Cub Cadet CC 500 BAT User Manual
Professional Shop Manual
Model 188 and CC 500 BAT Cordless Mower
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 provid e su pp lem ental information to assist the trained technician. Untrained or inexperienced individuals should seek the assistance of an experienced and tr ained professional. Read, understand, a nd follow all
instructions and use common sense when working on power equipment. This includes the contents of the product’s Operators 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 a nd accura te as possib le at the time of publica tion. 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 2007 MTD Products Inc. All Rights Reserved
MTD Products Inc - Product Training and Education Department
FORM NUMBER - 769-03397
08/2007
Table of Contents
Chapter 1: Introduction ......................................................................................................1
Professional Shop Manual Intent..................................................................................... 1
About the text format .......................................................................................................1
Fasteners .......................................................................................................................... 2
Assembly .........................................................................................................................2
Understanding model and serial numbers........................................................................ 2
Chapter 2: ELECTRICAL System ....................................................................................3
The first electrical value to be discussed is Voltage. .......................................................3
The second electrical value is Current............................................................................. 3
The third and final value is Resistance............................................................................ 3
Ohm’s law ........................................................................................................................3
Kirchhoff’s current law ....................................................................................................4
Kirchhoff’s voltage law ................................................................................................... 4
How the system is wired together ....................................................................................4
Equipment needed to diagnosis an electrical system....................................................... 4
Equipment that may be useful ......................................................................................... 4
Digital volt ohm meter..................................................................................................... 5
Inductive amp meter ........................................................................................................5
Wiring or a schematic diagram........................................................................................ 5
Fused jumper wires ..........................................................................................................5
Types of circuits ...............................................................................................................5
Series ................................................................................................................................6
Parallel ............................................................................................................................. 6
Series/parallel ...................................................................................................................6
Types of failures ..............................................................................................................6
Shorts ............................................................................................................................... 6
Opens ...............................................................................................................................6
Increased resistance ......................................................................................................... 6
Switches ...........................................................................................................................7
Diodes ..............................................................................................................................7
Fuses ................................................................................................................................ 8
Initial trouble shooting .....................................................................................................9
Checking the motor ........................................................................................................10
Testing the switch box and harness ..............................................................................11
Batteries and charger .....................................................................................................15
Batteries .........................................................................................................................15
Charging the battery .......................................................................................................15
To test the battery pack.................................................................................................. 15
Battery charger ...............................................................................................................17
Battery indicator ............................................................................................................17
Returning to service .......................................................................................................19
System schematic drawing .............................................................................................20
Chapter 3: Repair Procedures ..........................................................................................21
General safety warning ..................................................................................................21
Blades .............................................................................................................................21
Switch box assembly ..................................................................................................... 23
To replace the switch box.............................................................................................. 24
Motor .............................................................................................................................25
Motor mount ..................................................................................................................26
CHAPTER 1: INTRODUCTION
INTRODUCTION
Professional Shop Manual Intent
This Manual is intended to provide service dealers with
an introduction to the electrical and mechanical
aspects of the new cordless electric mower for both
MTD and Cub Cadet.
Disclaimer: This manual was written using a pilot unit.
The information contained in this manual is correct at
the time of writing. Both the product and the information about the product are subject to change without
notice.
This manual covers the newly designed th ird generation of 19” DC powered (cordless) electric mowers. The
mower is to be designated 18A-188-xxx and is to be
introduced during the 2007-2008 season.
MTD Products has made two previous models of cordless mowers. The first model was produced from 1995
to 1997. it was designated 185-708-xxx, 186-708-xxx
and 18A-708-xxx. The second model was produced in
the same time period. The model numbers were 185798-xxx, 186-798-xxx and 18A-798-xxx.
The first model used a bail operated switch and the
second used a lever operated switch. Very few parts
are interchangeable between the mowers.
The electrical theory is the same for all three models of
cordless mower. However the test procedures will vary
between the different generations. The servic e procedures for the first two models of cordless mower can be
found in the 1996 Service Update Seminar Book (form
number 770-8877L).
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 procedure.
CAUTION: Indicates a potent ially hazardous situation that, if not avoided, may result in minor or
moderate injury. It may also be used to alert
against unsafe practices.
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.
WARNING: Indicates a potentially hazardous
situation that, if not avoided, could result in
death of serious injury.
• Bullet points: indicate sub-steps or points.
Disclaimer: This Professional Shop 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
procedures 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, MTD or
Cub Cadet Technical Support.
1
INTRODUCTION
Fasteners
• Most of the fasteners used on the vehicle are
sized in fractional inches. Some are metric.
For this reason, wrench sizes are frequently
identified in the text, and measurements are
given in U.S. and metric scales.
• If a fastener has a locking feature that has
worn, replace the fastener or apply a small
amount of releasable 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 judgement of
the technician.
Assembly
Torque specifications may be noted in the part of the
text that covers assembly or they may also be summarized in tables along with special instructions regarding
locking or lubrication. Whichever method is more
appropriate will be used. In many 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 and of reassembly, and
by the potential for unsafe conditions to arise from mistakes made in assembl y.
Some instructions may refer t o other parts of the manual for subsidiary procedures. This avoids repeating
the same procedure two or three times in the manual.
Understanding model and serial numbers
The model number is 18A-188-710. The break d own of
what the number mean is as follows:
• 18 - - - - - - - - - indicates that this is an electric
mower
• - - A - - - - - - - - indicates the sales level
• - - - - 18 - - - - - indicates the series and trim
• - - - - - - 8 - - - - indicates it is DC powered (cordless)
• - - - - - - - - 710 indicates that it is a Cub Cadet
The serial number is 1J056G10005. The serial number
reads as follows:
1...........................engineering level
..J.........................month of production (J = October)
.....05....................day of the month
.........6..................last digit of the year
...........G................plant it was built in
..............1.............assembly line number
.................0005.....number of unit built
Additional technical and service information may also
be available to our company authorized service center
personnel through our company corporate offices,
regional parts distributors and regional service center
field support personnel. Please contact the de signated
support office in your area or our corporate offices
directly should further service information be needed.
For Cub Cadet
Cub Cadet LLC
P.O. Box 368022
Cleveland, OH 44136
Telephone: (330) 273-8669
www.cubcadet.com
Or for MTD Brands
MTD Products LLC
P.O. Box 368022
Cleveland, OH 44136
Telephone: (800) 800-7310
www.mtdproducts.com
2
CHAPTER 2: ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
ELECTRICAL THEORY
In order to diagnosis any electrical system there are
few things the technician must know:
• Basic electrical values.
•Ohm’s law.
• Kirchhoff’s current law.
• Kirchhoff’s voltage law.
• How the system is wired together.
The first electrical value to be discussed is Voltage.
• Voltage is the “pressure” that electricity has. It is
the amount of force pushing electrons through a
circuit.
• This pressure is measured in volts.
• The capital letter “V” is used to represent volts.
The second electrical value is Current:
• Current is the “flow” of electricity. It is the amount
of electrons flowing in circuit.
• The flow of current is measured in Ampe res or
Amps for short.
• The capital letter “I” is used to represent Amps.
Ohm’s law
Ohm’s law state that voltage is the product of resistance times current. It is written as V=IxR. An example
of how ohm’s law works goes like this: It takes 1 volt to
push 1 amp through a resistance of 1 ohm (1=1x1).
Ohm’s law can be drawn in a triangle. When using the
triangle, cover the value to be found, and the two values left exposed signify how to obtain that value.
See Figure 2.1.
V
I
Figure 2.1
R
The third and final value is Resistance:
• Resistance is the opposition to current flow. It is
a restriction that slows down the flow of current.
• Resistance is measured in Ohm’s.
• The greek letter omega “
Ohm’s.
Ω” is used to represent
As an example if the “R” is covered, the “V” is over the
“I” which means V is divided by I. If the “V” is covered,
“I” and “R” is exposed, meaning IxR and so on.
3
ELECTRICAL SYSTEM
Kirchhoff’s current law
Kirchhoff’s current law deals with nod es. No des a re th e
junction of two or more wires or the junction of a wire to
a component.
Kirchhoff’s current law states that what ever current
goes into a node must come out.
As an example: Three wires are connected with a wire
nut. one wire has 5 amps going into the wire nut. The
sum of the current coming out of the other two wires
must equal 5 amps. That could be 3 amps in one wire
and 2 amps in the other or it could be 2.5 amps in each
wire, but the total must be the same as the current
coming in. See Figure 2.2.
Node
5 Amps
3 Amps
2 Amps
How the system is wired together
All circuits have some basic rules that must be followed:
1. All circuits must have at least one voltage
source. It is could be a battery, an altenator or
both.
2. All circuits must have a load. To make a circuit
with out a load is the same as shorting out the
power source. A load could be:
• light
• motor
•resistor
•starter
• etc....
3. All circuits must have a complete path back to
the voltage source. This is also known as having
continuity.
NOTE: On outdoor power equipment, the frame
of the machine is used as the return path to the
battery. This is referred to as grounding the
machine. Any point on the frame should be the
same as the negative post of the battery (Electrically), unless there is a bad connection between
the battery and the frame.
Figure 2.2
Kirchhoff’s voltage law
Kirchhoff’s voltage law deals with voltage drops. A voltage drop is the amount of voltage used up or “dropped ”
by a resistance in the circuit. Ohm’s law stated that V =
IxR, every component in a circuit has resistance, even
the wires. T o push current through a resistance, it takes
voltage. Kirchhoff’s voltage law states that the sum of
all the voltage drops equals the source voltage.
An example: a circuit has a battery of 12V, a light bulb
that creates 3 ohms of resistance and there is 4 amps
of current in the circuit. The wires are assumed to have
0 ohms, if the proper size wire is used and there is no
corrosion in the wire, the resistance will be too small to
worry about. The light bulb uses 12 volts (4 amps x 3
ohms = 12 volts). the battery has 12 volts that equals
the 12 volts used by the light bulb.
4. Most circuits have additional components like
switches and fuses.
Equipment needed to diagnosis an electrical system:
• Digital volt ohm meter
• Wiring or a schematic diagram.
Equipment that may be useful:
• Fused jumper wires.
• Hand tools to gain access to components.
• Flash light.
CAUTION: A test light can not be used on this
mower. The system voltage is 48 volts. It will
destroy the test light and may result in injury to
the technician.
4
ELECTRICAL SYSTEM
Digital volt ohm meter
Digital volt ohm meters or DVOMs are the most useful
tool to troubleshoot any electrical system. Depending
on the model of DVOM used, DVOMs can measure
Volts, Amps, Ohms and more. DVOMs are a must
when working on circuits with solid state components
(microchips). They have very high impedance, that
means they have very high resistance and pull very little current from the circuit. Use of analog equipment or
test lights will pull enough current to damage the microchips in the circuit. See Figure 2.3.
Inductive amp meter
An inductive amp meter, sometimes referred to as an
“amp clamp” or clamp meter, measures current following through a wire by the magnetic field created around
the wire. Clamp meters are very important when dealing with currents over 10 amps. A DVOM typically can
not measure current over 10 amps. Clamp meters are
also helpful because they can read current in a circuit
without opening it up to hook the meter into the circuit.
See Figure 2.4.
Figure 2.3
When measuring volts, always hook the meter in parallel with the circuit. That means do not disconnect the
component where measuring voltage.
When measuring current the meter must be connected
in series with the component to be measured. That
means opening the circuit and having the circuit go
through the meter.
NOTE: The only exception to this is when us ing
an inductive amp clamp.
When measuring resistance, the component must be
isolated from the circuit.
CAUTION: The meter has it’s own power source
to measure resistance. connecting the meter to
a component that has current going through it
will damage the meter (usually beyond repair).
NOTE: When measuring resistance and there is
no continuity, the meter will read infinity. This is
represented in a few different ways like: OL
(open line) or 1.0 displayed to the far left. Check
the operator’s manual for th e DVOM to see how
it is represented on your meter..
Figure 2.4
Wiring or a schematic diagram
A wiring or a schematic diagram is very important in
troubleshooting a circuit. The diagram shows how the
circuit was designed and what paths the electricity is
suppose to flow.
Fused jumper wires
Fused jumper wires are handy to he lp find b ad groun ds
or to jump across switches for testing purposes.
CAUTION: Only use fused jumper wires. If there
is a short in the circuit, using an unfused jump
could damage components in the circuit further.
Types of circuits
There are three ways a circuit can be wired. They are:
•Series
• Parallel
• Series/parallel
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