HUSTLER Super Z HD General Service Manual

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Page 1

Super Z® HD

General Service Manual

117592 REV C

200 South Ridge Road Hesston, Kansas 67062

Page 2

The Engine Owner’s Manual provides information regarding the U.S. Environmental Protection Agency (EPA) and the California Emission Control Regulation of emission systems, maintenance and warranty.

Keep Engine Owner’s Manual with your unit. Should the Engine Owner’s Manual become damaged or illegible, replace immediately. Replacements may be ordered per the information found in the Product Information section of the owner’s manual.

Federal law and California State law prohibit the following acts or the causing thereof:

1. The removal or rendering inoperative by any person other than for purposes of maintenance, repair, replacement, of any device or element of design incorporated into any equipment for the purposes of emissions control prior to or after its sales or delivery to the ultimate purchaser or while it is in use, or

2. The use of the equipment after such device or element of design has been removed or rendered inoperative by any person.

WARNINGWARNING

The engine exhaust from this product

contains chemicals known to the state

of California to cause cancer, birth

defects or other reproductive harm.

NOTICE OF REQUIREMENT OF SPARK ARRESTER MUFFLER

This equipment may create sparks that can start fires around dry vegetation. California Public Resources Code Section 4442.6 provides that it is unlawful to use or operate an internal combustion engine on any forest-covered, brush-covered, or grass-covered la nd unless the engine is equipped with a spark arrester maintained in effective working order. A spark arrester is a device constructed of nonflammable materials specifically for the purpose of removing and retaining carbon and other flammable particles over 0.0232 of an inch in size from the exhaust flow of an internal combustion engine that uses hydrocarbon fuels or which is qualified and rated by the United States Forest Service. Other states or federal areas may have similar laws. The Operator Should Contact Local Fire Agencies For Laws or Regulations Relating to Fire Prevention Requirement s. THIS EQUIPMENT DOES NOT HAVE A SPARK ARRESTER AND YOU SHOULD CONTACT YOUR AUTHORIZED DEALER FOR THE PURCHASE OF A SPARK ARRESTER.

Inspect spark arrester daily; replace every 500 hours or as needed.

REV C 117592

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Table of Contents

General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Service Program. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Maintenance Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

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

Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Safe Servicing Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Pre-Operation Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Operation Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Operate Machine Safely. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

General Maintenance Precautions. . . . . . . . . . . . . . . . . . . . . . . 2-2

Maintenance Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Standard Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Special Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Power Unit Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Steering Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

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

Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Hydraulic Pump Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Test Procedure for DDC20 Pump . . . . . . . . . . . . . . . . . . . . . . . 4-7

New or Rebuilt DDC20 Pump Startup Procedure . . . . . . . . . . . 4-8

Warner Clutch Re-gap Adjustment Procedures. . . . . . . . . . . . 4-11

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

General Engine Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Engine Oil and Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Engine Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Carbon canister . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Fuel evaporation system filter . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Fuel & evaporative system line routings. . . . . . . . . . . . . . . . . . . 5-3

Engine RPM Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Deck Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Deck Leveling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Deck Belt Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

60”, 66” & 72” Side Discharge Deck Belt Routing & Tensioning 6-6

60” Rear Discharge Deck Belt Routing & Tensioning . . . . . . . . 6-7

117592 toc-1 REV C

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72” Rear Discharge Deck Belt Routing & Tensioning . . . . . . . . .6-8

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

Electrical Schematic – Kawasaki. . . . . . . . . . . . . . . . . . . . . . . . .7-1

Electrical Schematic – Kawasaki. . . . . . . . . . . . . . . . . . . . . . . . .7-2

Electrical Schematic – Kawasaki DFI . . . . . . . . . . . . . . . . . . . . .7-3

Electrical Schematic – Briggs & Stratton. . . . . . . . . . . . . . . . . . .7-4

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1

Maintenance Locator Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2

Maintenance Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-4

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1

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GENERAL INFORMATION

Service Program

This manual is part of a service package for the Hustler Super Z® HD mower. Use of this manual in conjunction with other Hustler information necessary to service and maintain Hustler

mower and component manuals will provide the

Super Z

HD mowers.

This General Service Manual is a service guide for use by Service Technicians. It provides the necessary information needed to perform normal maintenance requirements on these units.

The Parts Manual provides a complete parts listing for the unit. Use this manual when ordering parts.

The Operator's Manual provides fundamental operational information and operational safety that is needed when operating the mower.

The component manuals are furnished by the various manufacturers to be used for the troubleshooting and servicing of their components.

Maintenance Introduction

Regular maintenance is the best prevention for d owntime or premature failure. The following pages contain suggested maintenance information and schedules which the operator/ mechanic 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.

Clear away heavy build-up of grease, oil and dirt, especially in the engine compartment and under the seat platform areas;

minute dust particles 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 lesser quality of cut. Therefore it should be removed routinely.

To do this it will be necessary to raise and block the deck, using jack stands or blocks, 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

Turf Equipment service center when

assistance is needed.

Information included in this manual was 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 service manual contact the Customer Service Department at Hustler Equipment for additional information.

Warranty

Warranty repair must be performed by a Hustler® Turf Equipment Authorized Dealer before warranty credit can be allowed. Work performed by anyone other than an Authorized Dealer will invalidate the warranty claim and warranty credit will not be approved.

Turf

117592 1-1 REV C

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REV C 1-2 117592

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SAFETY

DANGER

WARNING

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.

– denotes immediate hazards which WILL result in severe personal injury or death.

– denotes a hazard or unsafe practice which COULD result in severe personal injury or death.

Safe Servicing Practices

This product is capable of amputating hands and feet and throwing objects. Always follow all safety instructions to avoid serious injury or death.

Understand Correct Service

 Be sure you understand a service procedure before you

work on the machine.

 Unauthorized modifications to the machine may impair

the function and/or safety and affect machine life.

 If it is necessary to make checks with the engine running,

always use two people - with the operator at the controls, able to see the person doing the checking.

Pre-Operation Precautions

Fuel Handling

 To avoid personal injury or property damage, use

extreme care in handling fuel. Fuel is extremely flammable and the vapors are explosive.

 Observe usual fuel handling precautions:

• Do not smoke while refueling. Extinguish all cigarettes, cigars, pipes and other sources of ignition.

• Do not remove fuel cap or fill tank with engine running or while engine is hot. Clean up any fuel spills.

• 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 or pilot light such as on a water heater or appliances.

• Use extreme care when handling gasoline and other fuels. They are extremely flammable and vapors are explosive. A fire or explosion from fuel can burn you and others and can damage property.

• Refuel outdoors. Never refuel or drain the fuel from the machine indoors.

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

• Store fuel in an approved container and keep it out of the reach of children. Never buy more than a 30 day supply of fuel.

• Do not fill fuel containers inside a vehicle or on a truck or trailer bed with interior carpets or plastic truck bed liners. Always place fuel containers on the ground away from your vehicle before filling.

• When practical, remove gas or diesel fuel powered equipment from the truck or trailer and refuel the equipment with its wheels on the ground. If this is not possible, then refuel such equipment on the truck or trailer using a portable container and not a fuel dispenser nozzle. If a fuel dispenser nozzle must be used, keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete. Do not use a nozzle lock-open device.

• Never use gasoline or diesel fuel for cleaning parts.

• Read and observe safety precautions elsewhere in this manual.

 Gasoline and diesel fuel is harmful or fatal if swallowed.

• Long-term exposure to vapors can cause serious injury and illness.

• Avoid prolonged breathing of vapors.

• Keep face away from nozzle and gas tank or fuel container opening.

• Keep fuel away from eyes and skin.

• If fuel is spilled on clothing, change clothing immediately.

Understand Machine Operation

 Only qualified and trained personnel should operate the

equipment.

 Carefully read the operator’s manual and all manuals fur-

nished with the attachments. Learn the location and purpose of all controls, instruments, indicators and labels.

Wear Protective Clothing

 Do not operate or service the equipment while wearing

sandals, tennis shoes, sneakers, shorts or any type of loose fitting clothing. Long hair, loose clothing or jewelry may get tangled in moving parts. Always wear long pants, safety glasses, ear protection and safety shoes when operating or servicing this machine.

 Always wear adequate eye protection when servicing the

hydraulic system and battery, or when grinding mower blades and removing accumulated debris.

 Prolonged exposure to loud noise can cause impairment

or loss of hearing.

• Always wear adequate ear protection, such as earplugs, when operating this equipment as prolonged exposure to uncomfortable or loud noises can cause impairme nt or loss of hearing.

117592 2-1 REV C

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• Do not wear radios or music headphones while operating the machinery. Safe operation requires your full attention.

Operation Precautions

Avoid Fire Hazards

 Clean flammable material from machine. Prevent

fires by keeping engine compartment, top of deck, exhaust area, 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.

Start Engine Safely

 Avoid possible injury or death from machine runaway.  Do not start engine by shorting across starter terminals.  Before you start the engine:

• Sit on the operator’s seat.

• Move control levers to the neutral/brake position.

Operate Machine Safely

 Refer to the unit’s operator’s manual for complete safety

information on safe machine operation.

 Always maintain a safe distance from people and pets

when mowing

 Always be aware of what is behind the machine before

backing up.

 Never leave machine unattended with ignition key in

switch, especially with children present.

 Follow daily and weekly checklists, making su re hoses

are tightly secured and bolts are tightened.

 Always keep engine and machine clean, removing accu-

mulated dirt, trash and other material from machine.

 Never put hands or feet under any part of the machine

while it is running.

 Never attempt to start engine when there is a strong odor

of gasoline fumes present. Locate and correct cause.

 Keep all safety shields and covers in place, except for

servicing.

 Do not touch hot parts of machine.

General Maintenance Precautions

sure proper ventilation is available when engine must be operated in an enclosed area.

 Before working on or under the deck, make certain

engine cannot be accidentally started. Shut engine off, remove ignition switch key and disconnect negative battery cable for maximum safety.

 Except when changing or checking belt, always keep belt

covers on mower deck for safety as well as cleanliness.

 Use a stick or similar instrument to clean under the

mower making sure that no part of the body, especially arms and hands are under mower.

 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. Clean up oil or fuel spillage. Allow machine to cool before storing.

 Always wear adequate eye protection when servicing the

hydraulic system and battery, or when grinding mower blades and removing accumulated debris.

 Never attempt to make any adjustments or repairs to the

mower drive system, mower deck or any attachment while the engine is running or deck clutch is engaged.

 Exercise caution when releasing spring tension from any

of the belt idlers or when working with any of the deck lift components.

 Never work under the machine or attachment unless it is

safely supported with jack stands. 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. Use only appropriate jack stands, with a minimum weight rating of 2000 pounds to block the unit up. Use in pairs only. Follow the instructions supplied with the vehicle stands.

 Keep nuts and bolts tight, especially the blade attachment

bolts. Keep equipment in good working condition.

 Never tamper with safety devices. Check their proper

operation regularly.

 Exercise caution when working under the deck as the

mower blades are extremely sharp. Wrap the blade(s) or wear gloves and use extra caution when servicing them.

 Use only genuine Hustler

that original standards are maintained.

replacement parts to ensure

 Repairs or maintenance requiring engine power

should be performed by trained maintenance personnel only.

 Never run the engine in an enclosed area unless exhaust

is vented to the outside. Exhaust gases contain carbon monoxide which is an odorless and deadly poison.

 Unless specifically required, DO NOT have engine run-

ning when servicing or making adjustments to mower. Park the machine on level ground. Place steering control levers in the park brake position, disengage deck clutch, lower deck, remove ignition switch key and disconnect negative battery cable before doing any maintenance. Wait for all movement to stop before adjusting, cleaning or repairing. To prevent carbon monoxide poisoning, be

REV C 2-2 117592

Maintenance Precautions

Avoid Fire Hazards

 Be prepared if an accident or fire should occur. Know

where the first aid kit and the fire extinguishers are located and how to use them.

 Provide adequate ventilation when charging batteries.  Do not smoke near battery.  Never check fuel level with an open flame.  Never use an open flame to look for leaks anywhere on

the equipment.

 Never use an open flame as light anywhere on or around

the equipment.

 When preparing engine for storage, remember that fuel

stabilizer is volatile and therefore dangerous. Seal and

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tape openings after adding the inhibitor. Keep container tightly closed when not in use.

 Inspect electrical wiring for worn or frayed insulation.

Install new wiring if wires are damaged.

Prepare For Emergencies

 Be prepared if a fire starts.  Keep a first aid kit and fire extinguishers available.  Keep emergency numbers for doctor, ambulance service,

hospital, and fire department near the telephone.

Prevent Battery Explosions

 Battery posts, terminals, and related accessories contain

lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.

 Charge batteries in an open well-ventilated area, away

from sparks and flames. Unplug charger before connecting or disconnecting from battery. Wear protective clothing and use insulated tools.

 Avoid skin and clothing 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 drink the battery electrolyte.

• Do not allow open flame near the battery when charg-

ing.

• Hydrogen gas forms inside the battery. This gas is both

toxic and flammable and may cause an explosion if exposed to flame. Always disconnect the negative (black) battery cable(s) before disconnecting the positive (red) cable(s). Always connect the positive (red) battery cable(s) before connecting the negative (black) cable(s).

• 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. Clean the battery terminals with a solution of four

parts water and one part baking soda when they become corroded.

 Shorts caused by battery terminals or metal tools touch-

ing metal mower components can cause sparks. Sparks can cause a battery gas explosion which will result in personal injury.

• Prevent the battery terminals from touching any metal mower parts when removing or installing the battery.

• Do not allow metal tools to short between the battery terminals and metal mower parts.

 Incorrect battery cable routing could cause damage to the

mower and battery cables. This can cause sparks which can cause a battery gas explosion which will result in personal injury. Always disconnect the negative (black) battery cable(s) before disconnecting the positive (red) cable(s). Always connect the positive (red) battery cable(s) before connecting the negative (black) cable(s).

Avoid Acid Burns

 Sulfuric acid in battery electrolyte is poisonous. It is

strong enough to burn skin, eat holes in clothing and cause blindness if splashed in eyes.

Avoid the hazard by:

• Filling batteries in a well-ventilated area.

• Wearing eye protection and rubber gloves.

• Avoiding breathing fumes when electrolyte is added.

• Avoiding spilling or dripped electrolyte.

If you spill acid on yourself:

• Flush your skin with water.

• Apply baking soda or lime to help neutralize the acid.

• Flush your eyes with water for 10-15 minutes. Get medical attention immediately.

If acid is swallowed:

• Drink large amounts of water or milk.

• Then drink milk of magnesia, beaten eggs or veget able oil.

• Get medical attention immediately.

117592 2-3 REV C

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REV C 2-4 117592

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TORQUE

WARNING

Standard Torques

The following chart lists the standard torque values for the threaded fasteners found in this manual. Torque all cap screws, nuts and

set screws to these values unless a different torque is shown in the Special Torques section.

SIZE FT-LBS N-M SIZE FT-LBS N-M

#10 32.4 IN.-LBS. 3.6 M3 12 IN.-LBS. 1.3 .250 98.4 IN.-LBS. 11.1 M4 26.4 IN.-LBS. 3 .312 204 IN.-LBS. 23 M5 54 IN.-LBS. 6.1 .375 30 40 M6 92.4 IN.-LBS. 10.4 .438 48 65 M8 222 IN.-LBS. 25 .500 73 99 M10 37 50 .562 105 143 M12 64 87 .625 145 200 M14 103 140 .750 260 350 M16 160 215 .875 420 565 M20 320 435

Special Torques

DESCRIPTION FT-LBS N-M

Wheel (lug) nuts

Blade spindle bolt top 70 95

Blade spindle bolt bottom 118 160

Electric clutch mounting bolt

Front wheel axle bolt 100 136 Wheel motor hub nut 230 312

Hydraulic pump pulley screw 14 19

Engine torques

NOTE:

1. Lug nuts only – It is recommended that these be checked

after the first 2 hours of operation and every 50 hours and following removal for repair or replacement.

2. Engine torque values – Refer to the respective engine

owner’s manual.

3. If clutch mounting bolt is loosened or removed, do not re-use. Replace with a new bolt. Use only hand tools to

install this fastener.

70 95

47 64

N/A N/A

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

117592 3-1 REV C

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REV C 3-2 117592

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POWER UNIT MAINTENANCE

WARNING

Mower

harness

Seat

switch

Female spades

Mower

harness

Female spades

Steering Adjustments

Steering control lever neutral adjustment

The mower’s steering has been factory adjusted to eliminate creeping when the steering control levers are in the neutral position. However, should the mower begin to creep, the steering control lever linkage can be adjusted.

Before considering any adjustment, check the tire air pressure. Unequal tire pressure will cause the mower to drift to one side. Refer to tire pressure information in the Tires section for detailed information.

NOTE: Proper park brake adjustment must be completed

before the steering control lever neutral adjustment can be done. Refer to the Park Brake Spring Adjustment section for detailed information.

Fine adjustment to the unit’s steering is made with the transmission’s control rod.

Neutral is properly adjusted when the steering control levers are in the park brake position and the transmissions do not “whine”.

If this occurs, the steering control linkage may be adjusted as follows:

1. On the other seat you will disconnect the wire harness from the two connectors as shown in Figure 4-2.

Figure 4-1

This procedure will require that the unit be raised and blocked up off of the ground. It is necessary for the wheels to rotate without coming in contact wi th the floor or any object that would permit the unit to propel it self. Stay clear and exercise caution when rotating wheels to prevent injury. Use only appropriate vehicle stands, with a minimum weight rating of 2000 pounds to block the unit up. Use in pairs only. Follow the instructions supplied with the vehicle stands.

Untrained maintenance personnel should never attempt to make any adjustments or repairs to the mower’s drive system while the engine is running. The following proce-

dures should be performed by trained maintenance personnel only.

1. Raise the rear of the mower and block with certified jack

stands. The rear wheels need to be able to rotate freely and clear of all obstructions.

2. Chock the front tires.

3. Raise the seat platform and disconnect the mower harness

117592 4-1 REV C

Figure 4-2

4. Start the engine.

5. Position the steering control lever in the neutral position

and observe which way the wheels are rotating. Figure 43

6. 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. Figure 4-4

7. Repeat for the opposite side if necessary.

8. 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. Figure 4-4

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Figure 4-3

Park

brake

slot

Control

levers

Steering control levers in neutral position

Jam nut

Pump

arm

Pump linkage rod

WARNING

properly. Figure 4-1 & Figure 4-2

Do not operate the mower without plugging the mower ’s wiring harness into the seat switch. This switch is an important part of the safety start interlock system. Serious injury can result if the seat switch is not plugged into the mower’s wiring harness.

Never operate the mower with a non-functioning seat switch. Always reconnect the seat switch to the mower harness.

13. Check to make sure all tools or obstructions are removed

from under the mower.

14. Raise the rear of the mower and remove the jack stands.

Lower the mower.

15. Lower and secure the seat platform.

Control lever stops

The internal steering control lever stops (see Figure 4-5) are designed to keep the pumps from bottoming out internally. The external steering control lever stops (Figure 4-6) may be adjusted to help the mower drive straight when the steering control levers are pushed forward against the stops.

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

This adjustment is only required if the hydraulic pump(s) have been replaced.

Figure 4-4

Repeat for the opposite side if necessary

9. When both wheels remain in neutral, tighten the jam nuts

to lock the turnbuckle in place.

10. Test again by moving the steering 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.

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

adjust the control lever stop and/or damper.

12. IMPORTANT: With the engine off, disconnect the two

female spade connectors from each other (from step #3) and reconnect them to the seat switch. This must be completed so that the safety circuit is functioning

REV C 4-2 117592

Pump damage will occur if these stops are set incorrectly.

1. To make the first adjustment the mower engine must not

be running.

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

the stops before the pumps are bottomed out internally.

3. To do this, gently and slowly move the steering 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, turn the stop (set screw) inward to stop the steering control levers slightly before the pump bottoms out. Lock in place when the adjustment is correct by re-tightening the jam nut. Do this for each side.

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

1. Determine which drive tire is rotating too fast when both

steering control levers are against the stops in the control

Page 15

Figure 4-5

Stop screw

Steering

damper

Steering

control

lever

Stop

Jam nut

Control

levers

Steering control levers in neutral position

Steering damper

spring housing

Rear ball stud

panel (see Figure 4-6).

2. Then, stop the mower and loosen the lock nut on the side

which is rotating too fast and turn the stop (set screw) inward to stop the steering control lever sooner. Tighten the lock nut on the stop and test again.

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

1. Shut engine off, place steering control levers in the park

brake position, disengage deck clutch, remove ignition switch key and disconnect negative battery cable before doing any adjustments.

2. Place the steering control lever in the neutral position.

Figure 4-7

3. Loosen the steering damper’s rear ball stud. Figure 4-8

4. Pull the damper spring housing past the point that the

internal spring is engaged. Figure 4-8

5. Release the damper spring housing and allow the internal

spring to bring the housing back to the neutral position.

6. Tighten the nut on the steering damper’s front ball stud.

NOTE: The damper must not bottom out when the pump lever is fully stroked in either direction.

7. Reconnect the negative battery cable.

8. Lower and secure the seat platform.

9. To check, move the steering control lever to the reverse

position and release. The steering control lever should return to the neutral position. If not, repeat steps 1 through 6.

Figure 4-6

Steering damper

The steering dampers are 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 dampers in the correct operating position follow these steps:

117592 4-3 REV C

Figure 4-7

Figure 4-8

Page 16

Steering control lever adjustment

Cap

screws

Align steering

control lever

±.125” (3.175mm)

WARNING

Brake link

The steering control levers can be adjusted for operator

comfort.

1. By loosening the cap screws that attach the upper control

lever to the lower lever the upper control lever can be pivoted to fit the operator’s personal preference (see Figure 4-9)

2. The steering control levers should be adjusted so that

they align vertically with each other when in the neutral position. Figure 4-10

Park brake adjustment

This procedure will require that the unit be raised and blocked up off of the ground. It is necessary for the wheels to rotate without coming in contact with the floor or any object that would permit the unit to propel itself. Stay clear and exercise caution when rotating wheels to prevent injury. Use only appropriate vehicle stands, with a minimum weight rating of 2000 pounds to block the unit up. Use in pairs only. Follow the instructions supplied with the vehicle stands.

1. Shut engine off, place steering control levers in the park

brake position, disengage deck clutch, remove ignition switch key and disconnect negative battery cable before doing any adjustments.

2. Raise the rear of the mower and block with certified jack

stands. The rear wheels need to be able to rotate freely and clear of all obstructions.

3. Chock the front tires.

4. Position the steering control levers in the neutral position.

NOTE: The front brake link is not to be adjusted. Figure 4-11

Figure 4-9

Figure 4-10

REV C 4-4 117592

Figure 4-11

5. Open the hydraulic pump’s bypass valve, on the side that

is being adjusted, by turning the bypass valve counter clockwise one-half to one revolution. Figure 4-12

6. Try and rotate the tire by hand. 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.

7. Move the steering control lever to where it is just in side

(1/8” [3.175mm]) the park brake slot. Figure 4-13 NOTE: When the steering control lever is against the outside edge of the slot, the brakes should not be engaged.

8. 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:

Page 17

Figure 4-12

Bypass valve

Control lever

Park

brake

slot

Outside

edge

1/8”

(3.175mm)

Jam nuts

10. Repeat steps 4 through 9 for the other side.

11. Check to make sure all tools or obstructions are removed

from under the mower.

12. Raise the rear of the mower and remove the jack stands.

Lower the mower.

13. Reconnect the negative battery cable.

14. Lower and secure the seat platform.

Figure 4-14

Belts

Inspect belts frequently for wear and serviceability. Replace a belt that shows signs of severe cuts, tears, separation, weather checking and cracking, or burns caused by slipping. Slight raveling of belt covering does not indicate failure; trim ravelings with a sharp knife.

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, the 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.

Figure 4-13

a. Loosen the brake linkage jam nuts. (Figure 4-14)

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. Re-tighten the jam nuts on the turnbuckle.

b. Place the control lever in the park brake slot. The tire

should not rotate when the control lever is in the park brake position. Figure 4-13

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

should rotate freely.

9. Close the hydraulic pump’s bypass valve. Figure 4-12

117592 4-5 REV C

Hydraulic Pump Belt Adjustment

The transmission drive belt tension remains constant by means of a tension idler and spring. 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 the belt stretches and wears in, adjustment may become necessary.

The proper belt tension is achieved when the tension spring is stretched to a dimension of 8.75” – 9.25” (222 – 235mm) when measured from the outside of the hook to the outside of the other hook. Figure 4-15

To increase belt tension, loosen the jam nut on the eye bolt. Then, tighten the nut on the eyebolt until the 8.75” – 9.25” (222 – 235mm) dimension is attained. Lock the eyebolt in place by tightening the jam nut. Figure 4-15

IMPORTANT: Do not over tensio n the spring to compensate for a badly worn belt or pulley. Figure 4-15

Inspect the belt every 100 hours and replace as needed. Replace the belt every 400 hours or every two (2) years

Page 18

whichever comes first.

WARNING

Bottom View

Hydraulic

pump belt

Tension idler

Spring

Jam nut

Nut

8.75”- 9.25”

Hydraulic

reservoir

Heat exchanger

If the transmission belt fails, loss of control will occur especially when operating on a slope. If you lose steering control while operating the machine, place the steering control levers in the park brake position immediately. Inspect the machine and involve your dealer to resolve the problem.

only 15W50 Mobil One oil.

NOTE: The reservoir will require approximately 3 U.S. gal-

lons (11.35 liter) of 15W50 Mobil One oil when replacing the oil after an oil and filter change. Do not overfill the reservoir.

Change hydraulic system filter element and oil after first 50

hours of mower operation, then replace filter and oil in reservoir every 500 hours thereafter.

IMPORTANT: It is necessary to drain the system oil from

the hydraulic reservoir, using the reservoir drain plug, before removing the hydraulic filter. Replace the drain plug before adding system oil.

The system filter is located inside the hydraulic reservoir on

the underneath side of the tank. Use a Hustler

approved filter

element only. When changing the filter use a 15/16” socket.

The threads are right hand.

Figure 4-15

Hydraulic system

IMPORTANT: Never use hydraulic or auto matic transmis-

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

Hydraulic fluid escaping under pressure may have sufficient force to penetrate skin and cause serious injury. Foreign fluid injected into the skin must be surgically removed within a few hours by a doctor, familiar with this form of injury, or gangrene may result. 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.

Check oil level in hydraulic system after every 50 hours of operation or weekly, whichever occurs first. Check more often if system appears to be leaking or otherwise malfunctioning. Figure 4-16

Fluid level should be 1” (25.4mm) from top of reservoir. Use

Figure 4-16

Hydraulic oil heat exchanger

The Super Z® HD is equipped with a hydraulic oil heat exchanger. The heat exchanger coils must be kept clean to insure that the hydraulic oil is operating within the correct temperature range.

Check and clean the heat exchanger daily and more often in dirty, dusty conditions. Figure 4-17

Figure 4-17

REV C 4-6 117592

Page 19

Test Procedure for DDC20 Pump

WARNING

Mower

harness

Seat

switch

Female spades

Mower

harness

Female spades

Equipment required

Hustler Pressure Test Gauge Kit, part number 007898

Pump test procedure:

This procedure will require that the unit to be raised and blocked up off of the ground. It is necessary for the wheels to rotate without coming in contact wi th the floor or any object that would permit the unit to propel it self. Stay clear and exercise caution when rotating wheels to prevent injury. Use only appropriate vehicle stands, with a minimum weight rating of 2000 pounds to block the unit up. Use in pairs only. Follow the instructions supplied with the vehicle stands.

Figure 4-18

Untrained service personnel should never attempt to make any adjustments or repairs to the mower’s drive system while the engine is running. The following proce-

dures should be performed by trained service personnel only.

The drive system of this mower consists of two independent pump/motor combinations and will need to be tested separately. The oil supply (reservoir), filtering system (located in the bottom of the reservoir) and oil cooler are shared between the two independent systems. The testing sequence below is testing the hydrostatic pumps (only). If the test shows satisfactory results but performance is still deemed unacceptable, the motors, filtering, oil cooler and reservoir should be inspected.

1. Raise the rear of the mower and block with certified jack

stands. The rear wheels need to be able to rotate freely and clear of all obstructions.

2. Chock the front tires.

3. Raise the seat platform and disconnect the mower harness

from the seat switch. Bypass the seat switch by connecting the two mower harness female spades together. NOTE: There are two different seat options available for this mower. On one seat you will disconnect the mower harness directly from the seat switch as shown in Figure 4-18. On the other seat you will disconnect the wire harness from the two connectors as shown in Figure 4-19. NOTE: Remove the tire and wheel assembly.

4. Clean hydraulic oil lines connecting to motor thoroughly.

(Contamination allowed to enter in the hydrostatic system can cause pump and motor failures)

5. After cleaning, remove oil supply lines from the motor

and loosen supply lines at the pump. One wheel motor fitting may need to be removed to assist with test line installation. Cap the wheel motor ports or fittings.

117592 4-7 REV C

Figure 4-19

6. Test procedures are the same for both the right and left

sides.

7. Install Hustler Test Gauge Kit (p/n 007898) as shown in

Figure 4-20 and Figure 4-21. Check the bypass valve (tow valve) to make sure it is fully seated. Figure 4-22

8. Recheck hose and fittings to ensure they are tight.

9. Check oil reservoir for proper oil level and make sure

hydraulic filter is in good condition.

Page 20

Before applying pressure to hydraulic system, make

WARNING

Cap fitting

Supply

lines

Pressure Test Gauge Kit

shown installed

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.

10. Run engine at mid throttle for one or two minutes or until

top of pump is warm to the touch.

11. Increase engine speed to full throttle.

12. Slowly move the steering control lever forward. You

should easily get a 2600 PSI reading from one of the gauges. Return steering control lever to neutral. (Caution do not hold steering control lever in forward position for more than 10 seconds as oil will become extremely hot). Then, slowly move steering control lever in reverse, You should easily get a 2600 PSI reading from the other gauge. (Caution do not hold steering control lever in rearward position for more than 10 seconds as oil will become extremely hot). If pressure is less than 2600 PSI, causes are; internal relief valve is faulty or internal pump parts are damaged.

NOTE: Anytime a hydraulic pump is replaced the drive

motor, hydraulic lines a nd oil cooler must be inspected and cleaned or replaced due to possible contamination.

After testing is concluded

1. IMPORTANT: With the engine off, disconnect the two

female spade connectors from each other (from step #3) and reconnect them to the seat switch. This must be completed so that the safety circuit is functioning properly. Figure 4-1

Figure 4-20

Never operate the mower with a non-functioning seat switch. Always reconnect the seat switch to the mower harness.

2. Remove Hustler Pressure Test Gauge Kit.

3. After all repairs are completed, check to make sure all

tools and obstructions are removed from under the mower.

4. Raise the rear of the mower and remove the jack stands.

Lower the mower.

Figure 4-21

New or Rebuilt DDC20 Pump Startup Procedure

NOTE: Use this startup procedure any time a DDC20 pump

has been removed for service or replaced.

REV C 4-8 117592

Page 21

Figure 4-22

WARNING

RH Pump as viewed

from rear of mower

Bypass valve

(Tow valve)

Top of pump

Mower

harness

Seat

switch

Female spades

Mower

harness

Female spades

Pump replacement:

Untrained maintenance personnel should never attempt to make any adjustments or repairs to the mower’s drive system while the engine is running. The following proce-

dures should be performed by trained maintenance personnel only.

1. Raise the rear of the mower and block with certified jack

stands. The rear wheels need to be able to rotate freely and clear of all obstructions.

2. Chock the front tires.

3. Raise the seat platform and disconnect the mower harness

from the seat switch. Bypass the seat switch by connecting the two mower harness female spades together. NOTE: There are two different seat options available for this mower. On one seat you will disconnect the mower harness directly from the seat switch as shown in Figure 4-23. On the other seat you will disconnect the wire harness from the two connectors as shown in Figure 4-24.

117592 4-9 REV C

Figure 4-23

Figure 4-24

4. Before installing pump on machine, (either new or

rebuilt) fill pump case with fresh, clean oil by removing case drain plug and add 6 - 8 oz. of 15W50 Mobil 1 oil, then install the hose fitting. Figure 4-25

5. Install pump on machine and install lines.

6. Check reservoir for contamination, metal particles, dirt,

water, etc. and clean if necessary. Replace hydraulic filter and fill reservoir with oil until it is just below the reservoir neck.

7. Do not open tow valves.

8. Place the steering control levers in the neutral position.

9. Set engine throttle to the half throttle position.

10. Start engine. Run at idle for 30 seconds.

11. Stroke steering control lever to the forward position.

NOTE: If wheel motor does not rotate in 15 seconds, return steering control lever to neutral and shut off engine. Check hydraulic oil level and replenish if needed. Repeat steps 8 thru 11.

12. After wheel motor starts to rotate, increase engine speed

Page 22

Prefill pump

here

Right side pump

Prefill pump

here

Left side pump

WARNING

Do not operate the mower without plugging the mower ’s

WARNING

Mower

harness

Seat

switch

Female spades

Mower

harness

Female spades

wiring harness into the seat switch. This switch is an important part of the safety start interlock system. Serious injury can result if the seat switch is not plugged into the mower’s wiring harness.

Never operate the mower with a non-functioning seat switch. Always reconnect the seat switch to the mower harness.

Figure 4-25

to half throttle and stroke the steering control lever forward and reverse several times until the wheel motor operates smoothly through the entire speed range.

13. IMPORTANT: With the engine off, disconnect the two

female spade connectors from each other (from step #3) and reconnect them to the seat switch. This must be completed so that the safety circuit is functioning properly. Figure 4-26 & Figure 4-27

REV C 4-10 117592

Figure 4-26

Figure 4-27

14. Check to make sure all tools or obstructions are removed

Page 23

from under the mower.

WARNING

Be certain that the gap between the

rotor and armature face is greater

than .070” prior to shim removal.

15. Raise the rear of the mower and remove the jack stands.

Lower the mower.

16. Lower and secure the seat platform

Warner Clutch Re-gap Adjustment Procedures

The air gap is only adjustable on clutches that have a removable shim (see Figure 4-32).

When to remove shim:

When a clutch has worn to the extent that the existing air-gap is too large to allow for complete clutch engagement (clutch may engage easily when cold but has problems eng aging when hot), the brake shim can be removed to reduce air gap and allow the clutch to continue to function.

After verifying that proper voltage and current are supplied to the clutch, follow the procedure outlined below.

NOTE: Before proceeding, the clutch must be installed on

the engine crankshaft and the retaining bolt torqued to 45-48 ftlbs.

Figure 4-29

Figure 4-28

Procedure:

Always wear adequate eye protection when servicing the mower.

With engine off, key removed and clutch disengaged and using a pneumatic line, blow out any debris from under the brake pole and around the aluminum spacers. Figure 4-29

Check the air gap between rotor & armature with feeler gage. If the gap is less than .070”, then follow the troubleshooting procedure outlined in Warner Electric P1177 installation troubleshooting guide available on Warner Electric’s web sitewww.Warnerelectric.com. If the air gap is over .070”, follow the procedure outlined below. Figure 4-30

1. Loosen both brake mounting bolts 1/2 to 1 full turn as

117592 4-11 REV C

Figure 4-30

shown in Figure 4-31.

Do not remove brake pole from field shell/armature. The brake pole tracks match with the clutch brake and need to continue to match after shim is removed to ensure prop er brake torque. Figure 4-28

2. Using needle nose pliers, or by hand, take hold of the tab

and remove shim (do not discard shim until prop er cl utch function has been confirmed). Figure 4-32

3. Using a pneumatic line, blow out any debris from under

the brake pole and around the aluminum spacers. Figure 4-29

4. Re-torque each bolt (M6 X 1) to 120 in.-lbs.

5. Using a .015” thick feeler gage, verify that a gap is

present between the rotor and armature face on both ends of the brake pole as shown. Figure 4-33 and Figure 4-34 a. If the gap is less than .015” the clutch must be

Page 24

Figure 4-31

WARNING

M6 x 1 bolt

Figure 4-33

Figure 4-32

replaced

b. If sufficient gap is present, then proceed to safety

check outlined below.

Perform safety check:

Observe deck operation from the operator’s seat.

1. Start the engine and the deck should not be engaged with

the PTO switch “off” and clutch de-energized. Engage and disengage the PTO switch to ensure the proper function of the clutch.

2. If clutch still does not engage, then follow the

troubleshooting procedure outlined in Warner Electric

Figure 4-34

P1177 installation troubleshooting guide available on Wa rner Electric’s web site-www.Warnerelectric.com and consult owner’s manual.

Tires

It is important for level mowing that the tires have the same

amount of air pressure. The recommended pressures are:

Drive wheels . . . . . . . . . . . . . . . . . . . . . 8-12 psi (55-83 KPa)

Front wheels . . . . . . . . . . . . . . . . . . . . . 8-12 psi (55-83 KPa)

If you wish to use non-pneumatic tires on your Hustler

mower the tires must be an approved tire purchased from

Hustler any mower equipped with unapproved non-pneumatic tires.

Turf Equipment. Warranty claims will be denied on

REV C 4-12 117592

Page 25

ENGINE MAINTENANCE

WARNING

Oil drain valve

Pre-cleaner

Canister

Dust cap

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 engine manufacturer.

Engine Oil and Filter

If the engine has been running and is up to operating temperature, allow the engine to cool before changing the oil. Engine and engine oil will be very hot, so be very careful when changing oil and wear the appropriate protective gear to avoid being burned or exposed to engine oil.

Check engine oil daily and after every 4 hours of operation. Machine must be setting level when checking oil. Refer to engine manual and maintenance schedule for oil recommendation and capacities.

IMPORTANT: Change the engine oil and filter after the

first 5 hours of operation and per the engine manufacturer’s recommendations after that. If mower is being operated in extremely dirty conditions, then it is recommended oil be changed more frequently .

IMPORTANT: When removing the oil filter take precau-

tions to minimize oil spillage on the exhaust system.

Draining the engine oil:

1. Locate the oil drain valve on the engine. Figure 5-1,

2. Position a suitable oil drain container under the machine

below the oil drain valve.

3. Twist the valve counterclockwise to open the valve.

Allow 10 minutes for engine oil to adequately drain.

4. After oil is drained, close the valve by twisting it

clockwise.

5. Clean up any spilled oil.

IMPORTANT: All oil d rip s or spills must be cleaned off of the exhaust system before operating the machine.

Figure 5-1

Engine Air Filter

Perform engine air filter maintenance per the Maintenance

Schedule shown elsewhere in this manual.

A specially designed dry filter is standard equipment on these mowers and supplies clean combustion air to the engine. Figure 5-2

These mowers are equipped with a safety filter. The filter element slides over the safety filter. Figure 5-3

The safety element does not require servicing unless it becomes contaminated with dirt or moisture.

117592 5-1 REV C

Figure 5-2

Recommended service procedure

1. Release clamps and remove element. Clean the canister

with a damp cloth.

2. Before installing a new element, inspect it by placing a

bright light inside and rotating the element slowly, looking for any holes or tears in the paper. Also check gaskets for cuts or tears. Do not attempt to use a damaged

Page 26

Figure 5-3

Safety filter

Reset

button

Indicator

element which will allow abrasive particles to enter the engine.

3. Reinstall the dust cap. Make sure it seals all the way

around the air cleaner body, then tighten the clamps. Figure 5-2

4. Check all fittings and clamps periodically for tightness

and inspect hoses for holes or cracks.

5. Periodically check the intake hose for signs of ingested

dust. Locate and repair the source of ingested dirt.

6. Never operate the machine without an air filter installed.

Overservicing

Overservicing occurs when an air filter element is removed for cleaning or replacement before it is necessary. Each time the filter is removed a small amount of dirt and dust could fall in the intake system. This accumulated dirt can cause a dusted engine. It only takes a few grams of ingested dirt over the normal service life of an engine to cause a dusted engine.

Do not clean the element, but replace with a new element only. Cleaning used air filter elements, through improper

cleaning procedures, can get dust on the inside of the filter causing dirt ingestion and engine failure.

It is important to note that whenever an air filter element is cleaned by any method, the person or company performing the cleaning assumes responsibility for the integrity of the filter from then on. The warranty for air filters expires upon

cleaning or servicing in any manner because the condition of the filter after servicing is completely out of the filter manufacturer’s control. Ther efor e, on a dust inge sted engine failure, there will be no warranty consideration if the air filter element has been cleaned or serviced in any manner.

A partially dirty air filter element works better than a new element. Therefore, a dirty filter element is not bad for the engine unless it is excessively restricting the air flow and engine performance is affected. The reason is simple. The media in the filter must be porous to allow air to pass through it. When dirty air passes through the filter, the dirt plugs some of the holes in the media and actually acts as part of the filter media. When the next round of dirt enters, the first dirt helps filter out even smaller particles making the filter more efficient at stopping dirt from entering the engine. This is referred to as barrier filtration.

Of course, at some point the filter media becomes too clogged

to allow air to pass.

The mowing conditions will determine the frequency of air

filter element changing.

Air restriction indicator

These units have an air restriction indicator installed in the air

cleaner. Figure 5-4

Replace the element whenever the restriction indicator reaches the change filter red line. Check the indicator daily and replace element as needed or annually whichever occurs first.

Reset the indicator by pushing in on the yellow button after each element change. Figure 5-4

Figure 5-4

REV C 5-2 117592

Page 27

Carbon canister

Carbon

canister

Fuel evaporation

system filter

Fuel evaporation

system filter

Carbon

canister

Fuel evaporation

system filter

Fuel line

Fuel

shutoff

valve

Fuel tank

Fuel line

Seat support

Fuel evaporation

system filter

Vapor line

Tee

Fuel tank

Tee

Vapor line

Fuel & evaporative system line routings

Some Hustler® Super Z HD mowers will have a carbon

canister incorporated into the fuel system. Figure 5-5

This is a mandatory feature that is required on all mowers

using gasoline engines that are put into operation in California.

These canisters should be replaced every 5 years or if they

become damaged.

There are two rubber hoses that are connected to the fuel tanks. One is the fuel hose that is part of the fuel system. The other is the vapor line that is part of the fuel evaporative system.

The fuel hose is connected to the fuel tank as shown. It connects the fuel tank to the fuel shutoff valve. Figure 5-7

The vapor line is connected to the fuel tank as shown. It connects the fuel tank to the engine’s vapor port. Figure 5-8 & Figure 5-8

Fuel evaporation system filter

Some Super Z® HD mowers have a fuel evaporation system filter. This filter must be checked and replaced every 500 hours or annually whichever comes first. Figure 5-6

Figure 5-5

Figure 5-7

Figure 5-8

Figure 5-6

117592 5-3 REV C

Page 28

Figure 5-9

Fuel evaporation

system filter

Vapor line

Fuel tank

Carbon

canister

Carbon

canister

REV C 5-4 117592

Page 29

Engine RPM Settings

The engine rpm’s are set at the factory for maximum mowing efficiency. Occasionally it may be necessary to check and adjust the settings. The high idle speeds, with no load, should be set as follows:

Kawasaki FX850 & FX1000

ENGINE SPEED

MODEL NO. ENDING WITH: HIGH IDLE

MODEL NO. WITHOUT EXTENSION 3600 RPM

MODEL NO. WITH EX EXTENSION 3600 RPM

MODEL NO. WITH US EXTENSION 3600 RPM

Kawasaki FX1000VDFI

ENGINE SPEED

MODEL NO. ENDING WITH: HIGH IDLE

MODEL NO. WITHOUT EXTENSION 3600 RPM

MODEL NO. WITH EX EXTENSION 3600 RPM

MODEL NO. WITH US EXTENSION 3600 RPM

Briggs & Stratton Vanguard M61

ENGINE SPEED

MODEL NO. ENDING WITH: HIGH IDLE

MODEL NO. WITHOUT EXTENSION 3600 RPM

MODEL NO. WITH EX EXTENSION 3600 RPM

MODEL NO. WITH US EXTENSION 3600 RPM

NOTE: Model numbers may or may not end with an extension after the number. There are several different extensions that may be shown; i.e. EX or CE.

Example: 922222 (no extension)

922222 EX 922222 CE 922222 US

117592 5-5 REV C

Page 30

REV C 5-6 117592

Page 31

DECK ADJUSTMENTS

WARNING

Locator triangle

3.75” Block

60” Rear Discharge Deck shown

3” Block

3.75” Block

Stop

handle

Clamp here

Deck adjustment stop

Deck Leveling

Leveling the deck must be done in the following m anner 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 . . . . . . . . . . . . . . . 8-12 psi (55-83 KPa)

Front wheels. . . . . . . . . . . . . . . . 8-12 psi (55-83 KPa)

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. VX4 Side Discharge Decks – Place 3” high deck support

blocks (two stacked 2” x 4” blocks can be used to create a 3” [76.2mm] high support) at the four corners of the deck marked with the locator triangle as shown. Figure 6-1 NOTE: Back of deck will automatically be set 1/4” (6.35mm) higher. Rear Discharge Deck (all) (Figure 6-2) – Place two

3.75” (95.3mm) high deck support blocks (two stacked 2” x 4” blocks and one 1” x 4” can be used to create a

3.75” [95.3mm] high support) at the front of the deck as shown. Place two 3” high deck support blocks (two stacked 2” x 4” blocks can be used to create a 3” [7.62cm] high support) at the sides of the deck as shown.

4. VX4 Side Discharge Decks – Place the height stop in the

3” (76.2mm) hole, with the pin side of the height adjusting stop against the stop handle. Rear Discharge Decks (all) – Place the height stop in the 3.25” (82.6mm) hole, with the plate side of the height adjusting stop against the stop handle.

Figure 6-2

setting process. Otherwise, spring pressure from the deck lift springs will tend to pull the stop away from the handle. Figure 6-3

6. Loosen all nuts on the deck lift threaded rods, and the

hardware on the height indicator bar (on the right front), until all the deck lift chains are loose, and the deck is sitting tightly on all four blocks. Figure 6-4, Figure 6-5 & Figure 6-8

7. Loosen the two nuts on the front of height indicator so

that the foot pedal is free. Figure 6-4 & Figure 6-8

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

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

from the lift block at approximately 1" (25.4mm) (left & right side). Figure 6-5

10. Jam both nuts against the block.

Figure 6-1

5. Clamp the height adjusting stop against the stop handle.

This will assure that the height will not move du ring the

117592 6-1 REV C

Figure 6-3

Page 32

Figure 6-4

Foot pedal

Nuts

Deck lift rod

Lift block

1”

Hardware

Adjuster

Jam nut

5/16” bolt

Chains

Nuts

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 block.

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

deck lift block on the height indicator rod, just enough to carry most of the deck weight on that side — the block should be able to move with only a slight drag. Figure 6-5

13. Jam nuts tightly together against the deck lift block.

14. Go to the right front of the mower.

15. Loosen the 5/16” jam nut on the adjuster lift chain, and

back the adjuster bolt out to allow the adjuster t o move up and down freely. Figure 6-6

16. Tighten the adjuster bolt until the chain just becomes

tight. Then tighten just enough to carry the weight of the front of the deck on that side—to check, move the blocks back and forth; they should move with a slight drag. Figure 6-6

17. Tighten the adjuster bolt jam nut to prevent the adjuster

bolt from moving. Figure 6-6

18. Tighten the hardware holding the chain and adjuster onto

the deck lift arm. Figure 6-6

until there is slack in the deck lift chain.

21. Tighten the appropriate nut until the chain just becomes

tight, and carries most of the deck weight. Check by moving the block—it should move with a slight drag. Figure 6-7

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

and jam them tightly together against the block.

Figure 6-6

19. Go to the right rear of the mower.

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

loosen the two nuts on the block holding the threaded rod

REV C 6-2 117592

Figure 6-5

Figure 6-7

23. Go to the left rear of the mower.

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. Figure 6-8

25. Tighten the appropriate nut until the chain just becomes

tight, and carries most of the deck weight. Check by moving the block—it should move with a slight drag. Figure 6-8

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”

(25.4mm) of space between the front nut on the spring and the rear nut on the deck lift block. Typical both sides. Figure 6-5

28. When completed, all chains will be tight, and deck

Page 33

cutting height will be set to the deck height indicator.

WARNING

Nut

Chains

Deck lift

threaded rod

Nut

WARNING

Figure 6-8

Blades

Mower blade maintenance

Check the mower blades daily, they are the key to power efficiency and well groomed turf. Keep the blades 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.

Mower blade removal

Use a 15/16” wrench to remove the 5/8” cap screw holding

the blade to the spindle shaft from underneath. NOTE: A blade holding tool (part number 381442) is available from Hustler

Turf Equipment. It is designed to prevent the blades from rotating when they are being removed or installed on the

spindle. Contact your Hustler

Sharpen the blades on a grinder following pattern as shown

(Figure 6-9). Touch-up sharpening can be done with a file

Check the blades for balance following grinding. A commercial balancing tool is available through most hardware supply stores, or balancing can be done by placing the blade on an inverted line punch or 5/8” bolt. Blade should not lean or tilt. Spin the blade slowly, blade should not wobble. If blade is out of balance, true it up before reinstalling.

Lay the blade on a flat surface and check for distortion (Figure 6-10 & Figure 6-11). Replace any distorted blade.

Do not re-use spindle bolts which have stripped, worn or undercut threads. Torque bolts on spindles to 118 foot-pounds (160.0 N-m) when reinstalling blades.

Properly compressed cup washers maintain the correct compression load on the blades. Replace the cup washers if they are cracked or flattened.

IMPORTANT: The blade sail (curved part) must be point-

ing upward toward the inside of the deck to ensure proper cutting.

IMPORTANT: When mounting blades, rotate them after

installation to ensure blade tips do not touch each other or sides of the mower.

dealer for more information.

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. Replace worn or damaged blades.

Never work with blades while engine is running or deck clutch switch is engaged (on). Always place deck clutch switch in the disengaged position, place steering control levers in the park brake position and turn engine off and disconnect negative battery cable. Block up mower when you must work under it. Wear gloves when handling blades. Always check for blade damage if mower strikes a rock, branch or other foreign object during mowing!

Always wear adequate eye protection when grinding mower blades.

Failure to correctly torque the bolt may result in the loss of the blade which can cause serious injury.

Mower blades are sharp and can cut. Wrap the blade(s) or wear gloves and use extra caution when servicing them.

117592 6-3 REV C

Page 34

raveling of belt covering does not indicate failure; trim ravelings

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

Cutting

plane

Comparison of Warped and Straight Blades

Cutting edge

Twisted Blade Edge

(replace)

Cutting edgeCutting Plane

Straight Blade Edge

End view of blades, comparing

twisted and straightened blades

Spring

chain

Spring chain anchor point

Idler

spring

with a sharp knife.

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, the 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.

Deck Belt Adjustment

The spindle belt tension remains constant by means of a

tension idler and spring. 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 the 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 point on the deck frame. Figure 6-12, Figure 6-13, Figure 6-14, Figure 6-15, Figure 6-16 & Figure 617

IMPORTANT: Do not over tensio n the spring to compensate

for a badly worn belt or pulley.

Figure 6-9

Figure 6-10

Figure 6-11

Figure 6-12

Belts

Inspect 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

REV C 6-4 117592

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Figure 6-13

Spring

chain

Spring chain anchor point

Idler

spring

60” Rear Discharge Deck

Spring

chain

Spring chain anchor point

Idler

spring

72” Rear Discharge Deck

Figure 6-14

117592 6-5 REV C

Page 36

NOTE: The following notes are the same for the different decks shown.

9.3” – 10.3”

(236 – 262mm)

1. Spring length after tensioning new belt. Measured from outside of hook to outside of hook with deck set at 3¼” (8.2.6mm) cut

height.

2. Route belt as shown.

60”, 66” & 72” Side Discharge Deck Belt Routing & Tensioning

Figure 6-15

REV C 6-6 117592

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60” Rear Discharge Deck Belt Routing & Tensioning

9.3” – 10.3”

(23.6 – 26.2cm)

9.3” – 10.3”

(236 – 262mm)

Figure 6-16

117592 6-7 REV C

Page 38

72” Rear Discharge Deck Belt Routing & Tensioning

9.3” – 10.3”

(236 – 262mm)

9.3” – 10.3”

(236 – 262mm)

Figure 6-17

REV C 6-8 117592

Page 39

ELECTRICAL

Mowers prior to serial number 12122104

NOTE: If replacing this harness with the updated version the six pin connector pigtail that is attached to the

engine will need to be removed. The updated version has individual connections for the following circuits: Charge, Start, Oil Pressure Light, Fuel Solenoid, and Coil Ground.

Electrical Schematic – Kawasaki

117592 7-1 REV C

Page 40

Electrical Schematic – Kawasaki

Mowers with serial number 12122104 and later

REV C 7-2 117592

Page 41

Electrical Schematic – Kawasaki DFI

117592 7-3 REV C

Page 42

Electrical Schematic – Briggs & Stratton

REV C 7-4 117592

Page 43

MAINTENANCE

Maintenance Schedule

Figure 8-1, Figure 8-2, Figure 8-3,Figure 8-4 Figure 8-4,

Figure 8-5, Figure 8-6 & Figure 8-7

SERVICE AT

INTERVALS INDICATED

Verify safety start interlock system Prior to each use Visually inspect unit for loose hardware and/or damaged parts Prior to each use Visually inspect tires Prior to each use Check oil level, engine (1) Prior to each use or every 4 hours Clean oil heat exchanger (8) Prior to each use or every 4 hours Clean air intake screen (8) Prior to each use or every 4 hours Check fuel level Prior to each use Blades - sharpen & securely fastened Prior to each use Discharge chute - securely in place & in lowest position Prior to each use Clean engine and pump compartment Daily Replace air cleaner paper element (5) As needed Change engine oil and 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 Grease deck pusher arms (8) X Grease pump idler (8) X Grease deck height pivots (8) X Grease front wheel bearings (8) X Clean & regap spark plugs (a) X Check pump and deck belt tension and condition (6) X Check fuel system (7) X Check hydraulic lines X Check fuel valve and grommet (7) X Tighten lug nuts on wheels (2) X Change fuel filter (7) X Clean or replace hydraulic fill cap X Change hydraulic filter & oil (3) X Grease deck spindle housings X Replace spark plugs X Check ROPS mounting hardware (9) X Replace fuel evaporation system filter (8) X

WEEKLY

OR 50

HOURS

MONTHLY

OR 100 HOURS

ANNUALLY

OR 500 HOURS

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 dur-

ing hot weather periods.

2. Torque initially and after first 2 hours of operation.

3. Perform initial hydraulic oil and 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. Use caution when servicing to prevent dust contamination in the engine. Do not clean filter element. Replace

with a new one.

117592 8-1 REV C

Page 44

6. Pump drive belt only - Inspect belt every 100 hours and replace if worn or cr acking is noticed. Check spring tension adjustmen t. Otherwise, replace belt

Carbon canister equipped machines

every 400 hours or 2 years whichever comes first. Check and adjust spring tension after 50 hours of use as outlined in the Hydraulic Pump Belt Adjustment sec- tion of the General Service Manual (117592).

7. Chec k fuel system for any crack or leaks including , but not limit to, fuel line hoses, fuel valve, vent line hoses, vent valve, vapor valve, carbon canister, and

grommets. Repair as needed.

8. More often under dusty or dirty conditions and during hot weather.

9. Inspect ROPS after the first 20 hours of operation and then after every 500 hours of operation or yearly whichever comes first.

REFERENCES:

A. Refer to engine owner’s manual for engine service information. NOTE: After completing maintenance cycle (500 hours), repeat cycle.

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. Hydraulic Oil Filter

9. Front Wheel Bearing Zerks (2)

10. Engine Oil Filter

11. Deck Height Pivot Zerks (4)

12. Park Brake Switch

13. Drive Tires

14. Pump Idler Zerk (1)

15. Pump Belt

16. Deck Pusher Arm Zerks (2)

17. Deck Belt

18. Spindle Housing Zerk (3)

19. Blades

20. Fuel Evaporation System Filter

21. Hydraulic Oil Heat Exchanger

22. Carbon canister

Figure 8-1

Figure 8-2 Figure 8-3 Figure 8-4

REV C 8-2 117592

Page 45

Figure 8-5

18 19

60” Rear Discharge

deck shown

72” Rear Discharge

deck shown

Figure 8-6

Figure 8-7

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. Hydraulic Oil Filter

9. Front Wheel Bearing Zerks (2)

10. Engine Oil Filter

11. Deck Height Pivot Zerks (4)

12. Park Brake Switch

13. Drive Tires

14. Pump Idler Zerk (1)

15. Pump Belt

16. Deck Pusher Arm Zerks (2)

17. Deck Belt

18. Spindle Housing Zerk (3)

19. Blades

20. Fuel Evaporation System Filter

21. Hydraulic Oil Heat Exchanger

22. Carbon canister

117592 8-3 REV C

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