Hustler ® FasTrak® SDX General Service Manual
Contents
1. REVA OON 00 BON Engine Oil Fill amp Dipstick Fuel Filter Engine Air Cleaner Engine Oil Drain Valve Battery Fuel Tank Engine Oil Filter Deck Lift Pivot Zerks 4 Park Brake Switch 2 Drive Tire Pump Belt Engine Air Intake Screen Front Wheel Tires Front Wheel Zerks 2 Deck Belt Blades Hydraulic Oil Expansion Tank Hydraulic Oil Filter Fuel Evaporation System Filter Carbon Canister 121878 Figure 8 3 Engine Oil Fill amp Dipstick Fuel Filter Engine Air Cleaner Engine Oil Drain Valve Battery Fuel Tank Engine Oil Filter Deck Lift Pivot Zerks 4 Park Brake Switch 2 Drive Tire Pump Belt Engine Air Intake Screen Front Wheel Tires Front Wheel Zerks 2 Deck Belt Blades Hydraulic Oil Expansion Tank Hydraulic Oil Filter Fuel Evaporation System Filter Carbon Canister PON OOP NS O N2. ENTE T aS SIME YILIN ufoH a 2s 139Nv9 1304 81 889 980 ay aay SER oe 21 479 gt VA i 4 T x 391145 ONNOY9 E 81 XIB g ng T 02 LHM NY9 ANIONS J en ws 8 NYG 2 9 02 940 39uvH2 5 81 NYG 105 1103 N d SDNY ONO N 81 918 134 NA 81 980 SIT 8TFT87038 SSANYYH o ag 110 5 N s1H917 01 90018 un 911940 gt a NR 81 038 NVI m 8118 AYTIU 318 038 a LYVIS o s 810980 NL GDNIL A GNI E 5 HILIMS HOLIMS 183118 sanr ta IVY LN3N IVYLNIN lt 1811940 11138 EA LYVIS 91338 91 034 980 LT 91 080 07 910980 3903 HOLIMS N HOLN19 T 803318 038 E m HILIMS 21 und 21 940 ESA 512038 dr 81 419 038 REVA 7 1 121878 Main Hamess to Fuel Gauge Voltage Convertor Schematic bis BLK 20 ORG 20 ER j GRN 20 BLK 20 LE ORG 20 x PIN 2 PIN 3 PIN 3 T DIODE GRN 20 BI PIN 5 PIN 5 PIN 6 cn E PIN 6 PIN 7 4 i PIN 7 ORG 20 2 8 y J D in z FUEL GAUGE HARNESS CONNECTOR CONNECTOR 00 00 24 12V DC 5V DC CONVERTER REVA 7 2 121364 MAINTENANCE Maintenance Schedule Figure 8 1 Figure 8 2 amp Figure 8 3 SERVICE AT INTERVALS INDICATED WEEKLY MONTHLY ANNUALLY OR 50 OR 100 OR 300 HOURS HOURS HOURS Verify safety start interlock system Pri
3. 8 2 THOUDIGSNOOUMNG usa ne ar ee A 9 1 toc 2 121878 GENERAL INFORMATION Hustler Service Program This manual is part of a service package for the Hustler FasTrak SDX mowers Use of this manual in conjunction with other Hustler mower and component manuals will pro vide the information necessary to service and maintain the Hustler FasTrak SDX mower 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 oper ating the mower The component manuals are furnished by the various man ufacturers to be used for the troubleshooting and servicing of their components Maintenance Introduction Regular maintenance is the best prevention for downtime 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 th
4. ssssssssssss 4 1 Steering control lever neutral adjustment 4 1 Tresen e eite e t et 4 8 Understand correct service 2 1 Understand Machine Operation 2 1 Warranty ar ep ueni ede 1 1 Wear Protective Clothing nen 2 2 REVA
5. Figure 8 4 4 AC O N co N e 121878 8 3 REVA REVA 8 4 121878 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 will prevent many problems The following chart is designed to help you locate a problem by suggesting probable causes and the recommended solutions SYMPTOMS PROBABLE CAUSES SUGGESTED REMEDIES Starting motor does not crank The engine will not start starts hard or fails to keep running Steering control levers not in park brake position or switch not adjusted Deck clutch switch engaged Weak or dead battery Place steering control levers in park brake posi tion or re adjust switch Disengage clutch switch Recharge or replace Electrical connections are corroded or loose Check the electrical con nections Fuse is blown Check fuses replace blown fuse For additional causes No fuel or line plugged Fuel valve is turned off See engine manual Fill tank or replace line See Fuel System section for more details Open the fuel valve There is incorrect fuel in he fuel system Drain the tank and replace the fuel with th
6. Thereafter change oil after every 40 hours operation Change more often under dusty or dirty con ditions and during hot weather priods 2 Torqueinitially and after first 2 hours of operation 3 Change engine oil filter per the engine manufacturer s recommendations Refer to Engine Owner s Manual for recommendations and other maintenance items 4 Service more often under dusty or dirty conditions 5 Pump drive belt only Inspect every 100 hours and replace if worn or cracking is noticed Otherwise replace every 200 hours or 2 years which ever comes first 6 Checkfuel system for any crack or leaks including but not limit to fuel line hoses fuel valve vent line hoses vent valve vapor valve carbon can ister and grommets Repair as needed 7T Initial system oil and filter change must be afterthe first 75 hours of use or 1 year whichever comes first Thereafter replace filter and oil in each transaxle every 2 years or 200 hours whichever comes first 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 300 hours of operation or yearly whichever comes first REFERENCES A Referto engine owner s manual for engine service information NOTE After completing maintenance cycle 300 hours repeat cycle 121878 81 Maintenance Locator Chart
7. age 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 Afteroil is drained close the valve by twisting it clock wise 5 Oncethe valve is closed clean up any spilled oil 121878 5 1 IMPORTANT All oil drips or spills must be cleaned off of the exhaust system before operating the machine A Oil drain valve 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 filter does not require servicing unless it becomes contaminated with dirt or moisture Recommended service procedure 1 Release clamps and remove element Clean the canis ter 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 dam aged element which will allow abrasive particles to enter the engi
8. General Maintenance 6 2 2 Maintenance 2 3 Eois 3 1 Standard TOQUES socer e WO ERE PEN ams 3 1 Sp ial TOQUES e vtero LE RHET EMG Ea exta art des 3 1 Power Unit Maintenance 2222er nn 4 1 Steering Adjusiments etate Rem es 4 1 Steering Control Lever Stops 4 4 pn e 4 5 Hydraulic Pump Belt Adjustment 222er 4 5 Hydraulic System aa n a a 4 5 TOES uar s buta Eee Seek be pe es MN Cnt ar eee te mE 4 8 Engine Maintenance ous utc orn ed 5 1 General Engine 5 1 Engine Oil and Filter e ain masta Vaate S Detox d 5 1 the see radio E RENDER ase rate 5 1 Carbon Camiste ls 2 2 2er een BRE ENS EC cn rrt pe s 5 2 Fuel Evaporation System Filter 5 3 Fuel amp Evaporative System Line Routings 5 3 Engine RPM SeltlInds tadas otr cda net 5 5 Deck Adjustments seta a eet ee ie 6 1 Beck cutie REEL an EE 6 1 Blades fat hebt Rude Mtas bem Maer Meee De 6 2 Bell cede 4 db A Eric durs uitis 6 3 Deck Belt Adjustment sssusa s RTI YR eme 6 3 Deck Belt Installation 5 ci ren 6 3 toc 1 REVA REVA Maintenance 8 1 Maintenance Locator Chalt
9. a anne 7 48 ft lbs 65 Nem of torque Release the deck lift i 3 pedal and ensure that the deck can be raised and Figure 6 2 locked into the transport position Figure 6 2 121878 6 1 REV A A Deck lift assist spring B Eyebolt D Lock nut Figure 6 3 Blades Mower blade maintenance IMPORTANT Refer to the Safety section of this manual for blade handling safety information Refer to the Mower Blade Replacement section for blade removal and installation Mower blades are sharp and can cut Wrap the blade s or wear gloves and use extra caution when servicing them 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 Always check for blade damage if mower strikes a rock branch or other for eign object during mowing orif an abnormal vibration occurs while oper ating Make all necessary repairs before resuming opera tion Sharpen the blades following the pattern shown Figure 6 4 Touch up sharpening can be done with a file After grinding the blades check for balance Blade balanc ing can be done by placing the blade on an inverted
10. beneath the oil filter and remove the oil filter from the transaxle 4 After the oil has been drained wipe the filter base sur face off and apply a film of new oil to the gasket of the new replacement filter 5 Install the new filter by hand turn 3 4 to one full turn after the filter gasket contacts the filter base surface 6 Re install the filter guard with three 1 4 screws Torque the screws to 65 in Ibs each Figure 4 12 7 Repeat steps 2 6 for the opposite side transaxle A Top port plug 8 Drain oil filters of all free flowing oil prior to disposal Place used oil in appropriate containers Figure 4 13 9 IMPORTANT Remove the top port plug from both transaxles prior to filling with oil This will allow the transaxles to vent during oil fill Figure 4 13 IMPORTANT Purging procedures must be followed after changing the oil and filter Refer to Purging Procedure section for detailed information REVA 4 6 121878 IMPORTANT When washing the mower direct the spray away especially if using a power washer from the transaxle s seals to prevent water intrusion and to ensure component per formance Purging procedure Due to the affects air has on efficiency in hydrostatic drive applications it is critical that it is purged from the system Air creates inefficiency because its compression and expansion rate is higher than that of the oil approved for use in hydrostatic drive systems These purge proc
11. 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 REVA REVA 1 2 121878 SAFETY This safety alert symbol is used to call attention to a mes sage intended to provide a reasonable degree of PERSONAL SAFETY for operators and other persons during the normal operation and servicing of this equipment 4 O denotes immediate hazards which WILL result in i severe personal injury or death denotes a hazard or unsafe practice which COULD result in severe personal injury or death Safe Servicing Practices Refer to the Safety section of this manual for more detailed service safety information Understand correct service A Be sure you understand a service procedure before you work on the machine A Unauthorized modifications to the machine may impair the function and or safety and affect machine life A If it is necessary to make checks with the engine run ning always use two people with the operator at the controls able to see the person doing the checking Pre Operation Precautions Fuel Handling A To avoid personal injury or property damage use extreme care when handling gasoline Gasoline is extremely flammable and the vapors are explosive A fire or explosion from gasoline can burn you and others and can d
12. 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 veg etable oil Get medical attention immediately 121878 TORQUE 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 Nem Size ft lbs Nem pow IES Special Torques Size Ft Lbs N m Wheel lug nuts 70 95 Blade spindle bolt top 70 95 Blade spindle bolt bottom 118 160 Electric Clutch mounting bolt 3 45 48 61 65 Front wheel axle bolt Tighten the nut then back it off until the wheel spins freely Transaxle hub nut 275 339 Transaxle pump pulley nut 45 55 61 74 6 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 replace ment 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 121878
13. pound s Use in pairs only Follow the instructions supplied with the vehicle stands Do not allow the wheels to come in contact with the floor or any object that would permit the unit to propel itself To prevent injury stay clear and exercise cau tion when rotating the wheels Exercise extreme caution when the transmissions are engaged Keep hands hair clothing etc clear of the cooling fans on top of the transaxles to pre vent entanglement 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 procedures should be performed by trained maintenance personnel only IMPORTANT Make sure the hydraulic system oil is at operating temperature before beginning this procedure 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 Chock the front tires 3 Unbolt the seat platform from the mower frame Disconnect the mower harness from the seat switch Bypass the seat switch by connecting the two mower harness female spades together Figure 4 7 Re attach the seat platform to the mower frame 4 Startthe engine Move both steering control levers for ward against the stops located inside the steering cov ers 5 Determine if the drive wheels are rotating equally If one is rotating fasterthatthe other procee
14. with a minimum weight rating of 2000 pounds 907 kg to block the unit up Usein pairs only Follow the instructions supplied with the jack stands Keep nuts and bolts tight especially the blade attach ment bolts Keep equipment in good working condi tion 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 replacement parts to ensure that original standards are maintained The mower may not comply with the appropriate safety standards if aftermarket parts accesso ries or attachments are used Maintenance Precautions Avoid Fire Hazards A 121878 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 2 3 A A A A A A 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 tape openings after adding the inhibitor Keep con tainer tightly closed when not in use Inspect elect
15. 121878 Hustier FasTrak SDX General Service Manual HUSTUER ENGINEERING PERFORMANCE 200 South Ridge Road Hesston Kansas 67062 REVA A WARNING A 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 land 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 Requirements 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 The Engine Owner s Manual provides informati
16. 3 1 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 REVA REVA 3 2 121878 POWER UNIT MAINTENANCE Steering Adjustments Steering control lever neutral adjustment The mower s steering has been factory adjusted to elimi nate creeping when the steering control levers are in the neu tral position However should the mower begin to creep the steering control lever linkage can be adjusted Before considering any adjustment check the tire air pres sure Unequal tire pressure will cause the mower to drift to one side Refer to the 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 This procedure will require that the unit be raised to allow the drive wheel to rotate Block the mower up off of the ground using only appropriate veh
17. 4 121878 Fuel Evaporation System Filter The fuel hose is connected to the fuel tank as shown It connects the fuel tank to the engine s fuel pump Figure 5 7 Hustler FasTrak SDX mowers have a fuel evaporation system filter This filter must be checked and replaced every 300 hours or annually whichever comes first Figure5 5 amp B Figure 5 6 ER 30800380 MO j A Fuel tank B Fuel line Figure 5 7 The vapor lines are connected to the fuel tank as shown A Fuel evaporation system filter They connect the fuel tank to the engine s vapor port Figure 5 8 amp Figure 5 9 Figure 5 5 Mowers with carbon canisters A Fuel evaporation system filter B Carbon canister A Fuel tank C Fuel evaporation sys Figure 5 6 B Vapor lines tem filter Fuel amp Evaporative System Line Routings Figure 5 8 These mowers have a fuel evaporative system installed There are two different types of rubber hoses that are con nected to the fuel tank 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 121878 5 3 REVA
18. A Fuel tank C Fuel evaporation sys B Vapor lines tem filter D Carbon canister Figure 5 9 REVA 5 4 121878 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 idle speeds should be set as follows Kawasaki FX691 FX730 ENGINE SPEEDS LOW IDLE HIGH IDLE 1900 100 rpm 3600 50 rpm MODEL NO ENDING WITH Model NO without extension Model NO with EX extension Model NO with US extension 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 AU or CE Example 922222 no extension 922222 EX 922222 CE 922222 US 922222 AU 121878 5 5 REVA REVA 5 6 121878 DECK ADJ USTMENTS Deck Leveling 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 recom mended pressures are as follows Drive wheels tire pressure 8 12 psi Gauge wheels tire pressure 8 12 psi Stop engine Make sure the deck clutch switch is in the down OFF position Place the steering control levers in the park brake position before leaving the machine A Blocks Figure 6 1 2 Parkthe unit on a hard flat surface 11 Reinst
19. Maintenance nenn 5 1 General Maintenance Precautions 2 2 Hydraulic Pump Belt Adjustment 4 5 Main Electrical Harness Schematic 7 1 Main Harness to Fuel Gauge Voltage Convertor SCHOMALIC 3 rhet oras linia 7 2 Maintenance Introduction eeeeeee 1 1 Maintenance Locator Chart esses 8 2 121878 PAGE Maintenance Precautions 2 3 Maintenance schedule 8 1 Mower blade 6 2 Mower blade 6 3 Operate Machine Safely 2 2 Operate machine 58 6 2 2 Operation Precautions sesssssesee 2 2 Park Brake Spring Adjustment 4 5 Pre Operation Precautions s s s 2 1 Prepare For 2 3 Prevent Battery Explosions 2 3 Safe Servicing Practices nnennnennn 2 1 Service PEO AM eot er eee ege 1 1 Special TOrQU6S nete ei eius 3 1 Standard 5 3 1 Start Engine Safely ssssssssssss 2 2 Steering Adjustments
20. a nozzle lock open device Never use gasoline for cleaning parts Read and observe safety precautions elsewhere in this manual Gasoline is harmful or fatal if swallowed Avoid prolonged breathing of vapors Long term exposure to vapors can cause serious injury and illness Keep gasoline away from eyes and skin Keep face away from nozzle and fuel tank or fuel container opening f gasoline is spilled on clothing change clothing immediately Understand Machine Operation A Observe the usual gasoline handling precautions A Only qualified and trained personnel should operate Do not smoke while refueling Extinguish all ciga the equipment rettes cigars pipes and other sources of ignition A Carefully read the operator s manual and all manuals furnished with the attachments Learn the location 121878 2 1 REVA and purpose of all controls instruments indicators and labels Wear Protective Clothing A A 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 jew elry 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
21. aler to resolve the problem Hydraulic System This mower is equipped with two integrated hydrostatic transmissions Figure 4 10 121878 4 5 Lee MUUT 1 PALAT A Tension idler B Hydraulic pump belt C Spring Figure 4 9 IMPORTANT Never use hydraulic or automatic transmis sion fluid in this system use only the specified motor oil Remember dirt is the primary enemy of any hydraulic sys tem Each transaxle has its own hydraulic expansion tank The tanks are located in front of the engine and behind the opera tor s platform Figure 4 10 Check the oil level in the hydraulic system after every 50 hours of operation or weekly whichever occurs first Check more often if the system appears to be leaking or otherwise malfunctioning Fluid level should be at the Full Cold line on the expan sion tank Use only SAE 20W50 service motor oil Initial system oil and filter change must be after the first 75 hours of use or 1 year whichever comes first Thereafter replace filter and oil in each transmission every 2 years or 200 hours whichever comes first NOTE The filter guard must be removed to access the filter Figure 4 11 Each tran
22. all the eyebolt and deck lift assist spring Adjust 3 Using the deck lift pedal raise and lock the deck in the the spring tension using the lock nut and nut on the transport position Figure 6 2 eyebolt The spring extension should be 9 50 241 3 mm when locked in the transport position 4 Place 3 76 2 mm high deck support blocks two stacked 2 x 4 blocks can be used to create a 3 76 2 mm high support at the four corners of the deck as shown NOTE The back of deck will automatically be set 1 4 6 35 mm higher Figure 6 1 Figure 6 3 5 Remove the height adjusting stop pin and lower the deck until it rests on the support blocks Figure 6 2 6 Loosen the four flange nuts attaching the four deck links to the deck Figure 6 2 7 Push the deck lift pedal forward place the height adjusting stop pin in the indicator hole marked 3 25 82 6 mm and release the pedal 8 Unscrew the nut from the eyebolt and slide the eyebolt out of the mount This removes the tension from the deck lift assist spring Figure 6 3 9 Pull the pedal rearward so that the transport latch is held firmly against the deck height adjusting stop pin and the play in the pivot joint is removed secure the pedal in this position a bungee cord may be used A Transport latch E Eyebolt 10 Tighten the four deck links to the deck with the S a lift pedal K U N flange nuts clamping on either side of the slot with D s lift link H
23. amage property Do not remove fuel cap or fill tank with engine run ning or while engine is hot Clean up any gasoline spills f gasoline is spilled do not attempt to start the engine but move the machine away from the area of spillage and avoid creating any source of igni tion until gasoline vapors have dissipated Keep gasoline 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 appli ances Refuel outdoors Never refuel or drain the gaso line from the machine indoors Never attempt to start the engine when there is a strong odor of gasoline fumes present Locate and correct the cause Store gasoline in an approved container and keep it out of the reach of children Never buy more than a 30 day supply of gasoline 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 gasoline contain ers on the ground away from your vehicle before filling When practical remove the machine from the truck or trailer and refuel the machine with its wheels on the ground If this is not possible then refuel such machine on the truck ortrailer using a portable container and not a fuel dispenser noz zle 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
24. d to the next step 6 Return the steering control levers to the park brake position and shut the engine off 7 Loosen the side cap screw on the outside of the steer ing cover on the side that is rotating to fast Tighten REVA 4 4 A Seat switch C Mower harness B Female spades Figure 4 7 the top cap screw to adjust the drive straight bracket up This allows the steering control lever to make con tact with the drive straight bracket sooner Repeat until both drive wheels are rotating at the same speed Figure 4 8 Tighten the side cap screws on both the left and right sides to lock the drive straight brackets in place Snug the top cap screws to prevent loosening during opera tion Figure 4 8 A Top cap screw C Drive straight bracket B Side cap screw D Steering control lever Figure 4 8 IMPORTANT Unbolt the seat platform from the mower frame Disconnect the two female spade connectors from each other from step 3 Reconnect them to the seat switch This must be completed so that the safety circuit is function 121878 ing properly Figure 4 1 Re attach the seat platform to the mower frame 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
25. destroy the belt composition in a very short time Deck Belt Adjustment The deck belt tension remains constant by means of a ten sion idler and spring There is no tension adjustment of this belt Figure 6 7 A Deck belt C Tension idler B Idler spring Figure 6 7 Deck Belt Installation When replacing a deck belt use the following procedure 1 Route the belt around all the pulleys except the left deck spindle 2 Graspthe belt at the two locations shown in Figure 6 8 and pull the belt over the left spindle pulley 3 Release the belt REVA g Keep hands clear when pulling belt over the pulley to prevent pinching Do not get hand or fingers BN Li between pulley and belt 1 N 5 o 2 Ne Grasp the belt FA here and pull 497 Z over the pulley 1 EET amp I L LII NT 3 9 E 2 Figure 6 8 REVA 6 4 121878 ELECTRICAL Main Electrical Harness Schematic
26. e best insurance Clear away heavy build up of grease oil and dirt especially in the engine compartment and under the seat platform 121878 1 1 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 restrict ing 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 person nel 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 Equip ment 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 ser vice manual contact the Customer Service Department at Hustler Turf Equipment for additional information Warranty Warranty repair
27. e not sharp A cutting blade s is are bent The deck is not level An anti scalp wheel is not set correctly The underside of the deck is dirty Sharpen the blades Install new cutting blade s Level the deck per the Deck leveling and height adjust ment section of the General Service Manual Adjust the height of the anti scalp wheel Clean the underside of the deck Tires improperly inflated Adjust air pressure to 8 12 psi 55 83 KPa A blade spindle mount is bent Contact your Dealer REVA REVA 9 2 121878 INDEX PAGE Avoid Acid Burns isena ee R 2 4 Avoid Fire Hazards 2 2 2 3 Belts ayer bete ists 4 5 6 3 Blades nete eite uin 6 1 6 2 Carbon Canister seennnennnnnnnnnnnnnnnnnnnnnnnn 5 2 Deck Belt Adjustment essen nen 6 9 Deck Belt Installation 6 3 Deck Leveling iensen ene e t e 6 1 Draining the Engine Oil 5 1 Engine Air Filter 5 1 Engine Oil and Filter ssssseesss 5 1 Engine RPM settings eene 5 5 Fuel amp Evaporative System Line Routings 5 3 Fuel Evaporation System Filter 5 3 Fuel Handling oooococcconnncccconnnancccnnnnnncconononanncncnnnnnons 2 1 General Engine
28. e proper type There is dirt in the fuel filter Replace the fuel filter Dirt water or stale fuel in he fuel system The choke is not on Numerous Contact your Dealer Move the choke lever to ON See engine manual Engine Runs with continuous misfiring or engine runs unevenly or erratically Numerous See engine manual Loss of power or system will not operate in either direction Restrictions in air cleaner Service air cleaner Poor compression Steering linkage needs adjustment Tow valve open Contact your Dealer Adjust linkage Close tow valve The traction drive belt is worn loose or broken Install a new traction drive belt Air in system For additional causes Check filter and fittings See engine manual Air cooled engine over heating Low engine oil pressure Air intake screen or clean ing fins clogged Clean screen and fin For additional causes Oil diluted or too light See engine manual Change oil and check for source of contamination Failed oil pump Contact your Dealer High oil consumption 121878 Numerous Contact your Dealer SYMPTOMS PROBABLE CAUSES SUGGESTED REMEDIES Mower jerky when start ing or operates in one direction only Mower creeps when steering control levers are in neutral Mower circles or veers in one direction Steering control linkage needs adjustment Adjust
29. edures should be implemented any time a hydrostatic system has been opened to facilitate mainte nance or the oil has been changed The resulting symptoms in hydrostatic systems may be 1 Noisy operation 2 Lack of power or drive after short term operation 3 High operation temperature and excessive expansion of oil Before starting make sure the transaxle is at the proper oil level If it is not fill to the specifications outlined in this man ual The following procedures are best performed with the vehi cle drive wheels off the ground Then repeated under normal operating conditions If this is not possible then the proce dure should be performed in an open area free of any objects or bystanders 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 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 Use only certified jack stands Use only appropriate jack stands with a minimum weight rating of 2000 pounds 907 kg to block the unit up Usein pairs only Follow the instructions supplied with the jack stands The jack stands should not allow the machine to move when the engine is running and the drive wheels are rotating Do not allow the wheels to come in contact with the floor
30. ick or similar instrument to clean under the mower making sure that no part of the body especially arms and hands are under mower Clean flammable material from mower Prevent fires by keeping the engine compartment top of the deck exhaust area battery fuel line fuel tank and operator s station clean of accumulated trash grass clippings and other debris Always clean up spilled fuel and oil Prevent fires by keeping the engine and exhaust areas clear of grass clippings and other debris Do not back mower into flammable materials 121878 Allow the mower especially the engine to cool before storing inside a building Always wear adequate eye protection when servicing the hydraulic system servicing the battery grinding mower blades and removing accumu lated debris Never attempt to make any adjustments or repairs to the mower drive system mower deck or any attach ment 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 Useonly certified jack stands Use only appropri ate jack stands
31. icle stands minimum weight rating of 2000 pound s Use in pairs only Follow the instructions supplied with the vehicle stands Do not allow the wheels to come in contact with the floor or any object that would permit the unit to propel itself To prevent injury stay clear and exercise cau tion when rotating the wheels Exercise extreme caution when the transmissions are engaged Keep hands hair clothing etc clear of the cooling fans on top of the transaxles to pre vent entanglement 121878 4 1 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 procedures 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 Chockthe front tires Unbolt the seat platform from the mower frame Disconnect the mower harness from the seat switch Bypass the seat switch by connecting the two mower harness female spades together Figure 4 1 Re attach the seat platform to the mower frame A Seat switch C Mower harness B Female spades Figure 4 1 4 Loosen the jam nuts on each end of the steering con trol rod assemblies Figure 4 4 5 Set both steering control levers in the park brake posi tion Figure 4 2 NOTE Both stee
32. line REVA 6 2 punch or 5 8 bolt A commercial balancing tool is also avail able through most hardware supply stores The blade should not lean or tilt When spinning the blade slowly it should not wobble Balance the blade before rein stalling Lay the blade on a flat surface and check for distortion Figure 6 5 amp Figure 6 6 Replace any distorted blade Do not sharpen to original pattern below It is easierto get a straight cutting edge follow ing the re sharpening pattern shown above A Re sharpening pattern B Original edge Figure 6 4 Comparison of Warped and Straight Blades J Straight Blade A Warped blade replace B Straight blade C Cutting plane Figure 6 5 121878 End view of blades comparing twisted and straightened blades A Twisted blade edge replace blade B Straight blade edge C Cutting plane D Cutting edge Figure 6 6 Mower blade removal IMPORTANT Refer to the Safety section of this manual for blade handling safety information Mower blades are sharp and can cut Wrap the blade s or wear gloves and use extra caution when servicing them A 15 16 wrench is required to remove the 5 8 cap screw holding the blade to the spindle shaft 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
33. linkage Loose steering linkage Tighten linkage Transaxle component faulty Steering linkage needs adjustment Steering linkage needs adjustment Loose steering linkage Contact your Dealer Adjust linkage Adjust linkage Tighten linkage Tires improperly inflated Adjust air pressure to 8 12 psi 55 83 KPa Transaxle component faulty Contact your Dealer Mower creeps when park ing brake engaged There is abnormal vibra tion Steering linkage out of adjustment Brakes need adjustment The engine mounting bolts are loose Adjust steering linkage Adjust parking brakes Tighten the engine mount ing bolts The engine pulley idler pul ley or blade pulley is loose Tighten the appropriate pulley The engine pulley is dam aged Contact your Dealer The cutting blade s is are bent or unbalanced A blade mounting bolt is loose Spindle bearing is worn or loose A blade spindle mount is bent Install new cutting blade s Tighten the blade mount ing bolt Replace or tighten spindle bearing Contact your Dealer Blades do not rotate The deck drive belt is worn loose or broken Install a new deck drive belt The deck drive belt is off the pulley Install the deck drive belt and check for a reason Electric clutch is not engaging Check and or replace 15 amp fuse Contact your Dealer Uneven cutting height The blade s ar
34. manufac turers control Therefore on a dust ingested 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 Carbon Canister FasTrak SDX mowers that are put into operation in Cali fornia have a carbon canister incorporated into the fuel sys tem Figure 5 4 California requires all mowers using gasoline engines to have this feature These canisters should be replaced every 5 years or if they become damaged ES 20800300 B AN lt 0806000 hom T A Carbon canister B Fuel evaporation system filter Figure 5
35. ne 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 REVA A Pre cleaner B Canister A Safety filter Figure 5 3 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 REVA 5 2 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
36. ne and machine clean removing accumulated 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 A A A A Repairs or maintenance requiring engine power should be performed by trained maintenance personnel only Unless specifically required DO NOT have the engine running when servicing or making adjustments to the mower Park the mower on level ground Disengage the deck clutch Place the steering control levers in the park brake position Lower the deck Stop the engine Remove the ignition key Disconnect the negative battery cable Wait for all movement to stop before adjusting cleaning or repairing Repairs or maintenance requiring engine power should be performed by trained maintenance per sonnel only To prevent carbon monoxide poisoning operate the engine in a well ventilated area only Read and observe all safety warnings in this man ual Before working on or under the deck make certain engine cannot be accidentally started Always keep belt covers on mower deck for safety as well as for cleanliness except when changing or check ing the belt Use a st
37. noise can cause impair ment or loss of hearing Always wear adequate ear protection such as earplugs when operating this equipment as pro longed 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 Operation Precautions Avoid Fire Hazards A 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 A A A Avoid possible injury or death from machine runaway Do not start engine by shorting across starter termi nals Before you start the engine Sit on the operators seat Move control levers to the neutral brake position Operate Machine Safely A A REVA 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 sure hoses are tightly secured and bolts are tightened 2 2 A A Always keep engi
38. non functioning seat switch Always reconnect the seat switch to the mower hamess Belts Inspect belts frequently for wear and serviceability Replace a belt that shows signs of severe cuts tears separa tion weather checking and cracking or burns caused by slip ping 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 dam age 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 Hydraulic Pump Belt Adjustment The transmission drive belt tension remains constant by means of a tension idler and spring There is no tension adjustment of this belt Figure 4 9 IMPORTANT Inspect the belt every 100 hours and replace as needed Replace the belt every 200 hours or every two 2 years whichever comes first 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 de
39. on 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 REVA 121878 121878 Table of Contents General Information s s ves de bee tete et 1 1 Hustlers Service 8 1 1 Maintenance Introduction ep E ee er bees 1 1 Waranty ora a ee ee a ee My 1 1 crc beats EDER nee due 2 1 Safe Servicing Practices 222222 Rennen 2 1 6 2 1 Operation PreCauliOnS s batido betta Stet bad E 2 2 Operate Machine 98 6 ce eee eee 2 2
40. or any object that would permit the unit to propel itself To prevent injury stay clear and exercise cau tion when rotating the wheels 121878 4 7 2 3 W gt Exercise extreme caution when the transmissions are engaged Keep hands hair clothing etc clear of the cooling fans on top of the transmissions to prevent entanglement 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 procedures should be performed by trained maintenance personnel only Chock the front tires Unbolt the seat platform from the mower frame Disconnect the mower harness from the seat switch Bypass the seat switch by connecting the two mower harness female spades together Figure 4 14 Re attach the seat platform to the mower frame Seat switch C Mower harness Female spades Figure 4 14 Start the engine Position the steering control lever in the neutral posi tion IMPORTANT Make sure the deck clutch switch is in the OFF disengaged position Figure 4 15 With the bypass valve open and the engine running slowly move the steering control lever in both forward and reverse directions 5 or 6 times Figure 4 16 REVA 9 Unbolt the seat platform from the mower frame Shown with steering control levers in the neutral position Disconnect the two female spade connect
41. or to each use Visually inspect unit for loose hardware and or damaged parts Prior to each use Visually inspect tires Check oil level engine 1 Prior to each use Prior to each use or every 4 hours Clean air intake screen 4 Prior to each use or every 4 hours Clean foam element 4 Prior to each use or every 4 hours Check fuel level Prior to each use Blades sharpen amp securely fastened Prior to each use Discharge chute securely in place amp in lowest position Prior to each use Replace air cleaner paper element 4 As needed Clean engine and transaxle compartment Daily Change transaxle oil and filter 7 Every 200 hours or 2 years Grease deck height pivots Grease front wheel bearings Change engine oil and filter 1 3 Clean cylinder and head fins A Check battery connections Check tire pressure with a gauge Check hydraulic oil level gt lt gt lt x x x x x x Clean engine exterior A Clean amp regap spark plugs A Check pump and deck belt tension and condition 5 Check fuel system 6 Check hydraulic lines Check fuel valve 6 Tighten lug nuts on wheels 2 Change fuel filter 6 Replace spark plugs Check ROPS mounting hardware 9 Replace fuel evaporation system filter 8 gt lt gt lt x x x x x x x x NOTES 1 Initial oil change is after 5 hours of operation
42. ors from each other from step 3 Reconnect them to the seat switch This must be completed so that the safety circuit is function ing properly Figure 4 14 Re attach the seat platform to the mower frame 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 A Steering control lever mower hamess Figure 4 15 7 With the bypass valve closed and the engine running 7 slowly move the steering control lever in both forward Tires and reverse directions 5 or 6 times Check the oil level and add oil as required after stopping the engine It is important for level mowing that the tires have the me amount of air pr re The recommen r r 8 It may be necessary to repeat Steps 6 and 7 until all Same Amoun DEE DIT e recommended pressures the air is completely purged from the system When are the transaxle operates at normal noise levels and Drive wheels e see 8 12 psi 55 83 KPa moves smoothly forward and reverse at normal Front wheels si io es rece 8 12 psi 55 83 KPa speeds then the transaxle is considered purged If you wish to use non pneumatic tires on your Hustler mower the tires must be an appro
43. rical 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 ser vice hospital and fire department near the telephone Prevent Battery Explosions Battery posts terminals and related accessories con tain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling Charge batteries in a well ventilated open area away from sparks and flames Unplug charger before connect ing or disconnecting from battery Wear protective cloth ing 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 a physician immediately Acid will also damage clothing Do not drink the battery electrolyte 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 disconnect the negative black battery cable s before dis connecting the positive red cable s Always connect the positive red battery cable s before connecting the negative black cable s Do not overfill the batte
44. ring control levers need to be in the park brake position when starting the engine but need to be moved rapidly out of the park brake position once engine is started so that the brakes do not fight the transmis sions since they have not yet been adjusted REVA Place the steering control lever in the park brake Shown with steering control levers in the park brake position If neutral is set properly you should not position hearthe transmission whine Shown with steering control levers in the neutral position A Steering control lever Figure 4 2 6 Start the engine Move the steering control lever to barely engage the brake neutral slot and hold it in that position Do not engage the steering control lever far enough to engage the brakes in the brake slot A Steering control lever Figure 4 3 This operation is extremely dangerous Pay close attention when adjusting the steering control rod so you do not get your fingers tools or anything 9 Once both sides are properly adjusted check them else close to the transaxle s cooling fans together to make sure everything is working properly 8 Repeat steps 4 thru 10 for the left side Shown with steering control lever in the neutral position 7 Beginning with the right side of the mower Adjust the steering control rod so that the right side wheel starts rotating forward while holding the steering control lever in the neutral position Adju
45. ry Electrolyte may overflow and damage paint wir ing or structure When cleaning the battery use soap and water Be careful not to get soap and water into the battery Clean the battery termi nals with a solution of four parts water and one part baking soda when they become corroded Shorts caused by battery terminals or metal tools touching metal mower components can cause sparks Sparks can cause a battery gas explosion which will result in personal injury REVA 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 A 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 connectthe positive red battery cable s before connecting the negative black cable s Avoid Acid Burns A Sulfuric acid in battery electrolyte is poisonous It is REVA 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 2 4 Avoiding breathing fumes when electrolyte is added Avoiding spilling
46. smission s filter is located per Figure 4 11 A standard oil filter wrench is used to change filter threads are right handed Use a Hustler approved filter element only IMPORTANT When washing the mower direct the spray away especially if using a power washer from the transmis sion s seals to prevent water intrusion and to ensure compo nent performance Fluid changing procedure 1l Park the unit on a level surface Placethe steering control levers in the park brake position Disengage the deck clutch Removethe ignition switch key Disconnect the negative battery cable 2 Remove the three 1 4 filter guard screws and filter guard Clean any loose debris from around the filter Figure 4 12 REVA A Expansion tank A Screw B Filter C Filter guard Figure 4 12 10 Remove the cap from the transaxle s expansion tank 11 Fill with 20W50 motor oil until oil just appears at the bottom of each transaxles top port approximately 2 qts per transaxle Install the top port plug into each transaxle Torque plugs to 180 in lbs Clean up any oil that leaked from the ports Figure 4 13 12 Continue to fill the transaxles through the expansion tank until the Full Cold line is reached on the expan sion tank 13 Re install the expansion tank cap by hand Be careful not to overtighten 14 Proceed to the purge procedure A Filter B Filter guard Figure 4 11 3 Place an oil drain pan
47. st the steering rod back the opposite direc tion to the point when the wheel stops rotating From that point turn the steering rod back again Y turn This ensures that the steering rod is adjusted so that the transmission control arm is centered in the neutral band of the transmission Figure 4 5 Movethe steering control lever forward and back ward making sure that the wheel rotates forward and backward correctly Return the steering control lever to neutral and re check to make sure the wheel has stopped in the neutral position A Steering control lever B J am nuts C Steering control rod D Transaxle cooling fan Figure 4 4 REVA 4 2 121878 10 IMPORTANT Unbolt the seat platform from the mower frame Disconnect the two female spade connectors from each other from step 3 Reconnect them to the seat switch This must be completed so that the safety circuit is function ing properly Figure 4 1 Re attach the seat platform to the mower frame 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 hamess The steering control levers should be adjusted so that they align
48. the spindle Con tact your Hustler Dealer for more information Do not re use spindle bolts which have stripped worn or undercut threads Torque bolts on spindles to 118 ft lbs 160 0 Nm when reinstalling blades Failure to correctly torque the bolt may result in the loss of the blade which can cause serious injury 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 121878 6 3 When mounting blades rotate them after installation to ensure blade tips do not touch each other or sides of the mower Belts Inspect belts frequently for wear and serviceability Replace a belt that shows signs of severe cuts tears separa tion weather checking and cracking or burns caused by slip ping 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 dam age the fibers of the belt covering Keep oil and grease away from belts and never use belt dressings Any of these will
49. ved tire purchased from Hustler Turf Equipment Warranty claims will be denied on any mower equipped with unapproved non pneumatic tires A Bypass valve rod B Transaxle Figure 4 16 REVA 4 8 121878 ENGINE MAINTENANCE 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 recommenda tions 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 Engine Oil and Filter Allow the engine to cool before changing the g engine oil If the engine has been running use cau 5 tion when changing the engine oil as it will be very hot You should wear the appropriate protective gear to avoid being burned or exposed to engine oil Check the engine oil daily and after every 4 hours of opera tion The mower must be level when checking the oil Refer to the Engine Owner s Manual and maintenance schedule for oil recommendation and capacities Change the engine oil and filter after the first 5 hours of operation and per the engine manufacturer s recommenda tions after that Change the engine oil more frequently if operating in extremely dirty conditions IMPORTANT When removing the oil filter take precautions to minimize oil spill
50. within 125 of each other when in the neu tral position Figure 4 5 NOTE The space between the ends of steering control handles should be 50 25 Figure 4 5 Check to make sure all tools or obstructions are removed from under the mower 12 13 Raise the rear of the mower and remove the jack stands Lower the mower 14 Remove the chocks from the front wheels Figure 4 5 Park Brake Spring Adjustment Occasionally check the park brake spring adjustment using the following method 121878 4 3 1 This procedure does not require engine power there A Nylock nut B Park brake spring y aa r3 Zam fore Park the mower on level ground Disengage the deck clutch Placethe steering control levers in the park brake position Stop the engine Removethe ignition key Disconnect the negative battery cable On one side measure the park brake spring It should be compressed to 1 43 1 48 If it is not adjust the nylock nut until the proper spring compression is achieved Figure 4 6 Repeat for other side Reconnect the negative battery cable 4 s X F m E Xs MAR ES Ct p Wil C Park brake rod Figure 4 6 REVA Steering Control Lever Stops This procedure will require that the unit to be raised to allow the drive wheel to rotate Block the mower up off of the ground using only appropriate vehicle stands minimum weight rating of 2000
Download Pdf Manuals
Related Search