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Cub Cadet 900 series Professional Shop Manual Download Page 82

CVT Drive and brake system

76

4c.

Lift the pulley far enough to allow the belt 
to clear the belt keepers. See Figure 6.61.

4d.

The slack created will allow the upper belt 
to slip easily out of the top sheave of the 
variable speed pulley and off of the trans-
mission input pulley. See Figure 6.62.

4e.

Withdraw the belt through the battery 
opening under the seat.

5.

Remove the lower (front) drive belt:

5a.

Slip the belt off of the two tensioner pul-
leys. See Figure 6.63.

5b.

Roll the belt off of the lower sheave of the 
variable speed pulley. See Figure 6.64.

NOTE: 

The belt can be walked-up from the 

lower sheave to the upper sheave, then off.  
Rotate the variable speed pulley to help slip the 
belt past the belt keepers.

Figure 6.61

   Tension idler pulley

Rear drive belt

Figure 6.62

    

Variable speed pulley

                                  Upper belt

Figure 6.63

Figure 6.64

Lower belt

Variable speed pulley

Summary of Contents for 900 series

Page 1: ...ntents of the product s Oper ators Manual supplied with the equipment No liability can be accepted for any inaccuracies or omission in this publication although care has been taken to make it as complete and accurate as possible at the time of publication However due to the variety of outdoor power equipment and continuing product changes that occur over time updates will be made to these instruct...

Page 2: ......

Page 3: ...rill removal 17 Hood components pivot bracket removal 18 Seat and Fenders 18 Dash Panel 25 Chapter 5 Hydro Drive and brake system 29 About this chapter 29 Externally repairable drive system problems 29 Indications that a transaxle is not warrantable 34 Brake adjustment 34 Neutral control adjustment 36 Linkage pedal shaft 37 Pedal shaft assembly removal 38 Belt control tensioner and idler pulleys 4...

Page 4: ...ule 96 RMC module plug test electric PTO 97 RMC module plug test manual PTO 99 Electric PTO switch 101 PTO relay 102 PTO switch manual PTO 102 Brake switch manual PTO 103 Brake switch electric PTO 104 Park brake switch 104 Reverse Safety Switch 105 Seat Safety Switch 106 Starter solenoid 106 Fuse 107 Electrical environment AC Vs DC 109 Types of circuits 112 Series 112 Parallel 112 Series parallel ...

Page 5: ...Timing belt 139 Leveling the deck 141 Side to Side Leveling 141 Front To Rear Leveling 141 Deck Wheel Adjustment 142 Deck lift shaft assembly bushings 143 Deck lift shaft assembly removal replacement 143 Deck lift links and cables 144 Chapter 9 Maintenance intervals 147 Lubrication 147 Engine maintenance 147 The spark plug s 147 Air filter and foam pre cleaner 148 Oil change 148 Fuel system 149 Se...

Page 6: ......

Page 7: ... If the person using this manual is uncomfortable with any procedures they encounter they should seek the help of a qualified technician or Cub Cadet Technical Support Fasteners Most of the fasteners used on the tractor are sized in fractional inches Some are metric For this reason wrench sizes are frequently identi fied in the text and measurements are given in U S and metric scales If a fastener...

Page 8: ...the seat See Figure 1 2 The serial number is located to the right of the model number as shown above See Figure 1 2 The model number is 13AX90AR010 The break down of what the number mean is as follows 13 lawn tractor A sales level X engine code 9 tractor series 0 drive system A hood style R deck 010 customer number The serial number is 1J078H30003 The serial number reads as follows 1 engineering l...

Page 9: ...e hood and bumper by following the steps described in Chapter 4 Body Chassis 2 Remove the two screws on each side that secure the muffler guard bracket See Figure 2 1 Figure 2 1 Remove these screws 3 Disconnect the muffler from the engine For single cylinder engines Remove the two screws that secure the exhaust pipe to the cylinder head See Figure 2 2 Remove the screw that fastens the muffler sup ...

Page 10: ... Rotate the muffler out of the muffler cover See Figure 2 5 6 With the muffler on a work bench remove the four screws that hold the muffler deflector to the muffler See Figure 2 6 7 Install the muffler by following the above steps in reverse order 8 Test run the tractor before returning to service Figure 2 4 Remove these nuts Figure 2 5 Figure 2 6 Remove these screws Muffler deflector ...

Page 11: ... container 1 Open the hood 2 Drain the fuel in the fuel tank into an approved container NOTE The tank may be drained by mechanical syphon or by disconnecting the fuel line from the fuel filter 3 Remove the four screws that secure the fuel tank support rod See Figure 2 7 Hair pin clip Deck lift cable Figure 2 7 Remove the screws 4 Work the fuel tank support bracket off of the trac tor 5 Slide the f...

Page 12: ...ENGINE RELATED PARTS 6 ...

Page 13: ...the steering wheel and reinstall it so that it is Figure 3 1 Center the steering gear 5 In front of the axle measure the distance hori zontally from the inside of the left rim to the inside of the right rim See Figure 3 2 6 From behind the axle measure the distance hor izontally from the inside of the left rim to the inside of the right rim 7 The measurement taken in front of the axle should be be...

Page 14: ...is more than a couple turns differ ence then one or both of the drag links are bent 15 Secure the right hand ball joint to the right hand axle assembly with the lock washer and nut removed earlier using a 1 2 wrench and a 9 16 socket 16 Secure the right hand ball joint jam nut to the right hand drag link using a 1 2 wrench and an 11 16 wrench 17 Install the left hand ball joint using steps 14 15 a...

Page 15: ...ng in the 2010 season some trac tors will be equipped with a stamped pivot bar These tractors will have plastic bushing where the axle rides inside the pivot bar See Figure 3 8 NOTE The procedure to remove this axle is the same as previously described When installing the axle install new upper and lower bushings 7 Install the axle by following the previous steps in reverse order 8 Perform a wheel ...

Page 16: ...teer ing pinion gear to the steering shaft using an 11 16 socket See Figure 3 9 4 Slide the steering pinion gear off of the steering shaft 5 Lift up on the steering shaft and remove the washer See Figure 3 10 6 Push the steering shaft up through the frame of the tractor 7 Remove the hex bushing See Figure 3 11 8 Remove the drag links from the steering gear 9 Remove the six screws that secure the s...

Page 17: ...ring plate Figure 3 14 12 Remove the bolt that the steering gear pivots on using two 9 16 wrenches See Figure 3 13 NOTE When installing the steering gear coat the steering gear and the steering plate with a high quality lithium grease 13 Install the steering and steering pivot gears by following the previous steps in reverse order 14 Perform a wheel alignment by following the steps described in th...

Page 18: ...er ing wheel See Figure 3 16 3b Remove the bolt that holds the steering wheel to the steering shaft using a 1 2 wrench 3c Lift the steering wheel off of the steering shaft 4 Remove the flange lock nut securing the steer ing pinion gear to the steering shaft using an 11 16 socket See Figure 3 17 NOTE If the steering shaft rotates while remov ing the nut insert a pin punch or a 2 phillips screwdrive...

Page 19: ...om the steering gear Figure 3 18 Lift up on the steering shaft Remove the washer Figure 3 19 Remove the hex bushing 10 Remove the six screws that secure the steering plate to the frame See Figure 3 12 11 Remove the steering plate NOTE The steering shaft will come out with the steering plate 12 Install the steering shaft by following the above steps in reverse order 13 Test run the tractor in a saf...

Page 20: ...when installing the pivot bar See Figure 3 22 NOTE Starting in the 2010 season there will be a stamped pivot bar on some models The pro cedure to remove it is the same as the cast iron pivot bar described in the previous steps See Figure 3 23 7 Install the pivot bar by following the previous steps in reverse order NOTE Apply high quality grease to the frame spacer and the pivot bar 8 Preform a whe...

Page 21: ...e hood described in this section is the A style hood Other styles may be produced for different markets e g over seas or future style changes See Figure 4 1 Figure 4 1 A style hood Hood Hood removal 1 The hood is front hinged See Figure 4 2 2 Open the hood by lifting the rear edge to tilt it for ward 3 Disconnect the headlight wires See Figure 4 3 NOTE The ground terminals and power termi nals on ...

Page 22: ...ase it from the grill assembly See Figure 4 5 2 Rotate the bulb to release it from the socket See Figure 4 6 3 Install the replacement lamp following the above steps in reverse order Hood components side vent removal 1 Carefully pry the vent free of the lock tabs 2 Pull the vent out of the hood assembly 3 Install the hood side vent by pressing it into the hood side opening until the lock tabs clic...

Page 23: ...l Slotted mounting hole Screw washer Figure 4 9 Pivot bracket Large Screws Hood Grill 4 Once removed the headlight lens may be removed for cleaning by carefully prying the two lock tabs at the inner edge See Figure 4 10 NOTE The locating tab at the outer edge of each lens has no locking feature NOTE Replacement lenses are not presently available 5 Assemble and install the grill by reversing the st...

Page 24: ... one for the deck height control and one for the PTO Electric PTO models have one lever on the right fender to control the deck height CVT drive tractors single speed transmission variable speed pulleys use fenders with a single pedal opening on each side clutch brake on the left drive pedal on the right In addition a for ward neutral reverse lever is on the left fender Hydrostatic drive tractors ...

Page 25: ... torque of 60 80 in lbs 7 9 N m 1b Remove the locking bolt using a 9 16 wrench See Figure 4 15 Figure 4 14 cable battery Negative Figure 4 15 Locking bosses Bolt 1c Slide the seat forward to the end of its travel then lift it up to disengage the slide blocks from the T slots See Figure 4 16 1d Disconnect the seat safety switch from the harness plug to remove the seat 1e Lift the seat off of the tr...

Page 26: ...int on hydrostatic transaxles Electrical Solenoid main fuse battery cables Drive belt inspection Deck lift linkage inspection 2a Disconnect the positive battery cable from the battery the negative battery cable was disconnected in an earlier step See Figure 4 19 2b Remove the battery hold down by prying the end of the hold down out of the U shaped slot 2c Lift the battery out of the tractor See Fi...

Page 27: ...stead of a nut and bolt 3 Remove the grips from the fender mounted con trol levers 3a Pull the shift knob off of the forward neutral reverse lever on CVT equipped tractors See Figure 4 22 Figure 4 21 Figure 4 22 lever F N R 3b If the tractor has a deck lift assist spring remove the deck or lift the mower deck to the highest position and support it with wood blocks See Figure 4 23 NOTE Tractors equ...

Page 28: ...rs may be inserted into the small hole at the end of a rubber grip to inflate it slightly easing removal See Figure 4 26 4 Remove the rubber foot pads See Figure 4 27 5 Remove the drive pedals 5a Remove the reverse pad from the drive pedal hydrostatic drive tractors only See Figure 4 28 Figure 4 25 PTO lever Deck height lever Figure 4 26 Air blow gun Figure 4 27 Figure 4 28 Reverse pedal pad ...

Page 29: ...ck the back edge is closer to the fasteners that are concealed by the label Use wax paper to preserve the adhesive Figure 4 29 Drive pedal Drive linkage Figure 4 30 Bolts under label Wax paper 6b Remove the two bolts that are found under the label using a 3 8 wrench 6c Remove the four bolts that hold the fender to the seat box portion of the frame using a 1 2 wrench See Figure 4 31 6d Remove the n...

Page 30: ...33 NOTE The handle assemblies can be removed from the rear fenders using a 3 8 wrench from beneath the fender See Figure 4 34 NOTE With the handle assembly removed the steel reinforcement plate can be unbolted from the top side of the fender using a 3 8 wrench See Figure 4 35 Figure 4 33 Rubber bushing Steel spacer Figure 4 34 Screws that hold the handle assembly Steel reinforcement plate Figure 4...

Page 31: ...mable and steps should be taken to avoid fire hazard Work in a well ventilated area Allow the engine to cool fully before starting work on the tractor Eliminate any sources of possible ignition from the work area including but not limited to heat sources open flame potential sparks Clean up any spilled fuel quickly and properly disposing of cleaning materials in a way that will not produce a furth...

Page 32: ...ot allow fuel to spill See Figure 4 40 4 Disconnect the harness plugs from the following electrical devises under the dashboard See Figure 4 41 Hour meter Key switch RMC module PTO switch if so equipped 5 Use a phillips head screwdriver to remove the throttle control grip See Figure 4 42 6 Carefully peel off the throttle control label Gentle application of heat will help loosen the adhesive Use wa...

Page 33: ...rod to the engagement lever assembly See Figure 4 44 Figure 4 43 Figure 4 44 10 Disengage the rod from the lever assembly NOTE The rod is kept in slight tension by a light spring that hooks between the frame and the step in the middle of the rod See Figure 4 45 11 Remove the screws that hold the inside mount ing ears of the dash panel to the dash support brackets using a 3 8 wrench See Figure 4 46...

Page 34: ...re 4 47 13 Lift the dash panel off of the tractor See Figure 4 48 14 Assembly notes Assemble tractor by reversing the disassembly process Tighten fasteners to a torque of 20 22 in lbs 2 25 2 50 N m Test all tractor controls and features before returning the tractor to service Figure 4 47 Tor XTM head screw Hex head cap screw Figure 4 48 ...

Page 35: ...rnal the transmission is to be removed repaired and reinstalled unless the cost of repair exceeds 70 of the price of a new replacement transaxle If Hydro Gear transaxle is replaced under war ranty the original transaxle will be called back for evaluation and vendor recovery Warranty Claims will be denied returned or adjusted if the returned transaxle does not meet Cub Cadet s replacement criteria ...

Page 36: ...orce to move the by pass arm fully into the release position If the by pass linkage is working correctly con firm that the brakes are releasing fully 4 Check the brakes See Figure 5 3 4a The brake linkage applies the brakes and disengages the drive belt Confirm that both parts of the linkage are moving properly When the brake pedal is released the transmis sion drive belt should be under tension I...

Page 37: ...re 5 4 Brake return spring Travel stop Brake arm Actuator spring Figure 5 5 Left foot on clutch brake pedal Right foot on Reverse pedal Operator error 5 Check the drive belt See Figure 5 6 In normal use drive belts typically last for years without problems If the belt fails prematurely identify and correct the cause of the belt failure before returning the tractor to service 5a Look up the part nu...

Page 38: ...otion that would effect the ground speed of tractor are See Figure 5 9 The drive pedal itself being loose on the bracket Worn plastic bushings between the drive pedal bracket and the brake cross shaft 6d If the tractor makes drive noise or creeps while the pedal is in neutral but seems to have lost speed in just one direction for ward or reverse The rod connecting the pedal bracket to the arm on t...

Page 39: ...s probably a leak that needs to be found and repaired If the fluid is too full it will drain into the catch tank Figure 5 11 Fill port Expansion tank 8 Transaxle mounting 8a The primary symptoms of a transaxle that is loose in the frame are that it will lose drive or throw off the drive belt in reverse 8b Check the torque bracket and the axle mounting points at the frame See Figure 5 12 9 Eliminat...

Page 40: ...think it has been used pretty heavily even if the hour meter has been unplugged Bent axle broken housing or other obvious signs of impact damage Contaminated fluid or low fluid Damage to the cooling fan Enough dirt or debris on the transaxle to prevent the it from cooling properly Indication that the tractor has been over loaded Brake adjustment 1 Test the operation of the brakes 1a Disengage the ...

Page 41: ...e is a moving pad in the brake caliper Wiggle the brake rotor slightly and attempt to insert a 015 38mm feeler gauge between the rotor and either pad 2c Adjust the gap if necessary so that the feeler gauge slips between the pad and the rotor with light pressure See Figure 5 16 If adjustment is necessary remove and discard the cotter pin that locks the adjusting nut Turn the nut to adjust the gap A...

Page 42: ...a 1 2 wrench SLTX tractor drive wheels are hub mounted Remove the lug nuts using a 3 4 wrench 4 By pass the seat safety switch See Figure 5 17 4a Remove the seat from the tractor 4b Disconnect the seat safety switch NOTE This procedure is described in Chapter 4 Body Panels 5 Confirm that the linkage is in the neutral position The roller on the control arm must be centered in the elbow of the contr...

Page 43: ...n the bolt to a torque of 12 15 ft lbs 16 20 N m 14b Tighten the lugs on the SLTX tractors to a torque of 30 42 ft lbs 41 57 N m 15 Test the drive system and all safety features before returning the unit to service Linkage pedal shaft Description The Clutch brake pedal and the drive con trol pedal operate on two concentric shafts The clutch brake shaft runs the full width of the tractor The drive ...

Page 44: ...e 5 22 Remove and discard the cotter pin to disconnect the rod 4 Remove the locking clip that holds the travel limit pin in place 5 Withdraw the travel limit pin See Figure 5 23 6 Unhook the clutch brake pedal return spring See Figure 5 24 7 Remove and discard the push cap that holds the drive control pedal shaft onto the clutch brake shaft See Figure 5 25 Figure 5 22 Clutch brake shaft Rod Figure...

Page 45: ...re 5 27 Remove and discard the cotter pin Unhook the drive control rod Figure 5 26 Left pedal shaft support strap Figure 5 27 Drive control rod Drive pedal latch plate 11 Allow the drive pedal shaft to rotate down then pull it off of the pedal shaft assembly See Figure 5 28 12 Disconnect the brake rod from the clutch brake latch plate See Figure 5 29 Remove the cotter pin and flat washer to discon...

Page 46: ...re worn or damaged See Figure 5 32 The plastic bushings that fit between the two pedal shafts should be replaced any time they are removed Lubricate them with a dry PTFE or graphite based lubricant on assembly NOT grease Replace the push cap and all removed cotter pins with new parts 15 Install the pedal shaft assembly by reversing the steps used to remove it then install the fenders 15a Lubricate...

Page 47: ...g the tractor to service Figure 5 34 Belt control tensioner and idler pulleys NOTE The V idler pulleys can be removed from below using a 1 2 wrench with no disassembly beyond removing the cutting deck See Figure 5 35 NOTE Confirm that the parking brake is released before starting work 1 Remove the mowing deck 2 Remove the fenders by following the steps described in Chapter 4 Body Panels 3 Disconne...

Page 48: ...a pair of 9 16 wrenches See Figure 5 38 7 Maneuver the belt tensioner bracket assembly to clear the belt and remove it from the tractor See Figure 5 39 NOTE The bracket assembly pivots on the bolt that passes through the fixed flat sheave idler pulley 8 On the bench the flat sheave idler pulley and the spacers used to position it can be lifted off of the pulley bracket See Figure 5 40 Figure 5 37 ...

Page 49: ...t using a 1 2 wrench Figure 5 41 Shoulder height Figure 5 42 Flat surface Hex bushing Shoulder bushing Bolt Flat sheave pulley 10 The rod that connects the bracket to the clutch brake pedal shaft can be maneuvered to come out of its slot in the bracket See Figure 5 43 11 Assemble and install the belt tensioner pulley by reversing the steps used to remove and disas semble it Lubricate the pivot poi...

Page 50: ...ures described in Chapter 4 Body Panels See Figure 5 44 4 Remove drive belt from the transaxle pulley See Figure 5 45 4a Remove the nut using a 3 4 wrench An impact wrench with a socket will be most effective 4b Lift off the cooling fan 4c Remove the pulley The belt will clear the belt keepers on top of the transaxle as the pulley comes up See Figure 5 46 NOTE Correct orientation of input pulley S...

Page 51: ...te 7 Remove the single fixed idler from the frame of the tractor using a 1 2 wrench See Figure 5 50 8 Remove the belt keeper near the engine pulley or electric PTO clutch using a 1 2 wrench 8a With manual PTO a single bolt holds the belt keeper to the frame to the left side of the engine See Figure 5 51 Figure 5 50 Belt keeper pin Fixed idler Figure 5 51 Belt keeper Bolt Shoulder fits through hole...

Page 52: ...engine crankshaft The belt will clear the belt keepers as the pulley comes down See Figure 5 53 9c Remove the belt 10 Lower the engine pulley to remove the belt manual PTO 10a Disconnect the PTO clutch electrical plug from the harness See Figure 5 54 10b Remove the bolt that holds the PTO clutch to the engine crankshaft using a 5 8 wrench See Figure 5 55 NOTE An impact wrench and socket will be mo...

Page 53: ...crankshaft See Figure 5 58 11 If the drive belt failed prematurely identify and correct the cause of the failure before installing a new belt 12 Install the new belt by reversing the steps used to remove it Belt installation notes Install only a correct OEM belt Incorrect belts may cause problems that effect the performance and or safety of the tractor Apply a small amount of anti seize compound t...

Page 54: ...rain and fill in a reasonable amount of time CAUTION The battery will be removed in this procedure Review the Operator s Manual and the Electrical chapter of this manual for impor tant safety information about handling batteries before proceeding 1 Allow the drive system to cool before starting work on the tractor 2 Remove the battery and battery tray by following the procedures described in Chapt...

Page 55: ...he drive pedal 6 times from full forward to full reverse taking about 10 seconds to complete a stroke 11d Close the by pass valve 11e Slowly cycle the drive pedal 6 times from full forward to full reverse taking about 10 seconds to complete a stroke 11f Turn the engine off 11g Check the fluid level and add fluid if nec essary to bring the level within 1 1 4 of the top of the casting 11h Close the ...

Page 56: ... a 3 8 wrench See Figure 5 66 4 Slip the return to neutral spring off of the spacer on the front bolt 5 The yoke and outer pad will separate from the transaxle See Figure 5 67 6 Inside the brake yoke A steel backing plate fits between the friction pad and the actuator pins The pins fit into holes in the brake yoke housing The brake arm acts as a cam pushing the pins when it rotates A small compres...

Page 57: ...rake yoke bolts Tighten the brake yoke bolts to a torque of 80 to 120 in lbs 9 to 14 N m 9 Adjust and test the brakes after any work on brake system Figure 5 69 Brake pad Brake rotor By pass arm Transaxle removal and replacement CAUTION The battery will be removed in this procedure Review the Operator s Manual and the Electrical chapter of this manual for impor tant safety information about handli...

Page 58: ...m See Figure 5 73 NOTE There is a second shorter return to neu tral spring that stretches between the cam and the grooved spacer on the front mounting bolt of the brake yoke 7 Release the parking brake 8 Lift and safely support the tractor The rear of the tractor should be high enough to allow the transaxle to pass under it 9 Remove the rear wheels If the tractor has Dou ble D axles remove the whe...

Page 59: ... it can be lowered out of the tractor in a controlled fashion Figure 5 76 Drive control rod Trunnion arm Spring Cotter pin Figure 5 77 release rod Transmission Spring By pass arm 14 Remove the torque bracket bolts using a 1 2 wrench See Figure 5 78 15 Take the nuts off of the T bolts that hold the tran saxle to the frame using a 1 2 wrench See Figure 5 79 NOTE At this point the brake actuator spri...

Page 60: ... as needed 19 On the bench 19a The top of the reverse safety switch is held against the trunnion arm by the post on the drive control rod See Figure 5 82 NOTE The post passes through a round hole in the switch plate and an oblong hole in the trun nion arm 19b The bottom of the reverse safety switch fits into a T slot in the trunnion arm See Figure 5 83 Figure 5 80 Figure 5 81 Large r t n spring Br...

Page 61: ... into the tractor 20d Connect both ends of the brake actuator spring before lifting the transaxle back into the tractor 20e Lube the Double D axle shaft before install ing the wheels 20f The spring in the by pass linkage hooks downward into the transmission release rod 20g Tighten fasteners according to the accom panying torque table 20h Fully purge the drive system before operat ing the tractor 2...

Page 62: ...HYDRO DRIVE AND BRAKE SYSTEM 56 ...

Page 63: ...ers are encouraged to open transaxles for inspection allowing them to identify a problem within the transaxle Beyond warranty dealers are free to repair transmissions at customer expense If the dealer has questions regarding transaxle replacement they should call Cub Cadet Ser vice using the dealer only line before proceed ing About the variable speed drive system There are two drive belts in the ...

Page 64: ...re trying to diagnose drive system problems 2 Check the tires Confirm that the correct size tires are on the tractor Smaller rear tires will yield lower ground speed Under filled tires will put additional load on the drive system LTX 1040 Series has 20 x 8 rear tires LTX 1050 Series has 20 x 10 rear tires SLTX 1050 Series has 22 x 9 5 rear tires 3 Check the brakes See Figure 6 2 3a The brake linka...

Page 65: ...ch linkage and belt tensioning pulleys 4d Check for foreign objects jammed against the belt 4e Check for missing or out of place belt guides See the belt replacement section of this chapter 4f Check the engine crankshaft and transaxle input pulleys Confirm that the sheaves are not spread out causing a loose belt fit Figure 6 4 5 Check the drive control linkage See Figure 6 5 5a The travel limit pi...

Page 66: ... the tractor is out of warranty Abnormally high wear indicators for the age of the tractor usually consistent with high hours of usage As an example if the tires are com pletely worn out on a tractor that is 6 months old it is reasonable to think it has been used pretty heavily even if the hour meter has been unplugged Bent axle broken housing or other obvious signs of impact damage Contaminated f...

Page 67: ... released position Figure 6 10 Brake spring Brake rod 2b Check the gap between the brake rotor and the brake pads There is a fixed pad in the transaxle housing There is a moving pad in the brake caliper Wiggle the brake rotor slightly and attempt to insert a 010 38mm feeler gauge between the rotor and either pad 2c Adjust the gap if necessary so that the feeler gauge slips between the pad and the ...

Page 68: ... reverse safety switch tang when the tractor is in reverse The linkage is adjustable 1 To adjust the linkage put the gear selector in neutral position 2 Confirm that the tractor is in neutral by releasing the brakes and rolling it back and forth 3 Loosen the adjustment bolt using a 1 2 wrench See Figure 6 14 4 Check that the gear selector handle is fully seated in the N notch on the fender See Fig...

Page 69: ...r may not have it s full range of ground speeds Link too long The tensioner pulley control rod may also need to be adjusted after the drive belts are replaced Figure 6 16 tensioner pulley control rod To check and adjust the link 1 Set the belts to their lowest speed position 1a Start the engine 1b Place the gear selector in Neutral and release the brake pedal 1c Depress the drive pedal to the end ...

Page 70: ...st run the tractor to confirm that the drive and brake systems work correctly before reinstalling the mowing deck 13 Test run the tractor again after the mowing deck is installed and confirm that all of the safety fea tures work properly Linkage pedal shaft Description The Clutch brake pedal and the drive con trol pedal operate on two concentric shafts The clutch brake shaft runs the full width of...

Page 71: ... locking clip that holds the travel limit pin in place 5 Withdraw the travel limit pin See Figure 6 22 Figure 6 21 Clutch brake shaft Rod Figure 6 22 Travel limit pin 6 Unhook and remove the clutch brake pedal return spring 7 Remove the cotter pin and flat washer that hold the brake rod into the latch plate Discard the cotter pin 8 Remove and discard the cotter pin that holds the tensioner pulley ...

Page 72: ...of the brake pedal shaft to the tensioner pulley bracket will slip free 13 Remove the bolt from the left side pedal shaft support strap and remove the pedal shaft assembly from the tractor See Figure 6 27 14 Disconnect the cobra head rod from the pedal shaft tie plate See Figure 6 28 Slip the tie plate off of the cobra head rod Push the hex bushing out of the big end of the pedal shaft tie plate T...

Page 73: ... the push cap and all removed cotter pins with new parts Figure 6 29 Drive control pedal shaft Cobra head Bushings Brake pedal shaft 17 Install the pedal shaft assembly by reversing the steps used to remove it then install the fenders NOTE The pedal shaft support straps are two different sizes The smaller strap holds up the left brake pedal end of the pedal shaft assem bly The larger strap holds u...

Page 74: ... rod 17f Attach the belt tensioner pulley control rod 18 Test the drive system and all safety features before returning the tractor to service Linkage pedal tie strap NOTE If there is reason to remove the pedal tie strap it can be taken off without further disas sembly of the pedal shaft The most likely rea son for this would be the discovery of damage to the plate or hex bushing while making an a...

Page 75: ...tem is working correctly before returning it to service Figure 6 35 Hex bushing Figure 6 36 Belt control tension make up pulley CAUTION The battery will be removed in this procedure Review the Operator s Manual and Chapter 7 Electrical Systems for important safety information about handling batteries before proceeding 1 Remove the upper drive belt from the make up tensioner pulley as described in ...

Page 76: ...ed in this procedure Review the Operator s Manual and Chapter 7 Electrical Systems for important safety information about handling batteries before proceeding 1 Remove the battery and battery tray by following the procedures described in Chapter 4 Body Panels See Figure 6 41 2 Disconnect the lateral spring from the frame relieving tension from the make up pulley 3 Roll the upper drive belt off of ...

Page 77: ...ut of the tractor Figure 6 43 Variable speed pulley Bracket bolts Figure 6 44 Variable speed pulley bracket bolts 9 Bench repairs 9a Clamp the pulley and bracket assembly into a vise gripping the center shaft of the variable speed pulley 9b Use a 1 2 wrench to remove the pulley bolt See Figure 6 45 9c Lift the bracket belt keeper and bearing holder off of the pulley 9d Clamp the variable speed pul...

Page 78: ...iable speed pulley bolt Tighten the bolt to a torque of 150 180 in lbs 17 20 N m Tighten the bearing holder screws to a torque of 90 135 in lbs 10 15 N m 11 Run and test the drive system before returning the tractor to service Belt control tensioner pulleys NOTE The V pulley can be removed from below using a 1 2 wrench with no disassembly beyond removing the cutting deck See Figure 6 48 NOTE Confi...

Page 79: ...ee Figure 6 51 6 Note the belt routing then slip the drive belt off of the two pulleys on the tensioning bracket Figure 6 50 Return spring Figure 6 51 7 Remove the nut and bolt that hold the belt ten sioner pulley bracket to the frame using a pair of 9 16 wrenches See Figure 6 52 8 Maneuver the belt tensioner bracket assembly to clear the belt and remove it from the tractor See Figure 6 53 NOTE Th...

Page 80: ...tensioner pulley can be un bolted from the bracket using a1 2 wrench 11 The rod that connects the bracket to the clutch brake pedal shaft can be maneuvered to come out of its slot in the bracket See Figure 6 57 12 Assemble and install the belt tensioner pulley by reversing the steps used to remove and disas semble it Lubricate the pivot point with a good quality lith ium base grease 13 Reinstall t...

Page 81: ...ve system counts on an unusual cross section shape of the belts Use of a wrong belt will very likely cause the tractor not to drive properly Check the tensioner pulley control rod adjust ment after replacing belts 1 Remove the mowing deck 2 Set the park brake to release belt tension 3 Remove the battery and battery tray by following the procedures described in Chapter 4 Body Panels See Figure 6 58...

Page 82: ...ttery opening under the seat 5 Remove the lower front drive belt 5a Slip the belt off of the two tensioner pul leys See Figure 6 63 5b Roll the belt off of the lower sheave of the variable speed pulley See Figure 6 64 NOTE The belt can be walked up from the lower sheave to the upper sheave then off Rotate the variable speed pulley to help slip the belt past the belt keepers Figure 6 61 Tension idl...

Page 83: ...See Figure 6 65 C Work the belt past the PTO pulley and with draw it from the front of the tractor See Figure 6 66 Figure 6 65 Upper belt Crankshaft pulley Figure 6 66 Electric PTO A Remove the belt keeper near the crank shaft using a 1 2 wrench One bolt holds the belt keeper to the frame to the left side of the engine A nut holds the belt keeper to the right side frame channel NOTE The electric P...

Page 84: ... The belt will clear the belt keepers as the pulley comes down See Figure 6 71 F Withdraw the belt from the front of the trac tor NOTE The flat edge of the crankshaft pulley faces the electric PTO clutch The end with the inside diameter chamfered goes against the fillet near the base of the crankshaft See Figure 6 72 NOTE If the drive belt failed prematurely iden tify and correct the cause of the ...

Page 85: ...ghly test the operation of the drive sys tem and all safety features before returning the tractor to service Figure 6 73 Belt routing Transaxle removal and replacement CAUTION The battery will be removed in this procedure Review the Operator s Manual and the Electrical chapter of this manual for impor tant safety information about handling batteries before proceeding 1 Remove the upper drive belt ...

Page 86: ...as Dou ble D axles remove the wheel spacers too See Figure 6 77 7 Disconnect the forward neutral reverse gear selector rod from the transmission by removing the hair pin clip See Figure 6 78 8 Disconnect the forward neutral reverse gear selector rod from the gear selector by rotating the rod 90 degrees The coined ears on the rod will align with notches in the selector and the rod can be pulled fre...

Page 87: ...the brake actuator spring is still attached to the brake rod from the pedal shaft and the brake arm on the transaxle Figure 6 80 Torque bracket bolts Figure 6 81 T bolts 12 Carefully lower the transaxle out of the tractor See Figure 6 82 13 Move the transaxle forward to make some slack in the brake linkage Use the slack to unhook the brake spring from the brake rod See Figure 6 83 Figure 6 82 Figu...

Page 88: ...fore returning the tractor to service Transaxle repair 1 Assess the damage from the outside See Figure 6 85 1a If the tractor is within the warranty period is the damage consistent with a warrant able failure 1b If the tractor is beyond the warranty period is the transaxle feasible to repair 1c Are the axles bent 1d Is the housing broken from the outside in 1e Is the housing broken from the inside...

Page 89: ...rn the transaxle upside down to remove the detent ball and spring See Figure 6 87 Figure 6 86 Shift shaft Pillow block Figure 6 87 Detent ball Detent spring Detent screw Detent screw hole 6 Disassemble the brake 6a Unhook and remove the brake spring See Figure 6 88 6b Unbolt the brake yoke from the transaxle using a 3 8 wrench See Figure 6 89 Figure 6 88 Figure 6 89 Brake yoke ...

Page 90: ...axle housing to the lower transaxle housing using a 3 8 wrench 8 Separate the two housings See Figure 6 92 NOTE The axle shafts will generally be of differ ent lengths Mark or note the orientation of the differential and axle assembly to the transaxle housing before removing it 9 Lift the axle and differential housing out of the transaxle See Figure 6 93 10 Note the positions of the shim washers F...

Page 91: ... warranty related autopsy iden tify the root cause of the problem If it is not something that was done wrong at the fac tory the problem is not warrantable NOTE Cub Cadet does not have a part number for water and it is not installed at the factory Figure 6 94 Differential and axle assembly 13 Lift the bevel gears out of the transaxle for disas sembly and mostly visual inspection See Figure 6 95 13...

Page 92: ...rebuilt 14d If the transaxle is being warranted leave the grease and debris in place after the root cause of the failure is identified 14e If the transaxle is repaired the damage is isolated and the grease is not contami nated with anything it is acceptable to re use the grease See Figure 6 97 15 Inspect the pinion gear and input shaft assem bly See Figure 6 98 15a The pinion gear teeth should not...

Page 93: ...sary to fully disassemble the tran saxle to identify the damage or find the root cause of a warrantable failure At this point of disassembly or some point earlier in the process the technician should be able to make an assessment of whether it is feasible to repair the tran saxle It should also be possible to positively identify what went wrong in a warrantable transaxle replace ment If the transa...

Page 94: ...everse are functional references The reverse bevel gear is nearest the reduction gear while the forward gear is nearest the brake rotor spline 19c Re install the shims in their original loca tions on the bevel gear shaft 19d Smear some DurinaTM grease on the sur faces of the shaft that will ride in the flange bearings 19e Install new bevel gear shaft bearings with their flanges facing the shims Se...

Page 95: ...ntial and the reverse gears as close together as they will go while remaining properly seated in the housing 22 Confirm that there is at least 030 762mm between the rivet heads on the differential and the back side of the reverse gear See Figure 6 108 23 Collective axle end play the amount one axle shaft moves when the opposite axle is pushed should be between 010 080 25 2 0mm 24 Adjust the shims ...

Page 96: ...n lbs 10 15 N m 33 Install the detent ball spring and screw 34 Tighten the detent screw to a torque of 160 200 in lbs 18 23 N m 35 Assemble the brake yoke 35a Apply a small amount of anti seize com pound to the brake rotor splines and to the actuator pins in the brake yoke CAUTION Do not get anti seize on the friction surfaces of the brake 35b Install the steel backing plate against the pins then ...

Page 97: ...148 2X 20 fl oz 0 59 liters Brake clearance 010 015 25 38mm Table 2 Drive System Torque Specs Fastener Torque in lb Torque N m Seat bolt 60 80 17 20 Lug nut 350 500 41 57 Wheel bolt 160 190 18 22 Crankshaft bolt 450 600 51 68 Tq bracket bolt 175 250 20 28 Axle T bolt nuts 150 180 17 20 Tensioner bracket 150 180 17 20 Pedal shaft straps 150 180 17 20 Belt keeper nut bolt 150 180 17 20 Idler pulley ...

Page 98: ...CVT Drive and brake system 92 ...

Page 99: ...ctronic circuits burning out the module NOTE These tools are not outrageously expen sive or exotic High impedance test lights Thex ton model 125 is typical can be purchased locally from stores like NAPA for under 30 00 Appropriate multi meters can be purchased for under 100 00 and are an invaluable tool for any competent technician It is typical when industries shift from electro mechanical to ele...

Page 100: ... loud BANG when key is turned to the OFF position The after fire solenoid is not closing either because it is physically damaged or the power is not being turned off Check for power at the solenoid Check continuity between G and A1 terminals Check for no continuity between A1 and the B terminals NOTE If the engine is at an idle when the key is turned off fuel is drawn into the engine through the i...

Page 101: ...after start up A blown fuse will disable the starter circuit A simple quick test for the pres ence of alternator output at the battery is to check across the battery posts for DC voltage Symptom After fire solenoid does not work engine starts and dies The after fire solenoid is powered directly by the red wire from the B ter minal of the key switch and should operate independently of anything else...

Page 102: ... the tractor will operate identically to when the module is dis armed When the RMC module is armed and turned on The tractor will operate identically to when the module is disarmed except that the operator will be able to put the transmission in reverse with the PTO engaged and the cutting deck will continue to run The operator may put the tractor into and out of reverse as many times as they wish...

Page 103: ...ion of what the problem is if it is not a faulty RMC module If the problem is identified in a particular circuit check the safety switch that is associated with that circuit If the switch is good then the prob lem lies within the wiring harness NOTE Like the electronic components found on most cars the RMC module requires a fully charged battery to work properly If the system voltage falls below 1...

Page 104: ...itry This wire runs directly to the reverse safety switch Interpretation Continuity to ground when the tractor is not in reverse would indicate a short to ground This could take the form of a chafed wire contacting ground or a shorted reverse safety switch Lack of continuity to ground would indicate A broken or disconnected wire leading to the reverse safety switch A switch that is not closing bec...

Page 105: ... key switch to the RMC module including the molded connector between the two components 9 If the RMC plug test indicates fault with any of the safety switches the next step is to test the suspect switch The operation of those switches is described in the following sections RMC module plug test manual PTO 1 Disconnect the molded 8 pin plug from the RMC module See Figure 7 7 2 Looking at the plug he...

Page 106: ...es should always have continuity to ground Circuitry The green wires leads to ground Interpretation If this ground path is not good there will probably be other ground related issues with the tractor slow starter motor slow battery charge dim lights All ground connec tions should be mechanically secure and corro sion free 6 Bottom left square shape The red wire on the OCR plug carries battery volt...

Page 107: ...tch In A Com power is supplied to the PTO switch from the A1 terminal of the ignition switch through a red wire when the PTO switch is turned on this completes the circuit to allow power to go to the PTO clutch It is a normally opened NO set of contacts B COM is in the safety shut down circuit It is a normally opened NO set of contacts A circuit is completed from the NO terminal on the PTO relay t...

Page 108: ...y This will also help to keep moisture out of the relay NOTE Electrical tape that is wrapped tightly around the relay can prevent the relay from operating properly PTO switch manual PTO The manual PTO switch is mounted on the right side of the seat box section of the frame See Figure 7 11 The PTO switch plunger is depressed when the PTO lever is moved to the off position The switch has two pair of...

Page 109: ... normally open NO set of contacts is in the starter inhibit circuit When the clutch brake pedal is depressed the contacts are closed power coming from the key switch key switch in START through the orange wire is passed on to the PTO switch through the orange wire with black trace The other set of NO contacts receives the signal from the parking brake switch through the pur ple wire When the brake...

Page 110: ...h black trace A normally closed NC set of contacts is in the safety shut down circuit A circuit is completed from the ignition module s primary windings to ground The ground comes from the seat switch if the seat is empty through the yellow wire with black trace If the brake pedal is up that ground signal will pass through the brake switch to the ignition through the yellow wire Park brake switch ...

Page 111: ...hat goes directly to the RMC module See Figure 7 17 Figure 7 17 Reverse Safety Switch Hyrdostatic transmissions Tractors equipped with a hydrostatic transmission have the reverse switch mounted on the transmission next to the selector plate See Figure 7 18 This switch has a yellow wire with black trace con nected to it The yellow wire with black trace plugs into the main harness by the starter sol...

Page 112: ...onnects with the yellow wire from the seat switch at the PTO switch The other side of the PTO switch is connected to the pri mary windings of the ignition module If the seat is empty or the RMC module senses an unsafe condition while the PTO is on a ground signal is sent to the ignition module turning off the engine Starter solenoid The starter solenoid is mounted inside the seat box section of th...

Page 113: ...ift shaft See Figure 7 24 The solid red wire feeds the fuse with power picked up from the battery cable connection to the hot post of the starter solenoid The red wire with white trace carries fused power to the B terminal on the key switch A failed fuse will disable most of the tractor s electrical system Remember that a failed fuse has done it s job of protecting the rest of the circuit from an ...

Page 114: ...d regulatory demands continue to drive change in the industry while electronic controls have become relatively inexpensive In many cases electronic controls can simplify a sys tem that would otherwise be very complex Instead of creating a huge mass of switches and relays that are tied together by spaghetti like wiring harness sensors switches in an electronic system send signals to a processor The...

Page 115: ...ence of AC is very limited The primary concern of this section is 12 Volt DC systems though much of the theory and tech niques apply equally well to other DC systems 1 Voltage Pressure Voltage is the pressure that electricity has It is the amount of force pushing electrons through a circuit The unit of measurement for this pressure is volts The capital letter V is used to represent volts Most not ...

Page 116: ...vided by I will solve for the covered letter R V I R If the V is covered I and R are exposed on the same line meaning that the product of I times R will solve for the unknown V I x R V 5 Kirchhoff s current law Kirchhoff s current law deals with nodes Nodes are the junction of two or more wires or the junc tion of a wire to a component Kirchhoff s current law states that what ever cur rent goes in...

Page 117: ...sistance will be too small to worry about Figure 7 27 12 Volts 4 Amps 4 Amps flow X 3 Ω resistance 12 Volts 7 How the system is wired together The Rules All circuits have some basic rules that must be followed 7a All circuits must have at least one voltage source It could be a battery an altenator or both 7b All circuits must have a load A circuit with out a load is the same as shorting out the po...

Page 118: ...ns wired in series and some in parallel See Figure 7 30 What can go wrong There are three types of failures that can occur in an electrical circuit 1 Shorts 2 Opens 3 Increased resistance Shorts A short is when electricity takes a path that it was not designed to take by passing a compo nent in the circuit An common example of a short is a wire with insulation that chafed through exposing the cop ...

Page 119: ...charger Battery tester Battery jumper cables Hand tools to gain access to components Flash light Digital Multi meter A DMM is the most useful tool to trouble shoot any electrical system There is an amazing vari ety of DMMs on the market Some are very basic others are tailored to specific industries and some high end graphing meters function like oscilloscopes Even the most basic ones are quite ver...

Page 120: ...bad technique Poor connections between the probes and the point to be read can throw off readings False readings can be generated if the technician touches both probes with their fingers while taking the reading The meter has it s own power source to measure resistance Connecting the meter to a compo nent that has current going through it will dam age the meter usually beyond repair Wiring diagram...

Page 121: ...m testers Inductive ammeters are available in many forms Some are as simple as a gauge to be held against the circuit in question when it is ener gized See Figure 7 33 Figure 7 33 DMM with inductive ammeter feature Inductive ammeter There are two primary reasons to measure amperage 1 To check the out put of a charging system or battery 2 To check the performance of a component that draws a substan...

Page 122: ...eeds to be identi fied using more in depth techniques NOTE If system voltage is beyond roughly 15 7 volts it is over charging and there is a problem with the voltage regulator rectifier To identify a specific charging system problem isolate the components of the system and check their perfor mance individually 1 First check the raw AC Voltage out put from the stator It will be necessary to compare...

Page 123: ...ngs are shorted to ground NOTE If there is an intermittent charging sys tem problem perform these tests when the engine is cold and again when the engine is hot NOTE Low voltage readings may also result from poor test connections or low engine RPM 3 If the stator is good test the amperage out put from the regulator rectifier 3a Attach a DC shunt with DVOM or an ammeter capable of reading up to 25 ...

Page 124: ... amount of voltage to excite the fields in the alter nator Solid state components will not work if the sys tem voltage falls below a given threshold Some solid state components can be damaged by the jump starting that accompanies operation with a dead battery Many electric PTO clutches will fail to work dependably if battery needs to be replaced Even though the charging system produces enough out ...

Page 125: ...trolyte to stabilize after charging the battery or adding water to the cells 1c Measure the temperature of the electrolyte in the middle cells of the battery 1d Squeeze the bulb on the hydrometer then insert the hose into the cell 1e Release the bulb drawing electrolyte into the hydrometer to the fill line IMPORTANT Hold the hydrometer straight up and down when drawing up the electrolyte The float...

Page 126: ...er and the load tester to the appropriate terminals 1d Hook an amp probe onto the ground lead of the load tester NOTE A shunt can be used in place of the amp probe but a second voltmeter will be needed to get a measurement from the shunt 1e Apply a load equal to 50 of the battery s rated CCA for 15 seconds NOTE CCA stands for cold cranking amps The rating should be on the battery for aftermarket b...

Page 127: ...e meter on the load tester for the bat tery s performance 2e Refer to the manufacturer of the tester on how to read the test meter 2f The results of this test are not accurate and should only be relied on if the battery fails badly Figure 7 42 3 Capacitance testing There are several brands of capacitance battery testers presently on the market Capacitance battery testers use the battery being test...

Page 128: ... than a 2 volt drop the battery is bad 5 Storage of batteries 5a Always store a battery with a full charge unless the battery is a dry battery and the electrolyte has not been added yet This may require periodic re charging 5b Take measures to prevent the battery from freezing in cold weather The electrolyte in a fully charged battery has a lower freezing point than the electrolyte in a battery wi...

Page 129: ...for voltage back probe the terminals nearest the point to be checked DO NOT STAB THE WIRES See Figure 7 45 7a Starting with a fully charged battery and bat tery cable connections that are clean and tight measure the battery voltage See Figure 7 46 7b With the circuit energized start at either end of the circuit and check for voltage If starting at the battery end of a powered circuit trace it thro...

Page 130: ...eck ground side voltage drop set up a multimeter to measure 12V DC 1 Make a good electrical connection between the black probe and the negative post on the bat tery 2 Make a good electrical connection between the red probe and the suspect point of ground 3 Power up the circuit in question 4 The voltage that shows up on the meter is the voltage that is being used to pass current through a resistanc...

Page 131: ...y post Figure 7 50 16 Voltage drop on a good circuit should be less than 0 1 volts A voltage drop reading on the meter of greater than 0 2 volts indicates a fairly substantial problem that demands attention As an example if the tractor had a slow turning starter the ground side voltage drop measured below 0 1 volts and there was not a parasitic load on the engine e g PTO clutch that is not fully d...

Page 132: ...hes on Cub Cadet equipment are typed by their at rest state Normally Open Nor mally Closed Common Normally Open N O contacts do not complete a circuit when the switch is at rest plunger extended They close to complete a path through the switch when the plunger is depressed Normally Closed N C contacts complete a cir cuit when the switch is at rest plunger extended They open to break the path throu...

Page 133: ...al It connects to terminal 3 when the relay is ener gized When 3 4 are connected 3 5 are dis connected and vice versa An Ohm meter should show zero resistance or 0 0Ω between 3 4 when the relay is at rest and it should read no continuity when the relay is energized Figure 7 53 Spade 3 Common Spade 4 N C Spade 2 Windings Spade 1 Windings Spade 5 N O O O O O O O 3 4 5 1 2 Inset Circuit diagram of re...

Page 134: ...ode in the circuit 2 Set the DVOM to the diode or Ω scale See Figure 7 55 3 Attach the negative lead of the DVOM to the side of the diode with a band on it 4 Place the positive lead on the other side of the diode 5 There should be continuity See Figure 7 56 6 Switch the leads 7 The meter should indicate no continuity See Figure 7 57 8 If the results do not match the above replace the diode Figure ...

Page 135: ...ELECTRICAL SYSTEM 129 Schematics LECTRIC 04 ...

Page 136: ...ELECTRICAL SYSTEM 130 ANUAL 04 ...

Page 137: ...6 Triple blade deck T 46 Twin blade deck P 50 Triple blade deck K 54 Triple blade deck Deck removal 1 Place the tractor on firm level ground and set the parking brake 2 Lower the deck to the lowest cutting height 3 Remove the PTO belt Electric PTO A Slip the PTO belt off of the PTO clutch B Slide the belt out between the PTO clutch and the belt guard Manual PTO A Loosen the bolt that fastens the b...

Page 138: ...Slide the PTO belt off of the engine pulley E Remove the hair pin clip that secures the PTO cable to the deck See Figure 8 3 F Unhook the spring end of the PTO cable from the idler pulley bracket See Figure 8 4 4 Pull the deck pins on both sides and rotate them to keep them out See Figure 8 5 Figure 8 2 Remove this nut Figure 8 3 Remove this clip Figure 8 4 Unhook this spring Figure 8 5 Pull and r...

Page 139: ...tabilizer link Figure 8 7 Remove this click pin 6 Raise the deck lift lever to the highest setting 7 Slide the deck out to the right from underneath the tractor 8 Install the deck by following the above steps in reverse order NOTE The deck is easier to install if the front edge is supported by a length of 2 x4 lumber This brings the front hanger closer to the hori zontal position The closer the fr...

Page 140: ...ery five acres depending on local conditions A dull blade tears the grass instead of cutting it Torn grass blades leaves a rough look and makes the grass vul nerable to diseases Blades need to be examined for damage before sharp ening Blades must be balanced after sharpening to reduce the vibrations felt from the deck Bent blades are a sign of a blade impact The blades must be replaced and the spi...

Page 141: ... to within 1 5 8 from the edge or if any metal separation is present replace the blades with new ones It is important that each cutting blade edge be ground equally to maintain proper blade bal ance CAUTION A poorly balanced blade will cause excessive vibration and may cause damage to the tractor and result in personal injury The blade can be tested by using a blade bal ancer Grind metal from the ...

Page 142: ... the pulley nut See Figure 8 10 NOTE The spindle bearings are sealed The grease injected into the spindle housing will break down and seep through the seals to lubri cate the bearings It will also keep condensating moisture within the spindle from reaching the bearings 3 Slip the PTO belt off of the spindle pulley that is to be serviced NOTE Timed decks will need to have the timing belt removed al...

Page 143: ...Every time the electric PTO is engaged the PTO belt is subjected to an impact load When the electric PTO is engaged it goes from 0 to 3 600 RPM instantly This can actual remove sections of the belt NOTE Engaging the Electric PTO before the mowing deck is placed into the grass will reduce the impact load on the belt When a blade impacts an object like a rock or a tree root the belt is subjected to ...

Page 144: ...OTE On the 50 and the 54 deck The belt keeper on the brake side of the idler bracket must be removed and the other belt keeper needs to be loosened See Figure 8 15 4 Route the new belt around the pulleys For a 38 deck See Figure 8 16 For a 42 G deck and a 46 T deck See Figure 8 17 For a 42 timed R deck See Figure 8 18 Figure 8 14 Idler pulley Belt guide Figure 8 15 Remove this belt keeper Loosen t...

Page 145: ...ove the deck as describe at the begining of this chapter 2 Remove the PTO belt by following the steps described in the previous section of this manual 3 Remove the PTO belt idler spring See Figure 8 21 4 Remove the timing belt idler stop using a pair of 9 16 wrenches See Figure 8 22 NOTE The idler spring pulley applies the ten sion to the timing belt The timing belt idler stop will prevent the idl...

Page 146: ...25 NOTE Failure to time the blades will result in the blades hitting each other NOTE The timing marks will line up with the blades and would need to be 90o apart See Figure 8 26 NOTE The timing marks on the blade pulleys have been shown in white for clarity 8 Install the timing belt by following steps 1 through 6 in reverse order 9 Test run the tractor in a safe area before return ing it to servic...

Page 147: ... next step NOTE Use of Cub Cadet deck leveling gauge part number 490 900 0041 will make measuring the blade tip height easier See Figure 8 27 Figure 8 27 3 Working from the left side of the tractor loosen but do not remove the bolt on the left deck hanger bracket See Figure 8 28 4 To even the deck turn the adjustment gear located immediately behind the bolt clockwise rearward to raise the left sid...

Page 148: ...ment The cutting decks are of a floating design This means that they are suspended above the ground The gauge wheels occasionally touch the ground They are designed to bump the deck up and over irregularities This helps prevents scalping damage to the turf and damage to the deck Adjust the wheels as follows 1 Place the tractor on a smooth flat surface and move the deck to the desired mowing height...

Page 149: ...in 5 Install the E ring that retains the bushing 6 Repeat steps 2 6 on the opposite side 7 Install the deck 8 Test drive the tractor in a safe area before returning to service Figure 8 31 Remove the E ring Deck lift shaft assembly removal replacement 1 Remove the deck by following the steps described at the beginning of this chapter 2 Remove the fender by following the steps described in Chapter 4...

Page 150: ...n the 900 series tractors The links used on the 38 and 42 decks have a left and a right lift link The links used on the 46 50 and the 54 deck are all the same link The holes used in the lift link will vary depending on which deck is used See Figure 8 36 NOTE If the cable or the deck J pin is installed in the wrong hole the belt angle between the PTO and the deck will be off This will result in the...

Page 151: ...ews 4 Push the deck lift arm as far forward as it will go 5 Remove the hair pin clip that secures the lift cable to the lift shaft then slide the clevis pin out of the cable See Figure 8 39 NOTE With the indexing bracket loose there should be enough clearance to slide the clevis pin out past the frame 6 Disconnect the lift cable from the lift link by removing the cotter pin 7 Lift the cable off of...

Page 152: ...Cutting Decks And Lift Shaft 146 ...

Page 153: ... hrs Spark plugs 100 hrs Fuel filter 100 hrs Grease brake shaft 100 hrs Remove rear wheels or hub grease rear axle shaft yearly The spark plug s The spark plug s should be checked cleaned and re gapped on a monthly basis or every 100 hours of use The plugs should be replaced every six months or 300 hours of use When checking the spark plug s a dry light colored residue on the plugs is a sign of ru...

Page 154: ...consumption and make starting more difficult The foam pre cleaner should be checked before each use and cleaned every 25 hours The air filter should be cleaned before each use and replaced every two months or 50 hours of use Refer the engine manufacturer s service manual for the proper procedure access the air filter To clean a pre cleaner 1 Remove the pre cleaner following the steps described by ...

Page 155: ...done through the addition of ethanol Most engines offered for sale on outdoor power equipment in the North American markets are designed to tolerate no more than 10 ethanol by volume Ethanol is hygroscopic meaning it absorbs water If left exposed to air it will draw water out of the air Ethanol is an oxygenator which means that it will oxi dize corrode metal that it comes into contact with Exposur...

Page 156: ...fuel line IMPORTANT The 900 series tractor uses low permeation fuel line to meet EPA guidelines When replacing the fuel lines they must be replaced with the same type of low permeation fuel line 4 Install the new filter by following the above steps in reverse order 5 Test run the engine and check for leaks before returning to service Clean the engine Air cooled engines cool better if they are clea...

Page 157: ...APPENDIX 151 This Hydro Gear manual is reprinted in its entirety with permission from Hydro Gear HYDRO GEAR APPENDIX ...

Page 158: ...APPENDIX 152 ...

Page 159: ...We set the wheels in motion 310 0510 0610 0710 Integrated Hydrostatic Transaxle Service and Repair Manual BLN 51260 April 2008 ...

Page 160: ...hange 10 Purging Procedures 11 Return to Neutral Setting 12 Brake Maintenance 13 Friction Pack Adjustment 13 Section 5 Repair 14 How To Use This Section 14 General Instructions 14 Transaxle Removal 14 Limited Disassembly 14 Tools and Torques 15 Brake Assembly and Bypass Arm 16 Control Arm and Friction Pack 17 Seal Kit Replacement 18 Side Housing 19 Axle Shaft Differential and Reduction Gears 20 Mo...

Page 161: ...erminology is very important It is necessary and good shop practice that your service area be equipped with the proper tools and the mechanics be supplied with the latest information available All repair procedures illustrated in this guide are suggested but preferred methods of repair Repair procedures require that the transaxle unit be removed from the vehicle This is not a certification test or...

Page 162: ... mounted swashplate with a direct proportional displace ment control Reversing the direction of the swashplate reverses the flow of oil from the pump and thus reverses the direction of the motor output rotation The pump and motor are of the axial piston design and utilize spherical nosed pistons which are held against a thrust race by internal compression springs The 310 0510 has a self contained ...

Page 163: ...Reversing the angle of the swashplate will reverse the direction of oil flow During the operation of the transaxle fluid is lost from the hydraulic loop through leak paths designed into the product for lubrication purposes around pistons under the rotating cylinder blocks etc This lost fluid returns to the transaxle housing then is pulled back into one of the check valves depending upon the direct...

Page 164: ...S 310 0510 Return to Neutral Option Friction Pack Option AXLE SHAFT FILL PORT EXPANSION TANK INPUT SHAFT CONTROL ARM BRAKE DISC FAN BRAKE ARM BYPASS ARM FRICTION PACK ADJUSTING PUCK BELT KEEPER AXLE CLIP AXLE CLIP AXLE CLIP AXLE CLIP ...

Page 165: ...310 0510 IHT 5 MODEL RECOGNITION 618 0319 166768 104 1760 173839 036932 618 0389A ...

Page 166: ...he label shown in Figure 3 Figure 3 310 0510 Configuration Label H Y D R O G E A R SULLIVAN IL U S A I IIII III IIII II II 13054 318 2400 I II IIII IIII III III I II IIII 0 319 Z1 401 Made in U S A Year Built Date Julian day of year Type of Product and Build Information Serial Number unique number for that model for that day Model Number Hydro Gear Ref Number H Y D R O G E A R SULLIVAN IL U S A I ...

Page 167: ...ormance of your job Never allow untrained or unauthorized person nel to service or repair the equipment Wear appropriate clothing Loose or hanging clothing or jewelry can be hazardous Use the appropriate safety equipment such as eye and hearing protection and safety toe and slip proof shoes Never use compressed air to clean debris from yourself or your clothing TOOL SAFETY Use the proper tools and...

Page 168: ...ct Cooling fan damaged Oil level low or contaminated oil Excessive loading Air trapped in hydraulic system Clean off debris Page 9 Adjust brake to proper setting Page 13 Repair or replace cooling fan Fill to proper level or change oil Page 10 Reduce vehicle loading Page 9 Purge hydraulic system Page 11 Corrective Action Possible Cause VEHICLE DOES NOT DRIVE TRACK STRAIGHT Repair or replace linkage...

Page 169: ... is securely fastened to the trunnion arm of the transaxle 7 Inspect the bypass mechanism on the transaxle and vehicle linkage to insure it actuates and releases fully SERVICE AND MAINTENANCE PROCEDURES All the service and maintenance procedures presented on the following pages can be performed while the 310 0510 is mounted on the vehicle Any repair procedures as mentioned in the repair section of...

Page 170: ...l the tank support bracket and self tap ping bolt making sure not to cross thread the bolt Torque the bolt to the lower value of the torque specification listed in Table 5 9 Fill the transaxle at the oil fill port according to Figure 4 10 Install the oil fill port fitting EXPANSION TANK FUNCTION The expansion tank allows the 310 0510 to operate free of air entrainment and provides maximum lubricat...

Page 171: ...starting make sure the transaxle transmission is at the proper oil level If it is not fill to the specifications outlined on page 10 Figure 4 The following procedures should be performed with the vehicle drive wheels off the ground then repeated under normal operating condi tions 1 With the bypass valve open and the engine running slowly move the directional control in both forward and reverse dir...

Page 172: ... according to the OEM manual Recheck according to Step 3 and 4 Stop the vehicle engine Refer to Figure 5 6 Note the axle directional movement Stop the vehicle engine Loosen the adjusting puck screw until the puck can be rotated Rotate the adjusting puck the opposite di rection of the wheel rotation in 5 degree in crements Tighten the adjusting puck screw Refer to Table 5 Required Torque Values Pag...

Page 173: ...ustment for the amount of drag or holding force can be made by turning the friction pack nut in or out Adjustments should be made in no more than 1 4 turn increments Over tightening will result in difficulty or inability of the operator to move the control lever Note The factory setting for the friction pack is tightening of the friction pack nut to 100 in lbs 11 Nm torque The friction pack nut is...

Page 174: ...aces should be cleaned before beginning any repairs Upon removal it is recommended that all seals O rings and gaskets be replaced During installation lightly lubricate all seals O rings gaskets with a clean petroleum jelly prior to assembly Also protect the inner diameter of seals by covering the shaft with a cellophane plastic wrap etc material Parts requiring replacement must be replaced from th...

Page 175: ...on Pack Wedge Screw 30 70 in lb 3 4 8 Nm 88 Screw Self Tapping 10 32 x 5 Puck Inner Wedge Bolt 42 65 lb in 5 7 Nm 88 Bolt 10 32 x 0 5 Adjusting Puck Screw 250 320 lb in 28 36 Nm 95 Socket Hd CS 5 16 24 x 1 50 RTN Screw 180 240 lb in 20 27 Nm 97 Screw Countersunk 5 16 18 x 1 Bracket Screw 230 310 lb in 26 35 Nm 110 Screw Torx Hd 5 16 18 x 1 50 Fan Pulley Input Shaft Nut 300 460 lb in 34 52 Nm 121 N...

Page 176: ...ove the brake rotor 59 and puck 60 Note The hub on the rotor faces away from the transaxle INSPECTION 1 Inspect the brake arm bias spring 66 castle nut 69 washer 73 brake arm 68 actuating pins 62 spring 71 brake yoke screws 63 64 brake yoke 58 pucks 60 puck plate 61 bypass arm 49 spacer 65 and brake rotor 59 for wear or dam age ASSEMBLY 1 Install the brake puck 60 and brake rotor 59 2 Install the ...

Page 177: ...mage 3 Inspect the inner wedge puck 90 4 Inspect the friction pack stud 76 for wear or damage ASSEMBLY 1 Install the friction pack stud 76 if removed Torque according to specifications in Table 5 2 If previously removed install the friction pack wedge 81 and self tapping bolt 88 Refer to Table 5 for bolt torque specifica tions Use the marks made during disas sembly to reposition the wedge properly...

Page 178: ...at against the sleeve bearing 8 Install the seal retaining rings 12 9 Install the axle clips 93 if applicable Input Seal 1 Remove the input pulley and fan from the input shaft 2 The seal 13 can be replaced by following steps 2 6 of the procedure used to replace the axle seals Trunnion Seal 1 Remove the control arm and any attach ments to the control arm See page 17 2 The seal 17 can be replaced by...

Page 179: ...ad of sealant around the perime ter of the side housing face See sealant pattern on page 28 2 Install the axle and sleeve bearing 31 Note the orientation of the locating tab on the sleeve bearing It is essential for this to align with the side housing bore 3 Install the locating pins 83 if not already installed 4 Install the side housing 2 while aligning the bypass rod into its side housing bore U...

Page 180: ...for wear or damage 4 Inspect the reduction gears shaft and washers 5 Inspect the housing bores ASSEMBLY 1 Reassemble and install the reduction gears 28 29 jack shaft pin 41 and washers 72 2 Install the bull gear 30 3 Reassemble and install the center block bearing 54 earlier units differential cross shaft s 39 and miter gears 38 4 Install the washer 33 sleeve bearing 31 and axle assembly 36 5 Inst...

Page 181: ...nnion gear 27 and flat washers 52 108 for wear or damage 2 Inspect the bypass rod 48 for wear or damage ASSEMBLY 1 Insert the bypass rod s 48 short end into the housing while aligning the rod s flat with the bypass actuator Confirm proper bypass function 2 Insert the motor shaft 24 with the pinnion gear 27 and flat washers 52 108 into the center section 3 3 Install the axle shaft differential and ...

Page 182: ...aft components for wear or damage ASSEMBLY 1 Install the block thrust washer 56 and spring 55 onto the input shaft 9 2 Ensure that the pump block is aligned con centrically with the center section running face 3 Insert the input shaft 9 with bearing 14 and retaining ring 10 into the pump block assembly NOTE Do not force the shaft and bearing as damage may occur If alignment is correct the shaft as...

Page 183: ... may be held in place in the piston by residual oil 12 Reassemble the pistons springs and seats into the cylinder block and set aside 13 See Fig 18 Remove the thrust bearing assembly 19 from the swashplate 4 Center Section Filter 14 See Fig 19 Remove the center section mounting screws 44 NOTE The center section is under motor block piston spring pressure These screws are factory in stalled to 700 ...

Page 184: ...s the housing bearing cavity The thick race must face the pistons Center Section 3 See Fig 21 Install the new filter base 46 onto the center section 3 4 Install the check plugs 23 75 in their correct location into the center section 3 Tighten the check plugs according to Table 5 5 Install the bypass spring 43 into the filter base 46 6 Install the deflector 107 into the underside of the filter 45 7...

Page 185: ...side of the swashplate pump block assem bly Fig 24 into the housing while simulta neously compressing the pistons in the block NOTE To assist in the installation of these components insert the assembly un til of the pump block is covered by the center section Then slightly angle the trun nion shaft end away while pressing the short swashplate shaft into its pocket 18 Install the input shaft See pa...

Page 186: ...310 0510 IHT 26 3 46 HYDRAULIC COMPONENTS Figure 21 Figure 19 44 44 Figure 20 124 Post 75 23 43 47 107 45 Figure 22 1 19 5 Axle Horn Figure 23 5 3 24 Figure 24 Swashplate Pump Block Assembly Short Shaft ...

Page 187: ...mbly procedure is located by a page reference The part reference numbers provided in each assembly procedure are keyed to the individual exploded views and are also keyed to the complete unit exploded view on page 32 1 Install the hydraulic components See pages 23 26 2 Install the input shaft See page 22 3 Install the bypass rod See page 21 4 Install the axle shaft differential and reduc tion gear...

Page 188: ...Prior to applying the new sealant the old sealant must be removed from all surfaces A small consistent bead of the sealant around the housing face will be sufficient Use sparingly The illustration below indicates the correct areas Sealant Path ...

Page 189: ...m the vehicle 1 With the vehicle wheels on the ground loosen the nuts retaining the hubs on the transaxle Use an air impact wrench and socket to loosen the nuts 2 Lift the vehicle wheels from the ground and remove the nut completely 3 Remove the wheel from the hub 4 Using a wheel or gear puller remove the hub from the shaft Always inspect the hub for damage after removal 310 0510 0610 Features 310...

Page 190: ...310 0510 IHT 30 310 0710 EXPLODED VIEW ...

Page 191: ...6 Washer Thrust 59 x 79 x 04 57 20W 50 Oil 58 Brake Yoke Kit 59 Disk Brake 60 Brake Puck 61 Puck Plate 62 Brake Actuating Pin 63 Bolt Hex Head 1 4 20 x 2 w patch 65 Spacer 66 Spring Brake Arm Bias 68 Arm Brake 69 Nut Castle 5 16 24 70 Cotter Pin 3 32 X 3 4 71 Compression Spring Brake Anti Drag 72 Washer Flat 51 x 1 00 x 03 73 Washer Flat 34 x 88 x 06 74 Oil Seal 625 X 1 0 X 25 75 Check Plug Assy 0...

Page 192: ...310 0510 IHT 32 310 0610 EXPLODED VIEW ...

Page 193: ...ring Block 56 Washer Thrust 59 x 79 x 04 57 20W 50 Oil 58 Brake Yoke Kit Yoke Brake Bolt Sq Hd 5 16 24 Ribbed 59 Disk Brake 60 Brake Puck 61 Puck Plate 62 Brake Actuating Pin 63 Bolt Hex Head 1 4 20 x 2 w patch 64 Bolt Hex Head 1 4 20 x 1 w patch 65 Spacer 26 x 57 x 87 66 Spring Brake Arm Bias 68 Arm Brake 69 Nut Castle 5 16 24 70 Cotter Pin 3 32 X 3 4 71 Compression Spring Brake Anti Drag 72 Wash...

Page 194: ...310 0510 IHT 34 310 0510 EXPLODED VIEW 6 SEALANT 57 20W 50 OIL 127 SEAL O RING KIT ...

Page 195: ...3 Retaining Ring 55 Spring Helical Compression 56 Washer Thrust 59 x 79 x 04 57 20W 50 Oil 58 Brake Yoke 59 Rotor Brake 60 Brake Puck 61 Puck Plate 62 Brake Actuating Pin 63 Bolt Hex Hd 1 4 20 x 2 w patch 65 Spacer 66 Spring Brake Arm Bias 68 Arm Brake 69 Nut Castle 5 16 24 70 Cotter Pin 3 32 x 3 4 71 Compression Spring Brake Anti Drag 72 Washer HT 51 x 1 0 x 03 73 Flat Washer 34 x 88 x 06 74 Oil ...

Page 196: ...hing fluid to the fluid power system closed loop Charge Pressure The pressure at which replenishing fluid is forced into a fluid power system Charge Relief Valve A pressure control valve whose primary function is to limit pressure in the charge circuit Check Valve A valve whose primary function is to restrict flow in one direction Closed Loop A sealed and uninterrupted circulating path for fluid f...

Page 197: ... start up frequently achieved by pressurizing the fluid in the inlet line Purging The act of replacing air with fluid in a fluid power system by forcing fluid into all of the components and allowing the air a path of escape Rated Flow The maximum flow that the power supply system is capable of maintaining at a spe cific operating pressure Scoring Scratches in the direction of motion of mechanical ...

Page 198: ...310 0510 IHT 38 2008 HYDRO GEAR Printed in U S A Rev P1 ...

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