CUB CADET 2135 (01) PDF Document

To ensure your safety while servicing your CUB CADET 2135, always follow these instructions:

1. To prevent accidental starting, always pull the high tension wire(s) off the spark plug(s) before servicing and/or adjusting the machine.

2. To prevent injury, do not allow children or bystanders in the vicinity of the machine while it is being adjusted and/or serviced.

3. Do not wear jewelry (rings, wrist watches, necklaces, etc.) or loose fitting clothing when working on machinery; they could catch on moving parts, causing serious injury. Wear sturdy, tough-soled work shoes. Never adjust and/or service a machine in bare feet, sandals or sneakers.

4. Always wear safety glasses when using a hammer, chisel or other tools that may cause chips to fly.

5. Be sure to reinstall all safety devices, guards or shields after adjusting and/or servicing the machine.

6. When operating a power washer to clean a machine before servicing, be careful at all times to avoid injury. Maintain proper footing and balance at all times. Never direct the spray at people or animals, as high pressure spray can cause serious injury.

7. If a portable heater is used to heat the service area, the following precautions must be observed:

a. Do not use portable heaters in the presence of volatile materials such as gasoline, paint or paint thinner. A fire or explosion may result.

b. When in operation, locate the heater away from the immediate work area to avoid accidental contact, which could result in severe burns or ignite your clothing.

c. Portable heaters consume oxygen and emit hazardous combustion fumes. A heater should be used only in a well ventilated area. Keep a window or door partially open to provide ventilation.

d. Keep the heater at least four feet from all combustible materials.

e. Never use gasoline as fuel.

8. Gasoline is highly flammable — observe the following precautions when handling gasoline:

a. Use an approved gasoline container.

b. Never remove the fuel tank cap or fill the fuel tank when the engine is running, is hot, or is indoors. DO NOT SMOKE when working around flammable fuel.

c. Avoid fires — be sure container or funnel does not touch the battery. Do not overfill the fuel tank. Wipe up all spilled gasoline.

d. Replace fuel tank cap securely.

9. Never use trouble lights or electric powered tools that have cut or damaged cords or plugs. Be sure all electric tools are properly grounded.

10. Never run an engine in a confined area, such as a garage or storage building, any longer than is necessary for immediate moving of the machine out of or into the area. EXHAUST GASES ARE TOXIC. OPENING DOORS AND WINDOWS MAY NOT PROVIDE ADEQUATE VENTILATION.

11. After servicing, be sure all tools, spare parts, and/or servicing equipment are removed from the machine.

12. Electrical storage batteries give off highly flammable hydrogen gas when charging, and continue to do so for some time after receiving a steady charge. Do not, under any circumstances, allow an electrical spark or an open flame near the battery. Always disconnect the battery cables (negative cable first) before working on the electrical system.

13. Hydraulic fluid escaping under pressure can have enough force to penetrate the skin. Hydraulic fluid may also infect a minor cut or opening in the skin. If injured by escaping fluid, see a doctor at once. Serious infection or reaction can result if medical treatment is not given immediately. Do not attempt to repair or tighten hoses that are under pressure or with the tractor engine running. Cycle all hydraulic control valves to relieve all pressure before disconnecting lines or performing other work on the hydraulic system.

14. When using a welder or acetylene torch, always wear welding goggles and gloves. Keep a charged fire extinguisher within reach. Do not weld or heat areas near the fuel tank, fuel lines, hydraulic lines, or battery.

15. Always use safety stands in conjunction with hydraulic jacks or hoists. Do not rely on the jack or hoist to carry the load; it could fail, causing serious injury and/or damage. Be sure jack stands are properly positioned to prevent tipping or rollover.

16. When removing supporting components or disassembling machines, be sure to use safety stands and adequate supports to prevent tipping or rollover and to prevent components from falling.

17. Use a safety catch on all hoist hooks. Do not take a chance, the load could slip off the hook.

18. Use pullers to remove bearings, bushings, gears, sleeves, etc. when applicable. Use hammers, punches and chisels only when absolutely necessary. Then, be sure to wear safety glasses.

19. Petroleum based solvents used for cleaning parts are flammable. Use care to avoid fire or explosion when using these solvents.

20. Be careful when using compressed air to dry parts. Use approved air fixtures, do not exceed 30 psi, wear safety glasses or goggles, and use proper shielding to protect everyone in the work area.

Specifications are subject to change without notice.

Tractors are shipped with a dry battery. Electrolyte must be added and the battery activated. Follow these steps for proper battery activation:

1. Remove the battery from the tractor and place on a work bench or table.

2. Fill each cell to the top of the plates with electrolyte.

3. Allow the battery to sit 30 minutes. This will allow the chemical action to take place between the electrolyte and battery plates. When the battery is charged, the heat will cause expansion of the electrolyte.

4. Re-check the electrolyte level and, if necessary, add electrolyte to completely cover the plates.

5. Connect the charger to the battery per instructions with the charger. Charging the battery at more than the recommended 4 AMPS will shorten the service life of the battery, and may cause the plates to warp and short out the battery.

6. Charge the battery at 4 AMPS maximum until the specific gravity of each cell is 1.250 or higher.

7. Check the level of electrolyte in all cells and add, if necessary, to bring level up to split ring.

8. Wash off any spilled electrolyte.

9. Install the battery in the tractor and connect the POSITIVE battery cable to the positive terminal of the battery.

10. Connect the NEGATIVE battery cable to the negative terminal of the battery.

Important Safety Information:

– Battery cables must be disconnected in the proper order to avoid arcing. When disconnecting cables from the battery, ALWAYS remove the negative cable first, and then remove the positive cable.

– Electrolyte is diluted sulfuric acid. Use extreme care to avoid spilling and to avoid contact with skin and eyes. Acid can destroy clothing and burn your skin. Should acid come in contact with your skin, flush the area immediately with clean cold water. If acid spills on clothing, first dilute with clean water, then neutralize with a solution of baking soda and water.

– Battery cables must be installed in the proper order to avoid arcing. When connecting cables to the battery, ALWAYS connect the positive cable first, then connect the negative cable.

Follow this maintenance schedule for your CUB CADET 2135. Maintenance information for optional equipment may be found in the manual which is included with that specific piece of equipment.

If you are experiencing battery or charging system problems with your CUB CADET 2135, consult the following table for possible causes and solutions.

If your CUB CADET 2135 engine cranks but fails to start, follow these troubleshooting steps:

If the electric Power Take-Off (PTO) on your CUB CADET 2135 is not working correctly, use this guide to diagnose and resolve the issue.

If your CUB CADET 2135 will not move or is having other hydrostatic drive issues, refer to the troubleshooting chart below.

Removal:

1. Remove the right and left side panels as follows:

a. Open the hood and loosen the rear wing nuts.

b. Loosen the upper front wing nuts on each side of the grille.

c. Grasp the side panel just behind the grille and pull outward to release the side panel from the tapered bushings on the grille.

d. Slide the side panel forward and out of the slot in the dash panel.

2. Remove the hood and grille as an assembly as follows:

a. Disconnect the wire harness and remove the headlight lamp bulbs from the back of the headlight reflector.

b. Pinch the locking barbs to release, or cut the cable ties that secure the wire harness to the RH grille bracket.

c. Remove the hex wash. hd. tapp screws which secure the LH and RH grille brackets and hood and grille to the tractor frame.

d. Lift the hood and grille assembly off the tractor frame and place in a work area that will prevent scratches or damage to the painted surfaces.

Installation:

1. Install the hood and grille assembly as follows:

a. Position the hood and grille on the tractor so that the slotted holes of the LH and RH grille brackets align with the frame holes, and the hood guide engages the bulkhead slot.

b. Install the hex wash. hd. tapp screws, but do not completely tighten now.

c. Align the rear edge of the hood with the dash panel and close the hood.

d. Press the front of the hood down completely and recheck the rear edge alignment. Adjust the grille brackets as necessary to obtain an even spacing of approximately .100 inch.

e. While holding the hood in place, tighten the hex wash. hd. screws.

f. Secure the wire harness to the right hand side of the grille with the previously removed, or new, cable ties.

g. Install the head lamp bulbs and connect the wire harness.

2. Install the side panels as follows:

a. Slide the rear of the side panel into the slot of the dash panel, then swing the front toward the grille, making sure the rear tab is between the wing nut and the bulkhead.

b. Align the front side panel slots with the tapered bushings, and press the panel into place between the bushings and the grille. The tapered bushings should seat in the circular opening at the bottom of the slots.

c. Tighten the rear and upper front wing nuts and close the hood.

Servicing the PTO clutch on a CUB CADET 2135 involves removal, inspection, and installation. Follow these steps carefully.

Removal:

1. Set the parking brake and remove the battery ground cable for safety.

2. Remove the side panels and the hood and grille assembly.

3. Disconnect the electrical connection from the PTO clutch.

4. Remove the hex flange lock nuts securing the muffler to the tractor frame and remove the muffler.

5. The procedure varies based on the engine factory code. For CUB CADET 2135 models:

With Engine Factory Code 11187:

a. Remove the hex cap screw, lock washer, and flat washer from the engine crankshaft.

b. Loosen the hex nut and remove the hex cap screw from the engine.

c. Slide the PTO clutch assy. and spacer off the engine crankshaft. Note the position of the beveled I.D. of the spacer.

With Engine Factory Code 11317:

a. Remove the hex cap screw, lock washer, and step spacer end cap from the engine crankshaft.

b. Slide the PTO clutch assy. and spacer off the engine crankshaft. Note the position of the beveled I.D. of the spacer.

c. Remove the torque stud from the engine.

Inspection:

1. Inspect all threaded areas for damage.

2. Inspect for bent, nicked, or split pulley sheaves.

3. Inspect the armature plate leaf springs for cracks and broken or loose rivets.

4. Check the bearings for binding or excessive looseness, indicating internal wear.

5. Check the slot of the clutch brake plate and the torque stud for cracks, distortion, or excessive wear.

6. Inspect the crankshaft spacer for damage or wear.

7. Inspect the keyway of the PTO clutch and engine crankshaft for damage or wear.

Installation:

1. The procedure varies based on the engine factory code:

With Engine Factory Code 11317:

a. Install the torque stud on the engine.

b. With the beveled I.D. toward the engine, slide the spacer onto the crankshaft.

c. Align the key of the PTO clutch with the keyway of the crankshaft, and the slot of the clutch brake plate with the torque stud; then slide the PTO clutch onto the crankshaft.

d. Slide the step spacer end cap onto the crankshaft and secure with the lockwasher and hex cap screw. Torque the hex cap screw to 50-60 ft. lbs.

With Engine Factory Code 11187:

a. Install the torque stud on the engine.

b. With the beveled I.D. toward the engine, slide the spacer onto the crankshaft.

c. Align the key of the PTO clutch with the keyway of the crankshaft, and the slot of the clutch brake plate with the torque stud; then slide the PTO clutch onto the crankshaft.

d. With the hex nut threaded on hex cap screw, position the screw in the right clutch slot and tighten into the threaded hole of engine.

e. Secure the PTO clutch with the flat washer, lockwasher, and hex cap screw. Torque the hex cap screw to 50-60 ft. lbs.

2. Install the muffler and secure to the tractor frame with the hex flange lock nuts.

3. Connect the main harness connector to the PTO clutch.

4. Install the hood and grille assembly and the side panels.

The PTO air gap on Models 2130, 2135, 2140 and 2145 is factory preset. No air gap specifications or adjustments apply. You should inspect the clutch assembly per the service manual if you suspect a problem.

For models that do require adjustment (2160, 2165, and 2185), a burnishing procedure must be performed first on any new PTO clutch before adjustment.

PTO Clutch Burnishing Procedure (All Models):

Any time a new PTO clutch is put into service, this procedure should be performed prior to operating the new clutch under load.

1. With the engine warm (run approximately 5 minutes) and the mower deck installed, proceed as follows:

2. With the engine running at approximately 50% throttle, engage and disengage the clutch at ten second intervals (ten seconds ON/ ten seconds OFF) five times. The engine choke may have to be pulled out slightly to accomplish this.

3. Increase the engine speed to 75% throttle and again engage and disengage the PTO clutch at ten second intervals five times.

4. Make certain the PTO is disengaged and stop the engine.

The turning radius should be approximately equal in each direction, and the front wheels should toe-in approximately 1/8 inch. Check and adjust as follows:

1. Turn the steering wheel fully to the left and note the distance between the front pivot axle and the steering stop on the left steering knuckle.

2. Turn the steering wheel fully to the right and compare the distance between the axle and the right steering knuckle stop with the left knuckle distance observed in the previous step. The clearances should be approximately equal.

3. If the steering knuckle clearances differ significantly, check the lower steering arm. If it is not properly positioned, disassemble and reposition the steering arm per the service manual.

4. If the lower steering arm is correctly installed, re-adjust the tie rods and set the 1/8 inch toe-in as follows:

a. Remove the hex lock nuts from the tie rod assemblies from the arms.

b. Manually place each front wheel in the straight ahead position (as close as visually possible).

c. Place a mark at the same spot on both front wheels; for example, the mold seam in the center of the tire tread or the inner bead flange of the wheel rim.

d. Rotate the wheels to position the marks at the front horizontal diameter of the wheels, then measure the distance between the marks.

e. Rotate the marks to the rear horizontal diameter and measure the distance between the marks. The distance between the marks at the front should be 1/8 inch less than the distance measured at the rear.

f. If the difference between the measurements is more or less than 1/8 inch, move each wheel equally, in the direction necessary to achieve the required toe-in dimension.

g. Loosen the hex jam nuts from the front and rear ball joints, if necessary.

h. Turn the ball joint in or out on each tie rod, as necessary to align with the hole in each steering arm.

i. Reinstall the ball joints in the steering arms, but do not tighten the jam nuts against the ball joints now.

j. Remove the dowel pin from the segment gear, and repeat steps 1 and 2 above to ensure the steering knuckle clearances are approximately equal.

k. If the steering knuckle clearances are not approximately equal, determine the difference between the two measurements by subtracting the smaller from the larger.

l. Disconnect the tie rod assembly from the steering knuckle having the least clearance. Turn the ball joint into the tie rod if necessary, by an amount equal to half (or closest to half) the difference. Reinstall the tie rod assembly in the steering arm.

m. Disconnect the other tie rod assembly and lengthen by the number of full turns required in the previous step. Reinstall the tie rod assembly in the steering arm.

n. Tighten the hex jam nuts against the ball joints.

5. The turning radius and toe-in should now be correctly adjusted. Recheck and, if necessary, readjust per the previous instructions.

For proper operation and safety, the tractor brake system should be periodically tested and adjusted. Follow these steps:

1. Place the tractor on a firm and level surface and stop the engine.

2. This step applies to Models 2135, 2145, 2165, and 2185. Pull the hydro disengagement rod rearward and lock in the slot of the drawbar plate to disengage the hydro transmission.

3. Depress the brake pedal and engage the park brake lever. While observing the rear wheels, push the tractor forward or rearward. If the tractor can be pushed AND the wheels rotate, the brake tension must be increased.

4. Depress the brake pedal to disengage the park brake lever, then release the brake. While observing the rear wheels, push the tractor forward or rearward. If the wheels do not rotate, the brake tension must be decreased.

5. Release the brake pedal and adjust the brake tension as follows:

a. Working from underneath the tractor, remove the internal cotter pin from the adjustment ferrule and disconnect the brake rod assembly from the brake cam.

b. Lightly pull the brake rod forward to ensure the rod is fully seated in the spring and that the spring hook is at the front of the hole in the brake arm. DO NOT actuate the brake arm when pulling the rod.

c. Turning one full turn at a time, turn the adjustment ferrule inward or outward on the brake rod to align the ferrule with the hole in the brake cam.

d. Turn the ferrule outward one full turn and install the ferrule in the brake cam.

e. Depress and release the brake pedal, then check to ensure the spring is not tensioned. There should be a small amount of slack in the brake rod and spring.

f. Manually depress the brake pedal and observe that the spring begins to extend during the initial movement (approximately 1 inch) of the pedal.

g. Repeat steps 4 and 5 above to again test the brakes.

If you are still unable to rotate the wheels with the park brake engaged, check for oil on the brake shoes or drum, excessively worn brake shoes, or possible internal transaxle damage. If unable to push the tractor with the brake disengaged, check for possible brake assembly and/or internal transaxle damage.

The correct installation and adjustment of the hydro adjustment rod is essential to proper operation of the transmission. The adjustment ferrule must be installed in the REAR slotted hole of the clutch cam, and the pivot sleeve must be installed in the LOWER hole of the control arm. The hydro adjustment rod must be readjusted whenever a neutral adjustment is made to the centering spacer.

To verify the correct installation of the clutch rod:

1. Depress the brake pedal and engage the park brake.

2. Working from underneath the left frame channel of the tractor, remove the internal cotter pin, securing the pivot sleeve to the control arm. Disconnect the hydro adjustment rod from the control arm.

3. Ensure the adjustment ferrule is at the back of the proper slotted hole of the clutch cam. The extension spring should hold the ferrule against the back of the hole.

4. Without moving the clutch cam or control arm, check the pivot sleeve pin for direct alignment with the lower hole of the control arm. If not aligned, proceed as follows:

a. Loosen the hex jam nut from the front of the adjustment ferrule.

b. Turn the rod into, or out of, the adjustment ferrule as necessary to align the pivot sleeve with the hole in the control arm.

5. Install the pivot sleeve in the proper hole of the control arm and secure with the internal cotter pin.

6. Tighten the hex jam nut against the adjustment ferrule.

Incorrect neutral adjustment of the hydrostatic transmission will affect the output performance, most notably in reverse. If the tractor attempts to drive forward or rearward when neither the forward nor reverse pedal is depressed, a neutral adjustment should be checked and made.

1. Drive the tractor for approximately 5-10 minutes to warm up the hydro transmission, then stop the engine and engage the parking brake.

2. Place the tractor on a firm and level surface and chock the front wheels before raising the rear wheels from the ground. Use jack stands to support the rear of the tractor when raised. Raise the rear of the tractor so that the rear tires are at least one inch above the surface, and set it on jack stands. Make certain the jack stands are positioned to balance the tractor and prevent tipping.

3. Carefully start the tractor engine and release the parking brake. Observe both rear wheels for rotation in either direction.

4. If wheel rotation is observed, adjust the neutral setting as follows:

a. Disconnect the hydro adjustment rod from the control arm by removing the internal cotter pin from the pivot sleeve.

b. If wheel rotation stops when the rod is disconnected, check and readjust the rod per paragraph 6-10. Also check the pedal linkage and damper cylinder for binding.

c. If wheel rotation continues, loosen the hex top lock nut and hex cap screw securing the centering spacer to the neutral bracket.

d. If the rotation is in the forward direction, slide the centering spacer rearward until the wheels just begin to rotate in the reverse direction. Then slowly slide the spacer slightly forward until wheel rotation stops.

e. If the rotation is in the reverse direction, slide the centering spacer slightly forward until wheel rotation stops.

f. Carefully tighten the hex cap screw and top lock nut, making certain the spacer does not move.

g. Stop the engine and engage the parking brake.

h. Check and, if necessary, readjust the hydro adjustment rod per paragraph 6-10.

5. If unable to obtain a neutral setting by adjusting the centering spacer, refer to paragraph 5-25 for information concerning inspection and repair of the hydrostatic transmission.

Throttle Cable Adjustment:

If the engine does not achieve its high (no load) speed when the throttle control is moved to the full throttle position, check the cable adjustment before performing any other engine or carburetor inspections.

1. Raise the hood and locate the throttle cable connection at the engine.

2. While observing the direction of movement of the engine throttle arm, move the tractor’s throttle control lever to the full throttle position.

3. Loosen the screw securing the cable clamp.

4. Push and hold the engine throttle arm fully in the direction of movement noted in step 2 above.

5. While continuing to hold the throttle arm, pull the throttle cable conduit back through the clamp (away from the arm) to remove any slack in the cable and tighten the screw securing the clamp.

6. Start the engine. Use a tachometer to check the high and low speed engine rpm to specifications. Refer to the appropriate Engine Service Manual if adjustment is necessary.

Choke Cable Adjustment:

If the engine is difficult to start or runs roughly when warmed up, check the choke cable setting before performing any other engine or carburetor inspections.

1. Raise the hood and locate the choke cable connection at the engine.

2. While observing the direction of movement of the engine choke arm, pull the tractor’s choke handle out.

3. Loosen the screw securing the cable clamp.

4. Push and hold the engine choke arm fully in the direction of movement noted in step 2 above. If desired, the air cleaner cover and element may be removed to ensure that the carburetor choke plate is closed completely.

5. While continuing to hold the choke arm, pull the choke cable conduit back through the clamp (away from the arm) to remove any slack in the cable and tighten the screw securing the clamp.

The 190-314 Mulching Kit is designed for usage on the 38″ mower deck of Tractor Models 2130 and 2135. Follow these steps for installation:

1. Deck Removal:

Stop the tractor engine, disengage the PTO, place all controls in neutral, and engage the brake before beginning deck removal. Refer to the Deck Owner’s Manual to remove the deck. Do not remove the deck immediately after running the unit; both the grille and PTO clutch are hot.

2. Remove Cutting Blades:

When handling the blades, be careful not to cut yourself.

a. A block of wood may be placed between the housing and cutting edge of the blade to assist in removal of the hex nut securing the blade.

b. Remove the hex nuts, flat washers, cutting blades and spacers from the deck. Save the hex nuts and flat washers to mount the mulching blade assembly.

3. Assemble and Mount Mulching Baffle:

a. Assemble the top baffle to the side baffle with the carriage bolts and hex nuts.

b. Assemble the retaining bolt with the hex center lock nut. Tighten the center lock nut to eliminate side play, while still allowing the retaining bolt to pivot.

c. With the retaining bolt and locking bracket projecting through the discharge opening, position the baffle assembly in the underside of the deck, and press the side baffle into the discharge opening as far as possible.

d. Hook the locking bracket onto the edge of the deck and tighten the wing nut (or hex nut, if used) until snug.

e. Using a rubber mallet, tap the side baffle through the discharge opening. Alternately tap the rear area of the baffle and re-tighten the wing nut until the baffle is completely seated and the inner mounting hole of the baffle aligns with the hole in the deck.

f. Insert the hex cap screw from the underside of the deck and secure with the sec- and wing nut.

4. Install Mulching Blades:

With the blades removed, the spindle shafts can slip partially out of the spindle housings when the deck is inverted to re-install the blades. If necessary, hold the shafts from the top of the deck when installing the blades and hardware.

a. Slide the two flat washers onto each spindle shaft.

b. Install the mulching blades, making certain the sharpened edges are in the correct direction for blade rotation (sharpened edges pitch upward toward underside of deck).

c. Install the two plate adapters.

d. Making sure the lift wings point toward the deck housing, install the cutting blades and loosely secure with the flat washers and hex nuts removed earlier.

e. Align the pilot holes of the blades and adapters (the blades should be at 90° to each other) and insert a phillips screwdriver, drift punch, or similar type instrument through the pilot holes.

f. To prevent the spindle shaft from turning when tightening the hex nut, use a 1-1/4 inch wrench to hold the hex shaped hub of the V-pulley.

g. Tighten the hex nuts to 90 to 110 ft-lbs.

h. Install the mower deck on the tractor per the instructions in the Owner’s Manual.