Cub Cadet Z-Force Series Zero Turn Service Manual

Professional Shop Manual Z-Force S MTD Products Inc. - Product Training and Education Department FORM NUMBER - 769-05513 06/2010 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 inexperienced individuals should seek the assistance of an experienced and trained professional. Read, understand, and follow all instructions and use common sense when working on power equipment. This includes the contents of the product’s Oper- ators Manual, supplied with the equipment. No liability can be accepted for any inaccuracies or omission in this publication, although care has been taken to make it as complete and accurate as possible at the time of publication. However, due to the variety of outdoor power equipment and continuing product changes that occur over time, updates will be made to these instructions from time to time. Therefore, it may be necessary to obtain the latest materials before servicing or repairing a product. The company reserves the right to make changes at any time to this publication without prior notice and without incurring an obligation to make such changes to previously published versions. Instructions, photographs and illustrations used in this publication are for reference use only and may not depict actual model and component parts. © Copyright 2010 MTD Products Inc. All Rights Reserved

I Chapter 1: Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Professional Shop Manual intent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Description of the Z-Force-S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Model and Serial Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Chapter 2: Engine Related Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Fuel tank removal/replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Chapter 3: Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Brake system description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Brake adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Brake puck/rotor replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Brake shaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Parking brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Chapter 4: Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Floor pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Left control console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Right control console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Seat box assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Chapter 5: Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Drive belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Drive belt adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 EZT transmission removal/replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 ZT 2800 transmission removal/replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Drive pedal biasing adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Hydro neutral control adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Chapter 6: Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Wheel alignment and drive control link adjustments . . . . . . . . . . . . . . . . . . . . 43 Steering gear box removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Steering gearbox installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Rebuilding the steering gear box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Front wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Front yokes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Removal of the steering gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Tie rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Steering shaft, bushings and dampener removal . . . . . . . . . . . . . . . . . . . . . . 79 Table of Contents

II Chapter 7: Electrical System .............................................................................. 87 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 RMC Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Key switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 RMC Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 To identify a faulty RMC module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 PTO Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Reverse Safety Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Seat Safety Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Starter solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 PTO Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Lighting circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Run Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Run Circuit / Reverse Caution mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Engine shut-down circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Charging circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 PTO Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Reverse Mower Control (RMC) circuit operation . . . . . . . . . . . . . . . . . . . . . 109 Electrical diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Electrical environment: AC Vs. DC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Ohm’s Law . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Kirchhoff’s current law . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Kirchhoff’s voltage law . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 How the system is wired together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Types of circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Parallel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Series/parallel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Shorts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Increased resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 The Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Digital Multi-meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Wiring diagram or schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Fused jumper wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Test lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Self-powered continuity lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Ammeters and specialized charging system testers . . . . . . . . . . . . . . . . . . . 120 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Checking battery condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Battery Testers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Adjustable load testers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

III Fixed load testers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Conductance testers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Battery discharge test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Storage of batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Electrical Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Voltage Drop Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Testing switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Chapter 8: Decks And Lift Shaft ....................................................................... 137 Cutting decks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Cleaning the deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 To clean the deck while it is removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 PTO belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Deck Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 Spindle pulleys and spindle shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Spindle removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Spindle overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Leveling the deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 Side to Side Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 Front To Rear (pitch) Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Deck Gauge Wheel Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Front and rear deck lift shaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 Deck lift pedal lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 Chapter 9: Maintenance Intervals ..................................................................... 155 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 Engine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 The spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Servicing the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Clean the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Introduction 1 Professional Shop Manual intent This Manual is intended to provide service dealers with an introduction to the mechanical aspects of the Z-Force- S riding mower. • Detailed service information about the engine will be provided by the engine manufacturer, in most cases. Disclaimer: 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. 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. • Bullet points: indicate sub-steps or points. Disclaimer: This manual is intended for use by trained, professional technicians. • Common sense in operation and safety is assumed. • In no event shall MTD or Cub Cadet be liable for poor text interpretation or poor execution of the 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. Fasteners • Most of the fasteners used on these mowers are sized in fractional inches. The engine and transmissions 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 releas- able thread locking compound such as Loctite® 242 (blue). • Some fasteners like cotter pins are single-use items that are not to be reused. Other fasteners such as lock washers, retaining rings, and internal cotter pins (hairpin clips) may be reused if they do not show signs of wear or damage. This manual leaves that decision to the judgement of the technician. Caution is used to point out potential danger to the technician, operator, bystanders, or sur- rounding property. ! CAUTION Warning indicates a potentially hazardous situation that, if not avoided, could result in death of serious injury. ! WARNING ! DANGER Danger indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury. This signal word is to be limited to the most extreme situations CHAPTER 1: INTRODUCTION

Z-Force-S 2 Assembly Torque specifications may be noted in the part of the text that covers assembly, they may also be summarized in tables along with special instructions regarding locking or lubrication. Whichever method is more appropriate will be used. In 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 assembly. Some instructions may refer to other parts of the manual for subsidiary procedures. This avoids repeating the same procedure two or three times in the manual. Description of the Z-Force-S The Z-Force-S combines a traditional Z-force lap bar zero turn rider (ZTR) with Cub Cadet’s patented Syncro Steer TM technology. The magic of the system: variable ratio steering gears that turn the front wheels much further than conventional systems. The steering control is linked to the traction drive system control. The traction drive system synchronizes the steering angle of the front tires with the speed and direction of the rear tires. A true zero-turn is achieved when the operator turns the steering wheel far enough that the inside rear wheel spins in reverse just like a traditional lap-bar controlled ZTR. Figure 1.1

Introduction 3 Model and Serial Numbers The model and serial number tag can be found under the seat. See Figure 1.2. The serial number is located to the right of the model number as shown above. See Figure 1.2. The model number is 17AI5BHB010. The break down of what the number mean is as follows: 1 ...............................................................................................Residential machine ....7 ...........................................................................................Residential zero turn mower .......A........................................................................................Sales level ...........I. ....................................................................................Engine code .............5. .................................................................................Frame .................B..............................................................................Transmission (B = EZT, G = ZT2800) ....................H ..........................................................................Style series .........................B......................................................................Deck (B = 48”, D = 60”) .............................010 ..............................................................Customer number The serial number is 0J149Z20021. The serial number reads as follows: 0 ...............................................................................................Engineering level ..J .............................................................................................Month of production (J = October) .....14 ........................................................................................Day of the month .........9 ......................................................................................Last digit of the year ...........Z ....................................................................................Plant it was built in (Streetsboro, OH) ..............2 .................................................................................Assembly line number .................0005 ........................................................................Number of unit built Figure 1.2 Model number Serial number

Z-Force-S 4

Cub Cadet Z-Force Series Zero Turn Service Manual

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