MTD 188 Manuel utilisateur

Professional Shop Manual

Model 188 and CC 500 BAT Cordless Mower

MTD Products Inc - Product Training and Education Department

FORM NUMBER - 769-03397

08/2007

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.

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

Table of Contents

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

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 informa-

tion about the product are subject to change without

notice.

This manual covers the newly designed third genera-

tion 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 cord-

less 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 185-

798-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 service proce-

dures 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 potentially hazardous sit-

uation 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 lim-

ited 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.

CHAPTER 1: INTRODUCTION

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 inter-

nal 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 summa-

rized 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 mis-

takes made in assembly.

Some instructions may refer to other parts of the man-

ual 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 down 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 (cord-

less)

• - - - - - - - - 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 designated

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

ELECTRICAL SYSTEM

ELECTRICAL THEORY

In order to diagnosis any electrical system there are

few things the technician must know:

• Basic electrical values.

•Ohm’slaw.

• 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 Amperes or

Amps for short.

• The capital letter “I” is used to represent Amps.

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 “Ω” is used to represent

Ohm’s.

Ohm’s law

Ohm’s law state that voltage is the product of resis-

tance 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 val-

ues left exposed signify how to obtain that value.

See Figure 2.1.

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.

Figure 2.1

CHAPTER 2: ELECTRICAL SYSTEM

ELECTRICAL SYSTEM

Kirchhoff’s current law

Kirchhoff’s current law deals with nodes. Nodes are the

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.

Kirchhoff’s voltage law

Kirchhoff’s voltage law deals with voltage drops. A volt-

age 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. To 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.

How the system is wired together

All circuits have some basic rules that must be fol-

lowed:

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 (Electri-

cally), unless there is a bad connection between

the battery and the frame.

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.

Figure 2.2

5 Amps 3 Amps

2 Amps

Node

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 lit-

tle current from the circuit. Use of analog equipment or

test lights will pull enough current to damage the micro-

chips in the circuit. See Figure 2.3.

When measuring volts, always hook the meter in par-

allel 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 using

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 the DVOM to see how

it is represented on your meter..

Figure 2.3

Inductive amp meter

An inductive amp meter, sometimes referred to as an

“amp clamp” or clamp meter, measures current follow-

ing through a wire by the magnetic field created around

the wire. Clamp meters are very important when deal-

ing 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.

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 help find bad grounds

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

Figure 2.4

ELECTRICAL SYSTEM

Series

• Series circuits are wired so that the current has

only one path to follow. See Figure 2.5.

Parallel

Parallel circuits are wired so that current has multiple

paths to follow. See Figure 2.6.

Series/parallel

Series/parallel circuits have some sections wired in

series and some in parallel. See Figure 2.7.

Types of failures

There are three types of failures that can occur in an

electrical circuit:

1. Shorts

2. Opens

3. Increased resistance

Shorts

A short is when electricity takes a path that it was not

designed to take bypassing a component in the circuit.

An common example of a short is the wire that chafed

through. The bare copper will short the circuit when it

touches a ground source.

Opens

An open is when current can not complete its path back

to the power source.

A common example of this is a blown fuse.

Increased resistance

Increased resistance is as the name implies, an

increase in resistance.

Arguably the most common electrical failure, and the

hardest to find, it is when there is a loose connection or

corrosion. It is not an open because there is some cur-

rent that can get through, but the increase in resistance

is enough to affect the circuit

Figure 2.5

Switch

Bulb

Battery

Figure 2.6

Figure 2.7

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