ToroPCTM User`s Manual
Contents
1. A number of alternatives are available allowing the user to diagnose problems with the machine or ECU These options are displayed in a submenu which is described under the Toro Machine Diagnostics Menu section TOROPC Main Menu 10 ToroPC User s Manual Program and Read ECU Memory Menu P The ECU memory menu display and prompt is as follows The ECU memory menu gives the user a number of choices learning what software is currently in the ECU programming new software into the ECU and allowing calibration of the analog inputs The analog inputs to the ECU are capable of reading a voltage supplied through a variable resistor potentiometer In order for the ECU to know how to interpret how to scale the voltage reading it receives it must know the minimum and maximum readings of the potentiometer connected to the analog input With this option the user is able to allow the ECU to learn what these values are This option allows the user to erase the ECU memory Note this option is not required to be used even when reprogramming since option 4 Program new machine software from file erases memory as part of the programming function This option allows the user to program a new monitor to the ECU The monitor is the operating system for the ECU and is very rarely updated If this is done option 4 Program new monitor from file must also be done since programming a monitor erases the machine software This2. D sva EE a RERUM E EEEEQERRESAGE A 34 Compare Input to Functional State Requirements 2 000 c ce eee eee ee 35 Search Inputs for Functional State 3 0 0 0 0 teens 37 Display Input and Output Locations T 6 0 0 0 0 00 cee teens 39 ECU Probram status 127 2 sex ae ee kee Sed eee are eae woe eet hows xa eus 40 Activate Machine Program and Run J 0 tee eens 4 Reser the BC UTR ouo ceca 0 ta ofr qa NP BREST iir aden e aee Bar de ego rd EE Bee einn 42 Quit Dhis PEOP EO Ou serias ee xtd vd otov d ER Ead tui EM RH apo 43 IDiasnosmb VIDS uio E eR leit erar Rusia dud X durus pd dritto d 44 Languages other than English and Country Codes llle 46 Backing Up the Program Disk llslslllleeeee I I I 48 If Your Computer Has a Hard DiskK l llllleeeeeee rn 48 If Your Computer Does Not Have a Hard Disk llle 48 ToroPC User s Manual 1 Table of Contents This page is blank Introduction The program TOROPC is used to allow interaction with the Toro Electronic Control Unit ECU used on machines equipped with Toro AUTOMATED CONTROL ELECTRONICS ACE V This allows the user to perform diagnostics on a machine equipped with the ECU or to program new software into an ECU The program is menu driven which means that at each step you are prompted with the available choices At each point you need only to enter a minimum amount of information usually only one letter
3. each input switch Changing the enable switch from disable to enable should result in the Enable reels listing changing from Open to Closed for example This screen also allows the user to check the output state of each solenoid While in this display the machine will actually run if desired NOTE A more useful way to use the diagnostics is usually with the KEY SWITCH ON BUT THE MACHINE NOT RUNNING In this way the outputs will be turned on and off Toro Machine Diagnostics Menu T 24 ToroPC User s Manual as if the machine were running but the machine will not move Then as the inputs are changed the outputs will be turned on as required and the user can verify their performance Faults The Watch switches while running display will also display output faults if they occur In the example shown above the ECU has detected a fault F on the output for Solenoid S6 lower front rear This means that the output is either short circuited or open circuited The user is immediately directed to correct the electrical problem to S6 To reset a faulted output the ECU must be turned off by turning the key switch to the off position As long as the fault has been detected and not reset the ECU will not turn that output on again After the key is turned off and back on press ESC to back up the program and then reselect option Watch machine while running to restart the ECU NOTE You can use this option if
4. implement s to ground and lock the parking brakes before starting the program This option appears much like option 1 except that IN THIS OPTION THE MACHINE WILL FUNCTION NORMALLY For example you can start the engine operate cutting units etc Both inputs and outputs will be displayed on the PC Using this option is similar to both the inputs displayed and outputs displayed on the handheld diagnostic display tool ToroPC User s Manual 21 Toro Machine Diagnostics Menu T This option allows the user to have the program compare the input switch setting to a desired functional state The user is asked to select a desired function an a submenu and the program then compares the actual input settings to those required to allow that function to occur This option allows the user to capture and analyze data with a PC The display is the same as option 2 however a log of all input output changes is saved to disk for later review This option is used when the user wants to read the information from a Data Log controller and save it on a PC file or analyze it without saving it This option will tell the user which inputs are used for which switches and which outputs are used for which solenoids relays or other electrical loads This option will tell the user what program is in the ECU Toro Machine Diagnostics Menu T 22 ToroPC User s Manual Watch Switches Without Running Machine T 1 The watch switches without running ma
5. the diagnostic light on the machine is flashing By connecting the PC to the ECU on the machine without turning the ignition key switch off or changing a input switch the fault will be displayed If the machine is turned off the ECU will reset and not show the fault You can stop the engine by manually pushing the fuel stop lever on the diesel injection pump or engaging the parking brake then raising off the seat and pushing the traction pedal interlock circuit will shut off the engine ToroPC User s Manual 25 Toro Machine Diagnostics Menu T Filter Inputs by Functional States T 3 The Filter inputs by functional states display and prompt is as follows this screen is dependant upon the machine option selected upon program startup this example is of RM5100D Enter the number J to 72 in this example followed by CR This option allows the computer to compare the actual inputs to the inputs which are required to allow a certain machine function to occur For example if the machine will not lower the cutting units to mow the user could select choice 7 Toro Machine Diagnostics Menu T 26 ToroPC User s Manual The resulting display of inputs filtered by functional states is as follows This display again is machine specific this example is RM5100D NOTE After selecting this option if no data appears on the screen simply change any input switch i e move enable switch from enable to disable t
6. the file starting at the beginning until it finds the requested function occurring At that point the following display and prompt will appear In this instance the engine stopped because the Key Run switch was open either the key was turned OFF or the switch or wiring was bad Toro Machine Diagnostics Menu T 38 ToroPC User s Manual Search Inputs for Functional State 3 Selection of this option will cause the program to search through the data file to find a certain state of inputs Rather than the user being required to look at each record in the file the user can have the program look for the desired state This is very useful for the case of a machine which has intermittent shutdown problems for example The user would instruct the program to sort for engine kill as a state and the program would find each time that would happen and display the conditions at each of those times The display and prompt would be ToroPC User s Manual 39 Toro Machine Diagnostics Menu T The user should enter the number of the choice followed by a CR This instructs the program to search through the data file to find an occurrence of the requested state For example if the requested state was 12 Engine stops then the display and prompt might be In the example listed the user can look at the data record and learn that the High engine tem
7. 61 437 us English Italy 039 850 it Italian Japan 081 932 jp Japanese Kanji Latin America 003 850 la Spanish Netherlands 031 850 nl Dutch Norway 047 850 no Norwegian Portugal 35 850 po Portuguese Spain 034 850 sp Spanish Sweden 046 850 SV English Switzerland 041 850 Sg German United Kingdom 044 850 uk English USA 001 437 us English Note that the program defaults to USA English and no changes are required to cause the program to print English prompts to the screen To cause the program to display in another language the PC files config sys and autoexec bat must be changed Config sys must include Note Country code must be replaced by the number of the country code of the desired language and code page must be replaced by the number of the code page of the desired language cd is correct for portable computers with liquid crystal displays for a PC with an EGA or VGA display replace cd with ega Note If the files country sys and or display sys are in a subdirectory i e C DOS country sys rather than C country sys the subdirectory name must be included in the line in config sys Note Use of Japanese lanuage Kanji requires IBM PC DOS J4 0V Languages and Country Codes 48 ToroPC User s Manual Autoexec bat must include Note keyboard code must be replaced by the two letter code for the keyboard code of the PC keyboard layout and code page must be replaced by the number of the code page of the desired lang
8. Log OFF does not appear When the user exits from this option pressing ESC key the file which has been created is automatically saved under the file name which was specified at the beginning The user does not have to remember to save the file as it is done automatically Toro Machine Diagnostics Menu T 30 ToroPC User s Manual Watch Machine As It Ran 1 This option allows the user to look through a previously recorded file and observe what happened with the machine during that diagnostic session This option also allows the user to watch the machine with the PC connected and save the information to afile While the file is open and the machine is running each record of input and output information is saved to the file At the same time the inputs and outputs are displayed to the user The display and prompt will be example from a RM5100 D ToroPC User s Manual 31 Toro Machine Diagnostics Menu T Compare Input to Functional State Requirements 2 This option allows the user to look at a previously saved data file and to compare the information in the file to the settings which are required to allow a certain function to occur It is also useful for diagnosing a machine without the saved data file where the technician doing the troubleshooting is not certain what inputs are required for certain output functions to occur In this way the user may determine if the machine is being told to do th
9. Part No 92797SL Rev A ToroPC User s Manual AUTOMATED CONTROL ELECTRONICS Commercial Products The Toro Company 1992 1993 This page is blank FORM 92 797 SL Rev A ToroPC User s Manual This copyrighted software is for use on an IBM compatible PC and for use with the Toro ACE system ECU It is to be used by a trained technician only Loading and or using this software indicates your acceptance of the terms of the Software License Agreement stated below Software License Agreement 1 This software is a proprietary product of The Toro Company and is protected by U S and international copyright laws 2 You may make one 1 backup copy only 3 You can use the software only in conjunction with the Toro ACE system ECU 4 You may not sublicense rent or lease the software 5 Any decompilation recompilation or modification of the software not expressly authorized by Toro is unauthorized The Toro Company 1992 1993 All Rights Reserved Information in this document is subject to change without notice IBM is a registered trademark of International Business Machines Corporation MS DOS is a registered trademark of Microsoft Corporation This page is blank Table of Contents Iritroductotkbs 4 040052 bute eR orbe OCA S ed S dades Sedet d howe he utt ates utra ias Spp ee I LJETI ON Dd s ooi eiit P tri dedere dcin eiie dota i Dido eigene fuss 2 Gene SUA Ve Oi us sett ace aa te i ri
10. ans you are led through the program by a series of prompts The menu structure is as follows Some of these options may not be available to you depending upon your password Toro ECU Control Program Version 1 0a MM DD YY File name Machine machine description J Activate machine program and Run P gt Program and Read ECU Memory 1 Calibrate Analog Ports 2 Erase ECU Memory machine program 3 Program new monitor from file 4 Program new machine software from file 5 Display ECU program status 6 Display monitor revision Q Quit this program R Reset ECU T gt Toro Machine Diagnostics 1 Watch switches without running machine 2 Watch the machine while running 3 gt Filter inputs by functional states Choices of functional states depends on machine 4 gt Open Data file for PC capture Enter the file name 5 gt Analyze data from Data Log controller 1 gt Analyze a previously saved file Enter the file name 2 gt Read data from the Data Log controller from either 1 or 2 1 Watch the machine as it ran 2 Compare input to functional state requirements 3 Search inputs for functional state 4 Save file for analysis later 6 Display input and output locations 7 ECU program status ToroPC User s Manual 7 Introduction Moving Around in the Program Moving around in the program is accomplished by simply entering the letter or number of the option of choice In most
11. ator did Selection of this option will result in the following display and prompt The state of each of the inputs and outputs at that point in time is reported Stepping forward one record at a time will allow the user to watch exactly what the machine did while it was running The number is a timer which tells the user how many seconds before the end of the file that the currently displayed record was recorded This may be helpful to the diagnostic process if the user knows when the problem occurred This will display the latest record in time the one that just happened and the user will step backward in time through the data Toro Machine Diagnostics Menu T 36 ToroPC User s Manual Compare Input to Functional State Requirements 2 Selection of this option allows the user to filter the inputs to determine if they will allow a certain function to occur For example if the engine is unexpectedly stopping while being used the troubleshooting technician may choose this option and filter the inputs for an engine kill condition When this option is selected the following display and prompt will appear Enter the number of the function for which you desire to filter and a CR For this example of diagnosing and engine kill select option 72 ToroPC User s Manual 37 Toro Machine Diagnostics Menu T After the choice is entered the program will search through the data in
12. cases there is no need for a CR following the choice where a CR is required this manual reminds you to enter it The keyboard entries required to get to each selection are shown after the title of each section in parenthesis for ease of use To move back a menu or if a wrong choice is entered simply press the ESC key The ESC key will back up one level and you may return to the main menu by pressing ESC one or more times Introduction 8 ToroPC User s Manual TOROPC Main Menu The main menu display and prompt is as follows booo a a a a a a O O Machine machine description a d Activate machine program and Run _ P ProgamandReadMemoy 1 1 Q Quit this program 1 11 11 1 11 111 111 R Reset ECU 11 1 T gt Toro Machine Diagnostics nn a y MM DD YY is the current month day and year as read from the PC clock If this date or time is incorrect refer to your PC manual to correct it It is necessary to have this date and time correct since each file saved will have a date and time stamp so that looking at the files will tell you when they were saved This is necessary when using the Data Log controller to debug customer machines File name and Machine machine description are the name of the file and the description of the machine which were selected in the program startup stage If the wrong file was selected at s
13. certain that you select the correct file when you start The following message will be displayed this message is dependent upon the file chosen this example is for the RM5100D In order to program new machine software you must know the model number and serial number of the machine on which the ECU will be installed The model and serial number are located on the serial number plate on the machine At this point you must enter a valid model number followed by a CR The program will check the model number entered against the model number required for the software which you are attempting to load If you enter a valid model number the following message will appear You must enter a valid serial number The program will also check the serial number entered against the valid serial number range for the software which you are attempting to load ToroPC User s Manual 17 Program and Read ECU Memory Menu P After entering a valid model and serial number the following message will appear Pressing n allows the user to correct any mistake which may have been made and the user will again be asked to input the model and serial numbers Pressing q will cancel the attempt to program new machine software Pressing y will result in the following display zj O O go b As the program is loading the new software it will update the percent done The percent done is listed so t
14. chine display is as follows This display is different depending upon which machine option is selected at program startup this example is RM5100D The text will be different for different machines but the format is identical Toro controller Status Reelmaster 5100 D Revision 1 0 Open Not used Off Out of range lamp Open Not used Off Solenoid 8 S9 backlap Closed Run input from key Off Solenoid S2 rear reels Closed Traction neutral Off Solenoid S3 center lift lower Closed Seat switch Off Solenoid S4 wing lift lower Open High engine temperature Off Solenoid S5 rear lift lower Open Not used Off Solenoid S6 lower front rear Open Raise reels Off ETR hold Alt run Open Enable reels Off Solenoid VS1 front speed control Open Front reels down Off Solenoid VS2 rear speed control Open Front backlapping Off Solenoid S1 front reels Open Rear backlapping Off Solenoid S7 lift front rear Open Lower Mow reels Off Start Open 5 8 Cl 5 blade switch Off Preheat Open Front reel speed 3 Start Open Rear reel speed 3 HOC selection control Open Transmission speed 3 Not used Open Not used 3 Not used 3 Not used 0 Fri Dec 20 07 56 04 1991 1 Battery 13 7V This screen is used to check the performance of each input switch For example changing the enable switch from disable to enable should result in the Enable reels listing changing from Open to Closed When this option is selected the machine will not run and all of the outputs will a
15. del and serial number are listed for information as well as a software comment and the total number of times the ECU has been programmed Toro Machine Diagnostics Menu T 42 ToroPC User s Manual Activate Machine Program and Run J The ECU is designed with an operating system which is called the Monitor In addition to the Monitor it has a machine application program which is the software which makes the ECU know what machine it is on and how to control that machine When the ECU is powered up turned on it must be told whether or not to run the machine program The ECU is instructed to run the machine program by having the loopback connector on the 6 pin serial connector on the machine wiring harness If this connector is not connected the machine application software program will not run This means the machine will not operate without the loopback connector However when the PC is connected to the ECU during the use of TOROPC the loopback connector must be removed since it is connected via the same serial port connector Thus if the PC is connected when the key is off the machine will not operate when the key is turned on If you desire to run the machine with the PC connected selecting the option J Activate machine program and run will cause the ECU to start running the machine application program to allow the machine to operate Some of the other options in the program TOROPC will automatically issue the J Activate mach
16. drive you would do these commands C Scd toropc lt CR gt C TOROPC gt torope lt CR gt NOTE ANSI SYS must be in your config sys file If Your Computer Does Not Have a Hard Disk If you do not have a hard drive on your PC you will want to make a copy of the Toro program disk There are two choices 1 making a bootable copy the most useful choice or 2 making a plain copy the easiest choice To make a bootable copy Insert a blank disk into the disk drive C gt format a lt CR gt follow instructions for formatting C gt sys a CR puts DOS on the disk C gt copy command com a X CR puts command table on disk C gt copy ansi sys a X CR puts the file on disk C gt copy keyboard sys a X CR puts the file on disk Backing Up the Program Disk 50 ToroPC User s Manual C gt copy country sys a CR puts the file on disk Insert the MS DOS Operating System diskette came with the PC into the disk drive C gt copy a display sys b lt CR gt this will copy the file from the MS DOS disk to the new disk whenever you are prompted for disk a insert the MS DOS disk whenever you are prompted for disk b insert the new disk C gt copy a Mcd cpi b CR same as above Insert the Toro program disk in the disk drive C gt copy a b lt CR gt this will copy all of the program disk to the new disk whenever you are prompted for disk a insert the Toro disk whenever you are promp
17. e one which does not already exist may be opened and used to save data from the debugging session or an old file one which already exists may be opened and the data read from that The program will automatically add the MDD to the end of the entered file name This allows files generated with this option to be distinguished from all other files If the file already exists the message and prompt will be If O is chosen the old file will be destroyed and a new file created saving the data which is being generated while the user is diagnosing the machine If R is chosen the old file will be read and the user will be able to analyze this previously saved information When R is chosen the display and prompt will be If you would like to review the file from beginning to end enter record number J CR This will allow you to review the file just as the machine ran If you know that the problem occurred just before the data was saved which is just before the end of the file then enter a number which is about 10 less than the number of records in the file This will allow you to skip the initial part of the file in which you are likely not interested If you know that the problem occurred just at the end of the file and you want to look through the file backwards enter the value XX CR This will allow you to begin at the end of the data Note that this may be confusing since the information is in backwards order from how
18. e desired function The display will be as follows The user should enter the number which corresponds to the desired function followed by a CR The program will then filter the data in the file to tell if the desired function is allowed or not If the desired function is not allowed the display will tell which switch is not set correctly to allow the desired function The display will be as follows this example is for lower mow for a RM5100D Toro Machine Diagnostics Menu T 32 ToroPC User s Manual The display will be as follows this example is for lower mow for a RM5100D In this example the Lower Mow reels was found to be in the wrong position to allow the desired function to occur This may be because the switch is set wrong operator error or because the switch is malfunctioning In any case the technician is directed to the exact switch which is the cause of the desired function not occurring ToroPC User s Manual 33 Toro Machine Diagnostics Menu T Analyze Data From Data Log Controller T 5 NOTE When the Toro PC program is first started a list of program files to choose from is shown see Page 4 You must select the program for the machine you are diagnosing not Data Log Controller This option is selected to extract the information which was previously saved in a Data Log controller while on a machine The Data Log controller may be accessed in two ways either while still connected to the machine or after
19. formation to the PC so that you can tell what software is in the ECU The following 1s an example of this display Display Monitor Revision Level P 6 This option will read the monitor revision level from the ECU and display that information to the PC so that you may tell what monitor revision is in the ECU The following is an example of this display Program and Read ECU Memory Menu P 20 ToroPC User s Manual Toro Machine Diagnostics Menu T The Toro Machine Diagnostics menu and prompt is as follows The Toro machine diagnostics menu gives the user a number of choices of how to approach the diagnostic session depending upon the information which the user needs to fix the problem The options are explained below This is the RECOMMENDED METHOD TO VERIFY THAT ALL INPUTS TO THE ECU ARE FUNCTIONING NORMALLY This option allows the user to watch the state of all input switches without running the application software With this option the machine will not run so the outputs will not turn on but the ECU and the PC will be aware of each input switch change Using this option is somewhat similar to looking at the inputs displayed on the handheld diagnostic display tool A CAUTION When this menu selection is made the machine will function normally For example you can start the engine operate cutting units etc To avoid personal injury sit on the seat at operator s station warn personnel to stay clear of machine lower
20. hat you can see that the program is working as it takes several minutes to load a new software file When the programming process is complete the following message will be added to the display Program and Read ECU Memory Menu P 18 ToroPC User s Manual If you do not enter a valid model number or valid serial number for the software which you are trying to load the following message will appear If you have selected the wrong file at the start of TOROPC and are trying to load a new application program TOROPC will not allow it due to the model and serial numbers being out of the range If you are in the Program new application from file option and discover you have selected the wrong file simply enter CR until the Zs everything ok Y or N or Q prompt appears and then select choice Q Then you may quit from the program and start over selecting the correct file If the program fails to program the ECU successfully a number of error messages may occur Some examples of error messages are If any error messages occur and programming is not completed successfully do the following steps 1 Quit from TOROPC 2 Turn the machine key switch OFF for 2 5 seconds and ON again 3 Start TOROPC again 4 Try again to program the ECU ToroPC User s Manual 19 Program and Read ECU Memory Menu P Display ECU Program Status P 5 This option will read the program from the ECU and display that in
21. he original in a secure location This way if a disk is damaged another copy can be made To use all options of ToroPC the disk must not be write protected This is because the save option requires saving a file to the disk 1 In order to use TOROPC it must be connected to a Toro product which is equipped with a Toro ECU part number 85 4400 via the special cable part number 85 4560 To connect the PC to the machine Turn the key OFF Find the 6 pin communication connector on the machine wire harness and carefully remove the loop back connector Connect the 6 pin end of the special cable to the communication connector on the machine and the 9 pin end of the special cable to the COMI port communication RS232 port on the PC e Loop back conn E 5 v re DB Electronic Control Unit ECU Sagar Ne Reelmaster 5100 D shown PC connected to machine 2 Turn the ignition key switch on the machine to the ON RUN position DO NOT start the engine 3 Turn on the PC and wait for it to boot start up After it has booted insert the Toro program disk into the disk drive 4 Type a CR Then type toropc CR ToroPC User s Manual 5 Introduction 5 The program will prompt you with Toro ECU Control Program Started c Copyright 1991 The Toro Company All Rights Reserved Enter Password You must enter a valid password followed by a CR or the program will not allow you to continue 6 The program will prom
22. ine program and run command when it is required so that after using the program the machine may operate normally with the PC connected even though you may have never issued the command yourself Selection of this option will result in the following message ToroPC User s Manual 43 Activate Machine Program and Run J Reset the ECU R This option allows the user to reset the ECU forcing the ECU to start over and verifying that communications are working between the PC and the ECU This option is normally selected after starting the program to verify communications The ECU may only be reset if it is not yet executing the machine application program If the ECU is executing application program and the reset command is issued the following message will appear If this message appears follow the instructions and attempt to reset again If the ECU is executing application program you must turn off the key switch and turn it on again in order to allow the program to reset the ECU If this message appears and you do not wish to reset the ECU simply press ESC If the command is successful in resetting the ECU the following message appears Reset the ECU R 44 ToroPC User s Manual Quit This Program Q This option is selected when the diagnostic session is completed and the user wishes to exit from TOROPC to either use the PC for other use or turn off the PC It is not recommended to turn off the PC while in the progra
23. it actually happened ToroPC User s Manual 29 Toro Machine Diagnostics Menu T If A is chosen the old file is kept and new information will be added on to the end of the old file This can get very confusing since it is very difficult to know where the old data ends and the new data begins so use this option with care If Q is chosen the program will cancel the attempt to open a data file This may be selected if the wrong file name is entered and the user does not wish to overwrite read or append the selected file After the file is opened and the data if any is read the following message and prompt will appear One of the options listed in this menu J or 2 must be selected to capture data It is also used to watch an old file The message tells that File filename MDD is the name of the file which was input by the user Note that the MDD is automatically appended by the program The message Source Machine indicates that the information data which goes into the file will come from watching what is happening on the actual machine This would be the case for opening a new file The message Source filename MDD indicates that the information which is being interpreted by the program is coming from the file which was opened The message Data Log ON indicates that the file is capturing saving the information to the file This would be the case when opening a new file When reading data from a file the message Data
24. it has been disconnected from the machine The Data Log controller is used to capture what happens on a machine usually in the field and is usually used to diagnose a machine which is experiencing intermittent failures or problems which are elusive to find If the Data Log is still connected to the machine locate the 6 position connector on the Data Log which has a loopback connector on it Remove the loopback connector and connect the adapter harness between the 6 pin connector and the PC and then turn on the machine key switch The machine key switch must be turned on to power the Data Log controller and allow extraction If the Data Log is not connected to the machine a battery must be connected to the Data Log to power it The harness allows the connection of a standard Toro walk power mower battery for this purpose Remove the loopback connector from the 6 position connector on the Data Log harness and connect the adapter harness between the 6 pin connector and the PC and then connect the battery after connecting the PC If the Data Log does not have power it will not respond to communication Note When done accessing the information in the Data Log be certain to replace the loopback connector on the 6 pin connector If this is not done the Data Log will not be able to collect information the next time it is connected to a machine To analyze data from the Data Log controller the display and prompt will be as follows If op
25. lways be listed as Off This option can be used to verify the correct performance of the analog inputs to the ECU Start and HOC selection control NOTE When the key is off the ECU will not be powered For example the Start input is shown as 3 in this display above When the key is in the run position this number must be low However when the key is turned to the start position this number must become larger Or for the example above turning the HOC selector while watching this screen should result in the number in front of HOC selection control changing ToroPC User s Manual 23 Toro Machine Diagnostics Menu T Watch Switches While Running T 2 A CAUTION When in this part of the program the machine will function normally For example you can start the engine operate cutting units etc To avoid personal injury sit on the seat at operator s station warn personnel to stay clear of machine lower implement s to ground and lock the parking brakes before beginning diagnostics The watch switches while running display is as follows this display is different depending upon which machine option is selected at program startup this example is RM5100D NOTE after selecting this option if no data appears on the screen simply move any input switch i e move enable switch from enable to disable to get the data to appear This screen is used for two functions the first is to check the performance of
26. m TOROPC When disconnecting the PC from the machine always replace the loopback connector on the machine to allow the machine to operate Selection of this option will result in the PC displaying the DOS prompt ToroPC User s Manual 45 Quit This Program Q Diagnosing Tips In order to use TOROPC it must be connected to a Toro product which is equipped with a Toro ECU part number 85 4400 via the special cable part number 85 4560 To connect the PC to the machine find the 6 pin communication connector on the machine wiring harness and carefully remove the loop back connector Connect the 6 pin end of the special cable to the machine and the 9 pin end to the COMI port communication RS232 port on the PC Reelmaster 5100 D shown PC connected to machine If Controller Diagnostic Light is Flashing On and Off The PC may be connected while the Controller Diagnostic Lamp on the machine 1s still blinking and without turning off the machine NOTE If the machine is turned off the ECU will reset and not show the fault You can stop the engine by manually pushing the fuel stop lever on the diesel injection pump or engaging the parking brake then raising off the seat and pushing the traction pedal interlock circuit will shut off the engine Once the PC is connected and in the program TOROPC choose option Toro machine diagnostics then Watch machine while running and simply move any switch to get the display to show The fault indicato
27. m status ToroPC User s Manual 15 Program and Read ECU Memory Menu P Program New Monitor From File P 3 The monitor is the operating system for the ECU and is not likely to change However in case it would need to be changed this menu selection will allow a new monitor version to be programmed When this option is selected the program automatically starts to reprogram the monitor It gives the following message At this point the program will check to see that the disk which you have inserted into the PC actually has a new monitor file on it If the program does NOT find a new monitor file or if the Toro ECU Monitor Program was not selected when starting ToroPC it will display this message If the program does find a new monitor file it will load the new monitor into the ECU It will display the following message At this point the new monitor is loaded NOTE after loading a new monitor it is necessary to load the machine software again even if the ECU had machine software loaded prior to the new monitor being loaded since the ECU is like new Follow the instructions for Program new machine software from file Program and Read ECU Memory Menu P 16 ToroPC User s Manual Program New Machine Software From File P 4 When this option is selected the program automatically starts to reprogram the ECU It will attempt to load the file which you selected when you started TOROPC Be
28. o start the data display This display will help isolate hydraulic problems from electrical problems ToroPC User s Manual 27 Toro Machine Diagnostics Menu T If the ECU finds an error in the inputs causing the requested function not to occur the display would look like this again this is a RM5100D example This display indicates to the user that the reason that the machine will not perform the requested function is that the Lower Mow switch is not in the correct position The switch may be set incorrectly or may be non functional but the user is directed to the Lower Mow switch to determine the malfunction in this example The user has the choice to either return to the previous menu or continue filtering the input switches by selecting a new machine state by which to filter Toro Machine Diagnostics Menu T 28 ToroPC User s Manual Open Data File for PC Capture T 4 This option is used to open a file in the PC to save information while doing diagnostic servicing or to read such a file at a later date This is different from using the Data Log controller and the resulting files should not be confused with the Data Log controller files Choosing this option will result in the following display and prompt The user must type in the name of a file into which machine operating information will be saved There are several choices of how to proceed A new fil
29. o the Operator s Manual for your machine if you are not sure what the minimum setting is ToroPC User s Manual 13 Program and Read ECU Memory Menu P The new prompt will be Following the prompt turn the knob clockwise to the maximum setting on the decal not as far as it will go this will not be as far as in the first step and then press any key At this point you are telling the ECU of the maximum setting not how far it will turn The prompt will be If you want to save the calibration enter E If you want to quit without saving any changes enter Q This is rarely used The prompt will be This confirms that you do not want to save any changes If you changed the calibration and want the change to be permanent you must save with E Program and Read ECU Memory Menu P 14 ToroPC User s Manual Erasing ECU Memory Machine Program P 2 Erasing the memory is not normally required since when the ECU is programmed the memory is erased as part of the programming process If this option is selected the prompt will be If n is entered the prompt will be If y 1s entered the display will be When the erasing process is complete this prompt will appear After erasing the application program from the ECU it must be programmed before it can be used on any machine To verify what application program is loaded in an ECU chose option Program and Read ECU Memory then option Display ECU progra
30. od a Bg a a hae hoa eed toa deb tous 3 Usine the Prota iii uem cote ed ES ere bM ODE o Ad REL de 5 Moving Around in the Program 6 eee rh 6 TOROPC VISIO fiu Vu te n xw tH E a eere Dot RH eae tah a o Lace RR Si y Overview of Main Menu Options 00 cnet eee eens 8 Program and Read ECU Memory Menu P 0 0 ccc ccc cece cece eee eee 9 Calibrating Analog Ports P 1 0 0 0 0 eee II 11 Erasing ECU Memory Machine Program P 2 0 0 20 0 ccc eee eens 13 Program New Monitor From File P 3 2 0 0 0 0 eee eee nee 14 Program New Machine Software From File P 4 0 00000 15 Display ECU Proeram Status P 5 secu ete eo Bae ods kA E ERE oe he Ree he anes 18 Display Monitor Revision Level P 6 0 0 ccc ee ee eee e 18 Toro Machine Diagnostics Menu T 0 0 0 cc eee rs 19 Watch Switches Without Running Machine T 1 2 0 een 21 Watch Switches While Running T 2 llle 22 Eaultscom uua sdb Re dedii ud T E vut E ee etic Ss Shee cna eee 23 Filter Inputs by Functional States T 3 0 0 0 ee een ee 24 Open Data Pale Tor PE Capture 1 4 srt boe be Behe br De net Ud 24 Watch Machine As It Ran CD a ei db e rbd ve ree pL ES 20 Compare Input to Functional State Requirements 2 00 c cece eee 30 Analyze Data From Data Log Controller T 5 0 0 0 0 0 cee 32 Save File For Analysis Later 4 is orco cones cation athe Vee Ee Pn 33 Watch the Machine as It Ran
31. option allows the user to program new machine application software to the ECU This option would be selected to program a new ECU installed from service parts or to update a field unit after adding new options or when an improved version of software becomes available ToroPC User s Manual 11 Program and Read ECU Memory Menu P This option will read the current application program information from the ECU and display it on the PC screen In this way the user can learn what software is currently installed in an ECU This option will read the current monitor revision from the ECU and display it on the PC screen Program and Read ECU Memory Menu P 12 ToroPC User s Manual Calibrating Analog Ports P 1 The Calibrate Analog Ports menu is as follows This menu depends upon the specific machine software chosen and this example is from the RM5100D If you want to calibrate an analog input note the number of the analog channel and enter C The prompt will be Follow the prompt and enter the channel number followed by CR The prompt will be Following the prompt turn the knob clockwise to the maximum position as far as it will go and press any key The new prompt will be Following the prompt turn the knob counterclockwise to the minimum setting on the decal not as far as it will go and then press any key At this point you are telling the ECU of the minimum setting not how far it will turn Refer t
32. or number This makes the program more easily used by those who may not be good typists and those who use it infrequently There are two types of choices on the menus One type is indicated by two dashes following the menu choice i e This indicates that choosing this option will cause the requested action to occur The second type of menu choice is indicated by an arrow following the menu choice i e P gt This indicates that a submenu of choices will be displayed when this option is selected ToroPC User s Manual 3 Introduction Definitions Certain words are used in this manual which may be unfamiliar to the user Some of these words and their definitions are listed here as a quick reference NOTE Information which will be displayed on the PC will be shown like this NOTE Anything that you must enter into the PC type on the PC keyboard will be in bold italics UPPER and lower case letters may be used interchangeably within the program except for the password which must be entered in the correct case CR in this manual means pressing the ENTER or RETURN key on the PC keyboard ESC in the manual means pressing the key labelled ESC which is usually on the left top of the keyboard PC refers to the personal computer on which the program TOROPC is run DOS refers to the disk operating system which is supplied on the PC TOROPC is designed to run on any IBM or compatible PC and requires only an RS232 communica
33. ormation is lost If the information is inadvertently lost simply operate the machine as normal until the problem occurs again then save by pressing the switch 6 Turn off the key switch and remove the Data Log Connect the loop back connector on the machine wiring harness Connect the Data Log controller to the PC and with TOROPC select option Toro Machine diagnostics then option Analyze data from Data Log controller to read the information into the PC Analyze the data to determine the problem NOTE An alternate power source is required for the Data Log when it is connected to the PC Battery 55 7520 and Charger 92 1743 or 22 4710 for Toro walk power mowers are recommended LE xri La So siz Data Log Controller amp Data Log controller connected to machine Data Log controller connected to PC NOTE If the machine will not operate check to be certain that the loop back connector is installed on the 6 pin communication connector near the machine ECU ToroPC User s Manual 47 Diagnosing Tips Languages and Country Codes TOROPC is configured to print out text in the language of the user automatically If you desire a language other than English refer to the table below Country or location Country code Code page Keyboard code Language Belgium 032 850 be Dutch Canada French 002 863 cf French Denmark 045 850 dk Danish Finland 358 850 su English France 033 850 fr French Germany 049 850 gr German International English 0
34. perature input is closed indicating that the machine is overheating or the sensor is malfunctioning and has shut down because of that The program will search through the data file to find the first occurrence of that state If the first occurrence of that state does not appear to explain the problem then choose option S Continue search to instruct the program to continue looking through the data file to find that state again In this way the user can locate the data record associated with the problem quickly and determine the cause of the problem Toro Machine Diagnostics Menu T 40 ToroPC User s Manual Display Input and Output Locations T 6 The display input and output locations display is as follows This display is dependent upon which machine option was selected at program startup This example is RM5100D This display informs the user of which inputs outputs and analog inputs are located where on the wiring connector This display is used to check which inputs and outputs exist for a given machine ToroPC User s Manual 41 Toro Machine Diagnostics Menu T ECU Program Status T 7 The ECU program status display is as follows This display is dependent upon which software is loaded in the ECU which is being interrogated This example is RM5100D This display informs the user of the software which is loaded into the ECU The software revision level date programmed mo
35. pt you with for example Program files to choose from 1 854690 Reelmaster 5100 D Revision 1 0 production RM5100 D 2 854770 Reelmaster 223D Revision 1 0 field refit RM223 D 3 654630 Reelmaster 223D Revision 2 0 production RM223 D 4 854710 Data Log Controller Revision 1 0 service tool Enter number of your choice At this point you must chose the version of software with which you will be working and enter the number from J to 4 in this example of the desired choice and CR If you choose the wrong alternative the diagnostic prompts will not correspond to the actual machine information and or it will not be possible to program the ECU NOTE Selection 4 in this example is used only for programming the Data Log Controller You must select a machine program such as J in this example to analyze data from the Data Log Controller when doing machine diagnostics 7 The program will prompt you with depending upon which file you select in step 5 this example is for the RM5100D Toro ECU Control Program Version 1 0a 01 18 92 File 854690 Machine Reelmaster 5100 D Version 1 0 J Activate machine program and Run P gt Program and Read ECU Memory Q Quit this program R Reset ECU T gt Toro Machine Diagnostics Enter your choice You may select the letter which corresponds to whichever option you wish to use Introduction 6 ToroPC User s Manual Using the Program The program is menu driven which me
36. r will appear next to the faulted output If Controller Diagnostic Light is NOT Flashing Turn key switch OFF and connect the PC to the machine Once the PC is connected and in the program TOROPC select option Toro machine diagnostics then option Watch machine without running machine Move input switches and watch to see that the display shows that they change If the display does not show that the switch changes either the switch or the wiring to the switch is faulty Diagnosing Tips 46 ToroPC User s Manual To Find an Intermittent Problem Install the Data Log controller on the machine 1 Turn OFF key switch Find 6 pin communication connector on machine wiring harness and carefully remove loop back connector Connect 6 pin connector on Data Log to 6 pin connector on machine wiring harness 2 Put Data Log in a secure location on machine such as in toolbox on platform etc and fasten in place securely to prevent damage due to Data Log falling off the machine 3 Turn key switch to RUN position The green light on the Data Log will illuminate to indicate that the Data Log is connected and operating 4 Operate machine as normal until intermittent problem occurs DO NOT turn off key switch after problem has occurred 5 Press the switch on the Data Log The red light on the Data Log will illuminate to indicate that the Data Log has stored the information The switch MUST be pressed before the key switch is turned off or the inf
37. t dated correctly and to avoid confusion later If you are using the program with displays in some other language than English it is very advisable to create a bootable copy of the program disk This allows the config sys and autoexec bat files to be on the boot disk and makes starting the program much easier ToroPC User s Manual 51 Backing Up the Program Disk Backing Up the Program Disk 52 ToroPC User s Manual ToroPC User s Manual 53 Backing Up the Program Disk Backing Up the Program Disk 54 ToroPC User s Manual This page is blank Commercial Products The Toro Company
38. tartup you must exit the program and restart selecting the correct file If not the diagnostic prompts and input and output listings will be incorrect for the machine on which the user is working and it will not be possible to program the ECU There are two types of choices on the menus One type is indicated by two dashes following the menu choice i e This indicates that choosing this option will cause the requested action to occur The second type is indicated by an arrow following the menu choice i e P gt This indicates that a submenu of choices will be displayed when this option is selected ToroPC User s Manual 9 TOROPC Main Menu Overview of Main Menu Options In order for the machine to operate the machine program must be running If the PC was connected or the loopback connector disconnected when the key switch was turned on the machine program will not be running In order to activate the machine program select this option A number of alternatives are available including programming the ECU and reading what software is currently loaded in the ECU These options are displayed in a submenu which is described under the Program and Read Memory Menu section This option allows the user to quit using the program and exit to the DOS prompt on the PC This option allows the user to reset the ECU forcing it to start over and verifying that communications are working correctly between the PC and the ECU
39. ted for disk b insert the new disk both disks go into the same disk drive slot Create the config sys and autoexec bat files as described above and save them on the new disk If you make a bootable copy you may insert the disk into the disk drive before turning on the PC and then simply type toropc lt CR gt to start the program To make a plain copy C format a lt CR gt follow instructions for formatting Insert the Toro program disk in the disk drive C gt diskcopy a a CR if the computer has one disk drive or C gt diskcopy a b CR if the computer has two disk drives This will copy all of the program disk to the new disk If you make a plain copy you must turn on the PC and then insert the program disk and type a CR then toropc lt CR gt to start the program The advantage to making a bootable copy is this If the PC battery goes dead on a battery powered laptop computer such as the Toshiba TIOOOSE the PC will forget that you changed the config sys file to allow the display control to function correctly for ToroPC If it forgets you must again go through the process of changing the config sys file However if you make a bootable disk the new config sys file is on the disk and the PC boots from that disk so it knows to do the right thing even if the battery has gone dead in the mean time If the battery goes dead it is important to check and set the system date and time on the PC to be certain that files ge
40. tion J is chosen the prompt will be The user must enter the file name and CR which already must exist which contains previously saved data from the machine This file may have been created from previously reading of the Data Log controller Toro Machine Diagnostics Menu T 34 ToroPC User s Manual If the file does not exist the message will be If option 2 is chosen the display will be After the information is completely read in the following display and prompt will appear Enter the number of your choice Save File For Analysis Later 4 Often the user will save the file so that it can be called up later if desired If the option to save the file is chosen the prompt will be At this point enter your desired file name and a CR If the file already exists the message and prompt will be If Y is chosen the old file will be destroyed and a new file created If N 1s chosen the attempt to save the file will be aborted and the old file will remain The cursor moves to Enter the file name to allow entering a new filename ToroPC User s Manual 35 Toro Machine Diagnostics Menu T Watch the Machine as It Ran 1 The option watch machine as it ran will allow the user to step through the data in the Data Log file either forward or backward to examine the state of each input and each output every time one of the inputs or outputs changed This allows understanding exactly what the machine and oper
41. tion port configured as COMI a 3 5 inch low or high density floppy disk drive and DOS 3 1 or higher ECU refers to the Toro designed electronic control unit 85 4400 which is used as the machine controller on Toro products equipped with AUTOMATED CONTROL ELECTRONICS ACE Record is used with regard to the Data Log information All of the input settings all of the output settings and any fault indications for one moment of time are saved as one record When one of the settings changes a new record is saved Fault means that the controller has detected either a short circuit or open circuit condition on one of the outputs and has flagged that output as having a fault Functional state refers to one of the different machine functions which may be permitted if the required inputs are met For example START or engine cranking is one functional state LIFTing the cutting units is another functional state Introduction 4 ToroPC User s Manual Getting Started A CAUTION To avoid the possibility of personal injury before using TOROPC on a machine Certain machine functions such as lowering implement etc may occur even when the engine is not running To avoid personal injury be certain to lower implement s completely to the ground and lock the parking brakes before starting the program NOTE Before using the program make a backup copy of the program disk see Backing Up the Program Disk Use the backup and save t
42. uage lcd is correct for portable computers with liquid crystal displays for a PC with an EGA or VGA display replace cd with ega For example to cause the program to display in German for Germany the config sys file would look like this And the autoexec bat file would look like this for a PC with a German layout keyboard If you need help to change these files refer to the MS DOS manual with your PC Whenever the PC finds the country code in the Config sys file it will automatically print the prompts and messages in that language In order to change the language it is necessary to change the Config sys file and reboot the PC ToroPC User s Manual 49 Languages and Country Codes Backing Up the Program Disk It is recommended that you make a copy of the program disk to avoid the risk of being without the program if the disk should be damaged in some way There are a number of ways to do this depending upon what PC configuration you have If Your Computer Has a Hard Disk If you have a PC with a hard disk drive you will want to create a directory for just the Toro diagnostic and application program files Then you will want to copy the program disk onto the hard disk to the directory you created For example Insert the Toro program disk in drive A C md toropc lt CR gt to create a directory named toropc C gt copy a c MoropcV CR to copy on the files from the Toro program disk Then to use TOROPC from the hard
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