Professional Shop ManualModel 188 and CC 500 BAT Cordless MowerMTD Products Inc - Product Training and Education DepartmentFORM NUMBER - 769-0339708/2
ELECTRICAL SYSTEM6Series• Series circuits are wired so that the current hasonly one path to follow. See Figure 2.5.ParallelParallel circuits are wire
ELECTRICAL SYSTEM7SwitchesTo test a switch:1. Remove the switch from the circuit.2. Set the DVOM to the ohms scale (Ω).3. With the switch in the off p
ELECTRICAL SYSTEM85. There should be continuity. See Figure 2.10.6. Switch the leads.7. The meter should indicate no continuity.See Figure 2.11.8. If
ELECTRICAL SYSTEM9Initial trouble shootingThe first step in trouble shooting this mower is to makesure the circuit breaker is set. To do this, first m
ELECTRICAL SYSTEM10Checking the motorTo test the motor:1. Remove the motor cover by following the stepsdescribed in Chapter 3: Repair Procedures.2. Di
ELECTRICAL SYSTEM11Testing the switch box and harnessIMPORTANT: If the mower is within the warrantyperiod, Do Not open the switch box. Replace theent
ELECTRICAL SYSTEM122c. Circuit 1 is a normally closed circuit. Thatmeans there should be continuity throughthat circuit when the switch is at rest. 2
ELECTRICAL SYSTEM133. Test the circuit breaker.NOTE: Make sure the circuit breaker is cool and pressed in before testing it.3a. Disconnect the two wi
ELECTRICAL SYSTEM144b. Remove the fuse. See Figure 2.29.4c. Disconnect the circuit breaker. See Figure 2.30.NOTE: By unplugging t
ELECTRICAL SYSTEM154g. The DVOM should read less than 1 Ohm.4h. Reverse the leads. See Figure 2.33.4i. The DVOM should read open line or “OL”.4j.
ELECTRICAL SYSTEM163. Attach a digital amp clamp to either one of themotor leads (the current will be positive or nega-tive depending on which LED is
ELECTRICAL SYSTEM17Battery chargerThe batteries in the battery pack are wired in seriesresulting in a 48 volt system. The battery charger forthis mowe
ELECTRICAL SYSTEM184. Attach an alligator clip on to a piece of wire, atleast 12” in length.5. Solder the piece of wire onto one of the othertwo pins
ELECTRICAL SYSTEM198. Attach the positive lead of a DVOM to the posi-tive (smaller) tab of the indicator. See Figure2.40.9. Attach the negative lead o
ELECTRICAL SYSTEM20System schematic drawingCircuitBreaker
REPAIR PROCEDURES21General safety warningWhenever working on a cordless lawn mower, removethe safety key. Only leave the key in if it is needed toperf
REPAIR PROCEDURES223. Loosen and remove the blade bolt, locking plate,and blade using a 24 mm wrench. See Figure3.2.4. The blade can be sharpened with
REPAIR PROCEDURES23Switch box assemblyThe switch box assembly is located on the upper han-dle bar. The switch and circuit breaker are housedinside of
REPAIR PROCEDURES24To replace the switch box:1. Remove the safety key.2. Slide the safety bail out of the switch box assem-bly.3. Remove the motor cov
REPAIR PROCEDURES25MotorThe motor on this mower is a DC permanent magnetmotor. It is not serviceable. The test procedures for thismotor are covered in
Chapter 1: Introduction ...1Professional Shop Manua
REPAIR PROCEDURES266. Remove the four mounting screws. See Figure3.13.7. Install the motor by following the above steps inreverse order.8. Test run th
Chapter 3: Repair Procedures ...21General safety warning ...
INTRODUCTION1Professional Shop Manual IntentThis Manual is intended to provide service dealers withan introduction to the electrical and mechanicalasp
INTRODUCTION2Fasteners• Most of the fasteners used on the vehicle aresized in fractional inches. Some are metric.For this reason, wrench sizes are fr
ELECTRICAL SYSTEM3ELECTRICAL THEORYIn order to diagnosis any electrical system there arefew things the technician must know:• Basic electrical values.
ELECTRICAL SYSTEM4Kirchhoff’s current lawKirchhoff’s current law deals with nodes. Nodes are thejunction of two or more wires or the junction of a wir
ELECTRICAL SYSTEM5Digital volt ohm meterDigital volt ohm meters or DVOMs are the most usefultool to troubleshoot any electrical system. Dependingon th
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