1. Manuals
  2. Brands
  3. Toro Manuals
  4. Lawn Mower
  5. Greensmaster e1021
  6. Diagnostic manual

Toro Greensmaster e1021 Diagnostic Manual

Hide thumbs Also See for Greensmaster e1021:
Table of Contents

Advertisement

Quick Links

Download this manual
Register at www.Toro.com.
Original Instructions (EN)
Greensmaster
Greensmower and eFlex
1021 Greensmower
Model No. 04831—Serial No. 400000000 and Up
Model No. 04861—Serial No. 400000000 and Up
Form No. 22259SL Rev A
®
e1021
®
*22259SL*

Advertisement

Table of Contents
loading

Related Manuals for Toro Greensmaster e1021

Summary of Contents for Toro Greensmaster e1021

  • Page 1 Form No. 22259SL Rev A Greensmaster ® e1021 Greensmower and eFlex ® 1021 Greensmower Model No. 04831—Serial No. 400000000 and Up Model No. 04861—Serial No. 400000000 and Up *22259SL* Register at www.Toro.com. Original Instructions (EN)
  • Page 2 Refer to the Greensmaster® e1021/e1026 Service Manual or Greensmaster® eFlex® 1021 Service Manual for information on troubleshooting, testing, and repairing the machine and its components. Refer to the Toro DIAG User’s Guide for information on system operation, diagnostics, and machine programming.

  • Page 3: Reader Comments

    Reader Comments The Toro Company Technical Assistance Center maintains a continual effort to improve the quality and usefulness of its publications. To do this effectively, we encourage user feedback. Please comment on the completeness, accuracy, organization, usability, and readability of this manual by an email to servicemanuals@toro.com...

  • Page 4: Table Of Contents

    Preparing for Troubleshooting and/or Testing ....................16 Removing the Control Cover ........................16 Removing the Electric Cover ........................17 Toro DIAG–Quick Start ..........................18 Replacing a Toro Electronic Controller (TEC) ....................19 Returning the Machine to Service.........................20 Fault 1 Internal TEC.............................22 Fault 2 12Vdc Supply............................25 Fault 3 5V Supply ..............................33...

  • Page 5: Safety

    • Use only Toro-specified lithium-ion batteries designed for your machine. • Use only the Toro-specified lithium-ion charger designed to charge your machine. Do not attempt to use any other battery charger. • Do not over-charge or over-discharge lithium-ion batteries.
  • Page 6 WARNING Do not use a fire extinguisher on lithium-ion batteries. If any smoke is observed, move the product or battery to a safe outdoor area away from any building, vehicle, or combustible material if possible and call your local emergency services immediately. Failure to do so may result in personal injury and property damage.

  • Page 7: General Information

    This book is available on ToroConnect.com. Site login is required. Toro DIAG Software Toro DIAG software is downloaded from the Toro Dealer and Distributor Portal and then installed on a PC. This software assists with troubleshooting electrical issues on Toro machines that use a Toro electronic controller (TEC).

  • Page 8: General Electrical Diagnostic Information

    Use a digital multimeter when testing electrical circuits. Read and understand the manufacturer’s operating instructions for the multimeter. Toro DIAG USB/CAN Cable The Toro DIAG software uses a USB to CAN connection, via a Toro DIAG USB/CAN cable (Toro Part No. 115-1944).

  • Page 9: Inspecting The Wire Harnesses And Component Connector Assemblies

    M/S Samsung Service Wire Harness Toro P/N 122-1947 g317032 Figure 3 Use the M/S Samsung service wire harness when troubleshooting to: • determine if the BMS controller is working correctly • determine if the M/S Samsung interface wire harness is working correctly...

  • Page 10: Testing Electrical Circuits

    The lithium-ion battery contains high voltage, which could burn or electrocute you. • Never attempt to open the battery. • Do not place anything in the connector on the battery other than a Toro wire harness connector made for the product.

  • Page 11: Troubleshooting Intermittent Electrical Faults

    Testing the Voltage of a Circuit Measure the voltage between the identified wire harness connector pins or component terminals and the suspected points of failure. If the voltage that you measure is higher or lower than the specified voltage, clean and inspect the terminal connections along the circuit path that you are testing.

  • Page 12: Infocenter Icons

    Toro CANCapture (see the Toro DIAG Software User's Guide) • ToroScope Record function (see the Toro DIAG Software User's Guide) • Toro DIAG freeze frame data (see the Toro DIAG Software User's Guide) InfoCenter Icons InfoCenter icons are defined in the operator’s manual for your machine.

  • Page 13: Infocenter Screen Map

    InfoCenter Screen Map AFTER SECONDS MAIN INFORMATION SCREEN g339628 Figure 4...

  • Page 14: Frequently Used Procedures

    Reading Fault Codes You can read fault codes 2 different ways: on the InfoCenter or on a PC using Toro DIAG Software (page 7). This section focuses on the InfoCenter display. The InfoCenter display shows information about your machine, such as fault codes, the charge level of the...

  • Page 15: Clearing Fault Codes While Using The Machine

    g020650 Figure 7 1. Fault indicator light 2. Right button—press it to open a menu when a right arrow indicates additional content. 3. Middle button—press it to scroll down the menus or digits for PIN code. 4. Left button (menu access/back button)—press it to access the InfoCenter menus. Also use it to back out of any menu that you are currently using.

  • Page 16: Preparing For Troubleshooting And/Or Testing

    Press the middle button to scroll down through the faults until Clear System Faults is highlighted. Press the right button. A confirmation screen appears. Press the middle button to confirm clearing the InfoCenter fault log. An “All faults cleared” message appears.

  • Page 17: Removing The Electric Cover

    g364085 Figure 8 1. Control cover 2. Fasteners (4) Removing the Electric Cover The white electric cover must be removed to access some of the connectors on the wire harness, and some of the machine components. Disconnect the battery. Refer to Connecting and Disconnecting the Battery (page 14).

  • Page 18: Toro Diag-Quick Start

    Ensure that the Toro DIAG software and the drivers for the Toro DIAG Cable (Part No. 115-1944) are already installed on your PC. If they are not installed, go to the Toro DIAG Software Guide and follow the steps in the Toro DIAG Software Installation section.

  • Page 19: Replacing A Toro Electronic Controller (Tec)

    Toro DIAG–Quick Start (page 18). Use the Toro DIAG software to save the timers and counters file out of the original TEC. Refer to the Controller Reformatting section of the Toro DIAG User’s Guide. Move the key switch to the O...

  • Page 20: Returning The Machine To Service

    TEC is programmed during the reprogramming of the machine. Use the Toro DIAG software to restore the timers and counters file (the TD2 file) from the original TEC into the replacement TEC, in accordance with the Controller Reformatting section of the Toro DIAG User’s Guide.
  • Page 21 Start the engine. Note: If you replaced any electronic controller on the machine, you may receive a Software Version Incompatibility fault for the replacement component. If you do receive a fault, follow the diagnostic path in this manual for that specific fault. Run the machine and verify that all systems function safely and correctly.

  • Page 22: Fault 1 Internal Tec

    Fault 1 Internal TEC InfoCenter Display: Internal TEC Fault Fault Description The 13.3V regulator in the TEC-2402 is not able to maintain regulation at an acceptable voltage level. Circuit Description The TEC-2402 controller has an internal power supply. Recommended Service Actions Step 1: Verify that the fault repeats.
  • Page 23 One or more of the wiring and/or connector inspections failed. Repair or replace the worn or damaged parts. If you need to replace the TEC, perform the 3 procedures in the Replacing a Toro Electronic Controller (TEC) (page 19) section.
  • Page 24 Depending on troubleshooting that has been accomplished, some steps in these 3 procedures may already be done. Use Toro DIAG to save the machine timers and counters file out of the original TEC. (page 19) Replace the TEC-2402. (page 20) Use Toro DIAG to program the TEC, and then restore the TD2 file.

  • Page 25: Fault 2 12Vdc Supply

    Fault 2 12Vdc Supply InfoCenter Display: 12Vdc Supply Fault Fault Description This fault is not based on a voltage threshold, but rather whether the supply chip is operating properly. The supply chip determines whether it is working correctly. Circuit Description The TEC-2402 has an internal DC-DC converter that supplies 12V power for various circuits including the InfoCenter, the optional wireless hour meter, and various sensors.
  • Page 26 Pass The battery charge indicator shows at least one full block. Go to Step 3. Fail The battery charge indicator does not show at least one full block. Move the key switch to the O position. Disconnect the battery. Refer to Connecting and Disconnecting the Battery (page 14).
  • Page 27 The device on the telematics connector is not causing the fault. fault Plug harness connector P44 back in to the device. repeats Do not install the white electric cover at this time. Go to Step 4. The device on the telematics connector is causing the fault. fault Replace the device plugged in to P44.
  • Page 28 Remove the control cover. Refer to Removing the Control Cover (page 16). g365094 Figure 20 1. Hour meter 3. Harness connector P43 2. Control cover 4. Hour meter connector Unplug harness connector P43 from the hour meter connector. Turn on the machine by rotating the key switch to the O position.
  • Page 29 Step 5: Disconnect the traction switch. The traction switch is also referred to as the traction bail proximity sensor. Locate the traction switch. g365107 Figure 21 1. Traction switch 3. Traction switch connector 2. Harness connector P29. 4. Harness connector P43 (for the hour meter) Unplug harness connector P29 from the traction switch connector.
  • Page 30 Step 6: Swap the InfoCenter with a known good unit. Verify that the key switch is in the O position. Remove the 4 fasteners that secure the InfoCenter to the InfoCenter mount. g365109 Figure 22 1. InfoCenter 3. Fasteners (4) 2.
  • Page 31 Depending on troubleshooting that has been accomplished, some steps in these 3 procedures may already be done. Use Toro DIAG to save the machine timers and counters file out of the original TEC. (page 19) Replace the TEC-2402. (page 20) Use Toro DIAG to program the TEC, and then restore the TD2 file.
  • Page 32 Electrical Diagram g363562 Figure 24...

  • Page 33: Fault 3 5V Supply

    Fault 3 5V Supply InfoCenter Display: 5V Supply Fault Fault Description The TEC-2402 monitors its 5 VDC OUT signal for proper voltage. If the 5 VDC OUT drops below 4.91V, the TEC-2402 will report the fault. Circuit Description The TEC-2402 has an internal DC-DC converter that supplies 5V power for the throttle sensor and the traction bail sensor.
  • Page 34 Pass The battery charge indicator shows at least one full block. Go to Step 3. Fail The battery charge indicator does not show at least one full block. Move the key switch to the O position. Disconnect the battery. Refer to Connecting and Disconnecting the Battery (page 14).
  • Page 35 Depending on troubleshooting that has been accomplished, some steps in these 3 procedures may already be done. Use Toro DIAG to save the machine timers and counters file out of the original TEC. (page 19) Replace the TEC-2402. (page 20) Use Toro DIAG to program the TEC, and then restore the TD2 file.
  • Page 36 Electrical Diagram g363935 Figure 27...

  • Page 37: Fault 4 Precharge

    Fault 4 Precharge Note: If a fault 16 occurs with this fault, troubleshoot the fault 16 first. InfoCenter Display: Precharge Fault Fault Description There are multiple conditions that can cause this fault: • The battery voltage is too low for the machine to operate. •...
  • Page 38 g364041 Figure 28 1. Battery charge indicator • If the battery charge indicator shows at least one full block, go to Step 3. • If the battery charge indicator does not show at least one full block: Move the key switch to the O position.
  • Page 39 g365258 Figure 29 1. TEC-2402 controller 2. Contactor Step 4: Test the internal resistance of the main contactor. Verify that the key switch is in the O position. Disconnect the battery. Refer to Connecting and Disconnecting the Battery (page 14). Isolate the main contactor by disconnecting the wires.
  • Page 40 Wire Expected Location Harness Connector Connector Graphic Color Reading Main Figure 30 Infinite Main Main 180 to 220 Figure 30 ohms Main Pass The resistance readings were good. Turn the key switch to the O position. Disconnect the battery. Refer to Connecting and Disconnecting the Battery (page 14).
  • Page 41 Verify that the key switch is in the O position. Disconnect the battery. Refer to Connecting and Disconnecting the Battery (page 14). Locate the TEC-2402 controller (Figure 29) and unplug harness connectors P01 and P02 (Figure 31). g365074 Figure 31 1.
  • Page 42 Pass The resistance readings were good. Plug in harness connectors P01 and P02. Go to Step 7. Fail One or more of the resistance readings was not good. Repair or replace the defective wiring. Go to Returning the Machine to Service (page 20) and follow the steps listed.
  • Page 43 There are 3 procedures in this section that you must accomplish as part of replacing a TEC-2402 controller. Note: Depending on troubleshooting that has been accomplished, some steps in these 3 procedures may already be done. Use Toro DIAG to save the machine timers and counters file out of the original TEC. (page 19)
  • Page 44 Replace the TEC-2402. (page 20) Use Toro DIAG to program the TEC, and then restore the TD2 file. (page 20) Duplicate the operation of the machine when the fault occurred with the original primary controller. The fault no longer Go to Returning the Machine to Service (page 20) and follow the steps listed.
  • Page 45 Electrical Diagram g364566 Figure 34...

  • Page 46: Fault 5 Communication

    Fault 5 Communication InfoCenter Display: Communication Fault Fault Description This fault is reported when the TEC-2402 controller never establishes or loses communication with the controller in the motor. Circuit Description There are 4 controllers located throughout the electrical system—the TEC-2402, the InfoCenter, the battery controller, and the electric motor.
  • Page 47 Pass The battery charge indicator shows at least one full block. Go to Step 3. Fail The battery charge indicator does not show at least one full block. Move the key switch to the O position. Disconnect the battery. Refer to Connecting and Disconnecting the Battery (page 14).
  • Page 48 Step 4: Test the CAN bus wiring in harness connector P20. Use a multimeter to test the resistance between the following pair of locations: Wire Expected Location Harness Connector Connector Graphic Color Reading Main Yellow 54 to 66 ohms Main Green Pass The CAN bus wiring tests passed.
  • Page 49 (Greensmaster® e1021/e1026 Service Manual or Greensmaster® eFlex® 1021 Service Manual). Step 7: Use Toro DIAG to program the replacement motor. Connect a PC with Toro DIAG software to the machine via a Toro DIAG Cable (Part No. 115-1944). Refer Toro DIAG–Quick Start (page 18).
  • Page 50 Electrical Diagram g364566 Figure 37...
  • Page 51 g363509 Figure 38...

  • Page 52: Fault 7 Motor Over Temperature

    Fault 7 Motor Over Temperature InfoCenter Display: Motor Over Temperature Fault Description This fault is reported when the motor controller senses that the temperature of the motor is to great. Circuit Description Temperature sensors monitor components inside the motor to protect them from high temperature damage. The motor controller begins reducing the current to the motor when the temperature of the motor reaches the overtemp region.
  • Page 53 Pass The battery charge indicator shows at least one full block. Go to Step 3. Fail The battery charge indicator does not show at least one full block. Move the key switch to the O position. Disconnect the battery. Refer to Connecting and Disconnecting the Battery (page 14).
  • Page 54 Connecting and Disconnecting the Battery (page 14). Move the key switch to the O position. Connect a PC with Toro DIAG software to the machine through a Toro DIAG cable (Part No. 115-1944). Refer to Toro DIAG–Quick Start (page 18).

  • Page 55: Fault 9 Internal Motor

    Fault 9 Internal Motor InfoCenter Display: Internal Motor Fault Fault Description The motor is monitored for speed and high/low voltage conditions. Conditions for Setting the Fault The motor detected an internal fault condition. Possible conditions for this fault are that sensor states are invalid or the motor is detecting an overvoltage/undervoltage condition.
  • Page 56 Connecting and Disconnecting the Battery (page 14). Move the key switch to the O position. Connect a PC with Toro DIAG software to the machine through a Toro DIAG cable (Part No. 115-1944). Refer to Toro DIAG–Quick Start (page 18).

  • Page 57: Fault 10 Motor Stalled

    Fault 10 Motor Stalled InfoCenter Display: Motor Stalled Fault Description The motor was at zero rpm for more than 3 seconds during operation. Conditions for Setting the Fault Heavy cutting conditions or a cutting unit malfunction is causing excessive motor drag, resulting in an overcurrent or overvoltage condition.
  • Page 58 Pass The battery charge indicator shows at least one full block. Go to Step 3. Fail The battery charge indicator does not show at least one full block. Move the key switch to the O position. Disconnect the battery. Refer to Connecting and Disconnecting the Battery (page 14).
  • Page 59 Connecting and Disconnecting the Battery (page 14). Move the key switch to the O position. Connect a PC with Toro DIAG software to the machine through a Toro DIAG cable (Part No. 115-1944). Refer to Toro DIAG–Quick Start (page 18).

  • Page 60: Fault 11 Software Incompatible

    The fault repeated. Go to Step 2. Step 2: Use Toro DIAG to reprogram the machine. Connect a PC with Toro DIAG software to the machine through a Toro DIAG cable (Part No. 115-1944). Refer to Toro DIAG–Quick Start (page 18).

  • Page 61: Fault 13 Internal Battery

    Fault 13 Internal Battery Important: While this fault is active, the battery management system (BMS) controller keeps the battery contactor open, not allowing battery power to go to the machine. As a result, the machine will not respond when the key switch is turned to the O position.
  • Page 62 TAC will send the battery output file to Samsung for analysis. Step 4: Follow the repair advice provided by Toro TAC. After Samsung analyzes the battery output file, they will give their results to Toro TAC. In turn, Toro TAC may provide additional repair advice to you.

  • Page 63: Fault 15 Software

    Fault 15 Software InfoCenter Display: Software Error Fault Description The TEC-2402 controller has detected an issue with reading the throttle sensor. Conditions for Setting the Fault The throttle sensor has failed or there is a problem with the wiring between the TEC-2402 and throttle sensor. Recommended Service Actions Step 1: Verify that the fault repeats.
  • Page 64 Pass The battery charge indicator shows at least one full block. Go to Step 3. Fail The battery charge indicator does not show at least one full block. Move the key switch to the O position. Disconnect the battery. Refer to Connecting and Disconnecting the Battery (page 14).
  • Page 65 g365074 Figure 45 g364928 Figure 44 1. Harness connector P01 3. TEC-2402 controller 2. Harness connector P02 1. TEC-2402 controller Use a multimeter and measure the resistance between the following pairs of locations: Wire Expected Location Harness Connector Connector Graphic Color Reading Main...
  • Page 66 Depending on troubleshooting that has been accomplished, some steps in these 3 procedures may already be done. Use Toro DIAG to save the machine timers and counters file out of the original TEC. (page 19) Replace the TEC-2402. (page 20) Use Toro DIAG to program the TEC, and then restore the TD2 file.
  • Page 67 Electrical Diagram g364632 Figure 46...

  • Page 68: Fault 16 Contactor

    Fault 16 Contactor InfoCenter Display: Contactor Fault Fault Description The main contactor remains energized due to a stuck coil or internal damage. Circuit Description The main contactor connects the battery to the electric motor. The TEC-2402 circuitry monitors the voltage at several locations to ensure that the contactor is working properly and the voltage is correct at all components for operation.
  • Page 69 g364041 Figure 47 1. Battery charge indicator Pass The battery charge indicator shows at least one full block. Go to Step 3. Fail The battery charge indicator does not show at least one full block. Move the key switch to the O position.
  • Page 70 g365258 Figure 48 1. TEC-2402 controller 2. Main contactor Step 4: Test the internal resistance of the main contactor. Verify that the key switch is in the O position. Disconnect the battery. Refer to Connecting and Disconnecting the Battery (page 14).
  • Page 71 Wire Expected Location Harness Connector Connector Graphic Color Reading Main Figure 49 Infinite Main Main 180 to 220 Figure 49 ohms Main Pass The resistance readings were good. Leave the key switch in the O position. Leave the battery disconnected. Refer to Connecting and Disconnecting the Battery (page 14).
  • Page 72 Verify that the key switch is in the O position. Disconnect the battery. Refer to Connecting and Disconnecting the Battery (page 14). Locate the TEC-2402 controller (Figure 48) and unplug harness connectors P01 and P02 (Figure 50). g365074 Figure 50 1.
  • Page 73 Depending on troubleshooting that has been accomplished, some steps in these 3 procedures may already be done. Use Toro DIAG to save the machine timers and counters file out of the original TEC. (page 19) Replace the TEC-2402. (page 20) Use Toro DIAG to program the TEC, and then restore the TD2 file.
  • Page 74 Electrical Diagram g364566 Figure 51...

  • Page 75: Fault 17 Throttle Sensor

    Fault 17 Throttle Sensor InfoCenter Display: Throttle Sensor Fault Fault Description The TEC-2402 controller has detected an issue with reading the throttle sensor. Conditions for Setting the Fault The throttle sensor has failed or there is a problem with the wiring between the TEC-2402 and throttle sensor. Recommended Service Actions Step 1: Verify that the fault repeats.
  • Page 76 Pass The battery charge indicator shows at least one full block. Go to Step 3. Fail The battery charge indicator does not show at least one full block. Move the key switch to the O position. Disconnect the battery. Refer to Connecting and Disconnecting the Battery (page 14).
  • Page 77 g365074 Figure 55 g364928 Figure 54 1. Harness connector P01 3. TEC-2402 controller 2. Harness connector P02 1. TEC-2402 controller Use a multimeter and measure the resistance between the following pairs of locations: Wire Expected Location Harness Connector Connector Graphic Color Reading Main...
  • Page 78 Depending on troubleshooting that has been accomplished, some steps in these 3 procedures may already be done. Use Toro DIAG to save the machine timers and counters file out of the original TEC. (page 19) Replace the TEC-2402. (page 20) Use Toro DIAG to program the TEC, and then restore the TD2 file.
  • Page 79 Electrical Diagram g364632 Figure 56...

  • Page 80: Fault 18 Traction Bail Sensor

    Fault 18 Traction Bail Sensor InfoCenter Display: Traction Bail Sensor Fault Fault Description Recommended Service Actions Step 1: Verify that the fault repeats. Safely stop the machine and all attachments. Shut off the machine by rotating the key switch to the O position.
  • Page 81 Pass The battery charge indicator shows at least one full block. Go to Step 3. Fail The battery charge indicator does not show at least one full block. Move the key switch to the O position. Disconnect the battery. Refer to Connecting and Disconnecting the Battery (page 14).
  • Page 82 g365074 Figure 60 g364928 Figure 59 1. Harness connector P01 3. TEC-2402 controller 2. Harness connector P02 1. TEC-2402 controller Use a multimeter and measure the resistance between the following pairs of locations: Wire Expected Location Harness Connector Connector Graphic Color Reading Main...
  • Page 83 Depending on troubleshooting that has been accomplished, some steps in these 3 procedures may already be done. Use Toro DIAG to save the machine timers and counters file out of the original TEC. (page 19) Replace the TEC-2402. (page 20) Use Toro DIAG to program the TEC, and then restore the TD2 file.
  • Page 84 Electrical Diagram g364632 Figure 61...

This manual is also suitable for:

0483104861

Table of Contents