Ryobi RY48ZTR75 Manual de usuario

Confidential & Proprietary –Property of Techtronic Power Equipment –DO NOT COPY or DISCLOSE

SERVICE CENTER ELECTRICAL SYSTEM TROUBLESHOOTING AND TESTING GUIDE

RYOBI RY48ZTR75/100 AND RY48140 RIDING MOWER

Confidential & Proprietary –Property of Techtronic Power Equipment –DO NOT COPY or DISCLOSE

TABLE OF CONTENTS

•WARNING

•ZTR Mower Overview

•Brushless Motors

•Using this Manual

•ZTR Block Diagram and Control Flow

•Troubleshooting: General

•Troubleshooting: Detailed

•DMM and Other Tools

•Component Locations

•Controller and Label Locations

•Main Battery Connection

•Testing Main Fuse

•Testing Battery Voltage

•Control Panel

•Testing PTO Switch

•Testing Headlight Switch

•Testing the Drive Speed Switch

•Testing Blade Cutting Speed Switch

•Testing Fuel Gauge / Hour Meter

•Testing Key Switch

•Testing USB Port

•Testing the Neutral “Zero” Switches

•Testing Headlight Assembly

•Testing Accelerator (angular transducers)

•Testing Brake Switch

•Testing Beeper

•Testing Seat Switch

•Testing Primary Blade Motor Controller

•Testing Secondary Blade Motor Controller

•Testing Drive Motor Controllers

•Testing Blade Motors

•Testing Drive Motors

•Testing Drive Motor Hall Sensors

•Testing 48V-12V Converter and fuse

•Testing Relay

•Testing Relay Diode

•Testing Charge port and interlock

•Testing the Battery Charger

•Battery Charger Error Codes

•ZTR Beep Codes

•Testing the Temperature Sensor

•Wire Harness

•Pre and Post-Repair Checklist

•Electronic Tips for the Mechanical Small Engine Tech

•Electronics Terms, Symbols and Tools

•Using the Digital Multi-Meter (DMM)

Confidential & Proprietary –Property of Techtronic Power Equipment –DO NOT COPY or DISCLOSE

WARNING

THIS MATERIAL INTENDED ONLY FOR TECHNICIANS TRAINED IN ELECTRICAL REPAIR.

Technicians should wear personal protective equipment, such as rubber

gloves and safety glasses.

Dangerous voltages /currents are present. Exercise caution at all times.

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.

Confidential & Proprietary –Property of Techtronic Power Equipment –DO NOT COPY or DISCLOSE

The RYOBI ZTR riding mower is completely electrical, consisting of 4brushless

motors and acontroller for each motor:

•Abrushless motor and controller for each of the 2blades

•Abrushless motor/controller to drive each rear wheel.These Drive Motor Controllers

also contains the “brains” that responds to various inputs such as the accelerators,

seat switch,etc.

OVERVIEW

Confidential & Proprietary –Property of Techtronic Power Equipment –DO NOT COPY or DISCLOSE

Brushless motors operate quite differently than brushed motors, which you may be

used to (i.e. a starter motor).

Abrushed motor can be quickly tested by applying voltage to the two terminals.

Brushless motors can be recognized by 3wires. These 3wires 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.

Applying avoltage directly to these phases will cause damage.

BRUSHLESS MOTORS

Confidential & Proprietary –Property of Techtronic Power Equipment –DO NOT COPY or DISCLOSE

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

ABlock Diagram shows the general flow to visualize how the mower is connected and

achart shows general symptoms/solutions for repairs.

Electronics tips ,Terminology and Using a Digital Multi-Meter (DMM) are included for

the technician familiar only with gas machines.

USING THIS DOCUMENT

Confidential & Proprietary –Property of Techtronic Power Equipment –DO NOT COPY or DISCLOSE

TOOLS NEEDED

Torx

T27

T30

T40

Screwdrivers

Cross tip

Flat blade

Sockets and

Wrenches

8 mm

10 mm

13 mm

14 mm

15 mm

17 mm

19 mm

Confidential & Proprietary –Property of Techtronic Power Equipment –DO NOT COPY or DISCLOSE

48V

Batteries

Main Fuse

Charge

Port/lockout/

battery temp

48V to 12V

(DC to DC)

converter

Relay

Fuel

Gauge

Brake

Switch

Beeper

Seat

switch

Fuse

Primary

Blade

Control

Secondary

Blade

Control

Motor Motor

Head

Lights

Accelerator

Note: A detailed wire harness diagram is

located later in this document

USB

Important:Primary and secondary

have a communication link. If one

blade motor or controller fails,

BOTH will shut down.

48V

Secondary

Drive

Controller

Accelerator

PTO

Drive Speed

Switch

Blade

Speed

Key

Switch

12V

Left

Neutral

switch

5V out

Motor

Hall Sensors

Primary

Drive

Controller

Motor

Hall Sensors

RIGHT

Neutral

switch

Enables

BLOCK DIAGRAM AND CONTROL FLOW

Confidential & Proprietary –Property of Techtronic Power Equipment –DO NOT COPY or DISCLOSE

•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)

–Check for voltage at charge port.

–Check USB Indicator and Headlights are functional (this tests the 48V-12V converter)

•Remove Instrument Panel cover

–Test Key Switch

–Check all other connections while panel is removed.

TROUBLESHOOTING: GENERAL

Confidential & Proprietary –Property of Techtronic Power Equipment –DO NOT COPY or DISCLOSE

Use the block diagram as aguide

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.

2. If necessary, further test the charger and charge port.Replace as needed.Charge port,Interlock, and temperature sensor

should be replaced together.

3. Test the key switch by operating it, making sure it has atactile “click” when turned on or off. Replace if necessary

4. Test and replace main relay and diode as necessary. (Note: when you turn the mower on, you should hear the relay click)

5. Check the main fuse.If it is blown, check the system for signs of ashort circuit before replacing the main fuse

6. If the fuel gauge has power, but no display or malfunctions, replace the fuel gauge

7. If ONLY the fuel gage works when the key is turned on, test/replace the 48-to-12V DC converter and 5A fuse as

necessary Note: this fuse is acommon part available at any automotive store

TROUBLESHOOTING: DETAILED

Otros manuales para RY48ZTR75

Este manual sirve para los siguientes modelos

Tabla de contenidos

Otros manuales de Cortacésped de Ryobi

Ryobi

Ryobi RLM36 Manual de usuario

Ryobi

Ryobi R36LMW16 Manual de usuario

Ryobi

Ryobi RLM1956MEB Manual de usuario

Ryobi

Ryobi RLM18X33S40 Manual de usuario

Ryobi

Ryobi RLM46175SO Manual de usuario

Ryobi

Ryobi RLM36X41HPG Manual de usuario

Ryobi

Ryobi ORM1800 Manual de usuario

Ryobi

Ryobi RY40107 Guía de configuración rápida

Ryobi

Ryobi RY401022 Manual de usuario

Ryobi

Ryobi RY48130 Manual de usuario

Ryobi

Ryobi RY48131 Manual de usuario

Ryobi

Ryobi RY401014 Manual de usuario

Ryobi

Ryobi RY40100 Manual de usuario

Ryobi

Ryobi RY401020 Manual de usuario

Ryobi

Ryobi RLM4614 Manual de usuario

Ryobi

Ryobi R36XLMWP6 Manual de usuario

Ryobi

Ryobi RLM36X41H40 Manual de usuario

Ryobi

Ryobi RLM36X46X240 Manual de usuario

Ryobi

Ryobi RLM18X41H240 Manual de usuario

Ryobi

Ryobi RY401012 Manual de usuario

Ryobi

Ryobi RY48RM76A Manual de usuario

Ryobi

Ryobi ROM-65P Manual de operación

Ryobi

Ryobi RLM46175S Manual de usuario

Ryobi

Ryobi ROBOYAGI RY36LMRX Manual de usuario

Manuales populares de Cortacésped de otras marcas

RHINO

RHINO 1958 Manual de usuario

Wolf Garten

Wolf Garten Compact plus 40 B Manual de usuario

Cub Cadet

Cub Cadet LTX 1045 Manual de usuario

Craftsman

Craftsman 917.378461 Manual de usuario

GGP ITALY SPA

GGP ITALY SPA CR/CS 434 SERIES Manual de usuario

Challenge

Challenge CH18V2 Instrucciones de operación

TALEN TOOLS

TALEN TOOLS AVR HGM30 Manual de usuario

DEWEZE

DEWEZE ATM-725 Manual de operación

Weed Eater

Weed Eater 180083 Manual de usuario

Husqvarna

Husqvarna Poulan Pro PP185A42 Manual de usuario

Better Outdoor Products

Better Outdoor Products Quick Series Manual de usuario

Cub Cadet

Cub Cadet 23HP Z-Force 60 Manual de funcionamiento

MTD

MTD 795, 792, 791, 790 Manual de usuario

Toro

Toro Groundsmaster 3505-D Manual de usuario

Dennis

Dennis FT 610 Manual de usuario

AIRFORCE

AIRFORCE F-15 Gen 3 Manual de usuario

MTD

MTD 126-220-000 Manual de usuario

Toro

Toro 74806 Manual de usuario