Cub-cadet ISeries User Manual

Professional Shop ManualI Series Riding TractorsMTD Products Inc. - Product Training and Education DepartmentFORM NUMBER - 769-03231A08/2009NOTE: Thes

ENGINE RELATED PARTS45. With the muffler on a work bench, remove the four screws that fasten the muffler to the muffler bracket. See Figure 2.4.6. Rem

STEERING-IVT949. Remove the input sector gear. See Figure 6B.42.10. Inspect the input sector gear bushings for dam-age and/or

STEERING-IVT9513. Slide the rollers off of the bevel gears. See Figure 6B.46.NOTE: There are no retains for these rollers because they are

STEERING-IVT9618. Inspect the bearings. If they are worn or rough, carefully drive the inner bearing out of the upper housing using a pin punch and ha

STEERING-IVT973. Install the internal cam so that the rollers on the bevel gears ride in the groves of the cam. See Figure 6B.54.4. Set the thic

STEERING-IVT987. Insert the input sector gear into the internal cam.NOTE: The input sector gear and the internal cam have a master spline to time the

STEERING-IVT998e. Install the snap ring.8f. Repeat for the right output bevel gear assembly.8g. Test fit each of the assemblies in the hous-ing. T

STEERING-IVT100NOTE: If one or both of the output bevel gears are out of time, the steering rack will lose travel on the affected side. 12. Fill the l

STEERING-IVT10116. Install the snap ring on the input shaft. See Figure 6B.70.17. Install the wear block:17a. Insert the spring into the w

STEERING-IVT10222. Check the timing of the gear box:22a. Turn the input shaft until the steering rack has moved all the way to the left. The right sh

STEERING-IVT103To replace the front wheel ball bearings:1. Lift and safely support the front end of the trac-tor.2. Remove the front wheel by followin

ENGINE RELATED PARTS5Exhaust pipesThe exhaust pipes are manufactured by Cub Cadet. To remove/replace the exhaust pipes:1. Remove the muffler following

STEERING-IVT1047. Take the bolt all the way out.NOTE: The axle should fall out at this point.8. Install the axle by following the previous steps in re

STEERING-IVT1054. Loosen the jam nuts.5. Remove the spherical rod ends. NOTE: Count the number of turns to remove the spherica

STEERING-IVT106Inboard steering gearTo remove/replace the inboard steering gear or king pin:1. Remove the steering gear covers.2. Remove and discard t

STEERING-IVT107Pivot barTo remove/replace the pivot bar:1. Lift and safely support the front end of the trac-tor.2. Remove the front axles by followin

STEERING-IVT10810. With the pivot bar on a bench, the inboard steer-ing gear and the tie rod can be serviced.11. Remove the tie rod by removing and di

STEERING-IVT10920. Install the tie rod end using a new lock nut.21. Apply high quality grease to the frame and the inside of the pivot bar bracket, wh

STEERING-IVT110

ELECTRICAL SYSTEM111Introduction This chapter is divided into four sections:• Section 1: About this chapter and precautions• Section 2: Components

ELECTRICAL SYSTEM112information and the proper tools, a technician should be able to efficiently diagnose most elec-trical problems.2. Key switchThe K

ELECTRICAL SYSTEM113• Symptom-No crank and no starter solenoid click: Power is not getting to the trigger spade on the starter solenoid. Test for a

ENGINE RELATED PARTS65. Remove the two screws and two nuts that fasten the seat box cover. See Figure 2.10.6. Remove the seat box cover.7. Clamp the f

ELECTRICAL SYSTEM1142e. The RMC Module is in the same housing as the key switch, and is not available sepa-rately. For the purpose of diagnosis it is

ELECTRICAL SYSTEM115ton. It will be confirmed that the module is ON by the illumination of the red LED on the module.2f. To identify a faulty RMC mod

ELECTRICAL SYSTEM116• Circuitry: The yellow wire with black trace leads to the PTO switch, where it finds a path to ground when the PTO is ON.• Interp

ELECTRICAL SYSTEM1173b. B-COM is in the safety shut-down circuit. It is a normally opened (NO) set of contacts. A circuit is completed from the M ter

ELECTRICAL SYSTEM1185. The Reverse Safety Switch is a simple metal contact tang. When the drive pedal is pressed into reverse, the reverse switch is p

ELECTRICAL SYSTEM1198. The lighting circuit is hot whenever the engine is running. It does not draw from the battery, but runs directly off its own ci

ELECTRICAL SYSTEM120ELECTRICAL DIAGNOSISNOTE: Electrical diagnostic procedures and tools are the same for all Cub Cadet and MTD tractors. This section

ELECTRICAL SYSTEM121• Heat and Vibration: Heat and vibration are hard on most mechanical devices. The same is true of electronics. • Moisture

ELECTRICAL SYSTEM1224. Ohm’s LawOhm’s Law relates voltage, amperage, and resis-tance. It states that voltage is the product of resistance times curren

ELECTRICAL SYSTEM1236. Kirchhoff’s voltage lawKirchhoff’s voltage law deals with voltage drops. A voltage drop is the amount of voltage used up or “dr

BRAKES7Brake system descriptionThe I-series tractors have two braking systems available based on which transmission is used. HydroGear transmissions u

ELECTRICAL SYSTEM124Types of circuitsThere are three ways a circuit can be wired:•Series• Parallel• Series/parallelSeriesSeries circuits are wired so

ELECTRICAL SYSTEM125Increased resistanceIncreased resistance is, as the name implies, an increase in resistance. This can be caused by loose or corr

ELECTRICAL SYSTEM126AmperageMost DMMs have a very limited capacity to test amperage (2-3 Amperes). When measuring current flow, the meter must be conn

ELECTRICAL SYSTEM127Self-powered continuity lights Continuity lights can indicate whether a circuit is complete or not, but they give no indication of

ELECTRICAL SYSTEM128NOTE: Usage of the DC Shunt tool is detailed in the 1995 and 1999 editions of their Update Sem-inar materials.Kohler makes a propr

ELECTRICAL SYSTEM1292b. Check the stator for resistance across the leads. It should be in the range of 0.1 -0.2Ω. See Figure 7.28.2c. With the engin

ELECTRICAL SYSTEM1303f. With the engine off, connect Kohler tool #25 7651-20 to the regulator/rectifier: The two black leads go to the terminals norm

ELECTRICAL SYSTEM1312. Importance of battery charge level and condi-tion: A fully charged battery that is in good condi-tion is an important factor wh

ELECTRICAL SYSTEM1326c. Squeeze the bulb on the hydrometer, then insert the hose into the cell.6d. Release the bulb, drawing electrolyte into the hy

ELECTRICAL SYSTEM133NOTE: CCA stands for cold cranking amps. The rating should be on the battery for aftermarket batteries. For OEM batteries, contact

BRAKES8Brake adjustment - HydroGear transmissionsNOTE: Whenever performing a brake adjust-ment, inspect the brake components for signs of wear or dama

ELECTRICAL SYSTEM1343. Capacitance testingThere are several brands of capacitance battery tester presently on the market. Capacitance battery testers

ELECTRICAL SYSTEM1354e. If the battery is being checked indepen-dently of the equipment it powers, measure and note the battery voltage while it is d

ELECTRICAL SYSTEM1367a. Starting with a fully charged battery and bat-tery cable connections that are clean and tight, measure the battery voltage.

ELECTRICAL SYSTEM1379d. The voltage that shows-up on the meter is the voltage that is being used to pass cur-rent through a resistance in the circuit

ELECTRICAL SYSTEM13810. Applying this principle to the positive side of the system. See Figure 7.43.IMPORTANT: Ultimately, all positive current will f

ELECTRICAL SYSTEM13911. Testing switches:• Refer to the “COMPONENTS” section of this chapter that describes the function of the individ-ual switches t

ELECTRICAL SYSTEM140Testing a diode:12a. Isolate the diode in the circuit.12b. Set the DMM to the diode or Ω scale. See Figure 7.47.12c. Attach

ELECTRICAL SYSTEM141

ELECTRICAL SYSTEM142

CUTTING DECKS AND LIFT SHAFT143Cutting decksThe I-series comes with the option of a 42”, 46” or 50” deck. The procedure to remove the deck is the sam

BRAKES9Brake adjustment - IVT transmissionsTo adjust the brakes on IVT transmission:1. Lift the rear of the tractor and safely support it with a pair

CUTTING DECKS AND LIFT SHAFT144Cleaning the deckCleaning debris off of the deck should be done every time the deck is removed. It is routine mainte-na

CUTTING DECKS AND LIFT SHAFT145To remove the blades:1. Remove the deck as described in the previous section of this chapter or lift the tractor using

CUTTING DECKS AND LIFT SHAFT146PTO beltSome cutting deck designs use a single belt to transfer power from the engine crankshaft directly to the blade

CUTTING DECKS AND LIFT SHAFT147• For a 46” deck, See Figure 8.7.• For a 42” timed “R” deck, See Figure 8.8.4. Install the deck as describe at the begi

CUTTING DECKS AND LIFT SHAFT148NOTE: The idler pulley will back away from the idler stop bolt as the belt wears. The stop bolt should be adjusted afte

CUTTING DECKS AND LIFT SHAFT149SpindlesEach blade spindle is sold as a complete unit. The only replaceable parts are the pulley and nuts. The spindles

CUTTING DECKS AND LIFT SHAFT150To replace a spindle:1. Remove the deck as described at the beginning of this chapter.2. Remove the blade following the

CUTTING DECKS AND LIFT SHAFT1513. Working from the left side of the tractor, loosen, but do not remove, the bolt on the left deck hanger bracket. See

CUTTING DECKS AND LIFT SHAFT152Deck Gauge Wheel AdjustmentThe cutting decks are of a “floating” design. This means that they are suspended above the g

CUTTING DECKS AND LIFT SHAFT15350" Deck ONLYNOTE: The 50" deck roller assembly index bracket has five adjustment holes.A While supporting th

BRAKES104. Loosen the rear mounting bolt. See Figure 3.8.5. Remove the front mounting bolt, allowing the caliper to swing down. See Figure 3.9.6. The

CUTTING DECKS AND LIFT SHAFT154Deck lift shaft assembly removal/replacement1. Remove the deck by following the steps described at the beginning of thi

CUTTING DECKS AND LIFT SHAFT155Deck lift links and cablesThe deck lift links have two functions. The first function is to support the rear of the deck

CUTTING DECKS AND LIFT SHAFT156

MAINTENANCE INTERVALS157LubricationTo help keep the I-series in proper running order, Cub Cadet recommends the following lubrication inter-vals be use

MAINTENANCE INTERVALS1582. Remove the spark plugs with a 5/8” spark plug socket. See Figure 9.2.3. Clean the Spark plugs with carburetor cleaner or re

MAINTENANCE INTERVALS1593. Remove the air filter and pre cleaner.4. Slide the pre cleaner off of the air filter. See Figure 9.5.5. Install

MAINTENANCE INTERVALS1605. After all of the oil has been drained, close the oil drain by pushing it in.6. Remove the drain hose.7. Place the cap back

MAINTENANCE INTERVALS161Fuel systemWhat you should know about fuel.Most of the fuel presently available in North Amer-ica is oxygenated to some extent

MAINTENANCE INTERVALS162Clean the engineAir cooled engines cool better if they are clean. Check for nesting or signs of nesting especially after dorma

BRAKES1111. Slide the brake pins into the caliper.12. Place the backing plate in the caliper.13. Place a new puck into the caliper.

BRAKES12Brake shoes/drum - IVT transmissionsOn IVT transmissions, the brake shoes and drums are the wearing parts that will need to be serviced from t

BRAKES136. Remove the snap ring that secures the drum with a pair of snap ring pliers. See Figure 3.16.7. Install the drum and shoes by following step

BRAKES143. Remove the right side bushing first. This will allow the shaft to slide far enough to the left to let the other bushing to come out.4. Inst

BRAKES154. Loosen the shoulder bolt that the parking brake plate pivots on. See Figure 3.21.5. Remove the cotter pin from each end of the brake cross

BRAKES16

BODY/CHASSIS17The hoodThe I-series hood uses the same hood pivot sys-tem as the 1000 series for easy removal. To remove the hood:1. T

BODY/CHASSIS18BumperI-series tractors come equipped with a fast attach bumper. To remove the bumper:1. Remove the two screws, one on each side, that s

BODY/CHASSIS192. Remove the dash:2a. Disconnect the key switch, module, PTO switch and the hour meter. See Figu

BODY/CHASSIS202e. Remove the screws at the bottom of the dash, on each side. See Figure 4.13.2f. The dash can now by lifted over the steering shaft

BODY/CHASSIS215. Remove the nuts from the under side of the foot rests. See Figure 4.16.6. Remove the brake and drive pedals.7. Remove the screw from

BODY/CHASSIS22

DRIVE SYSTEM-HYDROGEAR23There are two drive systems available for the I-series tractor. One system uses two HydroGear trans-missions. The other system

IChapter 1: Introduction ...1Professional Shop M

DRIVE SYSTEM-HYDROGEAR245. Slide the engine pulley down far enough to slip the belt off of the pulley. See Figure 5A.3.NOTE: Note the direction of the

DRIVE SYSTEM-HYDROGEAR2510. Remove the two screws that hold the transmis-sion links to the shifter plate. See Figure 5A.6.11. The belt can now be snak

DRIVE SYSTEM-HYDROGEAR264. Slide the ferrule out of the idler bracket. See Figure 5A.8.5. Adjust the ferrule so that it lines up with the rea

DRIVE SYSTEM-HYDROGEAR277. Remove the two bolts that thread into the cross tubes. See Figure 5A.11.8. Support the transmission to prevent it from fall

DRIVE SYSTEM-HYDROGEAR28Drive pedal shaftTo remove the drive pedal shaft:1. Remove the deck as described in chapter 8 Cut-ting Decks and Lift Shaft.2.

DRIVE SYSTEM-IVT29There are two drive systems available for the I-series tractor. One system uses two HydroGear trans-missions. The other system uses

DRIVE SYSTEM-IVT30NOTE: The RPM numbers used in figures 5B.2, 5B.3 and 5B.4 are not the actual measurements of the disc speeds. They are just an examp

DRIVE SYSTEM-IVT31The output shaft of the T-box drives a sun gear in the center of the planetary gears at the same speed as the input discs. The plane

DRIVE SYSTEM-IVT32The transmission output shafts drive a pair of drop axles assemblies. The IVT transmissions are NOT serviceable. The drop axles and

DRIVE SYSTEM-IVT334. Slide the retainer clip half way out of the damp-ener end using small flat head screw driver. See Figure 5B.125. Disconnect

IIRebuilding the steering gear box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Wear block adjustment . .

DRIVE SYSTEM-IVT3411. Slide the engine pulley down far enough to slip the belt off of the pulley. See Figure 5B.16NOTE: If the engine pulley will not

DRIVE SYSTEM-IVT3515. Slip the belt off of the transmission pulley.16. Remove the belt from the tractor.17. Install the belt following the previous st

DRIVE SYSTEM-IVT363. Remove the cotter pin and washer from the fer-rule. See Figure 5B.224. Slide the ferrule out of the idler bracket. See

DRIVE SYSTEM-IVT378a. Remove the hair and clevis pins. See Figure 5B.258b. Slide the drive control links off of the input levers9. Re

DRIVE SYSTEM-IVT3813. If replacing the transmission assembly, remove the transmission fan.14. If only replacing the IVT (center section of the transmi

DRIVE SYSTEM-IVT393. Remove the four screws that secure the drop axle assembly to the IVT, using a 1/2” wrench. See Figure 5B.304. Tap the drop axle o

DRIVE SYSTEM-IVT404. Remove the by-pass lever.NOTE: The by-pass lever has a very tight fit on the by-pass fork. It will need to be persuaded off.5. Re

DRIVE SYSTEM-IVT4115. Separate the spur gear from the brake shaft by removing the retaining ring. See Figure 5B.3816. Remove the bearing. See Figure 5

DRIVE SYSTEM-IVT42Drive pedal shaftsThe I-series tractors equipped with the IVT trans-mission have two drive pedal assemblies. The main drive pedal sh

DRIVE SYSTEM-IVT434c. Rotate the reverse drive pedal shaft out of the reverse pedal support. See Figure 5B.455. Disconnect

IIIChapter 8: Cutting Decks and lift shaft ...143Cleaning the deck . . . . .

DRIVE SYSTEM-IVT448. Remove the hair pin clip, washer and hex bush-ing from the right side of the main drive pedal shaft. See Figure 5B.499. Drive out

DRIVE SYSTEM-IVT4515. Swing the rear of the drive pedal shaft support bracket down.16. Disconnect the steering gear box from the main shaft by removin

DRIVE SYSTEM-IVT465. Insert the main shaft into the hole for the left hex bushing by sliding it through the slot. See Figure 5B.57 NOTE:

DRIVE SYSTEM-IVT4715. Install the right side brake link onto the brake pedal shaft using a new cotter pin. See Figure 5B.6116. Insta

DRIVE SYSTEM-IVT4816e. Slide the reverse drive pedal shaft into the modified hex bushing while aligning the timing marks on the gears of the two sha

STEERING-HYDROGEAR49IntroductionThe steering on the I-series tractor works in two phases. • First it will steer like any other tractor by turning the

STEERING-HYDROGEAR502. Disconnect the transmission link from the right side of the gear box only.2a. Removing the nut and bolt that passes through th

STEERING-HYDROGEAR514. Insert the pins of the gauge block tool P/N 753-05437 into the cam slot. See Figure 6A.5.5. Rest the tool flat against the fram

STEERING-HYDROGEAR52Neutral and Transmission Links AdjustmentThe first step is to coordinate the neutral points of the steering gear box, both transmi

STEERING-HYDROGEAR533. Loosen the two screws that connect each drive control link to the shifter T-plate on each trans-mission. See Figure 6A.11.NOTE:

IV

STEERING-HYDROGEAR54Wheel alignmentNOTE: The transmission neutral adjustment must be done prior to adjusting the steering link-age. 1. Remove the thre

STEERING-HYDROGEAR553b. Adjust the drag link until the holes line up See Figure 6A.17.NOTE: The punch should slide in and out with-out binding. As th

STEERING-HYDROGEAR563. At the bottom of the lever with the cam slot there is a connector link. Remove the hairpin clip and push it out of the lever. S

STEERING-HYDROGEAR57NOTE: Rotating the steering shaft bushing 90 degrees will allow the bushing to pop out, reliev-ing the pressure on the steering sh

STEERING-HYDROGEAR5815. Apply anti-seize compound to the rollers and the cam slots on the gear box levers. See Figure 6A.28.16. Ad

STEERING-HYDROGEAR59Rebuilding the steering gear boxThere are two different gear boxes available for the I-series tractors that are equipped with Hydr

STEERING-HYDROGEAR605. Lift the upper housing off of the lower housing.NOTE: There is no sealant between the two housings. They should easily slip apa

STEERING-HYDROGEAR619. Separate the speed cam from the output bevel gear assembly by removing the small snap ring from the speed cam shaft. See Figure

STEERING-HYDROGEAR6213. Inspect the input sector gear bushings for dam-age and/or signs of wear. If they show signs of wear of damage, press both of t

STEERING-HYDROGEAR6317. Remove the snap ring from the input shaft. See Figure 6A.45.18. Remove the input shaft from the inside of the housing. See

INTRODUCTION1Professional Shop Manual intentThis Manual is intended to provide service dealers with an introduction to the mechanical aspects of the I

STEERING-HYDROGEAR6420. Inspect the bearings. If they are worn or rough, carefully drive the inner bearing out of the upper housing using a pin punch

STEERING-HYDROGEAR653. Insert the steering shaft. See Figure 6A.53.4. Place the large washer over the steering shaft. See Figure 6A.54.Figure 6A.53Ste

STEERING-HYDROGEAR667. Insert the input sector gear into the internal cam.NOTE: The input sector gear and the internal cam have a master spline to tim

STEERING-HYDROGEAR679e. Install both of the snap rings.9f. Repeat for the right output bevel gear assembly.10. Place both output bevel gear assembl

STEERING-HYDROGEAR6812. Fill the lower housing with 12 oz. of 737-0300A DurinaTM grease. See Figure 6A.65.13. Press in the upper ball bearing into t

STEERING-HYDROGEAR6916. Install the snap ring on the input shaft. See Figure 6A.69.17. Install the wear block:• For the 618-04430 steering

STEERING-HYDROGEAR7020. With the wear block facing the front, adjust the steering rack until the right side measures 1.8” from the case to the shoulde

STEERING-HYDROGEAR71Wear block adjustmentAll of the steering gear boxes have a wear block that presses the wear block against the steering rack to set

STEERING-HYDROGEAR72Front wheels and axlesRemove/ replace the front wheels:1. Lift and safely support the front end of the trac-tor.2. Gently pry off

STEERING-HYDROGEAR73To remove/ replace the front axles:1. Lift and safely support the front of the tractor.2. Remove the front wheel by following the

INTRODUCTION2Description of the I-seriesThe I-series is a revolutionary new tractor platform introduced in the 2007 season. This platform combines a t

STEERING-HYDROGEAR74Drag linksTo remove/replace a drag link:1. Remove the steering gear covers.2. Remove and discard the nut holding the drag link to

STEERING-HYDROGEAR75To remove/replace the tie rod:1. Remove the steering gear covers.2. Remove and discard the nut holding the tie rod spherical rod e

STEERING-HYDROGEAR767. Install the king pin.8. Align the timing marks and install the inboard steering gear.9. Attach the tie and drag link ends using

STEERING-HYDROGEAR776. Remove the pivot bar shoulder bolts. See Figure 6A.93.7. Slide the bumper mounting bracket and the pivot bar br

STEERING-HYDROGEAR7814. Start re-assembling the pivot bar by inserting the steering king pins into the pivot bar. Secure them with new cotter pins. Se

STEERING-HYDROGEAR7922. Install the pivot bar by following steps 3 - 7 in reverse order.NOTE: When installing the pivot bar, use a clamp to line up th

STEERING-HYDROGEAR80

STEERING-IVT81Introduction Just like the I-series with HydroGear transmis-sions, the steering on the I-series tractor with the Infinitely Variable Tr

STEERING-IVT822b. Using a 1/4”-20x2” bolt, thread it into the steering box centering port until you feel it touch the steering rack. While trying to

STEERING-IVT836b. Remove the bow tie and clevis pins.6c. Raise the drive control link away from the cam slot.NOTE: Catch the double roller when lif

ENGINE RELATED PARTS3This chapter will cover the engine accessories that are manufactured by Cub Cadet. IMPORTANT: The engine is manufactured by Kohle

STEERING-IVT84Neutral and drive control links AdjustmentIMPORTANT: Check the tire air pressure before attempting to diagnose any problems with the ste

STEERING-IVT854. Remove the two screws in the cargo net area, at the bottom of the dash. See Figure 6B.13.NOTE: The cargo net was removed for a cleare

STEERING-IVT868. Jack the tractor up so that both rear wheels are off of the ground and place a pair of jack stands under the rear transmissions.

STEERING-IVT87If the transmission needs adjusted:15. Turn off the engine.16. Loosen the two nuts and bolts in the center of the drive control linkage

STEERING-IVT88Wheel alignmentNOTE: The transmission neutral adjustment must be done prior to adjusting the steering link-age. 1. Remove the three scre

STEERING-IVT893b. Adjust the drag link until the holes line up See Figure 6B.25.NOTE: The punch should slide in and out with-out binding. As the drag

STEERING-IVT904. Disconnect the drive control link from both sides of the gear box by removing the nut and bolt. See Figure 6B.5.5. Raise the drive c

STEERING-IVT918. Remove the steering shaft by removing the two clamp bolts in the steering shaft receiver and lift-ing the shaft out. See Figure 6B.32

STEERING-IVT9217. Attach the steering links. Install the retainers.NOTE: If the retainers are bent or twisted, the whole link must be replaced. The re

STEERING-IVT934. Remove the six remaining case screws using a 3/8” wrench. See Figure 6B.38.5. Lift the upper housing off of the lower housing.NOTE: T