Page is loading ...
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.
© Copyright 2012 MTD Products Inc. All Rights Reserved
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
/
