Ryobi Homelite RY48110 Troubleshooting Manual

Riding tractor, electrical components troubleshooting and testing

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Ryobi RY48110/11/12 Riding Tractor

Electrical Components Troubleshooting and Testing

(Lead-Acid Battery Version)

J.Davis 9-4-2018

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Summary of Contents for Ryobi Homelite RY48110

Page 1 Ryobi RY48110/11/12 Riding Tractor Electrical Components Troubleshooting and Testing (Lead-Acid Battery Version) J.Davis 9-4-2018...
Page 2 Table of Contents • • WARNING Testing Brake Switch • Testing Beeper • Mower Overview • Testing Seat Switch • A Word about Brushless Motors • Testing Master Blade Motor Controller • Using this Manual • Testing Slave Blade Motor Controller •...
Page 3 THIS MATERIAL INTENDED ONLY FOR TECHNICIANS TRAINED IN ELECTRICITY. 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) to measure voltage, current, resistance, continuity, and diodes.
Page 4 Mower Overview The Ryobi riding tractor is completely electrical, consisting of 3 brushless Motors and controllers for each motor: • A brushless electric motors/controllers for each of the 2 blades • 1 brushless motor/controller to propel the mower. This Drive motor controller also contains the “brains”...
Page 5 A word about Brushless Motors Brushless motors operate quite differently than brushed motors, which you may be used to (i.e. a starter motor) With a brushed motor, you can quickly check them by applying voltage to the two terminals. Brushless motors can be recognized by terminals.
Page 6 Using this Document • Anything in blue 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 7 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 Drive Important: Master and slave have Master Slave A communication link.
Page 8 Troubleshooting: General • Follow the block diagram on the previous page • Test the easiest components first • Mower should be fully charged (if possible) • Before disassembly: – Attempt to charge mower (note any error LED indications) – Check for voltage at charge port –...
Page 9 Troubleshooting: Detailed Use the block diagram as a guide Verify the battery charger is functional by plugging it into the charge port on the back of the mower and let it charge. If necessary, further test the charger charge port. Replace as needed. Charge port, Interlock, and temp sensor should be replaced together. Test the key switch by operating it, making sure it has a solid “click”...
Page 10 Digital Multi Meter (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 red 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 <...
Page 11 Other Helpful Tools and Parts 12V output 5V output < Table of Contents...
Page 12 Component Locations Charge port Access panel Seat Switch (under seat) Drive DC-DC Controller converter (underside) Beeper Master/slave Blade controllers Accelerator Brake Switch transducer < Table of Contents Headlights...
Page 13 Main Battery Connection The main battery disconnect is located directly under the seat access cover. It may takes 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 14 Testing Main Fuse IMPORTANT: If the main fuse is blown, find the source of problem before replacing fuse 1. Disconnect main battery connection 2. Open the plastic box to access main fuse. 3. Set DMM to Resistance Measure where indicated below. Ensure the nuts are tight, but not overtightened, as this can cause the fuse to twist and break.
Page 15 Testing Battery Voltage 1. Set DMM to “DC Volt” mode. 2. Turn mower on. 3. Pull PTO switch up (Power Take Off/Blade Engage knob) to load the battery for more accurate measurement. 4. Place DMM probes indicated by red arrow, BLACK probe by black arrow Charge Indicator LED (LED should blink in similar pattern to charger when charger is...
Page 16 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. Extra care is needed to avoid damaging surrounding parts by the heat.
Page 17 Control Panel < Table of Contents...
Page 18 Testing PTO (Power Take Off) Switch 1. Mower Power OFF Note: Make sure 2. DMM set to measure spade lugs are Resistance secure. They should be locked in place and should not come loose if the wires are pulled on. 3.
Page 19 Testing RMO Switch 1. DISCONNECT MAIN POWER FROM MOWER. 2. Set DMM to “Diode” mode. 2.5V 3. Touch leads where Indicates unused terminals 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 20 Testing F-N-R Switch 1. DISCONNECT MAIN POWER TO MOWER 2. DMM set to measure Resistance 3. Set switch in N position: 4. Set switch in R position: Set switch in “F” position: No continuity between any pins. Continuity between 2 and 3. (with no wires connected) Continuity between 5 and 6.
Page 21 Testing Cruise Switch 1. DISCONNECT MAIN POWER FROM MOWER. 2. Set to DMM “Diode” mode. 3. Touch DMM leads where Indicates unused terminals Indicated. LED should light (polarity of probes does not 6.4V matter). 5-6V 4. Set DMM to Resistance mode. Switch is Normally Open (N.O.).
Page 22 Testing Headlight Switch 1. Disconnect Main Power from Mower. 2. DMM set to “Diode” mode. Indicates unused terminals 3. Touch leads where indicated. LED should light (polarity of probes does not matter). 4. Set DMM to Resistance mode This is a latching switch. Pressing the button alternates between open and closed switch.
Page 23 Testing Fuel Gauge / Hour Meter Note: Every time mower is turned on, The Fuel gage will display a 3 Step process: 1. Factory 2 digit factor code 2. Display “48” (set for A 48V system) 3. Hours display This is a normal operation Mode button* Not connected Connect main battery connector.
Page 24 Testing Key Switch 1. Disconnect main battery terminals. 2. Set DMM to measure Resistance. 48V DC Note this switch operates at Indicates unused terminals OFF position: No continuity between green and red wire. (approx 3.6M if connected) ON position: Continuity between green and red wire. AUX position: Not used at time of this writing.
Page 25 Testing USB Port 1. Power ON Mower. 2. Set DMM to measure DC Volts. 3. Connect a scrap USB cord with one end removed. Measure 5V between the red and black wire USB power indicator LED* Measure 12V where indicated. If Blue LED indicator is not on, USB port is bad.
Page 26 Testing Head Light Assembly To test Headlight module independantly: 1. Power on Mower. 2. Turn on Headlights. 1. Disconnect Headlight from wire harness. 3. Set DMM to measure DC Volts. 2. Supply 12V to the connector as shown above. 4. Measure for 12V at harness. Nominal current: 275mA <...
Page 27 Testing Angular Transducer (Accelerator) 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.
Page 28 Testing Brake Switch 1. Set DMM to measure DC Volts. 2. Disconnect brake switch connector. 3. Measure DC Volts between red and black terminals on the mating connector of the harness 5.4V nominal when plunger depressed To test brake switch independently: Power Off Mower.
Page 29 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 30 Testing Seat Switch Seat Switch is Normally Open (N.O.) when no pressure is applied to seat 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 when pressed To Measure the harness: 1.
Page 31 Testing Master Blade Controller Test for short circuit: 1. Disconnect all connectors to Master Controller. 2. Temporarily touch a wire between heavy red “+” and heavy black “-” wires to drain capacitance. 3. Set DMM to Resistance Mode. MASTER 4. Connect DMM probes to heavy red wire (power) and heavy black (ground) wire to check for short circuit Typical resistance: 1.46M Ohms Check resistance of controller output:...
Page 32 Testing Slave Blade Controller Test for short circuit: SLAVE 1. Disconnect all connectors to Slave Controller. 2. Temporarily touch a wire between heavy red “+” and heavy black “-” wires to drain capacitance. 3. Set DMM to Resistance Mode. 4. Connect DMM probes to heavy red wire (power) and heavy black (ground) wire to check for short circuit.
Page 33 Removing / Replacing Drive Controller Remove the side and back panels Remove the 4 bolts (red arrows) Disconnect all wires and cable connectors Carefully pull the controller out the rear of the mower < Table of Contents using caution not to snag or strain any wires. When installing new controller be sure to apply heat shrink tubing.
Page 34 Testing Drive Controller • Make sure all wires from the controller are disconnected from the Mower. • Connect a jumper wire from the ground wire to each of the other wires to drain capacitance Test for short circuit: 1. Set DMM to Resistance Mode. 2.
Page 35 Testing Master and Slave 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 0.1 Ohm < Table of Contents...
Page 36 Test 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 isHall sensors Heavy motor Drive phase wires...
Page 37 Testing Drive Motor Hall Sensors (in 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 38 Testing Drive Motor Hall Sensors (Independently) 1. Turn off mower. 2. Disconnect all wires from motor to mower. 3. Apply 5V (red to red, black to black). Note: a cell phone charger and scrap USB cord can be used to supply 5V. Repeat measurements from previous page, while turning the motor by hand.
Page 39 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 (12V, 5A automotive fuse) Testing Converter: 1. Turn mower on. Set DMM to “DC Volts” 2.
Page 40 Replacing the DC-to-DC Converter Note: This procedure does NOT require removing the batteries. The batteries have been removed for illustration purposes. A long 8mm combination ratchet wrench Is required (Available at The Home Depot) 1. Lower the deck to the lowest position. 2.
Page 41 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 42 Testing Relay Diode Diode Test: Turn Mower OFF. 2. Unbolt one leg of diode to disconnect from the circuit. Diode 3. Set DMM to “Diode”. 4. Connect lead at arrow, black lead at black arrow. DMM should read approx .7V. 5.
Page 43 Testing the Charge Port and Interlock 1. Turn mower on. 2. Turn headlights on. 3. Connect a jumper wire as shown. (any insulated wire will do.) 4. Green charge LED should glow as shown. 5. Mower should shut down (relay clicks, headlights go out).
Page 44 Testing the Battery Charger Note: There are no electronics needed for this test. But you will need suitable 12 gage wires Use caution especially as shown. This procedure will charge the batteries (if the charger and batteries are good). If using alligator clip jumper wires. Wear rubber gloves and eye protection. Refer to photos on next page for this procedure Disconnect main battery connection.
Page 45 Testing the Battery Charger Alligator clips BLACK CLIPS Charger indicator Refer to “Charger Error Codes” CLIP 12 AWG wire Alligator clips RED “+” BLACK “-” CONNECT MAIN POWER LAST CONNECT MAIN POWER LAST Testing the battery charger using commonly available alligator clips/jumper wires. <...
Page 46 Charger Error Codes < Table of Contents...
Page 47 Testing the Temperature 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 48 Wire Harness < Table of Contents...
Page 49 Pre and Post Repair Checklist Jack rear tires approximately 2” off the ground and support securely with jack stands. Sit on mower. Release the brake. 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 50 Troubleshooting < Table of Contents...
Page 51 Electronics Tips for the Mechanical Small Engine Technician 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. Keep in mind you were born with the most powerful trouble shooting tools: Eyes: LOOK for signs of wear, deformation, disconnection, pinched wires, charger LED patterns...
Page 52 Electronic Terms, Symbols, and 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 53 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 2.
Page 54 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.
Page 55 Revision Log 8-25-2018 Added: “Revision Log” Added “Mower Overview” Added “A word about Brushless Motors” Added “Block Diagram and Control Flow” Added “Trouble Shooting: General” Added “Trouble Shooting: Specific” Changed method (to DMM diode setting) and added pics for “Testing the Drive Controller” Added “Electronics Terms, Symbols”...

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