Ryobi RYRM8010 Troubleshooting Manual
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Ryobi RYRM8010 Troubleshooting Manual

80v zero turn mower
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80V Zero Turn Mower
Troubleshooting Guide

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Summary of Contents for Ryobi RYRM8010

  • Page 1 80V Zero Turn Mower Troubleshooting Guide...

  • Page 2: Table Of Contents

    Table of Contents • ZTR Mower Overview ………………………………. 5 • Boosters ……………………..……………………… 36 • Brushless Motors ……………………………………. 6 • ZTR Beep Diagnostic Codes ……………………… 37 ……………………. 38 • Digital Multimeter (DMM) .……..…………………… 7 • Testing Blade Motor Controller • Component Locations …………………....
  • Page 3 < Return to Table of Contents Warning THIS MATERIAL IS INTENDED ONLY FOR TECHNICIANS TRAINED IN ELECTRICITY! Technicians should wear personal protective equipment, such as rubber gloves, safety glasses, and hearing protection. Dangerous voltages /currents are present. EXERCISE CAUTION AT ALL TIMES! This guide assumes knowledge of basic electrical equipment such as DMM (Digital Multi Meter) to measure voltage, current, resistance, continuity, and diodes.

  • Page 4: Using This Document

    < Return to Table of Contents Using this Document • Any 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 •...

  • Page 5: Ztr Mower Overview

    < Return to Table of Contents ZTR Mower Overview The RYOBI ZTR is completely electrical, consisting of 4 (30” & 42” models) or 5 (54” model) brushless motors (one for each blade and one for each rear wheel) and a controller for each motor.
  • Page 6 < Return to Table of Contents Brushless Motors Overview Brushless motors operate quite differently than brushed motors with which you may be used to working. (e.g., a starter motor). A brushed motor, like the one pictured to the right, can be quickly tested by applying voltage to the two terminals.

  • Page 7: Digital Multimeter (Dmm)

    < Return to Table of Contents Digital Multimeter (DMM) A DMM is a standard diagnostic tool that serves as a voltmeter, ammeter, and ohmmeter. We use this tool for various tests throughout this guide. Ω VOLTAGE is potential RESISTANCE is the A DIODE is a device that energy.

  • Page 8: Component Locations

    < Return to Table of Contents 80v ZTR Troubleshooting Guide COMPONENT LOCATIONS Confidential and Proprietary - Property of Techtronic Power Equipment - DO NOT COPY or DISCLOSE...
  • Page 9 < Return to Table of Contents Component Locations RYRM8010 30” ZTR Mower Seat Switch under seat Access Port* under seat Brake Switch Charging Port Battery Booster iDRIVE Joystick Headlights LCD Panel Display Control Panel *NOTE Beeper, Drive Motor Controllers, Deck Motor...
  • Page 10 < Return to Table of Contents Component Locations RYRM8021 42” ZTR Mower Seat Switch RYRM8034 54” ZTR Mower under seat Access Port* under seat Brake Switch Battery Booster under Battery Box Headlights Charging Port iDRIVE Joystick LCD Panel Display Control Panel *NOTE Beeper, Drive Motor...
  • Page 11 < Return to Table of Contents Batteries Locations RYRM8021 42” ZTR Mower RYRM8010 30” ZTR Mower RYRM8034 54” ZTR Mower 40v Battery (1) 40v Batteries (2) 40v Batteries (3) 80v Batteries 80v Batteries Confidential and Proprietary - Property of Techtronic Power Equipment - DO NOT COPY or DISCLOSE...

  • Page 12: Tic Connections

    < Return to Table of Contents TIC Connections Pre-Charge Line The TIC has 2 connections to the mower. Main TIC Connector HELPFUL TIP There are 2 yellow tabs in the Pre-Charge Line Connectors. These can fall out during repair. Make sure they are reinserted correctly if they do fall out.

  • Page 13: Control Panel

    < Return to Table of Contents Control Panel Bagger Boost 30” & 42” models only! Key Switch Blade Power Switch a.k.a. “PTO” Switch USB Charging Port Confidential and Proprietary - Property of Techtronic Power Equipment - DO NOT COPY or DISCLOSE...

  • Page 14: Controller Locations

    Deck Motor under Junction Box Controllers* (3) RYRM8021 42” ZTR Mower RYRM8010 30” ZTR Mower RYRM8034 54” ZTR Mower *NOTE The RYRM8021 has (2) Deck Motor Controllers, not (3) Confidential and Proprietary - Property of Techtronic Power Equipment - DO NOT COPY or DISCLOSE...
  • Page 15 < Return to Table of Contents 80v ZTR Troubleshooting Guide DIAGRAMS Confidential and Proprietary - Property of Techtronic Power Equipment - DO NOT COPY or DISCLOSE...

  • Page 16: Block Diagram And Control Flow

    < Return to Table of Contents Block Diagram: Control Flow Batteries Batteries 5V out Bagger Boost Boosters Head Main Fuse Junction Box Lights Neutral Switch 80V to 12V Seat Mixing Relay Transducers DCDC switch Board Fuse Converter Switch Enable Brake Charge Port Switch Secondary...
  • Page 17 Battery Power Wiring Harness Confidential and Proprietary - Property of Techtronic Power Equipment - DO NOT COPY or DISCLOSE...
  • Page 18 Booster Wiring Harness Confidential and Proprietary - Property of Techtronic Power Equipment - DO NOT COPY or DISCLOSE...
  • Page 19 Controller Power Wiring Harness Confidential and Proprietary - Property of Techtronic Power Equipment - DO NOT COPY or DISCLOSE...

  • Page 20: Main Wiring Harness

    Main Wiring Harness Confidential and Proprietary - Property of Techtronic Power Equipment - DO NOT COPY or DISCLOSE...

  • Page 21: Troubleshooting

    < Return to Table of Contents 80v ZTR Troubleshooting Guide TROUBLESHOOTING Confidential and Proprietary - Property of Techtronic Power Equipment - DO NOT COPY or DISCLOSE...

  • Page 22: Troubleshooting Introduction

    < Return to Table of Contents Troubleshooting: Introduction 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.
  • Page 23 3. Release the Parking Brake. 4. Turn Main Power Key to the ON position. 5. The LCD Screen should display the RYOBI logo followed by the user interface. 6. Pull up on the Joystick to unlock it. 7. Push Joystick fully forward and hold. Rear wheels should rotate forward.

  • Page 24: Troubleshooting: Basic

    < Return to Table of Contents Troubleshooting: Basics • Follow the Block Diagram on the previous page. • CHECK FOR LOOSE AND/OR BAD CONNECTIONS. • Test the easiest components first, such as Power, Key Switch, DC-DC Converter, etc. • Mower should be fully charged, if possible. •...

  • Page 25: Troubleshooting: Detailed

    < Return to Table of Contents Troubleshooting: Detailed Use the block diagram as a guide. Also refer to the beep diagnostic code chart. Test Charger by plugging it into the Charging Port on the mower and checking if batteries charge. If necessary, further test the Charger and Charging Port.

  • Page 26: No Power To Mower

    < Return to Table of Contents No Power to Mower • LIKELY CAUSES: 80v Batteries; TIC (Main Relay doesn’t click) • Testing Steps: (check function after each step) 1. Turn mower off 2. Unplug all 80v Batteries 3. Insert (1) battery and attempt to turn mower on 4.

  • Page 27: Mower Drive Non-Functional

    2. Replace Mixing Board RYRM8034 54” ZTR Mower 3. Replace iDRIVE System Joystick 4. Replace Primary Drive Motor Controller Switch 5. Replace Secondary Drive Motor Controller RYRM8010 30” ZTR Mower Mixing Control Board Panel Mixing Board Confidential and Proprietary - Property of Techtronic Power Equipment - DO NOT COPY or DISCLOSE...
  • Page 28 < Return to Table of Contents Park / Neutral Light Malfunction • LIKELY CAUSES: Drive Motor Controller • Testing Steps: (check function after each step) 1. Ensure connections and wiring are secure Check Brake Switch connection b. Check Neutral Switch connection Check LCD Panel connection 2.

  • Page 29: Testing Main Fuse

    < Return to Table of Contents Checking Fuses • Testing Main Fuse (100A 70v) IMPORTANT: If fuse is blown, find source of problem before replacing the fuse. • Testing Steps: 1. Disconnect ALL batteries Main Fuse 2. Open Junction Box to access the Main Fuse Testing Points 3.

  • Page 30: Testing Headlight Assembly

    < Return to Table of Contents DC-DC Convertor / Headlights • Testing DC-DC Convertor • Testing Steps: DC-DC 1. Power mower on Convertor 2. Set DMM to DC Volts 3. Check for ~80v between the and BLACK wires 4. Check for ~12v between the BLUE YELLOW wires...

  • Page 31: Charging Port

    < Return to Table of Contents Charging Port • Testing Charging Port • Testing Steps: 1. Plug Charger into the mower while 80v batteries are installed 2. Check the LCD Display for charging status If LCD Display doesn’t power on, check connections to LCD Display If connections are secure, but LCD Display doesn’t power on, replace LCD Display b.

  • Page 32: Testing Blade (Pto) Switch

    < Return to Table of Contents Blade Power (PTO) Switch • Testing Blade Power (PTO) Switch • Testing Steps: 1. Disconnect main power from mower 2. Set DMM to Resistance 3. Test for continuity at the points indicated With the switch pulled out (closed), you should get very low resistance or Continuity b.

  • Page 33: Testing Bagger Boost Switch

    < Return to Table of Contents Bagger Boost Switch • Testing Bagger Boost Switch Bagger • Testing Steps: Boost Switch 1. Disconnect all batteries and charger from mower 2. Set DMM to Resistance 3. Test for continuity across input terminals With the switch pushed down (open), you should get very high resistance or no Continuity b.
  • Page 34 < Return to Table of Contents Key Switch / USB Port • Testing Key Switch (operates at 12v) • Testing Steps: (Wires Connected) Key Switch 1. Set DMM to DC Voltage 2. Measure Voltage between the two wires going into switch With the switch set to OFF, you should get approximately 12v b.

  • Page 35: Testing Beeper

    < Return to Table of Contents Seat Switch / Beeper • Testing Seat Switch • Testing Steps: Seat Switch 1. Power mower off 2. Set DMM to Resistance 3. Disconnect Seat Switch connectors 4. Test for continuity across input terminals With the switch pushed down, you should get very low resistance or Continuity b.
  • Page 36 < Return to Table of Contents Configuring Battery Boosters • Configuring Battery Boosters Required if a Battery Booster is replaced • Configuring Steps: 1. Remove all 40v Batteries 2. Enter Booster Configuration Mode (see picture to the right) 3. Insert 40v Battery into top left location (marked 1 on position on below picture) and wait for battery SOC data to appear for slot Hold Drive Speed, Mode,...

  • Page 37: Beep Codes

    < Return to Table of Contents Beep Codes EXAMPLE ERROR CODE: A0 0000000 BEEP # DESCRIPTION CHECK IF NOT SOLVED… Wiring and connections; ensure Angle Sensor not Replace both Drive Motor solid connection and no loose Replace Mixing Board Replace iDRIVE at neutral Controllers wires...
  • Page 38 < Return to Table of Contents Deck Motor Controllers • Testing Deck Motor Controller • Testing Steps: (resistance of output) 1. Set DMM to Resistance 2. Test for continuity between any two terminals 3. Test for continuity between other terminals 4.

  • Page 39: Testing Deck Motors

    < Return to Table of Contents Deck Motors • Testing Deck Motors • Testing Steps: 1. Set DMM to Resistance 2. Test for continuity between any two pins 3. Test for continuity between other pins 4. Measurements should be nearly identical Typical resistance should be ~0.1 Ohm NOTE: Ignore the N, L, and G labels on the connector.

  • Page 40: Testing Drive Motor Controllers

    < Return to Table of Contents Drive Motor Controllers • Testing Drive Motor Controller • Testing Steps: (resistance of output) 1. Set DMM to Resistance 2. Test for continuity between any two terminals 3. Test for continuity between other terminals 4.

  • Page 41: Testing Drive Motors

    < Return to Table of Contents Drive Motors / Hall Sensor • Testing Drive Motors • Testing Steps: 1. Unbolt heavy phase wires from Drive Motor Controller 2. Set DMM to Resistance 3. Test for resistance between heavy GREEN YELLOW &...

  • Page 42: Testing Brake Switch

    < Return to Table of Contents Brake Switch • Testing Brake Switch • Testing Steps: 1. Set DMM to DC Volts 2. Disconnect Brake Switch connector & BLACK terminals on 3. Measure between mating connector of the harness Contacts Nominal voltage should be 3.2v when plunger depressed and 0v when plunger released Plunger •...

  • Page 43: Relay Overview

    < Return to Table of Contents Relay Overview A Relay consists of an electromagnet and a Relay switch operated by the electromagnet within a single package. When 12v is supplied to the two small terminals on the left of the relay, it causes the switch to close and supply 80v to the mower.

  • Page 44: Testing Main Relay

    < Return to Table of Contents Main Relay • Testing Main Relay • Testing Steps: 1. Power the mower on. 2. You should hear an audible “click” as the Main Relay activates 3. Set DMM to DC Volts 4. Measure between two small terminals (under the black caps) Nominal voltage should be ~12v •...

  • Page 45: Mixing Board Locations

    (0 – 5V analog signal). iDRIVE Switch Mixing Board Mixing Board RYRM8010 30” ZTR Mower RYRM8021 42” ZTR Mower RYRM8034 54” ZTR Mower IMPORTANT NOTE Epoxy potting may have seeped into the header ports and totally insulated all metal from DMM probes. There should be some copper exposed, but if there is no exposed copper, either replace the Mixing Board to see if the problem persists or cut away some insulation on the wire to access metal.

  • Page 46: Testing Mixing Board

    < Return to Table of Contents Mixing Board • Testing Mixing Board • Testing Steps: 1. Set Parking Brake 2. Set Joystick to neutral position 3. Remove necessary panels for access to Mixing Board and iDRIVE 4. Power mower on 5.
  • Page 47 < Return to Table of Contents Mixing Board • Testing Mixing Board (continued) • Testing Steps: 7. Test left wheel Drive Motor Controller Set Joystick to neutral position b. Place black DMM lead onto socket 4 (Left Drive Ground) Place red DMM lead onto socket 2 (Left Drive Signal) Voltage should measure ~2.4v;...
  • Page 48 < Return to Table of Contents Mixing Board • Testing Mixing Board (continued) • Testing Steps: 8. Test right wheel Drive Motor Controller Set Joystick to neutral position b. Place black DMM lead onto socket R4 (Right Drive Ground) Place red DMM lead onto socket R2 (Right Drive Signal) Voltage should measure ~2.4v;...

  • Page 49: Lcd Display

    < Return to Table of Contents 80v ZTR Troubleshooting Guide LCD DISPLAY Confidential and Proprietary - Property of Techtronic Power Equipment - DO NOT COPY or DISCLOSE...

  • Page 50: Main Dashboard

    < Return to Table of Contents Main Dashboard Headlight Parking Brake Bluetooth Indicator Indicator Indicator Neutral Indicator (Joystick locked) Blade Speed Indicator Drive Speed Indicator Screen Tabs Battery % Bluetooth Drive Speed Blade Speed Lights Mode After booting up/powering on, defaults to Main Dashboard. After 20s of no inputs, GUI will default to Main Dashboard.
  • Page 51 < Return to Table of Contents Error Code Interface Main Dashboard Error Code History To return to the Main Dashboard, press If you press and hold the Mode Button for 10s, the Error Code and hold the Mode Button for 10s. The History is accessed.

  • Page 52: Error Codes

    < Return to Table of Contents Error Codes EXAMPLE ERROR CODE: A0 0000000 INDICATOR CODE KEY CODE MEANING Bit7 Bit6 Bit5 Bit4 Bit3 Bit2 Bit1 Bit0 This INDICATOR CODE Drive Controller data0 shows the area where The BIT CODE indicates the error(s). A 0 in the space Drive Controller data1 the error is present.
  • Page 53 < Return to Table of Contents Error Codes INDICATOR CODE MEANING MEANING NOT USED Over-voltage protection NOT USED NOT USED Drive Controller data1 CPU self-test failure Primary & Secondary self-test fault AD acquisition failure Accelerator failure Undervoltage protection (primary) Overvoltage (primary) Temperature protection (primary) Blocking protection (primary) Deck Controller data0...
  • Page 54 < Return to Table of Contents Error Codes (continued) INDICATOR CODE MEANING MEANING Seat Switch is not closed PTO switch is not closed Error with the seat and PTO logic F gear Deck Controller data2 R gear RMO enable flag NOT USED NOT USED Undervoltage protection (secondary control 1)
  • Page 55 < Return to Table of Contents Error Codes (continued) INDICATOR CODE MEANING MEANING Undervoltage protection (secondary control 2) Overvoltage protection (secondary control 2) Temperature protection (secondary control 2) Stall protection (secondary control 2) Deck Controller data5 Motor out of step (secondary control 2) Low speed protection (secondary control 2) MCU self-test fault (secondary control 2) NOT USED...

  • Page 56: Update Log

    < Return to Table of Contents Update Log 07.19.2022: Guide complete and ready for distribution (MLB) Confidential and Proprietary - Property of Techtronic Power Equipment - DO NOT COPY or DISCLOSE...

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