Cub Cadet RZT-S Zero Shop Manual

Professional Shop ManualProfessional Shop Manual

NOTE: These materials are for use by trained technicians who are experienced in the service and repair of outdoor power

equipment of the kind described in this publication, and are not intended for use by untrained or inexperienced individuals.

These materials are intended to provide supplemental information to assist the trained technician. Untrained or inexperi-

enced individuals should seek the assistance of an experienced and trained professional. Read, understand, and follow all

instructions and use common sense when working on power equipment. This includes the contents of the product’s Oper-

ators Manual, supplied with the equipment. No liability can be accepted for any inaccuracies or omission in this publication,

although care has been taken to make it as complete and accurate as possible at the time of publication. However, due to

the variety of outdoor power equipment and continuing product changes that occur over time, updates will be made to these

instructions from time to time. Therefore, it may be necessary to obtain the latest materials before servicing or repairing a

product. The company reserves the right to make changes at any time to this publication without prior notice and without

incurring an obligation to make such changes to previously published versions. Instructions, photographs and illustrations

used in this publication are for reference use only and may not depict actual model and component parts.

I

Chapter 1: Introduction

Professional Shop Manual Intent ..................................................................1

Fasteners...................................................................................................... 1

Assembly ......................................................................................................3

Description of the RZT-S Zero ......................................................................3

Model and Serial Numbers ...........................................................................4

Chapter 2: Body

Floor Pan ......................................................................................................5

Left Pod ........................................................................................................8

Right Pod ....................................................................................................11

Seat Box Assembly .....................................................................................13

Chapter 3: Brake and Drive System

Brake System Description........................................................................... 23

Brake Adjustment .......................................................................................24

Brake Puck/rotor Replacement ...................................................................25

Brake Shaft Assembly ................................................................................28

Drop Axle and Hub Motor Assemblies ........................................................29

Rebuilding the Drop Axles ..........................................................................34

Chapter 4: Steering

Introduction .................................................................................................39

Wheel Alignment......................................................................................... 39

Front Wheels ..............................................................................................41

Front Yokes ................................................................................................43

Removal of the Steering Gears ...................................................................46

Drag Links ...................................................................................................50

Steering Sensor ..........................................................................................52

Throttle Position Sensor (TPS) Sensor ......................................................55

Steering and TPS Calibration .....................................................................56

Chapter 5: Electrical System

Introduction .................................................................................................57

System Operation .......................................................................................57

Electric Motors ............................................................................................63

Vehicle Control Module (VCM) ................................................................... 65

Control Panel ..............................................................................................67

Controllers ..................................................................................................70

Troubleshooting ..........................................................................................72

No Power/VCM Does Not Light Up .............................................................73

No Start .......................................................................................................75

Steering Faults ............................................................................................75

Throttle Position Sensor (TPS) Faults ........................................................78

Motor Faults ................................................................................................81

Control Panel Faults ...................................................................................84

Table of Contents

II

Switch Faults ..............................................................................................88

Schematic ...................................................................................................94

Error Codes ................................................................................................95

Chapter 6: Battery Pack and Charger

Valve Regulated Lead-Acid Batteries .......................................................109

Deep Cycle Batteries ................................................................................110

Evaluating the Batteries and the Charger .................................................110

Battery Testing ..........................................................................................113

Capacity/Discharge Test ...........................................................................114

Charger .....................................................................................................115

5-Stage Charge ........................................................................................ 116

Charger Trouble Codes ............................................................................117

Battery Removal/Installation .....................................................................118

Electric Rider Battery Replacement Check List ........................................127

Charger Trouble Codes ............................................................................ 128

Chapter 7: Decks and Lift Shaft

Cutting Decks ...........................................................................................129

Cleaning the Deck ....................................................................................131

Blades .......................................................................................................132

Blade Removal .........................................................................................132

Leveling the Deck .....................................................................................134

Front To Rear (pitch) Leveling ..................................................................135

Deck Gauge Wheel Adjustment ................................................................136

Deck Lift Shaft Assembly ..........................................................................137

Deck Motor ...............................................................................................138

Appendix

Assembly Instruction Manual ..................................................................... A1

Pre-delivery Checklist............................................................................... A11

Introduction

1

Professional Shop Manual intent

This Manual is intended to provide service dealers with an introduction to the mechanical aspects of the RZT-S

Zero zero-turn mower.

Disclaimer: The information contained in this manual is correct at the time of writing. Both the product and the infor-

mation about the product are subject to change without notice.

About the text format:

NOTE: is used to point out information that is relevant to the procedure, but does not fit as a step in the proce-

dure.

• Bullet points: indicate sub-steps or points.

Disclaimer: This manual is intended for use by trained, professional technicians.

• Common sense in operation and safety is assumed.

• In no event shall MTD or Cub Cadet be liable for poor text interpretation or poor execution of the proce-

dures described in the text.

• If the person using this manual is uncomfortable with any procedures they encounter, they should seek

the help of a qualified technician or Cub Cadet Technical Support.

Fasteners

• All of the fasteners used on these mowers are sized in fractional inches.

• If a fastener has a locking feature that has worn, replace the fastener or apply a small amount of releas-

able thread locking compound such as Loctite® 242 (blue).

• Some fasteners like cotter pins are single-use items that are not to be reused. Other fasteners such as

lock washers, retaining rings, and internal cotter pins (hairpin clips) may be reused if they do not show

signs of wear or damage. This manual leaves that decision to the judgment of the technician.

Caution is used to point out potential danger to the technician, operator, bystanders, or sur-

rounding property.

! CAUTION! CAUTION

Warning indicates a potentially hazardous situation that, if not avoided, could result in death

or serious injury.

! WARNING! WARNING

! DANGER! DANGER

Danger indicates an imminently hazardous situation that, if not avoided, will result in death or

serious injury. This signal word is to be limited to the most extreme situations.

CHAPTER 1: INTRODUCTION

RZT-S Zero

2

• Be prepared in case of emergency:

Keep a fire extinguisher nearby

Keep a first aid kit nearby

Keep emergency contact numbers handy

• Replace any missing or damaged safety labels on shop equipment.

• Replace any missing or damaged safety labels on equipment being serviced.

! CAUTION! CAUTION

• Grooming and attire:

Do not wear loose fitting clothing that may become entangled in equipment.

Long hair should be secured to prevent entanglement in equipment.

Jewelry is best removed.

• Protective gear: includes, but is not limited to

Clear eye protection ................................ while working around any machinery

Protective gloves..................................... where necessary

Armored footwear.................................... when working around any machinery

Hearing protection................................... in noisy environments

Chemically resistant gloves..................... when working with chemicals or solvents

Respirator................................................ when working with chemical or solvents

Appropriate tinted eye protection............. when cutting or welding

Flame resistant headgear, jacket, chaps. when cutting or welding

! WARNING! WARNING

! CAUTION! CAUTION

• Remember that some hazards have a cumulative effect. A single exposure may

cause little or no harm, but continual or repeated exposure may cause very serious

harm.

• Clean spills and fix obviously dangerous conditions as soon as they are noticed.

• Lift and support heavy objects safely and securely.

• Be aware of your surroundings and potential hazards that are inherent to all power

equipment. All the labels in the world cannot protect a technician from an instant of

carelessness.

Always test-run the mower in a safe place before returning it to service.

Never allow an unsafe mower to go back into service.

! CAUTION! CAUTION

Introduction

3

Assembly

Torque specifications may be noted in the part of the text that covers assembly. They may also be summarized in

tables along with special instructions regarding locking or lubrication. Whichever method is more appropriate will be

used. In some cases, both will be used so that the manual is handy as a quick-reference guide as well as a step-by-

step procedure guide that does not require the user to hunt for information.

The level of assembly instructions provided will be determined by the complexity of disassembly/reassembly, and

by the potential for unsafe conditions to arise from mistakes made in assembly.

Some instructions may refer to other parts of the manual for subsidiary procedures. This avoids repeating the

same procedure two or three times in the manual.

Description of the RZT-S Zero

The RZT-S Zero is a 48 volt electric zero turn mower

that is based on Cub Cadet’s RZT-S mower platform.

There are four electric motors that are used on these rid-

ers:

• One motor connected to each rear wheel through

a drop axle.

• Two motors on the deck, one for each blade.

The RZT-S Zero also features:

• The only electric zero-turn rider with four-wheel

steering and steering wheel control

• Extreme level of quietness:

* 70% quieter than a standard gasoline rider.

• Unsurpassed results of the cub cadet signature

cut™:

* Designed by aerospace engineers. System

components and deck design have been opti-

mized for flawless performance, low mainte-

nance and professional quality cut

• Lower operating cost per use:

* Never have to purchase gasoline, oil, filters or

belts.

• Better for users and the environment:

* Zero emissions, reduced noise, zero gasoline

smell/fumes/spills

Figure 1.1

RZT-S Zero

4

Model and Serial Numbers

The model and serial number tag can be found

under the seat. See Figure 1.2.

The serial number is located to the right of the model

number as shown above. See Figure 1.2.

The model number is 17AV2EDS010. The break down of what the number mean is as follows:

1 .............................................................................................. Residential machine

....7 .......................................................................................... Residential zero turn mower

.......A....................................................................................... Sales level/type of crate

...........V................................................................................... 48 volt battery pack

.............2. ................................................................................ Frame

.................E............................................................................. Transmission (E = Dual infinite speed drop axle)

....................D.......................................................................... Style series

.........................S..................................................................... Deck (S = 42”)

.............................010 ............................................................. Customer number

The serial number is 1J142H20124. The serial number reads as follows:

1 .............................................................................................. Engineering level

...B........................................................................................... Month of production (B = February)

.....14 ....................................................................................... Day of the month

.........2 ..................................................................................... Last digit of the year

...........H................................................................................... Plant it was built in (H = Martin, TN)

..............2 ................................................................................ Assembly line number

.................0124 ....................................................................... Number of unit built

1J142H20124

17AV2EDS010

Meets ANSI B71.1-2003 Safety Standard

MODEL NUMBER SERIAL NUMBER

CUB CADET LLC

P.O.BOX 361131

CLEVELAND,OHIO 44136

EZT-S Zero

J142H20124

_____________________

10/2012

DOM

Figure 1.2

Body

5

Floor pan

Removing the floor pan will provide access to the steering

gears and the throttle position sensor.

To remove/replace the floor pan:

1. Remove the steering wheel:

1a. Gently pry the cover off of the steering wheel.

1b. Remove the screw and washer that secures the

steering wheel to the steering shaft using a 1/2”

wrench. See Figure 2.1.

1c. Lift the steering wheel off of the steering shaft.

2. Remove the upper steering column cover:

2a. Remove the six screws that hold the upper

cover to the steering column using a T-30 torx

driver. See Figure 2.2.

2b. Unplug the LED headlight.

2c. Unplug both of the VCM harness connections.

Figure 2.1

Screw

Figure 2.2

Screws

CHAPTER 2: BODY

RZT-S Zero

6

3. Remove the brake pedal: See Figure 2.3.

3a. Remove the screw that secures the brake

pedal to the pedal shaft bell crank using a 1/2”

wrench.

3b. Unhook the brake pedal from the bell crank.

4. Remove the screw that secures the reverse pedal

using a 1/2” wrench. See Figure 2.4.

5. Remove the forward drive pedal: See Figure 2.5.

5a. Remove the screw that secures the drive

pedal to the pedal shaft bell crank using a 1/2”

wrench.

5b. Unhook the drive pedal from the bell crank.

Figure 2.3

Brake pedal

Pedal shaft bell crank

Figure 2.4

Reverse pedal

Figure 2.5

Forward drive pedal

Body

7

6. Remove the lower steering column cover by remov-

ing the two screws, indicated by the arrows in Figure

2.6, using a T-30 torx driver.

7. Remove the nine screws that hold the floor pan to the

frame using a T-30 torx driver.

8. Lift the floor pan off of the mower.

9. Install the floor pan by following the previous steps in

reverse order.

Figure 2.6

RZT-S Zero

8

Left pod

Remove the left pod to gain access to the control panel

and the charger door switch.

To remove/replace the left pod:

NOTE: The control panel is nested inside the left

pod.

1. Disconnect the battery pack’s positive lead from the

contactor assembly:

1a. Remove the three screws, indicated by the

arrows in Figure 2.7, that hold the left access

cover in place using a 1/2” wrench.

1b. Disconnect the battery pack’s positive lead

from the contactor assembly using a 7/16”

wrench. See Figure 2.8.

.

Figure 2.7

! CAUTION! CAUTION

The RZT-S Zero is equipped with

a 48 volt system. Removing the

pods will expose the high voltage

wiring.

Figure 2.8

Contactor assembly

Positive lead

Figure 2.9

Positive lead

! CAUTION! CAUTION

The battery pack’s positive lead is

still hot. Take measures, such as

taping up the cable lug with electri-

cal tape or a plastic bag, to prevent the cable

end from making contact with any metal sur-

face on the mower. See Figure 2.9.

Body

9

2. Remove the two screws, indicated by the arrows in

Figure 2.10, from the underside of the pod using a

3/8” wrench.

3. Remove the rear battery cover by following the pro-

cedures described in Chapter 6: Battery Pack and

Charger.

4. Remove the two screws, indicated by the arrows in

Figure 2.11, from the inboard side of the pod using a

T-30 torx driver.

5. Disconnect the charger harness.

6. Remove the screw from the front of the pod using a

T-30 torx driver. See Figure 2.12.

Figure 2.10

Figure 2.11

Charger harness

Figure 2.12

Screw

RZT-S Zero

10

7. Lift the pod enough to gain access to the charger

door switch.

8. Disconnect the charger door switch.

See Figure 2.13.

9. Lift the pod off of the mower.

10. Install the pod by following the previous steps in

reverse order.

NOTE: Ensure that the charger harness is recon-

nected when installing the left pod. It is pos-

sibly to reassemble the mower with the

charger disconnected. It will run but will not

charge the batteries.

11. Test drive the mower in a safe area before returning

it to service.

Figure 2.13

Charger door switch

Body

11

Right pod

Remove the right pod to gain access to the PTO and key

switches.

To remove/replace the right side pod:

1. Disconnect the battery pack’s positive lead from the

contactor assembly by following the procedures

described in the left pod section of this chapter.

2. Remove the rear battery cover by following the pro-

cedures described in Chapter 6: Battery Pack and

Charger.

3. Remove the two screws, indicated by the arrows in

Figure 2.14, from the inboard side of the pod using a

T-30 torx driver.

4. Remove the screw from the front of the pod using a

T-30 torx driver. See Figure 2.15.

5. Remove the two screws, indicated by the arrows in

Figure 2.16, from the underside of the right pod using

a 3/8” wrench.

6. Lift the pod enough to gain access to the PTO and

key switches.

7. Disconnect the key switch.

8. Disconnect the PTO switch.

9. Lift the pod off of the mower.

10. Install the pod by following the previous steps in

reverse order.

11. Test drive the mower in a safe area before returning

it to service.

Figure 2.14

Figure 2.15

Screw

! CAUTION! CAUTION

The RZT-S Zero is equipped with a

48 volt system. Removing the pods

will expose the high voltage wiring.

Figure 2.16

RZT-S Zero

12

Seat

To remove the seat:

NOTE: The seat and seat bracket must be removed

to remove the seat box top plate or the front

battery bracket.

1. Slide the seat all the way to the rear most position.

NOTE: If the seat is not all the way back, the seat

will hit the front battery cover when the seat

is tipped forward.

2. Tip the seat forward.

3. Pull the excess reverse switch harness from the slot

in the slot in the seat bracket. See Figure 2.17.

4. Disconnect the seat switch.

5. Pull the seat switch harness out of the seat bracket.

6. Remove the two shoulder bolts and nuts the seat

bracket pivots on using a 5/8” wrench and a 1/2”

wrench.

7. Install the seat be following the previous steps in

reverse order.

NOTE: When tightening the shoulder bolts and

nuts, make sure the shoulders are in the

holes of the seat bracket.

NOTE: Be sure to push the excess wire from the wire harness into the seat box hole before continuing.

8. Test drive the mower in a safe area before returning it to service.

Figure 2.17

Seat switch harness Seat switch

Seat bracket

Shoulder bolts

Body

13

Seat box assembly

The RZT-S Zero has a bolt together seat box assembly. The individual parts of the seat box are serviced sepa-

rately, not as one complete assembly. This section will be divided into three sections to cover the service procedures

for the three main parts of the seat box assembly.

Seat box top plate

The seat box top plate will need to be removed to perform service procedures such as:

• Removing the deck

• Replacing the slotted deck lift links

• Replacing the deck lift shaft brackets

• Removing the deck motors

• Removing the hub motors

To remove/replace the seat box top plate:

1. Disconnect the battery pack’s positive lead from the

contactor assembly by following the procedures

described in the left pod section of this chapter.

2. Remove the rear battery cover by following the pro-

cedures described in Chapter 6: Battery Pack and

Charger.

3. Remove the left and right pods by following the pro-

cedures described earlier sections of this chapter.

4. Disconnect the seat switch

5. Remove the two nuts that secure the seat bracket to

the mower using a 1/2” wrench. See Figure 2.18.

6. Lift the seat off of the mower.

7. Remove the four screws, indicated by the arrows in

Figure 2.19, that secures the front battery cover to

the mower using a T-30 torx driver.

8. Lift the front battery cover off of the mower.

Figure 2.18

Battery

Nuts

! CAUTION! CAUTION

The RZT-S Zero is equipped with a

48 volt system. Removing the pods

will expose the high voltage wiring.

Figure 2.19

RZT-S Zero

14

9. Remove the front battery bracket:

9a. Lower the mowing deck to its lowest setting.

9b. Remove the four screws, indicated by the

arrows in Figure 2.20, using a 1/2” wrench.

9c. Reaching underneath the mower’s frame,

remove the nuts from the three carriage bolts

indicated by the arrows in Figure 2.20.

9d. Lift the bracket over the seat bracket studs

and off of the mower.

10. Remove the six screws, indicated by the arrows in

Figure 2.21, using a 1/2” wrench.

11. Carefully lift the top plate off of the mower while fish-

ing the seat switch harness thought the slot in the

top plate.

12. Install the top plate by following the previous steps

in reverse order.

13. Test drive the mower in a safe area before returning

it to service.

Figure 2.20

Figure 2.21

Seat switch harness

Body

15

Seat box front main section

NOTE: There are only two reasons to remove the seat box front main section:

• To replace the deck lift shaft

• Physical damage to the seat box front main section

To remove/replace the seat box front main section:

1. Disconnect the battery pack’s positive lead from the

contactor assembly by following the procedures

described in the left pod section of this chapter.

2. Remove the seat box top plate by following the pro-

cedures described in the previous section of this

chapter.

3. Remove the front (4th) battery:

3a. Slide the battery out of the seat box assembly.

See Figure 2.22.

3b. Disconnect the negative cable from the battery.

3c. Disconnect the lead with the blue tape from the

positive terminal of the battery using a 1/2”

wrench.

3d. Remove the battery from the mower.

Figure 2.22

Blue cable

Negative cable

! CAUTION! CAUTION

The RZT-S Zero is equipped with a

48 volt system. Removing the pods

will expose the high voltage wiring.

Figure 2.23

Blue lead

! CAUTION! CAUTION

Wrap the exposed cable end with

electrical tape or a plastic bag to

help prevent the cable from con-

tacting the frame. See Figure 2.23.

RZT-S Zero

16

4. Disconnect the negative cable from the master

ground bus using a 9/16” wrench. See Figure 2.24.

NOTE: The master ground bus has an over sized

stud to minimize the possibility of improper

wiring.

5. Fish the negative cable through the opening in the

seat box assembly.

6. Fish the positive cable through the opening in the

seat box assembly.

7. Disconnect the VCM harness from the contactor

assembly. See Figure 2.25.

8. Fish the VCM through the hole in the seat box

assembly.

9. Fish the PTO switch/key switch harness through the

opening in the seat box assembly. See Figure 2.26.

Figure 2.24

Master ground bus

Figure 2.25

VCM harness

Contactor assembly

Figure 2.26

PTO switch/

Key switch

harness

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Cub Cadet RZT-S Zero Shop Manual

Cub Cadet RZT-S Zero Shop Manual

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