Cub Cadet RZT-S Zero Shop Manual

Hide thumbs Also See for RZT-S Zero:

Operator's manual (32 pages)

Table Of Contents

100

101

102

103

104

105

106

107

108

109

110

111

112

113

114

115

116

117

118

119

120

121

122

123

124

125

126

127

128

129

130

131

132

133

134

135

136

137

138

139

140

141

142

143

144

145

146

147

148

149

150

151

152

153

154

155

156

Table of Contents

Quick Links

Summary of Contents for Cub Cadet RZT-S Zero

Page 1 Professional Shop Manual Professional 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.
Page 3: Table Of Contents
Table of Contents 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................
Page 4 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...
Page 5: Chapter 1: Introduction
• 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.
Page 6 RZT-S Zero • Be prepared in case of emergency: ! CAUTION ! CAUTION 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.
Page 7: Assembly
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: •...
Page 8: Model And Serial Numbers
RZT-S Zero 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 Meets ANSI B71.1-2003 Safety Standard number as shown above. See Figure 1.2.
Page 9: Chapter 2: Body
Body CHAPTER 2: BODY Floor pan Removing the floor pan will provide access to the steering gears and the throttle position sensor. To remove/replace the floor pan: Remove the steering wheel: 1a. Gently pry the cover off of the steering wheel. 1b.
Page 10 RZT-S Zero Remove the brake pedal: See Figure 2.3. Remove the screw that secures the brake pedal to the pedal shaft bell crank using a 1/2” wrench. Unhook the brake pedal from the bell crank. Brake pedal Pedal shaft bell crank Figure 2.3...
Page 11 Body 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. Remove the nine screws that hold the floor pan to the frame using a T-30 torx driver. Lift the floor pan off of the mower.
Page 12: Left Pod
To remove/replace the left pod: NOTE: The control panel is nested inside the left pod. The RZT-S Zero is equipped with ! CAUTION ! CAUTION a 48 volt system. Removing the pods will expose the high voltage wiring.
Page 13 Body Remove the two screws, indicated by the arrows in Figure 2.10, from the underside of the pod using a 3/8” wrench. Figure 2.10 Remove the rear battery cover by following the pro- cedures described in Chapter 6: Battery Pack and Charger.
Page 14 RZT-S Zero Lift the pod enough to gain access to the charger door switch. Disconnect the charger door switch. Charger door switch See Figure 2.13. Lift the pod off of the mower. Install the pod by following the previous steps in reverse order.
Page 15: Right Pod
Right pod Remove the right pod to gain access to the PTO and key switches. To remove/replace the right side pod: The RZT-S Zero is equipped with a ! CAUTION ! CAUTION 48 volt system. Removing the pods will expose the high voltage wiring.
Page 16 RZT-S Zero 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. Seat switch harness Seat switch Slide the seat all the way to the rear most position.
Page 17: Seat Box Assembly
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.
Page 18 RZT-S Zero Remove the front battery bracket: Lower the mowing deck to its lowest setting. Remove the four screws, indicated by the arrows in Figure 2.20, using a 1/2” wrench. Reaching underneath the mower’s frame, remove the nuts from the three carriage bolts indicated by the arrows in Figure 2.20.
Page 19 To replace the deck lift shaft • Physical damage to the seat box front main section To remove/replace the seat box front main section: The RZT-S Zero is equipped with a ! CAUTION ! CAUTION 48 volt system. Removing the pods will expose the high voltage wiring.
Page 20 RZT-S Zero Disconnect the negative cable from the master Master ground bus 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. Fish the negative cable through the opening in the seat box assembly.
Page 21 Body 10. Remove the two screws, indicated by the arrows in Figure 2.27, that hold down the front battery tray using a 1/2” wrench. 11. Slide the battery tray out of the seat box assembly. Figure 2.27 12. Remove the hex screw from the front of the seat box assembly using a 1/2”...
Page 22 RZT-S Zero NOTE: The front main and rear seat box assem- blies can be removed together. If both assemblies are being removed, skip to step Remove the screw, indicated by the arrows in Fig- ure 2.30, that secures the left side of the front main assembly to the rear assembly using a 1/2”...
Page 23 Body NOTE: If the front main seat box assembly is being replaced: • Cut off the speed nuts that attach the seat bracket studs to the front main seat box assembly. See Figure 2.33. • Slide the stud assembly out of the front main seat box assembly.
Page 24 RZT-S Zero Seat box rear section To remove/replace the seat box rear section: Remove the batteries by following the procedures described in Chapter 6: Battery Pack and Charger. NOTE: The front main and the rear seat box sec- tions can be removed as one assembly. If...
Page 25 Body 3d. Remove the four screws that hold the control panel bracket to the mower using a 3/8” wrench. See Figure 2.37. 3e. Lift the control panel and the bracket off of the mower. Do not remove the controller cov- ! CAUTION ! CAUTION ers.
Page 26 RZT-S Zero Remove the screw that holds the left rear finger guard to the frame using a 1/2” wrench. See Figure 2.40. Slide the finger guard off of the mower. Left rear finger guard Figure 2.40 Remove the six screws that hold the rear section to the frame using a 1/2”...
Page 27: Chapter 3: Brake And Drive System
Charging the batteries will load down the motors enough to slow or stop the mower similar to the way a hydro pump will slow down a hydrostatic drive system. The RZT-S Zero also has a mechanical brake that is primarily used as a parking brake, but can be used as an emergency brake in case the regenerative braking fails.
Page 28: Brake Adjustment
RZT-S Zero Brake adjustment NOTE: When performing a brake adjustment, inspect the brake components for signs of wear or damage. NOTE: Brakes that are dragging will affect battery run time and can mimic a bad battery pack. Test the operation of the brakes: See Figure 3.3.
Page 29: Brake Puck/Rotor Replacement
Brakes and Drive System Brake puck/rotor replacement On RZT-S Zeros, the brake pucks are wearing parts that will need to be serviced from time to time. If a mower is operated with the parking brake dragging, the pucks will wear out rapidly and the brake rotor will develop hot spots. If the mower is operated long enough, the rotor may have grinding marks on it with excessively worn pucks.
Page 30 RZT-S Zero Remove the caliper mounting screws using a 3/8” wrench. See Figure 3.7. The outboard brake puck should fall out as the brake caliper is removed. If it did not, it can be removed now. Mounting screws Figure 3.7 Slide the brake rotor off to reach the inboard brake puck.
Page 31 Brakes and Drive System 14. Place a new brake puck into the recess in the trans- mission. Use a piece of scotch tape to hold it in place. 15. Slide the brake rotor in place, shoulder out. 16. Place a new puck into the caliper. NOTE: A piece of scotch tape may be used to hold the new brake pucks in place for assembly.
Page 32: Brake Shaft Assembly
RZT-S Zero Brake shaft assembly To remove/replace the brake shaft:. Lift and safely support the rear of the mower. Brake shaft return spring If the parking brake is set, release it. Disconnect the brake shaft return spring. See Figure 3.11.
Page 33: Drop Axle And Hub Motor Assemblies
NOTE: The hub motor can be removed separately from the drop axle, however it is very easy to damage the hub motor housing doing that. Cub cadet rec- ommends removing the drop axle and hub motor as an assembly and separating the two on the work bench.
Page 34 RZT-S Zero Remove the two screws that hold the top of the drop axle mounting bracket to the frame using a 1/2” wrench. See Figure 3.16. Screws Figure 3.16 Disconnect the brake rod by removing the bow tie clip and sliding the rod out of the brake shaft’s bell crank.
Page 35 Brakes and Drive System 10. Disconnect the brake shaft return spring. See Figure 3.19. Brake shaft return spring Figure 3.19 11. Unhook the spring from the drive release rod. Spring See Figure 3.20. 12. Slide the rod out of the mower. Figure 3.20 13.
Page 36 RZT-S Zero Remove the two screws that attach the top support plate to the drop axle using a 1/2” wrench. See Figure 3.22. Screws Figure 3.22 Remove the bottom support plate. See Figure 3.23. Bottom support plate Figure 3.23 While supporting the drop axle assembly, remove the two nuts that hold the motor bracket to the frame using a 1/2”...
Page 37 Brakes and Drive System 19. Place the drop axle assembly on a workbench. 20. Remove the two screws that hold the motor bracket to the motor using a 1/2” wrench. See Figure 3.25. 21. Lift the bracket off of the assembly. Screws Figure 3.25 22.
Page 38: Rebuilding The Drop Axles
RZT-S Zero Rebuilding the drop axles Remove the drop axle by following the procedures described in the previous section of this chapter. Remove the patch bolt and washer that holds the hub to the axle shaft using a 9/16” wrench.
Page 39 Brakes and Drive System Drive axle Slide the bushing and the bearing off of the drive axle. 10. Remove the thrust bearing. Spacer 11. Remove the nut securing the drive gear to the drive axle. See Figure 3.31. NOTE: The nut is installed with Loctite #271 thread-locker. Ball bearing Bushing Needle bearing...
Page 40 RZT-S Zero Separate the spur gear from the brake shaft by removing the retaining ring. See Figure 3.34. Retaining ring Figure 3.34 Remove the bearing. See Figure 3.35. Input spur gear Remove the input spur gear. Bearing Figure 3.35 Notch Clean and inspect all for the parts for damage and signs of wear.
Page 41 Brakes and Drive System A = 1/4-20 x 1.00” NOTE: Apply Loctite #271 or an equivalent thread-locker B = 1/4-20 x 1.25” to the threaded section of the drive axle. Tighten C = 1/4-20 x 1.50” the nut that secures the drive gear to a torque of D = 1/4-20 x 2.00”...
Page 42 RZT-S Zero...
Page 43: Chapter 4: Steering
CHAPTER 4: STEERING Introduction The steering on the RZT-S Zero mower is similar to that of other mowers with Cub Cadet’s Syncro Steer Tech- nology. The Syncro Steer Technology steers by: It steers like any other riding mower by turning the front wheels.
Page 44 RZT-S Zero Install a 1/4” alignment pin in the left segment gear. 1/4” Alignment pin See Figure 4.2. Install a 1/4” alignment pin in the right segment gear. Figure 4.2 Remove the axle casting covers. Insert the axle casting (5/16”) alignment pins into Alignment pin the alignment holes in both axle castings.
Page 45: Front Wheels
Steering Front wheels Remove/ replace the front wheels: Axle bolt 1. Lift and safely support the front end of the riding mower. 2. Remove the axle bolt and nut using a pair of 3/4” wrenches. See Figure 4.5. Figure 4.5 3.
Page 46 RZT-S Zero To replace the front wheel bearings: Lift and safely support the front of the mower. Punch Remove the front wheel by following the procedures describe in the previous section of this chapter. Drive the bearings out of the wheel hub using a drift or pin punch.
Page 47: Front Yokes
Steering Front yokes To remove/ replace the front yokes: Yoke cover NOTE: There is a magnet in the head of the screw that holds the left yoke in place. This screw should not be removed unless absolutely necessary. Lift and safely support the front of the mower. 2.
Page 48 RZT-S Zero Magnet Remove the hex screw using a 9/16” wrench. See Figure 4.12. NOTE: The yoke will slide out as the screw is removed. NOTE: Do not use an impact wrench on the left side. The impact pulses can cause the mag- net to pop out of the screw head.
Page 49 Steering For the Left yoke 5a. Install the hex screw with the magnet, lock washer and the fender washer. 5b. Apply a small amount of a thread locking com- pound such as Loctite® 262 (red) to the threads of the hex screw with the magnet. Tighten the hex screw holding the yoke to a torque of 25 ft lbs (34 Nm).
Page 50: Removal Of The Steering Gears
RZT-S Zero Removal of the steering gears To remove the steering gears: Remove the floor pan, following the procedures described in Chapter 3: Body. Remove the nut from the bolt that holds the drag link to the inboard steering gear using a pair of 9/16”...
Page 51 Steering NOTE: The same part number gear is used on both yokes. If the gear is to be used on the left yoke, install it so that the LH stamped into the gear is facing up. If the gear is to be used on the right yoke, install it so that the RH stamped into the gear is facing up.
Page 52 RZT-S Zero Installation and timing of the steering gears To install and time the steering gears: Install the alignment pins by following the proce- dures described in the wheel alignment section of this chapter. “RH” facing up Slide the double-D of the steering gear shaft into the double-D hole of the inboard steering gear.
Page 53 Steering 9. Tighten the hex screw holding the steering gear shaft to a torque of 17 ft lbs (23 Nm). Socket headed cap screw 10. Attach the outboard steering gear to the yoke with the socket headed cap screw using a 1/4” hex key. See Figure 4.24.
Page 54: Drag Links
RZT-S Zero Drag links To remove a drag link: Remove the floor pan by following the procedures described in Chapter 3: Body. Steering sensor connector Turn the steering wheel so that the drag links outer ball joint is accessible through the opening in the frame.
Page 55 Steering To install a drag link: Install the jam nuts on the new drag link. NOTE: Thread the jam nuts all the way to the unthreaded section of the drag link. 2. Install the ball joint ends on the drag link. Alignment pin NOTE: The ball joint ends should be threaded on to the drag link the same number of turns as was...
Page 56: Steering Sensor
RZT-S Zero Steering sensor To remove/replace the steering sensor: Yoke cover NOTE: The function and troubleshooting proce- dures for the steering sensor are covered in Chapter 5: Electrical System. Remove the floor pan by following the procedures described in Chapter 3: Body.
Page 57 Steering 5. Remove the nuts and bolts that hold the sensor to the sensor bracket using a #2 Phillips screwdriver and a 1/4” wrench. See Figure 4.34. Bolts Figure 4.34 6. Install a new sensor to the sensor bracket using the nuts and bolts that held the old one in place.
Page 58 RZT-S Zero Plug the steering sensor into the harness. Install the yoke cover: 11a. Place the two spacers over the screw holes in the axle casting with the necked in side facing up. 11b. Place the star washers on top of the spacers.
Page 59: Throttle Position Sensor (Tps) Sensor
Steering Throttle Position Sensor (TPS) sensor To remove/replace the TPS: Remove the floor pan by following the procedures described in Chapter 2: Body. NOTE: Disconnecting the battery pack is not necessary when working with the sensors under the floor pan. TPS pigtails They run on a 5 volt signal.
Page 60: Steering And Tps Calibration
RZT-S Zero Steering and TPS calibration NOTE: The mower must be calibrated every time: • VCM is replaced • Steering sensor is removed/replaced • TPS is disconnected To calibrate the mower: Hold down the mow in reverse and the headlight buttons while turning the key to the “ON”...
Page 61: Chapter 5: Electrical System
Introduction The RZT-S Zero has a 48 volt electrical system. This system is an isolated or “fully floating” system. This means that the electrical system is not grounded to the chassis and is insulated from the non-electrical components of the mower.
Page 62 Most of the inputs to the VCM are doubled up for safety reasons. If the VCM senses a discrepancy in any of the sensor inputs, the VCM will show a fault code and will either shut down the mower or limit its functionality, depending which sensor is causing the fault. The components of the RZT-S Zero’s electrical system and their function: •...
Page 63 See Figure 5.6. • A 748-0376E blade adapter fits over the shaft to mount a blade. NOTE: The blades used on the RZT-S Zero are specifi- cally designed for these mowers to maximize run time and cut performance. Do not use after-market Deck motor blades.
Page 64 RZT-S Zero • Hub motors: The hub motors are 3-phase, brushless DC motors that are mounted onto a pair of drop axles to drive the rear wheels. See Figure 5.7. NOTE: The motor harness is part of the motor and can not be serviced.
Page 65 Electrical System • Brake switch: The brake switch is a SPDT switch Brake switch with one set of contacts that are Normally Open (N.O.) and the other set of contacts that are Nor- mally Closed (N.C.). See Figure 5.10. NOTE: The red wire with a white trace carries a 5 volt sig- nal to one of the NC tabs of the brake switch.
Page 66 RZT-S Zero • PTO switch: There is a standard PTO switch mounted in the right pod. The switch is used to send a signal to the VCM to turn the deck on or off. See Figure 5.13. NOTE: A red wire with a white trace splits and car- ries 5 volts to the “B”...
Page 67: Electric Motors
Electrical System Electric motors The electric motors used on the RZT-S Zero are 3 Stator phase, brushless, DC motors. This type of motor allows for Green - U phase fine control of the motor’s speed and torque. The construc- Yellow - V phase tion of the hub and deck motors are very similar.
Page 68 RZT-S Zero • DC Motor: These motors use DC voltage pulses that will go in one phase as a positive pulse and leave another as a negative pulse. The inputs and outputs are constantly switching so that one phase will be positive, one will be negative and the third phase will be zero.
Page 69: Vehicle Control Module (Vcm)
Electrical System Vehicle Control Module (VCM) Remove the upper steering column cover: 1a. Remove the six screws that hold the upper cover to the steering column using a T-30 torx driver. See Figure 5.17. 1b. Carefully lift the upper cover off of the steering column.
Page 70 RZT-S Zero VCM Connector Pin Designations Name Voltage Current LIGHTS+ Output < 1A LIGHTS- Return < 1A SPEAKER- Return < 1A SPEAKER+ Output < 1A COMMUNICATION < 1A COMMUNICATION < 1A RETURN BAT- < 5A BATTERY+ BAT+ < 5A PRE-CHARGE BAT+ <...
Page 71: Control Panel
Electrical System Control panel NOTE: The control panel is serviced as one assembly during the warranty period. Outside of warranty, the individual controllers can be replaced. NOTE: The contactor assembly is not serviceable and should not be opened. This would void the warranty. Before disconnecting any electrical component, take precautions to prevent the component ! CAUTION ! CAUTION...
Page 72 RZT-S Zero Remove the left pod by following the procedures described in Chapter 2: Body. Master ground bus Disconnect the 12 pin harness connector from the contactor assembly. Disconnect the negative battery pack cable from the master ground bus. See Figure 5.21.
Page 73 Electrical System Disconnect the motor harness connectors. Motor connectors See Figure 5.23. NOTE: Do not disconnect the five wires that go under the controller cover. Do not remove the controller cov- ! CAUTION ! CAUTION ers. There are pre-charge capaci- tors in the controllers.
Page 74: Controllers
RZT-S Zero Controllers To remove/replace a controller NOTE: The control panel is serviced as one assem- bly during the warranty period. Outside of warranty, the individual controllers can be replaced. NOTE: The contactor assembly is not serviceable and should not be opened. This would void the warranty.
Page 75 Electrical System Test light Discharge the pre-charge capacitors. NOTE: Do not use a high impedance test light for this pro- cedure. There is a very high likelihood that the capacitor’s charge will damage it. 4a. Remove the controller cover. 4b. Attach an incandescent test light to the negative (black) wire attached to the controller.
Page 76: Troubleshooting
Troubleshooting Unlike all other mowers produced by MTD, the RZT-S Zero has an insulated 48 volt system. This means that the usual methods of troubleshooting will not apply to this mower. On this mower the system can be boiled down to this: •...
Page 77: No Power/Vcm Does Not Light Up
Electrical System No Power/VCM does not light up When the key switch is turned on, the VCM should light up. If it does not: Open the charger door on the mower. Measure the voltage across the charger port with a DMM set to the DC volts scale.
Page 78 RZT-S Zero Remove the VCM by following the procedures described in the Vehicle Control Module (VCM) sec- tion of this chapter. 12 pin adapter Install the harness break out adapters. Measure the voltage across pins 7 and 8 of the 12 pin VCM connector.
Page 79: No Start
Electrical System No Start This screen indicates that the VCM is waiting for the operator to start the mower. The VCM will stay at this screen until it checks all of its ports and the controllers turn on (should take approximately 2 seconds). Icon If the operator holds the start button down, but the mower does not start:...
Page 80 RZT-S Zero • The VCM has lost communication with the steering sensor. • The VCM cannot understand the signal it is getting from the steering sensor. • The steering sensor jumps from one end of its scale to the other.
Page 81 Electrical System Sensor Rotate the steering wheel while observing the VCM’s screen. A. The steering angle jumps up and down in value: • Check the sensor’s air gap by following the pro- cedures described in Chapter 4: Steering. Magnet • Check for steering yokes ability to move in and out of the axle casting.
Page 82: Throttle Position Sensor (Tps) Faults
RZT-S Zero Throttle Position Sensor (TPS) faults The TPS assembly consists of two rotary hall effect Magnet sensors that are from the same series as the steering sen- sor. The TPS bracket has an arm that holds a magnet. As...
Page 83 Electrical System NOTE: If one or both of the sensors reads “0”, the VCM can not see that sensor(s) because it is either disconnected or the harness is dam- aged. • Remove the floor pan enough to gain access to the TPS assembly connectors.
Page 84 RZT-S Zero NOTE: If the one or both of the sensors jump from one end of the scale to the other: • Remove the two Phillips headed screws that hold one of the hall effect sensor to the TPS bracket. See Figure 5.44.
Page 85: Motor Faults
Electrical System Motor faults To troubleshoot motor faults: NOTE: When troubleshooting the motors, hub or deck, the procedures are basically the same. Inspect the motor: • For a deck motor fault, sharpen the blades and remove any debris from motor. NOTE: If there are any signs of impact damage on a blade, check the motor for a bent shaft.
Page 86 RZT-S Zero Test run the mower to verify any faults NOTE: There are several service screens that will Deck allow the technician to observe the system conditions and motor performance in real time. Depress the down arrow seven times, until the motor speeds screen appears.
Page 87 Electrical System Depress the down arrow button one time to bring up the base temp. screen. See Figure 5.48. NOTE: The screen shows the temperature of each control- ler. If there is a temperature that is drastically dif- ferent than the rest, refer to the control panel trouble shooting section.
Page 88: Control Panel Faults
RZT-S Zero Control panel faults The control panel consists of the: Master ground bus • The contactor assembly • The master ground bus • 4 controllers • A communication harness Controller • Aluminum back plate The contactor assembly can be thought of as the main power distribution center of the system.
Page 89 Electrical System To determine if the contactor assembly is functioning prop- erly: Remove the left pod by following the procedures described in Chapter 2: Body. NOTE: Do not disconnect the battery pack while removing the pod. Break out Install a jumper in the charger door switch connector. adapter Install the 12 pin harness breakout adapter between the harness and the contactor assembly.
Page 90 RZT-S Zero C. If all of the controllers read battery voltage, the pre-charge voltage is reaching the controllers, but this does not mean that the master relay is func- tional. To test the master relay: Set a DMM to measure DC volts.
Page 91 Electrical System The contactor assembly also distributes the VCM’s signals to and from the controllers: Jumper • The VCM actually communicates with the control- lers by a series of positive and negative 5 volt pulses that travel through pins 11 and 12 of the contactor’s main harness connection.
Page 92: Switch Faults
RZT-S Zero Switch faults The VCM sends 5 volts out pin 8 of the 16 pin connector. This 5 volts goes to the: • Charger door switch • Brake switch • TPS assembly • Steering sensor • PTO switch •...
Page 93 Electrical System With the charger door closed, measure the voltage from pin 7 (- probe) of the 12 pin connector of the VCM to pins 2 and 4 of the seat switch connector. NOTE: Removing the seat switch will make it easier to close the seat switch for testing.
Page 94 RZT-S Zero Inspect the charger door switch connection. Turn the key switch to the “ON” position. Charger door switch Set a DMM to measure DC volts. Back probe the red wire with a white trace using the positive probe of the DMM. See Figure 5.63.
Page 95 Electrical System Brake switch The brake switch receives 4 - 5 volts through a red wire with a white trace. A brown wire with a white trace carries the voltage from the N.O. contact of the brake switch to pin 1 of the VCM’s 16 pin connector. If there is a brake switch fault: Remove the VCM by following the procedures described in the Vehicle Control Module (VCM) sec-...
Page 96 RZT-S Zero PTO switch The PTO switch receives 4 - 5 volts at B-Com and C- Com through a red wire with a white trace. When the PTO switch is in the “OFF” state, a black wire with a white trace carries the voltage from the C- N.O.
Page 97 Electrical System Remove screws securing the right pod by following the procedures described in Chapter 2: Body. NOTE: Do not remove the pod. NOTE: Do not disconnect the battery pack while removing the right pod. Lift the pod enough to gain access to the key switch. Push the PTO switch in to the “OFF”...
Page 98: Schematic
RZT-S Zero Schematic...
Page 99: Error Codes
Error codes Code Message number Message Mower's action Trigger Possible causes type (engineering screen)** For Best Battery Life Avoid Information Display message only Battery power in the Heavy Load Only Heavy Load range for 10 continuous seconds. Battery Low: Charge Soon Information Display message only Battery state of charge...
Page 100 Code Message number Message Mower's action Trigger Possible causes type (engineering screen)** To Start: Sit in seat Starter disable Won't start until condition 0 volts at pin B3 and B4 Seat switch is not being met. depressed, poor connec- tion, faulty switch, dam- aged harness To Start: Push blade knob Starter disable...
Page 101 Code Message number Message Mower's action Trigger Possible causes type (engineering screen)** Blades off: Left Deck Fault Operator error Disables Blades One or both of the deck Too much material being Blades off: Right Deck motors are pulling 110 cut, build up of clippings Fault amps or more under the deck, binding of...
Page 102 Code Message number Message Mower's action Trigger Possible causes type (engineering screen)** Stopped: Left hub fault / Fault Disables Blades and Drive Motor hall sensor fault Disconnected harness Restart, if problem persists connector, damaged har- contact service ness, corrosion, faulty motor Overload: Slow down or Fault...
Page 103 Code Message number Message Mower's action Trigger Possible causes type (engineering screen)** Overload: Slow down or Fault Disables Blades and Drive 32768 Instantaneous under volt- Momentary drop in bat- raise deck tery voltage from the motor pulling too much current, short bursts Stopped: Right hub fault / Fault Disables Blades and Drive...
Page 104 Code Message number Message Mower's action Trigger Possible causes type (engineering screen)** Stopped: Right hub fault / Fault Disables Blades and Drive POST static gating test Controller failure Restart, if problem per- sists contact service Stopped: Right hub fault / Fault Disables Blades and Drive Instantaneous phase over...
Page 105 Code Message number Message Mower's action Trigger Possible causes type (engineering screen)** Blades off: Left deck fault Fault Disables Blades Phase over current Motor pulling too much Restart, if problem per- current, short bursts sists contact service Blades off: Left deck fault Fault Disables Blades Current sensor calibration...
Page 106 Code Message number Message Mower's action Trigger Possible causes type (engineering screen)** Blades off: Left deck fault Fault Disables Blades 2048 Throttle voltage outside Restart, if problem per- range sists contact service Blades off: Left deck fault Fault Disables Blades 4096 Instantaneous controller Batteries over charged,...
Page 107 Code Message number Message Mower's action Trigger Possible causes type (engineering screen)** Blades off: Right deck fault Fault Disables Blades Controller temperature is Controller overheating Restart, if problem per- from the motor pulling too over 100 sists contact service much current, usually from being overloaded, faulty controller Blades off: Right deck fault...
Page 108 Code Message number Message Mower's action Trigger Possible causes type (engineering screen)** Blades off: Right deck fault Fault Disables Blades 16384 POST dynamic gating test Controller failure Restart, if problem per- sists contact service Overload: Slow down or Fault Disables Blades and Drive 32768 Instantaneous under volt- Momentary drop in bat-...
Page 109 Code Message number Message Mower's action Trigger Possible causes type (engineering screen)** Stopped: Steering sensor Fault Disables Blades and Drive Steering signal drops to or Faulty steering sensor, fault / Restart, if problem near 0V, or rises to or near calibration error, move- persists contact service ment between the yoke...
Page 110 Code Message number Message Mower's action Trigger Possible causes type (engineering screen)** Stopped: Right wheel Fault Disables Blades and Drive 256 (or no code Network communications Disconnected harness comm fault / Restart, if if VCM timed timeout connector, damaged har- problem persists contact out and is not ness, corrosion...
Page 111 Code Message number Message Mower's action Trigger Possible causes type (engineering screen)** Stopped: Seat switch fault Fault Disables Blades and Drive Interlock1 Dual seat switch inputs Poor connection, faulty / Check to see if seat is code 8 are not equal switch, damaged harness plugged in / Restart, if code 16...
Page 113: Chapter 6: Battery Pack And Charger
NOTE: The batteries used on the RZT-S Zero mowers are a special AGM, deep cycle battery that is made to be mounted at any angle and can with stand the heavy vibration loads that the mower will impose on these batteries.
Page 114: Deep Cycle Batteries
Evaluating the batteries and the charger The batteries on the RZT-S Zero are AGM deep cycle batteries. Because of this, standard load testing or con- ductance testing will not fully test them. The inaccessibility also creates an issue for troubleshooting. For these rea- sons, a special troubleshooting procedure has been developed.
Page 115 Battery Pack and Charger 1g. Open the charger door on the mower. 1h. Measure the voltage across the charger port with a DMM set to the DC volts scale. Document the battery packs current state of charge on the battery check list. NOTE: Leaving batteries in a fully discharged state will damage them.
Page 116 If the battery pack needs replaced under warranty, contact Cub Cadet for a battery replacement authorization. NOTE: The battery check list will be needed when calling for an authorization and it goes with the batteries...
Page 117: Battery Testing
However, because the batteries used on an RZT-S Zero are sealed, AGM deep cell batteries, the conductance testers are ineffective. Load and conductance testing will test a batteries ability in a momentary heavy (starting) load condition. For automotive purposes, this is all that is really required.
Page 118: Capacity/Discharge Test
NOTE: The Lester #17770 will test the batteries at their 1 hour rate, which is 59 AH for the RZT-S zero. NOTE: The tester must be for a 48 volt system and apply a 54 amp load.
Page 119: Charger
Battery Pack and Charger Charger The RZT-S Zero has a 48 volt system. The mower gets 48 volts through four batteries, wired in series. These batteries form a battery pack and are all charged as one unit. NOTE: Only use the charger that came with the mower to charge the batteries.
Page 120: 5-Stage Charge
NOTE: The charge has four modes. The modes refer to the jumper setting on the charger’s control panel. The different modes only affect the initial (stage 1) output voltage of the charger. All four modes work with the battery pack on the RZT-S Zero. STAGE ONE - PRE-QUALIFICATION TEST •...
Page 121: Charger Trouble Codes
Battery Pack and Charger Charger Trouble Codes Under normal charge circumstances, the L.E.D.s operate as follows: • Power On (Red) Illuminates continuously when AC power is present. • Abnormal Shutdown (Red) Normally not illuminated. • Detection Error (Red) If connected to A.C. Power, but not connected to a battery pack, or battery pack is discharged to near 0V, L.E.D.
Page 122: Battery Removal/Installation
RZT-S Zero Battery removal/installation This mower has four batteries that need to be installed. They must be installed in a specific order to minimize shorting hazards and to prevent improper wiring of the system. ! WARNING ! WARNING Never let the battery terminals or any live harness connection contact the frame.
Page 123 Battery Pack and Charger 1b. Disconnect the battery pack’s positive lead from the contactor assembly using a 7/16” wrench. Positive lead See Figure 6.6. Contactor assembly Figure 6.6 The battery pack’s positive lead is ! CAUTION ! CAUTION positive lead still hot.
Page 124 RZT-S Zero Remove the four black shoulder screws that secure the front battery cover to the mower using a T-30 torx driver. See Figure 6.9. Screws Figure 6.9 Remove the front bracket: See Figure 6.10. Lower the mowing deck to its lowest setting.
Page 125 Battery Pack and Charger 12. Remove the rear battery cover: 12a. Remove the two screws at the front of the rear battery cover using T-30 torx driver. See Figure 6.12. Screws Figure 6.12 12b. Remove the two nuts and screws that hold the rear of the battery cover in place using a T-30 torx driver and a 7/16”...
Page 126 RZT-S Zero Disconnect the jumper wire (green tape) from the two batteries that are standing on end. See Figure 6.15. Disconnect the battery cable with the blue tape. Disconnect the battery cable with the yellow tape. NOTE: The battery cable with the yellow tape is still connected to battery number one.
Page 127 Battery Pack and Charger To install the batteries: NOTE: Before installing the batteries, remove the month and year from the label or write the date of installa- tion on the side of the batteries with a permanent marker. This will be helpful in diagnosing the bat- teries after they have been in service for a while.
Page 128 RZT-S Zero Battery terminals Insert the battery terminals cover into the slot in the cover battery tray. NOTE: There is a notch in the cover to allow the battery cables to pass through it. This notch should be at the bottom, on the right hand side.
Page 129 Battery Pack and Charger 17. Install the front bracket: See Figure 6.24. 17a. Lower the mowing deck to its lowest setting. 17b. Slide the front bracket over the two studs for the Self tapping seat bracket. screws 17c. Install the four self tapping screws using a 1/2” wrench.
Page 130 RZT-S Zero Install the front cover using the four black shoulder screws. Screws Figure 6.27 Seat switch harness Seat switch Install the seat: See Figure 6.24. 20a. Set the seat and seat bracket over the studs in the seat box.
Page 131: Electric Rider Battery Replacement Check List
NOTE: An Authorization is required from Cub Cadet before the batteries can be replaced under warranty. This check list must be performed prior to calling Cub Cadet for an authorization number and returned with the old batteries. The battery pack is not considered bad until they fall below 30 AH (50% of the 1 hour rat- ing).
Page 132: Charger Trouble Codes
Charger Trouble Codes Under normal charge circumstances, the L.E.D.s operate as follows: • Power On (Red) Illuminates continuously when AC power is present. • Abnormal Shutdown (Red) Normally not illuminated. • Detection Error (Red) If connected to A.C. Power, but not connected to a battery pack, or battery pack is discharged to near 0V, L.E.D.
Page 133: Chapter 7: Decks And Lift Shaft
CHAPTER 7: DECKS AND LIFT SHAFT Cutting decks The RZT-S Zero comes with a 42” floating deck. The deck is made of 13-gauge stamped steel. The deck is NOT a quick release deck and is not intended to be removed as part of normal service.
Page 134 RZT-S Zero NOTE: Each of the high current connectors coming from the motors are actually three separate connectors that hook onto each other. They can, but do not have to, be separated in order to fish the connectors through smaller openings.
Page 135: Cleaning The Deck
Decks and Lift Shaft Cleaning the deck Clean debris off of the deck every time the mower is used. It is routine maintenance that will make the deck eas- ier to work on and prolong the life of the deck and spindles. Debris build up on the mower deck is an unsafe condition.
Page 136: Blades
NOTE: Mulching with the RZT-S Zero will reduce the run time of the mower. The cutting deck on the RZT-S Zero mower is mounted with a slight rake, meaning that the front of the deck is a 1/4” lower than the rear of the deck. This is very important to get the proper air flow in the deck so that the blades can make the grass blades stand up to get cut.
Page 137 Decks and Lift Shaft Check the blade adapter, motor shaft and hardware for damage: See Figure 7.9. • The end of the motor shaft should not wobble or orbit when the motor shaft is rotated. • The key in the blade adapter and the keyway in the motor shaft should engage firmly.
Page 138: Leveling The Deck
RZT-S Zero Leveling the deck For the best quality cut, the deck must be level side to side and the front of the deck should be 1/4” lower than the rear of the deck. To level the deck: NOTE: Deck leveling is part of initial mower setup. Before adjusting an out of level deck on a mower that has been used, inspect all of the deck lift and suspension linkages.
Page 139: Front To Rear (Pitch) Leveling
Decks and Lift Shaft Front To Rear (pitch) Leveling With the mower parked on a firm, level surface, move the deck to the mid height or most commonly used position using the deck lift pedal. Rotate the blade nearest the discharge chute so that it is paral- lel with the mower frame.
Page 140: Deck Gauge Wheel Adjustment
RZT-S Zero Deck Gauge Wheel Adjustment The cutting decks are of a “floating” design. This means that they are suspended above the ground. The gauge wheels occasionally touch the ground. They are designed to bump the deck up and over irregularities. This prevents scalping damage to the turf and to the deck.
Page 141: Deck Lift Shaft Assembly
• Attaches the lift shaft to the frame. • Acts as bushings for the lift shaft assembly. Cub Cadet recommends that the bracket be replaced every time the lift shaft is removed. 11. Install the deck lift shaft by following the previous Figure 7.16...
Page 142: Deck Motor
Hole in frame NOTE: The deck motors and the harness are ser- viced as one assembly. They can not be separated. The RZT-S Zero is equipped with a ! CAUTION ! CAUTION 48 volt system. Removing the pods will expose the high voltage wiring.
Page 143: Assembly Instruction Manual
Assembly Instruction Manual ASSEMBLY INSTRUCTION MANUAL IMPORTANT: The RZT-S Zero must be assembled by the Cub Cadet dealer prior to delivery to the customer. The Underwriters Laboratories certification for these mowers does not allow for the consumer to access the batteries or any of the wiring. This Manual is intended to provide service dealers with the instructions to assemble a RZT-S Zero mower.
Page 144 RZT-S Zero Disconnect the seat switch harness. See Figure 3. Remove the seat. Seat switch harness Figure 3 Slide the steering column cover out from under the steering column. See Figure 4. Upper steering column cover NOTE: There is a wire harness running through the cover.
Page 145 Assembly Instruction Manual 11. Remove the rear battery cover: 11a. Remove the two screws from the front of the Screws rear battery cover using T-30 torx driver. See Figure 6. Figure 6 11b. Cut off the tie strap that is holding the rear of the rear cover to the bumper.
Page 146 RZT-S Zero NOTE: There are two different height settings the steering column can be mounted at. Lift the steering column to the desired height and secure it with the patch bolts and flat washers from the hardware packet. See Figure 9.
Page 147 Assembly Instruction Manual 20. Install the deck discharge chute deflector: The discharge chute deflector must ! WARNING ! WARNING Flange lock nuts be installed before operating the mower. Never operate the mower deck without the chute deflector installed and in the down position.
Page 148 RZT-S Zero 21a. Insert 1 battery under seat box so that the terminals are down and facing the rear of trac- tor. See Figure 14. Positive terminal Figure 14 21b. Connect the red wire with the fuse attached to it, from under left pod, to the positive terminal of 1 battery.
Page 149 Assembly Instruction Manual 21e. Attach the wire with the yellow tape to the nega- tive terminal of 1 battery. NOTE: Tighten the terminal nut to a torque of 10 - 15 ft lbs (14 - 20 Nm). Yellow tape Figure 17 21f.
Page 150 RZT-S Zero Battery terminals 21l. Insert the battery terminals cover into the slot cover in the battery tray. NOTE: There is a notch in the cover to allow the battery cables to pass through it. This notch should be at the bottom, on the right hand side.
Page 151 Assembly Instruction Manual 22. Install the front bracket: 22a. Lower the mowing deck to its lowest setting. 22b. Slide the front bracket over the two studs for the seat bracket. 22c. Install the four self-tapping screws using a 1/2” wrench. Self tapping screws 22d.
Page 152 RZT-S Zero Install the front cover using the four black shoulder screws with a T-30 torx driver. Screws Figure 26 Install the seat: Seat switch harness Seat switch 25a. Place the seat on the seat bracket. 25b. Install the two shoulder bolts and nuts so that the nuts are on the inboard side.
Page 153: Pre-Delivery Checklist
Pre- Delivery Check List RZT-S Zero SERIES CUSTOMER NAME_____________________________ MODEL NUMBER______________________________ ADDRESS____________________________________ SERIAL NUMBER______________________________ CITY_________________________________________ IF APPLICABLE: STATE________________________ZIP____________ ATTACHMENT MODEL NUMBER_________________ HOME PHONE NUMBER________________________ ATTACHMENT SERIAL NUMBER_________________ ELECTRIC MOTORS: CHECK-ADJUST AS REQUIRED. Inspection time for these RH HUB MOTOR SERIAL NUMBER_____________________ checks are not reimbursable under warranty.
Page 154 NOTES:...
Page 156 MTD Products Inc - Product Training and Education Department FORM NUMBER - 769-08008-02 05/2013...

Cub Cadet RZT-S Zero Shop Manual

Chapter 1: Introduction

Chapter 2: Body

Chapter 3: Brake and Drive System

Chapter 4: Steering

Chapter 5: Electrical System

Chapter 6: Battery Pack and Charger

Chapter 7: Decks and Lift Shaft

Appendix

Quick Links

Related Manuals for Cub Cadet RZT-S Zero

Summary of Contents for Cub Cadet RZT-S Zero

Table of Contents