Toro Greensmaster e1021 User manual

FormNo.22259SLRevA
Greensmaster®e1021
GreensmowerandeFlex®
1021Greensmower
ModelNo.04831—SerialNo.400000000andUp
ModelNo.04861—SerialNo.400000000andUp
Registeratwww.Toro.com.
OriginalInstructions(EN)*22259SL*

Introduction
Thepurposeofthispublicationistoprovideaservicetechnicianwithinformationfordiagnostictroubleshooting
andtestingoffaultcodesontheGreensmastereFlex1021ande1021.
RefertotheGreensmaster®1021GreensmowerOperator’sManualorGreensmaster®eFlex®1021
GreensmowerOperator’sManualforinformationonoperating,maintaining,andadjustingthemachineandits
components.
RefertotheGreensmaster®e1021/e1026ServiceManualorGreensmaster®eFlex®1021ServiceManualfor
informationontroubleshooting,testing,andrepairingthemachineanditscomponents.
RefertotheToroDIAGUser’sGuideforinformationonsystemoperation,diagnostics,andmachine
programming.
TheToroCompanyreservestherighttochangeproductspecicationsorthispublicationwithoutnotice.
Improperuseormaintenancebytheoperatororownercanresultininjury.Toreducethepotentialforinjury,
complywithallsafetyinstructionsinthismanual,andalwayspayattentiontothesafetyalertsymbol(Figure
1),whichmeanscaution,warning,ordanger(i.e.,personalsafetyinstruction.)Failuretocomplywiththe
instructionmayresultinpersonalinjuryordeath.
g000502
Figure1
SafetyAlertSymbol
©2021—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
Registeratwww.Toro.com.OriginalInstructions(EN)
PrintedintheUSA
AllRightsReserved*22259SL*

ReaderComments
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usefulnessofitspublications.Todothiseffectively,weencourageuserfeedback.Pleasecomment
onthecompleteness,accuracy,organization,usability,andreadabilityofthismanualbyanemailto
[email protected]
ormailto:
TechnicalPublicationManager,Commercial
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8111LyndaleAvenueSouth
Bloomington,MN55420-1196
Phone:[phone]
RevisionHistory
RevisionDateDescription
A08/2021InitialRelease
3

Contents
ReaderComments.........................................................................................................................................3
RevisionHistory.............................................................................................................................................3
Safety...................................................................................................................................................................5
MaintenanceandService...............................................................................................................................5
AvoidingInjuryfromLithium-IonBatteries......................................................................................................5
GeneralInformation...............................................................................................................................................7
ExternalReferenceMaterial...........................................................................................................................7
ToroDIAGSoftware.......................................................................................................................................7
Abbreviations..................................................................................................................................................7
Glossary.........................................................................................................................................................7
GeneralElectricalDiagnosticInformation..............................................................................................................8
GroundConnectionforTroubleshooting.........................................................................................................8
SpecialT ools..................................................................................................................................................8
InspectingtheWireHarnessesandComponentConnectorAssemblies........................................................9
RepairingHarnessWireInsulation.................................................................................................................9
TestingElectricalCircuits..............................................................................................................................10
TroubleshootingIntermittentElectricalFaults...............................................................................................11
InfoCenterIcons...........................................................................................................................................12
InfoCenterScreenMap................................................................................................................................13
FrequentlyUsedProcedures...............................................................................................................................14
ConnectingandDisconnectingtheBattery...................................................................................................14
ReadingFaultCodes....................................................................................................................................14
ClearingFaultCodeswhileUsingtheMachine.............................................................................................15
ClearingtheInfoCenterFaultLog.................................................................................................................15
PreparingforTroubleshootingand/orTesting...............................................................................................16
RemovingtheControlCover........................................................................................................................16
RemovingtheElectricCover........................................................................................................................17
ToroDIAG–QuickStart.................................................................................................................................18
ReplacingaT oroElectronicController(TEC)...............................................................................................19
ReturningtheMachinetoService.................................................................................................................20
Fault1InternalTEC.............................................................................................................................................22
Fault212VdcSupply...........................................................................................................................................25
Fault35VSupply................................................................................................................................................33
Fault4Precharge................................................................................................................................................37
Fault5Communication........................................................................................................................................46
Fault7MotorOverTemperature..........................................................................................................................52
Fault9InternalMotor...........................................................................................................................................55
Fault10MotorStalled..........................................................................................................................................57
Fault11SoftwareIncompatible...........................................................................................................................60
Fault13InternalBattery......................................................................................................................................61
Fault15Software................................................................................................................................................63
Fault16Contactor...............................................................................................................................................68
Fault17ThrottleSensor......................................................................................................................................75
Fault18TractionBailSensor...............................................................................................................................80
4

Safety
ThemachinehasbeentestedandcertiedbyT oroforcompliancewithexistingsafetystandardsand
specications.Improperuseormaintenanceofthemachinecanresultininjuryordeath.Toreducethe
potentialforinjuryordeath,complywiththesafetyinstructionsfoundintheGreensmaster®1021Greensmower
Operator’sManual,theGreensmaster®eFlex®1021GreensmowerOperator’sManual,Greensmaster®
e1021/e1026ServiceManual,andtheGreensmaster®eFlex®1021ServiceManualandthefollowingspecic
service-relatedprecautions.
MaintenanceandService
•Beforeservicingormakingadjustmentstothemachine,settheparkingbrake,turnthekeyswitchtothe
OFFposition,andremovethekeyfromthekeyswitch.Waitforallmachinemotiontostop,andthen
disconnectthetopreventunintentionalmachineoperation.RefertoConnectingandDisconnectingthe
Battery(page14).
•Keepallnuts,bolts,screws,andbeltsproperlytightened.
•Toreducepotentialrehazard,keepthebattery,batterycontroller,electricalconnectors,cuttingunit,
anddrivecomponentsfreeofdebris.
•Wearcut-resistantorheavyleatherglovesandusecautionwhencheckingorservicingthecuttingunit.
•Ifyoumustperformmaintenanceormakeanadjustmentwiththeelectricmotorrunning,keepyourhands,
feet,clothing,andallpartsofyourbodyawayfromthecuttingunitandallothermovingparts.
Note:Keepbystandersawaywhenrunningtheelectricmotorforthecuttingunit.
•Beforeinstalling,removing,orworkingonthecuttingunit,disconnectthebattery.RefertoConnectingand
DisconnectingtheBattery(page14).
•Donotopenoralterthebatteryorthebatterycontroller.Openingthebatteryorbatterycontrollermay
exposeyoutodangerousvoltage.Thewarrantywillbevoidedifyouattempttoopenthebatteryorthe
batterycontroller.Thebatteryanditscontrollercontainnouserserviceableparts.
•Ifyoumustshipyourlithium-ionbattery,youwillneedspecialpackagingtocomplywithshippingregulations.
Refertotheoperator’smanualforadditionalbatteryshippinginformation.
•Atthetimeofmanufacture,themachineconformedtoallapplicablesafetystandards.Toensureoptimum
performanceandcontinuedsafetycerticationofthemachine,useonlygenuineTororeplacementparts
andaccessories.
AvoidingInjuryfromLithium-IonBatteries
•Immediatelydiscontinueuseofthebatteryifthebatteryemitsanunusualsmell,feelshot,changescoloror
shape,orappearsabnormalinanyotherway.Movetheproductorbatterytoasafeoutdoorareaaway
fromanybuilding,vehicle,orcombustiblematerial.Observethebatteryforatleast1hourtoensurethat
anyreactionhasstopped.Ifthereactioncontinues,orifanysmokeisobserved,callyourlocalemergency
servicesimmediately.
•UseonlyToro-speciedlithium-ionbatteriesdesignedforyourmachine.
•UseonlytheT oro-speciedlithium-ionchargerdesignedtochargeyourmachine.Donotattempttouseany
otherbatterycharger.
•Donotover-chargeorover-dischargelithium-ionbatteries.
•Donotheat,puncture,oropenthebatterycase.
•Alwaysdisconnectthebatteriesatthebatterydisconnectprovidedwhenservicingproductswithlithium-ion
batteries.
•Alwaysservicelithium-ionbatterieswiththemachineparkednearaservicedoorlargeenoughtomovethe
productorbatteryoutsideincaseofanemergencyandkeepareblanketnearby.
5

WARNING
Donotuseareextinguisheronlithium-ionbatteries.Ifanysmokeisobserved,movethe
productorbatterytoasafeoutdoorareaawayfromanybuilding,vehicle,orcombustible
materialifpossibleandcallyourlocalemergencyservicesimmediately.Failuretodosomay
resultinpersonalinjuryandpropertydamage.
6

GeneralInformation
ExternalReferenceMaterial
ThismanualreferencesinformationfoundinotherTorosourcematerialyoucanaccessonline.
RefertotheGreensmaster®1021GreensmowerOperator’sManualorGreensmaster®eFlex®1021
GreensmowerOperator’sManualforinformationonoperating,maintaining,andadjustingthemachineandits
components.Thesetwobooksareavailablethroughwww.Toro.com.Siteloginisnotrequired.
RefertotheGreensmaster®e1021/e1026ServiceManualorGreensmaster®eFlex®1021ServiceManualfor
informationontroubleshooting,testing,andrepairingthemachineanditscomponents.Thesetwobooksare
availablethroughwww.Toro.com.Siteloginisnotrequired.
RefertotheToroDIAGUser’sGuideforinformationonsystemoperation,diagnostics,andmachine
programming.ThisbookisavailableonToroConnect.com.Siteloginisrequired.
ToroDIAGSoftware
ToroDIAGsoftwareisdownloadedfromtheToroDealerandDistributorPortalandtheninstalledonaPC.This
softwareassistswithtroubleshootingelectricalissuesonToromachinesthatuseaToroelectroniccontroller
(TEC).
FeaturesandbenetsoftheToroDIAGsoftwareincludeusingaUSBtoCANconnection,updatesaresent
automatically,andyoucaneasilyreprogramthemachineandreviewfaultcodes.
TheToroDIAGUser’sGuideisavailableonT oroConnect.com.Siteloginisrequired.
TheToroDIAGsoftwareisavailablefordownloadingonToroConnect.com.Siteloginisrequired.
Abbreviations
AcronymDenition
CANControllerareanetwork
Li-ionLithium-ion(battery)
TECToroelectroniccontroller
ToroDIAGToroDiagnosticssoftware
Glossary
ConnectionTerminology
Pinsarethemetalcontactscontainedinsideaconnectorhousing.
Terminalsaretheexposedmetaltabsorpoststhatarenotcontainedinsideaconnectorhousing.T erminals
aremostoftenpartofacomponent.Examplesofterminalsincludethreadedpostsandsoldercups.Often,
crimplugs(e.g.,rings,hooks,forks,etc.)areattachedtoterminalsbytighteninganutorascrew.
Fault
Afaultiscomposedofanumericcode(faultcode)andadescription.
Afaultisintendedtohelpidentifythesourceofproblemsfordiagnostictroubleshooting.
AnactivefaultisdisplayedontheInfoCenterwhilethefaultconditionispresentuntilyouclearthefaultor
youturnthemachineoff.AllfaultsarearchivedinandaccessiblefromthenonvolatilememoryoftheToro
electroniccontroller(TEC).
7

GeneralElectricalDiagnosticInformation
Machineelectricalschematicsandwireharnessdiagramsarenecessaryfortroubleshootingmachine
circuits.Theschematicsanddiagramsareavailableintheservicemanualforyourmachine(Greensmaster®
e1021/e1026ServiceManualorGreensmaster®eFlex®1021ServiceManual).
TheGreensmastereFlex1021ande1021usea48Vbattery-basedelectricalsystem.Thevoltagewillvary,
dependingonthechargelevelofthebattery.
GroundConnectionforTroubleshooting
Important:Themachineframeisnotusedasanelectricalground.Groundisdistributedthroughthe
machinewiring.
Aneasy-to-useelectricalgroundisthenegativeterminalonthebatterycontroller.
g365285
Figure2
Shownwithwhiteelectriccoverremoved
1.Batterycontroller3.TEC-2402controller
2.Negativeterminal(ground)
SpecialTools
Multimeter
Useadigitalmultimeterwhentestingelectricalcircuits.
Readandunderstandthemanufacturer’soperatinginstructionsforthemultimeter.
ToroDIAGUSB/CANCable
TheT oroDIAGsoftwareusesaUSBtoCANconnection,viaaToroDIAGUSB/CANcable(ToroPartNo.
115-1944).
8

M/SSamsungServiceWireHarness
ToroP/N122-1947
g317032
Figure3
UsetheM/SSamsungservicewireharnesswhentroubleshootingto:
•determineiftheBMScontrollerisworkingcorrectly
•determineiftheM/SSamsunginterfacewireharnessisworkingcorrectly
Note:Whileabattery-relatedfaultisactive,theBMScontrollerkeepsitsinternalbatterycontactoropen,not
allowingbatterypowertogotothemachine.Asaresult,themachinewillnotrespondwhenthekeyswitchis
turnedtotheONposition.
InspectingtheWireHarnessesandComponent
ConnectorAssemblies
Thewireharnessesandelectricalcomponentsinclude:
•Electricalconnectors
•Connectorpins
•Electricalterminals
•Insulatedwire
Whileyouaretroubleshooting,inspectthepartsforwear,damage,andcorrosion.
Commonelectricalproblemsinclude:
•Open,shorted,orburnedwires
Note:Debris,suchaswetgrassclippings,canactasaconductor.
•Corrodedterminalsorpins
•Waterintheconnector
•Connectorpinsthatareloose,bent,orrecessed
•Connectorsthatarenotfullyseated
•Wiresthatarepinched,frayed,oraremissinginsulation
•Damagedconnectorlocks,clips,orhousings
•Missingorinadequatedielectricgrease
Note:Dielectricgreaseisusedinallunsealedwireharnessconnectors.
RepairingHarnessWireInsulation
Ifdamageextendsthroughtheinsulationandstrandsofthewirearebroken,replacethewireharness.
9

Ifthereisdamagetotheouterinsulationonly,orifthedamagetotheshieldingisabrasionordeformationonly
withnobrokenstrands,repairthewireharnessasfollows:
1.Cleanthedamagedareaofthepartwithisopropylalcohol.
2.Drythepartwithacleanlint-freecloth.
3.Wrapthedamagedareawith2layersofall-weatherelectricaltapeoranequivalent.
Note:Ensurethatthetapeextendspastthedamagebyaminimumof1.3cm(1/2inch).
Note:Heatshrinktapethatisproperlyinstalledwiththesameprecautionaselectricaltapeisacceptable.
Installtheheatshrinktapeaccordingtothemanufacturer’sinstructions.
AttachingWireHarnesses
Properlyattachingthewireharnessestothemachinehelpskeeptheconnectorsfromlooseningandprotects
theharnessesfromaccidentaldamagecausedbyvibration.
•Ensurethatnodeviceusedtoattachawireharnesstothemachinecanrotateorslidefreelyonthewire
harness.
•Forwiresnotcontainedinconvolutedtubingorprotectivesleeving,securethewireswithelectricaltape
oracabletieevery10to15cm(4to6inches).
•Forsplit-loom,convolutedtubing,ensurethatthetapeorcabletiesare1.3cm(1/2inch)awayfromany
connectorsorlabels.
TestingElectricalCircuits
Important:TheGreensmastereFlex1021ande1021useabattery-basedelectricalsystem.Actual
voltagemeasurementswillvary,dependingonthechargelevelofthebattery.
Important:Themachineframeisnotusedasanelectricalground.Groundisdistributedthroughthe
machinewiring.
WARNING
Thelithium-ionbatterycontainshighvoltage,whichcouldburnorelectrocuteyou.
•Neverattempttoopenthebattery.
•DonotplaceanythingintheconnectoronthebatteryotherthanaTorowireharness
connectormadefortheproduct.
•Donotallowtoolsorvehiclecomponentstocompletethebatterycircuit.
•Useextremecarewhenhandlingabatterywithacrackedcase.
•Removeabatterywithacrackedcaseimmediately.
•UseonlytheTorobatterychargerdesignedforthebattery.
TestingforaShortCircuit
Ashortcircuitisanabnormalelectricalconnectionbetween2electricalcircuits.Youcandiagnoseashortcircuit
byperformingvoltagechecksand/orcontinuitytests.
•Ashortcircuittogroundbeforeanelectricalcomponentusuallycausesthefuseforthecircuittoopen.
•Ashortcircuittogroundafteranelectricalcomponentusuallycausestheelectricalcomponenttostay
onaslongasthereispowertothecomponent.
Useamultimetertotestbetweentheidentiedwireharnessconnectorpinsorcomponentterminalsand
thesuspectedpointsoffailure.
Foraccurateresistanceand/orcontinuitychecks,electricallyisolatethecomponentbeingtestedby
disconnectingallwiringorremovingitfromthecircuit.
10

TestingtheVoltageofaCircuit
1.Measurethevoltagebetweentheidentiedwireharnessconnectorpinsorcomponentterminalsand
thesuspectedpointsoffailure.
2.Ifthevoltagethatyoumeasureishigherorlowerthanthespeciedvoltage,cleanandinspecttheterminal
connectionsalongthecircuitpaththatyouaretesting.
CleaningElectronicComponentsandConnections
Note:Useelectricalcontactcleaneronly.Donotusebrakecleaner,asitmaypermanentlydamageelectrical
connectorbodiesandotherplasticcomponentsofthemachine.Avoidusingmineralsolvents,astheymay
damageconnectors,seals,andwireinsulation.
WARNING
Cleaningchemicalsandtoolscancauseinjuryifusedimproperly.
Refertotheapplicablesafetydatasheet(SDS)forappropriatepersonalprotectivegear,such
asgloves,respirators,andsafetyglasses.
1.Markthewiresforproperinstallationaftercleaningiscompleted.Removepinsfromconnectorswiththe
properextractiontool.
2.Cleantheterminalsortheconnectorpinsusinganeraser,mildabrasivepaper,oranylonorberbristle
brush.Donotusemetalormetaloxides.
3.Finishthecleaningwithaberbristlebrushdippedinisopropylalcohol.
4.Gentlywipeoffthecleanpins,terminals,andcomponentswithalint-freeclothdampenedwithisopropyl
alcohol.
5.Whenavailable,drythecomponentswithdry,oil-freecompressedairwithapressureofnomorethan
138kPa(20psi).
6.Ensurethatallconnectorsandcomponentsarecleananddrypriortoreassemblyandtesting.
UsingtheInfoCenterDisplay
TheInfoCenterdisplayshowsinformationaboutyourmachine,suchastheoperatingstatus,various
diagnostics,andotherinformationaboutthemachine.Whenyoustartthemachine,thescreenappearsand
displaysthecorrespondingiconsthatapply.
TondadditionalinformationonnavigatingtheInfoCentermenuitems,refertotheoperator’smanualor
servicemanualforyourmachine.
TroubleshootingIntermittentElectricalFaults
AttempttoDuplicatetheFault
1.Operatethemachinebasedontheinformationprovidedbytheoperator.
2.Observethemachineduringnormaloperation.Payattentiontohowthemachineisbeingoperated.
3.Worktowardbeingabletoduplicatethefaultpredictably.
4.Makenotesasyouproceedthroughyourdiagnosis.Documentyourstepsandanytestresultsforfuture
reference.
CompletetheBasicMaintenanceChecks
ChecktheConditionoftheBattery
1.Inspectforanycorroded,loose,ordamagedwiresandconnections.
2.Loosen,clean,andtightenthebatteryconnections(cables,posts,etc.).
3.Loadtestthebatterytoensureitmeetstheoutputspecication.
11

TesttheChargingSystem
Testthechargingsystemtoensureitmeetstheoutputspecication.
InspectFusesandFusibleLinks
1.Verifyallfusesareofthecorrectratingandthatthecontactsarecleanandsecurelyseated.
2.Verifyallfusiblelinksareofthecorrectratingandthattheconnectorsarecleanandsecurelyseated.
Note:Openfusesarenotnecessarilythecauseofafailure.
CircuitWiringandConnectors
Commonissuestolookforare:
•Damagedwiringinsulation
•Corrosion
•Brokenwirestrands
•Incorrectwiringcircuitorharnessrouting
•Looseconnectionsbetweenconnectors
•Loose,bent,orimproperlyseatedpinsinconnectors
•Connectorhousinglocksthatarebrokenornotengagingfully
•Improperorweakcrimps,splices,andsolderedjoints
•Discoloredorburnedconnectors
CANCircuitsandCommunicationCapture
Iftheintermittentissueremainsafterthebasicdiagnosticprocessesarecomplete,usethecontroller-specic
diagnostictoolsandfunctionsavailabletomonitororcapturedataasthemalfunctionoccurs.Theseinclude:
•ToroDIAGSavefunction(seetheToroDIAGSoftwareUser'sGuide)
•ToroCANCapture(seetheToroDIAGSoftwareUser'sGuide)
•ToroScopeRecordfunction(seetheToroDIAGSoftwareUser'sGuide)
•ToroDIAGfreezeframedata(seetheToroDIAGSoftwareUser'sGuide)
InfoCenterIcons
InfoCentericonsaredenedintheoperator’smanualforyourmachine.
12

InfoCenterScreenMap
KEY SWITCHED
ON
AFTER
5
SECONDS
MAIN INFORMATION SCREEN
%
%
g339628
Figure4
13

FrequentlyUsedProcedures
ConnectingandDisconnectingtheBattery
CAUTION
Beforeinstalling,removing,orservicingcomponents,separatethebatterydisconnect.This
willpreventunexpectedoperationofsystemcomponents.
1.Disconnectingthebattery.
A.Parkthemachineonalevelsurface.
B.Applytheparkingbrake,shutofftheengine,andwaitforallmachinemovementtostop.
C.UnplugtheT-handleconnector.
2.Connectingthebattery.
A.Removethekeyfromthekeyswitch.
B.PlugintheT-handleconnector.
g364232
Figure5
1.Electriccover
2.Batteryinterconnect(withT-handle)
3.Batteryinterconnect(mounted)
g364233
Figure6
1.Electriccover
2.Batteryinterconnect(withT-handle)
3.Batteryinterconnect(mounted)
ReadingFaultCodes
Youcanreadfaultcodes2differentways:ontheInfoCenteroronaPCusingToroDIAGSoftware(page
7).ThissectionfocusesontheInfoCenterdisplay.
TheInfoCenterdisplayshowsinformationaboutyourmachine,suchasfaultcodes,thechargelevelofthe
battery,andvariousdiagnosticmessagesandiconsthatprovideinformationaboutthemachineandthebattery.
14

g020650
Figure7
1.Faultindicatorlight
2.Rightbutton—pressittoopenamenuwhenarightarrowindicatesadditionalcontent.
3.Middlebutton—pressittoscrolldownthemenusordigitsforPINcode.
4.Leftbutton(menuaccess/backbutton)—pressittoaccesstheInfoCentermenus.Alsouseittobackoutofanymenuthatyou
arecurrentlyusing.
Ifanelectricalfaultoccurs,theInfoCenterindicatorlightashesandatextmessageappearsimmediatelyto
notifyyouaboutthefault.
•Faultsthatarecurrentlyhappeningarecalledactivefaults.Assoonasafaultoccurs,informationabout
thatfaultisdisplayedontheInfoCenter.Faultsremainactiveuntilyouclearthemortheconditionthat
createdthefaultnolongerexists.
•Toseealistoffaultsthatoccurredbeforethemostrecentstartingofthemachine,usetheInfoCenter
Faultsscreen.TheFaultsscreenlistsallthemachinefaultsthathaveoccurredsincetheInfoCenter
faultlogwaslastcleared.
ClearingFaultCodeswhileUsingtheMachine
Ifafaultoccurswhileyouareoperatingthemachine,attempttoclearthefaultbyperformingthefollowingsteps:
1.MovethetractionlevertotheNEUTRALposition.
2.MovethekeyswitchtotheOFFposition.
3.Allowallmachinefunctionstostop.
4.Startthemachineandtestittoseeifoperationhasreturnedtonormal.
Ifafaultrepeatseachtimeyoustartthemachine,conductdiagnostictroubleshootingoftheaffectedsystem
andrelatedcomponents.
ClearingtheInfoCenterFaultLog
YoucanclearthefaultsfromtheInfoCenterfaultlog;however,thefaulthistorywillberetainedintheTEC-2402
memory.
Note:RefertoFigure7forhelpusingthisprocedure.
1.PresstheleftbuttonasneededtodisplaytheMainMenu.
Note:Ifnofaultshaveoccurredsincethelasttimethefaultswerecleared,aNoFaultsLoggedmenu
itemwillbedisplayedinsteadoftheFaultsmenuitem.PresstheleftbuttonasneededtoexittheMain
Menu.
2.PressthemiddlebuttonasneededtohighlightFaults,andthenpresstherightbutton.TheFaults
screenappears.
15

3.PressthemiddlebuttontoscrolldownthroughthefaultsuntilClearSystemFaultsishighlighted.
4.Presstherightbutton.Aconrmationscreenappears.
5.PressthemiddlebuttontoconrmclearingtheInfoCenterfaultlog.An“Allfaultscleared”message
appears.
6.Presstheleftbuttonasneededtoreturntoanoperatorinformationscreen.
Note:Somefaultsclearwhenyoustartthemachine.Afterthefaultclears,youcanresumenormaloperationof
themachine.
Ifafaultrepeatseachtimeyoustartthemachine,conductdiagnostictroubleshootingoftheaffectedsystem
andrelatedcomponents.
PreparingforTroubleshootingand/orTesting
Note:Refertoyourmachine’soperator’smanualformoreinformationaboutcontrols,switches,andusing
thekickstand.
CAUTION
Rings,watches,bracelets,necklaces,andotherjewelrycancauseanelectricalshockor
becomeentangledwiththemachine.
Removealljewelry,especiallyringsandwatches,beforedoinganytroubleshootingortesting.
Beforeperformingtroubleshootingand/ortestingproceduresonthemachine,dothefollowingsteps:
1.Parkthemachineonalevelsurface.
2.EnsurethatthetractionleverisintheNEUTRALposition.
3.Engagetheparkingbrake.
4.Shutofftheengineandremovethekeyfromtheignitionswitch.
5.MovethekickstandintotheSERVICEposition.
6.Disconnectthebatterybeforeservicingthemachine,unlessitisneededfortroubleshootingortesting.
RefertoConnectingandDisconnectingtheBattery(page14).
Themachineisnowreadyfortestinganddiagnosticworktotakeplace.
RemovingtheControlCover
Thecontrolcovermustberemovedtoaccesssomeoftheconnectorsonthewireharness,andsomeofthe
machinecomponents.
1.Disconnectthebattery.RefertoConnectingandDisconnectingtheBattery(page14).
2.Removethe4fastenersthatsecurethecontrolcovertothemachine.
3.Removethecontrolcoverfromthemachine.
16

g364085
Figure8
1.Controlcover2.Fasteners(4)
RemovingtheElectricCover
Thewhiteelectriccovermustberemovedtoaccesssomeoftheconnectorsonthewireharness,andsome
ofthemachinecomponents.
1.Disconnectthebattery.RefertoConnectingandDisconnectingtheBattery(page14).
2.Removethe4fastenersthatsecurethewhiteelectriccovertothemachine.
3.Removethewhiteelectriccoverfromthemachine.
g364086
Figure9
1.Electriccover2.Frontfasteners(rearfastenersnotshown)
17

ToroDIAG–QuickStart
EnsurethattheT oroDIAGsoftwareandthedriversfortheToroDIAGCable(PartNo.115-1944)arealready
installedonyourPC.Iftheyarenotinstalled,gototheToroDIAGSoftwareGuideandfollowthestepsinthe
ToroDIAGSoftwareInstallationsection.
Important:ThisprocedureassumesthattheToroDIAGcablehasbeenphysicallyconnectedtothe
PCatleastonceandthatthePChasfoundandrecognizedthecableas“NewHardware.”Ifthese2
actionshavenotoccurred,gototheToroDIAGSoftwareGuideandfollowthestepsintheToroDIAG
CableInstallationsection.
FortheToroDIAGsoftwaretoconnectbetweenthePCandthemachine,performthefollowingstepsexactly
aswritten:
1.Verifythatthemachineisshutoff.
2.TurnonthePC,butleavethemachineshutoff.
Important:DonotstarttheToroDIAGsoftwareuntillaterinthisprocedure.
Important:Leavethemachineturnedoffuntillaterinthisprocedure.
3.ConnecttheToroDIAGcable(PartNo.115-1944)betweenaUSBportonthePCandtheCANdiagnostic
portonthemachine.
g364925
Figure10
1.CANdiagnosticportconnector
2.Protectivecap
3.Controlcover
4.StarttheT oroDIAGsoftware.(ToroDIAGgoesthroughashortDiscoveryroutinetoinitializetheprogram.)
5.WaitfortheToroDIAGsoftwaretodisplaythemessage,“NoMachineConnected”.
18

g205684
Figure11
1.“NoMachineConnected”message
6.TurnthekeyswitchonthemachinetotheONposition.(ThisactioncausestheT oroDIAGprogram
toconnecttothemachine.)
ReplacingaToroElectronicController(TEC)
Thereare3proceduresinthissectionthatyoumustaccomplishaspartofreplacingaprimarycontroller.
Note:Dependingontroubleshootingthathasbeenaccomplished,somestepsinthese3proceduresmay
alreadybedone.
1.UseToroDIAGtosavethemachinetimersandcountersleoutoftheoriginalTEC.(page19)
2.ReplacetheTEC-2402.(page20)
3.UseT oroDIAGtoprogramtheTEC,andthenrestoretheTD2le.(page20)
UseToroDIAGtosavethemachinetimersandcountersleoutof
theoriginalTEC.
Savethetimersandcountersle(theTD2le)outoftheoriginalTECandthenlaterrestoreitintothe
replacementTECsothatthemachineinformation(e.g.,runninghours,etc.)isretained.
1.Parkthemachineonalevelsurface.
2.EnsurethatthetractionpedalisintheNEUTRALposition.
3.Engagetheparkingbrake.
4.ConnectaPCwithToroDIAGsoftwaretothemachinethroughaToroDIAGCable(PartNo.115-1944).
RefertoT oroDIAG–QuickStart(page18).
5.UsetheT oroDIAGsoftwaretosavethetimersandcountersleoutoftheoriginalTEC.Refertothe
ControllerReformattingsectionoftheToroDIAGUser’sGuide.
6.MovethekeyswitchtotheOFFposition.
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ReplacetheTEC-2402.
1.Removethewhiteelectriccover.RefertoRemovingtheElectricCover(page17)
2.LocatetheTEC-2402controller,thenunplugharnessconnectorsP01andP02.
g364928
Figure12
1.TEC-2402controller
g365074
Figure13
1.HarnessconnectorP013.TEC-2402controller
2.HarnessconnectorP02
3.Removethefourmountingbolts(1oneachcorner)securingtheoriginalTEC-2402controller,andremove
theoriginalcontroller.
4.SecurethereplacementTECwiththefourmountingbolts.
5.PluginharnessconnectorsP01andP02.
UseToroDIAGtoprogramtheTEC,andthenrestoretheTD2le.
Note:TECcontrollersareprogrammedtospecicmachinemodelandserialnumbers.TECcontrollersdonot
functionuntilprogrammedbyT oroDIAG.
1.ConnectaPCwithToroDIAGsoftwaretothemachinethroughaToroDIAGcable(PartNo.115-1944).
RefertoT oroDIAG–QuickStart(page18).
2.UsetheT oroDIAGsoftwaretoreprogramthemachineinaccordancewithToroDIAGUser’sGuide.The
replacementTECisprogrammedduringthereprogrammingofthemachine.
3.UsetheToroDIAGsoftwaretorestorethetimersandcountersle(theTD2le)fromtheoriginalTEC
intothereplacementTEC,inaccordancewiththeControllerReformattingsectionoftheToroDIAG
User’sGuide.
4.DisconnecttheToroDIAGcablefromthemachine.
ReturningtheMachinetoService
Ensureoptimumperformanceandcontinuedsafetybyperformingallstepsinthefollowingprocedureafterall
diagnostic,maintenance,and/orrepairactivitiesarecomplete:
Ensureoptimumperformanceandcontinuedsafetybyperformingallstepsinthefollowingprocedureafterall
diagnostic,maintenance,and/orrepairactivitiesarecomplete:
1.Removealldiagnosticequipmentandtoolsthatareattachedtothemachinefortroubleshootingorrepair.
2.Fullyreassemblethemachine.Thisincludesallguards,covers,cableties,andpartsloosenedorremoved.
3.Ensurethatallnuts,bolts,screws,andbeltsareproperlytightened.
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