Service Manual

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TRIFLEX DIAGNOSTIC FAULT CODE QUICK REFERENCE TABLE – Revision B Page 1

GREENSMASTER 3300, 3400, 3320, 3420 TRIFLEX

DIAGNOSTIC FAULT CODE QUICK REFERENCE TABLE

Fault

Number

Fault Title

Controller

Affected

Fault Condition/Circuit

Description

Additional Notes

Service Actions

Reel Speed

Potentiometer Bad

Master

This fault is reported when the

reel speed potentiometer

reading is out of range,

indicating either an open or

short circuit.

1) Test the circuit wiring

2) Replace the potentiometer

Line Contactor is

Open

S/G

This fault is reported when the

line contactor fault indicates a

fault associated with control of

the 48 Vdc contactor. If the 48

Vdc logic and Bus voltage of the

starter/generator have more

than an 8 Vdc difference when

the contactor is engaged, this

fault will be reported.

The main contactor

exists in the 48 Vdc

system to connect the

48 Vdc battery pack

with the

starter/generator and

reel motor controllers.

The starter/generator

controller determines

when the main

contactor is engaged.

1) Check the voltage across the

coil of the contactor. If the coil is

energized by the

starter/generator, the voltage

should be approximately 48 Vdc.

2) Check the voltage across the

contactor. It should be 0 Vdc if

the contactor is closed.

3) Manually test the functionality of

the contactor using the battery

and jumpers.

4) Replace the contactor if tests

fail.

High Temperature

Warning - Cutting

Unit 1

Cutting unit

This fault is reported when the

cutting unit controller

temperature exceeds 90 °C

(195 °F). When the 90 °C

threshold is reached, the fault

reports and the current being

sent to the motor is limited on a

linear basis until 100 °C (212 °F)

is reached. If either the motor

controller or the cutting unit

motor reach 100 °C, the cutting

unit is shut down. This fault is

not produced by a bad sensor.

If the fault continues to

occur at relatively low

loads, replace the

cutting unit electric

motor.

1) Let the machine cool.

2) Inspect the cutting unit to ensure

the reel spins freely, without

binding.

3) Reduce the reel speed.

4) Reduce the mowing speed.

5) If the fault is intermittent, check

the 48 Vdc ground to the motor.

Summary of content (22 pages)

PAGE 1
GREENSMASTER 3300, 3400, 3320, 3420 TRIFLEX DIAGNOSTIC FAULT CODE QUICK REFERENCE TABLE Fault Number 11 Fault Title Controller Affected Fault Condition/Circuit Description Reel Speed Potentiometer Bad Master 12 Line Contactor is Open S/G This fault is reported when the reel speed potentiometer reading is out of range, indicating either an open or short circuit. This fault is reported when the line contactor fault indicates a fault associated with control of the 48 Vdc contactor.
PAGE 2
Fault Number 14 15 Fault Title Controller Affected Fault Condition/Circuit Description High Temperature Warning - Cutting Unit 2 Cutting unit High Temperature Warning - Cutting Unit 3 Cutting unit This fault is reported when the cutting unit controller temperature exceeds 90 °C (195 °F). When the 90 °C threshold is reached, the fault reports and the current being sent to the motor is limited on a linear basis until 100 °C (212 °F) is reached.
PAGE 3
Fault Number 16 Fault Title High Temperature Warning – Starter/Generator Controller Affected Fault Condition/Circuit Description Additional Notes Starter/Generator This fault is reported when the starter/generator controller temperature exceeds the design limit set point. When the overtemp region is entered, motor current is limited on a linear basis until the absolute overtemp value is reached. This fault is not produced by a bad sensor.
PAGE 4
Fault Number 19 Fault Title Controller Affected Fault Condition/Circuit Description Additional Notes Motor Speed Stall – CU3 Cutting unit This fault is reported when the cutting unit is active, yet remains at zero rpm for more than three seconds. 1) Check cutting unit 3 for any debris clogging the reel. 2) Check the bedknife adjustment of cutting unit 3. 3) Check to see if the motor can spin without a load. 21 Model Number Unknown Master Swap motors between cutting units to test the motor.
PAGE 5
Fault Number 25 Fault Title Controller Affected Fault Condition/Circuit Description Additional Notes Service Actions CAN Bus Fault – CU3 Master If communication is never established, this fault will trigger 2.5 seconds after the ignition key turns power on. 1) Inspect the CAN bus connection. 2) Verify power to the cutting unit controller. 3) Check the resistance between the CAN bus connector pins on the motor harness to ensure it is approximately 156k ohms.
PAGE 6
Fault Number 32 Fault Title Controller Affected Fault Condition/Circuit Description Additional Notes Service Actions Engine Hot - Engine Kill Master This fault is reported when the TEC sensed the engine temperature to be beyond 115 ºC (240 ºF) for more than 10 seconds. This fault is for diesel engine-equipped units only. The TEC will shut the engine down to prevent damage.
PAGE 7
Fault Number 35 Fault Title Controller Affected Fault Condition/Circuit Description 48 Vdc Logic (Keyswitch) Undervolt – CU3 Cutting unit This fault is reported when the 48 Vdc system voltage drops below 32 Vdc at cutting unit 3. 36 48 Vdc Logic (Keyswitch) Undervolt – S/G Cutting unit This fault is reported when the 48 Vdc system voltage drops below 32 Vdc at the starter/generator.
PAGE 8
Fault Number 41 Fault Title 48 Vdc Precharge Fault Controller Affected Fault Condition/Circuit Description Starter/Generator This fault is reported when a failure exists in the precharge circuit that charges the 48 Vdc line contactor. The 38 Vdc minimum voltage was not achieved. 43 Oil Temperature Sensor Fault Master 44 48 Vdc Battery Undervoltage Cutting unit This fault is reported when the oil temperature sensor is open, not shorted.
PAGE 9
Fault Number 45 Fault Title Controller Affected Fault Condition/Circuit Description Additional Notes Service Actions 48 Vdc Bus Overvoltage System Cutting unit This fault is reported when all 4 individual 48 Vdc bus circuit high voltage alerts are active at the same time. 1) Test the battery voltage. 2) Inspect the battery terminal connections. 3) Test the internal S/G connections. 4) Test the S/G for proper function.
PAGE 10
Fault Number 51 52 57 59 Fault Title Controller Affected Alternator Master Fault Condition/Circuit Description This fault is reported when the alternator generation is faulty. This is determined by the TEC in conjunction with S/G rpm data. Charging System – Master This fault is reported when the Charge Voltage Too alternator is producing voltage High beyond the high limit as determined by the TEC.
PAGE 11
Fault Number 66 Fault Title Controller Affected Fault Condition/Circuit Description Software Version Incompatibility Master 67 S1 Enable - Current Too High Master This fault is reported when one or more of the bus component controllers (cutting unit controllers or the S/G controller) have software that is incompatible with the TEC master controller. This fault is reported when the TEC determines that the S1 coil current is too high.
PAGE 12
Fault Number 81 Fault Title Controller Affected Fault Condition/Circuit Description Start Relay – Current Too High Master This fault is reported when the current from the TEC to the start relay is too high. 83 Master Contention Fault Master This fault is reported when the TEC receives a message from another TEC controller on the same bus. 84 E-reel Enable – Current Too High Master This fault is reported when the cutting unit enable current exceeds 5 amps.
PAGE 13
Fault Number 87 88 Fault Title Controller Affected Fault Condition/Circuit Description 48V Bus Overvolt – CU2 Cutting unit This fault is reported when the 48 Vdc Bus circuit exceeds 67.5 Vdc at cutting unit 2. This fault will cause the TEC to disable the cutting unit motor. Note: This fault can also occur if the generator is faulting and not generating. 48V Bus Overvolt – CU3 Cutting unit Additional Notes All of the machine’s 48 Vdc devices connect to the same 48 Vdc bus.
PAGE 14
Fault Number 89 94 Fault Title 48V Bus Overvolt – S/G 48V Bus Undervolt – CU1 Controller Affected Fault Condition/Circuit Description Additional Notes Starter/Generator This fault is reported when the 48 Vdc Bus circuit exceeds 65 Vdc at the starter/generator. This fault will cause the TEC to disable the starter/generator. Note: This fault can also occur if the generator is faulting and not generating. All of the machine’s 48 Vdc devices connect to the same 48 Vdc bus.
PAGE 15
Fault Number 95 96 Fault Title Controller Affected Fault Condition/Circuit Description Additional Notes 48V Bus Undervolt – CU2 Cutting unit This fault is reported when the 48 Vdc Bus system voltage is below 32 Vdc at cutting unit 2. This fault only reports when the S/G contactor is closed. Cutting unit This fault is reported when the 48 Vdc Bus system voltage is below 32 Vdc at cutting unit 3. This fault only reports when the S/G contactor is closed.
PAGE 16
Fault Number 97 98 Fault Title Controller Affected Fault Condition/Circuit Description Additional Notes Service Actions 48V Bus Undervolt – S/G Cutting unit This fault is reported when the 48 Vdc Bus system voltage is below 36 Vdc at the starter/generator. This fault only reports when the S/G contactor is closed. 1) Check to see if a precharge fault exists because the contactor won't engage. 2) Test the contactor for proper function. 3) Inspect the S/G connector.
PAGE 17
Fault Number 99 101 Fault Title Controller Affected Fault Condition/Circuit Description Additional Notes 48V Keyswitch Overvolt – CU2 Cutting unit This fault is reported when the 48 Vdc low current logic circuit exceeds 67.5 Vdc at cutting unit 2. This fault will cause the TEC to disable the motor. 48V Keyswitch Overvolt – CU3 Cutting unit This fault is reported when the 48 Vdc low current logic circuit exceeds 67.5 Vdc at cutting unit 3. This fault will cause the TEC to disable the motor.
PAGE 18
Fault Number 102 Fault Title 48V Keyswitch Overvolt – S/G Controller Affected Fault Condition/Circuit Description Starter/Generator This fault is reported when the 48 Vdc low current logic circuit exceeds 65 Vdc at the S/G. This fault will cause the TEC to disable the S/G. 103 Temperature Sensor Fault Master 104 Over Current Disable – CU1 Cutting unit This fault is reported when the FET temperature sensor and the Motor temperature sensor in the S/G controller have both failed.
PAGE 19
Fault Number 105 Fault Title Controller Affected Fault Condition/Circuit Description Over Current Disable – CU2 Cutting unit This fault is reported when the hardware in CU2 detects an overcurrent condition and disables the PWM to stop the motor. This happens when the FET current is measured in excess of a design limit set point. 106 Over Current Disable – CU3 Cutting unit This fault is reported when the hardware in CU3 detects an overcurrent condition and disables the PWM to stop the motor.
PAGE 20
Fault Number 114 Fault Title Controller Affected Fault Condition/Circuit Description Internal Regulator Undervolt – CU3 Cutting unit 121 Invalid Hall State – CU1 Cutting unit This fault is reported when system voltage drops below the 8.5 Vdc minimum. This fault will disable the motor. This fault is reported when an invalid hall state is indicated. 122 Invalid Hall State – CU2 Cutting unit This fault is reported when an invalid hall state is indicated.
PAGE 21
Fault Number 129 Fault Title S/G Current Sensor Fault Controller Affected Fault Condition/Circuit Description Starter/Generator This fault is reported when one of the three current sensors inside the S/G controller has failed. 131 Internal TEC Controller Fault Master This fault is reported when the software is corrupted. 132 Internal TEC Controller Fault Master This fault is reported when the software is corrupted.
PAGE 22
Fault Number 142 Fault Title Controller Affected Fault Condition/Circuit Description Software Version Incompatibility – CU2 Master 143 Software Version Incompatibility – CU3 Master 144 Software Version Incompatibility – S/G Master 145 Software Version Incompatibility – InfoCenter Master 146 CAN Bus Fault – InfoCenter Master This fault is reported when the CU2 controller software is incompatible with the TEC controller software.