Page 1 Professional Shop Handbook 4x4 Utility Vehicle w/Kohler Engine 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.
Page 3: Table Of Contents
Table of Contents Chapter 1: Introduction.....................1 Chapter 2 - Drive Sytem: CVT and Transfer Case............9 Kohler Enclosed CVT Addendum................63 Caterpillar Enclosed CVT Addendum................75 Chapter 3 - Drive System: Drive Shafts and Differentials..........89 Chapter 4 - Front Suspension and Steering..............123 Chapter 5 - Rear Suspension..................159 Chapter 6 - Hydraulic Brakes..................173 Chapter 7 - Kohler Engine Service Access and Fuel System........195 Kohler Engine Speed and Throttle Adjustment Addendum........215...
Page 5: Chapter 1: Introduction
Cub Cadet entered the utility vehicle market in the system sourced from Kawasaki. See Figure 1.3. 2003 season with a 6X4 vehicle having fully indepen- dent suspension and Honda power (20 H.P.). The Big Country 6X4 continues in production with evolutionary changes and a switch to Kohler power.
Page 6 - - - - - - - D - - - indicates the type of tires will be provided by the engine manufacturer, in • - - - - - - - - 710 indicates that it is Cub Cadet most cases. 2.1.
Page 7 Chapter 1: Introduction Fasteners: LIFTING AND SUPPORTING • Most of the fasteners used on the vehicle are CAUTION: Use common sense and safety when sized in fractional inches. Some are metric. lifting and supporting any equipment: For this reason, wrench sizes are frequently identified in the text, and measurements are •...
Page 8 Chapter 1: Introduction Jack stands can safely be positioned beneath the up- Jack stands will safely support the front of the vehicle if right frame members that are roughly even with the positioned beneath the frame, where the front out-rig- centerline of the tray that supports the engine and ger extends to meet the base of the OPS.
Page 9 Chapter 1: Introduction DRIVE SYSTEM DESCRIPTION • The transfer case is mounted adjacent to the engine, with the input shaft running fore-and-aft • A belt-type CVT (Continuously Variable Trans- in the frame. See Figure 1.11. mission) system carries power from the engine crankshaft to the transfer case.
Page 10 Kohler Engines will be serviced as they are in the rest of the Cub Cadet product Line. They are seen as an integral part of the Cub cadet product, with parts and warranty coverage provided through Cub Cadet.
Page 11 NOTE: There are many specialized tools that ley after any procedure that may have disturbed will make servicing the Cub Cadet 4X4 easier. the alignment, or if unusual belt wear occurs. There are only a couple of tools that are not See Figure 1.16.
Page 12 Chapter 1: Introduction...
Page 13 RPM and a called back for engineering analysis. CVT belt drive system. • If the failure is warrantable, Cub Cadet will cover The CVT belt drive system consists of : the cost of replacement. See Figure 2.1.
Page 14 Chapter 2- Drive System: CVT and Transfer Case The driving elements are tuned to get the 5b. At about 1,400 RPM, the sheaves move best vehicle performance out of each closer to each-other. As they do, they model engine, taking into account: engine touch the sides of the belt and begin to power band and top speed, vehicle transmit power.
Page 15 Chapter 2- Drive System: CVT and Transfer Case • The further the drive point (contact patch At about 3,000 RPM (Kohler) or 2,500 between the belt and the sheaves) is from the RPM (Caterpillar) the driving element crankshaft, the greater the effective circumfer- reaches the end of its travel.
Page 16 Chapter 2- Drive System: CVT and Transfer Case • Slower idle speeds will result in poor idle quality, DRIVE SYSTEM SERVICE ACCESS, SAFETY, AND reduced flow of cooling air, and reduced oil flow. TIPS • Higher idle speeds will result in harsh gear When working on the belt, block the wheels to selector action and possible internal damage to prevent the UV from rolling.
Page 17 • While it is mechanically possible to disassemble the driving and driven elements, individual parts will not be available through Cub Cadet. Figure 2.10 CVT SERVICE NOTE: A 6mm screw with a thread pitch of 1.0 BELT REMOVAL may be purchased locally.
Page 18 Chapter 2- Drive System: CVT and Transfer Case 1d. Thread the screw into the tapped hole in the outer half of the driven element sheave. NOTE: On the Caterpillar engines, The belt may The end of the screw will press against be harder to roll off the sheave, but it will roll off.
Page 19 Chapter 2- Drive System: CVT and Transfer Case Remove the three screws holding the Install the clutch removal tool (M14 - 2.O) by cover in place, then remove the cover. threading it into the clutch, pressing against the See Figure 2.15. crankshaft.
Page 20 Chapter 2- Drive System: CVT and Transfer Case 4b. Place the transfer case in H position, and Make the wood block spacer as described in the set the parking brake. accompanying illustration. See Figure 2.19. Loosen the bolt that holds the driven ele- ment to the input shaft using a 9/16”...
Page 21 Chapter 2- Drive System: CVT and Transfer Case 6b. Install the belt around the pulleys and insert 6f. Secure the driven element to the input shaft the wood block tool between the pulleys using the bolt, washer, and shoulder to establish correct spacing. spacer previously removed.
Page 22 Chapter 2- Drive System: CVT and Transfer Case Remove the wood block tool. DRIVE SYSTEM ADJUSTMENTS: See Figure 2.24. TRANSFER CASE SHIFT LINKAGE Before attempting any linkage repair of adjust- ment, confirm whether the problem at hand is in the linkage or elsewhere in the system. A handy quick-check to confirm that the transfer case is in neutral when the gear selector is in neutral can be made using the two safety...
Page 23 Chapter 2- Drive System: CVT and Transfer Case Centering the linkage: See Figure 2.27. NOTE: Methodology: start at the source (the transfer case), and work toward the control input (the gear selector). Operate the gear selector through its full range of motion (high range forward, low range for- ward, neutral, and reverse).
Page 24 Chapter 2- Drive System: CVT and Transfer Case Rod adjustment is made by lengthening or short- After the rod adjustment is done, operate the ening the shift rods to make neutral at the Hurst linkage to confirm that the shift forks move fully gear selector lever correspond with neutral to their engaged detent positions.
Page 25 Chapter 2- Drive System: CVT and Transfer Case 10d. Unbolt the console cover / cup holder using When adjustment is complete: a 9/16” wrench to remove the two screws 14a. Snug the jam nut. that hold the back of the console cover. A 9/16”...
Page 26 Chapter 2- Drive System: CVT and Transfer Case DRIVE SYSTEM ADJUSTMENT: PARKING BRAKE Checking caliper adjustment: See Figure 2.31. NOTE: The parking brake is mounted to the Feeler gauge transfer case, and its operation is completely Parking brake .010-.013 (.254-.330mm) independent of the hydraulic service brakes.
Page 27 Chapter 2- Drive System: CVT and Transfer Case The caliper can be adjusted using the screw and • There is a park brake switch mounted beneath jam nut on the caliper. Us a 7/16” wrench and an the lever. The contacts within the switch are nor- 11/16”...
Page 28 Chapter 2- Drive System: CVT and Transfer Case By the fourth notch, it should be impossible to 11.1. Adjustment can be made using a pair of 1/2” rotate the drive shaft. See Figure 2.35. wrenches at the anchor point of either end of the cable.
Page 29 Chapter 2- Drive System: CVT and Transfer Case DRIVE SYSTEM SERVICE: LUBRICATION The transfer case contains 64 fl.oz. (1.9 l.) of 80W-90 Low Foam Oil (Cub Cadet P/N: 737- The universal joints in the drive shafts that con- 04040). See Figure 2.40.
Page 30 Chapter 2- Drive System: CVT and Transfer Case 13.4. Transfer case, continued... 6a. The fill plug can be removed with a 5/8” open-end wrench. Park the vehicle on a firm level surface. Inspect the gear lube for debris or metal Allow the engine and drive system to cool chafe, then dispose of it properly.
Page 31 Chapter 2- Drive System: CVT and Transfer Case DRIVE SYSTEM SERVICE: TRANSFER CASE Disconnect the black cable from the negative REMOVAL WITH KOHLER ENGINE terminal on the battery using a 10mm wrench. Remove the cargo box from the vehicle: Remove the CVT belt and pulleys as described See Figure 2.44.
Page 32 Chapter 2- Drive System: CVT and Transfer Case Confirm that the transfer case is in neutral. Confirm that the parking brake is released. Disconnect the heavy Forward-Neutral-Reverse Disconnect the parking brake cable from the shift rod from the shift arm mounted to the trans- parking brake caliper by removing the hairpin fer case.
Page 33 Chapter 2- Drive System: CVT and Transfer Case Lift and safely support the utility vehicle, as Slide the transfer case forward to disengage the described in the LIFTING AND SUPPORTING drive shaft that connects it to the rear differential. section of this manual. See Figure 2.53.
Page 34 Chapter 2- Drive System: CVT and Transfer Case Disconnect the transfer case wiring harness 27a. Place the transfer case in the engine bay from the two neutral safety switches, and with sufficient access to connect the remove it. This will prevent the harness and transfer case wiring harness, and install switches from being damaged when the transfer the harness.
Page 35 Chapter 2- Drive System: CVT and Transfer Case 28c. Install the CVT as described in the DRIVE DRIVE SYSTEM SERVICE: TRANSFER CASE SYSTEM SERVICE:CVT BELT AND REMOVAL WITH CATERPILLAR ENGINE PULLEYS section of this manual. Remove the cargo box from the vehicle: Make the remaining electrical and mechanical See Figure 2.56.
Page 36 Chapter 2- Drive System: CVT and Transfer Case Disconnect the black cable from the negative Disconnect the heavy Forward-Neutral-Reverse terminal on the battery using a 10mm wrench. shift rod from the shift arm mounted to the trans- fer case. use a pair of 9/16” wrenches. Remove the CVT belt and pulleys as described See Figure 2.58.
Page 37 Chapter 2- Drive System: CVT and Transfer Case Disconnect the parking brake cable from the Lift and safely support the utility vehicle, as parking brake caliper by removing the hairpin described in the LIFTING AND SUPPORTING clip and clevis pin. See Figure 2.60. section of this manual.
Page 38 Chapter 2- Drive System: CVT and Transfer Case Attach a lifting apparatus to the transfer case, If the transfer case is to be replaced, match- being careful not to fowl the linkages. mark the position of each mounting bracket so See Figure 2.64.
Page 39 Chapter 2- Drive System: CVT and Transfer Case 24e. Move the transfer case into it’s mounting Make the remaining electrical and mechanical position in the drive system tray. connections: 24f. Secure the transfer case with the four sets 26a. Connect the transfer case safety switch of 5/16”...
Page 40 Chapter 2- Drive System: CVT and Transfer Case DRIVE SYSTEM BENCH SERVICE: Examine the contents of the drain pan and TRANSFER CASE DISASSEMBLY the residue that is stuck to the magnetic tip of the drain plug. See Figure 2.70. Preliminary steps: 1a.
Page 41 Chapter 2- Drive System: CVT and Transfer Case If the parking brake is being removed for transfer If the parking brake is being removed for brake to a replacement transfer case: replacement or other service: Remove the screws that hold the caliper NOTE: The inner brake pad is epoxied into the bracket to the transfer case housing using caliper.
Page 42 Chapter 2- Drive System: CVT and Transfer Case Remove the outer caliper housing. Slide the inner caliper housing off of the See Figure 2.76. two bolts that locate it. See Figure 2.78. Outer caliper housing Inner caliper housing Figure 2.76 Figure 2.78 Slip the rotor off of the brake shaft.
Page 43 Chapter 2- Drive System: CVT and Transfer Case • The adjustment screw acts by moving the con- Loosen but do not remove the nut and bolt tact point that the cam arm pivots against. that the Low-range shift arm pivots on See Figure 2.80.
Page 44 Chapter 2- Drive System: CVT and Transfer Case Check the plastic split-busings for wear. Remove the detent plate using a 3/8” They are inexpensive, and replacing them wrench. See Figure 2.86. if there is any significant wear will improve shift action. See Figure 2.84. Detent plate Bolt Detent...
Page 45 Chapter 2- Drive System: CVT and Transfer Case Remove the four screws that hold the Remove the screws that hold the case adaptor housing to the transfer case using halves together using a 1/2” wrench. a 1/2” wrench. See Figure 2.88. Gently separate the case halves using the three pry points, and a soft hammer if nec- essary.
Page 46 Chapter 2- Drive System: CVT and Transfer Case Lift the input shaft assembly straight out of Middle shaft and output shaft: the case. See Figure 2.92. NOTE: The middle shaft gears all have features that dictate their orientation during assembly. Output shaft Input shaft assembly Remove and discard the square-section...
Page 47 Chapter 2- Drive System: CVT and Transfer Case Lift the low gear shift shaft assembly (shift Lift the output shaft out of the housing. shaft and fork) out of the right side hous- See Figure 2.98. ing. See Figure 2.96. Output shaft Low gear shift collar...
Page 48 Chapter 2- Drive System: CVT and Transfer Case The middle shaft is easily disassembled Lift-out the reverse gear and washer. using a pair of external snap ring pliers. See Figure 2.102. See Figure 2.100. Reverse gear washer Figure 2.102 Figure 2.100 The reverse idler is the last gear left in the Lift the forward-neutral-reverse shift shaft, case, secured by a 1/2”-13 grade-8 cap...
Page 49 Chapter 2- Drive System: CVT and Transfer Case Remove and discard the seals from both halves 11b. The left side case half contains three bear- of the transfer case housing. See Figure 2.104. ings: See Figure 2.106. Left side case half Shift shaft seals (use hook tool Bearing seal bores...
Page 50 Chapter 2- Drive System: CVT and Transfer Case DRIVE SYSTEM BENCH SERVICE: Check the middle shaft gears: TRANSFER CASE INSPECTION Figure 2.108. Clean and inspect the case and all internal parts. NOTE: Most of the inspection process is visual or tactile. A limited amount of measurement is necessary, mostly to confirm whether a part that is usually worn is still serviceable.
Page 51 Chapter 2- Drive System: CVT and Transfer Case Check the forward / reverse shift yoke (fork) and Inspect the shift shaft for wear on the mat- shift collar groove for wear: ing and seal surfaces. Check the thickness of the shift yoke pad Check that the snap rings are seated in that contacts the shift collar using a their grooves.
Page 52 Chapter 2- Drive System: CVT and Transfer Case Check the forward / neutral / reverse shift The forward, reverse, and low range gears spin collar groove for wear: Use a .035” on the middle shaft. Check the bearing contact (.889mm) feeler-gauge as a go / no-go surfaces on the middle shaft for wear.
Page 53 Chapter 2- Drive System: CVT and Transfer Case The bearing surface that the low gear The bearing surface that the reverse gear rides-on (opposite end from the brake rides on (second largest cross-section of rotor spline, measured inboard from the shaft, adjacent to large set of dog teeth) snap-ring groove) should be a minimum should be a minimum of .970”...
Page 54 Chapter 2- Drive System: CVT and Transfer Case Inspect output shaft: See Figure 2.119. 8a. Visually check: *The end spline (CVT mounting) *The reverse pinion (machined onto shaft) *The spline that engages the Low pinion. Bull gear *The spline that engages the high pinion. *The surfaces that ride in the ball bearings and seals for galling, fretting, and Bull gear/shaft...
Page 55 NOTE: The bearings should be pressed only by the outer race. If the case is heated in hot water, dry the bearings and spray them with a suitable lubricant such as Cub Cadet Penetrating Oil (P/N: 737-3037) to displace any remaining water.
Page 56 Chapter 2- Drive System: CVT and Transfer Case Assemble the three main shafts: Apply a small amount of grease such as Cub Cadet multi-purpose grease (P/N Position the input shaft /reverse gear in 737-3034) to the shift shaft, and insert the...
Page 57 Position the shift collar on the low-range shift shaft assembly. Apply a small amount of grease such as Cub Cadet multi-purpose grease (P/N 737-3034) to the low range shift shaft.
Page 58 New hog ring Figure 2.130 Apply a small amount of grease such as Figure 2.132 Cub Cadet multi-purpose grease (P/N 737-3034) to the inside diameter of the low gear. Place the socket on top of the middle Install the low gear on the middle shaft,...
Page 59 Chapter 2- Drive System: CVT and Transfer Case Install the low pinion on the input shaft, fol- Checking and final assembly: lowed by the .060” (1.52mm) flat washer. Affix a dial indicator to the input shaft, so See Figure 2.134. that it reads against the case.
Page 60 Chapter 2- Drive System: CVT and Transfer Case Work the axle up and down to get and end- Position the low range shift shaft (the one play measurement on the dial indicator. closer to the input shaft) so that it extends end play should be between .005”-.015”...
Page 61 Chapter 2- Drive System: CVT and Transfer Case 4j. Test-spin the input shaft: Insert the detent balls, followed by the detent springs into the detent bores. Neutral See Figure 2.142. • With both shift shafts in neutral, the output shaft should not spin with any significant force when the input shaft is turned.
Page 62 Chapter 2- Drive System: CVT and Transfer Case 4s. Fasten the lug nut to the input shaft using a 5/16”-18 bolt. The tapered side of the lug NOTE: Seal installation tips: nut should face away from the input shaft. • The sealing surface on the shaft should be Slip the new hog ring over the lug nut, and inspected before assembly.
Page 63 4ae. Fill the case with 64 fl.oz. (1.9L) of 80W-90 Low Foam Oil (Cub Cadet P/N: 737- 04040). When full, gear lube will trickle- out of the level plug hole.
Page 64 Chapter 2- Drive System: CVT and Transfer Case Install the low-gear shift arm. Install the parking brake: See Figure 2.150. Apply a small amount of thread locking compound such as Loctite® 262 (red) to Low range shift arm the screws that hold the caliper bracket to the case.
Page 65 Chapter 2- Drive System: CVT and Transfer Case Item ft-lbs 32-40 43-54 Reverse idler bolt Neutral safety 32-36 43-49 switches Detent plate screw 16-21 Case screws 16-21 Adaptor housing 16-21 screws Drain and level plugs 18-23 25-32 Fill plug and vent snug snug 16-21...
Page 66 Chapter 2- Drive System: CVT and Transfer Case...
Page 67: Kohler Enclosed Cvt Addendum
Kohler Enclosed CVT Addendum KOHLER ENCLOSED CVT ADDENDUM DRIVE SYSTEM SERVICE: SAFETY AND TIPS Standard tools that will be useful include: When working on the vehicle, set the parking brake or block the wheels to keep it from rolling. Item Sizes Place the transmission in neutral.
Page 68 Kohler Enclosed CVT Addendum CONVERSION INSTRUCTIONS: ENCLOSED CVT ACCESS PREPARATION Lift the load box (bed). Review and understand these instructions Slide the driver’s seat all the way back on before starting to work on the vehicle. its tracks. Collect all necessary tools. Tilt the seats forward.
Page 69 Kohler Enclosed CVT Addendum Remove the original seat plate from the Remove the three screws that hold the grab handle, and replace it with the seat right rear fender to the splash shield using plate from the kit. See Figure 2a.3. a 5/16”...
Page 70 Kohler Enclosed CVT Addendum 2l. Remove the fender: See Figure 2a.7. BELT REMOVAL To remove the belt, a 6mm/1.0 screw with a minimum thread length of 1.15" (2.9cm) will be required. See Figure 2a.9. 1.15” (2.9cm) thread length Figure 2a.7 •...
Page 71 Kohler Enclosed CVT Addendum Lubricate the screw with a small amount of REMOVE THE CVT PULLEYS grease or motor oil, then thread the screw Remove the three screws holding the into the tapped hole in the outer sheave of cover in place using a T-20 driver, then the driven element.
Page 72 Kohler Enclosed CVT Addendum 4c. Withdraw the bolt, washers, and shoulder Slide the driven pulley off of the splined spacer. transfer case input shaft. See Figure 2a.16. Install the clutch removal tool by threading it into the clutch (driving pulley), pressing against the crankshaft.
Page 73 Kohler Enclosed CVT Addendum Loosen all the screws that hold the back Attach the heat shield to the new back plate to the transfer case using a 1/2” plate using the 1/4-20 screws and spac- wrench. Remove all but one. ers.
Page 74 Kohler Enclosed CVT Addendum • Tighten the 5/16-18 screws to a torque of 18-22 CVT Installation ft-lbs. (24-30 N-m). Prepare the CVT for installation: • Tighten the 3/8-16 screws to a torque of 22-25 ft- • Clean the shafts and the surrounding area lbs.
Page 75 Kohler Enclosed CVT Addendum Check the alignment of the two pulleys: Install the cooling fan on the driving pulley, Place the alignment tool over the hub of securing it with the flat washer and castle the driven pulley so that it lays flat against nut.
Page 76 Kohler Enclosed CVT Addendum Remove the screw that was used to Rotate the CVT cover down into position. spread the sheaves of the driven pulley. Fasten the CVT cover to the back plate Place the gear selector in neutral. using the (12) 1/4-20 self tapping screws. See Figure 2a.29.
Page 77 Kohler Enclosed CVT Addendum Center-punch and drill the two mounting holes in the seat box using a 9/32” (7mm) drill bit. Mount the bracket beneath the front lip of the seat box. Tighten the two 1/4-14 screws using a T-27 driver. See Figure 2a.31.
Page 78 Kohler Enclosed CVT Addendum...
Page 79: Caterpillar Enclosed Cvt Addendum
Caterpillar Enclosed CVT Addendum CATERPILLAR ENCLOSED CVT ADDENDUM DRIVE SYSTEM SERVICE: SAFETY AND TIPS Standard tools that will be useful include: When working on the vehicle, set the parking brake or block the wheels to keep it from rolling. Item Sizes Place the transmission in neutral.
Page 80 Caterpillar Enclosed CVT Addendum CONVERSION INSTRUCTIONS: ENCLOSED CVT ACCESS PREPARATION Lift the load box (bed). Review and understand these instructions Slide the driver’s seat all the way back on before starting to work on the vehicle. its tracks. Collect all necessary tools. Tilt the seats forward.
Page 81 Caterpillar Enclosed CVT Addendum Unbolt the fuel filter bracket from the vehicle Remove the original seat plate from the using a 1/2” wrench. See Figure 2b.3. grab handle, and replace it with the seat plate from the kit. See Figure 2b.5. Grab bar Flange bearings Old seat plate...
Page 82 Caterpillar Enclosed CVT Addendum Unbolt the electric fuel pump from the con- BELT REMOVAL sole-cup holder support using a pair of 7/ To remove the belt, a 6mm/1.0 screw with 16” wrenches. See Figure 2b.7. a minimum thread length of 1.15" (2.9cm) will be required.
Page 83 Caterpillar Enclosed CVT Addendum Lubricate the screw with a small amount of REMOVE THE CVT PULLEYS grease or motor oil, then thread the screw Remove the three screws holding the into the tapped hole in the outer sheave of cover in place using a T-20 driver, then the driven element.
Page 84 Caterpillar Enclosed CVT Addendum 5c. Withdraw the bolt, washers, and shoulder Slide the driven pulley off of the splined spacer. transfer case input shaft. See Figure 2b.16. Install the clutch removal tool by threading it into the clutch (driving pulley), pressing against the crankshaft.
Page 85 Caterpillar Enclosed CVT Addendum Loosen the four screws that hold the back Position the new aluminum back plate, plate to the transfer case adaptor using a connecting the engine to the transfer 1/2” wrench. Remove all but one. case. See Figure 2b.20. See Figure 2b.18.
Page 86 Caterpillar Enclosed CVT Addendum Seat the opening at the transfer case end 6l. Re-mount the starter motor. of the back plate over the boss that sur- See Figure 2b.24. rounds the input shaft. See Figure 2b.22. Starter motor Mounting boss Screws Back plate Transfer case...
Page 87 Caterpillar Enclosed CVT Addendum • Confirm the presence of four .030” (.75mm) Fasten the driving pulley to the crankshaft spacers on the shaft between the driven element using the, washer and shoulder spacer and the transfer case housing. previously removed on the double-ended See Figure 2b.25.
Page 88 Caterpillar Enclosed CVT Addendum Adjust the number of shims (spacers) Roll the drive belt back onto the pulleys. behind the driven pulley to achieve cor- Refer to the marks made before the belt rect alignment. Use the three .800” (2 cm) was removed, to confirm that the direction I.D.
Page 89 Caterpillar Enclosed CVT Addendum FINAL ASSEMBLY Fasten the CVT cover to the back plate using the (12) 1/4-20 self tapping screws. Install the drain plug in the CVT cover, and Tighten the screws using a 3/8” wrench. carefully tighten it until snug, using a 9/16” See Figure 2b.32.
Page 90 Caterpillar Enclosed CVT Addendum Position the air filter and intake tube in the Reinstall the grab handle with the new vehicle. See Figure 2b.34. seat plate. See Figure 2b.36. Air filter Flange bushings intake tube Spacers (secured with tape to ease mounting) Figure 2b.34 Figure 2b.36...
Page 91 Caterpillar Enclosed CVT Addendum Install the intake tube between the bracket and the spigot on the front of the CVT cover. Secure it with the hose clamp. See Figure 2b.38. Intake tube Figure 2b.38 Install the passenger seat and its new bracket to the new seat plate using a pair of 1/2”...
Page 92 Caterpillar Enclosed CVT Addendum...
Page 93: Chapter 3 - Drive System: Drive Shafts And Differentials
Chapter 3 - Drive System: Drive Shafts and Differentials CHAPTER 3 - DRIVE SYSTEM: DRIVE SHAFTS AND DIFFERENTIALS DRIVE SYSTEM DESCRIPTION The rear differential has a cast iron housing and a cable-actuated locking feature. Chapter 2 of this manual covers the drive sys- See Figure 3.2.
Page 94 5.3. Each differential transfers power to the drive • If the failure is warrantable, Cub Cadet will cover hubs through a drive shaft with Rzeppa-type the cost of replacement. constant velocity joints at each end. •...
Page 95 Chapter 3 - Drive System: Drive Shafts and Differentials Manually rotate one rear wheel, with the differ- When the differential lock is engaged, there ential lock disengaged: should be about 3/4” (19mm) from the centerline of the pin to the end housing that supports the •...
Page 96 Chapter 3 - Drive System: Drive Shafts and Differentials The control lever operates in a cam-over fash- When the differential lock is released, the pivot ion, with an extension spring and pivot link link is held horizontal by spring tension. between the control lever and the cable.
Page 97 Chapter 3 - Drive System: Drive Shafts and Differentials LUBRICATION The rear differential contains roughly 32 fl.oz. (950 ml.) of 80W-90 Low Foam Oil (Cub Cadet The universal joints in the driveshafts that con- P/N: 737-04040). nect the transfer case to the front and rear differ- entials are lubricated on assembly, and should •...
Page 98 Chapter 3 - Drive System: Drive Shafts and Differentials If the fluid level is low, gear lube may be Clean the area surrounding the fill plug added through the level plug, or through and level plug. See Figure 3.14. the vent at the top of the differential hous- Front of vehicle ing.
Page 99 Chapter 3 - Drive System: Drive Shafts and Differentials REMOVAL OF FRONT DRIVE SHAFT Remove the six nuts and bolts that hold the brush guard to the front of the frame, and NOTE: If the universal joints exhibit enough play remove the brush guard.
Page 100 Chapter 3 - Drive System: Drive Shafts and Differentials Carefully slide the cooling matrix straight Lift the rear of the cover, and draw it back forward. Do not allow the radiator core to to disengage the locating tabs at the front come into contact with anything that might edge.
Page 101 Chapter 3 - Drive System: Drive Shafts and Differentials Loosen the front differential. Release the Camloc® fasteners that secure the tool bin under the driver’s seat, and remove the Remove the four bolts that hold the bottom tool bin. of the front differential to the frame using a 9/16”...
Page 102 Chapter 3 - Drive System: Drive Shafts and Differentials 11b. After it is free of the pinion shaft on the 11d. Maneuver the front driveshaft to clear the front differential, move the front end of the bulkheads and front differential, and draw driveshaft to the right of the vehicle and it forward.
Page 103 Chapter 3 - Drive System: Drive Shafts and Differentials Assembly notes: FRONT HALF SHAFT REMOVAL • Inspect the splines and shaft seals before install- Failure mode, cause, and remedy: ing the front drive shaft. Make any necessary • The Rzeppa type constant velocity joints at each repairs before reassembly.
Page 104 Chapter 3 - Drive System: Drive Shafts and Differentials Remove the axle nut Disconnect the upper ball joint and tie rod end Remove and discard the cotter pin that Loosen the nut that holds the upper ball locks the axle nut. See Figure 3.29. joint to the front hub as far as possible using a 19mm wrench.
Page 105 Chapter 3 - Drive System: Drive Shafts and Differentials Support the lower control arm and the hub Use a soft drift to drive the axle out of the with enough stability that they will not fall, hub. See Figure 3.35. yet allow some freedom of movement.
Page 106 Chapter 3 - Drive System: Drive Shafts and Differentials Move the hub and lower control arm out Installation notes: and forward far enough to slip the end of • Apply anti-seize compound to the splines of the the axle out of the hub. See Figure 3.37. axle before assembly.
Page 107 Chapter 3 - Drive System: Drive Shafts and Differentials FRONT DIFFERENTIAL REMOVAL • When locating the brush guard, slip it straight on from the front, then secure it by inserting the Remove one front axle shaft as described in the bolts in the holes for the top two attachment FRONT HALF SHAFT REMOVAL section of this points.
Page 108 Disassembly of the differential is not meant to imply that the technician should disassemble the differential. NOTE: Disassembly of the front differential used in the Cub Cadet 4X4 Utility vehicle will void the warranty. Contact plate NOTE: There are no service parts available...
Page 109 Chapter 3 - Drive System: Drive Shafts and Differentials The height of the pin is adjusted by a set screw The pinion shaft and bearing slip out of the hous- that is accessible from the outside of the hous- ing once the cover is removed. See Figure 3.44. ing.
Page 110 Chapter 3 - Drive System: Drive Shafts and Differentials The left side of the housing contains a small • The toothed ring engages the end of a cage that electromagnet. See Figure 3.46. surrounds two sets of rollers. See Figure 3.48. •...
Page 111 Chapter 3 - Drive System: Drive Shafts and Differentials • The right side drive spool is supported in a simi- The caged rollers fit down into the drum, with the lar Timken ball bearing in the larger right-side drive spools rotating freely within the rollers, as housing.
Page 112 Chapter 3 - Drive System: Drive Shafts and Differentials When driving through a curve: REAR DRIVE SHAFT REMOVAL 13a. The wheel to the inside of the curve will NOTE: If the universal joints exhibit enough play rotate the fastest, clamping the rollers to indicate that they are worn, or if the rear drive- tightest between the inside drive spool shaft is identified as the source of a driveline...
Page 113 Chapter 3 - Drive System: Drive Shafts and Differentials Remove the four bolts that hold the bottom of the Once disconnected, remove the driveshaft. rear differential to the frame using a 9/16” See Figure 3.55. wrench. See Figure 3.53. Accessible from beneath vehicle Rear drive shaft Rear differential...
Page 114 Chapter 3 - Drive System: Drive Shafts and Differentials 6.1. Test-run the vehicle in a safe area before return- Preparation for removal of a rear axle: ing it to service. If an impact wrench is unavailable: • Engage the differential lock and apply the park- Item ft-lbs ing brake.
Page 115 Chapter 3 - Drive System: Drive Shafts and Differentials Disconnect the top of the rear hub from the Carefully pivot the hub forward, pushing in on upper control arm using a pair of 9/16” the end of the axle. This will separate the hub wrenches.
Page 116 Chapter 3 - Drive System: Drive Shafts and Differentials From this point, any repairs made to the axle can Assembly notes: be done on the bench, or it may be replaced as a • Inspect the splines and shaft seals before install- complete unit.
Page 117 Chapter 3 - Drive System: Drive Shafts and Differentials REAR DIFFERENTIAL REMOVAL Remove one of the rear axles as described in NOTE: It is not strictly necessary to remove the the REAR AXLE REMOVAL section of this man- cargo box for the remainder of this procedure, ual.
Page 118 Chapter 3 - Drive System: Drive Shafts and Differentials Remove one of the two bolts that hold the Clean the area surrounding the connection to exhaust system bracket to the forward cross- the second axle, and pop the axle loose from the member using a pair of 1/2”...
Page 119 NOTE: Disassembly of the rear differential used • Replace any worn hardware or components in the Cub Cadet 4X4 Utility vehicle will void the before reassembly. warranty. If the self-locking feature of any of the nuts is degraded, replace the nuts or apply thread lock- NOTE: There are no service parts available ing compound such as Loctite®...
Page 120 Chapter 3 - Drive System: Drive Shafts and Differentials To remove the pinion cartridge: Keep track of the number of shims on each cartridge if the differential is disassem- Remove the four screws that secure the bled. See Figure 3.73. cartridge using a 1/2”...
Page 121 Chapter 3 - Drive System: Drive Shafts and Differentials Keep track of the 1.0mm shims beneath With the left bearing cartridge removed, the mounting flange of the bearing car- the differential carrier bearing cone is tridge. exposed. See Figure 3.77. NOTE: The shims set the end-play and position Carrier bearing of the differential.
Page 122 Chapter 3 - Drive System: Drive Shafts and Differentials The right side case half can also be The differential components and ring gear removed with the cartridge in-place. are held together by one set of 3/8”-24 gr. See Figure 3.79. 8 screws.
Page 123 Chapter 3 - Drive System: Drive Shafts and Differentials The four pins on the differential lock collar With the block and cross-pins removed, the extend through the differential side plate four 10-tooth meter gears can be lifted-out when the lock is engaged. This locks the of the differential body.
Page 124 Chapter 3 - Drive System: Drive Shafts and Differentials The first step is to set the pre-load on the Once the number of shims is correct, the carrier bearings. Pre-load is set with the distribution from left-to right must be total number of shims separating the car- determined.
Page 125 Chapter 3 - Drive System: Drive Shafts and Differentials • Removing shims from the pinion cartridge Once the back-lash and gear mesh are set correctly, reduces back-lash, moves the contact patch install the O-ring seals on each of the cartridges. Lubri- toward the base of the pinion gear and inward on cate the seals with gear lube, and make the final the radius of the ring gear.
Page 126 Chapter 3 - Drive System: Drive Shafts and Differentials...
Page 127: Chapter 4 - Front Suspension And Steering
Chapter 4 - Front Suspension and steering CHAPTER 4 - FRONT SUSPENSION AND STEERING ABOUT THIS CHAPTER: FRONT SUSPENSION & STEERING: INSPECTION Layout: There are three main sections of this chapter Adjustability: The first section is concerned with identifying • The toe angle and spring rates are adjustable on problems in the front suspension and steering the front wheels.
Page 128 Chapter 4 - Front Suspension and steering Things to know about tire pressure: • Front tread blocks that appear “smeared” inward on the front surface of the tire indicate a toe-out A large imbalance in air pressure from left to condition.
Page 129 The upper joint operates at a much more severe • The Cub Cadet Utility Vehicle has automotive angle, and is more likely to create this style rack and pinion steering. kind of symptom. See Figure 4.5.
Page 130 Chapter 4 - Front Suspension and steering Ride height See Figure 4.6. Spring and damper units See Figure 4.7. Front spring and damper assembly 10” Figure 4.7 Figure 4.6 Prior to checking ride height, roll the vehicle • Make a visual inspection for: back and forth, bouncing it slightly to settle the _Broken coils suspension.
Page 131 Chapter 4 - Front Suspension and steering Wheel bearings See Figure 4.8. Brakes • While spinning the wheels to check the wheel bearings, pay attention to the amount of effort necessary to spin the wheel. • A wheel that does not spin easily most likely indi- cates a dragging brake.
Page 132 Chapter 4 - Front Suspension and steering Grasp the tire as described in the FRONT SUS- To check the control arm bushings: See Figure 4.10. PENSION INSPECTION: WHEEL BEARINGS With the weight of the vehicle resting on the sus- portion of this section of the manual. pension, pry outward on the control arm, from Apply a lifting/tilting force of 50-75 lbs.
Page 133 Chapter 4 - Front Suspension and steering FRONT SUSPENSION ALIGNMENT Alignment Specifications: Adjustability: Item Specification The toe angle and spring rates are adjustable on the front wheels. Ride height 10”+ .5” / 25.4+1.27cm Need for adjustment: Tire pressure 14-22PSI / .97-1.5 Bar. •...
Page 134 Chapter 4 - Front Suspension and steering Position the framer’s square vertical against a Adjust the front spring tension to adjust the cam- plain area on the sidewall of the tire. It should ber angle using the factory tool touch the lower part of the sidewall, but there Part# 759-04125 or a strap wrench.
Page 135 Chapter 4 - Front Suspension and steering If the camber is out of adjustment, and the ride Toe angle reacts to braking forces: height is correct, there are worn or damaged Under braking, the front wheels tend to toe-out, parts in the front suspension. The primary sus- because the contact patch of the tires lies out- pects are: board of the axis established by drawing an...
Page 136 Chapter 4 - Front Suspension and steering Take measurements between the string and the To correct the illustrated toe-in condition on the gussets where the base of the rear OPS support left front wheel, shorten the tie rod. structure meets the floor of the vehicle. See Figure 4.19.
Page 137 Chapter 4 - Front Suspension and steering Correcting a steering wheel that is not visually 16a. Pry the cover off of the center of the steer- centered when the wheels are pointed straight ing wheel. ahead: 16b. Remove the cap screw and washer that •...
Page 138 Chapter 4 - Front Suspension and steering Steering travel stop bolts If adjustment is necessary: See Figure 4.22. In normal service, these should not need adjusting. If it is necessary to adjust the stop bolts, use the following guidelines. Travel stop bolt Contact point The stop bolts should be adjusted so that the maximum on bracket on...
Page 139 Chapter 4 - Front Suspension and steering FRONT SUSPENSION AND STEERING Install the replacement spring and damper unit. COMPONENT REPLACEMENT Tighten the nuts to a torque of 42-64 ft-lbs (60- 88 N-m). Spring and Damper Unit If the spring and damper that was removed was Refer to the INSPECTION section of this chapter adjusted to meet the operating conditions of the for information on when to replace spring and...
Page 140 Chapter 4 - Front Suspension and steering Tie Rod End Loosen the nut that holds the tie rod end to the hub assembly using a 19mm wrench. Loosen Refer to the INSPECTION section of this chapter the nut far enough that it can be turned easily for information on when to replace tie rod ends.
Page 141 Chapter 4 - Front Suspension and steering Once released from the steering arm on the hub Upper Ball Joint assembly, spin the tie rod end out of the tie rod. Refer to the INSPECTION section of this chapter A 9/16” wrench may be used on the square sec- for information on when to replace ball joints.
Page 142 Chapter 4 - Front Suspension and steering Separate the upper ball joint from the upper con- Position a two-jaw puller to drive the ball joint trol arm: See Figure 4.31. downward, out of the upper control arm. See Figure 4.33. Two-jaw puller Chisel Drive ball...
Page 143 Chapter 4 - Front Suspension and steering Position the new ball joint for installation: 11e. Remove the socket when it meets the bot- See Figure 4.35. tom of the upper control arm. 11f. Continue driving the ball joint until it is fully Upper control arm seated.
Page 144 Chapter 4 - Front Suspension and steering Re-connect the bottom of the spring and damper Upper Control Arm (and bushings) unit to the control arm, tightening the nut to a Refer to the INSPECTION section of this chapter torque of 42-26 ft-lbs (60-88 N-m). If the locking for information on when to replace control arm feature of the nut has worn, replace the nut or bushings.
Page 145 Chapter 4 - Front Suspension and steering Remove the bolts that fasten the upper control Drive the bushing out of the arm. arm to the frame using a pair of 9/16” wrenches. Clean and lubricate the bore that the bush- See Figure 4.40.
Page 146 Chapter 4 - Front Suspension and steering Install the wheel, and tighten the lug nuts to a Lower Ball Joint torque of 75 ft-lbs (102 N-m). Refer to the INSPECTION section of this chapter Lower the vehicle to the ground. for information on when to replace ball joints.
Page 147 Chapter 4 - Front Suspension and steering Loosen the bolts (one turn) that hold the lower Carefully pry or drive a wedge between the control arm to the frame using a 9/16” wrench. lower control arm and the hub assembly to pull See Figure 4.44.
Page 148 Chapter 4 - Front Suspension and steering To separate the lower ball joint from the control To install the new ball joint into the hub: arm: See Figure 4.48. 11a. Position the new ball joint under the hub, with the metal shoulder of the ball joint Drive ball joint into Brass drift supported by a seal driver or a length of...
Page 149 Chapter 4 - Front Suspension and steering 11d. Secure the new ball joint with a new retain- Secure the ball joint stud to the hub assembly, ing ring. See Figure 4.51. tightening the nut to a torque of 22-28 ft-lbs (30- 38 N-m).
Page 150 Chapter 4 - Front Suspension and steering Wheel Bearings Remove the C-Clips from the brake caliper mounting pins using a small screwdriver. Refer to the INSPECTION section of this chapter See Figure 4.53. for information on when to replace the wheel bearings.
Page 151 Chapter 4 - Front Suspension and steering When the mounting pins are removed the pads Affix an automotive hub puller to the axle and will come loose, and the caliper will come free of hub assembly. See Figure 4.57. the bracket on the hub assembly. See Figure 4.55.
Page 152 Chapter 4 - Front Suspension and steering Remove the nut that holds the upper ball joint to Support the hub assembly and separate the the hub, and separate the upper ball joint from lower ball joint from the hub, as described in the the hub as described in the Upper Ball Joint sec- Lower Ball Joint section of this chapter.
Page 153 Chapter 4 - Front Suspension and steering Press the bearing assembly using a round arbor 19c. Strike the hubcap on top of a work bench that has an outside diameter of roughly 2.125” with sufficient force to cause the bearing (5.39cm), pressing against the outer edge of the cone to dislodge the seal.
Page 154 Chapter 4 - Front Suspension and steering Position each bearing cone in its side of the cup, 23j. Install the brake pads and caliper. Tighten and press the seal in flush behind it using a flat the mounting pins to a torque of 22-26ft- driver.
Page 155 Chapter 4 - Front Suspension and steering Steering Gear Remove the pad from the brake pedal using a 9/ 16” wrench. Refer to the INSPECTION section of this chapter for information on when to replace the steering NOTE: Diesel models: The radiator, bracket, gear.
Page 156 Chapter 4 - Front Suspension and steering Carefully slide the cooling matrix directly for- Remove the shoulder bolt that the throttle ward. Do not allow the radiator core to come into pedal pivots on using a 9/16” wrench and contact with anything that might damage it. a 3/4”...
Page 157 Chapter 4 - Front Suspension and steering Remove the kick panel: 11a. Remove the 4 screws that hold the kick NOTE: The far left bolt can be most easily loos- panel to the floor using a 3/8” wrench. ened from below the vehicle. A socket and a See Figure 4.73.
Page 158 Chapter 4 - Front Suspension and steering 13b. Three bolts hold the left side of the steer- 15c. Insert the steering rack mounting bolts, ing gear box. See Figure 4.77. threading the nuts on finger tight. After all the nuts and bolts are in position, tighten each to a torque of 18-22 ft-lbs.
Page 159 See Figure 4.79. mounting brackets Key Switch Hour meter 4-wheel-drive Power outlet Figure 4.81 Figure 4.79 • Key switch • Hour meter • Four wheel drive engagement switch • 12 Volt power outlet • Cub Cadet accessories that have been added.
Page 160 Chapter 4 - Front Suspension and steering Remove the steering wheel: See Figure 4.82. Remove the driver’s side hood and dash support bracket using a 3/8” wrench. See Figure 4.84. Hood and dash support bracket bolts Figure 4.82 Figure 4.84 Remove the cover from the center of the steering wheel by carefully prying it off.
Page 161 Chapter 4 - Front Suspension and steering Remove the four sets of nuts and bolts that hold If the steering shaft is to be removed, disconnect the steering wheel bracket to the frame using a it from the splined input shaft of the steering gear pair of 9/16”...
Page 162 Chapter 4 - Front Suspension and steering Assembly notes: 16k. Connect the negative cable to the battery. 16a. Lubricate the splines that join the steering 16l. Install the hood. shaft to the steering gear box with anti- 16m. Test run the vehicle in a safe area before seize compound.
Page 163: Chapter 5 - Rear Suspension
Chapter 5 - Rear Suspension CHAPTER 5 - REAR SUSPENSION Rear suspension inspection: Tire inflation ABOUT THIS CHAPTER: See Figure 5.1. Layout: There are two main sections of this chapter The first section is concerned with identifying problems in the rear suspension. The second section covers component replacement methods.
Page 164 Chapter 5 - Rear Suspension Rear suspension inspection: tire size and condi- Checking the rear wheel camber: tion. • What is camber angle? Camber angle is • Do not rotate the tires. Tire sizes differ from explained in Chapter 4-Front Suspension and front-to-rear and are directional.
Page 165 Chapter 5 - Rear Suspension Checking rear wheel toe angle: Inspecting spring and damper units. See Figure 5.5. NOTE: Rear wheel toe angle should be ZERO, and is not adjustable. If there is toe-in or toe-out in the rear suspension, it is due to worn or dam- SPRING AND aged parts that should be identified and DAMPER...
Page 166 Chapter 5 - Rear Suspension Inspecting wheel bearings. See Figure 5.6. Lift and safely support the rear of the vehi- cle as described in the LIFTING AND SUPPORTING section of the INTRO- DUCTION chapter of this manual. Rock the wheel around a horizontal axis with greater force than was used to check the wheel bearings.
Page 167 Chapter 5 - Rear Suspension Inspecting the rear control arm bushings: Anti-sway bar inspection. See Figure 5.10. See Figure 5.9. Anti-sway bar Anti-sway mount and pillow block bar end link Curved end of prybar Upper control arm bushing Figure 5.10 Figure 5.9 11a.
Page 168 Chapter 5 - Rear Suspension COMPONENT REPLACEMENT Install the replacement spring and damper unit. Tighten the nuts to a torque of 42-64 ft-lbs (60- Spring and Damper Unit 88 N-m). Refer to the INSPECTION section of this chapter If the spring and damper that was removed was for information on when to replace spring and adjusted to meet the operating conditions of the damper units.
Page 169 Chapter 5 - Rear Suspension Control Arms and Bushings Remove the bolts that fasten the control arm to the frame using a pair of 9/16” wrenches. See Refer to the INSPECTION section of this chapter Figure 5.16. for information on when to replace control arm bushings.
Page 170 Chapter 5 - Rear Suspension Drive the bushing out of the arm. Fasten the control arm to the frame of the vehi- cle. The brake line should go over the top of the Clean and lubricate the bore that the bush- arm.
Page 171 Chapter 5 - Rear Suspension Control arm to Hub bushings Remove the control arm from the hub by follow- Wheel Bearings ing the steps described in the previous section of Refer to the INSPECTION section of this chapter this chapter. for information on when to replace the wheel Press the spacer out.
Page 172 Chapter 5 - Rear Suspension When the mounting pins are removed the pads will come loose, and the caliper will come free of Remove the rear wheel using a 3/4” wrench. the bracket on the hub assembly. Remove the C-Clips from the brake caliper See Figure 5.22.
Page 173 Chapter 5 - Rear Suspension Remove the axle nut and the heavy flat washer Remove the hub bolts using a pair of 9/16” behind it using a 1 5/16” wrench. wrenches. See Figure 5.26. Affix an automotive hub puller to the axle and hub assembly.
Page 174 Chapter 5 - Rear Suspension Press the bearing assembly using a round arbor 16c. Strike the hubcap on top of a work bench that has an outside diameter of roughly 2.125” with sufficient force to cause the bearing (5.39cm), pressing against the outer edge of the cone to dislodge the seal.
Page 175 Chapter 5 - Rear Suspension Position each bearing cone in its side of the cup, 20f. Install the brake rotor on the hub, and and press the seal in flush behind it using a flat secure it with the heavy washer and cas- driver.
Page 176 Chapter 5 - Rear Suspension SWAY BAR AND LINKS Sway bar and bushings removal: Sway Bar and Bushings service intent: Remove the sway bar links as described above. • If the sway bar bushings show signs of wear, Remove the sway bar bushing mounts using a replace them.
Page 177: Chapter 6 - Hydraulic Brakes
Rebuild kits may eventually become avail- able through Cub Cadet, but failures in the initial two years of production will be serviced primarily with replacement master cylinders or calipers.
Page 178 Chapter 6 - Hydraulic Brakes The brake hydraulic system is divided into two circuits: BRAKE PUSH ROD ADJUSTMENT: front and rear. See Figure 6.3. • In the course of normal operation, brake adjust- ment should not be necessary. Front chamber Rear chamber •...
Page 179 While the powder-coat pro- ized portion of the hydraulic system has been opened. cess used on the frame of the Cub Cadet utility If only one side of the system has been opened (front vehicle line is relatively resilient to brake fluid, or rear) then only that side needs to be bled.
Page 180 Chapter 6 - Hydraulic Brakes To bleed under pedal-pressure: See Figure 6.9. NOTE: If it is suspected that air is trapped in the master cylinder it may be necessary to bleed the master cylinder. The procedure for bleeding at the master cylin- Apply der closely follows the procedure use to bleed pressure...
Page 181 Chapter 6 - Hydraulic Brakes BRAKE SYSTEM DIAGNOSIS Firm pedal but poor brake performance Soft Pedal • Friction surface problems are the most likely cause of this situation. Clean any liquids off the • Leakage: Make a visual inspection of the com- brake rotor, and identify the source of those liq- plete system.
Page 182 Chapter 6 - Hydraulic Brakes Brake drag / pulling (if at front caliper) AT-WHEEL COMPONENTS • Caliper frozen on slide pins: After a long The brake calipers (single-piston, floating) are identi- period of dis-use or extremely gentle use, the cal front to rear, and the pad replacement method is calipers may have become stuck on the slide identical as well.
Page 183 Chapter 6 - Hydraulic Brakes Brake Pads: The brake caliper must be removed to When the mounting pins are completely replace the brake pads. removed, the caliper will come free of the bracket on the hub. See Figure 6.15. Remove the C-clips from the mounting pins using a small screwdriver.
Page 184 Chapter 6 - Hydraulic Brakes Check the slide bushings. See Figure 6.17. Check the brake rotor as described in the follow- ing section of this manual before reinstalling the Slide bushing caliper. Replace the rotor if necessary. Installation notes: brake caliper See Figure 6.19.
Page 185 Chapter 6 - Hydraulic Brakes Bleed the hydraulic system, if necessary. Component Repair: Brake calipers Install the wheels, and lower the vehicle to the Remove the brake caliper as described previ- ground. ously in the AT-WHEEL COMPONENTS section of this manual. Test-drive the vehicle in a safe area before returning it to service.
Page 186 Chapter 6 - Hydraulic Brakes Remove both bleeder screws with a 1/4” wrench. With the piston removed from the bore, the See Figure 6.22. square section O-rings can be removed from their grooves in the bore. See Figure 6.24. Caliper housing Piston bore Bleeder screws O-rings...
Page 187 Chapter 6 - Hydraulic Brakes Assemble the caliper using the new parts con- Carefully insert the piston into the bore of the tained in the kit, installed as described in the dis- cylinder. See Figure 6.26. assembly process. See Figure 6.25. Insert piston into bore Caliper housing...
Page 188 Chapter 6 - Hydraulic Brakes Brake Rotors Remove and discard the cotter pin that secures the axle nut. See Figure 6.29. Examine the brake rotors. Original thickness is .1875” (4.76mm). See Figure 6.27. Axle nut Cotter pin Dial indicator mounted to steering travel stop bolt Figure 6.29...
Page 189 Chapter 6 - Hydraulic Brakes Use the puller to draw the hub and rotor assem- Installation notes: brake rotor bly off of the axle and hub carrier (upright) Inspect the axle splines, hub splines, assembly. See Figure 6.31. wheel studs, and axle threads before assembly.
Page 190 Chapter 6 - Hydraulic Brakes MASTER CYLINDER To Replace a Master Cylinder: Before condemning a master cylinder, check the fol- Open and remove the hood for easy access to lowing: the master cylinder: • Leaking lines or fittings Tilt the hood forward •...
Page 191 Chapter 6 - Hydraulic Brakes Remove the left front fender from the vehicle: Disconnect the brake lines using a 1/2” wrench. See Figure 6.35. See Figure 6.37. Left front fender Nuts / bolts Copper Self-tapping screws washers 90 degree 45 degree front rear Figure 6.37...
Page 192 Chapter 6 - Hydraulic Brakes Installation notes: Mounting the master cylinder Bleed the entire brake hydraulic system, starting See Figure 6.39. at the furthest point of each circuit: • Check for leaks and pedal feel. Final assembly: Mounting bolts 16a. Install the front fender 16b.
Page 193 Chapter 6 - Hydraulic Brakes Pedal Linkage Once the brake pedal is loose, the bushings can be easily pried-out and replaced. The pedal pivots on a pair of thin-wall split plastic bush- ings. A dry graphite or PTFE-based spray lube may To remove the brake pedal arm from the vehicle: extend the life of the bushings.
Page 194 Chapter 6 - Hydraulic Brakes Component Repair: Master Cylinder Remove the busings that seal the reservoir to the cylinder housing. See Figure 6.45. NOTE: Master cylinder repair will not be avail- able during the initial year of production. • Pending availability, this section of the manual will provide guidance repairing the master cylin- der.
Page 195 Chapter 6 - Hydraulic Brakes Remove the dust seal from the push rod Remove the rear piston and spring from the end of the master cylinder. master cylinder bore. See Figure 6.49. See Figure 6.47. Dust seal Rear piston assembly Match mark for jam nut Figure 6.49 Figure 6.47...
Page 196 Chapter 6 - Hydraulic Brakes Install the repair kit components on the rear pis- Remove the make-up seal from the rear ton: end of the rear piston. See Figure 6.52. Carefully fixture the front piston in a vice, Makeup seal gripping it by the necked-down section of the piston.
Page 197 Chapter 6 - Hydraulic Brakes Remove the power seal and flat washer Inspect the bore of the master cylinder. from the front end of the front piston. • If the bore is undamaged, clean it thoroughly See Figure 6.54. and continue with assembly. •...
Page 198 Chapter 6 - Hydraulic Brakes Compress the springs, pushing the pistons into the bore using the push rod. See Figure 6.56. Push rod Retaining ring Retainer plate Rear piston Figure 6.56 Secure the push rod and retaining plate by installing the snap ring. NOTE: Use a new snap ring if the original shows signs of stress.
Page 199: Chapter 7 - Kohler Engine Service Access And Fuel System
Chapter 7 - Kohler Engine Service Access and Fuel System CHAPTER 7 - KOHLER ENGINE SERVICE ACCESS AND FUEL SYSTEM Routine engine maintenance includes: ENGINE MAINTENANCE ACCESS • Air filter CAUTION: Allow the engine and it’s exhaust system to cool before performing any work on or •...
Page 200 Chapter 7 - Kohler Engine Service Access and Fuel System The air filter can be reached by removing the air Look for evidence of dirt ingestion inside of filter cover. The cover is secured by a captive the filter. It will be most pronounced near wing-nut.
Page 201 Chapter 7 - Kohler Engine Service Access and Fuel System To Change the oil and filter: The Spark plugs should be checked and gapped at 200 hour intervals. They will normally Lift and safely support the vehicle. need to be replaced at 500 hour intervals. Position a drain pan beneath the oil filter NOTE: The spark plug is a Champion RC12YC and drain.
Page 202 Chapter 7 - Kohler Engine Service Access and Fuel System Remove the remaining fasteners that hold The high tension lead and spark plug can the fender to the vehicle: See Figure 7.9. be reached through an opening between the top frame member and the fuel tank. See Figure 7.11.
Page 203 Chapter 7 - Kohler Engine Service Access and Fuel System Removing the splash shield provides access To remove the starter motor: See Figure 7.14. to the right side of the engine. See Figure 7.12. Starter solenoid Heavy-gauge Mounting screws “Hot” cable Trigger wire Starter motor body...
Page 204 Cooling Shroud: Unlike previous V-twin pow- ered Cub Cadet utility vehicles, the cooling shroud can be removed from the engine while the engine is in place in the vehicle. This pro- vides access to: •...
Page 205 Chapter 7 - Kohler Engine Service Access and Fuel System Remove the screws that hold the voltage 9.8. Remove the fan, followed by the cooling shroud. regulator and it’s ground strap to the See Figure 7.21. engine using an 8mm wrench. See Figure 7.19.
Page 206 Chapter 7 - Kohler Engine Service Access and Fuel System Cylinder head removal Engine removal NOTE: The Cylinder head can be removed from Remove the cargo box from the vehicle: the #1 cylinder without removing the engine from See Figure 7.24. the vehicle.
Page 207 Chapter 7 - Kohler Engine Service Access and Fuel System Remove the CVT belt and pulleys as described Carefully disconnect the fuel line from the fuel in the DRIVE SYSTEM: CVT BELT AND PUL- pump inlet barb on the valve cover on the #1 cyl- LEYS section of this manual.
Page 208 Chapter 7 - Kohler Engine Service Access and Fuel System Remove the nuts that secure the exhaust mani- fold to the cylinder heads using a 13mm wrench. NOTE: It is nearly as easy to separate the muf- See Figure 7.29. fler from the exhaust manifold, but reassembly requires a fresh gasket.
Page 209 Chapter 7 - Kohler Engine Service Access and Fuel System Attach a lifting apparatus, and carefully raise the Remove the engine completely, placing it on a engine. Support the engine without straining strong workbench or stable work platform. any of the electrical connections. Prior to engine installation, check all the service See Figure 7.32.
Page 210 Chapter 7 - Kohler Engine Service Access and Fuel System Reverse the removal process to install the Final assembly: engine. • Install the front fender • Install the engine mounting bolts loosely, then • Install the front spring and damper unit. tighten them after the heavy plate connecting the engine to the transfer case is installed.
Page 211 Chapter 7 - Kohler Engine Service Access and Fuel System FUEL SYSTEM: DESCRIPTION Fuel line: CAUTION: Gasoline and it vapors are extremely • Gasoline powered utility vehicles made for the flammable. Use common sense when working year 2006 are subject to CARB Tier III Emission around the fuel system: regulations.
Page 212 Chapter 7 - Kohler Engine Service Access and Fuel System There are three fittings on top of the fuel tank: Remove the two screws that fasten the fuel tank See Figure 7.37. hold-down wire to the frame. See Figure 7.39. Fuel level sender Fuel tank vent...
Page 213 Chapter 7 - Kohler Engine Service Access and Fuel System Fuel pick-up fitting: See Figure 7.41. When diagnosing a fuel starvation or flooding issue confirm that the vent is not blocked. See Figure 7.43. Fuel pick-up Bushing No pressure Vent good No vacuum Figure 7.41 Figure 7.43...
Page 214 Chapter 7 - Kohler Engine Service Access and Fuel System Sender diagnostics: See Figure 18.0. ADJUSTMENTS: ENGINE SPEED AND THROTTLE LINKAGE • Lower the float to the lowest position to close the contacts in the sender. The engine should idle at 1,200 RPM: See Figure 7.45.
Page 215 Chapter 7 - Kohler Engine Service Access and Fuel System The governed idle can be adjusted by bending the tab that holds the light spring that applies NOTE: A photo tachometer can be used on the tension between the governor bracket and the driving clutch element, which is connected governor arm.
Page 216 Chapter 7 - Kohler Engine Service Access and Fuel System After the idle and throttle stop are set, check and Confirm that the cable is securely clamped in adjust top no-load speed. See Figure 7.49. place at the engine end. See Figure 7.50. Governor input arm Intermediate governor arm...
Page 217 Chapter 7 - Kohler Engine Service Access and Fuel System Final Throttle Cable Adjustment: Have an assistant hold the throttle pedal all the way down. The throttle pedal arm stop against To get full travel, adjust the pedal end of the the head of the travel-stop bolt.
Page 218 Chapter 7 - Kohler Engine Service Access and Fuel System CHOKE If the choke does not open and close completely with the operation of the knob, the cable may be If a vehicle exhibits any of the following symp- adjusted: See Figure 7.58. toms, inspect the operation of the choke: See Figure 7.56.
Page 219: Kohler Engine Speed And Throttle Adjustment Addendum
Kohler Engine Speed and Throttle Adjustment Addendum KOHLER ENGINE SPEED AND THROTTLE ADJUSTMENT ADDENDUM ADJUSTMENTS: ENGINE SPEED AND THROTTLE LINKAGE NOTE: A photo tachometer can be used on the The engine should idle at 1,200 RPM: driving clutch element, which is connected See Figure 7a.1.
Page 220 Kohler Engine Speed and Throttle Adjustment Addendum The governed idle can be adjusted by bending After the idle and throttle stop are set, check and the tab that holds the light spring that applies adjust top no-load speed. See Figure 7a.5. tension between the governor bracket and the governor arm.
Page 221 Kohler Engine Speed and Throttle Adjustment Addendum Confirm that the cable is securely clamped in Final Throttle Cable Adjustment: place at the engine end. See Figure 7a.6. To get full travel, adjust the pedal end of the cable so that the eyelet on the cable core just rests against the socket head cap screw that passes through it.
Page 222 Kohler Engine Speed and Throttle Adjustment Addendum Have an assistant hold the throttle pedal all the way down or block the pedal down with a weight. The throttle pedal arm should be against the head of the travel-stop bolt. See Figure 7a.10. Depress gas pedal Figure 7a.10 Pull the throttle cable housing to apply tension to...
Page 223: Chapter 8 - Caterpillar Engine And Related Systems
Follow all safety guidelines (WARNINGs and CAUTIONs) and service instructions that pertain to Caterpillar Engine Model C0.7 and the Cub Cadet Operator’s Manual. Access to most routine maintenance points can be achieved by raising the cargo box, releasing the Camloc® fasteners that secure the engine cover, and removing the engine cover.
Page 224 Chapter 8 - Caterpillar Engine and Related Systems The cooling system extends to the front of the • The tag Identifies the Model Number (C0.7), vehicle. See Figure 8.4. Arrangement Number, and Serial Number • These numbers will be necessary when dealing Front-mounted radiator with a Caterpillar Service Center.
Page 225 To reach the air filter: Immediately insert the replacement ele- Turn-off the engine. Removing the air filter ment (Cub Cadet part # 751-10376) with the engine running will allow dirt to Replace the cover: Align the #1 on the enter the engine.
Page 226 • Cleanliness and sealing are of the utmost impor- • The Cub Cadet utility vehicle is not equipped tance any time any connections in the air filter with an air filter service indicator. system are disturbed. • In summary: If it is not necessary to remove the •...
Page 227 • The typical Caterpillar service rating Definition tion when draining the oil and do not come in for the engines used in Cub Cadet utility vehicles direct contact with it. is “C”. Position a clean drain pan beneath the oil •...
Page 228 Chapter 8 - Caterpillar Engine and Related Systems Clean thoroughly around the filter before Disconnect the fuel solenoid by unplugging removing it. the connection from the engine wiring har- ness. See Figure 8.14. Use an appropriate filter wrench to remove the oil filter from the engine.
Page 229 Chapter 8 - Caterpillar Engine and Related Systems Cut the oil filter open using a commercially Fuel Filter Maintenance: draining condensate available filter cutter. CAUTION: Diesel fuel is flammable. Do not ser- • Break apart the pleats to look for excessive vice the fuel filter or any other part of the fuel debris.
Page 230 Chapter 8 - Caterpillar Engine and Related Systems With the engine turned-off and cool, tilt the Fuel Filter Maintenance: changing filter passenger seat forward to reveal the fuel CAUTION: Diesel fuel is flammable. Do not filter. service the fuel filter or any other part of the fuel Place a suitable container under the fuel system when the engine is hot or near any filter.
Page 231 Chapter 8 - Caterpillar Engine and Related Systems Open the air bleed to drain the filter Install the replacement filter cartridge by assembly completely. See Figure 8.17. pushing it straight onto the filter housing, with the ears aligned to fit the notches in the housing.
Page 232 Chapter 8 - Caterpillar Engine and Related Systems Other maintenance items 8m. Wipe-up any spilled fuel. Dispose of any waste fuel in a safe, legal, and environ- The crankcase breather valve is mounted on mentally responsible manner. top of the valve cover/intake manifold assembly. It should be serviced every 2,000 hrs.
Page 233 Chapter 8 - Caterpillar Engine and Related Systems Remove the spring from the breather Correct belt tension is 4.4lbs. (2kg.) using cover. a 7” (18cm) belt span. See Figure 8.23. 1e. Clean the cover thoroughly, making certain that the vent hole is clear. Apply a very sparing amount of thread locking compound such as Loctite®...
Page 234: Chapter 9 - Electrical
Chapter 8 - Caterpillar Engine and Related Systems 3e. Use a 5/16” wrench to remove the screws If the previous belt failed prematurely, that hold the splash shield to the fender. identify and correct the cause of the belt See Figure 8.25. failure.
Page 235 Chapter 8 - Caterpillar Engine and Related Systems Disconnect the heavy gauge red cable Withdraw the pivot bolt carefully so as not from the alternator using a 10mm wrench. to drop the shouldered spacer that fits See Figure 8.28. between the alternator and the engine block.
Page 236 Chapter 8 - Caterpillar Engine and Related Systems Remove the splash shield, and disconnect Again working from the front of the engine, the alternator as described in the proced- loosen the upper screw that holds the ing section of this chapter. The alternator starter to the engine.
Page 237 Chapter 8 - Caterpillar Engine and Related Systems Install the starter by reversing the removal Remove the tapered shaft adaptor using a process. 16mm wrench. See Figure 8.36. • Use a magnetic socket, or wedge the screws into a conventional socket with a sheet of paper. Flywheel This will make it easier to reach the threads with Tapered shaft adaptor...
Page 238 Chapter 8 - Caterpillar Engine and Related Systems 6c. Note the match-mark that indexes the fly- Wiggle the flywheel or rap it with a soft wheel to the crankshaft to maintain factory hammer to release it from the crankshaft. balance of the rotating assembly. See Figure 8.40.
Page 239 Chapter 8 - Caterpillar Engine and Related Systems • An M10 - 1.25 stud may be temporarily installed The exhaust system is covered by a series in one of the holes to aid positioning. of heat shields. See Figure 8.42. See Figure 8.41.
Page 240 Chapter 8 - Caterpillar Engine and Related Systems • Although it is not directly related to the exhaust • The spark arrestor may be removed for cleaning system, the engine cover also helps to protect or replacement using a 1/4” wrench. the cargo box and operators from engine heat.
Page 241 Chapter 8 - Caterpillar Engine and Related Systems • Temporarily creating extra back pressure while COOLING SYSTEM the engine runs will cause leaking exhaust gas- Precautions: ses to hiss, making them easier to locate. See Figure 8.47. CAUTION: Removing the radiator cap or discon- necting any part of the cooling system when it is hot will allow it to expel hot coolant under pres- sure, which may cause sever burns.
Page 242 Chapter 8 - Caterpillar Engine and Related Systems Cooling System Description A thermostat on the engine regulates the flow of coolant between the engine and The liquid-cooled engine is mid-mounted, the radiator. under the cargo box. A belt-driven water pump circulates cool- 2b.
Page 243 Chapter 8 - Caterpillar Engine and Related Systems • The vent point at the back of the system is a set- • The coolant enters the top (rear) of the radiator, screw at the highest point: the metal coolant on the left side. See Figure 8.54. pipe that connects to the thermostat housing.
Page 244 Chapter 8 - Caterpillar Engine and Related Systems • Coolant returns to the engine through the hose • The fan switch is mounted on the bottom front that connects to bottom of the water pump. edge of the radiator, next to the return hose con- See Figure 8.56.
Page 245 Chapter 8 - Caterpillar Engine and Related Systems COOLING SYSTEM MAINTENANCE Coolant requirements NOTE: Refer to the accompanying table for water content specifications. Most cities or • The engine coolant should be sampled annually counties can provide information about the con- or every 250 hrs of operation.
Page 246 Chapter 8 - Caterpillar Engine and Related Systems • The coolant level should be between 1”-4” Draining and filling coolant (2.54cm-10.16cm) deep, as indicated by the two NOTE: Before draining the coolant, pressure lines on the reservoir. See Figure 8.60. test the cooling system and inspect it for any signs of leakage.
Page 247 Chapter 8 - Caterpillar Engine and Related Systems Remove the air vent plug from the to-radi- ator pipe, above the thermostat housing. NOTE: With the plugs removed, it is acceptable A 3/16” allen wrench will fit the plug. to apply 30 PSI (2.0 Bar) of pressure with a See Figure 8.62.
Page 248 Chapter 8 - Caterpillar Engine and Related Systems If liquid does not come out of the air vent Check the coolant level at the radiator filler port, it may be necessary to pressurize neck. Top-up if necessary before return- the front of the system using a cooling ing the vehicle to service.
Page 249 Chapter 8 - Caterpillar Engine and Related Systems Cleaning the radiator (external) Heavier mud can be cleared using a water hose. Use line head pressure only. Do 5a. The radiator should be visually checked for not pressure-wash the radiator. air blockage at the start of each operating See Figure 8.67.
Page 250 Chapter 8 - Caterpillar Engine and Related Systems Cooling system checking: radiator Cooling system checking: radiator cap See Figure 8.68. See Figure 8.69. Look for corrosion or blockages within the core. Pressure-test cap: It should release at 13-14 PSI (0.9 Bar) Figure 8.68 Figure 8.69 A fair indication of the radiator’s internal...
Page 251 Chapter 8 - Caterpillar Engine and Related Systems The system can be tested using a com- • The thermostat is referred-to in Caterpillar text mercially available tester and a 45mm as a “water temperature regulator”. For the pur- adaptor that also fits Toyota, Mitsubishi, poses of this text, the two terms are used inter- and Subaru cars as well as water-cooled changeably.
Page 252 Chapter 8 - Caterpillar Engine and Related Systems Use the non-contact thermometer to moni- tor the temperature in two spots as the NOTE: The thermostat opens at 167 deg. f. (75 engine warms-up from a cold start: deg.c.), but the insulating properties of the metal Check the engine block adjacent to the reduce the surface reading.
Page 253 Chapter 8 - Caterpillar Engine and Related Systems Cooling system checking: flow Cooling system component removal: cooling matrix 10a. The presence of coolant flow or the lack of coolant flow can be detected using a non- NOTE: Generally, the cooling matrix is most contact thermometer.
Page 254 Chapter 8 - Caterpillar Engine and Related Systems 11d. Disconnect the plug that connects the fan to the main wiring harness. That plug is NOTE: With the coolant drained from only the between the cooling matrix and the dash radiator, it can be removed with minimal fluid panel, and the lock-tabs are on the short loss and minimal drainage.
Page 255 Chapter 8 - Caterpillar Engine and Related Systems 11m. Loosen the hose clamp, disconnect the hose, and remove the cooling matrix to a NOTE: Each screw passes through a heavy flat clear workbench. See Figure 8.82. washer and a spacer, providing controlled com- pression of the rubber mounting bushings.
Page 256 Chapter 8 - Caterpillar Engine and Related Systems Cooling system component removal: 13e. Place a catch-pan under the match- coolant pipes and hoses marked joint, and disconnect the pipe from the hose. Loosen the hose clamp NOTE: The procedure described in this section using a 5/16”...
Page 257 Chapter 8 - Caterpillar Engine and Related Systems 13h. Match-mark the two coolant pipes at the 13m. Match-mark the return pipe for alignment engine end of the system. Disconnect the in such a way that the pieces can be dis- to-radiator pipe by loosening the hose tinguished from the pieces of the to-radia- clamp using a 5/16”...
Page 258 Chapter 8 - Caterpillar Engine and Related Systems 13r. Connect the rear pieces of pipe to the appropriate hoses coming-off the engine: The to-radiator pipe connects to the hose from the thermostat housing. The return pipe connects to the hose from the water pump.
Page 259 Chapter 8 - Caterpillar Engine and Related Systems FUEL SYSTEM: DESCRIPTION Fuel line: CAUTION: Diesel fuel is extremely flammable. The fuel line leads from a fitting atop the Use common sense when working around the fuel tank to the fuel filter. See Figure 8.94. fuel system: •...
Page 260 Chapter 8 - Caterpillar Engine and Related Systems The fuel pump feeds the injector pump mounted Tilt-up the load bed on the side of the engine. See Figure 8.96. Remove the 3 screws that hold the fender to the splash shield using a 5/16” wrench. See Figure 8.98.
Page 261 Chapter 8 - Caterpillar Engine and Related Systems 7d. Remove the fender: See Figure 8.100. The fuel level sending unit, forward of the others. The fuel pick-up for the engine (brass fit- ting) is mounted out-board. The fuel return from the injector pump is mounted furthest in-board.
Page 262 Chapter 8 - Caterpillar Engine and Related Systems Un-bolt the fuel filter and bracket from the frame Lift the fuel tank hold-down wire up, and pivot using a pair of 7/16” wrenches, and move the the front of the tank inward. See Figure 8.105. fuel filter assembly out of the way.
Page 263 Chapter 8 - Caterpillar Engine and Related Systems Vent fitting See Figure 8.107. Fuel level sender: See Figure 8.109. Figure 8.107 Figure 8.109 • The vent fitting regulates the amount of vapor • As the fuel level goes down the float lowers that escapes.
Page 264 Chapter 8 - Caterpillar Engine and Related Systems Return-line fitting See Figure 8.111. ADJUSTMENTS: ENGINE SPEED AND THROTTLE LINKAGE The engine should idle at 1,200 RPM: See Figure 8.112. Photo-tach: suitable for use on the driving element Figure 8.111 • This is a simple elbow with no orifices or regula- tion.
Page 265 Chapter 8 - Caterpillar Engine and Related Systems NOTE: A photo tachometer can be used on the NOTE: The governor feature is built into the driving clutch element, which is connected fuel injector pump. If the engine over-speeds, directly to the engine crankshaft. A photo fails to reach 3,600 RPM top no-load speed, or tachometer used on the driven clutch element fails to idle at the correct speed, and the throttle...
Page 266 Chapter 8 - Caterpillar Engine and Related Systems Confirm that the cable is securely clamped in Final Throttle Cable Adjustment: place at the engine end. The return spring To get full travel, adjust the pedal end of the should not bind or be pulled off-center. cable so that the eyelet on the cable core just See Figure 8.115.
Page 267 Chapter 8 - Caterpillar Engine and Related Systems Tighten the cable clamp screw. ENGINE PERFORMANCE ISSUES Release and depress the throttle pedal fully: If the over-temp light on the panel, or oil pres- sure light on the instrument cluster come-on, 15a.
Page 268 Chapter 8 - Caterpillar Engine and Related Systems • The cylinder or cylinders having poor combus- ENGINE REMOVAL tion can be identified by checking the tempera- CAUTION: Allow the engine to cool before start- ture of the individual exhaust runners using a ing work on it.
Page 269 Chapter 8 - Caterpillar Engine and Related Systems Remove the right rear fender and splash shield, Drain the coolant from the engine and coolant as described in the water pump and alternator pipes as describe in the Draining and Filling belt section of this chapter.
Page 270 Chapter 8 - Caterpillar Engine and Related Systems Unplug the main connection between the engine Unbolt and remove the exhaust system heat harness and the main harness. shield using a 3/8” wrench. See Figure 8.127. See Figure 8.125. Heat shields Bed locators / bump stops Main harness Engine...
Page 271 Chapter 8 - Caterpillar Engine and Related Systems Remove the exhaust system, complete. • Remove the hoses and rigid pipe that connect See Figure 8.129. the thermostat housing to the to-radiator pipe. • Remove the hose that connects the return pipe to the water pump.
Page 272 Chapter 8 - Caterpillar Engine and Related Systems Disconnect the air intake hose. Remove the 3 screws that hold the tapered shaft See Figure 8.133. adaptor to the flywheel using a 16mm wrench, and remove the adaptor. Remove the 5 sets of nut and bolts that hold the steel engine-to-transmission plate to the engine using a pair of 1/2”...
Page 273: Switches
Chapter 8 - Caterpillar Engine and Related Systems Disconnect the transfer case harness from the 22d. Remove all but 2 of the screws. The neutral switches on the transfer case. Move the screws left in place should be at opposite wires out of the way.
Page 274 Chapter 8 - Caterpillar Engine and Related Systems 24a. Contact the partnering Caterpillar dealer Reverse the removal steps to install the engine: for major engine repair or a service • Connect the ground wire and cable to the engine replacement engine. before lowering it into position.
Page 275: Screws
Chapter 8 - Caterpillar Engine and Related Systems ENGINE AND TRANSFER CASE TRAY Item ft-lbs NOTE: Because of clearance issues and the complexity of the removal process, it is not likely Engine to tray & 32-36 43-49 that a technician would remove the tray with the Engine to bracket engine and transfer case still attached.
Page 276 Chapter 8 - Caterpillar Engine and Related Systems Examine the rear-center mount with the Lift-up the engine and transfer case tray jacking-load released. far enough to allow easy access to the fasteners that hold the mount to the If the rear-center mount is pulled substan- frame.
Page 277 Chapter 8 - Caterpillar Engine and Related Systems Replacing a corner mount: 3e. Reverse the removal procedure to install the mount. Loosen the center bolt on each of the four corner mounts using a pair of 9/16” • Use caution not to pinch the brake line when wrenches.
Page 278 Chapter 8 - Caterpillar Engine and Related Systems...
Page 279 Chapter 9 - Electrical CHAPTER 9 - ELECTRICAL COMPONENTS ABOUT THIS CHAPTER Fuse and Relay Center, Kohler Gas Engine: This chapter is divided into four sections: • Location: Open the hood to reach the fuse and • Section 1: About this chapter and Precautions relay center.
Page 280 Chapter 9 - Electrical Fuse and Relay Center, • If it is necessary to remove one of the fuse and Caterpillar diesel engine relay holders from the fuse and relay center, Insert a pair of small screwdrivers into the cavi- •...
Page 281 Chapter 9 - Electrical Additional Fuses and Relays Additional Fuses and Relays at Center Position One: at Relay Center Position Two: • Location: Open the hood to reach the fuse and • Location: Open the hood to reach the fuse and relay center.
Page 282 The part number for the glow plug timer relay is Glow plug relay not listed in the Illustrated Parts List, but it may be ordered as Cub Cadet part number 725-04218. See Figure 9.5. Glow plug timer relay Fuse and relay center...
Page 283 Chapter 9 - Electrical Relay Function • Terminal 5 is the “Normally Open” terminal. It connects to terminal 3 when the relay is ener- • Most of the relays used on this vehicle have five gized. When 3 & 4 are connected, 3 & 5 are dis- pins.
Page 284 Chapter 9 - Electrical Safety Switches Terminal Key Position The transmission switches are located in Continuity a separate sub harness that consists of a simple loop connecting the two switches STOP M - G - A1 in series. Run w/ Lights B - A1 L - A2 •...
Page 285 Chapter 9 - Electrical • If there is continuity through the circuit when The brake switch is not tied to the starter the transfer case is in gear the problem must circuit. It illuminates an LED on the hour be identified and repaired to prevent the engine meter when the brake is engaged, and from being started when the vehicle is in gear.
Page 286 Chapter 9 - Electrical The Starter motor on the Kohler engine is • The Alternator feeds A.C. power out-put to the located on the outboard side of the engine block. regulator/rectifier that is attached to the inboard The starter solenoid is part of the starter. side of the cooling fan shroud.
Page 287 Chapter 9 - Electrical • The connector is most easily reached by remov- The Alternator / Regulator / Rectifier of the ing the right rear wheel and the splash shield Caterpillar engine is mounted at the rear of the behind the right rear wheel. outboard side of the engine.
Page 288 Chapter 9 - Electrical • The engine harness contains wires for the cir- The Fuel Pump for the Caterpillar engine is mounted under the console support bracket. It cuits listed in the table below: is easily accessible by lifting the passenger’s seat.
Page 289 Chapter 9 - Electrical The Fuel Shut-off solenoid for the Caterpillar The 4x4 Activation switch contains a simple engine is mounted on the front of the injector open-or closed set of contacts. The switch is pump, on the inboard side of the engine. easily removed from the dash panel by unplug- See Figure 9.20.
Page 290 Chapter 9 - Electrical • When power is applied from the engagement • The function of each wire connected to the switch, the clutch engages without any noise or Instrument Cluster / Hour Meter is described in perceivable motion. the table below: •...
Page 291 Chapter 9 - Electrical • The oil pressure sensor on the Caterpillar engine 21b. The Fuel light is Illuminated when a float is located on the inboard side of the block, in the fuel tank sinks far enough to close a between the oil filter and the injector pump.
Page 292 Chapter 9 - Electrical • If the key is left in the RUN position, the meter 21f. The Glow Plug light (diesel only) is the will continue to count-off hours and tenth-hours yellow lamp between the key switch and until it is turned-off or the battery goes flat. the warning light cluster / hour meter.
Page 293 Chapter 9 - Electrical • The black wire with white trace leads to the over- The Cooling fan (diesel only) is mounted under temp sensor on the engine water pump. When the hood, atop the radiator. It is wired to blow the coolant temperature exceeds 230 deg.f.
Page 294 Chapter 9 - Electrical Fan Switch, continued • The lamps only go into the housing in one orien- tation, and they are removed with a 45 degree • Take steps to minimize coolant loss if the switch counter-clockwise twist. is removed. Refill and purge the coolant system after a fan switch is replaced.
Page 295 Chapter 9 - Electrical The 12V. Power Outlet is located directly below • The accessory harness plug itself is located near the Warning Light Cluster / Hour Meter in the the fuse and relay center. It is the connection dash panel. See Figure 9.38. point for the accessory harness.
Page 296 Chapter 9 - Electrical • The rear accessory harness wires terminate • The battery is secured by a metal strap and two under the bed, near the bumper on the passen- 5/16” screws. They can be removed using a 1/2” ger side upper frame channel.
Page 297 Chapter 9 - Electrical ELECTRICAL DIAGNOSIS Outputs can include power to run an electric PTO clutch, a trigger signal to a starter solenoid, or the With a basic understanding of the behavior of electricity grounding of a magneto to turn-off an engine if an and the tools used to measure that behavior, a techni- unsafe condition exists.
Page 298 Chapter 9 - Electrical Electrical environment: AC Vs. DC Ohm’s Law: relates voltage, amperage, and Most modern outdoor power equipment that has an resistance electrical system complex enough to require diagnosis • Ohm’s law states that voltage is the product of will be equipped with an alternator that produces alter- resistance times current.
Page 299 Chapter 9 - Electrical Kirchhoff’s current law: Kirchhoff’s voltage law: • Kirchhoff’s current law deals with nodes. Nodes • Kirchhoff’s voltage law deals with voltage drops. are the junction of two or more wires or the junc- A voltage drop is the amount of voltage used up tion of a wire to a component.
Page 300 Chapter 9 - Electrical How the system is wired together Types of circuits The Rules: All circuits have some basic rules that There are three ways a circuit can be wired: must be followed: • Series All circuits must have at least one voltage •...
Page 301 Chapter 9 - Electrical Series/parallel Increased resistance • Series/parallel circuits have some sections wired • Increased resistance is as the name implies, an in series and some in parallel. See Figure 9.49. increase in resistance. • Causes: This can be caused by loose or cor- Lamp roded connections, or connections that are insu- lated by grease, paint, or coatings.
Page 302 Chapter 9 - Electrical Digital Volt Ohm Meter Amperage: Most DVOMs have a very limited capac- ity to test amperage (2-3 Amperes). When measuring • A DVOM is the most useful tool to trouble-shoot current flow, the meter must be connected in series any electrical system.
Page 303 Chapter 9 - Electrical Wiring diagram or schematic • Some high impedance test lights are capable of indicating whether the current being sampled is • A wiring or a schematic diagram, and the ability AC or DC. to read it are very important in troubleshooting a circuit.
Page 304 Chapter 9 - Electrical Ammeters and specialized charging system testers • Usage of the DC Shunt tool is detailed in the 1995 and 1999 editions of their Update Seminar • Inductive ammeters are available in many forms. materials. Some are as simple as a gauge to be held against the circuit in question when it is ener- NOTE: The operating principle is based on gized.
Page 305 Figure 9.56 normal resistance through stator windings: GOOD NOTE: On Caterpillar 45 amp alternators used in the Cub Cadet 4X4, it is not possible to isolate Figure 9.57 the raw voltage out-put. NOTE: On the Kohler 15 amp system used in...
Page 306 Chapter 9 - Electrical Interpretation: With the engine off, connect Kohler tool If the ohm meter indicates no continuity #25 7651-20 to the regulator/rectifier: between the two the purple stator leads, The two black leads go to the terminals there is a fault in the stator windings. normally connected to purple stator If the ohm meter indicates continuity leads.
Page 307 State of California to cause cancer and reproductive harm. Wash hands after handling. NOTE: The batteries used in Current Cub Cadet equipment are sealed. It is not possible to check, test or add fluid. CAUTION: Batteries contain electrolyte, which is highly corrosive.
Page 308 Chapter 9 - Electrical • Some charging systems do not work if the sys- Checking battery condition: There are three tem voltage falls below 6V. It takes a certain things to do when testing a battery: amount of voltage to excite the fields in the alter- •...
Page 309 Chapter 9 - Electrical Squeeze the bulb on the hydrometer, then Battery Testers: insert the hose into the cell. There are four major ways to check a battery: Release the bulb, drawing electrolyte into • Electrolyte test using a Specific Gravity tester the hydrometer to the fill line.
Page 310 For OEM batteries, contact the manu- See Figure 9.65. facturer for the CCA rating. Most riding mower batteries are 200-275 CCA. The Cub Cadet 4X4 has a nominal CCA of 500. See Figure 9.64. OEM batteries do not list the CCA’s Figure 9.65...
Page 311 Chapter 9 - Electrical Capacitance testing Battery discharge test There are several brands of capacitance battery tester Occasionally a battery will discharge while sitting presently on the market. Capacitance battery testers unused. To test for a battery that is “leaking” voltage: use the battery being tested as their power source.
Page 312 Chapter 9 - Electrical If the battery is being checked indepen- Take a methodical approach to finding the dently of the equipment it powers, mea- problem. sure and note the battery voltage while it As a rule of thumb, start at one end of the is disconnected, over a three-day period.
Page 313 Chapter 9 - Electrical Starting with a fully charged battery and Voltage Drop Test battery cable connections that are clean To review: and tight, measure the battery voltage. See Figure 9.69. • Ohm’s law states that it takes voltage to push current through a resistance.
Page 314 Chapter 9 - Electrical The voltage that shows-up on the meter is A similar ground-side test on a tractor with the voltage that is being used to pass cur- a slow-cranking starter motor can be con- rent through a resistance in the circuit. ducted between the engine block and the negative battery post.
Page 315 Chapter 9 - Electrical Applying this principle to the positive side of the • As an example, if the tractor had a slow-turning system: See Figure 9.73. starter, the ground-side voltage drop measured below 0.1 volts, and there was not a parasitic load on the engine (e.g.
Page 316 Chapter 9 - Electrical Testing switches: • Some Cub cadet switches contain more than one pair of contacts. The same switch housing • Refer to the “COMPONENTS” section of this can contain normally open and normally closed chapter that describes the function of the individ- switch elements.
Page 317 Chapter 9 - Electrical • Which way does this electrical check-valve 13f. Switch the leads. work?: There will be a band on one end of the 13g. The meter should indicate no continuity. diode. The band indicates the negative side of See Figure 9.79.
Page 318 Chapter 9 - Electrical Electrical Schematic: Main Wiring Harness w/Kohler engine 725-04351 / 725-04365...
Page 319 Chapter 9 - Electrical Electrical Schematic: Engine Harness w/Kohler engine...
Page 320 Chapter 9 - Electrical Electrical Schematic: Main Harness w/Caterpillar engine 725-04327 / 725-04365...
Page 321 Chapter 9 - Electrical Electrical Schematic: Engine Harness w/Caterpillar engine 725-04341...
Page 322 Chapter 9 - Electrical...
Page 323 Front Drive System Differential Gearcase P/N 6203-01-280 Parts and Service Manual Rev. 0 Released 1/16/2012...
Page 324: Specifications
Basic Operation: The Hilliard Front Drive System (Differential) is an electro-mechanically-activated bi-directional overrunning clutch. When 12 volts of power is sent to the 4WD switch, the unit is activated to engage both front wheels instantaneously, whenever the rear wheels loose traction. The clutch also releases or overruns automatically the instant the rear wheels regain traction.
Page 325: Troubleshooting
Troubleshooting: Problem: 4WD will not engage Check the minimum battery voltage going to the CFD Gearcase. The voltage should not read below 11 volts for the unit to operate properly. If the voltage is at or above 11 volts, continue on to step #2. Check the resistance of the coil harness on the large output cover.
Page 326 flat surface or granite block and making sure the plate does not rock. If the armature plate wear is consistent and the plate is flat, continue on to step #2. Clean and inspect the internal clutch components. Slowly remove the roll cage (part #22) from the clutch housing/ring gear (part #20).

This manual is also suitable for:

Poly bed 4x2 Steel-bed 4x2 4x4

Cub Cadet 6X4 Shop Handbook

Chapter 1: Introduction

Chapter 2 - Drive Sytem: CVT and Transfer Case

Chapter 3 - Drive System: Drive Shafts and Differentials

Chapter 4 - Front Suspension and Steering

Chapter 5 - Rear Suspension

Chapter 6 - Hydraulic Brakes

Chapter 7 - Kohler Engine Service Access and Fuel System

Chapter 8 - Caterpillar Engine and Related Systems

Chapter 9 - Electrical

Quick Links

Troubleshooting

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Summary of Contents for Cub Cadet 6X4

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Table of Contents