CUB CADET 2160 (01) PDF Document

To ensure your safety while servicing your CUB CADET 2160, please follow these rules:

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 fall, 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 so not exceed 30 psi, wear safety glasses or goggles, and use proper shielding to protect everyone in the work area.

Tractors are shipped with a dry battery. Electrolyte must be added and the battery activated. Follow these procedures 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.

NOTE: Maintenance information for optional equipment may be found in the manual which is included with that specific piece of equipment.

If the battery on your CUB CADET 2160 will not hold a charge, please check the following:

If the engine on your CUB CADET 2160 cranks but fails to start, investigate these possible causes and solutions:

If the engine on your CUB CADET 2160 does not crank, here are the potential causes and solutions:

If you are experiencing blowing fuses on your CUB CADET 2160, please consult the following troubleshooting steps:

If you are experiencing electrical issues with your CUB CADET 2160, please refer to the following guide:

If the electric PTO will not engage on your CUB CADET 2160, please follow these troubleshooting steps:

If the PTO on your CUB CADET 2160 is not engaging properly or is disengaging while you are operating it, consider the following possible causes and solutions:

If your six-speed CUB CADET 2160 tractor will not move forward or in reverse, please check the following possibilities:

If your CUB CADET 2160 is not reaching its normal operating speed in one or both directions, or only operates in one direction, here are the potential causes and solutions:

If your CUB CADET 2160 tractor creeps forward or rearward when the forward or reverse pedals are released, consult this troubleshooting guide:

If your six-speed CUB CADET 2160 is exhibiting issues such as noise, slipping, or shifting problems, please review the following table for potential causes and solutions:

If you are experiencing steering issues with your CUB CADET 2160, such as looseness, excessive effort, or tightness, refer to the troubleshooting guide below. Note that for models 2160, 2165, and 2185, some issues may be related to early production configurations.

The hood, grille, and side panels serve to protect the operator as well as the equipment. They may have sharp edges which could cause cuts to the skin. Use extreme caution when handling these metal components.

Side Panel Removal:

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

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

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

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

Hood and Grille Removal:

1. Disconnect the wire harness and remove the head lamp bulbs from the back of the head-light reflector. Pinch the locking barbs to release, or cut the cable ties that secure the wire harness to the RH grille bracket.

2. Before removing the hood and grille assembly, close the hood. Failure to do so will allow the hood and grille to flip off the tractor when the screws are removed in the following step. This could cause damage or injury.

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

4. 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.

To service the battery and electrical components for models 2160 and 2185, follow these steps. Always be aware that the electrical system contains safety interlock switches that are essential for operator safety and must be in proper working order. Battery electrolyte is diluted sulfuric acid. Use extreme care to avoid spilling, and to avoid contact with the skin and eyes.

Removal Procedure:

1. Remove the side panels.

2. Remove the battery. Battery cables must be disconnected in the proper order to avoid arcing. ALWAYS remove the negative battery cable from the battery before removing the positive cable.

a. Remove the negative battery cable and main harness ground lead from the battery by removing the battery bolt AND NUT.

b. Place the battery nut in the opening of the positive battery terminal. Position the positive cable (and main harness lead, if applicable) on top of the terminal and secure with the battery bolt.

c. Loosen the hose clamp and remove the drain tube from the battery vent nipple.

d. From underneath the battery, pull the bottom of the battery retainer strap down and forward to release from the pedestal tab.

e. Lift the battery out of the tractor.

f. Remove the battery retainer strap by pulling it down through the pedestal opening.

3. Unplug the reverse relay from the main harness.

4. Slide the fuse holders off the fuse holder mounting clips and remove the fuses from the holders.

5. Pinch the locking barbs of the fuse holder mounting clips to remove them from their mounting location.

6. Disconnect the main harness connector and ground wire from the voltage indicator. Remove the indicator and quick connect lug by removing the hex cap screw and hex sems nut.

7. Unplug the wire harness connector from the PTO switch by pinching the locking tabs and pushing the switch up through the dash panel.

8. Unplug the harness connector and ground lead from the ignition switch by removing the ignition switch cap and switch nut.

9. After unplugging the harness leads, remove the hour meter and dash label by removing the truss hd. tapp screws and pushing the meter outward from the underside of the dash panel.

10. From underneath dash panel, turn the indicator bulb sockets counterclockwise and pull from the dash panel to remove the indicator bulbs.

11. Lift the retaining clip and unplug the wire harness connector from the reverse switch; then depress the locking tabs and push the switch outward from inside the frame pedestal.

12. Remove the interlock switch as follows:

a. Release the parking brake.

b. Disconnect the main harness connector from the interlock switch.

c. Pinch the locking tabs, and remove the switch from the lower right frame pedestal.

13. Spread the locking clips of the harness connector to disconnect from the sockets of the head lamp bulbs. Turn the sockets 1/4 turn counterclockwise to release from the headlight reflector and remove the bulb assemblies.

14. Remove the solenoid as follows:

a. Disconnect the starter cable and battery cable (and the main harness battery lead, if applicable) from the solenoid by removing the hex nuts and lock washers.

b. Disconnect the actuation lead from the solenoid by removing the hex nut and external lock washer.

c. Pull the ground lead from the quick connect lug; then remove the solenoid and quick connect lug from the bulkhead by removing the hex sems nuts and hex cap screws.

15. Remove the main harness as follows:

a. Disconnect the harness leads from the seat switch.

b. Remove the fender and running boards.

c. Unplug the wire harness connector from the PTO clutch.

d. Remove the hex cap screw and external lock washer securing the engine ground.

e. Remove the starter cable and diode assy. from the starter. Tag the harness leads and unplug from all other engine components.

f. Pinch the locking barbs to remove, or cut the several cable ties holding the harness to the tractor frame.

g. Note the routing of the harness and remove from the tractor.

Servicing the PTO clutch (Models 2160 and 2185) requires care. Usage of impact tools is recommended when removing or installing the hex cap screw that secures the PTO clutch assembly to the engine crankshaft.

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. Do not attempt to remove the muffler or PTO clutch when the engine is hot.

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

6. Remove the PTO clutch assy. from the engine crankshaft by removing the hex cap screw, lock washer, and flat washer. Note the position of the electrical lead wires before removing the clutch assy.

7. Slide the spacer off the crankshaft. Note the position of the beveled I.D. of the spacer.

8. Remove the torque bracket from the engine by removing the hex cap screws and bell washers.

Installation:

1. Install the torque bracket on the engine with the hex cap screws and bell washers. Slide the torque bracket to its highest position and snug the screws.

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

3. Position the electrical lead, as noted during removal, and align the rotor key with the crankshaft keyway; then slide the PTO clutch assembly onto the crankshaft.

4. Secure the clutch assy. with the flat washer, lock washer, and hex cap screw. For Mod els 2160 and 2165, torque the screw to 45 ft. lbs. On Model 2185, torque the screw to 50-60 ft. lbs.

5. Using a feeler gauge, adjust the air gap to .017 inch. Refer to Adjustments in Section 6 for a description of this procedure.

6. Adjust the torque bracket evenly against the top edge of the field coil back plate and tighten the cap screws.

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

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

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

Any time a new PTO clutch is put into service, this procedure should be performed prior to operating the new clutch under load. The PTO clutch may be hot. Use care when handling the clutch assembly if the engine has been run recently. Allow the clutch assembly to cool.

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.

5. On Models 2160, 2165 and 2185, recheck the PTO air gap and adjust if necessary.

To adjust the PTO clutch air gap on models 2160, 2165, and 2185, follow these steps. Disengage the PTO, stop the engine and engage the parking brake. The PTO clutch may be hot. Allow the engine and clutch to cool before adjusting.

1. Locate the three access slots which are equally spaced around the circumference of the armature brake plate.

2. Using a feeler gauge, measure the gap between the armature drive plate and the rotor at all three access slots. The air gap measurements should be equal and between .012 to .017 inch.

3. Loosen or tighten the self-locking nuts as necessary to achieve an equal air gap measurement, within specification, at all three locations. Re-measure each location after adjusting any of the self locking nuts.

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. Place the tractor on a firm and level surface and chock the rear wheels before beginning alignment procedures.

2. The front of the tractor may be raised slightly to reduce the weight and ease movement of the front wheels.

a. Remove the hex lock nuts from the arms, and disconnect 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 ball joints.

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 (and tie rod if necessary) in full turn increments, shortening the assembly 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 I. Reinstall the tie rod assembly in the steering arm.

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

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

The tractor brake system should be periodically tested for proper operation and adjusted as follows. The tractor must be placed on a firm and level surface when testing and/or adjusting the braking system.

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

2. For models 2130, 2140 and 2160: Move the speed control lever to the fully rearward (neutral) position.

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 cam 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 able to rotate the wheels with the park brake engaged, check for oil on brake shoes, 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.

For AGS Six Speed Tractors (Models 2130, 2140, and 2160), the correct installation and adjustment of the clutch adjustment rod is essential to proper operation of the transmission. The adjustment ferrule must be installed in the FRONT slotted hole of the clutch cam, and the pivot sleeve must be installed in the UPPER hole of the control arm.

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 clutch 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 upper hole in 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.

Correct neutral adjustment of the clutch assembly is essential to the proper operation of the clutch. While on a level surface, if the tractor attempts to drive (creep) forward or rearward when neither forward nor reverse pedal is depressed, neutral adjustment should be checked and readjusted. The operator presence safety circuit will stop the engine if the seat is empty when the brake pedal is released.

1. Drive the tractor for approximately 5-10 minutes to warm up the clutch assembly, 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.

3. 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.

4. Carefully start the tractor engine and release the parking brake.

5. Move the speed control lever to the mid (third or fourth gear) speed setting, and observe both rear wheels for rotation in either direction.

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

a. Disconnect the clutch 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 6-9. Also check the pedal linkage 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 spacer slightly rearward until the rotation stops. If rotating in the reverse direction, slide the spacer forward until rotation stops.

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

f. Stop the engine and engage the parking brake.

g. Check and, if necessary, readjust the clutch adjustment rod per paragraph 6-9.

h. Check and, if necessary, readjust the interlock rod per paragraph 6-11.

7. The inability to attain a neutral setting by adjusting the centering spacer could indicate internal problems with the clutch assembly. Refer to paragraph 5-24 for clutch inspection procedures.

Throttle Cable Adjustment:

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 (see Section1). Refer to the appropriate Engine Service Manual if adjustment is necessary.

Choke Cable Adjustment:

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.