Cub Cadet Big Country 2004 Technisches Handbuch

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

www.mymowerparts.com

K&T Saw Shop 606-678-9623 or 606-561-4983

www.mymowerparts.com

K&T Saw Shop 606-678-9623 or 606-561-4983

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. 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

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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Big Country 6 x 4 and 4 X 2 Update

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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Big Country 6 x 4 and 4 X 2 Update

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

center

Accessory relay

sockets (covers

off)

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Big Country 6 x 4 and 4 X 2 Update

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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Big Country 6 x 4 and 4 X 2 Update

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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