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Professional Shop Manual
Model 188 and CC 500 BAT Cordless Mower
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 inexperi-
enced 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 2007 MTD Products Inc. All Rights Reserved
MTD Products Inc - Product Training and Education Department
FORM NUMBER - 769-03397
08/2007
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Table of Contents
Related Manuals for MTD 188
Summary of Contents for MTD 188
- Page 1 Professional Shop Manual Model 188 and CC 500 BAT Cordless Mower 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.
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Page 3: Table Of Contents
Table of Contents Chapter 1: Introduction ......................1 Professional Shop Manual Intent ..................1 About the text format .......................1 Fasteners .......................... 2 Assembly .........................2 Understanding model and serial numbers................ 2 Chapter 2: ELECTRICAL System ..................3 The first electrical value to be discussed is Voltage............3 The second electrical value is Current ................ - Page 4 Chapter 3: Repair Procedures ..................21 General safety warning ....................21 Blades ..........................21 Switch box assembly ..................... 23 To replace the switch box ....................24 Motor ..........................25 Motor mount ........................26...
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Page 5: Chapter 1: Introduction
This signal word is to be lim- tion of 19” DC powered (cordless) electric mowers. The ited to the most extreme situations. mower is to be designated 18A-188-xxx and is to be introduced during the 2007-2008 season. WARNING: Indicates a potentially hazardous... -
Page 6: Fasteners
Understanding model and serial numbers • Most of the fasteners used on the vehicle are The model number is 18A-188-710. The break down of sized in fractional inches. Some are metric. what the number mean is as follows: For this reason, wrench sizes are frequently •... -
Page 7: Chapter 2: Electrical System
ELECTRICAL SYSTEM CHAPTER 2: ELECTRICAL SYSTEM ELECTRICAL THEORY Ohm’s law In order to diagnosis any electrical system there are Ohm’s law state that voltage is the product of resis- few things the technician must know: tance times current. It is written as V=IxR. An example of how ohm’s law works goes like this: It takes 1 volt to •... -
Page 8: Kirchhoff's Current Law
ELECTRICAL SYSTEM Kirchhoff’s current law How the system is wired together Kirchhoff’s current law deals with nodes. Nodes are the All circuits have some basic rules that must be fol- junction of two or more wires or the junction of a wire to lowed: a component. -
Page 9: Digital Volt Ohm Meter
ELECTRICAL SYSTEM Digital volt ohm meter Inductive amp meter Digital volt ohm meters or DVOMs are the most useful An inductive amp meter, sometimes referred to as an tool to troubleshoot any electrical system. Depending “amp clamp” or clamp meter, measures current follow- on the model of DVOM used, DVOMs can measure ing through a wire by the magnetic field created around Volts, Amps, Ohms and more. -
Page 10: Series
ELECTRICAL SYSTEM Series Series/parallel • Series circuits are wired so that the current has Series/parallel circuits have some sections wired in only one path to follow. See Figure 2.5. series and some in parallel. See Figure 2.7. Switch Bulb Battery Figure 2.5 Figure 2.7 Parallel... -
Page 11: Switches
ELECTRICAL SYSTEM Switches Testing a diode: To test a switch: Isolate the diode in the circuit. Remove the switch from the circuit. DVOM diode scale. See Figure 2.9. Ω). Set the DVOM to the ohms scale ( With the switch in the off position touch one probe to one of the tabs and the other probe to the other tab. -
Page 12: Fuses
ELECTRICAL SYSTEM There should be continuity. See Figure 2.10. Fuses Fuses can be visually inspected to indicate they are bad/blown (a dark spot or the element inside will be in two pieces). Some times a fuse can be bad and not Continuity show signs of this visually. -
Page 13: Initial Trouble Shooting
ELECTRICAL SYSTEM Initial trouble shooting After assuring the breaker is set and the safety key is in place, remove the motor cover by following the steps The first step in trouble shooting this mower is to make outlined in Chapter 3: Repair Procedures, and check sure the circuit breaker is set. -
Page 14: Checking The Motor
ELECTRICAL SYSTEM Checking the motor The reading on the meter should be within .1 volts of the battery voltage. If it is, the switch box To test the motor: is working properly and by process of elimina- Remove the motor cover by following the steps tion, the motor is the problem. -
Page 15: Testing The Switch Box And Harness
See Figure 2.19. the mower will not work properly, if at all. 2b. Test each circuit separately. NOTE: Unlike most MTD switches, the terminals that are in-line with each other, edge to edge, are in the same circuit. See Figure 2.21. - Page 16 ELECTRICAL SYSTEM 2c. Circuit 1 is a normally closed circuit. That Circuit 2 is a normally open circuit. That means there should be continuity through means there should not be continuity that circuit when the switch is at rest. through that circuit when the switch is at rest.
- Page 17 ELECTRICAL SYSTEM Test the circuit breaker. Test the diode. NOTE: Make sure the circuit breaker is cool and NOTE: There is a diode between the charger pressed in before testing it. jack and the circuit breaker. It has two jobs. First it protects the batteries from a short in the 3a.
- Page 18 ELECTRICAL SYSTEM 4b. Remove the fuse. See Figure 2.29. Set the DVOM to the diode test scale. See Figure 2.31. Fuse Diode test scale Figure 2.29 Figure 2.31 4c. Disconnect the circuit breaker. See Figure 2.30. 4e. Insert the positive probe of the DVOM into the port of the charger jack that has the green wire.
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Page 19: Batteries And Charger
ELECTRICAL SYSTEM 4g. The DVOM should read less than 1 Ohm. Batteries and charger 4h. Reverse the leads. See Figure 2.33. Batteries Before an electrical system can be diagnosed, the bat- Positive probe tery must be fully charged and in good working order. Charging the battery NOTE: Batteries on most modern outdoor power equipment are 12 volts. - Page 20 ELECTRICAL SYSTEM Attach a digital amp clamp to either one of the Interpreting the results motor leads (the current will be positive or nega- Table 1: tive depending on which LED is used). Voltage Current Possible reasons >47.0 < 9.5 Normal readings >47.0 >9.5...
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Page 21: Battery Charger
ELECTRICAL SYSTEM Battery charger Battery indicator The batteries in the battery pack are wired in series This mower is equipped with a battery level indicator. resulting in a 48 volt system. The battery charger for The indicator has five LEDs, the number of LEDs that this mower has an output of 54.5 volts so that the are lit is an indication of the voltage level of the battery. - Page 22 ELECTRICAL SYSTEM Attach an alligator clip on to a piece of wire, at Testing the battery indicator least 12” in length. NOTE: The battery pack should be fully charged Solder the piece of wire onto one of the other to test the battery indicator. two pins on the variable resistor.
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Page 23: Returning To Service
ELECTRICAL SYSTEM Attach the positive lead of a DVOM to the posi- Compare the results to Table 2. tive (smaller) tab of the indicator. See Figure Table 2: 2.40. operation Voltage green green green green 52 - 47.9 47.9- Positive lead of 46.7 DVOM 46.7-... -
Page 24: System Schematic Drawing
ELECTRICAL SYSTEM System schematic drawing Circuit Breaker... -
Page 25: Chapter 3: Repair Procedures
If the blades are mounted upside NOTE: The blade locking tool pictured above is down, the air flow will be reversed pushing the grass available through MTD parts. The part number is down instead of standing up. BB-100. - Page 26 REPAIR PROCEDURES Loosen and remove the blade bolt, locking plate, and blade using a 24 mm wrench. See Figure NOTE: Make certain to replace the parts in the 3.2. exact order in which they were removed. When installing the cutting blade, be sure it is installed with the curved ends pointing towards the mower deck and not towards the ground.
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Page 27: Switch Box Assembly
REPAIR PROCEDURES Switch box assembly Remove the five screws holding the housing together using a #2 phillips screwdriver. See Fig- The switch box assembly is located on the upper han- ure 3.5. dle bar. The switch and circuit breaker are housed inside of it. -
Page 28: To Replace The Switch Box
REPAIR PROCEDURES To replace the switch box: Remove the two mounting screws using a T-27 Torx driver. See Figure 3.8. Remove the safety key. Slide the safety bail out of the switch box assem- bly. Mounting screws Remove the motor cover by following the steps describe in the motor section of this chapter. -
Page 29: Motor
REPAIR PROCEDURES Motor Remove the blade by following the steps described in the blade section of this chapter. The motor on this mower is a DC permanent magnet motor. It is not serviceable. The test procedures for this Remove the fan and blade hub from the motor motor are covered in chapter 2 Electrical system. -
Page 30: Motor Mount
REPAIR PROCEDURES Remove the four mounting screws. See Figure Motor mount 3.13. To replace the motor mount: Remove the safety key. Remove the motor by following the steps described in the previous section of this manual. Remove the three mounting screws using T-40 torx driver.