Cub Cadet ISeries User Manual

Professional Shop Manual

I Series Riding Tractors

NOTE: These materials are for use by trained technicians who are experienced in the service and repair of outd oor power equipment of the kind described in this publication, and are not intended for use by untrained or inexperienced individuals. These materials are intended to provide supplemental information to assist the trained technician. Untrained or inexperienced individuals should seek the assistance of an experienced and trained professional. Read, understand, and follow all instructions and use common sense when working on power equipment. This includes the contents of the product’s Operators 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 accura te as possible at the time of publication. However, du e to the variety of outdoor power equipment and continuing product changes that occur over time, updates will be made to these instructions from time to time. Therefore, it may be necessary to obtain the latest materials before servicing or repairing a product. The company reserves the right to make changes at any time to this publication without prior notice and without incurring an obligation to make such changes to previously published versions. Instructions, photographs and illustrations used in this publication are for reference use only and may not depict actual model and component parts.

MTD Products Inc. - Product Training and Education Department

FORM NUMBER - 769-03231A

08/2009

Table of Contents

Chapter 1: Introduction .........................................................................................................1

Professional Shop Manual intent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Description of the I-series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Model and Serial Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Chapter 2: Engine related parts............................................................................................ 3

Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Exhaust pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Fuel tank removal/replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Chapter 3: Brakes ...................................................................................................................7

Brake system description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Brake adjustment - HydroGear transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Brake adjustment - IVT transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Brake puck/rotor replacement - HydroGear Transmissions . . . . . . . . . . . . . . . . . . . . . . . . 9

Brake shoes/drum - IVT transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Brake cross shaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Chapter 4: Body/chassis .......................................................................................................17

The hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Remove the fender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Chapter 5A: Drive system - HydroGear Transmissions .................................................. 23

Drive belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Belt adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Drive pedal shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Chapter 5B: Drive system - IVT Transmission .................................................................. 29

Drive belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Belt adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Drop axle assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Rebuilding the drop axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Drive pedal shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Chapter 6A: Steering - Hydrogear Transmissions........................................................... 49

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Cam Slot Angle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Neutral and Transmission Links Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Steering gear box removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Rebuilding the steering gear box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Wear block adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Front wheels and axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Drag links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Tie rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Inboard steering gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Pivot bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Chapter 6B: Steering - IVT Transmission ......................................................................... 81

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Cam Slot Angle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Neutral and drive control links Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Steering gear box removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Rebuilding the steering gear box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Front wheels and axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Drag links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Tie rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Inboard steering gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Pivot bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Chapter 7: electrical system ...............................................................................................111

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Electrical environment: AC Vs. DC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Types of circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Parallel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Series/parallel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Shorts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Opens 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Increased resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

The Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Equipment that may be useful. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Digital Multi-meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Wiring diagram or schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Fused jumper wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Test lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Ammeters and specialized charging system testers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Battery Testers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Testing the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Voltage Drop Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Cutting decks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

Chapter 8: Cutting Decks and lift shaft ............................................................................143

Cleaning the deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

To clean the deck while it is removed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

PTO belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Timing belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Spindles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

To replace a spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

Leaving the deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

Side to Side Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

Front To Rear Leveling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

Deck Gauge Wheel Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

Deck Rear Roller Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

Deck lift shaft assembly bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Deck lift shaft assembly removal/replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

Deck lift links and cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

Chapter 9: Maintenance intervals .................................................................................... 157

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

Engine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

The spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

Air filter and foam pre cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Servicing the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Clean the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

III

CHAPTER 1: INTRODUCTION

INTRODUCTION

Professional Shop Manual intent

This Manual is intended to provide service dealers

with an introduction to the mechanical aspects of the Iseries tractor.

This Professional Shop Manual covers the I-series

tractor more specifically, and in greater depth than the original Shop Handbook.

• The content in this manual supersedes any content in the handbook.

• Detailed service information about the engine will be provided by the engine manufacturer, in most cases.

Disclaimer: The information contained in this manual is correct at the time of writing. Both the product and the information about the product are subject to change without notice.

About the text format:

NOTE: is used to point out information that is relevant to the procedure, but does not fit as a step in the procedure.

• Bullet points: indicate sub-steps or points.

Caution is used to point out poten-

! CAUTION! CAUTION

property.

! WA RNING! WA RNING

injury.

! DANGER! DANGER

This signal word is to be limited to the most extreme situations

tial danger to the technician, operator, bystanders, or surrounding

Warning indicates a pote ntially hazardous situation that, if not avoided, could result in death of serious

Danger indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.

Disclaimer: This manual is intended for use by trained, professional technicians.

• Common sense in operation and safety is assumed.

• In no event shall MTD or Cub Cadet be liable for poor text interpretation or poor execution of the procedures described in the text.

• If the person using this manual is uncomfort able with any procedures they encounter , they shou ld seek the help of a qualified technician or Cub Cadet Technical Support.

Fasteners

• Most of the fasteners used on the vehicle are sized in fractional inches. Some are metric. For this reason, wrench sizes are frequently identified in the text, and measurements are given in U.S. and metric scales.

• If a fastener has a locking feature that has worn, replace the fastener or apply a small amount of releasable threadlocking compound such as Loctite® 242 (blue).

• Some fasteners like cotter pins are single-use items that are not to be reused. Other fasteners such as lock washers, retaining rings, and internal cotter pins (hairpin clips) may be reused if the do not show signs of wear or damage. This manual leaves that decision to the judgement of the technician.

Assembly

Torque specifications may be noted in the part of the text that covers assembly, they may also be summarized in tables along with special instructions regarding locking or lubrication. Whichever method is more appropriate will be used. In many cases, both will be used so that the manual is handy as a quick-reference guide as well as a step-by-step proced ur e guid e that does not require the user to hunt for information.

The level of assembly instructions provided will be determined by the complexity and of reassembly, and by the potential for unsafe conditions to arise from mistakes made in assembly.

Some instructions may refer to other parts of the manual for subsidiary procedures. This avoids repeating the same procedure two or three times in the manual.

INTRODUCTION

Description of the I-series

The I-series is a revolutionary new tractor platform introduced in the 2007 season. This platform combines a traditional lawn tractor with zero-turning capabilities. This is accomplished by controlling the drive of the rear wheels independently and the use of an innovative steering system. See Figure 1.1.

Figure 1.1

The Steering gear box operates the control linkages for the transmissions while turning the front wheels. This gives the I-series zero-turning capabilities while using a traditional steering wheel.

The I-series comes with 42”, 46” and 50” deck options. The I-series tractors also have the Cub Cadet Rev-Tek system.

The I-series tractor can be equipped with two HydroGear Transmissions or an IVT transmissio n. The Infinitrak full-toroidal Infinitely Variable Transmission (IVT) was first introduced in Europe for the 2009 model year.

Model and Serial Numbers

The model and serial number tag can be found

under the seat. See Figure 1.2.

Serial number

Model number

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 17AF9BKH710. The break

down of what the number mean is as follows:

17.........................residential zero turn mower

...A.......................sales level

......F.....................engine code

........9...................frame

..........B................drive system

............K..............hood style

...............H...........deck (H = 46” K = 50”)

...................710....customer number

The serial number is 1J056G10005. The serial numbe r reads as follows:

1...........................engineering level

..J.........................month of production (J = October)

.....05....................day of the month

.........6..................last digit of the year

...........G................plant it was built in

..............1.............assembly line number

.................0005.....number of unit built

CHAPTER 2: ENGINE RELATED PARTS

ENGINE RELATED PARTS

This chapter will cover the engine accessories that

are manufactured by Cub Cadet.

IMPORTANT: The engine is manufactured by Kohler. Refer to the Kohler manual for engine specific service information.

Muffler

Remove the muffler by following these steps:

1. Remove the hood and bumper by following the steps described in Chapter 4: Body/Chassis.

2. Remove the two screws on each side that hold the muffler guard bracket. See Figure 2.1.

Remove these screws

3. Remove the hood pivot brackets by removing the two screws that secure each one in place. See Figure 2.2.

Remove these screws

Figure 2.2

4. Pull the muffler cover and muffler out together. See Figure 2.3.

Figure 2.1

Pull muffler foreword

Figure 2.3

NOTE: The muffler slides onto the exhaust

pipes. The heat of the exhaust makes the pipe s expand and forms a seal with the muffler. Do not weld or place a sealer between the muffler and exhaust pipes.

ENGINE RELATED PARTS

5. With the muffler on a work bench, remove the four screws that fasten the muffler to the muffler bracket. See Figure 2.4.

Remove these screws

Figure 2.4

6. Remove the two screws that fasten the muffler guard to the muffler bracket. See Figure 2.5.

Remove these screws

7. The muffler, muffler cover and the muffler bracket can now be separated. See Figure 2.6.

Muffler brackets

Heat shield

Muffler

Figure 2.6

NOTE: The heat shield and muf fler bracket s can

be left together and handled as one part.

8. Install the muffler by following the above steps in reverse order.

Figure 2.5

ENGINE RELATED PARTS

Exhaust pipes

The exhaust pipes are manufactured by Cub

Cadet. To remove/replace the exhaust pipes:

1. Remove the muffler following the steps described in the previous section.

2. Remove the mounting bolts using a 1/2” wrench. See Figure 2.7.

Remove these bolts

Fuel tank removal/replacement

Remove/replace the fuel tank by following these steps:

Gasoline and it vapors are

! CA UTION! CA UTION

system

1. Remove the deck.

2. Remove the fender by following the steps described in Chapter 4: Body/Chassis.

3. Remove the hair pin clips retaining the deck lift cables and disconnect the cables. See Figure 2.8.

Hair pin clip

extremely flammable. Use common sense when working around the fuel

Deck lift cable

Figure 2.7

3. DIscard the old exhaust gaskets. Clean all gasket material from the cylinder head (and exhaust pipe if it is being reused.

4. Using new gaskets, install the exhaust pipes following the above steps in reverse order.

Figure 2.8

4. Unhook the deck lift assist spring. See Figure 2.9.

Deck lift assist spring

Figure 2.9

ENGINE RELATED PARTS

5. Remove the two screws and two nuts that fasten the seat box cover. See Figure 2.10.

Remove these screws

Seat box

Figure 2.10

6. Remove the seat box cover.

7. Clamp the fuel line. See Figure 2.11.

Fuel line clamp

Fuel line

Figure 2.11

8. Remove the fuel line clamp and slide the fuel line off.

NOTE: The fuel tank has a barbed fitting. Anytime a fuel line is removed from a barbed fitting it should be replaced because of the damag e caused to the fuel line liner.

9. Lift the fuel tank out of the seat box.

10. Install the fuel tank by following the above steps in reverse order.

11. Test run the tractor and check for leaks before returning to service.

CHAPTER 3: BRAKES

BRAKES

Brake system description

The I-series tractors have two braking systems available based on which transmission is used. HydroGear transmissions use a disc type brakes. The IVT transmission uses an external drum brake system.

For HydroGear transmissions:

• The brakes are located on each transmission.

• They are activated by pressing on the brake

pedal.

• The brake pedal is attached to a brake cross

shaft assembly. This will pull on the two brake rods.

• The brake rods are attached to the cam arms, in

the brake calipers, by over travel springs.

• When the cam arms are pulled forward they

push on the brake pins by a cam action applying pressure to the brake pads.

• The brake cross shaft assembly also has a link

that is connected to the drive belt idler pulley bracket. When the brakes are applied, the idler pulley is pulled away from the drive belt. This detensions the belt, disengaging drive to the transmissions. See Figure 3.1.

For the IVT transmission:

The IVT transmission has two drop axles. On each drop axle there is an external drum brake. See Figure 3.2.

Brake

Figure 3.2

• The brakes are applied whenever the drive

pedal is released.

• Depressing the brake pedal will disengage the

drive belt and apply extra force to the rear shoes.

Idler pulley

Brake rods

Drive pedal shaft

Figure 3.1

• The idler pulley bracket has a gas charged

dampener attached to it. This dampener will smooth out the engagement of the drive belt when the brake pedal is released.

Belt de-tensioned

BRAKES

Brake adjustment - HydroGear transmissions

NOTE: Whenever performing a brake adjust-

ment, inspect the brake components for signs of wear or damage.

1. Block the front wheels.

2. Lift and safely support the rear of the tractor. See Figure 3.3.

Place jack stands here

Figure 3.3

5. Back the castle nut off a few turns using a 9/16” wrench.

NOTE: Even if the brakes are set to the correct clearance, inserting a feeler gauge between the rotor and the brake puck can be very difficult. Loosen the castle nut first, then insert the feeler gauge and tighten the nut to set the pro per clearances

6. Insert a .030” (0.8 mm) feeler gauge between the brake rotor and the outboard brake puck. See Figure 3.5.

0.030” feeler gauge

NOTE: Make sure the brake and parking brake are released.

3. Remove the rear wheels.

4. Remove the cotter pin locking the castle nut on the brake caliper. See Figure 3.4.

Castellated nut

Figure 3.4

Cotter pin

Figure 3.5

NOTE: The tolerance for the brake clearance is

.020” - .040” (0.5 - 1.0mm). The .030 feeler gauge will set the clearance at the midpoint.

7. Tighten the nut until there is a slight drag on the feeler gauge when sliding it out.

NOTE: For even braking, both sides should be set to the same clearance.

8. Install a new cotter pin.

9. Repeat same procedure on the other side.

10. Put the wheels back on. Tighten the lug nuts to a torque of 53 - 60 ft lbs. (72 - 81 Nm).

11. Take the tractor off of the jack stands.

12. O pen the by-pass valves and check the parking brake before returning the tractor to service.

• With the brakes released, the tractor should have only hydraulic drag when it is pushed.

• With the brakes engaged, the wheels should slide before they rotate when the tractor is pushed.

BRAKES

Brake adjustment - IVT transmissions

To adjust the brakes on IVT transmission:

1. Lift the rear of the tractor and safely support it with a pair of jack stands.

2. Remove the rear wheels with a 3/4” wrench.

3. Release the parking brake.

4. Remove the cotter pin that retains the ferrule of the drive control rod. See Figure 3.6.

brake disengagement block

Drive control rod

Ferrule

Brake puck/rotor replacement - HydroGear Trans-

missions

On HydroGear transmissions, the brake pucks are a wearing part that will need to be serviced from time to time. If a tractor is operated with the parking brake dragging, the pucks will wear out rapidly and the brake rotor will develop hot spots. If the tractor is operated long enough, the rotor may have grinding marks on it with excessively worn pucks.

If the rotor shows hot spots or any

! CA UTION! CA UTION

ure to do so can result in the failure of the brakes

The brake pucks and the rotors are serviced at the same time. To service the brake pucks:

1. Jack up the tractor and remove the rear wheels

as described in the previous section.

2. Make sure the brakes are released.

3. Disconnect the brake rod spring. See Figure 3.7.

other signs of damage, including warpage, it must be replaced. Fail-

Figure 3.6

5. Slide the ferrule of the drive control rod out of the brake disengagement block.

NOTE: Once the control rod is disengaged, the springs will clamp the brake shoes against the drum. This will automatically center the disengagement block.

6. Adjust the ferrule until it slides into the hole in the disengagement block with out applying pressure to it.

7. Install a new cotter pin into the ferrule to secure it to the disengagement block.

8. Repeat the steps 4 - 6 on the other side of the tractor.

9. Install the rear wheels. Tighten the lug nuts to a torque of 53 - 60 ft lbs. (72 - 81 Nm).

10. Take the tractor off of the jack stands.

11. Test drive the tractor in a safe area before returning it to service.

Disconnect this spring

Figure 3.7

BRAKES

4. Loosen the rear mounting bolt. See Figure 3.8.

Remove this bolt

Loosen this bolt

Figure 3.8

5. Remove the front mounting bolt, allowing the caliper to swing down. See Figure 3.9.

7. Slide the brake rotor off to reach the inboard brake puck. See Figure 3.10.

Inboard brake puck

Figure 3.10

8. Remove the caliper for inspection when servicing the brake pucks. To do this, remove the rear bolt loosened in step 4.

9. With the caliper on a work bench, remove the brake puck, backing plate and the two brake pins. See Figure 3.11.

Figure 3.9

6. The outboard brake puck should fall out when the brake caliper swings down. If it did not, it can be removed now.

Brake caliper

Brake pins

Backing plate

Brake puck

Figure 3.11

10. Check for free movement of the brake pins. A dry lubricant can be used on the brake pins sparingly.

Never put grease or anti-seize on

! CA UTION! CA UTION

action of the pucks.

brake pins. It can migrate to the brake pucks, preventing the braking

BRAKES

11. Slide the brake pins into the caliper.

12. Place the backing plate in the caliper.

13. Place a new puck into the caliper. See Figure 3.12.

Brake caliper re-assembled

Figure 3.12

NOTE: A piece of scotch tape may be used to

hold the new brake pucks in place for assembly. The tape will grind away when the brakes are applied.

16. Mount the brake caliper to the transmission. Apply a small amount of releasable thread locking compound such as Loctite® 242 (blue) to the mounting bolts and tighten to a torque of 80 120 in-lbs (9 - 13.5Nm).

17. Reconnect the brake rod spring.

18. Adjust the brakes as described in the previous section.

19. Put the wheel on.

20. Repeat steps 4-19 on the other side.

21. When both sides are completed and both wheels are back on, take the tractor off of the jack stands.

22. O pen the by-pass valves and check the parking brake before returning the tractor to service.

• With the brakes released, the tractor should have only hydraulic drag when it is pushed.

• With the brakes engaged, the wheels should slide before they rotate when the tractor is pushed.

14. Place a new brake puck into the recess in the transmission. Use a piece of scotch tape to hold it in place.

15. Slide the brake rotor in place, shoulder out.

BRAKES

Brake shoes/drum - IVT transmissions

On IVT transmissions, the brake shoes and drums are the wearing parts that will need to be serviced from time to time. If a tractor is operated with the parking brake dragging, the shoes will wear out rapidly and the brake drum will develop hot spots. If the tractor is operated long enough, the drum may have grinding marks on it with excessively worn shoes.

If the drum shows hot spots or any

! CA UTION! CA UTION

ure to do so can result in the failure of the brakes

IMPORTANT: The brake shoes and the drums must be replaced at the same time.

To service the brakes:

1. Jack up the tractor and remove the rear wheels

as described in the previous section.

2. Make sure the brakes are released .

3. Disconnect the brake rod spring.

See Figure 3.13.

other signs of damage, including warpage, it must be replaced. Fail-

4. Disconnect the brake shoe spring. See Figure 3.14.

Brake shoe spring

Figure 3.14

NOTE: There is a lot of tension in the brake

shoe springs. A piece of starter rope can be used to remove the spring.

Do not remove the screws to dis-

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and can cause the screw to become a projectile as it is being removed.

connect the brake shoe springs. The springs are under high tension

Brake rod

Figure 3.13

5. Remove the pivot bolt at the bottom of the brake shoes.

NOTE: There is a spacer behind the shoes that will fall out as the pivot bolt is removed. See Figure 3.15.

Spacer

Pivot bolt

Figure 3.15

BRAKES

6. Remove the snap ring that secures the drum with a pair of snap ring pliers. See Figure 3.16.

Remove the snap ring

Figure 3.16

7. Install the drum and shoes by following step s 1 7 in reverse order.

8. Repeat steps 1-8 on the other side of the tractor.

Brake cross shaft assembly

The brake cross shaft assembly for the HydroGear transmissions and the IVT transmissions are not the same. The procedure to service them are the same.

The brake cross shaft assembly is supported by two bushings. Excessive movement in the brak e cro ss shaft assembly may be an indication that the bushings are worn out.

To replace the brake cross shaft bushings:

1. Remove the cotter pins that retain the three

brake rods. Slide the brake rods out of the brake cross shaft assembly. See Figure 3.17.

Brake rods

Never put grease or anti-seize on

! CA UTION! CA UTION

braking surfaces, preventing the braking action of the shoes.

9. Test drive the tractor in a safe area before returning it to service.

the brake shoe pivot screw or the drum splines. It can migrate to the

Figure 3.17

2. Remove the cotter pins on each end of the brake cross shaft. See Figure 3.18.

Remove cotter pins

Figure 3.18

BRAKES

3. Remove the right side bushing first. This will allow the shaft to slide far enough to the lef t to let the other bushing to come out.

4. Install new bushings by following the above steps in reverse order.

NOTE: Do not put grease on the bushings. Grease can trap dirt that will accelerate the wear of the bushing.

5. Check the operation of linkage and test drive the tractor in a safe area before returning to service.

To remove/replace the brake cross shaft assembly:

1. Remove the brake pedal by removing the two screws using a 1/2” wrench.

2. Remove the cotter pins that retain the three brake rods. Slide the brake rods out of the brake cross shaft assembly. See Figure 3.19.

Brake rods

Figure 3.19

3. Remove the four screws (two on each side) that hold the sub-frame in place and slide it down. See Figure 3.20.

Remove these screws

Figure 3.20

BRAKES

4. Loosen the shoulder bolt that the parking brake plate pivots on. See Figure 3.21.

Parking brake plate

Shoulder bolt

Figure 3.21

5. Remove the cotter pin from each end of the brake cross shaft. See Figure 3.22.

6. Slide the split bushings out of their pockets in the sub-frame, then pull them off of the brake cross shaft assembly. See Figure 3.23.

Figure 3.23

7. Work the brake cross shaft ou t of the sub frame . NOTE: Take care not to bend the parking brake

plate while working the brake cross shaft out. Make sure the shoulder bolt is loose enough to give the shaft clearance. The plate can be removed if necessary. See Figure 3.24.

Remove cotter pins

Slide pin out of plate

Figure 3.22

Figure 3.24

8. Replace the brake cross shaft by following the above steps in reverse order.

9. Test drive the tractor in a safe area before returning to service.

BRAKES

CHAPTER 4: BODY/CHASSIS

BODY/CHASSIS

The hood

The I-series hood uses the same hood pivot sys-

tem as the 1000 series for easy removal. To remove the hood:

1. The hood is front-hinged. See Figure 4.1.

Lift here

Figure 4.1

2. Open the hood by lifting the rear edge to tilt it forward.

3. Disconnect the headlight wires. See Figure 4.2.

4. Cut the wire tie that secures the headlight harness to the hood. See Figure 4.3.

Headlight harness

Wire tie

Figure 4.3

5. The hood hinges on a pair of shoulder bolts on each side that fit into slots in the hood bracket.

6. The hinge travel is limited by the top shoulder bolt that fits into a channel in the hood bracket.

7. Open the hood far enough to align the tabs with the slots, then lift the hood off of the tractor. See Figure 4.5.

Inset: headlight detail

Figure 4.2

NOTE: The ground terminals and powe r te rm i-

nals on the headlights are two different sizes. The green wires (ground) fit the larger terminals. The red wires (power) fit the smaller terminals.

Slots

Bracket

Shoulder bolts

Figure 4.4

BODY/CHASSIS

Bumper

I-series tractors come equipped with a fast attach

bumper. To remove the bumper:

1. Remove the two screws, one on each side, that secures the bumper bracket. See Figure 4.5.

Remove screw

Bumper

Figure 4.5

Dash Removal

The dash for the I-series is easy to remove. There are a few repair procedures, such as the cam angle adjustment or replacing the steering gearbox, that require the dash to be removed. The step s to remove it are as follows:

1. Remove the steering wheel:

1a. Remove the center cover. See Figure 4.7.

Center cover

2. Pull the bumper straight forward, sliding th e bumper off of the shoulder bolts. See Figure 4.6.

Shoulder bolt

Figure 4.6

3. Install the bumper following the above steps in reverse order.

Figure 4.7

1b. Remove the bolt with a 1/2” wrench.

See Figure 4.8.

Remove

this

bolt

Figure 4.8

NOTE: There is no puller needed for the steer-

ing wheel. Once the bolt is removed it will lift off of the steering shaft.

NOTE: When replacing the steering wheel, lock

the steering gear box in neutral as described in steering chapters (6A or 6B). This will make it easier to center the steering wheel.

BODY/CHASSIS

2. Remove the dash: 2a. Disconnect the key switch, module, PTO

switch and the hour meter. See Figure 4.9.

Hour meter

PTO switch

Figure 4.9

2b. Disconnect the parking brake by removing

the hair pin clip and sliding the rod out of the lever. See Figure 4.10.

2c. Remove the two screws attaching the dash

to the dash support. See Figure 4.11.

One on each side

Module and key switch

Figure 4.11

2d. Remove the two screws in the cargo net

area, at the bottom of the dash. See Figure 4.12.

Hair pin

clip

Rod

Figure 4.10

Remove these screws

Figure 4.12

NOTE: The cargo net was removed for a clearer

picture. Do not remove the net to remove the dash.

NOTE: If removing the dash, disconnect the throttle and choke cables at this point.

BODY/CHASSIS

2e. Remove the screws at the bottom of the

dash, on each side. See Figure 4.13.

Screw removed

Figure 4.13

2f. The dash can now by lifted ov er the steering

shaft and placed to the side or on top of the engine.

NOTE: If the throttle and choke cable are still attached to the dash, care should be taken to prevent damage to them when lifting the dash.

3. Install the dash by following the above steps in reverse order.

Remove the fender

1. Remove the dash by following the steps described in the previous section of this chapter.

2. Disconnect the wires to the seat switch. NOTE: Tractors built prior to 2008 have two yel-

low wires that go to a switch on the side of the seat bracket. See Figure 4.14.

Seat switch wires

Remove the nut

and bolt to remov

seat

Figure 4.14

NOTE: Tractor built from 2008 to present have

two yellow wires and a green wire that go to a switch inside the seat.

Seat switch

Seat bracket

mounting screws

Figure 4.15

NOTE: When reconnecting the wires, the posi-

tion of the two yellow wires does not affect the

operation of the tractor.

3. Remove the seat bracket and seat as one piece.

4. Remove the grip from the deck lift handle.

BODY/CHASSIS

5. Remove the nuts from the under side of the foot rests. See Figure 4.16.

Remove these nuts

Figure 4.16

6. Remove the brake and drive pedals.

7. Remove the screw from the center of the fender. See Figure 4.17.

10. Place the steering wheel on the steering shaft. Turn the wheels to the left and right to allow the fenders to clear the steering arm assembly. See Figure 4.18.

Steering arm assembly

Place some tape here to protect the paint

Figure 4.18

NOTE: When lifting the fender off of the tractor,

clear the left side first and rotate the fender to clear the deck lift lever.

Remove this screw

Figure 4.17

8. Remove the fuel cap.

9. Standing behind the tractor , lif t the fender up till it clears the studs for the seat.

1 1. Install the fender by following the previous steps

in reverse.

BODY/CHASSIS

DRIVE SYSTEM-HYDROGEAR

CHAPTER 5A: DRIVE SYSTEM - HYDROGEAR TRANSMISSIONS

There are two drive systems available for the Iseries tractor. One system uses two HydroGear transmissions. The other system uses an Infinitrak full-toroidal Infinitely Variable Transmission (IVT). Th is chap ter will cover the HydroGear version of the tractor.

The HydroGear version of this tractor uses two EZT transmissions. The transmission control linkages work in unison with the steering linkage to create the zero-turn feature. The neutral adjustments for the transmissions and the transmission links are covered in chapter 6A: Steering - HydroGear.

The Hydro-gear shop manual for the EZT transmissions is form number BLN-52622.

Drive belt

The drive belt is the most common drive system component that will need attention. To remove/replace the drive belt:

1. Remove the deck as described in chapter 8:

Cutting Decks and Lift Shaft.

2. Set the parking brake.

3. Unplug the electric PTO harness.

See Figure 5A.1.

4. Unbolt the electric PTO using an impact wrench and a 5/8” socket. See Figure 5A.2.

PTO clutch

Remove bolt with an impact wrench

Figure 5A.2

NOTE: If the PTO clutch will not slide off of the

crankshaft, thread the bolt half way into the crankshaft. Make sure the belt keeper is in place to prevent the clutch from rotating. Start the engine and turn the PTO on and off several times to shake it loose.

Starter

PTO connector

Figure 5A.1

NOTE: If the PTO will not come off using the

steps above, remove the engine mounting bolts and slide the engine back. This will give enough clearance to slide the belt off of the engine pulley.

Cub Cadet belts are designed to fit

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prevent the de-clutching mechanism from working properly when the brakes are applied.

our equipment and are not standard lengths. Use of a non-OEM belt may

DRIVE SYSTEM-HYDROGEAR

5. Slide the engine pulley down far enough to slip the belt off of the pulley. See Figure 5A.3.

Engine pulley

Figure 5A.3

NOTE: Note the direction of the key in the

engine pulley. It should be facing down. If the pulley is installed upside down, the belt alignment will be off.

NOTE: When installing the engine pulley and electric PTO, coat the crank sh aft with anti-seize. This will ease pulley and clutch removal in the future.

NOTE: If the engine pulley is seized to the crankshaft, the engine bolts can be removed to slide the engine to the rear. This will provide enough clearance to remove the belt.

7. Work belt off of the idler pulleys. NOTE: It may be necessary to loosen the move-

able idler pulley to get the belt to clear the belt guide on the idler bracket. See Figure 5A.4.

8. The transmission brace doubles as a belt keeper. Remove the two screws that hold the transmission brace to the transmission. Slide the brace to the rear of the tractor to make enough clearance to remove the belt. See Figure 5A.5.

Remove this

screw on each side

Figure 5A.5

9. Work belt around the transmission pulleys and fans.

NOTE: Use care to prevent damage to the fans when removing the belt.

6. Remove the three belt guides near the idler pulleys. See Figure 5A.4.

Belt guides

Moveable idler

Figure 5A.4

DRIVE SYSTEM-HYDROGEAR

10. Remove the two screws that hold the transmission links to the shifter plate. See Figure 5A.6.

Transmission link

Remove these screws

Figure 5A.6

11. The belt can now be snaked out of the tractor.

12. Install the belt following the above steps in reverse order.

Belt adjustment

The drive belt is tensioned by a spring loaded moveable idler pulley. When the brakes are applied, the drive belt is de-clutched. An adjustable linkage connects the tensioner pulley to the brake shaft. A brake link that is out of adjustment will prevent the moveable idler from correctly tensioning and de-tensioning the belt.

As the belt wears and stretches, the moveable idler needs to push the belt in further to keep proper belt tension. To do this, the ferrule at the end of the brake link needs to be at the middle of the slot in the idler pulley bracket. To adjust this brake link:

NOTE: The belt must be on when performing this adjustment.

1. Release the parking brake.

2. Remove the deck as described in chapter 8 Cut-

ting Decks and Lift Shaft.

3. Remove the cotter pin and washer from the fer-

rule. See Figure 5A.7.

NOTE: Tighten the electric PTO clutch bolt to a torque of 450 - 600 in-lbs (51 - 68 Nm).

13. Test drive the tractor before returning to service.

Cotter pin

Ferrule

Figure 5A.7

DRIVE SYSTEM-HYDROGEAR

4. Slide the ferrule out of the idler bracket. See Figure 5A.8.

Washer

Slot

Figure 5A.8

5. Adjust the ferrule so that it lines up with the rear of the slot and slides in without pulling on the spring. See Figure 5A.9.

Transmissions

The I-series tractor uses two EZT transmissions from Hydro-gear. The transmissions can be removed separately. To remove a transmission:

NOTE: The transmission model and serial number tags are located on the frame channel next to the transmission that they refer to.

1. Remove the deck as described in chapter 8 Cut-

ting Decks and Lift Shaft.

2. Remove the drive belt as described previously in

this chapter. NOTE: Leave the transmission links and the

transmission brace disconnected.

3. Lift and safely support the rear of the tractor.

4. Remove the rear wheels.

5. Unhook the by-pass rod. See Figure 5A.10.

Front of tractor

Figure 5A.9

6. Install the washer and a new cotter pin.

7. Test drive the tractor before returning to se rvic e.

8. Re-attach the deck.

Bad spring

Unhook the spring

Figure 5A.10

6. Disconnect the brake rod by following the steps

described in Chapter 3: Brakes.

DRIVE SYSTEM-HYDROGEAR

7. Remove the two bolts that thread into the cross tubes. See Figure 5A.11.

Cross truss

Bolts

Figure 5A.11

8. Support the transmission to prevent it from fa lling while the mounting bolts are removed.

9. Remove the bolt holding the transmission to the torque bracket. See Figure 5A.12.

10. Remove the two bolts that fasten the transmission to the frame. See Figure 5A.13.

Reinforcing strap

Spacer

Figure 5A.13

NOTE: The two transmission bolts pass through

a spacer and a reinforcing strap. When the bolt s are removed, the spacer and strap can be removed. See Figure 5A.13.

11. The transmission can now be removed from the tractor.

Torque bracket

Bolt

Figure 5A.12

NOTE: There is a nut on the top side of the

torque bracket. Use a 7/16” wrench to hold it while removing the bolt.

12. If replacing the transmission, remove the transmission pulley and fan assembly.

13. Remove the wheel hub assembly.

14. Install the hub on the new transmission and tighten to a torque of 420 - 480 in-lbs (47.5 54Nm).

15. Install the transmission pulley and fan assembly on the new transmission and tighten to a torque of 300 - 460 in-lbs (34 - 52Nm).

16. Install the transmission by following steps 1 - 11 in reverse order.

17. Perform a neutral adjustment and wheel alignment by following the steps described in 6A: Steering - HydroGear.

18. Test drive the tractor in a safe area before returning to service.

DRIVE SYSTEM-HYDROGEAR

Drive pedal shaft

To remove the drive pedal shaft:

1. Remove the deck as described in chapter 8 Cutting Decks and Lift Shaft.

2. Disconnect the link between the steering gear-

box and the bell crank on the drive pedal shaft. See Figure 5A.14.

Steering gear box lever

Bell

crank

Link

Reverse switch

Figure 5A.14

6. Drive out the two roll pins that secure the drive pedal bracket to the drive pedal shaft. See Figure 5A.16.

Drive pedal bracket

Hex bushing

Figure 5A.16

7. Remove the hex bushing. See Figure 5A.16.

8. Slide the drive pedal shaft to the left to clear the hole for the right side hex bushing. See Figure 5A.17.

NOTE: It does not matter which side of the link is disconnected.

3. Disconnect the reverse switch.

4. Remove and discard the cotter pin on the left side of the drive pedal shaft. See Figure 5A.15.

Washer

cotter pin

Hex bushing

Figure 5A.15

Hole for hex bushing

Figure 5A.17

9. Install the drive pedal shaft by following the previous steps in reverse order.

10. Test drive the tractor before returning it to service.

5. Remove the washer and hex bushing. See Figure 5A.15.

CHAPTER 5B: DRIVE SYSTEM - IVT TRANSMISSION

DRIVE SYSTEM-IVT

There are two drive systems available for the Iseries tractor. One system uses two HydroGear transmissions. The other system uses an Infinitrak full-toroidal Infinitely Variable Transmission (IVT). This chapter will cover the IVT version of the tractor.

The Infinitrak full-toroidal Infinitely Variable Transmission (IVT) removes the constraints of conventional stepped ratio transmissions. Instead of using a system of gears to determine the ratio range, the IVT uses a variator that is made of a set of discs and rollers called a “full toroidal” variator. In the IVT, the torque is controlled allowing optimization of the power train by allowing the engine to run at its most efficient RPM range and stay there.

The IVT used on the I-series is a twin variator version. This means that there is one input and two outputs. See Figure 5B.1

“T” box

Input shaft

The power from the engine is transferred to the transmission via a belt and pulleys. The power is applied to a “T” box assembly. The “T” box output drives the inner discs of the variator assemblies. See Figure 5B.2

“T” box assembly

Inner disks

Figure 5B.2

Each inner disc drives a pair of rollers that drive the output discs. The angle of the rollers determines the speed of the output discs. When the rollers rides near the center of the input discs, they are pressing against the outer edge of the output discs. In this position, the output disc will be turning at a much slower rate than the input discs. See Figure 5B.3

Variators

Figure 5B.1

Rollers

Output disc

500 rpm

50 rpm

Input discs

Figure 5B.3

DRIVE SYSTEM-IVT

NOTE: 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 example to demonstrate the speed differences.

When the rollers rides near the outer edge of the input discs, they are pressing against the center of the output discs. In this position, the output disc will be turning at a much faster rate than the input discs. See Figure 5B.4

500 rpm

1,000 rpm

The key to making this work is a special traction fluid that was developed for this transmission. A Traction fluid is a synthetic transmission fluid designed with properties specifically for transmitting torque between the discs and rollers.

Under normal load conditions this fluid acts like a conventional lubricating fluid. When the fluid is subjected to extreme pressure, such as in the contact area between the discs and rollers, the fluid changes to exhibit its ElastoHydrodynamic Lubricant (EHL) properties. The EHL property of the traction fluid causes the molecules in the fluid to become almost solid. This increases the shear force transmitting properties of the fluid.

The traction fluid in the contact area between the rollers and discs turns into a semi-solid. This allows the fluid to act like a gear tooth, transferring the torque from the disc to the roller or vise versa. It also prevents metal to metal contact extending the life of the moving parts.

Figure 5B.4

When the rollers are in the neutral position o r in the center of the disc valley, all of the discs are rotating at the same speed. See Figure 5B.5

500 rpm

NOTE: Putting motor oil or hydraulic fluid in an IVT transmission will destroy it.

Each of the variators are attached to a epicyclic,

also know as planetary, gear set. See Figure 5B.6

Epicyclic gear sets

Figure 5B.6

Figure 5B.5

DRIVE SYSTEM-IVT

The output shaft of the T-box drives a sun gear in the center of the planetary ge ars at the sa me sp eed a s the input discs. The planetary gear carriers are attached to the output discs. See Figure 5B.7

Output disk

Carrier

Planetary

gears

Epicyclic gear set

Figure 5B.7

The epicyclic gear set acts like an adding machine, it subtracts the input (sun gear) speed from the output (planetary gear carrier). See Figure 5B.8

Planetary gear

If the answer is positive, transmission drives in a forward direction. If the answer is negative, the tra n s mission drives in reverse. If the answer is zero, the transmission will have zero output and be in what is known as a geared neutral state. See Figure 5B.9

Figure 5B.9

The answers from the epicyclic gear sets are collected by the transmission output shaf t s that a re dr iven b the planetary gears. See Figure 5B.10

Carrier

Sun gear

Output shaft

Figure 5B.8

Figure 5B.10

DRIVE SYSTEM-IVT

The transmission output shafts drive a pair of drop

axles assemblies.

The IVT transmissions are NOT serviceable. The drop axles and brakes are serviceable and will be covered in later sections of this chapter.

NOTE: Currently replacement traction fluid is n ot available for purchase.

Drive belt

The drive belt is the most common drive system component that will need attention. To remove/replace the drive belt:

Cub Cadet belts are design to fit

! CAUTION! CAUTION

belt may prevent the de-clutching mechanism from working properly when the brakes are applied.

1. Remove the deck as described in chapter 8:

Cutting Decks and Lift Shaft.

2. Lift and safely support the rear of the tractor.

3. Remove the three belt guides near the idler pul-

leys. See Figure 5B.11

our equipment and are not standard lengths. Use of a non-OEM

Belt Guides

Figure 5B.11

DRIVE SYSTEM-IVT

4. Slide the retainer clip half way out of the dampener end using small flat head screw driver. See Figure 5B.12

Moveable idler

Dampener end

Retainer clip

Figure 5B.12

5. Disconnect the dampener from the moveable idler pulley bracket.

6. Disconnect the brake link from the moveable idler pulley bracket.

9. Unplug the electric PTO harness. See Figure 5B.14

Starter

PTO connector

Figure 5B.14

10. Unbolt the electric PTO using an impact wrench and a 5/8” socket. See Figure 5B.15

7. Loosen the moveable idler pulley enough for the belt to slip past the belt guide using a pair of 9/16” wrenches. See Figure 5B.13

Belt guide

Figure 5B.13

8. Slip the belt off of the idler pulleys.

PTO clutch

Remove bolt with an impact wrench

Figure 5B.15

NOTE: If the PTO clutch will not slide off of the

crankshaft, thread the bolt half way into the crankshaft. Make sure the belt keeper is in place to prevent the clutch from rotating. Plug in the PTO clutch harness. Start the engine and turn the PTO on and off several times to shake it loose.

DRIVE SYSTEM-IVT

11. Slide the engine pulley down far enough to slip the belt off of the pulley. See Figure 5B.16

Engine pulley

Figure 5B.16

NOTE: If the engine pulley will not slide down

the crankshaft using the steps above, remove the engine mounting bolts and slide the engine back. This will give enough clearance to slide the belt off of the engine pulley.

NOTE: Note the direction of the key in the engine pulley. It should be facing down. If the pulley is installed upside down, the belt alignment will be off.

NOTE: When installing the engine pulley and electric PTO, coat the cran kshaft with anti-seize. This will ease pulley and clutch removal in the future.

NOTE: There is a spacer above the engine pulley. It is symmetrical and can not be put on upside down. See Figure 5B.17

12. Remove the rear wheels.

13. Remove the transmission fan. 13a. Reach in through the wheel opening. 13b. Remove the three transmission fan screws

using a 5/16” wrench. See Figure 5B.18

Transmission

fan

Figure 5B.18

13c. Remove the transmission fan. NOTE: Never use an impact wrench to remove

the transmission pulley. It will destroy the one way bearing on the input shaft.

14. Remove the transmission belt guard. 14a. Remove the four screws using a 5/16”

wrench. See Figure 5B.19

Spacer

Belt guard

Engine pulley

Figure 5B.19

14b. Remove the belt guard.

Figure 5B.17

DRIVE SYSTEM-IVT

15. Slip the belt off of the transmission pulley.

16. Remove the belt from the tractor.

17. Install the belt following the previous steps in reverse order.

Drive belt routing

Figure 5B.20

NOTE: Tighten the electric PTO clutch bolt to a

torque of 450 - 600 in-lbs (51 - 68 Nm).

18. Test drive the tractor before returning to service.

Belt adjustment

As the belt wears and stretches, the moveable idler needs to push the belt in further to keep proper belt tension. To do this, the ferrule at the end of the brake link needs to be at the rear of the slot in the idler pulley bracket.

NOTE: The moveable idler pulley has a dampener on it. The dampener allows a slow, smooth engagement of the drive belt. See Figure 5B.21

Brake

link

Dampener

Moveable idler pulley

Figure 5B.21

The brake link is adjusted to the rear of the slot in the moveable idler bracket. This allows the brake pedal can return rapidly when the pedal is released, while the dampener slows the engagement of the drive belt.

Operating the tractor with the idler

! CAUTION! CAUTION

the brake pedal is released.

To adjust this brake link:

NOTE: The belt must be on when performing this adjustment.

1. Release the parking brake.

2. Remove the deck as described in chapter 8 Cut-

ting Decks and Lift Shaft.

pulley dampener removed will result in the tractor lurching when

DRIVE SYSTEM-IVT

3. Remove the cotter pin and washer from the ferrule. See Figure 5B.22

Cotter pin

Ferrule

Figure 5B.22

4. Slide the ferrule out of the idler bracket. See Figure 5B.23

Transmissions

To remove the transmission:

1. Remove the deck as described in chapter 8 Cutting Decks and Lift Shaft.

2. Lift and safely support the rear of the tractor.

3. Remove the dash and fender by following the steps described in Chapter 4: Body/Chassis.

4. Remove the rear wheels.

5. Remove the drive belt from the engine pulley and the idler pulleys by following the procedures described in the drive belt section of this chapter.

NOTE: The belt can stay on the transmission pulley while the transmission is removed.

6. Unhook the by-pass rod spring on both sides of the transmission. See Figure 5B.24

Washer

Slot

Figure 5B.23

5. Adjust the ferrule so that it lines up with the rear of the slot and slides in without pulling on the spring.

6. Install the washer and a new cotter pin.

7. Re-attach the deck.

8. Test drive the tractor before returning to se rvic e.

By-pass rod spring

Figure 5B.24

7. Disconnect the brake rods by following the steps described in Chapter 3: Brakes.

8. Disconnect the drive control links:

DRIVE SYSTEM-IVT

8a. Remove the hair and clevis pins.

See Figure 5B.25

drive control link

Hair pin clip

Clevis pin

Figure 5B.25

8b. Slide the drive control links off of the input

levers

9. Remove the two screws that fasten the expansion tank to the left side of the frame. See Figure 5B.26

10. Remove front mounting screw on each side of the tractor using a 1/2” wrench. See Figure 5B.27

Front mounting

screw

Figure 5B.27

NOTE: Support the transmission to prevent it

from falling while the mounting bolts are removed.

11. Remove the two bolts that fasten the transmission to the frame and the support plate on each side of the tractor. See Figure 5B.28

Expansion

tank

Figure 5B.26

NOTE: The seat frame plate was removed for a

clearer picture. NOTE: Clamp off both of the lines going to the

expansion tank to help prevent loss of traction fluid. Currently replacement traction fluid is not available for purchase.

Support plate

Mounting bolts and nuts

Figure 5B.28

12. Lower the transmission out of the tractor. NOTE: Avoid spilling traction fluid while moving

the transmission. Currently replacement traction fluid is not available for purchase.

DRIVE SYSTEM-IVT

13. If replacing the transmission assembly, remove the transmission fan.

14. If only replacing the IVT (center section of the transmission), remove the drop axles by following the procedures described in the drop axle section of this manual.

15. Install the transmission by following the previous steps in reverse order.

16. Perform a neutral adjustment and wheel alignment by following the steps described in 6B: Steering - IVT.

17. Test drive the tractor in a safe area before returning to service.

Drop axle assemblies

The drop axle assemblies on the IVT transmission

perform three functions:

• The drop axle assemblies are a gearbox that will transmit the power of the IVT at a reduced speed to the drive wheels.

• The drop axle contains a dog clutch assembly to disconnect the transmission from the drive wheel. This allowing the tractor to be pushed by hand.

The drop axle assemblies are serviceable, sepa-

rately from the IVT. To remove the drop axles:

1. Remove transmission assembly from the tractor by following the procedures described in the previous section of this chapter.

2. Remove the eight screws the secure the transmission support bracket to the drop axles using a 1/2” wrench. See Figure 5B.29

Transmission support bracket

Figure 5B.29

DRIVE SYSTEM-IVT

3. Remove the four screws that secure the drop axle assembly to the IVT, using a 1/2” wrench. See Figure 5B.30

Remove these screws

Figure 5B.30

4. Tap the drop axle off of the alignment dowels using a soft faced hammer. See Figure 5B.31

Rebuilding the drop axles

1. Remove the drop axle by following the procedures described in the previous section of this chapter.

2. Remove the brake: 2a. Remove the snap ring that secures the

brake drum to the brake shaft. See Figure 5B.32

Pivot Screw

Snap ring

Brake lever

Drop axle

Figure 5B.31

5. Install the drop axle by following the previous steps in reverse order.

6. Test drive the tractor before returning it to service.

Figure 5B.32

2b. Remove the brake lever using a 3/8”

wrench. See Figure 5B.32

2c. Unthread the pivot bolt from the brake

mounting plate, but do not remove it.

2d. Slide the brake drum and shoes off of the

brake shaft as one assembly.

3. Remove the push nut that secures the by-pass lever to the by-pass fork. See Figure 5B.33

By-pass lever

push nut

Figure 5B.33

NOTE: If the by-pass lever or fork are not being

replaced, the push nut can be left in place.

DRIVE SYSTEM-IVT

4. 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. Remove the eleven housing screws using a 3/8” wrench.

6. Lift the upper housing off of the gearbox.

7. Remove the drive axle assembly. See Figure 5B.34

Drive axle

11. Remove the brake shaft assembly. See Figure 5B.36

By-pass fork

Brake shaft assembly

Figure 5B.36

12. Slide the bushings off of the brake shaft.

13. Slide the washer and the spring off of the brake shaft.

Figure 5B.34

8. Slide the bushing and the bearing off o f the drive axle.

9. Remove the thrust bearing.

10. Remove the nut securing drive gear to the drive axle. See Figure 5B.35

Drive axle

Drive gear

Thrust bearing

Nut

Bushing

Bearing

14. Slide the dog clutch off of the brake shaft.

spur gear

Brake shaft

Washer

Bushing

NOTE: The dog clutch is spring loaded to engage the spur gear . When the by-p ass lever is operated, the dog clutch slides out of the spur gear. This disconnects the Drive axle from the IVT.

Dog

clutch

Figure 5B.37

Spring

Bushing

Figure 5B.35

NOTE: The nut is installed with Loctite #271

threadlocker.

15. Separate the spur gear from the brake shaft by

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removing the retaining ring. See Figure 5B.38

DRIVE SYSTEM-IVT

NOTE: When seating the bushings of the brake

shaft in the drop axle housing, the tab on the bushings must seat in the notch in the housing.

Retaining ring

Figure 5B.38

16. Remove the bearing. See Figure 5B.39

Input spur gear

Notch

Tab

Figure 5B.40

NOTE: Apply Loctite #271 or an equivalent

threadlocker to the threaded section of the drive axle. Tighten the nut that secures the drive gear to a torque of 42 - 50 ft lbs. ( 56 - 68 Nm).

NOTE: Fill the drop axle with 10.5 ounces of 737-0300A Durina

grease.

NOTE: The drop axle has four different length screws securing the housings together.Figure 5B.51 shows were the different screws go.

Bearing

Figure 5B.39

17. Remove the input spur gear. See Figure 5B.39

18. Clean and inspect all for the parts for damage and signs of wear.

NOTE: Any parts that have damage or signs of wear must be replaced.

19. Re-assemble the drop axle by following the previous steps in reverse order.

Figure 5B.41

NOTE: T ighten the screws to a torque of 90-120

in lbs. (10 - 14 Nm).

20. Test drive the tractor in a safe area before returning it to service.

DRIVE SYSTEM-IVT

Drive pedal shafts

The I-series tractors equipped with the IVT transmission have two drive pedal assemblies. The main drive pedal shaft is attached to the forward drive pedal. It operates the brakes and pulls the drive control links in the forward direction. The reverse drive pedal shaft is geared to the main drive shaft. When the reverse pedal is depressed, the reverse drive pedal shaft will rotate the main drive pedal shaft in the reverse direction.

To remove the drive pedal shafts:

1. Remove the deck as described in chapter 8 Cut-

ting Decks and Lift Shaft.

2. Remove the fender by following the steps

described in Chapter 4: Body/Chassis.

3. Put a timing mark on the gears of the two shafts.

• One mark on the fourth tooth from the bottom of

the reverse gear.

• One mark on the fourth valley from the valley of

the main drive shaft gear. See Figure 5B.42

Timing marks

4. Remove the reverse drive pedal: NOTE: If the main drive pedal shaft is the only

part that needs to be serviced, the reverse p edal shaft can be left in place. However Cub Cadet recommends removing the reverse pedal shaft and replacing the bushings at the same time.

NOTE: Worn bushings on either drive pedal shaft will cause some loss of wheel speed.

4a. Remove the hair pin clip and washer.

See Figure 5B.43

Washer

Reverse pedal

shaft

Hair pin clip

Figure 5B.42

NOTE: The timing marks will make re-assembly

easier.

Figure 5B.43

4b. Remove the split hex bushing.

See Figure 5B.44

Split hex bushing

Figure 5B.44

DRIVE SYSTEM-IVT

4c. Rotate the reverse drive pedal shaft out of

the reverse pedal support. See Figure 5B.45

reverse drive pedal shaft

Reverse pedal support

Figure 5B.45

5. Disconnect the right side brake link from the brake pedal shaft by removing the cotter pin. See Figure 5B.46

6. Disconnect both brake release rods from the main drive pedal shaft by removing the cotter pins. See Figure 5B.47

Brake release rod

Cotter pin

Figure 5B.47

7. Remove the cotter pin and the split hex bushing on the left side of the main drive pedal shaft. See Figure 5B.48

Brake link

Figure 5B.46

Cotter

Split hex bushing

Figure 5B.48

DRIVE SYSTEM-IVT

8. Remove the hair pin clip, washer and hex bushing from the right side of the main drive pedal shaft. See Figure 5B.49

Washer

Hex bushing

Figure 5B.49

9. Drive out both of the roll pins securing the drive pedal bracket to the main shaft using a 1/4” pin punch. See Figure 5B.50

Hair pin clip

10. Remove the three screws that secure the reverse pedal support using a 1/2” wrench. See Figure 5B.51

Remove these screws

Figure 5B.51

11. Lift up on the outer edge of the reverse pedal support while rotating it to the front to remove the support.

Roll pins

Figure 5B.50

12. Slide the drive pedal bracket off of the main shaft.

13. Remove the rear screw on both sides of the drive pedal shaft support bracket. See Figure 5B.52

Remove this screw

Middle hex

bushing

Figure 5B.52

14. Remove the middle hex bushing. See Figure 5B.52

DRIVE SYSTEM-IVT

15. Swing the rear of the drive pedal shaft support bracket down.

16. Disconnect the steering gear box from the main shaft by removing the hair pin clip. See Figure 5B.53

Steering gearbox

arm

Hair pin clip

Figure 5B.53

To install the drive shaft assemblies:

1. Install the middle hex bushing. See Figure 5B.55

Middle hex bushing

Figure 5B.55

2. Slide the right side of the main shaft through the middle hex bushing. See Figure 5B.55

17. Disconnect the reverse switch. See Figure 5B.54

Reverse switch.

Figure 5B.54

18. Drop the left side of the main shaft out of slot.

19. Slide the main shaft out of the tractor.

3. Connect the reverse switch.

4. Connect the steering gearbox: 4a. Slide the hole in the bell crank on the main

shaft over the pin on the steering gearbox lever. See Figure 5B.56

Steering gearbox

lever

Hair pin clip

Bell crank

Figure 5B.56

4b. Install the hair pin clip. See Figure 5B.56

DRIVE SYSTEM-IVT

5. Insert the main shaft into the hole for the le ft hex bushing by sliding it through the slot. See Figure 5B.57

Hole for

hex bushing

Slot

Figure 5B.57

NOTE: Do not install the hex bushing at this

point. It will cause the main shaft to bind while working on the right side of the tractor.

8. Slide the drive pedal bracket onto the main shaft.

NOTE: Do not install the roll pins at this point.

9. Install the reverse pedal support.

10. Install the hair pin clip, washer and hex bushing on the right side of the main drive pedal shaft. See Figure 5B.59

Washer

Hex bushing

Hair pin clip

6. Swing the rear of the drive pedal shaft support bracket into place.

7. Install the rear screw on each side of the drive pedal shaft support bracket. See Figure 5B.58

Rear screw

Drive pedal shaft support

bracket

Figure 5B.58

Figure 5B.59

11. Secure the drive pedal bracket to the main shaft by driving the two roll pins.

12. Install the split hex bushing on the left side of the main shaft. See Figure 5B.60

Left brake release rod

Cotter pin

Split hex bushing

Figure 5B.60

13. Install a new cotter pin. See Figure 5B.60

14. Install both brake release rods from the main drive pedal shaft using new cotter pins. See Figure 5B.60

DRIVE SYSTEM-IVT

´

´

´

´

1(:

02',),('

15. Install the right side brake link onto the brake pedal shaft using a new cotter pin. See Figure 5B.61

Brake link

Cotter

Figure 5B.61

16. Install the reverse drive pedal shaft. 16a. Rotate the reverse drive pedal shaft into

the reverse pedal support. See Figure 5B.45

16c. Modify the hex bushing by:

• Cut or grind the bushing to an overall height of 1/2” . See Figure 5B.63

Figure 5B.63

• Grind a 30

tapper on the hex end of the

bushing.

NOTE: The hex part of the bushing must be at least 0.2” in height.

reverse drive pedal shaft

Reverse pedal support

Figure 5B.62

16b. Install the split hex bushing. NOTE: The split must face up while the bushing

is installed.

NOTE: Using a modified bushing will allow the bushings on the reverse drive pedal shaft to be serviced in the future without taking the fenders off of the tractor.

16d. Install the modified hex bushing.

See Figure 5B.64

Modified hex bushing

Figure 5B.64

DRIVE SYSTEM-IVT

16e. Slide the reverse drive pedal shaft into the

modified hex bushing while aligning the timing marks on the gears of the two shafts. See Figure 5B.65.

• One mark on the fourth tooth from the bottom of the reverse gear.

• One mark on the fourth valley from the valley of the main drive shaft gear.

Timing marks

17. Install the fender by following the steps described in Chapter 4: Body/Chassis.

18. Test drive the tractor before returning it to service.

19. Install the deck as described in chapter 8 Cutting Decks and Lift Shaft.

Figure 5B.65

16f. Install the washer and hair pin clip.

See Figure 5B.66

Hair pin clip

Figure 5B.66

STEERING-HYDROGEAR

CHAPTER 6A: STEERING - HYDROGEAR TRANSMISSIONS

Introduction

The steering on the I-series tractor works in two

phases.

• First it will steer like any other tractor by turning the front wheels.

• Second and more importantly, the steering linkage will control the drive output of the rear wheels through the use of two HydroGear transmissions.

The steering gear box is connected to the front wheels by drag links. When the steering wheel is turned, the gear box will turn the wheels. The gear box will slow the drive speed of the inside rear wheel. At approximately 50

the steering gear box will start to slow down the outside drive wheel. When the inside front wheel reaches an angle of 90

, the rear wheel on

that side will stop driving. Turning the wheel past that point will make the inside rear wheel go in reverse The inside front wheel can reach a 108

angle and with the transmission on the inside of the turn driving in reverse. The tractor will then be in a zero turn.

Because the steering gear box is linked to the transmissions, the transmission adjustments and the wheel alignment must be addressed together. A transmission that is out of adjustment can make the steering look out of adjustment just as a steering linkage that is out of adjustment will affect the transmissions.

IMPORTANT: Check the tire air pressure before attempting to diagnose any problems with the steering or tracking of an I-series tractor. If the tire air pressures are not equal across the same axles, it will greatly affect the performance of the tractor.

Cam Slot Angle Adjustment

The cam slot adjustment is a critical adjustment on the I-series tractor, but it should only be necessary in two cases.

1. The cam slot angle adjustment must be set if the

steering gear box is replaced.

2. In the extremely rare case that the angle is sim-

ply out of adjustment. The indications are as follows:

NOTE: Test tractor in a safe area in case the tractor moves during testing.

A The tractor is running. B Parking brake released. C Feet off of the brake and drive pedals. D Turn the steering wheel fully in both direc-

tions.

E If the tractor creeps, cam angle needs

adjusted. If the tractor does not creep, cam slot angle adjustment is not needed. Proceed to the neutral and alignment adjustments.

The second would be a safety issue

! CA UTION! CA UTION

and must be addressed before returning the tractor to service

To adjust the cam slot angle:

NOTE: A special tool P/N 753-05437 is needed to make this adjustment. Do not attempt to make this tool, if needed it can be ordered from the Cub Cadet parts department.

1. Remove the dash and fender by following the

steps described in Chapter 4: Body/Chassis.

STEERING-HYDROGEAR

2. Disconnect the transmission link from the right side of the gear box only.

2a. Removing the nut and bolt that passes

through the double roller. See Figure 6A.1.

Remove this nut

and bolt

Cam slot

Figure 6A.1

2b. Remove the cotter pin and clevis pin.

See Figure 6A.2.

2c. Raise the transmission link away from the

cam slot.

NOTE: Catch the double roller when lifting the transmission link away from the steering gear box. See Figure 6A.3.

Double roller

Figure 6A.3

3. Loosen the return to neutral bolt using a 9/16” wrench and a 1/4” hex key. See Figure 6A.4.

Cotter pin

Clevis pin

Figure 6A.2

Return to neutral bolt

Figure 6A.4

STEERING-HYDROGEAR

4. Insert the pins of the gauge block tool P/N 75305437 into the cam slot. See Figure 6A.5.

Pins

Gauge block tool

Figure 6A.5

5. Rest the tool flat against the frame. See Figure 6A.6.

6. Tighten the return to neutral bolt. See Figure 6A.7.

Return to neutral bolt

Figure 6A.7

7. Remove the gauge block.

8. Adjust the transmission for neutral and align the front wheels as described in the following sections of this chapter.

P/N 753-05437

Figure 6A.6

9. Reassemble the tractor.

10. Test drive the tractor in a safe area before returning it to service.

STEERING-HYDROGEAR

Neutral and Transmission Links Adjustment

The first step is to coordinate the neutral points of the steering gear box, both transmissions and the control linkages. The transmission links will self adjust when the neutral adjustment and wheel alignment are done. To establish neutral:

1. Lock Steering Gear Box in Neutral Position:

1a. Remove the 1/4”-20 plug screw from the

steering gear box centering port using a 3/8” wrench. See Figure 6A.8.

Remove this screw

1d. Finger tighten the screw to set the screw

fully into the detent. The steering gear box is now centered and locked. See Figure 6A.9.

2” bolt

Figure 6A.9

2. Jack the tractor up so that both rear wheels are off of the ground. Place a pair of jack stands under the rear transmissions. See Figure 6A.10.

Figure 6A.8

1b. Thread a 1/4”-20x2” bolt into the steering

box centering port until you feel it touch the steering rack.

1c. While trying to gently thread the bolt further,

slowly rotate the steering shaft back and forth until the bolt seats into the detent in the steering rack.

Place jack stands here

Figure 6A.10

STEERING-HYDROGEAR

3. Loosen the two screws that connect each drive control link to the shifter T-plate on each transmission. See Figure 6A.11.

Loosen these screws

Figure 6A.11

NOTE: Feel the shifter T-plate, it should be free

of any input from the transmission links. If tension is felt there, disconnect the links completely .

4. While sitting in the seat, start the tractor and run it at full throttle. Release the brake.

The tractor engine and drive system

! CA UTION! CA UTION

Confirm that no hazards will be incurred by running the engine or operating the drive system

5. Check the rear wheels. NOTE: The rear wheels should not turn. If either

wheel turns, adjust the transmission for neutral by:

must be operated to complete this procedure.

Shifter T-plate

5a. Loosen the socket head cap screw in the

slot of the shift selector plate. See Figure 6A.12.

Loosen this bolt

Shift selector plate

Figure 6A.12

NOTE: It is not necessary to remove the fender

for this step. The fender was removed in this photo for clarity.

NOTE: Only loosen the screws on the side that creeps.

5b. With the tractor still running, move the shift

selector plate until the wheel stops moving.

NOTE: For the best zero-turn performa n ce , Set the selector plate to the reverse side of the neutral band (region where the transmission is in neutral).

5c. Tighten the socket head cap screw. NOTE: Leave the transmission links loose until

the wheels are aligned.

6. Perform the wheel alignment by following the procedures described in the next section of this manual.

STEERING-HYDROGEAR

Wheel alignment

NOTE: The transmission neutral adjustment

must be done prior to adjusting the steering linkage.

1. Remove the three screws holding each steering gear cover in place. See Figure 6A.13.

Remove these screws

Figure 6A.13

3. Insert a 5/16” pin through the hole in the steering gear on each side. The pins should pass through the gears, through the lower cover plate and into the pivot bar. See Figure 6A.15.

5/16” punch

Figure 6A.15

NOTE: If the alignment is off, the holes may not

line up. If this is the case, adjust the front end by:

2. Rotate the front tires until the marks on the axle gears and the steering gears align. See Figure 6A.14.

Insert a 5/16” pin here

Align the timing marks

Steering gear

Axle gear

Figure 6A.14

3a. Loosen the jam nuts on both ends of the

drag link. See Figure 6A.16.

Loosen both jam nuts

Figure 6A.16

STEERING-HYDROGEAR

3b. Adjust the drag link until the holes line up

See Figure 6A.17.

Rotate to lengthen or shorten

Figure 6A.17

NOTE: The punch should slide in and out with-

out binding. As the drag links are being adjusted, rock the tires back and forth to remove the load created from the tires twisting on the floor.

Steering gear box removal

To replace the gear box:

1. Remove the dash and fender by following the steps described in Chapter 4: Body/Chassis.

2. Disconnect the transmission linkages: 2a. Remove the cotter pins, washers and clevis

pins in the linkages. See Figure 3.18.

Hair pin clip

Clevis pin

3c. Tighten the jam nuts.

4. Tighten the drive control links to the T-plates.

5. Remove the 1/4”-20x2” screw from the steering gear box.

6. Reinstall the original plug screw in the steering gear box.

7. Install the steering gear covers.

Never allow an I-series tractor to be

! CA UTION! CA UTION

8. Test drive the tractor in a safe area before returning it to service.

operated with out the steering gear covers. Personal injury may result.

Figure 3.18

2b. Remove the nuts and bolts conn ecting the

transmission linkages to the levers on the steering gear box. See Figure 6A.19.

Roller

Cam slot

Connector link

Figure 6A.19

2c. Lift the links away from the gear box. NOTE: There are rollers in the slots. Take care

not to lose them when removing the bolts.

STEERING-HYDROGEAR

3. 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. See Figur e 6A.20.

Remove hair pin clip

Figure 6A.20

4. Disconnect the steering links on both sides: 4a. Gently pry the link retainer over the master

link. See Figure 6A.21.

5. Remove the transmission dampener cylinder using two 1/2” wrenches. See Figure 6A.22.

Transmission dampener

Figure 6A.22

6. Remove the steering shaft by removing the two clamp bolts in the steering shaft receiver and lifting the shaft out. See Figure 6A.23.

Steering shaft

Steering link

Figure 6A.21

Retainer

Steering shaft Receiver

Figure 6A.23

NOTE: Rotating the steering shaft bushing 90

degrees will allow the bushing to pop out, relieving the pressure on the steering shaft. This will make it easier to remove or install the shaft. See Figure 6A.24.

STEERING-HYDROGEAR

8. Remove the four screws holding the g ear bo x to the frame with a 1/2” wrench. See Figure 6A.26.

Rotate the bushing 90

Figure 6A.24

7. Disconnect the ground wire. See Figure 6A.25.

Ground wire

Figure 6A.26

9. The new gear box should come with 1/4”-20 x 2” screw to lock it into the neutral/centered position.

10. Bolt the gear box to the frame with the four bolts removed in step 8.

11. Insert the steering shaft into the steering shaft receiver. Tighten the nuts to a torque of 130 160 in lbs (14.7 - 18.0 Nm).

12. Attach the steering links. Install the retainers.

13. Attach the transmission dampener to the gear box.

14. Place the link into the bottom of the lever with the cam slot. Insert the hairpin clip to hold it in place. See Figure 6A.27.

Figure 6A.25

Link connecting the drive pedal to the cam slot

Figure 6A.27

STEERING-HYDROGEAR

15. Apply anti-seize compound to the rollers and the cam slots on the gear box levers. See Figure 6A.28.

Apply never seize

Figure 6A.28

16. Adjust the speed cam angle by following the steps described in the previous section.

17. Connect the transmission links.

18. Insert the clevis pins, washers and cotter pins.

19. Align the wheels and adjust the transmission links by following the steps described at the beginning of this chapter.

20. Remove the 1/4”-20x2” bolt that came with the steering gearbox, and install the short one from the old gearbox.

21. Install the fender and dash by following the steps described in Chapter 4: Body/Chassis.

22. Test drive the tractor in a safe area before returning to service.

17a. Place the rollers into the cam slots and

slide the transmission links over the levers.

17b. Insert the bolt through the transmission link

and roller .

17c. Install the nut on the bolt and tighten to a

torque of 8 ft lbs (11 Nm). See Figure 6A.29.

Roller

Figure 6A.29

STEERING-HYDROGEAR

Rebuilding the steering gear box

There are two different gear boxes available for the I-series tractors that are equipped with HydroGear transmissions.

• The 618-04430 steering gear box was used until

the end of the 2007 model year.

• The 618-04634 steering gear box was used in

2008 through current production.

The procedures to rebuild both gear boxes are similar. Wh ere there are di ffe rences, they will be called ou t in the text.

To take the steering gear box apart:

1. Remove the steering gear box by following the

procedures described in the previous section of this chapter.

2. Identify the gearbox assembly using the serial

number tag located on the return to neutral bracket. See Figure 6A.30.

Model number

3. Remove the return to neutral bracket using a 3/8” wrench. See Figure 6A.31.

Remove these

screws

Figure 6A.31

4. Remove the six remaining case screws using a 3/8” wrench. See Figure 6A.32.

Figure 6A.30

Remove

these

screws

Figure 6A.32

STEERING-HYDROGEAR

5. Lift the upper housing off of the lower housing. NOTE: There is no sealant between the two

housings. They should easily slip apart. If they are stuck together, there are three pry points cast into the housings that can be used to separate the housings. See Figure 6A.33.

Using one of the pry points to separate the housings.

Figure 6A.33

7. Remove the speed cam assemblies. See Figure 6A.35.

Speed cam assemblies

Figure 6A.35

8. Separate the speed cam assemblies. See Figure 6A.36.

6. Remove the steering rack. See Figure 6A.34.

Steering

rack

Figure 6A.34

Figure 6A.36

STEERING-HYDROGEAR

9. Separate the speed cam from the output bevel gear assembly by removing the small snap ring from the speed cam shaft. See Figure 6A.37.

Speed cam

Output bevel gear assembly

Small snap ring

Figure 6A.37

10. Separate the output bevel gear assembly by removing the snap ring. See Figure 6A.38.

11. Remove the washer from the input sector gear. See Figure 6A.39.

NOTE: The 618-04430 gear boxes only

Remove the washer

Input sector

gear

Figure 6A.39

12. Remove the input sector gear. See Figure 6A.40.

Remove this snap ring

Figure 6A.38

Figure 6A.40

STEERING-HYDROGEAR

13. Inspect the input sector gear bushings for damage and/or signs of wear. If they show signs of wear of damage, press both of the bushings out of the input sector gear using a press. See Figure 6A.41.

Press out the

bushings

Figure 6A.41

14. Remove the internal cam, the washer under it and the steering shaft. See Figure 6A.42.

15. Remove both of the bevel gears. See Figure 6A.43.

Bevel gears

Figure 6A.43

16. Remove the spiral ring from the post on the bevel gear. Slide the roller off of the bevel gear. See Figure 6A.44.

Washer

Internal cam

Figure 6A.42

Steering shaft

Post

Roller

Spira l ring

Figure 6A.44

STEERING-HYDROGEAR

17. Remove the snap ring from the input shaft. See Figure 6A.45.

Figure 6A.45

18. Remove the input shaft from the inside of the housing. See Figure 6A.46.

19. Remove the wear block. NOTE: On early production models of the 618-

04430 and all versions of the 618-04634 steering gear boxes there is a spring that presses the wear block against the steering rack. See Figure 6A.47.

Wear block

Figure 6A.47

Input shaft

Figure 6A.46

NOTE: On late production models of the 618-

04430 steering gear boxes there is a bolt that applies pressure to the wear block. When removing the wear block; make sure to get the washer out of it. See Figure 6A.48.

Adjustment bolt

Washer

Figure 6A.48

NOTE: Unless the upper housing or wear block

is being replaced, leave the adjustment bolt in place.

Wear block

STEERING-HYDROGEAR

20. 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 mmer. See Figure 6A.49.

Drive out the inner bearing

Figure 6A.49

21. Drive the outer bearing out of the upper housing using a pin or brass punch and hammer. See Figure 6A.50.

To assemble the steering gear box:

1. Put a dab of 737-0300A Durina

grease into

each of the bushings in the lower housing. See Figure 6A.51.

Put a dab of grease in each bushing

Figure 6A.51

2. Install both of the bevel gears with the rollers line with the center of the housing. See Figure 6A.52.

Figure 6A.50

22. T horoughly clean and degrease all parts.

23. Inspect all parts for signs of wear or damage. NOTE: If the part has signs of wear or damage;

discard the part. NOTE: If the two bushings in the bottom of lower

gear box housing are worn, replace the lower housing and press in two new bushings.

Rollers in line with the

center of housing

Figure 6A.52

STEERING-HYDROGEAR

3. Insert the steering shaft. See Figure 6A.53.

Steering shaft

Figure 6A.53

4. Place the large washer over the steering shaft. See Figure 6A.54.

5. Install the internal cam with the shoulder facing up. The bevel gear rollers in the slots. See Figure 6A.55.

Slots

Shoulder

Figure 6A.55

6. Apply a dab of 737-0300A Durina

grease to

the side of the steering shaft. See Figure 6A.56.

Large washer

Figure 6A.54

Figure 6A.56

STEERING-HYDROGEAR

7. 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 two to each other. See Figure 6A.57.

Master spline

Figure 6A.57

8. On the 618-04430 gear boxes, place the smaller washer over the steering shaft. See Figure 6A.58.

Speed cam

Shim

Bushing

Hydro arm

Figure 6A.59

9c. Place a .030” shim over the hydro arm.

See Figure 6A.59.

NOTE: The bevel gear needs to be shimmed to a bind. That means that once the assembly is installed in the lower housing, there is zero play between the bushing and the bevel gear. It may take a few attempts to get the shims correct.

9d. Place the output bevel gear on the hydro

arm with the chamfer facing away from the hydro arm. See Figure 6A.59.

Output bevel gear

Chamfer

Smaller washer

Figure 6A.58

9. Assemble the output bevel gear assemblies. 9a. Insert the shaft of the left speed cam into the

left hydro arm. See Figure 6A.59.

9b. Place a bushing over the hydro arm with the

flange facing away from the arm. See Figure 6A.59.

NOTE: If the output bevel gears are put on backwards it will throw off the timing of the gearbox.

NOTE: The hydro arms and output bevel gears have master splines to time them to each other. See Figure 6A.60.

Master spline

Figure 6A.60

STEERING-HYDROGEAR

9e. Install both of the snap rings. 9f. Repeat for the right output bevel gear

assembly.

10. Place both output bevel gear assemblies on the bench, facing each other. With both assemblies resting on the same points of the speed cam, insert both shafts into the coupler. See Figure 6A.61.

Coupler

Both speed cam are in line

Figure 6A.61

• The bevel gears should face away from the input sector gear.

• The first tooth of each output bevel gear should rest in the first valley the bevel gears in the bottom of the lower housing.

• The output bevel gear should have no play once it is installed. If it does have play go back to step

9. See Figure 6A.63.

Shimmed to a bind

Output bevel gear

Proper gear

timing

Figure 6A.63

NOTE: The coupler has a master spline, but the

speed cam shafts do not. If both speed cams are not resting on the same points when coupled they are out of time.

11. Insert the speed cam assemblies in the lower housing.

• Align the hole in the input sector gear with the the center of the square recess at the front of the lower housing. See Figure 6A.62.

Recess

NOTE: To test proper gear timing; measure from the farthest point of the output bevel gear to the top of the housing. It should measure a 1/4” for both sides. See Figure 6A.64.

1/4”

Figure 6A.64

NOTE: If one or both of the output bevel gears

are out of time; the steering rack will lose travel on the affected side.

Figure 6A.62

STEERING-HYDROGEAR

12. Fill the lower housing with 12 oz. of 737-0300A

Durina

grease. See Figure 6A.65.

Figure 6A.65

13. Press in the upper ball bearing into the upper housing. See Figure 6A.66.

Press in the upper ball bearing

14. Press the lower ball bearing into the upper housing. See Figure 6A.67.

A socket can

be used to press

in the ball bearing

Figure 6A.67

15. Insert the input shaft thought the ball bearings from the inside of the steering gear box. See Figure 6A.68.

Figure 6A.66

Inset the

input shaft

Figure 6A.68

STEERING-HYDROGEAR

16. Install the snap ring on the input shaft. See Figure 6A.69.

Snap ring

Figure 6A.69

17. Install the wear block:

• For the 618-04430 steering gear boxes with the adjustment bolt:

• For all other steering gear boxes: 17c. Insert the spring into the wear block. 17d. Set the wear block and spring into the

square recess in the upper housing. See Figure 6A.71.

Wear block

Figure 6A.71

17a. Insert the washer into the hole in the wear

block.

17b. Slide the wear block and washer onto the

adjustment bolt. See Figure 6A.70.

wear block

Figure 6A.70

18. Slide one new bushing onto each side of the steering rack, with the flanges facing the center of the rack.

19. Set the steering rack into the grove in the upper housing; trapping it between the input shaft and the wear block. See Figure 6A.72.

NOTE: The hole in the steering rack should line up with the hole in the housing. See Figure 6A.72 Insert.

Align

holes

Figure 6A.72

STEERING-HYDROGEAR

20. With the wear block facing the front, adjust the steering rack until the right side measures 1.8” from the case to the shoulder at the end of the shaft. See Figure 6A.73.

1.8”

Figure 6A.73

21. Holding the steering rack in place, carefully set the upper case onto the lower case.

NOTE: Removal of the return to neutral bolt and the dampener post from the speed cam assemblies will make it a lot easier to put the upper case half onto the lower case half.

NOTE: If removing the dampener post, mark its location on the speed cam assembly to ensure proper reassembly.

NOTE: The upper case should drop into place. Do not force it.

22. 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 shoulder should be flush with the housing. See Figure 6A.74.

Shoulder be flush with the housing

Figure 6A.74

22b. Turn the input shaft until the steering rack

has moved all the way to the right. The left shoulder should be flush with the housing.

23. Install the return to neutral bracket.

24. Install the remaining housing screws.

25. If the dampener post was removed, re-install it.

26. If the return to neutral bolt was removed, reinstall it.

NOTE: The return to neutral bolt does not need to be tightened at this time. It will be adjusted and tightened when it is installed in the tractor.

NOTE: On 618-04430 gear boxes with the

adjustment bolt, perform the wear block adjustment by following the steps described in the wear bolt adjustment section of this chapter.

27. Thread a 1/4”-20x2” bolt into the hole in the gear box to lock the gear box in neutral.

28. Install the steering gear box in the tractor and perform the neutral adjustments, speed cam adjustments and the wheel alignment by following the procedures described in this chapter.

29. Test drive the tractor in a safe area before returning to service.

STEERING-HYDROGEAR

Wear block adjustment

All of the steering gear boxes have a wear block that presses the wear block against the steering rack to set the back lash between the steering rack and the input shaft. Most of the steering gear boxes have a spring that holds a constant pressure on the wear block.

On some of the 618-04430 steering gear boxes, there is an adjustment bolt for the wear block. To adjust the bolt:

NOTE: This procedure can be performed while the steering gear box is installed in the tractor.

1. If the steering gear box is installed in the tractor,

isolate it by disconnecting both of the steering links. See Figure 6A.75.

Retainer

Steering link

3. While turning the input shaft, tighten the adjustment bolt until increased drag is felt. See Figure 6A.77.

Rotate

input

shaft

Tighten bolt until drag increases

Figure 6A.77

4. Back the bolt off a quarter to a half turn.

5. While holding the adjustment bolt with one wrench, tighten the jam nut to lock it in place.

Figure 6A.75

2. Loosen the jam nut on the adjustment bolt using a 9/16” wrench. See Figure 6A.76.

6. Check the steering gearbox by turning it through its full range of motion. Drag should be consistent through the complete range.

7. Install the gear box in the tractor or attach the steering links if it was already installed.

8. Test drive the tractor in a safe area before returning to service.

Loosen the jam nut

Figure 6A.76

STEERING-HYDROGEAR

Front wheels and axles

Remove/ replace the front wheels:

1. Lift and safely support the front end of the tractor.

2. Gently pry off the hub cap. See Figure 6A.78.

Hub cap

Figure 6A.78

To replace the front wheel ball bearings:

1. Lift and safely support the front end of the tractor.

2. Remove the front wheel by following the procedures describe in the previous section of this chapter.

3. Drive the bearings out of the wheel hub using a drift or pin punch. See Figure 6A.80.

Ball bearing

3. Remove and discard the cotter pin. See Figure 6A.79.

Cotter pin

Washer

Figure 6A.79

4. Remove the washer. See Figure 6A.79.

5. Slide the wheel off of the axle.

Figure 6A.80

4. Drive in the new bearings using a brass punch. See Figure 6A.81.

Figure 6A.81

5. Install the front wheel.

6. Pump grease in the grease fitting on the front wheel until it starts to squirt out of the hub.

7. Test drive the tractor before returning it to service.

STEERING-HYDROGEAR

To remove/ replace the front axles:

1. Lift and safely support the front of the tractor.

2. Remove the front wheel by following the procedures the front wheel section of this chapter.

3. Remove the steering gear covers.

4. Insert a 5/16” pin punch into one of the alignment holes to lock the steering gears in place. See Figure 6A.82.

Pin punch

Steering gear

7. 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 reverse order.

NOTE: Align the timing marks when installing the outboard steering gear. See Figure 6A.84.

Timing marks

Figure 6A.84

Figure 6A.82

5. Loosen the bolt that holds the outboard steering gear to the axle. Back the bolt half way out.

NOTE: The axle had a tapered double-D shaft. The steering gear will be very tight on the shaft.

6. Strike the bolt head, using a brass punch and a hammer. This will loosen the axle from the outboard steering gear. See Figure 6A.83.

Brass punch

9. Test drive the tractor in a safe area before returning it to service.

Figure 6A.83

STEERING-HYDROGEAR

Drag links

To remove/replace a drag link:

1. Remove the steering gear covers.

2. Remove and discard the nut holding th e dr ag link to the inboard steering gear using two 9/16” wrenches (one of them should be a slim-line wrench). See Figure 6A.85.

Drag link

5. Remove the spherical rod ends. NOTE: Count the number of turns to remove the

spherical rod ends.

6. Install new spherical rod ends. NOTE: Install the spherical rod ends the same

number of turn as it took to remove them from the old drag link.

NOTE: Leave the jam nuts loose.

7. Install the drag link on the tractor.

8. Perform a wheel alignment by following the procedures described in the wheel alignment section of this chapter.

9. Test drive the tractor in a safe area before returning it to service.

Figure 6A.85

The nuts used on the drag links and

! CAUTION! CAUTION

thread locking compound. Use new nuts every time.

3. Remove the nut and bolt that secures the drag link to the steering arm. See Figure 6A.86.

Steering arm

the tie rod are single use only. Do not try to reuse them by applying a

Drag link

Figure 6A.86

4. Loosen the jam nuts.

Tie rod

STEERING-HYDROGEAR

To remove/replace the tie rod:

1. Remove the steering gear covers.

2. Remove and discard the nut holding the tie rod spherical rod ends to the inboard steering gear using two 9/16” wrenches (one of them should be a slim-line wrench). See Figure 6A.87.

tie rod

spherical rod

end

Figure 6A.87

To remove/replace the inboard steering gear or king pin:

1. Remove the steering gear covers.

2. Remove and discard the nut holding the tie rod spherical rod ends to the inboard steering gear using two 9/16” wrenches (one of them should be a slim-line wrench). See Figure 6A.88.

3. Remove and discard the nut holding the dr a g link to the inboard steering gear using two 9/16” wrenches (one of them should be a slim-line wrench). See Figure 6A.88.

Tie rod end

Bolt

Drag link

end

Timing marks

The nuts used on the drag links and

! CAUTION! CAUTION

thread locking compound. Use new nuts every time.

3. Repeat on the other side of the tractor.

4. Slide the tie rod out of the tractor.

5. Loosen the jam nuts.

6. Remove the spherical rod ends. NOTE: Count the number of turns to remove the

spherical rod ends.

7. Install new spherical rod ends. NOTE: Install the spherical rod ends the same

number of turns as it took to remove them from the old tie rod.

8. Install the tie rod on the tractor using new lock nuts.

9. Perform a wheel alignment by following the procedures described in the wheel alignment section of this chapter.

the tie rod are single use only. Do not try to reuse them by applying a

Figure 6A.88

4. Remove the inboard steering gear by removing the bolt using a 9/16” wrench.

5. Remove the cotter pin in the bottom of the king pins. See Figure 6A.89.

6. Push the king pins out of the pivot bar.

King pin

Cotter

10. Test drive the tractor in a safe area before returning it to service.

Inboard steering gear

Figure 6A.89

STEERING-HYDROGEAR

7. Install the king pin.

8. Align the timing marks and install the inboard steering gear.

Tie rod end

Bolt

Drag link

end

Timing marks

Figure 6A.90

9. Attach the tie and drag link ends using new lock nuts.

Pivot bar

To remove/replace the pivot bar:

1. Lift and safely support the front end of the tractor.

2. Remove the front axles by following the procedures described in the front wheels and axles section of this chapter.

3. Remove and discard the nut holding the dr a g link to the inboard steering gear using two 9/16” wrenches (one of them should be a slim-line wrench). See Figure 6A.91.

Drag link

10. Perform a wheel alignment by following the procedures described in the wheel alignment section of this chapter.

11. Test drive the tractor in a safe area before returning it to service.

Figure 6A.91

4. Remove the muffler by following the steps described in Chapter 2: Engine Related Parts.

5. Remove the four screws fastening the bumper mount bracket to the frame. See Figure 6A.92.

Bumper mounting bracket

Remove these screws on each side

Figure 6A.92

STEERING-HYDROGEAR

6. Remove the pivot bar shoulder bolts. See Figure 6A.93.

Shoulder bolts

Pivot bar bracket

Figure 6A.93

At this point there is nothing hold-

! WA RNING! WA RNING

ing the pivot bar in place. Take care to prevent the pivot bar from falling

off of the tractor.

7. Slide the bumper mounting bracket and the pivot bar bracket off of the tractor.

8. Remove the pivot bar.

9. Inspect the contact areas where the pivot bar meets the frame. If there is any material that h as erupted or any galling, sand it down. Repeat inspection on the inside of the pivot bar bracket. See Figure 6A.94.

10. With the pivot bar on a bench, the inboard steering gear and the tie rod can be serviced.

11. Remove the tie rod by removing and discarding the nut holding the tie rod ends to the in board steering gear. See Figure 6A.95.

Remove nuts

Figure 6A.95

12. Remove the inboard steering gear by removing the bolt using a 9/16” wrench.

13. Remove the steering king pins by: 13a. Removing the cotter pins in the bottom of

the king pins.

13b. Push the king pins out of the pivot bar.

See Figure 6A.96.

Inspect contact area

Figure 6A.94

Cotter pin

King pin

Figure 6A.96

STEERING-HYDROGEAR

14. Start re-assembling the pivot bar by inserting the steering king pins into the pivot bar . Secu re them with new cotter pins. See Figure 6A.97.

King pin

Cotter pin

Figure 6A.97

15. Install the axle assemblies.

16. Place the outboard steering gears on the axle s and tighten to a torque of 100 - 150 in-lbs (11 17 Nm).

NOTE: The steering gears are marked LH and RH. Make sure the LH is facing up on the left hand side and that the RH is facing up on the right.

18. Insert a 5/16” pin punch in the alignment holes of the out board steering gears.

NOTE: Make sure they go all the way through into the pivot bar to lock the gears in position. See Figure 6A.98.

5/16” pin punch

Timing marks

Adjust tie rod end

jam nut

Figure 6A.98

19. Adjust the tie rod ends by loosening the jam nuts and rotating the tie rod ends until they slide on to the 1/4” bolts sticking up through the inboard steering gears. Tighten the jam nuts to lock the tie rod ends in place. See Figure 6A.98.

20. Install the tie rod end using a new lock nut.

17. Apply a small amount of releasable thread locking compound such as Loctite® 242 (blue) to the bolt for the in board steering gears. Align the timing marks on the inboard and outboard steering gears and tighten the bolt that fastens the inboard steering gears to a torque of 380 - 450 in- lbs (43 - 51 Nm).

NOTE: Make sure the bolts for the drag link and tie rod are in the in place before installing the steering gears.

21. Apply high quality grease to the frame and the inside of the pivot bar bracket, where the pivot bar rides. See Figure 6A.99.

Apply grease here

Figure 6A.99

22. Install the pivot bar by following steps 3 - 7 in reverse order.

NOTE: When installing the pivot bar, use a clamp to line up the screw holes in the frame, pivot bar and bumper mounting brackets. See Figure 6A.100.

STEERING-HYDROGEAR

Figure 6A.100

23. Slide the front wheels on and secure them with new cotter pins.

NOTE: Make sure the washer is installed between the wheel bearings and the cotter pin.

24. Push the hub caps on till they snap in place.

25. Take the tractor off of the jack stands.

26. Perform a neutral adjustment and wheel alignment as described in the beginning of this chapter.

27. Test drive the tractor in a safe area before returning to service.

STEERING-HYDROGEAR

CHAPTER 6B: STEERING - IVT T RANSMISSION

STEERING-IVT

Introduction

Just like the I-series with HydroGear transmissions, the steering on the I-series tractor with the Infinitely Variable Transmission (IVT) works in two phases. First it will steer like any other tractor by turning the front wheels. Second and more importantly, the steering linkage will control the drive output of the rear wheels through the use of the IVT transmission.

The steering gear box is attached to the front wheels by drag links. When the steering wheel is turned, the gear box will turn the wheels. When the wheels reaches around a 55

angle from straight ahead, the gear box will start to slow the transmission on the inside of the turn and continue turning the front wheels. When the inside wheel reaches an angle of

, the rear wheel on that side will stop driving. Turning the wheel past that point will make the inside rear wheel go in reverse The inside front whee l can reach a

108

angle. With the inside front wheel at a 108o angle and the transmission on the inside of the turn going in reverse, the tractor will be in a zero turn.

Because the steering gear box is linked to the transmission, the transmission adjustments and the wheel alignment must be addressed together. A transmission that is out of adjustment can make the steering look out of adjustment just as a front end that is out of adjustment will affect the adjustment of the transmission.

Cam Slot Angle Adjustment

The cam slot adjustment is a critical adjustment on the I-series tractor. It should only be necessary when replacing the steering gear box.

1. The cam slot angle adjustment must be set if the

steering gear box is replaced.

2. In the extremely rare case that the angle is sim-

ply out of adjustment. The indications are as follows:

A The tractor is running. B Parking brake released. C Feet off of the brake and drive pedals. D Turn the steering wheel fully in both direc-

tions.

E If it creeps, cam angle needs adjusted.

The second would be a safety issue

! CA UTION! CA UTION

and must be addressed before returning the tractor to service

To adjust the cam slot angle:

1. Remove the dash and fender by following the

steps described in Chapter 4: Body/Chassis.

2. Lock Steering Gear Box in Neutral Position:

2a. Remove the 1/4”-20 plug screw from the

steering gear box centering port using a 3/8” wrench. See Figure 6B.1.

Plug screw

Figure 6B.1

STEERING-IVT

2b. 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 gently thread the bolt further, slowly rotate the steering shaft back and forth until the bolt seats into the detent in the steering rack. Finger tighten the screw to set the screw fully into the detent. The steering gear box is now centered and locked. See Figure 6B.2.

2” bolt

4. Loosen the two nuts and bolts on the drive control link.

5. Remove the bow tie clip and clevis pin from the drive control link. See Figure 6B.4.

bow tie clip

Clevis pin

Figure 6B.4

6. Disconnect the drive control link from the right side of the gear box only:

Figure 6B.2

3. Match mark the drive control link betwee n th e two nuts and bolts. See Figure 6B.3.

Match mark

Figure 6B.3

NOTE: The match mark will make it easier to do

the neutral adjustment later on.

6a. Removing the nut and bolt.

See Figure 6B.5.

Remove this nut

and bolt

Clevis pin

Cam slot

Figure 6B.5

STEERING-IVT

6b. Remove the bow tie and clevis pins. 6c. Raise the drive control link away from the

cam slot.

NOTE: Catch the double roller when lifting the drive control link away from the steering gear box. See Figure 6B.6.

Double roller

Figure 6B.6

8. Set the cam slot angle at 90o to the frame using a combination square. See Figure 6B.8.

Figure 6B.8

9. Tighten the return to neutral bolt.

10. Adjust the transmission for neutral and align the front wheels as described in the following sections of this chapter.

7. Loosen the return to neutral bolt using a 9/16” wrench and a 1/4” hex key. See Figure 6B.7.

Return to neutral bolt

Figure 6B.7

STEERING-IVT

Neutral and drive control links Adjustment

IMPORTANT: Check the tire air pressure before

attempting to diagnose any problems with the steering or tracking of an I-series tractor. If the tire air pressures are not equal across the same axles, it will greatly affect the performance of the tractor.

Because the steering gear box is linked to the transmission, it is important to make sure the transmission is adjusted for neutral first. To establish neutral:

1. Remove the steering wheel by:

1a. Remove the center cover. See Figure 6B.9.

Center cover

NOTE: There is no puller needed for the steering wheel. Once the bolt is removed it will lift off of the steering shaft.

2. Disconnect the parking brake by removing the hair pin clip and sliding the rod out of the lever. See Figure 6B.11.

Hair pin clip

Rod

Figure 6B.11

Figure 6B.9

1b. Remove the bolt with a 1/2” wrench.

See Figure 6B.10.

Remove

this

bolt

3. Remove the two screws attaching the dash to the dash support. See Figure 6B.12.

One on each side

Figure 6B.12

Figure 6B.10

STEERING-IVT

4. Remove the two screws in the cargo net area, at the bottom of the dash. See Figure 6B.13.

Remove these screws

Figure 6B.13

NOTE: The cargo net was removed for a clear er

picture. Do not remove the net to remove the screws.

5. Remove the screws at the bottom of the dash, on each side. See Figure 6B.14.

Screw removed

7. Lock Steering Gear Box in Neutral Position: 7a. Remove the 1/4”-20 plug screw from the

steering gear box centering port using a 3/8” wrench. See Figure 6B.15.

2” screw

Figure 6B.15

7b. Using a 1/4”-20x2” bolt, thread it into the

Figure 6B.14

NOTE: Do not disconnect the wiring. Leave the

dash lose so that it can be lifted to remove the fender.

6. Remove fender by following the steps described in Chapter 4: Body/Chassis.

2” bolt

Figure 6B.16

STEERING-IVT

8. 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.

9. Remove the rear wheels.

10. Wedge the brakes open on both sides of the transmission. See Figure 6B.17.

Chisels used to hold brakes open

NOTE: If a tachometer is not available: 14a. Before starting the tractor, mark the brake

drum and shoe with a reference mark. See Figure 6B.18.

Reference mark

Figure 6B.17

1 1. Make sure all tools and wires are away from any

moving parts.

12. Depress the brake pedal and start the tractor.

13. Release the brake pedal.

14. Measure the RPMs of the brake shaft on both sides of the transmission.

The tractor engine and drive system

! CA UTION! CA UTION

Confirm that no hazards will be incurred by running the engine or operating the drive system

must be operated to complete this procedure.

Figure 6B.18

14b. Time how long it takes for the brake drum

to complete one revolution.

NOTE: The brake drum should be turning at 8RPMs or lower (more than 7.5 seconds per revolution).

NOTE: The closer to 0 RPMs the better the steering performance will be.

STEERING-IVT

If the transmission needs adjusted:

15. Turn off the engine.

16. Loosen the two nuts and bolts in the center of the drive control linkage on the side that needs adjusted . See Figure 6B.19.

Loosen these nuts and bolts

Figure 6B.19

17. Depress the brake pedal and start the tractor.

18. Release the brake pedal.

19. Adjust the length of the drive control linkages until the brake drum speed is less than 8 RPMs. See Figure 6B.20.

20. Tighten the two nuts and bolts in the center of the drive control linkage.

21. Reassemble the tractor. NOTE: Leave the 1/4”-20x2” bolt thre aded in the

steering gearbox.

22. Perform the wheel alignment by following the procedures described in the next section of this manual.

Keep hands away from the fan and

! CAUTION! CAUTION

Keep hands

clear of the fan

NOTE: Holding the control link near the center

will help keep the technicians hands clear of the fan and belt. See Figure 6B.20.

belt while the engine is running.

Grab at center

of the control link

Figure 6B.20

STEERING-IVT

Wheel alignment

NOTE: The transmission neutral adjustment

must be done prior to adjusting the steering linkage.

1. Remove the three screws holding each steering gear cover in place. See Figure 6B.21.

Remove these screws

Figure 6B.21

3. Insert a 5/16” pin through the hole in the steering gear on each side. The pins should pass through the gears, through the lower cover plate and into the pivot bar. See Figure 6B.23.

5/16” punch

Figure 6B.23

NOTE: If the alignment is off, the holes may not

line up. If this is the case, adjust the front end by:

2. Rotate the front tires until the marks on the axle gears and the steering gears align. See Figure 6B.22.

Insert a 5/16” pin here

Align the timing marks

Figure 6B.22

3a. Loosen the jam nuts on both ends of the

drag link. See Figure 6B.24.

Loosen both jam nuts

Figure 6B.24

STEERING-IVT

3b. Adjust the drag link until the holes line up

See Figure 6B.25.

Rotate to lengthen or shorten

Figure 6B.25

NOTE: The punch should slide in and out with-

out binding. As the drag links are being adjusted, rock the tires back and forth to remove the load created from the tires twisting on the floor.

3c. Tighten the jam nuts.

4. Remove the 1/4”-20x2” screw from the steering gear box.

5. Reinstall the original plug screw in the steering gear box.

Steering gear box removal

To replace the gear box:

1. Remove the dash and fender by following the steps described in Chapter 4: Body/Chassis.

2. Match mark the drive control link between the two nuts and bolts. See Figure 6B.26.

Match mark

Figure 6B.26

NOTE: The match mark will make it easier to do

the neutral adjustment later on.

3. Remove the bow tie clip and clevis pin from both drive control links. See Figure 6B.4.

6. Install the steering gear covers.

7. Install the dash and fender by following the procedures described in Chapter 4: Body/Chassis.

Never allow an I-series tractor to be

! CAUTION! CAUTION

8. Test drive the tractor in a safe area before returning it to service.

! WA RNING! WA RNING

operated without the steering gear covers. Personal injury may result.

Make sure all safety features are working properly before returning to service.

bow tie clip

Clevis pin

Figure 6B.27

STEERING-IVT

4. Disconnect the drive control link from both sides of the gear box by removing the nut and bolt. See Figure 6B.5.

Remove this nut and bolt

Cam slot

Figure 6B.28

5. Raise the drive control link away from the cam slot.

NOTE: Catch the double roller when lifting the drive control link away from the steering gear box. See Figure 6B.6.

6. On the right side cam slot lever there is a connector link. Remove the hairpin clip. See Figure 6B.30.

Remove hair

pin clip

Figure 6B.30

7. Disconnect the steering links on both sides: 7a. Gently pry the link retainer over the master

link. See Figure 6B.31.

Retainer

Figure 6B.29

Double roller

Steering link

Figure 6B.31

STEERING-IVT

8. Remove the steering shaft by removing the two clamp bolts in the steering shaft receiver and lifting the shaft out. See Figure 6B.32.

Steering shaft

Steering shaft Receiver

Figure 6B.32

NOTE: Rotating the steering shaft bushing 90

degrees will allow the bushing to pop out relieving the pressure on the steering shaft. This will make it easier to remove or install the shaft. See Figure 6B.33.

9. Disconnect the ground wire. See Figure 6B.34.

Ground wire

Figure 6B.34

10. Remove the four screws holding the gear box to the frame with a 1/2” wrench. See Figure 6B.35.

Rotate the bushing 90

Figure 6B.33

Figure 6B.35

11. Slide the gear box to the right to disconnect the connector link, then lift out of the tractor.

12. The new gear box should come with 1/4”-20 x 2” screw to lock it into the neutral/centered position.

13. Work the gear box so that the connector link can be inserted into the hole in the cam slot lever.

14. Install the hair pin clip removed in step 5.

15. Bolt the gear box to the frame with the four bolts removed in step 8.

16. Insert the steering shaft into the steering shaft receiver. Tighten the nuts to a torque of 130 160 in lbs (15 - 18 Nm).

STEERING-IVT

17. Attach the steering links. Install the retainers. NOTE: If the retainers are bent or twisted, the

whole link must be replaced. The retainers are not available separately.

18. Apply anti-seize compound to the rollers and the cam slots on the gear box levers.

19. Adjust the speed cam angle by following the step described in the cam slot angle section of the chapter.

20. Connect the drive control links. 20a. Place the rollers into the cam slots and

slide the drive control links over the levers.

20b. Insert the bolt through the drive control link

and roller .

20c. Install the nut on the bolt and tighten to a

torque of 8 ft lbs (11 Nm).

21. Insert the clevis pin, washers and bow tie clips.

22. Align the wheels and adjust the drive control links by following the steps described in the previous sections of this chapter.

23. Remove the 1/4”-20x2” bolt that came with the steering gearbox and install the short one from the old gearbox.

24. Install the fender and dash by following the steps described in Chapter 4: Body/Chassis.

Rebuilding the steering gear box

To take the steering gear box apart:

1. Remove the steering gear box by following the procedures described in the previous section of this chapter.

2. Remove the return to neutral bolt using a 9/16” wrench and a 1/4” hex key. See Figure 6B.36.

Figure 6B.36

3. Remove the return to neutral bracket using a 3/8” wrench. See Figure 6B.37.

25. Test drive the tractor in a safe area before returning to service.

Make sure all safety features are

! WA RNING! WA RNING

working properly before returning to service.

Remove these

screws

Figure 6B.37

STEERING-IVT

4. Remove the six remaining case screws using a 3/8” wrench. See Figure 6B.38.

Remove

these

screws

Figure 6B.38

5. Lift the upper housing off of the lower housing. NOTE: There is no sealant between the two

housings. They should easily slip apart. If they are stuck together, there are three pry points cast into the housings that can be used to separate the housings.

7. Separate the speed cam assemblies by driving out the two roll pins using a 5/32” pin punch and a hammer. See Figure 6B.40.

5/32” pin punch

Figure 6B.40

8. Separate the output bevel gear assembly by removing the snap ring. See Figure 6B.41.

6. Remove the speed cam assemblies. See Figure 6B.39.

Speed cam assemblies

Figure 6B.39

Remove this

snap ring

Figure 6B.41

STEERING-IVT

9. Remove the input sector gear. See Figure 6B.42.

Input sector gear

Figure 6B.42

10. Inspect the input sector gear bushings for damage and/or signs of wear. If they show signs of wear or damage, press both of the bushings out of the input sector gear using a press. See Figure 6B.43.

11. Remove the internal cam and both of the washers on top of the cam. See Figure 6B.44.

Washers

Steering

shaft

Internal cam

Figure 6B.44

NOTE: The steering shaft is pressed into the

lower housing.

12. Remove both of the bevel gears. See Figure 6B.45.

Press out the

bushings

Figure 6B.43

Bevel gears

Figure 6B.45

NOTE: There may be a pocket of suction

between the bevel gear and the lower housing because of the grease. It may be necessary to use a pry tool to lift the bevel gear out of the lower housing.

Cub Cadet ISeries User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

CHAPTER 1: INTRODUCTION

Professional Shop Manual intent

Description of the I-series

Model and Serial Numbers

CHAPTER 2: ENGINE RELATED PARTS

Muffler

Exhaust pipes

Fuel tank removal/replacement

CHAPTER 3: BRAKES

Brake system description

Brake adjustment - HydroGear transmissions

Brake adjustment - IVT transmissions

Brake shoes/drum - IVT transmissions

Brake cross shaft assembly

CHAPTER 4: BODY/CHASSIS

The hood

Bumper

Remove the fender

CHAPTER 5A: DRIVE SYSTEM - HYDROGEAR TRANSMISSIONS

Drive belt

Belt adjustment

Transmissions

Drive pedal shaft

CHAPTER 5B: DRIVE SYSTEM - IVT TRANSMISSION

Drive belt

Belt adjustment

Transmissions

Drop axle assemblies

Rebuilding the drop axles

Drive pedal shafts

CHAPTER 6A: STEERING - HYDROGEAR TRANSMISSIONS

Introduction

Cam Slot Angle Adjustment

Neutral and Transmission Links Adjustment

Wheel alignment

Steering gear box removal

Rebuilding the steering gear box

Wear block adjustment

Front wheels and axles

Drag links

Tie rod

Inboard steering gear

Pivot bar

CHAPTER 6B: STEERING - IVT T RANSMISSION

Introduction

Cam Slot Angle Adjustment

Neutral and drive control links Adjustment

Wheel alignment

Steering gear box removal

Rebuilding the steering gear box