Cub-cadet Z-Force S Series Instrukcja Użytkownika

Professional Shop ManualZ-Force SMTD Products Inc. - Product Training and Education DepartmentFORM NUMBER - 769-0551306/2010NOTE: These materials are

Z-Force-S4

Z-Force-S94Reverse Safety SwitchThe Reverse Safety Switch is mounted on the right side of the steering gear box. It is the same part number as the par

Electrical System95Starter solenoid The starter solenoid is mounted to the rear frame cross member, under the seat. See Figure 7.10.• When the pr

Z-Force-S96Lighting circuitThe Z-Force-S Headlight available as an optional kit. The headlight kit comes with a harness and a rocker switch to turn th

Electrical System97 Once the starter motor spins, we still need spark and fuel to make the engine run. Looking at the circuits that do that:1. Th

Z-Force-S983. The A1 terminal on the key switch sends power to:• the afterfire solenoid• the windings of the PTO relay• the PTO switch C-COM termi

Electrical System99Run Circuit With the key switch in the RUN position, the A1 terminal sends power to: • the afterfire solenoid•

Z-Force-S100Run Circuit / Reverse Caution mode.1. With the key in Reverse Caution mode, A1 gets power from the B terminal, just like the normal run po

Electrical System101Engine shut-down circuits Engine shutdown circuits stop the engine by disabling the ignition and removes power from the after

Z-Force-S102Charging circuitHow it works1. When the engine is running, magnets attached to the underside of the flywheel induce A.C. (Alternating Curr

Electrical System1035. From the harness connector: See Figure 7.22.5a. The red/white trace wire leads to the 20A fuse.5b. From the fuse, the wire con

Engine Related Parts5This chapter will cover the engine accessories that are manufactured by Cub Cadet. IMPORTANT: The engine is manufactured by Kawas

Z-Force-S1044. System check, to identify the problem The system check consists of: •Stator Check• Regulator Rectifier Check• Down stream Check5. Stato

Electrical System1055d. Interpretation:• If the stator fails either or both tests, it is likely to be bad.• If the stator fails the out put test, but

Z-Force-S1067. If the regulator/rectifier fails any one of these tests, replace it with a new one. 8. Check the D.C. amperage output of the regulator/

Electrical System107PTO CircuitBasic Operation: See Figure 7.29.1. With the key switch in any position other than OFF, the A1 terminal supplies p

Z-Force-S1082. The seat switch contains two sets of contacts. The set with the yellow wire leads to ground when the contacts of the seat switch are cl

Electrical System109Reverse Mower Control (RMC) circuit operationHistorically, Cub Cadet home owner mowers have not been able to mow in reverse. This

Z-Force-S110When the RMC module is armed and activated, it effectively disconnects the reverse switch from the circuit. See Figure 7.34.The RMC module

Electrical System111Electrical diagnosisNOTE: Electrical diagnostic procedures and tools are the same for all Cub Cadet and MTD mowers. This sec-tion

Z-Force-S112• Low Voltage: Many electronic devices simply stop working if system voltage falls below a given threshold. If a 12 volt system is run at

Electrical System113Ohm’s LawOhm’s Law relates voltage, amperage, and resistance. It states that voltage is the product of resistance times current.•

Z-Force-S6Fuel tank removal/replacementRemove/replace the fuel tank by following these steps:1. Clamp off the fuel line between the fuel tank and the

Z-Force-S114Kirchhoff’s voltage lawKirchhoff’s voltage law deals with voltage drops. A voltage drop is the amount of voltage used up or “dropped” by r

Electrical System115Types of circuitsThere are three ways a circuit can be wired:•Series• Parallel• Series/parallelSeries Series circuits are wir

Z-Force-S116Series/parallel Series/parallel circuits have some sections wired in series and some in parallel. See Figure 7.40.What can go wrong?Th

Electrical System117The ToolsEquipment needed to diagnose an electrical system:• DMM (Digital Multi-Meter)• Wiring schematic or diagramEquipment that

Z-Force-S118Digital Multi-meter A DMM is the most useful tool to troubleshoot any electrical system. There is an amazing variety of DMMs on the ma

Electrical System119Wiring diagram or schematic A wiring or a schematic diagram, and the ability to read it are very important in troubleshooting a c

Z-Force-S120Ammeters and specialized charging system testers Inductive ammeters are available in many forms. Some are as simple as a gauge to be h

Electrical System121BatteriesA fully charged battery that is in good condition is an important factor when trying to diagnose other parts of an elect

Z-Force-S122Checking battery conditionThere are three things to do when testing a battery:• Visual inspection• Electrolyte test• Operational test1. Vi

Electrical System123Battery TestersThere are four major ways to check a battery:• Electrolyte test using a specific gravity tester (hydrometer) to co

Brakes7Brake system descriptionThe Z-Force-S uses twin HydroGear transmissions to drive the rear wheels. The hydraulic action of the transmis-sions wi

Z-Force-S124Fixed load testers Fixed load testers (sometimes called toasters) are inexpensive load testers found at any auto parts store.

Electrical System125Battery discharge test Occasionally a battery will discharge while sitting unused. To test for a battery that is “leaking” vo

Z-Force-S126Electrical Troubleshooting1. The first step in troubleshooting is to always verify the complaint. Defining and verifying the problem reduc

Electrical System1276. Starting with a fully charged battery and battery cable connections that are clean and tight, measure the battery voltage. See

Z-Force-S128Voltage Drop TestTo review:• Ohm’s law states that it takes voltage to push current through a resistance.• Kirchhoff’s voltage law states

Electrical System129 A similar ground-side test on a mower with a slow-cranking starter motor can be conducted between the engine block and the n

Z-Force-S1306. 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

Electrical System131Testing switches• Refer to the “COMPONENTS” section of this chapter that describes the function of the individual switches to be

Z-Force-S132Diodes What is a diode? A diode acts like a one way valve, allowing current to flow in only one direction. See Figur

Electrical System1336. Switch the leads and repeat the test.7. The meter should indicate no continuity. See Figure 7.59.8. If the

Z-Force-S8Brake adjustment NOTE: When performing a brake adjustment, inspect the brake components for signs of wear or damage.1. Block the front wheel

Z-Force-S134Relay Most of the relays used by MTD or Cub Cadet have five pins. See Figure 7.60.• Windings: Terminals 1 & 2 are the outer-most o

Electrical System135Schematic

Z-Force-S136Headlight harness

Decks and Lift Shaft137Cutting decksThe Z-Force-S comes with the option of a 46” or 60” floating deck. The decks are made of 11-gauge steel and featur

Z-Force-S138Cleaning the deckCleaning debris off of the deck should be done every time the mower is used. It is routine maintenance that will make the

Decks and Lift Shaft139BladesThe condition of the blades will greatly effect the quality of the cut. The blades should be sharpened and bal-anced afte

Z-Force-S1404. Remove the blade.NOTE: The blade spacer and a bearing protector will come off with the blade. The bearing pro-tector and the space must

Decks and Lift Shaft141PTO beltSome cutting deck designs use a single belt to transfer power from the engine crankshaft directly to the blade spindles

Z-Force-S142Deck BeltTo replace the 46” deck belt:1. Remove the deck as describe at the beginning of this chapter.2. Slide the belt off of the pulleys

Decks and Lift Shaft143Belt tension The belt tension for the PTO belt for the 60” deck and the deck belt for the 48” deck is about a 1/2” deflecti

Brakes9Brake puck/rotor replacement On HydroGear transmissions, the brake pucks are wearing parts that will need to be serviced from time to time. If

Z-Force-S144Spindle pulleys and spindle shaftsTo replace a pulley or spindle shaft:1. Remove the deck as described at the beginning of this chapter.2.

Decks and Lift Shaft145Spindle removal/installationTo remove/rebuild a spindle:1. Remove the deck as described at the beginning of this chapter.2.

Z-Force-S146Spindle overhaulTo rebuild a spindle:1. Remove the spindle by following the procedures described in the spindle removal section of this ch

Decks and Lift Shaft1477. Remove the lower bearing seal. See Figure 8.20.8. Remove the lower bearing.NOTE: The grease fitting in the spindle housing a

Z-Force-S148Leveling 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” - 3/8” lower

Decks and Lift Shaft1493. Loosen, but do NOT remove, the hex bolt on the front left deck hanger link. See Figure 8.25.NOTE: The front right deck hange

Z-Force-S150Deck Gauge Wheel AdjustmentThe cutting decks are of a “floating” design. This means that they are suspended above the ground. The gauge wh

Decks and Lift Shaft151Front and rear deck lift shaft assembly The Z-force-S has two deck lift shafts. The same proce-dure is used to remove eithe

Z-Force-S1526. Remove the nut and bolt that attach the drive con-trol links to the drive bell cranks using a pair of 1/2” wrenches. See Figure 8.31.7.

Decks and Lift Shaft153Deck lift pedal leverTo remove/replace the deck lift pedal lever:1. Remove the floor pan by following the procedures descri

Z-Force-S105. Remove the front mounting bolt, allowing the caliper to swing down. See Figure 3.7.6. The outboard brake puck should fall out when the b

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Maintanence Intervals155LubricationTo help keep the Z-Force-S in proper running order, Cub Cadet recommends the following lubrication intervals be use

Z-Force-S156The spark plugsThe spark plugs should be checked, cleaned and re-gapped on a monthly basis or every 100 hours of use. The plugs should be

Maintanence Intervals157Air filter A dirty air filter can reduce engine power, increase fuel consumption and make starting more difficult. The ai

Z-Force-S158Oil changeThe oil change interval is every 100 hrs.NOTE: The first oil change should be preformed at 8 hours.To change the oil:1. Remove t

Maintanence Intervals159Oil filterTo replace the oil filter:1. Drain the oil by following the steps described in the previous section of this chap

Z-Force-S160Fuel systemWhat you should know about fuel.Most of the fuel presently available in North America is oxygenated to some extent. This is com

Maintanence Intervals1613. Carefully slide the fuel lines off of the filter. If there are pieces of rubber on the barbs of the fuel filter, replace th

Z-Force-S162

Brakes1113. Place a new puck into the caliper. See Figure 3.10.NOTE: A piece of scotch tape may be used to hold the new brake pucks in place for assem

Z-Force-S12Brake shaft assemblyTo remove/replace the brake shaft:1. Remove the cutting deck by following the proce-dures described in Chapter 8: Cutti

Brakes137. Remove the extension spring that runs from the brake lever to the brake shaft. See Figure 3.14.8. Remove the nut and shoulder bolt that att

Z-Force-S14Parking brake leverTo remove/replace the parking brake lever:1. Remove the cutting deck by following the proce-dures described in Chapter 8

Brakes158. Carefully raise the control panel enough to gain access to the inside of the control pod.9. Disconnect the spring that runs from the parkin

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Body17Floor panTo remove/replace the floor pan:1. Remove the deck by following the procedures described in Chapter 8: Decks and Lift Shafts.2. Remove

Z-Force-S188. Remove the reverse pedal using a 7/16” wrench. See Figure 4.3.9. Remove the drive pedal using a 1/2” wrench. See Figure 4.3.10. Re

Body19Left control consoleTo remove/replace the left side control console:1. Disconnect the negative battery cable.2. Remove the deck by following the

Z-Force-S206. Disconnect the engine harness from the main har-ness. See Figure 4.8.7. Disconnect the starter cable. See Figure 4.8.8. Remove the grip

Body2114. Disconnect the deck lift assist spring. See Figure 4.11.NOTE: The lift assist spring exerts a lot of force. 15. Remove

Z-Force-S2217. Remove the screws that hold the front of the control console to the front of the seat box assembly using a T-30 torx driver and a 7/16”

Body23Right control consoleTo remove/replace the right side control console:1. Disconnect the choke and throttle cables from the engine. See Figur

IChapter 1: Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Professional Shop Manual intent .

Z-Force-S24NOTE: On mowers equipped with a 60” deck, dis-connect the deck lift assist spring.6. Remove the nuts and bolts that hold the fuel tank brac

Body258. Remove the screws that hold the front of the control console to the front of the seat box assembly using a T-30 torx driver and a 7/16” wrenc

Z-Force-S26SeatTo remove/replace the seat:1. Disconnect the seat switch.2. Remove the four nuts that hold the seat track to the seat base using a 1/2”

Body27Seat box assemblyTo remove/replace the seat box assembly:1. Remove the battery and battery box. See Figure 4.24.2. Disconnect the seat switc

Z-Force-S289. Disconnect the reverse switch harness from the conduit clip on the right side of the seat box. See Figure 4.27.10. Remov

Drive29The Z-Force S is built using two different models of HydroGear transmissions. The 48” deck version is equipped with two HydroGear EZT transmiss

Z-Force-S307. Remove the two screws that secure the fan cover to the frame using a 1/2” wrench. See Figure 5.3.NOTE: On the mowers equipped with a 60”

Drive3113. Slide the engine pulley down far enough to slip the belt off of the pulley. See Figure 5.6.NOTE: Note the direction of the key in the engin

Z-Force-S32Drive belt adjustmentThe drive belt is tensioned by a spring loaded idler pulley. When the brakes are applied, the drive belt is de-clutche

Drive33EZT transmission removal/replacement1. Remove the deck as described in Chapter 8 Cutting Decks and Lift Shaft.2. Lift and safely support th

IIChapter 7: Electrical System ...87Introduction . . . . . . . . . . . . .

Z-Force-S349. Remove the bolt holding the rear of the transmis-sion to the torque bracket. See Figure 5.12.10. Support the transmission to prevent it

Drive35ZT 2800 transmission removal/replacement1. Remove the deck as described in chapter 8 Cutting Decks and Lift Shaft.2. Lift and safely suppor

Z-Force-S3611. Remove the nut and bolt that hold the front of the transmission to the frame cross member using a pair of 1/2” wrenches. See Figure 5.1

Drive3714. Support the transmission to prevent it from falling while the mounting bolts are removed.15. Remove the two bolts that fasten the transmiss

Z-Force-S38Drive pedal biasing adjustment The Z-Force-S is equipped with a pedal biasing cam. This cam allows the pedals to be adjusted to increas

Drive39Hydro neutral control adjustmentNOTE: Neutral control rarely goes out of adjustment on its own. If it needs adjustment, check for damaged linka

Z-Force-S405. Disconnect both of the drive control arms from the speed selector plates. See Figure 5.28.6. Start the engine and advance throttle to ma

Drive4114. Adjust the drive control rods so they slide freely into the hole in the selector plate. Install the hairpin clips.15. Remove the spring cla

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Steering43IntroductionThe steering on the Z-Force-S mower works in two phases. • First it will steer like any other riding mower by turning the front

IIIFixed load testers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124Conductance testers . . . . . . .

Z-Force-S442. Lock Steering Gear Box in Neutral Position:2a. Remove the 1/4”-20 plug screw from the steering gear box centering port using a 3/8” wren

Steering45NOTE: The flat side of the yoke should be parallel to the box section of the frame when the pins are installed. See Figure 6.5.NOTE: A coupl

Z-Force-S4610. Adjust the tie rods until the ends line up with their mounting point. See Figure 6.8.11. Re-attach the tie rod(s).12. Tighten the jam n

Steering47Steering gear box removalTo remove/replace the gear box:1 Remove the deck by following the procedures described in Chapter 8: Decks and Lift

Z-Force-S488. Disconnect both of the tie rods from the steering gearbox using a pair of 1/2” wrenches. See Figure 6.12.NOTE: There is

Steering4911. Remove the four nuts and bolts (two on each side) that hold the gearbox to the frame using a pair of 1/2” wrenches. See Figure 6.15.12.

Z-Force-S50Steering gearbox installation1. Attach the drive control link connector plates to the steering gearbox. See Figure 6.17.2. Install the reve

Steering516. Insert two 5/16” pins through the holes in the axle castings. The pins should pass through the casting down to the wheel yokes. See Figur

Z-Force-S528. Lift the steering gearbox into the frame while sliding the gearbox input shaft into the steering shaft cou-pler. See Figure 6.23.9. Inst

Steering5315. Install the return to neutral spring. See Figure 6.26.16. Connect the reverse switch. See Figure 6.27.17. Connect both of the drive cont

IV

Z-Force-S54Rebuilding the steering gear boxTo take the steering gear box apart:1. Remove the steering gear box by following the pro-cedures described

Steering555. Lift the upper housing off of the lower housing.NOTE: There is no sealant between the two housings. They should easily slip apart. If the

Z-Force-S569. Separate the speed cam assemblies by driving out the two roll pins using a 5/32” pin punch and a ham-mer. See Figure 6.35.10. Slide the

Steering5712. Remove the input sector gear. See Figure 6.38.NOTE: Some gearboxes were built with a spring washer on top of the sector gear. If the sec

Z-Force-S5815. Remove the internal cam and the thin washer. See Figure 6.41.16. Remove both of the bevel gears and the washer on the steering sha

Steering5918. Remove the input shaft from the inside of the hous-ing. See Figure 6.44.19. Inspect the bearings. If they are worn or rough, care-fully

Z-Force-S60To assemble the steering gear box:1. Put a dab of 737-0300A DurinaTM grease into each of the bushings in the lower housing.

Steering617. Apply a dab of 737-0300A DurinaTM grease to the side of the steering shaft.8. Install the internal cam so that the rollers on the bevel g

Z-Force-S62NOTE: The hydro arms and output bevel gears have master splines to time them to each other. See Figure 6.53.10d. Install the snap ring.10e.

Steering6314. Fill the lower housing with 12 oz. of 737-0300A Duri-naTM grease. See Figure 6.56.15. Install the steering rack and bushings.

Introduction1Professional Shop Manual intentThis Manual is intended to provide service dealers with an introduction to the mechanical aspects of the Z

Z-Force-S6417. Install the wear block and spring. See Figure 6.59.NOTE: The groove in the wear block faces the bot-tom of the gearbox housing.18. Pres

Steering65NOTE: If used, remove the wooden block first.20. Lower the gearbox cover straight down over the input shaft.NOTE: Removal of the screw and s

Z-Force-S6624. Install the snap ring on the input shaft. See Figure 6.65.25. Install the return to neutral bracket.26. If the screw a

Steering67Front wheels Remove/ replace the front wheels:1. Lift and safely support the front end of the riding mower.2. Remove the axle bolt and nut u

Z-Force-S68To replace the front wheel ball bearings:1. Lift and safely support the front end of the riding mower.2. Remove the front wheel by followin

Steering69Front yokes To remove/ replace the front yokes:1 Lift and safely support the front of the riding mower.2. Remove the front wheel by followin

Z-Force-S7010. Install the hex screw with a lock washer and the fender washer. See Figure 6.75.11. Tighten the hex screw holding the yoke to a torque

Steering71Removal of the steering gearsTo remove the steering gears:1 Remove the four screws that hold the steering col-umn cover in place using a T-3

Z-Force-S727. Loosen the jam nuts on both ends of the tie rod(s). See Figure 6.79. 8. Disconnect the tie rod end from inboard steering gear using a pa

Steering7311. Remove the hex screw that holds the steering gear to the shaft using a 9/16” wrench. See Figure 6.82.12. Slide the steering gear off of

Z-Force-S2AssemblyTorque specifications may be noted in the part of the text that covers assembly, they may also be summarized in tables along with sp

Z-Force-S74Installation and timing of the steering gearsTo install and time the steering gears:1. Slide the double-D of the steering gear shaft into t

Steering759. 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 f

Z-Force-S76Tie rodsTo remove/replace a tie rod:1. Lift and safely support the front of the mower.2. Remove the four screws that hold the steering col-

Steering775. Disconnect the tie rod end from inboard steering gear using a pair of 1/2” wrenches. See Figure 6.91.6. Disconnect the tie rod end from t

Z-Force-S7811. Manually move the front wheel yoke until the align-ment holes line up.12. Insert the 5/16” pin.NOTE: The flat side of the yoke should b

Steering79Steering shaft, bushings and dampener removalTo remove the steering shaft:1 Remove the floor pan by following the steps described in Chapter

Z-Force-S8010. Remove the lower steering shaft bushing.NOTE: The long half of the steering shaft can be inserted through the upper bushing hole and us

Steering8114. Remove the pivot bracket from the dampener using a pair of 17 mm wrenches. See Figure 6.102.NOTE: This dampener has a locking feature. T

Z-Force-S82Steering shaft, bushings and dampener installation1. Attach the pivot bracket to the end of the dampener using a pair of 17 mm wrenches. Se

Steering835. Slide the steering shaft and bushing into the bottom of the steering column.6. Align the bushing with the hole in the steering col-umn.7.

Introduction3Model 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

Z-Force-S8410. Lower the steering column assembly onto the frame of the mower.NOTE: Slide the steering shaft coupler over the input shaft of the steer

Steering8518. Center and install the steering wheel.19. Tighten the steering wheel screw using a 1/2” wrench. See Figure 6.112.20. Remove the 5/16” pi

Z-Force-S86

Electrical System87Introduction This chapter is divided into four sections:• Section 1: About this chapter and precautions• Section 2: Components

Z-Force-S88Key switchThe Key Switch is similar to those used in a variety of MTD applications since 1999. The difference, in this case, is that it is

Electrical System89• 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 t

Z-Force-S90RMC ModuleThe RMC Module is in the same housing as the key switch, and is not available separately. For the purpose of diagnosis, it is tre

Electrical System91To identify a faulty RMC module: If the RMC module does not function as described, the RMC plug test should be the first step

Z-Force-S92Red wire with black trace• Behavior: There is a red wire with black trace between yellow wire with a black trace and the green wire. This w

Electrical System93PTO SwitchUnderstanding the PTO switch1. A-COM is in the starter inhibit circuit. It is a normally closed (NC) set of contacts