Hustler 104893 User Manual

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•••••••
Hustler Turf Equipment
•••••
P.O. Box 7000
•••
Hesston, Kansas
67062-2097
Operator’s Manual
104893 10/05
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The engine exhaust from this product
contains chemicals known to the State
of California to cause cancer, birth
defects or other reproductive harm.
WARNING:
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TABLE OF CONTENTS
1. General Information.............................................................Sect. 1
2. Safety Precautions................................................................Sect. 2
3. Operation..............................................................................Sect. 3
4. Maintenance.........................................................................Sect. 4
5. Adjustments .........................................................................Sect. 5
6. Troubleshooting...................................................................Sect. 6
7. Storage .................................................................................Sect. 7
8. Product Literature ................................................................Sect. 8
9. Index...................................................................................Sect. 10
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This manual applies to the following equipment:
TS15KAW36HBA (927400) TS17KAW48HBA (927426)
To the new owner
The purpose of this manual is to assist owners and operators in maintaining and operating the Hustler TrimStar Hydro. Please read it carefully; information and instructions furnished can help you achieve years of dependable performance.
A separate Engine Manual is included with your owner’s packet which contains additional engine information that will not be repeated in this manual. You are urged to read it before attempting any operation or repair of the engine.
The Quick Reference Decals located on the unit are designed to give the operator brief information needed in the daily operation of the machine. These decals are not intended to be used in place of this manual but instead are to be used as an extension of this manual. These decals should not be remove or obliterated. Replace these decals if they become unreadable.
It is the owner’s responsibility to make certain that the operator reads and understands this manual and the Quick Reference Decals before operating this machine. It is also the owner’s responsibility to make certain that the operator is a qualified and physically able individual, properly trained in the operation of this equipment.
Using this manual
General operation, adjustment and maintenance guidance is outlined for both the experienced and novice Hustler user. Operating conditions vary considerably and cannot all be addressed individually. Through experience, however, operators should find no difficulty in developing good operating skills suitable to most conditions.
Directions used in this manual, for example RIGHT or LEFT, refer to directions when facing forward while operating the unit, unless otherwise stated.
Photographs and illustrations used were current at the time of printing, but subsequent production changes may cause your machine to vary slightly in detail. Hustler Turf Equipment reserves the right to redesign and change the machine as deemed necessary, without notification. If a change has been made to your machine which is not reflected in this owner’s manual, or the parts manual, see your Hustler dealer for current information and parts.
Warranty registration
The Delivery and Warranty Registration form must be completed and signed to validate your warranty protection. As the new equipment owner, you are expected to see that the form is completed and forwarded to Hustler Turf Equipment at time of delivery.
Be sure to register the unit with Hustler Turf Equipment.
IMPORTANT: Any unauthorized modification, alteration, or use of non-approved attachments voids the warranty and releases Hustler Turf Equipment from any liability arising from subsequent use of this equipment.
Model and serial number
Unit model and serial numbers are found on the serial identification plate, located on the left side of the frame next to the left drive wheel.
These numbers are required on the Warranty Registration form. They will also assure you of the correct service parts when replacement becomes necessary.
Parts and service
Use original Hustler replacement parts only. These parts are available through your local Hustler dealer. To obtain prompt, efficient service, always provide the following information when ordering parts:
1. Correct part description and number, as given in the
parts manual supplied with your owner’s packet.
2. Correct model number.
3. Correct serial number.
All warranty repair and service must be handled through an authorized Hustler dealer. Arrangements should be made through your local service center.
GENERAL INFORMATION
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TrimStar Hydro
TWO YEAR LIMITED WARRANTY FOR POWER UNITS AND DECKS
(THREE YEAR LIMITED WARRANTY ON DECK
SPINDLE BEARING & DECK GAUGE FORK BEARING)
WHAT IS COVERED BY THIS WARRANTY
Hustler Turf Equipment, makes the following warranty to the original purchaser only:
a. First and Second Year: Hustler Turf Equipment
Tractors and Power Units are warranted for two (2) years from date of delivery on all materials and workmanship. If the Purchaser discovers within this warranty period a defect in materials or workmanship:
He must promptly notify Hustler Turf Equipment, or
an authorized dealer, in writing of the defect. In no event shall such notification be received by Hustler Turf Equipment, or an authorized dealer later than twenty-five (25) months from date of delivery.
Within a reasonable time after such notification,
Hustler Turf Equipment, will correct any defect in material or workmanship on the Hustler Turf Equipment, by repairing or replacing part(s) with either new or used replacement parts.
Such repair, including parts and labor shall be at the
expense of Hustler Turf Equipment, and,
b. Third Year: At the conclusion of the two year limited
warranty described in paragraph (a) above, there shall be an additional one year limited warranty on deck gauge fork bearings and deck spindle bearings only, no
labor.
If the Purchaser discovers within this warranty period a defect in either of these bearings:
He must promptly notify Hustler Turf Equipment, or
an authorized dealer, in writing of the defect. In no event shall such notification be received by Hustler Turf Equipment, or an authorized dealer later than thirty-seven (37) months from date of delivery.
Within a reasonable time after such notification,
Hustler Turf Equipment, will provide new replacement bearing to install on the Hustler Turf Equipment.
The installation of the deck gauge fork bearing and
deck spindle bearing shall be at the expense of the owner, and,
c. Rental Units (90 days): Within 90 days of date of
delivery Hustler Turf Equipment, provides a limited warranty on all materials and workmanship for units used for rental purposes. If the Purchaser discovers within this warranty period a defect in materials or workmanship:
He must promptly notify Hustler Turf Equipment, or
an authorized dealer, in writing of the defect. In no event shall such notification be received by Hustler Turf Equipment, or an authorized dealer later than 120 days from date of delivery.
Within a reasonable time after such notification,
Hustler Turf Equipment, will correct any defect in
material or workmanship on the Hustler Turf Equipment, by repairing or replacing part(s) with either new or used replacement parts.
Such repair, including parts and labor shall be at the
expense of Hustler Turf Equipment, and,
d. Hustler Turf Equipment provides a limited warranty
for the entire length of ownership by the original
purchaser for the following items:
Against all defects in the mowing deck which results
in the front edge of the deck being bent into the the
blades. If the original Purchaser discovers within this warranty period such a defect:
He must promptly notify Hustler Turf Equipment or
an authorized dealer, in writing of the defect. Such
notification must be received by Hustler Turf
Equipment or an authorized dealer during the period
when the equipment is owned by the original
purchaser.
Hustler Turf Equipment will correct any defect in
the frame resulting in frame breakage by repairing or
replacing part(s) with new or used replacement parts.
Hustler Turf Equipment will correct any defect in
the deck resulting in the front edge of the deck being
bent into the blades by repairing or replacing part(s)
with either new or used replacement parts.
Such repair, including parts and labor, shall be at the
expense of Hustler Turf Equipment, and,
e. The engine is covered by a two (2) year limited
warranty, by the engine manufacturer, to the original owner (commercial or residential) only, and,
WHO MUST PERFORM THE WARRANTY SERVICE
All warranty service will be performed by dealers authorized by Hustler Turf Equipment. Service calls and/or transportation expense of the product to and from the authorized dealer, for warranty work, will be paid by the owner of the product. For warranty service you can contact an authorized dealer or write Hustler Turf Equipment, 200 South Ridge Road, Hesston, Kansas 67062, or call 1-620­327-4911.
WHAT IS NOT COVERED BY THIS WARRANTY
Hustler Turf Equipment, does not warranty:
Some product, components or parts not
manufactured by Hustler Turf Equipment
Repairs made by unauthorized persons
Damage caused by use of the Hustler Turf
Equipment for purposes other than those for which it
was designed
Damages caused by disasters such as fire, flood,
wind, and lightening
Damages caused by neglect, abuse, abnormal use,
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improper or unreasonable use, accident, negligence or misuse
Repairs or replacement resulting from the use of
unauthorized parts, accessories or attachments
Repairs or replacement as the result if any alterations
or modifications, in the determination of Hustler Turf Equipment, which adversely affects the operation, performance or durability of the equipment.
Hustler Turf Equipment which has the serial number
removed or made illegible
Depreciation or damage caused by normal wear, lack
of reasonable and proper maintenance, failure to follow the product’s owner’s manual operating, maintenance and adjustment instructions or other operational instructions provided by Hustler Turf Equipment.
Normal maintenance parts and service including, but
not limited to, filters, fuel, lubricants, tune-up parts, belts, blades, blade sharpening, bearings, brake or steering adjustments
Repairs necessary due to improper fuel,
contaminates in the fuel system, or failure to properly prepare the fuel system prior to any period of non-use over three months
DISCLAIMER OF WARRANTY
The foregoing warranties are in lieu of all other warranties, expressed or implied, including but not limited to the implied warranties of merchantability and fitness for a particular purpose. However, if the Hustler Turf Equipment is purchased as a consumer product, any implied warranty of merchantability or fitness for a particular purpose is limited to the duration of this limited warranty. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
LIMITATION OF REMEDIES
In no case shall Hustler Turf Equipment, be liable for any special, incidental, or consequential damages based upon breach of warranty, breach of contract, negligence, strict liability in tort, or any other legal theory. Such damages include, but are not limited to:
Loss of profits
Loss of savings or revenue
Loss of use of Hustler Turf Equipment or any
associated equipment
Cost of capital
Cost of any substitute equipment, facilities, services
or downtime
The claims of third parties including customers, and
injury to property Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you.
TIME LIMIT
Any action for breach of warranty must be commenced within twenty-five (25) months following delivery of the goods in a non-rental application. Any action for breach of warranty must be commenced within 120 days following delivery of the goods in a rental application.
NO OTHER WARRANTIES
Unless modified in writing, signed by both parties, and approved by the President of Hustler Turf Equipment, this agreement is understood to be the complete and exclusive agreement between the parties, superseding all prior agreements, oral or written, and all other communications between the parties relating to the subject matter of this agreement. No employee of Hustler Turf Equipment, or any other party is authorized to make any warranty in addition to those made in this agreement.
ALLOCATION OF RISKS
This agreement allocates the risks of product failure between Hustler Turf Equipment, and the purchaser. This allocation is recognized by both parties and is reflected in the price of the goods.
OWNER'S RESPONSIBILITY
You must maintain your Hustler Turf Equipment product following the maintenance procedures described in your owner's manual. Such routine maintenance, whether performed by a dealer or by you, is at your expense.
This machine like any other powered equipment is potentially dangerous unless properly operated. Any
operator must be cautious and keep safety in mind at all times. Any operator, prior to using the Hustler Turf Equipment, should thoroughly familiarize himself with the owner's manual regarding operation and safety of the machine, as well as all safety warnings on the machine itself.
WARRANTY REGISTRATION
1. The Warranty registration form MUST be completed
and signed by the authorized dealer and original purchaser.
2. For validation, the completed Warranty registration
form MUST be forwarded to Hustler Turf Equipment, within ten (10) days following date of purchase.
3. The date of purchase constitutes delivery.
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This safety alert symbol is used to call attention to a
message intended to provide a reasonable degree of PERSONAL SAFETY for operators and other persons during the normal operation and servicing of this equipment.
DANGER – denotes immediate hazards which WILL result in severe personal injury or death.
WARNING - denotes a hazard or unsafe practice which COULD result in severe personal injury or death.
This manual uses two other words to highlight
information. IMPORTANT calls attention to special mechanical information and NOTE: emphasizes general information worthy of special attention.
All operators should read this manual, or be instructed about safe operating and maintenance procedures. This is the owner’s responsibility.
Improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert symbol, which means DANGER or WARNING - “personal safety instructions.” Failure to comply with the instructions may result in personal injury or death.
Incorrect usage of this machine may result in severe injury. Personnel operating and maintain- ing it should be trained in the proper use and should read the manuals completely and thoroughly before attempting to set-up, operate, adjust, or service this machine.
The Quick Reference Decals located on the unit are designed to give the operator brief information needed in the daily operation of the machine. These decals are not intended to be used in place of this manual but instead are to be used as an extension of this manual. These decals should not be remove or obliterated. Replace these decals if they become unreadable.
It is the owner’s responsibility to make certain that the operator reads and understands this manual and the Quick Reference Decal before operating this machine. It is also the owner’s responsibility to make certain that the operator is a qualified and physically able individual, properly trained in the operation of this equipment. Local regulations may restrict the age of the operator.
The owner should also ensure that the operator/mechanic know that they are responsible for their own safety as well as the safety of other persons within the vicinity. Remember, the operator is responsible for accidents or hazards occuring to other people or their property.
Safe Operating Practices
This product is capable of amputating hands and feet and throwing objects. Always follow all safety instructions to avoid serious injury or death.
Operation
Never leave a running machine unattended. Always disengage deck clutch, engage park brake, place H-bar steering in neutral, place cruise control lever in neutral position, stop engine, and remove ignition key when leaving the unit.
If you lose steering control while operating the machine, place the park brake lever in the park brake position immediately. Inspect the machine and involve your Hustler dealer to resolve the problem before continuing to operate.
Always keep safety shields and covers in place, except for servicing.
Always maintain a safe distance from people and pets when mowing. Always stop machine if someone enters the area.
Always operate machine in daylight or with adequate working lights.
Follow daily and weekly checklists, making sure hoses are tightly secured and bolts are tightened.
Always observe traffic laws while driving machine from one location to another. Watch for traffic when operating near or crossing roadways.
Always keep engine and machine clean, removing accumulated dirt, trash and other material from machine. Clean up oil or fuel spillage. Allow machine to cool before storing.
Inspect area to be mowed for hazards such as rocks, metal objects and other debris which may be thrown or entangled by mower blades. Remove these objects before mowing.
Always be alert for hazards such as rocks, metal objects and other debris which may be thrown or entangled by mower blades. Watch out for holes or deep depressions.
Always wear adequate ear protection, such as
earplugs, when operating this equipment as prolonged exposure to uncomfortable or loud noises can cause impairment or loss of hearing. Do not wear radios or music headphones while operating the machinery. Safe operation requires your full attention.
Always inspect machine for damage after striking a foreign object. If damage is found, repair machine immediately. Be sure to disengage deck clutch, place park brake lever in park brake position, stop tractor engine, and remove ignition key when leaving operator’s seat to inspect damage.
Always be aware of what is behind the machine before backing up.
Never rotate forward suddenly on H-bar handle while the machine is in rearward motion.
When traveling in reverse, rotate handle forward gently and avoid sudden movement. Rapid movement
SAFETY PRECAUTIONS
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of the handle in either direction could result in a reaction of the tractor that can cause serious injury.
Never operate a poorly maintained machine.
Never attempt high speed maneuvering, especially in crowded or congested areas.
Never allow persons to operate this machine without proper instruction or allow children to operate machine. Allow only responsible adults who are familiar with these instructions to operate this machine.
Never put hands or feet under any part of the machine while it is running.
Never carry passengers.
Never direct discharge of material from mower deck towards bystanders. Do not operate the mower without either the discharge chute or the entire grass collection system in place.
Always disengage the blades and wait for them to stop before crossing gravel drives, walks or roads.
Always keep clear of the mower blades and attachments during their operation.
Turn off blades when not mowing.
Slow down before turning.
Stop the engine before removing the grass catcher or unclogging the discharge chute. Never clear the discharge chute with the engine running. Turn off the engine and be sure the blades have stopped before cleaning. Use a stick to clear a plugged discharge area.
Never use your hand!
Do not operate the machine while under the influence of alcohol or drugs.
Exercise caution when loading or unloading the machine onto a trailer or truck.
Always wear safety goggles or safety glasses with side shields when operating the mower.
Data indicates that operators, age 60 years and above, are involved in a large percentage of mower-related injuries. These operators should evaluate their ability to operate the mower safely enough to protect themselves and others from serious injury.
Never make sudden starts, stops, turns, or reverse direction, especially when maneuvering on slopes. The steering is designed for sensitive response. Rapid movement of the H-bar handle in either direction could result in a reaction of the unit that can cause serious injury.
If any attachment or additional weight is mounted on the rear of the unit, any sudden movement of the H-bar handle could cause the front of mower to come off of the ground resulting in possible loss of control and serious injury.
The use of any other manufacturer’s attachments, including stand-up sulkies, increases the risk of operator injury, therefore, extreme caution must be exercised when using these devises.
Clean flammable material from machine. Prevent fires by keeping engine compartment, battery, fuel line, fuel tank and operator’s station clean of accumulated trash, grass clippings, and other debris. Always clean up spilled fuel and oil.
Slope Operation
Slopes are a major factor in loss-of-control and tip-over accidents, which can result in sever injury or death. All slopes require extra caution. If you cannot back up the slope or if you feel uneasy on it; do not mow it.
Use extreme caution when operating on slopes.
• Be extremely careful changing directions on a slope. Slow down.
• Do not operate where the machine could slip or tip.
• To check a slope, attempt to back up it. If the unit can back up the slope without the operator and drive wheels slipping, reduce ground speed and proceed with caution.
• Do not operate the TrimStar Hydro on slopes when using a stand-up sulky.
Always be sure of your footing. Keep a firm hold on the H-Bar handle and walk - never run.
Block or chock the machine when parked on a slope or when trailering.
Watch for holes, ruts or bumps. Uneven terrain could overturn the machine. Tall grass can hide obstacles.
Remove obstacles such as rocks, tree limbs, etc.
Keep all movement on slopes slow and gradual. Do not make sudden changes in speed or direction.
Avoid starting and stopping on a slope. If tires lose traction, disengage the blades and proceed slowly straight down the slope.
Do not mow near drop-offs, ditches, or embankments. The machine could suddenly turn over if a wheel goes over the edge of a cliff or ditch, or if an edge caves in.
Do not mow on wet grass. Reduced traction could cause sliding.
The Hustler mower is capable of operating horizontally (traverse) on moderately steep slopes. When operating on slopes of 15 degrees or more, be aware of any conditions that may cause the drive tires to lose traction resulting in a possible loss of control of the machine. An operator should not operate on a slope until he is thoroughly familiar with the equipment.
Do not operate the machine on slopes greater than 15 degrees.
Refer to Figure 2-1, page 2-5, when determining the degree of slope to be mowed.
It is strongly recommended that the operator drive
the machine off of the slope, using extreme caution, if any sign of loss of traction is detected. Wait until the condition that caused the problem is resolved before attempting to operate on the slope again.
Terrain conditions can affect traction resulting in
possible loss of control of the machine. Some of the conditions to be aware of are:
1. Wet terrain
2. Depressions in the ground; i.e. holes, ruts,
washouts
3. Mounds of dirt
4. Soil type; i.e. sand, loose dirt, gravel, clay
5. Grass type, density, and height
6. Extremely dry conditions of grass
7. Tire pressure
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Another consideration to safe mowing on slopes is to be aware of what is located at the bottom of the slope. Extreme caution should be used when there is a hazard located at the bottom of the slope. Some examples are:
1. Water; i.e. lake, river
2. Cliffs, retaining walls
3. Roads, highways
4. Buildings
5. Rocks
These are just a few examples of situations when caution must be used when operating on a slope. There are many other possibilities too numerous to mention. Just remember to always exercise extreme caution when operating on any slope.
Children
Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the machine and the mowing activity. Never assume that children will remain where you last saw them.
Never leave machine unattended with ignition key in switch, especially with children present.
Keep children out of the mowing area and under the watchful care of another responsible adult.
Be alert and turn the machine off if children enter the area.
Before and while backing, look behind and down for small children.
Never carry children, even with the blades off. They may fall off and be seriously injured or interfere with safe machine operation.
Never allow children to operate the machine.
Use care when approaching blind corners, shrubs, trees, the end of a fence or other objects that may obscure vision.
Service
Always keep engine and machine clean, removing accumulated dirt, trash and other material from machine. Clean up oil or fuel spillage. Allow machine to cool before storing.
Always wear adequate eye protection when servicing the hydraulic system and battery, or when grinding mower blades and removing accumulated debris.
Use extra caution when handling gasoline and other fuels. They are flammable and vapors are explosive.
Never refuel unit while engine is running; never refuel near an open flame or near devices which can create a spark. Refuel outdoors preferably, or in well ventilated areas.
Never attempt to start engine when there is a strong odor of gasoline fumes present. Locate and correct cause.
Never run the engine in an enclosed area unless exhaust is vented to the outside. Exhaust gases contain carbon monoxide which is odorless and deadly poison.
Never attempt to make any adjustments or repairs to the drive system or mower deck while the engine is running or deck clutch is engaged. Mower blades cannot be seen and are located very close to the deck housing. Fingers and toes can be cut off instantly. Repairs or maintenance requiring engine power should be performed by trained personnel only.
Never work under the machine or attachment unless it is safely supported with stands, blocks or a hoist.
Do not touch hot parts of machine.
Keep nuts and bolts tight, especially the blade attachment bolts. Keep equipment in good condition.
Never tamper with safety devices. Check their proper operation regularly.
Grass collection system components are subject to wear, damage and deterioration, which could expose moving parts or allow objects to be thrown. Frequently check components and replace with manufacturer’s recommended parts, when necessary.
Mower blades are sharp and can cut. Wrap the blade(s) or wear gloves and use extra caution when servicing them.
Use only genuine Hustler replacement parts to ensure that original standards are maintained
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Read Owner’s Manual and Quick
Reference Decal before attempting to
operate this machine.
Keep shields or covers in place while machine is in operation. Keep hands away from rotating pulleys and belts.
Never operate the mower deck with side deflector removed or in raised position, except when the grass catcher attachment is being used.
Do not smoke while refueling. Do not fill tank with engine running, or while the engine is hot. Allow engine to cool before storing machine inside a building. Store away from open flame or spark if there is fuel in tank. Clean up any gasoline spills. Do not refuel while in enclosed trailer or other enclosed areas
Safety and Instruction Decals
Specific safety warning decals are located on the equipment near the immediate areas of potential hazards. These decals should not be removed or obliterated. Replace them if they become non-readable.
The following illustrations show the various safety decals that are located on the machine. A brief explanation is shown to help the operator understand the meanings of these decals.
Part Number
793570
Never operate the mower deck with side deflector removed or in raised position, except when the grass catcher attachment is being used. Stay clear of mower blades as long as engine is running. Keep a safe distance from machine.
Keep shields or covers in place while machine is in operation. Keep hands away from rotating pulleys and belts. Whirling blades! Keep hands and feet away. Beware of thrown objects.
Part Number
727453
Part Number
794545
Part Number
788844
Help Avoid Injury Operator training required. Know all controls. Keep shields in place. Maintain all safety devices. Look behind before backing. Keep children and others away. Stay clear of power driven parts. Do not operate where machine could tip.
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794545
793570
Read Owner’s Manual
Help Avoid Injury
s Operator training required. s Know all controls. s Keep shields in place. s Maintain all safety devices. s Look behind before backing. s Keep children and others away. s Stay clear of power driven parts. s Do not operate where machine
could tip.
Before Starting
s Transmission must be in neutral.
s Deck clutch switch must be in off position. s Check performance of all safety interlock switches daily (including operator presence switches).
While Operating
s Never perform maneuvers at high speeds.
s Avoid sudden turns. s Avoid quick movements
of steering controls. s Reduce speed and use extreme caution when operating on slopes of 15 degrees or more.
Before Leaving Operating Platform
s Place drive/steering system in neutral position. s Chock machine when parked on a slope. s Switch deck engagement lever to off position. s Turn engine off and remove key.
788844
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2-5
1. Hold this sheet of paper in front of you. Make sure that line A is horizontal.
2. Align line B with a verticle surface such as a pole, tree or building.
3. Fold the paper along the slope guide lines (C, D or E).
4. Align the closest slope guide line with the ground slope. This will give you a close estimation of the ground slope to be mowed.
Slope Guide Lines
C (5o)
D (10o)
E (15o)
Line A
Line B
SLOPE GUIDE
Figure 2-1
Use this diagram when determining the degree of slope to be mowed.
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1. Ignition Switch 6. Deck clutch switch 14. Cruise control
2. Choke Lever 7. Operator presence control lever 15. Left deck cover
3. Throttle 8. Anti-scalp wheels 11. Discharge chute 16. Center deck cover
4. Serial number plate 9. Hour meter 12. Pump clutch chain 17. Right deck cover
5. H-bar handle 10. Height adjusting pins 13. Fuel tank 18. Park brake (located under tank)
1
6
2
11
5
13
9
3
12
10
10
10
10
7
7
15
16
17
4
14
8
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OPERATION
Figure 3-1
Controls
For general location of the controls described in this
section, refer to Figure 3-1.
1. Ignition switch (Fig. 3-2) – a two position switch: off
and run. With key inserted, rotate it clockwise to RUN position.
2. Throttle (Fig. 3-2) — a cable is linked to engine
throttle for controlling engine speed. Move lever forward to increase engine rpm, move lever rearward to decrease engine rpm.
3. Choke control (Fig. 3-2) – a cable is linked to
manually operate the engine choke. When the knob is in the down position, the choke is in the off (run) position. When the knob is pulled up, the choke is in the on (start) position. Do not operate the machine in the on (start) position.
3. H-bar handle (Fig. 3-1) — this handle controls the
unit’s acceleration, speed, steering direction and dynamic braking.
4. Deck clutch switch (Fig. 3-2) — this switch engages
the deck. Pull the switch up to engage and push switch down to disengage the clutch. IMPORTANT: Never engage clutch with engine running at high rpm or when the deck is under load. Clutch, belts or deck could be damaged.
5. Cruise control (Fig. 3-2) — the cruise control, when
engaged, controls the maximum forward speed of the unit. When it is engaged the H-bar handle can be rotated forward.
6. Operator presence control levers (Fig. 3-4) —
engages the operator presence switches. If the switch is not engaged the unit will not operate. Refer to the Safety Interlock system for more information.
7. Park brake lever (Fig. 3-3) — has three positions:
park brake, drive & bypass valve.
Instrumentation
8. Electronic hour meter (Fig. 3-2) — registers 1/10
hour increments up to 9,999.9 total hours. Connected to the ignition switch, the meter records the accumulative time while the engine is running.
Ignition
switch
Choke
Cruise
control
Deck
clutch
switch
Hour
meter
Figure 3-2
Throttle
TrimStar Hydro
Controls
18
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Engine starting
The TrimStar Hydro safety interlock system is also designed to protect the operator and others from accidental injury due to unintentional engine starting. The engine will not start until:
A. Cruise control is in the neutral (down) position.
Fig. 3-5
B. Deck clutch switch is in the disengaged (down)
position.
WARNING: The safety interlock system must not be disconnected or bypassed.
NOTE: The machine is equipped with operator presence control switches. If for any reason the operator should release both of the operator presence control levers when the cruise control is not in neutral (up) or the deck clutch switch is engaged (up position), the engine will stop.
DANGER: The operator presence switches should never be engaged when starting the unit. When the operator presence switches are engaged, they override the cruise control’s neutral switch and the deck clutch interlock system. Severe personal injury could result when starting the unit if the operator presence switches are engaged.
The following steps are the correct procedures for starting the engine. If difficulty is encountered, contact the Authorized Hustler Dealer in your area.
1. Before starting tractor each day, perform daily pre-
operation checking.
2. Make sure the cruise control is in the neutral (down)
position and deck clutch switch is disengaged (down position).
3. When the engine is cold place the choke lever in the
choke (up) position. Avoid flooding and operate engine without choking as soon as possible. When the engine is already warmed up set throttle to approximately 1/2 throttle position. NOTE: If the ambient temperature is below 50 degrees disengage the cold weather pump clutch before attempting to start the engine. Refer to the Cold Weather Pump Clutch section for more information.
4. Insert key in ignition switch and rotate full clockwise.
Pull engine recoil start rope.
5. Perform test to make sure safety interlock system is
operating properly. Refer to Safety interlock system section.
6. Allow the engine to idle a few minutes before
advancing the throttle and engaging the clutch. Press operator’s presence control levers, the cruise control is not in neutral (Fig. 3-6) and rotate the H-bar slowly forward.
7. Before stopping the engine, place the H-bar handle in
the neutral position, set cruise control in the neutral (down) position, disengage the deck clutch, and
104893 10/05
3-2
Figure 3-5
Cruise control in neutral position
Figure 3-4
H-bar handle
Operator presence control levers
Operator presence
control levers in
disengaged position
Figure 3-3
Park
brake
lever
Drive
Park
brake
Bypass
valve
Figure 3-6
Cruise control not in neutral position
Page 17
throttle back to 1/2 throttle for a couple of minutes; then rotate ignition key counter-clockwise to the OFF position. Remove the key from switch before leaving the tractor and engage the park brake.
WARNING: Never leave the machine unattended with key in ignition switch.
Cold weather pump clutch
The TrimStar Hydro is equipped with a pump clutch that disengages the pump clutch belt. When the belt is disengaged, the engine will start easier in colder temp­eratures.
To disengage the pump clutch, pull the chain until the tension is released from the pump drive belt and latch in the slot. Fig. 3-7
To engage the pump clutch, with H-bar locked in neutral, release the chain from the latching slot.
Never operate the unit with the pump clutch partially engaged. Make sure the clutch is completely released and
the chain has slack.
Safety interlock system
The unit is equipped with a safety interlock system consisting of the cruise control neutral switch, operator presence control levers (Fig. 3-4), and deck clutch switch.
Check the safety interlock system daily, prior to operation. This system is an important safety feature. It should be repaired immediately if it malfunctions. The machine incorporates two operator presence control switches which will stop the tractor engine when the operator releases both of the operator presence control levers for any reason while the tractor is operating. However, if only one operator presence control lever is released, the unit will continue to operate. This is a safety feature designed to prevent runaway or accidental entanglement. To inspect the system:
1. Place the H-bar lever in the neutral position, move
cruise control to the neutral (down position), and move deck clutch switch to the disengaged (down) position.
2. Start the engine and allow it to warm up to operating
temperature.
3. With the cruise control out of neutral (up) position
and/or the deck clutch switch engaged (up position),
slowly release both operator presence control levers.
The engine should stop within a few seconds.
4. Place the cruise control to the neutral (down) position
and the deck clutch switch disengaged (down) position. The engine should continue to run without
the operator presence control switches engaged.
5. If the engine fails to stop when the deck clutch switch
is engaged or the cruise control is not in the neutral position and both operator presence control levers are released, check the function of the operator presence control switches. If these switches are not operating properly (not opening or closing) contact your Authorized Hustler Dealer.
WARNING: The safety interlock system should always function per steps 4 and 5. If it does not function properly, it should be corrected immediately. Do not operate machine without properly functioning operator presence control switches.
Moving unit with stalled engine
If it becomes necessary to move the tractor when the engine is inoperative, the integrated pump/motor units are equipped with bypass valves. Before moving the unit, shift the park brake lever to the bypass valve position. (Fig. 3-8)
Do not tow the machine. Move it by hand or use a winch to load on a trailer for transporting.
When transporting on another vehicle, the unit must be tied down to the transporting vehicle.
IMPORTANT: Always make certain the park brake lever is returned to the drive position before running the unit following repairs.
Steering the unit
DANGER: Never make sudden stops or reverse
direction, especially when operating on a slope. The steering is designed for sensitive response. Rapid rotation of the H-bar handle in either direction could result in a reaction of the tractor that can cause serious injury.
Figure 3-8
Park
brake
lever
Shown in the bypass valve position
Chain
Figure 3-7
Slot
104893 10/05
3-3
Page 18
After starting engine, steer as follows: To go forward, move park brake lever to drive position,
and move the cruise control out of neutral (up posiiton) and rotate H-bar handle forward (Fig. 3-9).
To go in reverse, rotate the H-bar handle to the neutral
position. After achieving neutral, rotate lever rearward.
To turn left, rotate the H-bar handle to the left and out of
the neutral position.
To turn right, rotate the H-bar handle to the right and out
of the neutral position.
To zero turn, rotate H-bar handle the direction desired
with the handle in the neutral position. This will allow the drive wheels to counter-rotate.
To stop or decrease speed, move H-bar handle to neutral.
When going forward rotate handle rearward gently. When going in reverse rotate handle forward.
DANGER: When traveling in reverse rotate handle forward gently and avoid sudden movement. Any sudden movement could cause the front of the mower to come off of the ground resulting in possible loss of control.
To increase speed, move the cruise control lever farther
forward. This allows the H-bar handle to rotate further from neutral. The farther the H-bar handle is rotated forward from neutral, the faster unit will travel forward. The farther the H-bar handle is rotated rearward from neutral, the faster unit will go in reverse.
Mower deck leveling
The mower deck has three areas that may need to be checked and adjusted periodically. Before considering any mower deck leveling adjustments, check that the tire air pressure is within the specified range.
Deck level adjustments
Leveling the deck must be done in the following manner and order:
1. Check tire pressures to make certain they are properly
inflated before starting to level deck. The recommended pressures are as follows:
Drive wheels tire pressure....................8 - 12 psi
Gauge wheels tire pressure.................12 - 16 psi
WARNING: Stop engine. Place the H-bar lever in the neutral position, move cruise control to the neutral (down position), place park brake lever in the park brake position and move deck clutch switch to the disengaged (down) position.
2. Park the unit on a flat surface.
3. Set the deck at a cutting height of 3” (4th hole from the
top of pin).
4. Loosen the rear deck pin lock nut hardware. Fig. 3-11
5. Measure from level surface to top of mower deck (as
indicated in Fig. 3-10). Note this dimension.
6. Add 1/8” to this measurement and adjust the rear deck
pins until this dimension is achieved. Measure near the rear deck pins.
7. Tighten the rear deck pin lock nut.
Figure 3-9
Bar Steering
FRONT OF TRACTOR FACES THIS DIRECTION
104893 10/05
3-4
Figure 3-10
Measure
from here
Rear
deck pin
Front
deck pin
Lock
nut
Page 19
Deck cutting height adjustment
Deck height is adjustable from 1.25” to 4.5” (3.18 cm -
11.43 cm) in 1/4” increments. The holes in the height
adjusting pins are spaced at 1/2” intervals. When the hair
pin is placed in the uppermost hole of the height adjusting
pin, with the two spacers under it, the cutting height is at
1-1/4”. (Fig. 3-11) NOTE: There should always be at
least one spacer under the hair pin.
If the hair pin is placed in one of these holes, with one spacer between the hair pin and the deck carrier height adjusting bracket, then the deck height will be set at one of the following: 1-1/4”, 1-3/4”, 2-1/4”, 2-3/4”, 3-1/4”, 3-3/4” or 4-1/4”.
If the two spacers are placed between the hair pin and the deck carrier height adjusting bracket (Fig. 3-9), then the deck height will be set at one of the following: 1-1/2”, 2”, 2­1/2”, 3”, 3-1/2”, 4” or 4-1/2”.
Mower deck operation
DANGER: Never attempt to make any
adjustments to the mower deck while the engine is running or with the deck drive clutch engaged. Mower blades cannot be seen and are located very close to deck housing. Fingers and toes can be cut off instantly.
With the engine running, engage the deck clutch switch (Fig. 3-2) and advance engine throttle to full rpm.
NOTE: Engaging the deck clutch at high engine rpm or when under heavy load (in tall grass for example) can cause belts to slip, resulting in premature wear or possible damage.
Operating suggestions
DANGER: Prior to operating the unit the
operator should be thoroughly familiar with the proper use and operation of the equipment, should have read the manual completely and thoroughly, and should have attempted slow moving maneuvers to become familiar with the operation of the equipment before attempting normal speed operation. An untrained and inexperienced operator should not mow on slopes or on uneven terrain.
WARNING: Do not operate the equipment while wearing sandals, tennis shoes, sneakers, shorts or any type of loose fitting clothing. Always wear long pants, safety glasses and safety shoes when operating this machine.
WARNING: The unit’s H-bar handle is very responsive: Easy does it! For smooth operation, rotate handle slowly, avoid sudden movement. Skill and ease of operation come with practice and experience.
Inexperienced operators may have a tendency to oversteer and lose control. Slow-moving practice maneuvers are recommended to become familiar with these characteristics before attempting normal speed operation.
WARNING: Sharp depressions or raised obstacles (such as gutters or curbs) should not be directly approached at high speed in an attempt to “jump” them as the operator could lose control of the equipment. If the depression or obstacle can not be avoided, approach at a slow speed and angle one drive wheel at the obstruction. Continue at an angle until the wheel clears and then pivot the opposite wheel around.
The following list is not all inclusive.
When turning on soft wet turf, keep both wheels rolling either forward or backward. Pivoting on one stopped wheel can damage turf. This is especially important when mowing.
Unit performance is maximum when the throttle is set at full rpm. This gives maximum power to the drive wheels and deck when needed. Use the cruise control and the H-bar handle to control ground speed rather than engine rpm. Set the cruise control to a comfortable walking speed.
The safety interlock system is designed to shut the engine off if the operator releases the operator presence control levers when the cruise control is engaged or the deck clutch lever is engaged the engine will stop.
When operating the TrimStar Hydro on slopes, the operator should mow traversing the slope. The operator should stay more on the uphill side of the unit when mowing.
104893 10/05
3-5
Figure 3-11
Spacers
Height
adjusting
pin
Page 20
WARNING: To check a slope, attempt to back
up it. If the unit can back up the slope without the operator and drive wheels slipping, reduce ground speed and proceed with caution.
For additional safety issues regarding slope mowing refer
to the Safety section of this manual.
Keep blades sharp. Many professional mowing
companies have additional sets of blades and change blades twice a day: once in the morning and again at noon. Many
problems with incorrect cutting patterns are due to dull blades or blades which have been sharpened incorrectly.
Information on sharpening blades is listed in this manual’s maintenance section. In addition, most communities have individuals or companies which specialize in sharpening mower blades. Blade sharpness should be checked daily.
Use high blade speed. Your Hustler TrimStar Hydro is
designed to operate at full throttle. The throttle setting directly controls blade speed. The highest blade speed generally gives best cut.
Direct grass discharge to right, away from unmown
area. Select a mowing pattern that directs grass discharge
towards the outside, not towards center, of mowing area. Generally, this means using a pattern utilizing left turns because side discharge (Fig. 3-12) is to right. In any case, avoid throwing grass discharge onto unmowed area because grass is then mowed “twice”. Mowing twice puts an unnecessary load on the unit and reduces mowing efficiency.
WARNING: Never direct discharge of material from mower deck towards bystanders.
WARNING: Never operate the mower deck with discharge chute removed or in raised position.
Avoid sudden turns on wet turf. This can damage turf
unnecessarily.
Always check area to be mown for rocks and other debris
before mowing.
Stand-up sulkies
Hustler Turf Equipment does not warrant or accept
liability for the use of any attachments not manufactured by Hustler Turf Equipment, including the use of stand­up sulkies.
All manufacturer’s safety instructions issued with any
attachments including stand-up sulkies must be followed.
WARNING: Never operate the Hydro Walk­Behind on slopes when using a stand-up sulky.
WARNING:The use of any other manufact­urer’s attachments, including stand-up sulkies, increases the risk of operator injury, therefore, extreme caution must be exercised when using these devises.
104893 10/05
3-6
Figure 3-12
Side
discharge
chute
Page 21
MAINTENANCE LOCATOR
CHART
MAINTENANCE
4-1
104893 10/05
48” Deck
Viewed from bottom of unit
Viewed from top of unit
36” Deck
Viewed from bottom of unit
10
14
13
10
14
10
14
10
14
10
14
Figure 4-1
9
11
6
7
15
8
1
2
8
9
5
3
12
4
1. Engine oil fill & dipstick
2. Fuel filter
3. Engine air cleaner
4. Engine oil drain plug (under fuel tank)
5. Fuel tank
6. Deck clutch switch
7. Engine oil filter
8. Drive tire
9. Gauge wheel bearings
10. Blades
11. Discharge chute
12. Deck drive belt
13. Pump belt
14. Spindle housing zerk
15. Deck spindle belt
Page 22
NOTES:
1. Initial oil change is after 5 hours of operation. Thereafter, change oil after every 100
hours operation. Change more often under dusty or dirty conditions and during hot weather periods.
2. Torque initially and after first 2 hours of operation.
3. Change engine oil filter per the engine manufacturer’s recommendations. Refer to
Engine Owner’s Manual for recommendations and other maintenance items.
4. Inspect every 100 hours and replace if worn or cracking is noticed. Otherwise, replace every 500 hours or 2 years whichever comes first.
5. Check fuel line hoses, fuel valve and grommet for any cracks or leaks.
6. Change the filter and oil using 20W50 motor oil. REFERENCES: a — Refer to Engine Owner’s Manual
NOTE: After completing maintenance cycle (500
hours), repeat cycle.
Introduction
WARNING: Unless specifically required, DO
NOT have engine running when servicing or making adjustments to tractor. Always disengage deck clutch, place H-bar steering in neutral, place cruise control lever in neutral position, stop engine, and remove ignition key. Repairs or maintenance requiring engine power should be performed by trained personnel only. To prevent carbon monoxide poisoning, be sure proper ventilation is available when engine must be operated in an enclosed area. Read and observe safety warnings in front of manual.
DANGER: Before working on or under the deck, make certain engine cannot be accidentally started. Shut engine off and remove ignition switch key for maximum safety. Repairs or maintenance requiring engine power should be performed by trained personnel only.
DANGER: Exercise caution when working under the deck as the mower blades are extremely sharp. Wearing gloves is advisable when working around or with the blades.
WARNING: Except when changing or checking belt, always keep belt covers on mower for safety as well as cleanliness.
WARNING: When possible clean under mower, using a stick or similar instrument making sure that no part of the body, especially arms and hands are under mower.
Regular maintenance is the best prevention for costly downtime or expensive, premature repair. The following pages contain suggested maintenance information and schedules which the operator should follow on a routine basis.
Remain alert for unusual noises, they could be signaling a problem. Visually inspect the machine for any abnormal wear or damage. A good time to detect potential problems is while performing scheduled maintenance service. Correcting the problem as quickly as possible is the best insurance.
WARNING: Keep your machine clean and remove any deposits of trash and clippings, which can cause engine fires and hydraulic overheating as well as excessive belt wear.
Clear away heavy build-up of grease, oil and dirt, especially in the engine and hydraulic reservoir area; minute dust particle are abrasive to close-tolerance engine and hydraulic assemblies.
Daily inspect mower for grass clippings and wire and string tangles. The underside of the mower deck will collect a build-up of grass clippings and dirt, especially when grass is wet or has high moisture content. This build-up will harden, restricting blade and air movement and will probably show a poorer quality of cutting. Therefore it should be removed routinely.
To do this it will be necessary to raise and block the deck in the full up position and scrape the build-up from underneath.
Some repairs require the assistance of a trained service mechanic and should not be attempted by unskilled personnel. Consult your Hustler service center when assistance is needed.
Description of deck operation
The blades are indirectly driven by the engine through a V-belt drive system. The V-belt drives a pulley located on top of spindle housing assemblies. The pulleys drive 1” spindle shafts which in turn drive the blades. A blade is affixed to each spindle shaft by a 5/8” bolt.
104893 10/05
4-2
WEEKLY MONTHLY ANNUALLY OR
SERVICE AT OR 50 OR 100 500
INTERVALS INDICATED HOURS HOURS HOURS
Verify safety start interlock system Daily
Visually inspect unit for loose
hardware and/or damaged parts Daily
Visually inspect tires Daily
Check oil level, engine (1) Daily or every 4 hrs.
Clean air intake screen Daily or every 4 hrs.
Check fuel level Daily
Blades - sharpen & securely fastened Daily
Discharge chute - securely in place &
in lowest position Daily
Replace air cleaner paper element As needed
Grease gauge wheel bearings x
Change engine oil filter x
Change engine oil and filter (3) After first 5 hours operation
Clean cylinder and head fins (a) x
Replace air cleaner element x
Change engine oil x
Check tire pressure with a gauge x
Tighten lug nuts on wheels (2) x
Check hydraulic oil level x
Clean engine exterior (a) x
Clean and regap spark plugs (a) x
Check pump and deck belt tension
& condition (4) x
Check fuel lines (5) x
Check fuel valve and grommet (5) x
Change fuel filter x
H-bar lever tension x
Grease deck spindle housings x
Replace spark plugs x
Change C-IZT pump/motor
transmission oil & filter (6) Every 200 hours or 2 years
Page 23
Torque values
WARNING: Particular attention must be given
to tightening the drive wheel lug nuts and wheel motor nuts. Failure to correctly torque these items may result in the loss of a wheel, which can cause serious damage or personal injury.
Torque values given below:
Ft-lbs. Nm
Wheel (lug) nuts..................65-75..................88 -102
Blade spindle bolts (top).....65-75..................88 -102
Blade spindle bolt (bottom)....118...................160.01
It is recommended that these be checked after the first 2 hours of operation, initially and every 50 hours following removal for repair or replacement.
For all other torques refer to the tractor parts manual for standard torque chart.
For engine torque values, see engine owner’s manual.
Tires
It is important for level mowing that the tires have the same amount of air pressure. The recommended pressure are:
Drive wheels...............................................8-12 psi
Solid fill tires are not recommended for Hustler turf equipment. On any machine, with solid filled tires, the warranty claim will be denied.
Hour meter
To recognize when your machine needs servicing, check the hour meter and the maintenance schedule. The hour meter shows the number of hours the engine has run and the maintenance schedule lists the service intervals. Fig. 4-2
Lubrication
The mower blade spindle assemblies require lubrication after every 500 hours of use or annually, whichever occurs first. Each spindle shaft is equipped with a grease zerk
located on under the deck. Use no more than one or two ounces of SAE multi-purpose grease, (1 to 2 pumps on an average grease gun). Do not force lubricant in to grease zerks. Bearings are sealed and do not require much lubricant.
Hydraulic system
The TrimStar Hydro is equipped with two Hydro-Gear
C-IZT integrated pump/motor transmissions.
These units have a replaceable filter which will require replacement every 200 hours or 2 years whichever comes first. The required service involves draining the oil and installing a new filter kit (Hustler p/n 789511). Fill with new 20W50 engine oil.
WARNING: Make certain machine is secure when it is raised and placed on the jack stands. The jack stands should not allow the machine to move when the engine is running and the drive wheels are rotating. Use only certified jack
stands.
To replace the filter use the following procedure:
1. Raise and block the tractor up so the drive wheels are
off the floor. Place the jack stands under the izt guard to support the machine.
WARNING: Make sure the transmissions are cool before performing service procedures.
2. Remove the drain plug and filter from the integrated
pump/motor transmission and drain the oil into a drain pan. Dispose of the oil in a proper manner. This oil will not be re-used. Fig. 4-3
3. Install a new filter kit into the transmission.
4. Remove the lower side plug and install the magnetic
plug included with the kit. Fig. 4-3
5. Repeat steps 2 through 4 for the other side.
6. Lower the tractor. NOTE: The unit must be level
when filling and checking the oil.
104893 10/05
4-3
Figure 4-2
Hour
meter
Figure 4-3
Drain plug
& filter
Lower side plug
Page 24
7. Remove the fill plug from the transmission and fill
with new, clean 20W50 engine oil. It will require approximately 2 - 2.46 quarts of oil to fill the transmission. Re-install the fill plug. Fig. 4-4
WARNING: Do not overfill. If you overfill the unit while it is “cold”, it may overflow as it reaches normal operating temperatures. The oil level should be to the bottom of the fill plug. Fig. 4-4
8. Start the unit and drive it forward and rearward 5
times approximately 10 - 20 feet each time. If it feels smooth then the unit is ready to operate. If either side moves slower than the other or sluggish then the system will need to be purged. Follow steps 9 through 12 until the air is purged from the system.
9. Raise and block the tractor up so the drive wheels are
off the floor.
10. With the park brake lever in the bypass valve position
and the engine running at 1/2 throttle, rotate the H-bar slowly forward and rearward 5 to 6 times to allow air to be purged from the system. As this occurs, the oil level will drop.
11. With the park brake lever in the drive position and the
engine running, rotate the H-bar slowly forward and rearward 5 - 6 times. Stop engine and place H-bar in the neutral position. Lower the tractor and check the oil level. Add oil as required.
12. Start the unit and drive it forward and rearward 5
times approximately 10 - 20 feet each time. If it feels smooth then the unit is ready to operate. If either side moves slower than the other or sluggish then the system will need to be purged again. Follow steps 9 through 12
NOTE: The C-IZT integrated pump/motor transmissions are equipped with bypass valves. For more information refer to Operation section, Moving tractor with stalled engine.
WARNING: When washing the mower, direct spray away (especially if using a power washer) from the Hydro-Gear C-IZT transmission’s seals to prevent water intrusion and to ensure component performance.
Fuel system
WARNING: Observe usual fuel handling
precautions; do not smoke while refueling, do not fill tank with engine running or while engine is hot; allow engine to cool before storing machine inside a building, keep fuel away from open flame or spark and store machine away from open flame or spark if there is fuel in the tank. Read and observe safety precautions at front of this manual.
The 5.0 U.S. gallon (18.9 liter) fuel tank is located
behind the engine. Fig. 4-5
Use regular unleaded gasoline with an octane rating of 87
or higher.
The fuel filter is installed in the fuel line between fuel tank and engine fuel pump. Replace filter annually or after every 500 hours of operation, whichever occurs first. Fig. 4­6
When replacing the fuel filter, check the fuel line hoses and fuel shut-off valve grommet for any cracks or leaks. Replace as needed.
A fuel shut-off valve is located on the underneath side of the fuel tank. Close this valve to prevent fuel flow to the engine.
104893 10/05
4-4
Figure 4-6
Fuel filter
Figure 4-5
Fuel tank
Figure 4-4
Fill plug
Page 25
Engine oil and filter
Check engine oil daily and after every 4 hours of operation. Tractor must be setting level when checking oil. Refer to engine manual and maintenance schedule for oil recommendation and capacities.
Change the engine oil and filter after the first 5 hours of operation, per the engine manufacturer’s recommendations after that. If tractor is being operated in extremely dirty conditions, then it is recommended oil be changed more frequently.
The oil filter is located on the front of the engine. Fig. 4­7 The oil drain hose is located under th fuel tank.
Engine air filter
Perform engine air filter maintenance per the respective Engine Owner’s manual. Fig. 4-8
General engine maintenance
Detailed instructions and recommendations for break-in and regular maintenance are specified in the respective Engine Owner’s manual. Please refer to this manual for engine servicing, lubricating oil levels with quality and viscosity recommendations, bolt torques, etc. The engine warranty is backed by engine manufacturer. Special attention should be paid to applicable data which will not be duplicated here.
Belt replacement
Figures 4-9 and 4-10 show diagrams and descriptions of the unit’s belt drive systems.
Inspect these belts frequently for wear and serviceability. Replace a belt that shows signs of severe cuts, tears, separation, weather checking and cracking, or burns caused by slipping. Slight raveling of belt covering does not indicate failure, trim ravelings with a sharp knife.
104893 10/05
4-5
Figure 4-8
Air
filter
1
3
2
4
5
6
6
8
7
9
36” Viewed from
bottom for unit
Figure 4-9
1. Pump belt
2. Engine pulley
3. Pump idler pulley
4. Pump idler arm
5. Deck drive belt
6. Pump pulley
7. Electric deck clutch
8. Cold weather pump
clutch chain
9. Pump idler spring
10. Deck belt
48” Viewed from
bottom for unit
10
1
3
2
4
10
6
6
8
7
9
5
Figure 4-7
Engine oil
filter
Page 26
WARNING: If the pump belt fails, loss of
control may occur when operating on a slope.
Inspect the belt pulley grooves and flanges for wear. A new belt, or one in good condition, should never run against the bottom of the groove. Replace the pulley when this is the case, otherwise belt will lose power and slip excessively.
Never pry a belt to get it on a pulley as this will cut or damage the fibers of the belt covering.
Keep oil and grease away from belts, and never use belt dressings. Any of these will destroy the belt composition in a very short time.
Mower blade maintenance
Check the mower blades daily, they are the key to power efficiency and well groomed turf. Keep them sharp, a dull blade will tear rather than cut the grass, leaving a brown ragged top on the grass within a few hours. A dull blade also requires more power from the engine.
Replace any blade which is bent, cracked or broken.
WARNING: Never attempt to straighten a bent blade by heating, or weld a cracked or broken blade as the blade may break and cause serious injury.
DANGER: Never work with blades while engine is running or deck clutch is engaged. Always place deck clutch in the disengaged position, engage parking brake and neutral lock levers and turn engine off. Block up mower when you must work under it. Wear gloves when handling blades. Always check for blade damage if mower strikes rock, branch or other foreign object during mowing!
Mower blade removal
Use a 15/16" wrench to remove the 5/8" cap screw holding blade to spindle shaft from underneath.
Sharpen the blades on a grinder following pattern as shown (Fig. 4-11). Touch-up sharpening can be done with a file.
Check the blades for balance following grinding. A commercial balancing tool is available through most hardware supply stores, or balancing can be done by placing the blade on an inverted line punch or 5/8" bolt. Blade should not lean or tilt. Spin the blade slowly, blade should not wobble. If blade is out of balance, true it up before reinstalling.
Lay the blade on a flat surface and check for distortion (Fig. 4-12 and 4-13). Replace any distorted blade.
Do not re-use spindle bolts which have stripped, worn or undercut threads. Torque bolts to 118 foot-pounds (160.01 Nm) when reinstalling blades.
WARNING: When mounting blades, rotate them after installation to ensure blade tips do not touch each other or sides of the mower.
WARNING: Failure to correctly torque the bolt may result in the loss of the blade which can cause serious injury.
Deck height adjusting shaft and bushing
The deck height adjusting pin and bushing can be replaced if they become worn. Refer to the Parts Manual for the proper replacement parts. Fig. 4-14 and 4-15
104893 10/05
4-6
Figure 4-10
3
4
48” Deck
1
5
2
2
6
4
2
3
6
1
5
2
4
2
Deck Belt Drive Layout
1. Spindle drive belt
2. Deck blade spindle pulley
3. Spindle belt tension idler
4. Spindle belt tension idler spring
(5.0" - 6.0" extension)
5. Deck belt idler
6. Deck belt tension idler spring
(5.0” - 6.0” extension)
36” Deck
Page 27
104893 10/05
4-7
Figure 4-11
Resharpening Pattern
Do not sharpen to original pattern (below). It is easier to get a straight cutting edge following the resharpening pattern shown above.
Original Edge
Warped Blade (Replace)
Straight Blade
Comparison of Warped and Straight Blades
Cutting
Plane
Figure 4-12
Figure 4-13
Twisted Blade Edge
(Replace)
Cutting Edge
Straight Blade Edge
End view of blades, comparing
twisted and straighten blades.
Cutting Plane
Cutting Edge
Figure 4-15
Figure 4-14
Bushing
Height
adjusting
pin
Bushing
Height
adjusting
pin
Page 28
Page 29
For engine torque values, see engine owner’s manual. For all other torques refer to the parts manual for
standard torque chart.
Drive linkage adjustment
If the tractor tracks to the right or left when operating use
the following method to adjust the drive linkage.
1. Loosen the locking hardware on the steering rod
assembly on the side that the tractor pulls toward. Fig. 5-1
2. Start the engine and move the cruise control lever from
the park brake position to the drive position. Set the cruise control lever to a comfortable walking speed.
3. While driving, lengthen the steering rod assembly by
rotating the center adjustment rod until the tractor tracks straight.
4. Stop the machine and shutoff the engine.
5. Tighten the locking hardware on the steering rod
assembly.
6. Repeat steps 2 - 5 for the other side if necessary.
Neutral adjustment
In order for the neutral lock switch to function properly, neutral must be adjusted per the following instructions. To adjust:
1. Place the H-bar in the neutral position.
2. Raise and block the tractor so that the drive wheels are
not making contact with the floor. Approximately 2” ­3” off of ground.
3. Start the engine. Leave the H-bar in the neutral
position.
4. If rear wheels rotate forward or rearward, loosen the
locking hardware on the turnbuckle assembly. Fig. 5­2
5. Tighten or loosen the turnbuckle until rear wheel
comes to a stop. Retighten locking hardware.
6. Neutral should now be set.
7. With engine running, move cruise control lever out of
the neutral position to allow wheels to rotate forward.
ADJUSTMENTS
Introduction
WARNING: Unless specifically required, DO
NOT have engine running when servicing or making adjustments to the unit. Place H-bar handle in the neutral position, engage neutral lock lever, and remove ignition switch key. Repairs or maintenance requiring engine power should be performed by trained personnel only. To prevent carbon monoxide poisoning, be sure proper ventilation is available when engine must be operated in an enclosed area. Read and observe safety warnings in front of manual.
Your Hustler TrimStar Hydro was adjusted before it left the factory and was checked during predelivery setup. However, after start-up and continued use, a certain amount of break-in wear will cause some adjustments to change.
Remain alert for unusual noises, they could be signaling a problem. Visually inspect the machine for any abnormal wear or damage. A good time to detect potential problems is while performing scheduled maintenance service. Correcting the problem as quickly as possible is the best insurance.
WARNING: Keep your machine clean and remove heavy deposits of trash and clippings, they can cause engine fires and hydraulic overheating as well as excessive belt wear.
Clear away heavy build-up of grease, oil and dirt, especially in the area of reservoir, engine oil and engine combustion air; minute dust particle are abrasive to close­tolerance engine and hydraulic assemblies.
Some repairs require the assistance of a trained service mechanic and should not be attempted by unskilled personnel. Consult your Hustler service center when assistance is needed.
Torque values
WARNING: Particular attention must be given
to tightening the drive wheel lug nuts and wheel motor nuts. Failure to correctly torque these items may result in the loss of a wheel, which can cause serious damage or personal injury.
Torque values given below:
Ft-lbs. Nm
Wheel (lug) nuts..................65-75..................88 -102
Blade spindle bolts (top).....65-75..................88 -102
Blade spindle bolt (bottom)....118...................160.01
It is recommended that these be checked after the first 2 hours of operation, initially and every 50 hours following removal for repair or replacement.
5-1
104893 10/05
Figure 5-1
Cruise control lever
Steering
rod
assembly
Page 30
Fig. 5-1
8. Return cruise control lever to neutral and check to
make sure wheels are not rotating.
9. If wheels rotate, repeat steps 4 thru 5.
10. Once neutral is set, stop engine and lower machine.
Brake linkage adjustment
Occassionally it may be necessary to adjust the brake
linkage. Use the following procedure to adjust:
1. Turn the engine off. Disconnect the spark plug wire
from the spark plug.
2. Place the H-bar handle in the neutral position and the
cruise control lever in the neutral position.
3. Place the park brake lever in the drive position. Fig. 5-
3
4. Remove the deck cover.
5. Remove the brake spring. Fig. 5-4
6. Loosen the locking nut and the outside adjusting nut.
Measure from the end of the threaded linkage rod to
the inside adjusting nut. This dimension should be 1-
1/4” - 1-1/2””. If it is not adjust the inside adjusting
nut until the dimension is attained. Fig. 5-5 & 5-6
7. Tighten the outside adjusting nut until there is a 1/16”
gap between it and the brake linkage adjusting plate.
Fig. 5-6
8. Tighten the locking nut against the outside adjusting
nut. Fig. 5-6
9. Re-attach the brake spring.
10. To test the brake adjustment, slide the park brake lever
from the drive position into the park brake position (Fig. 5-7). The brakes should be engaged. If they are not, it will be necessary to adjust the two adjusting nuts a little one way or the other until the brakes are fully engaged.
104893 10/05
5-2
Threaded
linkage
rod
Figure 5-7
Figure 5-2
Lock nut
Inside
adjusting
nut
Brake spring
Figure 5-4
Figure 5-3
Park brake lever in the drive position
Turnbuckle
- left side
Outside
adjusting
nut
Locking
hardware
Turnbuckle
- right side
Locking
hardware
Page 31
11. Replace the deck cover.
12. Lower the unit.
Pump drive belt adjustment
The pump drive belt tension remains constant by means of a tension idler and spring (Fig. 5-8). The spring tension should be such that the belt does not slip under normal operating load conditions, assuming the belt is not excessively worn or damaged. As belt stretches and wears in, adjustment may become necessary. To increase belt tension, move the spring chain one (or more) link(s) at the anchor bracket. Installed spring length should be 5.0" ± .5" (12.7 cm ± 1.27 cm) originally with adjustments of .60" (15.2mm) per chain link. Fig. 5-9
IMPORTANT: Do not over tension the spring to compensate for a badly worn belt or pulley.
Deck drive belt adjustment
The deck drive belt tension remains constant by means of a tension idler and spring (Fig. 5-8). The spring tension should be such that the belt does not slip under normal operating load conditions, assuming the belt is not
excessively worn or damaged. As belt stretches and wears in, adjustment may become necessary. To increase belt tension, move the spring chain one (or more) link(s) at the anchor bracket. Installed spring length should be 5.50" ± .5" (12.7 cm ± 1.27 cm) originally with adjustments of .60" (15.2mm) per chain link. Fig. 5-10
IMPORTANT: Do not over tension the spring to
compensate for a badly worn belt or pulley.
Deck spindle belt adjustment
The spindle belt tension remains constant by means of a tension idler and spring (Fig. 5-8). The spring tension should be such that the belt does not slip under normal operating load conditions, assuming the belt is not
Figure 5-7
Park brake lever in the park brake position
104893 10/05
5-3
Figure 5-6
Lock nut
1-1/4” -
1-1/2”
1/16”
Lock nut
Outside
adjusting
nut
Inside
adjusting
nut
Threaded
linkage
rod
Figure 5-8
48” Deck
6
2
1
5
3
4
Deck Belt Drive Layout
1. Deck drive belt
2. Deck drive belt tension spring
(5.0” - 6.0” extension)
3. Spindle drive belt
4. Spindle belt tension spring
(5.0” - 6.0” extension)
5. Pump drive belt
6. Pump drive belt tension spring
(4.5” - 5.5” extension)
36” Deck
6
2
1
5
3
4
Page 32
excessively worn or damaged. As belt stretches and wears in, adjustment may become necessary. To increase belt tension, move the spring chain one (or more) link(s) at the anchor bracket. Installed spring length should be 5.50" ± .5" (12.7 cm ± 1.27 cm) originally with adjustments of .60" (15.2mm) per chain link. Fig. 5-11
IMPORTANT: Do not over tension the spring to
compensate for a badly worn belt or pulley.
Engine RPM setting
The TrimStar Hydro is designed so that the engine will run at 3600 rpm static pump load only. At this speed the hydraulic pumps are running at their maximum rated speed.
Cruise control spring adjustment
The cruise control tension can be adjusted. The more tension that is placed on the spring results in the cruise control engaging quicker. Less spring tension results in the operator having more control over the cruise control.
Adjust the cruise control tension by moving the spring chain at the anchor bracket. Fig. 5-12
Anti-scalp wheels
Anti-scalp wheel kits are standard on the TrimStar Hydro. (Fig. 5-13) This anti-scalp kit is recommended to minimize scalping when mowing on rough uneven terrain.
After setting the cutting height, adjust the anti-scalp wheels so they extend below the deck but do not contact the ground. They should always be at least 1/4” to 3/4” (.6 cm to 1.9 cm) below the deck. With the unit sitting on a flat level surface, the wheel position can be adjusted up or down as needed from 3/4” to 1-3/4” (1.9 cm to 9.5 cm) below the blade surface. Move the wheels up or down, in 1/2” (1.3 cm) increments, using the different axle mount holes in the wheel mount bracket. Fig. 5-13
NOTE: When the anti-scalp wheels are installed the minimum cutting height is 1” (2.5 cm) with the anti-scalp wheels set at 3/4”.
Figure 5-12
Cruise control spring
Anchor
bracket
Cruise control chain
Figure 5-13
Axle
mount
holes
Anti-scalp
wheels
Figure 5-10
Figure 5-9
Spring extension
1.2' - 2.0”
3.30”
Idler return spring
Free spring length
5.00" +.50"
Figure 5-11
5.50" +.50"
Maximum spring extension
3.30"
1.7" - 2.7”
Free spring length
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5-4
5.50" +.50"
Maximum spring extension
3.30"
1.7" - 2.7”
Free spring length
Page 33
104893 10/05
6-1
TROUBLESHOOTING
The majority of operating problems that occur with a system can be traced to improper adjustments or delayed service. A consistently applied preventative maintenance program, as outlined in the maintenance section of this manual, will prevent many problems. The following chart is designed to help you locate a problem by suggesting probable causes and the recommended solutions.
SYMPTOMS PROBABLE CAUSES SUGGESTED REMEDIES
There is abnormal The engine mounting bolts Tighten the engine vibration are loose mounting bolts
The engine pulley, idler Tighten the appropriate pulley or blade pulley is pulley loose
The engine pulley is Contact your Hustler Dealer damaged
The cutting blade(s) is/are Install new cutting blade(s) bent or unbalanced
A blade mounting bolt Tighten the blade mounting is loose bolt
Spindle bearing is worn Replace or tighten spindle or loose bearing
A blade spindle is bent Contact your Hustler Dealer
Uneven cutting height The blade(s) are not sharp Sharpen the blades
A cutting blade(s) is/are Install new cutting blade(s) bent
The deck is not level Level the deck per the
Mower Deck Leveling section of this manual
An anti-scalp wheel is not Adjust the height of the set correctly anti-scalp wheel
The underside of the Clean the underside deck is dirty of the deck
Tire pressure is incorrect Adjust the tire pressure
to 8 - 10 psi
A blade spindle is bent Contact your Hustler Dealer
Blades do not rotate The deck drive belt is worn, Install a new deck drive belt
loose or broken
The deck drive belt is Install the deck drive belt off the pulley and check for a reason
Electric clutch is not Contact your Hustler dealer engaging
SYMPTOMS PROBABLE CAUSES SUGGESTED REMEDIES
The engine will not start, Cruise control not in neutral Place cruise control in starts hard, or fails to or switch not adjusted neutral position or keep running re-adjust switch
Deck clutch switch engaged Disengage clutch switch
No fuel or line Fill tank or replace plugged line
Fuel valve is turned off Open the fuel valve
There is incorrect fuel in Drain the tank and replace the fuel system the fuel with the proper type
There is dirt in the fuel filter Replace the fuel filter
Dirt, water, or stale fuel in Contact your Hustler Dealer the fuel system
The choke is not on Move the choke lever to On
Numerous See engine manual
Engine: Numerous See engine manual
Runs with continuous misfiring or engine runs unevenly or erratically
Loss of power or Restrictions in air cleaner Service air cleaner
system will not operate in either direction Poor compression See your dealer
Steering linkage Adjust linkage needs adjustment
Park brake lever not in Place park brake lever in drive position drive position
The tractrion drive belt is Install a new traction worn, loose or broken drive belt
The traction drive belt is Install the traction drive belt off the pulley and check for a reason
For additional causes See engine manual
Overheating Air intake screen or Clean screen and fin
cleaning fins clogged
For additional causes See engine manual
Low engine oil pressure Low oil level Add oil
Oil diluted or too light Change oil and check for
source of contamination
High oil consumption Numerous See your dealer
Tractor jerky when starting Steering control linkage Adjust linkage
or needs adjustment
operates in one direction
only IZT component faulty See your dealer
Tractor creeps when Steering linkage needs Adjust linkage
steering control levers adjustment are in neutral
Tractor circles or veers Steering linkage needs Adjust linkage
in one direction adjustment
IZT component faulty See your dealer
Tires improperly inflated Adjust tire pressure to
8 - 10 psi
Page 34
Page 35
104893 10/05
7-1
When storing the unit at the the end of the mowing season, the following steps should be taken to ensure readiness for the next mowing season.
1. Remove all grass, dirt, and trash from tractor and
mower. Clean tractor and mower and touch up all scrapes with Hustler spray paint.
2. Clean paper air filter. Replace if necessary. Wash and
re-oil foam precleaner.
3. Check thoroughly for any worn or damaged parts that
need replacing and order them from your dealer.
4. Thoroughly lubricate machine, according to
lubrication instructions.
5. Block unit up so weight is off tires.
NOTE: Do not deflate tires.
6. Perform separate engine preparation as listed below.
7. Store tractor in a clean, dry place.
Preparation of engine for storage
When engine is to be unused for long periods, proceed as follows:
1. Run engine for a minimum of 15 minutes.
2. Drain oil from crankcase while engine is still warm.
3. Refill with fresh oil of proper viscosity.
4. Drain fuel tank and run the engine until it stops from
lack of fuel. Gasoline evaporates if left in carburetor for long periods, forming gum and varnish deposits in carburetor. These deposits will cause engine flooding and loss of power.
5. Remove and replace fuel filter if not done in previous
100 hours.
6. Clean exterior surface of engine. Spread a light film
of oil over any exposed metal surfaces of engine that are subject to corrosion.
7. Clean dirt and chaff from cylinders and fins, blower
housing and muffler.
8. Check oil filler cap and fuel tank cap to make certain
they are securely in place.
New season preparation
Before starting the tractor following post season storage,
the following servicing is required:
1. Clean tractor, removing trash and dirt accumulation.
2. Check engine oil oil levels.
3. Fill fuel tank with fresh gasoline. Run machine at half
speed for 5 minutes, checking operation of steering control lever. Stop engine and check for oil leaks, loose fittings and so forth.
4. Tighten any bolts that have loosened and make sure all
hair pins, cotter pins and clevis pins are in place.
5. Install all safety shields and review safety precautions
listed in this manual.
6. Check and inflate drive tires to 8-12 psi.
STORAGE
Page 36
Page 37
This section contains sources of additional literature concerning your tractor. Literature should be ordered from your Hustler dealer, or direct from indicated source.
NOTE: For parts information on your unit, refer to the Hustler TrimStar Hydro Parts Manual (Hustler P/N
103234).
Engine information
The TrimStar Hydro uses a Kawasaki 15hp or 17hp engine. Primary source of information is the engine operator’s manual, which is included with the TrimStar Hydro owner’s manual packet. For additional copies order Hustler P/N 771501. Other information includes:
For more information:
See your local Kawasaki dealer.
104893 10/05
Hydraulic transmission information
Power to wheels is supplied by two Hydro-Gear IZT
integrated pump/motor units.
During warranty period, check with your Hustler dealer before attempting repairs on any tractor system. Unauthorized repair work can void warranty of tractor, engine, and other components.
PRODUCT LITERATURE
8-1
ORDER
KAWASAKI HUSTLER
DESCRIPTION PART NUMBER PART NUMBER
Kawasaki Service Manual 15/17hp 99924-2045-02 771535
Kawasaki Service Manual 99920-2145-04 778423
19/23/25 hp
Page 38
Page 39
104893 10/05
INDEX
PAGE
Adjustment introduction...................................................5-1
Anti-scalp wheels.............................................................5-4
Belt replacement...............................................................4-5
Brake linkage adjustment.................................................5-2
Cold weather pump clutch ...............................................3-3
Controls............................................................................3-1
Cruise control spring adjustment .....................................5-4
Decals...............................................................................2-4
Deck cutting height adjustment........................................3-5
Deck drive belt adjustment...............................................5-3
Deck spindle belt adjustment...........................................5-3
Deck height adjusting shaft and bushing .........................4-6
Description of deck operation..........................................4-2
Drive linkage adjustment .................................................5-1
Engine air filter ................................................................4-5
Engine information...........................................................8-1
Engine oil and filter..........................................................4-5
Engine RPM setting .........................................................5-4
Engine starting .................................................................3-2
Fuel system.......................................................................4-4
General engine maintenance ............................................4-5
Hour meter .......................................................................4-3
Hydraulic transmission information.................................8-1
Hydraulic system..............................................................4-3
PAGE
Instrumentation ................................................................3-1
Lubrication.......................................................................4-3
Maintenance introduction.................................................4-2
Model and serial number..................................................1-1
Moving unit with stalled engine.......................................3-3
Mower blade maintenance ...............................................4-6
Mower blade removal ......................................................4-6
Mower deck leveling........................................................3-4
Mower deck operation......................................................3-5
New season preparation ...................................................7-1
Neutral adjustment...........................................................5-1
Operating suggestions......................................................3-5
Parts and service...............................................................1-1
Preparation of engine for storage.....................................7-1
Pump drive belt adjustment..............................................5-3
Safety interlock system....................................................3-3
Stand-up sulkies...............................................................3-6
Steering the unit ...............................................................3-3
Tires..................................................................................4-3
To the new owner.............................................................1-1
Torque values............................................................4-3, 5-1
Using this manual.............................................................1-1
Warranty certificate..........................................................1-2
Warranty registration .......................................................1-1
9-1
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