Related Manuals for Ryobi RY48130 Series
Summary of Contents for Ryobi RY48130 Series
- Page 1 SERVICE CENTER ELECTRICAL SYSTEM TROUBLESHOOTING AND TESTING GUIDE SERIES RY48130/131 RIDING LAWN MOWERS Confidential & Proprietary – Property of Techtronic Power Equipment – DO NOT COPY or DISCLOSE...
-
Page 2: Table Of Contents
TABLE OF CONTENTS • WARNING • Testing Primary Blade Deck Motor Controller Testing • Secondary Blade Motor Controller • DMM and Other Tools • Controller layout • Component Locations Main Battery • Testing Primary and Secondary Deck Motors • Connection Testing Main Fuse •... -
Page 3: Warning
WARNING THIS MATERIAL INTENDED ONLY FOR TECHNICIANS TRAINED IN ELECTRICAL REPAIR. Technicians should wear personal protective equipment, such as rubber gloves and safety glasses. Exercise caution at all times. Dangerous voltages /currents are present. This manual assumes knowledge of basic electrical equipment such as DMM (Digital Multi Meter) and clamping Amp Meter to measure voltage, current, resistance, continuity, and diodes. - Page 4 OVERVIEW The RYOBI riding mower is completely electrical, consisting of 3 brushless motors and a controller for each motor: • A brushless motor and controller for each of the 2 blades • A brushless motor/controller to drive each rear wheel. These Drive Motor Controllers also contains the “brains”...
- Page 5 BRUSHLESS MOTORS Brushless motors operate quite differently than brushed motors, which you may be used to (i.e. a starter motor). A brushed motor can be quickly tested by applying voltage to the two terminals. Brushless motors can be recognized by 3 wires. These 3 wires require a controller to operate them and to turn on these 3 phases in a precise fashion similar to spark plugs firing a 3-cylinder gas motor.
- Page 6 USING THIS DOCUMENT blue text can be clicked on to jump directly to the page of that topic. (This document is also printer-friendly, so you can have it in front of you while servicing the mower.) If you print this document, we recommend printing it in landscape mode and in color Block Diagram shows the general flow to visualize how the mower is connected and a chart shows general symptoms/solutions for repairs.
- Page 7 TOOLS NEEDED Sockets and Wrenches Torx Screwdrivers 8 mm Cross tip 10 mm Flat blade 13 mm 14 mm 15 mm 17 mm 19 mm Confidential & Proprietary – Property of Techtronic Power Equipment – DO NOT COPY or DISCLOSE...
- Page 8 BLOCK DIAGRAM AND CONTROL FLOW Batteries Control Panel Head Cruz Light Lights Gage Fuel Main gage Fuse 48V to 12V Accelerator Charge (DC to DC) Relay Port/lockout/ Fuse converter Switch battery temp Brake Switch Important: Primary and secondary Drive Primary Secondary have A communication link.
- Page 9 TROUBLESHOOTING: GENERAL • Follow the Block Diagram on the previous page. • Check for loose/bad connections. • Test the easiest components first. (power, key switch, DC-DC converter) • Mower should be fully charged (if possible) • Before disassembly: – Attempt to charge mower (note any error LED indications) –...
- Page 10 TROUBLESHOOTING: DETAILED Use the block diagram as a guide Also refer to the beep diagnostic code chart 1. Verify the battery charger is functional by plugging it into the charge port on the back of the mower and let the mower fully charge.
- Page 11 TROUBLESHOOTING: DETAILED CONT… 8. If the mower will not drive a. Make sure the seat switch is functional and activated. b. Test the angular transducers. Replace if necessary. c. Test the neutral switches. Replace if necessary. d. Test the brake switch.
- Page 12 DIGITAL MULTIMETER (DMM) Typical DMM (Fluke 87). Note the dial is set to the “DIODE” function. this function will be used in many of the following procedures. Also note where the and black jacks of the test leads are connected to the DMM. If you are unfamiliar with a DMM, please read the section Electronics Tips for the Mechanical Small Engine Technician Confidential &...
- Page 13 COMPONETS LOCATION Charge port Seat Access panel Switch (under seat) Drive DC-DC Controller converter Beeper Primary/secondary Blade controllers Angular Transducer Brake Switch (FWD/REV) Headlights Confidential & Proprietary – Property of Techtronic Power Equipment – DO NOT COPY or DISCLOSE...
- Page 14 MAIN BATTERY CONNECTION The main battery disconnect is located directly under the seat access cover. It may take considerable pressure to separate the halves. If you can not separate by hand, you may need a blunt instrument to push in the hole in the direction indicated. NOTE THAT ONE HALF OF THE CONNECTOR IS SCREWED TO THE FRAME AND WILL NOT MOVE.
- Page 15 MAIN FUSE 1.Disconnect main battery connection IMPORTANT: If the main fuse is blown, find the source of problem before replacing fuse 2. Open the plastic box to access main fuse. 3. Set DMM to Resistance Ω symbol on DMM • Measure were indicated to the left. •...
- Page 16 TESTING THE BATTERY VOLTAGE 1. Set DMM to “DC Volt” mode. Note: If a valid voltage cannot be 2. Turn mower on. read, the electronics built into the charge port may be bad. In this 3. Pull PTO switch up (Power Take Off/Blade Engage knob) to load the battery for more accurate event, find the blue connector measurement.
- Page 17 SEPARATING CONNECTORS Many of the connectors are sealed together with heat shrink tubing. To separate the connectors, soften the heat shrink with a heat gun, then peel the heat shrink tubing off with pliers as shown. Heat Connector Connector When reassembling connectors, be sure to apply new heat shrink tubing and shrink with a heat gun to protect against elements and hold the connections together.
-
Page 18: Control Panel
CONTROL PANEL (Power Take Off) Headlight switch Main Power Key Switch RMO (Reverse Mow Option) Switch Fuel Gauge/ Hour Meter Confidential & Proprietary – Property of Techtronic Power Equipment – DO NOT COPY or DISCLOSE... -
Page 19: Testing Pto Switch
TESTING THE PTO SWITCH 1. Mower Power OFF Note: Make sure spade plugs 2. DMM set to measure Resistance are secure. They should be 3. Insert DMM probes where indicated. When red button is locked in place and should PULLED OUT, the switch is CLOSED (very LOW resistance or not come loose if the wires continuity) are pulled on. -
Page 20: Testing Rmo Switch
TESTING THE RMO SWITCH 1. DISCONNECT MAIN POWER FROM MOWER. 2. Set DMM to “Diode” mode. 2.5V Touch leads where indicated. LED should light (polarity of probes does not matter). 5-6V 4. Set DMM to Resistance mode. Switch is normally open (N.O.). -
Page 21: Testing Cruise Switch
TESTING THE CRUISE SWITCH 1. Disconnect Main Power from Mower. 2. DMM set to “Diode” mode. 6.4V 3. Touch the leads where indicated. LED should light 4. Set DMM to Resistance mode. This is a latching switch. Pressing the buttons alternates between open and closed. 5-6V Confidential &... - Page 22 TESTING HEADLIGHT SWITCH 1. Disconnect Main Power from Mower. 2. DMM set to “Diode” mode. 3. Touch the leads where indicated. LED should light 4. Set DMM to Resistance mode. This is a latching switch. Pressing the buttons alternates between open and closed. Confidential &...
-
Page 23: Testing Fuel Gage / Hour Meter
TESTING FUEL GAUGE/ HOUR METER Charge remaining Total hours of use (mower must be on Continuously for a minimum Turn Mower switch ON. of 6 minutes for time to change) Set Volt meter to “DC VOLTS”. Measure battery voltage between and Black wire (below, left) Measure battery voltage between Black and Blue... -
Page 24: Testing Key Switch
TESTING KEY SWITCH 1. Set DMM to DC Volts 2. With Power switch OFF, measure battery voltage where indicated 3. With Power ON, measure approx. 0V where indicated 48V DC Note this switch operates at To measure Switch with wires disconnected: Set DMM to measure continuity OFF position: No continuity between green and red wire. -
Page 25: Testing Led Headlight Assembly
TESTING HEADLIGHT ASSEMBLY POSITIVE ”+” “-” NEGATIVE To test Headlight module independently: 1. Power on Mower. 2. Turn on Headlights. Disconnect Headlight from wire harness. 3. Set DMM to measure DC Volts. 1. 2. Supply 12V to the connector as shown above. 4. -
Page 26: Testing Accelerator (Angular Transducer)
TESTING ANGULAR TRANSDUCER Test for Voltage at Harness 1. Set DMM to measure DC Volts. 2. Disconnect Accelerator connector. 3. Turn mower on. 4. Measure 4-5V between red and black wires on harness. 4.25V typical To Test Transducer Independently: 1. Set DMM to measure DC Volts. 2. -
Page 27: Testing Brake Switch
TESTING BREAK SWITCH 1. Turn Power Off. 5.4V nominal when plunger depressed 2. Disconnect brake switch connector. 3. Measure voltage at the contacts. To test brake switch independently: 1. Power OFF Mower. 2. Set DMM to measure Resistance. contacts 3. Connect DMM leads to black and red contacts. Plunger Continuity when plunger is NOT pressed. -
Page 28: Testing Beeper
TESTING THE BEEPER Test by disconnecting connector and connecting 12V “+” to red wire and “-” to black ground wire of beeper. Or put mower in Reverse. This should cause beeper to activate. To measure the voltage at the harness: 1. -
Page 29: Testing Seat Switch
TESTING THE SEAT SWITCH 1. Power Mower OFF. 2. Set DMM to measure Resistance. 3. Disconnect seat switch connectors. 4. Measure continuity when switch is pressed. 5. Measure very high resistance when switch is released. 0-.2 Ohms nominal continuity when pressed To Measure the harness: 1. - Page 30 CONTROLLER LOCATION Confidential & Proprietary – Property of Techtronic Power Equipment – DO NOT COPY or DISCLOSE...
- Page 31 TESTING PRIMARY BLADE CONTROLLER Test for short circuit: Disconnect all connectors to Primary Controller. Temporarily touch a wire between “+” and “-” wires to drain capacitance. Set meter to Resistance Mode. Connect DMM probes to heavy red wire (power) and heavy black (ground) wire to check for short circuit Typical resistance: 1.46M Check resistance of controller output:...
- Page 32 TESTING SECONDARY BLADE CONTROLLER Test for short circuit: Disconnect all connectors to Secondary Controller. Temporarily touch a wire between “+” and “-” wires to drain capacitance. Set meter to Resistance Mode. Connect DMM probes to heavy red wire (power) and heavy black (ground) wire to check for short circuit.
- Page 33 TESTING DRIVE CONTROLLER Test for short circuit: Test for short circuit: Set meter to Resistance Mode. Set meter to Resistance Mode. Connect DMM probes to heavy red wire (power) and heavy black (ground) wire to check Connect DMM probes to heavy red wire (power) and heavy black (ground) wire to check for short circuit.
-
Page 34: Testing Primary And Secondary Deck Motors
TESTING THE PRIMARY AND SECONDARY DECK MOTORS 1. Disconnect Motor from controller. 2. Set DMM to Resistance mode. 3. Measure between any 2 pins. 4. Measure between other pins. 5. Measurements should be nearly identical. Nominal resistance .1 Ohm Confidential & Proprietary – Property of Techtronic Power Equipment – DO NOT COPY or DISCLOSE... -
Page 35: Testing Drive Motor
TESTING DRIVE MOTOR 1. Set DMM to Resistance mode 2. Measure resistance between heavy green and heavy yellow wire. 3 Measure resistance between heavy green and heavy blue wire. 4. Measurements should be nearly identical. Nominal resistance: 0.1 Ohm Heavy motor Hall sensors Drive phase wires... - Page 36 TESTING DRIVE MOTOR HALL SENSORS IN THE MOWER Note: power should be ON, and rear wheels raised so they can be rotated by hand. Set DMM to “DC Volts” 1. Touch red probe to red wire. 2. Black probe to black wire. 3.
- Page 37 TESTING 48V TO 12V (DC-DC) CONVERTER Testing Converter Fuse: 1. DISCONNECT MAIN POWER. 2. Check continuity of fuse. 3. If fuse is bad, replace only with same type and Amperage. Testing Converter: 1. Turn mower on. Set DMM to “Volts” 2.
-
Page 38: Relay Basics
RELAY BASICS Relay A relay consist of an electromagnet and a switch, controlled by the electromagnet, within a single package +12V When 12V is supplied to the two small terminals on the left of the relay, it causes the switch to close and supply 48V to the mower. It is standard practice to add a diode across the electromagnet to Diode Electromagnet... -
Page 39: Testing Relay
TESTING RELAY General rules of thumb: Relay 1. When you turn on mower, you should hear a “clunk” when the relay engages. and also when you turn off the mower +12V and the relay disengages. 2. If headlights work, the relay is good 3. - Page 40 TESTING RELAY 1. Power Mower ON. 2. Set DMM to “DC Volts”. 3. Check for 12V on the small terminals (under the black caps). 4. Check for approximately 39+V on the large terminals (under the red caps). Alternate method to test relay independent of mower: 1.
-
Page 41: Testing Relay Diode
TESTING RELAY DIODE Diode Test: Turn Mower OFF. 2. Unbolt one leg of diode to disconnect from the circuit. 3. Set DMM to “Diode”. 4. Connect lead at arrow, black lead at Diode black arrow. DMM should read approx 7V. and black leads. -
Page 42: Testing Charge Port And Interlock
TESTING CHARGING PORT AND INTERLOCK Turn mower on. Turn headlights on. Connect a jumper wire as shown. (any insulated wire will do.) Green charge LED should glow as shown. Mower should shut down (relay clicks, headlights go out). Remove the jumper wire. After a few seconds, the mower should come back on(relay clicks) and headlights light again. -
Page 43: Testing Deltaq Battery Charger
TESTING BATTERY CHARGER 1. Refer to photos on next page for this procedure 2. Disconnect main battery connection. 3. Disconnect the blue charger wire connector 4. Connect the red alligator clip to the charger plug. 5. Connect the 2 black alligator clips to the other 2 plugs on the charger connector 6. - Page 44 CHARGER ERROR CODES CODE MEANING SOLUTION Charge Enable Fault: May indicate poor contact at the charger connector or the battery Check charger/ mower connection and remove any debris. One red flash temp is too hot (Greater than 122 F Allow hot batteries to cool, Then try charging again. Batteries must be charged by another means to bring Battery Voltage Fault: May indicate installed battery or batteries are less than 36v or more Two red flash...
-
Page 45: Testing Temperature Sensor
TESTING TEMPATURE SENSOR • Disconnect the plastic connector • Set DMM to measure RESISTANCE. • At room temperature, measurement should be approx 10K Ohms. • As the sensor is heated, the resistance will decrease. • If sensor is not connected, the charger will blink an error code. -
Page 46: Wire Harness
WIRE HARNESS Confidential & Proprietary – Property of Techtronic Power Equipment – DO NOT COPY or DISCLOSE... - Page 47 PRE AND POST REPAIR CHECKLIST Jack rear tires approximately 2” off the ground and support securely with jack stands. Sit on mower. Turn main power key to “ON”. The Fuel Gauge/Hour meter should light up. Put FNR switch in FORWARD position. Put accelerator at full speed and hold.
-
Page 48: Troubleshooting
TROUBLESHOOTING ACTION TAKEN UNIT RESPONSE ISSUE CHECK Key turned ON with user on seat Relay activates powering the 12V circuits No power after turning key Battery dead short Battery and hour meter activated Open relay(should hear relay click closed) Power to the controllers Defective Power converter (12V power supply) Power to the head lights switch and lights Charger still plugged into unit... - Page 49 ELECTRONICS TIPS FOR THE SMALL ENGINE TECHNICAN A service person who has spent many years working on gas mowers may feel uneasy when working on the new generation of electric mower. If this sounds like you, fear not, you’re not alone. This section is for you.
-
Page 50: Electronics Terms, Symbols, And Tools
ELECTRONICS TERMS, SYMBOLS, TOOLS Voltage is potential Energy noted by the symbol “V”. For the scope of this document, we are only concerned With DC voltage. So be sure when setting the DMM to Measure voltage it is set to DC. Resistance is opposition to the flow of current. -
Page 51: Using The Dmm To Measure Volts
USING THE DMM TO MEASURE VOLTS Before touching the probes of a DMM to Anything, be sure it is set to the correct setting To measure DC voltage: 1. first set the DMM to measure voltage, ensuring DC (NOT AC) setting DMM shows 12.55V DC battery voltage 2. -
Page 52: Using The Dmm To Measure Resistance
USING THE DMM TO MEASURE RESISTANCE Before touching the probes of a DMM to anything, be sure it is set to the correct setting. Power must be OFF when measuring resistance To measure DC voltage: 1. First, set the DMM to measure resistance 2.