Ry48ztr75 ServiceManual

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 • Testing Headlight Switch • Testing Drive Motors

• ZTR Mower Overview • Testing the Drive Speed Switch • Testing Drive Motor Hall Sensors
• Brushless Motors • Testing Blade Cutting Speed Switch • Testing 48V-12V Converter and fuse
• Using this Manual • Testing Fuel Gauge / Hour Meter • Testing Relay
• ZTR Block Diagram and Control Flow • Testing Key Switch • Testing Relay Diode
• Troubleshooting: General • Testing USB Port • Testing Charge port and interlock
• Troubleshooting: Detailed • Testing the Neutral “Zero” Switches • Testing the Battery Charger
• DMM and Other Tools • Testing Headlight Assembly • Battery Charger Error Codes
• Component Locations • Testing Accelerator (angular transducers) • ZTR Beep Codes
• Controller and Label Locations • Testing Brake Switch • Testing the Temperature Sensor
• Main Battery Connection • Testing Beeper • Wire Harness
• Testing Main Fuse • Testing Seat Switch • Pre and Post-Repair Checklist
• Testing Battery Voltage • Testing Primary Blade Motor Controller • Electronic Tips for the Mechanical Small Engine Tech
• Control Panel • Testing Secondary Blade Motor Controller • Electronics Terms, Symbols and Tools
• Testing PTO Switch • Testing Drive Motor Controllers • Using the Digital Multi-Meter (DMM)
• Testing Blade Motors
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.
OVERVIEW
The RYOBI ZTR riding mower is completely electrical, consisting of 4 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” that responds to various inputs such as the accelerators,
seat switch, etc.
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.
Applying a voltage directly to these phases will cause damage.
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
A Block Diagram shows the general flow to visualize how the mower is connected and
a chart 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.
TOOLS NEEDED
Sockets and
Torx Screwdrivers
Wrenches
T27 Cross tip 8 mm
T30 Flat blade 10 mm
T40 13 mm
14 mm
15 mm
17 mm
19 mm
BLOCK DIAGRAM AND CONTROL FLOW
48V 5V out RIGHT Left
Head
Batteries USB Neutral Neutral
Lights
switch switch
Main Fuse
Accelerator Accelerator
Charge
Port/lockout/ 12V
Drive Speed
battery temp Switch
48V to 12V Seat
Relay
(DC to DC) switch
Key Fuse converter Brake
Switch 48V Switch
Enables
Beeper
Fuel Blade Secondary Primary Secondary Primary
Gauge Speed Blade Blade Drive Drive
Control Control Controller Controller
PTO
Hall Sensors
Hall Sensors
Note: A detailed wire harness diagram is Motor Motor Motor Motor
located later in this document
Important:Primary and secondary

have a communication link. If one
blade motor or controller fails,
BOTH will shut down.
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.
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.
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 a tactile “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 a short 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 a common part available at any automotive store
TROUBLESHOOTING: DETAILED CONTINUED
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. Replace if necessary.
e. If the mower still will not drive, test the Drive Motor controllers. Replace if necessary.
f. Test the drive motors and Hall sensors, replace as necessary
9. Test the blade operation by pulling up on the PTO switch
a. Make sure the seat switch is functional and activated.
b. Test the primary and secondary motors. Replace as a pair if found bad
c. Test the primary blade and secondary blade controllers. Replace as a pair if found bad.
d. If the mower blades still will not operate, replace the Drive motor controllers (same as step 8e above)
10. If the mower works except for the headlights, test the headlight switch and headlights. Replace as necessary
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 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
COMPONENT LOCATIONS
Charge port Seat

Switch
Access panel
(under seat) Beeper
DC-DC Controllers
converter
Neutral “zero” Brake Switch

Switches Headlights
Accelerator
transducers
CONTROLLERS AND LABEL LOCATIONS
(Shown with passenger leg panel removed)
As a note the
RY48140 will
have 3 deck
motor controllers
with 2 being
Secondary and
1 as a Primary
“Deck Motor Controller” “Deck Motor Controller” “Drive Motor Controller 2” “Drive Motor Controller”
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.
BE CAREFUL NOT TO DAMAGE THE CONNECTOR.
MAIN FUSE
IMPORTANT: If the main fuse is blown, find 1.Disconnect main battery connection
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.
• Ensure the nuts are tight, but not
• overtightened, as this can cause the fuse
• to twist and break.
Where probes go
If fuse is blown,
Replace only with the same physical size and same
Amperage.
CHARGING PORT
Two Different Charging Ports
The Charging port on the Left is the Gen 1 The Charging port on the Right is the Gen 2
charger. charger.
Note the Different

indexing plugs.
Make sure when

ordering charging
port or charger
they are the same
type.
BATTERY VOLTAGE TEST
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 event, find the blue connector
more accurate measurement. which connects directly to the
batteries. Disconnect it, and
4. Place RED DMM probes indicated by red arrow, BLACK probe by black arrow measure battery voltage
Charge Indicator LED (LED should blink in

similar pattern to charger when charger is
connected)
Charger Interlock
Note: New mowers have a different

pattern of Indexing pin. When requesting
repair parts, send a picture of this
connector to ensure proper parts
For the charger and charge port
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
Gun
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.
Extra care is needed to avoid damaging surrounding parts by the heat. Be careful of the batteries.
CONTROL PANEL
Main Power Key Switch

PTO
(Power Take Off)
Headlight switch
Low Speed Cut Button
Low Speed Button

Fuel Gauge/ Hour Meter
USB Charger
TESTING PTO SWITCH
1. Mower Power OFF

2. DMM set to measure Resistance Note: Make sure spade plugs
are secure. They should be
3. Insert DMM probes where indicated. When red button is
PULLED OUT, the switch is CLOSED (very LOW resistance or locked in place and should
5 not come loose if the wires
continuity)
v are pulled on.
Note: these terminals

are not used
4. When red button is PUSHED IN, the switch is OPEN (very

HIGH resistance or no continuity)
TESTING THE RMO SWITCH
1. DISCONNECT MAIN POWER FROM MOWER.
2. Set DMM to “Diode” mode.
3. Touch leads where indicated. LED should light (polarity of 2.5V

probes does not matter).
4. Set DMM to Resistance mode. Switch is normally open

(N.O.). Measure continuity when button held in. Measure
high resistance when released. 5-6V
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.

5-6V
Pressing the buttons alternates between open and closed.
TESTING HEADLIGHT SWITCH
1. Disconnect Main Power from Mower.
2. DMM set to “Diode” mode.

12V
3. Touch the leads where indicated. LED should light
4. Set DMM to Resistance mode. This is a latching switch.

12V
Pressing the buttons alternates between open and closed.
TESTING DRIVE SPEED SWITCH AND CUTTING SPEED SWITCH
• This test procedure is the same as the headlight switch procedure.

• The only difference is these switches are momentary.
• When the button is held in, the switch is closed.
• When the button is released, the switch is open.
TESTING FUEL GAUGE/ HOUR METER
Percent Charge remaining
Approximate charge remaining Total hours of use

(mower must be on
Continuously for a minimum
1. Turn Mower switch ON. of 6 minutes for time to change)
2. Set Volt meter to “DC VOLTS”.
3. Measure battery voltage between Red and Black wire (below, left)
4. Measure battery voltage between Black and Blue wires (below, right) Approximately 51V fully charges, no load
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
Note this switch operates at 48V DC

To measure Switch with wires disconnected:
Set DMM to measure continuity
OFF position: No continuity between green and red wire.

ON position: Continuity between green and red wire.
AUX position: Not used at time of this writing.
TESTING USB PORT
The USB port is marked “+” (yellow wire) Note: The “+” spade lug is larger than the “-” lug
and “-” (black wire).
1. Power ON Mower. *USB operated 11.5v-12.5V nominal
2. Set DMM to measure DC Volts. power IN, 5V OUT. The LED indicates
3. Connect a scrap USB cord with one end there is power IN, But does not
removed. guarantee the USB 5V out is working.
4. Measure 5V between the red and black wire
USB power indicator LED*
Measure 12V where indicated below. If LED
indicator is not on, USB port is bad.
TESTING THE ZERO SWITCHES
A zero switch is located at the base of each steering arm

TESTING THE NEUTRAL SWITCHES
1. Set meter to measure continuity and connect probes

2. With switch NOT pressed, measure No continuity
3. With switch pressed, measure continuity
4. Make sure wires and connector are in good shape and wires don’t pull loose
Note: the switches are pressed when the steering arms are in the out position
TESTING HEAD LIGHT ASSEMBLY
POSITIVE ”+”
“-” NEGATIVE
1. Power on Mower. To test Headlight module independently:
2. Turn on Headlights.
3. Set DMM to measure DC Volts. 1. Disconnect Headlight from wire harness.
4. Measure for 12V at harness. 2. Supply 12V to the connector as shown above.
Nominal current: 275mA
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. Connect 5V power to pin that mates with Red wire on harness and ground to pin that
mates with black wire to harness.
3. Place probes on White (signal wire) and black (ground).
4. Slowly turn the accelerator with a coin. Voltage should change gradually
between 0V and approx. 4.7V.
TESTING BRAKE 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.

High resistance when plunger pressed.
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. Set DMM to measure voltage.
2. Set mower to REVERSE.
3. Place probes in harness socket.
4. Measurement display should alternate between 0 and 12V.
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. Turn ON the mower.
2. Set DMM to Volts.
Note: this switch operates at 5V.
3. Measure 5VDC between the 2 pins on the
harness.
CONTROLLER LOCATION
The only difference between the RY48ZTR’s and the RY48140 it that there are 3 deck controllers
One primary and two secondary controllers
TESTING PRIMARY BLADE CONTROLLER
Test for short circuit:
1. Disconnect all connectors to Primary Controller.
2. Temporarily touch a wire between “+” and “-” wires to drain
capacitance.
3. Set meter to Resistance Mode.
4. 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:
1. Set DMM to Resistance Mode.
Note: Primary Controller is
2. Check continuity between any two terminals .
identified by additional large square
3. Check continuity between other terminals. connector as shown above.
4. Both measurements should be nearly identical. Secondary Controller does not have
this connector
Test Power and Ground to output circuitry
1. Set DMM to “Diode” mode
2. Connect black lead of DMM to heavy black wire (ground).
3. Sequentially connect the red probe wire to each pin shown above.
4. Meter should read “Open” for each pin.
5. Connect black lead of DMM to heavy RED wire (ground).
6. Sequentially connect the red probe to each pin.
DMM should measure approx .48V for each pin (indicating diode good).
TESTING SECONDARY BLADE CONTROLLER
1. Disconnect all connectors to Secondary Controller.
2. Temporarily touch a wire between “+” and “-” wires
to drain capacitance.
4. Connect DMM probes to heavy red wire (power) and
heavy black (ground) wire to check for short circuit.
Nominal resistance: 1.45M Ohms
Check for resistance controller output:
Note: Primary Controller is identified
1. Set DMM to Resistance Mode. by large square connector (see
2. Check continuity between any two terminals. previous page).
3. Check continuity between two other terminals.
Secondary Controller does not have
Nominal resistance: 18K Ohms this connector.
Test Power and Ground to output circuitry

1. SET DMM to “DIODE”
3. Sequentially connect the red probe wire to each pin. Meter
should measure “open”.
5. Sequentially connect the red probe to each pin (diode test .4V).
6. Meter should measure approximately .48V.
TESTING DRIVE CONTROLLER
2. Connect DMM probes to heavy red wire (power) and heavy black (ground) wire to check
for short circuit.
Nominal resistance: 750K Ohms

Check resistance in controller output:
1. Set DMM to Resistance Mode.
2. Check continuity between any two terminals (heavy Yellow and heavy green for
example). BATT + BATT -
3. Check continuity between two other terminals (2 and 3 for example).
4. The 2 measurements should be nearly identical.
U
Nominal resistance: 20K Ohms
Test Power and Ground Resistance at output circuitry V

2. Sequentially connect the red probe wire to each pin.
3. The measurements should be nearly identical. W
Nominal resistance : open circuit

2. Sequentially connect the red probe to each pin.
3. The measurements should be nearly identical.
Nominal resistance 10k Ohms Confidential & Proprietary – Property of Techtronic Power Equipment – DO NOT COPY or DISCLOSE
TESTING 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
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
Drive Heavy motor Hall sensors

Motor phase wires
Hall Sensor Bundle
(white connector)
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. Should measure 4-5V.
Leave black probe connected to black wire.
1. Touch red probe to yellow wire Slowly

rotate motor. Voltage should Jump
between 0V and 4-5V.
2. Repeat with green wire.
3. Repeat with blue wire.
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. Measure ~48V between Red and black wire as indicated.
3. Check for 12V output at blue and yellow wire.
To test Converter Module Independently:
1. Apply 48V “+” to Red AND Yellow wire.
2. Apply “-” to black wire.
3. Check for 12V output at blue and green wire.
Note: Red and Black are 48V input Blue and green are 12V output
Yellow is a control wire (48V) to turn on the output
RELAY BASICS
Relay A relay consist of an electromagnet

+ and a switch, controlled by the electromagnet,
within a single package
+12V 48V
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.
-
Diode Electromagnet Switch It is standard practice to add a diode across the electromagnet to
or “coil” suppress spikes. It is very Important to connect the diode in the
correct orientation!
TESTING RELAY
Relay General rules of thumb:
+ 1. When you turn on mower, you should hear a “clunk” when

the relay engages. and also when you turn off the mower
+12V 48V
and the relay disengages.
2. If headlights work, the relay is good

-
3. If the relay “chatters”, ensure all
Diode Electromagnet Switch
nuts are securely tightened on the relay
or “coil”
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

POS independent of mower:
NEG (+)
(-)
1. Unbolt one leg of diode if equipped.
2. Set DMM to measure Resistance.
3. Connect DMM to large terminals.
4. Apply 12V to small terminals.
5. You should hear a click as the relay switch Is activated,
and measure small resistance at relay terminals
Nominal resistance 1.5 Ohms

TESTING RELAY DIODE
Diode Test:
1. Turn Mower OFF.
2. Unbolt one leg of diode to disconnect from the
circuit.
3. Set DMM to “Diode”.
Diode 4. Connect red lead at red arrow, black lead at
black arrow. DMM should read approx 7V.
5. Reverse the red and black leads. DMM should
read “open circuit”
6. Replace or reconnect diode.
Note: Make sure diode is installed correctly. band on
diode indicates polarity.
TESTING CHARGING 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).
6. Remove the jumper wire.

7. After a few seconds, the mower should come back on(relay clicks)
and headlights light again.
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. Plug the charger into a 120V outlet.
7. Connect the other end of the jumper wires to the blue connector as shown (red to red, black to black)
8. Reconnect main battery connection.
9. The Charger LED should blink green.
10. This is a temporary test. Remove wires immediately after test. Test should only take a few second
Note: There are no electronics needed for this test. But you will need suitable 12 gage wires as shown. This procedure will charge the batteries (if the
charger and batteries are good). Use caution Especially If using alligator clip jumper wires. Wear rubber gloves and eye protection.
* Note: The LED on the charger will NOT light until connected to mower
CHARGER ERROR CODES
CODE MEANING SOLUTION
Check charger/ mower connection and remove any
Charge Enable Fault: May indicate poor contact at the charger connector or the
One red flash debris. Allow hot batteries to cool, Then try charging
battery temp is too hot (Greater than 122 F
again.
Batteries must be charged by another means to bring
Battery Voltage Fault: May indicate installed battery or batteries are less than 36v or
Two red flash them to 36v or mower must be run to discharge
more than 67.2v or they are too discharged or overcharged to be charged.
batteries to below 67.2v.
Battery Charge Timeout: Charge time exceeded may indicate a problem with the
Disconnect charger. Allow batteries to cool, then try
Three red flash mower batteries or that the charger output current was reduced due to high ambient
charging again.
temperatures.
Disconnect charger. Check battery series
Battery Fault: Charge time exceeded indicates a problem with battery voltage not configuration to be sure batteries are properly
Four red flash
attaining the required nominal level within the maximum time allowed. connected. Allow batteries to cool then try charging
again.
Make sure the charger cooling fins are clear of
Temperature Delay: Charger had to turn off its output due to excessive internal obstruction and that the charger itself is not sitting in
Five red flash
temperature. direct sunlight. If charger is hot, allow to cool before
attempting to charge again.
Unplug charger, then plug back in and try charging
Six red flash Charger Fault: Internal fault detected
again.
*Delta Q Charger Only
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.
WIRING HARNESS
PRE AND POST REPAIR CHECKLIST
1. Jack rear tires approximately 2” off the ground and support securely with jack stands.
2. Sit on mower.
3. Turn main power key to “ON”. The Fuel Gauge/Hour meter should light up.
4. Put FNR switch in FORWARD position.
5. Put accelerator at full speed and hold. Rear wheels should be turning…
6. Pull PTO knob up, blade motors should run and rear wheels should slow down . Turn off PTO, ensure blade
7. motors stop.
8. Put accelerator about ½ way down and press cruise. Cruise switch should light and wheels should continue to turn when accelerator is released.
9. Press RMO button. RMO light should come on.
10. Put in REVERSE and press accelerator. Turn on PTO. Blades should operate while wheels turn backwards. Beeper should sound.
11. Press headlights button. Button should light and both headlights should come on.
12. Check that USB has power by verifying blue indicator light is on.
13. Remove yourself from mower seat. Beeping should be heard when there is no weight on chair. Connect charger and verify charging LEDs are working correctly (green)
14. Attempt to start mower and drive away with charger connected. This should not be possible.
Beep codes: Continuous beeping = Normal occurrence when F-N-R switch is in REVERSE condition 3 beeps = key is switched to “ON” but no operator on seat.
ZTR BEEP DIAGNOSTIC CODES
BEEP # DESCRIPTION CHECK: IF NOT SOLVED… IF NOT SOLVED… IF NOT SOLVED…
Angle sensor not at Replace control lever
1 Turn key off, return both levers to open, turn key on Replace charger board Check angle sensor connections
neutral assembly
2 Over current Return both levers to open and try operate again Replace both drive controllers
Lift up the unit to allow rear wheels to spin freely.

Turn key off, push unit by hand and check if it can be Check each wheel spining and replace the
Motor stall Return both levers to open and try operate again easily pushed, if hard to push, chech which side is motor/tranmission assembly on the side that is
hard to push. binding
3
Disconnect seat switch and short circuit the male
Use hand to push down the center of the seat and try terminal(mower side), if resolved, replace seat
Check seat switch connection and wiring integrity
Seat switch open again switch
4
Fuel gauge if battery was charged above 5%, if not,
5 Under voltage charge the unit
7 Over temperature Return both levers to open and try operate again Wait 30 minute and try again Replace drive controllers
Check hall sensor connectors and unplug and plug in Replace drive motor/gearbox assembly for
8 Hall sensor fault Return both levers to open and try operate again
again the affected side
Check com connectors, unplug and plug in again and
tug on the wire to see if any wire is loose Replace drive controllers
10 Com port
Check com connectors, unplug and plug in again and
tug on the wire to see if any wire is loose Turn key off, and turn key back on Replace drive controllers
11 Com port
Turn key off, push unit by hand and check if it can be
Check charger connector, unplug and plug in again and
easily pushed, if hard to push, replace drive
tug on the wires to see if any wire is loose
13 Self test controllers
17 Angle sensor failure Return both levers to open and try operate again Check angle sensor connections Replace control lever assembly
Return both levers to open and try operate again Replace control lever assembly
19 AD error
Turn key off, return both levers to open, turn key on Replace drive controllers
20 CPU error
ELECTRONIC 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.
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
Ears: LISTEN for beeps (error codes), clicks (relay), squeals (bearings)…
Nose: SMELL overheated components, tranny oil leaks…
Touch: FEEL (carefully) if components are too hot or not warm at all, vibration
Mouth: ASK for help or a second opinion if something is in question. A second set of eyes and
ears can do wonders.
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. Resistance is noted

by the Greek “Omega” symbol, Which resembles a horse shoe or Digital
upside down “u” Measuring resistance is often used to detect Multi
continuity Or a break in a wire or switch. Meter
(DMM)
A Diode is a device that allows current to flow in only

one direction and blocks current flow in the other direction.
A Diode is noted by the symbol
The diode has a white band to indicate the polarity
White band
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. Touch the Black probe to ground
3. Touch the Red probe to voltage being
measured
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. Touch the black probe to one point.
3. Touch the red probe to the other point.
The DMM in the photo displays 18.46 K ohms

“K” means Kilo or 1,000 or 18460 Ohms

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SERVICE CENTER ELECTRICAL SYSTEM TROUBLESHOOTING AND TESTING GUIDE

RYOBI RY48ZTR75/100 AND RY48140 RIDING MOWER

• WARNING • Testing Headlight Switch • Testing Drive Motors

THIS MATERIAL INTENDED ONLY FOR TECHNICIANS TRAINED IN ELECTRICAL REPAIR.

Technicians should wear personal protective equipment, such as rubber

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

• A brushless motor and controller for each of the 2 blades

Brushless motors can be recognized by 3 wires. These 3 wires require a controller to

Applying a voltage directly to these phases will cause damage.

Important:Primary and secondary

• Follow the Block Diagram on the previous page.

Also note where the red and black jacks

If you are unfamiliar with a DMM, please read the section

Charge port Seat

Neutral “zero” Brake Switch

(Shown with passenger leg panel removed)

The main battery disconnect is located directly under the seat

NOTE THAT ONE HALF OF THE CONNECTOR IS

Note the Different

Make sure when

Charge Indicator LED (LED should blink in

Note: New mowers have a different

Main Power Key Switch

Low Speed Button

1. Mower Power OFF

Note: these terminals

4. When red button is PUSHED IN, the switch is OPEN (very

1. DISCONNECT MAIN POWER FROM MOWER.

2. Set DMM to “Diode” mode.

3. Touch leads where indicated. LED should light (polarity of 2.5V

4. Set DMM to Resistance mode. Switch is normally open

1. Disconnect Main Power from Mower.

2. DMM set to “Diode” mode.

4. Set DMM to Resistance mode. This is a latching switch.

1. Disconnect Main Power from Mower.

2. DMM set to “Diode” mode.

4. Set DMM to Resistance mode. This is a latching switch.

• This test procedure is the same as the headlight switch procedure.

Percent Charge remaining

Approximate charge remaining Total hours of use

1. Set DMM to DC Volts

2. With Power switch OFF, measure battery voltage

3. With Power ON, measure approx. 0V where indicated

Note this switch operates at 48V DC

Set DMM to measure continuity

OFF position: No continuity between green and red wire.

A zero switch is located at the base of each steering arm

1. Set meter to measure continuity and connect probes

To Test Transducer Independently:

1. Turn Power Off.

To test brake switch independently:

Continuity when plunger is NOT pressed.

Or put mower in Reverse.

This should cause beeper to activate.

To measure the voltage at the harness:

1. Power Mower OFF.

To Measure the harness:

Typical resistance: 1.46M

Test Power and Ground to output circuitry