Cub Cadet Big Country 2004 Technical manual

2004 Technical Update
IMPORTANT: READ SAFETY RULES AND INSTRUCTIONS CAREFULLY
PRINTED IN USA FORM NO.769-00971
This Service Manual is not a substitute for the Operator’s Manual. You must read, understand
and follow all of the directions in this manual as well as the Operator’s Manual before working
on this power equipment.
(11/2003)
CUB CADET LLC, P.O. BOX 361131, CLEVELAND, OH 44136-0019
Cub Cadet Big Country
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TABLE OF CONTENTS
Battery Drain.....................................................................................................1
Bed Lift Switch ..................................................................................................3
New Wiring Harness..........................................................................................4
General Improvements......................................................................................6
Opening Price Point Unit...................................................................................11
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1
1. ISSUE: BATTERY DRAIN IN LONG TERM
STORAGE (CC 431)
Some first-year production Big country Utility Vehicles
(prior to serial number 1A013B000001) may experi-
ence an electrical draw that drains the battery. The
problem will generally occur when the Big Country is
not in use for a month or more. If a customer has com-
plained of this situation, the following change should be
made to the wiring harness.
1.1. Turn the engine off and remove the key from the
key switch. Tilt the driver’s seat forward and
check the serial number. If the serial number is
not legible, identify the wiring harness.
1.2. Remove the bolts, flat washers, and rubber
washers that secure the hood in the closed posi-
tion using a 1/2” wrench. Open the hood.
1.3. Vehicles equipped with the wiring harness that is
subject to his occurrence are readily identifiable
by the location of the fuse box, relays and volt-
age regulator-rectifier. The fuse box is mounted
under the hood in a vertical position on driver’s
side of the firewall. Directly beneath it are
molded plugs for three relays. The regulator-
rectifier is located under the hood on the pas-
senger’s side firewall, directly above the bat-
tery. See Figure 1.3.
Figure 1.3
Fuses
Accessory
Relay
Bed lift relay location
1.4. If not equipped with the effected harness further
diagnosis is necessary. If equipped with the
effected harness, disconnect the negative bat-
tery cable using a 7/16” wrench.
1.5. Unplug the harness connector from the pigtail on
the regulator-rectifier. See Figure 1.5.
1.6. Cut the two red wires that enter the harness
connector roughly 6” from the connector.
NOTE: It may be necessary to remove some of
the protective covering (conduit) from the har-
ness.
1.7. Strip 1/4” of insulation from the loose ends of the
red wires that are attached to the harness plug.
1.8. Twist the stripped ends together, and crimp them
securely into the yellow butt connector.
1.9. Strip 1/2” of insulation from the end of the red
wire provided in the kit.
Figure 1.5
Regulator-
rectifier
Negative
battery cable
Harness
Cut here
plug
Big Country 6 x 4 and 4 X 2 Update
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Big Country 6 x 4 and 4 X 2 Update
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1.10. Fold the stripped end back on itself, and crimp it
securely into the other end of the yellow butt
connector. See Figure 1.10.
1.11. Remove the accessory relay from the relay block
on the firewall. See Figure 1.11.
1.12. Remove the relay block from the firewall using a
phillips head screwdriver, and separate it from
the other two relay blocks.
NOTE: The relay blocks have interlocking chan-
nels on each side.
1.13. Cut the white wire that enters the accessory
relay block. Leave enough length accessible on
each side of the cut to strip the insulation from
the wire and install a butt connector.
NOTE: It may be necessary to remove some of
the protective covering (conduit) from the har-
ness.
1.14. Strip 1/4” of insulation from the ends of the two
lengths of white wire and 1/2” of insulation from
the loose end of the red wire that was previously
added to the harness connector.
1.15. Twist the two stripped ends of the white wire
together and crimp them securely into the sec-
ond yellow butt connector.
1.16. Fold the stripped end of the red wire back on
itself, and crimp it securely into the other end of
the yellow butt connector. See Figure 1.16.
1.17. Install the relay block back on the firewall, and
plug-in the relay.
1.18. Plug the voltage regulator-rectifier connector
back into the harness connector.
1.19. Connect the negative battery cable to the nega-
tive battery terminal.
1.20. Close and secure the hood.
1.21. Test-run the Big Country 6 X 4 before returning it
to service.
Figure 1.10
New red wire
Yellow butt
connector
Harness
connector
2 Original
red wires
Figure 1.11
Accessory relay
Mounting
crews
White wire
Figure 1.16
Yellow butt
connector
Red
wire
White
wires
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2. ISSUE: REVERSED OPERATION OF ACCES-
SORY (BED LIFT) SWITCH (CC 438)
Some first-year production Big country Utility Vehicles
(after serial number 1A013B000001) may have been
made with mis-wired accessory connectors in the wir-
ing harness. If this situation exists, rocking the bed lift
switch up will lower the bed, and rocking the bed lift
switch down will tilt the bed. If a customer has com-
plained of this situation, the following change should be
made to the wiring harness:
2.1. The service kit consists of three adaptors that
reverse the polarity of the connections.
See Figure 2.1.
2.2. Remove the two wing screws that secure the
hood, and open the hood.
2.3. Identify the front accessory relay connector.
See Figure 2.3.
Figure 2.1
Three adaptors
contained in
CC348 kit
Figure 2.3
Front
accessory
relay
connector
The front accessory relay
connector has one red wire
and one red wire with a
white trace.
2.4. Install one adaptor from the service kit as an
interface connector between the harness and
the accessory. See Figure 2.4.
2.5. Raise the bed. The final two connectors are
located among the bundle near the right rear
corner of the engine compartment, at the top of
the frame. See Figure 2.5.
2.6. Identify the connector that joins the lift motor to
the lift motor relays. It has one red wire and
one yellow wire. Install the second adaptor as
an interface connector between the lift motor
and the harness connection to the lift motor
relays.
2.7. Identify the rear accessory relay connector, and
install the third adaptor to it in similar fashion to
the first two adaptors. The rear accessory relay
connector has one purple wire and one black
wire.
Figure 2.4
Figure 2.5
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2.8. The adaptors will reverse the polarity of the con-
nections. If reveres action of accessories or bed
lift is not encountered, the adaptors are not nec-
essary on that unit. See Figure 2.8.
2.9. Lower the bed. Close and secure the hood.
2.10. Test the operation of the bed lift and accessories
before returning the unit to service.
3. FEATURE: NEW WIRING HARNESS
3.1. The relays have been consolidated into a relay
center above the battery, in the place formerly
occupied by the voltage regulator-rectifier. The
fuse block has been moved from the vertical sur-
face of the firewall. See Figure 3.1.
NOTE: The 4 X 2 and 6 X 4 use the same wiring
harness after serial number 1A013B000001. the
features listed apply to both models.
3.2. The relays and their sockets in the relay cen-
tered protected by plastic covers.
See Figure 3.2.
Figure 2.8
Polarity reversed
Figure 3.1
Fuse block
Relay
center
Figure 3.2
Key to rela
y
center
Accessory relay
sockets (covers
off)
_
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3.3. One relay in this block is used by the original
equipment. The rest of the sockets accommo-
date pre-wired accessories. See Figure 3.3.
3.4. The relay covers go on in one direction only.
There is a notch in each cover that matches a
notch in the relay socket. See Figure 3.4.
Figure 3.3
Detail of key to relay center
Figure 3.4
Wrong Right
3.5. The one relay that is not in this group is the
starter relay, which is located on the outside of
the harness, just below the center of the upper
cross-member at the front of the engine com-
partment. See Figure 3.5.
NOTE: The starter relay is different from the
other relays on the Big country 6 X 4, but is inter-
changeable with the relays used on the 2000
series, 3000 series, and the recent 1000 series.
3.6. The fuse block has been moved to the horizontal
surface at the top of the firewall on the driver’s
side of the vehicle. See Figure 3.6.
Figure 3.5
Figure 3.6
Dashboard
Fuse
block
Front of vehicle Key to
fuse block
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3.7. The fuse block also contains capacity for expan-
sion, allowing the easy addition of accessories
See Figure 3.7.
3.8. The voltage regulator-rectifier has been relo-
cated to the right side of the cross-member at
the top front corner of the engine compartment.
See Figure 3.8.
3.9. The instrument panel has been revised slightly,
and may be further revised for ‘04 production.
3.10. The 4 X 2 and the 6 X 4 use the same wiring har-
ness. The 6 X 4 has a mechanical gear selector
system while the 4 X 2 has an electrically con-
trolled, vacuum actuated gear selector system.
The harness connections that join the push-but-
ton gear selector to the main harness in the 4 X
2 exist in the 6 x 4 as well. They are secured
behind the dashboard, but are not connected to
anything. See Figure 3.10.
4. FEATURES: GENERAL IMPROVEMENTS
NOTE: Most of the features listed in this section
are present on the 4 X 2 and the 6 X 4. Lessons
learned in the first year of production have been
applied to all models.
4.1. Suspension travel has been increased.
See Figure 4.1.
Figure 3.7
Detail of key to fuse block
Figure 3.8
Regulator / Rectifier
Figure 3.10
Instrument panel
Blanks for accessory
switches
Controller and buttoner
connections for 4 x 2
gear selector
4 X 2
gear
selector
button
holes
Figure 4.1
New front
suspension travel
Old front
suspension
travel
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