Toro Using Diagnostic ACE Reelmaster 5100 D 5300 D TM Commercial Products 92800SL Rev B I

Using the Diagnostic ACE Reelmaster ® 5100-D/5300-D TM Commercial Products Part No. 92800SL, Rev. B If the machine malfunctions, check the green Controller Diagnostic Lamp. If the lamp is ON, with ignition key switch in ON position, the electronic control unit (ECU) is functioning normally. If the lamp is blinking, the controller has detected a problem in the electrical circuit. The lamp will stop blinking and automatically reset when the key switch is turned OFF.

If Controller Diagnostic Lamp is BLINKING ON and OFF : 1. ECU has detected an output with a short circuit. 2. ECU has detected an output with an open circuit. Use Diagnostic ACETM to find which output is malfunctioning. NOTE: If the green Controller Diagnostic Lamp is blinking on and off, connect the Diagnostic ACE, without turning the key switch off, then toggle to “OUTPUTS DISPLAYED “. The blinking LED on the Diagnostic ACE will indicate which output is faulty. To stop the engine without turning off the key switch, use the manual fuel stop lever on the injection pump or grasp the steering wheel, raise yourself up off the seat and lightly push the traction pedal so the interlock circuit stops the engine. If the controller diagnostic lamp is OFF : 1. ECU is not powered on. 2. Loop-back connector is not attached. 3. Diagnostic lamp is burned out. 4. ECU is not functioning correctly. Check electrical connections, input fuses and diagnostic lamp to find malfunction. Make sure loop-back connector is secured to wire harness connector. NOTE: Part number under CONTROLLER DIAGNOSTIC LAMP is the decal part number; not the lamp. The lamp part number is 85-4491 Controller Diagnostic Lamp Using the Diagnostic ACE (RM 5100-D/5300-D) Page 1 1. Park machine on a level surface, engage parking brake, lower cutting units and turn ignition key switch OFF. 2. Carefully disconnect loop-back connector from wire harness. 3. Connect Diagnostic ACE to connector on wiring harness (where loop-back connector was removed). Disconnect loop-back connector and connect Diagnostic ACE Display Installing Diagnostic ACE Using the Diagnostic ACE (RM 5100-D/5300-D) TM Page 2 1. After connecting Diagnostic ACE and turning key switch ON, move any input switch, such as the Enable/Disable switch, to get the Diagnostic ACE display to function. DO NOT start the engine. CAUTION: To prevent possible personal injury, lower cutting units before working on machine. If ignition key switch is on, cutting units will lower when joystick is moved to lower/mow position. NOTE: After doing step 1, the “INPUTS DISPLAYED ” LED will be on. This indicates that the ECU and Diagnostic ACE are operating properly. If the green Controller Diagnostic Lamp on the machine comes on, but the “INPUTS DISPLAYED ” LED does not come on, there is a problem with the Diagnostic ACE. 2. If necessary, push input-output toggle button so “INPUTS DISPLAYED ” LED is on. Do not hold the button down. NOTE: Red text on overlay decal refers to input switches and green text to outputs. 3. The Diagnostic ACE will illuminate the LED associated with each input when that input switch is closed. Check each switch (input) by opening and closing the switch, then verifying that the corresponding LED goes on and off as the switch position is changed. For example, with traction pedal in neutral, “TR. NEUTRAL ” LED should be on, then go off, when traction pedal is moved out of neutral. Check function for each switch that can be changed manually. 4. If a switch is closed and corresponding LED does not go on, check all wiring and connections to switch and/or test switch with a continuity tester or ohm-meter. Replace any faulty switches and repair or replace any faulty wiring or connectors. Push INPUT-OUTPUT TOGGLE so INPUTS DISPLAYED light is ON. Checking INPUTS Using the Diagnostic ACE (RM 5100-D/5300-D) Page 3 INPUT ­ KEY RUN Using the Diagnostic ACE (RM 5100-D/5300-D) Page 4 INPUT ­ TR. NEUTRAL Using the Diagnostic ACE (RM 5100-D/5300-D) Page 5 INPUT ­ SEAT SWITCH Using the Diagnostic ACE (RM 5100-D/5300-D) Page 6 To test, disconnect and ground terminal to engine block. INPUT ­ ENGINE HOT Using the Diagnostic ACE (RM 5100-D/5300-D) Page 7 INPUT ­ RAISE Using the Diagnostic ACE (RM 5100-D/5300-D) Page 8 INPUT ­ ENABLE Using the Diagnostic ACE (RM 5100-D/5300-D) Page 9 INPUT ­ FR. UNIT DN. Using the Diagnostic ACE (RM 5100-D/5300-D) Page 10 INPUT ­ BACKLAP FR. Using the Diagnostic ACE (RM 5100-D/5300-D) Page 11 INPUT ­ BACKLAP RR. Using the Diagnostic ACE (RM 5100-D/5300-D) Page 12 INPUT ­ LOWER/MOW Using the Diagnostic ACE (RM 5100-D/5300-D) Page 13 INPUT ­ 5/8 (ON = 5) Using the Diagnostic ACE (RM 5100-D/5300-D) Page 14 Use a piece of wood to manually turn the reel. INPUT ­ F. REEL SPD. Using the Diagnostic ACE (RM 5100-D/5300-D) Page 15 Use a piece of wood to manually turn the reel. INPUT ­ R. REEL SPD. Using the Diagnostic ACE (RM 5100-D/5300-D) Page 16 Release parking brake and move machine a small distance (1 to 2 inches). INPUT ­ TRAC. SPD Using the Diagnostic ACE (RM 5100-D/5300-D) Page 17 1. Remove overlay decal from front of Diagnostic ACE so numbers “0 ” to “17 ” next to LED’s are visible. 2. Set ECU to special diagnostic mode: A. Turn ignition key switch OFF. B. Raise seat and set Backlap switch to FRONT backlap position. C. Set Enable/Disable switch to DISABLE position. D. Hold Lower/Mow-Raise lever in RAISE position and turn ignition key switch to ON position. Release Lower/Mow-Raise lever. 3. Slowly turn HOC Selector. LED’s on Diagnostic ACE will show how ECU is enterpreting HOC Selector. LED labeled “0 ” should be illuminated when knob is pointed to “A “, and LED labeled “15 ” should be illuminated when knob is pointed to “P “. Table below shows when machine is set for correct clip. It is not necessary for knob to line up with letters on decal for machine to function normally. Diagnostic ACE Display LED 0 11 12 13 14 15 HOC Selector Position A B C D E F G H I J K L M N O P 0.25 0.30 0.35 0.40 0.45 0.50 0.55 0.60 0.65 0.70 0.75 0.80 0.85 0.90 0.95 8 Blade Height-of-cut Inches Full Speed ­ DO NOT start the engine. The appropriate output LED’s should illuminate to indicate that the ECU is turning on that function. If any output LED is FLASHING ON and OFF, this indicates an electrical problem with that OUTPUT. To reset a flashing LED, turn the key switch OFF, then back ON. If no output LED’s are flashing on and off, but the correct output LED’s do not illuminate, verify that the required input switches are in the necessary positions to allow that function to occur. If input switches are correct, but output LED’s are not correct, this indicates a controller malfunction. If output LED’s are core Front reel speed Rear reel speed Front reels On/Off Rear reels On/Off Lift / Lower front wing cutting units Lift / Lower center cutting unit Lift / Lower rear cutting units Lower any cutting unit Lift any cutting unit Backlap Backlap OUTPUT ­ VS1 Using the Diagnostic ACE (RM 5100-D/5300-D) Page 28 Solenoid VS1 VS2 S1 S2 S3 S4 S5 S6 S7 S8 S9 Power Wire Color Function Orange/Black Orange/White Pink/Blue Brown/White Orange/Blue Yellow/Black Yellow/White Orange/Red Yellow/Blue Black/Red Brown/White Front reel speed Rear reel speed Front reels On/Off Rear reels On/Off Lift / Lower front wing cutting units Lift / Lower center cutting unit Lift / Lower rear cutting units Lower any cutting unit Lift any cutting unit Backlap Backlap OUTPUT ­ VS2 Using the Diagnostic ACE (RM 5100-D/5300-D) Page 29 Solenoid VS1 VS2 S1 S2 S3 S4 S5 S6 S7 S8 S9 Power Wire Color Function Orange/Black Orange/White Pink/Blue Brown/White Orange/Blue Yellow/Black Yellow/White Orange/Red Yellow/Blue Black/Red Brown/White Front reel speed Rear reel speed Front reels On/Off Rear reels On/Off Lift / Lower front wing cutting units Lift / Lower center cutting unit Lift / Lower rear cutting units Lower any cutting unit Lift any cutting unit Backlap Backlap OUTPUT ­ S1 Using the Diagnostic ACE (RM 5100-D/5300-D) Page 30 Solenoid VS1 VS2 S1 S2 S3 S4 S5 S6 S7 S8 S9 Power Wire Color Function Orange/Black Orange/White Pink/Blue Brown/White Orange/Blue Yellow/Black Yellow/White Orange/Red Yellow/Blue Black/Red Brown/White Front reel speed Rear reel speed Front reels On/Off Rear reels On/Off Lift / Lower front wing cutting units Lift / Lower center cutting unit Lift / Lower rear cutting units Lower any cutting unit Lift any cutting unit Backlap Backlap OUTPUT ­ S7 Using the Diagnostic ACE (RM 5100-D/5300-D) Page 31 Start relay OUTPUT ­ START Using the Diagnostic ACE (RM 5100-D/5300-D) Page 32 Glow relay OUTPUT ­ PREHEAT Using the Diagnostic ACE (RM 5100-D/5300-D) Page 33 Electrical Schematic PIN NO’S. 1 2 3 A B C D E F G H I J K EXAMPLE: See 3A on Controller Diagram

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