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Electrical System

97

6.

Voltage drop on a good circuit should be less than
0.1 volts. A voltage drop reading on the meter of
greater than 0.2 volts indicates a fairly substantial
problem that demands attention.

•

As an example, if the mower had a slow-turning
starter, the ground-side voltage drop measured
below 0.1 volts, and there was not a parasitic
load on the engine (e.g. PTO clutch that is not
fully disengaged), it would be logical for the
technician to check voltage drop to the starter.
See Figure 7.45.

•

With the starter motor engaged, the voltage
drop reading here is nearly 0.6 volts, indicating
a serious problem in the heavy-gauge circuit
between the starter and the battery.

•

Checking voltage-drop at various points along the circuit can help pin-point the problem.

•

Check voltage-drop at the output lug on the starter solenoid.

•

If there is a significant difference, the problem lies between the lug on the solenoid and the lug on the
starter.

•

If there is little change, the problem lies further upstream.

•

Check voltage drop at the input lug on the solenoid. If there is significant difference (greater than 0.10 volt)
between the reading here and the reading at the output lug, then the contacts inside the solenoid may be
burned. If there is little change, the problem lies further upstream, between the battery and the solenoid.

•

Results may be cross-checked by testing voltage drop across the two posts of the starter solenoid while
cranking the starter motor.

Figure 7.45

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Summary of Contents for RZT-S

Page 1: ... 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 la...

Page 2: ...www mymowerparts com For Discount Cub Cadet Parts Call 606 678 9623 or 606 561 4983 ...

Page 3: ...ft fender 17 Right fender 18 Seat box assembly 20 Chapter 4 Brake and Drive System Brake system description 23 Brake adjustment 24 Brake puck rotor replacement 25 Brake shaft Bushings 28 Drive belt 30 Drive belt adjustment 32 Hydro neutral control adjustment 38 Control pedal shaft assembly 41 Chapter 5 Steering Introduction 47 Wheel alignment and drive control link adjustments 48 Front wheels 51 F...

Page 4: ...cuits 82 Series 82 Parallel 82 Series parallel 83 Shorts 83 Opens 83 Increased resistance 83 The Tools 84 Digital Multi meter 85 Wiring diagram or schematic 86 Fused jumper wires 86 Test lights 86 Self powered continuity lights 86 Ammeters and specialized charging system testers 87 Batteries 88 Charging the battery 88 Checking battery condition 89 Battery Testers 90 Adjustable load testers 90 Fixe...

Page 5: ...le overhaul 113 Leveling the deck 115 Front To Rear pitch Leveling 116 Deck Gauge Wheel Adjustment 117 Deck lift shaft assembly 118 Chapter 8 Maintenance intervals Lubrication 121 Engine maintenance 121 The spark plugs 122 Air filter 123 Oil change 124 Oil filter 125 Fuel system 126 Servicing the fuel system 126 Fuel filter 126 Clean the engine 127 Transmissions 127 www mymowerparts com For Discou...

Page 6: ...IV www mymowerparts com For Discount Cub Cadet Parts Call 606 678 9623 or 606 561 4983 ...

Page 7: ...l 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 Locti...

Page 8: ...opriate tinted eye protection when cutting or welding Flame resistant headgear jacket chaps when cutting or welding WARNING WARNING CAUTION CAUTION Remember that some hazards have a cumulative effect A single exposure may cause little or no harm but continual or repeated exposure may cause very serious harm Clean spills and fix obviously dangerous conditions as soon as they are noticed Lift and su...

Page 9: ...r parts of the manual for subsidiary procedures This avoids repeating the same procedure two or three times in the manual Description of the RZT S The RZT S combines a traditional RZT lap bar zero turn rider ZTR with Cub Cadet s patented Syncro SteerTM technology The magic of the system variable ratio steering gears that turn the front wheels much further than conventional systems The steering con...

Page 10: ...ine 7 Residential zero turn mower W Returnable crate F Engine code 2 Frame B Transmission B EZT G ZT2800 D Style series S Deck S 42 T 46 P 50 056 Customer number The serial number is 1B142H20124 The serial number reads as follows 1 Engineering level B Month of production B February 14 Day of the month 2 Last digit of the year H Plant it was built in Martin TN 2 Assembly line number 0124 Number of ...

Page 11: ... 2 4 Remove the muffler and exhaust pipes NOTE The exhaust pipes are welded to the muffler The pipes and the muffler are serviced as one assem bly 5 Clean and remove all gasket material from the cylin der head and the exhaust pipe if they are being reused 6 Using new gaskets install the muffler by following the previous steps in reverse order NOTE Tighten the exhaust screws to a torque of 150 in l...

Page 12: ...g a 3 8 wrench NOTE The left rear wheel was removed for a clear view of the screws 1b Remove the two screws indicated by the arrows in Figure 2 4 from the inboard side of the fender using a T 27 torx driver Figure 2 3 CAUTION CAUTION Gasoline and its vapors are extremely flammable Use com mon sense when working around the fuel system Figure 2 4 www mymowerparts com For Discount Cub Cadet Parts Cal...

Page 13: ...he fuel filter See Figure 2 6 3 Disconnect the fuel line from the fuel tank at the fuel filter 4 Disconnect the fuel tank vent line from the roll over valve 5 Lift the fuel tank off of the mower 6 Drain the fuel into an approved container 7 Install the fuel tank by reversing previous steps 8 Test drive the mower in a safe area before returning it to service Figure 2 5 Screw Figure 2 6 Vent hose Fu...

Page 14: ... To remove replace the pick up tube 1 Remove the left fender by following the procedures described in Chapter 3 Body 2 Clamp off the fuel line between the fuel tank and the fuel filter See Figure 2 7 3 Disconnect the fuel line from the pick up tube 4 Gently pry the pick up tube and grommet out of the fuel tank See Figure 2 8 5 Inspect the grommet NOTE If the grommet is cracked or damaged replace a...

Page 15: ...et is GREENbarTM This is a multi layer fuel line that meets the current EPA guide lines NOTE This fuel line has a thin inner liner If a tear forms in this inner liner fuel can get between the liner and the hose This will cause the liner to collapse cut ting off the fuel flow NOTE Replace the fuel line only with GREENbarTM 700 series fuel line Figure 2 9 Fitting Grommet pick up tube Figure 2 10 NBR...

Page 16: ...s by engine manu facturer but on most engines the vent hose will go to the air intake manifold NOTE Units sold in California will have a charcoal canister to further reduce the amount of emissions that escape from the fuel system The fuel tank will vent through the charcoal canister The charcoal in the canister will act as a filter and remove some of the vapors that are venting out of the fuel tan...

Page 17: ...een the charcoal canister if equipped and the intake manifold Engine runs lean Wrong fuel cap installed Leak in the vacuum lines Gasoline vapor escaping from the engine The charcoal canister if equipped is saturated A blockage in the line between the charcoal canister if equipped and the intake manifold Wrong fuel cap installed Leak in the vacuum lines www mymowerparts com For Discount Cub Cadet P...

Page 18: ... tank See Figure 2 14 4 Inspect the rubber grommet replace if damaged To install the roll over valve 1 With the grommet on the roll over valve install the roll over valve by pressing it into the opening in the tank 2 Install the vacuum line 3 Install the left fender 4 Test run the engine in a safe area before returning to service Figure 2 13 Vent hose Red trace Figure 2 14 Roll over valve www mymo...

Page 19: ...nect a vacuum pump to the roll over valve 3 Hold the roll over valve in an inverted position 4 Apply a vacuum to the roll over valve See Figure 2 15 NOTE The roll over valve should hold 15 in Hg for 15 seconds 5 With the vacuum still applied turn the roll over valve over See Figure 2 16 NOTE The vacuum should be relieved 6 If the results do not match what is listed above replace the roll over valv...

Page 20: ...lide the cable jacket until the speed control lever makes contact with the choke lever 4 Tighten the control cable jacket 5 Move the throttle lever to the choke position 6 Verify that the choke is fully closed 7 Test run the mower in a safe area before returning it to service Figure 2 17 Speed control lever Control cable clamp Choke lever Contact point www mymowerparts com For Discount Cub Cadet P...

Page 21: ...wheel to the steering shaft using a 1 2 wrench See Figure 3 1 1d Lift the steering wheel off of the steering shaft 2 Remove the brake pedal See Figure 3 2 2a Remove the screw that secures the brake pedal to the pedal shaft bell crank using a 1 2 wrench 2b Unhook the brake pedal from the bell crank Figure 3 1 Screw Figure 3 2 Brake pedal Pedal shaft bell crank CHAPTER 3 BODY www mymowerparts com Fo...

Page 22: ...mov ing the two screws indicated by the arrows in Fig ure 3 4 using a T 30 torx driver 6 Remove the nine screws that hold the floor pan to the frame using a T 30 torx driver 7 Lift the floor pan off of the mower 8 Install the floor pan by reversing the previous steps NOTE Confirm that all safety and control features work correctly Do Not return an unsafe mower to service Figure 3 3 Reverse pedal F...

Page 23: ...rew from the front of the fender using a T 27 torx driver See Figure 3 8 4 Unscrew the fuel cap NOTE The fuel cap is tethered to the fender This is an EPA tier III requirement 5 Lift the fender off of the mower 6 Install the fender by following the previous steps in reverse order NOTE Confirm that all safety and control features work correctly Do Not return an unsafe mower to ser vice Figure 3 6 C...

Page 24: ...ing a T 30 torx driver See Figure 3 9 3 Remove the two screws indicated by the arrows in Figure 3 10 from the inboard side of the fender using a T 27 torx driver 4 Remove the screw from the front of the fender using a T 27 torx driver See Figure 3 11 5 Remove the deck lift lever grip Figure 3 9 Figure 3 10 Figure 3 11 Screw www mymowerparts com For Discount Cub Cadet Parts Call 606 678 9623 or 606...

Page 25: ...the fender off of the mower 11 Install the fender by following the previous steps in reverse order 12 Test drive the mower in a safe area before returning it to service NOTE Confirm that all safety and control features work correctly Do Not return an unsafe mower to ser vice Figure 3 12 Key switch PTO switch Hour meter Figure 3 13 www mymowerparts com For Discount Cub Cadet Parts Call 606 678 9623...

Page 26: ...t fender section of this chapter 5 Disconnect the harness from the seat switch 6 Remove the two screws securing the seat frame to the seat box using a 1 2 wrench See Figure 3 14 7 Remove both of the seat springs using a 1 2 wrench See Figure 3 15 8 Remove the seat box cover using a 1 2 wrench 9 Remove the two screws that hold the deck lift index ing bracket to the seat box using a 1 2 wrench See F...

Page 27: ...s indicated by the arrows in Figure 3 19 that hold the front of the seat box to the frame using a T 30 torx driver 14 Fish the wiring harness out of the seat box 15 Lift the seat box assembly off of the mower 16 Install the seat box by reversing the previous steps 17 Test drive the mower in a safe area before returning it to service NOTE Confirm that all safety and control features work correctly ...

Page 28: ...Z Force S 22 www mymowerparts com For Discount Cub Cadet Parts Call 606 678 9623 or 606 561 4983 ...

Page 29: ...to rotate NOTE The brake shaft is held captive on the deck lift shaft It is serviced with the deck lift shaft Refer to the deck lift shaft section of Chapter 7 Decks and Lift Shaft for removal replacement procedures As the brake shaft rotates the two bell cranks will pull the secondary brake rods The secondary brake rods will pull on the brake caliper arm push ing the brake pins into the caliper a...

Page 30: ...he tolerance for the brake clearance is 0 020 0 040 0 5 1 0mm The 0 030 feeler gauge will set the clearance at the midpoint 6 Tighten the nut until there is slight drag on the feeler gauge NOTE For even braking both sides should be set to the same clearance 7 Install a new cotter pin 8 Repeat same procedure on the other side 9 Take the mower off of the jack stands 10 Open the bypass valves and che...

Page 31: ...ion The brake pucks and the rotors are serviced at the same time To service the brake pucks 1 Lift and safely support the rear of the mower 2 Make sure the parking brake is released 3 Disconnect the secondary brake rod from the brake shaft bell crank by removing the bowtie clip See Figure 4 5 4 Slide the brake rod spring and washer out of the brake cam arm 5 Loosen the rear mounting bolt See Figur...

Page 32: ...aliper on a work bench remove the brake puck backing plate and the two brake pins See Figure 4 9 11 Check for free movement of the brake pins A dry lubricant can be used on the brake pins sparingly 12 Slide the brake pins into the caliper 13 Place the backing plate in the caliper Figure 4 7 Caliper Figure 4 8 Inboard brake puck Figure 4 9 Brake caliper Brake pins Backing plate Brake puck CAUTION C...

Page 33: ...ke cam arm 19 Connect the secondary brake rod to the brake shaft bell crank and install the bowtie clip 20 Adjust the brakes as described in the previous sec tion of this chapter 21 Repeat steps 4 19 on the other side 22 When both sides are completed take the mower off of the jack stands 23 Open the by pass valves and check the parking brake before returning the mower to service With the brakes re...

Page 34: ...ift Shaft 3 Remove the left fender by following the procedures described in Chapter 3 Body 4 Remove the right fender by following the proce dures described in Chapter 3 Body 5 Disconnect the harness from the seat switch 6 Remove the two screws securing the seat frame to the seat box using a 1 2 wrench See Figure 4 11 7 Remove both of the seat springs using a 1 2 wrench See Figure 4 12 8 Remove the...

Page 35: ...llow the left split bushing to be fully exposed 14 Remove the bushing 15 Install a new bushing 16 Slide the brake shaft to the left enough to allow the split spacer to be installed 17 Install the split spacer 18 Put the mower back together by reversing steps 1 8 19 Test run the mower in a safe area before returning it to service NOTE Check all safety and control features Do Not return an unsafe mo...

Page 36: ...See Figure 4 16 4 Remove the nuts that hold the right belt guard to the frame using a 7 16 wrench See Figure 4 17 5 Remove the right belt guard 6 Remove the nuts that hold the left belt guard to the frame using a 7 16 wrench NOTE The front nut on the left belt guide will be inside the seat box under the harness 7 Remove the left belt guard Figure 4 16 Battery Figure 4 17 Nuts Figure 4 18 Nuts www ...

Page 37: ... can now be snaked out of the mower 14 Install the belt by reversing the above steps 15 Test drive the mower before returning to service NOTE Check all safety and control features Do Not return an unsafe mower to service Figure 4 19 PTO Harness Belt guard Figure 4 20 Brake de clutching rod Figure 4 21 Spring idler pulley CAUTION CAUTION Cub Cadet belts are designed to fit our equipment and are not...

Page 38: ...e is applied and fully tensioned when the brake is released NOTE The belt must be on when performing this adjustment 1 Release the parking brake 2 Remove the deck as described in Chapter 7 Cut ting Decks and Lift Shaft 3 Remove the bow tie clip and washer from the ferrule on the end of the brake link See Figure 4 22 4 Slide the ferrule out of the idler bracket 5 Adjust the ferrule so that it lines...

Page 39: ... Drive System Fluid Plus 1 qt P N 737 3120 is a pre mium alternative if the fluid is being completely drained and replaced After refilling the transmission must be purged of air and the fluid topped up to the specified level Symptoms and Causes Because of the unique nature of the drive system on the RZTS there are symptoms that are not covered by the generic check list Slow right turns General los...

Page 40: ...tigating complaints of slow drive speed 2 Dragging brakes on both transmissions If both brakes are dragging pay close attention to the portion of the linkage that is common to both brakes It may also be that both brake calipers have stuck If both calipers are in a very dirty or very corrosive environment they may both stick 3 If both hydraulic relief rods are bent or partially engaged both transmi...

Page 41: ...on being ser viced using a 3 4 wrench 5 Disconnect the secondary brake rod from the brake shaft bell crank by removing the bowtie clip 6 Slide the brake rod spring and washer out of the brake cam arm 7 Disconnect the drive control rod from the transmis sion control arms using a pair of 9 16 wrenches See Figure 4 26 Figure 4 24 Spring Figure 4 25 Secondary brake rod Figure 4 26 Drive control rod ww...

Page 42: ...smissions to each other using a 1 2 wrench and an 11 16 wrench See Figure 4 28 10 Remove the bolt holding the rear of the transmis sion to the rear transmission mounting bracket using a 5 8 wrench and an 11 16 wrench See Figure 4 29 Figure 4 27 Mounting bracket Figure 4 28 Nut Spacer Figure 4 29 Mounting bracket Bolt www mymowerparts com For Discount Cub Cadet Parts Call 606 678 9623 or 606 561 49...

Page 43: ... transmission by following the previous steps in reverse order NOTE Before lowering the mower to the ground purge the transmission 18 Perform a neutral adjustment and wheel alignment by following the steps described in 5 Steering 19 Test drive the mower before returning it to service Figure 4 30 Bypass rod Figure 4 31 Transmission bolts Figure 4 32 Belt Purge procedure Move the bypass rod to the b...

Page 44: ...ch connector is a shorted NC connector That means when the connector is unplugged a tiny jumper inside the con nector shorts out the contacts When the connector is shorted the circuit behaves as if the seat were empty 2d Compress the switch plunger with a spring clamp See Figure 4 32 CAUTION CAUTION The mower engine and drive system must be operated to complete this procedure Confirm that no hazar...

Page 45: ...ng brake 6 Observe the movement of both rear wheels See Figure 4 35 If there is no wheel movement the hyrdo transmis sions are in neutral and don t need to be adjusted Skip ahead to step 13 If one or both rear wheels move the hydro trans missions need to be adjusted Continue on to step 7 Figure 4 34 Drive control rods Figure 4 35 No movement www mymowerparts com For Discount Cub Cadet Parts Call 6...

Page 46: ...hex key 11 Turn the engine off 12 Adjust the drive control rods so that the hole s in the ball joint s aligns with the hole s in the trans mission control arm s 13 Remove the spring clamp from the seat switch 14 Install the seat switch 15 Lower the mower to the ground 16 Test the drive system and all safety features before returning the unit to service NOTE Check all safety and control features Do...

Page 47: ...Steering 3 Remove the steering shaft bolt from the bottom of the steering shaft using a 7 16 wrench See Figure 4 37 4 Install the screw and washer from the steering wheel into the top of the steering shaft 5 Disconnect the parking brake cruise latch spring See Figure 4 38 6 Remove the bowtie clip from the travel stop pin See Figure 4 39 7 Slide the travel stop pin out of the steering column assemb...

Page 48: ...olumn assembly to the mower using a 1 2 wrench See Figure 4 41 10 Lift the steering column assembly off of the mower 11 Remove the nut bolt and shoulder spacers that attach the speed brackets to the control pedal shaft using a pair of 7 16 wrenches See Figure 4 42 Figure 4 40 Bolts Figure 4 41 Screws Figure 4 42 Speed brackets www mymowerparts com For Discount Cub Cadet Parts Call 606 678 9623 or ...

Page 49: ...t that does not press against the control pedal bracket replace it with a 3 8 16 x 2 50 grade 5 bolt 710 0859 See Service Advisory CC 749 13 Remove the bowtie clip and disconnect the main brake rod See Figure 4 44 14 Remove the reverse switch See Figure 4 45 15 Remove the two screws that hold the left control pedal bracket to the frame using a 1 2 wrench Figure 4 43 Bolt Figure 4 44 Main brake rod...

Page 50: ... the pedal shaft 20 Remove the bowtie clip that holds the right control bracket to the pedal shaft See Figure 4 47 21 Slide the right bracket and hex bushing off of the pedal shaft 22 Slide the drive pedal shaft off of the brake pedal shaft See Figure 4 48 23 Remove the bushings Figure 4 46 Screws Reverse switch Figure 4 47 Bowtie clip Figure 4 48 Brake pedal shaft Drive pedal shaft www mymowerpar...

Page 51: ...installation of the steering col umn They are not used for alignment adjustments 25 Install the control pedal shaft by following steps 1 through 23 in reverse order 26 Test drive the mower in a safe area before returning it to service NOTE Check all safety and control features Do Not return an unsafe mower to service Figure 4 49 Pinion gear Timing marks www mymowerparts com For Discount Cub Cadet ...

Page 52: ...RZT S 46 www mymowerparts com For Discount Cub Cadet Parts Call 606 678 9623 or 606 561 4983 ...

Page 53: ...more than the outside drive wheel When the inside front wheel reaches an angle of 90o the rear wheel on that side will stop driving Turning the wheel past that point will make the inside rear wheel drive in reverse The inside front wheel can reach a 108o angle The mower will then make a zero radius turn Because the segment gears are linked to the transmissions the transmission adjustments and the ...

Page 54: ... control link adjustments 1 Remove the floor pan following the procedures described in Chapter 3 Body 2 Position the steering wheel on the steering shaft 3 Turn the steering wheel to center the segment gears 4 Loosen the drag link ball joint jam nuts using a 9 16 wrench 5 Disconnect the drag links from the segment gears using a pair of 9 16 wrenches See Figure 5 1 NOTE There is a hole in the frame...

Page 55: ...per of the 5 16 alignment pin will center the pin in the align ment hole 10 Adjust the ball joints on the threaded drag links to align them with the holes in the segment gears See Figure 5 5 11 Install the nuts and bolts that attach the drag links to the segment gears 12 Tighten the drag link ball joint jam nuts Figure 5 3 Alignment pin Figure 5 4 Alignment pin Figure 5 5 Holes aligned www mymower...

Page 56: ...ach the control links to the transmission control arms 17 Tighten the control link jam nuts 18 Remove all of the alignment pins and alignment fix tures 19 Install the floor pan following the procedures described in Chapter 3 Body 20 Test drive the mower in a safe area before returning it to service NOTE Do not put a mower back into service if it does not react properly to control inputs Figure 5 6...

Page 57: ...each side of the wheel The short spacers slide over the long spacer that the axle bolt passes through See Figure 5 10 4 Slide the long spacer out of the wheel bearings NOTE The long spacer is a tight fit to the bearing and may need to driven out with a hammer and a brass punch 5 Install the front wheel by reversing the previous steps Figure 5 9 Axle bolt Figure 5 10 Short spacer Long spacer www my...

Page 58: ...drift or pin punch See Figure 5 11 4 Drive in the new bearings using a brass punch or a tube that has the same O D as the bearing See Figure 5 12 5 Install the front wheel 6 Pump grease in the grease fitting on the front wheel until it starts to squirt out of the hub 7 Test drive the mower before returning it to service Figure 5 11 Punch Figure 5 12 Brass punch www mymowerparts com For Discount Cu...

Page 59: ...er To install the yoke 8 Slide the yoke into the axle casting from the under side NOTE The flat side of the yoke should be parallel with the box section of the frame 9 Slide the wave washer over the yoke shaft See Figure 5 15 10 Install the hex screw with a lock washer and the fender washer 11 Tighten the hex screw holding the yoke to a torque of 31 ft lbs 42 Nm 12 Install the yoke cover 13 Instal...

Page 60: ...crew and washer that holds the inboard steering gear pivot shaft to the axle casting using a 1 2 wrench See Figure 5 17 NOTE The 5 16 alignment pin can be used to lock the inboard steering gear unless the gear is broken 5 Slide the steering gear out of the axle casting 6 Remove the socket headed cap screw that holds the outboard steering gear to the yoke using a 1 4 hex key See Figure 5 18 Figure ...

Page 61: ...tamped into the gear is facing up See Figure 5 19 7 Slide the gear off of the yoke 8 Remove the hex screw that holds the steering gear to the shaft using a 9 16 wrench See Figure 5 20 9 Slide the steering gear off of the shaft NOTE The shaft has a double D It may be necessary to drive it off with a hammer and a brass punch Figure 5 19 Figure 5 20 Hex screw www mymowerparts com For Discount Cub Cad...

Page 62: ...the steering gear shaft to a torque of 17 ft lbs 23 Nm 5 Attach the outboard steering gear to the yoke with the socket headed cap screw using a 1 4 hex key See Figure 5 22 6 The socket head cap screw acts as the turn stop for the front wheels NOTE The socket head cap screw acts as a travel stop Do not replace it with a hex head screw 7 Align the bolt in the drag link ball joint with its corre spon...

Page 63: ...the yoke shaft 14 Install the hex screw and the fender washer 15 Tighten the hex screw holding the yoke to a torque of 31 ft lbs 42 Nm 16 Remove the alignment fixtures and alignment pins 17 Install the yoke cover 18 Pump grease in the grease fittings on the axle cast ing until it starts to squirt out around the yoke 19 Install the floor pan by following the steps described in Chapter 3 Body 20 Tes...

Page 64: ...am nuts using a 9 16 wrench 4 Remove the outer ball joint using a pair of 9 16 wrenches 5 Turn the steering wheel to bring the sector gears to the center neutral position NOTE Install the 1 4 alignment pin to insure that the sector gears are in the neutral position See Figure 5 26 6 Disconnect the inner drag link ball joint from the sector gear using a pair of 9 16 wrenches Figure 5 25 outer ball ...

Page 65: ...red to remove them from the old drag link 11 Install the drag links by following steps 1 6 in reverse order 12 Align the front end by following the procedures described in the wheel alignment and drive control link adjustments section of this chapter 13 Install the floor pan by following the procedures described in Chapter 3 Body 14 Test drive the mower in a safe area before returning it to servic...

Page 66: ...RZT S 60 www mymowerparts com For Discount Cub Cadet Parts Call 606 678 9623 or 606 561 4983 ...

Page 67: ...n the magneto primary windings are grounded disabling the ignition system The after fire solenoid loses its power from the B termi nal This turns off the fuel supply Symptom engine runs with key in OFF position The key switch is not completing the path to ground either because of an internal fault or a bad ground connection elsewhere in the harness Check continuity between M G and L terminals with...

Page 68: ...tage battery cables starter cable solenoid or ground issue Symptom Crank spark but no fuel First check the fuel tank to verify that there is fuel in it If there is fuel in the fuel tank test for power at the after fire solenoid If there is no power there then check for continuity from B to L in the START position If power is reaching the red wire that connects to the L terminal in the start positi...

Page 69: ... It is a normally opened NO set of contacts NOTE The top terminals are showing normally closed at rest and the middle terminals are normally open at rest NOTE There are three contacts on the right side in the C COM For this application the normally opened NO contact is used Brake Switch The brake switch the left brake pedal shaft support bra ket See Figure 7 3 The plunger on the switch is depresse...

Page 70: ...PTO relay When the seat is vacant the con tacts close providing a ground path to the coil of the PTO relay This will energize the relay deactivating the PTO clutch The yellow wire with white trace goes to the brake switch When the seat is vacant the con tacts close providing a ground path in series with the brake switch If the brakes are not applied and the seat is empty the circuit is completed s...

Page 71: ...below details the function of the PTO relay Figure 7 6 Fuse PTO Relay Starter Solenoid 3 Green wire COM Common terminal Ground for PTO clutch not energized or relay latch energized Hard wired to ground 5 White black trace Normally Open NO ter minal Connects to COM terminal when the relay is ener gized Power from PTO switch B NO when PTO is ON 2 Red wire Power for windings Hot when the key switch i...

Page 72: ...inue to the A NC terminal of the PTO switch orange black trace 3a If the PTO switch is on the NC terminal on the A set of contacts will not connect to anything The system monitor will measure open circuit voltage illuminating the PTO symbol 3b If the PTO switch is off the NC terminal on the A set of contacts will be connected to the COM terminal on the C set of contacts Power will be passed along ...

Page 73: ... 7 9 2 There is an afterfire solenoid on the carburetor When it is energized fuel flows normally through the carburetor When it is not energized it closes off the fuel flow through the main jet of the carburetor The purpose of the solenoid is to prevent unburned fuel from being pumped through the engine after the igni tion is turned off This unburned fuel accumulates in the muffler and may ignite ...

Page 74: ...gs of the PTO Relay the PTO Switch C COM terminal the System Monitor See Figure 7 11 3TARTER 3OLENOID ATTERY 0 3 USE RND ROUND ROUND 04 3WITCH 3YSTEM ONITOR 04 2ELAY T 2EST FTERFIRE 3OLENOID ROUND 3 Figure 7 11 www mymowerparts com For Discount Cub Cadet Parts Call 606 678 9623 or 606 561 4983 ...

Page 75: ...Ystem Monitor See Figure 7 12 NOTE This is identical to what happens with the key in the START position except that the circuit that actually spins the starter motor is not energized 3TARTER 3OLENOID ATTERY 0 3 USE RND ROUND ROUND 04 3WITCH 3YSTEM ONITOR 04 2ELAY T 2EST FTERFIRE 3OLENOID ROUND 3 Figure 7 12 www mymowerparts com For Discount Cub Cadet Parts Call 606 678 9623 or 606 561 4983 ...

Page 76: ...o primary windings if the brakes are released while the seat is vacant 1 The magneto yellow wire is connected to the NC terminal of the brake switch 1a When the brakes are applied the plunger of the brake switch is depressed opening the NC contacts within the switch 1b When the brakes are released the plunger on the switch is extended closing the NC con tacts within the switch This completes part ...

Page 77: ...to DC Direct Current The reg ulator rectifier also regulates the voltage to a nominal 12 volts See Figure 7 16 Actual output is closer to 14 volts but should be no more than 15 volts To work properly the regulator rectifier must have a good ground connection to the engine block and ultimately back to the battery negative post 4 Regulated DC power leaves the regulator rectifier 4a A purple wire com...

Page 78: ...ness burns chafed wires kinks Service as needed 3 Quick check to see if there is a problem See Figure 7 18 3a Check baseline battery voltage 3b Start the engine and advance the throttle to 3 000 RPM 3c Check operating voltage 3d If operating voltage does not rise with engine RPM proceed with the system check H 6ZLWFK 6WDUWHU 6ROHQRLG DWWHU 1 326 XVH UQG URXQG 5HJXODWRU 5HFWLILHU OWHUQDWRU 6WDWRU U...

Page 79: ...There should be a reading of O L Open Line between either lead and the engine block It is good practice to check the stator cold and again when the engine is at operating temperature As the winding warm up the insulation can break down and allow the wires to short out 5c Check the raw output of the stator See Figure 7 20 Connect a meter set to read Volts AC to the output leads of the stator Start ...

Page 80: ...r rectifier perform a ground side voltage drop test from the regulator rectifier to the engine block If the voltage reading is greater than 0 1 Volts DC replace or properly fasten the ground wire that connects the regulator rectifier to the engine block Retest to confirm good connection 6b Bench Test See Figure 7 22 Set a digital multi meter to read on the X100Ω scale With the key OFF and the fuse...

Page 81: ...tput B terminal and the battery positive post for a voltage drop See Figure 7 23 The harness connector the 20A fuse and the hot post on the starter solenoid all lie between the reg ulator rectifier and the battery Test Pos Probe COM Probe Results 1 Housing B O L infinite resistance 2 Housing AC 1 O L infinite resistance 3 Housing AC2 1 0 Ω 5 second delay 4 B AC1 0 Ω Perfect continuity 5 B AC2 1 0 ...

Page 82: ...one terminal is a ground path A Yellow black trace wire on the second terminal leads to the ground terminal of the PTO relay winding 1b When the mower is put in reverse the plunger on the switch is depressed closing the contacts 1c The closed contacts complete a ground path that reaches the PTO relay windings and the PTO relay is energized when the mower is put in reverse 2 The seat switch contain...

Page 83: ...ly energized the relay is broken 3d The second ground path loops through the B contacts inside the PTO switch As long as the PTO switch is in the ON position the second ground path will continue Therefore when the PTO is shut off by the seat switch or the reverse switch it is necessary to get back in the seat or take the mower out or reverse and turn the PTO switch off and back on again to re enga...

Page 84: ...ms on outdoor power equipment Electronics Outdoor power equipment has historically had relatively simple electromechanical controls Customer expecta tions and regulatory demands has driven change in the industry while electronic controls have become relatively inexpensive In many cases electronic controls can simplify a system that would otherwise be very complex Instead of creat ing a huge mass o...

Page 85: ...ternating current AC In most systems this current is immediately rectified to direct current DC and regulated to a nominal 12 Volts The presence of AC is very limited The primary concern of this section is 12 Volt DC systems though much of the theory and techniques apply equally well to other DC systems 1 Voltage Pressure Voltage is the pressure that electricity has It is the amount of force pushi...

Page 86: ... V I R If the V is covered I and R are exposed on the same line meaning that the product of I times R will solve for the unknown V I x R V 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 ...

Page 87: ...t How the system is wired together The Rules All circuits have some basic rules that must be followed 1 All circuits must have at least one voltage source It could be a battery an altenator or both 2 All circuits must have a load A circuit without a load is the same as shorting out the power source Typical loads could be lights a motor a solenoid 3 All circuits must have a complete path back to th...

Page 88: ...ils the circuit will be broken and whole system will not work See Figure 7 29 Parallel Parallel circuits are wired so that current has multi ple paths to follow If a component in one of the parallel paths fails the rest of the circuit will keep working See Figure 7 30 Figure 7 29 Switch Battery Lamp Figure 7 30 Battery Lamp Lamp Lamp www mymowerparts com For Discount Cub Cadet Parts Call 606 678 9...

Page 89: ...ce is as the name implies an increase in resistance Arguably the most common electrical failure and the hardest to find increased resistance can have more subtle symptoms than outright open circuits Many times affected circuits will still partially function It is not an open because there is some current that can get through but the increase in resistance is enough to affect the circuit This can b...

Page 90: ...hematic or diagram Equipment that may be useful Fused jumper wires Test light Self powered continuity light Ammeter Battery charger Battery tester Battery jumper cables Hand tools to gain access to components Flashlight www mymowerparts com For Discount Cub Cadet Parts Call 606 678 9623 or 606 561 4983 ...

Page 91: ... the circuit and having the circuit go through the meter NOTE Some meters have an inductive Amp clamp accessory that can be used without breaking the circuit Resistance Set the meter for the Ω scale Isolate the part of the circuit to be tested disconnect it from the source of power Most auto ranging meters will provide readings on several scales For outdoor power equipment the straight Ohm scale i...

Page 92: ...powered continuity lights Continuity lights can indicate whether a circuit is complete or not but they give no indication of resistance They are handy for finding point break when static timing some older engines but have largely been replaced by DMMs There are some powered high impedance test lights on the market that have a continuity feature and some technicians like the fact that they can be l...

Page 93: ... a motor or clutch Briggs and Stratton sells a DC Shunt that converts amperage into a reading on the millivolt scale of a DMM Briggs and Stratton part 19359 covers low amperage systems while part 19468 tests higher amperage sys tems The operating principle is based on Ohm s Law as described earlier in this section See Figure 7 35 Usage of the DC Shunt tool is detailed in the 1995 and 1999 editions...

Page 94: ...ing the battery CAUTION CAUTION Batteries produce flammable and explosive gases particularly during charging Do not smoke or allow an open flame or heat source near the battery Charge batteries in an open area Wear eye protection and acid resistant gloves when handling batteries Do not allow direct metal contact across the posts This will produce extreme heat that may cause direct burns or ignite ...

Page 95: ...drawing electrolyte into the hydrometer to the fill line IMPORTANT Hold the hydrometer straight up and down when drawing up the electro lyte The float needs to float free not rubbing against the sides of the hydrometer 3e Write down the specific gravity of each cell 3f The readings must be corrected for the tem perature of the electrolyte The hydrometer manufacture should list the temperature the ...

Page 96: ...elp prevent a shorting hazard 2 Measure the temperature of the electrolyte 3 Connect a voltmeter and the load tester to the appro priate terminals 4 Hook an amp probe onto the ground lead of the load tester NOTE A shunt can be used in place of the amp probe but a second voltmeter will be needed to get a mea surement from the shunt 5 Apply a load equal to 50 of the battery s rated CCA for 15 second...

Page 97: ...n if the battery fails badly NOTE Do not use any fixed load tester on a battery under 200 CCA Doing so can boil the water out of the battery and damage the plates in the battery Conductance testers There are several brands of conductance battery testers presently on the market Conductance battery testers use the battery being tested as their power source These testers send a small AC signal throug...

Page 98: ...e mower 5 Once the presence of a draw is confirmed disconnect components of the system one at a time while monitor ing an ammeter to see which makes the draw stop 6 If the battery is being checked independently of the equipment it powers measure and note the battery voltage while it is disconnected over a three day period 7 There should be less than a 0 2 volt drop in the readings If there is more...

Page 99: ...ule of thumb start at one end of the circuit and work to the other 4 The next step is to decide what method to use to troubleshoot the circuit If checking a safety circuit that grounds the magneto use an Ohms meter to test for continuity If checking a safety circuit that enables a starter motor or accessory use a volt meter to confirm the pres ence of power at each junction in the system If a circ...

Page 100: ... in this section on the circuit to find the source of resistance NOTE When working toward the battery check each junction with the connector disconnected then re check it with the junction reconnected If there is voltage with the connector unplugged but not when it is con nected there is a short between that point and the last connector tested NOTE When working toward the battery if one junction h...

Page 101: ... negative battery post to the positive battery post To check ground side voltage drop set up a multimeter to measure 12V DC 1 Make a good electrical connection between the black probe and the negative post on the battery 2 Make a good electrical connection between the red probe and the suspect point of ground 3 Power up the circuit in question 4 The voltage indicated on the meter is the voltage th...

Page 102: ... the same mower a common point in the system would be the primary suspect e g poor connection between neg ative battery cable and frame Applying this principle to the positive side of the system NOTE Ultimately all current will find its way from the negative battery post to the positive bat tery post 1 To check hot side voltage drop Use a multi meter set to measure 12V DC See Figure 7 44 2 Make a ...

Page 103: ...ery Checking voltage drop at various points along the circuit can help pin point the problem Check voltage drop at the output lug on the starter solenoid If there is a significant difference the problem lies between the lug on the solenoid and the lug on the starter If there is little change the problem lies further upstream Check voltage drop at the input lug on the solenoid If there is significa...

Page 104: ... state Normally Open Normally Closed Common Normally Open NO contacts do not complete a circuit when the switch is at rest plunger extended They close to complete a path through the switch when the plunger is depressed Normally Closed NC contacts complete a cir cuit when the switch is at rest plunger extended They open to break the path through the switch when the plunger is depressed Some Cub cad...

Page 105: ...test a diode Testing a diode 1 Isolate the diode in the circuit 2 Set the DMM to the diode or Ω scale See Figure 7 48 3 Attach the negative lead of the DMM to the side of the diode with a band on it 4 Place the positive lead on the other side of the diode 5 There should be continuity See Figure 7 49 Figure 7 47 Silver band electrons flow from the negative to the positive Figure 7 48 Diode scale Fi...

Page 106: ...e test 7 The meter should indicate no continuity See Figure 7 50 8 If the results do not match the above replace the diode Figure 7 50 No continuity Silver band www mymowerparts com For Discount Cub Cadet Parts Call 606 678 9623 or 606 561 4983 ...

Page 107: ... is energized When 3 4 are connected 3 5 are disconnected and vice versa An Ohm meter should show zero resistance or 0 0Ω between 3 4 when the relay is at rest and it should read no continuity when the relay is ener gized To test a relay 1 Test for continuity between the common and the NC terminals using a DMM 2 Test for continuity between the common and the NO terminals using a DMM NOTE There sho...

Page 108: ...RZT S 102 Schematic 7 211 725 www mymowerparts com For Discount Cub Cadet Parts Call 606 678 9623 or 606 561 4983 ...

Page 109: ...pulley to the right until the belt rides out onto the edge of the lower sheave of the pulley 5 While still holding the belt downward continue turn ing the PTO pulley until the belt is rolled off the pul ley Gently release the belt tension 6 Lower the deck into the lowest position using the deck lift handle 7 Pull the cotter pin out of the front deck lift rod that secures it to the deck Slide the d...

Page 110: ...n the deck while it is removed 1 Blow all the debris off of the top of the deck using compressed air 2 Scrape off the debris build up from the under side of the deck using a plastic scraper NOTE Applying a light coating of oil to the underside of the deck after scraping it clean will help prevent rust ing of the deck and help keep debris from building up on the underside of the deck FDL JGU SN FDL...

Page 111: ...ke 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 The air flow in the cutting deck is generated by the spinning blades If the blades are mounted upside down the air flow will be reversed pushing the grass down instead of standing up NOTE Blades...

Page 112: ... the blades along the cutting edges parallel to the trailing edge at a 25 to 30 angle Sharpen the top of the blade only maintaining the factory cutting edge angle IMPORTANT If the cutting edge of the blade has already been sharpened to within 1 2 8 from the edge or if any metal separation is present replace the blades with new ones IMPORTANT It is important that each cutting blade edge be ground e...

Page 113: ...rubber in it As the rubber ages it becomes brittle and weaker NOTE A damaged belt can cause the deck to vibrate when the deck is engaged The vibration can be bad enough to simulate an engine issue NOTE Not all belt damage is visible Broken cords inside the belt are not visible to the naked eye but can cause vibration issues and greatly reduce the life of the belt To replace the 42 deck belt 1 Remo...

Page 114: ... before returning to service To replace the 50 deck belt 1 Remove the deck as described at the beginning of this chapter NOTE Removal of the deck is not necessary but makes it easier to route the belt around the spindles 2 Loosen the two rear idler pulleys enough to allow the belt to slip between them and the belt keepers 3 Slide the belt off of the pulleys 4 Route the new belt around the pulleys ...

Page 115: ...elt guide to help hold them together 5 Bolt the pulley to the deck ensuring that the detent on the belt guide seats in the hole in the deck See Figure 7 10 6 Re install the deck if removed 7 Test run the mower before returning to service Moveable idler pulleys and brackets To remove replace a moveable idler pulley 1 Remove the deck as describe at the beginning of this chapter NOTE Removal of the d...

Page 116: ...the idler bracket 6 Attach the idler spring to the idler bracket 7 Slide the belt guide onto the pulley bolt so that the detect in the guide rests in the hole in the bracket See Figure 7 13 8 Install the pulley and bearing cup NOTE Wrap the belt around the pulley as it is low ered onto the pulley bolt 9 Re install the deck if removed 10 Test run the mower before returning to service Figure 7 12 Id...

Page 117: ...to the spindle shaft using an impact wrench and a 15 16 socket See Figure 7 15 NOTE The spindle shaft may slide out of the spindle housing as the nut is removed 6 Remove the pulley 7 Lower the spindle shaft out of the housing NOTE There is a washer and a spacer between the pulley and the spindle housing See Figure 7 16 8 Install the spindle shaft by following the above steps in reverse order NOTE ...

Page 118: ...e spindle pulley that is to be serviced 5 Remove the four screws fastening the spindle to the deck See Figure 7 18 6 Lift the spindle out of the deck shell 7 Install the spindle by following the previous steps in reverse order NOTE The four spindle bolts are self tapping screws The new spindle housing will not have threads in it NOTE Tighten the spindle screws to a torque of 200 300 in lbs 23 34 N...

Page 119: ...spindle housing See Figure 7 19 4 Remove the upper bearing NOTE The spindle bearings are sealed ball bearings The bearing should have a slip fit in the housing If the bearing does not slide out of the housing it can be driven out of the housing using a drift or a punch See Figure 7 20 5 Remove the spacer See Figure 7 21 Figure 7 19 Shaft Pulley Washer Spacer Nut Figure 7 20 Drift Figure 7 21 Upper...

Page 120: ... If they show signs of wear or damage they must be replaced 8 Re assemble the spindle by following the previous steps in reverse order NOTE The bearings should slip into place with the use of a bearing driver 9 Install the spindle on the deck 10 Install the deck 11 Test run the mower in a safe area before returning it to service Figure 7 22 Brass punch www mymowerparts com For Discount Cub Cadet P...

Page 121: ...ing NOTE When leveling the deck side to side make sure the two rear adjustment gears are set in the middle of the adjustment range See Figure 7 23 1 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 lever Rotate the outside blades so that they are perpendicular with the mower frame 2 Measure the distance from the outsid...

Page 122: ...he mower frame NOTE Check the mower s tire pressure before performing any deck leveling adjustments The recommended operating tire pressure is Approximately 10 psi for the rear tires Approximately 20 psi for the front tires 2 Measure the distances from the front of the blade tip to the ground and the rear of the blade tip to the ground 3 The front measurement taken should be 1 4 3 8 less than the ...

Page 123: ...si for the rear tires Approximately 20 psi for the front tires 2 Check gauge wheels distance from the flat surface below The gauge wheels should have between 1 4 1 2 clearance above the ground NOTE The 42 Decks do not have four wheels There is one wheel on the front right of the deck and one on the left rear of the deck 3 Remove the shoulder bolt securing the gauge wheel to the index bracket 4 Rep...

Page 124: ...ollowing the steps described in Chapter 3 Body Chassis 3 Remove the bow tie clips that hold the brake rods in the brake shaft bell cranks See Figure 7 28 4 Remove the brake return spring See Figure 7 29 5 Remove the shoulder bolts that connect the lift links to the lift shaft arms using a 15 16 wrench and a 9 16 wrench See Figure 7 29 Figure 7 28 Brake shaft Figure 7 29 Brake return spring Figure ...

Page 125: ...the lift shaft 9 Install the deck lift shaft by following steps 1 through 6 in reverse order NOTE Do not put grease on the lift shaft or bushings Grease will hold dirt and accelerate the wear of the bushings 10 Operate the deck through its full range of travel 11 Check the deck for levelness and pitch 12 Test run the mower in a safe area before returning it to service Figure 7 31 Lift shaft bracke...

Page 126: ...RZT S 120 www mymowerparts com For Discount Cub Cadet Parts Call 606 678 9623 or 606 561 4983 ...

Page 127: ...The recommended maintenance intervals listed in this manual are a guideline They are adjustable for local con ditions Lube Point Number of fittings Interval Wheel yokes 4 25 hours Steering gears 2 25 hours Front wheel bearings 2 25 hours Lube pedal pivot points 10 hours Maintenance items Interval Oil Change 100 hrs Oil filter 100 hrs Clean the air filter pre cleaner 25 hrs Replace the air filter 1...

Page 128: ...Damage to the wire can result 2 Remove the spark plugs with a 13 16 spark plug socket See Figure 8 2 3 Clean the Spark plugs with carburetor cleaner or replace them with two Champion RC12YC spark plugs NOTE Do not clean the spark plugs mechanically sand blasting or scraping This will damage the insulator 4 Gap the electrodes to 0 030 0 75mm 5 Thread the spark plugs into the spark plug holes 6 Tigh...

Page 129: ...er squeeze it inside of a paper towel or let it air dry DO NOT wring it because the filter will tear 6 Before installing any foam filter after it has been washed it needs to be free of moisture NOTE Do not oil the foam pre filter The paper filer will absorb the oil and it will become plugged 7 The air filter can be cleaned by lightly tapping it on a hard surface NOTE Never blow compressed air thro...

Page 130: ... new oil Use a good quality motor oil that meets the specifications recommended by engine manufacturer NOTE Refer to the oil chart to determine the proper weight of oil to use 6 Check the dip stick to verify that the oil is at the proper level before returning to service 7 Dispose of waste oil in a safe responsible and legal manner Engine Oil Capacity Oil filter was not removed 1 7 US qt 1 6L Oil ...

Page 131: ... the right side of the mower See Figure 8 8 4 Place a light coating of oil on the O ring of the new fil ter 5 Pre fill the new filter with fresh clean oil 6 Thread the new filter on to the engine Hand tighten only 7 Fill the engine with oil 8 Test run the engine re check the oil level and check for leaks before returning the mower to service Figure 8 8 Oil filter Fuel filter www mymowerparts com F...

Page 132: ...el should be run out of the tank and engine Anti oxidation additives will help keep the fuel fresher Servicing the fuel system Inspect the fuel system every time the mower is operated If dirty fuel is found in the fuel tank or fuel that does not smell right drain the fuel tank and replace the fuel filter Drain the fuel tank by removing the fuel line from the fuel filter and drain the fuel into an ...

Page 133: ... Test run the engine and check for leaks before returning the mower to service Clean the engine Air cooled engines cool better if they are clean Check for critter nesting or signs of nesting especially after dor mant season storage See Figure 8 10 Transmissions The RZT S is equipped with two Hydro Gear EZT transmissions The maintenance procedures for the transmissions are located in the Hydro Gear...

Page 134: ...RZT S 128 www mymowerparts com For Discount Cub Cadet Parts Call 606 678 9623 or 606 561 4983 ...

Page 135: ...www mymowerparts com For Discount Cub Cadet Parts Call 606 678 9623 or 606 561 4983 ...

Page 136: ...MTD Products Inc Product Training and Education Department FORM NUMBER 769 08005 00 5 2012 www mymowerparts com For Discount Cub Cadet Parts Call 606 678 9623 or 606 561 4983 ...

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