Cub Cadet Challenger Series Manual de usuario

SERVICE MANUAL

Challenger 550 & 750

Foreword

Brief introduction to the service and maintenance handbook

for 550/750 Challenger UV

This manual gives methods to check, maintain and repair the Cub Cadet 550 & 750

utility vehicles (UV’s), and supplies some relevant techniques and performance

data.

Please read the handbook through and fully understand it; otherwise, any

improper repairing could cause problems, and or an accident may occur.

Proper use and maintenance will reduce malfunctions, and help the vehicle

remain at its best performance level.

The standards, procedures and specifications mentioned in this manual are based on

the sample in design, and they are subject to changes according to the product’s

improvement without prior notice.

Chapter 1

General

Chapter 1

General

Chapter 3

Periodic

Maintenance and

Adjustments

Chapter 5

Chassis

Chapter 7

Engine

Management

System

Chapter 6

Electrical

Diagram

Chapter 8

Troubleshooting

INDEX

Chapter 2

Specifications

Chapter 4

Engine

INDEX

General Information

Chapter 1

Warning, Caution, Note

Description

Vehicle Identification Code, Engine

Number

Safety

Handling Gasoline, Cleaning Parts

Warning Labels, Serial Numbers,

Fasteners

Self Locking Fasteners, Washers,

Cotter Pins, Snap Rings and E-

clips

Shop Supplies

Lubricants and Fluids,

Engine Oils, Greases, Brake Fluid

Coolant, Cleaners, Degreasers,

and solvents

Gasket Sealant, Gasket Remover,

Thread Locking Compound

Basic Tools

Screwdrivers

Wrenches

Adjustable Wrenches, Sockets,

Ratchets, and Handles

Impact Drivers

Allen Wrenches

Torque Wrenches, Torque

Adapters

Pliers, Snap Ring Pliers

Ignition Grounding Tool

Precision Measuring Tools

Feeler Gauge, Calipers

Micrometers

Adjustment and Care

Metric Micrometer

Standard Micrometer

Telescoping and Small Bore

Gauges

Dial Indicator, Compression Gauge

Multi meter

1-1

1-2

1-3

1-4

1-5

1-6

1-7

1-8

1-9

1-10

1-11

1-12

1-13

1-14

1-15

1-16

1-17

1-18

1-19

1-20

1-21

1-22

1-23

1-24

Electrical System Fundamentals

Voltage

Resistance, Amperage

Basic Service Methods

Removing Frozen Fasteners

Removing Broken Fastener

Stud Removal, Removing Hoses

Bearings

Removal

Installation

Interference Fit

Seal Replacement

Storage

Area Selection

Preparing the UV for storage

Returning the UV to Service

Specifications

Chapter 2

General Specifications

Engine Torque Specifications

Chassis Torque Specifications

General Torque Specifications

Chassis Lubrication points

Periodic Maintenance

Chapter 3

Periodic Maintenance Table

Periodic Maintenance

Engine

Valve Clearance

Spark Plug

Compression Test

Engine oil

Oil Change

Oil Pressure

Air Filter cleaning

Coolant Change

Coolant Bleeding

V-Belt Inspection

Replacement

Cleaning the Spark Arrester

Adjustment of the Parking Brake

Brake Fluid Level check

1-24

1-25

1-27

1-28

1-29

1-30

1-31

1-32

1-33

2-1

2-18

2-21

2-23

2-24

3-1

3-3

3-4

3-6

3-7

3-8

3-9

3-11

3-13

3-15

3-16

3-18

3-19

INDEX

Brake lines, Bleeding the Brake

3-21

Crankcase, Starter Motor and Oil

4-31

Select Lever Shift Rod adjustment

3-24

Filter

Checking Final Gear Oil

3-25

Crankcase

4-32

Adjusting Toe In

3-26

Bearings

4-33

Front Shock Adjustment

3-27

Inspection

4-34

Brake light switch adjustment

3-27

Assembly

4-35

Steering system Inspection

3-29

Crankshaft and Oil Pump

4-36

Oil Pump

4-37

Inspection

4-38

Installation

4-39

Transmission

4-40

Drive Axle Assembly

4-41

Engine

Chapter 4

Special Notes

Engine removal

Cylinder Head and Cover

Inspection, installation

Rocker Arm and Camshaft

4-1

4-2

4-3

4-4

4-6

Inspection

Installation

Middle Gear, Middle Drive Shaft

Middle Driven Shaft

Inspection

Installation

Chassis

4-42

4-43

4-44

4-45

4-46

4-47

Inspection

4-7

Chapter 5

Installation

4-8

Valves and Valve springs

4-9

Inspection

5-1

Inspection

4-10

Steering System

5-4

Installation

4-11

Steering Wheel Assembly

5-5

Cylinder and Piston

4-12

Disassembly, Inspection

5-6

Inspection

4-13

Installation

5-8

Installation

4-14

Brake System Inspection

5-9

Engine Cooling Fan and A.C.

4-15

Brake Line Removal

5-10

Magneto

Brake Disc Removal

5-11

Inspection

4-16

Inspection

5-12

Installation

4-17

Brake Pad Removal

5-13

Balancer Gears and Oil Pump

4-19

Installation

5-14

Gears

Front Brake Caliper Removal

5-15

Inspection

4-20

Brake Caliper Disassembly

5-16

Installation

4-20

Installation

5-17

Primary and Secondary Sheaves

4-21

Rear Brake Disc Removal

5-19

Primary Sheave

4-22

Inspection

5-20

Secondary Sheave

4-23

Rear Brake Caliper and Pads

5-21

Inspection

4-24

Rear Brake Pad Replacement,

5-23

Installation

4-25

Inspection

5-23

Clutch

4-27

Assembly and Installation

5-24

Disassembly

4-28

Brake Master Cylinder

5-26

Inspection

4-29

Inspection, Installation

5-27

Installation

4-30

Footrest Assembly

5-28

INDEX

Front Wheel and Tire

Rear Wheel

Inspection, Installation

Transmission Front Bridge

Front Bridge Removal

Disassembly

CV Joint Inspection

Differential Gear and Gear Motor

Operation

U Joint Assembly

Differential Gear Motor Adjustment

Front Bridge Installation

Rear Bridge

Rear Differential Removal

Gear Shift Mechanism

Adjustment

Front Suspension and A Arm

Inspection, Installation

Rear Suspension

Rear A Arm

Inspection, Installation

Cooling System

Inspection, Coolant replacement

Water Pump Assembly

Disassembly, Inspection

Assembly

Seat Assembly

Fuel System

Fuel Pump Inspection

Electrical

Chapter 6

Components

Battery

Lead Acid Battery Charging

Maintenance Free Battery

Charging

Checking Fuses

Switch Inspection

Switch Locations

Bulbs and Sockets

Ignition Circuit Diagram

Ignition Troubleshoot

Starting Circuit Diagram

5-30

5-31

5-32

5-33

5-34

5-38

5-40

5-41

5-42

5-44

5-47

5-48

5-49

5-51

5-52

5-53

5-54

5-55

5-57

5-58

5-60

5-61

5-62

5-63

5-65

6-1

6-3

6-4

6-6

6-7

6-8

6-9

6-10

6-11

6-12

6-15

Brake Master Cylinder

Inspection, Installation

Footrest Assembly

Starter Motor Troubleshoot

Starter Motor Removal

Charging Circuit Diagram

Charging System Troubleshoot

Lighting Circuit Diagram

Signaling Circuit Diagram

Cooling Circuit Diagram

2WD / 4WD Select Circuit Diagram

Engine Management

System Chapter 7

Components

E.C.U.

Fuel Injectors

Installation Guidelines

Replacement

Cleaning Procedure

Throttle Body

Engine Coolant Temperature

Sensor

Oxygen Sensor

Fuel Pump Module

Inspection

Removal, Installation

Fuel Leak Check

E.M.S. Fault Codes

Troubleshooting

Chapter 8

Spark Test

Fuel System Check

Compression Test

Engine Overheating

Engine Noises

Cylinder Leak down

Electrical checks

Intermittent Problems

E.C.U.

5-26

5-27

5-28

6-16

6-17

6-18

6-19

6-20

6-21

6-22

6-23

7-1

7-2

7-3

7-5

7-6

7-7

7-8

7-9

7-10

7-11

8-1

8-2

8-3

8-4

8-5

8-7

8-8

8-9

Vehicle Identification Number

LWG MD WZ 44 E B 123456

LWG

MDM

Manufacturer

UV below 750cc

UV above 750 cc

ZZ 550cc

WZ 750cc

44 DOT Check Digits

H 2017 Model Year

J 2018 Model year

K 2019 Model Year

L 2020 Model Year

M 2021 Model Year

A Manufacturing Plant A

B Manufacturing Plant B

12345 123456 Sequential Serial Number

General Information

1‐1

This manual provides complete information on maintenance, tune-up, repair and

overhaul. Hundreds of photographs and illustrations created during the complete

disassembly of Utility Vehicles (UV) guide the reader through every job. All procedures

are in step by step format and designed for the reader who may be working on the UV

for the first time.

Warnings, Cautions and Notes

The terms Warning, Caution and Note have specific meanings in this manual.

Warning

Emphasizes areas where injury or even death could result from

negligence.

Caution

Note

Emphasizes areas where equipment damage could result.

Disregarding a Caution could cause permanent

Mechanical damage, although injury is unlikely.

Provides additional information to make a step or procedure easier

or clearer. Disregarding a Note could cause inconvenience, but

would not cause equipment damage or injury.

General Information

1‐2

Description

1. Front bumper assy.

2. Headlights

3. Front shock absorber

4. Brake pump

5. Steering wheel

6. Left door comp.

7. Driver seat belt

8. Cargo bed

9. Rear shock absorber

10. Tail lights

11. Muffler

12. Invert bracket assy

13. Fuel tank cap

14. Passenger seat belt

15. Right door comp.

16. Drive select lever

17. Air filter case (engine and air

intake duct) Rear brake fluid

reservoir

18. Head turn signal lamp

19. Water cooler

20. Front turning lights

21. High/low beam lights

22. 2/4 WD

23. The front axle differential

24. Range gear shift lever

25. Parking brake

26. Emergency light

27. Left/right turning switch

28. Brake pedal

29. Accelerator pedal

30. Winch cable

31. Rear axle differential unlock/lock

32. Cover storage box

33. Hand hold

NOTE:

The vehicle you have purchased may

differ slightly from those in the figures

of this manual.

General Information

1‐3

Engine Identification Number

Part Three consists of Feature code I, year code, Feature code II, month code and serial

number.

Rear Spacer

Serial Number

Month Code

Feature Code II

Year Code

Feature Code I

Spacer

Feature Code I

Configuration

Code

Configuration

Code

φ140 Clutch, 1:5 Taper

φ150 Clutch, 1:7 Taper

φ150 Clutch, 1:7 Taper, CARB Comp.

Year Code

Year

Code

Year

Code

Year

Code

Year

Code

2010

2013

2016

2019

2011

2014

2017

2020

2012

2015

2018

2021

Feature Code II

Code Transmission Gear Ratios

0 41/21 Fixed Reduction +H（26/21）+L（35/17）

R 41/21 Fixed Reduction +H（30/18）+L（34/14）

2 42/19 Fixed Reduction +H（30/18）+L（34/14）

Month Code

Month

Jan

Feb

Mar

Apr

May

Jun

Jul

Aug

Sep

Oct

Nov

Dec

Code

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