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Trouble Trouble shooting shooting In the In the Electrical Electrical System System

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Page 1: Trouble shooting In the Electrical System TROUBLE SHOOTING On every lawn tractor,circuit On every lawn tractor, the safety circuit work in two ways:

Trouble shootingTrouble shootingIn theIn the

Electrical SystemElectrical System

Page 2: Trouble shooting In the Electrical System TROUBLE SHOOTING On every lawn tractor,circuit On every lawn tractor, the safety circuit work in two ways:

TROUBLE SHOOTING

On every lawn tractor,On every lawn tractor, the safety circuitcircuit work in two ways:

These are?These are?

Starting circuitStarting circuit&&

Work safety circuitWork safety circuit

Lawn-tractors and Rider Models

Page 3: Trouble shooting In the Electrical System TROUBLE SHOOTING On every lawn tractor,circuit On every lawn tractor, the safety circuit work in two ways:

Starting circuitStarting circuitBy preventing the engine from starting if all the safety requirements have not been

met

Work safety circuitWork safety circuitStopping the engine if even just one of the

safety requirements is lacking.

TROUBLE SHOOTING

Lawn-tractors and Rider Models

Page 4: Trouble shooting In the Electrical System TROUBLE SHOOTING On every lawn tractor,circuit On every lawn tractor, the safety circuit work in two ways:

Ignition Switch ConfigurationIgnition Switch Configuration

PCB FEEDING ENGINE STARTING

The ignition works as a simple switch.Lights and „Engine Grounding“ are managed by PCB.

TROUBLE SHOOTING

Lawn-tractors and Rider Models

Page 5: Trouble shooting In the Electrical System TROUBLE SHOOTING On every lawn tractor,circuit On every lawn tractor, the safety circuit work in two ways:

Ignition Switch ConfigurationIgnition Switch Configurationfor SD98/108 Modelsfor SD98/108 Models

TROUBLE SHOOTING

Lawn-tractors and Rider Models

Page 6: Trouble shooting In the Electrical System TROUBLE SHOOTING On every lawn tractor,circuit On every lawn tractor, the safety circuit work in two ways:

There are electrical parts common to all PCB There are electrical parts common to all PCB on every lawn tractor.on every lawn tractor.

(not for (not for 63 63 andand 98/108 98/108 withwith GGP EnginesGGP Engines Model)Model)

These are?These are?Protectors

They breaks the circuit if there is a fault in the electrical system. It results in the stopping of the engine and:

an audible signal (for 102/122...) which can only be stopped by turning the key (OFF position).

the lamp‘s turning off (for 92 and 72).

TROUBLE SHOOTING

Lawn-tractors and Rider Models

on 98/108 Series NO signals, No lamps.

Page 7: Trouble shooting In the Electrical System TROUBLE SHOOTING On every lawn tractor,circuit On every lawn tractor, the safety circuit work in two ways:

TROUBLE SHOOTING

Lawn-tractors and Rider Models

PCB (type)Self-resetting PROTECTION

Self-resetting protection ATTIVATION

Battery terminal crossed

PROTECTION

6327722354/0 (Elect. START)

27722357/0 (manual START) NO N/A NO

72 25722415/1 YESfailure of the LED to light

or switching off during work

YES

NJ92-NJ10225722430/1 (1 LED)25722431/0 (6 LED) YES ? YES

25722433/0 (GGPEngine) NO N/A YES82722429/0 (B&S/HONDA

Engine) YESNO visible or audible

SIGNALS YES

102-122

25722413/1 (6-7-8 LED)82722420/2 (No LCD Type A)

82722421/2 (LCD Type B)82722423/2 (LCD Type C)82722422/3 (LCD Type D)

YES

It is signalled by a beep, except in cases where the battery is missing, flat or

with the terminal crossed.

YES

2-4WD102-122

82722423/2 (LCD Type C)82722422/3 (LCD Type D) YES

It is signalled by a beep, except in cases where the battery is missing, flat or

with the terminal crossed.

YES

SD98-SD108

ELECTRONIC CARDS (PCB) INFO

MODEL

FEATURES (from 2010/2011)

Page 8: Trouble shooting In the Electrical System TROUBLE SHOOTING On every lawn tractor,circuit On every lawn tractor, the safety circuit work in two ways:

TROUBLE SHOOTING

Lawn-tractors and Rider Models

PCB (type)Self-resetting PROTECTION

Self-resetting protection ATTIVATION

Battery terminal crossed

PROTECTION

6327722354/0 (Elect. START)

27722357/0 (manual START) NO N/A NO

72 25722415/1 YESfailure of the LED to light

or switching off during work

YES

NJ92-NJ10225722430/1 (1 LED)25722431/0 (6 LED) YES ? YES

25722433/0 (GGPEngine) NO N/A YES82722429/0 (B&S/HONDA

Engine) YESNO visible or audible

SIGNALS YES

102-122

25722413/1 (6-7-8 LED)82722420/2 (No LCD Type A)

82722421/2 (LCD Type B)82722423/2 (LCD Type C)82722422/3 (LCD Type D)

YES

It is signalled by a beep, except in cases where the battery is missing, flat or

with the terminal crossed.

YES

2-4WD102-122

82722423/2 (LCD Type C)82722422/3 (LCD Type D) YES

It is signalled by a beep, except in cases where the battery is missing, flat or

with the terminal crossed.

YES

SD98-SD108

ELECTRONIC CARDS (PCB) INFO

MODEL

FEATURES (from 2010/2011)

NOTA : l'intervento della protezione autoripristinante è associabile a TUTTE le casistiche dove c'è una sovratensione

NOTE : in general the attivation of the SELF RESETTING PROTECTION is caused by an OVERVOLTAGE on the circuit

· Battery terminal crossed

· Short circuit to earth (microswitches)

· Overvoltage from a malfunction in the regulator

· Sulphated battery

Page 9: Trouble shooting In the Electrical System TROUBLE SHOOTING On every lawn tractor,circuit On every lawn tractor, the safety circuit work in two ways:

Activation of the protection

Trouble shooting within the starting circuitTrouble shooting within the starting circuit(not for (not for 6363 Model) Model)

Possible reasons :Possible reasons :

1.1. Check the battery (battery terminals corroded or with Check the battery (battery terminals corroded or with poor contact)poor contact)

2.2. Check the connectors and wiring of the microswitches Check the connectors and wiring of the microswitches (Short circuit to ground).(Short circuit to ground).

... in position «ON» or after a few seconds use:

TROUBLE SHOOTING

Lawn-tractors and Rider Models

Page 10: Trouble shooting In the Electrical System TROUBLE SHOOTING On every lawn tractor,circuit On every lawn tractor, the safety circuit work in two ways:

The cause of the fault should be ascertained and dealt with to avoid re-activating the protection device.

Trouble shooting within the starting circuitTrouble shooting within the starting circuit(not for (not for 6363 Model) Model)

Possible reasons :Possible reasons :

1.1. Poor or missing ground contact on the charge regulator Poor or missing ground contact on the charge regulator or on the PCBor on the PCB

2.2. Overvoltage from a malfunction in the regulatorOvervoltage from a malfunction in the regulator

... after several minutes’ use:

3.3. Battery disconnected or faulty during useBattery disconnected or faulty during use

Activation of the protection

TROUBLE SHOOTING

Lawn-tractors and Rider Models

Page 11: Trouble shooting In the Electrical System TROUBLE SHOOTING On every lawn tractor,circuit On every lawn tractor, the safety circuit work in two ways:

Starting CircuitStarting CircuitWhat must be given to start the tractor?What must be given to start the tractor?

(From a safety point of view)(From a safety point of view)

the transmission is in “neutral”;the transmission is in “neutral”;the blades are not engaged;the blades are not engaged;

andandthe operator is seated or the parking the operator is seated or the parking

brake is engaged.brake is engaged.TROUBLE SHOOTING

Lawn-tractors and Rider Models

Page 12: Trouble shooting In the Electrical System TROUBLE SHOOTING On every lawn tractor,circuit On every lawn tractor, the safety circuit work in two ways:

On every lawn tractor On every lawn tractor when the operator is SEATED, the operator safety switch plunger must be fully depressed.

MICROSWITCH

TROUBLE SHOOTING

Lawn-tractors and Rider Models

Page 13: Trouble shooting In the Electrical System TROUBLE SHOOTING On every lawn tractor,circuit On every lawn tractor, the safety circuit work in two ways:

MICROSWITCH

On every lawn tractor On every lawn tractor when the blades are NOT ENGAGED, the BLADES safety switch plunger must be fully

depressed.

Blade Engagement Lever

FOR ELECTROMAGNETIC CLUTCH MODEL, THERE IS A BUTTON (SWITCH) ON THE DASHBOARD

BLADES ARE NOT ENGAGED

TROUBLE SHOOTING

Lawn-tractors and Rider Models

Page 14: Trouble shooting In the Electrical System TROUBLE SHOOTING On every lawn tractor,circuit On every lawn tractor, the safety circuit work in two ways:

MICROSWITCH

On every lawn tractor On every lawn tractor when the parking brake IS NOT ENGAGEDIS NOT ENGAGED, the BRAKE safety switch plunger must be fully depressed.

PARKING BRAKE IS NOT ENGAGED

TROUBLE SHOOTING

Lawn-tractors and Rider Models

Page 15: Trouble shooting In the Electrical System TROUBLE SHOOTING On every lawn tractor,circuit On every lawn tractor, the safety circuit work in two ways:

On Hydrostatic Transmission On Hydrostatic Transmission when the transmission IS NOT IS NOT ENGAGEDENGAGED, the safety switch plunger must be fully depressed.

MICROSWITCH

TROUBLE SHOOTING

Lawn-tractors and Rider Models

Page 16: Trouble shooting In the Electrical System TROUBLE SHOOTING On every lawn tractor,circuit On every lawn tractor, the safety circuit work in two ways:

At last, GEAR TRANSMISSION safety switch, for PEERLESS transmission (on starting configuration) must be depressed too

MICROSWITCH is positioned inside of the transmission

TROUBLE SHOOTING

Lawn-tractors and Rider Models

Page 17: Trouble shooting In the Electrical System TROUBLE SHOOTING On every lawn tractor,circuit On every lawn tractor, the safety circuit work in two ways:

STARTER

ENGINE

BATTERY

SOLENOID

BATTERYBATTERY

IGNITION SWITCH

NC - 3

NO - 2C

START

BLADES SWITCH

NC - 3

NO - 2C

NC - 3

NO - 2C

NEUTRAL SWITCH

SEAT SWITCHBRAKE SWITCH

TROUBLE SHOOTING

Page 18: Trouble shooting In the Electrical System TROUBLE SHOOTING On every lawn tractor,circuit On every lawn tractor, the safety circuit work in two ways:

Trouble shooting within the starting circuitTrouble shooting within the starting circuit

If the engine cranks but does not start, when If the engine cranks but does not start, when turning the ignition key to the start position, the turning the ignition key to the start position, the

electrical starting circuit is...?electrical starting circuit is...?

IntactIntact..

TROUBLE SHOOTING

Lawn-tractors and Rider Models

Page 19: Trouble shooting In the Electrical System TROUBLE SHOOTING On every lawn tractor,circuit On every lawn tractor, the safety circuit work in two ways:

The dashboard (for The dashboard (for 102/122) or the pilot lamp (or the pilot lamp (for,92 and 72) ) remains offremains off when the ignition key is turned to when the ignition key is turned to

the the ONON position then the starting circuit is not working. position then the starting circuit is not working.What are the logical trouble shooting steps? What are the logical trouble shooting steps?

Trouble shooting within the starting circuitTrouble shooting within the starting circuit(not for (not for 6363 Model) Model)

1.1. Check and replace fuse 10 ACheck and replace fuse 10 A

2.2. Battery or card not earthed to frame... check (and put right) Battery or card not earthed to frame... check (and put right)

3.3. Check the battery (connection cables and battery’s condition)Check the battery (connection cables and battery’s condition)

TROUBLE SHOOTING

Lawn-tractors and Rider Models

Page 20: Trouble shooting In the Electrical System TROUBLE SHOOTING On every lawn tractor,circuit On every lawn tractor, the safety circuit work in two ways:

The dashboard (for The dashboard (for 102/122) or the pilot lamp (for,or the pilot lamp (for,92 and 72) ) switches onswitches on when the ignition key is turned to the when the ignition key is turned to the STARTSTART position, but the starter does not turn or lacks position, but the starter does not turn or lacks

power.power.What are the logical trouble shooting steps? What are the logical trouble shooting steps?

Trouble shooting within the starting circuitTrouble shooting within the starting circuit

1.1. Check the battery charge.Check the battery charge.

2.2. Check (and put right) : badly earthed battery, or the starter relay or motor not Check (and put right) : badly earthed battery, or the starter relay or motor not earthedearthed

3.3. Check the starter relayCheck the starter relay

These trouble shooting steps + the ones with the key in the „ON“

position, are are OK for 63cm63cm

TROUBLE SHOOTING

Lawn-tractors and Rider Models

Page 21: Trouble shooting In the Electrical System TROUBLE SHOOTING On every lawn tractor,circuit On every lawn tractor, the safety circuit work in two ways:

Work safety Work safety circuitcircuit

TROUBLE SHOOTING

Page 22: Trouble shooting In the Electrical System TROUBLE SHOOTING On every lawn tractor,circuit On every lawn tractor, the safety circuit work in two ways:

Work safety CircuitWork safety Circuit

We can identify 3 „work situation“.We can identify 3 „work situation“.These are ...?These are ...?

1.1. When the Lawn-Tractor is cutting.When the Lawn-Tractor is cutting.

2 . When the Lawn-Tractor is moving (blade OFF).2 . When the Lawn-Tractor is moving (blade OFF).

3 . When the Engine is runing and Lawn-Tractor is standing 3 . When the Engine is runing and Lawn-Tractor is standing (blade OFF).(blade OFF).

TROUBLE SHOOTING

Lawn-tractors and Rider Models

Page 23: Trouble shooting In the Electrical System TROUBLE SHOOTING On every lawn tractor,circuit On every lawn tractor, the safety circuit work in two ways:

Work safety CircuitWork safety Circuit

The operator is seatedThe operator is seated

What must be given that the engine continues to run What must be given that the engine continues to run when the Lawn-Tractor is cutting when the Lawn-Tractor is cutting ??

(From a safety point of view)(From a safety point of view)

The parking brake is not engaged.The parking brake is not engaged.

The grass-catcher or the stone-guard are fitted.The grass-catcher or the stone-guard are fitted.

TROUBLE SHOOTING

Lawn-tractors and Rider Models

Page 24: Trouble shooting In the Electrical System TROUBLE SHOOTING On every lawn tractor,circuit On every lawn tractor, the safety circuit work in two ways:

On every lawn tractor (Side Discharge apart) On every lawn tractor (Side Discharge apart) when the grass-catcher or the stone-guard ARE FITTED, the safety switch plunger

must be fully depressed.

MICROSWITCH

TROUBLE SHOOTING

Lawn-tractors and Rider Models

Page 25: Trouble shooting In the Electrical System TROUBLE SHOOTING On every lawn tractor,circuit On every lawn tractor, the safety circuit work in two ways:

NC - 3

NO - 2C

OPERATOR SWITCH

ENGINE

NC - 3

NO - 2C

BRAKE SWITCH

NC - 3

NO - 2C

NC - 3

NO - 2C

GRASS-CATCHER SWITCH

NC - 3

NO - 2C

NC - 3

NO - 2C

TROUBLE SHOOTING

Page 26: Trouble shooting In the Electrical System TROUBLE SHOOTING On every lawn tractor,circuit On every lawn tractor, the safety circuit work in two ways:

Work safety CircuitWork safety Circuit

The operator is seatedThe operator is seated

What must be given that the engine continues to run What must be given that the engine continues to run when the Lawn-Tractor is movingwhen the Lawn-Tractor is moving ??

(From a safety point of view)(From a safety point of view)

The parking brake is not engaged.The parking brake is not engaged.

TROUBLE SHOOTING

Lawn-tractors and Rider Models

Page 27: Trouble shooting In the Electrical System TROUBLE SHOOTING On every lawn tractor,circuit On every lawn tractor, the safety circuit work in two ways:

NC - 3

NO - 2C

OPERATOR SWITCH

ENGINE

NC - 3

NO - 2C

NC - 3

NO - 2C

BRAKE SWITCH

NC - 3

NO - 2C

TRANSMISSION ENGAGED

TROUBLE SHOOTING

Page 28: Trouble shooting In the Electrical System TROUBLE SHOOTING On every lawn tractor,circuit On every lawn tractor, the safety circuit work in two ways:

Work safety CircuitWork safety Circuit

If the operator leaves his seat, the parking If the operator leaves his seat, the parking brake must be engagedbrake must be engaged

What must be given that the engine continues to run What must be given that the engine continues to run when the engine is runing and Lawn-Tractor is when the engine is runing and Lawn-Tractor is

standingstanding??(From a safety point of view)(From a safety point of view)

TROUBLE SHOOTING

Lawn-tractors and Rider Models

Page 29: Trouble shooting In the Electrical System TROUBLE SHOOTING On every lawn tractor,circuit On every lawn tractor, the safety circuit work in two ways:

DOES THEDOES THELIGHTING CIRCUITLIGHTING CIRCUIT

USE SERIES ORUSE SERIES ORPARALLEL CIRCUITY ?PARALLEL CIRCUITY ?

PARALLELPARALLELTROUBLE SHOOTING

Lawn-tractors and Rider Models

Page 30: Trouble shooting In the Electrical System TROUBLE SHOOTING On every lawn tractor,circuit On every lawn tractor, the safety circuit work in two ways:

HEAD LIGHTS

BATTERYBATTERYBATTERY

IGNITION SWITCH

3

1

2

ON

LIGHT SWITCH

Lighting CircuitLighting Circuit

Lights are glowingLights are glowing withoutwithout

the engine running!the engine running!

TROUBLE SHOOTING

Page 31: Trouble shooting In the Electrical System TROUBLE SHOOTING On every lawn tractor,circuit On every lawn tractor, the safety circuit work in two ways:

The FUSESThe FUSES

Which others „safety catches“ break the circuit if Which others „safety catches“ break the circuit if there is a fault in the electrical system?there is a fault in the electrical system?

10 A fuse = protects the main and power circuits of the electronic circuit board.

25 A fuse = protects the battery charger circuit.

15 A fuse = protects the control motor circuit for grass bag dumper (where the Electric bag tipping control is FITTED).

TROUBLE SHOOTING

Lawn-tractors and Rider Models

5 A fuse = protects the 12 Volt auxiliary accessory socket (where is FITTED).

Page 32: Trouble shooting In the Electrical System TROUBLE SHOOTING On every lawn tractor,circuit On every lawn tractor, the safety circuit work in two ways:

What are the logical trouble shooting steps, What are the logical trouble shooting steps, when the 10 A blows ?when the 10 A blows ?

Trouble shooting for Trouble shooting for FUSESFUSES

1.1. Find and replace the defective user (ignition block, Find and replace the defective user (ignition block, starter relay, headlamps and recharger connector)starter relay, headlamps and recharger connector)

2.2. Replace the panel/board group (PCB) with one that is Replace the panel/board group (PCB) with one that is known to work;known to work;

TROUBLE SHOOTING

Lawn-tractors and Rider Models

Page 33: Trouble shooting In the Electrical System TROUBLE SHOOTING On every lawn tractor,circuit On every lawn tractor, the safety circuit work in two ways:

What are the logical trouble shooting steps, when the What are the logical trouble shooting steps, when the 25 A blows ? 25 A blows ?

1.1. Check the recharge circuit and replace fuseCheck the recharge circuit and replace fuse

Trouble shooting for Trouble shooting for FUSESFUSES

TROUBLE SHOOTING

Lawn-tractors and Rider Models

Page 34: Trouble shooting In the Electrical System TROUBLE SHOOTING On every lawn tractor,circuit On every lawn tractor, the safety circuit work in two ways:

The electric system, the electronic card (PCB) The electric system, the electronic card (PCB) and the battery are protected by only one fuse.and the battery are protected by only one fuse.

Trouble shooting for Trouble shooting for FUSESFUSES

.... For .... For 63cm model63cm model

10 A10 A

TROUBLE SHOOTING

Lawn-tractors and Rider Models

Page 35: Trouble shooting In the Electrical System TROUBLE SHOOTING On every lawn tractor,circuit On every lawn tractor, the safety circuit work in two ways:

So which So which MESSAGEMESSAGE can we focus on our can we focus on our troubleshooting?troubleshooting?

The operator CAN NEVER work on The operator CAN NEVER work on „UNSAFE “ condition.„UNSAFE “ condition.

TROUBLE SHOOTING

Lawn-tractors and Rider Models