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Kubota G2160 Troubleshooting

The Kubota G2160 garden tractor was manufactured between 2001 and 2008. The components of Kubota G2160 driveline system: a 47.5 cu.in (778 cc) Kubota D782 four-cycle vertical three-cylinder indirect injection water-cooled diesel engine and hydrostatic transmission with infinite forward and reverse gears.

The engine has a cylinder bore of 2.64" (67 mm), piston stroke of 2.90" (73.6 mm), and rated power of 18.1 hp (13.5 kW). The maximum forward speed - 9.3 km/h (15 mph), max. reverse speed - 3.8 km/h (6.1 mph).

The garden tractor was equipped with an electronic power steering, internal expanding brakes, 16x6.50-8 front tires, and 23x10.50-12 rear tires. The wheelbase is 50.8" (1290 mm). The Kubota G2160 is compatible with the following attachments: 48", 54", or 60" mid-mount 3-blade mower decks with cutting height of 1.0-4.0" (25-100 mm) and hydraulic lift system, 50" front-mount Kubota G2726 snowblower, and 54" front-mount Kubota TG2754 blade.

Diesel Engine Troubleshooting
Engine will not start or hard to start
Plugged fuel filter - Clean the filter element
Fuel shut-off valve closed - Open the fuel shut-off valve
Air trapped in fuel system - Bleed air
Fuel injectors are clogged or faulty - Inspect fuel injectors and replace if necessary
Damaged fuel injection pump - Change pump or rebuild it
Low engine compression - Inspect and replace faulty parts
Engine stops running unexpectedly
Coolant temperature is low - Warm up engine as required
Water, dirt, or air in fuel system - Drain, flush, fill, and bleed system
Irregular fuel injection - Adjust fuel injection timing
Fuel filter clogging - Install new filter element
Dirty or damaged injectors - Change fuel injectors
Engine stops after starting
Unadjusted fuel injection pump timing - Correct injection timing
Dirty fuel filter element - Clean the filter or install new filter element
Damaged or clogged injector nozzles - Replace fuel injector nozzles
Fuel injection pump failure - Change or repair the pump
Clogged air cleaner element - Service or replace the air cleaner
Engine stops while idle
Incorrect low idle speed adjustment - Need to adjust idle speed
Fuel injection pump is not working correctly - Install a new fuel pump or repair
Fuel injector nozzles are damaged or dirty - Test injector nozzles and replace as required
Valve clearance is out of adjustment - Need to adjust valve clearance
Engine overheated
Low coolant level - Fill the cooling system. Check and repair damage to the cooling system if required
Cooling system is dirty or cooling components are damaged - Change faulty components or service cooling system
Lack of engine oil - Need to add engine oil
Broken fan belt or improper belt tension - Replace or adjust belt tension properly
Defective or wrong type of thermostat - Thermostat needs to be replaced
Reduced engine power
Dirty or damaged injectors - Inspect fuel injectors and replace if necessary
Fuel injection pressure is wrong - Adjust pressure to proper level
Air filter is dirty - Replace or clean the air filter element
Plugged engine oil filter - Clean or change engine oil filter
Engine overloaded - Shift to lower gear or reduce the load
Improper valve clearance - Check and adjust
Incorrectly adjusted low idle speed - Correct low idle settings
Fuel pipes or hoses are dirty - Clean fuel system pipes and hoses
Engine compression is insufficient: Valves are broken or leaking - Have valves replaced
Engine knocking or noise
Incorrect setting of fuel injection pump timing - Fuel pump timing settings need to be corrected
Faulty fuel injector nozzles - Install new set of properly balanced nozzles
Engine oil level low - Fill up the engine oil
Engine is not fully warmed up - Warm up the engine
Worn crankshaft or main bearings - Crankshaft or bearings need to be replaced
Piston rings failure - Piston rings need to be replaced
Loose flywheel bolts - Check flywheel bolts and tighten properly
High oil consumption
Oil leaking: Seals or gaskets are wearing excessively - New components need to be installed
Improper oil viscosity - Use correct viscosity oil
Worn or stuck piston rings - Change the piston rings as required
Damaged valve stems or valve guides - Valves replacement required
Scored cylinder liners or pistons - Inspect pistons and liners, fit new components as necessary

Hydrostatic Transmission Troubleshooting
Hydrostatic transmission makes excessive noise
Bent or unadjusted speed control pedal linkage - Adjust or change linkage
Excessive transmission load - Reduce loading
Fluid is contaminated or fluid level is insufficient - Add fluid to the correct level or fill transmission with fresh fluid
Transmission parts are worm or defective - Change or repair defective parts
Shifting is hard
Damaged or loose shift linkage - Change or repair linkage
Stuck or defective hydrostatic pump - Repair or change pump
Worn or misadjusted transmission shift control parts - Adjust properly or change
Low power
Low oil level - Fill the transmission housing with oil
Worn or defective drive pulley - Change pulley
Shifting linkage is misadjusted or broken - Change or adjust linkage
Speed control pedal linkage is damaged or out of adjustment - Repair or adjust linkage
Transmission leaks
Worn transmission seals or gaskets - Install new gaskets or seals
Final drive shaft leaks - Replace shaft seals
Cracked transmission case - Install a new transmission case

Mower Deck Troubleshooting
Mower vibrates too much
Dirty or worn mower drive sheave - Replace or clean sheave
Damaged or loose drive belt - Change belt or adjust belt tension
Mower blades are bent or out of balance - Balance or change as needed
Blade bolts are not tightened well - Tighten it fast
Discharge chute is constantly plugged
Fast ground speed - Select a lower speed
Long grass - Adjust mower to lower cutting height
Reduced engine rpm - Choke is not fully opening
Low cutting height - Use correct cutting height
Drive belt installed improperly - Drive belt must be installed correctly
Streaking of uncut grass
Discharge area is clogged - Clean out the mower deck
Excessive blade dullness - Blades need to be sharpened
Damaged or worn blades - Replace the blades
Fast mowing speed - Use a lower speed
Cutting level is too low - Adjust mower to higher cutting height
Filled bagger - Clean bagger
Blades scalp the grass
Bumpy or unleveled lawn - Lawn leveling required
Cutting height is too low - Adjust mower to higher cutting height
Fast ground speed - Use a slower speed
Incorrect level of mower deck - Adjust mower deck level properly
Blades are bent or worn - Change the blades
Tires are not correctly inflated - Correct tire pressure
Uneven cut
Tires are not properly inflated - Inflate tires correctly
Incorrectly leveled mower deck - Deck should be adjusted correctly
Excessive blade dullness - Sharpen the blades
Worn or bent blades - Install new blades
Discharge area is clogged - Inspect and clean cutting deck
Damaged mower deck housing - Rebuild or change mower deck
Mower spindle is faulty or loose - Install new spindle or repair it

Electrical Troubleshooting
Battery won’t charge
Electrical cable connections are corroded or loose - Service or tighten connections
Battery terminal connectors are faulty - Terminal connectors should be replaced
Bad cell in battery - Use a new battery
Starter motor turns slow
Low battery output - Battery is drained, recharge it
Battery will not hold charge - Service or change the battery
Disconnected cables or faulty battery terminals - Check wire connections and change or service terminals
Starter will not work
Battery is drained or worn - Charge or replace the battery
Wiring harness is disconnected or improperly connected - Check wiring harness and connect as required
Low battery capacity - Battery is drained, charge it
Incorrectly gapped or worn spark plug - Clean, gap or replace spark plug
Solenoid or starter motor failure - Starter/solenoid should be replaced



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