Download Print this page

Toro Reelmaster 5010-H Diagnostic Manual

Fault code

Hide thumbs Also See for Reelmaster 5010-H:

Diagnostic manual (476 pages)

,

Service manual (335 pages)

,

Operator's manual (128 pages)

Table Of Contents

Table of Contents

Advertisement

Quick Links

Download this manual

Diagnostics Manual

Reelmaster® 5010-H Diagnostic Fault

Code Manual

Model—Serial Range

03950—400000000 and Up

*24278SL* A

24278SLA

Original Instructions (EN)

Table of Contents

Advertisement

Table of Contents

Troubleshooting

Need help?

Need help?

Do you have a question about the Reelmaster 5010-H and is the answer not in the manual?

Questions and answers

Summary of Contents for Toro Reelmaster 5010-H

Page 1 Diagnostics Manual Reelmaster® 5010-H Diagnostic Fault Code Manual Model—Serial Range 03950—400000000 and Up *24278SL* A 24278SLA Original Instructions (EN)
Page 2: Revision History
The purpose of this publication is to provide the service technician with information for diagnostic troubleshooting and testing on the Reelmaster™ 5010-H fairway mower. The Toro® Company reserves the right to change product specifications or this publication without notice. Improper use or maintenance by the operator or owner can result in injury. To reduce...
Page 3: Service Procedure Icons
Service Procedure Icons The following icons appear throughout this service manual to bring attention to specific important details of a service procedure. Critical Process is used to highlight: • installing safety equipment (shields, guards, seat belts, brakes and R.O.P.S. components) that may have been removed •...
Page 4: Table Of Contents
Chapter 3: General Repair Information ................3–1 Consumable Materials List..................... 3–2 Special Tools ........................3–3 Multimeter ........................3–3 Toro DIAG USB/CAN Cable ..................3–3 Harness and Component Connector Wear and Damage .......... 3–4 Repairing the Wire Insulation..................3–5 Wire Harness Attachment and Protection..............3–6 Chapter 4: General Testing Information ................
Page 5 Preparing for Troubleshooting and/or Testing............. 7–22 Returning the Machine to Service.................. 7–23 Toro DIAG—Quick Start ....................7–24 Replacing or Swapping the Primary Toro Electronic Controller (TEC)....7–26 Replacing the Controller....................7–26 Calibrating the Traction Pedal, Traction Pump, and Virtual Speed Sensor ..7–34 Calibrating the Traction Pedal..................
Page 6 C1801: T2, T3, T4, T5, T6 Cutting Unit Motor - High Temp Shutdown ....8–124 C180C: T2, T3, T4, T5, T6 Cutting Unit Motor - High Temp Warning....8–148 C1811: T2, T3, T4, T5, T6 Cutting Unit Motor Controller - High Temp Shutdown ...........................8–169 C181C: T2, T3, T4, T5, T6 Cutting Unit Motor Controller - High Temp Warning ..........................8–189...
Page 7 P110D: T1 Traction Coil 1 FWD - Validation Failure - PWM Converge....8–558 P110E: T1 Traction Coil 1 FWD - Feedback Measurement Validation Failure..........................8–564 P1114: T1 Traction Coil 1 REV - Overcurrent............8–570 P111C: T1 Traction Coil 1 REV - Validation Failure - Current Converge ....8–576 P111D: T1 Traction Coil 1 REV - Validation Failure - PWM Converge ....8–583 P111E: T1 Traction Coil 1 REV - Feedback Measurement Validation Failure ...8–589 P1164: T1 Swashplate 1 - Signal Shorted to Gnd............8–596...
Page 8 U1303: T1, T4 Software Version Incompatibility - CU Motor 3......8–970 U1307: T1, T7 Software Version Incompatibility - Generator........8–973 U130A: SC1, T1 Software Version Incompatibility - InfoCenter ......8–975 U130F: T1 Software Version Incompatibility - Unknown ........8–977 U1314: T1, T5 Software Version Incompatibility - CU Motor 4......8–979 U1315: T1, T6 Software Version Incompatibility - CU Motor 5......8–982 U1501: T1, T2, T3, T4, T5, T6, T7 48V System Logic Voltage - High ....8–984 U1502: T1, T2, T3, T4, T5, T6, T7 48V System Logic Voltage - Low ....8–996...
Page 9 Chapter 1 Safety Table of Contents Introduction..............................1–2 Maintenance and Service .......................... 1–3 24278SL A Page 1–1 Safety...
Page 10: Introduction
Introduction 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 safety instructions found in the Operator’s Manual and Service Manual, and the...
Page 11: Maintenance And Service
• At the time of manufacture, the machine conformed to all applicable safety standards. To ensure optimum performance and continued safety certification of the machine, use only genuine Toro replacement parts and accessories. 24278SLA Page 1–3...
Page 12 Safety: Maintenance and Service Page 1–4 24278SL A...
Page 13: General Information
Chapter 2 General Information Table of Contents External Reference Material........................2–2 Obtaining Reference Material ....................... 2–2 Resource Documents ..........................2–3 Toro DIAG Software ............................ 2–3 Table of Acronyms ............................2–4 Glossary ................................. 2–5 Connection Terminology......................... 2–5 Fault ................................2–5 24278SL A Page 2–1...
Page 14: External Reference Material
Toro DIAG guide for specific test and repair procedures. Obtaining Reference Material 1. Go to the Toro Gateway site and login with your username and password. 2. On the Publication Search page, type the model number of your machine and then click Go.
Page 15: Resource Documents
10 Schematics and Harness Drawings, page 10–1 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 CAN connected controllers.
Page 16: Table Of Acronyms
Input pull-up enable Kilopascal Motor generator Liquid crystal display Light emitting diode Pounds/square inch Power take-off SV (SV1, SV2, Solenoid valve SV3) SVRV (SV4) Solenoid valve, relief valve Toro electronic controller General Information: Table of Acronyms Page 2–4 24278SL A...
Page 17: Glossary
An active fault is displayed on the InfoCenter while the fault condition is present (active) until you clear the fault, or you turn the machine off. All faults are archived in and accessible from the nonvolatile memory of the T1 controller (Toro electronic controller). 24278SLA Page 2–5...
Page 18 General Information: Glossary Page 2–6 24278SL A...
Page 19: General Repair Information
Table of Contents Consumable Materials List........................3–2 Special Tools ............................... 3–3 Multimeter ..............................3–3 Toro DIAG USB/CAN Cable ........................3–3 Harness and Component Connector Wear and Damage ..............3–4 Repairing the Wire Insulation........................ 3–5 Wire Harness Attachment and Protection....................3–6 24278SL A Page 3–1...
Page 20: Consumable Materials List
Eraser (pink pearl) Commercially available Isopropyl alcohol Commercially available Non-conductive abrasive paper (120 grit) Manufacturer/Supplier (3M), commercially available Super Lube™ oil Toro Part No. 145- 5053 Wire dryer aerosol Commercially available General Repair Information: Consumable Materials List Page 3–2 24278SL A...
Page 21: Special Tools
Read and understand the manufacturer’s operating instructions before using the multimeter. Toro DIAG USB/CAN Cable The Toro DIAG software uses a USB port (computer) and a diagnostic port (machine) connector. TheToro DIAG USB/CAN cable (Part No. 115-1944) connects the computer to the machine.
Page 22: Harness And Component Connector Wear And Damage
Harness and Component Connector Wear and Damage The wire harnesses and electrical components include the following: • Electrical connectors • Connector pins • Electrical terminals • Insulated wire While you are troubleshooting, inspect the parts for wear, damage, and corrosion. Other common electrical problems include: •...
Page 23: Repairing The Wire Insulation
Repairing the Wire Insulation If damage extends through the insulation and strands of the wire are broken, repair or replace the wire harness. If there is damage to the outer insulation only, or if the damage to the shielding is abrasion or deformation only with no broken strands, repair the wire harness as follows: 1.
Page 24: Wire Harness Attachment And Protection
Wire Harness Attachment and Protection Properly attaching the wire harnesses to the machine helps keep the connectors from loosening and protects the harnesses from accidental damage caused by vibration. • Ensure that no device used to attach a wire harness to the machine can rotate or slide freely on the wire harness.
Page 25 Chapter 4 General Testing Information Table of Contents Testing the Electrical Circuits ....................... 4–2 Cleaning the Electronic Components and Connections ..............4–2 Short Circuits and Tests.......................... 4–2 Circuit Voltage Tests..........................4–3 24278SL A Page 4–1 General Testing Information...
Page 26: Testing The Electrical Circuits
Testing the Electrical Circuits Cleaning the Electronic Components and Connections IMPORTANT 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. Avoid using mineral solvents, as they may damage connectors, seals, and wire insulation.
Page 27: Circuit Voltage Tests
Short Circuits and Tests (continued) For accurate resistance and/or continuity tests, electrically isolate the component being tested by disconnecting all wiring or removing it from the circuit. Circuit Voltage Tests Measure the voltage between the identified wire harness connector pins or component terminals and the suspected points of failure.
Page 28 General Testing Information: Testing the Electrical Page 4–4 24278SL A Circuits...
Page 29 Chapter 5 The InfoCenter Display Table of Contents InfoCenter Diagnostics—3 Button InfoCenter..................5–2 InfoCenter Diagnostics—6 Button InfoCenter..................5–3 The InfoCenter display shows information about your machine, such as faults, the charge level of the battery and charging system, various diagnostic messages, and icons that provide current information about the machine.
Page 30: Infocenter Diagnostics-3 Button Infocenter
InfoCenter Diagnostics—3 Button InfoCenter The InfoCenter Diagnostics screen displays the status of various machine electrical components and battery voltages (Figure 1Figure 1). Use the Diagnostics screen to test machine switches and controls when possible. Note: The InfoCenter is sometimes referred to as the mini-InfoCenter (MIC). Figure 1 Indicator light Right button...
Page 31: Infocenter Diagnostics-6 Button Infocenter
InfoCenter Diagnostics—6 Button InfoCenter The InfoCenter Diagnostics screen displays the status of various machine electrical components and battery voltages (Figure 2Figure 1). Use the Diagnostics screen to test machine switches and controls when possible. Note: The InfoCenter is sometimes referred to as the mini-InfoCenter (MIC). Figure 2 Indicator light Display brightness sensor...
Page 32 The InfoCenter Display: InfoCenter Diagnostics—6 Page 5–4 24278SL A Button InfoCenter...
Page 33: General Troubleshooting Information
Chapter 6 General Troubleshooting Information Table of Contents Troubleshooting Intermittent Electrical Faults ................6–2 Attempt to Duplicate the Fault ......................6–2 Complete the Basic Maintenance Checks ..................6–2 CAN Circuits and Communication Capture ................. 6–3 24278SL A Page 6–1 General Troubleshooting Information...
Page 34: Troubleshooting Intermittent Electrical Faults
Troubleshooting Intermittent Electrical Faults Attempt to Duplicate the Fault 1. Ask the operator the following questions to understand operating conditions: • The outdoor temperature when the fault occurred. • How the machine was being used when the fault occurred. • The condition of the job site where the fault occurred. 2.
Page 35: Can Circuits And Communication Capture
• Toro DIAG Save function; refer to the Toro DIAG Software User’s Guide. • Toro DIAG CAN Capture function; refer to the Toro DIAG Software User’s Guide. • Machines with Yanmar Engines: Yanmar SA-D Error Diagnosis Data Save and Display Functions;...
Page 36 General Troubleshooting Information: Troubleshooting Page 6–4 24278SL A Intermittent Electrical Faults...
Page 37 Preparing for Troubleshooting and/or Testing..................7–22 Returning the Machine to Service......................7–23 Toro DIAG—Quick Start ........................... 7–24 Replacing or Swapping the Primary Toro Electronic Controller (TEC).......... 7–26 Replacing the Controller........................7–26 Calibrating the Traction Pedal, Traction Pump, and Virtual Speed Sensor ......... 7–34 Calibrating the Traction Pedal.........................
Page 38 Removing the Generator/Motor Controller ..................7–69 Installing the Generator/Motor Controller..................7–71 Finishing the Generator/Motor Controller Installation ..............7–75 Accessing the Machine..........................7–77 Removing the Left Console Cover..................... 7–77 Installing the Left Console Cover ....................... 7–78 Removing the Right Console Cover ....................7–79 Installing the Right Console Cover ....................
Page 39: Connecting And Disconnecting The 12V Battery
Connecting and Disconnecting the 12V Battery CAUTION Before installing, removing, or servicing components in the 12V system (e.g., starter, alternator, control arm components, etc.), disconnect the 12V battery. This prevents unexpected operation of 12V system components. Preparing the Machine 1. Press the PTO switch to the disengage position. 2.
Page 40: Disconnecting The 12V Battery
Opening the Screen (continued) Figure 3 G491356.svg Latch Bracket Ball pin 2. Pull the handle and disengage the latch from the bracket. 3. Pivot the screen to open it. Disconnecting the 12V Battery 1. Squeeze the sides of the battery cover to disengage the tabs from the slots in the battery tray and remove the cover.
Page 41: Connecting The 12V Battery
Disconnecting the 12V Battery (continued) Figure 4 G491304.svg Negative battery post Battery cover Positive battery post 2. Loosen the clamp hardware and disconnect the negative-battery cable from the battery post. 3. Slide the insulator boot off the positive battery-cable clamp. 4.
Page 42: Closing The Screen
4. Coat the battery posts and the cable connectors with battery terminal protector (Toro Part No. 107-0392). 5. Assemble the insulator boot onto the positive battery-cable clamp. 6. Align the battery cover to the battery and insert the tabs of the cover into the slots in the battery tray.
Page 43 Closing the Screen (continued) Figure 6 G491356.svg Latch Bracket Ball pin 3. Insert the ball pin into the holes in the screen latch to secure it. 24278SLA Page 7–7 Frequently Used Procedures: Connecting and Disconnecting the 12V Battery...
Page 44: Connecting And Disconnecting The 48V Battery System
Connecting and Disconnecting the 48V Battery System CAUTION Before installing, removing, or servicing components in the 48Vdc system (i.e., cutting reel motors and generator/motor systems), unplug the 48Vdc battery disconnect. This prevents unexpected operation of 48Vdc system components. Preparing the Machine 1.
Page 45: Plugging-In The 48V Battery Disconnect
Unplugging the 48V Battery Disconnect (continued) Figure 8 G491947 Battery disconnect socket 48V battery disconnect plug Plugging-In the 48V Battery Disconnect 1. After servicing or repairing the 48 Vdc system, apply a coat of dielectric grease to the contact surfaces of the 48V battery disconnect plug into the socket. Figure 9 G491947 Battery disconnect socket...
Page 46: Reading And Understanding Fault Codes
Reading and Understanding Fault Codes You can read fault codes 2 ways: on the on the operator display (InfoCenter), or on a PC using Toro DIAG Software, page 2–3. This section focuses on the operator display. Fault Codes Displayed During Machine Operation When a fault occurs, the LED indicator flashes on the InfoCenter and the fault code displays.
Page 47 Fault Codes Displayed During Machine Operation (continued) 6-Button InfoCenter G491684.svg LED Indicator Navigation button—up Enter button Navigation button— increase/right Navigation button—down Navigation button— decrease/left Back button G491950 Fault Codes Displayed in the Fault Codes List Additional fault code information can be displayed on the InfoCenter by navigating the Fault Codes list.
Page 48 Fault Codes Displayed During Machine Operation (continued) Figure 11 3-Button InfoCenter G492152 6-Button InfoCenter G492153 The fault code numbers include 2 pieces of information: the 5-character fault code, and the 1- or 2-character designator for the associated controller. For example, translating the fault code P1146:T1 yields: •...
Page 49 Fault Codes Displayed During Machine Operation (continued) • T1 = TEC 5004 (primary controller) Refer to the following table for an example list of the 1- or 2-character designators for controllers. Designator for Definition Controller Represents the TEC 5004 (primary controller) Represents the InfoCenter Represents the engine controller (ECU) 24278SLA...
Page 50: Clearing Faults From The T1 Controller
To clear the list of active faults you need to know the PIN number to access the protected fault options in the Faults menu of the InfoCenter. The complete fault history is retained in the controller memory and can be viewed using the Toro DIAG software.
Page 51 Entering the PIN Code—3 Button InfoCenter (continued) Figure 13 G489722.svg 24278SLA Page 7–15 Frequently Used Procedures: Clearing Faults from the T1 Controller...
Page 52: Entering The Pin Code-6 Button Infocenter
Entering the PIN Code—3 Button InfoCenter (continued) 4. In the Enter PIN screen, enter the 4-character PIN, press the right Enter button, and press the center Confirm button. Figure 14 G489746.svg Figure 15 G489745.svg Entering the PIN Code—6 Button InfoCenter 1.
Page 53 Entering the PIN Code—6 Button InfoCenter (continued) 2. In the InfoCenter, navigate to the Main Menu, and select the Settings option. Figure 16 G489048.svg 3. In the Settings menu, select the Enter PIN option. Figure 17 G489050.svg 24278SLA Page 7–17 Frequently Used Procedures: Clearing Faults from the T1 Controller...
Page 54: Clearing The Active Faults List-3 Button Infocenter
Entering the PIN Code—6 Button InfoCenter (continued) 4. In the Enter PIN screen, enter the 4-character PIN and press the right enter button. Figure 18 G487427.svg Clearing the Active Faults List—3 Button InfoCenter When you clear the list of active faults, all the listed faults are cleared in one process. 1.
Page 55 Clearing the Active Faults List—3 Button InfoCenter (continued) Figure 19 G491985 3. In the Code screen, select the Clear System Faults option, and press the right button. Figure 20 G491984 4. When the Clear System Faults screen displays, press the center button. 24278SLA Page 7–19 Frequently Used Procedures: Clearing Faults from the T1...
Page 56: Clearing The Active Faults List-6 Button Infocenter
Clearing the Active Faults List—3 Button InfoCenter (continued) Figure 21 G491983 Clearing the Active Faults List—6 Button InfoCenter When you clear the list of active faults, all the listed faults are cleared in one process. 1. Ensure that the key switch is in the P position.
Page 57 Clearing the Active Faults List—6 Button InfoCenter (continued) Figure 23 G491987 4. When the Clear Faults screen displays, press the right Enter button. Figure 24 G491986 24278SLA Page 7–21 Frequently Used Procedures: Clearing Faults from the T1 Controller...
Page 58: Preparing For Troubleshooting And/Or Testing
Preparing for Troubleshooting and/or Testing CAUTION Rings, watches, bracelets, necklaces, and other jewelry can cause an electrical shock or become entangled with the machine. Remove all jewelry, especially rings and watches, before doing any troubleshooting or testing. Before performing troubleshooting and/or testing procedures on the machine, do the following steps: 1.
Page 59: Returning The Machine To Service
Returning the Machine to Service Ensure optimum performance and continued safety by performing all steps in the following procedure after all diagnostic, maintenance, and/or repair activities are complete: 1. Remove all diagnostic equipment and tools that are attached to the machine for troubleshooting or repair.
Page 60: Toro Diag-Quick Start
Ensure that the Toro DIAG software and the drivers for the Toro DIAG USB/CAN cable (Part No. 115-1944) are already installed on your PC. If they are not installed, go to the Toro DIAG Software User’s Guide and follow the steps in the Download and Installation section.
Page 61 P27 Stowage cap G501864 5. Connect the Toro DIAG cable between a USB port on the laptop computer and the CAN Port A connector of the machine. 6. Ensure that the key switch is the O position and start the Toro DIAG software.
Page 62: Replacing Or Swapping The Primary Toro Electronic Controller (Tec)
Programming Procedures: You must perform 5 programming procedures in the following order when replacing a primary Toro electronic controller: 7.1 Preparing the Machine, page 7–27 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 4.
Page 63 6. Unlatch the seat and console, raise them, and support them with the forward prop rod. Figure 28 G490754 Seat and console latch Forward prop rod 24278SLA Page 7–27 Frequently Used Procedures: Replacing or Swapping the Primary Toro Electronic Controller (TEC)
Page 64 Toro DIAG—Quick Start, page 7–24. 2. Use the Toro DIAG software to save the TD2 file from the machine. Refer to the Controller Reformatting section of the Toro DIAG Software User’s Guide. Frequently Used Procedures: Replacing or Swapping the Page 7–28...
Page 65 Figure 29 G490767.svg Retaining fastener (location) 2. Remove the 4 fasteners securing the T1 controller to the controller bracket and remove the controller from the machine. 24278SLA Page 7–29 Frequently Used Procedures: Replacing or Swapping the Primary Toro Electronic Controller (TEC)
Page 66 4. Secure the T1 controller to the controller bracket with the 4 fasteners. Figure 31 G490771.sng Fastener Controller bracket 5. Plug main-harness connector into the T1 controller. Frequently Used Procedures: Replacing or Swapping the Page 7–30 24278SL A Primary Toro Electronic Controller (TEC)
Page 67 Replacing the Controller (continued) Figure 32 G490767.svg Retaining fastener (location) 6. Torque the retaining fastener for the main-harness connector to 2.8 to 3.2 N∙m (25 to 28 in-lb). 24278SLA Page 7–31 Frequently Used Procedures: Replacing or Swapping the Primary Toro Electronic Controller (TEC)
Page 68 Replacing the Controller (continued) 7.4 Using Toro DIAG to Program the Machine 1. Connect a laptop computer with Toro DIAG software to the machine using a Toro DIAG USB/CAN cable (Part No. 115-1944). Refer to Toro DIAG—Quick Start, page 7–24.
Page 69 7–24. 2. Use the Toro DIAG software to restore the timers and counters file that you saved from the original T1 controller into the replacement T1 controller; refer to the How to Restore a TD2 File procedure in the Controller section of the Toro DIAG Software User’s Guide.
Page 70: Calibrating The Traction Pedal, Traction Pump, And Virtual Speed Sensor
Calibrating the Traction Pedal, Traction Pump, and Virtual Speed Sensor When replacing the T1 controller, perform the 3 calibration procedures in the following order when replacing a T1 controller (primary TEC): Traction Pedal Calibration, page 7–34 Traction Pump Calibration, page 7–43 Virtual Speed Sensor Calibration, page 7–53 Calibrating the Traction Pedal Calibrate the traction pedal when any of the following events occur:...
Page 71 Preparing the Machine—3 Button InfoCenter (continued) 5. In the Settings menu, select the Protected Menus option. Figure 36 G489722 6. In the Enter PIN screen, enter the 4-character PIN, press the right Enter button, and press the center Confirm button. 24278SLA Page 7–35 Frequently Used Procedures: Calibrating the Traction...
Page 72: Calibrating Traction Pedal Position-3 Button Infocenter
Preparing the Machine—3 Button InfoCenter (continued) Figure 37 G489746 G489745 Calibrating Traction Pedal Position—3 Button InfoCenter 1. Navigate to the Service menu and select the Traction Pedal option. Frequently Used Procedures: Calibrating the Traction Page 7–36 24278SL A Pedal, Traction Pump, and Virtual Speed Sensor...
Page 73 Calibrating Traction Pedal Position—3 Button InfoCenter (continued) Figure 38 G489759 2. In the Traction Pedal menu, select the Start Teach option. Figure 39 G489760 3. Follow the instructions displayed in the InfoCenter. IMPORTANT When instructed to press the traction pedal, press and hold the traction pedal until the InfoCenter displays the next step.
Page 74: Preparing The Machine-6 Button Infocenter
Calibrating Traction Pedal Position—3 Button InfoCenter (continued) 4. When the traction pedal calibration completes, the Message 4 (exit calibration) message displays, and then the InfoCenter returns to the Traction Pedal menu. Figure 40 G489761 Figure 41 G489762 5. Rotate the key switch to the O position and remove the key.
Page 75 Preparing the Machine—6 Button InfoCenter (continued) Figure 42 G489048 5. In the Settings menu, select the Enter PIN option. Figure 43 G489050 24278SLA Page 7–39 Frequently Used Procedures: Calibrating the Traction Pedal, Traction Pump, and Virtual Speed Sensor...
Page 76: Calibrating Traction Pedal Position-6 Button Infocenter
Preparing the Machine—6 Button InfoCenter (continued) 6. In the Enter PIN screen, enter the 4-character PIN and press the right enter button. Figure 44 G487427.svg Calibrating Traction Pedal Position—6 Button InfoCenter 1. Navigate to the Service menu and select the Traction Pedal option. Frequently Used Procedures: Calibrating the Traction Page 7–40 24278SL A...
Page 77 Calibrating Traction Pedal Position—6 Button InfoCenter (continued) Figure 45 G487434.svg 2. In the Traction Pedal menu, select the Start Teach option. Figure 46 G514393 3. Follow the instructions displayed in the InfoCenter. IMPORTANT When instructed to press the traction pedal, press and hold the traction pedal until the InfoCenter displays the next step.
Page 78 Calibrating Traction Pedal Position—6 Button InfoCenter (continued) Frequently Used Procedures: Calibrating the Traction Page 7–42 24278SL A Pedal, Traction Pump, and Virtual Speed Sensor...
Page 79: Calibrating The Traction Pump
Calibrating Traction Pedal Position—6 Button InfoCenter (continued) 4. When the traction pedal calibration completes, the Exit calibration message displays, and then the InfoCenter returns to the Traction Pedal menu. Figure 47 G488594 Figure 48 G488595 5. Rotate the key switch to the O position and remove the key.
Page 80 Preparing the Machine—3 Button InfoCenter (continued) 1. Ensure that the PTO switch is in the D position, park the machine on a ISENGAGE level surface, and move the traction pedal to the N position. EUTRAL 2. Shut off the engine. 3.
Page 81 Preparing the Machine—3 Button InfoCenter (continued) Figure 50 G489722.svg 7. In the Enter PIN screen, enter the 4-character PIN, press the right Enter button, and press the center Confirm button. Figure 51 G489746.svg 24278SLA Page 7–45 Frequently Used Procedures: Calibrating the Traction Pedal, Traction Pump, and Virtual Speed Sensor...
Page 82: Calibrating Traction Pump Operation-3 Button Infocenter
Preparing the Machine—3 Button InfoCenter (continued) Figure 52 G489745.svg Calibrating Traction Pump Operation—3 Button InfoCenter 1. Rotate the key switch to the O position. 2. Navigate to the Service menu and select the Traction Pump option. Figure 53 G489864 Frequently Used Procedures: Calibrating the Traction Page 7–46 24278SL A Pedal, Traction Pump, and Virtual Speed Sensor...
Page 83 Calibrating Traction Pump Operation—3 Button InfoCenter (continued) 3. Ensure that the parking-brake switch is in the D position, start the engine, ISENGAGE and set engine speed to full F 4. In the Traction Pump menu, select the Start Teach option. Figure 54 G489865 5.
Page 84: Preparing The Machine-6 Button Infocenter
Calibrating Traction Pump Operation—3 Button InfoCenter (continued) 6. When the traction pump calibration completes the InfoCenter displays the Traction Pump menu. Figure 55 G490094 7. Ensure that the traction pedal is in the N position and set engine speed to EUTRAL full S (idle).
Page 85 Preparing the Machine—6 Button InfoCenter (continued) Figure 56 G489048 24278SLA Page 7–49 Frequently Used Procedures: Calibrating the Traction Pedal, Traction Pump, and Virtual Speed Sensor...
Page 86 Preparing the Machine—6 Button InfoCenter (continued) 6. In the Settings menu, select the Enter PIN option. Figure 57 G489050 7. In the Enter PIN screen, enter the 4-character PIN and press the right enter button. Figure 58 G487427 Frequently Used Procedures: Calibrating the Traction Page 7–50 24278SL A Pedal, Traction Pump, and Virtual Speed Sensor...
Page 87: Calibrating Traction Pump Operation-6 Button Infocenter
Calibrating Traction Pump Operation—6 Button InfoCenter 1. Navigate to the Service menu and select the Traction Pump option. Figure 59 G487428 2. Ensure that the parking brake switch is in the D position, start the engine, ISENGAGE and set engine speed to full F 3.
Page 88 Calibrating Traction Pump Operation—6 Button InfoCenter (continued) IMPORTANT When instructed to press the traction pedal, press and hold the traction pedal until the InfoCenter displays the next step. Frequently Used Procedures: Calibrating the Traction Page 7–52 24278SL A Pedal, Traction Pump, and Virtual Speed Sensor...
Page 89: Calibrating The Virtual Speed Sensor
Calibrating Traction Pump Operation—6 Button InfoCenter (continued) 5. When the traction pump calibration completes the InfoCenter displays the Traction Pump menu. Figure 61 G488607 6. Set engine speed to full (Idle), shut off the engine, and remove the key. SLOW 7.
Page 90 Preparing the Machine (continued) 6. Prepare the wheel hub for measuring rotational speed according to the manufacturer’s instructions for the hand-held tachometer. Figure 62 G488902 7. Route the ratchet strap around the right-front tire and secure the strap to the roll- bar tube.
Page 91: Accessing Protected Menus-3 Button Infocenter
Preparing the Machine (continued) Figure 63 G488914 Roll-bar tube Accessing Protected Menus—3 Button InfoCenter 1. Rotate the key switch to P position. REHEAT Do not start the engine. 2. In the InfoCenter, navigate to the Main Menu, and select the Settings option. Figure 64 G489734 3.
Page 92 Accessing Protected Menus—3 Button InfoCenter (continued) Figure 65 G489722 4. In the Enter PIN screen, enter the 4-character PIN, press the right Enter button, and press the center Confirm button. Frequently Used Procedures: Calibrating the Traction Page 7–56 24278SL A Pedal, Traction Pump, and Virtual Speed Sensor...
Page 93: Measuring Wheel Hub Speed-3 Button Infocenter
Accessing Protected Menus—3 Button InfoCenter (continued) Figure 66 G489746 G489745 Measuring Wheel Hub Speed—3 Button InfoCenter This procedure requires the following: • Hand-held tachometer • A second person 1. Rotate the key switch to the O position. 2. Navigate to the Service menu and select the Virtual Speed Sensor option. 24278SLA Page 7–57 Frequently Used Procedures: Calibrating the Traction...
Page 94 Measuring Wheel Hub Speed—3 Button InfoCenter (continued) Figure 67 G490073 3. Ensure that the parking-brake switch is in the D position, start the engine, ISENGAGE and set engine speed to full F 4. In the Virtual Speed Sensor menu, select the Start Teach option. Figure 68 G490076 Frequently Used Procedures: Calibrating the Traction...
Page 95 Measuring Wheel Hub Speed—3 Button InfoCenter (continued) 5. Follow the instructions displayed in the InfoCenter. IMPORTANT When instructed to press the traction pedal, press and hold the traction pedal until the InfoCenter displays the next step. 6. When instructed in the InfoCenter, have the second person measure the rotational speed of the wheel hub with the hand-held tachometer.
Page 96: Adjusting The Actual Rpm Setting-3 Button Infocenter
Measuring Wheel Hub Speed—3 Button InfoCenter (continued) 8. Set engine speed to full (Idle), shut off the engine, and remove the key. SLOW Adjusting the Actual RPM Setting—3 Button InfoCenter 1. Rotate the key switch to P position. REHEAT 2. Navigate to the Virtual Speed Sensor menu and select the RPM Actual option. Figure 71 G490047 3.
Page 97: Accessing Protected Menus-6 Button Infocenter
Adjusting the Actual RPM Setting—3 Button InfoCenter (continued) Figure 72 G490046 4. Press the left button to save the setting. 5. Remove the jack stands and lower the machine. Accessing Protected Menus—6 Button InfoCenter Calibrating the Virtual Speed Sensor 1. Rotate the key switch to P position.
Page 98 Accessing Protected Menus—6 Button InfoCenter (continued) Figure 73 G489048 3. In the Settings menu, select the Enter PIN option. Figure 74 G489050 4. In the Enter PIN screen, enter the 4-character PIN and press the right enter button. Frequently Used Procedures: Calibrating the Traction Page 7–62 24278SL A Pedal, Traction Pump, and Virtual Speed Sensor...
Page 99: Measuring Wheel Hub Speed-6 Button Infocenter
Accessing Protected Menus—6 Button InfoCenter (continued) Figure 75 G487427 Measuring Wheel Hub Speed—6 Button InfoCenter This procedure requires the following: • Hand-held tachometer • A second person 1. Rotate the key switch to the O position. 2. Navigate to the Service menu and select the Virtual Speed Sensor option. 24278SLA Page 7–63 Frequently Used Procedures: Calibrating the Traction...
Page 100 Measuring Wheel Hub Speed—6 Button InfoCenter (continued) Figure 76 G487429 3. Ensure that the parking-brake switch is in the D position, start the engine, ISENGAGE and set engine speed to full F 4. In the Virtual Speed Sensor menu, select the Start Teach option. Figure 77 G487430 5.
Page 101 Measuring Wheel Hub Speed—6 Button InfoCenter (continued) IMPORTANT When instructed to press the traction pedal, press and hold the traction pedal until the InfoCenter displays the next step. 6. When instructed in the InfoCenter, have the second person measure the rotational speed of the wheel hub with the hand-held tachometer.
Page 102: Adjusting The Actual Rpm Setting-6 Button Infocenter
Adjusting the Actual RPM Setting—6 Button InfoCenter 1. Rotate the key switch to P position. REHEAT 2. Navigate to the Virtual Speed Sensor menu and select the RPM Actual option. Figure 80 G488917 3. Change the RPM Actual value using the left or right buttons to enter the RPM measurement that you recorded in Measuring Wheel Hub Speed—6 Button InfoCenter, page...
Page 103: Replacing The Generator/Motor Controller
Replacing the Generator/Motor Controller The Generator/Motor Controller is also known as the T7 controller. IMPORTANT You must program the machine after replacing the generator/motor controller. Preparing the Machine 1. Verify the key switch is in the O position. 2. Raise the seat and console, and support them with the forward prop rod. 3.
Page 104 Preparing the Machine (continued) Figure 83 Cooling-air hose Hose clamp Upper intake shroud G509434 7. Remove the 4 capscrews, spacers, and locknuts that secure the top and bottom intake shrouds, and remove the shrouds from the generator cover. Figure 84 Upper intake shroud Capscrew Spacer...
Page 105: Removing The Generator/Motor Controller
1. Remove the 2 capscrews that secure the access cover to the generator/motor controller, and remove the cover. Figure 86 Capscrews Access cover (generator/ motor controller) Gasket Super Lube™ oil (Toro Part No. 145-5053) G496723 24278SLA Page 7–69 Frequently Used Procedures: Replacing the Generator/ Motor Controller...
Page 106 Removing the Generator/Motor Controller (continued) 2. Remove the 3 flange-head capscrews that secure the 3 high-current terminals of the generator/motor to busbars of the generator/motor controller. Figure 87 Capscrews (cable terminal) High-current terminal G502656 3. Unplug the harness connector for the generator/motor from the harness connector for the generator/motor controller.
Page 107: Installing The Generator/Motor Controller
G505210 Locknut Capscrew Washer Installing the Generator/Motor Controller Required Shop Supplies: Description Toro Part No. Super Lube™ oil 145-5053 1. Assemble the generator/motor controller to the generator housing with the 2 capscrews, washers, and locknuts. 24278SLA Page 7–71 Frequently Used Procedures: Replacing the Generator/...
Page 108 Installing the Generator/Motor Controller (continued) Figure 90 G505210 Locknut Capscrew Washer 2. Plug the harness connector for the generator/motor into the harness connector for the generator/motor controller. Figure 91 Harness connector (generator/motor controller) Harness connector (generator/motor) G502702 Frequently Used Procedures: Replacing the Generator/ Page 7–72 24278SL A Motor Controller...
Page 109 Figure 92 Capscrews (cable terminal) High-current terminal G502656 4. Apply a coat of Super Lube oil (Toro Part No. 145-5053) to the seal and assemble the access cover to the generator/motor controller with the 2 capscrews. Figure 93 Capscrews Access cover (generator/...
Page 110 Installing the Generator/Motor Controller (continued) 5. Assemble the generator cover to the generator/motor and the controller with the 6 capscrews. Torque the capscrews to 8 to 9 N∙m (70 to 80 in-lb). Figure 94 Generator cover Capscrew G509435 6. Insert the seal-brushes into the groove of the top and bottom intake shrouds. Figure 95 Upper intake shroud Capscrew...
Page 111: Finishing The Generator/Motor Controller Installation
Installing the Generator/Motor Controller (continued) 7. Align the top and bottom intake shrouds to the flange of the generator cover and secure the top intake shroud to the bottom intake shroud with the 4 capscrews, spacers, and locknuts. 8. Assemble the cooling air hose to the top intake shroud with the hose clamp. Figure 96 Cooling-air hose Hose clamp...
Page 112 3. Lower the seat and console, and secure them with the latch. 4. Program the machine; refer to the Toro DIAG—Quick Start, page 7–24 Using Toro DIAG to Program the Machine, page 7–32. Note: A new generator/motor controller does not function until programmed using Toro DIAG.
Page 113: Accessing The Machine
Accessing the Machine Removing the Left Console Cover 1. Park the machine on a level surface, move the traction pedal to the N EUTRAL position, engage the parking brake, lower the cutting units, and shut off the engine. 2. Remove the Phillips-head screw, locknut, and 5 flange-head capscrews that secure the left-console cover to the console arm.
Page 114: Installing The Left Console Cover
Installing the Left Console Cover 1. Align the holes in the left-console cover with the holes in the console arm. Figure 100 G500063 2. Loosely assemble the left and right console cover with the Phillips-head screw and locknut. Figure 101 Phillips-head screw Locknut Flange-head capscrews...
Page 115: Removing The Right Console Cover
Removing the Right Console Cover 1. Park the machine on a level surface, move the traction pedal to the N EUTRAL position, engage the parking brake, lower the cutting units, and shut off the engine. 2. Open the latches for the console-access panel, and remove the access panel from the console.
Page 116: Installing The Right Console Cover
Removing the Right Console Cover (continued) Figure 104 G500042 Installing the Right Console Cover 1. Align the holes in the right-console cover with the holes in the console arm. Figure 105 G500064 2. Loosely assemble the left and right console cover with the Phillips-head screw and locknut.
Page 117 Installing the Right Console Cover (continued) Figure 106 Phillips-head screw Locknut Flange-head capscrews G500041 3. Loosely assemble the left-console cover to the console arm with the 5 flange- head capscrews. 4. Tighten the screws and locknut. 5. Assemble the console-access panel to the console and secure the panel with the latches.
Page 118 Frequently Used Procedures: Accessing the Machine Page 7–82 24278SL A...
Page 119 Chapter 8 Troubleshooting Fault Code Table of Contents B1007:T1 Joystick Raise/Lower Broken ....................8–4 C1024:T1 Park Brake Disengage - Short to Ground/Overcurrent ..........8–17 C1025:T1 Park Brake Disengage - Open Circuit ................8–23 C10E3:T1 48V Logic Enable - Short to Battery .................. 8–30 C10E4:T1 48V Logic Enable - Short to Ground/Overcurrent ............
Page 120 P0616: T1 Start Output - Short to Ground/Overcurrent ..............8–385 P0617: T1 Start Output - Short to Battery ..................8–392 P0627: T1 Fuel Pump Output - Open Circuit..................8–400 P0628: T1 Fuel Pump Output - Short to Ground/Overcurrent............8–406 P0629: T1 Fuel Pump Output - Short to Battery................8–412 P0670: T1 Glow Plug Output - Open Circuit..................8–416 P063C: T7 Generator Logic Voltage - Low ..................8–422 P063D: T7 Generator Logic Voltage - High ..................8–438...
Page 121 P2504: Alternator - Charging Too High....................8–757 P2530: T1 Key Start/Run Correlation Fault ..................8–761 U0120: T1/T7 CAN Bus Communication Fault - Generator ............8–775 U0156: T1/SC1 CAN Bus Communication Fault - IC ..............8–801 U1007: T1 Controller Main Power Relay....................8–818 U1022: T1 TEC Fuse 2 Failure......................8–830 U1023: T1 TEC Fuse 3 Failure......................8–837 U1024: T1 TEC Fuse 4 Failure......................8–844 U1025: T1 TEC Fuse 5 Failure......................8–851...
Page 122: B1007:T1 Joystick Raise/Lower Broken
B1007:T1 Joystick Raise/Lower Broken Fault Description The T1 controller monitors and compares the output signal from the raise switch and lower switch of the joystick. The T1 controller has detected the JS Raise and JS Lower signals are active at the same time. Note: Depending on which switch failed, the cutting units may not raise or lower.
Page 123 Test the joystick input signals. (continued) Figure 108 3-Button InfoCenter G492413 6-Button InfoCenter G492418 3. In the Diagnostics menu, select the Cutting Units option, and press the select button. 4. In the Cutting Units screen, select the Inputs option, and press the select button. Note: The Cutting Unit Input screen displays the Joystick Lower and Joystick Raise fields with empty boxes.
Page 124 Test the joystick input signals. (continued) Figure 109 3-Button InfoCenter G492415 6-Button InfoCenter G492423 5. While watching the InfoCenter screen, move the joystick to lower the cutting units (full forward). Note: The signal checkmark appears in the box for the Joystick Lower field. Figure 110 3-Button InfoCenter G492414...
Page 125 Test the joystick input signals. (continued) 6-Button InfoCenter G492419 6. Move the joystick to raise the cutting units (full rearward). Note: The InfoCenter indicates an input signal by showing a signal checkmark in the box for the Joystick Raise field. Figure 111 3-Button InfoCenter G492416...
Page 126 Inspect joystick switches and seat harness. Note: The forward micro-switch signals the T1 controller when raising the cutting units. The rear micro-switch signals the T1 controller when lowering the cutting units. 1. Verify the key switch is in the O position.
Page 127 Test the micro-switch. 1. Verify the key switch is in the O position. 2. Test the micro switch; refer to the Testing the Joystick Raise and Lower Switches procedure in the Service Manual for the machine. The test passed. Go to Inspect the seat-harness and main-harness Pass connectors, page...
Page 128 Inspect the seat-harness and main-harness connectors. (continued) 4. Inspect the wiring, inside the seat-harness connector, and inside the main- harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector. Check for proper fit between all pins and their corresponding sockets.
Page 129 Test the seat harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Brown/ Seat White Less than 2 ohms Brown/ Seat Figure 114. White Green Seat /Pink Less than 2 ohms Green Seat Figure 114. /Pink Green Seat /Pink Open Engine Ground...
Page 130 Test the seat harness. (continued) Figure 114 G492633 The test is good. Plug seat-harness connector P03 or P04 into the micro switch. Leave main-harness connector P51 unplugged from seat-harness Pass connector P51. Go to Inspect the T1 controller and main-harness connector, page 8– One or more tests failed.
Page 131 Test the seat harness. (continued) Rotate the key switch to the O position. The fault did not repeat. Install the right console cover; refer to the Service Manual for the machine. Go to Returning the Machine to Service, page 7–23. The fault repeated.
Page 132 Inspect the T1 controller and main-harness connector. (continued) The inspection passed. Leave main-harness connector P29 unplugged from the T1 controller. Pass Go to Test the main harness, page 8–14. One or more inspections failed. Repair or replace the worn or damaged parts. Fail Leave main-harness connector P29 unplugged from the T1 controller.
Page 133 Test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Green Main Figure 116. /Pink Open Engine Ground Figure 116 G508550 The test is good. Plug main-harness connector P51 into seat-harness connector P51. Pass Leave main-harness connector P29 unplugged from the T1 controller. Go to Swap the T1 controller, page 8–16.
Page 134 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 135: Circuit Diagram
Swap the T1 controller. (continued) Go to Returning the Machine to Service, page 7–23. Pass Follow the steps listed. Reinstall the original T1 controller. Fail Repeat the diagnostic process for this fault. Circuit Diagram G492605 C1024:T1 Park Brake Disengage - Short to Ground/Overcurrent Fault Description The T1 controller has measured overcurrent on the Pbrake Release...
Page 136 Verify the fault repeats. (continued) The fault did not repeat. Go to Returning the Machine to Service, page 7–23. Pass Follow the steps listed. Note: If the fault does not repeat, an isolated event has occurred. The fault repeated. Go to Preparing for Troubleshooting and/or Testing, page 7–22.
Page 137 Test the parking brake-disengage solenoid. (continued) Expected Connector Component Location Reading Graphic Solenoid SV1 Open Engine Ground Solenoid SV1 Approximately 12.2 ohms Solenoid SV1 The test is good. Leave main-harness connector P67 unplugged from the parking brake- Pass disengage solenoid SV1. Go to Test the main harness., page 8–19 One or more tests failed.
Page 138 Test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Red/ Main Blue Open Engine Ground Main Black Less than 2 ohms Engine Ground The test is good. Plug main-harness connector P67 into the parking brake-disengage Pass solenoid SV1.
Page 139 Inspect the T1 controller and main-harness connector. (continued) Figure 117 G490767.svg Retaining fastener (location) 4. Inspect the wiring, inside the seat-harness connector, and inside the main harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector. Check for proper fit between all pins and their corresponding sockets.
Page 140 Replacing or Swapping the Primary Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 Troubleshooting Fault Code: C1024:T1 Park Brake Page 8–22...
Page 141: C1025:T1 Park Brake Disengage - Open Circuit
7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33 Calibrating the Traction Pedal, page 7–34 Calibrating the Traction Pump, page 7–43 Calibrating the Virtual Speed Sensor, page 7–53...
Page 142 Verify the fault repeats. 1. Safely stop the machine, shut off attachments, and fully lower them. 2. Rotate the key switch to the O position. 3. Rotate the key switch to the P position. REHEAT 4. Look at the InfoCenter display to see if the fault repeats. Note: If the fault does not repeat immediately, duplicate the operation of the machine when the fault occurred.
Page 143 Test the parking brake-disengage solenoid. (continued) Expected Connector Component Location Reading Graphic Solenoid SV1 Open Engine Ground Solenoid SV1 Open Engine Ground Solenoid SV1 Approximately 12.2 ohms Solenoid SV1 The test is good. Leave main-harness connector P67 unplugged from the parking brake- Pass disengage solenoid SV1.
Page 144 Test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Red/ Main Blue Open Main Black Red/ Main Blue Open Engine Ground Main Black Less than 2 ohms Engine Ground The test is good. Plug main-harness connector P67 into the parking brake-disengage Pass solenoid SV1.
Page 145 Inspect the T1 controller and main-harness connector. (continued) Figure 118 G490767.svg Retaining fastener (location) 4. Inspect the wiring, inside the seat-harness connector, and inside the main harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector. Check for proper fit between all pins and their corresponding sockets.
Page 146 Replacing or Swapping the Primary Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 Troubleshooting Fault Code: C1025:T1 Park Brake Page 8–28...
Page 147 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33 Calibrating the Traction Pedal, page 7–34 Calibrating the Traction Pump, page 7–43 Calibrating the Virtual Speed Sensor, page 7–53...
Page 148: C10E3:T1 48V Logic Enable - Short To Battery
C10E3:T1 48V Logic Enable - Short to Battery Fault Description The T1 controller measured low current on the 48V Enable Relay signal, indicating a short to a high (+) source. Note: This short could be to battery voltage or to another signal that is in a high state.
Page 149 Inspect 48V enable relay and main harness. (continued) Figure 119 48V Enable Relay Connector P32 (main harness) G493279 4. Inspect the wiring, inside the enable relay, and inside the main harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector.
Page 150 Test the 48V enable relay. (continued) Expected Connector Component Location Reading Graphic 48V Enable Relay Open 48V Enable Relay 48V Enable Relay Open 48V Enable Relay 48V Enable Relay 81 to 99 ohms 48V Enable Relay The test is good. Leave main-harness connector P32 unplugged from the 48V Logic Pass Relay.
Page 151 Voltage test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Blue Main Approxi- /Red mately 12V Engine Ground 4. Rotate the key switch to the O position. The test is good. Leave main-harness connector P32 unplugged from the 48V Logic Pass Relay.
Page 152 Inspect the T1 controller and main-harness connector. (continued) Figure 120 G490767.svg Retaining fastener (location) 4. Inspect the wiring, inside the seat-harness connector, and inside the main harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector. Check for proper fit between all pins and their corresponding sockets.
Page 153 Replacing or Swapping the Primary Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 24278SLA Page 8–35...
Page 154: C10E4:T1 48V Logic Enable - Short To Ground/Overcurrent
Swap the T1 controller. (continued) 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33 Calibrating the Traction Pedal, page 7–34 Calibrating the Traction Pump, page 7–43 Calibrating the Virtual Speed Sensor, page 7–53 8.
Page 155 Verify the fault repeats. (continued) 4. Look at the InfoCenter display to see if the fault repeats. Note: If the fault does not repeat immediately, duplicate the operation of the machine when the fault occurred. 5. Rotate the key switch to the O position.
Page 156 Inspect 48V enable relay and main harness. (continued) The inspection passed. Leave main-harness connector P32 unplugged from 48V Enable Relay. Pass Go to Test the 48V enable relay, page 8–38. One or more of the inspections failed. Repair or replace the worn or damaged parts. Fail Leave main-harness connector P32 unplugged from 48V Enable Relay.
Page 157 Test the 48V enable relay. (continued) Plug main-harness connector P32 into the 48V Logic Relay. Rotate the key switch to the P position. REHEAT Look at the InfoCenter display to see if the fault repeats. Rotate the key switch to the O position.
Page 158 Inspect the T1 controller and main-harness connector 1. Verify the key switch is in the O position. 2. Raise the seat and console, and support them with the forward prop rod. 3. Fully loosen the retaining fastener that secures the main-harness connector P29 to the T1 controller and unplug the connector from the controller.
Page 159 Swap the T1 controller. Note: The T1 controller is programmed to the specific machine model and serial number. The T1 controller does not function until programmed using Toro DIAG. IMPORTANT 7 programming and calibrations procedures must accomplish when replacing or swapping a T1 controller. Refer to the...
Page 160: C10E5:T1 48V Logic Enable - Open Circuit
Swap the T1 controller. (continued) 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33 Calibrating the Traction Pedal, page 7–34...
Page 161 Verify the fault repeats. (continued) 3. Rotate the key switch to the P position. REHEAT 4. Look at the InfoCenter display to see if the fault repeats. Note: If the fault does not repeat immediately, duplicate the operation of the machine when the fault occurred.
Page 162 Inspect 48V enable relay and main harness. (continued) The inspection passed. Leave main-harness connector P32 unplugged from 48V Enable relay. Pass Go to Test the 48V enable relay, page 8–44. One or more inspections failed. Repair or replace the worn or damaged parts. Fail Leave main-harness connector P32 unplugged from 48V Enable relay.
Page 163 Test the 48V Enable relay. (continued) Plug main-harness connector P32 into the 48V Logic Relay. Rotate the key switch to the P position. REHEAT Look at the InfoCenter display to see if the fault repeats. Rotate the key switch to the O position.
Page 164 Inspect the T1 controller and main-harness connector 1. Verify the key switch is in the O position. 2. Raise the seat and console, and support them with the forward prop rod. 3. Fully loosen the retaining fastener that secures the main-harness connector P29 to the T1 controller and unplug the connector from the controller.
Page 165 Swap the T1 controller. Note: The T1 controller is programmed to the specific machine model and serial number. The T1 controller does not function until programmed using Toro DIAG. IMPORTANT 7 programming and calibrations procedures must accomplish when replacing or swapping a T1 controller. Refer to the...
Page 166: C1413:T1 Solenoid 1 - Short To Battery
Swap the T1 controller. (continued) 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33 Calibrating the Traction Pedal, page 7–34...
Page 167 Verify the fault repeats. 1. Safely stop the machine, shut off attachments, and fully lower them. 2. Rotate the key switch to the O position. 3. Rotate the key switch to the P position. REHEAT 4. Look at the InfoCenter display to see if the fault repeats. Note: If the fault does not repeat immediately, duplicate the operation of the machine when the fault occurred.
Page 168 Inspect SV1 solenoid and main harness. (continued) 5. Inspect the wiring, inside the enable relay, and inside the main harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector. Check for proper fit between all pins and their corresponding sockets.
Page 169 Test the SV1 solenoid. (continued) Replace the SV1 solenoid; refer to the Service Manual for the machine. Plug main-harness connector P10 into the SV1 solenoid. Start the engine. While looking at the InfoCenter display to see if the fault has repeated, raise and lower the cutting units.
Page 170 Voltage test the main harness. (continued) Start the engine. While looking at the InfoCenter display to see if the fault has repeated, raise and lower the cutting units. Fully lower the cutting units. Rotate the key switch to the O position.
Page 171 Inspect the T1 controller and main-harness connector (continued) The inspection passed. Leave main-harness connector P29 unplugged from the T1 controller. Pass Go to Resistance test the main harness, page 8–53. One or more inspections failed. Repair or replace the worn or damaged parts. Fail Leave main-harness connector P29 unplugged from the T1 controller.
Page 172 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 173: C1414:T1 Solenoid 1 - Short To Ground/Overcurrent
Circuit Diagram G493511 C1414:T1 Solenoid 1 - Short to Ground/ Overcurrent Fault Description The T1 Controller measured overcurrent on the SV1 Front signal, indicating a short to ground. Circuit Description The SV1 solenoid is located in the lift-control manifold. SV1 solenoid controls hydraulic flow used to raise and lower the front cutting units.
Page 174 Inspect SV1 solenoid and main harness. (continued) 3. Remove the floor plate; refer to the Service Manual for the machine. 4. At port SV1 of the cutting unit lift manifold, unplug main-harness connector P10 from the SV1 solenoid. Figure 127 G493430 Connector P10 (main harness) SV1 solenoid...
Page 175 Test the SV1 solenoid. (continued) Expected Connector Component Location Reading Graphic SV1 solenoid Open Engine Ground SV1 solenoid Open Engine Ground SV1 solenoid Approximately 8.8 ohms SV1 solenoid The test is good. Leave main-harness connector P10 unplugged from the SV1 solenoid. Pass Go to Inspect the T1 controller and main-harness connector, page 8–...
Page 176 Inspect the T1 controller and main-harness connector 1. Verify the key switch is in the O position. 2. Raise the seat and console, and support them with the forward prop rod. 3. Fully loosen the retaining fastener that secures the main-harness connector P29 to the T1 controller and unplug the connector from the controller.
Page 177 Resistance test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color White Main /Blue Less than 2 ohms White Main /Blue Main Black Open Engine Ground Main Black Less than 2 ohms Engine Ground The test is good. Plug main-harness connector P10 into the SV1 solenoid.
Page 178 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 179: C1415:T1 Solenoid 1 - Open Circuit
C1415:T1 Solenoid 1 - Open Circuit Fault Description The T1 Controller measured an open circuit on the SV1 Front signal. Circuit Description The SV1 solenoid is located in the lift-control manifold. SV1 solenoid controls hydraulic flow used to raise and lower the front cutting units. The T1 controller signal energizes the SV1 lift solenoid.
Page 180 Inspect SV1 solenoid and main harness. (continued) Figure 129 G493430 Connector P10 (main harness) SV1 solenoid 5. Inspect the wiring, inside the enable relay, and inside the main harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector.
Page 181 Test the SV1 solenoid. (continued) Expected Connector Component Location Reading Graphic SV1 solenoid Open Engine Ground SV1 solenoid Approximately 8.8 ohms SV1 solenoid The test is good. Leave main-harness connector P10 unplugged from the SV1 solenoid. Pass Go to Inspect the T1 controller and main-harness connector, page 8– One or more tests failed.
Page 182 Inspect the T1 controller and main-harness connector (continued) Figure 130 G490767.svg Retaining fastener (location) 4. Inspect the wiring, inside the seat-harness connector, and inside the main harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector. Check for proper fit between all pins and their corresponding sockets.
Page 183 Resistance test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color White Main /Blue White Main /Blue Open Engine Ground Main Black Less than 2 ohms Engine Ground The test is good. Plug main-harness connector P10 into the SV1 solenoid. Pass Leave main-harness connector P29 unplugged from the T1 controller.
Page 184 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 185: C1423:T1 Solenoid 2 - Short To Battery
C1423:T1 Solenoid 2 - Short to Battery Fault Description The T1 Controller measured low current on the SV2 Raise signal, indicating a short to a high (+) source. Note: This short could be to battery voltage or to another signal that is in a high state.
Page 186 Inspect SV2 solenoid and main harness. (continued) Figure 131 G493570 Connector P13 (main harness) SV2 solenoid The inspection passed. Leave main-harness connector P13 unplugged from SV2 solenoid. Pass Go to Test the SV2 solenoid, page 8–68. One or more inspections failed. Repair or replace the worn or damaged parts.
Page 187 Test the SV2 solenoid. (continued) Expected Connector Component Location Reading Graphic SV2 solenoid Open Engine Ground SV2 solenoid Approximately 8.8 ohms SV2 solenoid The test is good. Leave main-harness connector P13 unplugged from the SV2 solenoid. Pass Go to Voltage test the main harness, page 8–69.
Page 188 Voltage test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color White Main /Blue 0.0V Engine Ground Main Black 0.0V Engine Ground 4. Rotate the key switch to the O position. The test is good. Leave main-harness connector P10 unplugged from the SV1 solenoid. Pass Go to Inspect the T1 controller and main-harness connector, page 8–...
Page 189 Inspect the T1 controller and main-harness connector (continued) Figure 132 G490767.svg Retaining fastener (location) 4. Inspect the wiring, inside the seat-harness connector, and inside the main harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector. Check for proper fit between all pins and their corresponding sockets.
Page 190 Resistance test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Pink/ Main White Pink/ Main White Open Engine Ground Main Black Less than 2 ohms Engine Ground The test is good. Plug main-harness connector P13 into the SV2 solenoid. Pass Leave main-harness connector P29 unplugged from the T1 controller.
Page 191 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 192: C1424:T1 Solenoid 2 - Short To Ground/Overcurrent
C1424:T1 Solenoid 2 - Short to Ground/ Overcurrent Fault Description The T1 Controller measured overcurrent on the SV2 Raise signal, indicating a short to ground. Circuit Description The SV2 solenoid is located in the lift-control manifold. SV2 solenoid controls hydraulic flow used to change the raise or lower direction of the cutting units.
Page 193 Inspect SV2 solenoid and main harness. (continued) Figure 133 G493570 Connector P13 (main harness) SV2 solenoid The inspection passed. Leave main-harness connector P13 unplugged from SV2 solenoid. Pass Go to Test the SV2 solenoid, page 8–75. One or more inspections failed. Repair or replace the worn or damaged parts.
Page 194 Test the SV2 solenoid. (continued) Expected Connector Component Location Reading Graphic SV2 solenoid Open Engine Ground SV2 solenoid Approximately 8.8 ohms SV2 solenoid The test is good. Leave main-harness connector P13 unplugged from the SV2 solenoid. Pass Go to Inspect the T1 controller and main-harness connector, page 8– One or more tests failed.
Page 195 Inspect the T1 controller and main-harness connector. (continued) Figure 134 G490767.svg Retaining fastener (location) 4. Inspect the wiring, inside the seat-harness connector, and inside the main harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector. Check for proper fit between all pins and their corresponding sockets.
Page 196 Resistance test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Pink/ Main White Pink/ Main White Open Engine Ground Main Black Less than 2 ohms Engine Ground The test is good. Plug main-harness connector P13 into the SV2 solenoid. Pass Leave main-harness connector P29 unplugged from the T1 controller.
Page 197 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 198: C1425:T1 Solenoid 2 - Open Circuit
C1425:T1 Solenoid 2 - Open Circuit Fault Description The T1 Controller measured an open circuit on the SV2 Raise signal. Circuit Description The SV2 solenoid is located in the lift-control manifold. SV2 solenoid controls hydraulic flow used to change the raise or lower direction of the cutting units.
Page 199 Inspect SV2 solenoid and main harness. (continued) Figure 135 G493570 Connector P13 (main harness) SV2 solenoid The inspection passed. Leave main-harness connector P13 unplugged from SV2 solenoid. Pass Go to Test the SV2 solenoid, page 8–81. One or more inspections failed. Repair or replace the worn or damaged parts.
Page 200 Test the SV2 solenoid. (continued) Expected Connector Component Location Reading Graphic SV2 solenoid Open Engine Ground SV2 solenoid Approximately 8.8 ohms SV2 solenoid The test is good. Leave main-harness connector P13 unplugged from the SV2 solenoid. Pass Go to Inspect the T1 controller and main-harness connector, page 8– One or more tests failed.
Page 201 Inspect the T1 controller and main-harness connector. (continued) Figure 136 G490767.svg Retaining fastener (location) 4. Inspect the wiring, inside the seat-harness connector, and inside the main harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector. Check for proper fit between all pins and their corresponding sockets.
Page 202 Resistance test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Pink/ Main White Pink/ Main White Open Engine Ground Main Black Less than 2 ohms Engine Ground The test is good. Plug main-harness connector P13 into the SV2 solenoid. Pass Leave main-harness connector P29 unplugged from the T1 controller.
Page 203 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 204: C1433:T1 Solenoid 3 - Short To Battery
C1433:T1 Solenoid 3 - Short to Battery Fault Description The T1 Controller measured low current on the SV3 Raise Rear signal, indicating a short to a high (+) source. Note: This short could be to battery voltage or to another signal that is in a high state.
Page 205 Inspect SV3 solenoid and main harness. (continued) Figure 137 SV3 solenoid Connector P19 (main harness) G494807 5. Inspect the wiring, inside the enable relay, and inside the main harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector.
Page 206 Test the SV3 solenoid. (continued) Expected Connector Component Location Reading Graphic SV3 solenoid Open Engine Ground SV3 solenoid Approximately 8.8 ohms SV3 solenoid The test is good. Leave main-harness connector P19 unplugged from the SV3 solenoid. Pass Go to Voltage test the main harness, page 8–88.
Page 207 Voltage test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Gray/ Main White 0.0V Engine Ground Main Black 0.0V Engine Ground 4. Rotate the key switch to the O position. The test is good. Leave main-harness connector P19 unplugged from the SV3 solenoid. Pass Go to Inspect the T1 controller and main-harness connector, page 8–...
Page 208 Inspect the T1 controller and main-harness connector. (continued) Figure 138 G490767.svg Retaining fastener (location) 4. Inspect the wiring, inside the seat-harness connector, and inside the main harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector. Check for proper fit between all pins and their corresponding sockets.
Page 209 Resistance test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Gray/ Main White Main Black Open Engine Ground Main Black Less than 2 ohms Engine Ground The test is good. Plug main-harness connector P19 into the SV3 solenoid. Pass Leave main-harness connector P29 unplugged from the T1 controller.
Page 210 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 211: C1434:T1 Solenoid 3 - Short To Ground/Overcurrent
C1434:T1 Solenoid 3 - Short to Ground/ Overcurrent Fault Description The T1 Controller measured overcurrent on the SV3 Raise Rear signal indicating a short to ground. Circuit Description The SV3 solenoid is located in the lift-control manifold. SV3 solenoid controls hydraulic flow used to raise or lower the rear cutting units. The T1 controller signal energizes the SV3 lift solenoid.
Page 212 Inspect SV3 solenoid and main harness. (continued) Figure 139 SV3 solenoid Connector P19 (main harness) G494807 5. Inspect the wiring, inside the enable relay, and inside the main harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector.
Page 213 Test the SV3 solenoid. (continued) Expected Connector Component Location Reading Graphic SV3 solenoid Open Engine Ground SV3 solenoid Approximately 8.8 ohms SV3 solenoid The test is good. Leave main-harness connector P19 unplugged from the SV3 solenoid. Pass Go to Inspect the T1 controller and main-harness connector, page 8– One or more tests failed.
Page 214 Inspect the T1 controller and main-harness connector. (continued) Figure 140 G490767.svg Retaining fastener (location) 4. Inspect the wiring, inside the seat-harness connector, and inside the main harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector. Check for proper fit between all pins and their corresponding sockets.
Page 215 Resistance test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Gray/ Main White Main Black Open Engine Ground Main Black Less than 2 ohms Engine Ground The test is good. Plug main-harness connector P19 into the SV3 solenoid. Pass Leave main-harness connector P29 unplugged from the T1 controller.
Page 216 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 217: C1435:T1 Solenoid 3 - Open Circuit
C1435:T1 Solenoid 3 - Open Circuit Fault Description The T1 Controller measured an open circuit on the SV3 Raise Rear signal. Circuit Description The SV3 solenoid is located in the lift-control manifold. SV3 solenoid controls hydraulic flow used to raise or lower the rear cutting units. The T1 controller signal energizes the SV3 lift solenoid.
Page 218 Inspect SV3 solenoid and main harness. (continued) Figure 141 SV3 solenoid Connector P19 (main harness) G494807 5. Inspect the wiring, inside the enable relay, and inside the main harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector.
Page 219 Test the SV3 solenoid. (continued) Expected Connector Component Location Reading Graphic SV3 solenoid Open Engine Ground SV3 solenoid Approximately 8.8 ohms SV3 solenoid The test is good. Leave main-harness connector P19 unplugged from the SV3 solenoid. Pass Go to Inspect the T1 controller and main-harness connector, page 8– 101.
Page 220 Inspect the T1 controller and main-harness connector. (continued) Figure 142 G490767.svg Retaining fastener (location) 4. Inspect the wiring, inside the seat-harness connector, and inside the main harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector. Check for proper fit between all pins and their corresponding sockets.
Page 221 Resistance test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Gray/ Main White Main Black Open Engine Ground Main Black Less than 2 ohms Engine Ground The test is good. Plug main-harness connector P19 into the SV3 solenoid. Pass Leave main-harness connector P29 unplugged from the T1 controller.
Page 222 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 223: C1443:T1 Solenoid 4 - Short To Battery
C1443:T1 Solenoid 4 - Short to Battery Fault Description The T1 controller measured low current on the SV4 Enable signal, indicating a short to a high (+) source. Note: This short could be to battery voltage or to another signal that is in a high state.
Page 224 Inspect SVRV solenoid and main harness. (continued) Figure 143 SVRV solenoid Connector P18 (main harness) G494956 5. Inspect the wiring, inside the enable relay, and inside the main harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector.
Page 225 Test the SVRV solenoid. (continued) Expected Connector Component Location Reading Graphic SVRV solenoid Open Engine Ground SVRV solenoid Approximately 8.8 ohms SVRV solenoid The test is good. Leave main-harness connector P18 unplugged from the SVRV Pass solenoid. Go to Voltage test the main harness, page 8–107.
Page 226 Voltage test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Gray/ Main White 0.0V Engine Ground Main Black 0.0V Engine Ground 4. Rotate the key switch to the O position. The test is good. Leave main-harness connector P18 unplugged from the SVRV Pass solenoid.
Page 227 Inspect the T1 controller and main-harness connector. (continued) Figure 144 G490767.svg Retaining fastener (location) 4. Inspect the wiring, inside the seat-harness connector, and inside the main harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector. Check for proper fit between all pins and their corresponding sockets.
Page 228 Resistance test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Gray/ Main White Main Black Open Engine Ground Main Black Less than 2 ohms Engine Ground The test is good. Plug main-harness connector P18 into the SVRV solenoid. Pass Leave main-harness connector P29 unplugged from the T1 controller.
Page 229 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 230: C1444:T1 Solenoid 4 - Short To Ground/Overcurrent
C1444:T1 Solenoid 4 - Short to Ground/ Overcurrent Fault Description The T1 Controller measured overcurrent on the SV4 Enable signal indicating a short to ground. Circuit Description The SVRV (SV4) solenoid is located in the lift-control manifold. SVRV solenoid is used to direct hydraulic flow to SV2 spool valve (raise/lower direction) or to bypass hydraulic flow to the tank.
Page 231 Inspect SVRV solenoid and main harness. (continued) Figure 145 SVRV solenoid Connector P18 (main harness) G494956 5. Inspect the wiring, inside the enable relay, and inside the main harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector.
Page 232 Test the SVRV solenoid. (continued) Expected Connector Component Location Reading Graphic SVRV solenoid Open Engine Ground SVRV solenoid Approximately 8.8 ohms SVRV solenoid The test is good. Leave main-harness connector P18 unplugged from the SVRV Pass solenoid. Go to Inspect the T1 controller and main-harness connector, page 8– 114.
Page 233 Inspect the T1 controller and main-harness connector. (continued) Figure 146 G490767.svg Retaining fastener (location) 4. Inspect the wiring, inside the seat-harness connector, and inside the main harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector. Check for proper fit between all pins and their corresponding sockets.
Page 234 Resistance test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Gray/ Main White Main Black Open Engine Ground Main Black Less than 2 ohms Engine Ground The test is good. Plug main-harness connector P18 into the SVRV solenoid. Pass Leave main-harness connector P29 unplugged from the T1 controller.
Page 235 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 236: C1445:T1 Solenoid 4 - Open Circuit
C1445:T1 Solenoid 4 - Open Circuit Fault Description The T1 controller measured an open circuit on the SV4 Enable signal. Circuit Description The SVRV (SV4) solenoid is located in the lift-control manifold. SVRV solenoid is used to direct hydraulic flow to SV2 spool valve (raise/lower direction) or to bypass hydraulic flow to the tank.
Page 237 Inspect SVRV solenoid and main harness. (continued) Figure 147 SVRV solenoid Connector P18 (main harness) G494956 5. Inspect the wiring, inside the enable relay, and inside the main harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector.
Page 238 Test the SVRV solenoid. (continued) Expected Connector Component Location Reading Graphic SVRV solenoid Open Engine Ground SVRV solenoid Approximately 8.8 ohms SVRV solenoid The test is good. Leave main-harness connector P18 unplugged from the SVRV Pass solenoid. Go to Inspect the T1 controller and main-harness connector, page 8– 120.
Page 239 Inspect the T1 controller and main-harness connector. (continued) Figure 148 G490767.svg Retaining fastener (location) 4. Inspect the wiring, inside the seat-harness connector, and inside the main harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector. Check for proper fit between all pins and their corresponding sockets.
Page 240 Resistance test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Gray/ Main White Main Black Open Engine Ground Main Black Less than 2 ohms Engine Ground The test is good. Plug main-harness connector P18 into the SVRV solenoid. Pass Leave main-harness connector P29 unplugged from the T1 controller.
Page 241 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 242: C1801: T2, T3, T4, T5, T6 Cutting Unit Motor - High Temp Shutdown
C1801: T2, T3, T4, T5, T6 Cutting Unit Motor - High Temp Shutdown Fault Description The inverter/controller measured the internal-motor temperature exceeded 130° C (266° F). The inverter/controller broadcasts the Cutting Unit Motor - High Temp Shutdown message on the CAN bus.
Page 243 Identify the operating conditions and affected cutting unit. (continued) IMPORTANT If the operator was using the machine to scalp the turf, excessive cutting-unit motor load may cause high motor temperature. 2. Rotate the key switch to the P position. REHEAT 3.
Page 244 Identify the operating conditions and affected cutting unit. (continued) Figure 150 G495441 6. Rotate the key switch to the O position. 7. Go to Allow the cutting-unit motor to cool, page 8–126. Allow the cutting-unit motor to cool. Recommended Equipment: Non-contact infrared thermometer 1.
Page 245 Allow the cutting-unit motor to cool. (continued) Figure 151 G495736 3. Start the engine. 4. Press the PTO switch to the E position. NGAGE 5. Look at the InfoCenter display to see if the fault repeats. Note: If the fault does not repeat immediately, duplicate the operation of the machine when the fault occurred.
Page 246 Inspect the cutting unit. (continued) 3. Remove the cutting unit from the machine; refer to the Operator’s Manual for the machine. 4. Inspect the condition of the cutting unit for wear and damage. 5. If the machine is equipped with Verticutter cutting units, skip to Inspect the Verticutter, page 8–129.
Page 247 Inspect the cutting unit. (continued) The fault repeated. Go to Swap reel motor positions, page 8–136. Inspect the Verticutter. Machines equipped with the optional Verticutter cutting unit. 1. Verify the key switch is in the O position. 2. Rotate the shaft and blade assembly, check rotation resistance, and check reel- bearing wear;...
Page 248 Inspect the universal groomer brush and drive. (continued) Figure 152 G495962 3. Rotate the reel, check rotation resistance, and check reel-bearing wear; refer to the Service Manual for the machine. Note: The reel should rotate freely. 4. Rotate the knob of the groomer drive to the F position.
Page 249 Inspect the universal groomer brush and drive. (continued) Figure 153 G495939 8. If the driven shaft rotates freely, remove the gearbox and inspect it for damage and wear; refer to the Service Manual for the machine. The cutting unit and universal groomer drive are good. •...
Page 250 Inspect the rear roller brush and drive. (continued) 2. Rotate the reel, check rotation resistance, and check reel-bearing wear; refer to the Service Manual for the machine. The reel should rotate with slight drag from the rear roller brush and drive. 3.
Page 251 Inspect the rear roller brush and drive. (continued) The fault repeated. Go to Inspect the inverter/controller and cutting-unit motor connectors, page 8–133. Inspect the inverter/controller and cutting-unit motor connectors. G495441 1. Verify the key switch is in the O position. 2.
Page 252 Inspect the inverter/controller and cutting-unit motor connectors. (continued) Connector (inverter/ controller) Edge-card connector (cutting-unit motor) G495860 6. Inspect the and inverter/controller connector and the edge-card connector of the motor for damage and corrosion. The inspection passed. Leave the inverter/controller removed from the cutting-unit motor. Pass Go to Swap reel motor positions, page...
Page 253 Inspect the inverter/controller and cutting-unit motor connectors. (continued) The fault code did not repeat. Unplug the 48V battery disconnect from the socket; refer to Connecting and Disconnecting the 48V Battery System, page 7–8. Remove the 6 socket-head screws (old) that secure the inverter/ controller to the cutting-unit motor, and carefully separate the controller from the motor.
Page 254 Go to Swap reel motor positions, page 8–136. Swap reel motor positions. Parts needed for this procedure: Description Toro Part No. Quantity O-Ring Service Kit 144-6731 1. Verify the key switch is in the O position. 2. Verify the 48V battery disconnect is plugged into the socket.
Page 255 Test the reel motor at the swap position. Parts needed for this procedure: Description Toro Part No. Quantity O-Ring Service Kit 144-6731 1. Verify the key switch is in the O position. 2. Plug the 48V battery disconnect into the socket; refer to...
Page 256 Test the reel motor at the swap position. (continued) The motor is damaged or worn. Raise the seat and support them with the forward prop rod. Unplug the 48V battery disconnect from the socket; refer to Connecting and Disconnecting the 48V Battery System, page 7–8.
Page 257 Test the reel motor at the swap position. (continued) 16. Plug main-harness connectors from the inverter/controller connectors. 17. Plug the 48V battery disconnect into the socket; refer to Connecting and Disconnecting the 48V Battery System, page 7–8. 18. Lower the seat and console, and secure them with the latch. 19.
Page 258 Test the reel motor at the swap position. (continued) 11. Go to Inspect the main-harness and inverter/controller connectors, page 8–140. Inspect the main-harness and inverter/controller connectors. G495441 1. Verify the key switch is in the O position. 2. If you identified cutting unit 2 or cutting unit 3 in Identify the operating conditions and affected cutting unit, page 8–124, open the hood.
Page 259 Inspect the main-harness and inverter/controller connectors. (continued) Figure 156 Cutting Unit 1 Connector P47 (main harness) Connector P46 (main harness) Signal connector (inverter/ controller) 48V battery connector (inverter/controller) G503147 Figure 157 Cutting Unit 5 48V battery connector (inverter/controller) Connector P45 (main harness) Connector P44 (main harness)
Page 260 Inspect the main-harness and inverter/controller connectors. (continued) Figure 158 Cutting Unit 2 Signal connector (inverter/ controller) 48V battery connector (inverter/controller) Connector P39 (main harness) Connector P38 (main harness) G503151 Figure 159 Cutting Unit 3 48V battery connector (inverter/controller) Connector P49 (main harness) Connector P48 (main harness)
Page 261 Inspect the main-harness and inverter/controller connectors. (continued) The inspection is good. Leave main-harness connectors unplugged from the inverter/controller Pass connectors. Go to Inspect the main harness and 48V ground junction, page 8–143. One or more inspections failed. Clean any corrosion or replace the corroded or damaged parts; refer to the Service Manual for the machine.
Page 262 Inspect the main harness and 48V ground junction. (continued) The inspection passed. Pass Torque the 3/8-inch locknuts at both sides the ground junction to 15.6 to 17 N∙m (138 to 150 in-lb). Go to Resistance test the main harness, page 8–144.
Page 263 Resistance test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color 48V ground junction P45 (CU5) Main Black Less than 2 ohms 48V ground junction The test is good. Leave the inverter/controller-harness connector for the 48V bus unplugged.
Page 264 Using Toro DIAG to Program the Machine, page 7–32. Note: A new inverter/controller does not function until programmed using Toro DIAG. 3. Run the cutting units under light load on a test plot. 4. Look at the InfoCenter display to see if the fault has repeated.
Page 265: Circuit Diagram
Advise best operating practices. (continued) Proper Mowing Scalping/Circle Cutting Verticutting Techniques Maintain proper reel-to- Reduce the number of bedknife clearance. Use blades (increasing blade light contact. spacing) to reduce the amount of required power. Follow and maintain the 1/ Follow and maintain the 1/ Set the verticutter blade 3rd rule (cut only 1/3 of 3rd rule (cut only 1/3 of...
Page 266: C180C: T2, T3, T4, T5, T6 Cutting Unit Motor - High Temp Warning
C180C: T2, T3, T4, T5, T6 Cutting Unit Motor - High Temp Warning Fault Description The inverter/controller measured the internal-motor temperature exceeded 120° C (248° F). The inverter/controller broadcasts the Cutting Unit Motor - High Temp Warning message on the CAN bus.
Page 267 Identify the operating conditions and affected cutting unit. (continued) 2. Rotate the key switch to the P position. REHEAT 3. In the InfoCenter, navigate to the Faults option and select it. Figure 161 G496129 Note: The Code list displays. 4. In the Code list, and record the controller number (T2, T3, T4, T5, or T6) associated fault C180C.
Page 268 Identify the operating conditions and affected cutting unit. (continued) Figure 162 G495441 6. Rotate the key switch to the O position. 7. Go to Allow the cutting-unit motor to cool, page 8–150. Allow the cutting-unit motor to cool. Recommended Equipment: Non-contact infrared thermometer 1.
Page 269 Allow the cutting-unit motor to cool. (continued) Figure 163 G495736 3. Rotate the key switch to the P position. REHEAT 4. Look at the InfoCenter display to see if the fault repeats. Note: If the fault does not repeat immediately, duplicate the operation of the machine when the fault occurred.
Page 270 Inspect the cutting unit. (continued) 5. If the machine is equipped with Verticutter cutting units, skip to Inspect the Verticutter, page 8–153. 6. Check the bedknife selection; refer to the Operator’s Manual for the cutting units. Note: If the bedknife is incorrect for effective height-of-cut, excessive cutting-unit motor load may cause high motor temperature.
Page 271 Inspect the Verticutter. Machines equipped with the optional Verticutter cutting unit. 1. Verify the key switch is in the O position. 2. Rotate the shaft and blade assembly, check rotation resistance, and check reel- bearing wear; refer to the Service Manual for the machine. Note: The shaft and blade assembly should rotate freely.
Page 272 Inspect the universal groomer brush and drive. (continued) Figure 164 G495962 3. Rotate the reel, check rotation resistance, and check reel-bearing wear; refer to the Service Manual for the machine. Note: The reel should rotate freely. 4. Rotate the knob of the groomer drive to the F position.
Page 273 Inspect the universal groomer brush and drive. (continued) Figure 165 G495939 8. If the driven shaft rotates freely, remove the gearbox and inspect it for damage and wear; refer to the Service Manual for the machine. The cutting unit and universal groomer drive are good. •...
Page 274 Inspect the rear roller brush and drive. (continued) 2. Rotate the reel, check rotation resistance, and check reel-bearing wear; refer to the Service Manual for the machine. The reel should rotate with slight drag from the rear roller brush and drive. 3.
Page 275 Inspect the rear roller brush and drive. (continued) The fault repeated. Go to Inspect the inverter/controller and cutting-unit motor connectors, page 8–157. Inspect the inverter/controller and cutting-unit motor connectors. G495441 1. Verify the key switch is in the O position. 2.
Page 276 Inspect the inverter/controller and cutting-unit motor connectors. (continued) Connector (inverter/ controller) Edge-card connector (cutting-unit motor) G495860 6. Inspect the and inverter/controller connector and the edge-card connector of the motor for damage and corrosion. The inspection passed. Leave the inverter/controller removed from the cutting-unit motor. Pass Go to Swap reel motor positions, page...
Page 277 Inspect the inverter/controller and cutting-unit motor connectors. (continued) The fault code did not repeat. Unplug the 48V battery disconnect from the socket; refer to Connecting and Disconnecting the 48V Battery System, page 7–8. Remove the 6 socket-head screws (old) that secure the inverter/ controller to the cutting-unit motor, and carefully separate the controller from the motor.
Page 278 Go to Swap reel motor positions, page 8–160. Swap reel motor positions. Parts needed for this procedure: Description Toro Part No. Quantity O-Ring Service Kit 144-6731 1. Verify the key switch is in the O position. 2. Verify the 48V battery disconnect is plugged into the socket.
Page 279 Test the reel motor at the swap position. (continued) 1. Verify the key switch is in the O position. 2. Plug the 48V battery disconnect into the socket; refer to Connecting and Disconnecting the 48V Battery System, page 7–8. 3. Lower the seat and console, and secure them with the latch. 4.
Page 280 Test the reel motor at the swap position. (continued) The motor is damaged or worn. Raise the seat and console, and support them with the forward prop rod. Unplug the 48V battery disconnect from the socket; refer to Connecting and Disconnecting the 48V Battery System, page 7–8.
Page 281 Test the reel motor at the swap position. (continued) The fault repeated. Unplug the 48V battery disconnect from the socket; refer to Connecting and Disconnecting the 48V Battery System, page 7–8. Reinstall the old cutting unit motor to the cutting unit at the identified cutting-unit location.
Page 282 Inspect the inverter/controller and main harness connectors. (continued) Cutting Unit Position Main-Harness Connector (Cutting Unit 48 Bus) Figure 167 Cutting Unit 3 Inverter/controller-harness connector (48V bus) Main-harness connector (cutting unit 48V bus) G495749 4. Inspect the wiring, inside the inverter/controller-harness connector, and inside the main harness connector for damage and corrosion.
Page 283 Inspect the main harness and 48V ground junction. (continued) Figure 168 48V ground junction Negative battery cable Front of the machine 48V bus ground wire (cutting units 1, 4, and 5) 48V bus ground wire (cutting units 2 and 3) G495752 Note: The 48V bus ground wires for the inverter/controllers are 10-gauge wire with...
Page 284 Resistance test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color P47 (CU1) Main Black Less than 2 ohms 48V ground junction P39 (CU2) Main Black Open 48V ground junction P41 (CU3) Main Black Less than 2 ohms 48V ground junction P49 (CU4)
Page 285 Using Toro DIAG to Program the Machine, page 7–32. Note: A new inverter/controller does not function until programmed using Toro DIAG. 3. Run the cutting units under light load on a test plot. 4. Look at the InfoCenter display to see if the fault repeats.
Page 286 Advise best operating practices. 1. Discuss with the machine operator changing how the machine is run when cutting grass. Recommend the following changes: • Reduce the maximum allowed mow speed setting; refer to the Operator Manual for the machine. • Lower the cruise-control speed setting; refer to the Operator Manual for the machine.
Page 287: Circuit Diagram
Circuit Diagram G496007 C1811: T2, T3, T4, T5, T6 Cutting Unit Motor Controller - High Temp Shutdown Fault Description The inverter/controller measured its internal temperature exceeded 100° C (212° F). The inverter/controller broadcasts the Cutting Unit Motor Controller - High Temp Shutdown message on the CAN bus.
Page 288 Verify the fault repeats. (continued) Note: If the fault does not repeat immediately, duplicate the operation of the machine when the fault occurred. 6. Park the machine and rotate the key switch to the O position. The fault did not repeat. Go to Returning the Machine to Service, page 7–23.
Page 289 Identify the operating conditions and affected cutting unit. (continued) 4. In the Code list, and record the controller number (T2, T3, T4, T5, or T6) associated fault C1811. Note: It is possible that fault code C1811 may display more than once when a high temperature shutdown occurs for more than 1 cutting unit motors.
Page 290 Allow the inverter/controller to cool. (continued) Figure 171 G496128 3. Start the engine. 4. Pull the PTO switch to the E position. NGAGE 5. Look at the InfoCenter display to see if the fault repeats. 6. Press the PTO switch to the D position.
Page 291 Inspect the cutting unit. (continued) 5. If the machine is equipped with Verticutter cutting units, skip to Inspect the Verticutter, page 8–174. 6. Check the bedknife selection; refer to the Operator’s Manual for the cutting units. Note: If the bedknife is incorrect for effective height-of-cut, excessive cutting-unit inverter/controller load may cause high inverter temperature.
Page 292 Inspect the Verticutter. Machines equipped with the optional Verticutter cutting unit. 1. Verify the key switch is in the O position. 2. Rotate the shaft and blade assembly, check rotation resistance, and check reel- bearing wear; refer to the Service Manual for the machine. Note: The shaft and blade assembly should rotate freely.
Page 293 Inspect the universal groomer brush and drive. (continued) Figure 172 G495962 3. Rotate the reel, check rotation resistance, and check reel-bearing wear; refer to the Service Manual for the machine. Note: The reel should rotate freely. 4. Rotate the knob of the groomer drive to the F position.
Page 294 Inspect the universal groomer brush and drive. (continued) Figure 173 G495939 8. If the driven shaft rotates freely, remove the gearbox and inspect it for damage and wear; refer to the Service Manual for the machine. The cutting unit and universal groomer drive are good. •...
Page 295 Inspect the rear roller brush and drive. (continued) 2. Rotate the reel, check rotation resistance, and check reel-bearing wear; refer to the Service Manual for the machine. The reel should rotate with slight drag from the rear roller brush and drive. 3.
Page 296 Inspect the rear roller brush and drive. (continued) The fault repeated. Go to Inspect the inverter/controller and main harness connectors, page 8–178. Inspect the inverter/controller and main harness connectors. G495441 1. Verify the key switch is in the O position. 2.
Page 297 Inspect the inverter/controller and main harness connectors. (continued) Figure 176 Cutting Unit 1 Connector P47 (main harness) Connector P46 (main harness) Signal connector (inverter/ controller) 48V battery connector (inverter/controller) G503147 Figure 177 Cutting Unit 5 48V battery connector (inverter/controller) Connector P45 (main harness) Connector P44 (main harness)
Page 298 Inspect the inverter/controller and main harness connectors. (continued) Figure 178 Cutting Unit 2 Signal connector (inverter/ controller) 48V battery connector (inverter/controller) Connector P39 (main harness) Connector P38 (main harness) G503151 Figure 179 Cutting Unit 3 48V battery connector (inverter/controller) Connector P49 (main harness) Connector P48 (main harness)
Page 299 Inspect the inverter/controller and main harness connectors. (continued) The inspection passed. Leave main-harness connector unplugged from the inverter/controller- Pass harness connector. Go to Inspect the main harness and 48V ground junction, page 8–181. One or more inspections failed. Repair or replace the worn or damaged parts. Leave main-harness connector unplugged from the inverter/controller- Fail harness connector.
Page 300 Inspect the main harness and 48V ground junction. (continued) The inspection passed. Pass Torque the 3/8-inch locknuts at both sides the ground junction to 15.6 to 17 N∙m (138 to 150 in-lb). Go to Resistance test the main harness, page 8–182.
Page 301 Resistance test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color 48V ground junction P45 (CU5) Main Black Less than 2 ohms 48V ground junction The test is good. Leave the inverter/controller-harness connector for the 48V bus unplugged.
Page 302 Inspect the inverter/controller and cutting-unit motor connectors. G495441 1. Verify the key switch is in the O position. 2. Raise the seat and console, and support them with the forward prop rod. 3. Unplug the 48V battery disconnect from the socket; refer to Connecting and Disconnecting the 48V Battery System, page 7–8.
Page 303 Inspect the inverter/controller and cutting-unit motor connectors. (continued) 6. Inspect the and inverter/controller connector and the edge-card connector of the motor for damage and corrosion. The inspection passed. Leave the inverter/controller removed from the cutting-unit motor. Pass Go to Replace the inverter/controller, page 8–187.
Page 304 Inspect the inverter/controller and cutting-unit motor connectors. (continued) The fault code did not repeat. Unplug the 48V battery disconnect from the socket; refer to Connecting and Disconnecting the 48V Battery System, page 7–8. Remove the 6 socket-head screws (old) that secure the inverter/ controller to the cutting-unit motor, and carefully separate the controller from the motor.
Page 305 Using Toro DIAG to Program the Machine, page 7–32. Note: A new inverter/controller does not function until programmed using Toro DIAG. 3. Run the cutting units under light load on a test plot. 4. Look at the InfoCenter display to see if the fault repeats.
Page 306 Advise best operating practices. (continued) Proper Mowing Scalping/Circle Cutting Verticutting Techniques Maintain reel and Scalping and circle cutting Ensure that the cutting- bedknife sharpness. are considered severe unit blades are sharp, applications. Dedicate adjusted correctly, and reels specifically to these that none of the blades applications.
Page 307: Circuit Diagram
Circuit Diagram G496007 C181C: T2, T3, T4, T5, T6 Cutting Unit Motor Controller - High Temp Warning Fault Description The inverter/controller measured its internal temperature exceeded 95° C (203° F). The inverter/controller broadcasts the Cutting Unit Motor Controller - High Temp Warning message on the CAN bus.
Page 308 Verify the fault repeats. (continued) 5. Rotate the key switch to the O position. The fault did not repeat. Go to Returning the Machine to Service, page 7–23. Pass Follow the steps listed. Note: If the fault does not repeat, an isolated event has occurred. The fault repeated.
Page 309 Identify the operating conditions and affected cutting unit. (continued) Note: It is possible that fault code C181C may display more than once when a high temperature shutdown occurs for more than 1 cutting unit motors. 5. Use table below and 182 Figure 2, page 8–191 to identify the cutting unit(s) causing the fault.
Page 310 Allow the inverter/controller to cool. (continued) Figure 183 G496128 2. Rotate the key switch to the P position. REHEAT 3. Look at the InfoCenter display to see if the fault repeats. Note: If the fault does not repeat immediately, duplicate the operation of the machine when the fault occurred.
Page 311 Inspect the cutting unit. (continued) 6. Check the bedknife selection; refer to the Operator’s Manual for the cutting units. Note: If the bedknife is incorrect for effective height-of-cut, excessive cutting-unit inverter/controller load may cause high inverter temperature. 7. Check the sharpness of the reel and bedknife; refer to the Operator’s Manual for the cutting units.
Page 312 Inspect the Verticutter. Machines equipped with the optional Verticutter cutting unit. 1. Verify the key switch is in the O position. 2. Rotate the shaft and blade assembly, check rotation resistance, and check reel- bearing wear; refer to the Service Manual for the machine. Note: The shaft and blade assembly should rotate freely.
Page 313 Inspect the universal groomer brush and drive. (continued) Figure 184 G495962 3. Rotate the reel, check rotation resistance, and check reel-bearing wear; refer to the Service Manual for the machine. Note: The reel should rotate freely. 4. Rotate the knob of the groomer drive to the F position.
Page 314 Inspect the universal groomer brush and drive. (continued) Figure 185 G495939 8. If the driven shaft rotates freely, remove the gearbox and inspect it for damage and wear; refer to the Service Manual for the machine. The cutting unit and universal groomer drive are good. •...
Page 315 Inspect the rear roller brush and drive. (continued) 2. Rotate the reel, check rotation resistance, and check reel-bearing wear; refer to the Service Manual for the machine. The reel should rotate with slight drag from the rear roller brush and drive. 3.
Page 316 Inspect the rear roller brush and drive. (continued) The fault repeated. Go to Inspect the inverter/controller and main harness connectors, page 8–198. Inspect the inverter/controller and main harness connectors. 1. Verify the key switch is in the O position. 2. If fault C181C occurred for cutting-unit 2 or cutting-unit 3, open the hood. 3.
Page 317 Inspect the inverter/controller and main harness connectors. (continued) The inspection passed. Leave main-harness connector unplugged from the inverter/controller- Pass harness connector. Go to Inspect the main harness and 48V ground junction, page 8–199. One or more inspections failed. Repair or replace the worn or damaged parts. Leave main-harness connector unplugged from the inverter/controller- Fail harness connector.
Page 318 Inspect the main harness and 48V ground junction. (continued) The inspection passed. Pass Torque the 3/8-inch locknuts at both sides the ground junction to 15.6 to 17 N∙m (138 to 150 in-lb). Go to Resistance test the main harness, page 8–200.
Page 319 Toro DIAG—Quick Start, page 7–24 Using Toro DIAG to Program the Machine, page 7–32. Note: A new inverter/controller does not function until programmed using Toro DIAG. 24278SLA Page 8–201 Troubleshooting Fault Code: C181C: T2, T3, T4, T5, T6 Cutting Unit Motor Controller - High Temp Warning...
Page 320 Replace the inverter/controller. (continued) 3. Run the cutting units under light load on a test plot. 4. Look at the InfoCenter display to see if the fault repeats. 5. Shut off the cutting units. 6. Park the machine and rotate the key switch to the O position.
Page 321: Circuit Diagram
Advise best operating practices. (continued) Proper Mowing Scalping/Circle Cutting Verticutting Techniques When mowing in wet Open the rear cutting-unit Open the rear cutting-unit conditions, open the rear shields. shields. shield of the cutting unit. Reduce the maximum Reduce the maximum mowing speed to 6 km/h mowing speed to 6 km/h (4 mph) or slower.
Page 322: C1820: T2, T3, T4, T5, T6 Cutting Unit Motor Speed Sensor - Out Of Range
C1820: T2, T3, T4, T5, T6 Cutting Unit Motor Speed Sensor - Out of Range Fault Description The motor controller detects the signal from a Hall effect sensor in the motor is out of range. If a Hall effect sensor fails, motor speed becomes unstable.
Page 323 Identify the affected cutting unit. (continued) Figure 189 G496146 Note: The Code list displays. 3. In the Code list, and record the controller number (T2, T3, T4, T5, or T6) associated fault C1820. 4. Use table below and 190 Figure 2, page 8–205 to identify the cutting unit(s) causing the fault.
Page 324 Identify the affected cutting unit. (continued) 6. Go to Inspect the inverter/controller and cutting-unit motor connectors, page 8– 206. Inspect the inverter/controller and cutting-unit motor connectors. G495441 1. Verify the key switch is in the O position. 2. Raise the seat and console, and support them with the forward prop rod. 3.
Page 325 Inspect the inverter/controller and cutting-unit motor connectors. (continued) Connector (inverter/ controller) Edge-card connector (cutting-unit motor) G495860 6. Inspect the and inverter/controller connector and the edge-card connector of the motor for damage and corrosion. The inspection passed. Leave the inverter/controller removed from the cutting-unit motor. Pass Go to Swap reel motor positions, page...
Page 326 Inspect the inverter/controller and cutting-unit motor connectors. (continued) The fault code did not repeat. Unplug the 48V battery disconnect from the socket; refer to Connecting and Disconnecting the 48V Battery System, page 7–8. Remove the 6 socket-head screws (old) that secure the inverter/ controller to the cutting-unit motor, and carefully separate the controller from the motor.
Page 327 Go to Swap reel motor positions, page 8–209. Swap reel motor positions. Parts needed for this procedure: Description Toro Part No. Quantity O-Ring Service Kit 144-6731 1. Verify the key switch is in the O position. 2. Verify the 48V battery disconnect is plugged into the socket.
Page 328 Test the reel motor at the swap position. Parts needed for this procedure: Description Toro Part No. Quantity O-Ring Service Kit 144-6731 1. Verify the key switch is in the O position. 2. Plug the 48V battery disconnect into the socket; refer to...
Page 329 Test the reel motor at the swap position. (continued) The motor is damaged or worn. Raise the seat and console, and support them with the forward prop rod. Unplug the 48V battery disconnect from the socket; refer to Connecting and Disconnecting the 48V Battery System, page 7–8.
Page 330 Test the reel motor at the swap position. (continued) 15. Torque the screws that secure the inverter/controller to the good motor according to the Service Manual for the machine. 16. Plug main-harness connectors from the inverter/controller connectors. 17. Plug the 48V battery disconnect into the socket; refer to Connecting and Disconnecting the 48V Battery System, page 7–8.
Page 331 Test the reel motor at the swap position. (continued) 11. Go to Inspect the main-harness and inverter/controller connectors, page 8–213. Inspect the main-harness and inverter/controller connectors. G495441 1. Verify the key switch is in the O position. 2. If you identified cutting unit 2 or cutting unit 3 in Identify the affected cutting unit, page 8–204, open the hood.
Page 332 Inspect the main-harness and inverter/controller connectors. (continued) Figure 192 Cutting Unit 1 Connector P47 (main harness) Connector P46 (main harness) Signal connector (inverter/ controller) 48V battery connector (inverter/controller) G503147 Figure 193 Cutting Unit 5 48V battery connector (inverter/controller) Connector P45 (main harness) Connector P44 (main harness)
Page 333 Inspect the main-harness and inverter/controller connectors. (continued) Figure 194 Cutting Unit 2 Signal connector (inverter/ controller) 48V battery connector (inverter/controller) Connector P39 (main harness) Connector P38 (main harness) G503151 Figure 195 Cutting Unit 3 48V battery connector (inverter/controller) Connector P49 (main harness) Connector P48 (main harness)
Page 334: C1821: T2, T3, T4, T5, T6 Cutting Unit Motor Speed Sensor - Cutting Unit Motor Speed - High
Using Toro DIAG to Program the Machine, page 7–32. Note: A new inverter/controller does not function until programmed using Toro DIAG. 3. Run the cutting units under light load on a test plot. 4. Look at the InfoCenter display to see if the fault repeats.
Page 335 Verify the fault repeats. (continued) 3. Start the engine. 4. Run the cutting units under light load on a test plot. 5. Look at the InfoCenter display to see if the fault repeats. 6. Shut off the cutting units. 7. Park the machine and rotate the key switch to the O position.
Page 336 Identify the affected cutting unit. (continued) Controller Number Cutting Unit Cutting Unit Cutting Unit Cutting Unit Cutting Unit Cutting Unit Position Figure 197 G495441 5. Rotate the key switch to the O position. 6. Go to Inspect the inverter/controller and cutting-unit motor connectors, page 8– 218.
Page 337 Inspect the inverter/controller and cutting-unit motor connectors. (continued) 3. Unplug the 48V battery disconnect from the socket; refer to Connecting and Disconnecting the 48V Battery System, page 7–8. 4. Ensure that the cutting-unit motor and inverter/controller that you identified in Identify the affected cutting unit, page 8–217 are clean of dirt and debris.
Page 338 Inspect the inverter/controller and cutting-unit motor connectors. (continued) Rotate the key switch to the P position. REHEAT Look at the InfoCenter display to see if the fault repeats. Rotate the key switch to the O position. The fault code did not repeat. Unplug the 48V battery disconnect from the socket;...
Page 339 Go to Swap reel motor positions, page 8–221. Swap reel motor positions. Parts needed for this procedure: Description Toro Part No. Quantity O-Ring Service Kit 144-6731 1. Verify the key switch is in the O position. 2. Verify the 48V battery disconnect is plugged into the socket.
Page 340 Test the reel motor at the swap position, page 8–222. Test the reel motor at the swap position. Parts needed for this procedure: Description Toro Part No. Quantity O-Ring Service Kit 144-6731 1. Verify the key switch is in the O position.
Page 341 Test the reel motor at the swap position. (continued) The motor is damaged or worn. Raise the seat and console, and support them with the forward prop rod. Unplug the 48V battery disconnect from the socket; refer to Connecting and Disconnecting the 48V Battery System, page 7–8.
Page 342 Test the reel motor at the swap position. (continued) Torque the screws that secure the inverter/controller to the good motor according to the Service Manual for the machine. 16. Plug main-harness connectors from the inverter/controller connectors. 17. Plug the 48V battery disconnect into the socket; refer to Connecting and Disconnecting the 48V Battery System, page 7–8.
Page 343 Test the reel motor at the swap position. (continued) 10. Reinstall the old cutting unit motor to the cutting unit at the identified cutting-unit location. Note: Do not install the inverter/controller to the motor. 11. Go to Inspect the main-harness and inverter/controller connectors, page 8–225.
Page 344 Inspect the main-harness and inverter/controller connectors. (continued) Figure 199 Cutting Unit 1 Connector P47 (main harness) Connector P46 (main harness) Signal connector (inverter/ controller) 48V battery connector (inverter/controller) G503147 Figure 200 Cutting Unit 5 48V battery connector (inverter/controller) Connector P45 (main harness) Connector P44 (main harness)
Page 345 Inspect the main-harness and inverter/controller connectors. (continued) Figure 201 Cutting Unit 2 Signal connector (inverter/ controller) 48V battery connector (inverter/controller) Connector P39 (main harness) Connector P38 (main harness) G503151 Figure 202 Cutting Unit 3 48V battery connector (inverter/controller) Connector P49 (main harness) Connector P48 (main harness)
Page 346: C1822: T2, T3, T4, T5, T6 Cutting Unit Motor - Stall
Using Toro DIAG to Program the Machine, page 7–32. Note: A new inverter/controller does not function until programmed using Toro DIAG. 3. Run the cutting units under light load on a test plot. 4. Look at the InfoCenter display to see if the fault repeats.
Page 347 Verify the fault repeats. 1. Safely stop the machine, shut off attachments, and fully lower them. 2. Rotate the key switch to the O position. 3. Start the engine. 4. Operate the machine and cutting units using the same conditions that you discussed with the machine operator.
Page 348 Identify the affected cutting unit. (continued) 4. Use table below and 204 Figure 2, page 8–230 to identify the cutting unit(s) causing the fault. Controller Number Cutting Unit Cutting Unit Cutting Unit Cutting Unit Cutting Unit Cutting Unit Position Figure 204 G495441 5.
Page 349 Check motor shaft rotation. (continued) The shaft rotated with moderate resistance. Leave the identified motor and inverter/controller removed from the Pass cutting unit Go to Inspect the cutting unit, page 8–231. The shaft rotated with high resistance or would not rotate. Remove the 6 socket-head screws that secure the inverter/controller to the motor, and carefully separate the controller from the motor;...
Page 350 Inspect the cutting unit. (continued) 7. Check the sharpness of the reel and bedknife; refer to the Operator’s Manual for the cutting units. 8. Check the reel-to-bedknife clearance for the cutting unit(s); refer to the Operator’s Manual. 9. Check the height-of-cut for the cutting unit(s); refer to the Operator’s Manual for the cutting units.
Page 351 Inspect the Verticutter. Machines equipped with the optional Verticutter cutting unit. 1. Verify the key switch is in the O position. 2. Rotate the shaft and blade assembly, check rotation resistance, and check reel- bearing wear; refer to the Service Manual for the machine. Note: The shaft and blade assembly should rotate freely.
Page 352: C1831: T2, T3, T4, T5, T6 Cutting Unit Motor Internal Regulator Voltage - High
Using Toro DIAG to Program the Machine, page 7–32. Note: A new inverter/controller does not function until programmed using Toro DIAG. 3. Run the cutting units under light load on a test plot. 4. Look at the InfoCenter display to see if the fault repeats.
Page 353 Verify the fault repeats. (continued) The fault did not repeat. Go to Returning the Machine to Service, page 7–23. Pass Follow the steps listed. Note: If the fault does not repeat, an isolated event has occurred. The fault repeated. Go to Preparing for Troubleshooting and/or Testing, page 7–22.
Page 354 Using Toro DIAG to Program the Machine, page 7–32. Note: A new inverter/controller does not function until programmed using Toro DIAG. 3. Run the cutting units under light load on a test plot. 4. Look at the InfoCenter display to see if the fault repeats.
Page 355: C1832: T2, T3, T4, T5, T6 Cutting Unit Motor Internal Regulator Voltage - Low
C1832: T2, T3, T4, T5, T6 Cutting Unit Motor Internal Regulator Voltage - Low Fault Description The motor controller measured that its internal 12V-regulator produced 10V or lower. The inverter/controller broadcasts the Cutting Unit Motor Internal Regulator Voltage - Low message on the CAN bus.
Page 356 Identify the affected cutting unit. (continued) Figure 208 G496189 Note: The Code list displays. 3. In the Code list, and record the controller number (T2, T3, T4, T5, or T6) associated fault C1832. Note: Fault C1832 may affect multiple controller numbers. 4.
Page 357 Identify the affected cutting unit. (continued) 5. Rotate the key switch to the O position. 6. Go to Inspect the inverter/controller and main harness connectors, page 8–239. Inspect the inverter/controller and main harness connectors. 1. Verify the key switch is in the O position.
Page 358 Inspect the inverter/controller and main harness connectors. (continued) Cutting Unit Position 4-Socket Main-Harness Connector 5. Inspect the wiring, inside the inverter/controller-harness connector, and inside the main harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector. Check for proper fit between all pins and their corresponding sockets.
Page 359 Inspect 48V enable relay and main harness. (continued) Figure 211 48V Enable Relay Connector P32 (main harness) G493279 4. Inspect the wiring, inside the enable relay, and inside the main harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector.
Page 360 Voltage test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Main Yellow 48V system voltage 48V Ground Junction 5. Rotate the key switch to the O position. The test is good. Leave main-harness connector P32 unplugged from the 48V Logic Pass Relay.
Page 361 Resistance test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Main White Cutting Unit 3 Main White Less than 2 ohms Main White Cutting Unit 4 Main White Less than 2 ohms Main White Cutting Unit 5 Main White...
Page 362 Test the 48V enable relay. (continued) Expected Connector Component Location Reading Graphic 48V Enable Relay Open Frame Ground 48V Enable Relay Open 48V Enable Relay 48V Enable Relay Open 48V Enable Relay 48V Enable Relay 81 to 99 ohms 48V Enable Relay The resistance test is good.
Page 363 Inspect the battery cables. 1. Verify the key switch is in the O position. 2. Raise the seat and console, and support them with the forward prop rod. 3. Unplug the 48V battery disconnect from the socket; refer to Connecting and Disconnecting the 48V Battery System, page 7–8.
Page 364 Toro DIAG—Quick Start, page 7–24 Using Toro DIAG to Program the Machine, page 7–32. Note: A new inverter/controller does not function until programmed using Toro DIAG. Troubleshooting Fault Code: C1832: T2, T3, T4, T5, T6 Page 8–246 24278SL A Cutting Unit Motor Internal Regulator Voltage - Low...
Page 365 Replace the inverter/controller. (continued) 3. Run the cutting units under light load on a test plot. 4. Look at the InfoCenter display to see if the fault repeats. 5. Shut off the cutting units. 6. Park the machine and rotate the key switch to the O position.
Page 366: Circuit Diagram
Circuit Diagram G496367 Troubleshooting Fault Code: C1832: T2, T3, T4, T5, T6 Page 8–248 24278SL A Cutting Unit Motor Internal Regulator Voltage - Low...
Page 367: C1841: T2, T3, T4, T5, T6 Cutting Unit Motor Logic Voltage - High
Circuit Description The inverter/controller monitors the 48V logic voltage controller by the 48V Enable Relay. Required Shop Supplies: Description Toro Part No. Super Lube™ oil 145-5053 Verify the fault repeats. 1. Safely stop the machine, shut off attachments, and fully lower them.
Page 368 Identify the affected cutting unit. (continued) Figure 214 G496389 Note: The Code list displays. 3. In the Code list, and record the controller number (T2, T3, T4, T5, or T6) associated fault C1841. Note: Fault C1841 may affect multiple controller numbers. 4.
Page 369: Check Battery Voltage
Identify the affected cutting unit. (continued) 5. Rotate the key switch to the O position. Fault C1841 The 48V system battery voltage is 67.5V or lower. Go to Check battery affects voltage, page 8–251. multiple controller numbers. Fault C1841 Go to Inspect the inverter/controller and main harness connectors, page 8–...
Page 370 Check battery voltage. (continued) Figure 217 6-Button InfoCenter G496515 3. Go to Check 48V system generator charging, page 8–252. Check 48V system generator charging. 1. Start the engine. 2. If needed, press the right button on the InfoCenter until the 48V system voltage displays.
Page 371 Check 48V system generator charging. (continued) Figure 219 6-Button InfoCenter G496516 4. Shut off the engine. The 48V system battery voltage is 67.5V or lower. Go to Inspect the inverter/ Pass controller and main harness connectors, page 8–258. The 48V system battery voltage is higher than 67.5V. Go to Inspect the Fail generator/motor controller and main harness connectors, page...
Page 372 Inspect the generator/motor controller and main harness connectors. (continued) Figure 220 Connector (generator/ motor controller) Connector P37 (main harness) G496721 6. Inspect the wiring, inside the main-harness connector, and inside the generator/ motor controller connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector.
Page 373 Inspect the generator/motor to controller connections. 1. Verify the key switch is in the O position. 2. Remove the cooling air hose from the top intake shroud for the generator/motor; refer to the Service Manual for the machine. Figure 221 Cooling-air hose Hose clamp Upper intake shroud...
Page 374 Figure 222 Capscrews Access cover (generator/ motor controller) Gasket Super Lube oil (Toro Part No. 145-5053) G496723 6. Inspect the 3 cable terminals and capscrews that connect high-current circuits of the generator/motor to the controller for damage and corrosion. Figure 223...
Page 375 Inspect the generator/motor to controller connections. (continued) The inspection is good. Torque the 3 cable terminal capscrews to 8.5 N∙m (75 in-lb). Lightly coat the access cover gasket with Super Lube oil (Toro Part No. 145-5053). Install the access cover to the generator/motor controller with the capscrews.
Page 376 Inspect the generator/motor to controller connections. (continued) The fault repeated. Go to Inspect the generator/motor to controller connections, page 8–258. Inspect the inverter/controller and main harness connectors. 1. Verify the key switch is in the O position. 2. If fault C1841 occurred for cutting-unit 2 or cutting-unit 3, open the hood. 3.
Page 377 Inspect the inverter/controller and main harness connectors. (continued) The inspection passed. Leave the 4-socket main-harness connector unplugged from each 4-pin Pass inverter/controller connectors. Go to Inspect 48V enable relay and main harness, page 8–259. One or more inspections failed. Repair or replace the worn or damaged parts. Plug the 4-socket main-harness connector into each 4-pin inverter/ controller connectors.
Page 378 Inspect 48V enable relay and main harness. (continued) 4. Inspect the wiring, inside the enable relay, and inside the main harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector. Check for proper fit between all pins and their corresponding sockets.
Page 379 Resistance test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Main White less than 2 ohms Cutting Unit 4 Main White Main White less than 2 ohms Cutting Unit 5 Main White The test is good. Plug main-harness connector P32 into the 48V Logic Relay.
Page 380 Using Toro DIAG to Program the Machine, page 7–32. Note: A new inverter/controller does not function until programmed using Toro DIAG. 3. Run the cutting units under light load on a test plot. 4. Look at the InfoCenter display to see if the fault repeats.
Page 381: Circuit Diagram
Circuit Diagram G496924 24278SLA Page 8–263 Troubleshooting Fault Code: C1841: T2, T3, T4, T5, T6 Cutting Unit Motor Logic Voltage - High...
Page 382: C1842: T2, T3, T4, T5, T6 Cutting Unit Motor Logic Voltage - Low
C1842: T2, T3, T4, T5, T6 Cutting Unit Motor Logic Voltage - Low Fault Description The motor controller measured logic voltage is 32V or lower. The inverter/controller broadcasts the Cutting Unit Motor Logic Voltage - Low message on the CAN bus. Note: When this fault is active, the primary controller broadcasts a message to all inverter/controllers to shut off the motors.
Page 383 Identify the affected cutting unit. (continued) Figure 226 G496483 Note: The Code list displays. 3. In the Code list, and record the controller number (T2, T3, T4, T5, or T6) associated fault C1842. Note: Fault C1842 may affect multiple controller numbers. 4.
Page 384: Check Battery Voltage
Identify the affected cutting unit. (continued) 5. Rotate the key switch to the O position. Fault C1841 The 48V system battery voltage is 32V or lower. Go to Check battery voltage, affects page 8–266. multiple controller numbers. Fault C1841 Go to Inspect the inverter/controller and main harness connectors, page 8–...
Page 385 Check battery voltage. (continued) 6-Button InfoCenter G496515 3. Rotate the key switch to the O position. The 48V system battery voltage is higher than 32V. Go to Check 48V system Pass generator charging, page 8–271. The 48V system battery voltage is 32V or lower. Go to Test battery 48V Fail battery voltage, page...
Page 386: Check The Batteries
Test battery 48V battery voltage. (continued) 4. Locate the 48V ground junction at the bottom of the machine and inboard of the right-front tire. Figure 230 48V ground junction Negative battery cable Front of the machine Positive battery cable G496556 5.
Page 387 Check the batteries. (continued) Figure 231 G496294 5. Slip the insulator boots off the battery-cable clamps. Figure 232 Front batteries shown. Battery-cable clamps G496738 6. Remove the battery-cable clamps from the battery posts. 7. Clean any corrosion or replace the corroded or damaged parts. 8.
Page 388 Assemble the cable clamps onto the battery posts. Torque the nuts for all cable clamps to 5.6 to 7.9 N∙m (50 to 70 in-lb). Apply battery terminal protector (Toro Part No. 107-0392) to all battery posts and cable connectors. Pass Slip the insulator boots over the battery-cable clamps.
Page 389 Check 48V system generator charging. 1. Start the engine. 2. Look at the InfoCenter until the 48V system voltage. 3. 48V system battery voltage must display 67.5V or lower. Figure 233 3-Button InfoCenter G496513 6-Button InfoCenter G496516 The 48V system battery voltage is 32V or higher. Go to Inspect the inverter/ Pass controller and main harness connectors, page...
Page 390 Inspect the generator/motor controller and main harness connectors. 1. Verify the key switch is in the O position. 2. Raise the seat and console, and support them with the forward prop rod. 3. Unplug the 48V battery disconnect from the socket; refer to Connecting and Disconnecting the 48V Battery System, page 7–8.
Page 391 Inspect the generator/motor to controller connections, page 8– 273. Inspect the generator/motor to controller connections. Required Shop Supplies: Description Toro Part No. Super Lube™ oil 145-5053 1. Verify the key switch is in the O position. 2. Remove the cooling air hose from the top intake shroud for the generator/motor;...
Page 392 Figure 236 Capscrews Access cover (generator/ motor controller) Gasket Super Lube oil (Toro Part No. 145-5053) G496723 6. Inspect the 3 cable terminals and capscrews that connect high-current circuits of the generator/motor to the controller for damage and corrosion. Figure 237...
Page 393 Inspect the generator/motor to controller connections. (continued) The inspection is good. Torque the 3 cable terminal capscrews to 8.5 N∙m (75 in-lb). Lightly coat the access cover gasket with Super Lube oil (Toro Part No. 145-5053). Install the access cover to the generator/motor controller with the capscrews.
Page 394 Inspect the generator/motor to controller connections. (continued) The fault repeated. Go to Inspect the inverter/controller and main harness connectors, page 8–276. Inspect the inverter/controller and main harness connectors. 1. Verify the key switch is in the O position. 2. If fault C1842 occurred for cutting-unit 2 or cutting-unit 3, open the hood. 3.
Page 395 Inspect the inverter/controller and main harness connectors. (continued) The inspection passed. Leave the main-harness connector (cutting unit data) unplugged from Pass each the inverter/controller-harness connector (data). Go to Inspect 48V enable relay and main harness, page 8–277. One or more inspections failed. Repair or replace the worn or damaged parts.
Page 396 Inspect 48V enable relay and main harness. (continued) 4. Inspect the wiring, inside the enable relay, and inside the main harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector. Check for proper fit between all pins and their corresponding sockets.
Page 397 Resistance test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Main White Less than 2 ohms Cutting Unit 4 Main White Main White Less than 2 ohms Cutting Unit 5 Main White The test is good. Plug main-harness connector P32 into the 48V Logic Relay.
Page 398 Using Toro DIAG to Program the Machine, page 7–32. Note: A new inverter/controller does not function until programmed using Toro DIAG. 3. Run the cutting units under light load on a test plot. 4. Look at the InfoCenter display to see if the fault repeats.
Page 399: Circuit Diagram
Circuit Diagram G496924 24278SLA Page 8–281 Troubleshooting Fault Code: C1842: T2, T3, T4, T5, T6 Cutting Unit Motor Logic Voltage - Low...
Page 400: C1851: T2, T3, T4, T5, T6 Cutting Unit Motor Bus Voltage - High
C1851: T2, T3, T4, T5, T6 Cutting Unit Motor Bus Voltage - High Fault Description The motor controller measured bus voltage is 67.5V or higher. The inverter/controller broadcasts the Cutting Unit Motor Bus Voltage - High message on the CAN bus. Note: When this fault is active, the primary controller broadcasts a message to all inverter/controllers to shut off the motors.
Page 401 Identify the affected cutting unit. (continued) Figure 240 G496389 Note: The Code list displays. 3. In the Code list, and record the controller number (T2, T3, T4, T5, or T6) associated fault C1851. Note: Fault C1851 may affect multiple controller numbers. 4.
Page 402: Check Battery Voltage
Identify the affected cutting unit. (continued) 5. Rotate the key switch to the O position. Fault C1851 The 48V system battery voltage is 67.5V or lower. Go to Check battery affects voltage, page 8–284. multiple controller numbers. Fault C1851 Go to Inspect the inverter/controller and main harness connectors, page 8–...
Page 403 Check battery voltage. (continued) Figure 243 6-Button InfoCenter G496515 3. Go to Check 48V system generator charging, page 8–285. Check 48V system generator charging. 1. Start the engine. 2. If needed, press the right button on the InfoCenter until the 48V system voltage displays.
Page 404 Check 48V system generator charging. (continued) Figure 245 6-Button InfoCenter G496516 4. Shut off the engine. The 48V system battery voltage is 67.5V or lower. Go to Inspect the inverter/ Pass controller and main harness connectors, page 8–291. The 48V system battery voltage is higher than 67.5V. Go to Inspect the Fail generator/motor controller and main harness connectors, page...
Page 405 Inspect the generator/motor controller and main harness connectors. (continued) Figure 246 Connector (generator/ motor controller) Connector P37 (main harness) G496721 6. Inspect the wiring, inside the main-harness connector, and inside the generator/ motor controller connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector.
Page 406 Inspect the generator/motor to controller connections. Required Shop Supplies: Description Toro Part No. Super Lube™ oil 145-5053 1. Verify the key switch is in the O position. 2. Remove the cooling air hose from the top intake shroud for the generator/motor;...
Page 407 Figure 248 Capscrews Access cover (generator/ motor controller) Gasket Super Lube oil (Toro Part No. 145-5053) G496723 6. Inspect the 3 cable terminals and capscrews that connect high-current circuits of the generator/motor to the controller for damage and corrosion. Figure 249...
Page 408 Inspect the generator/motor to controller connections. (continued) The inspection is good. Torque the 3 cable terminal capscrews to 8.5 N∙m (75 in-lb). Lightly coat the access cover gasket with Super Lube oil (Toro Part No. 145-5053). Install the access cover to the generator/motor controller with the capscrews.
Page 409 Inspect the generator/motor to controller connections. (continued) The fault did not repeat. Close and latch the hood. Go to Returning the Machine to Service, page 7–23. The fault repeated. Go to Inspect the generator/motor to controller connections, page 8–291. Inspect the inverter/controller and main harness connectors. 1.
Page 410 Using Toro DIAG to Program the Machine, page 7–32. Note: A new inverter/controller does not function until programmed using Toro DIAG. 3. Run the cutting units under light load on a test plot. 4. Look at the InfoCenter display to see if the fault repeats.
Page 411: C1852: T2, T3, T4, T5, T6 Cutting Unit Motor Bus Voltage - Low
Circuit Diagram G497027 C1852: T2, T3, T4, T5, T6 Cutting Unit Motor Bus Voltage - Low Fault Description The motor controller measured bus voltage is less than 32V. The inverter/controller broadcasts the Cutting Unit Motor Bus Voltage - Low message on the CAN bus. Note: When this fault is active, the primary controller broadcasts a message to all inverter/controllers to shut off the motors.
Page 412 Verify the fault repeats. (continued) 4. Operate the machine and cutting units using the same conditions that you discussed with the machine operator. 5. Look at the InfoCenter display to see if the fault repeats. Note: If the fault does not repeat immediately, duplicate the operation of the machine when the fault occurred.
Page 413 Identify the affected cutting unit. (continued) Controller Number Cutting Unit Cutting Unit Cutting Unit Cutting Unit Cutting Unit Cutting Unit Position Figure 252 G495441 5. Rotate the key switch to the O position. 6. Go to Test the fuse, page 8–295.
Page 414 Test the fuse. (continued) Figure 253 Fuse (cutting unit 1) Fuse (cutting unit 5) G497162 6. Continuity test the fuse. The fuse tests good. Plug the fuse into the fuse block slots. Pass Go to Inspect the generator/motor to controller connections, page 8– 296.
Page 415 Inspect the inverter/controller and main harness connectors. (continued) 3. Unplug the 4-socket main-harness connector from the 4-pin inverter/controller connector of each cutting unit that you identified in Identify the affected cutting unit, page 8–294; refer to the table that follows: Cutting Unit Position 4-Socket Main-Harness Connector Figure 254...
Page 416 Inspect the inverter/controller and main harness connectors. (continued) Rotate the key switch to the O position. The fault did not repeat. If the hood is open, close and latch it. Go to Returning the Machine to Service, page 7–23. The fault repeated. Unplug the 4-socket main-harness connector from the 4-pin inverter/ controller connector of each cutting unit that you identified in Identify the...
Page 417 Resistance test the main harness. 1. Verify the key switch is in the O position. 2. Verify main-harness connector P32 is unplugged from 48V Enable Relay. 3. Verify the 4-socket main-harness connector is unplugged from the 4-pin inverter/ controller connector of each cutting unit that you identified in Identify the affected cutting unit, page 8–294.
Page 418 Using Toro DIAG to Program the Machine, page 7–32. Note: A new inverter/controller does not function until programmed using Toro DIAG. 3. Run the cutting units under light load on a test plot. 4. Look at the InfoCenter display to see if the fault repeats.
Page 419: C1861: T2, T3, T4, T5, T6 Cutting Unit Motor - Over Current
Circuit Diagram G497027 C1861: T2, T3, T4, T5, T6 Cutting Unit Motor - Over Current Fault Description The motor controller measured an overcurrent condition through the motor and shut off power to it. The inverter/controller broadcasts the Cutting Unit Motor - Over Current message on the CAN bus. Note: When this fault is active, the primary controller broadcasts a message to all inverter/controllers to shut off the motors.
Page 420 Verify the fault repeats. (continued) 3. Rotate the key switch to the O position. 4. Start the engine. 5. Operate the machine and cutting units using the same conditions that you discussed with the machine operator. 6. Look at the InfoCenter display to see if the fault repeats. Note: If the fault does not repeat immediately, duplicate the operation of the machine when the fault occurred.
Page 421 Identify the affected cutting unit. (continued) 4. Use table below and 257 Figure 2, page 8–303 to identify the cutting unit(s) causing the fault. Controller Number Cutting Unit Cutting Unit Cutting Unit Cutting Unit Cutting Unit Cutting Unit Position Figure 257 G495441 5.
Page 422 Using Toro DIAG to Program the Machine, page 7–32. Note: A new inverter/controller does not function until programmed using Toro DIAG. 3. Run the cutting units under light load on a test plot. 4. Look at the InfoCenter display to see if the fault repeats.
Page 423: P0115: T1 Engine Coolant Temp Sensor - Open Circuit
Advise best operating practices. (continued) Proper Mowing Scalping/Circle Cutting Verticutting Techniques Maintain proper reel-to- Reduce the number of bedknife clearance. Use blades (increasing blade light contact. spacing) to reduce the amount of required power. Follow and maintain the 1/ Follow and maintain the 1/ Set the verticutter blade 3rd rule (cut only 1/3 of 3rd rule (cut only 1/3 of...
Page 424 Verify the fault repeats. (continued) Note: If the fault does not repeat immediately, duplicate the operation of the machine when the fault occurred. 6. Rotate the key switch to the O position. The fault did not repeat. Go to Returning the Machine to Service, page 7–23.
Page 425 Inspect the coolant-temperature sensor and main-harness connector. (continued) The inspection passed. Leave the main-harness connector P16 unplugged from the coolant- Pass temperature sensor. Go to Test the coolant temperature sensor, page 8–307. One or more inspections failed. Repair or replace the worn or damaged parts. Leave the main-harness connector P16 unplugged from the coolant- Fail temperature sensor.
Page 426 Test the coolant temperature sensor. (continued) The fault did not repeat. Close and latch the hood. Go to Returning the Machine to Service, page 7–23. Unplug main-harness connector P16 from the coolant-temperature sensor. Go to Inspect the T1 controller and main-harness connector, page 8– 308.
Page 427 Test the main harness. 1. Verify the key switch is in the O position. 2. Verify main-harness connector P16 is unplugged from the coolant-temperature sensor. 3. Verify main-harness connector P29 is unplugged from the T1 controller. 4. Use a multimeter to test the resistance between the following pairs of locations: Expected Connector Wire...
Page 428 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 429: P0116: T1 Engine Coolant Temp Sensor - Out Of Range
Swap the T1 controller. (continued) Go to Returning the Machine to Service, page 7–23. Pass Follow the steps listed. Reinstall the original T1 controller. Fail Repeat the diagnostic process for this fault. Circuit Diagram G497207 P0116: T1 Engine Coolant Temp Sensor - Out of Range Fault Description The T1 controller has measured the voltage of the Engine Temp...
Page 430 Verify the Fault Repeats. (continued) The fault did not repeat. Go to Returning the Machine to Service, page 7–23. Pass Follow the steps listed. Note: If the fault does not repeat, an isolated event has occurred. The fault repeated. Go to Preparing for Troubleshooting and/or Testing, page 7–22.
Page 431 Verify the temperature voltage value. (continued) Figure 261 6-Button InfoCenter G498567 3. Navigate to the Engine option and select it. 4. Navigate to the Inputs option and select it. 5. Record the voltage value for the Engine Temp (3-button InfoCenter) or Coolant Temp (6-button InfoCenter) input: Note: If the InfoCenter does not display a voltage value, record “0”.
Page 432 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 433 Swap the T1 controller. (continued) 8. Duplicate the operation of the machine when the fault occurred with the original primary controller. Go to Returning the Machine to Service, page 7–23. Pass Follow the steps listed. Reinstall the original T1 controller. Fail Go to Inspect the coolant-temperature sensor and main-harness...
Page 434: Temperature-Resistance Table
Test the coolant temperature sensor. 1. Verify the key switch is in the O position. 2. Verify main-harness connector P16 is unplugged from the coolant-temperature sensor. 3. Use a multimeter to test the resistance between the following pairs of locations: Expected Connector Component...
Page 435 Test the coolant temperature sensor. (continued) The test passed. Leave the main-harness connector P16 unplugged from the coolant- Pass temperature sensor. Go to Inspect the T1 controller and main-harness connector, page 8– 317. One or more tests failed. Repair or replace the worn or damaged parts. Plug main-harness connector P16 into the coolant-temperature sensor.
Page 436 Inspect the T1 controller and main-harness connector. (continued) 3. Inspect the wiring, inside the seat-harness connector, and inside the main- harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector. Check for proper fit between all pins and their corresponding sockets.
Page 437 8–319. Swap the T1 controller. Note: The T1 controller is programmed to the specific machine model and serial number. The T1 controller does not function until programmed using Toro DIAG. 24278SLA Page 8–319 Troubleshooting Fault Code: P0116: T1 Engine Coolant...
Page 438: P0117: T1 Engine Coolant Temp Sensor - Short To Ground
Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 439 Verify the fault repeats. 1. Safely stop the machine, shut off attachments, and fully lower them. 2. Rotate the key switch to the O position. 3. Start the engine. 4. Operate the machine and cutting units using the same conditions that you discussed with the machine operator.
Page 440 Inspect the coolant-temperature sensor and main-harness connector. (continued) 4. Inspect the wiring, inside the main-harness connector, and the coolant- temperature sensor for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector. Check for proper fit between all pins and their corresponding sockets.
Page 441 Test the coolant temperature sensor. (continued) The fault did not repeat. Close and latch the hood. Go to Returning the Machine to Service, page 7–23. Unplug main-harness connector P16 from the coolant-temperature sensor. Go to Inspect the T1 controller and main-harness connector, page 8– 323.
Page 442 Test the main harness. 1. Verify the key switch is in the O position. 2. Verify main-harness connector P16 is unplugged from the coolant-temperature sensor. 3. Verify main-harness connector P29 is unplugged from the T1 controller. 4. Use a multimeter to test the resistance between the following pairs of locations: Expected Connector Wire...
Page 443 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 444 Swap the T1 controller. (continued) Go to Returning the Machine to Service, page 7–23. Pass Follow the steps listed. Reinstall the original T1 controller. Fail Repeat the diagnostic process for this fault. Circuit Diagram G497207 P0225: T1 Traction Pedal 1 Analog Sensor 1 - Open Circuit Fault Description The T1 controller has detected an open circuit on the Traction Pedal...
Page 445 Verify the fault repeats. (continued) The fault did not repeat. Go to Returning the Machine to Service, page 7–23. Pass Follow the steps listed. Note: If the fault does not repeat, an isolated event has occurred. The fault repeated. Go to Preparing for Troubleshooting and/or Testing, page 7–22.
Page 446 Inspect the E-pedal sensor and engine-harness connector. (continued) Figure 269 Hex-socket screw Traction pedal E-pedal sensor G498696 6. Remove the 2 locknuts and flange head screws that secure the pedal-mount bracket to the gusset of the platform. Figure 270 G498695 Gusset (platform) Locknuts Carriage bolt...
Page 447 Inspect the E-pedal sensor and engine-harness connector. (continued) Figure 271 Connector (E-pedal sensor) Connector P58 (main harness) G498694 9. Inspect the wiring, inside the main-harness connector, and the E-pedal sensor for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector.
Page 448 Inspect the T1 controller and main-harness connector. (continued) Figure 272 G490767.svg Retaining fastener (location) 3. Inspect the wiring, inside the seat-harness connector, and inside the main- harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector. Check for proper fit between all pins and their corresponding sockets.
Page 449 Test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Main Brown Main Brown Open Frame Ground Main Brown Less than 2 ohms Brown Yellow Main /Green Less than 2 ohms Yellow Main /Green Yellow Main /Green Open Frame Ground...
Page 450 Test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Gray/ Main Black Less than 2 ohms Gray/ Main Black Gray/ Main Black Open Frame Ground The test is good. Leave main-harness connector P58 unplugged from the traction-pedal sensor.
Page 451 Replace the E-pedal sensor. 1. Remove the 4 flange-head capscrews and locknuts that secure the old E-pedal sensor to the pedal-mount bracket. Figure 273 Flange-head capscrew E-pedal sensor Pedal-mount bracket Locknut G498775 2. Assemble the new E-pedal sensor to the pedal-mount bracket with the 4 flange- head capscrews and locknuts.
Page 452 Replace the E-pedal sensor. (continued) Figure 275 G498695 Gusset (platform) Locknuts Carriage bolt Flange head screw Pedal-mount bracket 5. Loosely assemble the pedal-mount bracket to the platform gusset with the 2 flange head screws and locknuts. 6. Tighten the screws, bolts, and locknuts. 7.
Page 453 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 24278SLA Page 8–335...
Page 454: P0227: T1 Traction Pedal Analog Sensor 1 - Short To Ground
Swap the T1 controller. (continued) 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33 Calibrating the Traction Pedal, page 7–34 Calibrating the Traction Pump, page 7–43 Calibrating the Virtual Speed Sensor, page 7–53 8. Duplicate the operation of the machine when the fault occurred with the original primary controller.
Page 455 Verify the fault repeats. (continued) 3. Start the engine. 4. Operate the machine and cutting units using the same conditions that you discussed with the machine operator. 5. Look at the InfoCenter display to see if the fault repeats. Note: If the fault does not repeat immediately, duplicate the operation of the machine when the fault occurred.
Page 456 Inspect the E-pedal sensor and engine-harness connector. (continued) Figure 277 G498693 Spacer Bracket Phillips-head screw Washer-head screw Washer Platform shroud 5. Remove the 2 hex-socket screws that secure the traction pedal to the E-pedal sensor, and remove the traction pedal from the machine. Figure 278 Hex-socket screw Traction pedal...
Page 457 Inspect the E-pedal sensor and engine-harness connector. (continued) Figure 279 G498695 Gusset (platform) Locknuts Carriage bolt Flange head screw Pedal-mount bracket 7. Remove the 2 locknuts and carriage bolts that secure the pedal-mount bracket to the platform plate. 8. Unplug main-harness connector P58 from the E-pedal sensor. Figure 280 Connector (E-pedal sensor)
Page 458 Inspect the E-pedal sensor and engine-harness connector. (continued) The inspection passed. Leave main-harness connector P58 unplugged from the E-pedal sensor. Pass Do not install the pedal-mount bracket and sensor. Go to Inspect the T1 controller and main-harness connector, page 8– 340.
Page 459 Inspect the T1 controller and main-harness connector. (continued) The inspection passed. Leave main-harness connector P29 unplugged from the T1 controller. Pass Go to Test the main harness, page 8–341. One or more inspections failed. Repair or replace the worn or damaged parts. Fail Leave main-harness connector P29 unplugged from the T1 controller.
Page 460 Test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Blue/ Main Yellow Less than 2 ohms Blue/ Main Yellow Blue/ Main Yellow Open Frame Ground Blue/ Main Yellow Open Blue/ Main Yellow Gray/ Main Black Less than 2 ohms Gray/...
Page 461 Test the main harness. (continued) The fault did not repeat. Loosely assemble the pedal-mount bracket to the platform plate with the 2 carriage bolts and locknuts. Loosely assemble the pedal-mount bracket to the platform gusset with the 2 flange head screws and locknuts. Tighten the screws, bolts, and locknuts.
Page 462 Replace the E-pedal sensor. (continued) Figure 283 Connector (E-pedal sensor) Connector P58 (main harness) G498694 4. Loosely assemble the pedal-mount bracket to the platform plate with the 2 carriage bolts and locknuts. Figure 284 G498695 Gusset (platform) Locknuts Carriage bolt Flange head screw Pedal-mount bracket 5.
Page 463 Replace the E-pedal sensor. (continued) Figure 285 Hex-socket screw Traction pedal E-pedal sensor G498696 8. Torque the hex-socket screws to 15.6 to 19.6 N∙m (138 to 174 in-lb). 9. Rotate the key switch to the P position. REHEAT 10. Watch the InfoCenter screen to see if the fault repeats. 11.
Page 464 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 465: P0383: T1 Glow Plug Output - Short To Ground/Overcurrent
Swap the T1 controller. (continued) Calibrating the Virtual Speed Sensor, page 7–53 8. Duplicate the operation of the machine when the fault occurred with the original primary controller. Go to Returning the Machine to Service, page 7–23. Pass Follow the steps listed. Reinstall the original T1 controller.
Page 466 Verify the fault repeats. (continued) The fault did not repeat. Go to Returning the Machine to Service, page 7–23. Pass Follow the steps listed. Note: If the fault does not repeat, an isolated event has occurred. The fault repeated. Go to Preparing for Troubleshooting and/or Testing, page 7–22.
Page 467 Test the glow-plug relay. 1. Verify the key switch is in the O position. 2. Verify main-harness connector P20 is unplugged from glow-plug relay. 3. Use a multimeter to test the resistance between the following pairs of locations: Expected Connector Component Location Reading...
Page 468 Test the glow-plug relay. (continued) The fault repeated. Unplug main-harness connector P20 from the glow-plug relay. Install the original glow-plug relay. Go to Inspect the T1 controller and main-harness connector, page 8– 350. Inspect the T1 controller and main-harness connector. 1.
Page 469 8–351. Swap the T1 controller. Note: The T1 controller is programmed to the specific machine model and serial number. The T1 controller does not function until programmed using Toro DIAG. 24278SLA Page 8–351 Troubleshooting Fault Code: P0383: T1 Glow Plug...
Page 470 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 471: P0384: T1 Glow Plug Output - Short To Battery
P0384: T1 Glow Plug Output - Short to Battery Fault Description The T1 controller has detected lower current through the FET that normal on the circuit for the Glow Plug signal. Note: This short could be to battery voltage or to another signal that is in a high state.
Page 472 Inspect the main-harness connector and glow-plug relay. (continued) Figure 288 Relay (glow -plug) Connector P20 (main harness) G499726 3. Inspect the wiring, inside the main-harness connector, and the glow-plug relay for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector.
Page 473 Test the glow-plug relay. (continued) Expected Connector Component Location Reading Graphic Glow-plug relay Open Glow-plug relay Glow-plug relay Open Glow-plug relay Glow-plug relay 81 to 99 ohms Glow-Plug Relay The resistance test is good. Leave main-harness connector P20 unplugged from the glow-plug Pass relay.
Page 474 Voltage test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Main Blue 0.0 V Engine Ground The test is good. Plug main-harness connector P20 into the glow-plug relay. Pass Close and latch the hood. Go to Inspect the T1 controller and main-harness connector, page 8–...
Page 475 Replacing or Swapping the Primary Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 24278SLA Page 8–357 Troubleshooting Fault Code: P0384: T1 Glow Plug...
Page 476: P0524: T1 Oil Pressure Low - Kill Engine
7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33 Calibrating the Traction Pedal, page 7–34 Calibrating the Traction Pump, page 7–43 Calibrating the Virtual Speed Sensor, page 7–53...
Page 477 Check the engine oil level. (continued) 2. Open the hood. 3. Check the engine for external oil leaks. Note: Repair all engine oil leaks; refer to the Kubota 05-E4B Series/E4BG Series Workshop Manual. 4. Check the engine oil level; refer to the Operator’s Manual for the machine. Note: Add or remove engine oil as needed.
Page 478 Inspect the oil-pressure switch and main harness. (continued) Figure 290 Oil-pressure switch Connector J05 (main harness) G499818 3. Inspect the wiring, the main-harness connector, and the oil-pressure switch for damage and corrosion. Ensure that the terminal is secure to the harness. Check that the terminal is secure to the oil-pressure switch.
Page 479 Continuity test the oil-pressure switch. (continued) 4. Use a multimeter to test continuity between the following pairs of locations: Note: The engine is allowed to run for 10 seconds without the oil-pressure signal. Expected Connector Component Location Reading Graphic Main Close Circuit Engine Ground 5.
Page 480 Test the engine oil pressure. (continued) Troubleshoot and repair the oil pressure problem; refer to the Kubota 05- E4B Series/E4BG Series Workshop Manual. Remove the mechanical oil pressure test gauge. Install the oil pressure switch. Plug main-harness connector J05 into the switch. Start the engine.
Page 481 Inspect the T1 controller and main-harness connector. (continued) the pins and the pins are secure to the connector. Check for proper fit between all pins and their corresponding sockets. The inspection passed. Leave main-harness connector P29 unplugged from the T1 controller. Pass Go to Resistance test the main harness, page...
Page 482 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 483: P0575: T1 Cruise Control Switch Correlation Fault
Circuit Diagram G499852 P0575: T1 Cruise Control Switch Correlation Fault Fault Description The T1 controller has detected that the Cruise Engage signal is active but the Cruise Enable signal is not active. Circuit Description The T1 controller monitors the signals controlled by the cruise- control switch (OFF, ON, or ENGAGE) Verify the fault repeats.
Page 484 Check the InfoCenter Diagnostic screen. (continued) Figure 292 G500254 position position position (cruise- NABLE control switch) 2. Rotate the key to the P position. REHEAT Note: Do not start the engine. 3. In the InfoCenter, navigate to the Main menu, select the Diagnostics option, and press the select button.
Page 485 Check the InfoCenter Diagnostic screen. (continued) Figure 293 3-button InfoCenter G492746 Figure 294 6-button InfoCenter G492749 4. In the Diagnostics menu, select the Traction option, and press the select button. 5. In the Traction screen, select the Inputs option, and press the select button. Note: The Traction Input screen displays.
Page 486 Check the InfoCenter Diagnostic screen. (continued) Figure 295 3-button InfoCenter G500317 Figure 296 6-button InfoCenter G500318 7. Press the cruise-control switch to the E position (Figure 292Figure NABLE Note: Ensure that the cruise-control switch is not pressed to the E NGAGE position.
Page 487 Inspect the seat-harness connector and cruise control switch. 1. Verify the key switch is in the O position. 2. Remove the cruise-control switch; refer to the Service Manual for the machine. 3. Inspect the wiring, inside the seat-harness connector, and the cruise control switch for damage and corrosion.
Page 488 Inspect the seat-harness and main-harness connectors. 1. Verify the key switch is in the O position. 2. Raise the seat and console, and support them with the forward prop rod. 3. Unplug main-harness connector P51 from seat-harness connector P51. Figure 297 Connector P51 (main harness) Connector P51 (seat...
Page 489 Test the seat harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Gray Seat Blue Open Green Seat /Black Brown/ Seat White Open Green Seat /Black Brown/ Seat White Open Frame Ground Gray Seat White Open Frame Ground Green Seat /Black...
Page 490 Test the seat harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Green Seat Figure 298. /Black Figure 298 G492633 Troubleshooting Fault Code: P0575: T1 Cruise Control Page 8–372 24278SL A Switch Correlation Fault...
Page 491 Test the seat harness. (continued) The test is good. Plug seat-harness connector P31 into the cruise-control switch. Leave main-harness connector P51 unplugged from seat-harness connector P51. Insert the cruise-control switch into the control console; refer to the Pass Service Manual for the machine.. Install the left console cover;...
Page 492 Inspect the T1 controller and main-harness connector. (continued) Figure 299 G490767.svg Retaining fastener (location) 3. Inspect the wiring, inside the seat-harness connector and the main-harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector. Check for proper fit between all pins and their corresponding sockets.
Page 493 Test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Green Main Figure 300. /Black Brown/ Main Figure 300. White Open Green Main Figure 300. /Black Gray Main Figure 300. Blue Open Frame Ground Green Main Figure 300.
Page 494 Test the main harness. (continued) Figure 300 G508550 The test is good. Plug main-harness connector P51 into seat-harness connector P51. Pass Leave main-harness connector P29 unplugged from the T1 controller. Go to Swap the T1 controller, page 8–377. One or more tests failed. Repair or replace the damaged wiring.
Page 495 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 496: Circuit Diagram
Circuit Diagram G500448 P0615: T1 Start Output - Open Circuit Fault Description The T1 controller has detected an open circuit on the Start signal. Circuit Description An output signal from the T1 controller is used to control the Start relay. Verify the fault repeats.
Page 497 Inspect the fuse block and start relay. (continued) 2. Unlatch the seat and console, raise them, and support them with the forward prop rod. Figure 301 G490754 Seat and console latch Forward prop rod 3. Remove the cover from the fuse block (connector P99). 4.
Page 498 Inspect the fuse block and start relay. (continued) G500505 Start relay TEC Relay Main relay 5. Inspect the inside the fuse block and the start relay for damage and corrosion. Check for proper fit between all relay terminals and their corresponding fuse- block sockets.
Page 499 Test the start relay. (continued) The test is good. Leave start relay unplugged from the fuse block. Pass Go to Inspect the T1 controller and main-harness connector, page 8– 381. One or more of the tests failed. Replace the start relay. Plug the start relay from the fuse block sockets 13, 15, 19, and 21.
Page 500 Inspect the T1 controller and main-harness connector. (continued) Figure 303 G490767.svg Retaining fastener (location) 3. Inspect the wiring, inside the seat-harness connector, and inside the main- harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector. Check for proper fit between all pins and their corresponding sockets.
Page 501 Test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Brown Main Figure 304. /Black Brown Main /Black Open Engine Ground Main Black Less than 2 Figure 304. ohms Engine Ground Figure 304 G500582 The test is good. Plug the start relay from the fuse block sockets 13, 15, 19, and 21.
Page 502 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 503: P0616: T1 Start Output - Short To Ground/Overcurrent
Circuit Diagram G500583 P0616: T1 Start Output - Short to Ground/ Overcurrent Fault Description The T1 controller has detected a short to ground on the circuit for the Start signal. Circuit Description An output signal from the T1 controller is used to control the Start relay.
Page 504 Inspect the fuse block and start relay. Note: The fuse block is also referred to as connector P99. 1. Verify the key switch is in the O position. 2. Unlatch the seat and console, raise them, and support them with the forward prop rod.
Page 505 Inspect the fuse block and start relay. (continued) G500505 Start relay TEC Relay Main relay 5. Inspect the inside the fuse block and the start relay for damage and corrosion. Check for proper fit between all relay terminals and their corresponding fuse- block sockets.
Page 506 Test the start relay. (continued) The test is good. Leave start relay unplugged from the fuse block. Pass Go to Inspect the T1 controller and main-harness connector, page 8– 388. One or more tests failed. Replace the start relay. Plug the start relay from the fuse block sockets 13, 15, 19, and 21. Lower the seat and control console, and secure them with the latch.
Page 507 Inspect the T1 controller and main-harness connector. (continued) Figure 307 G490767.svg Retaining fastener (location) 3. Inspect the wiring, inside the seat-harness connector, and inside the main- harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector. Check for proper fit between all pins and their corresponding sockets.
Page 508 Test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Brown Main Figure 308. /Black Brown Main /Black Open Engine Ground Main Black Less than 2 Figure 308. ohms Engine Ground Figure 308 G500582 The test is good. Plug the start relay from the fuse block sockets 13, 15, 19, and 21.
Page 509 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 510: P0617: T1 Start Output - Short To Battery
Circuit Diagram G500583 P0617: T1 Start Output - Short to Battery Fault Description The T1 controller has detected a short to a high (+) source on the circuit for the Start signal. Note: The short could be to battery voltage or to another signal that is in a high (+) state.
Page 511 Inspect the 12V fuse block and start relay. Note: The 12V fuse block is also refer to as connector P99. 1. Verify the key switch is in the O position. 2. Unlatch the eat and control console, raise them, and support them with the forward prop rod.
Page 512 Inspect the 12V fuse block and start relay. (continued) G500505 Start relay TEC Relay Main relay 5. Inspect the inside the 12V fuse block and the start relay for damage and corrosion. Check for proper fit between all relay terminals and their corresponding fuse-block sockets.
Page 513 Test the start relay. (continued) Expected Connector Component Location Reading Graphic Start relay Open 86 (+) 86 (+) Start relay Open The test is good. Leave start relay unplugged from the 12V fuse block. Pass Go to Voltage test the main harness, page 8–395.
Page 514 Voltage test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Brown Main /Black Brown Main Figure 311. /Black 0.0 volts Frame Ground Brown Main Figure 311. /Black 0.0 volts Engine Ground Figure 311 G500582 4. Rotate the key switch top the O position.
Page 515 Voltage test the main harness. (continued) The fault did not repeat. Go to Returning the Machine to Service, page 7– The fault repeated. Raise the seat and control console, and support them with the forward prop rod. Unplug the start relay from the 12V fuse block Go to Inspect the T1 controller and main-harness connector, page 8–...
Page 516 Voltage test the main harness. 1. Verify start relay is unplugged from the 12V fuse block. 2. Verify main-harness connector P29 is unplugged from the T1 controller. 3. Rotate the key switch to the P position. REHEAT 4. Use a multimeter to voltage test the following pairs of locations: Note: The 12V fuse block is also referred to connector 99.
Page 517 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 518: P0627: T1 Fuel Pump Output - Open Circuit
Swap the T1 controller. (continued) Calibrating the Virtual Speed Sensor, page 7–53 8. Duplicate the operation of the machine when the fault occurred with the original primary controller. Go to Returning the Machine to Service, page 7–23. Pass Follow the steps listed. Reinstall the original T1 controller.
Page 519 Verify the fault repeats. (continued) The fault did not repeat. Go to Returning the Machine to Service, page 7–23. Pass Follow the steps listed. Note: If the fault does not repeat, an isolated event has occurred. The fault repeated. Go to Preparing for Troubleshooting and/or Testing, page 7–22.
Page 520 Resistance test the fuel pump. 1. Verify the key switch is in the O position. 2. Verify main-harness connector P09 is unplugged from the fuel-pump connector. 3. Use a multimeter to test the resistance between the following pairs of locations: Expected Connector Component...
Page 521 Inspect the T1 controller and main-harness connector. (continued) 3. Fully loosen the retaining fastener that secures the main-harness connector P29 to the T1 controller and unplug the connector from the controller. Figure 315 G490767.svg Retaining fastener (location) 4. Inspect the wiring, inside the seat-harness connector, and inside the main harness connector for damage and corrosion.
Page 522 Resistance test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Red/ Main Black Less than 2 ohms Red/ Main Black Red/ Main Black Open Main Black Red/ Main Black Open Frame Ground Main Black Less than 2 ohms Engine Ground The test is good.
Page 523 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 524: P0628: T1 Fuel Pump Output - Short To Ground/Overcurrent
Circuit Diagram G500903 P0628: T1 Fuel Pump Output - Short to Ground/Overcurrent Fault Description The T1 controller has detected a short to ground on the Fuel Pump signal. Circuit Description An output signal from the T1 controller is used to control the fuel pump.
Page 525 Inspect the fuel-pump connector and main-harness connector. (continued) 2. Remove the floor plate; refer to the Service Manual for the machine. 3. Unplug main-harness connector P09 from the fuel-pump connector. Figure 316 Fuel-pump connector Main-harness connector G500992 4. Inspect the wiring, inside the main-harness connector, and inside the fuel-pump connector for damage and corrosion.
Page 526 Resistance test the fuel pump. (continued) Expected Connector Component Location Reading Graphic Fuel pump 4.2 to 8.4 ohms Fuel pump Open Frame Ground The test is good. Leave main-harness connector P09 unplugged from the fuel-pump Pass connector. Go to Inspect the T1 controller and main-harness connector, page 8– 408.
Page 527 Inspect the T1 controller and main-harness connector. (continued) Figure 317 G490767.svg Retaining fastener (location) 4. Inspect the wiring, inside the seat-harness connector, and inside the main harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector. Check for proper fit between all pins and their corresponding sockets.
Page 528 Resistance test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Red/ Main Black Red/ Main Black Open Main Black Red/ Main Black Open Frame Ground Main Black Less than 2 ohms Engine Ground The test is good. Plug main-harness connector P09 into the fuel pump.
Page 529 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 530: P0629: T1 Fuel Pump Output - Short To Battery
P0629: T1 Fuel Pump Output - Short to Battery Fault Description The T1 controller has detected a short to a high (+) source on the circuit for the Fuel Pump signal. Note: The T1 controller shuts off power to the fuel pump while fault P0629 is active.
Page 531 Inspect the fuel-pump connector and main-harness connector. (continued) Figure 318 Fuel-pump connector Main-harness connector G500992 4. Inspect the wiring, inside the main-harness connector, and inside the fuel-pump connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector.
Page 532 Voltage test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Red/ Main Black 0.0 V Engine Ground Red/ Main Black 0.0 V Frame Ground Main Black 0.0 V Engine Ground Main Black 0.0 V Frame Ground The test is good.
Page 533 Replacing or Swapping the Primary Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 24278SLA Page 8–415 Troubleshooting Fault Code: P0629: T1 Fuel Pump...
Page 534: P0670: T1 Glow Plug Output - Open Circuit
7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33 Calibrating the Traction Pedal, page 7–34 Calibrating the Traction Pump, page 7–43 Calibrating the Virtual Speed Sensor, page 7–53...
Page 535 Verify the fault repeats. (continued) Note: If the fault does not repeat immediately, duplicate the operation of the machine when the fault occurred. 6. Rotate the key switch to the O position. The fault did not repeat. Go to Returning the Machine to Service, page 7–23.
Page 536 Inspect the main-harness connector and glow-plug relay. (continued) The inspection passed. Leave main-harness connector P20 unplugged from the glow-plug Pass relay. Go to Test the glow-plug relay, page 8–418. One or more inspections failed. Repair or replace the worn or damaged parts. Leave main-harness connector P20 unplugged from the glow-plug Fail relay.
Page 537 Inspect the T1 controller and main-harness connector. 1. Verify the key switch is in the O position. 2. Raise the seat and control console, and support them with the forward prop rod. 3. Fully loosen the retaining fastener that secures the main-harness connector P29 to the T1 controller and unplug the connector from the controller.
Page 538 Resistance test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Main Blue Less than 2 ohms Main Blue Main Blue Open Engine Ground Main Black Less than 2 ohms Engine Ground The test is good. Plug main-harness connector P20 into the glow-plug relay.
Page 539 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 540: P063C: T7 Generator Logic Voltage - Low
P063C: T7 Generator Logic Voltage - Low Fault Description The T7 generator/motor controller has detected the logic circuit voltage is lower than 36V. Note: When this fault is active, the T1 controller shuts off the cutting units and the T7 generator/motor controller shuts off generator/motor.
Page 541 Check battery voltage. (continued) Figure 322 3-Button InfoCenter G496512 Figure 323 6-Button InfoCenter G496515 The 48V system battery voltage is 36V or higher. Go to Inspect the generator/ Pass motor controller and main harness connectors, page 8–424. The 48V system battery voltage is lower than 36V. Go to Test the 48V battery Fail voltage, page...
Page 542 Inspect the generator/motor controller and main harness connectors. 1. Verify the key switch is in the O position. 2. Raise the seat and control console, and support them with the forward prop rod. 3. Unplug the 48V battery disconnect from the socket; refer to Connecting and Disconnecting the 48V Battery System, page 7–8.
Page 543 Inspect the generator/motor controller and main harness connectors. (continued) The fault did not repeat. Close the hood and latch it. Go to Returning the Machine to Service, page 7–23. The fault repeated. Raise the seat and control console, and support them with the forward prop rod.
Page 544 Test the 10A fuse. (continued) Figure 325 Fuse-holder cover Fuse holder (connector P54) 10A fuse G501236 4. Unplug the 10A fuse from the fuse holder (connector P54). 5. Use a multimeter to continuity test the fuse. Note: Replace the fuse if it measures open. The test is good.
Page 545 Voltage test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Main Black The test is good. Unplug the 48V battery disconnect from the socket; refer to Connecting and Disconnecting the 48V Battery System, page 7–8. Leave main harness connector P37 unplugged from the generator/ Pass motor controller.
Page 546 Inspect 48V enable relay and main harness. 1. Verify the key switch is in the O position. 2. Verify the 48V battery disconnect is unplugged from the socket. 3. At the right side of the machine, unplug main-harness connector P32 from the 48V Enable relay.
Page 547 Resistance test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Main Yellow Less than 2 ohms Main Yellow Main White Less than 2 ohms Main White The test is good. Plug main-harness connector P32 into the 48V Logic Relay. Pass Leave main-harness connector P29 unplugged from the T1 controller.
Page 548 Test the 48V battery voltage. (continued) 3. Unplug the 48V battery disconnect from the socket; refer to Connecting and Disconnecting the 48V Battery System, page 7–8. Figure 327 Battery contact (outboard —48V battery disconnect socket) G496541 4. Locate the 48V ground junction at the bottom of the machine and inboard of the right-front tire.
Page 549: Check The Batteries
Test the 48V battery voltage. (continued) The test passed. Go to Inspect the generator/motor controller and main Pass harness connectors, page 8–433. The test failed. Go to Check the batteries, page 8–431. Fail Check the batteries. 1. Verify the key switch is in the O position.
Page 550 Assemble the cable clamps onto the battery posts. Torque the nuts for all cable clamps to 5.6 to 7.9 N∙m (50 to 70 in-lb). Apply battery terminal protector (Toro Part No. 107-0392) to all battery posts and cable connectors. Slip the insulator boots over the battery-cable clamps.
Page 551 Check the batteries. (continued) The fault repeated. If fault C1842 did not occur for cutting-unit 2 or cutting-unit 3, close and latch the hood. Plug the 48V battery disconnect into the socket; refer to Connecting and Disconnecting the 48V Battery System, page 7–8.
Page 552 Inspect the generator/motor to controller connections, page 8– 434. Inspect the generator/motor to controller connections. Required Shop Supplies: Description Toro Part No. Super Lube™ oil 145-5053 1. Verify the key switch is in the O position. 2. Remove the cooling air hose from the top intake shroud for the generator/motor;...
Page 553 5. Remove the 2 capscrews that secure the access cover to the generator/motor controller. Figure 333 Capscrews Access cover (generator/ motor controller) Gasket Super Lube oil (Toro DIAG Part No. 145-5053) G496723 24278SLA Page 8–435 Troubleshooting Fault Code: P063C: T7 Generator Logic Voltage - Low...
Page 554 G496722 The inspection is good. Torque the 3 cable terminal capscrews to 8.5 N∙m (75 in-lb). Lightly coat the access cover gasket with Super Lube oil (Toro Part No. 145-5053). Install the access cover to the generator/motor controller with the capscrews.
Page 555 Inspect the generator/motor to controller connections. (continued) Torque the 3 cable terminal capscrews to 8.5 N∙m (75 in-lb). Lightly coat the access cover gasket with Super Lube oil (Toro Part No. 145-5053). Install the access cover to the generator/motor controller with the capscrews.
Page 556: Circuit Diagram
Replace the generator/motor controller. (continued) 9. Press the PTO switch to the D position. ISENGAGE 10. Rotate the key switch to the O position. The fault did not repeat. Close and latch the hood. Pass Go to Returning the Machine to Service, page 7–23.
Page 557 Verify the fault repeats. 1. Safely stop the machine, shut off attachments, and fully lower them. 2. Rotate the key switch to the O position. 3. Start the engine. 4. Operate the machine and cutting units using the same conditions that you discussed with the machine operator.
Page 558 Check battery voltage. (continued) Figure 335 3-Button InfoCenter G496512 6-Button InfoCenter G496515 The 48V system battery voltage is 65V or lower. Go to Inspect the generator/ Pass motor controller and main harness connectors, page 8–444. The 48V system battery voltage is higher than 65V. Go to Test the 48V Fail battery voltage, page...
Page 559 Test the 48V battery voltage. 1. Verify the key switch is in the O position. 2. Raise the seat and control console, and support them with the forward prop rod. 3. Unplug the 48V battery disconnect from the socket; refer to Connecting and Disconnecting the 48V Battery System, page 7–8.
Page 560 Test the 48V battery voltage. (continued) Expected Connector Con- Wire Location Connector Reading Graphic tact Color 48V Ground Junction Black The test passed. Go to Inspect the generator/motor controller and main Pass harness connectors, page 8–444. The test failed. Go to Check the batteries, page 8–442.
Page 561 Assemble the cable clamps onto the battery posts. Torque the nuts for all cable clamps to 5.6 to 7.9 N∙m (50 to 70 in-lb). Apply battery terminal protector (Toro Part No. 107-0392) to all battery posts and cable connectors. Slip the insulator boots over the battery-cable clamps.
Page 562 Check the batteries. (continued) Install the forward and rear cover to the batteries of the 48V system; refer to the Service Manual for the machine. Plug the 48V battery disconnect into the socket; refer to Connecting and Disconnecting the 48V Battery System, page 7–8.
Page 563 Inspect the generator/motor controller and main harness connectors. (continued) Figure 340 Connector (generator/ motor controller) Connector P37 (main harness) G496721 6. Inspect the wiring, inside the main-harness connector, and inside the generator/ motor controller connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector.
Page 564 Inspect the generator/motor to controller connections, page 8– 446. Inspect the generator/motor to controller connections. Required Shop Supplies: Description Toro Part No. Super Lube™ oil 145-5053 1. Verify the key switch is in the O position. 2. Remove the cooling air hose from the top intake shroud for the generator/motor;...
Page 565 Figure 342 Capscrews Access cover (generator/ motor controller) Gasket Super Lube oil (Toro Part No. 145-5053) G496723 6. Inspect the 3 cable terminals and capscrews that connect high-current circuits of the generator/motor to the controller for damage and corrosion. Figure 343...
Page 566 Inspect the generator/motor to controller connections. (continued) The inspection passed. Torque the 3 cable terminal capscrews to 8.5 N∙m (75 in-lb). Lightly coat the access cover gasket with Super Lube oil (Toro Part No. 145-5053). Install the access cover to the generator/motor controller with the capscrews.
Page 567 4. Lower the seat and control console, and secure them with the latch. 5. Program the machine; refer to the Toro DIAG—Quick Start, page 7–24 Using Toro DIAG to Program the Machine, page 7–32. Note: A new generator/motor controller does not function until programmed using Toro DIAG.
Page 568: P06E9: T1 Starter Timeout
Circuit Diagram G501314 P06E9: T1 Starter Timeout Fault Description The T1 controller has detected that the Key Start signal has been active for more than 15 seconds. The key switch has been held in the START position for more than 15 seconds, or the key switch is faulty and the Key Start input is stuck.
Page 569: Test The Key Switch
Replacing or Swapping the Primary Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 24278SLA Page 8–451 Troubleshooting Fault Code: P06E9: T1 Starter Timeout...
Page 570 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33 Calibrating the Traction Pedal, page 7–34 Calibrating the Traction Pump, page 7–43 Calibrating the Virtual Speed Sensor, page 7–53...
Page 571: P0A36: T7 Generator - Temperature Sensor Failure
P0A36: T7 Generator - Temperature Sensor Failure Fault Description The T7 generator/motor controller has detected its temperature sensor has failed. Note: When this fault is active, the T1 controller shuts off the cutting units and the T7 generator/motor controller shuts off generator/motor.
Page 572: P0A3B: T7 Generator Motor - High Temp Warning
Replace the generator/motor. (continued) Note: Refer to the disassemble instructions in the Generator/Motor Assembly Service section the Service Manual for the machine. A. Generator cover. B. Generator/motor controller C. Generator fan 7. Install the following components to the new generator/motor: Note: Refer to the assemble instructions in the Generator/Motor Assembly Service section the Service Manual for the machine.
Page 573 Verify the fault repeats. (continued) 5. Look at the InfoCenter display to see if the fault repeats. Note: If the fault does not repeat immediately, duplicate the operation of the machine when the fault occurred. 6. Rotate the key switch to the O position.
Page 574 Inspect and clean the air-intake screen. 1. Verify the key switch is in the O position. 2. Open the hood. 3. Inspect the air-intake screen for an accumulation of dust and debris. Figure 345 G501616 4. If the screen is dirty, remove the 5 flange-head capscrews, spacers, and locknuts that secure the air-intake screen and seal to the radiator and fan shroud.
Page 575 Inspect the cooling-air hose and shrouds. (continued) 2. Inspect the rear end of the cooling-air hose is securely attached to the flange of the fan shroud with the hose clamp. Figure 347 Cooling-air hose Hose clamp Fan shroud G501527 3. Inspect the forward end of the cooling-air hose is securely attached to the flange of the upper intake shroud with the hose clamp.
Page 576 Test the intake air flow. 1. Start the engine. 2. Hold a strip of paper to the rear of the air-intake screen align with the cooling-air hose. Figure 349 G501615 3. Go to Advise best operating practices, page 8–458. Advise best operating practices. 1.
Page 577: P0A3E: T7 Generator Controller - High Temp Warning
Advise best operating practices. (continued) Proper Mowing Scalping/Circle Cutting Verticutting Techniques Maintain proper reel-to- Reduce the number of bedknife clearance. Use blades (increasing blade light contact. spacing) to reduce the amount of required power. Follow and maintain the 1/ Follow and maintain the 1/ Set the verticutter blade 3rd rule (cut only 1/3 of 3rd rule (cut only 1/3 of...
Page 578 Verify the fault repeats. (continued) 5. Look at the InfoCenter display to see if the fault repeats. Note: If the fault does not repeat immediately, duplicate the operation of the machine when the fault occurred. 6. Rotate the key switch to the O position.
Page 579 Allow the machine to cool. (continued) 6. Rotate the key switch to the O position. 7. Go to Inspect and clean the air-intake screen, page 8–461. Inspect and clean the air-intake screen. 1. Verify the key switch is in the O position.
Page 580 Inspect the cooling-air hose and shrouds. 1. Inspect the cooling-air hose for wear or damage. 2. Inspect the rear end of the cooling-air hose is securely attached to the flange of the fan shroud with the hose clamp. Figure 353 Cooling-air hose Hose clamp Fan shroud...
Page 581 Inspect the cooling-air hose and shrouds. (continued) 7. Go to Test the intake air flow, page 8–463. Test the intake air flow. 1. Start the engine. 2. Hold a strip of paper to the rear of the air-intake screen align with the cooling-air hose.
Page 582: P0A5A: T7 Generator Current Sensor Out Of Range
Advise best operating practices. (continued) Proper Mowing Scalping/Circle Cutting Verticutting Techniques Maintain reel and Scalping and circle cutting Ensure that the cutting- bedknife sharpness. are considered severe unit blades are sharp, applications. Dedicate adjusted correctly, and reels specifically to these that none of the blades applications.
Page 583 4. Lower the seat and control console, and secure them with the latch. 5. Program the machine; refer to the Toro DIAG—Quick Start, page 7–24 Using Toro DIAG to Program the Machine, page 7–32. Note: A new generator/motor controller does not function until programmed using Toro DIAG.
Page 584: P0A5C: T7 Generator Hardware Dc Over Current
P0A5C: T7 Generator Hardware DC Over Current Fault Description The T7 generator/motor controller has detected an internal over- current condition. Current-limiting circuits inside the generator/motor controller are set off because of contactor over current. Note: When this fault is active, the T1 controller shuts off the cutting units and the T7 generator/motor controller shuts off generator/motor.
Page 585 4. Lower the seat and control console, and secure them with the latch. 5. Program the machine; refer to the Toro DIAG—Quick Start, page 7–24 Using Toro DIAG to Program the Machine, page 7–32. Note: A new generator/motor controller does not function until programmed using Toro DIAG.
Page 586: P0Ae4: T7 Hybrid/Ev - Contactor Stuck Open
Advise best operating practices. (continued) Proper Mowing Scalping/Circle Cutting Verticutting Techniques Maintain reel and Scalping and circle cutting Ensure that the cutting- bedknife sharpness. are considered severe unit blades are sharp, applications. Dedicate adjusted correctly, and reels specifically to these that none of the blades applications.
Page 587 Verify the fault repeats. 1. Safely stop the machine, shut off attachments, and fully lower them. 2. Rotate the key switch to the O position. 3. Start the engine. 4. Operate the machine and cutting units using the same conditions that you discussed with the machine operator.
Page 588 Inspect the main contactor and main-harness terminals. (continued) 5. Inspect the wiring, the main contactor, main-harness terminal J24 (white harness wire) and main-harness terminal J25 (brown harness wire) for damage and corrosion. Ensure that the wires are secure to the terminals and the terminals are secure to the contactor.
Page 589 Inspect the main contactor and main-harness terminals. (continued) The fault repeated. Raise the seat and control console, and support them with the forward prop rod. Unplug the 48V battery disconnect from the socket; refer to Connecting and Disconnecting the 48V Battery System, page 7–8.
Page 590 Voltage test the 250A fuse. (continued) Figure 358 G502022 48V positive junction Terminal J23 (main contactor—B) 48V ground junction J21 4. Unplug the 48V battery disconnect from the socket; refer to Connecting and Disconnecting the 48V Battery System, page 7–8. The test is good.
Page 591 Voltage test the 250A fuse. (continued) The fault did not repeat. Raise the seat and control console, and support them with the forward prop rod. Unplug the 48V battery disconnect from the socket; refer to Connecting and Disconnecting the 48V Battery System, page 7–8.
Page 592 Test the main contactor. (continued) Figure 360 Terminal J23 (main contactor—B) Terminal J24 (main contactor—H) G501926 5. Plug the 48V battery disconnect into the socket; refer to Connecting and Disconnecting the 48V Battery System, page 7–8. 6. Use a multimeter to voltage test between the following pairs of locations: Expected Connector Component...
Page 593 Test the main contactor. (continued) 7. Unplug the 48V battery disconnect from the socket; refer to Connecting and Disconnecting the 48V Battery System, page 7–8. Remove the jumper wires from the main contactor. The test is good. Leave the electrical cover removed. Plug the 48V battery disconnect into the socket;...
Page 594 Test the 10A fuse. (continued) Figure 362 Fuse-holder cover Fuse holder (connector P54) 10A fuse G501236 5. Unplug the 10A fuse from the fuse holder (connector P54). 6. Use a multimeter to continuity test the fuse. Note: Replace the fuse if it measures open. The voltage test is good.
Page 595 Inspect the 48V enable relay and main-harness connector. (continued) Figure 363 48V Enable Relay Connector P32 (main harness) G493279 3. Inspect the wiring, inside the enable relay, and inside the main-harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector.
Page 596 Resistance test the main harness. (continued) Pin/ Expected Connector Wire Location Harness Connector Termi- Reading Graphic Color Main Main Yellow Less than 2 ohms Main Yellow Main Yellow Less than 2 ohms Main Yellow Figure 364 G502065 Terminal J23 (main contactor—B) Terminal J24 (main contactor—H) Troubleshooting Fault Code: P0AE4: T7 Hybrid/EV - Page 8–478...
Page 597 Resistance test the main harness. (continued) The test is good. Plug the 10A fuse into the fuse holder (connector P54) and assemble the fuse holder to the fuse-holder cover. Pass Leave the relay unplugged from main-harness connector P32. Leave the 48V battery disconnect unplugged. Go to Swap the Glow Plug relay and the 48V Enable relay, page 8–479.
Page 598 Swap the Glow Plug relay and the 48V Enable relay. (continued) Figure 365 G502082 Connector P20 (main harness) Glow-plug relay 48V Enable relay Connector P32 (main harness) 4. Unplug the main-harness connector P20 from the glow-plug relay. 5. Plug main-harness connector P20 into the 48V Enable relay. 6.
Page 599 Swap the Glow Plug relay and the 48V Enable relay. (continued) Unplug main-harness connector P32 from the glow-plug relay. Unplug main-harness connector P20 from the 48V Enable relay. Plug main-harness connector P20 into the glow-plug relay. Replace the 48V Enable relay. Plug main-harness connector P32.
Page 600 Inspect the generator/motor controller and main-harness connectors. (continued) Figure 366 Connector (generator/ motor controller) Connector P37 (main harness) G496721 5. Inspect the wiring, inside the main-harness connector, and inside the generator/ motor controller connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector.
Page 601 Resistance test the with main harness. (continued) Pin/ Expected Connector Wire Location Harness Connector Termi- Reading Graphic Color Main Black Main Figure 367. Less than 2 ohms Main Main White Figure 367. Less than 2 ohms Main White Main Brown Figure 367.
Page 602 Resistance test the with main harness. (continued) Figure 367 G502102 Terminal J24 (main contactor—H) Terminal J22 (main contactor—E) Terminal J25 (main contactor—K) 48V ground junction J21 The test is good. Install the electrical cover. Leave main-harness connector P37 unplugged from the generator/ Pass motor controller.
Page 603 4. Lower the seat and control console, and secure them with the latch. 5. Program the machine; refer to the Toro DIAG—Quick Start, page 7–24 Using Toro DIAG to Program the Machine, page 7–32. Note: A new generator/motor controller does not function until programmed using Toro DIAG.
Page 604: Circuit Diagram
Circuit Diagram G501314 P0AE5: T7 Hybrid/EV - Contactor Stuck Closed Fault Description The T7 generator/motor controller in charge sensed that the main contactor is closed when it should be open. When the main contactor should be open, voltage on the (T7) 48V Logic Power circuit is 5 volts or less than voltage on the (T7) 48V circuit.
Page 605 Verify the fault repeats. (continued) 5. Look at the InfoCenter display to see if the fault repeats. Note: If the fault does not repeat immediately, duplicate the operation of the machine when the fault occurred. 6. Rotate the key switch to the O position.
Page 606 Inspect the main contactor and main-harness terminals. (continued) Figure 369 Terminal J25 (main contactor—K) Terminal J24 (main contactor—H) G505919 The inspection is good. Leave electrical cover removed. Plug the 48V battery disconnect into the socket; refer to Connecting and Pass Disconnecting the 48V Battery System, page 7–8.
Page 607 Voltage test the 48V Enable relay circuit. (continued) 2. Use a multimeter to voltage test between the following pairs of locations: Expected Connector Component Location Terminal Reading Graphic Main Contactor Figure 370. 0.0V volts 48V ground junction Figure 370 G502227 48V ground junction J21 Terminal J24 (main contactor—H) The test is good.
Page 608 Voltage test the main contactor. (continued) Expected Connector Component Location Terminal Reading Graphic 48V ground junction Figure 371 G502233 48V ground junction J21 Terminal J22 (main contactor—E) The test is good. Unplug the 48V battery disconnect from the socket; refer to Connecting and Disconnecting the 48V Battery System, page 7–8.
Page 609 4. Lower the seat and control console, and secure them with the latch. 5. Program the machine; refer to the Toro DIAG—Quick Start, page 7–24 Using Toro DIAG to Program the Machine, page 7–32. Note: A new generator/motor controller does not function until programmed using Toro DIAG.
Page 610 Inspect the 48V enable relay and main-harness connector. (continued) Figure 372 48V Enable Relay Connector P32 (main harness) G493279 4. Inspect the wiring, inside the enable relay, and inside the main harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector.
Page 611 Swap the Glow Plug relay and the 48V Enable relay. (continued) Figure 373 G502082 Connector P20 (main harness) Glow-plug relay 48V Enable relay Connector P32 (main harness) 4. Unplug the main harness connector P20 from the glow-plug relay. 5. Plug main-harness connector P20 into the 48V Enable relay. 6.
Page 612 Swap the Glow Plug relay and the 48V Enable relay. (continued) Unplug main-harness connector P20 from the 48V Enable relay. Plug main-harness connector P20 into the glow-plug relay. Replace the 48V Enable relay. Plug main harness connector P32. into the 48V Enable relay. Plug the 48V battery disconnect into the socket;...
Page 613 Voltage test the main harness. (continued) The test is good. Plug main-harness connector P32 into the 48V Logic Relay. Pass Close and latch the hood. Go to Voltage test the main contactor, page 8–495. One or more tests failed. Replace the 48V Logic Relay. Plug main-harness connector P32 into the 48V Logic Relay.
Page 614 Voltage test the main contactor. (continued) Figure 374 G502233 48V ground junction J21 Terminal J22 (main contactor—E) 3. Unplug the 48V battery disconnect from the socket; refer to Connecting and Disconnecting the 48V Battery System, page 7–8. The test is good. Install the electrical cover.
Page 615 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 616: P0Ae6: T7 Precharge Failure
Circuit Diagram G501314 P0AE6: T7 Precharge Failure Fault Description The T7 generator/motor controller has detected a short on the 48V bus or too much resistance or too much capacitance. Note: When this fault is active the T7 generator/motor controller shuts off the 48V system. Circuit Description The precharge circuit charges the bus capacitance prior to pulling in the 48V main contactor.
Page 617 Verify the fault repeats. (continued) Note: If the fault does not repeat immediately, duplicate the operation of the machine when the fault occurred. 6. Rotate the key switch to the O position. The fault did not repeat. Go to Returning the Machine to Service, page 7–23.
Page 618 Inspect the main-harness and inverter/controller connectors for cutting unit 4. (continued) Figure 375 Connector P48 (main harness) Signal connector (inverter/ controller) 48V battery connector (inverter/controller) Connector P49 (main harness) G503149 3. Inspect the wiring, the main-harness connector P48 and connector P49, and inverter/controller connectors for damage and corrosion.
Page 619 Isolation test the inverter/controller and motor for cutting unit 4. (continued) Fault code P0AE6 did not repeat. Mark the inverter/controller for cutting unit with a piece of tape. Plug main-harness connector P48 and connector P49 into the inverter/ Pass controller connectors. Go to Inspect the inverter/controller and cutting-unit motor connectors, page...
Page 620 Inspect the main-harness and inverter/controller connectors for cutting unit 1. (continued) Figure 376 Connector P47 (main harness) Connector P46 (main harness) Signal connector (inverter/ controller) 48V battery connector (inverter/controller) G503147 3. Inspect the wiring, the main-harness connector P46 and connector P47, and inverter/controller connectors for damage and corrosion.
Page 621 Isolation test the inverter/controller and motor for cutting unit 1. (continued) Fault code P0AE6 did not repeat. Mark the inverter/controller for cutting unit with a piece of tape. Plug main-harness connector P46 and connector P47 into the inverter/ Pass controller connectors. Go to Inspect the inverter/controller and cutting-unit motor connectors, page...
Page 622 Inspect the main-harness and inverter/controller connectors for cutting unit 5. (continued) Figure 377 48V battery connector (inverter/controller) Connector P45 (main harness) Connector P44 (main harness) Signal connector (inverter/ controller) G503150 3. Inspect the wiring, the main-harness connector P44 and connector P45, and inverter/controller connectors for damage and corrosion.
Page 623 Isolation test the inverter/controller and motor for cutting unit 5. (continued) Fault code P0AE6 did not repeat. Mark the inverter/controller for cutting unit with a piece of tape. Plug main-harness connector P44 and connector P45 into the inverter/ Pass controller connectors. Go to Inspect the inverter/controller and cutting-unit motor connectors, page 8–509.
Page 624 Inspect the main-harness and inverter/controller connectors for cutting unit 2. (continued) Figure 378 Signal connector (inverter/ controller) 48V battery connector (inverter/controller) Connector P39 (main harness) Connector P38 (main harness) G503151 4. Inspect the wiring, the main-harness connector P38 and connector P39, and inverter/controller connectors for damage and corrosion.
Page 625 Isolation test the inverter/controller and motor for cutting unit 2. (continued) Fault code P0AE6 did not repeat. Mark the inverter/controller for cutting unit with a piece of tape. Plug main-harness connector P38 and connector P39 into the inverter/ Pass controller connectors. Go to Inspect the inverter/controller and cutting-unit motor connectors, page...
Page 626 Inspect the main-harness and inverter/controller connectors for cutting unit 3. (continued) Figure 379 48V battery connector (inverter/controller) Connector P49 (main harness) Connector P48 (main harness) Signal connector (inverter/ controller) G503148 3. Inspect the wiring, the main-harness connector P40 and connector P41, and inverter/controller connectors for damage and corrosion.
Page 627 Isolation test the inverter/controller and motor for cutting unit 3. (continued) Fault code P0AE6 did not repeat. Mark the inverter/controller for cutting unit with a piece of tape. Plug main-harness connector P40 and connector P41 into the inverter/ Pass controller connectors. Go to Inspect the inverter/controller and cutting-unit motor connectors, page...
Page 628 Inspect the inverter/controller and cutting-unit motor connectors. (continued) Replace the inverter/controller, the cutting motor, or both; refer to the Service Manual for the machine. Using the old screws and controller O-ring, assemble the inverter/ controller to the motor; refer to the Service Manual for the machine. IMPORTANT The edge-card of the motor can be easily damaged.
Page 629 Inspect the inverter/controller and cutting-unit motor connectors. (continued) IMPORTANT To ensure that the inverter/controller and the motor seal, follow the torque specification in the Service Manual for the machine. If the inverter/controller or motor for cutting-unit 2 or 3 were replaced, close and latch the hood.
Page 630 Go to Returning the Machine to Service, page 7–23. Fault code P0AE6 repeated. Parts required for this procedure: Description Toro Part No. Quantity O-Ring Service Kit 144-6731 Pass with Replace the cutting-unit motor; refer to the Service Manual for the machine.
Page 631 Isolation test the inverter/controller. (continued) Torque the screws that secure the inverter/controller to the motor according to the Service Manual for the machine. IMPORTANT To ensure that the inverter/controller and the motor seal, follow the torque specification in the Service Manual for the machine. Plug the main harness connectors into the inverter/controller connectors.
Page 632 10. Lower the seat and control console, and secure them with the latch. 11. Go to Returning the Machine to Service, page 7–23. Fault code P0AE6 repeated. Parts required for this procedure: Description Toro Part No. Quantity O-Ring Service Kit 144-6731 Troubleshooting Fault Code: P0AE6: T7 Precharge Page 8–514 24278SL A...
Page 633 Isolation test the inverter/controller. (continued) Unplug the main harness connectors inverter/controller connector and remove the new inverter/controller from the cutting-unit motor; refer to the Service Manual for the machine. Install the original inverter/controller; refer to the Service Manual for the machine.
Page 634 Inspect the generator/motor controller and main harness connectors. (continued) Figure 380 Connector (generator/ motor controller) Connector P37 (main harness) G496721 5. Inspect the wiring, inside the main-harness connector, and inside the generator/ motor controller connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector.
Page 635 Swap the T1 controller, page 8–523. Inspect the generator/motor controller bus bar, generator/motor harness terminals, and harness connectors. Required Shop Supplies: Description Toro Part No. Super Lube™ oil 145-5053 1. Verify the key switch is in the O position. 24278SLA Page 8–517...
Page 636 Inspect the generator/motor controller bus bar, generator/motor harness terminals, and harness connectors. (continued) 2. Verify the 48V battery disconnect is unplugged from the socket. 3. Remove the hose clamp and cooling air hose from the top intake shroud for the generator/motor;...
Page 637 (continued) Figure 382 Capscrews Access cover (generator/ motor controller) Gasket Super Lube oil (Toro Part No. 145-5053) G502815 7. Remove the 3 capscrews that secure high-current terminals of the generator/ motor to the busbars of the generator/motor controller. Figure 383...
Page 638 Inspect the generator/motor controller bus bar, generator/motor harness terminals, and harness connectors. (continued) Figure 384 Harness connector (generator/motor controller) Harness connector (generator/motor) G502702 9. Remove the 2 capscrews, washers, and locknuts that secure the generator/motor controller to the generator housing. Figure 385 G502816 Locknut...
Page 639 Inspect the generator/motor controller bus bar, generator/motor harness terminals, and harness connectors. (continued) • inside the 6-pin generator/motor controller harness connector (Figure 384) • the 3 high current generator/motor cable terminals (Figure 383) • the 3 generator/motor controller busbars (Figure 386) •...
Page 640 Torque the capscrews to 8 to 9 N∙m (70 to 80 in-lb). Apply a coat of Super Lube oil (Toro Part No. 145-5053) to the seal and assemble the access cover to the generator/motor Fault code controller.
Page 641 Torque the capscrews to 8 to 9 N∙m (70 to 80 in-lb). Apply a coat of Super Lube oil (Toro Part No. 145-5053) to the seal and assemble the access cover to the generator/motor controller.
Page 642: P100C: T1 Engine Coolant Temperature Above Threshold - Pto Kill
Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 643: Check The Engine Oil Level
Verify the fault repeats. 1. Safely stop the machine, shut off attachments, and fully lower them. 2. Rotate the key switch to the O position. 3. Start the engine. 4. Operate the machine and cutting units using the same conditions that you discussed with the machine operator.
Page 644 Perform cooling system maintenance. Refer to the Operator’s Manual for the machine. 1. Clean the engine cooling system of dust and debris. 2. Inspect the radiator for bent and damaged cooling fins. 3. Check the coolant level. 4. Check alternator belt tension. Test thermostat opening temperature.
Page 645 Test thermostat opening temperature. (continued) Figure 388 6-Button InfoCenter G503563 3. Start the engine. 4. Watch the coolant temperature in the InfoCenter. When coolant temperature reaches 70º C (157º F), feel the upper hose at the thermostat housing. 5. When you feel coolant flowing through the hose, look at the coolant temperature in the InfoCenter.
Page 646 Test cooling system operation. (continued) 2. Look at the InfoCenter display to see if the fault repeats. Note: If the fault P100C displays, immediately go to Step 3. 3. Park the machine on a level surface, engage the parking brake, lower the cutting units, and shut off the engine.
Page 647: P100D: T1 Engine Coolant Temperature Above Threshold - Engine Kill
Replace the coolant temperature sender. (continued) 6. Look at the InfoCenter display to see if the fault repeats. 7. Park the machine on a level surface, engage the parking brake, lower the cutting units, and shut off the engine. The fault did not repeat. Go to Returning the Machine to Service, page 7–23.
Page 648 Verify the fault repeats. (continued) 4. Operate the machine and cutting units using the same conditions that you discussed with the machine operator. 5. Look at the InfoCenter display to see if the fault repeats. Note: If the fault does not repeat immediately, duplicate the operation of the machine when the fault occurred.
Page 649 Perform cooling system maintenance. (continued) 1. Clean the engine cooling system of dust and debris. 2. Inspect the radiator for bent and damaged cooling fins. 3. Check the coolant level. 4. Check alternator belt tension. Test thermostat opening temperature. 1. Rotate the key switch to the P position.
Page 650 Test thermostat opening temperature. (continued) Figure 390 6-Button InfoCenter G503563 3. Start the engine. 4. Watch the coolant temperature in the InfoCenter. When coolant temperature reaches 70º C (157º F), feel the upper hose at the thermostat housing. 5. When you feel coolant flowing through the hose, look at the coolant temperature in the InfoCenter.
Page 651 Test cooling system operation. (continued) 2. Look at the InfoCenter display to see if the fault repeats. Note: If the fault P100C displays, immediately park the machine on a level surface, engage the parking brake, lower the cutting units, and shut off the engine. 3.
Page 652: P1014: T1 Fuel Actuator - Short To Ground/Overcurrent
Replace the coolant temperature sender. (continued) 6. Look at the InfoCenter display to see if the fault repeats. 7. Park the machine on a level surface, engage the parking brake, lower the cutting units, and shut off the engine. The fault did not repeat. Go to Returning the Machine to Service, page 7–23.
Page 653 Verify the fault repeats. (continued) The fault did not repeat. Go to Returning the Machine to Service, page 7–23. Pass Follow the steps listed. Note: If the fault does not repeat, an isolated event has occurred. The fault repeated. Go to Preparing for Troubleshooting and/or Testing, page 7–22.
Page 654 Test the fuel actuator. 1. Verify the key switch is in the O position. 2. Verify main-harness connector P52 is unplugged from the fuel actuator. 3. Use a multimeter to test resistance between the following pairs of locations: Expected Connector Component Location Reading...
Page 655 Inspect the T1 controller and main-harness connector. (continued) Figure 392 G490767.svg Retaining fastener (location) 3. Inspect the wiring, inside the seat-harness connector, and inside the main- harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector. Check for proper fit between all pins and their corresponding sockets.
Page 656 Test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Red/ Main Yellow Red/ Main Yellow Open Engine Ground Red/ Main Less than 2 Yellow ohms Engine Ground Red/ Main Yellow Open Red/ Main Yellow The test is good. Plug main harness connector P52 into the fuel actuator.
Page 657: Circuit Diagram
Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 658 Verify the fault repeats. 1. Safely stop the machine, shut off attachments, and fully lower them. 2. Rotate the key switch to the O position. 3. Start the engine. 4. Operate the machine and cutting units using the same conditions that you discussed with the machine operator.
Page 659 Inspect fuel actuator and main-harness connector. (continued) the pins and the pins are secure to the connector. Check for proper fit between all pins and their corresponding sockets. The inspection passed. Leave main-harness connector P52 unplugged from the fuel actuator. Pass Go to Test the fuel actuator, page...
Page 660 Test the fuel actuator. (continued) Rotate the key switch to the O position. The fault did not repeat. Close and latch the hood. Go to Returning the Machine to Service, page 7–23. The fault repeated. Unplug main harness connector P52 from the fuel actuator. Go to Inspect the T1 controller and main-harness connector, page 8–...
Page 661 Inspect the T1 controller and main-harness connector. (continued) The inspection passed. Leave main-harness connector P29 unplugged from the T1 controller. Pass Go to Test the main harness, page 8–543. One or more inspections failed. Repair or replace the worn or damaged parts. Fail Leave main-harness connector P29 unplugged from the T1 controller.
Page 662 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 663: P1104: T1 Traction Coil 1 Fwd - Overcurrent
Swap the T1 controller. (continued) Go to Returning the Machine to Service, page 7–23. Pass Follow the steps listed. Reinstall the original T1 controller. Fail Repeat the diagnostic process for this fault. Circuit Diagram G503877 P1104: T1 Traction Coil 1 FWD - Overcurrent Fault Description The T1 controller has detected the Hydrostat FWD circuit is overcurrent, indicating a short to ground.
Page 664 Verify the fault repeats. (continued) 6. Rotate the key switch to the O position. The fault did not repeat. Go to Returning the Machine to Service, page 7–23. Pass Follow the steps listed. Note: If the fault does not repeat, an isolated event has occurred. The fault repeated.
Page 665 Inspect traction pump and main-harness connector. (continued) The inspection passed. Leave main-harness connector P60 unplugged from the servo-control Pass valve. Go to Test the Hydrostat FWD C1 coil, page 8–547. One or more of the inspections failed. Repair or replace the worn or damaged parts. Leave main-harness connector P60 unplugged from the servo-control Fail valve.
Page 666 Test the Hydrostat FWD C1 coil. (continued) Lower the seat and control console, and secure them with the latch. Start the engine and drive the machine. Look at the InfoCenter display to see if the fault repeats. Park the machine, engage the parking brake, and rotate the key switch to the O position.
Page 667 Inspect the T1 controller and main-harness connector. (continued) The inspection passed. Leave main-harness connector P29 unplugged from the T1 controller. Pass Go to Test the main harness, page 8–549. One or more inspections failed. Repair or replace the worn or damaged parts. Fail Leave main-harness connector P29 unplugged from the T1 controller.
Page 668 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 669: P110C: T1 Traction Coil 1 Fwd - Validation Failure - Current Converge
Swap the T1 controller. (continued) Go to Returning the Machine to Service, page 7–23. Pass Follow the steps listed. Reinstall the original T1 controller. Fail Repeat the diagnostic process for this fault. Circuit Diagram G504230 P110C: T1 Traction Coil 1 FWD - Validation Failure - Current Converge Fault Description The T1 controller has detected a difference between the target...
Page 670 Verify the fault repeats. (continued) 2. Rotate the key switch to the O position. 3. Start the engine. 4. Operate the machine and cutting units using the same conditions that you discussed with the machine operator. 5. Look at the InfoCenter display to see if the fault repeats. Note: If the fault does not repeat immediately, duplicate the operation of the machine when the fault occurred.
Page 671 Inspect traction pump and main-harness connector. (continued) Figure 397 G504202 Servo-control valve connector FWD C1 Connector P60 (main harness) (hydrostat—traction pump) 4. Inspect the wiring, inside the traction pump connector, and inside the main- harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector.
Page 672 Test the Hydrostat FWD C1 coil. (continued) Expected Connector Component Location Reading Graphic Hydrostat FWD 3.66 ohms Hydrostat FWD Open Engine Ground Hydrostat FWD Less than 2 ohms Engine Ground The test is good. Leave main-harness connector P60 unplugged from the servo-control Pass valve.
Page 673 Inspect the T1 controller and main-harness connector. (continued) 2. Fully loosen the retaining fastener that secures the main-harness connector P29 to the T1 controller and unplug the connector from the controller. Figure 398 G490767.svg Retaining fastener (location) 3. Inspect the wiring, inside the seat-harness connector, and inside the main- harness connector for damage and corrosion.
Page 674 Test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Orange Main Less than 2 ohms Orange Main Orange Main Open Engine Ground Main Black Less than 2 ohms Engine Ground Orange Main Open Main Black The test is good.
Page 675 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 676: P110D: T1 Traction Coil 1 Fwd - Validation Failure - Pwm Converge
P110D: T1 Traction Coil 1 FWD - Validation Failure - PWM Converge Fault Description The T1 controller has detected the desired current on the Hydrostat FWD circuit is 0, the duty cycle is greater than 15%, and the duty cycle across the Hydrostat FWD C1 coil is not decreasing. This fault may also result when the T1 controller detects the duty cycle across the Hydrostat FWD C1 coil is greater than 98%.
Page 677 Inspect traction pump and main-harness connector. 1. Verify the key switch is in the O position. 2. Raise the seat and control console, and support them with the forward prop rod. 3. At the left side of the machine, unplug the main-harness connector P60 from the servo-control valve connector—Hydrostat FWD C1 of the traction pump.
Page 678 Test the Hydrostat FWD C1 coil. (continued) 2. Verify main-harness connector P60 is unplugged from the servo-control valve. 3. Warm or cool the FWD C1 coil to 20°C (68°F). 4. Use a multimeter to test resistance between the following pairs of locations: Expected Connector Component...
Page 679 Inspect the T1 controller and main-harness connector. 1. Verify the key switch is in the O position. 2. Fully loosen the retaining fastener that secures the main-harness connector P29 to the T1 controller and unplug the connector from the controller. Figure 400 G490767.svg Retaining fastener (location)
Page 680 Test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Orange Main Less than 2 ohms Orange Main Orange Main Open Engine Ground Main Black Less than 2 ohms Engine Ground Orange Main Open Main Black The test is good.
Page 681 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 682: P110E: T1 Traction Coil 1 Fwd - Feedback Measurement Validation Failure
Circuit Diagram G504230 P110E: T1 Traction Coil 1 FWD - Feedback Measurement Validation Failure Fault Description The T1 controller has detected that the expected Hydrostat FWD circuit feedback (calculated) does not match the measured Hydrostat FWD circuit feedback. Note: When this fault is active, the T1 controller shuts off traction and machine will come to a sudden stop.
Page 683 Verify the fault repeats. (continued) The fault did not repeat. Go to Returning the Machine to Service, page 7–23. Pass Follow the steps listed. Note: If the fault does not repeat, an isolated event has occurred. The fault repeated. Go to Preparing for Troubleshooting and/or Testing, page 7–22.
Page 684 Inspect traction pump and main-harness connector. (continued) The inspection passed. Leave main-harness connector P60 unplugged from the servo-control Pass valve. Go to Test the hydrostat FWD C1 coil, page 8–566. One or more of the inspections failed. Repair or replace the worn or damaged parts. Leave main-harness connector P60 unplugged from the servo-control Fail valve.
Page 685 Test the Hydrostat FWD C1 coil. (continued) Lower the seat and control console, and secure them with the latch. Start the engine and drive the machine. Look at the InfoCenter display to see if the fault repeats. Park the machine, engage the parking brake, and rotate the key switch to the O position.
Page 686 Inspect the T1 controller and main-harness connector. (continued) The inspection passed. Leave main-harness connector P29 unplugged from the T1 controller. Pass Go to Test the main harness, page 8–568. One or more inspections failed. Repair or replace the worn or damaged parts. Fail Leave main-harness connector P29 unplugged from the T1 controller.
Page 687 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 688: P1114: T1 Traction Coil 1 Rev - Overcurrent
Swap the T1 controller. (continued) Go to Returning the Machine to Service, page 7–23. Pass Follow the steps listed. Reinstall the original T1 controller. Fail Repeat the diagnostic process for this fault. Circuit Diagram G504230 P1114: T1 Traction Coil 1 REV - Overcurrent Fault Description The T1 controller has detected the Hydrostat REV circuit is overcurrent, indicating a short to ground.
Page 689 Verify the fault repeats. (continued) Note: If the fault does not repeat immediately, duplicate the operation of the machine when the fault occurred. 6. Rotate the key switch to the O position. The fault did not repeat. Go to Returning the Machine to Service, page 7–23.
Page 690 Inspect traction pump and main-harness connector. (continued) the pins and the pins are secure to the connector. Check for proper fit between all pins and their corresponding sockets. The inspection passed. Leave main-harness connector P61 unplugged from the servo-control Pass valve.
Page 691 Test the Hydrostat REV C2 coil. (continued) Replace the worn or damaged hydrostat REVD C2 coil. Plug main harness connector P61 into the servo-control valve. Lower the seat and console, and secure them with the latch. Start the engine and drive the machine. Drive the machine backward to test reverse C2 coil.
Page 692 Inspect the T1 controller and main-harness connector. (continued) the pins and the pins are secure to the connector. Check for proper fit between all pins and their corresponding sockets. The inspection passed. Leave main-harness connector P29 unplugged from the T1 controller. Pass Go to Test the main harness, page...
Page 693 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 694: P111C: T1 Traction Coil 1 Rev - Validation Failure - Current Converge
Swap the T1 controller. (continued) 8. Duplicate the operation of the machine when the fault occurred with the original primary controller. Go to Returning the Machine to Service, page 7–23. Pass Follow the steps listed. Reinstall the original T1 controller. Fail Repeat the diagnostic process for this fault.
Page 695 Verify the fault repeats. 1. Safely stop the machine, shut off attachments, and fully lower them. 2. Rotate the key switch to the O position. 3. Start the engine. 4. Operate the machine and cutting units using the same conditions that you discussed with the machine operator.
Page 696 Inspect traction pump and main-harness connector. (continued) Figure 405 G504203 Servo-control valve connector REV C2 Connector P61 (main harness) (hydrostat—traction pump) 4. Inspect the wiring, inside the traction pump connector, and inside the main- harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector.
Page 697 Test the Hydrostat REV C2 coil. (continued) Expected Connector Component Location Reading Graphic Hydrostat REV 3.66 ohms Hydrostat REV Open Engine Ground Hydrostat REV Less than 2 ohms Engine Ground The test is good. Leave main-harness connector P61 unplugged from the servo-control Pass valve.
Page 698 Inspect the T1 controller and main-harness connector. (continued) 2. Fully loosen the retaining fastener that secures the main-harness connector P29 to the T1 controller and unplug the connector from the controller. Figure 406 G490767.svg Retaining fastener (location) 3. Inspect the wiring, inside the seat-harness connector, and inside the main- harness connector for damage and corrosion.
Page 699 Test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Main Green Less than 2 ohms Main Green Main Green Open Engine Ground Main Black Less than 2 ohms Engine Ground Main Green Open Main Black The test is good.
Page 700 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 701: P111D: T1 Traction Coil 1 Rev - Validation Failure - Pwm Converge
Circuit Diagram G504231 P111D: T1 Traction Coil 1 REV - Validation Failure - PWM Converge Fault Description The T1 controller has detected the desired current on the Hydrostat REV circuit is 0, the duty cycle is greater than 15%, and the duty cycle across the Hydrostat REV C2 coil is not decreasing.
Page 702 Verify the fault repeats. (continued) Note: If the fault does not repeat immediately, duplicate the operation of the machine when the fault occurred. 6. Rotate the key switch to the O position. The fault did not repeat. Go to Returning the Machine to Service, page 7–23.
Page 703 Inspect traction pump and main-harness connector. (continued) the pins and the pins are secure to the connector. Check for proper fit between all pins and their corresponding sockets. The inspection passed. Leave main-harness connector P61 unplugged from the servo-control Pass valve.
Page 704 Test the Hydrostat REV C2 coil. (continued) Replace the worn or damaged hydrostat REVD C2 coil. Plug main harness connector P61 into the servo-control valve. Lower the seat and control console, and secure them with the latch. Start the engine and drive the machine. Drive the machine backward to test reverse C2 coil.
Page 705 Inspect the T1 controller and main-harness connector. (continued) the pins and the pins are secure to the connector. Check for proper fit between all pins and their corresponding sockets. The inspection passed. Leave main-harness connector P29 unplugged from the T1 controller. Pass Go to Test the main harness., page 8–587...
Page 706 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 707: P111E: T1 Traction Coil 1 Rev - Feedback Measurement Validation Failure
Swap the T1 controller. (continued) Calibrating the Virtual Speed Sensor, page 7–53 8. Duplicate the operation of the machine when the fault occurred with the original primary controller. Go to Returning the Machine to Service, page 7–23. Pass Follow the steps listed. Reinstall the original T1 controller.
Page 708 Verify the fault repeats. 1. Safely stop the machine, shut off attachments, and fully lower them. 2. Rotate the key switch to the O position. 3. Start the engine. 4. Operate the machine and cutting units using the same conditions that you discussed with the machine operator.
Page 709 Inspect traction pump and main-harness connector. (continued) Figure 409 G504203 Servo-control valve connector REV C2 Connector P61 (main harness) (hydrostat—traction pump) 4. Inspect the wiring, inside the traction pump connector, and inside the main- harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector.
Page 710 Test the Hydrostat REV C2 coil. (continued) Expected Connector Component Location Reading Graphic Hydrostat REV 3.66 ohms Hydrostat REV Open Engine Ground Hydrostat REV Less than 2 ohms Engine Ground The test is good. Leave main-harness connector P61 unplugged from the servo-control Pass valve.
Page 711 Inspect the T1 controller and main-harness connector. (continued) 2. Fully loosen the retaining fastener that secures the main-harness connector P29 to the T1 controller and unplug the connector from the controller. Figure 410 G490767.svg Retaining fastener (location) 3. Inspect the wiring, inside the seat-harness connector, and inside the main- harness connector for damage and corrosion.
Page 712 Test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Main Green Less than 2 ohms Main Green Main Green Open Engine Ground Main Black Less than 2 ohms Engine Ground Main Green Open Main Black The test is good.
Page 713 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 714: P1164: T1 Swashplate 1 - Signal Shorted To Gnd
Circuit Diagram G504231 P1164: T1 Swashplate 1 - Signal Shorted to Fault Description The T1 controller has detected the swash plate-angle sensor signal is lower than 0.25V, indicating a short to ground. Note: When this fault is active, the T1 controller shuts off the cutting units and reduces traction speed 50%.
Page 715 Verify the fault repeats. (continued) The fault did not repeat. Go to Returning the Machine to Service, page 7–23. Pass Follow the steps listed. Note: If the fault does not repeat, an isolated event has occurred. The fault repeated. Go to Preparing for Troubleshooting and/or Testing, page 7–22.
Page 716 Inspect the swash plate-angle sensor and main harness. (continued) G504342 Swash plate-angle sensor connector Main-harness connector P59 4. Inspect the wiring, inside the main-harness connector, and inside the swash plate-angle sensor connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector.
Page 717 Test the swash plate-angle sensor. (continued) Expected Connector Component Location Reading Graphic Swash plate- angle sensor Open Frame Ground Swash plate- angle sensor Open Frame Ground Swash plate- angle sensor Open Frame Ground The test is good. Leave main-harness connector P59 unplugged from the swash plate- Pass angle sensor.
Page 718 Inspect the T1 controller and main-harness connector. 1. Verify the key switch is in the O position. 2. Fully loosen the retaining fastener that secures the main-harness connector P29 to the T1 controller and unplug the connector from the controller. Figure 412 G490767.svg Retaining fastener (location)
Page 719 Resistance test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Main Brown Less than 2 ohms Main Brown Main Brown Open Machine Ground Blue/ Main Yellow Less than 2 ohms Blue/ Main Yellow Blue/ Main Yellow Open Frame Ground...
Page 720 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 721: P1165: T1 Swashplate 1 - Signal Open Circuit
Circuit Diagram G504450 P1165: T1 Swashplate 1 - Signal Open Circuit Fault Description The T1 controller has detected the swash plate-angle sensor signal is higher than 4.5V, indicating an open circuit. Note: When this fault is active, the T1 controller shuts off the cutting units and reduces traction speed 50%.
Page 722 Verify the fault repeats. (continued) The fault did not repeat. Go to Returning the Machine to Service, page 7–23. Pass Follow the steps listed. Note: If the fault does not repeat, an isolated event has occurred. The fault repeated. Go to Preparing for Troubleshooting and/or Testing, page 7–22.
Page 723 Inspect the swash plate-angle sensor and main harness. (continued) G504342 Swash plate-angle sensor connector Main-harness connector P59 4. Inspect the wiring, inside the main-harness connector, and inside the swash plate-angle sensor connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector.
Page 724 Test the swash plate-angle sensor. (continued) Expected Connector Component Location Reading Graphic Swash plate- angle sensor Open Frame Ground Swash plate- angle sensor Open Frame Ground Swash plate- angle sensor Open Frame Ground The test is good. Leave main-harness connector P59 unplugged from the swash plate- Pass angle sensor.
Page 725 Inspect the T1 controller and main-harness connector. 1. Verify the key switch is in the O position. 2. Fully loosen the retaining fastener that secures the main-harness connector P29 to the T1 controller and unplug the connector from the controller. Figure 414 G490767.svg Retaining fastener (location)
Page 726 Resistance test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Main Brown Less than 2 ohms Main Brown Main Brown Open Machine Ground Blue/ Main Yellow Less than 2 ohms Blue/ Main Yellow Blue/ Main Yellow Open Frame Ground...
Page 727 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 728: P1167: T1 Swashplate 1 - Validation Failure - Position Converge
Circuit Diagram G504450 P1167: T1 Swashplate 1 - Validation Failure - Position Converge Fault Description The T1 controller has detected a difference between the target swash plate position and the measured swash plate position. The measured swash plate position should match the target swash plate position set in the T1 controller.
Page 729 Verify the fault repeats. (continued) The fault did not repeat. Go to Returning the Machine to Service, page 7–23. Pass Follow the steps listed. Note: If the fault does not repeat, an isolated event has occurred. The fault repeated. Go to Preparing for Troubleshooting and/or Testing, page 7–22.
Page 730 Inspect the forward solenoid, reverse solenoid, and swashplate angle sensor. (continued) G504766 The inspection passed. Lower the seat and control console, and secure them with the latch. Pass Go to Check the swashplate position variance, page 8–612. One or more inspections failed. Clean the forward solenoid, reverse solenoid, and swashplate angle sensor and the area around them.
Page 731 Check the swashplate position variance. (continued) Figure 416 3-Button InfoCenter G489734 Figure 417 6-Button InfoCenter G489048 3. In the Settings menu, select one of the following: • 3-Button InfoCenter: the Protected Menus option. • 6-Button InfoCenter: the Enter PIN option. 24278SLA Page 8–613 Troubleshooting Fault Code: P1167: T1 Swashplate 1 -...
Page 732 Check the swashplate position variance. (continued) G489722 Figure 418 6-Button InfoCenter G489050 4. In the Enter PIN screen, enter the 4-character PIN, press the right E button, NTER and press the center C button. ONFORM Figure 419 3-Button InfoCenter G489745 Troubleshooting Fault Code: P1167: T1 Swashplate 1 - Page 8–614 24278SL A...
Page 733 Check the swashplate position variance. (continued) Figure 420 6-Button InfoCenter G487427 5. Navigate to the Service menu and select the Traction Pump option. 6. In the Traction Pump menu, navigate to the N (neutral) value and record the voltage value: N (neutral)= 7.
Page 734 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 735 Swap the T1 controller. (continued) Go to Returning the Machine to Service, page 7–23. Pass Follow the steps listed. Reinstall the original T1 controller. Fail Repeat the diagnostic process for this fault. Inspect the swash plate-angle sensor and main harness. 1.
Page 736 Inspect the swash plate-angle sensor and main harness. (continued) G504342 Swash plate-angle sensor connector Main-harness connector P59 4. Inspect the wiring, inside the main-harness connector, and inside the swash plate-angle sensor connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector.
Page 737 Test swash plate-angle sensor power. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Main Brown Approxi- mately 5.0 Blue/ Main volts Yellow The test is good. Leave main-harness connector P59 unplugged from the swash plate- Pass angle sensor. Go to Inspect the T1 controller and main-harness connector, page 8–...
Page 738 Inspect the T1 controller and main-harness connector. (continued) Figure 422 G490767.svg Retaining fastener (location) 3. Inspect the wiring, inside the seat-harness connector, and inside the main harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector. Check for proper fit between all pins and their corresponding sockets.
Page 739 Resistance test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Main Brown Main Brown Open Machine Ground Blue/ Main Yellow Less than 2 ohms Blue/ Main Yellow Blue/ Main Yellow Open Frame Ground Main Violet Less than 2 ohms Main...
Page 740 Swap the T1 controller. Note: The T1 controller is programmed to the specific machine model and serial number. The T1 controller does not function until programmed using Toro DIAG. Troubleshooting Fault Code: P1167: T1 Swashplate 1 - Page 8–622 24278SL A...
Page 741: Circuit Diagram
Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 742: P1169: T1 Swashplate 1 - Invalid Calibration Data
P1169: T1 Swashplate 1 - Invalid Calibration Data Fault Description The T1 controller integrity check on swash plate-angle sensor calibration data failed. Note: When this fault is active, the T1 controller shuts off the cutting units and reduces traction speed 50%. Circuit Description The swash plate-angle sensor is located in the traction pump, and the angle sensor is used to measure the swash plate position of the traction pump.
Page 743 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 744: P116C: T1 Swashplate 1 - Signal Out Of Operational Range
P116C: T1 Swashplate 1 - Signal Out of Operational Range Fault Description The T1 controller has detected the swash plate-angle sensor signal is valid, but out of operating range. The EEPROM value was modified outside of the calibration routine. Note: When this fault is active, the T1 controller shuts off the cutting units and reduces traction speed 50%.
Page 745 Calibrate the traction pump. (continued) Go to Returning the Machine to Service, page 7–23. Pass Follow the steps listed. Go to Inspect the swash plate-angle sensor and main harness, page 8–627. Fail Inspect the swash plate-angle sensor and main harness. 1.
Page 746 Inspect the swash plate-angle sensor and main harness. (continued) G504342 Swash plate-angle sensor connector Main-harness connector P59 4. Inspect the wiring, inside the main-harness connector, and inside the swash plate-angle sensor connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector.
Page 747 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 748: P1189: T1 Traction Pump 1 - Invalid Calibration Data
Circuit Diagram G504450 P1189: T1 Traction Pump 1 - Invalid Calibration Data Fault Description The T1 controller detected that the calibration data integrity check failed. The EEPROM value was modified outside of the calibration routine. Note: When this fault is active, the T1 controller shuts off the cutting units and reduces traction speed 50%.
Page 749 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 750: P11A9: T1 Traction Pedal 1 - Invalid Calibration Data
Swap the T1 controller. (continued) Go to Returning the Machine to Service, page 7–23. Pass Follow the steps listed. Reinstall the original T1 controller. Fail Repeat the diagnostic process for this fault. P11A9: T1 Traction Pedal 1 - Invalid Calibration Data Fault Description The T1 controller detected that the calibration data integrity check failed.
Page 751 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 752: P11C9: T1 Speed Sensor 1 - Invalid Calibration Data
P11C9: T1 Speed Sensor 1 - Invalid Calibration Data Fault Description The T1 controller detected that the calibration data integrity check failed. Note: When this fault is active, the T1 controller reduces available traction speed. Circuit Description The swash plate-angle sensor is located in the traction pump, and the angle sensor is used to measure the swash plate position of the traction pump.
Page 753 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 754: P1B01: T7 Generator Motor - High Temp Shutdown
P1B01: T7 Generator Motor - High Temp Shutdown Fault Description The T7 generator/motor controller has detected the generator/motor temperature is 130°C (266°F) or higher. Note: When this fault is active, the T1 controller shuts off the cutting units and the T7 generator/motor controller shuts off generator/motor.
Page 755 Allow the machine to cool. (continued) Figure 424 G501721 4. Start the engine. 5. Pull the PTO switch to the E position. NGAGE 6. Look at the InfoCenter display to see if the fault repeats. 7. Press the PTO switch to the D position.
Page 756 Inspect and clean the air-intake screen. (continued) Figure 425 G501616 4. If the screen is dirty, remove the 5 flange-head capscrews, spacers, and locknuts that secure the air-intake screen and seal to the radiator and fan shroud. Figure 426 Locknut Fan shroud Spacer Seal...
Page 757 Inspect the cooling-air hose and shrouds. (continued) Figure 427 Cooling-air hose Hose clamp Fan shroud G501527 3. Inspect the forward end of the cooling-air hose is securely attached to the flange of the upper intake shroud with the hose clamp. Figure 428 Cooling-air hose Hose clamp...
Page 758 Test the intake air flow. (continued) 2. Hold a strip of paper to the rear of the air-intake screen align with the cooling-air hose. Figure 429 G501615 3. Go to Advise best operating practices, page 8–640. Advise best operating practices. 1.
Page 759: P1B11: T7 Generator Motor - High Temp Shutdown
Advise best operating practices. (continued) Proper Mowing Scalping/Circle Cutting Verticutting Techniques Maintain proper reel-to- Reduce the number of bedknife clearance. Use blades (increasing blade light contact. spacing) to reduce the amount of required power. Follow and maintain the 1/ Follow and maintain the 1/ Set the verticutter blade 3rd rule (cut only 1/3 of 3rd rule (cut only 1/3 of...
Page 760 Verify the fault repeats. (continued) 5. Look at the InfoCenter display to see if the fault repeats. Note: If the fault does not repeat immediately, duplicate the operation of the machine when the fault occurred. 6. Park the machine and rotate the key switch to the O position.
Page 761 Allow the machine to cool. (continued) 6. Look at the InfoCenter display to see if the fault repeats. 7. Press the PTO switch to the D position. ISENGAGE 8. Rotate the key switch to the O position. 9. Go to Inspect and clean the air-intake screen, page 8–643.
Page 762 Inspect and clean the air-intake screen. (continued) 6. Assemble the air-intake screen and seal to the radiator and fan shroud with the 5 flange-head capscrews, spacers, and locknuts. 7. Go to Inspect the cooling-air hose and shrouds, page 8–644. Inspect the cooling-air hose and shrouds. 1.
Page 763 Inspect the cooling-air hose and shrouds. (continued) 4. Torque the 6 flange-head capscrews that secure the generator cover to the generator/motor and controller to 8 to 9 N∙m (70 to 80 in-lb). 5. Inspect the upper intake shroud and lower intake shroud are secure to the generator cover.
Page 764: P1B20: T7 Generator Motor Speed Sensor Out Of Range
Advise best operating practices. (continued) • Encourage the operator to follow the operating tips described in the Operator’s Manual for the machine: Proper Mowing Scalping/Circle Cutting Verticutting Techniques Maintain reel and Scalping and circle cutting Ensure that the cutting- bedknife sharpness. are considered severe unit blades are sharp, applications.
Page 765 Verify the fault repeats. 1. Safely stop the machine, shut off attachments, and fully lower them. 2. Rotate the key switch to the O position. 3. Start the engine. 4. Operate the machine and cutting units using the same conditions that you discussed with the machine operator.
Page 766 Inspect the generator/motor controller and main-harness connectors. (continued) 5. Inspect the wiring, inside the main-harness connector, and inside the generator/ motor controller connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector. Check for proper fit between all pins and their corresponding sockets.
Page 767 6. Remove the 2 capscrews that secure the access cover to the generator/motor controller. Figure 438 Capscrews Access cover (generator/ motor controller) Gasket Super lube oil (Toro Part No.145-5053) G502815 24278SLA Page 8–649 Troubleshooting Fault Code: P1B20: T7 Generator Motor Speed Sensor Out of Range...
Page 768 Inspect the generator/motor controller and generator/motor harness connectors. (continued) 7. Remove the 3 capscrew that secure high-current terminals of the generator/ motor to the busbars of the generator/motor controller. Figure 439 Capscrews (cable terminal) High-current terminal G502656 8. Unplug the harness connector for the generator/motor from the harness connector for the generator/motor controller.
Page 769 Torque the capscrews to 8 to 9 N∙m (70 to 80 in-lb). Apply a coat of Super Lube oil (Toro Part No. 145-5053) to the seal and assemble the access cover to the generator/motor controller.
Page 770 Inspect the generator/motor controller and generator/motor harness connectors. (continued) Assemble the generator cover to the generator/motor and the controller with the 6 capscrews. Torque the capscrews to 8 to 9 N∙m (70 to 80 in-lb). Insert the seal-brushes into the groove of the top and bottom intake shrouds.
Page 771 Inspect the generator/motor controller and generator/motor harness connectors. (continued) The fault repeated. Note: If the expected steady engine speed seems to fluctuate or does not reach the desired speed, replace the T7 generator/motor controller. Raise the seat and control console, and support them with the forward prop rod.
Page 772 Replace the generator/motor controller. (continued) Figure 442 G505210 Locknut Capscrew Washer 4. Plug the harness connector for the generator/motor into the harness connector for the generator/motor controller. Figure 443 Harness connector (generator/motor controller) Harness connector (generator/motor) G502702 Troubleshooting Fault Code: P1B20: T7 Generator Motor Page 8–654 24278SL A Speed Sensor Out of Range...
Page 773 Figure 444 Capscrews (cable terminal) High-current terminal G502656 6. Apply a coat of Super Lube oil (Toro Part No. 145-5053) to the seal and assemble the access cover to the generator/motor controller. with the 2 capscrews. Figure 445 Capscrews Access cover (generator/...
Page 774 Replace the generator/motor controller. (continued) 7. Assemble the generator cover to the generator/motor and the controller with the 6 capscrews. Torque the capscrews to 8 to 9 N∙m (70 to 80 in-lb). Figure 446 Cooling-air hose Hose clamp Upper intake shroud Lower intake shroud Generator cover G501526...
Page 775 13. Lower the seat and control console, and secure them with the latch. 14. Program the machine; refer to the Toro DIAG—Quick Start, page 7–24 Using Toro DIAG to Program the Machine, page 7–32. Note: A new generator/motor controller does not function until programmed using Toro DIAG.
Page 776: P1B21: T7 Generator Motor Speed - High
P1B21: T7 Generator Motor Speed - High Fault Description The T7 generator/motor controller has detected that generator/motor speed exceeded 3600 RPM. Note: When this fault is active, the T1 controller shuts off the cutting units and the T7 motor/generator controller shuts off motor/ generator.
Page 777 4. Look at the InfoCenter to see the engine RPM. 5. Rotate the key switch to the O position. The fault Engine RPM is consistently higher than 3000 RPM, contact the Toro did not Technical Assistance Center (TAC). repeat. The fault Engine RPM is approximately 3000 RPM.
Page 778 Inspect the generator/motor controller and main-harness connectors. (continued) Figure 450 Connector (generator/ motor controller) Connector P37 (main harness) G496721 5. Inspect the wiring, inside the main-harness connector, and inside the generator/ motor controller connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector.
Page 779: P1B2C: T7 Generator Motor - Stall
4. Lower the seat and control console, and secure them with the latch. 5. Program the machine; refer to the Toro DIAG—Quick Start, page 7–24 Using Toro DIAG to Program the Machine, page 7–32. Note: A new generator/motor controller does not function until programmed using Toro DIAG.
Page 780 8–662. Inspect the motor/generator controller bus bar, motor/generator harness terminals, and harness connectors. Required Shop Supplies: Description Toro Part No. Super Lube™ oil 145-5053 1. Verify the key switch is in the O position. 2. Verify the 48V battery disconnect is unplugged from the socket.
Page 781 Figure 452 Capscrews Access cover (generator/ motor controller) Gasket Super Lube oil (Toro Part No. 145-5053) G502815 7. Remove the 3 capscrews that secure high-current terminals of the generator/ motor to the busbars of the generator/motor controller. Figure 453...
Page 782 Inspect the motor/generator controller bus bar, motor/generator harness terminals, and harness connectors. (continued) Figure 454 Harness connector (generator/motor controller) Harness connector (generator/motor) G502702 9. Remove the 2 capscrews, washers, and locknuts that secure the generator/motor controller to the generator housing. Figure 455 G505210 Locknut...
Page 783 Inspect the motor/generator controller bus bar, motor/generator harness terminals, and harness connectors. (continued) • inside the 6-socket generator/motor harness connector • the 3 high current generator/motor cable terminals (Figure 453) • the 3 generator/motor controller busbars (Figure 456) Ensure that the wires are secure to the pins or terminals and the pins are secure to the connectors.
Page 784 Inspect the motor/generator controller bus bar, motor/generator harness terminals, and harness connectors. (continued) Apply a coat of Super Lube oil (Toro Part No. 145-5053) to the seal and assemble the access cover to the generator/motor controller. with the 2 capscrews.
Page 785 Inspect the generator/motor rotor shaft and bearings. (continued) Figure 457 G505214 3. Check the rotor shaft for excess endplay. Figure 458 G505212 4. Check each end of the rotor shaft for excess horizontal and vertical movement. 24278SLA Page 8–667 Troubleshooting Fault Code: P1B2C: T7 Generator Motor - Stall...
Page 786 Torque the capscrews to 8 to 9 N∙m (70 to 80 in-lb). Apply a coat of Super Lube oil (Toro Part No. 145-5053) to the Fail seal and assemble the access cover to the generator/motor controller.
Page 787 Replace the generator/motor controller, page 8–669. Replace the generator/motor controller. Required Shop Supplies: Description Toro Part No. Super Lube™ oil 145-5053 1. Verify the key switch is in the O position. 2. Verify the 48V battery disconnect is unplugged from the socket.
Page 788 Replace the generator/motor controller. (continued) Figure 460 G505210 Locknut Capscrew Washer 5. Plug the harness connector for the generator/motor into the harness connector for the generator/motor controller. Figure 461 Harness connector (generator/motor controller) Harness connector (generator/motor) G502702 Troubleshooting Fault Code: P1B2C: T7 Generator Motor Page 8–670 24278SL A - Stall...
Page 789 Figure 462 Capscrews (cable terminal) High-current terminal G502656 7. Apply a coat of Super Lube oil (Toro Part No. 145-5053) to the seal and assemble the access cover to the generator/motor controller with the 2 capscrews. Figure 463 Capscrews Access cover (generator/...
Page 790 Replace the generator/motor controller. (continued) 8. Assemble the generator cover to the generator/motor and the controller with the 6 capscrews. Torque the capscrews to 8 to 9 N∙m (70 to 80 in-lb). Figure 464 Cooling-air hose Hose clamp Upper intake shroud Lower intake shroud Generator cover G501526...
Page 791 14. Lower the seat and control console, and secure them with the latch. 15. Program the machine; refer to the Toro DIAG—Quick Start, page 7–24 Using Toro DIAG to Program the Machine, page 7–32. Note: A new generator/motor controller does not function until programmed using Toro DIAG.
Page 792 Replace the generator/motor, page 8–674. Replace the generator/motor. Required Shop Supplies: Description Toro Part No. Super Lube™ oil 145-5053 1. Verify the key switch is in the O position. 2. Verify the 48V battery disconnect is unplugged from the socket.
Page 793 Replace the generator/motor. (continued) Figure 467 G502816 Locknut Capscrew Washer 5. Plug the harness connector for the generator/motor into the harness connector for the generator/motor controller. Figure 468 Harness connector (generator/motor controller) Harness connector (generator/motor) G502702 24278SLA Page 8–675 Troubleshooting Fault Code: P1B2C: T7 Generator Motor - Stall...
Page 794 Figure 469 Capscrews (cable terminal) High-current terminal G502656 7. Apply a coat of Super Lube oil (Toro Part No. 145-5053) to the seal and assemble the access cover to the generator/motor controller. with the 2 capscrews. Figure 470 Capscrews Access cover (generator/...
Page 795: P1B31: T7 Generator Motor Internal Regulator Voltage - High
Replace the generator/motor. (continued) 8. Assemble the generator cover to the generator/motor and the controller with the 6 capscrews. Torque the capscrews to 8 to 9 N∙m (70 to 80 in-lb). Figure 471 Cooling-air hose Hose clamp Upper intake shroud Lower intake shroud Generator cover G501526...
Page 796 Verify the fault repeats. 1. Safely stop the machine, shut off attachments, and fully lower them. 2. Rotate the key switch to the O position. 3. Start the engine. 4. Operate the machine and cutting units using the same conditions that you discussed with the machine operator.
Page 797 4. Lower the seat and control console, and secure them with the latch. 5. Program the machine; refer to the Toro DIAG—Quick Start, page 7–24 Using Toro DIAG to Program the Machine, page 7–32. Note: A new generator/motor controller does not function until programmed using Toro DIAG.
Page 798: P1B41: T7 Generator Bus Voltage - High
P1B41: T7 Generator Bus Voltage - High Fault Description The T7 generator/motor controller has detected bus voltage is 65V or higher. Note: When this fault is active, the T1 controller shuts off the cutting units and the T7 generator/motor controller shuts off generator/motor.
Page 799 Inspect the main contactor and main-harness terminals. 1. Verify the key switch is in the O position. 2. Raise the seat and control console, and support them with the forward prop rod. 3. Unplug the 48V battery disconnect from the socket; refer to Connecting and Disconnecting the 48V Battery System, page 7–8.
Page 800 Inspect the main contactor and main-harness terminals. (continued) The inspection is good. Leave electrical cover removed. Plug the 48V battery disconnect into the socket; refer to Connecting and Pass Disconnecting the 48V Battery System, page 7–8. Go to Test 48V system battery voltage, page 8–682.
Page 801 Test 48V system battery voltage. (continued) 3. Record the measured voltage value: 4. Rotate the key switch is in the O position. 5. Unplug the 48V battery disconnect from the socket; refer to Connecting and Disconnecting the 48V Battery System, page 7–8.
Page 802 Check 48V battery voltage. (continued) Figure 476 6-Button InfoCenter G496515 4. Record the voltage displayed in the InfoCenter: 5. Calculate the voltage-difference value: Measured voltage InfoCenter voltage Voltage difference Raise the seat and control console, and support them with the forward voltage- prop rod.
Page 803 8–685. Inspect the motor/generator controller bus bar, motor/generator harness terminals, and harness connectors. Required Shop Supplies: Description Toro Part No. Super Lube™ oil 145-5053 24278SLA Page 8–685 Troubleshooting Fault Code: P1B41: T7 Generator Bus...
Page 804 Inspect the motor/generator controller bus bar, motor/generator harness terminals, and harness connectors. (continued) 1. Verify the key switch is in the O position. 2. Verify the 48V battery disconnect is unplugged from the socket. 3. Remove the hose clamp and cooling air hose from the top intake shroud for the generator/motor;...
Page 805 (continued) Figure 479 Capscrews Access cover (generator/ motor controller) Gasket Super Lube oil (Toro Part No. 145-5053) G502815 7. Remove the 3 capscrews that secure high-current terminals of the generator/ motor to the busbars of the generator/motor controller. Figure 480...
Page 806 Inspect the motor/generator controller bus bar, motor/generator harness terminals, and harness connectors. (continued) Figure 481 Harness connector (generator/motor controller) Harness connector (generator/motor) G502702 9. Remove the 2 capscrews, washers, and locknuts that secure the generator/motor controller to the generator housing. Figure 482 G505210 Locknut...
Page 807 Torque the capscrews to 8 to 9 N∙m (70 to 80 in-lb). Apply a coat of Super Lube oil (Toro Part No. 145-5053) to the The cable seal and assemble the access cover to the generator/motor terminals controller.
Page 808 Torque the capscrews to 8 to 9 N∙m (70 to 80 in-lb). terminals Apply a coat ofSuper Lube oil (Toro Part No. 145-5053) to the damaged. seal and assemble the access cover to the generator/motor controller. with the 2 capscrews.
Page 809 4. Lower the seat and control console, and secure them with the latch. 5. Program the machine; refer to the Toro DIAG—Quick Start, page 7–24 Using Toro DIAG to Program the Machine, page 7–32. Note: A new generator/motor controller does not function until programmed using Toro DIAG.
Page 810: Circuit Diagram
Replace the generator/motor controller. (continued) The fault did not repeat. Close and latch the hood. Pass Go to Returning the Machine to Service, page 7–23. The fault repeated. Repeat the troubleshooting steps for this procedure. Fail Circuit Diagram G513639 P1B42: T7 Generator Bus Voltage - Low Fault Description The T7 generator/motor controller has detected bus voltage is 36V or lower.
Page 811 Verify the fault repeats. (continued) Note: If the fault does not repeat immediately, duplicate the operation of the machine when the fault occurred. 6. Park the machine and rotate the key switch to the O position. The fault did not repeat. Go to Returning the Machine to Service, page 7–23.
Page 812 Check 48V battery voltage. (continued) Figure 485 6-Button InfoCenter G496515 4. Record the voltage displayed in the InfoCenter: Raise the seat and control console, and support them with the forward Battery prop rod. voltage is Unplug the 48V battery disconnect from the socket; refer to Connecting higher than and Disconnecting the 48V Battery System, page...
Page 813 Inspect the main contactor and main-harness terminals. (continued) Figure 486 Slots (bracket) G501907 5. Inspect the wiring, the main contactor, main-harness terminal J22 (red-wire side), main-harness terminal J23 (250A fuse side), and the 48V ground junction J21 for damage and corrosion. Ensure that the wires are secure to the terminals and the terminals are secure to the contactor.
Page 814 Test 48V system battery voltage. 1. Verify the key switch is in the O position. 2. Use a multimeter to voltage test between the following pairs of locations: Battery to 48V Positive Junction Test Expected Connector Component Location Terminal Reading Graphic 48V positive junction...
Page 815 Test 48V system battery voltage. (continued) The test is good. Leave the 48V battery disconnect unplugged from the socket. Pass Go to Inspect the generator/motor controller and main harness connectors, page 8–697. One or more tests failed. If the Battery to 48V Positive Junction Test failed, troubleshoot the batteries, positive battery cables, negative battery cables, and the battery disconnect and socket.
Page 816 Inspect the generator/motor controller and main harness connectors. (continued) Figure 489 Connector (generator/ motor controller) Connector P37 (main harness) G496721 4. Inspect the wiring, inside the main-harness connector, and inside the generator/ motor controller connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector.
Page 817 8–699. Inspect the motor/generator controller bus bar, motor/generator harness terminals, and harness connectors. Required Shop Supplies: Description Toro Part No. Super Lube™ oil 145-5053 1. Verify the key switch is in the O position. 2. Verify the 48V battery disconnect is unplugged from the socket.
Page 818 Inspect the motor/generator controller bus bar, motor/generator harness terminals, and harness connectors. (continued) 3. Remove the hose clamp and cooling air hose from the top intake shroud for the generator/motor; refer to the Service Manual for the machine. Figure 490 Cooling-air hose Hose clamp Upper intake shroud...
Page 819 (continued) Figure 491 Capscrews Access cover (generator/ motor controller) Gasket Super lube oil (Toro Part No. 145-5053) G502815 7. Remove the 3 capscrew that secure high-current terminals of the generator/ motor to the busbars of the generator/motor controller. Figure 492...
Page 820 Inspect the motor/generator controller bus bar, motor/generator harness terminals, and harness connectors. (continued) Figure 493 Harness connector (generator/motor controller) Harness connector (generator/motor) G502702 9. Remove the 2 capscrews, washers, and locknuts that secure the generator/motor controller to the generator housing. Figure 494 G505210 Locknut...
Page 821 Torque the capscrews to 8 to 9 N∙m (70 to 80 in-lb). Apply a coat of Super Lube oil (Toro Part No. 145-5053) to the The cable seal and assemble the access cover to the generator/motor terminals controller.
Page 822 Torque the capscrews to 8 to 9 N∙m (70 to 80 in-lb). terminals Apply a coat of Super Lube oil (Toro Part No. 145-5053) to the damaged. seal and assemble the access cover to the generator/motor controller. with the 2 capscrews.
Page 823 4. Lower the seat and control console, and secure them with the latch. 5. Program the machine; refer to the Toro DIAG—Quick Start, page 7–24 Using Toro DIAG to Program the Machine, page 7–32. Note: A new generator/motor controller does not function until programmed using Toro DIAG.
Page 824: Circuit Diagram
Replace the generator/motor controller. (continued) The fault did not repeat. Close and latch the hood. Pass Go to Returning the Machine to Service, page 7–23. The fault repeated. Repeat the troubleshooting steps for this procedure. Fail Circuit Diagram G513639 P1B4C: T7 Generator Hardware Over Voltage Fault Description The T7 generator/motor controller hardware-voltage protection sensor triggered an over voltage fault.
Page 825 6. Lower the seat and console, and secure them with the latch. 7. Program the machine; refer to the Toro DIAG—Quick Start, page 7–24 Using Toro DIAG to Program the Machine, page 7–32. Note: A new generator/motor controller does not function until programmed using Toro DIAG.
Page 826: P1B51: T7 Generator Hardware Phase Over Current
P1B51: T7 Generator Hardware Phase Over Current Fault Description The T7 generator/motor controller has detected the phase over- current sensor activated at 240A of higher, indicating an internal short. Note: When this fault is active the T1 controller shuts off the cutting units and the T7 generator/motor controller shuts off generator/ motor.
Page 827: P1B6C: T7 Generator Internal Hardware Failure
6. Lower the seat and console, and secure them with the latch. 7. Program the machine; refer to the Toro DIAG—Quick Start, page 7–24 Using Toro DIAG to Program the Machine, page 7–32. Note: A new generator/motor controller does not function until programmed using Toro DIAG.
Page 828 6. Lower the seat and control console, and secure them with the latch. 7. Program the machine; refer to the Toro DIAG—Quick Start, page 7–24 Using Toro DIAG to Program the Machine, page 7–32. Note: A new generator/motor controller does not function until programmed using Toro DIAG.
Page 829: P210E: T1 Traction Pedal 1 Sensor/Switch Analog Vs Analog Conflict
P210E: T1 Traction Pedal 1 Sensor/Switch Analog vs Analog Conflict Fault Description The T1 controller has detected that the Traction Pedal 1 and Traction Pedal 2 signals are indicating differing positions of the traction pedal. Note: When this fault is active the T1 controller shuts off traction. Note: The traction pedal is also referred to as the throttle pedal and the accelerator pedal.
Page 830 Inspect the E-pedal sensor and engine-harness connector. (continued) Figure 496 G498693 Spacer Bracket Phillips-head screw Washer-head screw Washer Platform shroud 5. Remove the 2 hex-socket screws that secure the traction pedal to the E-pedal sensor, and remove the traction pedal from the machine. Figure 497 Hex-socket screw Traction pedal...
Page 831 Inspect the E-pedal sensor and engine-harness connector. (continued) Figure 498 G498695 Gusset (platform) Locknuts Carriage bolt Flange head screw Pedal-mount bracket 7. Remove the 2 locknuts and carriage bolts that secure the pedal-mount bracket to the platform plate. 8. Unplug main-harness connector P58 from the E-pedal sensor. Figure 499 Connector (E-pedal sensor)
Page 832 Inspect the E-pedal sensor and engine-harness connector. (continued) The inspection passed. Leave main-harness connector P58 unplugged from the E-pedal sensor. Pass Do not install the pedal-mount bracket and sensor. Go to Inspect the T1 controller and main-harness connector, page 8– 714.
Page 833 Inspect the T1 controller and main-harness connector. (continued) The inspection passed. Leave main-harness connector P29 unplugged from the T1 controller. Pass Go to Test the main harness, page 8–715. One or more inspections failed. Repair or replace the worn or damaged parts. Fail Leave main-harness connector P29 unplugged from the T1 controller.
Page 834 Test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Blue/ Main Yellow Less than 2 ohms Blue/ Main Yellow Blue/ Main Yellow Open Frame Ground Blue/ Main Yellow Open Blue/ Main Yellow Gray/ Main Black Less than 2 ohms Gray/...
Page 835 Test the main harness. (continued) The fault did not repeat. Loosely assemble the pedal-mount bracket to the platform plate with the 2 carriage bolts and locknuts. Loosely assemble the pedal-mount bracket to the platform gusset with the 2 flange head screws and locknuts. Tighten the screws, bolts, and locknuts.
Page 836 Replace the E-pedal sensor. (continued) Figure 502 Connector (E-pedal sensor) Connector P58 (main harness) G498694 4. Loosely assemble the pedal-mount bracket to the platform plate with the 2 carriage bolts and locknuts. Figure 503 G498695 Gusset (platform) Locknuts Carriage bolt Flange head screw Pedal-mount bracket 5.
Page 837 Replace the E-pedal sensor. (continued) Figure 504 Hex-socket screw Traction pedal E-pedal sensor G498696 8. Torque the hex-socket screws to 15.6 to 19.6 N∙m (138 to 174 in-lb). 9. Rotate the key switch to the P position. REHEAT 10. Watch the InfoCenter screen to see if the fault repeats. 11.
Page 838: Circuit Diagram
Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 839: P2130: T1 Traction Pedal Analog Sensor 2 - Short To Ground
P2130: T1 Traction Pedal Analog Sensor 2 - Short to Ground Fault Description The T1 controller has detected a short to ground on the circuit for the Traction Pedal 2 signal. Note: When this fault is active the T1 controller shuts off traction. Note: The traction pedal is also referred to as the throttle pedal and the accelerator pedal.
Page 840 Inspect the E-pedal sensor and engine-harness connector. (continued) Figure 505 G498693 Spacer Bracket Phillips-head screw Washer-head screw Washer Platform shroud 5. Remove the 2 hex-socket screws that secure the traction pedal to the E-pedal sensor, and remove the traction pedal from the machine. Figure 506 Hex-socket screw Traction pedal...
Page 841 Inspect the E-pedal sensor and engine-harness connector. (continued) Figure 507 G498695 Gusset (platform) Locknuts Carriage bolt Flange head screw Pedal-mount bracket 7. Remove the 2 locknuts and carriage bolts that secure the pedal-mount bracket to the platform plate. 8. Unplug main-harness connector P58 from the E-pedal sensor. Figure 508 Connector (E-pedal sensor)
Page 842 Inspect the E-pedal sensor and engine-harness connector. (continued) The inspection passed. Leave main-harness connector P58 unplugged from the E-pedal sensor. Pass Do not install the pedal-mount bracket and sensor. Go to Inspect the T1 controller and main-harness connector, page 8– 724.
Page 843 Inspect the T1 controller and main-harness connector. (continued) The inspection passed. Leave main-harness connector P29 unplugged from the T1 controller. Pass Go to Test the main harness, page 8–725. One or more inspections failed. Repair or replace the worn or damaged parts. Fail Leave main-harness connector P29 unplugged from the T1 controller.
Page 844 Test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Blue/ Main Yellow Less than 2 ohms Blue/ Main Yellow Blue/ Main Yellow Open Frame Ground Blue/ Main Yellow Open Blue/ Main Yellow Gray/ Main Black Less than 2 ohms Gray/...
Page 845 Test the main harness. (continued) The fault did not repeat. Loosely assemble the pedal-mount bracket to the platform plate with the 2 carriage bolts and locknuts. Loosely assemble the pedal-mount bracket to the platform gusset with the 2 flange head screws and locknuts. Tighten the screws, bolts, and locknuts.
Page 846 Replace the E-pedal sensor. (continued) Figure 511 Connector (E-pedal sensor) Connector P58 (main harness) G498694 4. Loosely assemble the pedal-mount bracket to the platform plate with the 2 carriage bolts and locknuts. Figure 512 G498695 Gusset (platform) Locknuts Carriage bolt Flange head screw Pedal-mount bracket 5.
Page 847 Replace the E-pedal sensor. (continued) Figure 513 Hex-socket screw Traction pedal E-pedal sensor G498696 8. Torque the hex-socket screws to 15.6 to 19.6 N∙m (138 to 174 in-lb). 9. Rotate the key switch to the P position. REHEAT 10. Watch the InfoCenter screen to see if the fault repeats. 11.
Page 848 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 849: P2132: T1 Traction Pedal Analog Sensor 2 - Open Circuit
Swap the T1 controller. (continued) Calibrating the Virtual Speed Sensor, page 7–53 8. Duplicate the operation of the machine when the fault occurred with the original primary controller. Go to Returning the Machine to Service, page 7–23. Pass Follow the steps listed. Reinstall the original T1 controller.
Page 850 Verify the fault repeats. (continued) 4. Operate the machine and cutting units using the same conditions that you discussed with the machine operator. 5. Look at the InfoCenter display to see if the fault repeats. Note: If the fault does not repeat immediately, duplicate the operation of the machine when the fault occurred.
Page 851 Inspect the E-pedal sensor and engine-harness connector. (continued) Figure 514 G498693 Spacer Bracket Phillips-head screw Washer-head screw Washer Platform shroud 5. Remove the 2 hex-socket screws that secure the traction pedal to the E-pedal sensor, and remove the traction pedal from the machine. Figure 515 Hex-socket screw Traction pedal...
Page 852 Inspect the E-pedal sensor and engine-harness connector. (continued) Figure 516 G498695 Gusset (platform) Locknuts Carriage bolt Flange head screw Pedal-mount bracket 7. Remove the 2 locknuts and carriage bolts that secure the pedal-mount bracket to the platform plate. 8. Unplug main-harness connector P58 from the E-pedal sensor. Figure 517 Connector (E-pedal sensor)
Page 853 Inspect the E-pedal sensor and engine-harness connector. (continued) The inspection passed. Leave main-harness connector P58 unplugged from the E-pedal sensor. Pass Do not install the pedal-mount bracket and sensor. Go to Inspect the T1 controller and main-harness connector, page 8– 735.
Page 854 Inspect the T1 controller and main-harness connector. (continued) The inspection passed. Leave main-harness connector P29 unplugged from the T1 controller. Pass Go to Test the main harness, page 8–736. One or more inspections failed. Repair or replace the worn or damaged parts. Fail Leave main-harness connector P29 unplugged from the T1 controller.
Page 855 Test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Blue/ Main Yellow Less than 2 ohms Blue/ Main Yellow Blue/ Main Yellow Open Frame Ground Blue/ Main Yellow Open Blue/ Main Yellow Gray/ Main Black Less than 2 ohms Gray/...
Page 856 Test the main harness. (continued) The fault did not repeat. Loosely assemble the pedal-mount bracket to the platform plate with the 2 carriage bolts and locknuts. Loosely assemble the pedal-mount bracket to the platform gusset with the 2 flange head screws and locknuts. Tighten the screws, bolts, and locknuts.
Page 857 Replace the E-pedal sensor. (continued) Figure 520 Connector (E-pedal sensor) Connector P58 (main harness) G498694 4. Loosely assemble the pedal-mount bracket to the platform plate with the 2 carriage bolts and locknuts. Figure 521 G498695 Gusset (platform) Locknuts Carriage bolt Flange head screw Pedal-mount bracket 5.
Page 858 Replace the E-pedal sensor. (continued) Figure 522 Hex-socket screw Traction pedal E-pedal sensor G498696 8. Torque the hex-socket screws to 15.6 to 19.6 N∙m (138 to 174 in-lb). 9. Rotate the key switch to the P position. REHEAT 10. Watch the InfoCenter screen to see if the fault repeats. 11.
Page 859 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 860: P2502: T1 Alternator Failure
Swap the T1 controller. (continued) Calibrating the Virtual Speed Sensor, page 7–53 8. Duplicate the operation of the machine when the fault occurred with the original primary controller. Go to Returning the Machine to Service, page 7–23. Pass Follow the steps listed. Reinstall the original T1 controller.
Page 861 Verify the fault repeats. (continued) The fault did not repeat. Go to Returning the Machine to Service, page 7–23. Pass Follow the steps listed. Note: If the fault does not repeat, an isolated event has occurred. The fault repeated. Go to Preparing for Troubleshooting and/or Testing, page 7–22.
Page 862 Measure 12V battery voltage. (continued) 6. Assemble the insulator boot over the alternator B+ stud. 7. Go to Inspect the alternator and main-harness connector, page 8–744. Inspect the alternator and main-harness connector. 1. Verify the key switch is in the O position.
Page 863 Test the Key Run circuit. (continued) 3. Use a multimeter to voltage test between the following pairs of locations: Expected Connector Wire Location Harness Connector Reading Graphic Color The voltage value Pink/ Main recorded in Black Test 12V battery voltage, Engine Ground page 8–...
Page 864 Test the –L circuit. (continued) The test is good. Leave main-harness connector P17 unplugged from the alternator. Pass Go to Replace the voltage regulator, page 8–748 One or more tests failed. Leave main-harness connector P17 unplugged from the alternator. Fail Go to Inspect the T1 controller and main-harness connector, page 8–...
Page 865 Test the main harness. 1. Verify the key switch is in the O position. 2. Verify main-harness connector P58 is unplugged from the traction-pedal sensor. 3. Verify main-harness connector P29 is unplugged from the T1 controller. 4. Use a multimeter to test the resistance between the following pairs of locations: Expected Connector Wire...
Page 866 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 867 Replace the voltage regulator. (continued) Figure 526 G506556 Alternator B+ stud 10-gauge cable terminal 6. Remove the nut that secures the 10-gauge cable terminal to the alternator B+ stud. 7. Replace the voltage regulator; refer to the Alternator procedure in the Disassembling and Assembling section in the Kubota 05-E4B Series/E4BG Series Workshop Manual...
Page 868: P2503: Alternator - Charging Too Low
Circuit Diagram G506555 P2503: Alternator - Charging Too Low Fault Description The T1 controller has detected the 12V power is lower than 8.8V. Note: This fault occurs after the engine runs for 5 seconds. Circuit Description The T1 controller measures power from the 12V bus to determine if bus voltage is within normal operating range.
Page 869 Verify the fault repeats. (continued) The fault did not repeat. Go to Returning the Machine to Service, page 7–23. Pass Follow the steps listed. Note: If the fault does not repeat, an isolated event has occurred. The fault repeated. Go to Preparing for Troubleshooting and/or Testing, page 7–22.
Page 870 Inspect the alternator and fan belt. (continued) The inspection is good. Tension of the alternator belt; refer to the Operator’s Manual for the machine. Pass Close and latch the hood. Go to Test the 12V battery, page 8–752. One or more of the inspections is failed. Replace the worn or damaged alternator bearings;...
Page 871 Test the 12V battery. (continued) The test is good. Go to Inspect the battery and cables, page 8–753. Pass One or more of the tests failed. Replace the battery Fail Inspect the battery cables, go to Inspect the battery and cables, page 8– 753.
Page 872 Test the voltage regulator. (continued) Figure 529 G506556 Alternator B+ stud 10-gauge cable terminal 5. Remove the nut that secures the 10-gauge cable terminal to the alternator B+ stud. 6. Remove the voltage regulator; refer to the Alternator procedure in the Disassembling and Assembling section of the Kubota 05-E4B Series/E4BG Series Workshop...
Page 873 Test the voltage regulator. (continued) Assemble the 10-gauge cable terminal onto the alternator B+ stud and secure the terminal with the nut. Plug main-harness connector P17 into the alternator. Connect the 12V battery; refer to Connecting and Disconnecting the 12V Battery, page 7–3.
Page 874 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 875: P2504: Alternator - Charging Too High
P2504: Alternator - Charging Too High Fault Description The T1 controller has detected the 12V power is higher than 16.3V. Note: This fault occurs after the engine runs for 5 seconds. Circuit Description The T1 controller measures power from the 12V bus to determine if bus voltage is within normal operating range.
Page 876 Test alternator output. (continued) Figure 531 Battery cover 4. Slip the insulator boot off the positive battery terminal. 5. Start the engine. 6. Test alternator output at the battery; refer to Alternator on Unit Test procedure in the Electrical System Checking and Adjusting section of the Kubota 05-E4B Series/E4BG Series Workshop Manual.
Page 877 Replace the voltage regulator. (continued) Figure 532 G506556 Alternator B+ stud 10-gauge cable terminal 7. Remove the nut that secures the 10-gauge cable terminal to the alternator B+ stud. 8. Replace the voltage regulator; refer to the Alternator procedure in the Disassembling and Assembling section in the Kubota 05-E4B Series/E4BG Series Workshop Manual...
Page 878 8–760. Swap the T1 controller. Note: The T1 controller is programmed to the specific machine model and serial number. The T1 controller does not function until programmed using Toro DIAG. Troubleshooting Fault Code: P2504: Alternator - Page 8–760 24278SL A...
Page 879: P2530: T1 Key Start/Run Correlation Fault
Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 880 Verify the fault repeats. (continued) Note: If the fault does not repeat immediately, duplicate the operation of the machine when the fault occurred. 5. Rotate the key switch to the O position. The fault did not repeat. Go to Returning the Machine to Service, page 7–23.
Page 881 Check the InfoCenter. (continued) Figure 535 6-Button InfoCenter G506863 3. In the Diagnostics menu, select the Engine option, and press the select button. Note: The Engine Input screen displays. 4. Record whether the check boxes for the Key Start and the Key Run fields are checked.
Page 882 Inspect the key switch and the seat harness connector. (continued) Figure 536 G506867 Connector P02 (seat harness) Key switch 4. Inspect the wiring, inside the seat-harness connector, and the key switch for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector.
Page 883 Inspect the key switch and the seat harness connector. (continued) The fault repeated. Unplug the seat-harness connector P02 from the key switch. Go to Test the key switch, page 8–765. Test the key switch. Test the key switch; refer to the Service Manual for the machine. The key switch passed the test.
Page 884 Inspect the seat-harness and main-harness connectors. (continued) Figure 537 Connector P51 (main harness) Connector P51 (seat harness) G492547 4. Inspect the wiring, inside the seat-harness connector, and inside the main- harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector.
Page 885 Test the seat harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Seat Yellow Figure 538. Figure 538 G492633 The test is good. Plug seat-harness connector P02 into the key switch. Pass Leave main-harness connector P51 unplugged from seat-harness connector P51.
Page 886 Test the seat harness. (continued) Lower the seat and control console, and secure them with the latch. Rotate the key to the P position. REHEAT Look at the InfoCenter display to see if the fault repeats. Rotate the key to the O position.
Page 887 Inspect the 12V fuse block and test the fuse. (continued) Figure 540 Cover 10A fuse (sockets 31 and 12V fuse block G507122 4. Unplug the 10A fuse from the fuse-block sockets 31 and 32. 5. Inspect the inside the 12V fuse block and fuse for damage and corrosion. Check for proper fit between the fuse and the corresponding fuse-block sockets.
Page 888 Inspect the T1 controller and main-harness connector. (continued) Figure 541 G490767.svg Retaining fastener (location) 2. Inspect the wiring, inside the seat-harness connector, and inside the main- harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector. Check for proper fit between all pins and their corresponding sockets.
Page 889 Test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Violet/ Main Black less than 2 ohms Violet/ Main Figur- Black Violet/ Main Figur- Black Open Violet/ Frame Ground Black Violet/ Main Figure 542. Black less than 2 ohms Violet/ Main...
Page 890 Test the main harness. (continued) Figure 542 G508550 Figure 543 Connector P99 (12V Fuse Block) G507299 Troubleshooting Fault Code: P2530: T1 Key Start/Run Page 8–772 24278SL A Correlation Fault...
Page 891 8–773. Swap the T1 controller. Note: The T1 controller is programmed to the specific machine model and serial number. The T1 controller does not function until programmed using Toro DIAG. 24278SLA Page 8–773 Troubleshooting Fault Code: P2530: T1 Key Start/Run...
Page 892 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 893: Electrical Diagram
Electrical Diagram G507301 U0120: T1/T7 CAN Bus Communication Fault - Generator Fault Description The T1 controller never established or lost communication with the T7 generator/motor controller. Note: When this fault is active, the T1 controller shuts off the cutting units and the T7 generator/motor controller shuts off generator/motor.
Page 894 Verify the fault repeats. (continued) 5. Rotate the key switch to the O position. The fault did not repeat. Go to Returning the Machine to Service, page 7–23. Pass Follow the steps listed. Note: If the fault does not repeat, an isolated event has occurred. The fault repeated.
Page 895 Inspect the generator/motor controller and main harness connectors. (continued) The inspection is good. Leave main harness connector P37 unplugged from the generator/ Pass motor controller. Go to Test 48V logic power at the generator/motor controller, page 8– 777. One or more inspections failed. Clean any corrosion or replace the corroded or damaged parts.
Page 896 Test 48V logic power at the generator/motor controller. (continued) The fault repeated. Unplug main-harness connector P37 from the generator/motor controller. Go to Inspect the CAN bus isolation module and main-harness connector, page 8–778. Inspect the CAN bus isolation module and main-harness connector. 1.
Page 897 Inspect the CAN bus isolation module and main-harness connector. (continued) Figure 546 G509040 CAN bus isolation module Cover 6. Inspect the areas where the wires of the CAN bus isolation module harness are soldered to the circuit board for damage and corrosion. The inspection passed.
Page 898 Inspect the CAN bus isolation module and main-harness connector. (continued) The fault repeated. Unplug the main-harness connector P42 from the CAN bus isolation- module connector. Go to Test the main harness (CAN isolation module power), page 8– 780. Test the main harness (CAN isolation module power). 1.
Page 899 Test the main harness (CAN isolation module power). (continued) The fault repeated. Raise the seat and control console, and support them with the forward prop rod. Unplug the 48V battery disconnect from the socket; refer to Connecting and Disconnecting the 48V Battery System, page 7–8.
Page 900 Test the main harness (48V CAN communication circuits). (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Main White Open Frame Ground The test is good. Leave main-harness connector P42 unplugged from the CAN bus isolation module connector. Pass Leave main-harness connector P37 unplugged from the generator/ motor controller.
Page 901 Test the main harness (48V CAN terminator and circuits). (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Main Blue 60 ohms Main White The test is good. Leave main-harness connector P42 unplugged from the CAN bus isolation connector. Plug main-harness connector P37 into the generator/motor controller.
Page 902 Inspect the 48V CAN terminating resistors and main harness. (continued) Figure 547 G509109 Terminating resistor Connector P65 (main harness) 3. At the front of the machine, remove the platform shroud from the machine; refer to the Service Manual for the machine. 4.
Page 903 Inspect the 48V CAN terminating resistors and main harness. (continued) 5. Inspect the wiring, inside the main-harness connectors, and the terminating resistors for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector. Check for proper fit between all pins and their corresponding sockets.
Page 904 Test the 48V terminating resistors. (continued) The fault did not repeat. Install the platform shroud to the machine; refer to the Service Manual for the machine. Go to Returning the Machine to Service, page 7–23. The fault repeated. Unplug main-harness connector P65 from the terminating resistor. Unplug main-harness connector P66 from the terminating resistor.
Page 905 Test the main harness (48V CAN terminating resistor circuits). (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Main Blue Open Frame Ground Main White Less than 2 ohms Main White Main White Open Frame Ground Main Blue Open Main Blue Main...
Page 906 Test the main harness (48V CAN terminating resistor circuits). (continued) Plug main-harness connector P66 into the terminating resistor. Rotate the key switch to the P position. REHEAT Look at the InfoCenter display to see if the fault repeats. Rotate the key to the O position.
Page 907 Inspect the 12V CAN terminating resistors and main harness. (continued) The inspection passed. Leave the main-harness connector P64 unplugged from the terminating Pass resistor. Go to Test the rear 12V terminating resistor, page 8–789. One or more inspections failed. Repair or replace the worn or damaged parts. Leave the main-harness connector P64 unplugged from the terminating Fail resistor.
Page 908 Test the main harness (12V CAN terminating circuits). 1. Verify the key switch is in the O position. 2. Verify main-harness connector P42 is unplugged from the CAN bus isolation- module connector. 3. Verify main-harness connector P64 is unplugged from the terminating resistor. 4.
Page 909 Test the main harness (12V CAN terminating circuits). (continued) The fault did not repeat. Close and latch the hood. Go to Returning the Machine to Service, page 7–23. The fault repeated. Unplug main-harness connector P42 unplugged from the CAN bus isolation-module connector.
Page 910 Inspect the T1 controller and main-harness connector. 1. Verify the key switch is in the O position. 2. Fully loosen the retaining fastener that secures the main-harness connector P29 to the T1 controller and unplug the connector from the controller. Figure 551 G490767.svg Retaining fastener (location)
Page 911 Test the main harness (12V CAN communication circuits). (continued) 5. Use a multimeter to test the resistance between the following pairs of locations: Expected Connector Wire Location Harness Connector Reading Graphic Color Main Yellow Figure 552. less than 2 ohms. Main Yellow Main...
Page 912 Test the main harness (12V CAN communication circuits). (continued) Figure 552 G492633 The test is good. Plug main-harness connector P42 into the CAN bus isolation- module connector. Plug main-harness connector P29 into the T1 controller. Pass Torque the retaining fastener for the main-harness connector to 2.8 to 3.2 N∙m (25 to 28 in-lb).
Page 913 Test the main harness (12V CAN communication circuits). (continued) Torque the retaining fastener for the main-harness connector to 2.8 to 3.2 N∙m (25 to 28 in-lb). Plug main-harness connector P51 into seat-harness connector P51. Lower the seat and control console, and secure them with the latch.
Page 914 Inspect the seat-harness and terminating resistor. (continued) The inspection passed. Leave seat-harness connector P32 unplugged from the terminating Pass resistor. Go to Test the forward 12V terminating resistor, page 8–796. One or more inspections failed. Repair or replace the worn or damaged parts. Leave seat-harness connector P32 unplugged from the terminating Fail resistor.
Page 915 Test the seat harness (12V CAN terminating resistor circuits). 1. Verify the key switch is in the O position. 2. Verify main-harness connector P51 is unplugged from seat-harness connector P51. 3. Verify seat-harness connector P32 is unplugged from the terminating resistor. 4.
Page 916 Test the seat harness (12V CAN terminating resistor circuits). (continued) Figure 554 G508550 The test is good. Plug seat-harness connector P32 into the terminating resistor. Leave main-harness connector P51 unplugged from seat-harness Pass connector P51. Go to Replace the CAN bus isolation module, page 8–799.
Page 917 4. Lower the seat and control console, and secure them with the latch. 5. Program the machine; refer to the Toro DIAG—Quick Start, page 7–24 Using Toro DIAG to Program the Machine, page 7–32. Note: A new generator/motor controller does not function until programmed using Toro DIAG.
Page 918 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 919: Circuit Diagram
Circuit Diagram G509588 U0156: T1/SC1 CAN Bus Communication Fault - IC Fault Description The T1 controller never established or lost communication with the InfoCenter (SC). Circuit Description The T1 controller and the InfoCenter communicate across a controller area network (CAN) bus. The T1 controller is responsible for managing and monitoring the other controllers in the CAN bus.
Page 920 Verify the fault repeats. (continued) Note: If the fault does not repeat immediately, duplicate the operation of the machine when the fault occurred. 5. Rotate the key switch to the O position. The fault did not repeat. Go to Returning the Machine to Service, page 7–23.
Page 921 Inspect the InfoCenter and main-harness connector. (continued) The inspection passed. Leave the seat-harness connector P52 unplugged from the InfoCenter. Pass Go to Test the main harness, page 8–803. One or more inspections failed. Repair or replace the worn or damaged parts. Plug main-harness connector P52 into the InfoCenter.
Page 922 Inspect the seat-harness and main-harness connectors (InfoCenter power). (continued) 3. Unplug main-harness connector P51 from seat-harness connector P51. Figure 556 Connector P51 (main harness) Connector P51 (seat harness) G492547 4. Inspect the wiring, inside the seat-harness connector, and inside the main- harness connector for damage and corrosion.
Page 923 Test the seat harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Seat Black Less than 2 ohms Seat Black Figure 557. Seat Black Figure 557. Open Frame Ground Pink/ Seat Black Less than 2 ohms Pink/ Seat Figure 557.
Page 924 Test the seat harness. (continued) Figure 557 G492633 The test is good. Plug the seat-harness connector P52 into the InfoCenter. Leave main-harness connector P51 unplugged from seat-harness Pass connector P51. Go to Test the seat harness (InfoCenter communication), page 8–811. One or more tests failed.
Page 925 Test the seat harness. (continued) The fault did not repeat. Install the right console cover; refer to Installing the Left Console Cover, page 7–78. Go to Returning the Machine to Service, page 7–23. The fault repeated. Verify the key switch is in the O position.
Page 926 Inspect the 12V fuse block and test the fuse. (continued) The inspection and test passed. Leave 10A fuse unplugged from the 12V fuse block. Pass Go to Test the main harness, page 8–808. One or more inspections or test failed. Repair or replace the worn or damaged parts.
Page 927 Test the main harness. (continued) Figure 559 G508550 Figure 560 Connector P99 (12V Fuse Block) G507299 24278SLA Page 8–809 Troubleshooting Fault Code: U0156: T1/SC1 CAN Bus Communication Fault - IC...
Page 928 Test the main harness. (continued) The test is good. Leave main-harness connector P51 unplugged from seat-harness connector P51. Pass Insert the 10A fuse into fuse-block sockets 31 and 32. Assemble the cover onto the 12V fuse block. Go to Test the seat harness (InfoCenter communication), page 8–811.
Page 929 Inspect the seat-harness and main-harness connectors (InfoCenter communication). (continued) Figure 561 Connector P51 (main harness) Connector P51 (seat harness) G492547 4. Inspect the wiring, inside the seat-harness connector, and inside the main- harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector.
Page 930 Test the seat harness (InfoCenter communication). (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Seat Yellow Seat Yellow Figure 562. Open Frame Ground Seat Green Figure 562. Less than 2 ohms Seat Green Seat Green Figure 562. Open Frame Ground Troubleshooting Fault Code: U0156: T1/SC1 CAN Bus Page 8–812...
Page 931 Test the seat harness (InfoCenter communication). (continued) Figure 562 G492633 The test is good. Plug seat-harness connector P52 into the InfoCenter Install the right console cover; refer to Installing the Left Console Cover, page 7–78. Pass Leave main-harness connector P51 unplugged from seat-harness connector P51.
Page 932 Test the seat harness (InfoCenter communication). (continued) Look at the InfoCenter display to see if the fault repeats. Rotate the key to the O position. The fault did not repeat. Go to Returning the Machine to Service, page 7– The fault repeated. Raise the seat and control console, and support them with the forward prop rod.
Page 933 Inspect the T1 controller and main-harness connector. (continued) The inspection passed. Leave main-harness connector P29 unplugged from the T1 controller. Pass Go to Test the main harness (T1 controller communication), page 8– 815. One or more inspections failed. Repair or replace the worn or damaged parts. Fail Leave main-harness connector P29 unplugged from the T1 controller.
Page 934 Test the main harness (T1 controller communication). (continued) Figure 564 G508550 The test is good. Plug main-harness connector P51 into seat-harness connector P51. Pass Leave main-harness connector P29 unplugged from the T1 controller. Go to Swap the T1 controller, page 8–817.
Page 935 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 936: Circuit Diagram
Circuit Diagram G509957 U1007: T1 Controller Main Power Relay Fault Description The T1 controller has detected that the main power relay has failed. Note: Although unlikely, this fault can also occur if all 4 of the 7.5A TEC PWR fuses fail at the same time. Circuit Description The main power relay provides switched power to the four 7.5A TEC PWR fuses and to the TEC 5004 power outputs 1 through 16.
Page 937 Inspect the fuse block TEC Power relay slots. 1. Verify the key switch is in the O position. 2. Raise the seat and control console, and support them with the forward prop rod. 3. Remove the cover from the fuse block (connector P99). Figure 565 Cover 12V fuse block...
Page 938 Inspect the fuse block TEC Power relay slots. (continued) 5. Inspect the inside the 12V fuse block and TEC Power relay for damage and corrosion. Check for proper fit between the relay terminals and their corresponding fuse-block sockets. The inspections and tests passed. Leave the TEC Power relay unplugged from the fuse block.
Page 939 Test the main harness. (continued) The test is good. Leave the TEC Power relay unplugged from the fuse block. Pass Go to Inspect the 12V fuse block and test the fuse, page 8–821. One or more tests failed. Repair or replace the damaged wiring. Plug the TEC Power relay into fuse-block slots 4, 5, 6, 10, and 12.
Page 940 Inspect the 12V fuse block and test the fuse. (continued) 3. Inspect the inside the 12V fuse block and fuses for damage and corrosion. Check for proper fit between the fuse and the corresponding fuse-block sockets. 4. Use a multimeter to continuity test the 7.5A fuses. The inspections and tests passed.
Page 941 Test the main harness. (continued) Figure 569 G510355 The test is good. Leave the TEC Power relay unplugged from the fuse block. Pass Leave the 4 fuses (7.5A) are unplugged from the fuse-block sockets Go to Inspect the T1 controller and main-harness connector, page 8– 824.
Page 942 Inspect the T1 controller and main-harness connector. 1. Fully loosen the retaining fastener that secures the main-harness connector P29 to the T1 controller and unplug the connector from the controller. Figure 570 G490767.svg Retaining fastener (location) 2. Inspect the wiring, inside the seat-harness connector, and inside the main- harness connector for damage and corrosion.
Page 943 Test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Orange Main Less than 2 ohms Orange Main Figure 571. Orange Main Figure 571. Open Frame Ground White Main /Violet Less than 2 ohms White Main Figure 571.
Page 944 Test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Main Yellow Less than 2 ohms Main Yellow Figure 571. Main Yellow Figure 571. Open Frame Ground Figure 571 G510356 The test is good. Leave the TEC Power relay unplugged from the fuse block. Plug the 4 fuses (7.5A) into fuse-block sockets 29 and 30, 35 and 36, Pass 41 and 42, and 47 and 48.
Page 945 Test the main harness. (continued) Torque the retaining fastener for the main-harness connector to 2.8 to 3.2 N∙m (25 to 28 in-lb). Lower the seat and control console, and secure them with the latch. Rotate the key switch to the P position.
Page 946 Swap the TEC Power relay and Main Power relay. (continued) 4. Unplug the Main Power relay from fuse-block slots 1, 2, 3, 7, and 9. 5. Plug the TEC Power relay into fuse-block slots 1, 2, 3, 7, and 9. Figure 573 TEC Power relay (block slots 1, 2, 3, 7, and 9)
Page 947 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 948: U1022: T1 Tec Fuse 2 Failure
Circuit Diagram U1022: T1 TEC Fuse 2 Failure Fault Description The T1 controller has detected an open circuit on the PWR 2 circuit. Circuit Description The PWR 2 circuit provides fuse protected power to the TEC 5004 power outputs 1 through 4. Note: The 12V fuse block is main harness connector P99.
Page 949 Verify the fault repeats. (continued) The fault did not repeat. Go to Returning the Machine to Service, page 7–23. Pass Follow the steps listed. Note: If the fault does not repeat, an isolated event has occurred. The fault repeated. Go to Preparing for Troubleshooting and/or Testing, page 7–22.
Page 950 Inspect the fuse block fuse slots. (continued) Figure 575 7.5A fuses G510521 5. Inspect the inside the 12V fuse block and fuse for damage and corrosion. Check for proper fit between the fuse and the corresponding fuse-block sockets. 6. Use a multimeter to continuity test the 7.5A fuse. The inspections and tests passed.
Page 951 Test the main harness. (continued) Figure 576 G510527 4. Rotate the key switch to the O position. The test is good. Leave the 7.5A fuse unplugged from the fuse block. Pass Go to Inspect the T1 controller and main-harness connector, page 8– 833.
Page 952 Inspect the T1 controller and main-harness connector. (continued) Figure 577 G490767.svg Retaining fastener (location) 2. Inspect the wiring, inside the seat-harness connector, and inside the main- harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector. Check for proper fit between all pins and their corresponding sockets.
Page 953 Test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color White Main Figure 578. /Violet White Main Figure 578. /Violet Open Frame Ground Figure 578 G510527 The test is good. Plug the 7.5A fuse into fuse-block sockets 29 and 30. Pass Assemble the cover onto the 12V fuse block.
Page 954 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 955: U1023: T1 Tec Fuse 3 Failure
Circuit Diagram G510450 U1023: T1 TEC Fuse 3 Failure Fault Description The T1 controller has detected an open circuit on the PWR 3 circuit. Circuit Description The PWR 3 circuit provides fuse protected power to the TEC 5004 power outputs 9 through 12. Note: The 12V fuse block is main harness connector P99.
Page 956 Verify the fault repeats. (continued) The fault did not repeat. Go to Returning the Machine to Service, page 7–23. Pass Follow the steps listed. Note: If the fault does not repeat, an isolated event has occurred. The fault repeated. Go to Preparing for Troubleshooting and/or Testing, page 7–22.
Page 957 Inspect the fuse block fuse slots. (continued) Figure 580 7.5A fuses G510522 5. Inspect the inside the 12V fuse block and fuse for damage and corrosion. Check for proper fit between the fuse and the corresponding fuse-block sockets. 6. Use a multimeter to continuity test the 7.5A fuse. The inspections and tests passed.
Page 958 Test the main harness. (continued) Figure 581 G510528 4. Rotate the key switch to the O position. The test is good. Leave the 7.5A fuse unplugged from the fuse block. Pass Go to Inspect the T1 controller and main-harness connector, page 8– 840.
Page 959 Inspect the T1 controller and main-harness connector. (continued) Figure 582 G490767.svg Retaining fastener (location) 2. Inspect the wiring, inside the seat-harness connector, and inside the main- harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector. Check for proper fit between all pins and their corresponding sockets.
Page 960 Test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Main Green Figure 583. Main Green Figure 583. Open Frame Ground Figure 583 G510528 The test is good. Plug the 7.5A fuse into fuse-block sockets 35 and 36. Pass Assemble the cover onto the 12V fuse block.
Page 961 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 962: U1024: T1 Tec Fuse 4 Failure
G510450 U1024: T1 TEC Fuse 4 Failure Fault Description The T1 controller has detected an open circuit on the PWR 4 circuit. Circuit Description The PWR 4 circuit provides fuse protected power to the TEC 5004 power outputs 5 through 8. Note: The 12V fuse block is main harness connector P99.
Page 963 Verify the fault repeats. (continued) The fault did not repeat. Go to Returning the Machine to Service, page 7–23. Pass Follow the steps listed. Note: If the fault does not repeat, an isolated event has occurred. The fault repeated. Go to Preparing for Troubleshooting and/or Testing, page 7–22.
Page 964 Inspect the fuse block fuse slots. (continued) Figure 585 7.5A fuses G510523 5. Inspect the inside the 12V fuse block and fuse for damage and corrosion. Check for proper fit between the fuse and the corresponding fuse-block sockets. 6. Use a multimeter to continuity test the 7.5A fuse. The inspections and tests passed.
Page 965 Test the main harness. (continued) Figure 586 G510529 4. Rotate the key switch to the O position. The test is good. Leave the 7.5A fuse unplugged from the fuse block. Pass Go to Inspect the T1 controller and main-harness connector, page 8– 847.
Page 966 Inspect the T1 controller and main-harness connector. (continued) Figure 587 G490767.svg Retaining fastener (location) 2. Inspect the wiring, inside the seat-harness connector, and inside the main- harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector. Check for proper fit between all pins and their corresponding sockets.
Page 967 Test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Orange Main Figure 588. Orange Main Figure 588. Open Frame Ground Figure 588 G510528 The test is good. Plug the 7.5A fuse into fuse-block sockets 41 and 42. Pass Assemble the cover onto the 12V fuse block.
Page 968 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 969: Circuit Diagram
Circuit Diagram G510450 U1025: T1 TEC Fuse 5 Failure Fault Description The T1 controller has detected an open circuit on the PWR 5 circuit. Circuit Description The PWR 5 circuit provides fuse protected power to the TEC 5004 power outputs 13 through 16. Note: The 12V fuse block is main harness connector P99.
Page 970 Verify the fault repeats. (continued) The fault did not repeat. Go to Returning the Machine to Service, page 7–23. Pass Follow the steps listed. Note: If the fault does not repeat, an isolated event has occurred. The fault repeated. Go to Preparing for Troubleshooting and/or Testing, page 7–22.
Page 971 Inspect the fuse block fuse slots. (continued) Figure 590 7.5A fuses G510524 5. Inspect the inside the 12V fuse block and fuse for damage and corrosion. Check for proper fit between the fuse and the corresponding fuse-block sockets. 6. Use a multimeter to continuity test the 7.5A fuse. The inspections and tests passed.
Page 972 Test the main harness. (continued) Figure 591 G510530 4. Rotate the key switch to the O position. The test is good. Leave the 7.5A fuse unplugged from the fuse block. Pass Go to Inspect the T1 controller and main-harness connector, page 8–854.
Page 973 Inspect the T1 controller and main-harness connector. (continued) Figure 592 G490767.svg Retaining fastener (location) 2. Inspect the wiring, inside the seat-harness connector, and inside the main- harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector. Check for proper fit between all pins and their corresponding sockets.
Page 974 Test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Main Yellow Figure 593. Main Yellow Figure 593. Open Frame Ground Figure 593 G510530 The test is good. Plug the 7.5A fuse into fuse-block sockets 41 and 42. Pass Assemble the cover onto the 12V fuse block.
Page 975 Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 976: U1030: T1 5V Supply - Out Of Range
Circuit Diagram G510450 U1030: T1 5V Supply - Out of Range Fault Description The T1 controller has detected that the 5V Supply signal is higher than 5.1V or lower than 4.8V. Circuit Description The T1 controller produces a 5V reference signal for the traction pedal position sensor and the traction pump swashplate sensor.
Page 977 Verify the fault repeats. (continued) The fault did not repeat. Go to Returning the Machine to Service, page 7–23. Pass Follow the steps listed. Note: If the fault does not repeat, an isolated event has occurred. The fault repeated. Go to Preparing for Troubleshooting and/or Testing, page 7–22.
Page 978 Inspect the capacitor and main harness. (continued) The inspection passed. Leave main-harness connector P35 unplugged from the capacitor Pass Go to Isolation test the main harness (capacitor), page 8–860. One or more inspection failed. Repair or replace the worn or damaged parts. Fail Leave main-harness connector P35 unplugged from the capacitor Go to...
Page 979 Inspect the E-pedal sensor and engine-harness connector. (continued) 3. Remove cutting unit 1; refer to the Operator’s Manual for the cutting unit and the Operator’s Manual for the machine. 4. Remove the 2 washer-head screws, 2 Phillips-head screws, washers, and spacers that secure the platform shroud to the platform.
Page 980 Inspect the E-pedal sensor and engine-harness connector. (continued) Figure 596 Hex-socket screw Traction pedal E-pedal sensor G498696 6. Remove the 2 locknuts and flange head screws that secure the pedal-mount bracket to the gusset of the platform. Figure 597 G498695 Gusset (platform) Locknuts Carriage bolt...
Page 981 Inspect the E-pedal sensor and engine-harness connector. (continued) Figure 598 Connector (E-pedal sensor) Connector P58 (main harness) G498694 9. Inspect the wiring, inside the main-harness connector, and the E-pedal sensor for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector.
Page 982 Isolation test the main harness (E-pedal sensor). (continued) The test is good. Plug main-harness connector P35 into the capacitor. Lower the seat and control console, and secure them with the latch. Plug main-harness connector P58 into a new traction-pedal sensor. Note: Do not install the new traction-pedal sensor.
Page 983 Replace the E-pedal sensor. (continued) Figure 599 Flange-head capscrew E-pedal sensor Pedal-mount bracket Locknut G498775 3. Assemble the new E-pedal sensor to the pedal-mount bracket with the 4 flange- head capscrews and locknuts. 4. Plug main-harness connector P58 into the traction-pedal sensor. Figure 600 Connector (E-pedal sensor)
Page 984 Replace the E-pedal sensor. (continued) Figure 601 G498695 Gusset (platform) Locknuts Carriage bolt Flange head screw Pedal-mount bracket 6. Loosely assemble the pedal-mount bracket to the platform gusset with the 2 flange head screws and locknuts. 7. Tighten the screws, bolts, and locknuts. 8.
Page 985 Replace the E-pedal sensor. (continued) 9. Torque the hex-socket screws to 15.6 to 19.6 N∙m (138 to 174 in-lb). 10. Assemble the platform shroud to the platform with the 2 washer-head screws, 2 Phillips-head screws, washers, and spacers 11. Calibrate the traction pedal; refer to the Service Manual for the machine. 12.
Page 986 Inspect the swash plate-angle sensor and main harness. (continued) G504342 Swash plate-angle sensor connector Main-harness connector P59 4. Inspect the wiring, inside the main-harness connector, and inside the swash plate-angle sensor connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector.
Page 987 Isolation test the main harness (swash plate-angle sensor). (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Main Brown 5.1V to Blue/ 4.8V Main Yellow 6. Rotate the key switch to the O position. The test is good. Plug main-harness connector P35 into the capacitor. Plug main-harness connector P58 into the traction-pedal sensor.
Page 988 Install the E-pedal sensor. (continued) Figure 604 Connector (E-pedal sensor) Connector P58 (main harness) G498694 2. Loosely assemble the pedal-mount bracket to the platform plate with the 2 carriage bolts and locknuts. Figure 605 G498695 Gusset (platform) Locknuts Carriage bolt Flange head screw Pedal-mount bracket 3.
Page 989 Install the E-pedal sensor. (continued) Figure 606 Hex-socket screw Traction pedal E-pedal sensor G498696 6. Torque the hex-socket screws to 15.6 to 19.6 N∙m (138 to 174 in-lb). 7. Assemble the platform shroud to the platform with the 2 washer-head screws, 2 Phillips-head screws, washers, and spacers 8.
Page 990 Inspect the T1 controller and main-harness connector. (continued) Figure 607 G490767.svg Retaining fastener (location) 2. Inspect the wiring, inside the seat-harness connector, and inside the main- harness connector for damage and corrosion. Ensure that the wires are secure to the pins and the pins are secure to the connector. Check for proper fit between all pins and their corresponding sockets.
Page 991 Test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Main Brown Less than 2 ohms Main Brown Main Brown Open Frame Ground Blue/ Main Yellow Less than 2 ohms Blue/ Main Yellow Blue/ Main Yellow Open Frame Ground Main...
Page 992 Test the main harness. (continued) Expected Connector Wire Location Harness Connector Reading Graphic Color Blue/ Main Yellow Less than 2 ohms Blue/ Main Yellow The test is good. Plug main-harness connector P35 into the capacitor. Plug main-harness connector P59 into the swash plate-angle sensor. Pass Go to Install the E-pedal sensor, page...
Page 993 Install the E-pedal sensor. (continued) Figure 608 Connector (E-pedal sensor) Connector P58 (main harness) G498694 2. Loosely assemble the pedal-mount bracket to the platform plate with the 2 carriage bolts and locknuts. Figure 609 G498695 Gusset (platform) Locknuts Carriage bolt Flange head screw Pedal-mount bracket 3.
Page 994 Install the E-pedal sensor. (continued) Figure 610 Hex-socket screw Traction pedal E-pedal sensor G498696 6. Torque the hex-socket screws to 15.6 to 19.6 N∙m (138 to 174 in-lb). 7. Assemble the platform shroud to the platform with the 2 washer-head screws, 2 Phillips-head screws, washers, and spacers 8.
Page 995 Replacing or Swapping the Primary Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 24278SLA Page 8–877 Troubleshooting Fault Code: U1030: T1 5V Supply - Out...
Page 996: Circuit Diagram
7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33 Calibrating the Traction Pedal, page 7–34 Calibrating the Traction Pump, page 7–43 Calibrating the Virtual Speed Sensor, page 7–53...
Page 997: U110C: T1 Model Number Unknown
1. Verify the key switch is in the O position. 2. Connect a PC with Toro DIAG software to the machine via a Toro DIAG USB/ CAN cable (Part No. 115-1944); refer to Toro DIAG—Quick Start, page 7–24.
Page 998: U1117: T1 Source Address Contention Fault
Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...
Page 999 1. Verify the key switch is in the O position. 2. Connect a PC with Toro DIAG software to the machine via a Toro DIAG USB/ CAN cable (Part No. 115-1944); refer to Toro DIAG—Quick Start, page 7–24.
Page 1000: U111F: T2, T3, T4, T5, Or T6 Source Id - Cu Motor Id Out Of Range
Toro Electronic Controller (TEC), page 7–26. Perform the procedures in the following sequence: 7.2 Using Toro DIAG to Save the TD2 File from the Original T1 Controller, page 7–28 7.3 Replacing the T1 Controller, page 7–29 7.4 Using Toro DIAG to Program the Machine, page 7–32 7.5 Using Toro DIAG to Restore the TD2 File, page 7–33...