to Step 6 3 and follow the steps listed Fail For those items that failed repair or replace the worn or damaged parts as required Go to Returning the Equipment to Service page 19 and follow the steps listed Step 6 3 Verify that no short conditions exist between th...

Page 97: ... 4 and follow the steps listed Fail For those items that failed repair or replace the worn or damaged parts as required Go to Returning the Equipment to Service page 19 and follow the steps listed Step 6 4 Check for continuity between the following pairs of locations Location Harness Connector Pin Connector Graphic 1 Battery Figure 83 P34 A A B C E F D 2 Main Figure 84 P13 A A B C D E F 97 ...

Page 98: ...nector Pin Identification Main Harness Key Switch P13 Connector Pin Identification Description Wire Color A 42 to 64 Vdc Key Start Battery Pack Wake up Blue B Blue B B Ground Black BK C 12 Vdc Key Run Violet VIO D 42 to 64 Vdc Logic Power White W E 42 to 64 Vdc Pre Charge Logic Power Tan T F Not used Not used 98 ...

Page 99: ...and follow the steps listed Step 6 5 Verify that no short conditions exist between the following pairs of locations Location Harness Connector Pin Connector Graphic 1 Main Figure 85 P01 1 1 12 7 6 2 Main Figure 85 P02 7 or 8 F E D A B C Pass No shorts are identified at the listed locations Go to Returning the Equipment to Service page 19 and follow the steps listed Fail For those items that failed...

Page 100: ...The fault did not repeat Go to Returning the Equipment to Service page 19 and follow the steps listed Note If the fault does not repeat a false detect event may have occurred Fail The fault repeated Go to step 2 Step 2 Charge the battery pack Refer to the Lithium Battery Pack Charger Operation section of the eFlex Service Manual chapter 4 Electrical System 1 Ensure the battery pack charger is turn...

Page 101: ...operation of the machine 1 Install the Li battery diagnostic wire harness Refer to Installing the Li Diagnostic Wire Harness page 8 2 Start the machine Note If the machine starts the fault is likely in the battery wire harness Pass The machine started Go to step 5 2 Fail The machine did not start Go to step 5 1 2 Step 5 1 2 Check the battery voltage 1 Rotate the key switch to the OFF position 2 Di...

Page 102: ...ck at this time 3 Check for continuity between the following harness connectors Location Harness Connector Pin Connector Graphic 1 Battery Figure 86 P04 POS POS NEG _ P1 P2 S1 S2 2 Battery Figure 86 P01 3 1 2 3 5 6 4 1 Battery Figure 86 P04 NEG POS NEG _ P1 P2 S1 S2 2 Battery Figure 86 P01 4 1 2 3 5 6 4 1 Battery Figure 86 P04 S1 POS NEG _ P1 P2 S1 S2 2 Battery Figure 86 P01 5 1 2 3 5 6 4 102 ...

Page 103: ...n Battery Harness P01 Connector Pin Identification Description Wire Color 1 CAN High Red White R W 2 CAN Low Black White BK W 3 42 to 64 Vdc Power Red R 4 Ground Black BK 5 Battery Pack Wake up Blue BU 6 Not used Not used Battery Harness P04 Connector Pin Identification Description Wire Color POS 42 to 64 Vdc Power Red R P1 CAN High Red White R W 103 ...

Page 104: ...ed Not used D CAN High Red White R W E Not used Not used F CAN Low Black White BK W Pass Circuit continuity tested good at the listed locations Go to Step 5 3 and follow the steps listed Fail For those items that failed repair or replace worn or damaged parts as required Go to Returning the Equipment to Service page 19 and follow the steps listed Step 5 3 Verify no short conditions exist between t...

Page 105: ...p 5 4 and follow the steps listed Fail For those items that failed repair or replace worn or damaged parts as required Go to Returning the Equipment to Service page 19 and follow the steps listed Step 5 4 Check for continuity between the following pairs of locations Location Harness Connector Pin Connector Graphic 1 Main Figure 87 P34 A F E D A B C 2 Main Figure 88 P13 A A B C D E F 105 ...

Page 106: ...1 Main Figure 87 P34 A F E D A B C 2 Main Figure 89 P01 1 1 12 7 6 1 g030573 Figure 87 1 Main wire harness P34 connector Figure 88 Main Harness P13 Connector Identification 106 ...

Page 107: ...ess TEC 2401 Connector Pin Identification Pass Circuit continuity tested good at the listed locations Go to Step 5 5 and follow the steps listed Fail For those items that failed repair or replace worn or damaged parts as required Go to Returning the Equipment to Service page 19 and follow the steps listed Step 5 5 Verify no short condition exists between the following pairs of locations Location H...

Page 108: ...ug Not used S1 Not used GT150 cavity plug Not used S2 Not used GT150 cavity plug Not used NEG Ground Black BK Battery Adapter Harness P26 Connector Pin Identification Description Wire Color A 42 to 64 Vdc Power Red R B Ground Black BK Pass No shorts are identified at the listed locations Go to Step 5 6 and follow the steps listed Fail For those items that failed repair or replace worn or damaged p...

Page 109: ...to Returning the Equipment to Service page 19 and follow the steps listed Step 6 Battery Internal Contactor Qualifier Fault May require Li diagnostic wire harness Toro part number 120 6339 to be installed for consulting with your Toro Service Representative Refer to Installing the Li Diagnostic Wire Harness page 8 as needed Note The battery diagnostic wire harness is configured with extra wire len...

Page 110: ...foCenter Fault Log page 19 2 Disconnect the battery pack for 30 seconds Refer to Disconnecting the Battery Pack page 17 3 Connect the battery pack Refer to Connecting the Battery Pack page 17 4 Start and operate the machine Refer to the eFlex Operator s Manual Pass The fault did not repeat Go to Returning the Equipment to Service page 19 and follow the steps listed Note If the fault does not repea...

Page 111: ...Fail The fault repeated Go to step 2 Step 2 Check the charge level of the battery Check the InfoCenter LCD screen to ensure that the charge level is adequate If the battery indicator does not show at least 1 full block connect the battery charger to the battery pack and charge the battery pack to at least 40 capacity Step 3 Remove 2 access covers to aid troubleshooting Performing these steps provi...

Page 112: ...ent to Service page 19 and follow the steps listed Fail The test identified a short in the main contactor and or wrong resistance in the coil Replace the contactor Go to Returning the Equipment to Service page 19 and follow the steps listed Electrical Diagram Figure 92 The main contactor connects the battery pack and the electric motor The TEC 2401 circuitry monitors the voltage at several locatio...

Page 113: ...nector ends are shown with mating side surface displayed Electrical System Harness Connector Pin and Terminal Identification The electrical system consists of 3 wire harness assemblies which connect the system components and accessories The main harness The battery harness The battery adapter harness Figure 93 The Main Harness the Battery Harness and the Battery Adapter Harness 113 ...

Page 114: ...7 P09 parking brake switch 2 P05 speed control potentiometer 8 P04 work light connector 3 P13 ignition switch key switch 9 P37 CAN diagnostic port Toro DIAG 4 P17 InfoCenter display 10 P14 CAN bus terminator 120 ohm 5 P06 EZ Turn Slow in Turn switch 11 P10 reel switch 6 P19 work light switch optional 12 P11 traction switch 114 ...

Page 115: ...ess supplied Black BK Note Pin B provides the ground connection for troubleshooting Figure 96 Main Harness P05 Connector Pin Identification Main Harness Speed Control Potentiometer P05 Connector Pin Identification Description Wire Color A Voltage Out Blue BU B Ground harness supplied Black BK C 5 Vdc In Yellow Y D Not used Not used E Not used Not used F Not used Not used 115 ...

Page 116: ...n Harness EZ Turn Slow in Turn Switch P06 Connector Pin Identification Description Wire Color 1 Not used Not used 2 12 Vdc Out Orange OR 3 12 Vdc In Yellow Y 4 Not used Not used 5 Not used Not used 6 Not used Not used 7 Not used Not used 8 Not used Not used 116 ...

Page 117: ... Switch P09 Connector Pin Identification Description Wire Color A 12 Vdc Orange OR B Ground Black BK Figure 99 Main Harness P10 Connector Pin Identification Main Harness Reel Engage Switch P10 Connector Pin Identification Description Wire Color A 12 Vdc White W B Ground Black BK 117 ...

Page 118: ...Figure 100 Main Harness P11 Connector Pin Identification Main Harness Traction Engage Switch P11 Connector Pin Identification Description Wire Color A 12 Vdc Tan T B Ground Black BK 118 ...

Page 119: ...witch Key Switch P13 Connector Pin Identification Description Wire Color A 42 to 64 Vdc Key Start Battery Pack Wake up Blue B Blue B B Ground Black BK C 12 Vdc Key Run Violet VIO D 42 to 64 Vdc Logic Power White W E 42 to 64 Vdc Pre Charge Logic Power Tan T F Not used Not used 119 ...

Page 120: ...ness P14 Connector Pin Identification Main Harness CAN Terminator P14 Connector and 120 ohm Terminator Pin Identification Description Wire Color A CAN High Red White R W B CAN Low Black White BK W C Not used Not used 120 ...

Page 121: ...Pin Identification Main Harness InfoCenter Display P17 Connector Pin Identification Description Wire Color 1 Ground Black BK 2 12 Vdc In Pink PK 3 CAN High Red White R W 4 CAN Low Black White BK W 5 Not used Not used 6 Not used Not used 121 ...

Page 122: ...olor 1 Not used Not used 2 42 to 64 Vdc In Yellow Y 3 42 to 64 Vdc Out Violet VIO 4 through 8 Not used Not used Figure 105 Main Harness P37 Connector Pin Identification Main Harness Toro Diag CAN Port P37 Connector and Cap Pin Identification Description Wire Color A CAN High Red White R W B CAN Low Black White BK W C Not used Not used 122 ...

Page 123: ...Color 1 12 Vdc In Pink PK 2 Not used Not used 3 Ground Black BK Lower Main Wire Harness Figure 107 Lower Main Wire Harness Connector Identification 1 P34 battery interconnect 5 P42 motor power 2 P02 TEC 2401 6 P41 motor controller 3 P01 TEC 2401 7 P23 EZ Turn Slow in Turn proximity sensor 4 P03 fuse block 8 P26 power connector 123 ...

Page 124: ...rness Main Contactor Connections Terminal Identification Description Wire Color J01 42 to 64 Vdc from the battery pack Red R J02 42 to 64 Vdc to the motor Red R J03 42 to 64 Vdc from the key switch Tan T J04 Ground from TEC 2401 P2 1 coil Violet VIO J05 Pre Charge Sense optional work light Brown BN 124 ...

Page 125: ...cing these connectors while the electrical schematic uses P1 and P2 Main Harness TEC 2401 P01 Connector gray Pin Identification Description Wire Color 1 Key Start Blue BU 2 Key Run Violet VIO 3 Pre Charge Brown BN 4 5 Vdc Out Tan T 5 12 Vdc Out Pink PK 6 Pre Charge Supply Brown BN 7 Not used Not used 8 Parking Brake Orange OR 9 Not used Not used 10 Reel White W 11 CAN High Red White R W 12 CAN Low...

Page 126: ... used Note Weather sealed Figure 110 Main Harness P03 Fuse Block Pin Identification Main Harness Fuse Block P03 Pins Pin Identification Description Wire Color 1 Battery Power In 30 amp Red R 2 Battery Power Out common BUS with pin 4 fused battery pack power out 30 amp Red R 3 Battery Power Out 3 amp White W 4 Battery Power In common BUS with pin 2 fused key switch and logic power 3 amp Not used 5 ...

Page 127: ...Slow in Turn Sensor P23 Connector Pin Identification Description Wire Color A 12 Vdc In Pink PK B 12 Vdc Out Orange OR C Ground Black BK Figure 112 Main Harness P26 Connector Pin Identification Main Harness Power P26 Connector Pin Identification Description Wire Color A 42 to 64 Vdc Power Red R B Ground Black BK 127 ...

Page 128: ...ntification Main Harness Battery Interconnect P34 Connector Pin Identification Description Wire Color A Battery Pack Present Blue BU B Not used Brown BN C Not used Not used D CAN High Red White R W E Ground Black BK F CAN Low Black White BK W 128 ...

Page 129: ...or Controller P41 Connector Pin Identification Description Wire Color Main 1 Logic Power Tan T 2 Not used Not used 3 CAN High Red White R W 4 CAN Low Black White BK W Main Harness Motor Power P42 Connector Pin Identification Description Wire Color 1 42 to 64 Vdc Power Red R 2 Ground Black BK 129 ...

Page 130: ...Battery Adapter Wire Harness Figure 115 Battery Adapter Harness Connector Identification 1 P04 Li battery pack 2 P26 power connector 130 ...

Page 131: ...olor POS 42 to 64 Vdc Power Red R P1 Not used GT150 cavity plug Not used P2 Not used GT150 cavity plug Not used S1 Not used GT150 cavity plug Not used S2 Not used GT150 cavity plug Not used NEG Ground Black BK Battery Adapter Harness Machine Power P26 Connector Pin Identification Description Wire Color A 42 to 64 Vdc Power Red R B Ground Black BK 131 ...

Page 132: ...Battery Wire Harness Figure 117 Battery Harness Connector Identification 1 P04 machine wire harness charger 3 P34 machine wire harness 2 P03 CAN bus terminator 120 ohm 4 P01 battery pack 132 ...

Page 133: ...tery Harness CAN Terminator P03 Connector and 120 ohm Terminator Pin Identification Description Wire Color A CAN High Red White R W B CAN Low Black White BK W C Not used Not used Battery Harness Machine Charger P04 Connector Pin Identification Description Wire Color POS 42 to 64 Vdc Power Red R P1 CAN High Red White R W P2 CAN Low Black White BK W S1 Battery Pack Wake up Blue BU S2 Not used Not us...

Page 134: ...Harness P34 Connector Pin Identification Description Wire Color A Battery Pack Wake up Blue BU B Not used Not used C Not used Not used D CAN High Red White R W E Not used Not used F CAN Low Black White BK W 134 ...

Page 135: ...r P1 6 Input voltage Tan T Pre Charge Charge Battery power to the TEC is turned on when the key switch is in the RUN position Required to power up the motor supplies circuit voltage output through pin P1 3 until battery pack power or greater motor capacitor charge is established P1 7 Input digital high low Not used Not used Not used P1 8 Input digital high low Orange OR Park Brake Prox SW NO 12 Vd...

Page 136: ...tal high low Yellow Y Reduce Mow Speed EZ Turn Slow in Turn 12 Vdc potential when the key switch is in the RUN position Waiting for ground through key switch and proximity sensor Speed control demands of more than 50 result in an EZ Turn reduction in speed of 60 12 Vdc Low state indicates digital On Active P2 10 Input digital high low Tan T Traction Prox SW NO 12 Vdc potential when the key switch ...