Hustler 350157 User Manual

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•••••••

Hustler Turf Equipment

•••••

P.O. Box 7000

•••

Hesston, Kansas

•

67062-2097

Hustler Z

Super Z

Owner’s Manual

350157 Rev 11/02

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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:

350157 Rev 11/02

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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. Technical Specifications.......................................................Sect. 9

10. Index...................................................................................Sect. 10

350157 Rev 11/02 350157 Rev 11/02

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This manual applies to the following equipment:

Hustler Z tractor & 60” deck, number 926253 Hustler Z tractor & 60” deck, number 926295 Hustler Z tractor & 52” deck, number 926311 Hustler Z tractor & 52” deck, number 926345 Hustler Z tractor & 60” deck, number 926451 Hustler Z tractor & 60” deck, number 926469 Hustler Z tractor & 72” deck, number 926550 Hustler Z tractor & 72” deck, number 926568 Super Z tractor & 60” deck, number 926360 Super Z tractor & 60” deck, number 926378 Super Z tractor & 52” deck, number 926485 Super Z tractor & 52” deck, number 926493 Super Z tractor & 72” deck, number 926436 Super Z tractor & 72” deck, number 926444

To the new owner

The purpose of this manual is to assist owners and operators in maintaining and operating the Hustler Z tractor and deck. 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 under the right front of the seat, the right front of the deck, and under the seat pan, 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 is to be used as an extension of this manual. These decals should not be removed 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. Local regulations may restrict the age of the operator.

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 seated on tractor facing forward, 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 tractor plus each attachment that displays a model and serial identification number plate 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

Tractor model and serial numbers are found on the serial identification plate, located on the frame directly below and to the left of the operator’s platform.

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

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.

For location of nearest dealer, or should you need further assistance, contact:

Customer Service Department Hustler Turf Equipment P.O. Box 7000 Hesston, KS 67062 Telephone (620) 327-4911 FAX (620) 327-2458

GENERAL INFORMATION

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HUSTLER Z AND SUPER Z

TWO YEAR LIMITED WARRANTY FOR TRACTORS AND DECKS

(THREE YEAR (1200 HOURS OF USE) 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 or 1200 hours of use, whichever comes first, 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, 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, if the 1200 hour of use limit has not been reached, 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. The third year of the warranty will be in effect until the 1200 hour of use limit is attained or the third year from the date of delivery is reached, whichever comes first. 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, 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 frame resulting from frame

breakage.

● Against all defects in the mowing deck which results

in the front edge of the deck being bent into the the blades.

● Against hydraulic hose and fitting leaks.

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 repair any defect in the

frame resulting in frame breakage 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,

f. The battery is covered by a one (1) year limited

warranty to the original owner only.

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

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350157 Rev 11/02

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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,

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.

All operators should read this manual, or be instructed about safe operating and maintenance procedures. This is the owner’s responsibility.

Incorrect usage of this machine may result in severe injury. Personnel operating and maintaining 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 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 occurring to other people or their property.

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Always disengage deck clutch, place steering control lever in neutral, engage neutral lock levers, stop tractor engine, engage parking brake and remove ignition key when leaving operator’s seat.

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Always remain seated while operating machine.

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Always keep safety shields and covers in place, except for servicing.

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Always maintain a safe distance from people and pets when mowing.

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Always operate machine in daylight or with adequate working lights.

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Follow daily and weekly checklists, making sure hoses are tightly secured and bolts are tightened.

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Always observe traffic laws while driving machine from one location to another.

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Always keep engine and machine clean, removing accumulated dirt, trash and other material from machine.

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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.

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Always wear adequate eye protection when servicing the hydraulic system and battery, or when grinding mower blades and removing accumulated debris.

▲ 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 be aware of what is behind the machine before backing up.

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Always inspect machine for damage after striking a foreign object. If damage is found, repair machine immediately. Be sure to disengage deck clutch, place steering control lever in neutral, engage neutral lock levers, stop tractor engine, engage parking brake, and remove ignition switch key before leaving operator’s seat to inspect damage.

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Always buckle seat belt, if provided with one, before starting tractor.

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Never pull back suddenly on your steering control lever while the machine is in forward motion.

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When going in reverse, push forward slowly on lever and avoid sudden movement. Rapid movement of the control levers in either direction could result in a reaction of the tractor that can cause serious injury.

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Never operate a poorly maintained machine.

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Never carry passengers.

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Never attempt high speed maneuvering, especially in crowded or congested areas.

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Never allow persons to operate this machine without proper instruction or allow children to operate machine.

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Never put hands or feet under any part of the machine while it is running.

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Never leave machine unattended with ignition key in switch, especially with children present.

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Never refuel tractor 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.

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Never attempt to start engine when there is a strong odor of gasoline fumes present. Locate and correct cause.

SAFETY PRECAUTIONS

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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

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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.

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Never attempt to make any adjustments or repairs to the tractor drive system, mower deck or any attachment while the tractor engine is running or deck clutch is engaged. Repairs or maintenance requiring engine power should be performed by trained personnel only.

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Never work under the machine or attachment unless it is safely supported with stands, blocks or a hoist.

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Do not touch hot parts of machine.

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Never direct discharge of material from mower deck towards bystanders.

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Always disengage the blades and wait for them to stop before crossing gravel drives, walks or roads.

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Always keep clear of the mower blades and attachments during their operation.

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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 steering lever in either direction could result in a reaction of the tractor that can cause serious injury.

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If any attachment or additional weight is mounted on the rear of the unit, any rapid movement of the control levers in either direction could result in a reaction of the tractor that can cause serious injury.

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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.

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Do not remove or modify the stabilizer wheels.

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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 tractor 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.

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

The attachments mounted to the tractor will also affect the way it handles on a slope. Be aware that each attachment’s characteristics vary.

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.

▲▲

Clean flammable material from machine. Prevent fires by keeping engine compartment, battery, hydraulic lines, fuel line, fuel tank and operator’s station clean of accumulated trash, grass clippings, and other debris. Always clean up spilled fuel and oil.

▲▲

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.

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Read Owner’s Manual and Quick

Reference Decal before attempting to

operate this machine.

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.

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350157 Rev 11/02

Avoid skin contact with battery acid. Always wear eye protection when checking the battery, acid can cause serious injury to skin and eyes. If contact occurs, flush area with clean water and call physician immediately. Acid will also damage clothing. Do not allow open flame near the battery when charging. Hydrogen gas forms inside the battery. This gas is both toxic and flammable and may cause an explosion if exposed to flame. Always remove the negative ground first and replace it last. Do not overfill battery. Electrolyte may overflow and damage paint, wiring or structure. When cleaning the battery, use soap and water. Be careful not to get soap and water into the battery. Use soda mixed in water to clean corrosion off the terminals.

Hydraulic fluid escaping under pressure can penetrate skin. Hydraulic fluid may also cause infection in a minor cut or opening in the skin; if exposed to hydraulic fluid, see a doctor at once. Before applying pressure to hydraulic system, make sure all connections are tight and all hoses and lines are in good condition. Relieve all pressure in the system before disconnecting or working on hydraulic lines. To find a leak under pressure, use a piece of cardboard or wood – never use your hands. To relieve all pressure in system, turn engine off and lower attachment.

2-3

Do not remove or modify stabilizer wheels or injury can result.

Never operate the mower deck with side deflector removed or in raised position, except when the grass catcher attachment is being used.

Hot surface!

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.

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350157 Rev 11/02

3-1

OPERATION

Figure 3-1

IMPORTANT: When access is required under the seat

platform make certain to place the control arms in the park brake position and pivot the arm rests upward before placing the seat platform in the full forward position to prevent arm rest damage.

Controls

For general location of the controls described in this

section, refer to Figure 3-1.

1. Ignition switch (Fig. 3-2) – a three position switch:

off, run, and start. With key inserted, rotate it clockwise to START position; release key when engine starts, and switch will automatically return to the RUN position.

2. Throttle control (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 lever is in the down position, the choke is in the off (run) position. When the lever is pulled up, the choke is in the on (start) position. Do not operate the machine in the on (start) position.

4. Control levers (Fig. 3-3) — these levers control the

tractor’s speed, direction, neutral lock, and park brake. Levers are used to steer, accelerate, decelerate and change direction. When the control levers are in the park brake position the tractor will not move when the engine is on and drive pumps are operating.

WARNING: The parking brake is not designed to hold the tractor on steep slopes.

Figure 3-2

Figure 3-3

1. Ignition Switch 5. Deck lift pedal 9. Hydraulic reservoir 14. Left deck cover

2. Throttle lever 6. Hour meter 10. Battery 15. Right deck cover

3. Control levers 7. Oil Pressure light 11. Deck adjusting rod 16. Deck height indicator

4. Deck clutch switch 8. Fuel tanks 12. Anti-scalp wheels 17. Brake switch

13. Discharge chute 18. Choke lever

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Deck clutch

switch

Control

lever

Hustler Z Controls

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CChhookkee

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5. 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.

6. Deck lift pedal (Fig. 3-4) — the deck lift pedal is used

to raise or lower the deck. Push on the pedal to raise the deck and then place the deck height locking pin into the desired cutting height hole. Push the deck lift pedal to raise the deck when going over obstructions.

Instrumentation

7. Electronic hour meter (Fig. 3-5) — 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 ignition key is switched to the RUN position and the operator is on the seat.

8. Oil pressure light (Fig. 3-2) — this light comes on

when the ignition switch is placed in the RUN position and stays lit until the engine is running and a safe oil pressure is developed. If light comes on during operation, shut engine off immediately and locate and correct the problem.

Safety interlock system

The tractor is equipped with a safety start interlock system consisting of the brake switches, seat switch, and deck clutch switch.

Check tractor safety start interlock system daily, prior to operation. This system is an important tractor safety feature. It should be repaired immediately if it malfunctions. The machine incorporates a separate seat switch which will stop the tractor engine when the operator is unseated for any reason while the tractor is operating. This is a safety feature designed to prevent runaway or accidental entanglement. To inspect the system:

1. The operator must be on the seat when testing the seat

switch.

2. Set both control levers in the park brake position.

3. Start the engine and allow it to warm up to operating

temperature.

4. With the deck clutch switch down and the control

levers in the brake position, slowly raise off of the seat.

The engine should continue to run.

5. With the deck clutch switch up and/or the control

levers in the neutral position, slowly raise off of the seat. The engine should stop within two seconds.

6. If the engine fails to stop when the deck clutch switch

is up or one or both of the control levers is up and the operator is off the seat, check the function of the seat switch. If the seat switch is not operating properly (is not opening or closing) and if the cause can not be determined, replace the seat switch.

If the problem can not be located, contact your 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 seat safety switch.

Engine starting

The Hustler Z safety start interlock system is also designed to protect the operator and others from accidental injury due to unintentional engine starting. The engine starting motor will not engage until:

A. Control levers are in the brake position. B. Deck clutch switch is in the down (OFF) position.

WARNING: The safety interlock system must not be disconnected or bypassed.

NOTE: The operator’s seat is equipped with a separate safety switch. If for any reason the operator should become unseated when the brake switches are disengaged or the deck clutch switch is engaged the engine will stop.

The following steps are the correct procedures for starting the engine. If difficulty is encountered, contact the Hustler Dealer in your area.

1. Before starting tractor each day, perform daily pre-

operation checking.

2. Make sure the control levers are in the brake position

350157 Rev 11/02

3-2

Figure 3-4

Deck lift

pedal

Figure 3-5

HHoouurr

mmeetteerr

Page 15

and deck clutch switch is disengaged.

3. Use choke when engine is cold, or if warm engine fails

to start within 5 seconds of cranking. Avoid flooding and operate engine without choking as soon as possible.

4. Set throttle at approximately 1/2 open position.

5. Insert key in ignition switch and rotate full clockwise

to engage starting motor. Release key when engine starts.

IMPORTANT: The engine starter should not be

operated for periods longer than 30 seconds at a time. An interval of at least two minutes should be allowed between such cranking periods to protect the starter from overheating and burn-out.

6. Perform test to make sure safety start interlock system

is operating properly. Refer to Safety start interlock system section.

7. As soon as engine begins to run, check to make certain

the oil warning light is off. If not, stop engine immediately and check for the cause.

8. Allow the engine to idle a few minutes before

advancing the throttle and/or engaging the deck clutch.

9. Before stopping the engine, place the control levers in

the brake position, disengage the deck clutch, and throttle back to low idle for a couple of minutes; then rotate ignition key counter-clockwise to the OFF position. Remove the key from switch before leaving the tractor.

WARNING: Never leave the machine unattended with key in ignition switch.

Moving tractor with stalled engine

If it becomes necessary to move the tractor when the engine is inoperative, the hydraulic pumps are equipped with bypass valves. Before moving the unit, turn bypass valves counter clockwise one-half to one revolution. The valve stems on each hydraulic pump are located near the top and are identified as a hex stud. The valve is located per Figure 3-6 on the Hustler Z or Figure 3-7 on the Super Z.

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 tractor should be facing forward and it must be secured.

IMPORTANT: Always make certain the two bypass valves are returned to their operating position before running the tractor following repairs.

Driving the tractor

DANGER: Never make sudden stops or reverse

direction, especially when going down a slope. The steering is designed for sensitive response. Rapid movement of the control levers in either direction could result in a reaction of the tractor that can cause serious injury.

After starting engine, engage the control levers and steer

as follows:

To go forward, push control levers forward an equal

distance (Fig. 3-8).

To go in reverse, pull control levers rearward an equal

distance (Fig. 3-8).

To turn left, move the right control lever farther forward

from neutral than the left control lever.(Fig. 3-8)

To turn right, move the left control lever farther forward

from neutral than the right control lever. (Fig. 3-8)

To pivot turn, move one control lever forward and the

other control lever back of neutral. This will allow the drive wheels to counter-rotate. (Fig. 3-8)

To stop or decrease speed, move control levers to

neutral. When going forward pull back gently on control levers. When going in reverse push forward gently on control levers.

DANGER: When going in reverse push forward gently on control levers 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, increase control lever’s distance from

neutral. The farther forward control levers are from neutral, the faster tractor will travel forward. The farther back

350157 Rev 11/02

3-3

Figure 3-6

Bypass valve

HHuussttlleerr ZZ sshhoowwnn

Figure 3-7

Bypass valve

Super Z shown

Page 16

control levers are from neutral, the faster tractor will go in reverse.

Operating suggestions

DANGER: Prior to operating the tractor the

operator should be thoroughly familiar with the proper use and operation of the equipment, should 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 inexperienced operator should not mow on slopes or on uneven terrain.

WARNING: The unit’s control levers are very responsive: Easy does it! For smooth operation, move lever 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 be thrown from the equipment. 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.

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.

Tractor 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 control levers to control ground speed rather than engine rpm.

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.

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 Z 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. 3-9) 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.

350157 Rev 11/02

3-4

FRONT OF TRACTOR FACES THIS DIRECTION

Figure 3-8

FORWARD TRAVEL PIVOT TURN REVERSE TRAVEL

RIGHT TURN

REVERSE TRAVEL

FORWARD TRAVEL

RIGHT TURN

N = Neutral Position Direction of arrows indicate direction of tractor movement.

Page 17

WARNING: Never operate the mower deck with discharge chute removed or in raised position.

WARNING: Always check area to be mown for rocks and other debris before mowing.

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.

350157 Rev 11/02

3-5

Figure 3-9

Side discharge chute

Page 18

Page 19

4-1

350157 Rev 11/02

MAINTENANCE

MAINTENANCE LOCATOR

CHART

1. Engine Oil Fill & Dipstick

2. Fuel Filter

3. Engine Air Cleaner

4. Engine Oil Drain Plug

5. Battery

6. Fuel Tanks

7. Hydraulic Oil Reservoir

8. Deck Idler Zerk (1)

9. Deck Pusher Arm Zerks (2)

10. Hydraulic Oil Filter

11. Gauge Wheel Bearing Zerks (2)

12. Engine Oil Filter

13. Deck Height Pivot Zerks (4)

14. Safety Interlock Switch (brake)

15. Drive Tire

16. Pump Idler Zerk (1)

17. Deck Belt

18. Spindle Housing Zerk (3)

19. Pump Belt

20. Blades

21. Oil Heat Exchanger

Figure 4-1

Page 20

NOTES:

1. Initial oil change is after 5 hours of operation. Thereafter, change oil after every 40

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. Perform initial hydraulic filter change after 50 hours (one week) of operation.

4. Change engine oil filter per the engine manufacturer’s recommendations. Refer to

Engine Owner’s Manual for recommendations and other maintenance items.

5. Service more often under dusty or dirty conditions.

6. Inspect every 100 hours and replace if worn or cracking is noticed. Otherwise, replace every 1000 hours or 2 years whichever comes first.

7. Check fuel line hoses, fuel valve and grommet for any cracks or leaks. 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. Place control levers in the neutral position, disengage deck clutch, 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.

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.

Torque values

WARNING: Particular attention must be given

to tightening the drive wheel lug nuts, wheel motor nuts, and blade spindle nuts. Failure to correctly torque these items may result in the loss of a wheel or blade, which can cause serious damage or personal injury.

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 (5) Daily or every 4 hrs. Clean foam element (5) Daily or every 4 hrs. Clean oil heat exchanger (5) Daily or every 4 hrs. Check fuel level Daily Blades - sharpen & securely fastened Daily Discharge chute - securely in place & in lowest position Daily Grease deck idler x Grease deck pusher arms x Grease pump idler x Grease deck height pivots x Grease gauge wheel bearings x Change engine oil & filter (1) (4) x Clean cylinder and head fins (a) x Check battery connections x Check tire pressure with a gauge x Check hydraulic oil level x Clean engine exterior (a) x Replace air cleaner paper element (5) x Clean and regap spark plugs (a) x Check pump and deck belt tension and condition (6) x Check fuel and hydraulic lines (7) x Check fuel valve and grommet (7) x Tighten lug nuts on wheels (2) x Change fuel filter x Clean or replace hydraulic fill cap x Change hydraulic filter and oil (3) x Grease deck spindle housings x Replace spark plugs x

4-2

350157 Rev 11/02

Page 21

Torque values given below:

Ft-lbs. Nm

Wheel (lug) nuts ................................65-75......88.14-101.7

Wheel motor nut (Hustler Z).........350-375 .....474.6-508.5

Wheel motor nut (Super Z)............290-310 .....393.2-420.4

Blade spindle bolt top........................65-75......88.14-101.7

Blade spindle bolt bottom

(spindle with blade saddle)......65-75......88.14-101.7

Blade spindle bolt bottom

(spindle without blade saddle)....118 ...........160.0

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...............................................8-10 psi

Gauge wheels.............................................8-10 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

1. Grease the front gauge wheel bearings per the

Maintenance Schedule. Use SAE multi-purpose grease.

2. Grease the four deck lift pivots, located to the side of

the operator’s footrest per the Maintenance Schedule. Use SAE multi-purpose grease.

3. Grease the deck idler per the Maintenance Schedule.

Use SAE multi-purpose grease.

4. Grease the pump idler per the Maintenance Schedule.

Use SAE multi-purpose grease.

5. Grease the two deck pusher arm pivots per the

Maintenance Schedule. Use SAE multi-purpose grease.

6. Grease the blade spindle assemblies per the

Maintenance Schedule. The spindle assemblies require lubrication annually. Each spindle shaft is equipped with a grease zerk located under the deck. Use no more than one or two ounces of SAE multipurpose 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.

Electrical system

The electrical system is a 12 volt, negative ground. Recommended battery size is a garden tractor BCI group U1R with 225 or better cranking AMP rating. A maintenance-free battery is recommended. Otherwise, follow battery manufacturer’s maintenance, safety, storing and charging specifications.

The battery is located under the seat. Fig. 4-3

WARNING: Avoid skin contact with battery acid. Always wear eye protection when checking the battery, acid can cause serious injury to skin and eyes. If contact occurs, flush area with clean water and call physician immediately. Acid will also damage clothing. Do not allow open flame near the battery when charging. Hydrogen gas forms inside the battery. This gas is both toxic and flammable and may cause an explosion if exposed to flame. Always remove the negative ground first and replace it last. Do not overfill battery. Electrolyte may overflow and damage paint, wiring or structure. When cleaning the battery, use soap and water. Be careful not to get soap and water into the battery. Use soda mixed in water to clean corrosion off the terminals.

350157 Rev 11/02

4-3

Figure 4-3

Battery

Figure 4-2

HHoouurr

mmeetteerr

Page 22

Common circuit failures are usually caused by shorting, corroded or dirty terminals; loose connections, defective wire insulation or broken wires. Switches, solenoids and ignition components may also fail, causing a shorted or open circuit.

Before attempting any failure diagnosis of the electrical system, use a test light or voltmeter to check the battery voltage. If the battery voltage is satisfactory, check the cleanliness and tightness of the terminals and ground connections. A general understanding of electrical servicing and use of basic test equipment is necessary for troubleshooting and repair.

Major overhaul or repair of the starting motor or alternator should be performed by trained technicians only.

Burnishing the electric clutch

WARNING: To insure maximum performance

and life, it is necessary to burnish the clutch.

Burnishing the electric clutch (Fig. 4-4) will develop better contact between the armature and rotor, helping to develop higher torque capabilities without slipping. The warranty on the new clutch will be voided if it is not burnished properly.

Use the following procedure to burnish the clutch:

1. Check the air gap between armature and rotor. Gap

should be .012” to .024”.

2. Cycle the clutch on and off 10 times (15 seconds on

and 15 seconds off) with the engine operating at half throttles, approximately 1500 rpm.

Access to engine and hydraulic pumps

The hydraulic pumps are accessed by lifting the seat platform. The seat platform is hinged at the front. To raise it, release seat latch and tilt seat platform up and forward. The seat platform catch (Fig. 4-5) will prevent the seat from going all the way over. However, if more access is desired under the seat platform, the seat platform catch can be raised allowing the seat to pivot more. Make certain to place the

control arms in the park brake position and pivot the arm rests upward before placing the seat platform in the full forward position.

WARNING: Always wear adequate eye protection when servicing the hydraulic system and battery.

Hydraulic system

IMPORTANT: Never use hydraulic or automatic

transmission fluid in this system; use only motor oil as specified. Remember, dirt is the primary enemy of any hydraulic system.

WARNING: Hydraulic oil escaping under pressure can penetrate skin. Hydraulic oil may cause infection in a minor cut or opening in the skin. If exposed to hydraulic fluid, see a doctor at once. Before applying pressure to hydraulic system, make sure all connections are tight and all hoses and lines are in good condition. To find a leak under pressure, use a piece of cardboard or wood — never use your hands. Relieve all pressure in the system before disconnecting or working on hydraulic lines. To relieve pressure, lower all attachments and shut off engine.

The 1.0 U.S. gallon (3.79 liter) hydraulic reservoir is located in front of the engine and under the operator’s platform. Fig. 4-6

Check oil level in hydraulic system after every 50 hours

EElleeccttrriicc cclluuttcchh

Figure 4-4

4-4

350157 Rev 11/02

Figure 4-6

Hydraulic reservoir

Hydraulic filter

Figure 4-5

SSeeaatt ppllaattffoorrmm ccaattcchh

CCoonnttrrooll lleevveerr

Seat platform

Page 23

of operation or weekly, whichever occurs first. Check more often if system appears to be leaking or otherwise malfunctioning.

Fluid level should be 1” from top of reservoir. Use only

SAE 10W40 SG, SF/CC, CD service motor oil.

Change hydraulic system filter element (Fig. 4-6) after first 50 hours of tractor operation, then replace filter and oil in reservoir every 500 hours thereafter. When changing hydraulic oil use 1/2 unit (approximately 3.5 oz.) of Lubrizol additive (Hustler P/N 027912). This additive, available from your Hustler dealer, will increase the performance life of the hydraulic system components.

The system filter is located directly in front of the hydraulic reservoir. A standard oil filter wrench is used to change filter, threads are right handed. Use a Hustler

approved filter element only.

IMPORTANT: Prefill the filter element with clean oil, before installing, to prevent drawing air into the system pump.

1. Fill the filter element with clean system oil. Smear a

light coating of oil on upper surface of rubber seal.

2. Install the filter element on base. Tighten the oil filter

by hand until the filter seal makes contact with the filter head, then tighten an additional 3/4 turn with a an oil filter wrench. — DO NOT OVERTIGHTEN.

3. Start tractor engine and let run at approximately 2/3

throttle for a few minutes to work any trapped air out of the system before engaging the steering control lever.

4. Stop the engine and check the filter and connections

for leaks.

5. Check the hydraulic reservoir for specified oil level.

Add clean oil as necessary.

Clean or replace hydraulic reservoir cap annually. Cap may be cleaned by dipping in or flushing with cleaning solvent. Follow manufacturer’s instructions and warnings for application of solvent type selected.

NOTE: The hydraulic pumps are equipped with bypass valves. For more information refer to Operation section, Moving tractor with stalled engine.

A hydraulic oil heat exchanger is installed on the Super Z. This heat exchanger is designed to keep hydraulic system oil temperature lower in hot operating conditions or heavy

continuous operating conditions.

This hydraulic heat exchanger is located above the engine. Air is drawn across the cooling fins by an electric fan located above the heat exchanger. Fig. 4-7

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 fuel tanks are located in the tractor’s fenders. (Fig. 4-8) Total capacity for the fuel tanks is 12 U.S. gallon (45.4 liter)

Use regular unleaded gasoline with an octane rating of 87 or higher.

The fuel filter (Fig. 4-9) is installed in the fuel line between fuel tanks and engine fuel pump on the front side of the engine. Replace filter annually or after every 500 hours of operation, whichever occurs first.

4-5

350157 Rev 11/02

Figure 4-7

CCoooolliinngg ffaann

HHeeaatt eexxcchhaannggeerr

Engine

Figure 4-8

FFuueell ttaannkk

Figure 4-9

Fuel filter

Page 24

When replacing the fuel filter, check the fuel line hoses

for any cracks or leaks. Replace as needed.

A fuel shut-off valve is located on each fuel tank (Fig. 4-

10). Close these valves to prevent fuel flow to the engine.

Engine oil and filter

Check engine oil daily and after every 4 hours of operation. Crankcase dipstick and oil filler tube are located at the rear of the machine (Fig. 4-11). 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 drain and oil filter are located at the rear of the engine. Fig. 4-11

Engine air filter

Perform engine air filter maintenance per the Engine Owner’s manual on units that have the standard engine air filter.

General engine maintenance

Detailed instructions and recommendations for break-in and regular maintenance are specified in the 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 the manufacturer. Special attention should be paid to applicable data which will not be duplicated here.

Belt replacement

Figures 4-12 and 4-13 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

4-6

350157 Rev 11/02

Figure 4-11

Engine oil drain plug

Engine oil filter

EEnnggiinnee ooiill ffiilllleerr ttuubbee

Figure 4-13

Deck Belt Drive Layout

1. Spindle drive belt

2. Deck blade spindle pulley

3. Spindle belt tension idler

4. Spindle belt tension idler spring

(9.0" at operation)

5. Deck belt idler

6. Idler arm

Figure 4-12

2, 6

1. Pump belt

2. Engine pulley

3. Pump idler pulley

4. Pump idler arm

5. Pump pulley

6. Electric deck clutch

7. Pump idler spring

Viewed from

bottom for unit

Figure 4-10

Fuel shut-off valve

Page 25

indicate failure, trim ravelings with a sharp knife.

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

On spindles with blade saddles, use a 3/4" wrench to remove the 1/2" cap screw holding the blade to the spindle saddle from underneath. On spindles without blade saddles, use a 15/16" wrench to remove the 5/8" cap screw holding the blade to the spindle shaft from underneath.

Sharpen the blades on a grinder following pattern as shown (Fig. 4-14). 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 1/2" 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. 4-15 and 4-16). Replace any distorted blade.

Do not re-use spindle bolts which have stripped, worn or undercut threads. Torque bolts on spindles with blade saddles to 65-75 foot-pounds when reinstalling blades.

Torque bolts on spindles without blade saddles to 118 footpounds 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.

4-7

350157 Rev 11/02

Figure 4-14

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 4-15

Figure 4-16

Twisted Blade Edge

(Replace)

Cutting Edge

Straight Blade Edge

End view of blades, comparing twisted and straighten blades.

Cutting Plane

Cutting Edge

Page 26

WARNING: Failure to correctly torque the bolt

may result in the loss of the blade which can cause serious injury.

4-8

350157 Rev 11/02

Page 27

ADJUSTMENTS

Introduction

WARNING: Unless specifically required, DO

NOT have engine running when servicing or making adjustments to tractor. Place control levers in the park brake position 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 Z or Super Z 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.

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 and 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......88.14-101.7

Wheel motor nut (Hustler Z).........350-375 .....474.6-508.5

Wheel motor nut (Super Z)............290-310 .....393.2-420.4

Blade spindle bolt top........................65-75......88.14-101.7

Blade spindle bolt bottom

(spindle with blade saddle)......65-75......88.14-101.7

Blade spindle bolt bottom

(spindle without blade saddle)....118 ...........160.0

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 engine torque values, see engine owner’s manual.

For all other torques refer to the parts manual for standard torque chart.

Steering linkage

The neutral adjustment for the control levers in the neutral

position is discussed in this section.

The tractor steering has been factory adjusted to eliminate creeping when the control levers are in the neutral position (Fig. 5-1). However, should the tractor begin to creep, the control lever linkage can be adjusted as follows:

Control Lever Neutral Adjustment

Before considering any adjustment, check the tire air pressure and make certain hydraulic system oil is at operating temperature. Unequal tire pressure will cause the tractor to drift to one side. Refer to tire pressure information in the Maintenance section of this manual.

Fine adjustment to the unit’s steering is made with the adjustable pump linkage rods located between the control

5-1

350157 Rev 11/02

Figure 5-1

PPaarrkk bbrraakkee sslloott

CCoonnttrrooll lleevveerr iinn tthhee

nneeuuttrraall ppoossiittiioonn

Control

lever

Figure 5-2

Pump linkage rod

Pump arm

Jam nut

Page 28

lever and pump arms. Fig. 5-2

Neutral is properly adjusted when the control levers are in

the neutral position and the drive wheels are not turning.

If the tractor creeps in the neutral position the control

linkage may be adjusted as follows:

1. Raise and block the tractor up so the drive wheels are

off of the floor.

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.

2. Position the control lever in the neutral position.

Disengage the deck clutch.

3. Start the engine and observe which way the wheels are

rotating.

4. If wheel(s) are rotating forward, loosen the jam nuts on

the pump linkage rods and rotate the rod to lengthen the steering control linkage until the wheel(s) come to a stop. Fig. 5-2 NOTE: The left linkage controls the left hydraulic pump and the right linkage controls the right hydraulic pump. Repeat for the opposite side if necessary.

5. If wheel(s) are rotating in reverse then loosen the jam

nuts on the pump linkage rods and rotate the rod to shorten the steering control linkage until the wheel(s) come to a stop. Fig. 5-2 NOTE: The left linkage controls the left hydraulic pump and the right linkage controls the right hydraulic pump. Repeat for the opposite side if necessary.

6. When both wheels remain in neutral, tighten the jam

nuts to lock the turnbuckle in place.

7. Test again by moving the control levers forward and

backward before returning them to the neutral position. If the tires are in neutral, the unit is now ready for operation.

8. After adjusting for neutral it may be necessary to re-

adjust the reverse spring and/or the control lever stop. Fig. 5-3 or Fig. 5-4

Control lever stops

The control lever stops (Fig. 5-3) are designed to do two things: First, and most important, they must keep the pumps from bottoming out internally. Secondly, the stops may be adjusted to help drive straight when the control levers are pushed forward against the stops.

To keep the pumps from bottoming out internally use the following procedure:

1. To make the first adjustment the tractor engine must

NOT be running.

2. Check to make sure the control levers are against the

stops before the pumps are bottomed out internally. To do this, gently and slowly move the control levers forward and feel if there is some resistance on the pump lever before the control levers hit the stops. Check one side at a time. If you sense that the pump arms are stopping the forward motion of the control arms, loosen the jam nut on the adjustable stop of the corresponding side and turn the stop (set screw) inward to stop the control levers slightly before the pump bottoms out. Lock in place when the adjustment is correct by re-tightening the jam nut.

3. Do this for each side.

To adjust the stops for driving straight when control levers are against the stops during operation:

1. Determine which drive tire is rotating too fast when

both control levers are against the stops. Then stop the tractor and loosen the lock nut on the side which is rotating too fast and turn the stop (set screw) inward to stop the control lever sooner. Tighten the lock nut on the stop and test again. Repeat this procedure until unit drives straight.

NOTE: Since this is a hydrostatic drive, variables such as temperature of oil, efficiency of pumps and motors, tire pressure etc. may effect the consistency of the ability to rely

Figure 5-4

350157 Rev 11/02

5-2

Figure 5-3

Top nylock nut

Lower

nylock nut

Spring linkage

Reverse

spring

Control

lever

Stop

Jam nut

Page 29

on the stops to drive straight without the operator making minor steering adjustments with the control arms.

Reverse spring adjustment

The reverse spring (Fig. 5-4) is designed to bring the control levers to the neutral position after they are released from the reverse position.

To adjust:

1. Make certain the control lever neutral adjustment is

correct. If not, refer to Steering linkage section.

2. When control lever is in the reverse position the spring

should force the control lever to return to neutral after the lever is released.

3. Adjust the top nylock nut (Fig. 5-4) on the spring

linkage until the control lever returns to the neutral position from the reverse position properly. Tightening the nylock nut will cause the control lever to travel forward less before stopping. Loosening the nylock nut will allow the control lever to travel further forward.

4. Check the length of the reverse spring when the

control lever is in the neutral position. This dimension should be 1.9”. If it is not, adjust the lower nylock nut (Fig. 5-4) until the dimension is achieved.

5. Repeat for other side.

Steering dampener

Hustler Z Models

The steering dampeners (Fig. 5-5) are incorporated into the unit to provide some resistance when the control levers are moving forward or rearward. To set the steering dampeners in the correct operating position follow these steps:

1. Place the control lever in the neutral position.

2. Check the center distance from the dampeners front

mounting hole to the rear mounting hole. This dimension should be 8.54”. If it is not, loosen the front ball stud and slide the dampener in the mounting slot until this dimension is attained. Re-tighten front ball stud. NOTE: The dampener must not bottom out when the pump lever is fully stroked in either direction.

Super Z Models

This steering dampener (Fig. 5-6) is spring loaded to return the control levers to the neutral position from the reverse position. This gives the operator a sense of neutral during operation.

To set the steering dampeners in the correct operating position follow these steps:

1. Place the control lever in the neutral position.

2. Loosen the steering dampener’s front ball stud.

3. Pull the dampener spring housing pass the point that

the internal spring is engaged.

4. Release the dampener spring housing and allow the

internal spring to bring the housing back to the neutral position.

5. Tighten the nut on the steering dampener’s front ball

stud.

Control lever adjustment

The control levers can be adjusted for operator comfort. By loosening the cap screws that attaches the upper control lever to the lower lever (Fig. 5-7), the upper control lever can be pivoted to fit the operator’s personal preference.

The control levers should be adjusted so that they align with each other when in the neutral position.

350157 Rev 11/02

5-3

Figure 5-7

Cap screw

UUppppeerr

ccoonnttrrooll

lleevveerr

Lower control

lever

Figure 5-5

8.54”

Steering

dampener

Figure 5-6

SSpprriinngg

hhoouussiinngg

Front ball

stud

Page 30

Park brake adjustment

Occasionally check the park brakes and adjustment using

the following method:

1. Position the control levers in the neutral position.

Disengage the deck clutch.

stands.

NOTE: The front brake link is not adjustable. Fig. 5-8

2. Raise and block the tractor up so the drive wheels are

off of the floor.

3. Open the hydraulic pump’s bypass valve (Fig. 5-9 & 5-

10), on the side that is being adjusted, by turning bypass valves counter clockwise one-half to one revolution. The valve stems on each hydraulic pump are located near the top and are identified as a hex stud.

4. Rotate the tire. The tire should rotate. Remember

hydraulic oil resistance will prevent the tire from rotating freely even with the bypass valves open. There should be no resistance from the brakes at this point.

5. Hustler Z - Move the control lever to where it is

touching the outside edge of the lever’s travel slot. Fig. 5-10

350157 Rev 11/02

5-4

Figure 5-10

Bypass valve

Super Z shown

Figure 5-8

Front brake link

(right side)

Figure 5-12

1/8”

OOuuttssiiddee eeddggee

CCoonnttrrooll lleevveerr

PPaarrkk bbrraakkee

sslloott

SSuuppeerr ZZ sshhoowwnn

Figure 5-11

Travel slot

OOuuttssiiddee eeddggee

CCoonnttrrooll lleevveerr

PPaarrkk bbrraakkee

sslloott

HHuussttlleerr ZZ sshhoowwnn

Figure 5-9

Bypass valve

HHuussttlleerr ZZ sshhoowwnn

Page 31

Super Z - Move the control lever to where it is just inside (1/8”) the park brake slot. Fig. 5-11 NOTE: When the control lever is against the outside edge of the the slot, the brakes should not be engaged.

6. Rotate the tire. If the brake is adjusted properly the

tire will still rotate but friction will start to become noticeable here. However, if no brake resistance is noticed, the brake needs adjusted as follows:

7. Loosen the brake linkage jam nuts. Fig. 5-13

8. Rotate the tire and at the same time rotate the

turnbuckle to shorten the length of the brake linkage to increase the brake pressure. When you feel the brake begin to engage, stop adjusting the turnbuckle. Retighten the jam nuts on the turnbuckle.

9. Place the control lever in the park brake slot (Fig. 5-11

& 5-12). The tire should not rotate when the control lever is in the park brake position.

10. Place the control lever in the neutral position. The tire

should rotate freely.

11. Close the hydraulic pump’s bypass valve.

12. Repeat steps 3 thru 11 for the other side.

13. Remove the jack stands and lower the unit. It is now

ready to operate.

Hydraulic pump belt adjustment

The pump drive belt tension remains constant by means of a tension idler and spring (Fig. 5-14). There is no tension adjustment of this belt.

Deck drive belt adjustment

The spindle belt tension remains constant by means of a tension idler and spring (Fig. 5-15). 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 (Fig. 5-15). Installed spring length should be

9.0" ± .3" (22.8 cm ± .76 cm) originally with adjustments of .60" (15.2mm) per chain link. (Fig. 5-16)

IMPORTANT: Do not over tension the spring to compensate for a badly worn belt or pulley.

Engine RPM setting

The Hustler Z 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.

Deck leveling and height adjustment

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 - 10 psi

Gauge wheels tire pressure...................8 - 10 psi

5-5

350157 Rev 11/02

Figure 5-16

3.0”

Spring Extension

9.0”

6.0”

Normal Spring Length

Figure 5-14

Spring

Tension

idler

Pump drive

belt

Figure 5-15

Spring

Tension idler

Chain

Anchor

bracket

Figure 5-13

Turnbuckle

Brake linkage

JJaamm nnuutt

Page 32

WARNING: Stop engine. Make sure deck

clutch switch is in the down (OFF) position. Place control levers in the brake position before leaving machine.

2. Park the unit on a flat surface.

3. Raise deck and place 3" of blocking under all 4 corners

of the deck (Fig. 5-17). This will set the cutting height at 3 ¼ ". NOTE: Back of deck will automatically be set ¼" higher.

4. Set cutting height at 3 ¼" in the height indicator by

placing the height adjusting stop in the 3" hole, and turning the height stop so that the flat side is against the stop handle. Fig. 5-18

5. Clamp the height adjusting stop against the stop handle

(5-16). This will assure that the height will not move during the setting process. Otherwise, spring pressure from the deck lift springs will tend to pull the stop away from the handle.

6. Loosen all nuts on the deck lift threaded rods, and the hardware on the adjuster (on the right front), until all the deck lift chains are loose, and the deck is sitting tightly on all four blocks. Fig. 5-19, 5-20, 5-21

7. Loosen the two nuts on the front of height indicator so that the foot pedal is free. Fig. 5-22

8. Start the leveling process on the left front of the

tractor.

9. Set the amount of threads protruding on the deck lift

rod from the lift block at approximately 1". Fig. 5-23

10. Jam both nuts against the block.

11. Push or pull on the deck lift foot pedal until the chain

on the left front just becomes tight, making sure that the deck stays tight against the 3" block.

12. While keeping the chain tight, tighten the nuts against

the deck lift block on the height indicator rod. Fig. 522

13. Go to the right front of the tractor.

14. Loosen the 5/16" jam nut on the adjuster lift chain (5-

21), and back the adjuster bolt out to allow the adjuster to move up and down freely.

15. Be sure that adjuster is free to move up and down.

16. Tighten the adjuster bolt until the chain just becomes

tight, making sure that the deck stays tight against the 3" block.

17. Tighten the adjuster bolt jam nut to prevent the

adjuster bolt from moving. Fig. 5-21

18. Tighten the hardware holding the chain and adjuster

onto the deck lift arm.

19. Go to the right rear of the tractor.

20. Make sure that there is still slack in the chain. If not,

loosen the two nuts on the block holding the threaded

350157 Rev 11/02

5-6

Figure 5-20

Deck lift

threaded

rod

Nut

Chains

Figure 5-18

Height

adjusting

stop

Stop

handle

Figure 5-19

Deck lift

threaded

rod

Nut

Chains

Figure 5-17

Blocks

Page 33

rod until there is slack in the deck lift chain. Fig. 5-20

21. Tighten the appropriate nut until the chain just

becomes tight, making sure that the deck stays tight against the 3" block.

22. Tighten the other nut on the opposite side of the block,

and jam them tightly together against the block.

23. Go to the left rear of the tractor.

24. Make sure that there is still slack in the chain. If not,

loosen the two nuts on the block holding the threaded rod until there is slack in the deck lift chain. Fig. 5-19

25. Tighten the appropriate nut until the chain just

becomes tight.

26. Tighten the other nut on the opposite side of the block,

and jam them tightly together against the block.

27. Compress the deck lift assist springs so that there is 1”

of space between the front nut and on the spring and the rear nut on the deck lift block (Fig. 5-23). Typical both sides.

28. When completed, all chains will be tight, and deck cutting height will be set to the deck height indicator.

Deck cutting height adjustment

Deck height is adjustable from 1” to 5” (2.54 cm - 12.7 cm) in 1/4” increments. The holes in the height adjusting bar are spaced at 1/2” intervals. By turning the height adjusting stop around, 1/4” increments can be attained due

to the 1/4” plate that is part of the stop. Fig. 5-24

EXAMPLE: When the height adjusting stop is placed in

the 1” hole, with the 1/4” plate facing to the front of the unit, the cutting height is at 1”. When the height adjusting stop is placed in the 1” hole, with the 1/4” plate on the operator’s side of the hole, the cutting height is at 1-1/4”.

When the height adjusting stop is placed in one of the holes, with the 1/4” plate on the operator’s side of the hole, the deck height will be set at one of the following: 1-1/4”, 13/4”, 2-1/4”, 2-3/4”, 3-1/4”, 3-3/4”, 4-1/4” or 4-3/4”.

When the height adjusting stop is placed in one of the holes, with the 1/4” plate facing to the front of the unit, the deck height will be set at one of the following: 1”, 1-1/2”, 2”, 2-1/2”, 3”, 3-1/2”, 4”, 4-1/2” or 5” .

The notch located at the rear of the right height adjusting bar is to be used when the deck is placed in the transport mode.

Anti-scalp wheels

Anti-scalp wheel kits are standard on the Hustler Z. These anti-scalp wheels are designed to minimize scalping when mowing on rough uneven terrain.

After setting the cutting height, adjust the front 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

Figure 5-24

Height

adjusting

stop

1/4” plate

Figure 5-23

Lift block

1”

Deck lift rod

1”

Deck lift

assist springs

Figure 5-21

5/16” bolt

Adjuster

Hardware

Jam nut

5-7

350157 Rev 11/02

Figure 5-22

Foot

pedal

Nuts

Page 34

cm to 1.9 cm) below the deck. With the unit sitting on a flat level surface, the front 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 front wheels up or down, in 1/2” (1.3 cm) increments, using the different axle mount holes in the wheel mount bracket. Fig. 5-25

When adjusting the rear anti-scalp wheels, the wheel should be in the lower axle mount hole when the front antiscalp wheels are in the lower or middle axle mount holes. When the front wheels are in the upper axle mount hole, the rear wheels should be in the upper axle mount hole as well.

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 5-25

Adjusting

holes

Anti-scalp

wheel

Page 35

350157 Rev 11/02

SYMPTOMS PROBABLE CAUSES SUGGESTED REMEDIES

Starting motor Control handle not in park Place control handle in park

does not crank brake position or switch not brake position or re-adjust

adjusted switch

Mower clutch switch engaged Disengage clutch switch

Weak or dead battery Recharge or replace

For additional causes See engine manual

Engine cranks but No fuel or line Fill tank or replace

does not start plugged line

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 Hydraulic line blockage See your dealer

Internal interference or See your dealer leakage in wheel motor

Insufficient hydraulic Check level in reservoir oil supply

Have dealer check hydraulic pump

Poor compression See your dealer

Steering linkage Adjust linkage needs adjustment

Air in system Check filter & fittings

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 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 Pump or wheel motors See your dealer

faulty

Hydraulic system operates Low hydraulic oil level Fill reservoir

hot (oil in reservoir smells rancid) Hydraulic pump 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

Wheel motors faulty See your dealer

Hydraulic pump faulty See your dealer

Tractor creeps when Steering linkage out of Adjust steering linkage parking brake engaged adjustment

Brakes need adjustment Adjust parking brakes

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.

6-1

Page 36

Page 37

350157 Rev 11/02

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. Check hydraulic oil level. Add oil if necessary. Change oil and filter if not done in last 500 hours. Lubrizol additive is required. Refer to Maintenance section.

6. Block tractor up so weight is off tires. NOTE: Do not deflate tires.

7. Protect battery from freezing temperatures. Occasionally recharging battery during storage will extend battery life.

8. Perform separate engine preparation as listed below.

9. 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. Remove spark plugs and pour a tablespoon of engine

oil into each spark plug hole, Install plugs, but do not reconnect plug leads.

7. Crank engine with starter at least a dozen revolutions

to distribute oil over cylinder walls and valve mechanism.

8. Clean exterior surface of engine. Spread a light film

of oil over any exposed metal surfaces of engine that are subject to corrosion.

9. Clean dirt and chaff from cylinders and fins, blower

housing and muffler.

10. 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 and hydraulic 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 tires to 8-10 psi.

STORAGE

Page 38

Page 39

This section contains sources of additional literature concerning your tractor. Literature should be ordered from your Hustler dealer or direct from indicated source.

Hustler Z & Super Z Parts Manual

If you would like to order a Parts Manual for this tractor, the Hustler p/n for that manual is listed below. Please call Hustler Turf Equipment at (620) 327-1246 to order the manual. You may also mail, FAX, or e-mail your order by using the form on page 8-3. Hustler Turf Equipment will accept credit card payment for this manual.

Engine information

The Hustler Z uses a Kawasaki 23hp or 25hp engine. The Super Z uses a Kawasaki 25hp engine. Primary source of information is the engine operator’s manual, which is included with the owner’s manual packet. For additional copies order Hustler P/N 778423.

For additional engine service manual information contact your local Kawasaki dealer.

350157 Rev 11/02

Hydraulic pump information

Power to wheel motors is supplied by two Hydro-Gear hydraulic pumps. For more information:

Hydro-Gear Customer Services 1411 So. Hamilton Street Sullivan, IL 61951 Phone: (217) 728-2581

NOTE: 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.

Wheel motors information

For more information on Hustler Z wheel motors:

Parker Hannifin Corporation 2745 Snapps Ferry Road Greenville, TN 37745 Phone: (423) 787-2499

For more information on Super Z wheel motors:

White Hydraulics P.O. Box 30250 Nashville, TN 37241-0250 Phone: (270) 885-1110

NOTE: During warranty period, check with 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

Parts

Model Manual List

Model Number P/N Price

Hustler Z 926253, 926295, 926311, 926345 350165 $22.50

926451, 926469, 926550, 926568

Super Z 926360, 926378, 926485, 926493

926436, 926444 355750 $22.50

ORDER

KAWASAKI HUSTLER

DESCRIPTION PART NUMBER PART NUMBER

Kawasaki Service Manual 9924-2045-02 771535

Page 40

FREQUENTLY ORDERED PARTS

Part No. Description

027912 Lubrizol 7 oz. bottle 027920 Lubrizol 10 oz. bottle 768341 Hydraulic oil filter (Hustler Z only) 783939 Hydraulic oil filter (Super Z only) 781443 Pump drive belt 782292 B-Section belt, deck (926311, 926345, 926485, 926593) 781310 B-Section belt, deck (926253, 926295, 926360, 926378) 068478 Fuel filter 780171 Air filter element assembly 780155 Precleaner air filter 772079 Engine oil filter 777391 21” High sail cw blade (60Z with blade saddles) 782516 21” High sail cw blade (60Z without blade saddles) 781898 18” High sail cw blade (52Z) 783977 24” High sail cw blade (72Z)

350157 Rev 11/02

8-2

Page 41

Hustler Z Parts Manual (P/N 350165) Order Form

Super Z Parts Manual (P/N 355750) Order Form

To order by mail:

Fill out this form, fill out the credit card information or attach a check and send it to:

Hustler Turf Equipment P.O. Box 808 Hesston, KS 67062

To order by e-mail:

Using this form as a guide, send all necessary information, including credit card information to:

jdewitt@excelhustler.com

To order by Telephone or FAX:

Telephone: call (620) 327-1246 to place an order FAX this completed form to (620) 327-2828

Name:

Address:

Telephone:

Master Card Number: Expiration Date:

Visa Card Number: Expiration Date:

QTY Part Number Description Unit Price Total Price

350165 Hustler Z Parts Manual $22.50 355750 Super Z Parts Manual $22.50

350157 Rev 11/02

8-3

Page 42

350157 Rev 11/02

8-4

Page 43

350157 Rev 11/02

9-1

TECHNICAL SPECIFICATIONS

Starter 12-volt (.8 KW), solenoid shift positive engagement.

Ignition Electronic. Charging System 12-volt,

15-amp. Fuel Unleaded gasoline with

octane rating of 87 or higher. Fuel Filter Replaceable,

automotive-type. Cooling Air cooled. Fly-

wheel fan.

Governor Mechanical. Warranty 1 year limited. TRACTION DRIVE

SYSTEM: Type Dual hydrostatic.

Individual pumps power two direct-drive wheel motors. Hydrostatic system operates on 10W40 motor oil.

Pumps

Hustler Z - Hydrogear BDP10 Two variable displacement, axial piston type. Each pump powers one drive wheel motor.

Super Z - Hydrogear BDP21 Two variable displacement, axial piston type. Each pump powers one drive wheel motor.

Pump Drive V-belt drive from engine crankshaft.

Final Drive

Hustler Z - Parker-Ross TF024OUS080AAFW Direct drive high-torque wheel motors. One for each drive wheel.

Super Z - White CE 20 Direct drive high-torque wheel motors. One for each drive wheel.

Filter Replaceable spin-on type.

Ground Speed - infinitely variable

Hustler Z - 0-11

MPH (0-17.7

KPH) forward and 0-5 MPH (0-

8 KPH) reverse Super Z Transport 0-15 MPH (0-24.14

KPH) forward

Mowing 0-10 MPH (0-16.09

KPH) forward and 0-7.5 MPH

(0-12.07 KPH) reverse Steering Twin lever steering

provides independent control of each drive wheel. Speed, forward, reverse, brake, and turns are all controlled with hand operated controls.

Turning Radius True zero

degree. Turns within its own length. Counter-rotating, independent drive wheels.

BRAKES: Service Hydrostatic dynamic

braking. Parking Automotive style

drum brakes. When steering levers are placed in neutral position, integral park brakes are automatically engaged.

Mower Drive Single V-belt drive from engine with electric clutch. Spring tension idler pulley for long belt life.

TIRES: Front Two – 13 x 6.50 – 6,

rib tread.

Drive tire:

24 x 12.00 – 12, turf tread.

CAPACITIES: Fuel System 12 US

GAL (45.4

Hydraulic Oil 1.5 US

GAL

(5.7 L) DIMENSIONS: Height 39

(39

CM).

W/60

IN Deck Length 75 IN

(190.5 CM). Overall width with 60” deck

and discharge chute up 62 IN (157.48 CM).

Tire-to-tire width 53

(134.62

CM).

Weight 1100

LBS (500 KG).

W/52 IN

Deck Length 74

(188 CM

Overall width with 52” deck and discharge chute up 59

(149.86 CM). Tire-to-tire width 52 IN

(132.08 CM). Weight 1075 LBS (488.6 KG).

W/72

Deck Length 79

(200.6 CM). Overall width with 72” deck

and discharge chute up 70.4

(178.8 CM). Tire-to-tire width 60 IN (152.4

CM).

Weight 1130

LBS (512.5 KG).

SAFETY FEATURES:

Operator presence system connected to deck and drive clutches. Stabilizer rollers at rear of tractor.

SEAT:

Standard: Molded-vinyl seat with armrests. Fore and aft adjustments.

Optional: Molded-vinyl, suspension seat with armrests.

Fore and aft adjustment

CONSTRUCTION:

Mainframe is 1.5

IN x 3 IN

.187

IN (3.8 CM

x 7.62 CM x

.47

CM) rectangular steel

tubing. Drive motors mounted to .179 IN (.45 CM

) welded steel. Front caster wheels mounted with roller bearings on each wheel. Front caster forks are .50

IN (1.27 CM

)

DECK LIFT: Foot-operated deck height adjustment. Pin for setting height, transport position.

CONTROLS: Hand-operated choke/throttle, ignition switch, electric mower clutch. Integrated parking brakes.

INDICATORS: Hour meter, engine warning light.

CUP HOLDER: Two cup holders molded into the left side fuel tank. Accommodates nearly any cup size.

DECKS Common Specifications Type: Free-floating mower

using three blades with center blade to the front. Mower is suspended at the corners. Includes 6 deck-mounted rollers to improve flotation in rolling and uneven terrain.

Deck Lift: Raise and lower deck from driver’s seat with simple foot-operated deck height adjustment. Pin for setting height, transport position. Change cutting heights, hop curbs, and trailer more easily.

Construction: .125

IN (.317

CM) welded steel. Solid 1 IN X

.375 IN (2.55 CM x .95 CM) steel bars reinforce impact areas on trim edges. .187 IN x .375 IN (.47 CM x .95 CM) in box-section reinforced front edge. Reinforcements welded onto spindle mount areas. Steel deck housing is 5 IN (1.27 CM) deep to provide room for high-capacity mowing.

Cutting Heights:

Foot-operated deck height adjustment. Pin for setting height, transport position. Height adjustment in .25

increments from 1

to 5 IN

(2.55

to 12.7 CM)

Blade Drive V-belt drive to all three spindles. Spring tension idler pulleys.

Spindles Machine ductile housing. 1

IN (2.5 CM)

diameter high carbon steel shafts and sealed ball bearings.

Flotation Suspended mower floats on four spring-assisted chains. 6 anti-scalp wheels are standard.

60” Side Discharge Deck Specifications Mowing Blades Heavy-duty,

heat-treated, high-lift steel blades.

21 INx 2.75

IN x .25 IN

(60Z deck with blade saddles) 21 IN x 3.00 IN x .25 IN (60Z deck without blade

saddles)

Blade Tip Speed

18,375

FPM

52” Side Discharge Deck Mowing Blades Heavy-duty,

heat-treated, high-lift steel blades.

18 IN x 3.00 IN x .25 IN

Blade Tip Speed

18,900 FPM

72” Side Discharge Deck Mowing Blades Heavy-duty,

heat-treated, high-lift steel blades.

IN x 3.00 IN x .25

Blade Tip Speed

18,525

FPM

ACCESSORIES Mulch Kit Recycles

clippings under deck allowing clippings to be cut and recut, then discharged down into the grass. Reduces handling of clippings, improves appearance, and recycles nutrients back into the soil.

BAC-VAC

Catcher Rear-

mounted, 9-bushel hopper is dumped from the seat without leaving the machine. Blower is powered from right-side deck spindle. Hopper and blower can be added or removed in seconds.

ENGINE SPECIFICATIONS

Kawasaki Kawasaki

Horsepower 23 25 No. of Cylinders 2 2 Displacement 41.2

CU IN

(675 CC) 41.2

CU IN

(675 CC) Compression Ratio 8.1:1 8.1:1 Max. Torque 39.8

FT LBS

@ 2400

RPM

41.0

FT LBS

@ 2400

RPM

Page 44

Page 45

350157 Rev 11/02

INDEX

PAGE

Access to engine and hydraulic pump..............................4-4

Adjustment introduction...................................................5-1

Anti-scalp wheels.............................................................5-7

Belt replacement...............................................................4-6

Brake specifications .........................................................9-1

Burnishing the electric clutch...........................................4-4

Capacities specification....................................................9-1

Construction specification................................................9-1

Control lever adjustment..................................................5-3

Control lever stops ...........................................................5-2

Controls............................................................................3-1

Controls specifications.....................................................9-1

Cup holder........................................................................9-1

Cutting height specifications............................................9-1

Decals...............................................................................2-2

Deck cutting height adjustment........................................5-7

Deck drive belt adjustment...............................................5-5

Deck leveling and height adjustment...............................5-5

Deck lift specifications.....................................................9-1

Deck warranty..................................................................1-2

Dimensions.......................................................................9-1

Driving the tractor............................................................3-3

Electrical system ..............................................................4-3

Engine air filter ................................................................4-6

Engine information...........................................................8-1

Engine oil and filter..........................................................4-6

Engine rpm setting ...........................................................5-5

Engine specifications .......................................................9-1

Engine starting .................................................................3-2

Frequently ordered parts ..................................................8-2

Fuel system.......................................................................4-5

General engine maintenance ............................................4-6

Hour meter .......................................................................4-3

Hustler Z Parts Manual.............................................8-1, 8-3

PAGE

Hydraulic pump belt adjustment......................................5-5

Hydraulic pump information............................................8-1

Hydraulic system..............................................................4-4

Indicators..........................................................................9-1

Instrumentation ................................................................3-2

Lubrication.......................................................................4-3

Maintenance introduction.................................................4-2

Model and serial number..................................................1-1

Moving tractor with stalled engine ..................................3-3

Mower blade maintenance ...............................................4-7

Mower blade removal ......................................................4-7

Mower deck operation......................................................3-4

New season preparation ...................................................7-1

Operating suggestions......................................................3-4

Park brake adjustment......................................................5-4

Parts and service...............................................................1-1

Preparation of engine for storage.....................................7-1

Reverse spring adjustment ...............................................5-3

Safety features specifications...........................................9-1

Safety start interlock system ............................................3-2

Seat...................................................................................9-1

Steering dampener............................................................5-3

Steering lever tension.......................................................5-2

Steering linkage................................................................5-1

Super Z Parts Manual ...............................................8-1, 8-3

Tires..................................................................................4-3

Tire specifications............................................................9-1

To the new owner.............................................................1-1

Torque values............................................................4-2, 5-1

Traction drive system specification .................................9-1

Tractor warranty...............................................................1-4

Using this manual.............................................................1-1

Warranty registration .......................................................1-1

Wheel motor information.................................................8-1

10-1

Hustler 350157 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual