Page 1 Form No. 16221SL Rev C Reelmaster ® 5010-H Traction Unit Model No. 03674—Serial No. 315000001 and Up *16221SL* C Register at www.Toro.com. Original Instructions (EN)
Page 2: Reader Comments
Reelmaster 5010-H Fairway Mower. Refer to the Reelmaster 5010-H Operator’s Manual for operating, maintenance, and adjustment instructions. Refer to the Reelmaster 5010-H Service Manual for troubleshooting, testing, and repairing assemblies and components. Refer to the Toro DIAG User’s Guide for system operation, diagnostics, and programming.
Page 3: Revision History
Revision History Revision Date Description 04/2016 Original release 05/2016 Updated procedures in faults 17 and 75. 07/2019 Updated procedures in faults 28 and 29.
Page 4: Table Of Contents
Preparing for Troubleshooting and/or Testing ....................22 Returning the Machine to Service.........................22 Toro DIAG - Quick Start ..........................24 Replacing a Toro Electronic Controller (TEC) ....................26 Fault 1: Engine Coolant Temperature High—CRM Stop..................28 Fault 2: Engine Coolant Temperature High—Engine Shutdown ................33 Fault 4: Input Pull-Up Enable (IPE) Voltage Too Low ...................39 Fault 5: Main Power Relay Failure........................40...
Page 5 Fault 43: CAN Bus Fault—M/G .........................153 Fault 44: CAN Bus Fault—InfoCenter .......................158 Fault 45: Software Incompatible—CRM 1 ......................162 Fault 46: Software Incompatible—CRM 2 ......................165 Fault 47: Software Incompatible—CRM 3 ......................168 Fault 48: Software Incompatible—CRM 4 ......................171 Fault 49: Software Incompatible—CRM 5 ......................174 Fault 50: Software Incompatible—M/G......................177 Fault 51: Software Incompatible—InfoCenter....................180 Fault 52: Software Incompatible—Master ......................184...
Page 6 Fault 101: Over Current Disable—CRM 2 ......................393 Fault 102: Over Current Disable—CRM 3 ......................396 Fault 103: Over Current Disable—CRM 4 ......................399 Fault 104: Over Current Disable—CRM 5 ......................402 Fault 111: Internal Regulator Overvolt—M/G.....................405 Fault 112: Internal Regulator Undervolt—CRM 1 ....................407 Fault 113: Internal Regulator Undervolt—CRM 2 ....................
Page 7: Safety
Safety The machine has been tested and certified by Toro for compliance with existing safety standards and specifications. Improper use or maintenance of the machine can result in injury or death. To reduce the potential for injury or death, comply with all of the safety instructions found in the 5010-H Operator's Manual and...
Page 8: General Information
General Information External Reference Material This manual refers to information found in other Toro source material. You can access the referenced manuals online. If your service area does not have Internet access, download the applicable manuals in advance. Refer to the Reelmaster® 5010-H Traction Unit Operator’s Manual for information on operating, maintaining, and adjusting the machine and its components.
Page 9: Toro Diag Software
Toro DIAG Software Download the Toro DIAG software from the Toro Dealer and Distributor Portal and then install the software on a computer. This software is intended to assist you with troubleshooting electrical issues on Toro machines that use a Toro electronic controller (TEC).
Page 10: Glossary
An active fault is displayed on the InfoCenter while the fault condition is present until you clear the fault or you turn the machine off. All faults are archived in and accessible from the nonvolatile memory of the Toro electronic controller (TEC).
Page 11: General Electrical Diagnostic Information
Read and understand the manufacturer’s operating instructions for the multimeter. Toro DIAG USB/CAN Cable The Toro DIAG software uses a USB to CAN connection, via a Toro DIAG USB/CAN cable (Toro Part No. 115-1944). Inspecting the Harness and Component Connector...
Page 12: Repairing The Wire Insulation
• Corroded terminals or pins • Water in the connector • Connector pins that are loose, bent, or recessed • Connectors that are not fully seated • Wires that are pinched, frayed, or are missing insulation • Damaged connector locks, clips, or housings •...
Page 13: Infocenter Diagnostics
If the voltage that you measure is higher or lower than the specified voltage, clean and inspect the terminal connections along the circuit path that you are testing. Cleaning the Electronic Components and Connections Note: Use electrical-contact cleaner only. Do not use brake cleaner, as it may permanently damage electrical connector bodies and other plastic components of the machine.
Page 14: Infocenter Icons
InfoCenter Icons Icon Definition Hour meter Info icon Fast Slow Fuel level Glow plugs are active Raise cutting units Lower cutting units Operator must sit in seat Parking brake indicator—indicates when the parking brake is O Identifies the range as High (Transport) Neutral Identifies the range as Low (Mow) Coolant Temperature-indicates the engine coolant temperature in either °C or °F...
Page 15 Icon Definition Motor/generator (not charging) Motor/generator (charging) Reel enable Electric cutting reel motor in a cutting unit Front backlap Rear backlap Indicates when the cutting units are being lowered Indicates when the cutting units are being raised PIN passcode CAN bus InfoCenter Bad or failed Bulb...
Page 16: Troubleshooting Intermittent Electrical Faults
Yanmar SA-D Error Diagnosis Data Save and Display Functions (see the Yanmar SmartAssist Operation Manual, Chapter 7) Note: It is also possible to coordinate with Toro TAC and obtain a memorator to record CAN bus activity to assist in identifying intermittent faults.
Page 17: Frequently Used Procedures
Frequently Used Procedures Connecting and Disconnecting the 12 Vdc Battery CAUTION Before installing, removing, or servicing components in the 12 Vdc system (e.g., starter, alternator, control arm components), disconnect the 12 Vdc battery. This prevents unexpected operation of 12 Vdc system components. Park the machine on a level surface and lower the cutting units.
Page 18 Press in the left and right sides of the battery cover and remove the battery cover from the battery tray. g032655 Figure 4 1. Battery cover 2. 12 Vdc battery Loosen and remove the negative cable from the battery (Figure g032656 Figure 5 1.
Page 19: Connecting And Disconnecting The 48 Vdc Battery System
Connect and tighten the negative cable to the battery. After servicing the 12 Vdc system, coat the battery posts and the cable connectors with battery terminal protector (Toro Part No. 107-0392) or petroleum jelly to prevent corrosion. Install the rubber boot onto the positive battery cable.
Page 20: Reading Faults
Vdc battery and the 48 Vdc battery pack, and various diagnostic messages and icons that provide current information about the machine. You can read faults 2 ways: on the InfoCenter display (Figure 8) or on a PC using Toro DIAG Software (page 9). This section focuses on the InfoCenter display.
Page 21: Clearing Faults From The Infocenter
Note: You can clear system faults from the InfoCenter if you have the PIN number for access. The complete fault history is retained in the TEC-5002 memory and can be viewed via Toro DIAG software. Entering the PIN code From the Main menu, press the left button as needed to access the Settings menu.
Page 22: Preparing For Troubleshooting And/Or Testing
Press the Left button. The Main Menu appears. Verify that the Faults menu item is selected, and then press the Right button. The Faults screen appears. Press the Middle button to scroll down through the faults until Clear System Faults is selected. Press the Right button.
Page 23 Fully reassemble the machine. This includes all guards, covers, cable ties, and parts loosened or removed. Note: If you unplugged connectors P51 or P37, align the tabs on the inside of the connector with the slots in the receptacle. Push the connector into the receptacle and rotate the locking collar on the connector clockwise until it engages with the receptacle and begins to pull the connector in.
Page 24: Toro Diag - Quick Start
Ensure that the Toro DIAG software and the drivers for the Toro DIAG Cable (Part No. 115-1944) are already installed on your PC. If they are not installed, go to the Toro DIAG User’s Guide and follow the steps in the Toro DIAG Software Installation section.
Page 25 1. Toro DIAG cable 2. CAN diagnostic port Start the Toro DIAG software. (Toro DIAG goes through a short Discovery routine to initialize the program.) Wait for the Toro DIAG software to display the message, “No machine found.” Turn the ignition switch on the machine to the R position.
Page 26: Replacing A Toro Electronic Controller (Tec)
Toro DIAG - Quick Start (page 24). Use the Toro DIAG software to save the timers and counters file out of the machine. Refer to the Controller Reformatting section of the Toro DIAG User’s Guide. Disconnect the Toro DIAG cable from the CAN diagnostic port.
Page 27 Align the outer cover to the control arm and secure the cover with the 6 fasteners that you removed in substep 1. Use Toro DIAG to Program the TEC-5002. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 28: Fault 1: Engine Coolant Temperature High-Crm Stop
Fault 1: Engine Coolant Temperature High—CRM Stop InfoCenter Display: _____FAULT #1_____ Fault Description The TEC-5002 detected that the engine coolant temperature is more than 220 °F (104.4 °C) for more than 10 seconds. Circuit Description The engine coolant temperature (ECT) sender is a submersible thermistor that sends a voltage to the TEC-5002. Conditions for Setting the Fault When coolant temperature reaches or exceeds 220 °F (104.4 °C) for 10 seconds or longer, the TEC-5002 reports the fault, which stops all of the cutting reel motors.
Page 29 Pass The fault did not repeat. Go to Returning the Machine to Service (page 22) and follow the steps listed. Fail The fault repeated. Go to Step 3. Step 3: Test the coolant temperature sender. The temperature sender is located near the alternator, on the thermostat housing that is attached to the cylinder head of the engine (Figure 13).
Page 30 g032800 Figure 14 Wait 10 minutes to allow the engine to cool and measure the resistance across the pins of the temperature sender again. As the engine cools, the resistance across the pins of the temperature sender should increase. Note: The following table shows sample data across a wide range of temperatures.
Page 31 g036005 Figure 15 1. Access cover Loosen the socket-head screw that secures seat harness connector P75 to the TEC-5002 and unplug the connector (Figure 16). g036006 Figure 16 1. Main harness connector P75 2. Socket-head screw Use a multimeter to test the resistance between the following pair of locations:...
Page 32 Wire Expected Location Harness Connector Connector Graphic Color Reading Black Seat Within 1 or (Ground) 2 ohms of the reading Gray/ taken in Seat Brown Step 3. Gray/ Main Brown More than 1000 ohms Chassis ground Brown/ Main Yellow Less than 2 ohms Chassis ground Repair or replace worn or damaged parts as required.
Page 33: Fault 2: Engine Coolant Temperature High-Engine Shutdown
Fault 2: Engine Coolant Temperature High—Engine Shutdown InfoCenter Display: _____FAULT #2_____ Fault Description The TEC-5002 detected that the engine coolant temperature is over 240 °F (115 °C) for more than 10 seconds. Circuit Description The engine coolant temperature (ECT) sender is a submersible thermistor that sends a voltage to the TEC-5002. Conditions for Setting the Fault The TEC-5002 monitored the engine temperature being more than 240 °F (115 °C) for more than 10 seconds.
Page 34 Pass The fault did not repeat. Go to Returning the Machine to Service (page 22) and follow the steps listed. Fail The fault repeated. Go to Step 3. Step 3: Test the temperature sender. The temperature sender is located near the alternator, on the coolant thermostat housing attached to the engine cylinder head (Figure 18).
Page 35 g032800 Figure 19 Wait 10 minutes to allow the engine to cool and measure the resistance across the pins of the temperature sender again. As the engine cools, the resistance across the pins of the temperature sender should increase. Note: The following table shows sample data across a wide range of temperatures.
Page 36 g036005 Figure 20 1. Access cover...
Page 37 Loosen the socket-head screw that secures seat harness connector P75 to the TEC-5002 and unplug the connector (Figure 21). g036006 Figure 21 1. Main harness connector P75 2. Socket-head screw Use a multimeter to test the resistance between the following pairs of locations: Wire Expected Location...
Page 38 Electrical Diagram g031092 Figure 22...
Page 39: Fault 4: Input Pull-Up Enable (Ipe) Voltage Too Low
Replacing a Toro Electronic Controller (TEC) (page 26). Use Toro DIAG to save the machine timers and counters file out of the machine. (page 26) Replace the TEC-5002. (page 26) Use Toro DIAG to Program the TEC-5002. (page 27) Go to Returning the Machine to Service (page 22) and follow the steps listed.
Page 40: Fault 5: Main Power Relay Failure
Fault 5: Main Power Relay Failure InfoCenter Display: _____FAULT #5______ Main Relay Fault Description The main 12 Vdc power relay or circuit wiring is faulty. Circuit Description The main power relay is used to provide current to the TEC-5002, headlights, power port, and optional electric equipment.
Page 41 g032804 Figure 23 1. 7.5 amp fuses (3) Test each fuse for continuity. Pass All 3 fuses test good. Install the fuses. Go to Step 3. Fail Replace any bad fuses. Install any fuses that tested good. Go to Returning the Machine to Service (page 22) and follow the steps listed.
Page 42 g278812 Figure 24 1. Engine 3. Operator’s seat 2. Muffler 4. Main power relay Locate the main power relay and disconnect main harness connector P04 from the relay (Figure 25). g033260 Figure 25 1. Exhaust muffler 3. Main power relay 2.
Page 43 Note: A good relay has a coil resistance of approximately 72 ohms. g032876 Figure 26 Measure the resistance between terminals 30 and 87. Note: A good relay has an infinite value (open circuit). Apply 12 Vdc to terminal 85, and then ground terminal 86. Measure the resistance between terminals 30 and 87.
Page 44 Replacing a Toro Electronic Controller (TEC) (page 26). Use Toro DIAG to save the machine timers and counters file out of the machine. (page 26) Replace the TEC-5002. (page 26) Use Toro DIAG to Program the TEC-5002. (page 27) The fault no longer...
Page 45 Electrical Diagram g031094 Figure 28 1. Frame ground (12 Vdc circuit).
Page 46: Fault 6: Key Start Timeout
Fault 6: Key Start Timeout InfoCenter Display: _____FAULT #6_____ Timeout Fault Description The ignition switch was held in the S position for more than 30 seconds, so the TEC-5002 disabled the TART starting function. Note: The operator can rotate the ignition switch to the O position, and then try rotating the ignition REHEAT switch to the S...
Page 47 Pass The machine started and the fault did not repeat. Go to Returning the Machine to Service (page 22) and follow the steps listed. Fail The fault repeated. Go to Step 3. Step 3: Test the ignition switch using the InfoCenter. Perform the following steps to test the ignition switch using the InfoCenter (Figure 29):...
Page 48 Repair or replace worn or damaged parts as required. Go to Returning the Machine to Service (page and follow the steps listed. Electrical Diagram g031095 Figure 30...
Page 49: Fault 8: 12 Vdc Charging System Voltage Too High
Fault 8: 12 Vdc Charging System Voltage Too High InfoCenter Display: _____FAULT #8_____ Charging Fault Description The TEC-5002 has detected that the 12 Vdc charging system (alternator) is generating a voltage more than 16.3 Vdc. Circuit Description A 12 Vdc battery mounted at the rear of the machine and the engine alternator provide system electrical power. Conditions for Setting the Fault The TEC-5002 detected that the 12 Vdc charging system (alternator) is producing a voltage that is too high.
Page 50 g035714 Figure 31 1. Alternator 3. Muffler 2. Radiator 4. Engine Use a multimeter to perform the following steps to test the alternator. Go to Preparing for Troubleshooting and/or Testing (page 22) and follow the steps listed. Remove the battery cover to access the 12 Vdc battery at the rear of the machine. With the engine off, measure the battery voltage.
Page 51 Wire Expected Location Harness Connector Connector Graphic Color Reading Main Less than 2 ohms Main Main Pink Less than 2 ohms Main Pink Main White Less than 2 ohms Main White Repair or replace the damaged wiring. Go to Returning the Machine to Service (page 22) and follow the steps listed.
Page 52 Electrical Diagram g031096 Figure 32...
Page 53: Fault 9: 12 Vdc Charging System Voltage Too Low
Fault 9: 12 Vdc Charging System Voltage Too Low InfoCenter Display: _____FAULT #9_____ Charging Fault Description The TEC-5002 has determined that the 12 Vdc charging system (alternator) is generating a voltage less than 8.8 Vdc. Circuit Description A 12 Vdc battery mounted at the rear of the machine and the engine alternator provide system electrical power. Conditions for Setting the Fault The TEC-5002 detects that the 12 Vdc charging system (alternator) is producing a voltage that is too low.
Page 54 g035714 Figure 33 1. Alternator 3. Muffler 2. Radiator 4. Engine Inspect the belt for evidence of slippage (Figure 34). Ensure the belt is in good condition and is seated properly in the drive pulleys. Refer to the Kubota Workshop Manual, Diesel Engine, 05- E4B Series. g032797 Figure 34 1.
Page 55 Step 3: Test the alternator. Use a multimeter to perform the following steps to test the alternator: Go to Preparing for Troubleshooting and/or Testing (page 22) and follow the steps listed. Remove the battery cover to access the battery at the rear of the machine. With the engine off, measure the 12 Vdc battery voltage.
Page 56 Pass The wiring tested good. Go to Step 5. Fail The wiring did not test good. Repair or replace the damaged wiring. Go to Returning the Machine to Service (page 22) and follow the steps listed. Step 5: Replace the alternator. Refer to the Kubota Workshop Manual, Diesel Engine, 05- E4B Series.
Page 57: Fault 13: Ignition Switch Malfunction
Fault 13: Ignition Switch Malfunction InfoCenter Display: _____FAULT #13_____ Fault Description The TEC-5002 has detected the ignition S input is active but the key R input is off. TART Circuit Description The ignition switch has 2 output pins; one for S and one for R .
Page 58 Step 2: Use the InfoCenter to test the ignition switch. g020650 Figure 36 1. Indicator light 3. Middle button: press it to scroll down menus. 2. Right button: press it to open a menu where a right arrow 4. Left button (Menu Access/Back Button): press it to access the indicates additional content.
Page 59 Step 4: Test the ignition switch circuit wiring. Locate the ignition switch in the control arm (Figure 37). g033102 Figure 37 1. Connector P02 Use a multimeter to test the resistance between the following pair of locations: Wire Expected Location Harness Connector Connector Graphic...
Page 60 Electrical Diagram g031095 Figure 38 Component Location and Electrical Connections The key switch is located next to the InfoCenter display in the control arm.
Page 61: Fault 15: Engine Speed Switch Broken
Fault 15: Engine Speed Switch Broken InfoCenter Display: _____FAULT #15_____ Fault Description The TEC-5002 has detected both an engine speed increase signal and an engine speed decrease signal at the same time. Circuit Description The engine speed switch sends either an engine speed increase or engine speed decrease signal to the TEC-5002, which processes the request and sends an output signal to the fuel actuator.
Page 62 g033138 Figure 39 1. Fasteners for the inner control arm cover 2. Fastener with self-locking nut g033123 Figure 40 2. Engine speed switch 1. Connector P14 Test the engine speed switch according to the component testing procedure in Chapter 5 of the 5010-H Service Manual.
Page 63 Pass The engine speed switch tested good. Go to Step 3. Fail The engine speed switch did not test good. Replace the engine speed switch. Go to Returning the Machine to Service (page 22) and follow the steps listed. Step 3: Test the engine speed switch wiring. Remove the access panel from the outer cover of the control arm (Figure 41).
Page 64 g036006 Figure 42 1. Main harness connector P75 2. Socket-head screw Use a multimeter to test the resistance between the following pairs of locations: Wire Expected Location Harness Connector Connector Graphic Color Reading Blue/ Seat Black Less than 2 ohms Blue/ Seat Black...
Page 65 Black Seat (Ground) Less than 2 ohms Chassis ground Repair or replace the damaged wiring. Go to Returning the Machine to Service (page 22) and follow the steps listed. Electrical Diagram g032908 Figure 43 1. 12 Vdc chassis ground...
Page 66: Fault 16: 12 Vdc Alternator Malfunction
Fault 16: 12 Vdc Alternator Malfunction InfoCenter Display: _____FAULT #16_____ Alternator Fault Description The alternator is faulty. This is diagnosed in conjunction with motor/generator rpm data. Circuit Description The engine-driven alternator provides 12 Vdc electrical power. Conditions for Setting the Fault The TEC-5002 detects that the alternator is not performing within specifications.
Page 67 g032654 Figure 44 1. Screen 2. Screen latch Remove the battery cover to access the 12 Vdc battery at the rear of the machine (Figure 45). g032655 Figure 45 1. 12 Vdc Battery cover 2. 12 Vdc Battery With the engine off, measure the 12 Vdc battery voltage. It should be 12.5 to 12.8 volts. Start the engine.
Page 68 Pass The voltage readings were good. Go to Step 4. Fail The voltage readings were not good. Go to Step 3. Step 3: Replace the alternator. Refer to the Kubota Workshop Manual, Diesel Engine, 05- E4B Series. Go to Returning the Machine to Service (page 22) and follow the steps listed.
Page 69 Electrical Diagram g031096 Figure 46 Component Location and Electrical Connections The alternator is mounted to the engine, and is driven by a belt.
Page 70: Fault 17: The Reel Enable Output Is Over Current
Fault 17: The Reel Enable Output is Over Current InfoCenter Display: _____FAULT #17_____ Enable Out Fault Description The measured reel enable output voltage of the TEC is beyond the upper limits. Important: The reel engage/disengage switch is also referred to as the cutting unit enable/disable switch and as the PTO switch.
Page 71 g033157 Figure 47 1. 48 Vdc Logic Relay Remove the bolt and locknut that secure the 48 Vdc logic relay to the fuse bracket and remove the relay from the machine. Measure the coil resistance between terminals 85 and 86 of the 48 Vdc logic relay (Figure 48).
Page 72 Pass The 48 Vdc logic relay tests were good. Go to Step 3. Fail One or more of the 48 Vdc logic relay tests failed. Repair or replace the worn or damaged parts. Go Returning the Machine to Service (page 22) and follow the steps listed.
Page 73: Fault 19: Engine Coolant Temp Sensor Out Of Range
Fault 19: Engine Coolant Temp Sensor Out of Range InfoCenter Display: _____FAULT #19_____ Sensor Fault Description The engine coolant temperature sensor (also called the temperature sender) is either open or shorted. Its output is outside the normal functional range. Circuit Description The engine coolant temperature sensor (temperature sender) is a submersible thermistor which sends an analog signal of 0 to 5 Vdc to the TEC-5002.
Page 74 g032799 Figure 49 1. Temperature sender 2. Main harness connector P16 Unplug connector P16 from the temperature sender. Use a multimeter to test the following pair of locations: Wire Expected Location Harness Connector Connector Graphic Color Reading Gray/ Main Brown More than 200 ohms Brown/...
Page 75 Electrical Diagram g031092 Figure 50 Component Location and Electrical Connections The temperature sender is located near the alternator on the coolant thermostat housing attached to the engine cylinder head.
Page 76: Fault 21: Id Module Fault
Fault 21: ID Module Fault InfoCenter Display: _____FAULT #21_____ ID Module Fault Description Each cutting reel motor has its own unique module ID. This fault is reported when either: • an ID module is not functioning at all, or • more than 1 cutting reel motor is claiming the same node ID Circuit Description Each cutting reel motor has an electronic signature code so it can be identified.
Page 77 Locate the location ID module that is secured to the frame near the 48 Vdc fuse block. See Figure Figure g035715 Figure 51 1. Location ID module 3. Motor/generator 2. Operator’s seat g033156 Figure 52 1. Location ID module Disconnect the main wire harness connector P31 from the location ID module connector (Figure 53).
Page 78 g036165 Figure 53 1. Location ID module 2. ID module connector Using a multimeter, measure resistances between module connector pins as follows: ID Module Connector Pins Resistance A and F 15k ohms B and F 10k ohms C and F 6.2k ohms D and F 3.9k ohms...
Page 79 Wire Expected Location Harness Connector Connector Graphic Color Reading Main Yellow 3.9k ohms Black Main (48V Ground) Main 6.2k ohms Black Main (48V Ground) Main Orange 10k ohms Black Main (48V Ground) Main Violet 15k ohms Black Main (48V Ground) Repair or replace the damaged wiring.
Page 80 Electrical Diagram g033129 Figure 54 1. Frame ground (12 Vdc circuit). Component Location and Electrical Connections The ID module plugs into the main wire harness near the 48 Vdc fuse block. It is located under the engine hood, near the 48 Vdc fuse block.
Page 81: Fault 24: Joystick Broken
Fault 24: Joystick Broken InfoCenter Display: _____FAULT #24_____ Joystick Fault Description The TEC-5002 detected a “cutting unit raise” command and a “cutting unit lower” command at the same time from the joystick. Circuit Description There are 2 microswitches for the joystick located on the control arm. The rear switch on the control is used to lower (and engage) the cutting units and the front switch to raise (and disengage) them.
Page 82 g033101 Figure 55 1. Connector P03 (Down switch) 2. Connector P04 (Up switch) Pass The joystick switches tested good. Go to Step 3. Fail The joystick switches did not test good. Replace the failed joystick switches as needed. Go to Returning the Machine to Service (page 22) and follow the steps listed.
Page 83 Electrical Diagram g031099 Figure 56 1. Frame ground (12 Vdc) Component Location and Electrical Connections The 2 microswitches for the joystick are located on the lower mow/raise lever that is attached to the control arm. The rear switch on the control is used to lower (and engage) the cutting units, and the front switch is used to raise (and disengage) them.
Page 84: Fault 26: Engine Start Output Signal Current Is Too High
Fault 26: Engine Start Output Signal Current is Too High InfoCenter Display: _____FAULT #26_____ Fault Description The current from the TEC-5002 that is used to energize the starter relay coil is too high. Circuit Description A 12 Vdc starter relay is used in the engine starting circuit. When the TEC-5002 controller provides a control voltage of 12 Vdc to the starter relay, it provides a high-current path to energize the engine starter solenoid.
Page 85 Press the right button as needed to display the Inputs menu. Note: On the Inputs menu, the Key Start item appears. Because the ignition key is in the O position, the Key Start item status reads O When the ignition key is rotated to the S position, the starter engages the engine and attempts to TART start it.
Page 86 g035716 Figure 58 1. Engine 3. Operator’s seat 2. Muffler 4. Start relay g033155 Figure 59 1. Exhaust muffler 2. Start relay Perform the resistance and continuity tests with the start relay as described the Component Testing section in Chapter 5 of the 5010-H Service Manual. Replace the start relay if you determine that the relay is faulty. Clear the system faults from the InfoCenter.
Page 87 Replacing a Toro Electronic Controller (TEC) (page 26). Use Toro DIAG to save the machine timers and counters file out of the machine. (page 26) Replace the TEC-5002. (page 26) Use Toro DIAG to Program the TEC-5002. (page 27) The fault no longer...
Page 88 Component Location and Electrical Connections The starter relay has 5 terminals and is attached to a frame bracket under the hood of the machine, near the muffler of the engine. The ignition switch is mounted next to the InfoCenter display in the control arm.
Page 89: Fault 27: Engine Run Output Circuit Fault To Fuel Actuator
Fault 27: Engine Run Output Circuit Fault to Fuel Actuator InfoCenter Display: _____FAULT #27_____ Fault Description The “engine run” output circuit from the TEC-5002 is supplying too much current to the fuel actuator. The TEC-5002 is sensing that the output signal to the fuel actuator is above the maximum. Note: The fuel actuator is also referred to as the eGov.
Page 90 Follow the fuel actuator test procedure in Chapter 5 of the 5010-H Service Manual. g035717 Figure 61 1. Motor/generator 3. Fuel actuator 2. Radiator Pass The fuel actuator test was good. Go to Step 3. Fail The fuel actuator test was not good. Replace the fuel actuator. Go to Returning the Machine to Service (page 22) and follow the steps listed.
Page 91 g033199 Figure 62 1. Connector P52 3. Fuel filter 2. Fuel actuator Use a multimeter to test the resistance between the following pairs of locations: Wire Expected Location Harness Connector Connector Graphic Color Reading Red/ Main Yellow Less than 2 ohms Red/ Seat Yellow...
Page 92 Replacing a Toro Electronic Controller (TEC) (page 26). Use Toro DIAG to save the machine timers and counters file out of the machine. (page 26) Replace the TEC-5002. (page 26) Use Toro DIAG to Program the TEC-5002. (page 27) The fault no longer...
Page 93 The electric fuel pump is attached to the inside of the left side frame rail near the fuel tank.
Page 94: Fault 28: All 48V Can Bus Devices Offline
Fault 28: All 48V CAN Bus Devices Offline InfoCenter Display: _____FAULT #28_____ Devices Offline Fault Description All of the 48 Vdc devices that send signals on the CAN bus circuit (the motor/generator and all 5 cutting reel motors) are offline. Circuit Description The 48 Vdc component CAN bus circuit supports the 5 cutting reel motors and the motor/generator.
Page 95 g035727 Figure 64 1. 48V disconnect 3. Main contactor 2. Operator's seat Use a multimeter and measure the 48 Vdc battery pack voltage across the main contactor (Figure 65). The acceptable voltage range is 46 to 54 Vdc. g036085 Figure 65 Note: If you measure less than 46 Vdc, measure the voltage across each of the 4 individual batteries.
Page 96 Pass The 48 Vdc battery system checks were good. Go to Step 3. Fail One or more of the 48 Vdc battery system tests failed. Repair or replace the worn or damaged parts. Go to Returning the Machine to Service (page 22) and follow the steps listed.
Page 97 g032876 Figure 67 Test the continuity of the 48 Vdc logic relay. Note: You need a multimeter and a 12 Vdc power source to perform this test. Connect the multimeter probes to terminals 30 and 87 of the relay and set the meter to perform a continuity test.
Page 98 Turn the ignition key to the O position. Wire Expected Location Harness Connector Connector Graphic Color Reading Main Pink 12 Vdc Black Main (Ground) Pass The isolation module power test was good. Go to Step 7. Fail The isolation module power test failed. Repair or replace the damaged wiring. Go to Returning the Machine to Service (page 22) and follow the steps listed.
Page 99 Wire Expected Location Harness Connector Connector Graphic Color Reading Main Green 54 to 66 ohms Main Yellow Main Green Open (infinite) Chassis ground Main Yellow Open (infinite) Chassis ground Pass The CAN bus wiring to the isolation module tested good. Go to Step 8. Fail The CAN bus wiring to the isolation module did not test good.
Page 100 g032452 Figure 70 Component Location and Electrical Connections The relays are located under the hood, behind the operator’s platform.
Page 101: Fault 29: 48V Battery Low Voltage
Fault 29: 48V Battery Low Voltage Note: Fault 29 indicates a low-voltage condition in the 48 Vdc battery system, rather than an individual component signaling a low-voltage condition. InfoCenter Display: _____FAULT #29_____ Fault Description The entire 48 Vdc bus system (including the motor/generator and all 5 cutting reel motors) is supplied with 32 volts or less.
Page 102 g036201 Figure 71 1. Battery covers 3. Battery cables 2. 12 Vdc AGM batteries (4) Measure the voltage across each of the 4 individual batteries. The individual battery readings should be 11.5 to 13.5 Vdc. Inspect the following cables for damage, corrosion, and proper installation (Figure 71).
Page 103 Component Location and Electrical Connections The 48V battery pack is located beneath the front axle of the machine.
Page 104: Fault 30: 48V Bus High Voltage
Compare this to an individual overvoltage fault, which is indicative of a voltage regulator issue. Circuit Description The Reelmaster 5010-H 48 Vdc system includes a 48 Vdc battery array (4 12-Vdc AGM batteries in series), an engine-driven motor/generator assembly, 5 cutting reel motors, a main contactor used to energize the system, and additional circuit control components.
Page 105 g035727 Figure 72 1. 48V disconnect 3. Main contactor 2. Operator’s seat Use a multimeter to measure the voltage of the 48 Vdc battery pack across the main contactor (Figure 73). The acceptable voltage range is 46 to 54 Vdc. g036085 Figure 73 If the voltage reads high, remove cutting unit 1 and both of the battery covers.
Page 106 g036201 Figure 74 1. Battery covers 3. Battery cables 2. 12 Vdc AGM batteries (4) The individual readings should be 11.5 to 13.5 Vdc. Inspect the following cables for damage, corrosion, and proper installation (Figure 74). • The cables between the 4 individual batteries. •...
Page 107 Step 9: Use Toro DIAG to program the motor/generator. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 108: Fault 31: 48 Vdc Key Switch Overvolt
Circuit Description The Reelmaster 5010-H 48 Vdc system includes a 48 Vdc battery array (4 sealed 12 Vdc AGM batteries connected in series), an engine-driven motor/generator assembly, 5 cutting reel motors, a main contactor used to energize the system, and additional circuit control components.
Page 109 g035727 Figure 75 1. 48V disconnect 3. Main contactor 2. Operator’s seat Use a multimeter to measure the voltage of the 48 Vdc battery pack across the main contactor (Figure 76). The acceptable voltage range is 46 to 67.5 Vdc. g036085 Figure 76 If the voltage reads high, remove cutting unit 1 and both of the battery covers.
Page 110 g036201 Figure 77 1. Battery covers 3. Battery cables 2. 12 Vdc AGM batteries (4) Each individual battery should read 11.5 to 13.5 Vdc. Inspect the following cables for damage, corrosion, and proper installation (Figure 77). • The cables between the 4 individual batteries •...
Page 111 Step 9: Use Toro DIAG to program the motor/generator. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 112: Fault 32: Unknown Cutting Unit Fault
Note: If the fault does not repeat, an isolated event has occurred. Fail The fault repeated. Contact the Toro Technical Assistance Center for additional guidance. Note: You must fix this software fault; accomplish the TEC-5002 software repair with direct assistance from Toro.
Page 113: Fault 33: Unknown Motor/Generator Fault
Note: If the fault does not repeat, an isolated event has occurred. Fail The fault repeated. Contact the Toro Technical Assistance Center for additional guidance. Note: You must fix this software fault; accomplish the TEC-5002 software repair with direct assistance from Toro.
Page 114: Fault 34: Unknown Master Controller Fault
Note: If the fault does not repeat, an isolated event has occurred. Fail The fault repeated. Contact the Toro Technical Assistance Center for additional guidance. Note: You must fix this software fault; accomplish the TEC-5002 software repair with direct assistance from Toro.
Page 115: Fault 37: Tec Output Current To Glow Plug Relay Is Excessive
Fault 37: TEC Output Current to Glow Plug Relay is Excessive InfoCenter Display: _____FAULT #37_____ Glow Fault Description The TEC-5002 output current to energize the glow plug relay is excessive. Circuit Description When energized by the TEC-5002, the glow relay provides current to the engine glow plugs. The TEC controls and monitors the operation of the glow relay.
Page 116 g035722 Figure 78 1. Engine 3. Operator’s seat 2. Muffler 4. Glow relay Swap the main harness connector P20 (glow relay) with the main harness connector P04 (main power relay) (Figure 79). g033191 Figure 79 1. Exhaust muffler 4. Connector P20 2.
Page 117 Replacing a Toro Electronic Controller (TEC) (page 26). Use Toro DIAG to save the machine timers and counters file out of the machine. (page 26) Replace the TEC-5002. (page 26) Use Toro DIAG to Program the TEC-5002. (page 27) The fault no longer...
Page 118: Fault 38: Can Bus Fault-Crm 1
Fault 38: CAN Bus Fault—CRM 1 Note: When any individual cutting reel motor is shut off due to a fault, the TEC-5002 shuts off the other 4 cutting reel motors. Note: If multiple machine faults are reported within a few seconds, troubleshooting should begin with the first cutting reel motor to report a fault.
Page 119 g032972 Figure 80 1. Cutting unit 1, which includes cutting reel motor 1 4. Cutting unit 4, which includes cutting reel motor 4 2. Cutting unit 2, which includes cutting reel motor 2 5. Cutting unit 5, which includes cutting reel motor 5 3.
Page 120 Step 4: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 121 Rotate the ignition key to the O position. Measure the voltage between pins 1 and 2 of connector P47. The reading should be 48 Vdc. Measure the voltage between P46 pin 1 and P47 pin 2. The reading should be 48 Vdc. Rotate the ignition key to the O position.
Page 122 Step 7: Test the CAN bus wiring in main harness connector P46. Use a multimeter to test the resistance between the following pairs of locations: Wire Expected Location Harness Connector Connector Graphic Color Reading Main Yellow 54 to 66 ohms Main Green Main...
Page 123 Electrical Diagram g032452 Figure 81 CAN Bus...
Page 124 g033129 Figure 82 ID Module 1. 48V ground bus Component Location and Electrical Connections Cutting reel motor 1 is located in the front, center position. There are 2 electrical connections to the cutting reel motor: P46 (4-wire) and P47 (2-wire).
Page 125: Fault 39: Can Bus Fault-Crm 2
Fault 39: CAN Bus Fault—CRM 2 Note: When any individual cutting reel motor is shut off due to a fault, the TEC-5002 shuts off the other 4 cutting reel motors. Note: If multiple machine faults are reported within a few seconds, troubleshooting should begin with the first cutting reel motor to report a fault.
Page 126 g032972 Figure 83 1. Cutting unit 1, which includes cutting reel motor 1 4. Cutting unit 4, which includes cutting reel motor 4 2. Cutting unit 2, which includes cutting reel motor 2 5. Cutting unit 5, which includes cutting reel motor 5 3.
Page 127 Step 4: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 128 Rotate the ignition key to the O position. Measure the voltage between pins 1 and 2 of connector P39. The reading should be 48 Vdc. Measure the voltage between P38 pin 1 and P39 pin 2. The reading should be 48 Vdc. Rotate the ignition key to the O position.
Page 129 Step 7: Test the CAN bus wiring in main harness connector P38. Use a multimeter to test the resistance between the following pairs of locations: Wire Expected Location Harness Connector Connector Graphic Color Reading Main Yellow 54 to 66 ohms Main Green Main...
Page 130 Electrical Diagram g032452 Figure 84...
Page 131 g033129 Figure 85 1. 48V ground bus Component Location and Electrical Connections Cutting reel motor 2 is located in the rear, left position. There are 2 electrical connections to the cutting reel motor: P38 (4 wire) and P39 (2 wire).
Page 132: Fault 40: Can Bus Fault-Crm 3
Fault 40: CAN Bus Fault—CRM 3 Note: When any individual cutting reel motor is shut off due to a fault, the TEC-5002 shuts off the other 4 cutting reel motors. Note: If multiple machine faults are reported within a few seconds, troubleshooting should begin with the first cutting reel motor to report a fault.
Page 133 g032972 Figure 86 1. Cutting unit 1, which includes cutting reel motor 1 4. Cutting unit 4, which includes cutting reel motor 4 2. Cutting unit 2, which includes cutting reel motor 2 5. Cutting unit 5, which includes cutting reel motor 5 3.
Page 134 Step 4: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 135 Rotate the ignition key to the O position. Measure the voltage between pins 1 and 2 of connector P41. The reading should be 48 Vdc. Measure the voltage between P40 pin 1 and P41 pin 2. The reading should be 48 Vdc. Rotate the ignition key to the O position.
Page 136 Step 7: Test the CAN bus wiring in main harness connector P40. Use a multimeter to test the resistance between the following pairs of locations: Wire Expected Location Harness Connector Connector Graphic Color Reading Main Yellow 54 to 66 ohms Main Green Main...
Page 137 Electrical Diagram g031097 Figure 87...
Page 138 g033129 Figure 88 1. 48V ground bus Component Location and Electrical Connections Cutting reel motor 3 is located in the rear, right position. There are 2 electrical connections to the cutting reel motor: P40 (4 wire) and P41 (2 wire).
Page 139: Fault 41: Can Bus Fault-Crm 4
Fault 41: CAN Bus Fault—CRM 4 Note: When any individual cutting reel motor is shut off due to a fault, the TEC-5002 shuts off the other 4 cutting reel motors. Note: If multiple machine faults are reported within a few seconds, troubleshooting should begin with the first cutting reel motor to report a fault.
Page 140 g032972 Figure 89 1. Cutting unit 1, which includes cutting reel motor 1 4. Cutting unit 4, which includes cutting reel motor 4 2. Cutting unit 2, which includes cutting reel motor 2 5. Cutting unit 5, which includes cutting reel motor 5 3.
Page 141 Step 4: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 142 Rotate the ignition key to the O position. Measure the voltage between pins 1 and 2 of connector P49. The reading should be 48 Vdc. Measure the voltage between P48 pin 1 and P49 pin 2. The reading should be 48 Vdc. Rotate the ignition key to the O position.
Page 143 Step 7: Test the CAN bus wiring in main harness connector P48. Use a multimeter to test the resistance between the following pairs of locations: Wire Expected Location Harness Connector Connector Graphic Color Reading Main Yellow 54 to 66 ohms Main Green Main...
Page 144 Electrical Diagram g032452 Figure 90...
Page 145 g033129 Figure 91 1. 48V ground bus Component Location and Electrical Connections Cutting reel motor 4 is located in the front, left position. There are 2 electrical connections to the cutting reel motor: P48 (4 wire) and P49 (2 wire).
Page 146: Fault 42: Can Bus Fault-Crm 5
Fault 42: CAN Bus Fault—CRM 5 Note: When any individual cutting reel motor is shut off due to a fault, the TEC-5002 shuts off the other 4 cutting reel motors. Note: If multiple machine faults are reported within a few seconds, troubleshooting should begin with the first cutting reel motor to report a fault.
Page 147 g032972 Figure 92 1. Cutting unit 1, which includes cutting reel motor 1 4. Cutting unit 4, which includes cutting reel motor 4 2. Cutting unit 2, which includes cutting reel motor 2 5. Cutting unit 5, which includes cutting reel motor 5 3.
Page 148 Step 4: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 149 Rotate the ignition key to the O position. Measure the voltage between pins 1 and 2 of connector P45. The reading should be 48 Vdc. Measure the voltage between P44 pin 1 and P45 pin 2. The reading should be 48 Vdc. Rotate the ignition key to the O position.
Page 150 Step 7: Test the CAN bus wiring in main harness connector P44. Use a multimeter to test the resistance between the following pairs of locations: Wire Expected Location Harness Connector Connector Graphic Color Reading Main Yellow 54 to 66 ohms Main Green Main...
Page 151 Electrical Diagram g032452 Figure 93...
Page 152 g033129 Figure 94 1. 48V ground bus Component Location and Electrical Connections Cutting reel motor 5 is located in the front, right position. There are 2 electrical connections to the cutting reel motor: P44 (4 wire) and P45 (2 wire).
Page 153: Fault 43: Can Bus Fault-M/G
Fault 43: CAN Bus Fault—M/G InfoCenter Display: _____FAULT #43_____ Fault Description CAN bus fault for the motor/generator. The TEC-5002 never established communication or lost communication with the motor/generator controller. Circuit Description The motor/generator is connected to the 48 Vdc CAN bus, along with all 5 cutting reel motors. Conditions for Setting the Fault The TEC-5002 must lose communication with the motor/generator controller for at least 1 second.
Page 154 Wire Expected Location Harness Connector Connector Graphic Color Reading Main Less than 2 ohms Main Black Main (48V Ground) Less than 2 ohms Black Main (48V Ground) Main White 24k to 26k Black ohms Main (48V Ground) Pass The power and ground wiring tests passed. Go to Step 4. Fail One or more of the power and ground wiring tests failed.
Page 155 Step 9: Install the motor/generator assembly. Refer to Chapter 5 of the 5010-H Service Manual and follow the steps listed. Step 10: Use Toro DIAG to program the motor/generator. Remove the access panel from the outer cover of the control arm.
Page 156 Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24). Use the Toro DIAG software to reprogram the machine in accordance with Toro DIAG User’s Guide. The replacement motor/generator is programmed during the reprogramming of the machine.
Page 157 Electrical Diagram g032452 Figure 95...
Page 158: Fault 44: Can Bus Fault-Infocenter
Fault 44: CAN Bus Fault—InfoCenter InfoCenter Display: _____FAULT #44_____ Fault Description A CAN bus fault exists for the InfoCenter circuit. The TEC-5002 lost or never established communication with the InfoCenter. Circuit Description The InfoCenter is connected to the 12 Vdc CAN bus, along with the TEC-5002. Conditions for Setting the Fault The TEC-5002 must lose communication with the InfoCenter for at least 2 seconds to generate this fault.
Page 159 Step 4: Disconnect cutting reel motors 1 at a time. Note: As each cutting reel motor is disconnected, a corresponding cutting reel motor CAN bus fault occurs. Ignore these faults while conducting this test. Listen to the engine and observe the engine idle speed as each cutting reel motor is unplugged. If the idle smooths out when any 1 cutting reel motor is unplugged and the fault 44 stops repeating, that cutting reel motor requires replacement.
Page 160 Connect seat harness connector P52 to the InfoCenter. Step 7: Use Toro DIAG to program the InfoCenter. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 161 Electrical Diagram g032452 Figure 97 Component Location and Electrical Connections The InfoCenter is located on the control arm.
Page 162: Fault 45: Software Incompatible-Crm 1
Use Toro DIAG to reprogram the machine. If the first attempt to reprogram the machine is unsuccessful, try reprogramming the machine a second time. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 163 Pass If reprogramming the machine was successful, go to Returning the Machine to Service (page 22) and follow the steps listed. Fail If both attempts to reprogram the machine are unsuccessful, go to Step 3. Step 3: Inspect the wiring for cutting reel motor 1. Go to Preparing for Troubleshooting and/or Testing (page 22) and follow the steps listed.
Page 164 Step 6: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 165: Fault 46: Software Incompatible-Crm 2
Use Toro DIAG to reprogram the machine. If the first attempt to reprogram the machine is unsuccessful, try reprogramming the machine a second time. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 166 Pass If reprogramming the machine was successful, go to Returning the Machine to Service (page 22) and follow the steps listed. Fail If both attempts to reprogram the machine are unsuccessful, go to Step 3. Step 3: Inspect the wiring for cutting reel motor 2. Go to Preparing for Troubleshooting and/or Testing (page 22) and follow the steps listed.
Page 167 Step 6: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 168: Fault 47: Software Incompatible-Crm 3
Use Toro DIAG to reprogram the machine. If the first attempt to reprogram the machine is unsuccessful, try reprogramming the machine a second time. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 169 Pass If reprogramming the machine was successful, go to Returning the Machine to Service (page 22) and follow the steps listed. Fail If both attempts to reprogram the machine are unsuccessful, go to Step 3. Step 3: Inspect the wiring for cutting reel motor 3. Go to Preparing for Troubleshooting and/or Testing (page 22) and follow the steps listed.
Page 170 Step 6: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 171: Fault 48: Software Incompatible-Crm 4
Use Toro DIAG to reprogram the machine. If the first attempt to reprogram the machine is unsuccessful, try reprogramming the machine a second time. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 172 Pass If reprogramming the machine was successful, go to Returning the Machine to Service (page 22) and follow the steps listed. Fail If both attempts to reprogram the machine are unsuccessful, go to Step 3. Step 3: Inspect the wiring for cutting reel motor 4. Go to Preparing for Troubleshooting and/or Testing (page 22) and follow the steps listed.
Page 173 Step 6: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 174: Fault 49: Software Incompatible-Crm 5
Use Toro DIAG to reprogram the machine. If the first attempt to reprogram the machine is unsuccessful, try reprogramming the machine a second time. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 175 Pass If reprogramming the machine was successful, go to Returning the Machine to Service (page 22) and follow the steps listed. Fail If both attempts to reprogram the machine are unsuccessful, go to Step 3. Step 3: Inspect the wiring for cutting reel motor 5. Go to Preparing for Troubleshooting and/or Testing (page 22) and follow the steps listed.
Page 176 Step 6: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 177: Fault 50: Software Incompatible-M/G
Use Toro DIAG to reprogram the machine. If the first attempt to reprogram the machine is unsuccessful, try reprogramming the machine a second time. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 178 Pass If reprogramming the machine was successful, go to Returning the Machine to Service (page 22) and follow the steps listed. Fail If both attempts to reprogram the machine are unsuccessful, go to Step 3. Step 3: Test the CAN bus wiring in main harness connector P37. Use a multimeter to test the resistance between the following pairs of locations: Wire Expected...
Page 179 Step 9: Use Toro DIAG to program the motor/generator. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 180: Fault 51: Software Incompatible-Infocenter
Use Toro DIAG to reprogram the machine. If the first attempt to reprogram the machine is unsuccessful, try reprogramming the machine a second time. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 181 Pass If reprogramming the machine was successful, go to Returning the Machine to Service (page 22) and follow the steps listed. Fail If both attempts to reprogram the machine are unsuccessful, go to Step 3. Step 3: Prepare to test the InfoCenter wiring and/or replace the InfoCenter.
Page 182 Wire Expected Location Harness Connector Connector Graphic Color Reading Brown/ Seat Yellow Approx. 75 ohms Seat Pink Pass The power and ground wiring tests passed. Go to Step 5. Fail One or more of the power and ground wiring tests failed. Repair or replace the worn or damaged parts.
Page 183 Connect seat harness connector P52 to the InfoCenter. Step 7: Use Toro DIAG to program the InfoCenter. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 184: Fault 52: Software Incompatible-Master
Use Toro DIAG to reprogram the machine. If the first attempt to reprogram the machine is unsuccessful, try reprogramming the machine a second time. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 185 Replacing a Toro Electronic Controller (TEC) (page 26). Use Toro DIAG to save the machine timers and counters file out of the machine. (page 26) Replace the TEC-5002. (page 26) Use Toro DIAG to Program the TEC-5002. (page 27) The fault no longer...
Page 186: Fault 53: Sv1 Out
Fault 53: SV1 Out InfoCenter Display: _____FAULT #53_____ Fault Description The output current is too high from the TEC-5002 to the SV1 hydraulic lift/lower solenoid. Circuit Description The TEC controller uses inputs from various machine switches to determine when lift manifold solenoid valves (SV1, SV2, SV3, and SVRV) are to be energized.
Page 187 Step 3: Measure the resistance of the SV1 coil. Lift and support the operator’s seat. Remove the 4 fasteners securing the operator’s floor panel. See Figure 105. g035763 Figure 105 1. Operator’s floor panel fasteners (4) 2. Operator’s floor panel Remove the operator’s floor panel and locate the hydraulic lift manifold.
Page 188 g035764 Figure 107 1. SV1 solenoid 4. SVRV (SV4) solenoid 2. SV2 solenoid 5. Lift manifold 3. SV3 solenoid Unplug connector P10 from SV1 and use a multimeter to measure the resistance of the SV1 coil. It should be approximately 8.7 ohms. Pass The measurement was good.
Page 189 Reinstall the original primary TEC controller. Repeat the diagnostic process for this fault. Step 6: Use Toro DIAG to Program the TEC-5002. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 190 Electrical Diagram g034095 Figure 108 1. Chassis ground Component Location and Electrical Connections The SV1 coil is located in the lift control manifold and can be replaced without disconnecting the hydraulic system. The lift control manifold is attached to a frame bracket under the operator floor plate. Remove the floor plate to access the lift control manifold.
Page 191: Fault 54: Sv2 Out
Fault 54: SV2 Out InfoCenter Display: _____FAULT #54_____ Fault Description The output current is too high from the TEC-5002 to the SV2 hydraulic lift/lower solenoid. Circuit Description The TEC controller uses inputs from various machine switches to determine when lift manifold solenoid valves (SV1, SV2, SV3, and SVRV) are to be energized.
Page 192 Step 3: Measure the resistance of the SV2 coil. Lift and support the operator’s seat. Remove the 4 fasteners securing the operator’s floor panel. See Figure 109. g035763 Figure 109 1. Operator’s floor panel fasteners (4) 2. Operator’s floor panel Remove the operator’s floor panel and locate the hydraulic lift manifold.
Page 193 g035764 Figure 111 1. SV1 solenoid 4. SVRV (SV4) solenoid 2. SV2 solenoid 5. Lift manifold 3. SV3 solenoid Unplug main harness connector P13 and use a multimeter to measure the resistance of the SV2 coil. It should be approximately 7.1 ohms. Pass The measurement was good.
Page 194 Replacing a Toro Electronic Controller (TEC) (page 26). Use Toro DIAG to save the machine timers and counters file out of the machine. (page 26) Replace the TEC-5002. (page 26) Use Toro DIAG to Program the TEC-5002. (page 27) The fault no longer...
Page 195 Component Location and Electrical Connections The SV2 coil is located in the lift control manifold and can be replaced without disconnecting the hydraulic system. The lift control manifold is attached to a frame bracket under the operator floor plate. Remove the floor plate to access the lift control manifold.
Page 196: Fault 55: Sv3 Out
Fault 55: SV3 Out InfoCenter Display: _____FAULT #55_____ Fault Description The output current is too high from the TEC-5002 to the SV3 hydraulic lift/lower solenoid. Circuit Description The TEC controller uses inputs from various machine switches to determine when lift manifold solenoid valves (SV1, SV2, SV3, and SVRV) are to be energized.
Page 197 Step 3: Measure the resistance of the SV3 coil. Lift and support the operator’s seat. Remove the 4 fasteners securing the operator’s floor panel. g035763 Figure 113 1. Operator’s floor panel fasteners (4) 2. Operator’s floor panel Remove the operator’s floor panel and locate the hydraulic lift manifold. See Figure 114.
Page 198 g035764 Figure 115 1. SV1 solenoid 4. SVRV (SV4) solenoid 2. SV2 solenoid 5. Lift manifold 3. SV3 solenoid Unplug main harness connector P19 and use a multimeter to measure the resistance of the SV3 coil. It should be approximately 8.7 ohms. Pass The measurement was good.
Page 199 Replacing a Toro Electronic Controller (TEC) (page 26). Use Toro DIAG to save the machine timers and counters file out of the machine. (page 26) Replace the TEC-5002. (page 26) Use Toro DIAG to Program the TEC-5002. (page 27) The fault no longer...
Page 200 Component Location and Electrical Connections The SV3 coil is located in the lift control manifold and can be replaced without disconnecting the hydraulic system. The lift control manifold is attached to a frame bracket under the operator floor plate. Remove the floor plate to access the lift control manifold.
Page 201: Fault 56: Svrv Out
Fault 56: SVRV Out InfoCenter Display: _____FAULT #56_____ SVRV Fault Description The output current is too high from the TEC-5002 to the SVRV hydraulic lift/lower solenoid. Note: The SVRV solenoid is also referred to as the SV4 solenoid. Circuit Description The TEC controller uses inputs from various machine switches to determine when lift manifold solenoid valves (SV1, SV2, SV3, and SVRV) are to be energized.
Page 202 Pass The measurement was good. Go to Step 5. Fail The measurement was bad. Go to Step 3. Step 3: Measure the resistance of the SVRV coil. Lift and support the operator’s seat. Remove the 4 fasteners securing the operator’s floor panel. See Figure 117.
Page 203 g035726 Figure 118 1. Hydraulic lift manifold 3. 48V disconnect 2. Operator’s seat Locate the SVRV solenoid on the lift manifold. See Figure 119. g035764 Figure 119 1. SV1 solenoid 4. SVRV (SV4) solenoid 2. SV2 solenoid 5. Lift manifold 3.
Page 204 Replacing a Toro Electronic Controller (TEC) (page 26). Use Toro DIAG to save the machine timers and counters file out of the machine. (page 26) Replace the TEC-5002. (page 26) Use Toro DIAG to Program the TEC-5002. (page 27) The fault no longer...
Page 205 Electrical Diagram g034095 Figure 120 1. Chassis ground Component Location and Electrical Connections The SVRV coil is located in the lift control manifold and can be replaced without disconnecting the hydraulic system. The lift control manifold is attached to a frame bracket under the operator floor plate. Remove the floor plate to access the lift control manifold.
Page 206: Fault 57: Mismatched Cutting Unit Sizes
Fault 57: Mismatched Cutting Unit Sizes InfoCenter Display: _____FAULT #57_____ CU Size Incompatible Fault Description The cutting unit sizes (5-inch and 7-inch diameter reel units) are mixed. Circuit Description The TEC-5002 can detect whether a 5-inch or 7-inch reel cutting unit is installed. All cutting unit sizes must match in cutting units 1 through 5 before the machine functions normally.
Page 207 g032972 Figure 121 1. Cutting unit 1, which includes cutting reel motor 1 4. Cutting unit 4, which includes cutting reel motor 4 2. Cutting unit 2, which includes cutting reel motor 2 5. Cutting unit 5, which includes cutting reel motor 5 3.
Page 208: Fault 58: M/G Current Sensor Failure
Fault 58: M/G Current Sensor Failure InfoCenter Display: _____FAULT #58_____ Current Sensor Fault Description One of the 3 current sensors inside the motor/generator controller has failed. Circuit Description The motor/generator contains 3 internal current sensors. Conditions for Setting the Fault The motor/generator has 3 current sensors (2 phase-current sensors and 1 DC-current sensor).
Page 209 Step 7: Use Toro DIAG to program the motor/generator. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 210 Go to Returning the Machine to Service (page 22) and follow the steps listed.
Page 211: Fault 59: Main Contactor-Open Failure
Fault 59: Main Contactor—Open Failure InfoCenter Display: _____FAULT #59_____ Contactor Open Fault Description The main contactor—open fault indicates a failure associated with control of the 48 Vdc contactor. If the key switch (48V logic) and bus voltage of the motor/generator have more than an 8 Vdc difference when the contactor is engaged, this fault is reported.
Page 212 g033200 Figure 123 1. 48V battery disconnect 4. Main 48 Vdc contactor 2. 250A/58V fuse 5. Main contact posts 3. Contactor coil posts Pass The main contactor tested good. Go to Step 3. Fail The main contactor did not test good. Replace the main contactor. Refer to Chapter 5 of the 5010-H Service Manual.
Page 213 Main White Less than 2 ohms Main White Repair or replace the worn or damaged parts. Go to Returning the Machine to Service (page 22) follow the steps listed.
Page 214: Fault 60: Main Contactor-Closed
Fault 60: Main Contactor—Closed InfoCenter Display: _____FAULT #60_____ Contactor Closed Fault Description The main contactor closed fault indicates a failure associated with control of the 48 Vdc contactor. The motor/generator monitors the 48 Vdc bus in an effort to detect failures of the contactor or the contactor control circuit.
Page 215 g035727 Figure 124 1. 48 Vdc disconnect 3. Main contactor 2. Operator's seat Verify the ignition key is in the O position. Using a multimeter, measure the voltage across the contactor coil posts (Figure 125). The reading should be approximately 0 Vdc. g033200 Figure 125 1.
Page 216 Pass The reading is approximately 0 Vdc. Go to Step 3. Fail The reading is more than 0 Vdc. Replace the contactor. Refer to Chapter 5 of the 5010-H Service Manual. Go to Returning the Machine to Service (page 22) and follow the steps listed.
Page 217: Fault 61: Main Contactor Over Current
Fault 61: Main Contactor Over Current InfoCenter Display: _____FAULT #61_____ Contactor Fault Description Too much current is flowing through the main contactor. The motor/generator controller is reporting an internal over current fault. Circuit Description The motor/generator is a 48 Vdc, air cooled, brushless, permanent magnet device. The motor/generator has its own controller.
Page 218 Step 7: Use Toro DIAG to program the motor/generator. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 219: Fault 62: M/G Fault Latch-Phase Over Current
Fault 62: M/G Fault Latch—Phase Over Current InfoCenter Display: _____FAULT #62_____ Fault Latch - Phase OC Fault Description The over-current hardware protection on the phase current trips when the current limit is exceeded. Circuit Description The motor/generator is a 48 Vdc, air cooled, brushless, permanent magnet device. The motor/generator has its own controller.
Page 220 Step 2: Remove the motor/generator assembly from the machine. g035728 Figure 126 1. Operator’s seat 3. Motor/generator controller (mounted to motor/generator assembly) 2. Motor/generator connector P37 Remove the motor/generator assembly from the machine. Refer to Chapter 5 of the 5010-H Service Manual. Figure 126.
Page 221 Step 7: Use Toro DIAG to program the motor/generator. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 222: Fault 63: 48V Precharge Failure
Fault 63: 48V Precharge Failure InfoCenter Display: _____FAULT # 63_____ Precharge Fault Description This fault indicates a failure associated with the precharge circuit that charges the bus capacitance prior to closing the 48 Vdc line contactor. Circuit Description When the ignition key is turned to the O position, the motor/generator monitors the precharge voltage level and the time it takes to become fully charged.
Page 223 Harness The engine did not start. The problem is likely in the main wire harness. Go to Step 4. problem Cutting The engine started. Go to Step 3. reel motor problem Step 3: Connect 1 cutting reel motor and attempt to start the engine. Note: If any individual cutting reel motor is reporting an additional fault, that is likely the shorted cutting reel motor.
Page 224: Fault 64: M/G Temperature Sensor Failure
Fault 64: M/G Temperature Sensor Failure InfoCenter Display: _____FAULT #64_____ Sensor Fault Fault Description Temperature sensor failures were detected within the motor/generator controller. Circuit Description There are 3 separate temperature sensors located inside the motor/generator. They are: • Field effect transistor (FET) temperature •...
Page 225 Step 4: Use Toro DIAG to program the motor/generator. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 226: Fault 65: Speed Stall-Crm 1
Fault 65: Speed Stall—CRM 1 Note: When any individual cutting reel motor is shut off due to a fault, the TEC-5002 shuts off the other 4 cutting reel motors. Note: If multiple machine faults are reported within a few seconds, troubleshooting should begin with the first cutting reel motor to report a fault.
Page 227 Raise and support the operator’s seat and the hood. Separate system components from the 48 Vdc battery pack by unplugging the 48 Vdc battery disconnect. Refer to Connecting and Disconnecting the 48 Vdc Battery System (page 19). Check the cutting unit and the cutting reel motor for any mechanical resistance. Refer to Figure 129 to locate cutting unit 1.
Page 228 Step 5: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 229 Step 7: Inspect the wiring for cutting reel motor 1. Go to Preparing for Troubleshooting and/or Testing (page 22) and follow the steps listed. Unplug the 48 Vdc battery disconnect to prevent unexpected cutting unit operation. Refer to Connecting and Disconnecting the 48 Vdc Battery System (page 19).
Page 230 Wire Expected Location Harness Connector Connector Graphic Color Reading Black Main (48V Ground) Less than 2 ohms Black Main (48V Ground) Main White 24k to 26k ohms Black Main (48V Ground) Pass The resistance tests passed, but the voltage readings in Step 8 are still bad. Note: Do not go to Step 10 until after the voltage readings in Step 8 are good.
Page 231: Fault 66: Speed Stall-Crm 2
Fault 66: Speed Stall—CRM 2 Note: When any individual cutting reel motor is shut off due to a fault, the TEC-5002 shuts off the other 4 cutting reel motors. Note: If multiple machine faults are reported within a few seconds, troubleshooting should begin with the first cutting reel motor to report a fault.
Page 232 Raise and support the operator’s seat and the hood. Separate system components from the 48 Vdc battery pack by unplugging the 48 Vdc battery disconnect. Refer to Connecting and Disconnecting the 48 Vdc Battery System (page 19). Check the cutting unit and the cutting reel motor for any mechanical resistance. Refer to Figure 130 to locate cutting unit 2.
Page 233 Step 5: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 234 Step 7: Inspect the wiring for cutting reel motor 2. Go to Preparing for Troubleshooting and/or Testing (page 22) and follow the steps listed. Unplug the 48 Vdc battery disconnect to prevent unexpected cutting unit operation. Refer to Connecting and Disconnecting the 48 Vdc Battery System (page 19).
Page 235 Wire Expected Location Harness Connector Connector Graphic Color Reading Black Main (48V Ground) Less than 2 ohms Black Main (48V Ground) Main White 24k to 26k ohms Black Main (48V Ground) Pass The resistance tests passed, but the voltage readings in Step 8 are still bad. Note: Do not go to Step 10 until after the voltage readings in Step 8 are good.
Page 236: Fault 67: Speed Stall-Crm 3
Fault 67: Speed Stall—CRM 3 Note: When any individual cutting reel motor is shut off due to a fault, the TEC-5002 shuts off the other 4 cutting reel motors. Note: If multiple machine faults are reported within a few seconds, troubleshooting should begin with the first cutting reel motor to report a fault.
Page 237 Raise and support the operator’s seat and the hood. Separate system components from the 48 Vdc battery pack by unplugging the 48 Vdc battery disconnect. Refer to Connecting and Disconnecting the 48 Vdc Battery System (page 19). Check the cutting unit and the cutting reel motor for any mechanical resistance. Refer to Figure 131 to locate cutting unit 3.
Page 238 Step 5: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 239 Step 7: Inspect the wiring for cutting reel motor 3. Go to Preparing for Troubleshooting and/or Testing (page 22) and follow the steps listed. Unplug the 48 Vdc battery disconnect to prevent unexpected cutting unit operation. Refer to Connecting and Disconnecting the 48 Vdc Battery System (page 19).
Page 240 Wire Expected Location Harness Connector Connector Graphic Color Reading Black Main (48V Ground) Less than 2 ohms Black Main (48V Ground) Main White 24k to 26k ohms Black Main (48V Ground) Pass The resistance tests passed, but the voltage readings in Step 8 are still bad. Note: Do not go to Step 10 until after the voltage readings in Step 8 are good.
Page 241: Fault 68: Speed Stall-Crm 4
Fault 68: Speed Stall—CRM 4 Note: When any individual cutting reel motor is shut off due to a fault, the TEC-5002 shuts off the other 4 cutting reel motors. Note: If multiple machine faults are reported within a few seconds, troubleshooting should begin with the first cutting reel motor to report a fault.
Page 242 Raise and support the operator’s seat and the hood. Separate system components from the 48 Vdc battery pack by unplugging the 48 Vdc battery disconnect. Refer to Connecting and Disconnecting the 48 Vdc Battery System (page 19). Check the cutting unit and the cutting reel motor for any mechanical resistance. Refer to Figure 132 to locate cutting unit 4.
Page 243 Step 5: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 244 Unplug the 48 Vdc battery disconnect to prevent unexpected cutting unit operation. Refer to Connecting and Disconnecting the 48 Vdc Battery System (page 19). Disconnect main harness connectors P48 and P49 from the cutting reel motor cable connectors mounted on the traction unit. Inspect the 2 cutting reel motor cable connectors and the 2 main harness connectors for damage, corrosion, debris, and proper alignment of the pins inside the connectors.
Page 245 Wire Expected Location Harness Connector Connector Graphic Color Reading Black Main (48V Ground) Less than 2 ohms Black Main (48V Ground) Main White 24k to 26k ohms Black Main (48V Ground) Pass The resistance tests passed, but the voltage readings in Step 8 are still bad. Note: Do not go to Step 10 until after the voltage readings in Step 8 are good.
Page 246: Fault 69: Speed Stall-Crm 5
Fault 69: Speed Stall—CRM 5 Note: When any individual cutting reel motor is shut off due to a fault, the TEC-5002 shuts off the other 4 cutting reel motors. Note: If multiple machine faults are reported within a few seconds, troubleshooting should begin with the first cutting reel motor to report a fault.
Page 247 Raise and support the operator’s seat and the hood. Separate system components from the 48 Vdc battery pack by unplugging the 48 Vdc battery disconnect. Refer to Connecting and Disconnecting the 48 Vdc Battery System (page 19). Check the cutting unit and the cutting reel motor for any mechanical resistance. Refer to Figure 133 to locate cutting unit 5.
Page 248 Step 5: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 249 Step 7: Inspect the wiring for cutting unit 5. Go to Preparing for Troubleshooting and/or Testing (page 22) and follow the steps listed. Unplug the 48 Vdc battery disconnect to prevent unexpected cutting unit operation. Refer to Connecting and Disconnecting the 48 Vdc Battery System (page 19).
Page 250 Wire Expected Location Harness Connector Connector Graphic Color Reading Black Main (48V Ground) Less than 2 ohms Black Main (48V Ground) Main White 24k to 26k ohms Black Main (48V Ground) Pass The resistance tests passed, but the voltage readings in Step 8 are still bad. Note: Do not go to Step 10 until after the voltage readings in Step 8 are good.
Page 251: Fault 70: High Temp Warning-Crm 1
Fault 70: High Temp Warning—CRM 1 Note: When any individual cutting reel motor is shut off due to a fault, the TEC-5002 shuts off the other 4 cutting reel motors. Note: If multiple machine faults are reported within a few seconds, troubleshooting should begin with the first cutting reel motor to report a fault.
Page 252 g032972 Figure 134 1. Cutting unit 1, which includes cutting reel motor 1 4. Cutting unit 4, which includes cutting reel motor 4 2. Cutting unit 2, which includes cutting reel motor 2 5. Cutting unit 5, which includes cutting reel motor 5 3.
Page 253 Step 5: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 254 The fault moves to the If the fault follows the cutting unit, repair or replace the cutting unit. You can new position. obtain more information on installing and adjusting the cutting unit in the Setup section of the 5010-H Operator's Manual. Go to Preparing for Troubleshooting and/or Testing (page 22) and follow the steps listed.
Page 255 Wire Expected Location Harness Connector Connector Graphic Color Reading Main Less than 2 ohms Main Black Main (48V Ground) Less than 2 ohms Black Main (48V Ground) Main White 24k to 26k ohms Black Main (48V Ground) If one or more of the power and ground wiring tests failed, repair or replace any worn or damaged parts. Go to Returning the Machine to Service (page 22) and follow the steps listed.
Page 256: Fault 71: High Temp Warning-Crm 2
Fault 71: High Temp Warning—CRM 2 Note: When any individual cutting reel motor is shut off due to a fault, the TEC-5002 shuts off the other 4 cutting reel motors. Note: If multiple machine faults are reported within a few seconds, troubleshooting should begin with the first cutting reel motor to report a fault.
Page 257 g032972 Figure 135 1. Cutting unit 1, which includes cutting reel motor 1 4. Cutting unit 4, which includes cutting reel motor 4 2. Cutting unit 2, which includes cutting reel motor 2 5. Cutting unit 5, which includes cutting reel motor 5 3.
Page 258 Step 5: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 259 The fault moves to the If the fault follows the cutting unit, repair or replace the cutting unit. You can new position. obtain more information on installing and adjusting the cutting unit in the Setup section of the 5010-H Operator's Manual. Go to Preparing for Troubleshooting and/or Testing (page 22) and follow the steps listed.
Page 260 Wire Expected Location Harness Connector Connector Graphic Color Reading Main Less than 2 ohms Main Black Main (48V Ground) Less than 2 ohms Black Main (48V Ground) Main White 24k to 26k ohms Black Main (48V Ground) If one or more of the power and ground wiring tests failed, repair or replace any worn or damaged parts. Go to Returning the Machine to Service (page 22) and follow the steps listed.
Page 261: Fault 72: High Temp Warning-Crm 3
Fault 72: High Temp Warning—CRM 3 Note: When any individual cutting reel motor is shut off due to a fault, the TEC-5002 shuts off the other 4 cutting reel motors. Note: If multiple machine faults are reported within a few seconds, troubleshooting should begin with the first cutting reel motor to report a fault.
Page 262 g032972 Figure 136 1. Cutting unit 1, which includes cutting reel motor 1 4. Cutting unit 4, which includes cutting reel motor 4 2. Cutting unit 2, which includes cutting reel motor 2 5. Cutting unit 5, which includes cutting reel motor 5 3.
Page 263 Step 5: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 264 The fault moves to the If the fault follows the cutting unit, repair or replace the cutting unit. You can new position. obtain more information on installing and adjusting the cutting unit in the Setup section of the 5010-H Operator's Manual. Go to Preparing for Troubleshooting and/or Testing (page 22) and follow the steps listed.
Page 265 Wire Expected Location Harness Connector Connector Graphic Color Reading Main Less than 2 ohms Main Black Main (48V Ground) Less than 2 ohms Black Main (48V Ground) Main White 24k to 26k ohms Black Main (48V Ground) If one or more of the power and ground wiring tests failed, repair or replace any worn or damaged parts. Go to Returning the Machine to Service (page 22) and follow the steps listed.
Page 266: Fault 73: High Temp Warning-Crm 4
Fault 73: High Temp Warning—CRM 4 Note: When any individual cutting reel motor is shut off due to a fault, the TEC-5002 shuts off the other 4 cutting reel motors. Note: If multiple machine faults are reported within a few seconds, troubleshooting should begin with the first cutting reel motor to report a fault.
Page 267 g032972 Figure 137 1. Cutting unit 1, which includes cutting reel motor 1 4. Cutting unit 4, which includes cutting reel motor 4 2. Cutting unit 2, which includes cutting reel motor 2 5. Cutting unit 5, which includes cutting reel motor 5 3.
Page 268 Step 5: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 269 If the fault follows the cutting unit, repair or replace the cutting unit. You can The fault moves to the obtain more information on installing and adjusting the cutting unit in the Setup new position. section of the 5010-H Operator's Manual. Go to Preparing for Troubleshooting and/or Testing (page 22) and follow the steps listed.
Page 270 Wire Expected Location Harness Connector Connector Graphic Color Reading Main Less than 2 ohms Main Black Main (48V Ground) Less than 2 ohms Black Main (48V Ground) Main White 24k to 26k ohms Black Main (48V Ground) If one or more of the power and ground wiring tests failed, repair or replace any worn or damaged parts. Go to Returning the Machine to Service (page 22) and follow the steps listed.
Page 271: Fault 74: High Temp Warning-Crm 5
Fault 74: High Temp Warning—CRM 5 Note: When any individual cutting reel motor is shut off due to a fault, the TEC-5002 shuts off the other 4 cutting reel motors. Note: If multiple machine faults are reported within a few seconds, troubleshooting should begin with the first cutting reel motor to report a fault.
Page 272 g032972 Figure 138 1. Cutting unit 1, which includes cutting reel motor 1 4. Cutting unit 4, which includes cutting reel motor 4 2. Cutting unit 2, which includes cutting reel motor 2 5. Cutting unit 5, which includes cutting reel motor 5 3.
Page 273 Step 5: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 274 The fault moves to the If the fault follows the cutting unit, repair or replace the cutting unit. You can new position. obtain more information on installing and adjusting the cutting unit in the Setup section of the 5010-H Operator's Manual. Go to Preparing for Troubleshooting and/or Testing (page 22) and follow the steps listed.
Page 275 Wire Expected Location Harness Connector Connector Graphic Color Reading Main Less than 2 ohms Main Black Main (48V Ground) Less than 2 ohms Black Main (48V Ground) Main White 24k to 26k ohms Black Main (48V Ground) If one or more of the power and ground wiring tests failed, repair or replace any worn or damaged parts. Go to Returning the Machine to Service (page 22) and follow the steps listed.
Page 276: Fault 75: High Temp Warning-M/G
Fault 75: High Temp Warning—M/G InfoCenter Display: _____FAULT #75_____ Warning Fault Description High temperature warning for the motor/generator. Note: When the temperature of the motor/generator rises to the over-temperature range, the controller for the motor generator reduces electrical current in relation to the motor/generator temperature. This could result to a 48V system undervoltage warning or fault.
Page 277 Ensure that the traction pedal is in the N position. EUTRAL Shut off and lower the cutting units. Wait for all of the movement to stop. Engage the parking brake. Move the engine speed switch to the L position and wait for the engine to slow to low idle speed. Open the hood and let the machine cool off to lower motor/generator temperature.
Page 278: Fault 76: 48V Key Switch Undervolt-Crm 1
Fault 76: 48V Key Switch Undervolt—CRM 1 Important: For this fault, the term “key switch” refers to the 48 Vdc logic power circuit, not to the ignition switch. Note: When any individual cutting reel motor is shut off due to a fault, the TEC-5002 shuts off the other 4 cutting reel motors.
Page 279 If more than 1 cutting reel motor is reporting a key switch undervolt fault, the problem is more likely to be with the 48 Vdc system voltage. Perform the Recommended Service Actions for fault 31. Step 3: Inspect the wiring for cutting reel motor 1. Go to Preparing for Troubleshooting and/or Testing (page 22) and follow the steps listed.
Page 280 Cutting Reel Motor, 4-Pin Connector (cont'd.) Pin Number Wire Color White Blue Yellow Green...
Page 281 Cutting Reel Motor, 2-Pin Connector Pin Number Wire Color Black Pass The wiring inspection passed. Go to Step 4. Fail One or more of the inspection checks failed. Repair or replace the worn or damaged parts. Go to Returning the Machine to Service (page 22) and follow the steps listed.
Page 282 Step 7: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page...
Page 283 Use the Toro DIAG software to reprogram the machine in accordance with Toro DIAG User’s Guide. The replacement cutting reel motor is programmed during the reprogramming of the machine. Disconnect the Toro DIAG cable from the machine. Install the access panel onto the outer cover of the control arm.
Page 284: Fault 77: 48V Key Switch Undervolt-Crm 2
Fault 77: 48V Key Switch Undervolt—CRM 2 Important: For this fault, the term “key switch” refers to the 48 Vdc logic power circuit, not to the ignition switch. Note: When any individual cutting reel motor is shut off due to a fault, the TEC-5002 shuts off the other 4 cutting reel motors.
Page 285 If more than 1 cutting reel motor is reporting a key switch undervolt fault, the problem is more likely to be with the 48 Vdc system voltage. Perform the Recommended Service Actions for fault 31. Step 3: Inspect the wiring for cutting reel motor 2. Go to Preparing for Troubleshooting and/or Testing (page 22) and follow the steps listed.
Page 286 Cutting Reel Motor, 4-Pin Connector (cont'd.) Pin Number Wire Color White Blue Yellow Green...
Page 287 Cutting Reel Motor, 2-Pin Connector Pin Number Wire Color Black Pass The wiring inspection passed. Go to Step 4. Fail One or more of the inspection checks failed. Repair or replace the worn or damaged parts. Go to Returning the Machine to Service (page 22) and follow the steps listed.
Page 288 Step 7: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page...
Page 289 Use the Toro DIAG software to reprogram the machine in accordance with Toro DIAG User’s Guide. The replacement cutting reel motor is programmed during the reprogramming of the machine. Disconnect the Toro DIAG cable from the machine. Install the access panel onto the outer cover of the control arm.
Page 290: Fault 78: 48V Key Switch Undervolt-Crm 3
Fault 78: 48V Key Switch Undervolt—CRM 3 Important: For this fault, the term “key switch” refers to the 48 Vdc logic power circuit, not to the ignition switch. Note: When any individual cutting reel motor is shut off due to a fault, the TEC-5002 shuts off the other 4 cutting reel motors.
Page 291 If more than 1 cutting reel motor is reporting a key switch undervolt fault, the problem is more likely to be with the 48 Vdc system voltage. Perform the Recommended Service Actions for fault 31. Step 3: Inspect the wiring for cutting reel motor 3. Go to Preparing for Troubleshooting and/or Testing (page 22) and follow the steps listed.
Page 292 Cutting Reel Motor, 4-Pin Connector (cont'd.) Pin Number Wire Color White Blue Yellow Green...
Page 293 Cutting Reel Motor, 2-Pin Connector Pin Number Wire Color Black Pass The wiring inspection passed. Go to Step 4. Fail One or more of the inspection checks failed. Repair or replace the worn or damaged parts. Go to Returning the Machine to Service (page 22) and follow the steps listed.
Page 294 Step 7: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page...
Page 295 Use the Toro DIAG software to reprogram the machine in accordance with Toro DIAG User’s Guide. The replacement cutting reel motor is programmed during the reprogramming of the machine. Disconnect the Toro DIAG cable from the machine. Install the access panel onto the outer cover of the control arm.
Page 296: Fault 79: 48V Key Switch Undervolt-Crm 4
Fault 79: 48V Key Switch Undervolt—CRM 4 Important: For this fault, the term “key switch” refers to the 48 Vdc logic power circuit, not to the ignition switch. Note: When any individual cutting reel motor is shut off due to a fault, the TEC-5002 shuts off the other 4 cutting reel motors.
Page 297 If more than 1 cutting reel motor is reporting a key switch undervolt fault, the problem is more likely to be with the 48 Vdc system voltage. Perform the Recommended Service Actions for fault 31. Step 3: Inspect the wiring for cutting reel motor 4. Go to Preparing for Troubleshooting and/or Testing (page 22) and follow the steps listed.
Page 298 Cutting Reel Motor, 4-Pin Connector (cont'd.) Pin Number Wire Color White Blue Yellow Green...
Page 299 Cutting Reel Motor, 2-Pin Connector Pin Number Wire Color Black Pass The wiring inspection passed. Go to Step 4. Fail One or more of the inspection checks failed. Repair or replace the worn or damaged parts. Go to Returning the Machine to Service (page 22) and follow the steps listed.
Page 300 Step 7: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page...
Page 301 Use the Toro DIAG software to reprogram the machine in accordance with Toro DIAG User’s Guide. The replacement cutting reel motor is programmed during the reprogramming of the machine. Disconnect the Toro DIAG cable from the machine. Install the access panel onto the outer cover of the control arm.
Page 302: Fault 80: 48V Key Switch Undervolt-Crm 5
Fault 80: 48V Key Switch Undervolt—CRM 5 Important: For this fault, the term “key switch” refers to the 48 Vdc logic power circuit, not to the ignition switch. Note: When any individual cutting reel motor is shut off due to a fault, the TEC-5002 shuts off the other 4 cutting reel motors.
Page 303 If more than 1 cutting reel motor is reporting a key switch undervolt fault, the problem is more likely to be with the 48 Vdc system voltage. Perform the Recommended Service Actions for fault 31. Step 3: Inspect the wiring for cutting reel motor 5. Go to Preparing for Troubleshooting and/or Testing (page 22) and follow the steps listed.
Page 304 Cutting Reel Motor, 4-Pin Connector (cont'd.) Pin Number Wire Color White Blue Yellow Green...
Page 305 Cutting Reel Motor, 2-Pin Connector Pin Number Wire Color Black Pass The wiring inspection passed. Go to Step 4. Fail One or more of the inspection checks failed. Repair or replace the worn or damaged parts. Go to Returning the Machine to Service (page 22) and follow the steps listed.
Page 306 Step 7: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page...
Page 307 Use the Toro DIAG software to reprogram the machine in accordance with Toro DIAG User’s Guide. The replacement cutting reel motor is programmed during the reprogramming of the machine. Disconnect the Toro DIAG cable from the machine. Install the access panel onto the outer cover of the control arm.
Page 308: Fault 81: 48V Key Switch Undervolt-M/G
Fault 81: 48V Key Switch Undervolt—M/G Important: For this fault, the term “key switch” refers to the 48 Vdc logic power circuit, not to the ignition switch. InfoCenter Display: _____FAULT #81_____ Fault Description A key switch under voltage fault is reported when the motor/generator controller measures that the 48 Vdc logic voltage is less than 36 Vdc.
Page 309 Wire Expected Location Harness Connector Connector Graphic Color Reading Main Less than 2 ohms Main Black Main (48V Ground) Less than 2 ohms Black Main (48V Ground) Main White 24k to 26k ohms Black Main (48V Ground) Pass The power and ground wiring tests passed. Go to Step 4. Fail One or more of the power and ground wiring tests failed.
Page 310 g035727 Figure 144 1. 48V disconnect 3. Main contactor 2. Operator’s seat Use a multimeter to measure the voltage of the 48V battery pack across the main contactor. The reading should be 46 to 54 Vdc (Figure 145). g036085 Figure 145 If the voltage reads low, remove cutting unit 1 and both of the battery covers (Figure 146).
Page 311 g036201 Figure 146 1. Battery covers 3. Battery cables 2. 12 Vdc AGM batteries (4) The individual readings should be 11.5 to 13.5 Vdc. Inspect the following cables for damage, corrosion, and proper installation Figure 146. • The cables between the 4 individual batteries •...
Page 312 Step 11: Use Toro DIAG to program the motor/generator. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 313: Fault 82: 48V Key Switch Overvolt-Crm 1
Fault 82: 48V Key Switch Overvolt—CRM 1 Important: For this fault, the term “key switch” refers to the 48 Vdc logic power circuit, not to the ignition switch. Note: When any individual cutting reel motor is shut off due to a fault, the TEC-5002 shuts off the other 4 cutting reel motors.
Page 314 Step 4: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 315 Step 6: Measure 48 Vdc power in main harness connectors P46 and P47. Note: Connector diagrams are available in Step 7. Verify that the engine is shut off. Disconnect main harness connectors P46 and P47 from the cutting reel motor cable connectors. Rotate the ignition key to the O position.
Page 316 Wire Expected Location Harness Connector Connector Graphic Color Reading Main White 24k to 26k ohms Black Main (48V Ground) If one or more of the power and ground wiring tests failed, repair or replace any worn or damaged parts. Go to Returning the Machine to Service (page 22) and follow the steps listed.
Page 317: Fault 83: 48V Key Switch Overvolt-Crm 2
Fault 83: 48V Key Switch Overvolt—CRM 2 Important: For this fault, the term “key switch” refers to the 48 Vdc logic power circuit, not to the ignition switch. Note: When any individual cutting reel motor is shut off due to a fault, the TEC-5002 shuts off the other 4 cutting reel motors.
Page 318 Step 4: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 319 Step 6: Measure 48 Vdc power in main harness connectors P38 and P39. Note: Connector diagrams are available in Step 7. Verify that the engine is shut off. Disconnect main harness connectors P38 and P39 from the cutting reel motor cable connectors. Rotate the ignition key to the O position.
Page 320 Wire Expected Location Harness Connector Connector Graphic Color Reading Main White 24k to 26k ohms Black Main (48V Ground) If one or more of the power and ground wiring tests failed, repair or replace any worn or damaged parts. Go to Returning the Machine to Service (page 22) and follow the steps listed.
Page 321: Fault 84: 48V Key Switch Overvolt-Crm 3
Fault 84: 48V Key Switch Overvolt—CRM 3 Important: For this fault, the term “key switch” refers to the 48 Vdc logic power circuit, not to the ignition switch. Note: When any individual cutting reel motor is shut off due to a fault, the TEC-5002 shuts off the other 4 cutting reel motors.
Page 322 Step 4: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 323 Step 6: Measure 48 Vdc power in main harness connectors P40 and P41. Note: Connector diagrams are available in Step 7. Verify that the engine is shut off. Disconnect main harness connectors P40 and P41 from the cutting reel motor cable connectors. Rotate the ignition key to the O position.
Page 324 Wire Expected Location Harness Connector Connector Graphic Color Reading Main White 24k to 26k ohms Black Main (48V Ground) If one or more of the power and ground wiring tests failed, repair or replace any worn or damaged parts. Go to Returning the Machine to Service (page 22) and follow the steps listed.
Page 325: Fault 85: 48V Key Switch Overvolt-Crm 4
Fault 85: 48V Key Switch Overvolt—CRM 4 Important: For this fault, the term “key switch” refers to the 48 Vdc logic power circuit, not to the ignition switch. Note: When any individual cutting reel motor is shut off due to a fault, the TEC-5002 shuts off the other 4 cutting reel motors.
Page 326 Step 4: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 327 Step 6: Measure 48 Vdc power in main harness connectors P48 and P49. Note: Connector diagrams are available in Step 7. Verify that the engine is shut off. Disconnect main harness connectors P48 and P49 from the cutting reel motor cable connectors. Rotate the ignition key to the O position.
Page 328 Wire Expected Location Harness Connector Connector Graphic Color Reading Main White 24k to 26k ohms Black Main (48V Ground) If one or more of the power and ground wiring tests failed, repair or replace any worn or damaged parts. Go to Returning the Machine to Service (page 22) and follow the steps listed.
Page 329: Fault 86: 48V Key Switch Overvolt-Crm 5
Fault 86: 48V Key Switch Overvolt—CRM 5 Important: For this fault, the term “key switch” refers to the 48 Vdc logic power circuit, not to the ignition switch. Note: When any individual cutting reel motor is shut off due to a fault, the TEC-5002 shuts off the other 4 cutting reel motors.
Page 330 Step 4: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 331 Step 6: Measure 48 Vdc power in main harness connectors P44 and P45. Note: Connector diagrams are available in Step 7. Verify that the engine is shut off. Disconnect main harness connectors P44 and P45 from the cutting reel motor cable connectors. Rotate the ignition key to the O position.
Page 332 Wire Expected Location Harness Connector Connector Graphic Color Reading Main White 24k to 26k ohms Black Main (48V Ground) If one or more of the power and ground wiring tests failed, repair or replace any worn or damaged parts. Go to Returning the Machine to Service (page 22) and follow the steps listed.
Page 333: Fault 87: 48V Key Switch Overvolt-M/G
Fault 87: 48V Key Switch Overvolt—M/G Important: For this fault, the term “key switch” refers to the 48 Vdc logic power circuit, not to the ignition switch. InfoCenter Display: _____FAULT #87_____ Fault Description The motor/generator (M/G) controller has detected that the logic voltage has exceeded the high voltage limit. Circuit Description The M/G shares the 48 Vdc logic power with all 5 cutting reel motors.
Page 334 g035727 Figure 147 1. 48V disconnect 3. Main contactor 2. Operator’s seat Use a multimeter to measure the voltage of the 48 Vdc battery pack across the main contactor (Figure 148.) The reading should be 46 to 54 Vdc. g036085 Figure 148 If the voltage reads low, remove cutting unit 1 and both of the battery covers.
Page 335 g036201 Figure 149 1. Battery covers 3. Battery cables 2. 12 Vdc AGM batteries (4) The readings should be 11.5 to 13.5 Vdc. Inspect the following cables for damage, corrosion, and proper installation (Figure 149). • The cables between the 4 individual batteries •...
Page 336 Step 10: Use Toro DIAG to program the motor/generator. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 337: Fault 88: 48V Bus Undervolt-Crm 1
Fault 88: 48V Bus Undervolt—CRM 1 Note: When any individual cutting reel motor is shut off due to a fault, the TEC-5002 shuts off the other 4 cutting reel motors. Note: If multiple machine faults are reported within a few seconds, troubleshooting should begin with the first cutting reel motor to report a fault.
Page 338 Unplug the 48 Vdc battery disconnect to prevent unexpected cutting unit operation. Refer to Connecting and Disconnecting the 48 Vdc Battery System (page 19). Locate and remove fuse F2-1 (35 amp) for testing. Measure the resistance of the fuse. The reading should be 1 ohm or less. Pass The fuse tested good.
Page 339 Cutting Reel Motor, 4-Pin Connector (cont'd.) Pin Number Wire Color White Blue Yellow Green Cutting Reel Motor, 2-Pin Connector Pin Number Wire Color Black Pass The wiring inspection passed. Go to Step 4. Fail One or more of the inspection checks failed. Repair or replace the worn or damaged parts. Go to Returning the Machine to Service (page 22) and follow the steps listed.
Page 340 Wire Expected Location Harness Connector Connector Graphic Color Reading Main Less than 2 ohms Main Black Main (48V Ground) Less than 2 ohms Black Main (48V Ground) Main White 24k to 26k ohms Black Main (48V Ground) Pass The resistance tests passed, but the voltage readings in Step 4 are still bad. Note: Do not go to Step 6 until after the voltage readings in Step 4 are good.
Page 341 Step 7: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 342: Fault 89: 48V Bus Undervolt-Crm 2
Fault 89: 48V Bus Undervolt—CRM 2 Note: When any individual cutting reel motor is shut off due to a fault, the TEC-5002 shuts off the other 4 cutting reel motors. Note: If multiple machine faults are reported within a few seconds, troubleshooting should begin with the first cutting reel motor to report a fault.
Page 343 Unplug the 48 Vdc battery disconnect to prevent unexpected cutting unit operation. Refer to Connecting and Disconnecting the 48 Vdc Battery System (page 19). Locate and remove fuse F2-2 (35 amp) for testing. Measure the resistance of the fuse. The reading should be 1 ohm or less. Pass The fuse tested good.
Page 344 Cutting Reel Motor, 4-Pin Connector (cont'd.) Pin Number Wire Color White Blue Yellow Green Cutting Reel Motor, 2-Pin Connector Pin Number Wire Color Black Pass The wiring inspection passed. Go to Step 4. Fail One or more of the inspection checks failed. Repair or replace the worn or damaged parts. Go to Returning the Machine to Service (page 22) and follow the steps listed.
Page 345 Wire Expected Location Harness Connector Connector Graphic Color Reading Main Less than 2 ohms Main Black Main (48V Ground) Less than 2 ohms Black Main (48V Ground) Main White 24k to 26k ohms Black Main (48V Ground) Pass The resistance tests passed, but the voltage readings in Step 4 are still bad. Note: Do not go to Step 6 until after the voltage readings in Step 4 are good.
Page 346 Step 7: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 347: Fault 90: 48V Bus Undervolt-Crm 3
Fault 90: 48V Bus Undervolt—CRM 3 Note: When any individual cutting reel motor is shut off due to a fault, the TEC-5002 shuts off the other 4 cutting reel motors. Note: If multiple machine faults are reported within a few seconds, troubleshooting should begin with the first cutting reel motor to report a fault.
Page 348 Unplug the 48 Vdc battery disconnect to prevent unexpected cutting unit operation. Refer to Connecting and Disconnecting the 48 Vdc Battery System (page 19). Locate and remove fuse F2-3 (35 amp) for testing. Measure the resistance of the fuse. The reading should be 1 ohm or less. Pass The fuse tested good.
Page 349 Cutting Reel Motor, 4-Pin Connector (cont'd.) Pin Number Wire Color White Blue Yellow Green Cutting Reel Motor, 2-Pin Connector Pin Number Wire Color Black Pass The wiring inspection passed. Go to Step 4. Fail One or more of the inspection checks failed. Repair or replace the worn or damaged parts. Go to Returning the Machine to Service (page 22) and follow the steps listed.
Page 350 Wire Expected Location Harness Connector Connector Graphic Color Reading Main Less than 2 ohms Main Black Main (48V Ground) Less than 2 ohms Black Main (48V Ground) Main White 24k to 26k ohms Black Main (48V Ground) Pass The resistance tests passed, but the voltage readings in Step 4 are still bad. Note: Do not go to Step 6 until after the voltage readings in Step 4 are good.
Page 351 Step 7: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 352: Fault 91: 48V Bus Undervolt-Crm 4
Fault 91: 48V Bus Undervolt—CRM 4 Important: When any individual cutting reel motor is shut off due to a fault, the TEC-5002 shuts off the other 4 cutting reel motors. This may result in multiple machine faults being reported within a few seconds.
Page 353 Locate and remove fuse F2-4 (35 amp) for testing. Measure the resistance of the fuse. The reading should be 1 ohm or less. Pass The fuse tested good. Install fuse F2-4. Go to Step 3. Fail The fuse failed the test. Replace the fuse. Go to Returning the Machine to Service (page 22) follow the steps listed.
Page 354 Cutting Reel Motor, 4-Pin Connector (cont'd.) Pin Number Wire Color White Blue Yellow Green Cutting Reel Motor, 2-Pin Connector Pin Number Wire Color Black Pass The wiring inspection passed. Go to Step 4. Fail One or more of the inspection checks failed. Repair or replace the worn or damaged parts. Go to Returning the Machine to Service (page 22) and follow the steps listed.
Page 355 Wire Expected Location Harness Connector Connector Graphic Color Reading Main Less than 2 ohms Main Black Main (48V Ground) Less than 2 ohms Black Main (48V Ground) Main White 24k to 26k ohms Black Main (48V Ground) Pass The resistance tests passed, but the voltage readings in Step 4 are still bad. Note: Do not go to Step 6 until after the voltage readings in Step 4 are good.
Page 356 Step 7: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 357: Fault 92: 48V Bus Undervolt-Crm 5
Fault 92: 48V Bus Undervolt—CRM 5 Important: When any individual cutting reel motor is shut off due to a fault, the TEC-5002 shuts off the other 4 cutting reel motors. This may result in multiple machine faults being reported within a few seconds.
Page 358 Locate and remove fuse F2-5 (35 amp) for testing. Measure the resistance of the fuse. The reading should be 1 ohm or less. Pass The fuse tested good. Install fuse F2-5. Go to Step 3. Fail The fuse failed the test. Replace the fuse. Go to Returning the Machine to Service (page 22) follow the steps listed.
Page 359 Cutting Reel Motor, 4-Pin Connector (cont'd.) Pin Number Wire Color White Blue Yellow Green Cutting Reel Motor, 2-Pin Connector Pin Number Wire Color Black Pass The wiring inspection passed. Go to Step 4. Fail One or more of the inspection checks failed. Repair or replace the worn or damaged parts. Go to Returning the Machine to Service (page 22) and follow the steps listed.
Page 360 Wire Expected Location Harness Connector Connector Graphic Color Reading Main Less than 2 ohms Main Black Main (48V Ground) Less than 2 ohms Black Main (48V Ground) Main White 24k to 26k ohms Black Main (48V Ground) Pass The resistance tests passed, but the voltage readings in Step 4 are still bad. Note: Do not go to Step 6 until after the voltage readings in Step 4 are good.
Page 361 Step 7: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 362: Fault 93: 48V Bus Undervolt-M/G
Fault 93: 48V Bus Undervolt—M/G InfoCenter Display: _____FAULT #93_____ Fault Description The motor/generator controller has detected that the 48 Vdc bus dropped below the low voltage limit. Circuit Description The motor/generator supplies the 48 Vdc bus power to the 48 Vdc battery pack. Conditions for Setting the Fault When the M/G controller detects that the 48 Vdc bus has dropped below the low voltage limit of 36 Vdc, the M/G controller disables its motor.
Page 363 g035727 Figure 155 1. 48V disconnect 3. Main contactor 2. Operator’s seat Refer to Chapter 5 of the 5010-H Service Manual and test the main contactor. g033200 Figure 156 1. 48V battery disconnect 4. Main 48 Vdc contactor 2. 250A/58V fuse 5.
Page 364 Pass The main contactor tested good. Go to Step 4. Fail The main contactor did not test good. Replace the main contactor. Refer to Chapter 5 of the 5010-H Service Manual. Go to Returning the Machine to Service (page 22) and follow the steps listed.
Page 365 g036085 Figure 157 Turn the ignition key to the O position. Pass The reading is approximately 0 Vdc. Go to Step 6. Fail The reading is more than 0 Vdc. Replace the contactor. Go to Returning the Machine to Service (page 22) and follow the steps listed.
Page 366: Fault 94: 48V Bus Overvolt-Crm 1
Fault 94: 48V Bus Overvolt—CRM 1 Note: When any individual cutting reel motor is shut off due to a fault, the TEC-5002 shuts off the other 4 cutting reel motors. Note: If multiple machine faults are reported within a few seconds, troubleshooting should begin with the first cutting reel motor to report a fault.
Page 367 Step 4: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 368 Rotate the ignition key to the O position. Measure the voltage between pins 1 and 2 of connector P47. The reading should be 48 Vdc. Measure the voltage between P46 pin 1 and P47 pin 2. The reading should be 48 Vdc. Rotate the ignition key to the O position.
Page 369 Component Location and Electrical Connections Cutting reel motor 1 is located in the front, center position. There are 2 electrical connections to the cutting reel motor: P46 (4 wire) and P47 (2 wire). The motor/generator is connected to the forward-facing surface of the engine, and is driven by the crankshaft of the engine.
Page 370: Fault 95: 48V Bus Overvolt-Crm 2
Fault 95: 48V Bus Overvolt—CRM 2 Note: When any individual cutting reel motor is shut off due to a fault, the TEC-5002 shuts off the other 4 cutting reel motors. Note: If multiple machine faults are reported within a few seconds, troubleshooting should begin with the first cutting reel motor to report a fault.
Page 371 Step 4: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 372 Rotate the ignition key to the O position. Measure the voltage between pins 1 and 2 of connector P39. The reading should be 48 Vdc. Measure the voltage between P38 pin 1 and P39 pin 2. The reading should be 48 Vdc. Rotate the ignition key to the O position.
Page 373 Component Location and Electrical Connections Cutting reel motor 2 is located in the rear, left position. There are 2 electrical connections to the cutting reel motor: P38 (4 wire) and P39 (2 wire).
Page 374: Fault 96: 48V Bus Overvolt-Crm 3
Fault 96: 48V Bus Overvolt—CRM 3 Note: When any individual cutting reel motor is shut off due to a fault, the TEC-5002 shuts off the other 4 cutting reel motors. Note: If multiple machine faults are reported within a few seconds, troubleshooting should begin with the first cutting reel motor to report a fault.
Page 375 Step 4: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 376 Rotate the ignition key to the O position. Measure the voltage between pins 1 and 2 of connector P41. The reading should be 48 Vdc. Measure the voltage between P40 pin 1 and P41 pin 2. The reading should be 48 Vdc. Rotate the ignition key to the O position.
Page 377 Component Location and Electrical Connections Cutting reel motor 3 is located in the rear, right position. There are 2 electrical connections to the cutting reel motor: P40 (4 wire) and P41 (2 wire).
Page 378: Fault 97: 48V Bus Overvolt-Crm 4
Fault 97: 48V Bus Overvolt—CRM 4 Note: When any individual cutting reel motor is shut off due to a fault, the TEC-5002 shuts off the other 4 cutting reel motors. Note: If multiple machine faults are reported within a few seconds, troubleshooting should begin with the first cutting reel motor to report a fault.
Page 379 Step 4: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 380 Rotate the ignition key to the O position. Measure the voltage between pins 1 and 2 of connector P49. The reading should be 48 Vdc. Measure the voltage between P48 pin 1 and P49 pin 2. The reading should be 48 Vdc. Rotate the ignition key to the O position.
Page 381 Component Location and Electrical Connections Cutting reel motor 4 is located in the front, left position. There are 2 electrical connections to the cutting reel motor: P48 (4 wire) and P49 (2 wire).
Page 382: Fault 98: 48V Bus Overvolt-Crm 5
Fault 98: 48V Bus Overvolt—CRM 5 Note: When any individual cutting reel motor is shut off due to a fault, the TEC-5002 shuts off the other 4 cutting reel motors. Note: If multiple machine faults are reported within a few seconds, troubleshooting should begin with the first cutting reel motor to report a fault.
Page 383 Step 4: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 384 Rotate the ignition key to the O position. Measure the voltage between pins 1 and 2 of connector P45. The reading should be 48 Vdc. Measure the voltage between P44 pin 1 and P45 pin 2. The reading should be 48 Vdc. Rotate the ignition key to the O position.
Page 385 Component Location and Electrical Connections Cutting reel motor 5 is located in the front, right position. There are 2 electrical connections to the cutting reel motor: P44 (4 wire) and P45 (2 wire).
Page 386: Fault 99: 48V Bus Overvolt-M/G
Fault 99: 48V Bus Overvolt—M/G InfoCenter Display: _____FAULT #99_____ Fault Description System bus voltage over 65 Vdc has disabled the generator. A Bus Overvolt indicates the 48 Vdc bus circuit has exceeded an over-voltage set point (65 Vdc).This fault causes the motor to disable. Circuit Description The motor/generator controller monitors the 48V bus voltage.
Page 387 g035727 Figure 158 1. 48V disconnect 3. Main contactor 2. Operator’s seat Use a multimeter to measure the voltage of the 48 Vdc battery pack across the main contactor (Figure 159.) The acceptable voltage range is 46 to 54 Vdc. g036085 Figure 159 If the voltage reads low, remove cutting unit 1 and both of the battery covers.
Page 388 g036201 Figure 160 1. Battery covers 3. Battery cables 2. 12 Vdc AGM batteries (4) The readings should be 11.5 to 13.5 Vdc. Inspect the following cables for damage, corrosion, and proper installation (Figure 160). • The cables between the 4 individual batteries •...
Page 389 Step 10: Use Toro DIAG to program the motor/generator. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 390: Fault 100: Over Current Disable-Crm 1
Fault 100: Over Current Disable—CRM 1 Note: When any individual cutting reel motor is shut off due to a fault, the TEC-5002 shuts off the other 4 cutting reel motors. Note: If multiple machine faults are reported within a few seconds, troubleshooting should begin with the first cutting reel motor to report a fault.
Page 391 Step 3: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 392 Step 6: Test the power and ground wiring in main harness connectors P46 and P47. These are diagnostic steps to help isolate problems identified in Step 5. Use a multimeter to test the resistance between the following pairs of locations: Wire Expected Location...
Page 393: Fault 101: Over Current Disable-Crm 2
Fault 101: Over Current Disable—CRM 2 Note: When any individual cutting reel motor is shut off due to a fault, the TEC-5002 shuts off the other 4 cutting reel motors. Note: If multiple machine faults are reported within a few seconds, troubleshooting should begin with the first cutting reel motor to report a fault.
Page 394 Step 3: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 395 Step 6: Test the power and ground wiring in main harness connectors P38 and P39. These are diagnostic steps to help isolate problems identified in Step 5. Use a multimeter to test the resistance between the following pairs of locations: Wire Expected Location...
Page 396: Fault 102: Over Current Disable-Crm 3
Fault 102: Over Current Disable—CRM 3 Note: When any individual cutting reel motor is shut off due to a fault, the TEC-5002 shuts off the other 4 cutting reel motors. Note: If multiple machine faults are reported within a few seconds, troubleshooting should begin with the first cutting reel motor to report a fault.
Page 397 Step 3: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 398 Step 6: Test the power and ground wiring in main harness connectors P40 and P41. These are diagnostic steps to help isolate problems identified in Step 5. Use a multimeter to test the resistance between the following pairs of locations: Wire Expected Location...
Page 399: Fault 103: Over Current Disable-Crm 4
Fault 103: Over Current Disable—CRM 4 Note: When any individual cutting reel motor is shut off due to a fault, the TEC-5002 shuts off the other 4 cutting reel motors. Note: If multiple machine faults are reported within a few seconds, troubleshooting should begin with the first cutting reel motor to report a fault.
Page 400 Step 3: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 401 Step 6: Test the power and ground wiring in main harness connectors P48 and P49. These are diagnostic steps to help isolate problems identified in Step 5. Use a multimeter to test the resistance between the following pairs of locations: Wire Expected Location...
Page 402: Fault 104: Over Current Disable-Crm 5
Fault 104: Over Current Disable—CRM 5 Note: When any individual cutting reel motor is shut off due to a fault, the TEC-5002 shuts off the other 4 cutting reel motors. Note: If multiple machine faults are reported within a few seconds, troubleshooting should begin with the first cutting reel motor to report a fault.
Page 403 Step 3: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 404 Step 6: Test the power and ground wiring in main harness connectors P44 and P45. These are diagnostic steps to help isolate problems identified in Step 5. Use a multimeter to test the resistance between the following pairs of locations: Wire Expected Location...
Page 405: Fault 111: Internal Regulator Overvolt-M/G
Fault 111: Internal Regulator Overvolt—M/G InfoCenter Display: _____FAULT #111_____ Int. Reg. Fault Description Excessive voltage occurred at the motor/generator’s 15 Vdc internal regulator, and disabled the motor/generator. Circuit Description The motor/generator is attached to the engine and provides power for the 48 Vdc system. It has its own independent controller to regulate power generation levels.
Page 406 Step 7: Use Toro DIAG to program the motor/generator. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 407: Fault 112: Internal Regulator Undervolt-Crm 1
Fault 112: Internal Regulator Undervolt—CRM 1 Note: When any individual cutting reel motor is shut off due to a fault, the TEC-5002 shuts off the other 4 cutting reel motors. Note: If multiple machine faults are reported within a few seconds, troubleshooting should begin with the first cutting reel motor to report a fault.
Page 408 g032972 Figure 161 1. Cutting unit 1, which includes cutting reel motor 1 4. Cutting unit 4, which includes cutting reel motor 4 2. Cutting unit 2, which includes cutting reel motor 2 5. Cutting unit 5, which includes cutting reel motor 5 3.
Page 409 Step 4: Test the power and ground wiring in main harness connectors P46 and P47. These are diagnostic steps to help isolate problems identified in Step 3. Use a multimeter to test the resistance between the following pairs of locations: Wire Expected Location...
Page 410 Step 6: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 411: Fault 113: Internal Regulator Undervolt-Crm 2
Fault 113: Internal Regulator Undervolt—CRM 2 Note: When any individual cutting reel motor is shut off due to a fault, the TEC-5002 shuts off the other 4 cutting reel motors. Note: If multiple machine faults are reported within a few seconds, troubleshooting should begin with the first cutting reel motor to report a fault.
Page 412 g032972 Figure 162 1. Cutting unit 1, which includes cutting reel motor 1 4. Cutting unit 4, which includes cutting reel motor 4 2. Cutting unit 2, which includes cutting reel motor 2 5. Cutting unit 5, which includes cutting reel motor 5 3.
Page 413 Step 4: Test the power and ground wiring in main harness connectors P38 and P39. These are diagnostic steps to help isolate problems identified in Step 3. Use a multimeter to test the resistance between the following pairs of locations: Wire Expected Location...
Page 414 Step 6: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 415: Fault 114: Internal Regulator Undervolt-Crm 3
Fault 114: Internal Regulator Undervolt—CRM 3 Note: When any individual cutting reel motor is shut off due to a fault, the TEC-5002 shuts off the other 4 cutting reel motors. Note: If multiple machine faults are reported within a few seconds, troubleshooting should begin with the first cutting reel motor to report a fault.
Page 416 g032972 Figure 163 1. Cutting unit 1, which includes cutting reel motor 1 4. Cutting unit 4, which includes cutting reel motor 4 2. Cutting unit 2, which includes cutting reel motor 2 5. Cutting unit 5, which includes cutting reel motor 5 3.
Page 417 Step 4: Test the power and ground wiring in main harness connectors P40 and P41. These are diagnostic steps to help isolate problems identified in Step 3. Use a multimeter to test the resistance between the following pairs of locations: Wire Expected Location...
Page 418 Step 6: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 419: Fault 115: Internal Regulator Undervolt-Crm 4
Fault 115: Internal Regulator Undervolt—CRM 4 Note: When any individual cutting reel motor is shut off due to a fault, the TEC-5002 shuts off the other 4 cutting reel motors. Note: If multiple machine faults are reported within a few seconds, troubleshooting should begin with the first cutting reel motor to report a fault.
Page 420 g032972 Figure 164 1. Cutting unit 1, which includes cutting reel motor 1 4. Cutting unit 4, which includes cutting reel motor 4 2. Cutting unit 2, which includes cutting reel motor 2 5. Cutting unit 5, which includes cutting reel motor 5 3.
Page 421 Step 4: Test the power and ground wiring in main harness connectors P48 and P49. These are diagnostic steps to help isolate problems identified in Step 3. Use a multimeter to test the resistance between the following pairs of locations: Wire Expected Location...
Page 422 Step 6: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 423: Fault 116: Internal Regulator Undervolt-Crm 5
Fault 116: Internal Regulator Undervolt—CRM 5 Note: When any individual cutting reel motor is shut off due to a fault, the TEC-5002 shuts off the other 4 cutting reel motors. Note: If multiple machine faults are reported within a few seconds, troubleshooting should begin with the first cutting reel motor to report a fault.
Page 424 g032972 Figure 165 1. Cutting unit 1, which includes cutting reel motor 1 4. Cutting unit 4, which includes cutting reel motor 4 2. Cutting unit 2, which includes cutting reel motor 2 5. Cutting unit 5, which includes cutting reel motor 5 3.
Page 425 Step 4: Test the power and ground wiring in main harness connectors P44 and P45. These are diagnostic steps to help isolate problems identified in Step 3. Use a multimeter to test the resistance between the following pairs of locations: Wire Expected Location...
Page 426 Step 6: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 427: Fault 117: Internal Regulator Undervolt-M/G
Fault 117: Internal Regulator Undervolt—M/G InfoCenter Display: _____FAULT #117_____ Int. Reg. Fault Description Insufficient voltage occurred at the internal voltage regulator and disabled the generator. The 15V undervoltage fault is reported when the component measures a 15V system voltage under an undervoltage set point. This fault causes the motor to be disabled.
Page 428 Pass The main harness integrity checks were good. Attach connector P37 to the motor/generator. Go to Step 3. Fail The main harness connector inspection failed. Repair or replace the worn or damaged parts. Go to Returning the Machine to Service (page 22) and follow the steps listed.
Page 429 Step 8: Use Toro DIAG to program the motor/generator. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 430: Fault 123: Motor Over Speed-M/G
Fault 123: Motor Over Speed—M/G InfoCenter Display: _____FAULT #123_____ Speed Fault Description The measured speed of the motor/generator has exceeded 3,600 rpm. Circuit Description Motor/generator rpm is limited by the electronic control of the fuel actuator and the engine mechanical governor. This fault is reported when both of those rpm limiting systems have failed, and the motor/generator is allowed to rotate at more than 3,600 rpm.
Page 431 Wire Expected Location Harness Connector Connector Graphic Color Reading Main Yellow Open (infinite) Chassis ground Main Green Open (infinite) Chassis ground Pass The CAN bus wiring tests passed. Go to Step 3. Fail One or more of the CAN bus wiring tests failed. Repair or replace the worn or damaged parts. Go to Returning the Machine to Service (page 22) and follow the steps listed.
Page 432 Step 8: Use Toro DIAG to program the motor/generator. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 433: Fault 124: Invalid Hall State-Crm 1
Fault 124: Invalid Hall State—CRM 1 InfoCenter Display: _____FAULT #124_____ Hall State Fault Description The invalid Hall state fault indicates that the Hall effect sensors in the cutting reel motor are providing an invalid motor speed reading. When a sensor fails, the cutting reel motor cannot maintain steady speed and becomes unstable.
Page 434 Step 3: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 435: Fault 125: Invalid Hall State-Crm 2
Fault 125: Invalid Hall State—CRM 2 InfoCenter Display: _____FAULT #125_____ Hall State Fault Description The invalid Hall state fault indicates that the Hall effect sensors in the cutting reel motor are providing an invalid motor speed reading. When a sensor fails, the cutting reel motor cannot maintain steady speed and becomes unstable.
Page 436 Step 3: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 437: Fault 126: Invalid Hall State-Crm 3
Fault 126: Invalid Hall State—CRM 3 InfoCenter Display: _____FAULT #126_____ Hall State Fault Description The invalid Hall state fault indicates that the Hall effect sensors in the cutting reel motor are providing an invalid motor speed reading. When a sensor fails, the cutting reel motor cannot maintain steady speed and becomes unstable.
Page 438 Step 3: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 439: Fault 127: Invalid Hall State-Crm 4
Fault 127: Invalid Hall State—CRM 4 InfoCenter Display: _____FAULT #127_____ Hall State Fault Description The invalid Hall state fault indicates that the Hall effect sensors in the cutting reel motor are providing an invalid motor speed reading. When a sensor fails, the cutting reel motor cannot maintain steady speed and becomes unstable.
Page 440 Step 3: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 441: Fault 128: Invalid Hall State-Crm 5
Fault 128: Invalid Hall State—CRM 5 InfoCenter Display: _____FAULT #128_____ Hall State Fault Description The invalid Hall state fault indicates that the Hall effect sensors in the cutting reel motor are providing an invalid motor speed reading. When a sensor fails, the cutting reel motor cannot maintain steady speed and becomes unstable.
Page 442 Step 3: Use Toro DIAG to program the replacement cutting reel motor. Remove the access panel from the outer cover of the control arm. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG - Quick Start (page 24).
Page 443: Fault 129: Invalid Hall State-M/G
Fault 129: Invalid Hall State—M/G InfoCenter Display: _____FAULT #129_____ Hall State Fault Description The invalid Hall state fault indicates that the Hall effect sensors in the cutting reel motor are providing an invalid motor speed reading. Since the motor/generator reports the engine speed to the TEC-5002, the engine becomes unstable and unable to maintain the desired speed.
Page 444 Step 2: Remove the motor/generator assembly from the machine. g035728 Figure 168 1. Operator’s seat 3. Motor/generator controller (mounted to motor/generator assembly) 2. Motor/generator connector P37 Remove the motor/generator assembly from the machine. Refer to Chapter 5 of the 5010-H Service Manual. Figure 168.
Page 445: Appendix A: Wiring Harness And Connector Identification
Appendix A: Wiring Harness and Connector Identification The 5010-H electrical system consists of 4 separate wiring harnesses: Main wire harness Main Wire Harness (Forward Half) (page 446) Main Wire Harness (Rear Half) (page 457) Seat Wire Harness (page 467) Seat Switch Wire Harness (page 476) Fusible Link Harness (page 476) Main Wire Harness g035811...
Page 446 Main Wire Harness (Forward Half) g035808 Figure 170 Main Wire Harness (Forward Half) The following table shows the main harness connectors that are contained in the Main Wire Harness (Forward Half) section of this appendix: (Figure 171) (Figure 179) (Figure 187) (Figure 195)
Page 447 J16 Main Harness +48 Vdc Power Connector g034009 Figure 171 Pin Number Description (Signal Name) Wire Color 48 Vdc Red (R), Red (R), Red (R) J17 Main Harness +48 Vdc Power Connector g034010 Figure 172 Pin Number Description (Signal Name) Wire Color 48 Vdc Red (R), Red (R)
Page 448 J21 Main Harness 48 Vdc Ground Connector g034012 Figure 176 Pin Number Description (Signal Name) Wire Color Ground Common Bus Black (BK) J22 Main Harness Main Contactor (Switched Side) Connector g034013 Figure 177 Pin Number Description (Signal Name) Wire Color 48 Vdc Red (R) J23 Main Harness Main Contactor (Battery Side) Connector...
Page 449 P08 Main Harness Fuel Level Sender Connector Note: Weather sealed g034016 Figure 181 Pin Number Description (Signal Name) Wire Color Ground Brown/Yellow (BN/Y) Analog Signal Tan (T) P09 Main Harness Fuel Pump Connector Note: Weather sealed g032967 Figure 182 Pin Number Description (Signal Name) Wire Color 12 Vdc...
Page 450 P14 Main Harness Mow/Transport Switch Note: Weather sealed g034017 Figure 185 Pin Number Description (Signal Name) Wire Color 12 Vdc In Sensor (Key Run) Pink (PK) Mow/Transport Yellow (Y) Ground Black (BK) P15 Main Harness Reels Down Limit Switch Note: Weather sealed g034018 Figure 186...
Page 451 P19 Main Harness SV3 Rear Raise/Lower (Servo Solenoid, Hydraulic Reel Lift) Note: Weather sealed g032971 Figure 188 Pin Number Description (Signal Name) Wire Color 12 Vdc White/Green (W/GN) Ground Black (BK) P23 Main Harness Neutral Switch Note: Weather sealed g034018 Figure 189 Pin Number Description (Signal Name)
Page 452 P25 Main Harness Headlight (Right) Note: Weather sealed g034059 Figure 191 Pin Number Description (Signal Name) Wire Color Ground Black (BK) 12 Vdc Switched In Gray (GY) P26 Main Harness Headlight (Left) Note: Weather sealed g034059 Figure 192 Pin Number Description (Signal Name) Wire Color Ground...
Page 453 P44 Main Harness Cutting Reel Motor 5 Controller Note: Weather sealed g032909 Figure 194 Pin Number Description (Signal Name) Wire Color 48 Vdc In Logic Power White (W) Location ID Violet (VIO) CAN + (High) Yellow (Y) CAN - (Low) Green (GN) P45 Main Harness Cutting Reel Motor 5 Motor Power Note:...
Page 454 P47 Main Harness Cutting Reel Motor 1 Motor Power Note: Weather sealed g032910 Figure 197 Pin Number Description (Signal Name) Wire Color 48 Vdc In Red (R) Ground Black (BK) P48 Main Harness Cutting Reel Motor 4 Controller Note: Weather sealed g032909 Figure 198 Pin Number...
Page 455 P50 Main Harness CAN Termination Resistor Note: Weather sealed g030665 Figure 200 Pin Number Description (Signal Name) Wire Color CAN + (High) Yellow (Y) CAN - (Low) Green (GN) not used P51 Main Harness Seat Interconnect Note: Weather sealed g033126 Figure 201 Pin Number Description (Signal Name)
Page 456 Pin Number Description (Signal Name) Wire Color Key Start Violet/Black (VIO/BK) Glow Blue (BU) Hydraulic Servo, SV3 White/Green (W/GN) Hydraulic Servo, SV4 Enable Yellow/Black (Y/BK) Oil Pressure Green/White (GN/W) Alternator Fault White (W) Key Run Pink (PK) Fuel Level Sensor Tan (T) E-Reels Enable Relay Green (GN)
Page 457 Main Wire Harness (Rear Half) g035809 Figure 202 Main Wire Harness (Rear Half) The following table shows the main harness connectors that are contained in the Main Wire Harness (Rear Half) section of this appendix: (Figure 203) (Figure 210) (Figure 217) (Figure 224)
Page 458 J01 Main Harness Battery +12 Vdc Connector g034011 Figure 203 Pin Number Description (Signal Name) Wire Color 12 Vdc Battery Red (R) J02 Main Harness Engine Ground Connector g034010 Figure 204 Pin Number Description (Signal Name) Wire Color Ground (Engine) Black (BK), Black (BK) J03 Main Harness Glow Plugs Connector g034061...
Page 459 P02 Main Harness Diode Connector g034063 Figure 208 Pin Number Description (Signal Name) Wire Color Ground Black (BK) 12 Vdc Start Relay (Key Start), Starter Solenoid Blue (BU), Blue (BU) P03 Main Harness Starter Solenoid Connector g034064 Figure 209 Pin Number Description (Signal Name) Wire Color 12 Vdc Start Relay (Key Start)
Page 460 P16 Main Harness Temperature Sender Note: Weather sealed g033057 Figure 212 Pin Number Description (Signal Name) Wire Color S A_GND Brown/Yellow (BN/Y) S Temp Sender Gray/Brown (GY/BN) P17 Main Harness Alternator (Field, Sense Out/Fault) g032838 Figure 213 Pin Number Description (Signal Name) Wire Color 12 Vdc Field In (Key Run) Pink (PK)
Page 461 P21 Main Harness Start Relay g032968 Figure 215 Pin Number Description (Signal Name) Wire Color 12 Vdc Key Start (30, Ignition In) Violet/Black (VIO/BK) 12 Vdc In Engine Start (85, Relay Coil) Brown/Black (BN/BK) not used (87a, n/a) 12 Vdc Switched Out Diode (87, Relay Out) Blue (BU) Ground (86, Relay Coil) Black (BK)
Page 462 P31 Main Harness Location ID Module Note: Weather sealed g032959 Figure 217 Pin Number Description (Signal Name) Wire Color Reel 5 Controller (15k ohm) Violet (VIO) Reel 4 Controller (10k ohm) Orange (OR) Reel 3 Controller (6.2k ohm) Tan (T) Reel 2 Controller (3.9k ohm) Yellow (Y) Reel 1 Controller (1.6k ohm)
Page 463 P36 Main Harness CAN Termination Resistor 120 ohm Note: Weather sealed g030665 Figure 220 Pin Number Description (Signal Name) Wire Color CAN + (High) Yellow (Y) CAN - (Low) Green (GN) not used P37 Main Harness Generator Interface Note: Weather sealed g032970 Figure 221 Pin Number...
Page 464 P39 Main Harness Cutting Reel Motor 2 Motor Power Note: Weather sealed g032910 Figure 223 Pin Number Description (Signal Name) Wire Color 48 Vdc In Red (R) Ground Black (BK) P40 Main Harness Cutting Reel Motor 3 Controller Note: Weather sealed g032909 Figure 224 Pin Number...
Page 465 CAN - (Low) Black/White (BK/W) CAN + (High) Red/White (R/W) CAN - (Low) Green (GN) CAN + (High) Yellow (Y) P43 Main Harness CAN Toro DIAG Port with Cap Note: Weather sealed g030665 Figure 227 Pin Number Description (Signal Name) Wire Color...
Page 466 P53 Main Harness Fuse TEC-5002 Power Note: Weather sealed g034068 Figure 229 Pin Number Description (Signal Name) Wire Color 12 Vdc In Battery Power Red (R) 12 Vdc Out Fused (2 amp) White/Black (W/BK) P54 Main Harness Enable Fuse Note: Weather sealed g034068 Figure 230...
Page 467: Seat Wire Harness
Seat Wire Harness g035810 Figure 231 The following table shows the seat harness connectors that are contained in the Seat Wire Harness section of this appendix: (Figure 232) (Figure 237) (Figure 242) (Figure 247) (Figure 233) (Figure 238) (Figure 243) Figure 248 (Figure 234)
Page 468 P01 Seat Harness Hour Meter Connector g034089 Figure 232 Pin Number Description (Signal Name) Wire Color 12 Vdc In Pink (PK) not used Ground Black (BK) P02 Seat Harness Ignition Switch Connector g032958 Figure 233 Pin Number Description (Signal Name) Wire Color 12 Vdc Out Violet/Black (VIO/BK), Violet/Black (VIO/BK)
Page 469 P04 Seat Harness Joystick Lower Connector g032969 Figure 235 Pin Number Description (Signal Name) Wire Color Ground Black (BK) 12 Vdc In Pink/Blue (PK/BU) not used P05 Seat Harness Seat Switch Connector Note: Weather sealed g034091 Figure 236 Pin Number Description (Signal Name) Wire Color 12 Vdc In...
Page 470 P13 Seat Harness Light Switch g032906 Figure 238 Pin Number Description (Signal Name) Wire Color not used 12 Vdc Fused In Blue (BU) 12 Vdc Out Gray (GY) not used not used not used not used not used P14 Seat Harness Throttle Speed Request Connector g032906 Figure 239 Pin Number...
Page 471 P19 Seat Harness Fuse Block No. 1 Connector g034092 Figure 240 Pin Number Description (Signal Name) Wire Color 12 Vdc Out to Ignition switch (15 amp fuse, F1-1) Orange (OR) 12 Vdc In from Battery Power-Fusible Link C (15 amp fuse, F1-1) Red (R) 12 Vdc Out (shared power source) (10 amp fuse, F1-2)
Page 472 P24 Seat Harness Power Point Connector g034093 Figure 242 Pin Number Description (Signal Name) Wire Color Ground Black (BK) 12 Vdc In from Fuse Block No. 1 White (W) P25 Seat Harness Air Ride Seat (Optional) Connector Note: Weather sealed g034094 Figure 243 Pin Number...
Page 473 P51 Seat Harness Seat Interconnect Connector Note: Weather sealed g033127 Figure 246 Pin Number Description (Signal Name) Wire Color Battery Power Red (R) Ground Black (BK) Switched Power Red (R) not used Logic Power White/Black (W/BK) Head Light Gray (GY) Parking Brake Orange (OR) Neutral...
Page 474 Pin Number Description (Signal Name) Wire Color not used Servo 2 Raise Lower Direction Violet (VIO) Fuel Pump Red/Black (R/BK) CAN + (High) Red/White (R/W) Servo 1 Front Raise/Lower White/Blue (W/BU) CAN - (Low) Black/White (BK/W) P52 Seat Harness InfoCenter Connector Note: Weather sealed g032808...
Page 475 Pin Number Description (Signal Name) Wire Color Neutral Switch Green/Yellow (GN/Y) Mow/Transport Yellow (Y) Oil Pressure Green/White (GN/W) Throttle Speed Request (decrease) Blue/Black (BU/BK) Alternator L White (W) Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used...
Page 476: Seat Switch Wire Harness
Seat Switch Wire Harness P01 and P02 Seat Switch Wire Harness Note: P01 connects to Seat Wire Harness connector P05, and P02 connects to the seat switch. g034090 Figure 249 Pin Number Description (Signal Name) Wire Color 12 Vdc In Gray (GY) Ground Black (BK)

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