Ryobi RY48130 User manual

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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

•WARNING

•DMM and Other Tools

•Component Locations Main Battery

•Connection Testing Main Fuse

•Testing Battery Voltage

•Control Panel

•Testing PTO Switch

•Testing RMO Switch

•Testing Cruise Switch

•Testing Fuel Gage / Hour Meter

•Testing Key Switch

•Testing Headlight Switch

•Testing LED Headlight Assembly

•Testing Accelerator (angular transducer)

•Testing Brake Switch

•Testing Beeper

•Testing Seat Switch

•Testing Primary Blade Deck Motor Controller Testing

•Secondary Blade Motor Controller

•Controller layout

•Testing Primary and Secondary Deck Motors

•Testing Drive Motor

•Testing 48V-12V Converter and fuse

•Relay Basics

•Testing Relay

•Testing Relay Diode

•Testing Charge port and interlock

•Testing DeltaQ Battery Charger

•Testing Temperature Sensor

•Wire Harness

•Troubleshooting

•Electronic Tips for the mechanical Small Engine Tech

•Electronics Terms, Symbols, and Tools

•Using the DMM to Measure Volts

•Using the DMM to Measure Resistance

TABLE OF CONTENTS

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.

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OVERVIEW

The RYOBI riding mower is completely electrical, consisting of 3brushless

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.

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BRUSHLESS MOTORS

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.

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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

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.

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

Batteries

Main

Fuse

Charge

Port/lockout/

battery temp

48V to 12V

(DC to DC)

converter Relay

Fuel

gage

Drive

Controller

Control Panel

Brake

Switch

Beep

Seat

switch

Fuse

Primary

Blade

Control

Secondary

Blade

Control

MotorMotor

Motor

Head

Lights

PTO

RMO

FNR

Cruz

Light

Gage

USB

Key

Switch

Accelerator

Note: A detailed wire harness diagram is

located later in this document

USB

Hall Sensors

Important: Primary and secondary

have Acommunication link. If one

blade Motor or controller fails,

BOTH will Shut down

48V

BLOCK DIAGRAM AND CONTROL FLOW

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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)

–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.

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TROUBLESHOOTING: DETAILED

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

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