Toro Greensmaster eFlex 1800 Bedienungsanleitung

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

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

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.

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).

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.

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

InstallingtheLi+Diagnostic

WireHarness

Performthefollowing3shortprocedurestoinstalltheLi+

diagnosticwireharness:

PreparetheMachine

1.Parkthemachineonalevelsurfaceandmovethe

tractionlevertotheNEUTRALposition.

2.RotatethekeyswitchtotheOFFpositionandthen

removethekeyfromtheswitch.

3.Disconnectthebatterypack.RefertoDisconnecting

theBatteryPack(page17).

4.DisconnectthemainwireharnessP34connector

(Figure3).

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).

g030574

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

Figure8

1.MainwireharnessP34

connector

2.Li+diagnosticwire

harnessP34connector

4.ConnecttheLi+diagnosticwireharnessP04connector

tothebatteryadapterwireharnessP04connector

(Figure9).

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

Figure11

1.BatteryharnessP01

connector

3.Battery-packconnector

2.Lockingcollar

2.DisconnecttheLi+diagnosticwireharnessP34

connectorfromthemainwireharnessP34connector

(Figure12).

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