Cub Cadet CC 500 EL Installationsanleitung

Professional Shop Manual

CC 500 EL

MTD Products Inc. - Product Training and Education Department

FORM NUMBER - 769-03332

6/2007

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

Assembly .............................................................................................................................1

Understanding model and serial numbers.............................................................................2

Chapter 2: Electrical System .................................................................................................3

Basics of electricity...............................................................................................................3

Electrical circuits...................................................................................................................5

Tools ....................................................................................................................................7

Components and testing techniques......................................................................................8

Chapter 3: Repair Procedures .............................................................................................13

General safety warning........................................................................................................13

Blades .................................................................................................................................13

Switch box assembly...........................................................................................................15

To replace the switch box....................................................................................................16

Motor ................................................................................................................................17

Motor mount .......................................................................................................................18

Rectifier...............................................................................................................................18

Table of Contents

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 electric mower.

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” AC powered (corded) electric mowers. The

mower is to be designated 18A-182-xxx and is to be

introduced during the 2007-2008 season.

MTD Products has made two previous generations of

electric mower. The first generation was produced from

1996 to 1998. it was designated 186-407-xxx, 18A-

407-xxx and 18A-707-xxx. The second generation of

electric mowers were produced from 2001 to 2002. The

second generation of electric mowers shared the same

model numbers with the first generation.

The first generation of electric mowers used a bail

operated switch and the second generation used a

lever operated switch. Very few parts are interchange-

able between the first and second generation mowers.

The electrical theory is the same for all three genera-

tions of electric mower. However the test procedures

will vary between the different generations. The service

procedures for the first generation of electric mower

can be found in the 1996 Service Update Seminar

Book (form number 770-8877L). The service proce-

dures for the second generation of electric mower can

be found in the 2002 Technical Handbook (form num-

ber 770-8877S).

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 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-182-710. 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

• - - - - - - 2 - - - - indicates it is AC powered

• - - - - - - - - 710 indicates that it is 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.

Cub Cadet LLC

P.O. Box 368022

Cleveland, OH 44136

Telephone: (330) 273-8669

www.cubcadet.com

ELECTRICAL SYSTEM

Basics of electricity

In order to diagnosis any electrical system there are

few things the technician must understand:

• Basic electrical values: voltage, current and

resistance

•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” or the capital letter

“R” 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 SYSEM

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.

AC electricity

AC electricity is used to provide electricity to homes

and businesses because it can be easily transmitted

over long distances. Some house hold products can

run on straight AC power while most will convert it to a

usable DC form internally.

AC or alternating current is a current or voltage value

that varies with time and has an average value of zero.

If the current or voltage is observed using an oscillo-

scope, the waveform will look like a sine wave. this

means it will be positive for awhile then it will be nega-

tive for awhile. The time spent positive will equal the

time spent negative. Since it spends just as much time

positive as negative, the positive values cancel out the

negative values leaving an average value of zero. See

Figure 2.3.

Since AC varies with time, the time or phase angle of

the waveform is needed to compute voltage and cur-

rent. This manual will not go into how to do this. AC is

only mentioned here as a reference. This mower is

plugged into AC electricity, but it will change the elec-

tricity to a DC waveform to power the motor.

Figure 2.2

5 Amps 3 Amps

2 Amps

Node

ure 2.3

AC wave form 1 Cycle +

ELECTRICAL SYSTEM

DC electricity

Most outdoor power products will use DC electricity to

power its electrical systems. The simple way to look at

DC electricity is that current only flows in one direction.

The value of the current or voltage can vary, but as

long as it does not change polarity it is DC electricity.

The wave form of a battery operated DC system is a

straight line. See Figure 2.4.

The voltage in a DC system does not change polarity

like AC. This mower uses a rectifier to covert AC volt-

age into DC voltage. The rectifier operation will be cov-

ered in a later section of this chapter.

ure 2.4

DC wave form

Electric circuits

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:

•alamp

•amotor

•aresistor

• a starter

3. All circuits must have a complete path back to

the voltage source. This is also known as having

continuity.

4. Most circuits have additional components like

switches and fuses.

ELECTRICAL SYSEM

Types of circuits

There are three ways a circuit can be wired. They are:

•Series

• Parallel

• Series/parallel

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.

Circuit 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, 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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